Hybrid Disc Beam Elements for Slurry Grinding
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Solution Overview
Problem
Existing grinding processes for mineral slurries in industries like ceramics, pigment, paint, and pharmaceuticals do not utilize the full potential power of rotor-mounted discs, leading to lower power input, reduced feed rates, and shorter rotor disc lifetimes, with a need for improved efficiency, throughput, and reduced maintenance.
Innovation Solution
A circular disc element with beam elements extending beyond its circumference, featuring adjustable holes and beam lengths, which enhances power input, reduces bypass flow, and improves slurry throughput, allowing operation at lower rotational speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If classical mills are used with standard rotor discs, then the structure is simple and easy to manufacture, but the power input is low and feed rates are reduced
Solution Approach 1:
The rotor disc is segmented into a central disc portion and multiple beam elements that extend radially outward. This segmentation allows the beam elements to engage grinding media at different radii, creating multiple grinding zones that simultaneously process slurry, thereby increasing power input and feed rate without requiring a complete redesign of the entire disc structure
Solution Approach 2:
The beam elements extend the grinding action into the radial dimension by projecting beyond the outer circumference of the central disc. This dimensional extension creates additional leverage and grinding zones at larger radii where grinding media can be more effectively utilized, transforming the traditional two-dimensional disc surface into a three-dimensional grinding structure
2Power
If rotor discs run at higher speeds to increase power input, then power input increases, but the lifetime of the rotor discs decreases
Solution Approach 1:
The beam elements are designed with adjustable lengths and positions, allowing the grinding configuration to be dynamically optimized for different operating conditions. This adjustability enables the system to maintain effective grinding at lower rotational speeds by optimizing the radial position and length of beam elements, thereby reducing centrifugal forces and mechanical stress on the disc structure while still achieving high power input
3Manufacturing precision
If standard disc designs are used, then manufacturing is simple, but bypass flow is high and product quality is reduced
Solution Approach 1:
The beam elements are strategically positioned and dimensioned to create localized grinding zones where specific particle size reduction requirements can be met. By concentrating grinding action at specific radial locations through the beam elements, the design achieves superior product quality and reduced bypass flow without requiring complex overall disc structures, maintaining relative manufacturing simplicity
Data Source
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AI summary
The invention relates to a circular disc element (10) comprising at least two beam elements (20). Each beam element extends beyond an outer circumference (11) of the circular disc element (10) in an extension direction (100) which is parallel to a radial direction (101) of the disc element (101). The circular disc element (10) further comprises at least two holes (30) extending through the circular disc element (10) in a longitudinal direction (110) which is substantially perpendicular to each of the extension directions (100) of the at least two beam elements (20). The at least two 10beam elements (20) are equidistantly spaced apart from each other with respect to a circumferential direction (120) of the circular disc element (10), which circumferential direction (120) corresponds to the outer circumference (11) of the circular disc element (10). The invention further relates to a use of the circular disc element (10) as grinding means in a grinding process, to a device for grinding slurry (50) as well as to a method for grinding slurry (50).