Ceramic Waste Treatment Plant With Integrated Drying and Grinding
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Solution Overview
Problem
Current practices for handling waste and processing residues from ceramic and stone materials result in significant economic and environmental damage due to inefficient recovery and recycling, with high energy consumption.
Innovation Solution
A process and plant for treating waste and residues by collecting, homogenizing, drying, grinding, and classifying ceramic and stone materials to achieve a moisture content of less than 1%, followed by optional wetting and compaction, using a single machine like a pendulum mill with a burner and separator to achieve efficient recycling with reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional separate processes are used for drying and grinding waste materials, then each process can be optimized independently, but the total energy consumption increases and the process complexity increases
Solution Approach 1:
The patent combines drying and grinding operations into a single integrated process step, where waste materials are dried and ground simultaneously in one equipment unit. This merging eliminates the need for separate drying and grinding equipment, reducing overall energy consumption while simplifying the process flow and equipment requirements.
Solution Approach 2:
The grinding equipment is designed to perform multiple functions: it can grind both dry and humid waste materials, and it can operate in different modes (dry grinding vs. grinding with water addition). This multi-functionality allows the same equipment to handle varying waste conditions without requiring separate specialized equipment for each condition.
2Ease of manufacture
If waste materials are disposed of conventionally, then disposal is simple and quick, but economic and environmental damage occurs
Solution Approach 1:
The patent converts waste materials that would otherwise be harmful environmental pollutants into valuable recycled aggregates. By processing waste ceramic, stone, and construction materials through drying and grinding, the system transforms these harmful disposed materials into beneficial reusable aggregates for construction applications, eliminating environmental damage while creating economic value.
Solution Approach 2:
Instead of simply discarding waste materials, the patent implements a recovery system that collects, processes, and recycles waste ceramics, stones, and construction materials. The recovered aggregates are then reused in construction applications, creating a circular economy approach that prevents waste disposal while recovering valuable materials.
3Productivity
If waste materials are not homogenized before processing, then the processing step is skipped, but the quality and consistency of the final product deteriorates
Solution Approach 1:
The patent implements homogenization as a preliminary step before the main drying and grinding process. Waste materials are collected and homogenized in advance to ensure uniform composition and moisture distribution, which prepares the material for consistent processing and ensures high-quality, uniform aggregate products while maintaining efficient production flow.
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
Enables the efficient reuse of waste materials in construction processes, reducing disposal costs and energy consumption while producing reusable raw materials.
Implementation Method 1
simultaneously drying and grinding the waste and/or residues of step b)
Implementation Method 2
simultaneously drying and grinding the waste and/or residues of step b)
Data Source
Figure 1
AI summary
The present invention relates to a process for the treatment of waste and/or residues from a processing of ceramic and/or stone material comprising the steps of: a) providing waste and/or residues from a processing of ceramic and/or stone material; b) collecting, homogenizing and/or optionally humidifying the material of step a); c) simultaneously drying and grinding the waste and/or residues of step b) until the humidity content of the waste and/or residues of < 1% is reached and then classifying said waste and/or residues according their size. The present invention also relates to a plant in which said process is carried out.