Particulate Material XRD Analysis Using Sequential Coarse-Particle Measurement
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Solution Overview
Problem
Existing cement and ore analyzers face challenges in accurately analyzing crystalline and amorphous substances due to time-intensive sample preparation, variations in precision, and inaccuracies caused by non-uniform sample presentation, particularly in continuous analysis systems with large particle size distributions and non-crystalline substances.
Innovation Solution
An apparatus that grinds particulate material to a designated particle size, uses a carrier to convey a larger volume of powdered material through an X-ray diffraction station, and employs a processor to analyze sequential diffraction patterns, compensating for flux variations and detecting both crystalline and amorphous substances, with optional X-ray fluorescence for elemental analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If samples are ground to very fine particle size (e.g., than 5μm) using micronizing mills, then measurement precision is improved, but loss of time increases and device complexity increases
Solution Approach 1:
The patent changes the particle size parameter from conventional fine powder (5μm or finer) to coarse particles (0.5mm to 5mm), eliminating the need for micronizing mills while maintaining analysis accuracy through increased sample volume and sequential measurement of multiple particles
Solution Approach 2:
The patent segments the sample analysis into individual particle measurements, where multiple coarse particles are measured sequentially one by one, replacing the need to measure a large volume of fine powder together, thus enabling accurate analysis with coarser particles
2Measurement precision
If samples are ground to very fine particle size, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent changes the particle size parameter from fine powder requiring micronizing mills to coarse particles that can be handled by simple crushers, dramatically reducing equipment complexity while maintaining analysis accuracy through sequential measurement of multiple particles
Solution Approach 2:
The patent extracts and eliminates the complex micronizing mill equipment from the sample preparation process by using coarse particles instead, retaining only essential functions like crushing and magnetic separation
3Measurement precision
If sample preparation is performed manually with precision, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The patent implements automated sample preparation where the system itself performs particle separation, carrier preparation, and sequential measurement without manual intervention, eliminating time-consuming manual operations while maintaining precision through controlled automated processes
Solution Approach 2:
The patent performs preliminary actions by pre-coating carriers with binding material and pre-separating magnetic particles before measurement, enabling automated sequential analysis without time-intensive manual preparation during actual measurement
4Productivity
If a stream of material with large particle size distribution is analyzed, then productivity is improved, but measurement precision deteriorates
Solution Approach 1:
The patent applies local quality by selecting and measuring particles within a specific size range (0.5mm to 5mm) from the broader size distribution, ensuring each measured particle meets optimal criteria for accurate diffraction analysis while maintaining continuous processing of the overall stream
Solution Approach 2:
The patent performs preliminary magnetic separation to isolate ferrous particles from the stream before measurement, ensuring that only suitable particles are presented to the XRD system, thus maintaining both continuous processing capability and measurement precision
5Adaptability or versatility
If non-crystalline substances are present in the sample, then adaptability is improved, but measurement precision deteriorates
Solution Approach 1:
The patent extracts and separates magnetic ferrous particles from non-magnetic non-crystalline substances using magnetic separation before XRD measurement, eliminating interference from amorphous materials and enabling precise analysis of crystalline phases while maintaining adaptability to handle diverse cementitious materials
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
Enhances precision and accuracy by reducing user interaction, increasing the number of diffraction conditions, and improving sample representation, while minimizing power requirements and sample preparation time, allowing for better process control and quality monitoring.
Implementation Method 1
X-ray diffraction involves the use of an incident X-ray beam directed at a prepared powder sample and a sensor or detector for detecting X-ray beams diffracted from the powder sample. The X-ray beams diffract from the powder sample at distinct characteristic angles to form a diffraction pattern
Implementation Method 2
determining elemental composition of substances in the cement or ore sample by X-ray fluorescence
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method and apparatus for analysing particulate material having one or more crystalline substances, the apparatus including: a grinder for receiving a sample extracted from the particulate material and grinding the sample into powdered material having a designated particle size; a measurement station including an X-ray generator for illuminating the powdered material with an X-ray beam and an X-ray detector for detecting X-ray diffraction patterns from the powdered material; a carrier for receiving the powdered material from the grinder and conveying the powdered material through the measurement station; and a processor configured to: receive the X-ray diffraction patterns of the powdered material from the X-ray detector; analyse the X-ray diffraction patterns to determine a series of sequential composition determinations of one or more crystalline substances in the powdered material as the carrier conveys the powdered material through the measurement station; and determine composition of the one or more crystalline substances in the sample from the series of sequential composition determinations.