Serial Ceramic Milling System with Varying Diameters
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Solution Overview
Problem
Existing milling systems for ceramic production face challenges such as high energy consumption, uneven particle size distribution, and inefficiencies in processing materials with different hardness and particle sizes, leading to increased waste and suboptimal product quality.
Innovation Solution
A wet milling system comprising at least two serially connected continuous mills with varying diameters and lengths, where the first mill provides higher impact force for larger particles and the subsequent mill increases abrasive force for finer particle reduction, along with a hydrocyclone and dewatering unit for size classification and solid concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple serial mills with different sized balls are used to process different raw materials, then the desired particle size can be achieved, but the energy consumption increases excessively
Solution Approach 1:
The milling process is divided into multiple serial mills, each handling specific raw materials with appropriate ball sizes. This segmentation allows each mill to be optimized for its specific task, achieving desired particle size while managing energy consumption through targeted processing rather than uniform milling of all materials
Solution Approach 2:
Different ball sizes are used in different mills based on the specific raw materials being processed. Each mill has locally optimized ball sizes matched to the hardness and particle size requirements of its specific raw materials, ensuring efficient energy use for each material type
2Device complexity
If all raw materials are milled together in a single mill, then the process is simpler, but the particle size distribution becomes uneven and energy consumption increases
Solution Approach 1:
The milling system is segmented into multiple mills, each dedicated to specific raw materials. This prevents the mixing of different material types during milling, ensuring uniform particle size distribution for each material while maintaining a manageable system structure
Solution Approach 2:
A classification device is introduced as an intermediary between mills to separate milled materials by particle size. This ensures that materials are properly sorted and directed to appropriate processing stages, maintaining precise particle size control without requiring overly complex mill configurations
3Ease of operation
If easily milled materials are processed for the full milling time required by difficult materials, then all materials can be processed uniformly, but energy is wasted on materials that are already at desired size
Solution Approach 1:
The milling process is segmented into multiple stages with different mills processing different materials for different durations. Easily milled materials can be processed for shorter times in dedicated mills, while difficult materials receive the full milling time they require, eliminating energy waste while maintaining operational simplicity
Solution Approach 2:
Different mills operate with different processing times and cycles matched to their specific raw materials. This periodic action allows each mill to complete its task efficiently without waiting for other materials, reducing overall energy consumption while maintaining uniform process management
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 configuration reduces energy consumption by 35% compared to classic systems, achieves a more uniform particle size distribution, and enhances the quality of ceramic products by ensuring similar particle sizes, thereby minimizing waste and optimizing the sintering process.
Implementation Method 1
The balls that freely move inside the body of the mill during rotation fall onto the raw materials and create a certain amount of impact force. The impact force, enables to reduce the size of larger sized parts
Implementation Method 2
The balls, also move at the inner surface of the mill by means of centrifugal force and they create a friction motion by both sweeping against each other and over the raw materials
Implementation Method 3
The balls, also move at the inner surface of the mill by means of centrifugal force and they create a friction motion by both sweeping against each other and over the raw materials. This friction motion wears down and mills the raw materials
Implementation Method 4
a hydrocyclone, connected to an outlet of the last continuous mill in the flow direction, wherein one end of the hydrocyclone is connected to re-feed any of the continuous mills and the other end of the hydrocyclone is connected to discharge the milled material that has been separated by size
Data Source
Figure 1~1A
Figure 2~3
Figure 4
AI summary
The invention is related to a milling system characterized by comprising at least two continuous mills (2) that are serially connected to each other from the mill inlets (2a) and mill outlets (2.b), that can rotate around a rotation axis (A), and that have been configured to transfer the milled material from one to the other according to a flow direction (FD), balls (B)having an amount and size which can move freely inside the inner volume of the mills (2) by means of the rotation of the mill (2) around its rotation axis (A), a supply tank (1), that is coupled to the first mill, in order to feed the material tobe milled into said mill (2) at the flow direction (FD) and wherein the diameter of the mill (2) in the flow direction (FD) is larger than the diameter of another mill (2) next in the flow direction (FD).