Comminution Device with Sieve Recycle Loop
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Solution Overview
Problem
Existing grinding plants are inefficient in producing evenly distributed finely ground powders, leading to high energy consumption, labor costs, and environmental concerns due to uneven material processing and excessive waste production.
Innovation Solution
A device comprising a pre-shredding unit, a sieve for separating coarse and fine fractions, and a return unit for recycling coarse fractions to a secondary comminution unit, allowing for simultaneous production of powders with different hardness and chemical compositions in a closed loop with low energy consumption and process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional grinding plants with multiple stages and classifiers are used, then material can be crushed, but energy consumption is high and particle distribution is uneven
Solution Approach 1:
The grinding process is divided into distinct functional stages: pre-shredding unit for coarse grinding, screening unit for separation, and secondary comminution unit for fine grinding. Each stage performs a specific function to achieve progressive size reduction with uniform particle distribution, eliminating the need for energy-intensive classifiers and recirculation systems.
Solution Approach 2:
The pre-shredding unit performs preliminary coarse grinding before material enters the secondary comminution unit. This preliminary size reduction prepares the material for more efficient fine grinding, reducing the energy required in subsequent stages and eliminating the need for multiple recirculation cycles.
2Manufacturing precision
If additional classifiers and recirculation plants are added, then particle size control is improved, but device complexity and costs increase
Solution Approach 1:
The invention extracts and eliminates the need for separate classifiers and recirculation plants by integrating screening and separation functions directly into the grinding flow. The screening unit with separate discharge for oversize and undersize fractions provides particle size control without requiring additional complex equipment.
Solution Approach 2:
Multiple functions are merged into integrated units: the pre-shredding unit combines grinding and size reduction, the screening unit combines separation and classification, and the secondary comminution unit combines fine grinding and particle size control. This merging eliminates the need for separate classifiers and recirculation systems.
3Manufacturing precision
If multiple recirculation cycles are used, then fine grinding is achieved, but process time and labor costs increase
Solution Approach 1:
The pre-shredding unit performs preliminary coarse grinding to reduce material size before it enters the secondary comminution unit. This preliminary action significantly reduces the time required for fine grinding by starting with smaller, pre-processed particles rather than raw material.
Solution Approach 2:
The screening unit operates continuously to separate oversize fractions for immediate re-grinding while allowing undersize fractions to proceed directly to final product. This continuous separation and processing eliminates idle time and maintains constant productive action throughout the system.
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 solution enables the production of homogeneous powders with reduced energy consumption and waste, efficiently processing materials of varying hardnesses, and achieving high-quality particle size distribution without the need for additional classifiers or recirculation, thus lowering overall costs and environmental impact.
Implementation Method 1
at least one sieve to separate the finely ground material into a fine fraction and a coarse fraction
Data Source
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AI summary
The invention relates to a device for crushing solid materials, the device comprising: a pre-crushing unit with at least one first receiving container (6) for receiving coarsely crushed material, at least one first crusher (8) for finely crushing the coarsely crushed material, at least one sieve (10) for separating the finely crushed material into a fine fraction and a coarse fraction, a second container (14) for receiving the fine fraction of the finely crushed material, and a return unit for returning the coarse fraction of the finely crushed material to the first receiving container (6), and a post-crushing unit with at least one second crusher (20) for finely crushing the fine fraction of the finely crushed material, and at least one cyclone separator (22) for further processing of material exiting the second crusher.Furthermore, a method for comminuting materials and the use of the device for this purpose are specified.