Ash Particle Size Reduction via High-Frequency Pressure Waves
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Solution Overview
Problem
Conventional methods for recycling industrial and incineration ashes are inefficient due to high energy requirements, abrasive wear of milling tools, and inability to achieve a defined particle size and high reactivity, leading to low-quality products that are not effectively reintroduced into industrial processes.
Innovation Solution
A non-contact milling method using high-frequency pressure waves to disintegrate ash particles, allowing for energy-efficient production of basic products with defined particle sizes and high reactivity, enabling both dry and wet processing without subsequent drying processes and reducing machine downtimes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wet milling methods are used to recycle ash, then the process can handle ash material, but abrasive wear of milling tools and blockings occur, requiring high downtime
Solution Approach 1:
The patent replaces conventional mechanical milling systems with a high-frequency pressure wave system. The pressure waves are generated by a piezoelectric element that creates ultrasonic vibrations in a liquid medium, which then disintegrates ash particles through cavitation and mechanical oscillation, eliminating direct mechanical contact between milling tools and abrasive ash material.
Solution Approach 2:
The patent introduces a liquid medium as an intermediary between the pressure wave source and the ash particles. The liquid transmits the high-frequency pressure waves to the particles, enabling non-contact energy transfer. This intermediary prevents direct mechanical contact that would cause tool wear and blockages while still achieving effective particle disintegration.
2Productivity
If conventional milling machines are used, then ash can be processed, but dry processes cannot be used due to cakings and blockings, requiring subsequent drying processes
Solution Approach 1:
The patent employs periodic high-frequency pressure waves (ultrasonic frequency) that create cyclic compression and rarefaction in the liquid medium. This periodic action generates cavitation bubbles that collapse and create micro-jets, effectively disintegrating particles without causing agglomeration. The continuous periodic energy input maintains particles in a suspended state, eliminating the need for subsequent drying.
Solution Approach 2:
The patent changes the physical state parameters of the processing environment by using high-frequency pressure waves in a liquid medium. This creates a unique processing state where particles are suspended and dispersed through cavitation and mechanical oscillation, allowing dry-like processing without the harmful effects of conventional dry milling (cakings and blockings).
3Manufacturing precision
If conventional milling methods are used to achieve defined particle size, then processing can be performed, but high energy expenditure is required and basic products aggregate to form aggregates
Solution Approach 1:
The patent uses high-frequency mechanical vibrations (ultrasonic frequency) generated by piezoelectric elements to disintegrate ash particles. The vibrations create cavitation bubbles and mechanical oscillations that break particles into fine, uniformly sized aggregates. This vibrational mechanism is far more energy-efficient than conventional mechanical milling because it acts on the molecular level rather than requiring high-force mechanical contact.
Solution Approach 2:
The patent exploits phase transitions of water (liquid to vapor) through cavitation induced by high-frequency pressure waves. The rapid compression and expansion cycles cause liquid water to vaporize in micro-bubbles, creating explosive collapse that shatters particles. This phase transition mechanism enables efficient particle disintegration with minimal energy input compared to conventional mechanical methods.
4Productivity
If conventional methods are used, then ash recycling can be attempted, but basic products have low reactivity and cannot be effectively reintroduced into industrial processes
Solution Approach 1:
The patent segments ash particles into extremely fine particles through high-frequency pressure wave disintegration. The pressure waves break large particles into numerous small particles with high surface area to volume ratios. This segmentation dramatically increases the reactivity of the basic products, enabling their effective reintroduction into industrial processes such as paper recycling and ground stabilization.
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 method achieves energy-efficient production of reactive basic products with defined particle sizes, reducing energy consumption and preventing agglomeration, thus enabling their effective integration into industrial processes as alkalizing agents, fillers, and for ground stabilization.
Implementation Method 1
crushing the particles of the starting material by pressure waves
Implementation Method 2
the particles themselves are excited and resonated by the pressure waves and subsequently burst
Implementation Method 3
the particles themselves are excited and resonated by the pressure waves
Implementation Method 4
water is present in the individual particles, which assumes the gaseous state due to high-frequency impulses (pressure waves)
Implementation Method 5
water is present in the individual particles, which assumes the gaseous state due to high-frequency impulses (pressure waves)
Implementation Method 6
the in situ separation of at least two fractions with different average particle sizes
Data Source
AI summary
A method for producing basic products from ash, which includes the provision of a starting material in particle form, crushing the particles of the starting material by high-frequency pressure impulses and the in situ separation of at least two fractions with different average particle sizes, where the energy-efficient production of a basic product with a defined particle size and high reactivity is effected, such that the produced basic products can be used directly for further product production, e.g. as alkalizing agent, for ground stabilization or as filler.