Ultrasonic Starch Viscosity Reduction in Paper Industry

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Solution Overview

Problem

Current methods for manufacturing surface sizing starch, wet-end starch, and binder starch in the paper and pulp industry require chemical conversion to reduce starch viscosity, consume significant energy, and may alter the chemical structure of the starch, while also requiring steam and potentially leading to gelation issues.

Innovation Solution

The use of ultrasonic units to modify starch slurries by exposing them to high-frequency ultrasound, which reduces viscosity without chemical conversion, enhances dry substance content, and maintains the starch's properties, allowing for efficient production and disinfection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If chemical conversion is used to reduce starch viscosity, then the starch can be processed more easily, but the chemical structure of the starch is altered and additional chemicals are required

Engineering Contradiction:

Improvestarch processabilityVSAvoidstarch chemical structure

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent replaces chemical conversion methods with mechanical ultrasonic treatment. The ultrasonic device applies mechanical energy to the starch slurry to reduce viscosity and improve processability without introducing chemicals that would alter the starch's chemical structure. This substitution of mechanical action for chemical reaction resolves the contradiction between ease of operation and compositional stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If steam cooking is used to convert starch, then the starch viscosity is reduced, but energy consumption increases significantly

Engineering Contradiction:

Improvestarch viscosity reductionVSAvoidsteam energy consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The patent replaces thermal steam cooking with mechanical ultrasonic treatment to reduce starch viscosity. The ultrasonic device uses mechanical vibration energy instead of thermal energy, significantly reducing the energy consumption required for starch conversion while achieving the same viscosity reduction effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs ultrasonic vibration at high frequency to mechanically break down starch molecules and reduce viscosity. The ultrasonic device generates intense mechanical vibrations that disrupt the starch structure, providing an energy-efficient alternative to steam cooking by using mechanical rather than thermal energy.

Inventive Principle:

Principle #18Mechanical vibration

3Productivity

If steam cooking is used to manufacture starch size, then the starch is converted, but the risk of gelation increases and energy consumption rises

Engineering Contradiction:

Improvestarch conversion efficiencyVSAvoidsteam energy loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent replaces steam cooking with ultrasonic mechanical treatment to convert starch. This substitution eliminates the need for large amounts of steam energy while maintaining effective starch conversion, thereby reducing energy loss and improving productivity by using a more energy-efficient mechanical process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If conventional cooking processes are used, then starch is converted, but the process complexity and chemical usage increase

Engineering Contradiction:

Improvestarch conversionVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces complex chemical cooking processes with simple ultrasonic mechanical treatment. This substitution simplifies the overall process by eliminating the need for multiple chemical agents and complex process controls, achieving effective starch conversion through a single, straightforward mechanical treatment step.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method effectively reduces energy consumption, maintains the starch's chemical structure, and prevents gelation, enabling the production of a well-fluid starch size with improved efficiency and reduced chemical usage.

Implementation Method 1

The ultrasonic unit comprises at least one ultrasonic source, i.e. an ultrasonic element, near which or pass which the starch slurry is arranged to flow so that the energy produced by the ultrasonic source can be directed to the starch slurry flowing pass. The ultrasonic element vibrates in a high frequency (for example over 20 kHz, over 30 kHz or over 40 kHz) and causes cavitation and small cavitation bubbles in the liquid

Methodology Applied

Scientific EffectUltrasonic cavitation: Acoustic Cavitation

Data Source

PatentEP3068947B1Method and apparatus for continuous manufacture of surface sizing starch, wet-end starch or binder starch in paper, cardboard and chemical pulp industry

Publication Date: 2019.04.17 ADPAP

Figure 1~2
Figure 3~4
Figure 5A~5C

AI summary

The invention relates to a method and apparatus for continuous manufacture of surface sizing starch, wet-end starch or binder starch in paper, cardboard and chemical pulp industry. The starch slurry is modified as a starch size suitable for the application (6) by exposing the starch slurry to ultra sound in the ultrasonic unit (4, 4a, 4b).