Microporous Zirconium Silicate Particle Size Control
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Solution Overview
Problem
Existing methods for producing microporous zirconium silicate compositions for extracorporeal applications, such as dialysis columns, result in a broad particle size distribution, necessitating a screening step to achieve the desired particle size, which is inefficient and costly.
Innovation Solution
A method involving a reaction mixture of zirconium, silicon, and optional metal sources in a reactor with baffle-like structures at a specific agitation speed to produce zirconium silicate with a controlled particle size distribution between 5 and 20 microns, eliminating the need for subsequent screening or classification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screening is used to remove particles below 3 microns, then particle size distribution is improved, but productivity is reduced due to additional processing steps
Solution Approach 1:
The invention performs preliminary action by controlling particle size distribution during the synthesis process itself, rather than performing size separation after synthesis. The hydrothermal treatment conditions are optimized to directly produce particles within the desired size range (3-20 microns), eliminating the need for subsequent screening operations.
Solution Approach 2:
The invention extracts the particle size control function from the post-synthesis processing stage and integrates it into the synthesis stage. By adjusting hydrothermal treatment parameters (temperature, time, pH, precursor ratios), the desired particle size distribution is achieved inherently during synthesis, removing the need for separate size classification equipment and operations.
2Manufacturing precision
If screening equipment is added to achieve desired particle size distribution, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The invention merges the particle size control function with the synthesis process by integrating hydrothermal treatment parameters optimization. The synthesis and particle size control are combined into a single process stage, eliminating the need for separate screening equipment and reducing overall process complexity.
Solution Approach 2:
The invention achieves particle size control through parameter changes in the hydrothermal treatment process. By adjusting temperature, time, pH, and precursor ratios during synthesis, the desired particle size distribution (3-20 microns) is obtained directly, replacing the need for complex mechanical screening equipment.
3Object-affected harmful factors
If screening operations are performed, then harmful fine particles are removed, but loss of time occurs due to additional processing steps
Solution Approach 1:
The invention performs preliminary action by controlling particle size distribution during the synthesis process itself, rather than performing size separation after synthesis. The hydrothermal treatment conditions are optimized to directly produce particles within the desired size range (3-20 microns), eliminating the need for subsequent screening operations.
4Ease of manufacture
If heat exchange baffles are added to eliminate seed crystals, then ease of manufacture is improved, but particle size distribution broadens
Solution Approach 1:
The invention achieves particle size control through parameter changes in the hydrothermal treatment process. By adjusting temperature, time, pH, and precursor ratios during synthesis, the desired particle size distribution (3-20 microns) is obtained directly, replacing the need for complex mechanical screening equipment.
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
The method achieves a consistent, high cation exchange capacity zirconium silicate with a targeted particle size distribution, enhancing the efficiency of dialysis cartridges by eliminating the need for screening and improving manufacturing processes.
Implementation Method 1
agitating the reaction mixture with an agitator in the presence of one or more baffle-like structures with an agitation speed of 307 rpm
Implementation Method 2
GB 2 038 301 discloses a process for the semicontinuous production of zeolite A... which process comprises mixing a solution of sodium aluminate and a solution of sodium silicate instantaneously and continuously in a container and in such a manner that the average retention time in the container is from 30 seconds to 20 minutes thereby to form a gel which is subsequently crystallised
Data Source
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AI summary
The present invention relates to novel microporous zirconium silicate compositions having a desired particle size distribution and methods of making those compositions. These compositions have an ideal particle size distribution for use ex vivo, for example in a dialysis exchange cartridge, yet retain many of the desirable properties of prior improved absorbers including high cation exchange capacity. Further, the new zirconium silicate molecular sieve absorbers can be manufactured using a technique that achieves the desired particle size distribution while eliminating the screening step that was previously necessary.