CO2 Phase-Expansion Comminution for Low-Wear Ore Pulverization
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Solution Overview
Problem
Comminution of solid materials, particularly ore-bearing rocks, is energy-intensive and causes significant wear on machinery, necessitating a reduction in energy consumption and maintenance without compromising effectiveness.
Innovation Solution
A method involving the use of a working fluid, such as CO2, in a supercritical or subcritical phase, permeating into solid materials and rapidly expanding to create fractures, utilizing pressure and temperature conditions to achieve comminution with reduced energy and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional crushing and grinding methods are used to achieve fine particle sizes, then comminution effectiveness is improved, but energy consumption increases significantly
Solution Approach 1:
The patent utilizes phase transitions of a working fluid (e.g., from liquid to vapor or supercritical to subcritical) to generate rapid expansion forces that fracture solid materials. This phase change mechanism enables effective comminution without requiring continuous high-energy mechanical input, thus resolving the contradiction between achieving fine particle sizes and reducing energy consumption.
Solution Approach 2:
The invention replaces traditional mechanical crushing and grinding systems with a fluid-based fracture mechanism. Instead of using mechanical force from crushers and grinders, the system uses rapid fluid expansion to induce fractures within the solid material, thereby reducing the energy input required for comminution while maintaining effectiveness.
2Manufacturing precision
If traditional crushing and grinding methods are used to achieve fine particle sizes, then comminution effectiveness is improved, but machinery wear increases
Solution Approach 1:
The patent replaces mechanical contact-based crushing and grinding with a non-contact fluid expansion method. The working fluid penetrates the solid material and causes internal fractures through rapid expansion, eliminating the need for mechanical contact between grinding media and the material, thereby significantly reducing machinery wear.
Solution Approach 2:
The working fluid acts as an intermediary between the energy source and the solid material. Instead of direct mechanical contact causing wear, the fluid mediates the energy transfer by absorbing pressure and then rapidly expanding to create fractures internally, thus protecting the machinery from wear while achieving effective comminution.
3Manufacturing precision
If working fluid is allowed to permeate into solid materials at high pressure, then comminution effectiveness is improved, but system complexity increases
Solution Approach 1:
The patent employs parameter changes in the working fluid (pressure, temperature, phase state) to control the permeation and expansion process. By adjusting these parameters, the system achieves effective comminution without requiring complex mechanical structures, as the fluid properties themselves drive the permeation and fracture processes.
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
This method effectively reduces energy consumption and machinery wear by leveraging the rapid expansion of the working fluid to fracture solid materials, achieving efficient comminution with lower energy input and extended equipment lifespan.
Implementation Method 1
allowing the working fluid to permeate into the solid materials
Implementation Method 2
allowing the working fluid to permeate into the solid materials
Implementation Method 3
rapidly expanding the working fluid to thereby create fractured solid materials from the solid materials
Implementation Method 4
rapidly expanding the working fluid to thereby create fractured solid materials from the solid materials
Data Source
AI summary
Methods and apparatus for comminution of solid materials. Solid materials are introduced into a first pressure vessel. A working fluid is provided in the first pressure vessel at an operating pressure and an operating temperature. The working fluid is allowed to permeate into the solid materials. The working fluid may permeate into the solid materials while in a supercritical fluid phase. The working fluid is rapidly expanded to thereby create fractured solid materials from the solid materials. Rapidly expanding the working fluid may comprise causing a transition of the working fluid from a supercritical phase with a first density to a subcritical vapour phase with a second density.