The present invention generally relates to a chemical transformation system for the realization, for example, of 3D state materials.
In particular, the present invention relates to a system for the realization, also in supercritical and/or critical conditions, of 3D inorganic materials at high reactivity.
Still more in particular the present invention relates to a system for chemical transformation of 3D materials without changing the structural hierarchy, for example, through heterogeneous reactions at high temperature and/or pressure among solid 3D precursors and highly reactive and homogeneous gas or gas mixtures.
Generally, processes for the preparation of 3D materials, for example, based on calcium carbonate (CaCO3) at high reactivity to be used as precursors for the synthesis of calcium phosphates-based materials are known.
For example a process of this type is known from patent publication WO2017/021894_A1.
A problem found in the known process is that the transformation of 3D material from calcium oxide (CaO) to calcium carbonate (CaCO3) is, generally, particularly critical due to lack of reagent homogeneity.
In particular, Applicants observed that a possible use, in the known process of carbon dioxide (CO2) enriched of water (H2O) does not always guarantee to obtain 3D materials with initial structure preserved and/or completely transformed from calcium oxide (CaO) to calcium carbonate (CaCO3).
Applicants also observed that generally the known systems do not always guarantee to obtain 3D materials with initial structure completely preserved and/or at least partially transformed even in case of 3D materials based on nitrides, based on metal oxides, based on carbonates, etc.
Generally, Applicants observed that the known systems for transformation are not optimized to always guarantee the chemical transformation of 3D materials so that said materials, as regards the structure, are completely preserved and/or at least partially chemically transformed.
The object of the present invention is to solve in an optimized way the above mentioned problems of the prior art.
Such an object is achieved by the system for chemical transformation of 3D materials having the features set forth in the claims that follow.
The present invention relates also to a method for the realization, on 3D materials, of chemical converted and highly reactive surface layers with variable thickness.
The following synthetic description of the invention is given for the purpose of providing a basic understanding of some aspects of the invention.
This synthetic description is not an extended description and, as such, it is not intended as suitable to identifying key or critical elements of the invention or suitable to delineate the scope of the invention. Its only purpose is to introduce some contents of the invention in a simplified form as a preview of the below detailed description.
According to a feature of a preferred embodiment the system comprises a main body comprising a reaction chamber, in which one or more gas are released, and at least two turbines arranged to converge, in use, into the reaction chamber the one or more gas on 3D state material samples to be chemically transformed.
According to another feature the system is arranged to chemically transform the 3D state material samples in order to obtain 3D materials with initial structure preserved and/or completely o partially transformed.
According to another feature of the present invention the reaction chamber is realized so as to allow the release of one or more gas highly energized.
These and other features and advantages of the present invention will appear more clearly from the following description of preferred embodiments provided by way of non limiting examples with the aid of the attached drawings, in which components designated by same or a similar reference numerals indicate elements having the same or similar functionality and constructions and wherein:
Here it is specified that in the context of the present description the terms: superior, inferior, vertical and possible further terms related to geometrical arrangement of the various components of the system are used in their conventional meaning.
With reference to
According to the preferred embodiment the GAS group 14 comprises one or more gas cylinders 41 comprising reacting gas under pressure, for example carbon dioxide (CO2), and a gas control unit 42 arranged to suck air from the reactor group 12 by way of a known vacuum pump and to provide in a controlled way into the reactor group 12 gas coming from the one or more gas cylinders 41.
According to the preferred embodiment the gas control unit 42 is arranged to manage the flow of the reacting gas towards the reactor group 12.
Preferably the gas control unit 42 is arranged to control the flow of the gas into the reactor group 12 in an automated way, for example through an electronic pressure regulator or a mass flow regulator, controlled, in a known way, by a properly programmed PLC (Programmable Logic Controller).
Preferably, the gas control unit 42 comprises a pressure sensor device 45 and is connected to known-type devices, comprised in the reactor group 12, such as temperature sensor devices 44 (
The reactor group 12, for example of a metallic type and suitable to operate at high temperature and pressure, is arranged to transform in complete and uniform way the 3D samples from calcium oxide (CaO) to calcium carbonate (CaCO3).
In the preferred embodiment the reactor group 12 comprises a main body 20, preferably cylindrical, configured so as to shape a chamber (reaction chamber) 12a, and a bottom 22, for example a flat bottom, placed at the base of the reactor group 12 and arranged, preferably, to be connected, in a known way, to the gas cylinders 41, to the vacuum pump and to temperature 44 and/or pressure sensor devices 45 through the gas control unit 42.
The main body 20 comprises, preferably, at a upper end, a folder 20a arranged to co-operate in sealing the reaction chamber 12a through one or more known-type seals.
The main body 20 further comprises, preferably, a top component 21, for example a top cap comprising a hole 21a, for example a central hole. The top component 21, preferably, is arranged to seal, in use, the reaction chamber 12a, to support the samples 11 and to allow the passage through the central hole 21a of an axis 23 arranged, in use, to rotate in a controlled way, clockwise or counterclockwise by way of a motor, for example, two groups of fixed blades or turbines 25 secured, according to the present embodiment, to the axis 23.
The turbines 25, preferably at least two, are, for example, secured to the axis 23, spaced apart from each other, and are arranged to converge on samples 11 between the turbines 25 the chemical substances (gas) present into the reaction chamber 12a.
The main body 20 also comprises, according to the preferred embodiment, a lower component 26, for example a casing component arranged to contain a chemical agent, for example calcium hydroxide (Ca(OH)2), arranged to release, in use, steam into the reaction chamber 12a. The lower component or casing component 26 is connected, for example, to the top component 21 through a plurality of bars 26a that, in the preferred embodiment, comprise connection or hooking elements 26b arranged to support the samples 11 to be chemically transformed.
The main body 20 of the reactor group 12, preferably, is comprised inside an oven 15 arranged to heat, in use, in a controlled way, through, for example, electrical resistances placed in correspondence to the main body 20, the reaction chamber 12a of the reactor group 12.
Preferably, near the electrical resistances is placed an oven temperature sensor 54 arranged to acquire and transmit over time data recording of temperature coming from inside the oven 15 to an oven control unit 52, for example a known-type computer.
In use it is expected that the main body 20 can be sealed by means of jaws 29, for example two jaws, arranged to seal the folder 20a and the top component 21 of the main body 20.
According to the present embodiment it is expected that the main body 20 together with the components comprised in it, such as the top component 21, the lower component 26, the bars 26a and the hooking elements 26b, can be extracted, for example vertically, from the oven 15 in order to allow hooking to the hooking elements 26b the samples 11 to which the chemical reaction of transformation from calcium oxide (CaO) to calcium carbonate (CaCO3) is applied.
The operation of the system as described above is the following.
Generally, the system 10 has been realized, according to the first embodiment, to perform carbonation processes, at high temperature and pressure, on material samples 11 made of calcium oxide (CaO) by way of chemical transformation of or reaction with carbon dioxide (CO2) in the supercritical state and in the presence of steam (H2O) which is suitable to catalyze the reaction. The final result of the process implemented by the system is to obtain samples made of calcium carbonate (CaCO3), with the same initial macro- and micro-structure of the samples 11 made of CaO.
In other words the carbonation reaction can be summarized according to the following Equation 1:
Wherein:
(sc)=supercritical state;
(s)=solid state;
(g)=gaseous state.
The start-up procedure of the system 10 comprises, for example, the following steps, also in a different order than the one listed here:
The transformation procedure is carried out by checking over time the trend of pressure and temperature measured by the temperature sensor 44 comprised inside the reactor group 12, i.e. inside the reaction chamber 12a, and by the pressure sensor 45 comprised, preferably, in the GAS group 14 and by the temperature sensor 45 comprised in the oven 15. Preferably, the pressure sensor 45 is located out of the reaction chamber to avoid it being affected by temperatures inside the reaction chamber itself.
According to other embodiments it is expected that the temperature sensor 54 comprised in the oven is not present and that it is sufficient to control the temperature through the temperature sensor 44 comprised in the reaction chamber.
Preferably the temperature and pressure trends are displayed on a computer, for example on the oven control unit 52 also connected, in known way, to the gas control unit 42.
In the present description, the temperature and pressure trends are displayed in
As exemplified in
Applicants have verified experimentally that in case of absence of samples the trend of the curve would be linear with a slope greater than the previous one.
Experimentally it has been also verified that CO2 is placed in the supercritical state in the area of the diagram delimited by dashed line 63, for example with temperatures T>about 310° C. and P>72.9 atm.
Still more particularly it has been verified experimentally that the temperature from which starts the super-critical state is with temperature values at least higher than T>250° as a function of the amount of charged gas, of the ramp in time of temperature and of the number of samples.
Due to thermodynamic reasons linked to the reaction, only starting from about 300° C. and in presence of CO2 the calcium hydroxide is able to free H2O in the reaction chamber. The H2O will mix with the CO2 through the turbines 25, preferably mutually opposed, and starts the carbonation process of the samples made of CaO; the process can be represented by the following Equations 2 and 3 which are correspondent to the respective reactions:
or also by summary Equation 4 of reactions 2 and 3:
CaO (s3D)+CO2 (sc)+H2O (g)CaCO3 (s3D)+H2O (g) Eq. 4
(sc)=supercritical state;
(s)=solid state shaped as powder (p) or 3D (3D);
(g)=gaseous state.
The Equation 4 shows that in the reactor group 12, i.e. in the reaction chamber 12a, it is occurring a direct reaction with mixture CO2/H2O, which does not require that the CO2 is subjected to a preliminary hydration process.
Advantageously, thanks to the system 10, as described, ideal conditions of contextual hydration+carbonation are created.
As a matter of fact, in the described embodiment and in the concomitant carbonation process the formation of Ca(OH)2 is locally limited in every instant of the process; as a matter of fact the newly created Ca(OH)2 reacts immediately with CO2 to generate CaCO3.
With the introduction of the system 10 and, in particular, of the reactor group 12 comprising a plurality of blades or turbines 25 arranged to shake and contain near the samples 11 the substances present in the reaction chamber 12a, Applicants have experimentally verified that it is possible to create inside the same reaction chamber 12a, during the carbonation, an homogeneous, controlled and highly reactive CO2/H2O mixture, without the need of a hydration process of CO2 before the carbonation process.
In summary the system and, in particular, the described reactor group 12 are arranged to always guarantee samples completely transformed from calcium oxide (CaO) to calcium carbonate (CaCO3) without the need of a hydration process of CO2 before the carbonation process.
The system has been described by providing porous samples in CaO of variable shape.
As far as the Applicant have realized preferably the carbonation of samples of cylindrical shape with diameter comprised between Ø=30 mm and 10 mm, length comprises between 60 mm and 10 mm, weight comprises between 35 g and 2 g, it is easily understandable for a person skilled in the art that the samples can be of different shapes and sizes and weight even greater that those indicated as a function of the size of the reaction chamber, without departing from the scope of what has been described and claimed.
Similarly the samples can also be not porous or dense without departing from the scope of what has been described and claimed.
According to other embodiments it is expected to change the number or the arrangement of the turbines along the axis or, also, the shape of the turbines in order to change the type of gas turbulence inside the reaction chamber, especially as a function of placement, shape, size, weight, porosity or density of the samples. In case of high density samples it is expected that penetration depth of the transformation process from CaO to CaCO3 is a function of the density of the samples.
According to some further embodiments it is expected, for example, the introduction in the reaction chamber of alternatives hydroxides with respect of the calcium, for example strontium hydroxide (release of H2O at T>100° C.) or magnesium (release of H2O at T>200° C.) in order to anticipate the startup of the carbonation of CaO.
According to other embodiments it is expected that the described system and method are used, for example, for the production of 3D materials based on nitrides:
In this case the GAS group 14 comprises as reacting gas in pressure one or more gas cylinders containing nitrogen (e.g. ammonia (NH3), nitrogen (N2), etc.) and the reactor group 12 is substantially the same of the one described in the preferred embodiment with the only possible variant that the lower component 26 does not contain a chemical agent suitable to release steam, but however, if present, is connected to the top component 21 so as to allow hooking samples 11. In case of absence of the lower component 26, the only top component allow hooking samples to the reactor group 12.
The operation of the system 10 in case of nitrides requires that a chemical reaction takes place between a 3D solid oxide and/or a NH3—H2O mixture in presence of NH3, coming for example from the gas group 14 or from the lower component 26 (for example by way of generation of reactive NH3 starting from subject to deterioration salt containing nitrogen).
The chemical transformation can be represented, for example, in the following way, respectively:
B2O3+2NH32BN+ . . .
Al2O3+2NH32AlN+ . . .
TiO2+NaNH2TiN+ . . .
SiO2+NH3+H2OSi3N4+ . . .
. . . represent secondary products, as easily understandable by a person skilled in the art.
In addition to the nitriding processes, for example, metal nitrocarbonization processes in presence of NH3+CO2 mixture or metal oxycarbonation processes in presence of NH3+H2O mixture can also be expected as comprised in the object of the system 10 as described.
According to further embodiments it is expected that the described system and method are used, for example, for the production of 3D materials based on metal oxides:
In this case the GAS group 14 could be not present and the reactor group 12 is substantially the same as the one described in the preferred embodiment.
The operation of the system 10 in case of metal oxides provides that a chemical reaction will be realized as shown below:
TiO2+BaCl2+H2OBaTiO3+ . . .
TiO2+CaO+H2OCaTiO3+ . . .
. . . represent secondary products, as easily understandable by a person skilled in the art.
According to another further embodiments it is provided that the described system and method are used, for example, for the production of 3D materials based on carbonates:
In this case the reactor group 12 is substantially the same as the one described for the first preferred embodiment.
The operation of the system 10 in case of carbonates provides that a chemical reactions will be realized as shown below:
MgO+CO2+H2OMgCO3+ . . .
. . . represent secondary products, as easily understandable by a person skilled in the art.
Advantageously it will be appreciated that in all the embodiments the presence, for example, of at least two groups of fixed blades or turbines 25 are provided to the axis 23, according to the exemplary embodiments.
The groups of blades or turbines 25 are, preferably, fixed to the axis 23 and are arranged so as to converge, among the group of shovels or turbines 25, the substances present inside the reaction chamber 12a in which the samples are comprised.
It is shown below, for completeness of description, an example of the carbonation process used to realize intermediate steps of a more complex process arranged for generating 3D samples made of hydroxyapatite starting from natural porous structures:
Of course, obvious changes and/or variations to the above disclosure are possible, as regards dimensions, shapes, materials, components and connections, as well as details of the described construction and operation method without departing from the scope of the invention as specified in claims that follow.
Number | Date | Country | Kind |
---|---|---|---|
102018000007993 | Aug 2018 | IT | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/EP2019/070155 | 7/26/2019 | WO | 00 |