ACOUSTIC MIXERS

Abstract

A processing vessel (1) provided with a material inlet (2, 3, 4, 5) and a processed material outlet (25) wherein the material flows continuously through the vessel which is split into a series of zones (6, 7, 8) through which the material passes wherein the zones are shielded from each other by controlling the rate at which the material flows and an increasing level of vacuum is applied inconsecutive zones and the system is provided with acoustic energy which imparts energy to the process material by virtue of the contact between the zone dividers and the process material and processing material in such a vessel.

Claims

1. A continuous processing system comprising a processing vessel provided with a material inlet and a processed material outlet wherein the material flows through the vessel and the vessel comprises a series of dividers which split the process vessel into a series of zones through which the material passes wherein during operation the zones are shielded from each other by controlling the rate at which the material can flow passed the dividers and an increasing level of vacuum is applied in consecutive zones and wherein the system is provided with acoustic energy which imparts energy to the process material by virtue of the contact between the dividers and the process material.

2. A system according to claim 1 in which the process material is introduced at the top of the process vessel and passes downwards through the process vessel under gravity through the series of zones and is taken off towards the bottom of the process vessel through the process material outlet.

3. A system according to claim 1 in which the dividers are provided with holes for passage of the process material.

4. A system according to claim 3 in which the flow of the process material down the process vessel is controlled by the dividers such that it flows through the holes provided in the dividers whilst at the same time sufficient process material lies in the holes in the dividers as it passes through them to ensure that there is a shield between the zones of the process vessel.

5. A system according to claim 1 in which the dividers are shaped (either fixed or variable) so that the flow of the process material is such that a pool of process material is formed over the holes in the dividers allowing process material to flow through the holes whilst maintaining a pool of the flowing material over the holes.

6. A system according to claim 1 in which the dividers extend across the entire width of the process vessel and are conical with a downwardly extending skirt which extends to the interior wall of the process vessel and optionally the holes for flow of material through the dividers are provided within the skirt.

7. (canceled)

8. A system according to claim 6 provided with guide plates in one or more of the zones of the process vessel which direct the process material onto the conical surface of the dividers.

9. (canceled)

10. A system according to claim 1 in which the dividers and/or any plates that are present in the zones are hollow or contain channels to allow for a heating or cooling fluid to pass through the dividers and/or plates.

11. (canceled)

12. A system according to claim 1 comprising three zones in the process vessel the first zone being the zone in which the process material is introduced and which is at atmospheric pressure, the second zone beyond a first divider having an applied vacuum so that the pressure in the zone is no more than 50% of atmospheric and the third zone beyond a second divider has an applied vacuum which is greater than the vacuum applied in the second zone and the pressure in the second zone is no more than 25% of atmospheric pressure and the material is taken off from the vessel under an increased vacuum.

13. (canceled)

14. A system according to claim 1 in which an acoustic agitator is connected to the process vessel.

15. (canceled)

16. (canceled)

17. A system according to claim 1 including a spray nozzle to introduce the process materials into the process vessel.

18. (canceled)

19. (canceled)

20. A process for processing materials wherein materials are fed to and pass through a process vessel divided into a series of zones by dividers wherein the zones are shielded from each other during the process and progressively increasing vacuum is applied to consecutive zones in the process vessel and acoustic energy is applied to the process vessel wherein the dividers are provided with holes to allow passage of the materials and the holes are covered with process material during the processing to provide the shield.

21. A process according to claim 20 in which the process vessel is vertical and the processing materials flow through the vessel under gravity and vacuum.

22. A process according to claim 20 comprising injecting the at least one process ingredient from multiple spray nozzles and/or a plurality of ports coupled to the process vessel.

23. (canceled)

24. A process according to claim 20 wherein at least one zone includes at least one plate which directs the process material onto the dividers.

25. A process according to claim 20 in which the temperature of the process material is controlled by controlling the temperature of the dividers and/or any plates that may be employed.

26. A process according to claim 20 which the acoustic energy is supplied in the range of between 30 Hz to 1 kHz.

27. (canceled)

28. (canceled)

29. A process according to claim 20 comprising the preparation of polymer formulations such as polymer composites, adhesives, coatings and energetic materials.

30. A process according to claim 20 comprising the production of energetic materials or composite propellants by dispersion of an active material such as an oxidiser within a polymeric binder optionally in the presence of a plasticiser or resin.

31. A process according to claim 20 in which the quality of the processed material is monitored by quality control means.

Description

[0027] In a further embodiment of the invention quality control measures can be provided in the final zone of the vessel or at the outlet which can divert material away from product collection if any quality requirements are not met. For example, ultrasonic analysis or spectroscopy such as near infrared analysis of the product can be provided to detect any defects in the product and trigger the diversion of the material away from quality product collection.

[0028] The invention is illustrated by reference to the accompanying FIG. 1 which shows a vertical process vessel (1) provided with inlets for process materials (2), (3), (4) and (5). The process vessel is divided into three zones (6), (7) and (8) by cone shaped dividers (9) and (10) each of which are provided with a downwardly extending skirt (11), (12), (13) and (14). Plates (15) and (16) are provided in zone (6) to direct the process material onto divider (9) and plates (17) and (18) and provided in zone (7) to direct the material that passes through divider (9) onto the divider (10). The divider (9) is provided with holes (19) and (20) formed in skirt (11), (12) to allow passage of process material and divider (10) is provided with holes (21) and (22) formed in skirt (13) and (14) to allow passage of the process material.

[0029] Vacuum is applied to zone (17) by means of the exhaust (23) and a greater vacuum is applied to zone (8) by means of exhaust (24). The processed material exists the vessel (1) through the outlet (25).

[0030] An acoustic agitator (not shown) can be attached to the top or base of the process vessel (26). The arrows in the Figures illustrate schematically the passage of the process material through the process vessel. Although not illustrated the passage is controlled so that although there is continuous flow of process material there is sufficient process material over holes (19), (20), (21) and (22) to maintain a shield between zones (6) and (7) and between zones (7) and (8) so that the differential in the applied vacuum between the zones is maintained.

[0031] FIG. 2 shows how the shield is accomplished in relation to divider (9) between zones (6) and (7) by the process material (27) being over the holes (19) and (20).