Opposing Rotary Disk Milling Device for Energy-Efficient Granulation
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Solution Overview
Problem
Current crushing and milling devices face inefficiencies due to high energy consumption, significant abrasion, low production rates, environmental contamination, and poor durability, limiting their ability to effectively process materials into fine granules and particulates, especially when dealing with materials smaller than 3 mm.
Innovation Solution
A crushing and mill device utilizing high gravity energy by employing an outer and inner rotary disk configuration with through holes and carrier plates, where the disks rotate oppositely to impact and break feed materials into granules and particulates, reducing energy consumption and increasing production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional crushing and milling devices are used to process materials, then materials can be broken down, but energy consumption is high and production efficiency is low
Solution Approach 1:
The device divides the crushing and milling functions into separate zones: the outer rotary disk performs crushing with its crushing chambers, while the inner rotary disk performs milling with its milling chambers. This segmentation allows each zone to optimize its function, improving overall efficiency while reducing energy consumption compared to traditional single-zone devices.
Solution Approach 2:
The device utilizes periodic impact action where materials are repeatedly lifted and dropped through the crushing and milling chambers during rotation. This periodic action intensifies the breaking effect on materials, increasing productivity while maintaining lower energy consumption through efficient impact utilization.
2Manufacturing precision
If materials are crushed into fine granules using traditional devices, then particle size is reduced, but significant abrasion and device wear occur
Solution Approach 1:
By separating crushing and milling into distinct zones with different chamber designs, the device achieves fine particle size control in the milling zone without subjecting the entire device to excessive wear. The crushing zone handles coarse breakdown while the milling zone refines particles, distributing wear evenly and improving durability.
Solution Approach 2:
The device uses an intermediary mechanism where materials impact against wear-resistant chamber walls and each other rather than directly against traditional mill liners. This intermediary impact method reduces direct abrasion on critical components while achieving the desired fine particle size.
3Productivity
If separate crushing and milling devices are used, then each procedure can be optimized, but working efficiency decreases and device complexity increases
Solution Approach 1:
The device merges crushing and milling functions into a single integrated unit with concentric rotary disks. Materials flow sequentially through both zones in one continuous operation, improving working efficiency by eliminating transfer between separate devices while maintaining the functional optimization of each process zone.
Solution Approach 2:
The dual rotary disk structure serves multiple functions: the outer disk provides crushing chambers for coarse breakdown, while the inner disk provides milling chambers for fine grinding. Both disks can be independently adjusted to optimize for different material types, providing universal applicability across various crushing and milling applications.
4Productivity
If traditional milling devices operate at high energy consumption, then materials can be processed, but environmental contamination increases
Solution Approach 1:
The periodic impact and lifting action in the crushing and milling chambers intensifies material processing within a shorter time frame, increasing the processing rate without requiring continuously high energy input. This reduces overall energy consumption and associated environmental contamination while maintaining high productivity.
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 device achieves high efficiency in breaking and milling materials into fine particulates with reduced energy consumption, producing 50-80 T/h and lowering energy usage per ton to below 15 degrees, while maintaining a smaller footprint compared to traditional ball grinders.
Implementation Method 1
The outer and the inner disks are rotated by motors, and the rotation of the inner disk is directed oppositely to that of the outer disk. The feed material enters the inner and outer disks from the inlet, and the feed material is shot off oppositely by the rotations of the outer and the inner disks.
Implementation Method 2
The feed material passes the through holes of the inner disk and impacts with each other to be broken and milled into particulates
Data Source
AI summary
A crushing and mill device includes an outer rotary disk (1) and an inner rotary disk (2) put in said outer rotary disk, wherein, the outer and inner rotary disks communicate the inlet (3) of the feed material, some through holes (20) communicating the outer and inner disk are provided on the sidewall of the inner disk, some carrier plates (4) for carrying the feed material are provided on the places that correspond to the through holes (20) on the disks. The rotations of the outer and inner disks are driven by motors, and the rotations direction of the inner and outer disks are opposite. The sidewall of outer disk has an outlet (10) of the feed material. The feed material enters the inner and outer disks from the inlet, and the feed material is shot off oppositely by the rotations of the outer and inner disk. The feed material passes the through holes of the inner disk and impacts with each other to be broken and milled. The particulates formed by milling are shot off from the outlet on the sidewall of the outer disk. The device can lower energy consumption and raise output.