Titanium Cobble Production via Two-Stage Crushing and Dust Control
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Solution Overview
Problem
Current methods fail to produce a large amount of titanium cobbles with uniform particle size in high yield due to limitations in crushing scrap materials containing titanium, as they often result in excessive frictional heat and ignition issues.
Innovation Solution
A two-stage crushing process using a biaxial crusher followed by a hammer mill, accompanied by dust collection and classification into medium, large, and small particles, reduces frictional heat and ignition risks, allowing for the production of titanium cobbles with uniform particle sizes in high yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the scrap material is crushed to produce a large amount of titanium cobbles, then the productivity is improved, but the frictional heat increases causing ignition risks
Solution Approach 1:
The crushing process is divided into multiple stages with different crushers. A first crusher (jaw crusher or cone crusher) performs primary crushing, followed by a second crusher (impact crusher or hammer mill) for secondary crushing. This segmentation allows each stage to handle specific size reduction tasks, reducing excessive frictional heat generation in a single stage while maintaining high productivity.
Solution Approach 2:
A dust collection system is introduced as an intermediary between the crushing process and the environment. The system collects fine dust generated during crushing, preventing it from accumulating and being ignited by frictional heat or sparks. This mediator removes the harmful factor (fine dust) that could lead to ignition, allowing the crushing to proceed with higher productivity.
2Manufacturing precision
If the scrap material is crushed to produce titanium cobbles with uniform particle size, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
The particle size control process is segmented into multiple classification stages. After primary and secondary crushing, a first classification step separates particles into specified size ranges. Oversized particles are returned to the second crusher for further size reduction, while particles within the target range are collected as titanium cobbles. This segmented approach ensures uniform particle size without requiring excessive re-crushing of all material, thereby maintaining productivity.
Solution Approach 2:
Particles that do not meet the size specification are not discarded but recovered and returned to the crushing process. The classification system separates oversized particles, which are fed back to the second crusher for additional size reduction. This recovery and reprocessing approach ensures high manufacturing precision while minimizing waste and maintaining overall productivity by only re-crushing the necessary portion of material.
3Reliability
If the scrap material is crushed with limited amount to reduce ignition, then the productivity is reduced, but the safety is improved
Solution Approach 1:
A dust collection system is introduced as an intermediary between the crushing process and the environment. The system collects fine dust generated during crushing, preventing it from accumulating and being ignited by frictional heat or sparks. This mediator removes the harmful factor (fine dust) that could lead to ignition, allowing the crushing to proceed with higher productivity.
Solution Approach 2:
The dust collection system creates a controlled environment by removing combustible fine dust from the crushing area. By continuously collecting and removing dust particles, the system maintains an environment with reduced ignition risk, enabling safer operation at higher productivity levels without requiring excessive limitation of the crushing amount.
4Reliability
If fine dust is collected to prevent ignition, then the safety is improved, but the device complexity increases
Solution Approach 1:
A dust collection system is introduced as an intermediary between the crushing process and the environment. The system collects fine dust generated during crushing, preventing it from accumulating and being ignited by frictional heat or sparks. This mediator removes the harmful factor (fine dust) that could lead to ignition, allowing the crushing to proceed with higher 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 method effectively produces a large quantity of titanium cobbles with uniform particle sizes while maintaining safety, achieving a yield of 70% or higher, by reducing frictional heat and ignition risks through controlled crushing and classification.
Implementation Method 1
excessive frictional heat generated by contact between metal materials
Implementation Method 2
a first crushing step of roughly crushing the scrap material using a first crusher; a second crushing step of crushing the scrap material, which has been roughly crushed in the first crushing step, using a second crusher
Implementation Method 3
a dust collection step of collecting fine dust of the scrap material generated in the second crushing step
Implementation Method 4
a first classification step of classifying products obtained by crushing the scrap material, which have been generated in the second crushing step, into medium particles with particle sizes within a predetermined particle size range, large particles with particle sizes larger than the particle size range, and small particles with particle sizes smaller than the particle size range
Data Source
AI summary
A method of producing titanium cobbles includes: a preparation step of preparing a scrap material containing 50% by mass or more of metal titanium; a first crushing step of roughly crushing the scrap material using a first crusher; a second crushing step of crushing the scrap material, which has been roughly crushed in the first crushing step, using a second crusher; a dust collection step of collecting fine dust of the scrap material generated in the second crushing step; and a first classification step of classifying products obtained by crushing the scrap material, which have been generated in the second crushing step, into medium particles with particle sizes within a predetermined particle size range, large particles with particle sizes larger than the particle size range, and small particles with particle sizes smaller than the particle size range.