Calcium Carbonate Granulation with Polymeric Binders
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Solution Overview
Problem
Calcium carbonate containing mineral powders have low bulk density, making them difficult to handle, store, and transport, and existing methods to increase density, such as compaction or pelletization, either worsen flow properties or require excessive binders and water, increasing costs.
Innovation Solution
A process involving contacting calcium carbonate mineral powders with a solution or emulsion of a polymeric binder, such as copolymers of acrylonitrile, butadiene, acrylate, or styrene, to form composite particles with increased bulk density and improved flowability, while maintaining or enhancing other properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If calcium carbonate containing mineral powders are mechanically compacted using bricketting machines or pelletizers, then bulk density is increased, but flow properties deteriorate
Solution Approach 1:
The invention changes the physical-chemical parameters of the calcium carbonate powder by incorporating polymeric binders and performing controlled drying, transforming the material properties to achieve both high bulk density and good flowability simultaneously
Solution Approach 2:
The invention creates a composite material by combining calcium carbonate powder with polymeric binders (such as polyvinyl alcohol, polyacrylamide, or carboxymethyl cellulose), forming granulated products that exhibit improved bulk density and flow properties compared to pure calcium carbonate
2Strength
If pelletizing equipment relying upon water as a binder is used, then acceptable pellets can be formed, but large quantities of water (15 to 25 wt.-%) must be added, increasing shipping costs or production costs
Solution Approach 1:
The invention changes the binder parameter from water-based to polymer-based, allowing pellet formation with significantly reduced water content (less than 5 wt.-%, preferably less than 2 wt.-%), thereby reducing shipping costs and production costs
Solution Approach 2:
The invention introduces polymeric binders as an intermediary substance that facilitates pellet formation more efficiently than water, requiring much smaller quantities to achieve the same binding effect
3Quantity of substance
If pelletizing equipment relying upon binders other than water is used, then pellets can be formed with less water, but large amounts of binder are required and the pelletized product is difficult to make-down in water after pelletization and drying
Solution Approach 1:
The invention applies local quality by selecting water-soluble polymeric binders that provide the necessary binding function during pelletization but can be easily removed or degraded in water during subsequent processing, ensuring both low water content during formation and easy make-down later
4Ease of manufacture
If calcium carbonate containing mineral powders are prepared by dry grinding, then the powder is obtained, but the bulk density is low, making it difficult to handle
Solution Approach 1:
The invention transforms the low bulk density calcium carbonate powder into a composite granulated material by incorporating polymeric binders and performing drying, achieving high bulk density while maintaining the original powder's manufacturing advantages
Solution Approach 2:
The invention applies segmentation by granulating the fine powder particles into larger granules with improved bulk density characteristics, while the granules can still be easily handled and processed
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 process increases bulk density by 5 to 80% and improves flowability, reducing energy consumption for handling, while maintaining the desirable characteristics of the calcium carbonate powder, such as opacity and binding properties.
Implementation Method 1
contacting the at least one calcium carbonate containing mineral powder with the at least one solution or emulsion or dispersion of the binder to form solid calcium carbonate containing composite particles
Data Source
AI summary
The present invention concerns a calcium carbonate containing material having increased bulk density at equal or improved flowability, and a method of producing such a material. The inventive process comprises the step of contacting a calcium carbonate containing mineral powder with a solution or emulsion or dispersion of a binder.