Near Infrared Foamed Sand Production via High Power Density Heating
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Solution Overview
Problem
Current methods for producing expanded sand for insulation, which involves thermal treatment with an open flame, result in low yield and high costs due to inefficient processing and separation of unusable products.
Innovation Solution
A method utilizing short-wave infrared radiation, specifically near-infrared radiation with high power density, is applied to mineral or oxidic basic particles to achieve foaming or swelling, allowing for continuous process control and efficient conversion of starting materials into usable foamed sand products, with optional additional thermal treatment steps and separation using a multi-zone furnace and cyclone separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If open flame thermal treatment is used to produce expanded sand, then the basic particles can be thermally treated to achieve foaming, but the yield of usable end product is low and separation costs are high
Solution Approach 1:
The patent changes the thermal treatment parameter from conventional open flame heating to infrared radiation heating. This parameter change enables more uniform and controlled heating of the sand particles, resulting in better foaming quality and higher yield of usable expanded sand particles without requiring extensive separation processes.
Solution Approach 2:
The patent replaces the mechanical open flame heating system with an infrared radiation system. This substitution allows for more precise control of the thermal treatment process, enabling better penetration and uniform distribution of heat throughout the sand particles, which improves foaming efficiency and reduces the need for separation of defective particles.
2Temperature
If open flame thermal treatment is used, then thermal processing can be achieved, but the costs for separation of unusable parts are relatively high
Solution Approach 1:
The patent changes the thermal processing method from open flame to infrared radiation, which provides more uniform heat distribution and better control over the heating process. This results in fewer defective particles requiring separation, thereby reducing the energy and costs associated with separation operations.
Solution Approach 2:
By replacing the open flame system with infrared radiation, the patent achieves more efficient and uniform thermal processing. This substitution reduces the formation of unusable particles, thereby minimizing the need for separation processes and associated energy consumption and costs.
3Ease of manufacture
If conventional thermal treatment methods are used, then basic particles can be processed, but the process efficiency and throughput are limited
Solution Approach 1:
The patent replaces conventional thermal treatment with infrared radiation heating, which penetrates the material more effectively and heats it more uniformly and rapidly. This enables continuous processing with higher throughput while maintaining process simplicity and control.
Solution Approach 2:
The infrared radiation system enables continuous thermal treatment of the sand particles with consistent and uniform heating throughout the process. This continuous action improves throughput efficiency while maintaining the simplicity of the manufacturing process.
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 approach significantly increases the yield and cost-effectiveness of the process by producing a high proportion of usable foamed sand with excellent insulating properties, reducing the need for separation and minimizing environmental and occupational hazards.
Implementation Method 1
exposing the starting product, i.e. a bulk of mineral or oxidic basic particles, to a thermal treatment with short-wave infrared radiation, especially radiation in the near infrared range (with a wavelength of about 0.8 to 1.5 μm)
Implementation Method 2
achieve the desired swelling or foaming of the basic particles
Implementation Method 3
allowing the said short-wave infrared radiation (NIR radiation) to act on a layer transported through a radiation field
Data Source
AI summary
An arrangement for producing a bulk material consisting substantially of foamed or blown mineral or oxide particles by thermal treatment of a bulk material of basic particles. The arrangement includes NIR halogen radiators for generating a NIR radiation field of radiation with an active component in a near infrared, NIR, range having a wavelength in a range between 0.8 μm and 1.5 μm and which has a power density of at least 50 kW/m2 for thermally treating the basic particles, a conveying device for transporting a layer or stream of the bed of basic particles through the radiation field, and a controller that controls heating of the bed of basic particles such that a maximum temperature in the layer or stream is in a temperature range between 600 and 1500° C.