Wet Grinding Unit for High Concentration Polymer Dispersion
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Solution Overview
Problem
Current methods for dissolving high molecular weight water-soluble polymers in industrial applications are hindered by high viscosity, leading to limited polymer concentration, lengthy dissolution times, and costly, large-scale equipment, with existing wet grinding technologies facing issues of plugging, rapid wear, and incompatibility with safety standards.
Innovation Solution
A wet grinding unit operates at industrial speeds with a prewetting and chopping process, using a rotor with knives and a stator with tilted blades, supplemented by a secondary water ring to prevent clogging and increase concentration, allowing for efficient dispersion of high molecular weight polymers without degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high molecular weight water-soluble polymers are dissolved in water using conventional methods, then the polymer concentration is limited to 1-5 grams/liter due to high viscosity, but increasing the concentration is needed for industrial applications
Solution Approach 1:
The patent applies preliminary action by pre-grinding the polymer particles before dissolution. The polymer is ground in a wet grinding unit to reduce particle size and improve wettability before being introduced to the dissolution system, which enables higher concentrations to be achieved without excessive viscosity buildup during the dissolution process
Solution Approach 2:
The patent uses an intermediary approach by introducing a wetting agent or surfactant in combination with the polymer during grinding and dissolution. This intermediary substance reduces surface tension and improves polymer-water interaction, allowing higher concentrations to be dissolved while maintaining acceptable viscosity levels
2Quantity of substance
If conventional dissolution equipment is used for high molecular weight polymers, then large dissolution tanks are required, but this increases equipment cost and footprint
Solution Approach 1:
By pre-grinding the polymer in a wet grinding unit before dissolution, the polymer particles are reduced in size and pre-hydrated, which dramatically accelerates the dissolution rate. This allows much smaller dissolution vessels to be used while still achieving the required polymer concentrations, reducing equipment footprint and cost
3Productivity
If wet grinding is used to disperse polymer in water, then the rotor-stator assembly may be plugged by polymer gel, but continuous operation is needed
Solution Approach 1:
The patent introduces water jets as an intermediary flushing mechanism that continuously rinses the rotor-stator assembly during operation. These jets prevent polymer gel from accumulating and plugging the narrow gaps between the rotor knives and stator blades, enabling continuous uninterrupted operation
Solution Approach 2:
The system uses a portion of the process water or a dedicated flushing system to automatically clean the rotor-stator assembly during operation. This self-cleaning mechanism prevents plugging without requiring manual intervention or shutdown, maintaining continuous productivity
4Productivity
If high cutting speeds are used in wet grinding to maintain industrial productivity, then the rotor and stator experience rapid wear, but high speeds are needed for efficiency
Solution Approach 1:
The patent uses water jets and hydraulic flushing systems to cool and lubricate the rotor-stator assembly during high-speed operation. This hydraulic cooling reduces friction and heat generation, significantly decreasing wear rates and extending maintenance intervals while maintaining high grinding speeds for productivity
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 achieves rapid dissolution at high concentrations, reduces equipment wear, and extends maintenance intervals, enabling continuous operation while maintaining industrial speeds and safety standards, thus overcoming the limitations of previous technologies.
Implementation Method 1
a rotor with knives rotating in a stator with very close blades
Implementation Method 2
rotor with knives rotating in a stator with very close blades
Implementation Method 3
secondary water jets which disperse and dilute the polymer
Data Source
AI summary
A method for dispersing a water-soluble polymer includes: metering and prewetting polymer with primary water; grinding and draining of the dispersed polymer in a chamber comprising a rotor and a stator; and providing a ring with perforations fed by a secondary water circuit on all or part of the periphery of the chamber for spraying of pressurized water on the blades of the stator.