Ceramic Granulation via Air Classification
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Solution Overview
Problem
Non-spray-dried dry-granulated ceramic particulate mixtures often exhibit poor flowability, which hinders their transport, dosing, and uniform distribution in ceramic production processes, especially when incorporating recycled aluminum silicate materials, leading to defects and poor quality in ceramic articles like porcelain floor tiles.
Innovation Solution
A process involving compaction, crushing, and at least two air classification steps, specifically gravitational and centrifugal air classification, to achieve a tightly controlled water level and particle size distribution, enhancing flowability and incorporating recycled materials like aluminum silicate without compromising the quality of ceramic particulate mixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spray-drying is used to prepare ceramic particulate mixture, then good flowability is achieved, but high energy consumption occurs due to water evaporation
Solution Approach 1:
The invention extracts and removes the spray-drying step from the traditional ceramic particulate mixture preparation process. By taking out the energy-intensive water evaporation step, the process achieves significant energy savings while maintaining acceptable flowability through alternative granulation methods that control particle size distribution and moisture content differently.
Solution Approach 2:
The invention changes the key parameters of the particulate mixture preparation by controlling particle size distribution (D10, D50, D90 values) and moisture content (4-9 wt%) through mechanical granulation rather than spray-drying. This parameter transformation allows the material to achieve adequate flowability without the high energy input required for complete water evaporation.
2Use of energy by moving object
If non-spray-dried dry-granulation process is used to reduce energy consumption, then energy efficiency is improved, but poor flowability occurs
Solution Approach 1:
The invention addresses poor flowability in non-spray-dried processes by precisely controlling particle size distribution parameters (D10, D50, D90) and moisture content (4-9 wt%). These parameter adjustments transform the flow characteristics of the granulated material, enabling adequate flowability without requiring spray-drying.
Solution Approach 2:
The invention applies preliminary classification and moisture control measures during the granulation process itself, rather than relying on post-processing. By pre-establishing the correct particle size distribution and moisture content during granulation, the material achieves proper flowability characteristics before being used in ceramic production.
3Object-affected harmful factors
If recycled aluminum silicate material is incorporated to improve sustainability, then environmental friendliness is improved, but flowability deteriorates leading to defects
Solution Approach 1:
The invention controls the particle size distribution and moisture content parameters of the recycled aluminum silicate material to maintain flowability. By adjusting these parameters, the material can be incorporated at high levels (improving sustainability) without causing the flowability problems that would lead to production defects.
Solution Approach 2:
The invention creates a composite particulate mixture that combines recycled aluminum silicate material with other ceramic raw materials in specific proportions and particle size distributions. This composite approach allows the benefits of recycled material incorporation while maintaining the flowability needed for defect-free production through careful composition design.
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 ensures good flowability and energy efficiency, allowing for the production of high-quality ceramic articles with improved uniformity and robustness, even with high levels of recycled materials, by precisely controlling particle size and moisture levels, thus overcoming the limitations of traditional dry-granulation methods.
Implementation Method 1
one air classification step removes at least a portion of the particles having a particle size of greater than 600 μm from the crushed precursor material
Implementation Method 2
the other air classification step removes at least a portion of the particles having a particle size of less than 80 μm from the crushed precursor material
Data Source
AI summary
The present invention relates to a non-spray-drying, dry-granulation process for making a ceramic particulate mixture comprising from 4 wt % to 9 wt % water, wherein at least 90 wt % of the particles have a particle size of from 80 μm to 600 μm, wherein the process comprises the steps of:(a) forming a precursor material;(b) subjecting the precursor material to a compaction step to form a compacted precursor material;(c) subjecting the compacted precursor material to a crushing step to form a crushed precursor material; and(d) subjecting the crushed precursor material to at least two air classification steps, wherein one air classification step removes at least a portion of the particles having a particle size of greater than 600 μm from the crushed precursor material, and wherein the other air classification step removes at least a portion of the particles having a particle size of less than 80 μm from the crushed precursor material.