Sonic Pulverization of Combustion Ash for Cement
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Solution Overview
Problem
Current methods for upgrading combustion ash to enhance its pozzolanic properties and reduce particle size, ammonia, and carbon content are costly, inefficient, and require lengthy processing times, which degrades the quality of the ash and increases equipment costs.
Innovation Solution
A sonic pulverization process using an acoustic frequency sonicator with grinding media of maximum 2 mm diameter, applying sonic energy for 1-3 minutes to reduce particle size and increase specific surface area, followed by secondary processes like froth flotation or sieving to further enhance the ash's quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If particle size reduction is applied to combustion ash, then the surface area and reactivity are increased, but the processing time increases and equipment complexity increases
Solution Approach 1:
The patent replaces conventional mechanical grinding systems with ultrasonic vibration technology. The ultrasonic processor uses acoustic waves to generate cavitation and mechanical effects that rapidly reduce particle size without requiring lengthy mechanical grinding operations, thus achieving fine particle size reduction with shorter processing times.
Solution Approach 2:
The patent changes the physical state and energy input parameters by applying ultrasonic vibrations at specific frequencies (e.g., 20 kHz) to the ash material. This parameter change enables rapid particle size reduction through cavitation and mechanical disruption, achieving the desired particle size distribution much faster than conventional mechanical methods.
2Manufacturing precision
If particle size reduction is applied to combustion ash, then the surface area is increased, but the equipment complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical grinding systems with a relatively simple ultrasonic processor. The ultrasonic device uses acoustic waves to generate cavitation and mechanical effects that rapidly reduce particle size without requiring lengthy mechanical grinding operations, thus achieving fine particle size reduction with shorter processing times.
Solution Approach 2:
The ultrasonic processing system utilizes the self-generated cavitation and mechanical effects of the ultrasonic waves to achieve particle size reduction. The system does not require complex external mechanical grinding components, as the ultrasonic energy itself performs the particle disruption and size reduction function.
3Manufacturing precision
If carbon content is reduced in combustion ash, then the pozzolanic quality is enhanced, but the processing cost and time increase
Solution Approach 1:
The patent replaces conventional mechanical separation methods with ultrasonic vibration technology. The ultrasonic processor uses acoustic waves to generate cavitation and mechanical effects that rapidly reduce particle size and separate carbon from the ash matrix, achieving carbon removal with shorter processing times than conventional methods.
Solution Approach 2:
The patent changes the physical state and energy input parameters by applying ultrasonic vibrations at specific frequencies (e.g., 20 kHz) to the ash material. This parameter change enables rapid particle size reduction through cavitation and mechanical disruption, achieving the desired particle size distribution much faster than conventional mechanical methods.
4Manufacturing precision
If ammonia levels are reduced in combustion ash, then the cementitious quality is improved, but the processing complexity and cost increase
Solution Approach 1:
The patent replaces conventional mechanical processing with ultrasonic vibration technology. The ultrasonic processor uses acoustic waves to generate cavitation and mechanical effects that rapidly reduce particle size and facilitate the removal of ammonia and other contaminants, achieving improved cementitious quality with reduced processing complexity.
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 achieves significant reductions in particle size, increases specific surface area, and decreases contaminant levels, allowing for rapid and cost-effective production of high-quality combustion ash suitable for cementitious applications, with enhanced compressive strength and reduced water permeability.
Implementation Method 1
applying sonic energy for 1-3 minutes to reduce particle size and increase specific surface area
Implementation Method 2
The process achieves significant reductions in particle size, increases specific surface area
Data Source
Figure 1
AI summary
Described and claimed herein is a method of producing enhanced combustion ash for use in pozzolanic applications or cement clinker manufacture. The method employs a primary process in which wet or dry feedstock is pulverized with sonication using one or more grinding media having a maximum component size of about 2 mm. Alternatively, the media may have a true grinding medium volume to chamber volume ratio of at least 0.29. Also disclosed an claimed is an enhanced combustion ash produced by the method, whereby the enhanced combustion ash has one or more qualities that make it particularly suitable in pozzolanic applications or cement clinker manufacture.