Microwave plasma powder spheroidization device

Abstract

This invention discloses a microwave plasma powder spheroidization device, comprising a microwave generator, a working fan, a flare treatment chamber, a feeder, an ultracooling chamber, and an induced draft fan. The microwave generator ionizes the working gas to generate a high-temperature plasma flare (with a maximum center temperature of 6000K). The feeder delivers powder into the flare treatment chamber, where it melts into spherical droplets. These droplets then rapidly solidify into spherical particles in the ultracooling chamber. This device achieves efficient and low-pollution powder spheroidization through microwave discharge. It is suitable for various materials such as metals, ceramics, and quartz, and features high sphericity (≥95%), low energy consumption, and strong process controllability. It can be widely used in powder metallurgy, 3D printing, and other fields.

Description

Technical Field

[0001] This utility model belongs to the field of spheroidizing equipment technology, specifically relating to a microwave plasma powder spheroidizing device. Background Technology

[0002] Powder spheroidization is a key technology for transforming powder materials into spherical particles, and it is widely used in powder metallurgy, ceramics, chemicals, pharmaceuticals, 3D printing, and other fields. Spheroidization significantly improves the flowability, bulk density, uniformity, and stability of powder materials, enhancing the efficiency of subsequent processing and product quality, while simultaneously reducing production costs.

[0003] Limitations of existing powder spheroidization methods:

[0004] Roller spheroidizing method: Relies on mechanical tumbling and spheroidizing agents, it is only suitable for scenarios with moderate sphericity requirements (such as catalysts and chemical raw materials), which is difficult to meet the needs of high-precision fields and may introduce impurities.

[0005] High-speed airflow impact method: Although it is suitable for graphite-based anode materials, it has limited effect on hard or high-melting-point powders and causes significant equipment wear.

[0006] Vacuum induction gas atomization (VIGA) and plasma atomization (PA): mainly for metal powders, especially high-temperature alloys and active metals. The equipment is complex, costly, and requires inert gas protection, so the application range is relatively narrow.

[0007] Flame spheroidization method: Based on high-temperature flame melting (1600-2000℃), it has high energy consumption and poor temperature uniformity. It is only applicable to a few low-melting-point materials such as quartz, and the sphericity is difficult to control.

[0008] Plasma melting method: This method uses electric arc plasma, which has problems such as electrode wear and easy contamination of the molten material, affecting the purity and performance of the spheroidized powder.

[0009] Existing methods generally suffer from problems such as a narrow range of applicable materials, low spheroidization efficiency, high energy consumption, complex equipment, or pollution. In particular, there is a lack of a highly efficient, low-pollution spheroidization technology applicable to a variety of powder materials. Therefore, developing a novel powder spheroidization device based on microwave plasma has significant practical implications. Utility Model Content

[0010] To address the problems mentioned in the background section, this invention provides a microwave plasma powder spheroidizing device. This device generates a high-temperature plasma torch through microwave discharge, achieving efficient melting and spheroidizing of powders and rapid solidification. This solves the problems of limited applicable materials, high pollution risk, and high energy consumption in existing technologies.

[0011] A microwave plasma powder spheroidizing device utilizes the avalanche breakdown of an electromagnetic field to generate microwave plasma discharge in a plasma gas. Microwave radiation is converted into thermal plasma energy, forming a plasma torch with a core temperature reaching 6000K. Powder particles rapidly melt in the high-temperature torch, condensing into spherical droplets due to surface tension, and then rapidly solidify in an ultracold chamber to fix the spherical structure.

[0012] This device includes the following components:

[0013] Microwave generator: generates microwave energy to ionize working gas.

[0014] Working fan: Provides working gas (such as inert gases like argon and nitrogen, or air) to form a plasma discharge environment.

[0015] Flame processing chamber: Contains a high-temperature plasma flare and has a powder inlet to ensure full contact between the powder and the flare.

[0016] Feeder: Precisely controls the powder feeding rate to uniformly transport the powder to the flare processing chamber.

[0017] Ultra-cold chamber: It is equipped with a rapid cooling medium (such as low-temperature inert gas, coolant or cooling wall) to quickly solidify spherical droplets. A discharge valve is set at the bottom to collect the finished product.

[0018] Exhaust fan: Extracts the exhaust gas generated during the treatment process and can be connected to an exhaust gas treatment system.

[0019] Microwave discharge: Microwaves are transmitted through electrodes to form plasma at the electrode tip. With the cavity of the processing chamber insulated and the electrodes supplied with cooling water, the electrodes are consumed very slowly, avoiding the electrode wear and contamination problems of traditional electric arc plasma, and ensuring the high purity of the spheroidized powder.

[0020] High-temperature plasma torch: Provides instantaneous high temperature (up to 6000K), suitable for rapid melting of high-melting-point powders (such as metals and ceramics).

[0021] Rapid cooling solidification technology: The intense cooling environment inside the ultra-cold chamber ensures that spherical droplets solidify rapidly, preventing shape distortion and improving sphericity.

[0022] Modular design: Each component (such as microwave generator, flare treatment chamber, and ultra-cold box) can be disassembled and maintained independently, which facilitates equipment upgrades and process adjustments for different powder materials.

[0023] Compared with the prior art, the beneficial effects of this utility model are:

[0024] High-efficiency spheroidization: The high energy density of microwave plasma enables instantaneous melting of powder, resulting in a significantly higher processing efficiency than traditional methods.

[0025] Wide range of applications: It can process a variety of powder materials such as metals (such as titanium and stainless steel), ceramics (such as alumina and zirconium oxide), and quartz, with a sphericity of over 95%.

[0026] Low pollution: Electrode-free discharge avoids metal ion contamination, and the inert gas environment prevents powder oxidation, making it suitable for high-purity applications (such as 3D printing metal powder).

[0027] Energy consumption optimization: Microwave energy acts directly on plasma, resulting in high energy utilization and reducing energy consumption by more than 30% compared to the flame method.

[0028] High process controllability: By adjusting the microwave power, working gas flow rate, feeding speed and ultra-cold box temperature, the powder particle size (10-500μm) and sphericity can be precisely controlled. Attached Figure Description

[0029] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0030] Figure 1 This is a front view structural diagram of the present utility model;

[0031] Figure 2 This is a top view of the structure of this utility model;

[0032] In the picture:

[0033] 1. Microwave generator 2. Working fan 3. Flame treatment chamber 4. Feeder 5. Ultra-cold box 6. Exhaust fan. Detailed Implementation

[0034] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model. Example

[0035] like Figure 1-2 As shown;

[0036] A microwave plasma powder spheroidizing device.

[0037] In this implementation plan: In order to solve the technical problems existing in the prior art, such as the problems disclosed in the background art above, "existing methods generally have problems such as narrow applicable material range, low spheroidization efficiency, high energy consumption, complex equipment or pollution, and especially lack a high-efficiency, low-pollution spheroidization technology applicable to a variety of powder materials", in combination with practical use, this problem is obviously a real and difficult problem to solve. Therefore, in order to solve this technical problem, a microwave plasma powder spheroidization device is provided.

[0038] like Figure 1-2 As shown in the figure;

[0039] Based on the above, the system includes a microwave generator 1, a working fan 2, a flare treatment chamber 3, a feeder 4, an ultra-cooling chamber 5, and an induced draft fan 6 connected in sequence. The microwave generator 1 generates microwave energy to ionize the working gas delivered by the working fan 2, forming a high-temperature plasma flare in the flare treatment chamber 3. The feeder 4 delivers powdered material into the flare treatment chamber 3, where it comes into contact with the plasma flare and melts to form spherical droplets. The ultra-cooling chamber 5 is equipped with a rapid cooling environment to quickly solidify the spherical droplets into spherical particles. The induced draft fan 6 is used to extract exhaust gas.

[0040] The torch processing unit 3 has a cylindrical or conical cavity inside, with the inner wall made of high-temperature resistant and corrosion-resistant materials (such as corundum and silicon carbide). The feed inlet is located at the top or side of the cavity and is sealed to the feeder 4.

[0041] The ultra-cold chamber 5 includes a cooling chamber and a material collection unit. The cooling chamber is equipped with spray-type cooling nozzles or coil-type cooling structures, which can be circulated with liquid nitrogen, low-temperature inert gas or coolant. The cooling temperature range is -150℃ to room temperature.

[0042] The working gas is an inert gas such as argon, nitrogen, or helium, or air. The working gas flow rate is precisely controlled by a gas mass flow meter, ranging from 5 to 20 L / min.

[0043] The microwave generator 1 has a microwave frequency of 915MHz and an adjustable output power range of 15-30kW. It is connected to the flare treatment chamber 3 via a waveguide or coaxial cable.

[0044] Microwave discharge: Microwaves are transmitted through the electrodes to form plasma at the electrode tip. With the cavity of the processing chamber insulated and the electrodes supplied with cooling water, the electrodes are consumed very slowly, thus allowing for water cooling.

[0045] The feeder 4 is a screw feeder, vibrating feeder, or pneumatic conveying device, with an adjustable feeding rate of 0.1-5 kg / h, and features anti-clogging and metering functions.

[0046] The induced draft fan 6 is connected to the exhaust gas treatment system, which includes a filter, condenser or adsorption device, for removing dust and volatile substances from the exhaust gas.

[0047] It also includes a control system, which is electrically connected to the microwave generator 1, the working fan 2, the feeder 4, the ultra-cold box 5 and the induced draft fan 6, and is used to monitor and adjust the working parameters of each component in real time (such as microwave power, gas flow rate, temperature, feeding speed, etc.).

[0048] Microwave generator 1 and working fan 2 are respectively connected to flare treatment chamber 3. The working fan delivers working gas (such as argon, flow rate 5-20L / min) into the flare treatment chamber.

[0049] The feeder 4 feeds powder (such as titanium powder, with a particle size of 50-200μm) into the flare treatment chamber at a rate of 0.1-5kg / h through the feed inlet. The powder particles come into full contact with the high-temperature plasma flare, absorb heat to the melting state, and form spherical droplets.

[0050] Spherical droplets enter the ultracold chamber 5 with the airflow. Liquid nitrogen or low-temperature nitrogen gas (temperature -100℃ to -150℃) is introduced into the ultracold chamber. The droplets quickly solidify into spherical particles within 0.1-1 seconds, gather at the bottom of the ultracold chamber, and are periodically discharged and collected through the discharge valve.

[0051] The exhaust gas (containing a small amount of volatiles) generated during the treatment process is extracted by the induced draft fan 6 and can be connected to a filter or condenser for purification.

[0052] Finally, it should be noted that the above are merely preferred embodiments of this utility model and are not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A microwave plasma powder spheroidizing device, characterized in that, The system includes a microwave generator (1), a working fan (2), a flare treatment chamber (3), a feeder (4), an ultra-cold chamber (5), and an induced draft fan (6) connected in sequence. The microwave generator (1) is used to generate microwave energy to ionize the working gas transported by the working fan (2) and form a high-temperature plasma flare in the flare treatment chamber (3). The feeder (4) delivers powder material into the flare treatment chamber (3) and melts it in contact with the plasma flare to form spherical droplets. The ultra-cold chamber (5) is equipped with a rapid cooling environment to quickly solidify the spherical droplets into spherical particles. The induced draft fan (6) is used to extract exhaust gas.

2. The microwave plasma powder spheroidizing device according to claim 1, characterized in that, The inside of the flare treatment chamber (3) is a cylindrical or conical cavity. The flare treatment chamber (3) is provided with a feed inlet located at the top or side of the cavity. The feed inlet is sealed to the feeder (4).

3. The microwave plasma powder spheroidizing device according to claim 1, characterized in that, The ultra-cold box (5) includes a cooling chamber and a material collection unit. The cooling chamber is equipped with a spray-type cooling nozzle or a coil-type cooling structure.

4. The microwave plasma powder spheroidizing device according to claim 1, characterized in that, The working fan (2) is connected to a gas mass flow meter.

5. The microwave plasma powder spheroidizing apparatus according to claim 1, characterized in that, The microwave generator (1) is connected to the flare processing chamber (3) via a waveguide or coaxial cable.

6. The microwave plasma powder spheroidizing apparatus according to claim 1, characterized in that, The feeder (4) is a screw feeder, a vibrating feeder, or a pneumatic conveying device.

7. The microwave plasma powder spheroidizing device according to claim 1, characterized in that, The induced draft fan (6) is connected to the exhaust gas treatment system, which includes a filter, a condenser or an adsorption device.

8. The apparatus according to any one of claims 1-7, characterized in that, It also includes a control system, which is electrically connected to the microwave generator (1), working fan (2), feeder (4), ultra-cold box (5) and induced draft fan (6) for real-time monitoring and adjustment of the working parameters of each component.

Images