Continuous Mixing System for Water Absorbing Agent Production
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Solution Overview
Problem
The production of particulate water absorbing agents with water absorbent resins faces challenges in stabilizing property values, leading to unstable quality and increased disposal costs due to the need for large-capacity tanks and complex processes, especially when polymerization initiators are stored for extended periods.
Innovation Solution
A method involving the continuous mixing and feeding of liquids containing a polymerization initiator and a modifier, with controlled concentration and flow rates, to stabilize the properties of the particulate water absorbing agent, reducing the need for large tanks and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a large-capacity tank is used to store aqueous solution of polymerization initiator, then the production can continue during plant suspension, but the chemical reaction in stored solution impairs polymerization initiator function and increases disposal costs
Solution Approach 1:
The patent divides the storage system into multiple small-capacity tanks instead of using one large tank. Each tank stores a limited amount of aqueous solution, preventing prolonged storage and chemical degradation while ensuring continuous supply to the polymerization reactor even during plant suspensions.
Solution Approach 2:
The patent prepares and stores multiple small tanks of aqueous solution in advance before plant suspension occurs. This preliminary preparation ensures that fresh polymerization initiator solution is readily available when production resumes, avoiding the need to store large quantities for extended periods.
2Stability of the object's composition
If low-concentration aqueous solution of polymerization initiator is used, then sufficient mixing with monomer is achieved, but a large amount of aqueous solution is required and large-capacity tanks are needed
Solution Approach 1:
The patent uses multiple small tanks to store concentrated polymerization initiator aqueous solution. By segmenting the storage into smaller units, the system can supply concentrated solution in controlled amounts, achieving sufficient mixing without requiring large volumes or large-capacity storage tanks.
Solution Approach 2:
The patent changes the concentration parameter of the polymerization initiator aqueous solution from low-concentration to concentrated form. This parameter change reduces the total volume of solution needed while maintaining effective mixing through controlled addition to the monomer.
3Ease of manufacture
If line mixing is used to mix additive and other materials, then the process is simplified, but the solutions differ in concentration and quality becomes unstable
Solution Approach 1:
The patent implements a feedback control system with concentration detection devices that monitor the aqueous solution of polymerization initiator in real-time. When concentration deviations are detected, the system automatically adjusts the addition rate or replenishes the solution to maintain precise concentration, ensuring stable quality while keeping the process relatively simple.
Solution Approach 2:
The patent replaces simple mechanical line mixing with an automated control system that includes concentration detection and automatic adjustment mechanisms. This substitution of mechanical mixing with instrumented control ensures precise concentration management and stable quality output.
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 approach results in a high-quality particulate water absorbing agent with improved stability and reduced disposal costs, capable of continuous production at high volumes while maintaining consistent property values.
Implementation Method 1
a monomer for a water absorbent resin is polymerized with use of a polymerization initiator so as to obtain a hydrogel
Implementation Method 2
The water absorbent resin absorbs body fluids such as urine and blood
Data Source
AI summary
An apparatus (2) includes: a first tank (4); a line mixer (6); a second tank (8); a cooling jacket (10); a first tube (12); a second tube (14); and a third tube (16). In the first tank (4), (i) sodium persulfate serving as a polymerization initiator and (ii) water are fed so as to obtained an aqueous solution. The aqueous solution is continuously taken out and transferred via the first tube (12) to the line mixer (6). Between the first tank (4) and the line mixer (6), water is injected into the first tube (12). The water and the sodium persulfate aqueous solution are stirred together in the line mixer (6). This stirring decreases a concentration of the aqueous solution. The resulting aqueous solution is continuously fed to the second tank (8) via the second tube (14). The aqueous solution is then continuously taken out via the third tube (16) and is continuously added to an acrylic acid (salt) aqueous solution. This provides a production method which allows a high-quality water absorbing agent to be obtained with a compact apparatus.