Separate Milling of FBC Fly Ash for Ceramic Mixtures
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Solution Overview
Problem
Fluid bed combustion (FBC) fly ash, particularly circulating fluid bed (CFB) fly ash, is challenging to incorporate into granular ceramic mixtures due to its high sulfate levels and irregular shape, leading to defects such as cracking in ceramic articles during the firing process, especially when used in high-quality items like porcelain tiles.
Innovation Solution
Milling the FBC fly ash separately from clay and other ingredients, followed by blending, to form a granular ceramic mixture with controlled particle sizes, avoiding the high energy environment and surface contact issues that cause unwanted mineral phase formation and firing behavior changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If FBC fly ash is incorporated into granular ceramic mixture, then waste material utilization is improved, but manufacturing precision deteriorates due to cracking defects
Solution Approach 1:
The patent divides the milling process into separate stages: FBC fly ash is milled separately from clay and other ceramic ingredients. This segmentation prevents unwanted mineral phase formation that occurs when materials are milled together, thereby avoiding cracking defects while maximizing fly ash utilization in the ceramic mixture.
Solution Approach 2:
The patent applies preliminary action by pre-milling FBC fly ash to a specific particle size distribution before blending it with other ceramic ingredients. This preliminary size reduction ensures uniform particle distribution and prevents processing issues during subsequent ceramic formation and firing, eliminating cracking defects.
2Productivity
If FBC fly ash is used in high quantities, then productivity is improved, but reliability deteriorates due to firing defects
Solution Approach 1:
The patent changes the particle size parameter of FBC fly ash through controlled separate milling, achieving a specific size distribution that enables high fly ash incorporation (improving productivity) while maintaining firing process stability (ensuring reliability) by preventing unwanted mineral phase transformations during ceramic firing.
3Device complexity
If FBC fly ash is milled with clay, then manufacturing process is simplified, but manufacturing precision deteriorates due to unwanted mineral phase formation
Solution Approach 1:
The patent segments the milling operation into distinct processes: FBC fly ash is milled separately from clay and other ingredients. Although this increases process steps, it enables precise control over particle size distribution of each component, preventing unwanted mineral phase formation and ensuring high manufacturing precision in the final ceramic mixture.
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 effective incorporation of FBC fly ash into ceramic mixtures without defects, allowing for the production of high-quality ceramic articles with improved mechanical properties and reduced water absorption.
Implementation Method 1
Milling the FBC fly ash separately from clay and other ingredients, followed by blending, to form a granular ceramic mixture with controlled particle sizes
Data Source
AI summary
The present invention relates to a process for preparing a granular ceramic mixture, wherein the process comprises the steps of: (a) milling fluid bed combustion fly ash to obtain milled fluid bed combustion fly ash; (b) milling clay to obtain milled clay; (c) contacting together: (i) the milled fluid bed combustion fly ash obtained in step (a); (ii) the milled clay obtained in step (b); (iii) optionally, feldspar, and (iv) optionally, other ingredients, to form the granular ceramic mixture, wherein step (a) and step (b) are carried out separate milling steps.