Pigment Granulation Process for Building Materials
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Solution Overview
Problem
Current methods for producing granulated pigments for building materials face challenges such as dusty and non-free flowing powdered metal oxides, leading to handling difficulties and inefficiencies in storage, transportation, and dispersion in concrete.
Innovation Solution
A high-speed agitated granulation process using a horizontal flexible wall compactor with simultaneous addition of water and binders, producing near-polyhedral or irregular polyhedral shaped granules with rounded edges that are free-flowing and have low moisture content, facilitating easy dispersion in building materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If powdered metal oxide pigments are used for coloring building materials, then the pigment can be readily dispersed in the base material, but the powder is dusty, giving rise to health hazards and making storage and handling difficult
Solution Approach 1:
The patent transforms the physical state of the pigment from powder to granulated form through a granulation process that changes particle size, shape, and surface properties. This parameter change eliminates dustiness while maintaining dispersion capability, as the granulated pigment disperses as individual granules rather than fine powder particles.
Solution Approach 2:
The granulated pigment is formed as a composite structure containing the metal oxide pigment bound with a binding agent. This composite granule structure combines the coloring properties of the metal oxide with the handling properties of a free-flowing granulate, eliminating dust while preserving dispersion.
2Productivity
If powdered metal oxide pigments are used, then the pigment can be effectively transferred to building materials, but the powders are not free flowing and cannot readily be conveyed through pipes
Solution Approach 1:
The granulation process changes the physical parameters of the pigment including particle size (to granulated form), shape (angular to sub-rounded), and surface characteristics. These parameter changes transform the material from a non-free-flowing powder to a free-flowing granulate that can be conveyed through pipes and metered accurately.
3Object-affected harmful factors
If granulated pigment products are produced using conventional methods, then the dustiness is reduced, but the granules do not have sufficient shape and structure for optimal packaging, transportation and use
Solution Approach 1:
The granulation process is a dynamic, multi-stage operation that progressively builds granule structure through controlled agitation, moisture addition, and mechanical action. The process dynamically adjusts parameters like moisture content and agitation intensity to achieve optimal granule shape and structure for handling and dispersion.
Solution Approach 2:
The granulation process employs mechanical agitation and vibration to promote granule formation, shape development, and structural consolidation. The mechanical energy input creates optimal conditions for forming dense, free-flowing granules with desirable shape characteristics for packaging and transportation.
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 process results in robust, dust-resistant granules that are easily dispersible and transportable, improving the efficiency of pigment transfer and use in concrete and cementitious materials, reducing energy consumption and production costs compared to conventional methods.
Implementation Method 1
a horizontal flexible wall compactor provided with agitating means for granulation
Implementation Method 2
spray or injection means for adding a liquid
Implementation Method 3
disintegrating means for disintegrating particles arising from granulation
Implementation Method 4
drying means for drying the particles
Data Source
AI summary
A pigment granule having an irregular polyhedral shape with rounded edges and a method for the production of the granules by the use of a high speed agitated granulating machine provided with agitating means for agitating a pigment substance for granulation, spray means for spraying or injecting a binding liquid on the pigment substance while the mixture is processed through the turbulizer and drying means for drying the particles, characterized by effecting the production by causing the means to act on the substance for granulation simultaneously thereby performing the agitating and granulation.