Apparatus and process for continuous milling and drying of slurry and wet solid materials

Abstract

Apparatus (100) for the continuous treatment of slurry and wet solid materials comprises a supply blower (14) delivering heated air through a heater (4) into a milling and dispersion chamber (19) containing high-speed mills (17,18) for material processing. The dispersed material is then transferred to a drying chamber (1) where heat and mass transfer occur, facilitated by adjustable airflow via a flap valve (20). Coarse and fine particles are separated using first and second cyclone separators (2, 3), with collected particles stored in collectors (8, 15). An exhaust suction blower (6) maintains system airflow, while a control panel (7) equipped with temperature sensors (21), airflow controls, and motor speed controls ensures optimal operation. The apparatus (100) also features variable-speed blowers (6, 14), variable-speed motors for the mills (17,18), a screw feeder (16) for material introduction, and a hot air recirculation system to reduce energy consumption and achieve efficient treatment.

Description

[0001] APPARATUS AND PROCESS FOR CONTINUOUS MILLING AND DRYING OF SLURRY AND WET SOLID MATERIALS

[0002] FIELD OF INVENTION

[0003]

[0001] The present application generally relates to the field of material processing, and more particularly to an apparatus and process for continuous milling and drying milling of slurry and wet solid materials.

[0004] BACKGROUND OF THE INVENTION

[0005]

[0002] In the chemical, pharmaceutical, food, paper, and fertilizer industries, the production processes often generate slurry and wet solid materials that require drying and milling. These materials need to be dried to remove moisture content and then milled to achieve the desired particle size. The drying process typically employs various types of dryers, such as tray dryers, agitated nutsche filter dryers, paddle dryers, and rotary vacuum dryers. Following the drying process, the materials are milled using equipment like multi mills to break down larger particles and achieve uniformity.

[0006]

[0003] Existing methods for drying and milling slurry and wet solid materials generally involve batch operations. For instance, a common approach includes loading the material into a tray dryer, where it is indirectly heated under vacuum conditions to remove moisture. Once the drying process is complete, the dried material is transferred to a milling machine to reduce particle size. This sequential use of separate machines for drying and milling is standard practice in the industry.

[0007]

[0004] However, the batch operation method presents several limitations. The need for separate equipment for drying and milling results in larger equipment sizes, multiple stages of process and longer processing times. This approach also leads to higher energy consumption and inconsistent product quality due to the variability in batch processing. Additionally, the use of multiple machines increases capital and operating costs, requires more manpower, and occupies more space. Material losses during transfers, safety issues, and product exposure are further drawbacks associated with batch operations.

[0008]

[0005] Given these deficiencies, there is a clear need for an improved solution that addresses the inefficiencies of the current methods. The invention titled "Apparatus and Process for Continuous Milling and Drying of Slurry and Wet Solid Materials" aims to overcome these challenges by providing a more efficient and streamlined approach to the treatment of slurry and wet solid materials.

[0009] OBJECT OF THE INVENTION

[0010]

[0006] The object of the invention is to develop an apparatus that can perform milling, drying, and particle segregation continuously, thereby enhancing efficiency and productivity in the handling of wet solid materials.

[0011]

[0007] Another object of the invention is to enable the apparatus to mill and dry wet solid materials simultaneously, eliminating the need for separate drying and milling stages, which simplifies the process and reduces the time required for these operations.

[0012]

[0008] Yet another object of the invention is to ensure that the drying process operates at low temperatures, thereby preserving the quality of the material and potentially reducing energy consumption, which is particularly beneficial for heatsensitive materials.

[0013]

[0009] A further object of the invention is to design a compact and efficient apparatus capable of performing milling, drying, and particle size segregation within a single unit. This integration simplifies the process, reduces the need for multiple machines, and minimizes the space requirement of the equipment.

[0014]

[0010] An additional object of the invention is to minimize the overall energy consumption required for milling, drying, and particle segregation, making the process more sustainable and cost-effective. This is achieved through the efficient design and operation of the apparatus.

[0015] [OH] Another object of the invention is to reduce the overall time required for the combined processes, thereby increasing throughput and efficiency. This is particularly important in industrial applications where time efficiency translates to higher productivity.

[0016]

[0012] Yet another object of the invention is to ensure that the milling and drying processes take place almost instantaneously. This rapid drying process reduces the likelihood of drying-induced impurity pick-up, thereby maintaining the purity and quality of the final product.

[0017]

[0013] By achieving these objectives, the invention aims to streamline the processing of wet solid materials, making it more efficient, cost-effective, and environmentally friendly. The versatile machine described finds applications across various industries, including chemical production, pharmaceuticals, and pulp and paper, among others. In the food and vegetable industry, the apparatus is particularly effective for drying and powdering vegetables and fruits, preserving their nutritional integrity, natural flavours, and colors with minimal losses.

[0018] SUMMARY OF THE INVENTION

[0019]

[0014] This summary is provided to introduce a selection of concepts, in a simple manner, which is further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the subject matter, nor to determine the scope of the invention.

[0020]

[0015] Embodiments of the present invention provide an apparatus for continuous treatment of slurry and wet solid materials, comprising a supply blower configured to deliver air to heater, a heater connected to the supply blower for heating the air, a milling and dispersion chamber connected to the supply blower through heater, the chamber containing high-speed mills for milling and dispersing the slurry or wet solid material, a drying chamber connected to the milling and dispersion chamber, configured to receive dispersed material and hot air, facilitating heat and mass transfer for drying, a flap valve positioned between the drying chamber and a cyclone separator, adjustable to regulate airflow and residence time of the material, a first cyclone separator connected to the drying chamber for separating coarse particles from the dried material, a second cyclone separator connected to the first cyclone separator for further separating fine particles from the dried material, collectors positioned at the bottom of each cyclone separator for collecting separated particles, an exhaust suction blower connected to the second cyclone separator for maintaining airflow through the system, and a control panel for monitoring and controlling the apparatus, including temperature sensors, airflow controls, and motor speed controls.

[0021]

[0016] The apparatus offers several advantages, including the ability to perform milling, drying, and particle segregation in a single apparatus, continuous operation, thereby enhancing efficiency and productivity. The simultaneous milling and drying of wet solid materials eliminate the need for separate stages, reducing processing time and energy consumption. The low-temperature drying process preserves the quality of the material and further reduces energy usage. The compact design of the apparatus simplifies the process and reduces the need for multiple machines, making it more cost-effective and environmentally friendly.

[0022]

[0017] In accordance with an embodiment of the present invention, the supply blower and exhaust suction blower are variable-speed blowers for controlling airflow rates and velocities within the system. This feature allows for precise control over the drying and milling processes, ensuring optimal performance and energy efficiency.

[0023]

[0018] In accordance with an embodiment of the present invention, the high-speed mills in the milling and dispersion chamber are powered by variable-speed motors to adjust milling intensity based on material properties. This adaptability ensures that the apparatus can handle a variety of materials with different characteristics, maintaining consistent quality and efficiency.

[0024]

[0019] In accordance with an embodiment of the present invention, the apparatus further comprises a screw feeder configured to introduce slurry or wet solid material into the milling and dispersion chamber at a controlled rate. This controlled feeding mechanism ensures a steady flow of material into the chamber, optimizing the milling and drying processes.

[0020] In accordance with an embodiment of the present invention, the drying chamber is a vertical cylindrical pipe providing ample space for dispersed particles to interact with hot air, ensuring efficient drying. The vertical design facilitates the upward movement of particles, enhancing the heat and mass transfer processes.

[0025]

[0021] In accordance with an embodiment of the present invention, the apparatus further comprises a hot air recirculation system connected to the exhaust suction blower and supply blower, configured to recycle a portion of the exhaust air to reduce energy consumption. This system enhances the sustainability of the apparatus by minimizing energy waste.

[0026]

[0022] In accordance with an embodiment of the present invention, the hot air recirculation system includes a bleed control valve to exhaust a portion of the recirculated air and a suction control valve to introduce fresh air into the system. These valves ensure a balanced and controlled recirculation process, maintaining optimal drying conditions.

[0027]

[0023] In accordance with an embodiment of the present invention, the control panel includes programmable logic controllers (PLCs) to automate the operation of the temperature sensors, blowers, and heater. This automation ensures consistent and precise control over the apparatus, enhancing its efficiency and reliability.

[0028]

[0024] In accordance with an embodiment of the present invention, the apparatus further comprises pressure sensors in the drying chamber to monitor and maintain optimal pressure levels for efficient drying and milling processes. These sensors provide real-time data, allowing for adjustments to be made to maintain optimal operating conditions.

[0029]

[0025] Embodiments of the present invention also provide a process for continuous treatment of slurry and wet solid materials using the apparatus, comprising introducing the slurry or wet solid material into the milling and dispersion chamber using a screw feeder, milling and dispersing the material using high-speed mills while simultaneously introducing heated air from the supply blower, transferring the dispersed material and hot air into the drying chamber for heat and mass transfer, resulting in drying of the material, adjusting the flap valve to regulate airflow and material residence time within the drying chamber, separating coarse and fine particles using the first and second cyclone separators, respectively, collecting the separated particles in the collectors at the bottom of each cyclone separator, maintaining airflow through the system using the exhaust suction blower, and monitoring and controlling the process parameters, including temperature, airflow, and motor speeds, using the control panel.

[0030]

[0026] This process ensures a continuous and efficient treatment of slurry and wet solid materials, enhancing productivity and reducing processing time. The integration of milling, drying, and particle segregation into a single apparatus streamlines the process, making it more cost-effective and environmentally friendly. The use of variable-speed blowers and motors, along with automated control systems, ensures precise and consistent operation, maintaining high-quality output. The hot air recirculation system further enhances energy efficiency, making the apparatus a sustainable solution for the treatment of wet solid materials.

[0031] BRIEF DESCRIPTION OF THE DRAWINGS

[0032]

[0027] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments. These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:

[0033] Fig. 1 illustrates an apparatus for continuous treatment of slurry and wet solid materials, in accordance with an embodiment of the present invention; Fig. 2 illustrates a front view of the apparatus of Fig. 1, in accordance with an embodiment of the present invention;

[0034] Fig. 3 illustrates a side view of the apparatus, in accordance with an embodiment of the present invention;

[0035] Fig. 4 illustrates a back view of the apparatus, in accordance with an embodiment of the present invention; and

[0036] Fig. 5 illustrates A-A section of the apparatus shown in Fig. 4, in accordance with an embodiment of the present invention.

[0037] DETAILED DESCRIPTION OF THE DRAWINGS

[0038]

[0028] The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description.

[0039]

[0029] While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this description, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers, or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles, and the like is included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.

[0040]

[0030] This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.

[0041]

[0031] The present invention relates to an apparatus and process for the continuous milling and drying of slurry and wet solid materials. The apparatus integrates milling, drying, and particle segregation into a single, continuous operation, thereby enhancing efficiency and productivity. The invention aims to address the need for a compact and efficient system capable of performing multiple functions within one unit, simplifying the process and reducing the need for multiple machines.

[0042]

[0032] The apparatus comprises a milling and dispersion chamber equipped with high-speed mills powered by variable-speed motors, which facilitate the simultaneous milling and drying of wet solid materials. An inlet hot air duct connected to a supply blower and heater introduces hot air into the chamber, aiding in the dispersal and drying of the milled material. The drying chamber, positioned above the milling and dispersion chamber, provides ample space for dispersed particles to interact with the hot air, ensuring efficient heat and mass transfer. The system also includes a flap valve to regulate airflow and residence time, and cyclone separators to segregate coarse and fine particles, which are collected in designated collectors.

[0043]

[0033] Key features of the invention include low-temperature drying to preserve material quality, energy efficiency through minimized overall energy consumption, and time efficiency by reducing the overall time required for the combined processes. The apparatus is designed to operate continuously, with a control panel featuring programmable logic controllers to automate the operation of feeder, temperature sensors, blowers, and the heater. The system may also be configured for hot air recirculation to further reduce energy consumption, making the process more sustainable and cost-effective.

[0044] The invention will now be described in detail with reference to the accompanying drawings.

[0045]

[0034] Figure 1 illustrates an apparatus (100) for the continuous treatment of slurry and wet solid materials, in accordance with an embodiment of the present invention.

[0046]

[0035] The apparatus described in this invention is capable of processing a wide range of slurry and wet solid materials, making it highly versatile and applicable across various industries. In the chemical industry, it can handle chemical slurries such as titanium dioxide, calcium carbonate, silica, and iron oxide slurries. These materials require precise milling and drying processes to achieve the desired particle size and quality.

[0047]

[0036] In the pharmaceutical sector, the apparatus is suitable for processing active pharmaceutical ingredient (API) slurries, excipients, binders, vaccine adjuvants, and antibiotic fermentation slurries. The controlled environment ensures that the quality and efficacy of pharmaceutical products are maintained during processing.

[0048]

[0037] The food industry can benefit from this apparatus for drying and milling fruit and vegetable purees like apple, carrot, and tomato, as well as dairy slurries such as whey protein concentrate. It is also suitable for processing meat and fish by-products and cereal and grain slurries, preserving nutritional integrity and enhancing product quality.

[0049]

[0038] Agricultural applications include the processing of fertilizer slurries like ammonium nitrate and urea, pesticide formulations, and animal feed slurries. The apparatus's ability to handle these materials efficiently can improve productivity and reduce processing costs in the agricultural sector.

[0050]

[0039] In the pulp and paper industry, the apparatus can process wood pulp slurry, paper coating slurries, and starch slurry. These materials require precise moisture control to ensure the quality of the final paper products.

[0051]

[0040] The mining and mineral industries can utilize the apparatus for ore concentration slurries, including gold, copper, and bauxite, as well as coal slurry and mineral processing tailings. The apparatus's capability to handle high-volume, high-density slurries makes it ideal for these applications.

[0052]

[0041] Biotechnology and bioprocessing applications include the processing of biomass slurries such as algae and yeast, fermentation broths, and bio-waste slurries. The apparatus ensures efficient drying and milling, which are crucial for the production of bio-based products.

[0053]

[0042] In the cosmetics and personal care industry, the apparatus can process cosmetic creams and lotions, toothpaste slurry, and shampoo and conditioner formulations. The controlled drying environment helps maintain the stability and quality of these products.

[0054]

[0043] Environmental applications include the treatment of sewage sludge, industrial wastewater slurries, and sludge from water treatment plants. The apparatus can help reduce the moisture content of these materials, making them easier to handle and dispose of or further process.

[0055]

[0044] Finally, in the construction and building materials industry, the apparatus can process cement slurry, gypsum slurry, and plaster of Paris. These materials require precise moisture control to ensure the quality and durability of construction products.

[0056]

[0045] In that sense, the apparatus (100) is designed to facilitate the integrated processes of milling, drying, and particle segregation within a single, compact unit. The apparatus (100) comprises a modular design facilitated by various interconnected components enclosed within a casing (25). For better understanding of the apparatus (100), it would be better to simultaneously refer Figures 2-5 which illustrates the internal components of the apparatus (100), in different orthogonal views. As shown in figures 2-5, the components in the apparatus (100) includes a Milling and Dispersion chamber (19), a Drying chamber (1), two Cyclones — Coarse Cyclone (2) and Fine Cyclone (3) — with their respective powder collectors (8, 15), and several support systems such as the Heater (4), Supply Blower (14), Exhaust Blower (06), and Control panel (7).

[0057]

[0046] Figure 2 illustrates a front view of the apparatus (100) for continuous drying and milling of slurry and wet solid materials. The Milling and Dispersion chamber (19) features a horizontal cylindrical design equipped with high-speed mills (17,18) powered by variable-speed motors. The mills (17,18) host multiple blades disposed at varying angles to ensure efficient milling and dispersion of the material. An inlet hot air duct (12) connected to the Heater (4) via the Supply Blower (14) introduces hot air into the chamber, aiding in the dispersion and drying processes. Positioned above the milling blades and in proximity to the Milling and Dispersion chamber (19) is the Feed entry point (22), connected to a Screw feeder (16) with a feed hopper (10), driven by a geared motor. The Screw feeder (16) administers the wet material into the milling blades for processing.

[0058]

[0047] Figure 3 illustrates a side view of the apparatus (100). The Drying chamber (1) is a vertical cylindrical pipe mounted above the Milling and Dispersion chamber (19), providing sufficient space for the dispersed particles to interact with the incoming hot air for effective drying. The coarse particles separated by the Coarse Cyclone (2) are funnelled through a flap valve (20), which regulates air and powder residence time within the Drying chamber (1). The processed air-particle mixture is then drawn through the Cyclones (2, 3) by the Exhaust Blower (06), with larger particles collected in the coarse collector (8) and finer particles in the fine collector (15). An adjustable Flap valve (20) is positioned between the Drying chamber (1) and the Coarse Cyclone (2) to regulate airflow and residence time within the Drying chamber.

[0059]

[0048] Figure 4 illustrates a back view of the apparatus (100). The Exhaust Blower (06) is positioned at the top of the Fine Cyclone (3) and is responsible for creating the necessary airflow within the apparatus (100). The Coarse Powder Collector (8) and Fine Powder Collector (15) are situated at the bottom of the Coarse Cyclone

[0060] (2) and Fine Cyclone (3), respectively, for collecting segregated particles after drying. At the lower section, the High-speed Mill (17, 18), driven by the Mill Motor, is housed within the Milling and Dispersion Chamber (19), and the entire setup is mounted on a robust Square Tube Supporting Frame (9) with integrated levelling base (13) to ensure stability and proper alignment.

[0061]

[0049] Figure 5 illustrates the A-A section of the apparatus (100) shown in Figure 4. This detailed cross-sectional view provides insight into the internal configuration and layout of the apparatus (100) designed for the continuous drying and milling of slurry and wet solid materials. The section reveals the arrangement and interaction of various components central to the operation of the apparatus (100), enhancing the understanding of how the integrated functions of milling, drying, and particle segregation are accomplished. The illustrated components include the Milling and Dispersion chamber (19), which features high-speed mills (17,18) inside a horizontal cylindrical structure. These mills (17,18) are driven by variable-speed motors, which allow for adjustable milling speeds depending on material properties. Attached to the side of Milling and Dispersion chamber (19), the Feed hopper (10) is shown, through which slurry or wet solid material is introduced into the chamber by a Screw feeder (16) to the geared motor. The Control panel (7) is mounted on the side, offering operational commands and monitoring capabilities through a Programmable Logic Controller (PLC).

[0062]

[0050] In one embodiment of the invention, the milling and drying process is optimized by the strategic positioning of high-speed mills (17,18) within the Milling and Dispersion chamber (19). The mills (17,18) create a triturating and dispersive environment for wet materials, enhanced by the supply of hot air through the inlet hot air duct (12). The hot air generated by the integrated Heater (4) penetrates the material, facilitating rapid drying as the material is dispersed into the Drying chamber (1). The combination of mechanical milling and thermal drying in a continuous process result in efficient reduction and drying of particle size almost instantaneously, preserving the material's quality.

[0063]

[0051] The apparatus (100) further comprises the two Cyclones — Coarse Cyclone (2) and Fine Cyclone (3) — each dedicated to segregating particles based on their sizes. The Coarse Cyclone (2) captures and deposits larger particles into the coarse powder collector (8), while the Fine Cyclone (3) collects finer particles into the fine powder collector (15). The cyclonic action, induced by the connected Exhaust Blower (06), ensures that the particulates are segregated efficiently before being ejected as particle-free air.

[0064]

[0052] Additionally, temperature sensors (21) strategically placed at various points within the apparatus (100), such as the Exhaust Blower (06), Drying chamber (1), and at the Heater (4) outlet, ensure controlled and optimal process conditions. The precise regulation of mill speed, blower velocity, and other parameters through a Programmable Logic Controller (PLC) in the Control panel (7) guarantees the desired drying and milling characteristics for a range of materials, including slurries, pastes, and wet solid substances.

[0065]

[0053] The apparatus (100) is mounted on a square tube supporting frame (9) with levelling leg bases (13) to ensure stability during operation. The entire unit is enclosed in a sheet metal cover (25), providing an aesthetic and protective housing for the intricate components within. Optional configurations, such as air recirculation systems, can be incorporated to enhance energy efficiency. The outlet (11) of the exhaust blower can be connected to a supply blower (14) to form a closed-loop system with adjustable bleed and suction control valves, optimizing fresh air intake versus recirculated air for consistent drying efficiency. Specialty applications requiring nitrogen or other gases also benefit significantly from this energy-efficient, closed-loop design.

[0066]

[0054] In accordance with another embodiment, the apparatus (100) incorporates safety and efficiency-enhancing features, such as the dust extractor connected to the outlet of the exhaust blower (11), which could also be connected to a solvent recovery system to capture evaporated liquids before venting to the atmosphere. This feature is crucial for applications that necessitate solvent recovery or involve hazardous materials, ensuring safe and environmentally friendly operations.

[0067]

[0055] Thus, the described apparatus (100) meets the needs of various industries by integrating multiple processes into a single, compact unit, facilitating continuous operation, efficient energy use, reduced processing time, and minimal material degradation.

[0068]

[0056] By continuously feeding slurry or wet materials into the Milling and Dispersion chamber (19), followed by efficient heat and mass transfer in the Drying chamber (1), and finally segregating dried particles through the cyclones with precision, this integrated apparatus (100) showcases a highly efficient, compact, and versatile solution to milling and drying wet solid materials.

[0069]

[0057] Some embodiments of the present invention may include a hot air recirculation system connected to the Exhaust blower (6) and supply blower (14), configured to recycle a portion of the exhaust air to reduce energy consumption. The hot air recirculation system includes a bleed control valve to exhaust a portion of the recirculated air and a suction control valve to introduce fresh air into the system. Another embodiment may involve a use of nitrogen or other gases for drying, particularly in chemical and pharmaceutical applications, where the 80% recirculation system becomes ideal for drying, and the evaporated solvents can be recovered through a solvent recovery system.

[0070]

[0058] Method of operation: In one embodiment of the present invention, the apparatus (100) for continuous treatment of slurry and wet solid materials operates as follows:

[0071]

[0059] Step 1 : The slurry or wet solid material is initially introduced into the Feed hopper (10). From the Feed hopper (10), the material is directed into the Milling and Dispersion chamber (19) via the Screw feeder (16) equipped with a geared motor. This chamber is horizontally oriented and houses high-speed mills (17,18) which immediately interact with the incoming material.

[0072]

[0060] Step 2: Upon entry into the Milling and Dispersion chamber (19), the highspeed rotating blades of the mills (17,18) commence the milling process, effectively reducing the particle size and enhancing the dispersion of the material. This milling and dispersion expose a larger surface area of the material to the incoming hot air, facilitating rapid moisture evaporation.

[0073]

[0061] Step 3: The apparatus (100) incorporates a Supply blower (14) connected to a Heater (4), which heats the air before it is introduced into the Milling and Dispersion chamber (19) through the Inlet hot air duct (12). This hot air plays a crucial role in the drying process by rapidly evaporating the moisture content from the dispersed material.

[0074]

[0062] Step 4: Temperature sensors (21) are strategically integrated within critical points of the apparatus (100), including the Heater (4), the Drying chamber (1), and the Exhaust Blower (6). These sensors continuously monitor the operating temperatures, ensuring that the conditions remain optimal for both drying and milling processes. The Control panel (7) processes data from these sensors to regulate the heater and blower speeds, thereby maintaining the desired temperature and airflow.

[0075]

[0063] Step 5: After the initial milling and dispersion, the material, now combined with hot air, is transferred into the Drying chamber (1). This chamber is a vertical cylindrical pipe that allows for extensive interaction between the dispersed particles and the hot air, resulting in efficient heat and mass transfer. As the particles move upwards through the Drying chamber (1), they undergo further drying.

[0076]

[0064] Step 6: A pivotal component in this process is the adjustable Flap valve (20) located between the Drying chamber (1) and the Coarse Cyclone (2). By modulating the opening of this Flap valve (20), the residence time of particles within the Drying chamber (1) can be precisely controlled, thereby optimizing the drying efficiency to accommodate varying material feed rates and moisture contents.

[0077]

[0065] Step 7 : The dried material is subsequently directed into the Coarse Cyclone (2) and then into the Fine Cyclone (3) for particle segregation. The Coarse Cyclone (2) segregates the larger, coarse particles, which are collected in the Coarse powder collector (8). The remaining fine particles are directed into the Fine Cyclone (3) and collected in the Fine powder collector (15). The air, now devoid of particles, is channeled through controlled airflow pathways managed by the Exhaust Blower (6), ensuring systematic removal of moisture-laden air while maintaining a slight negative pressure within the system to support continuous operation.

[0078]

[0066] Step 8: The airflow rate and velocity are regulated by the variable-speed blowers (6, 14), which are critical for maintaining efficient drying and milling conditions. The continuous feedback provided by the temperature sensors (21) and the automated adjustments made by the Control panel (7) ensure consistent performance, minimal energy consumption, and high throughput.

[0079]

[0067] The integrated nature of this apparatus (100), from the material introduction via the Feed hopper (10) to the final particle collection in the powder collectors (8, 15), underscores its compact and multifunctional design. This design eliminates the need for multiple machines, thereby streamlining the drying and milling process into a singular, efficient, and environmentally friendly operation.

[0068] Exemplary Implementation / Application: The versatile apparatus (100) described above finds extensive applications across various industries due to its ability to efficiently process slurry and wet solid materials. These industries include, but are not limited to, chemical production, pharmaceuticals, pulp and paper, and more. The integration of high-speed mills and a continuous flow of hot air ensures that the fine-milled, wet cake gets dispersed, exposing a high surface area which, in turn, facilitates rapid drying when mixed with the incoming hot air.

[0080]

[0069] One distinctive application is in the Food and Vegetable industry, where the apparatus (100) is utilized for drying and powdering vegetables and fruits. Examples of such produce include Capsicum, Carrot, Okra, Onion, Potato, Tamarind, Ginger, as well as fruits like Apple and Amla. In this specific application, the following process is employed:

[0081] Step 1: Introduction of Produce

[0082] • Washed fruits and vegetables are introduced into the Milling and Dispersion chamber (19) through the Screw feeder (16).

[0083] Step 2: Milling and Dispersion

[0084] • The high-speed rotating blades within the Milling and Dispersion chamber (19) ensure thorough milling and dispersion of the produce. This milling process effectively reduces particle size and enhances the exposure of the material to hot air.

[0085] Step 3: Capillary-Induced Drying

[0086] • The fine cutting of fruits and vegetables opens up capillaries, allowing for capillary-induced drying. This technique facilitates efficient water removal when the produce is subjected to the incoming air currents.

[0087] Step 4: Application of Hot Air

[0088] • The application of hot air, typically at temperatures around 50-60 degrees Celsius, ensures effective drying. The hot air, introduced through the Inlet hot air duct (12), interacts with the dispersed material, rapidly evaporating moisture content.

[0089] Step 5: Preservation of Nutritional Integrity • Operating at low temperatures and with short drying times, the apparatus (100) preserves the nutritional integrity and energy content of the produce with minimal losses. The rapid drying process, which is almost instantaneous, maintains the natural flavors and colors of the fruits and vegetables, resulting in a product that closely resembles its fresh counterpart.

[0090]

[0070] Additional Industrial Applications: It will be appreciated by a skilled addressee that the described apparatus (100) is not limited to the food and vegetable industry. Its capability to handle various types of slurry and wet solid materials makes it suitable for a wide range of applications, including:

[0091] • Chemical Industry: Drying and milling of chemical powders and slurries.

[0092] • Pharmaceutical Industry: Processing of pharmaceutical intermediates and active ingredients.

[0093] • Pulp and Paper Industry: Treatment of pulp slurries and drying of paper coatings.

[0094]

[0071] The versatility and efficiency of the apparatus (100) make it an invaluable tool in any industry where the drying and milling of slurry and wet solid materials are required. Its continuous operation, compact design, and integration of multiple processes into a single unit provide significant advantages in terms of operational efficiency, cost reduction, and product quality.

[0095]

[0072] The present invention offers several notable advantages that enhance its appeal and utility across various industries. These advantages include:

[0096] 1. Continuous Operation: o The apparatus (100) is designed for continuous treatment of slurry and wet solid materials, significantly increasing efficiency and productivity compared to traditional batch processing methods.

[0097] 2. Integration of Processes: o By combining milling, drying, and particle segregation into a single apparatus (100), the invention eliminates the need for multiple machines. This integration simplifies the process, reduces equipment costs, and minimizes space requirements. Efficiency: The apparatus (100) incorporates a hot air recirculation system that reduces overall energy consumption. By recycling a portion of the exhaust air, the system maintains the required drying temperatures with less energy input, making the process more sustainable and cost-effective. rying: The use of high-speed mills and efficient heat and mass transfer within the drying chamber ensures rapid drying of materials. This quick processing time minimizes the risk of impurity pickup and preserves the quality of the dried material. l Temperature Control: Integrated temperature sensors continuously monitor and regulate the operating temperatures at critical points, ensuring optimal conditions for both drying and milling processes. This precise control helps maintain the integrity of heat-sensitive materials.lity: The apparatus (100) can handle a wide range of materials, including chemical powders, pharmaceutical intermediates, pulp slurries, and various food and vegetable products. Its adaptability makes it suitable for multiple industries. ed Product Quality: The apparatus (100)'s ability to operate at low temperatures preserves the nutritional integrity, natural flavors, and colors of food products. For other materials, the controlled drying process ensures consistent and high-quality output. ct and Multifunctional Design: The apparatus (100)'s compact design integrates several functions into one unit, reducing the need for multiple pieces of equipment. This design not only saves space but also simplifies installation and maintenance.

[0098] 9. Reduced Operational Costs: o By streamlining the drying and milling process and minimizing energy consumption, the invention lowers both capital and operational costs. The automation and efficient control system further contribute to cost savings by reducing labor requirements and process downtime.

[0099] 10. Scalability: o The design of the apparatus (100) allows for scalability, making it suitable for both small-scale operations and large industrial applications. The system's flexibility can accommodate varying production capacities and material characteristics.

[0100] 11. Environmental Friendliness: o The reduced energy consumption and efficient processing contribute to a lower environmental footprint. Additionally, the ability to use inert gases like nitrogen in a recirculating system makes it safer and more environmentally friendly, particularly in sensitive applications such as pharmaceuticals.

[0101] 12. Safety and Cleanliness: o The enclosed system minimizes material exposure, enhancing safety and cleanliness. The controlled environment reduces the risk of contamination and ensures a safer working condition for operators.

[0102]

[0073] In summary, the present invention offers a robust, efficient, and versatile solution for the continuous treatment of slurry and wet solid materials, providing substantial benefits in terms of productivity, cost efficiency, product quality, and environmental sustainability. These advantages make the apparatus (100) an essential tool across various industrial applications, driving innovation and operational excellence.

[0103]

[0074] It should also be understood that, unless specifically stated otherwise as apparent from the following discussion, it is appreciated that throughout the description, discussions utilizing terms such as "controlling" or "obtaining" or "computing" or "storing" or "receiving" or "determining" or the like, refer to the action and processes of a computer system, or similar electronic computing device, that processes and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.

[0104]

[0075] Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.

Claims

CLAIMS:

1. An apparatus (100) for continuous treatment of slurry and wet solid materials, comprising: a supply blower (14) configured to deliver heated air; a heater (4) connected to the supply blower (14) for heating the air; a milling and dispersion chamber (19) connected to the supply blower (14), the chamber containing high-speed mills (17,18) for milling and dispersing the slurry or wet solid material; a drying chamber (1) connected to the milling and dispersion chamber (19), configured to receive dispersed material and hot air, facilitating heat and mass transfer for drying; a flap valve (20) positioned between the drying chamber (1) and a cyclone separator, adjustable to regulate airflow and residence time of the material; a first cyclone separator (2) connected to the drying chamber (1) for separating coarse particles from the dried material; a second cyclone separator (3) connected to the first cyclone separator(2) for further separating fine particles from the dried material; collectors (8, 15) positioned at the bottom of each cyclone separator (2, 3) for collecting separated particles; an exhaust suction blower (6) connected to the second cyclone separator(3) for maintaining airflow through the system; and a control panel (7) for monitoring and controlling the apparatus (100), including temperature sensors (21), airflow controls, and motor speed controls.

2. The apparatus (100) of claim 1, wherein the supply blower (14) and exhaust blower (6) are variable-speed blowers for controlling airflow rates and velocities within the system.

3. The apparatus (100) of claim 1, wherein the high-speed mills (17,18) in the milling and dispersion chamber (19) are powered by variable-speed motors to adjust milling intensity based on material properties.

4. The apparatus (100) of claim 1, comprising a screw feeder (16) configured to introduce slurry or wet solid material into the milling and dispersion chamber (19) at a controlled rate.

5. The apparatus (100) of claim 1, wherein the drying chamber (1) is a vertical cylindrical pipe providing space for dispersed particles to interact with hot air, ensuring efficient drying.

6. The apparatus (100) of claim 1, comprising a hot air recirculation system connected to the exhaust suction blower (6) and supply blower (14), configured to recycle a portion of the exhaust air to reduce energy consumption.

7. The apparatus (100) of claim 6, wherein the hot air recirculation system includes a bleed control valve to exhaust a portion of the recirculated air and a suction control valve to introduce fresh air into the system.

8. The apparatus (100) of claim 1, wherein the control panel (7) includes programmable logic controllers (PLCs) to automate the operation of the temperature sensors (21), blowers (6, 14), and heater (4).

9. The apparatus (100) of claim 1, comprising pressure sensors in the drying chamber (1) to monitor and maintain optimal pressure levels for efficient drying and milling processes.

10. A process for continuous treatment of slurry and wet solid materials using the apparatus (100) of claim 1, comprising: introducing the slurry or wet solid material into the milling and dispersion chamber (19) using a screw feeder (16); milling and dispersing the material using high-speed mills (17,18) while simultaneously introducing heated air from the supply blower (14);transferring the dispersed material and hot air into the drying chamber (1) for heat and mass transfer, resulting in drying of the material; adjusting the flap valve (20) to regulate airflow and material residence time within the drying chamber (1); separating coarse and fine particles using the first and second cyclone separators (2, 3), respectively; collecting the separated particles in the collectors (8, 15) at the bottom of each cyclone separator (2, 3); maintaining airflow through the system using the exhaust suction blower (6); monitoring and controlling the process parameters, including temperature, airflow, and motor speeds, using the control panel (7).

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