Recovered Abrasive Grains via Fluidized Bed Combustion
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Solution Overview
Problem
Existing abrasive items become dull and clogged during use, leading to high disposal and replacement costs, with limited operational life and significant environmental impact.
Innovation Solution
Combustion of discarded abrasive items in a fluidized bed to separate abrasive grains from their substrate, enhancing their toughness and adhesion through chemical and structural changes, and depositing a slag layer to improve grinding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If abrasive items are used for grinding, then grinding function is provided, but abrasive grains become dull and operational life is limited
Solution Approach 1:
The patent recovers abrasive grains from used abrasive items by combusting the substrate and adhesive in a fluidized bed, separating and reusing the abrasive grains to extend their operational life while maintaining grinding efficiency
Solution Approach 2:
The patent changes the physical and chemical parameters of abrasive grains through thermal treatment in a fluidized bed, heating them to high temperatures to restore sharpness, improve toughness, and modify surface properties, thereby extending operational life while maintaining or enhancing grinding efficiency
2Productivity
If new abrasive items are produced, then grinding capability is provided, but production and disposal costs increase
Solution Approach 1:
The patent implements a recovery system that captures abrasive grains from discarded abrasive items, cleans and reprocesses them through fluidized bed combustion, and reintroduces them into production, reducing the need for new abrasive materials and lowering disposal costs
Solution Approach 2:
The patent converts the harmful waste stream of discarded abrasive items into a beneficial resource by using fluidized bed combustion to separate, purify, and rejuvenate abrasive grains, transforming waste disposal costs into cost-effective material recovery
3Productivity
If abrasive items are discarded, then they are replaced, but environmental impact increases
Solution Approach 1:
The patent establishes a closed-loop system that recovers abrasive grains from discarded items through fluidized bed processing, reducing the volume of waste sent to landfills and minimizing the environmental footprint associated with abrasive item disposal and replacement
4Strength
If abrasive grains are treated in hot fluidized bed, then toughness and adhesion are improved, but energy consumption increases
Solution Approach 1:
The patent combines multiple functions into a single fluidized bed process: substrate combustion, adhesive removal, abrasive grain separation, thermal treatment for toughness improvement, and surface modification all occur simultaneously, reducing total energy consumption compared to separate processing steps
Solution Approach 2:
The exothermic combustion of substrate and adhesive in the fluidized bed provides the heat required for abrasive grain treatment, reducing the need for external energy input while achieving the desired toughness and adhesion improvements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The treated abrasive grains exhibit improved toughness and adhesion, increasing grinding efficiency by up to 20% and reducing the need for new abrasive grains, while minimizing waste and environmental footprint.
Implementation Method 1
Combustion of rejected abrasive items in a fluidized bed may provide loose abrasive grains
Implementation Method 2
Treatment of abrasive grains in the hot fluidized bed may increase the toughness of the abrasive grains
Implementation Method 3
Treatment of the abrasive grains in the fluidized bed may e.g. locally increase the concentration of alumina. Treatment of the abrasive grains in the fluidized bed may e.g. change the oxidation state of titanium ions in the alumina crystals
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2a
AI summary
A method for providing abrasive grains (CG1, CG2, CG3, CG4) comprises: - providing first input material (FEED1), which comprises abrasive grains (G0) adhered to a combustible substrate (BASE0), and - separating the abrasive grains (G0) from the substrate (BASE0) by at least partly combusting the substrate (BASE0) in a fluidized bed (BED1).