Development and experimental evaluation of a mixing device for the dry production of sodium percarbonate

The growing global demand for detergents, cleaning agents, and disinfectants necessitates the production of high-quality and energy-efficient chemical products. Sodium percarbonate is considered an important industrial compound due to its environmental safety and high active oxygen release capacity. In this study, a dry-process technology for the production of high-active-oxygen sodium percarbonate was developed. The proposed method involves preconditioning sodium carbonate into a crystalline hydrate form, followed by its reaction with highly concentrated (60%) hydrogen peroxide, enabling the formation of sodium percarbonate under mild conditions. To enhance process efficiency, a specialized mixing device capable of direct interaction between liquid and solid phases was developed. The device is equipped with spray nozzles for the liquid phase and triangular, rectangular, and pentagonal blades for intensive mixing of the solid phase. A cooling jacket was installed to control the heat released during mixing, reducing the mixture temperature to 15 °C. The influence of blade geometry on process performance was experimentally investigated. The results showed that the pentagonal blade, operating at a rotational speed of 120 rpm, provided optimal performance, yielding sodium percarbonate with an active oxygen content of 14.8%. The obtained results comply with production requirements and industrial standards.

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