White Water Cooling in Fibre Molding to Prevent Additive Defects
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Solution Overview
Problem
The recycling of white water and steam during fibre molded product production leads to temperature increases in the storage tank, causing chemical additives to precipitate and form defects on the final products, deteriorating their quality.
Innovation Solution
A method and system that reduces the temperature of the mixed white water and steam stream to 50 °C or less before storage, using heat-exchanging, to prevent additive precipitation and improve product quality while recycling water and steam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If white water and steam are recycled during fibre molded product production, then water consumption is reduced and sustainability is improved, but temperature increases in the storage tank cause chemical additives to precipitate and form defects on the final products
Solution Approach 1:
The patent applies parameter changes by cooling the mixed white water and steam stream from high temperature (after recycling) to below 50°C before storage. This temperature parameter change prevents the precipitation of temperature-sensitive chemical additives like AKD, thereby eliminating remarking spots while maintaining the water recycling benefit. The cooling unit is specifically introduced to modify the temperature parameter of the recycled water stream.
Solution Approach 2:
The patent introduces a cooling unit as an intermediary component between the recycling system and the storage tank. This intermediary device mediates the conflict by reducing the temperature of the recycled white water and steam mixture, allowing the chemical additives to remain dissolved and preventing defects without requiring changes to the overall recycling process or storage system.
2Reliability
If white water and steam are recycled during fibre molded product production, then sustainability is enhanced, but chemical additives precipitate at elevated temperatures forming remarking spots that deteriorate product quality
Solution Approach 1:
The patent changes the temperature parameter of the recycled white water and steam stream by introducing a cooling unit that reduces the temperature to below 50°C. This parameter modification prevents the harmful precipitation of chemical additives while maintaining the sustainable recycling process, thereby eliminating the trade-off between sustainability and product quality.
Solution Approach 2:
The patent converts the harmful effect of high temperature (which causes additive precipitation) into a beneficial outcome by actively cooling the recycled stream. The cooling process transforms the potentially harmful thermal energy into a controlled parameter that prevents defects, turning what would be a harmful high-temperature condition into a beneficial low-temperature storage condition that preserves product quality.
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
Reduces defects on fibre molded products, minimizes waste water, and enhances sustainability by reusing white water without compromising product quality, while generating energy for district heating or electricity.
Implementation Method 1
condensing the steam stream by mixing the steam stream and the white water stream
Implementation Method 2
reducing the temperature of the mixed white water stream to 50 °C or less, such as 40 °C or less
Data Source
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AI summary
The present invention relates to a system and a method for recycling white water during production of fibre molded products. The method comprises: a) forming a wet fibre molded product in a forming unit (1) using a furnish comprising white water; b) dewatering the wet fibre product and producing a dewatered fibre molded product and a white water stream (4*); c) drying the dewatered fibre molded product and producing a dried fibre molded product and a steam stream (5*); d) condensing the steam stream (5*) by mixing the steam stream (5*) and the white water stream (4*) and producing a mixed white water stream (6*); e) reducing the temperature of the mixed white water stream (6*) to 50 °C or less; f) storing the mixed white water stream (7*) in a white water tank (8); and g) providing the white water (8*) from the white water tank (8) to the forming unit (1) for preparation of the furnish.