Field of technology

Invention concerns a construction of the multifunctional granulator with the use for the needs of granulation of any powder materials. Invention falls to the field of technology of machining and field of production equipment for the pharmaceutical industry, food industry, chemical industry, and so on.

Prior state of the art Powder materials are multi-component systems composed of particles which touch each other. These systems are composed of particles of the solid phase, liquid phase and gas phase. From the physical point of view they can be understood as disperse systems, produced by particles of varying sizes, dispersed in the continuous environment of the other phase. The particles of solid matter are in mutual contacts, whereby these contacts limit the possibility of movement of individual particles, and this affects the solidity, strength and rigidity of the particular substance understood as a whole. Granulation is an agglomeration process of the powder mixture, where the strengthening of at least one bonding mechanism between the substance-forming particles takes place to such degree that a smaller amount of larger and more solid particles is created from these particles. New products are achieved thanks to the granulation - briquettes, tablets, granules, and other -; the geometrical and physical features of these products are significantly different to the features of the original powder material. The most common methods of granulation are granulation by means of granulator, extruder, compactor, briquetting press, and so on. On the basis of this various mechanisms the force bonds arise in the mutual contact of the phases in the particular substance. These force bonds affect all mechanical features of the particular substance. The solid bridges arise in the contacts of the particles by producing the bridge from the solid phase, by diffusion of atoms and molecules. The liquid bridges are formed if there is larger amount of liquid in particular substance. In cases of petal-shaped, leaf-shaped or fiber-shaped particles, or in cases of particles with a lot of surface irregularities, which can connect these particles by appropriate relative movement and pressing in such a way that they mutually intertwine or lock in the irregularities of the surface. Such connection of particles is called shape bonds. Friction bonds produce direct stress and resistance of the particles against movement due to the existence of the friction in the places of contact of the particles. Due to the existence and interaction of force fields in the vicinity of the particles, the force bonds can arise even in cases where there is no bridge of any substance produced. Force fields can be invoked by the particles themselves. Granulation by means of a granulator is a process which is indispensable in pharmaceutical industry, low-tonnage chemistry, food industry, but also in other industries, too. Granulator produces, for example, drugs, fertilizers, sweets, animal food, and many others. Active pharmaceutical substances during the production of drugs - e.g. penicillin, ibuprofen or paracetamol - have unfit characteristics in the powder form, and therefore they have to be granulated. Granulation improves the flow features of the powder substances; exact dosage, homogenisability, and compressibility of the granulate is increased; dustiness is lowered, the risk of fire and explosion is decreased, and gradual and regulated release of the medicine is achieved.

The process of granulation is divided to dry and wet granulation. In case of dry granulation the liquid is not led to the device and the granules are produced by the operation of friction and shape bonds. Wet granulation requires the intake of the liquids and binders which ensure the production of binding mechanisms. The most common methods of granulation by means of granulation in the state of the art are tumbling granulation (or disc granulation, or plate granulation), fluid bed granulation and high shear granulation. The individual methods differ in a way of production of the final product, but also in the construction of the granulation device.

Tumbling granulation in the rotating disc is a process where the particles start to connect into larger units by effect of the rolling (tumbling) movement of the powder material, usually during the addition of the liquid. The basic binding mechanisms of the production of granules are liquid bridges. In order to produce liquid bridges a sloped rotating disc is used. The size of the granules depends on the ratio of dry powder material and liquid. The higher the amount of sprayed liquid is, the larger the produced granules are. Granulation discs are relatively simple devices. Whole process takes place on the sloped plate. Grainy material can be transferred to it by the feeder above the plate. Liquid can be sprayed to the plate from the jets. Resulting polydispersive agglomerate falls out through the discharge hopper. The plate is placed on the frame which allows tilting. In the process of fluid bed granulation the powder material is during the course of granulation in the fluid bed produced by the intaken air, thanks to which the particles are in constant stochastic movement. After the stabilization of the fluid bed the liquid is led in together with binder and creation and growth of granulate occurs. The governing binding mechanisms are liquid bridges. The air is led to the device by air distributor, for example in form of a perforated plate. Powder material is poured into the granulation process. Liquid with binder is sprayed in by means of jets.

High shear granulation is the most commonly used method of granulation in pharmaceutical industry. High shear granulation allows the mixing of various powder materials and their subsequent granulation. The growth of the granules is ensured by addition of the liquid with the binder and by the stochastic movement of the powder in the device. Granules where there is a demand for uniform size of the resulting product are produced by this method. A powder material is poured into the granulator, whereby an impeller ensures its movement. Liquid is added to the device by means of jets together with the binder, and disruptive mixer ensures the uniform size of the resulting product. The stochastic movement of the particles and their mutual movement cause high shear stress. In previous descriptions the basic principles of granulation using rotational movement of the devices for the production of granulates are described. All these devices are, however, designed for realization of a single granulation method only.

Publications US4967688A, DE19748504A1 , EP0228633A1 , JP2002253943A disclose typical granulators with fixed, vertical axis of the rotation of the impeller. Publication CN202169158U discloses a construction of the granulator (mainly high shear granulator) with fixed vertical axis of the rotation of the impeller, whereby the granulator includes a disruptive mixer with the horizontal axis of the rotation, too. The placement of these propulsions on the frame is solid and cannot be adjusted, which makes the device a single-purpose device without possibility to change the process.

Publication RU2170137 (C1 ) discloses an adjustable axis of the drum of the tumbling granulator, but it still remains a single-purpose device. During the production of the drugs with slow decay the granules are first produced by high shear granulation and then they are coated in the fluid bed granulation or on the granulation disc. Such produced granules are then transferred to the drying device. This increases the costs of the devices and transfer of the raw material between multiple devices. Some powder materials cannot be well processed in the granulation disc, but can be well granulated in the fluid bed granulator.

In order to make the production of, for example, drugs, more effective, an option appeared to solve this problem by technical means which are capable of ensuring the demand for effectiveness.

The result of these efforts is the further disclosed construction of the multifunction granulator according to this invention.

Essence of the invention The abovementioned deficiencies are significantly remedied by the construction of the multifunctional granulator according to this invention. The essence of the construction of the multifunctional granulator lies in the fact that it involves a static skeleton framework (or carrying construction) in which there is a rotationally placed tiltable frame with the angular guiding, and multiple functional elements within the tiltable frame are adjusted for the replacement or removal, which allows to produce various mutual arrangement of the functional elements of the granulator.

Static skeleton framework ensures the stability of the whole device; it serves as a stand, where the functional parts of the device are fixedly mounted on the tiltable frame, tiltably attached in the static skeleton framework. The mutual slope of the tiltable frame against the static skeleton framework can be adjusted and locked by means of an angular guiding. The position of the tiltable frame against the static skeleton framework is parallel in the modification of high shear granulator or fluid bed granulator with the rolling of the particles in the centrifugal field (centrifugal tumbling, where particles do not fly in the whole space, but only above the plate). In the modification with tumbling granulator (or disc granulator, or plate granulator) the tiltable frame is sloped with regard to the static skeleton framework. These three basic arrangements of the granulator are contained within a single device according to this invention, which brings about the advantage of the universal and flexible deployment in the industry, during the development and tests, during the production of smaller amount of granulates, and so on.

Usually, the technical realization will include two independent propulsions placed on the tiltable frame. The first propulsion serves for the rotation of the impeller or rotation disc or granulation plate. The output of this propulsion is adjusted for the attachment of the functional element of choice, that is, drive or rotation disc or granulation plate. The replacement of this functional element achieves the desired arrangement for the high shear granulator or fluid bed granulator or tumbling granulator. In case of adjustment for the high shear generator the disruptive mixer - whose operation is ensured by means of the second propulsion - is led in from the side. The first shaft and the second shaft will be usually placed in the mutually perpendicular position, without the tiltable frame sloped; the first shaft will be vertical and the latter will be horizontal. In case of an adjustment for the fluid bed granulator, the tiltable frame is tilted into the desired position of the axis of the first propulsion. The angle of sloping of the tiltable frame against static skeleton framework ranges from 0° to 90°.

In the tiltable frame there is a first bearing housing deposited with the first shaft, which is connected on one end - for example through the first claw clutch -to the first electric engine with the first frequency alternator with the continuous regulation of the rotation speed. The second end of the first shaft leads either to the closed working chamber in the modification for the high shear granulator - whereby the multi-point star-shaped, for example, three-pointed star-shaped impeller is connected to it replaceably and it is placed at the bottom of the working chamber, or in the modification of the fluid bed granulator the rotation disc is replaceably connected to it; or the second end of the first shaft leads to the working space in the modification of the tumbling granulator and the granulation plate is replaceably connected to it. The outlets of two nozzles of the agglomeration liquid - which ensure the spraying of the liquid binder - are directed to the working chamber or the working space. The liquid with the binder is dosed by means of a dosing diaphragm pump from the container of the agglomeration liquid. The flow of the liquid is adjusted directly on the control panel of the pump.

Second bearing housing is also mounted on the tiltable frame, which is connected on the one end - for example through the second claw clutch - to the second electric engine with the second frequency alternator with the continuous, gradual regulation of the rotation speed, whereby only in the modification with high shear granulator does the second shaft lead to the closed working chamber and disruptive mixer is attached to it, which crushes the larger particle clusters so that the resulting product has always identical dimensions. The disruptive mixer is removable and it is demounted in the modification for fluid bed granulator. The disruptive mixer is also demounted for the modification for tumbling granulator; the second end of the second shaft in such case leads directly outside the working space.

A closable air supply or inert gas supply leading to the closed working chamber is also mounted on the tiltable frame in the modification of the fluid bed granulator, where they lead out under the rotation disc, which is placed above the bottom of the working chamber. The air needed for aeration of the set is led by means of a compressor; the amount of the air is controlled by flowmeter and regulated by regulation valve. The entrance of the air to the set is ensured by means of the air distributors and the used air flows out cleaned through the filter. A warm-air furnace can be connected to the system of the air supply, by which the final product will be dried. The supply of air or inert gas leading to the closed working chamber in the modification of high shear granulator is closed. In the modification of tumbling granulator the air or inert gas supply leads outside the working space and it is closed. The working chamber is closed by the lid and the filter of the solid particles is attached in it.

The advantages of the construction of the multifunction granulator according to this invention are obvious from its outwardly manifested effects. In general we can say that the device - multifunctional granulator according to this invention - allows realizing tumbling granulation, fluid bed granulation with the rotation disc and high shear granulation in a single complex device, which eliminates the need for three independent apparatuses. Another advantage is the possibility of drying of the realized granules directly in the device. This sophisticated device allows for processing of any powder materials into the form of the granules with exactly defined dimensions. The granulator according to this invention allows for flexible deployment at low investment costs and it occupies small space on the floor.

Brief description of drawings

Construction of the multifunction granulator according to this invention is further disclosed on the drawings, where fig. 1 depicts a construction solution of the multifunctional granulator in the modification of a high shear granulator. Fig. 2 is a detail view of the working chamber with the impeller. Fig. 3 depicts the construction solution of the multifunction granulator in the modification of fluid bed granulator. Fig. 4 is a detail view of a working chamber with the rotation disc. Fig. 5 is a construction solution of the multifunctional granulator in the modification of tumbling granulator. Fig. 6 depicts a detailed view of the working space with the granulation plate.

Examples of realization

It is understood that the individual realizations of the invention are for illustration purposes only and cannot be understood as limitations of technical solutions. A person skilled in the art will be able to find many equivalents by means of no more than routine experimentation. Such equivalents fall within the scope of the following patent claims, too.

It will be no problem for a person skilled in the art to design optimal construction and choice of the elements; therefore these features are not tackled in detail.

Example 1

In this example of realization the construction of the multifunctional granulator in modification of high shear granulator is disclosed, as depicted on fig. 1 and 2. It consists of the skeleton framework 1 where the tiltable frame 2 with angular guiding 3 is rotationally placed. In this device the position of the tiltable frame 2 against static skeleton framework 1 is parallel. In the tiltable flame the first bearing housing 8 is deposited with the first shaft 7 which is on one end connected to the first electric engine 4 with the first frequency alternator 5 through the claw clutch 6. The second end of the shaft 7 leads to the closed working chamber 12, where a impeller 9 is remove ably attached to it, whereby the impeller 9 has a shape of a three-pointed star and it is placed on the bottom of the working chamber 12. The outlets of the nozzles 2J. of the agglomeration liquid are led to the closed working chamber 12, whereby the liquid is dosed by means of a diaphragm pump 23 from the container 22 of the agglomeration liquid. A second bearing housing 15 with the second shaft 14 is also placed in the tiltable frame 2; the second shaft 14 is connected on the one end to the second electric engine 17 with the second frequency alternator 8 through the claw clutch 16. The second end of the shaft 14 leads to the closed working chamber 12 and the disruptive mixer 13 is connected to it. The closable air or inert gas supply 24 leading to the closed working chamber 12 is also on the tiltable frame 2; in this case it is closed. The working chamber 12 is closed by a lid 9 and the solid particles filter 20 is mounted in it.

Example 2

In this example of the particular realization of the invention a construction of the multifunctional granulator in the modification of fluid bed granulator as depicted on the fig. 3 and 4 is described. It consists of the skeleton framework 1 where the tiltable frame 2 with angular guiding 3 is rotationally placed. In this device the position of the tiltable frame 2 against static skeleton framework 1 is parallel. In the tiltable flame the first bearing housing 8 is deposited with the first shaft 7 which is on one end connected to the first electric engine 4 with the first frequency alternator 5 through the claw clutch 6. The second end of the shaft 7 leads to the closed working chamber 12, where a rotation disc 1Q is removed ably attached to it. The outlets of the nozzles 2J_ of the agglomeration liquid are led to the closed working chamber 12, whereby the liquid is dosed by means of a diaphragm pump 23 from the container 22 of the agglomeration liquid. A second bearing housing 15 with the second shaft 14 is also placed in the tiltable frame 2; the second shaft 14 is connected on the one end to the second electric engine 17 with the second frequency alternator 18 through the claw clutch 16. The second end of the shaft 14 leads to the closed working chamber 12 and nothing is connected to it. The closable air or inert gas supply 24 leading below the rotation disc 10 placed above the bottom of the working chamber 12 is also on the tiltable frame 2. The working chamber 12 is closed by a lid 19 and the solid particles filter 20 is mounted in it.

Example 3

In this example of the realization a construction of the multifunctional granulator in the modification of tumbling granulator is described, as depicted on fig. 5 and 6. It consists of the skeleton framework 1 where the tiltable frame 2 with angular guiding 3 is rotationally placed. In this device the position of the tiltable frame 2 against static skeleton framework 1 is sloped. In the tiltable frame the first bearing housing 8 is deposited with the first shaft 7 which is on one end connected to the first electric engine 4 with the first frequency alternator 5 through the claw clutch 6. The second end of the first shaft 7 leads to the working space 25 and the granulation plate is removable attached H to it. The outlets of the nozzles 2J_ of the agglomeration liquid are led to the closed working space 25, whereby the liquid is dosed by means of a diaphragm pump 23 from the container 22 of the agglomeration liquid. A second bearing housing 5 with the second shaft 14 is also placed in the tiltable frame 2; the second shaft 14 is connected on the one end to the second electric engine 17 with the second frequency alternator 18 through the claw clutch 16. The second end of the shaft 14 leads outside the working space 25 and nothing is connected to it. The closable air or inert gas supply 24 leading outside the working space 25 is also on the tiltable frame 2 and it is closed.

Industrial applicability

The industrial applicability is obvious. The presented construction of the multifunctional granulator according to this invention can be used mainly in field of pharmaceutical, food or chemical industry, but also in technologies of processing of the recycled materials and plastics.