Wet Master Batch Dehydration via Drum Pressurization

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Solution Overview

Problem

Conventional methods fail to efficiently solid-liquid separate and dehydrate coagulum slurries with small particle sizes, leading to low production capacity and high costs due to instability in moisture content and coagulum loss during the dehydration process.

Innovation Solution

A method involving gravity and vacuum filtration followed by pressure dehydration using a drum pressurizer, with a belt-like filtration filter running in a circulated manner, effectively separates and dehydrates coagulum slurries, achieving a moisture content of 40-65% and suppressing energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional solid-liquid separation methods (centrifugal separation, screw press, filter cloth sedimentation) are used for coagulum slurry with small particle sizes, then the process can be implemented, but water cannot be effectively separated and the coagulum slurry fails to dehydrate properly

Engineering Contradiction:

Improvedehydration effectivenessVSAvoidproduction capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention changes the physical parameters of the coagulum slurry by controlling particle size to 10-100 micrometers and adjusting moisture content to 70-85%, creating optimal conditions for effective dehydration through the filtration-drying system

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces conventional mechanical separation methods (centrifugal separation, screw press) with a filtration-based system using filter cloth and drying apparatus, achieving superior dehydration effectiveness for fine particle coagulum slurries

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If filter cloth sedimentation is used for solid-liquid separation, then water can be separated to some extent, but the obtained solid is unstable in moisture content and requires additional crashing step

Engineering Contradiction:

Improvemoisture content stabilityVSAvoidprocess steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention implements continuous filtration and drying action where coagulum slurry continuously passes through filter cloth and enters drying apparatus, maintaining stable moisture content (40-65%) without requiring intermittent crashing operations

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The invention performs preliminary filtration through filter cloth before drying, pre-concentrating the coagulum and removing excess water, which stabilizes moisture content and eliminates the need for subsequent crashing steps

Inventive Principle:

Principle #10Preliminary action

3Reliability

If additional crashing step is added to stabilize moisture content, then moisture content stability improves, but production capacity decreases and cost increases

Engineering Contradiction:

Improvemoisture content stabilityVSAvoidproduction capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention merges the filtration and drying functions into a single integrated system where filter cloth and drying apparatus work together continuously, eliminating the need for separate crashing step and maintaining both stability and production capacity

Inventive Principle:

Principle #5Merging (Combining)

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 enhances the efficiency of solid-liquid separation and dehydration, improving the quality and stability of the wet master batch, reducing coagulum loss, and increasing production capacity while maintaining cost-effectiveness.

Implementation Method 1

solid-liquid separating and dehydrating a coagulum slurry obtained by mixing a rubber latex with a carbon black slurry containing a carbon black dispersed in water and coagulating the mixture, in which the solid-liquid separating and dehydrating step comprises gravity filtering and vacuum filtering the coagulum slurry on a filtration filter

Methodology Applied

Scientific EffectGravity filtration: Gravitation

Implementation Method 2

Methodology Applied

Scientific EffectVacuum filtration: Vacuum

Implementation Method 3

pressurizing, by means of a pressurizer, the coagulum slurry on the outer peripheral surface of a drum, to thereby pressure dehydrate the coagulum slurry

Methodology Applied

Scientific EffectPressure dehydration: Pressurisation

Data Source

PatentUS9932450B2Method of producing wet master batch, wet master batch, rubber composition, and solid-liquid separating and dehydrating apparatus for wet master batch production

Publication Date: 2018.04.03 BRIDGESTONE CORP

AI summary

Provided is a method of producing a wet master batch, including the step of: solid-liquid separating and dehydrating a coagulum slurry obtained by mixing a rubber latex with a carbon black slurry containing a carbon black dispersed in water and coagulating the mixture, the solid-liquid separating and dehydrating step including gravity filtering and vacuum filtering the coagulum slurry on a filtration filter and then pressurizing, by means of a pressurizer, the coagulum slurry on the outer peripheral surface of a drum, to thereby pressure dehydrate the coagulum slurry. Also provided is a solid-liquid separating and dehydrating apparatus for wet master batch production, which includes: a filtration filter; a filtration portion; a drum; and a pressurizer.