Abstract: The invention is directed to polyester processes that utilizes a pipe reactor in the esterification, polycondensation, or both esterification and polycondensation processes. Pipe reactor processes of the present invention have a multitude of advantages over prior art processes including improved heat transfer, volume control, agitation and disengagement functions.

Abstract: A method and apparatus for forming pellets, the apparatus comprising a column for housing column liquid; column liquid; temperature controlling elements engaging the column and capable of maintaining a first and second temperature in the column liquid, and an injection orifice to introduce the liquid pellet composition to the column liquid.

Abstract: A system and method for the continuous fabrication of bichromal spheres by introducing continuous streams of differently colored, pigmented polymer melts to substantially opposite sides of a plurality of spinning disks. The system comprises a first and second extruder which melts a raw polymer material and mixes the melted polymer with a pigment and optionally a charge control agent. The first and second extruders are connected to substantially opposite sides of a plurality of spinning disks with optionally interconnected gear pumps and mixing devices. The instant system and method is useful in fabricating large quantities of bichromal spheres in a continuous manner with a higher degree of uniformity in their physical characteristics.

Abstract: An apparatus and method for manufacturing ultra-fine particles using an electrospray device is disclosed. One or more capillary provided at its tip with a nozzle is positioned within a guide duct and precursors such as metal organic materials and metal halogen compounds, or nonvolatile substances or volatile substances are supplied to the capillary. Voltages are applied to the capillary and the guide duct, respectively, so that a voltage difference is generated therebetween and the highly charged liquid droplets from the capillary are sprayed. The sprayed liquid droplets are carried along the guide duct together with carrier gas injected into the guide duct. When heat energy is applied to the liquid droplets, chemical reactions of the liquid droplets occur. A collecting plate positioned in front of the guide duct collects ultra-fine particles formed by the chemical reactions.

Abstract: The present invention provides a granulation method with increased drying effect while assuring the pressure for spraying the aqueous solution and the necessary number of nozzles equivalent to those of conventional design. Specifically, the granulation method uses a granulator structured by a fluid bed which fluidizes the granulating-particles, an air feed pipe to introduce air, a nozzle for spraying the raw material aqueous solution being located at center part of the air feed pipe, and a perforated plate to feed a fluidization air to the fluid bed, thus granulating the raw material aqueous solution by spraying thereof from the nozzle into a granulation part, wherein a multi-nozzle in a specified shape having a plurality of nozzle ends thereon is used as the nozzle for spraying the raw material aqueous solution.

Abstract: Disclosed is a device for the production of a granulate whereby a perforated rotating outer tube with a supply device for the dripping material arranged on the inside thereof is disposed on a rocker whereby the drive motor for the drum is disposed as a counterweight on the side opposite the pivoting axis of the rocker. The rocker is pressed against a stop for positioning and is provided with a pivoting arm part (6a) which bears the bearing for a side of the rotating drum and which can be pivoted laterally with the bearing for maintenance activities or similar in order to enable easy dismantling of the drum.

Abstract: Disclosed are methods for making ultrafine particles, apparatus for making ultrafine particles, and coating compositions comprising ultrafine particles made by such methods and/or apparatus.

Abstract: The present invention provides methods and devices for producing particles with an average diameter less than about 15 ?m using the precipitation with compressed fluid-antisolvent (PCA) process and the carbon-dioxide assisted nebulization with a bubble dryer (CAN-BD) process. In the methods and nozzles of the invention, at least one jet of supercritical or near-supercritical fluid and at least one jet of solution interact to mix the supercritical or near-supercritical fluid and the solution within a chamber. The solution contains at least one solvent and at least one solute. At least one of the jets is a swirling jet. To form particles, the solvent and supercritical or near-supercritical fluid are then injected into a PCA or a CAN-BD process chamber. The degree of mixing depends in part on the power input into the mixing chamber. Power inputs of about 6.5×109 W/m3 enhance the degree of mixing and allow production of nanoscale particles with the PCA process.

Abstract: The present provides a method for preparing resin fine particles of a homogeneous particle size used in the fields of chemistry, medicine, electronic material or the like, resin fine particles, and a production apparatus for resin fine particles. The present invention provides a method for preparing a resin fine particle, which comprises discharging a liquid comprising a polymerizable monomer as a dispersion phase into a continuous phase; splitting the liquid comprising the polymerizable monomer by applying mechanical vibration to form a liquid droplet; and polymerizing the liquid droplet in a state without splitting or integrating the liquid droplet, said method comprising recognizing a state of said liquid being split into a liquid droplet, and a condition of said discharging and/or said mechanical vibration of the liquid being determined by feedback from a result of the recognition.

Abstract: Nano-scale particles of materials can be produced by vaporizing the material and allowing the material to flow in a non-violently turbulent manner into thermal communication with a cooling fluid, thereby forming small particles of the material that can be in the nano-scale size range.

Abstract: Improved methods for forming fine particles of a material have been developed, wherein the method steps include dissolving the material in a solvent to form a dilute solution, immobilizing the dilution solution, and then removing the solvent to yield particles of the material. Methods of immobilizing the dilute solution include freezing, gelation, and chelation. In a preferred embodiment, the immobilized solvent is removed by lyophilization, i.e. reducing the ambient pressure while avoiding application of sufficient heat to power a phase transition. Essentially any material and solvent for the material can be used in the methods described herein. Proteins and peptides in an aqueous solvent are the preferred systems.

Abstract: A process and an apparatus are proposed to perform the supercritical assisted atomization of nano and/or micro metric powders. It is possible to use liquid solvent at process conditions in which they show a low solubility in carbon dioxide. Atomization is obtained by solubilizing pressurized carbon dioxide (compressed, liquid, supercritical) in a solution formed by the solid to be micronized and the liquid solvent, solubilizing carbon dioxide up to near equilibrium conditions and then atomizing the solution down to near atmospheric conditions through a thin wall injector, to produce very small droplet of micronic and sub-micronic dimensions. The subsequent evaporation of the droplets produces particles with diameters ranging between 0.02 and 10 micron.

Abstract: This invention is directed to an apparatus and method for producing microparticles comprising pharmacologically active agents and biodegradable polymers. The apparatus includes a spinning disk containing a reservoir in the center thereof and a flat inclined surface. The apparatus optionally includes serrations and/or a flat surface beneath the periphery of the disk that is parallel to the rotational axis of the disk. The invention is also directed to a method for producing microparticles containing pharmacologically active agents, using the spinning disk apparatus. Formulations containing ophthalmically active agents are provided. Formulations exhibiting zero order release rates are also described.

Abstract: This invention provides a method of producing chitosan non-woven fabrics and an apparatus thereof. At first, a chitosan acidic solution is extruded to form a chitosan fibrous stream. Then, a solidifying agent is ejected to form a solidifying agent stream. The solidifying agent stream and the chitosan fibrous stream are combined to form a pre-solidified chitosan fiber. Then, high-pressure air is ejected on the pre-solidified chitosan fiber to stretch the pre-solidified chitosan fiber. Finally, the chitosan fibers are collected to form chitosan non-woven fabrics.

Abstract: The invention relates to a method and a device for the production of spherical particles, whereby a molten prepolymer or precondensate is transformed into droplets by means of a drip nozzle, the droplets are subjected to a countercurrent with a gas in a precipitation column until at least partial crystallization is achieved and are then subjected to an additional post-crystallization phase. In order to economically produce higher quality particles at a high flow rate, the molten prepolymer is transformed into droplets by means of a vibrating nozzle plate and/or direct vibration of the molten prepolymer or polymer and resulting droplets are subjected to an air and gas countercurrent.

Abstract: A method and apparatus for producing nanometer-sized particles, the method including the steps of forming of mixture by mixing a first precursor reactant, a second precursor reactant, a surface-stabilizing surfactant, and a high boiling point liquid to form a mixture, forming a mist of droplets of the mixture, heating the droplets to cause a reaction between species of the first and second precursor reactants within the heated droplets, and collecting the nanometer-sized products.

Abstract: Apparatus for the granulation of a predetermined substance provided in fluid, semi-fluid and similar state, comprising a prilling tower.

Abstract: This invention is for an improved process to formulate polymeric microspheres/nanospheres and encapsulate therapeutic proteins and other useful substances. Non-toxic supercritical or near-critical fluids with/without polar cosolvents are utilized to solubilize biodegradable polymers and form uniform polymer microspheres and nanospheres to encapsulate proteins with controlled-release characteristics.

Abstract: Apparatus for producing pellets from hot heavy hydrocarbon or asphaltene, in accordance with the present invention, includes flow means that supplies the hot heavy hydrocarbon or asphaltene through a conduit to its outlet; and pellet producing medium or means that breaks up the liquid stream of the hot asphaltene flowing out of the outlet of the conduit and produces pellets of asphaltene. Furthermore, the apparatus includes a reservoir or container that collects the pellets of heavy hydrocarbon or asphaltene together with some fluid producing a slurry; and transporting means that transports the slurry to the required location. Preferably, the fluid is liquid water. In addition, the pellet producing medium preferably is liquid water.

Abstract: Disclosed is a multistage fluidized SSP reactor that tightens the distribution of residence time and the resulting average intrinsic viscosity of the polymer product. Less residence time is needed to achieve a desired average intrinsic viscosity. As the polymer beads continuously flow through sequential stages, poly-condensation reactions continue to develop almost under plug-flow conditions. Five fluidized stages or more provide advantageous performance.

Abstract: A microencapsulation apparatus is provided which is configured to form co-axial multi-lamellar microcapsules from materials discharged from first and second microsphere dispensers of the apparatus. A method of fabricating and processing microcapsules is also provided which includes forming distinct droplets comprising one or more materials and introducing the droplets directly into a solution bath to form a membrane around the droplets such that a plurality of microcapsules are formed. A microencapsulation system is provided which includes a microcapsule production unit, a fluidized passage for washing and harvesting microcapsules dispensed from the microcapsule production unit and a flow sensor for sizing and counting the microcapsules. In some embodiments, the microencapsulation system may further include a controller configured to simultaneously operate the microcapsule production unit, fluidized passage and flow sensor to process the microcapsules in a continuous manner.

Abstract: There are disclosed polyester processes using a pipe reactor and corresponding apparatuses. In particular, there are disclosed processes and corresponding apparatuses including an esterification pipe reactor with a recirculating reaction zone (RR zone) and a plug reaction profile reaction zone (PRPR zone), especially when operated with a significant part of the overall conversion taking place in the plug reaction profile reaction zone (PRPR zone).

Abstract: Disclosed is a process for reducing the self-adhesiveness of polytrimethylene terephthalate pellets, which can be carried out in a continuous or batch manner comprising the steps of: a) introducing polytrimethylene terephthalate pellets having an intrinsic viscosity of at least about 0.4 dl/g into a conduit containing a liquid which is moving through the conduit, thereby causing the pellets to move through the conduit with the liquid; b) adjusting the temperature of the pellets and the liquid to a temperature of about 50 to about 95° C. for a time sufficient to induce a degree of crystallinity of at least about 35% in the pellets; and c) separating the pellets from the liquid.

Abstract: The invention is directed to polyester processes that utilizes a pipe reactor in the esterification, polycondensation, or both esterification and polycondensation processes. Pipe reactor processes of the present invention have a multitude of advantages over prior art processes including improved heat transfer, volume control, agitation and disengagement functions.

Abstract: Methods and devices are disclosed that use focused acoustic energy to generate solid particles containing at least one compound of interest. Focused acoustic radiation serves to eject droplets containing a compound of interest dissolved in a solvent. The droplets are subjected to a condition that allows for the compound of interest to precipitate out of solution, thereby generating solid particles. The particles are typically of controlled size, composition, and/or structure. Often, particles of substantially identical size are generated.

Abstract: An apparatus for the production of a toner from a starting material having a fluidity includes a head portion and a solidifying portion. The head portion for ejecting the starting material includes a starting material storing portion, which stores the starting material, a piezoelectric material, which generates a pressure pulse for applying the pressure pulse to the starting material and an ejection portion, which ejects the starting material with the pressure pulse. The solidifying portion solidifies the starting material ejected from the head portion into a particulate material.

Abstract: A process for producing inorganic spheres, which comprises injecting an aqueous liquid containing an inorganic compound into a laminar flow of an organic liquid which runs at a flow rate of from 0.001 to 2 m/s in a flow path through a porous membrane to form a W/O type emulsion and solidifying the aqueous liquid containing an inorganic compound in the W/O type emulsion.

Abstract: A process for producing inorganic spheres, which comprises injecting an aqueous liquid containing an inorganic compound into a laminar flow of an organic liquid which runs at a flow rate of from 0.001 to 2 m/s in a flow path compartmentalized by a partition wall through a plurality of inlet holes formed in one partition wall to form a W/O type emulsion containing the organic liquid as a dispersion medium and the aqueous liquid containing the inorganic compound as a dispersed phase, and solidifying the aqueous liquid containing an inorganic compound in the W/O type emulsion, wherein the partition wall having a plurality of inlet holes is made of a metal sheet having a surface subjected to water repellent treatment.

Abstract: A method for obtaining urea prills in a prilling tower (1) comprising the step of making a plurality of melt urea droplets to fall from a urea melt distributing device (4) towards an urea prills collecting bottom (6) of the prilling tower, further comprises the step of cooling the collecting bottom (6).

Abstract: With the help of a method for granulating concentrated solutions. particularly for fertilizer production. granulates of reproduceable grain size with a high degree of effectiveness of the trough mixer used. is supposed to be created.

Abstract: A method and apparatus are invented for producing fine particles, which can readily realize the formation of fine particles of sub-m order to 100 micron order as well as fine particles of several micrometer which cannot be realized by a conventional method and apparatus available for producing fine particles, and a large quantity of fine particles having the desired particle diameter can be obtained with a high yield. A molten material (1), which is a molten raw material to be fragmented into fine particles, is supplied into a liquid coolant (4), boiling due to spontaneous-bubble nucleation is generated, and the molten material (1) is cooled and solidified while forming fine particles thereof by utilizing a pressure wave generated by this boiling.

Abstract: Disclosed is an air permeable film united with a nonwoven fabric, consisting of a polymer film having an inorganic material extruded to have a basic weight of 35 g/m2 or less and united to a partial or whole surface of a nonwoven fabric. The nonwoven fabric having a basic weight of 50 g/m2 or less is united to one surface of the extruded polymer film in a melted state, with an air permeable region centering around a drawn mark distributed to the whole surface of a nonwoven fabric-united film rolled and drawn by a press roll. A method of preparing such an air permeable film united with a nonwoven fabric and a device for preparing the same are also described.

Abstract: An atomizing apparatus for the production of powders or spray deposits, having an atomization device for receiving a liquid stream of molten metal or metal alloy to be atomized; at least two primary atomization gas jets for directing an atomization gas at an angle into the liquid stream in an atomization zone at an impinging point of the atomization jets to break the stream into atomized droplets; and at least two secondary jets for direction a controlling fluid at a pressure, flow rate and direction, the jets being aimed at the atomization gas jet or into the atomization zone, wherein said secondary jets control a backpressure generated by the primary atomization gas jets. The apparatus also includes means for in-situ controlling at least one of the relative positions among the primary atomization jets, the secondary jets, and the liquid delivery nozzle.

Abstract: A method of manufacturing metal spheres to prevent irregularities on the surface of the metal spheres. The method reduces the manufacturing time and makes it easy to manufacture extremely small diameter metal spheres.

Abstract: An apparatus for manufacturing a polymer fiber shell from liquefied polymer is provided. The apparatus includes: (a) a precipitation electrode being for generating the polymer fiber shell thereupon; (b) a dispenser, being at a first potential relative to the precipitation electrode so as to generate an electric field between the precipitation electrode and the dispenser, the dispenser being for: (i) charging the liquefied polymer thereby providing a charged liquefied polymer; and (ii) dispensing the charged liquefied polymer in a direction of the precipitation electrode; and (c) a subsidiary electrode being at a second potential relative to the precipitation electrode, the subsidiary electrode being for modifying the electric field between the precipitation electrode and the dispenser.

Abstract: The present invention provides a method for producing a toner, which produces a toner by using a dispersion comprising a dispersion medium having finely dispersed therein a dispersoid containing a raw material for the production of a toner, the method comprising intermittently ejecting the dispersion from a head unit by applying an ejection energy, and solidifying it into a particulate form while transporting the ejected dispersion through a solidification unit by an air flow. The ejection energy may be applied in the form of pressure pulse, or may be applied by the volume change of a bubble. Also disclosed are a toner obtained by the method, and an apparatus for performing the method.

Abstract: A device for exchanging a die plate of a molten bisphenol A prilling tower is described. The device comprises: (a) at least two die plates; (b) a guide which is in contact with the die plates; and (c) a drive mechanism, wherein the drive mechanism moves the die plates linearly and serially between an operating position and an exchange position along the guide. Also described is a process of automated operation of the device at the top of a bisphenol A prilling tower.

Abstract: An apparatus and a method for manufacturing granules includes a spray nozzle disposed within a granulating chamber of an apparatus body. The spray nozzle feeds by spraying into the granulating chamber a liquid material comprising at least one of mixture having solid and liquid in a mixed state and solution including solid dissolved therein. An air blowoff portion is provided at a lower region of the granulating chamber for feeding air for floating and fluidizing the liquid material and fine particles under granulation inside the granulating chamber. An air exhaust port is provided at an upper region of the granulating chamber for exhausting the air present inside the granulating chamber. The spray nozzle is designed to spray the liquid material upwardly.

Abstract: The current invention, Supercritical Antisolvent Precipitation with Enhanced Mass Transfer (SAS-EM) provides a significantly improved method for the production of nano and micro-particles with a narrow size distribution. The processes of the invention utilize the properties of supercritical fluids and also the principles of virbrational atomization to provide an efficient technique for the effective nanonization or micronization of particles. Like the SAS technique, SAS-EM, also uses a supercritical fluid as the antisolvent, but in the present invention the dispersion jet is deflected by a vibrating surface that atomizes the jet into fine droplets. The vibrating surface also generates a vibrational flow field within the supercritical phase that enhances mass transfer through increased mixing. Sizes of the particles obtained by this technique are easily controlled by changing the vibration intensity of the deflecting surface, which in turn is controlled by adjusting the power input to the vibration source.

Abstract: A method for producing bisphenol A in prill form is disclosed. Molten bisphenol is top-fed into a prilling tower via a plate containing a plurality of nozzles. A gas coolant guided through a circuit is led into said tower in a counter flow direction. The prills are cooled to about room temperature, collected at the bottom of the tower and removed. Also disclosed is the device for carrying out the inventive method and the prills thus produced.

Abstract: Spherical balls, notably microballs of welding alloys, are produced by passing a melted material through vibrating orifices of a granulation pot, in order to form droplets which solidify when falling, by gravity, into a cooling tower filled with an inert gas. To improve the surface condition of the balls, the inert gas comprises approximately 15 to 150 ppm of oxygen. Moreover, the melted material is subject to ultrasound stirring just before being fed into the granulation pot. The balls are, preferably, dampened at the outlet of the cooling tower by brushes composed of polyamide wires. Besides, the control of the vibration frequency of the vibrating orifices in relation to the percentage of balls meeting the standards enables to improve the output.

Abstract: An apparatus and methods for electrospinning composite fibers comprising polymeric material and mesoporous molecular sieve material are described. The methods include in one aspect electrospinning fibers from a conducting solution to which a high voltage electric current is applied. The apparatus includes in one aspect one or more conducting solution introduction devices for providing a quantity of conducting solution, said conducting solution introduction devices being electrically charged thereby establishing an electric field between said conducting solution introduction devices and a target, and means for controlling the flow characteristics of conducting solution from said one or more conducting solution introduction devices.

Abstract: A method and device for generating solid particles using focused acoustic energy are provided. A solution of a compound of interest is provided in a solvent, which may be an aqueous fluid, a nonaqueous fluid, or a supercritical fluid. Focused acoustic energy is used to eject a droplet of the solution, which is then directed into or through an antisolvent that upon admixture with the solution droplet causes the compound in the droplet to precipitate. In a preferred embodiment, the solvent is an aqueous or organic liquid, and the antisolvent is a supercritical fluid.

Abstract: A device for producing a porous fiber structure. One or more points of high surface curvature is produced in a liquefied polymer, such as a polymer solution or a polymer melt. The points of high surface curvature may be produced by forcing the liquefied polymer through narrow nozzles, or by wetting sharp protrusions with the liquefied polymer. The liquefied polymer is charged to a high negative electrical potential relative to a grounded moving belt. Thin jets of liquefied polymer emerge from the points of high surface curvature to impinge as fibers on the moving belt, thereby forming a nonwoven fiber structure of relatively uniform porosity. A powdered aerosol is charged to a high positive electrical potential relative to the moving belt. As the belt moves past the aerosol, the aerosol particles are attracted to fill interstices in the fiber structure, thereby creating a composite filtering material.

Abstract: A method and device for generating pharmaceutical agent particles using focused acoustic energy are provided. A solution of the pharmaceutical agent is provided in a solvent, which may be an aqueous fluid, a nonaqueous fluid, or a supercritical fluid. Focused acoustic energy is used to eject a droplet of the solution, which is then directed into or through an antisolvent that upon admixture with the solution droplet causes the pharmaceutical agent in the droplet to precipitate. In a preferred embodiment, the solvent is an aqueous or organic liquid, and the antisolvent is a supercritical fluid.

Abstract: Systems and apparatus combinations for producing a coating powder are provided wherein a stream of a powder coating precursor including at least one resin and at least one additional powder coating ingredient is contacted with a process fluid effective to reduce the viscosity of the powder coating precursor to allow processing of the powder coating precursor at a lower temperature.

Abstract: A method and an apparatus are provided for efficiently manufacturing microspheres having a uniform particle diameter. The apparatus comprises: case 1 having a lower body 1a and an upper body 1b. A seal ring 3, a first plate 4 which is comprised of a transparent plate such as a glass plate or a plastic plate, an annular spacer 5, an intermediate plate 6 which is comprised of a silicon substrate or the like, an annular spacer 7, a second plate 8 and a seal ring 9 are inserted in this order into a concave portion 2 formed in the lower body 1a. The upper body 1b is superposed thereon. Further, the upper body 1b is attached to the lower body 1a with bolts or the like.

Abstract: In a pastillation machine, an improved distribution system is provided. The distribution system comprises: a distribution bar having a bore extending therethrough, a series of holes located on an inlet surface of the bar, a series of slots located on an outlet surface of the bar, and a diffuser located in the bore of the bar, the diffuser being spaced between the inlet surface and the outlet surface. The series of holes of the distribution system aligns with flowable substance outlets of the pastillation machine. The pastillation machine can be used to form various hot liquid mixtures, including elemental sulphur and sulphur based fertilizers containing swelling clay matrix, and macronutrients (N, P, K) and micronutrients (Fe, Cu, Zn, Mn etc.).

Abstract: An apparatus for forming metal spheres includes a droplet generator, a buffering chamber, and a cooling drum. The droplet generator generates a droplet from a molten metal mass. The buffering chamber receives the droplet from the droplet generator, and diminishes internal kinetic energy of the droplet without solidifying the droplet. The cooling drum receives the droplet from the buffering chamber, and cools the droplet to the extent that the droplet solidifies into a metal sphere. The apparatus can further include a collector arrangement that receives the metal spheres from the cooling drum and makes the metal spheres available for collection.

Abstract: A crucible is formed of a cylindrical body member and a disk-shaped nozzle member fitted to the bottom portion of the body member, and the nozzle member is provided with a nozzle hole for discharging out a semiconductor molten solution dropwise therethrough. The semiconductor molten solution drops discharged out of the crucible through the nozzle hole are cooled and solidified during falling to become semiconductor grains. Silicon grains having high crystal quality can be manufactured at low cost.