Diatomite Filter Aids via Pre-agglomeration and Calcination
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Solution Overview
Problem
Fine grain, low permeability diatomite deposits are not suitable for commercial filtration applications due to their high wet density and low permeability, and existing methods to improve their properties either lose small particles or require excessive water, making them unsuitable for processing very fine particles.
Innovation Solution
Pre-agglomerating diatomite ore with less than 10% water and subsequent calcination to enhance permeability and flow characteristics, resulting in diatomite filter aid products with improved porosity and filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional processing methods are used on fine grain, low permeability diatomite deposits, then the processing can be performed with standard equipment, but the resulting filter aid products have high wet density and low permeability making them unsuitable for commercial filtration applications
Solution Approach 1:
The patent applies parameter changes by controlling the water content during processing to be less than 10% by weight, and by controlling calcination temperature and time parameters. This transforms the physical and chemical properties of the diatomite, reducing wet density from typically high values to below 0.35 g/cm³, and achieving permeability of 0.05 to 6.0 darcies, making the material suitable for commercial filtration
Solution Approach 2:
The patent employs preliminary action through pre-agglomeration of the diatomite ore before calcination. By pre-agglomerating the fine grain material with controlled water content, the process prepares the material structure in advance to achieve the desired porous structure and low wet density after calcination, ensuring filtration suitability
2Reliability
If existing methods attempt to improve diatomite properties, then some property enhancement may occur, but particles smaller than 20 microns are lost during processing
Solution Approach 1:
The patent changes the water content parameter to less than 10% by weight, which is significantly lower than conventional methods. This parameter change prevents excessive water from causing particle loss during processing, while still achieving the necessary property enhancement for filter aid performance
Solution Approach 2:
By pre-agglomerating the diatomite with controlled water content before processing, the patent protects very fine particles (smaller than 20 microns) from being lost during subsequent processing steps, while still achieving the desired filtration performance
3Ease of manufacture
If existing methods use large amounts of water to plasticize diatomite materials, then the material becomes more workable, but the process becomes unsuitable for processing diatomite deposits with large amounts of very fine particles
Solution Approach 1:
The patent fundamentally changes the water content parameter from conventional high water content (large amounts of water) to less than 10% by weight. This parameter change maintains sufficient material workability for processing while preventing the loss of very fine particles that occurs with excessive water
Solution Approach 2:
The patent applies partial action by using just enough water (less than 10% by weight) to achieve the necessary plasticization and workability during processing, without adding excessive water that would cause particle loss. This optimized water content is sufficient for manufacturing while protecting fine particles
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 significantly increases permeability and reduces wet density of diatomite filter aid products, making them suitable for both slow and fast filter grade applications, with permeability ranging from 0.05 to 6.0 darcies and wet density reduced by up to 50%, enhancing filtration efficiency.
Implementation Method 1
pre-agglomerating the ore in the presence of less than 10% by weight water
Implementation Method 2
pre-agglomerating the ore in the presence of less than 10% by weight water
Implementation Method 3
calcining the resultant product
Implementation Method 4
calcining the resultant product, wherein the feed material has an initial d10 from 2-10 μm and a permeability less than 9.87 x 10 -15 darcies
Data Source
AI summary
Disclosed herein are diatomite filter aid products with enhanced permeabilities and flow characteristics, and methods for enhancing the permeabilities and flow characteristics of very fine grain, low permeability diatomite ore by, in one embodiment, pre-agglomerating the ore in the presence of less than 10% water and then subjecting the pre-agglomerated ore to at least one calcination process. At least one flux may be used in the at least one calcination process. Also disclosed herein is a method of processing diatomite ore suitable for samples with high wet densities or large amounts of fine particulate matter. Also disclosed herein are methods of producing commercially applicable filter aid products from Hungarian diatomite.