Underwater Granulation Water Box Circumferential Inlets
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Solution Overview
Problem
Underwater granulation systems face issues with particle stickiness and deformation due to high viscosity of polymer melts, leading to agglomeration and contamination, which affects the homogeneity and size of granules produced, resulting in shorter maintenance cycles and higher operational costs.
Innovation Solution
The system improves water circulation in the water box by distributing water inlets and outlets circumferentially, creating a whirlpool effect that reduces particle residence time and exposure to collisions, along with a modular design and arcuate support arms to minimize turbulence and facilitate better water flow, thereby enhancing particle homogeneity and reducing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water inlets and outlets are arranged in a conventional single-point configuration, then the system structure is simple, but particle residence time is excessive causing agglomeration and deformation
Solution Approach 1:
The water supply and drainage systems are segmented into multiple circumferentially distributed inlets and outlets around the water box. This segmentation creates multiple water flow paths that simultaneously cool and transport particles, reducing residence time and preventing agglomeration while maintaining structural manageability through modular arrangement.
Solution Approach 2:
The patent transitions from a single-point water inlet/outlet configuration to a circumferential distribution arrangement, adding spatial dimensionality to the water flow system. This dimensional change creates a three-dimensional water circulation pattern that efficiently covers the entire particle processing area, reducing hot spots and deformation zones.
2Strength
If polymer melt is fed at high viscosity to ensure material integrity, then material strength is maintained, but particle stickiness increases causing agglomeration
Solution Approach 1:
The circumferential water inlets are positioned to provide preliminary cooling action immediately after particles are separated from the polymer melt. This preliminary cooling reduces particle temperature and viscosity before particles can adhere to each other, preventing agglomeration while maintaining material integrity through controlled cooling rates.
Solution Approach 2:
The patent converts the harmful effect of high-temperature sticky particles into a benefit by using the same thermal energy that causes stickiness as a driver for enhanced water circulation. The circumferential water flow system leverages temperature gradients to create beneficial convection currents that rapidly cool and separate particles, transforming the stickiness problem into an enhanced cooling mechanism.
3Manufacturing precision
If water flow rate is increased to reduce particle residence time, then particle homogeneity improves, but system energy consumption increases
Solution Approach 1:
The water circulation system is segmented into multiple circumferential inlets and outlets that create distributed flow paths. This segmentation allows water to flow through multiple smaller channels simultaneously, achieving the same particle cooling and transport effect with lower velocity requirements, thereby reducing overall energy consumption while maintaining particle homogeneity.
Solution Approach 2:
The patent implements a dynamic water circulation pattern where circumferential inlets and outlets create rotating flow patterns that adapt to particle distribution. This dynamic flow configuration optimizes cooling efficiency at different zones of the water box, achieving uniform particle cooling with reduced energy input compared to static high-velocity flow systems.
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
The improved water circulation and design reduce particle collisions and adhesion, resulting in more homogeneous and spherical granules with reduced deformation, leading to increased system efficiency and extended maintenance cycles.
Implementation Method 1
distributing water inlets and outlets circumferentially, creating a whirlpool effect that reduces particle residence time and exposure to collisions
Implementation Method 2
the water box is connected to a water supply for heat removal and for removing the separated particles from the water box
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to an underwater granulation system (1) comprising a water box (3), a perforated plate with multiple through-openings for supplying a polymer melt into the water box (3), a cutting plate support (5) which is arranged in the water box (3) in a rotationally driven manner about a rotational axis (X) in a cutting direction (5), wherein the cutting plate support (5) has multiple cutting plates (31) which face the perforated plate and are designed to form a granulate by shearing particles from the polymer melt entering through the perforated plate, and the water box (3) is connected to a water supply in order to transfer heat and transport the separated particles out of the water box (3). According to the invention, the water box (3) has a hollow cylindrical section relative to the rotational axis (x), said section being equipped with multiple water inlets (11) distributed over the circumference and multiple water outlets (13) distributed over the circumference.