Zeolite Film Production via Movable Reactors in Constant-Temperature Apparatus
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Solution Overview
Problem
Current methods for producing zeolite films are labor-intensive and lack a continuous, automated process, leading to high production costs and inefficiencies.
Innovation Solution
A method involving attaching zeolite fine crystals to a support, preparing synthetic gel, performing hydrothermal synthesis in movable reactors within a constant-temperature apparatus, and subsequent cleaning, allowing for continuous and efficient film production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch production method with manual operations is used, then zeolite films can be produced with acceptable quality, but production cost increases and efficiency decreases due to manpower requirements
Solution Approach 1:
The patent implements continuous production by circulating the slurry suspension through the reaction system, allowing zeolite films to be continuously deposited on support bodies without interruption. The slurry is continuously supplied, reacts with the support surface, and the product is continuously removed, eliminating the batch-wise manual operations of prior art.
Solution Approach 2:
The reaction system is designed to automatically maintain optimal reaction conditions through continuous circulation and temperature control. The slurry suspension self-regulates the deposition process on support bodies, reducing the need for manual intervention in monitoring and adjusting production parameters.
2Productivity
If continuous production method is implemented, then production efficiency increases, but process complexity increases due to multiple equipment requirements
Solution Approach 1:
The reaction vessel serves multiple functions: it acts as both the reaction chamber and the circulation loop, while the heating apparatus provides both temperature control and thermal energy for the hydrothermal reaction. The slurry circulation system simultaneously performs mixing, heating, and transport functions, simplifying the overall equipment requirements despite continuous operation.
Solution Approach 2:
The patent combines the reaction zone and the slurry circulation system into an integrated process. The support bodies are immersed directly in the circulating slurry within the same vessel, merging the deposition process with the reaction process, thereby reducing the number of separate equipment components needed.
3Ease of manufacture
If batch production method is used, then process simplicity is maintained, but production cost increases due to manual labor
Solution Approach 1:
The continuous circulation of slurry suspension through the reaction vessel enables uninterrupted zeolite film formation on support bodies. This continuous process eliminates the repeated setup, processing, and cleanup cycles inherent in batch methods, thereby improving production efficiency while maintaining operational simplicity through automated circulation.
Solution Approach 2:
The patent replaces manual handling and batch processing operations with an automated slurry circulation system. The continuous flow and circulation of the slurry suspension automatically achieve uniform coating and reaction, substituting mechanical manual operations with a controlled fluid dynamic system that is both simple and efficient.
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
Enables the continuous and efficient production of high-quality zeolite films by forming zeolite in a film shape on a support within movable reactors, reducing manpower requirements and increasing production efficiency.
Implementation Method 1
performing hydrothermal synthesis in movable reactors within a constant-temperature apparatus
Implementation Method 2
the reaction time of the hydrothermal synthesis is adjusted by setting the time from when the reactors enter the constant-temperature apparatus to when the reactors exit the constant-temperature apparatus
Data Source
AI summary
Provided is a method of producing a zeolite film continuously and efficiently.Zeolite is formed on a surface of a support using a method including: a first step of attaching zeolite fine crystals to a surface of a support; a second step of preparing synthetic gel for growing the fine crystals; a third step of putting the support and the synthetic gel into a reactor and performing hydrothermal synthesis; and a fourth step of cleaning the support subjected to the hydrothermal synthesis, in which in the third step, multiple containers arranged to be movable in a constant-temperature apparatus are each used as the reactor, the temperature and pressure for the hydrothermal synthesis is adjusted by the temperature and pressure in the constant-temperature apparatus, and the reaction time of the hydrothermal synthesis is adjusted by setting the time from when the reactor enters the constant-temperature apparatus to when the reactor exits the constant-temperature apparatus.