U.S. patent application number 10/782452 was filed with the patent office on 2004-08-26 for methods and apparatus for producing granular compositions.
This patent application is currently assigned to The Procter & Gamble Company. Invention is credited to Pinyayev, Aleksey Mikhailovich.
Application Number | 20040164435 10/782452 |
Document ID | / |
Family ID | 22832683 |
Filed Date | 2004-08-26 |
United States Patent
Application |
20040164435 |
Kind Code |
A1 |
Pinyayev, Aleksey
Mikhailovich |
August 26, 2004 |
Methods and apparatus for producing granular compositions
Abstract
Methods for producing granular compositions comprise the steps
of preparing a viscous liquid mixture, forming a plurality of
ligaments from the viscous liquid mixture, cutting the ligaments
with one or more liquid jet streams to form pieces, and drying the
pieces to form the granular compositions. Apparatus for producing a
granular compositions comprise a viscous liquid composition supply,
a ligament forming device in fluid communication with a viscous
liquid composition supply, one or more liquid jet nozzles adjacent
an outlet of a ligament forming device, and a dryer.
Inventors: |
Pinyayev, Aleksey Mikhailovich;
(Fairfield, OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY
INTELLECTUAL PROPERTY DIVISION
WINTON HILL TECHNICAL CENTER - BOX 161
6110 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Assignee: |
The Procter & Gamble
Company
|
Family ID: |
22832683 |
Appl. No.: |
10/782452 |
Filed: |
February 19, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10782452 |
Feb 19, 2004 |
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09923009 |
Aug 3, 2001 |
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6733709 |
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60222553 |
Aug 3, 2000 |
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Current U.S.
Class: |
264/11 ;
425/7 |
Current CPC
Class: |
C11D 11/0082 20130101;
B01J 2/20 20130101; C11D 17/06 20130101; B01J 2/04 20130101 |
Class at
Publication: |
264/011 ;
425/007 |
International
Class: |
B29B 009/00 |
Claims
What is claimed is:
1. A method for producing a granular composition comprising the
steps of: a) providing a viscous liquid mixture; b) forming a
plurality of ligaments from the viscous liquid mixture; c) cutting
the ligaments with one or more liquid jet streams to form pieces;
and d) drying the pieces to form the granular composition.
2. The method of claim 1, wherein the step of forming a plurality
of ligaments comprises extruding the viscous liquid mixture.
3. The method of claim 1, wherein the viscous liquid mixture
comprises a slurry.
4. The method of claim 1, wherein the viscous liquid mixture
comprises a paste.
5. The method of claim 1, wherein the liquid jet streams move in a
linear motion.
6. The method of claim 1, wherein the liquid jet nozzles have a
diameter of from about 0.002 inch to about 0.2 inch.
7. The method of claim 1, wherein the liquid jet nozzles have a
diameter of from about 0.002 inch to about 0.004 inch.
8. The method of claim 1, wherein the liquid jet nozzles expel
liquid at a pressure of from about 100 psi to about 55,000 psi.
9. The method of claim 1, wherein the liquid jet nozzles expel
liquid at a pressure of from about 500 psi to about 20,000 psi.
10. The method of claim 1, wherein the liquid jet nozzles expel
liquid at a pressure of from about 10,000 psi to about 20,000
psi.
11. The method of claim 1, wherein the step of forming a plurality
of ligaments comprises extruding the slurry through an orifice
plate having one or more holes.
12. The method of claim 11, wherein the holes in the orifice plate
have a diameter of from about 0.001 inch to about 0.1 inch.
13. The method of claim 11, wherein the holes in the orifice plate
have a diameter of from about 0.01 inch to about 0.05 inch.
14. The method of claim 11, wherein the holes in the orifice plate
have a diameter of from about 0.0125 inch to about 0.02 inch.
15. The method of claim 1, wherein the viscous liquid composition
comprises from about 20 to about 80 weight percent solids.
16. The method of claim 1, wherein the viscous liquid composition
comprises from about 55 to about 70 weight percent solids.
17. An apparatus for producing a granular composition comprising:
a) a viscous liquid composition supply; b) a ligament forming
device in fluid communication with the viscous liquid composition
supply; c) one or more liquid jet nozzles adjacent an outlet of the
ligament forming device; and d) a dryer.
18. The apparatus of claim 17, wherein each liquid jet nozzle has a
diameter of from about 0.002 inches to about 0.2 inch.
19. The apparatus of claim 17, wherein the ligament forming device
comprises an orifice plate having one or more holes.
20. The apparatus of claim 19, wherein the holes in the orifice
plate have a diameter of from about 0.001 inch to about 0.1
inch.
21. The apparatus of claim 19, wherein the orifice plate has a
diameter of from about 3 inches to about 50 inches.
22. The apparatus of claim 19, wherein the holes in the orifice
plate has a diameter of from about 0.01 inch to about 0.05
inch.
23. The apparatus of claim 19, wherein the liquid jet nozzles expel
liquid at a pressure of from about 100 psi to about 55,000 psi.
24. The apparatus of claim 19, wherein the liquid jet nozzles expel
liquid at a pressure of from about 10,000 psi to about 20,000
psi.
25. A method for producing a granular composition comprising the
steps of: a) producing a viscous liquid mixture; b) forming a
plurality of ligaments from the viscous liquid mixture; c) cutting
the ligaments with one or more liquid jet streams to form pieces;
and d) solidifying the pieces to form the granular composition.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser.
No. 09/923,009, filed Aug. 3, 2001 which claims priority under 37
U.S.C. .sctn. 119(e) to U.S. Provisional Application Serial No.
60/222,553, filed Aug. 3, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to methods and apparatus for
producing uniform granular compositions, and more particularly to
methods and apparatus which may be used for producing of uniform
granular detergent compositions.
BACKGROUND OF THE INVENTION
[0003] One of the most widespread ways of manufacturing detergent
granules is through a spray drying process. A detergent mixture is
sprayed through an atomization nozzle and the resulting droplets
are dried in a gas flow in a drying tower. Spraying is usually done
through pressure or swirl nozzles. The detergent product obtained
by these technologies typically contains particles which widely
vary in size. For example, for a swirl atomizer with counterflow
drying air, typical particle sizes range from about 100 microns to
about 1100 microns, resulting in non-uniform particles or
granules.
[0004] The difficulty in producing uniform droplets and resulting
granules is a well-known problem for conventional atomization
technology. Certain atomization methods are known for minimizing
this problem. Among them are ultra-sonic, electrostatic, and
acoustic atomization techniques. However, none of these techniques
are applicable for making detergent granules having a large
particle size (i.e. of at least 500 microns). Detergent slurry is
typically a highly viscous, non-Newtonian, water-based mixture
containing approximately 70% solids. In addition, detergent slurry
is typically conductive and corrosive (pH>12). Because of the
detergent slurry's typical high viscosity and high solids content,
the slurry cannot be properly processed by conventional ultrasonic
atomizers. In addition, the detergent slurry usually cannot be
processed by electrostatic atomizers due to the conductivity and
viscosity of the detergent slurry. Furthermore, acoustic
atomization is typically not possible because the slurry
efficiently attenuates the sound waves necessary for such
processes.
[0005] To meet commercial manufacturing demands, it is typically
desired that any atomization method applied to a detergent slurry
have a throughput capacity of about 50-60 tons per hour. However,
typically atomization technologies are viewed as low-throughput
methods and none of the prior known atomization methods are able to
process such amounts of slurry in one unit. Accordingly, multiple
atomization units would be required to provide the desired
throughput capacity. The use of multiple units however requires
additional capital expenditures. As such, there remains a need for
an efficient process for the preparation of uniform granular
compositions, such as detergent compositions, with a relativity
high throughput.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is an object of the present invention to
provide novel methods and apparatus for the preparation of uniform
granular compositions, which methods and apparatus overcome one or
more disadvantages of the prior art. It is a more specific object
of the invention to provide methods and apparatus for producing of
uniform granular detergent compositions. Another object of the
present invention is to provide methods and apparatus having high
throughput for the production of uniform granular detergent
compositions.
[0007] These and additional objects and advantages are provided by
methods and apparatus for manufacturing granular compositions
according to the invention.
[0008] One embodiment of the present invention relates to methods
for producing granular compositions. The methods comprise the steps
of preparing a viscous liquid mixture, forming a plurality of
ligaments from the viscous liquid mixture, cutting the ligaments
with one or more liquid jet streams to form pieces, and drying the
pieces to form the granular composition.
[0009] Another embodiment of the present invention relates to
apparatus for producing granular compositions. The apparatus
comprise a viscous liquid composition supply, a ligament forming
device in fluid communication with the viscous liquid composition
supply, one or more liquid jet nozzles adjacent an outlet of the
ligament forming device, and a dryer. The methods and apparatus of
the present invention are advantageous in providing uniform
granular compositions at a relatively high throughput if desired.
These and additional objects and advantages will be further
apparent in view of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention as set forth in the detailed
description will be more fully understood when viewed in connection
with the drawings in which:
[0011] FIG. 1 depicts a flowchart of a method for producing a
granular composition according to the present invention;
[0012] FIG. 2 depicts a schematic illustration of an apparatus
according to the present invention; and
[0013] FIG. 3 depicts a schematic illustration of an exemplary
orifice plate included in an embodiment of an apparatus according
to the present invention.
DETAILED DESCRIPTION
[0014] In the methods of the present invention for producing
granular compositions having a uniform size, fluid cutting
technology as described herein is utilized. The fluid cutting
technology comprises cutting multiple ligaments of a liquid moving
at a relatively low rate, by means of a stream having high energy
which is concentrated in space and moving in a direction different
than the direction of the liquid being atomized. High speed water
jets and laser beams are examples of such high energy streams that
can be utilized.
[0015] One aspect of the present invention is a method for
producing a granular composition comprising the steps of providing
a viscous liquid mixture, forming a plurality of ligaments from the
viscous liquid mixture, cutting the ligaments with one or more
liquid jet streams to form pieces, and drying the pieces to form
the granular composition. In one embodiment, the step of forming a
plurality of ligaments from the viscous liquid mixture comprises
extruding the viscous liquid mixture through an orifice plate. The
orifice plate preferably has multiple orifices. These orifices
preferably divide a bulk volume of the viscous liquid mixture, for
example a slurry, into multiple ligaments extruded through the
orifice plate under the combined action of pressure and gravity.
The resulting ligaments are preferably free hanging. These free
hanging ligaments are then cut by one or more, preferably multiple,
jets of liquid. The jets of liquid may be formed by a rotating
head, wherein the liquid is supplied under high pressure, although
other apparatus for forming liquid jets will be apparent to one
skilled in the art after reading the present disclosure. Preferred
liquids include water. Optionally, the liquid, for example water,
may be modified with a polymeric binder or the like to enhance the
cohesiveness of the liquid stream.
[0016] In an embodiment of the present invention depicted in FIG.
1, the method of producing a granular composition comprises the
steps of preparing a viscous liquid mixture (step 50), and
providing a pressure differential on the viscous liquid composition
(step 54) across an orifice plate resulting in a pre-determined
flow rate of the viscous liquid composition through the orifice
plate to create a plurality of ligaments. The ligaments are then
cut (step 58) with one or more liquid jet streams to form pieces
having a pre-determined particle size. The pieces are then dried in
a drying tower with a gas flow (step 62). Preferably, the ligaments
are cut with liquid jets supplied from a rotary head comprising a
predetermined number of individual jets having a predetermined
rotational speed. The particle size of the pieces is proportional
to the flow rate of the viscous liquid composition and inversely
proportional to the number of individual jets and their rotational
speed.
[0017] In one embodiment, the viscous liquid mixture comprises a
slurry, while in another embodiment the viscous liquid mixture
comprises a paste. By "slurry," the Applicant means a complex,
non-uniform composition of liquids and solids. By "paste," the
Applicant means a more uniform composition of liquids and solids.
In another embodiment, the viscous liquid composition comprises at
least from about 20 to about 80 weight percent solids, and more
preferably from about 55 to about 70 weight percent solids. In a
specific embodiment, the viscous liquid composition is employed to
form granular detergent compositions and comprises one or more of
the following components: surfactant selected from anionic,
nonanionic, cationic, amphoteric and zwitterionic detergent-active
components and mixtures thereof; detergency builder, bleaching
agents, suds suppression agents, enzymes, polymer dye transfer
inhibiting agents, corrosion inhibitor, heavy metal ion
sequestrant, softening agents, calcium, magnesium, solvent,
perfumes, colors and filler salts.
[0018] Another aspect of the present invention, depicted in FIG. 2,
is an apparatus 20 for producing a granular composition. The
apparatus 20 comprises a viscous liquid composition supply 23, a
ligament forming device 26 in fluid communication with the viscous
liquid composition supply 23, one or more liquid jet nozzles 28
adjacent an outlet 27 on the ligament forming device 26, multiple
liquid jets, and in one embodiment comprises a dryer 45.
Preferably, the apparatus 20 comprises from about 1 to about 128
individual liquid jet nozzles 28 provided on a rotary head 30. Each
liquid jet nozzle 28 preferably has a diameter of a size sufficient
to provide the desired liquid jet, and preferably has a diameter of
from about 0.002 inch to about 0.2 inch. Preferably, the ligament
forming device 26 comprises an orifice plate. FIG. 3 depicts an
exemplary orifice plate for inclusion in an apparatus of the
present invention. The orifice plate typically has a diameter range
of from about 3 inches to about 50 inches. The orifice plate 26 has
one or more holes 34, having a diameter sufficient to form the
desired size of granules, and in one embodiment have a diameter of
from about 0.001 inch to about 0.1 inch, and more preferably, a
diameter of from about 0.01 inch to about 0.05 inch, and most
preferably, a diameter of from about 0.0125 inch to about 0.02
inch. The dryer 45 preferably comprises one or more gas streams,
wherein at least one gas stream preferably flows counter current to
the pieces. The viscous liquid composition is extruded at a flow
rate based on the desired dried particle size and the number of
water jets and their rotational speed.
[0019] Preferably, the liquid jet nozzles have a diameter of from
about 0.002 inch to about 0.2 inch, and more preferably from about
0.002 inch to about 0.004 inch. The liquid jet nozzles expel liquid
at a pressure of from about 100 psi to about 55,000 psi, more
preferably at a pressure of from about 500 psi to about 20,000 psi
and most preferably, the liquid jet nozzles expel liquid from about
10,000 psi to 20,000 psi.
[0020] Preferably, the rotational speed of the jet nozzles, the
number of jet nozzles, the rate of the slurry's movement and the
ligament's movement are kept constant so that pieces of a
pre-defined volume are obtained.
[0021] In one embodiment of the present invention, the apparatus
further comprises a catcher system. The catcher system is
configured to catch the liquid jet and any debris from the ligament
during the cutting process. As one skilled in the art will
appreciate, various catcher systems can be employed in the present
invention. In another embodiment, the liquid jet stream from the
catcher stream can be recycled and preferably any ligament debris
is recycled back into the viscous liquid supply.
[0022] In another embodiment of the present invention, the liquid
jets comprise a kinetic energy which separates and distributes the
pieces of the ligaments in a cross sectional plane. In one
embodiment, multiple liquid jet nozzles are utilized to reduce
rotational speed of the liquid jet nozzles. Preferably, the
ligaments are cut with a rotary head having from about 1 to about
128 individual jet nozzles, more preferably the rotary head
comprises from about 10 to about 128 individual jet nozzles, and
most preferably the rotary head comprises from about 12 to about 16
individual jet nozzles.
[0023] In another embodiment of the present invention, the rotary
head rotates at a speed of from about 500 RPM (revolutions per
minute) to about 6000 RPM, more preferably at a speed of from about
2000 RPM to about 4000 RPM, and most preferably at a speed of from
about 2500 RPM to about 3000 RPM.
[0024] In one embodiment of the present invention, the liquid jet
nozzles preferably rotate on a rotary axis and the formed ligaments
do not rotate. Alternatively, the liquid jet nozzles may remain
stationary and ligaments may rotate on an rotary axis. In yet
another embodiment, both the liquid jet nozzles and the ligaments
rotate on rotary axes. The liquid jet nozzles may rotate in the
same direction as that of the ligaments, or alternatively, the
liquid jet nozzles may rotate in a different direction as that of
the ligaments. Preferably, the nozzles rotate in a circular motion,
alternatively the liquid jet nozzles may rotate in a linear motion.
The circular motion of the liquid jet nozzles may be constant or
reciprocated.
[0025] After cutting the ligaments, the pieces are substantially
cylindrical in shape. However, due to surface tension from the gas
stream and drying, the pieces become quasi-spherical in shape.
While not limiting the invention, it is believed that when the
pieces are dried in the hot gas flow, steam is liberated from the
granule due to the heating of the granule which causes the granule
to expand and promotes the shape transfer from a cylindrical shape
to the quasi-spherical shape.
[0026] The fluid cutting technology of the present invention is
especially applicable to forming granular compositions from
high-viscosity compositions because the concentrated energy of the
cutting stream (kinetic energy in case of the water jet) usually
exceeds the energy required to overcome the viscosity. The water
jet atomization technology efficiently atomizes non-Newtonian
liquids. It is believed that a non-Newtonian liquid's velocity is
reduced as the shear rate increases. Thus, the technology of the
present invention allows cutting very viscous streams as a result
of the high shear rate. Preferably, the shear rate at which the
water jet cuts the liquid is very high (on the order of 10,000
s-.sup.1) typically from about 10,000 s-.sup.1 to about 150,000
s-.sup.1 and the corresponding shear time is low.
[0027] In another embodiment of the present invention, the
apparatus comprises a viscous liquid composition supply, a ligament
forming device in fluid communication with the viscous liquid
composition supply, one or more laser beams adjacent an outlet on
the ligament forming device and a dryer. Preferably, multiple laser
beams are utilized. In another embodiment, the laser beams rotate
around a rotary axis.
[0028] The methods and apparatus of the invention are advantageous
for producing granular compositions of uniform size and shape. In
one embodiment of the present invention, the granular composition
produced by the methods of the present invention has a relative
span factor of less than 1.0, wherein relative span factor is
(D.sub.0.9-D.sub.0.1)/D.sub.0.5 wherein D.sub.0.9 is the maximum
granule size (diameter), D.sub.0.1 is the minimum granule size and
D.sub.0.5 is the average granule size.
[0029] The present invention provides the ability to produce
detergent granules from detergent components having a high
corrosivity (pH>12) due to the cutting tool (water jet or laser
beam) having minimal contact with the detergent components. In
addition, the cutting tool is not greatly influenced by the
conductivity of the detergent components.
[0030] The above-described embodiments of the present invention for
producing a granular composition have comprised the step of drying
the pieces to form the granular composition. As will be appreciated
by one skilled in the art, this step could entail any solidifying
process, for example, freezing, cooling, evaporating, drying or the
like. As such, another embodiment of the present invention includes
a method for producing a granular composition comprising the steps
of: producing a viscous liquid mixture; forming a plurality of
ligaments from the viscous liquid mixture; cutting the ligaments
with one or more liquid jet streams to form pieces; and solidifying
the pieces to form the granular composition.
[0031] Likewise, one skilled in the art will appreciate that the
dryer in the apparatus for producing a granular composition could
entail any solidifying device, i.e. (freezer, dryer or the
like).
[0032] The foregoing description of various embodiments of the
invention has been presented for the purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form disclosed. Many alternatives,
modifications and variations within the scope of the invention will
be apparent to those skilled in the art. Accordingly, this
invention is intended to embrace all alternatives, modifications
and variations that have been discussed herein and others that fall
within the spirit and broad scope of the claims.
* * * * *