Patent Application
20140110884
The present invention relates to a method for preventing adhesion of processed material using forced thin film fluid treatment apparatus.
Fine particles are wanted in the entire industrial fields, wherein it is necessary to selectively produce fine particles whose size is from a micrometer to a nanometer in accordance with the intended use thereof. Especially, nanoparticles (fine particles with the size of nanometers), the fine particles whose diameter is less than 1 μm, express new characteristics that are different from those of particles; and therefore, a new industrial method for producing nanoparticles is wanted to be developed. In fine particles with the size of micrometers too, there have been problems of reproducibility and energy cost in conventional methods; and thus, demand on the method for producing fine particles with which particle diameter thereof can be easily controlled from micrometers to nanometers is growing. Simultaneously with this, demand on the throughput in production of fine particles is growing; and thus, similarly to control of the particle diameter, a method for producing fine particles with a high throughput is wanted.
In order to solve subjects and problems of the conventional technology, called as “a microchemical process technology”, the present applicant provided a method for producing nanoparticles (Patent Document 2) by using stirring and instantaneous/uniform mixing of a plurality of fluids in a narrow flow path based on the microchemical process with a totally new concept, more precisely, based on the principle of the apparatus shown in Patent Document 1 filed by the present applicant. This apparatus makes use of the principle of a mechanical seal, wherein a forced thin film fluid of a fluid to be processed is formed between processing surfaces which relatively moves so as to be able to approach to and separate from each other, and the said fluid to be processed is charged into between the rotating processing surfaces, whereby realizing to make the distance between the processing surfaces a minute space by a pressure balance between the supply pressure of the fluid and the pressure applied between the rotating processing surfaces. In the methods before the method based on the above-mentioned principle, the distance between these processing surfaces was controlled by a mechanical means and the like; but in these methods, a heat generated by rotation, a deformation or a misalignment of an axis caused by it, and others could not be absorbed; and thus, to realize the minute distance between the processing surfaces, at least 10 μm or less for this distance, had been substantially impossible. That is, by using the principle of the apparatus in Patent Document 1, production of nanoparticles became possible by instantaneous chemical reaction, physicochemical reaction, or the like in the minute flow path; and inventors of the present application further carried out an extensive investigation, and as result, surprisingly, instantaneous stirring, mixing, reaction, and separation could be realized in a minute flow path of 0.1 to 10 μm, without saying 1 mm or less.
The method for producing fine particles proposed in Patent Document 2 is an extremely effective method for producing fine particles because fine particles can be produced with a low cost and a low energy: however, depending on process conditions, there is a case that the produced fine particles adhere onto processing surfaces which constitute the flow path of a thin film fluid, whereby causing a case that fine particles cannot be produced stably. This problem might be solved by preventing fine particles from adhering onto the processing surfaces, but until now there has been no description as to the method for preventing this adhesion. Accordingly, upon conducting this production method, a method for preventing the adhesion has been eagerly wanted.
In view of the situation mentioned above, the problem to be solved by the present invention is to provide a method for preventing a processed material from adhering onto processing surfaces which constitute a fluid flow path.
The present invention provides a method for preventing adhesion of a processed material, wherein in a method for processing a fluid to obtain a processed raw material, at least two kinds of fluids are used as fluids to be processed; of these fluids, at least one fluid is a raw material fluid which contains at least one kind of raw material, while at least one kind of fluid other than the said fluid is a fluid to process the raw material, and the said two or more fluids to be processed are mixed in a thin film fluid formed between at least two processing surfaces which are disposed in a position they are faced with each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other; and the raw material fluid is introduced from a center of the at least two processing surfaces which are disposed in a position they are faced with each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other, thereby preventing the raw material that is processed between the processing surfaces from adhering onto the processing surfaces.
In the present invention, the phrase “preventing the raw material that is processed between the processing surfaces from adhering onto the processing surfaces” does not necessary mean the complete prevention of the adhesion, but it is only necessary to substantially prevent the adhesion. For example, when a fluid which contains a silver ion (raw material fluid) and a fluid which contains a reducing agent (fluid to process the raw material) are mixed between the processing surfaces thereby separating silver fine particles, it is important to avoid the situation that the separated silver fine particles adhere onto the processing surfaces thereby causing, with the passage of the processing time, change of particle diameter of the silver fine particles discharged from between the processing surfaces, and the situation that the silver fine particles adhered onto the processing surfaces grow to coarse particles with the passage of the processing time thereby causing discharge of the coarsened silver fine particles from between the processing surfaces.
In addition, the present invention may be carried out as at least one process selected from separation, emulsification, dispersion, reaction, and aggregation.
The present invention may be carried out as a process, wherein the raw material fluid passes through between both the processing surfaces while forming the thin film fluid, an another introduction flow path independent of a flow path through which the raw material fluid passes is arranged; at least one opening leading to the another introduction flow path is provided to at least any one of the at least two processing surfaces; the at least one other kind of fluid is introduced into between the processing surfaces through the opening, whereby mixing the raw material fluid with the at least one other kind of fluid in the thin film fluid.
The present invention may be carried out as a process, wherein the raw material that is processed between the processing surfaces is fine particles having a primary particle diameter of less than a distance between the processing surfaces.
In addition, the present invention may be carried out as a process, wherein at least one of the processing surfaces is in the form of a ring, through a center of which the raw material fluid is introduced into between the processing surfaces, wherein a total open area (a) of a space between both the processing surfaces in the nearest point to a center of the ring, in which space the raw material fluid and the at least one other kind of the fluid are joined together, is 5 or less times relative to a total open area (b) of the opening leading to the another introduction path.
In addition, the present invention may be carried out as a process, wherein at least one of the processing surfaces is in the form of a ring, through a center of which the raw material fluid is introduced into between the processing surfaces; at least two or more openings of the another introduction path leading to between the processing surfaces are provided, and a total open area (a) of a space between both the processing surfaces in the nearest point to the center of the ring, in which space the raw material fluid and the at least one other kind of the fluid are joined together, is 5 or less times relative to each open area of the openings that lead to the another introduction path.
In addition, the present invention may be carried out as a process, wherein a form of the opening of another introduction flow path leading to the processing surface is a circular ring.
Further in addition, the present invention may be carried out as a process, wherein at least one of the processing surfaces is in the form of a ring, from a center of which the raw material fluid is introduced into between the processing surfaces, and a flow amount per unit time of the raw material fluid introduced into between the processing surfaces from the center of this ring is in the range of 0.1 to 20000 times relative to a flow amount per unit time of the at least one other fluid that is introduced from the opening.
The present invention is carried out suitably by using an apparatus provided with: a fluid pressure imparting mechanism for imparting a pressure to the fluids to be processed, a first processing member is provided with a first processing surface of the two processing surfaces, a second processing member is provided with a second processing surface of the two processing surfaces, and a rotation drive mechanism for rotating these processing members relative to each other; of the first processing member and the second processing member, at least the second processing member is provided with a pressure-receiving surface, and at least part of the pressure-receiving surface is comprised of the second processing surface, wherein and this pressure-receiving surface receives a pressure applied to the fluids to be processed by the fluid pressure imparting mechanism thereby generating a force to move in the direction of separating the second processing surface from the first processing surface.
In addition, the present invention is carried out suitably as a process, wherein a flow amount per unit time of the raw material fluid introduced into between the processing surfaces from the center of the ring is 20 mL or more per minute.
In the method for processing a fluid by introducing a fluid to be processed into between at least two processing surfaces which are disposed in a position they are faced with each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other thereby obtaining a raw material that is processed in a thin film formed between the processing surfaces, the inventor of the present invention found that, of fluids to be processed that are to be introduced into between the processing surfaces, if a raw material fluid is introduced into between the processing surfaces from a center of a ring-like processing surface, adhesion of the raw material that is processed between the processing surfaces onto the processing surfaces can be prevented from occurring, thereby providing a novel method for stably processing a fluid between the processing surfaces. Especially in the case that production of fine particles is intended whereby carrying out production of the fine particles between the processing surfaces for a long period of time, it was found that uniform fine particles can be produced continuously and stably, and thereby completed the present invention.
Hereinafter, the present invention will be explained in detail by referring to an example of the embodiments of the present invention. However, technical scope of the present invention is not restricted by the following embodiments and Examples.
The fluid processing apparatus shown in
In this apparatus provided with processing surfaces arranged opposite to each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other, at least two kinds of fluids as fluids to be processed are used, wherein at least one fluid thereof contains at least one kind of material to be processed, a thin film fluid is formed by converging the respective fluids between these processing surfaces, and the material to be processed is processed in this thin film fluid. With this apparatus, mentioned-above, a plurality of fluids to be processed may be processed; but a single fluid to be processed may be processed as well.
This fluid processing apparatus is provided with two processing members of a first processing member 10 and a second processing member 20 arranged opposite to each other, wherein at least one of these processing members rotates. The surfaces arranged opposite to each other of the respective processing members 10 and 20 are made to be the respective processing surfaces. The first processing member 10 is provided with a first processing surface 1 and the second processing member 20 is provided with a second processing surface 2.
The processing surfaces 1 and 2 are connected to a flow path of the fluid to be processed and constitute part of the flow path of the fluid to be processed. Distance between these processing surfaces 1 and 2 can be changed as appropriate; and thus, the distance thereof is controlled so as to form a minute space usually in the range of 1 μm to 1 mm, especially 1 μm to 50 μm. With this, the fluid to be processed passing through between the processing surfaces 1 and 2 becomes a forced thin film fluid forced by the processing surfaces 1 and 2.
With this apparatus, when a plurality of fluids to be processed are processed, the apparatus is connected to a flow path of the first fluid to be processed whereby forming part of the flow path of the first fluid to be processed; and part of the flow path of the second fluid to be processed other than the first fluid to be processed is formed. In this apparatus, the two paths converge into one, and two fluids to be processed are mixed between the processing surfaces 1 and 2 so that the fluids may be processed by reaction and so on. It is noted here that the term “process(ing)” includes not only the embodiment wherein a material to be processed is reacted but also the embodiment wherein a material to be processed is only mixed or dispersed without accompanying reaction.
To specifically explain, this apparatus is provided with a first holder 11 for holding the first processing member 10, a second holder 21 for holding the second processing member 20, a surface-approaching pressure imparting mechanism, a rotation drive mechanism, a first introduction part d1, a second introduction part d2, and a fluid pressure imparting mechanism p.
As shown in
Roughness of this mirror polished surface is not particularly limited; but surface roughness Ra is preferably 0.01 μm to 1.0 μm, or more preferably 0.03 μm to 0.3 μm.
At least one of the holders can rotate relative to the other holder by a rotation drive mechanism such as an electric motor (not shown in drawings). A reference numeral 50 in
At least any one of the first processing member 10 and the second processing member 20 is able to approach to and separate from at least any other member, thereby the processing surfaces 1 and 2 are able to approach to and separate from each other.
In this embodiment, the second processing member 20 approaches to and separates from the first processing member 10, wherein the second processing member 20 is accepted in an accepting part 41 arranged in the second holder 21 so as to be able to rise and set. However, as opposed to the above, the first processing member 10 may approach to and separate from the second processing member 20, or both the processing members 10 and 20 may approach to and separate from each other.
This accepting part 41 is a concave portion for mainly accepting that side of the second processing member 20 opposite to the second processing surface 2, and this concave portion is a groove being formed into a circle, i.e., a ring when viewed in a plane. This accepting part 41 accepts the second processing member 20 with sufficient clearance so that the second processing member 20 may rotate. Meanwhile, the second processing member 20 may be arranged so as to be movable only parallel to the axial direction; alternatively, the second processing member 20 may be made movable, by making this clearance larger, relative to the accepting part 41 so as to make the center line of the processing member 20 inclined, namely unparallel, to the axial direction of the accepting part 41, or movable so as to depart the center line of the processing member 20 and the center line of the accepting part 41 toward the radius direction.
It is preferable that the second processing member 20 be accepted by a floating mechanism so as to be movable in the three dimensional direction, as described above.
The fluids to be processed are introduced into between the processing surfaces 1 and 2 from the first introduction part d1 and the second introduction part d2, the flow paths through which the fluids flow, under the state that pressure is applied thereto by a fluid pressure imparting mechanism p consisting of various pumps, potential energy, and so on. In this embodiment, the first introduction part d1 is a path arranged in the center of the circular, second holder 21, and one end thereof is introduced into between the processing surfaces 1 and 2 from inside the circular, processing members 10 and 20. Through the second introduction part d2, the first fluid to be processed and the second fluid to be processed for reaction are introduced into between the processing surfaces 1 and 2. In this embodiment, the second introduction part d2 is a path arranged inside the second processing member 20, and one end thereof is open at the second processing surface 2. The first fluid to be processed which is pressurized with the fluid pressure imparting mechanism p is introduced from the first introduction part d1 to the space inside the processing members 10 and 20 so as to pass through between the first and processing surfaces 1 and 2 to outside the processing members 10 and 20. From the second introduction part d2, the second fluid to be processed which is pressurized with the fluid pressure imparting mechanism p is provided into between the processing surfaces 1 and 2, whereat this fluid is converged with the first fluid to be processed, and there, various fluid processing such as mixing, stirring, emulsification, dispersion, reaction, deposition, crystallization, and separation are effected, and then the fluid thus processed is discharged from the processing surfaces 1 and 2 to outside the processing members 10 and 20. Meanwhile, an environment outside the processing members 10 and 20 may be made negative pressure by a vacuum pump.
The surface-approaching pressure imparting mechanism mentioned above supplies the processing members with force exerting in the direction of approaching the first processing surface 1 and the second processing surface 2 each other. In this embodiment, the surface-approaching pressure imparting mechanism is arranged in the second holder 21 and biases the second processing member 20 toward the first processing member 10.
The surface-approaching pressure imparting mechanism is a mechanism to generate force (hereinafter, surface-approaching pressure) to press the first processing surface 1 of the first processing member 10 and the second processing surface 2 of the second processing member 20 in the direction to make them approach to each other. The mechanism generates a thin film fluid having minute thickness in a level of nanometer or micrometer by the balance between the surface-approaching pressure and the force to separate the processing surfaces 1 and 2 from each other, i.e., the force such as the fluid pressure. In other words, the distance between the processing surfaces 1 and 2 is kept in a predetermined minute distance by the balance between these forces.
In the embodiment shown in
To specifically explain the separation force, the second processing member 20 has the second processing surface 2 and a separation controlling surface 23 which is positioned inside the processing surface 2 (namely at the entering side of the fluid to be processed into between the first and second processing surfaces 1 and 2) and next to the second processing surface 2. In this embodiment, the separation controlling surface 23 is an inclined plane, but may be a horizontal plane. The pressure of the fluid to be processed acts to the separation controlling surface 23 to generate force directing to separate the second processing member 20 from the first processing member 10. Therefore, the second processing surface 2 and the separation controlling surface 23 constitute a pressure receiving surface to generate the separation force.
In the example shown in
Meanwhile, the pressure of the fluid to be processed exerted on the second processing surface 2 and the separation controlling surface 23, i.e., the fluid pressure, is understood as force constituting an opening force in a mechanical seal. The ratio (area ratio A1/A2) of a projected area A1 of the approach controlling surface 24 projected on a virtual plane perpendicular to the direction of approaching and separating the processing surfaces 1 and 2, that is, in the direction of rising and setting of the second processing member 20 (axial direction in
Sliding surface actual surface pressure P, i.e., the fluid pressure out of the surface-approaching pressures, is calculated according to the following equation:
P=P1×(K−k)+Ps
Here, P1 represents the pressure of a fluid to be processed, i.e., the fluid pressure, K represents the balance ratio, k represents an opening force coefficient, and Ps represents a spring and back pressure.
By controlling this balance line to control the sliding surface actual surface pressure P, the space between the processing surfaces 1 and 2 is formed as a desired minute space, thereby forming a fluid film of the fluid to be processed so as to make the processed substance such as a product fine and to effect uniform processing by reaction.
Meanwhile, the approach controlling surface 24 may have a larger area than the separation controlling surface 23, though this is not shown in the drawing.
The fluid to be processed becomes a forced thin film fluid by the processing surfaces 1 and 2 that keep the minute space therebetween, whereby the fluid is forced to move out from the circular, processing surfaces 1 and 2. However, the first processing member 10 is rotating; and thus, the mixed fluid to be processed does not move linearly from inside the circular, processing surfaces 1 and 2 to outside thereof, but does move spirally from the inside to the outside thereof by a resultant vector acting on the fluid to be processed, the vector being composed of a moving vector toward the radius direction of the circle and a moving vector toward the circumferential direction.
Meanwhile, a rotary shaft 50 is not only limited to be placed vertically, but may also be placed horizontally, or at a slant. This is because the fluid to be processed is processed in a minute space between the processing surfaces 1 and 2 so that the influence of gravity can be substantially eliminated. In addition, this surface-approaching pressure imparting mechanism can function as a buffer mechanism of micro-vibration and rotation alignment by concurrent use of the foregoing floating mechanism with which the second processing member 20 may be held displaceably.
In the first and second processing members 10 and 20, the temperature thereof may be controlled by cooling or heating at least any one of them; in
As shown in
It is preferable that the base edge of this depression 13 reach the inner periphery of the first processing member 10. The front edge of the depression 13 is extended to the direction of the outer periphery of the first processing surface 1; the depth thereof (cross section area) is made gradually shallower (smaller) from the base edge to the front edge.
Between the front edge of the depression 13 and the outer peripheral of the first processing surface 1 is formed the flat plane 16 not having the depression 13.
When an opening d20 of the second introduction part d2 is arranged in the second processing surface 2, the arrangement is done preferably at a position opposite to the flat surface 16 of the first processing surface 1 arranged at a position opposite thereto.
This opening d20 is arranged preferably in the downstream (outside in this case) of the depression 13 of the first processing surface 1. The opening is arranged especially preferably at a position opposite to the flat surface 16 located nearer to the outer diameter than a position where the direction of flow upon introduction by the micro-pump effect is changed to the direction of a spiral and laminar flow formed between the processing surfaces. Specifically, in
This second introduction part d2 may have directionality. For example, as shown in
In addition, as shown in
This angle (θ2) can vary depending on various conditions such as the type of fluid, the reaction speed, viscosity, and the rotation speed of the processing surface. In addition, it is also possible not to give the directionality to the second introduction part d2 at all.
In the embodiment shown in
Meanwhile, because it is good enough only if the reaction could be effected between the processing surfaces 1 and 2, as opposed to the foregoing method, a method wherein the second fluid is introduced from the first introduction part d1 and a solution containing the first fluid is introduced from the second introduction part d2 may also be used. That is, the expression “first” or “second” for each fluid has a meaning for merely discriminating an nth fluid among a plurality of the fluids present; and therefore, a third or more fluids can also exist.
As discussed above, the processing apparatus may be provided with the third introduction part d3, in addition to the first introduction part d1 and the second introduction part d2; and in this case, from each introduction part, for example, the first fluid, the second fluid, and the third fluid respectively may be introduced into the processing apparatus separately. By so doing, concentration and pressure of each fluid can be controlled separately so that the process to obtain the fine particles and the fine particles to be obtained, especially in the case that production of fine particles is intended, stabilization of the particle diameter of the fine particles, and so on can be controlled more precisely. Meanwhile, a combination of the fluids to be processed (first to third fluids) that are introduced into the respective introduction parts may be set arbitrarily. The same is applied if the forth or more introduction parts are arranged; and by so doing, fluids to be introduced into the processing apparatus may be subdivided.
In addition, temperatures of the fluids to be processed such as the first fluid, the second fluid, and so on may be controlled; and temperature difference among the first fluid, the second fluid, and so on (namely, temperature difference among each of the supplied fluids to be processed) may be controlled either. To control temperature and temperature difference of each of the supplied fluids to be processed, a mechanism with which temperature of each of the fluids to be processed is measured (temperature of the fluid before introduction to the processing apparatus, or in more detail, just before introduction into between the processing surfaces 1 and 2) so that each of the fluids to be processed that is introduced into between the processing surfaces 1 and 2 may be heated or cooled may be installed.
Regardless of the number of the flow paths, in the present invention, if the raw material fluid which contains at least one kind of raw material (this will be explained later) is introduced from the first introduction part d1, the processed material can be prevented from adhering onto the processing surfaces 1 and 2 which constitute the flow path of the fluid between the processing surfaces 1 and 2. The specific reason for this is still being studied, however, it may be assumed that as to the fluid to be processed flowing between the processing surfaces 1 and 2, the fluid to be processed around the processing surface 1 of the rotating processing member 10 flows at the same velocity as the rotation speed of the processing member 10, or at the velocity extremely near to the rotation speed, while the fluid to be processed around the processing surface 2 of the non-rotating processing member 20 does not have the velocity, or the flow thereof is difficult or slower than the flow around the processing surface 1 of the rotating processing member 10. Accordingly, the reason for adhesion occurred in the past is considered to be as following: in the technological content mentioned above, in the case that at least two fluids to be processed are processed while arranging the opening d20 in the processing surface 2 of the non-rotating processing member 20 (this is a relatively easy case to carry out), when at least one kind of fluid other than the raw material fluid, i.e., a fluid to process the raw material, is introduced from the first introduction part d1 while the raw material fluid is introduced from the second introduction part d2, the processed raw material is readily processed in the place where the flow thereof is relatively sluggish between the processing surfaces 1 and 2. And therefore, it is considered that, if the raw material fluid is introduced from the first introduction part d1, the processed raw material can be obtained in the place where the flow between the processing surfaces 1 and 2 is fast or the flow thereof is relatively fast; and as a result, the processed material could be prevented from adhering onto the processing surfaces 1 and 2. Accordingly, because adhesion onto the processing surfaces 1 and 2 could be prevented from occurring by introducing the raw material fluid from the first introduction part d1, it became possible to produce fine particles continuously and stably more than ever, especially in the case that production of fine particles is intended.
In this embodiment, both the first and the second processing surfaces 1 and 2 are in the form of a ring having opening in the center thereof; however, an embodiment may also be possible that any one of the processing surfaces 1 and 2 is in the form of a ring having opening in the center thereof while the other is not arranged with the opening in the center thereof. The total open area (a) of the space between the first and the second processing surfaces 1 and 2 in this central first introduction part d1 is preferably 5 or less times relative to the total open area (b) of the opening d20. Note here that, the total open area (a) means the total open area between both the processing surfaces in the nearest point “f” to the center of the ring (hereinafter, this point is referred to as the nearest point “f”) at which point the first fluid and the second fluid are joined together (see,
The nearest point “f” means the innermost side in the opening d20 (the point near to the center in the radius direction); and when two or more openings 20 are arranged, this means the innermost radius side thereof.
Meanwhile, when two or more of the openings d20a and d20b are arranged as shown in
The total open area (a) at the nearest point “f” is preferably 5 or less times, but more preferably 3 or less times, or still more preferably 2 or less times, relative to the total open area (b) of the opening d20. Further, the lower limit thereof is not particularly restricted, but preferably 0.001 or more times, or more preferably 0.01 or more times in reality.
Furthermore, the flow amount per unit time of the raw material fluid from the center of the first introduction part d1 is preferably in the range of 0.1 to 20000 times relative to the flow amount per unit time of the at least one other fluid from the second introduction part d2. If it is less than 0.1 times, the flow amount introduced from the center cannot be increased so much, thereby decreasing the effect. Even if the flow amount exceeds 20000 or more times, there is no particular problem; but there is a risk of causing problems such as extremely small total flow amount of the second introduction part d2 and imbalance of the entire system.
In addition, the flow amount per unit time of the raw material fluid introduced into between the processing surfaces 1 and 2 from the first introduction part d1 is preferably 20 mL or more per minute. If the flow amount thereof per unit time is less than 20 mL per minute, the flow amount from the center cannot be increased so much, thereby leading to deterioration in the advantage effect of the present invention.
In the apparatus mentioned above, a process such as separation, precipitation, emulsification, and crystallization takes place while the mixing takes place forcibly and uniformly between the processing surfaces 1 and 2 which are disposed in a position they are faced with each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other, as shown in
In the present invention, the at least one kind of raw material that is contained in the raw material fluid is not particularly restricted. All substances that are intended to be obtained may be mentioned; however, especially in the case that production of fine particles is intended, a raw material capable of becoming fine particles may be used as the raw material thereof. Illustrative example of the raw material includes an inorganic substance, an organic substance, and an inorganic-organic composite substance, such as a metal, a nonmetal, an organic and/or inorganic compound of a metal and a nonmetal, a pigment, a biologically ingestible substance (a compound used as a medical drug and a substance to be ingested into a living body), a resin, and an oil ingredient, so that all substances that are intended to be processed between the processing surfaces 1 and 2 may be mentioned. The raw material may be introduced into between the processing surfaces 1 and 2 from the first introduction part d1 as the raw material fluid as it is, or it may be introduced into between the processing surfaces 1 and 2 as the raw material fluid having the raw material mixed with and/or dissolved in various solvents such as water and an organic solvent.
In the present invention, the at least one kind of fluid other than the raw material fluid, i.e., the fluid to process the raw material, is not particularly restricted. This process is not particularly restricted; and thus, separation, emulsification, dispersion, reaction, aggregation, and the like may be mentioned. For example, in the case that the raw material that is processed by separation is obtained, the present invention may be carried out by mixing the raw material fluid with the fluid to separate the raw material that is contained in the raw material fluid in the thin film fluid formed between at least two processing surfaces which are disposed in a position they are faced with each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other, thereby obtaining the separated raw material. Alternatively, in the case that the raw material which is processed by a reduction reaction is obtained, the present invention may be carried out by mixing the raw material fluid with the fluid to reduce the raw material that is contained in the raw material fluid in the thin film fluid formed between at least two processing surfaces which are disposed in a position they are faced with each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other, thereby obtaining the reduced raw material. As seen above, the raw material and the processed raw material may be the same or different before and after the processing.
In the present invention, a dispersing agent such as a block copolymer, a polymer, and a surfactant may be contained in a fluid which contains a raw material fluid, or in a fluid which contains at least one fluid other than the raw material fluid, or in both of these fluids, to a degree not affecting the present invention. Alternatively, this dispersing agent may be contained in a third fluid other than the fluid which contains the raw material fluid and the fluid which contains at least one kind of fluid other than the raw material fluid.
The method for preventing adhesion of processed material according to the present invention may be used in production of the following fine particles. Note that, the present invention is not applied only to the following examples; it can also be used for producing of fine particles that have been produced by means of conventional methods such as a batch process, a continuous process, a microreactor, and a micromixer.
Thus, the example mentioned above includes:
a reaction to obtain pigment particles by mixing an acidic pigment solution, prepared by dissolving at least one kind of pigment in a strong acid such as sulfuric acid, nitric acid, and hydrochloric acid, with a solution including water (acid pasting method),
a reaction to precipitate pigment particles by pouring a pigment solution, prepared by dissolving at least one kind of pigment in an organic solvent, into a poor solvent which is a poor solvent to the said pigment and is compatible with the organic solvent used to prepare the pigment solution (reprecipitation method), or
a reaction to obtain pigment particles by mixing a pigment solution, obtained by dissolving at least one kind of pigment either into a pH adjusting acidic or alkaline solution or into a mixed solution of the said pH adjusting solution with an organic solvent, with a pigment-separating solution not showing solubility to the pigment contained in the pigment solution or showing smaller solubility to the pigment than the solvent contained in the pigment solution, and yet being capable of changing pH of the pH adjusting solution.
A reaction to carry metal fine particles on a carbon and a carbon black surface by a liquid phase reduction method (illustrative example of the metal includes at least one metal selected from the group consisting of platinum, palladium, gold, silver, rhodium, iridium, ruthenium, osmium, cobalt, manganese, nickel, iron, chromium, molybdenum, and titanium).
A reaction to produce crystals formed of a fullerene molecule and a fullerene nanowhisker/nanofiber nanotube by mixing a solution containing a first solvent having dissolved therein the fullerene with a second solvent having smaller solubility of the fullerene than the first solvent.
A reaction to reduce a metal compound or a metal ion (illustrative example of the metal includes a precious metal such as gold, silver, ruthenium, rhodium, palladium, osmium, iridium, and platinum, or cupper, or a metal alloy of two or more metals mentioned above).
A reaction to hydrolyze a ceramic raw material (illustrative example of the ceramic raw material includes at least one kind selected from Al, Ba, Mg, Ca, La, Fe, Si, Ti, Zr, Pb, Sn, Zn, Cd, As, Ga, Sr, Bi, Ta, Se, Te, Hf, Ni, Mn, Co, S, Ge, Li, B, and Ce).
A reaction to separate titanium dioxide superfine particles by hydrolysis of a titanium compound (illustrative example of the titanium compound includes at least one kind selected from tetraalkoxy titanium such as tetramethoxy titanium, tetraethoxy titanium, tetra-n-propoxy titanium, tetraisopropoxy titanium, tetra-n-butoxy titanium, tetraisobutoxy titanium, and tetra-t-butoxy titanium, or a derivative of them; and titanium tetrachloride, titanyl sulfate, titanium citrate, and titanium tetranitrate).
A producing reaction to co-precipitate and separate fine particles of a compound semiconductor by joining with an ion-containing fluid, which is a semiconductor raw material and contains different elements (illustrative example of the compound semiconductor includes a compound semiconductor of the II-VI groups, a compound semiconductor of the III-V groups, a compound semiconductor of the IV group, a compound semiconductor of the groups).
A reaction to produce semiconductor fine particles by reducing a semiconductor element (illustrative example of the semiconductor element includes an element selected form the group consisting of silicon (Si), germanium (Ge), carbon (C), and tin (Sn)).
A reaction to produce magnetic fine particles by reducing a magnetic raw material (illustrative example of the magnetic raw material includes at least one kind selected from nickel, cobalt, iridium, iron, platinum, gold, silver, manganese, chromium, palladium, yttrium, and lanthanide (neodymium, samarium, gadolinium, and terbium)).
A reaction to separate biologically ingestible fine particles by mixing a fluid which at least one kind of raw material of the biologically ingestible fine particles is dissolved in a first solvent with a solvent capable of becoming a second solvent having lower solubility of the biologically ingestible fine particles than the first solvent.
Alternatively, a reaction to separate biologically ingestible fine particles by a neutralization reaction caused by mixing a fluid containing at least one kind of an acidic substance or a cationic substance with a fluid containing at least one kind of a basic substance or an anionic substance. In the present invention, for example, in the case that barium sulfate fine particles to be ingested into a living body as a contrast agent are separated, a water-soluble barium salt solution as the raw material fluid is mixed with a water-soluble sulfate compound solution including sulfuric acid as the at least one kind of fluid other than the raw material fluid, whereby separating barium sulfate fine particles by a neutralization reaction.
A treatment to obtain microemulsion particles by mixing a fluid to be processed that contains an oil phase component which contains a fat-soluble pharmacologically active substance with a fluid to be processed comprising at least aqueous dispersion solvent, or by mixing a fluid to be processed that contains a aqueous phase component which contains a water-soluble pharmacologically active substance with a fluid to be processed comprising at least an oil-based dispersion solvent.
Alternatively, a treatment to obtain a liposome by mixing a dispersed phase of a fluid to be processed with a continuous phase of a fluid to be processed, wherein at least any one of the dispersed phase or the continuous phase contains one or more kind of phospholipid, the dispersed phase contains a pharmacologically active substance, and the continuous phase is comprised of at least an aqueous dispersion solvent.
A treatment to obtain resin fine particles by mixing a fluid in which a resin is dissolved in a solvent that has solubility and compatibility to the said resin with an aqueous solvent, thereby effecting separation or emulsification; and a treatment to obtain an emulsion by mixing an oil phase component such as a resin and an oil with a water phase component.
Alternatively, a treatment to obtain resin fine particles by mixing a resin in the molten state obtained by heating with a solvent (there is no restriction as to whether it is aqueous or oily), thereby effecting emulsification and dispersion. Further alternatively, a treatment to agglutinate resin fine particles by mixing a dispersion solution of resin fine particles with a compound solution having a compound such as a salt dissolved therein.
Reactions to obtain an organic compound by an organic reaction of an organic compound starting raw material with various reactants, the reactions such as Friedel-Crafts reaction, nitration reaction, addition reaction, elimination reaction, transfer reaction, polymerization reaction, condensation reaction, coupling reaction, acylation, carbonylation, aldehyde synthesis, peptide synthesis, aldol reaction, indole reaction, electrophilic substitution reaction, nucleophilic substitution reaction, Wittig reaction, Michael addition reaction, enamine synthesis, ester synthesis, enzymatic reaction, diazo coupling reaction, oxidation reaction, reducing reaction, multistep reaction, selective addition reaction, Suzuki-Miyaura coupling reaction, Kumada-Corriu reaction, methathesis reaction, isomerization reaction, radical polymerization reaction, anionic polymerization reaction, cationic polymerization reaction, metal-catalyzed polymerization reaction, consecutive reaction, polymer synthesis, acetylene coupling reaction, episulfide synthesis, episulfide synthesis, Bamberger rearrangement, Chapman rearrangement, Claisen condensation, quinoline synthesis, Paal-Knorr furan synthesis, Paal-Knorr pyrole synthesis, Passerini reaction, Paterno-Buchi reaction, carbonyl-ene reaction (Prins reaction), Jacobsen rearrangement, Koenigs-Knorr glucosidation reaction, Leuckart-Wallach reaction, Horner-Wadsworth-Emmons reaction, Gassman reaction, Noyori assymmetric hydrogenation reaction, Perkin reaction, Petasis reaction, Tishchenko reaction, Tishchenko reaction, Ullmann coupling, Nazarov cyclization, Tiffeneau-Demjanov rearrangement, template synthesis, oxidation using selenium dioxide, Reimer-Tiemann reaction, Grob cleavage reaction, haloform reaction, Malaprade glycol oxidative cleavage, Hofmann elimination, thiocarbonylation by using Lawesson reagent, Lossen rearrangement, cyclic ketone synthesis by using FAMSO, Favorskii rearrangement, Feist-Benary furan synthesis, Gabriel amine synthesis, Glaser reaction, Grignard reaction, Cope elimination, Cope rearrangement, diimide reduction of alkynes, Eschenmoser aminomethylation reaction, [2+2] photocyclization reaction, Appel reaction, aza-Wittig reaction, Bartoli indole synthesis, Carroll rearrangement, Chichibabin reaction, Clemmensen reduction, Combes quinoline synthesis, Tsuzi-Trost reaction, TEMPO oxidation, dihydroxylation by using osmium tetraoxide, Fries rearrangement, Neber rearrangement, Barton-McCombie deoxygenation, Barton decarboxylation, Seyferth-Gilbert alkyne synthesis, Pinnick (Kraus) oxidation, Itoh-Saegusa oxidation, Eschenmoser cleavage reaction, Eschenmoser-Claisen rearrangement, Doering-LaFlamme allene synthesis, Corey-Chakovsky reaction, acyloin condensation, Wolff-Kishner reduction, IBX oxidation, Parkin-Doering oxidation, Reissert reaction, Jacobsen's kinetic optical resolution hydrolysis, benzilic acid rearrangement, Hiyama cross-coupling, Luche reduction, oxymerculation, Vilismeier-Haak reaction, Wolff rearrangement, Kolbe-Schmitt reaction, Corey-Kim oxidation, Cannizzaro reaction, Henry reaction, transformation of an alcohol to an alkane, Arndt-Eistert synthesis, hydroformylation reaction, Peterson olefination, decarbonylation reaction, Curtius rearrangement, Wohl-Zeigler bromination at allyl position, Pfitzner-Moffatt oxidation, McMurry coupling, Barton reaction, Balz-Shiemann reaction, Masamune-Bergman reaction, Dieckmann condensation, pinacol coupling, Williamson ether synthesis, iodolactonization reaction, Harries ozone decomposition, oxidation by active manganese dioxide, alkyne cyclotrimerization reaction, Kumada-Tamao-Corriu cross-coupling, syn-β elimination of a sulfoxide and a selnoxide, Fisher indole synthesis, Oppenauer oxidation, Darzens condensation reaction, Alder ene reaction, Sarett-Collins oxidation, Nozaki-Hiyama-Kishi coupling reaction, Weinreb ketone synthesis, DAST fluorination, Corey-Winter olefin synthesis, Hosomi-Sakurai reaction, alcohol oxidation by using PCC (PDC), Jones oxidation, Keck allylation reaction, cyanide addition by using Nagata reagent, Negishi coupling, Ireland-Claisen rearrangement, Baeyer-Villiger oxidation, p-methoxybenzyl (PMB or MPM), dimethoxybenzyl (DMB) protection, deprotection, Wacker oxidation, Myers assymmetric alkylation, Yamaguchi macrolactonization, Mukaiyama-Corey macrolactonization, Bode peptide synthesis, Lindlar reduction, homogeneous hydrogenation, orthometallation, Wagner-Meerwein rearrangement, Wurtz reaction, ketone synthesis by using 1,3-dithiane, Michael addition, ketone synthesis by Stork enamine, Pauson-Khand cyclopentene synthesis, and Tebbe reaction.
Hereinafter, the present invention will be explained in more detail by showing Examples; but, the present invention is not limited only to these Examples.
Note that, in the following Examples, the term “from the center” means “from the first introduction part d1” of the fluid processing apparatus shown in
The separation reaction is done by mixing a quinacridone solution having an organic pigment (C. I. Pigment Violet 19, hereinafter PV-19) dissolved in concentrated sulfuric acid with methanol in a thin film fluid formed between the processing surfaces 1 and 2 which are disposed in a position they are faced with each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other by using the reaction apparatus shown in
While the PV-19 solution (concentration of 2.0% by weight) having PV-19 powders dissolved in concentrated sulfuric acid was introduced as the first fluid (raw material fluid) from the center with the supply pressure of 0.350 MPa and the back pressure of 0.02 MPa, methanol was introduced as the second fluid into between the processing surfaces (rotation number of 1500 rpm).
The first fluid and the second fluid were mixed in the thin film fluid, and the dispersion solution of the PV-19 nanoparticles was discharged from the processing surfaces 1 and 2. The PV-19 nanoparticles in the discharged dispersion solution of the PV-19 nanoparticles were loosely aggregated, collected by filtration using a filter cloth with opening of 1.0 μm, and then washed by pure water to obtain a wet cake of the PV-19 nanoparticles. Apart of the wet cake of the PV-19 nanoparticles was diluted by an aqueous surfactant solution of NEOGEN R-K (manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd.), and then redispersed by using a rotating disperser Clearmix CLM-2.2S (trade name; manufactured by M. Technique Co., Ltd.) to produce a dispersion solution of PV-19 nanoparticles.
The obtained dispersion solution of the PV-19 nanoparticles was diluted, put on a collodion film, and then, the particle diameter of the primary particle thereof was confirmed by the TEM observation. The TEM observation was conducted by using JEM-2100 (manufactured by JEOL Ltd.) to measure the particle diameter of the primary particle in a plurality of observation spots with the observation magnification of 20,000; and the average value thereof was used.
The first fluid, the second fluid, the adhesion state of the PV-19 nanoparticles onto the processing surfaces 1 and 2, and the change of the primary particle diameter (shown by “particle diameter” in Table 1) during the continuous operation are shown in Table 1. Meanwhile, the adhesion state of the PV-19 nanoparticles onto the processing surfaces 1 and 2 was confirmed by visual observation with the passage of processing time. Specifically, when adhesion of the PV-19 nanoparticles on the processing surfaces 1 and 2 was confirmed with the naked eye, it was judged by “Some” in “Adhesion of separated material onto processing surfaces”.
Note that, in the apparatus used in these Examples and Comparative Examples, the opening d20 of the separate introduction part d2 was in the form of one concentric circular ring surrounding the central opening of the processing surface 2 as described above, and the ratio (a/b) of the total open area (a) of the space between both processing surfaces to the total open area (b) of the opening that leads to the separate introduction path was set at 0.2 in Example 1, 3.0 in Example 2, 4.8 in Example 3, 5.4 in Comparative Example 1, 20.0 in Comparative Example 2, and 60.0 in Comparative Example 3.
From Table 1, it can be seen that, when the qunacridone solution containing PV-19 (raw material) was used as the raw material solution (first fluid), adhesion onto the processing surfaces 1 and 2 could be easily prevented from occurring, and thereby uniform fine particles could be continuously obtained stably even in the operation for a long period of time.
The reduction reaction was done by mixing a tin chloride solution having tin chloride dissolved in methanol, sodium borohydride as a reducing agent, and Thiokalcol 08 (manufactured by Kao Corporation) as a surfactant with a reducing agent solution dissolved in a mixed solvent of methanol and toluene in a thin film fluid formed between the processing surfaces 1 and 2 which are disposed in a position they are faced with each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other, in the reaction apparatus shown
While the tin chloride solution (concentration of 5.3% by weight) having tin chloride dissolved in methanol was introduced as the first fluid (raw material fluid) from the center with the supply pressure of 0.300 MPa and the back pressure of 0.02 MPa, the reducing agent solution was introduced as the second fluid into between the processing surfaces (rotation number of 1700 rpm).
The first fluid and the second fluid were mixed in the thin film fluid, and the dispersion solution of tin nanoparticles was discharged from the processing surfaces 1 and 2. The tin nanoparticles in the discharged dispersion solution of the tin nanoparticles were loosely aggregated, collected by filtration using a filter cloth with opening of 1.0 μm, and then washed by methanol to obtain a wet cake of tin nanoparticles. Apart of the wet cake of tin nanoparticles was diluted by methanol, and then dispersed by using an ultrasonic cleaning machine to obtain a dispersion solution of tin nanoparticles.
The obtained dispersion solution of the tin nanoparticles was diluted, put on a collodion film, and then, the particle diameter of the primary particle thereof was confirmed by the TEM observation. The TEM observation was conducted by using JEM-2100 (manufactured by JEOL Ltd.) to measure the particle diameter of the primary particle in a plurality of observation spots with the observation magnification of 20,000; and the average value thereof was used.
The first fluid, the second fluid, the adhesion state of the tin nanoparticles onto the processing surfaces 1 and 2, and the change of the primary particle diameter (shown by “particle diameter” in Table 2) during the continuous operation are shown in Table 2. Meanwhile, the adhesion state of the tin nanoparticles onto the processing surfaces 1 and 2 was confirmed by visual observation with the passage of processing time. Specifically, when adhesion of the tin nanoparticles on the processing surfaces 1 and 2 was confirmed with the naked eye, it was judged by “Some” in “Adhesion of separated material onto processing surfaces”.
Note that, in the apparatus used in these Examples and Comparative Examples, the opening d20 of the separate introduction part d2 was in the form of one concentric circular ring surrounding the central opening of the processing surface 2 as described above, and the ratio (a/b) of the total open area (a) of the space between both processing surfaces to the total open area (b) of the opening that leads to the separate introduction path was set at 0.3 in Example 4, 2.0 in Example 5, 4.8 in Example 6, 5.6 in Comparative Example 4, 20.0 in Comparative Example 5, and 50.0 in Comparative Example 6.
From Table 1, it can be seen that, when the qunacridone solution containing PV-19 (raw material) was used as the raw material solution (first fluid), adhesion onto the processing surfaces 1 and 2 could be easily prevented from occurring, and thereby uniform fine particles could be continuously obtained stably even in the operation for a long period of time.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-119801 | May 2011 | JP | national |
| 2011-121038 | May 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/056735 | 3/15/2012 | WO | 00 | 11/27/2013 |
