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CONTINUOUS DRY BEAD MILL
DRY BEAD MILL which is made bya Fine technology company, Ashizawa
DRYSTARSDA5
SEPA ALPHACFA100
Ashizawa Finetech Ltd.
Your Partner for Fine Particle Technologies
CLASSIFIER FOR DRYSTAR'S EXCLUSIVE USE
DRYSTARDRYSTAR
SEPA ALPHASEPA ALPHA
1
4
5
2
3
Feature Structure
: SiO2 (Mohs Hardness 7)Case1BEFORE
100μm
AFTER
100μm
10001001010.10
5
10
15
Particle Size (μm)
After 1 PASS
Before Grinding
15
2.5
After 1PASS
BeforeGrinding
d50
520
140
(μm)
dMAX
: Al2O3 (Mohs Hardness 9)Case2BEFORE
100μm
AFTER
100μm
10001001010.10
5
10
15
20
Particle Size (μm)
Before Grinding
9
2.1
After 1PASS
BeforeGrinding
d50
200
52
(μm)
dMAX
Particle Size Distribution
Particle Size Distribution
Specifications
CONTINUOUS DRY BEAD MILL DRYSTAR
Grinding High Hardness Material intoSingle Micron-sized PowderHigh Energy Efficiency and Mass Production
Dry and continuous operating Horizontal Mill
Enable to grind a few hundred micron of materials into single micron by one pass operation
Save a lot of energy costs(compared with jet mill: 1/10 of energy spending.)
Using air for ONLY shaft seal protecting
Efficious surface modification
Ground Powder
Spot Dust Collector
Grinding Chamber Separator(Screen)
Rotating Shaft
GrindingAid
Raw Materials
FeederPowder
(Particles)
Air
Grinding Data by
Fre
que
ncy
(%)
Fre
que
ncy
(%)
After 1 PASS
DRYSTAR
DRYSTAR
Specifications are subject to change without notice.
Grinding Chamber Volume(L)
Motor(kW)
Weight(kg)
Chamber Material
3.8
5.5
600
1300
1400
550
○
1.0
3.5
400
600
500
50
○
12.2
15
850
2000
1700
800
○
25
22
1100
2500
2800
1600
50
45
1300
3200
3300
2700
125
75
2000
3500
1100
5000
-
250
132
2300
4500
1400
7500
500
200
2600
6000
1700
12000
Dimensions(W×D×H)
W(mm)
D(mm)
H(mm)
Model 51 25 50 125 250 50012.5
Ceramics, Metal (Metal Only in SGD125)Corresponds to the φ1.5mm beads
Fine particle Outlet
Materials Inlet
Coarse particle Outlet
Processing data sample
Wider processability of grinding and mechanochemical
Particle size after grinding is below 1µmThe maximum particle size is reachable below 10µm without classifier
The 100 times ability of grinding compared to the ball mill
Circulation system with 1L as grinding camber volumeTrial can be started from 0.5L as a minimize volume
User friendly design
feature②
feature①
Before processing
10μm
1μm d50=0.89μm dMAX=9.25μm
d50=6.53μm dMAX=44μm
<activated carbon>
Table sized machine appear!
Reachable to submicron range
Corresponds to the �1.5㎜beads
Scale-up to Production Size
For R&D DRYSTAR
CLASSIFIER FOR DRYSTAR'S EXCLUSIVE USE
Classifier made for DRYSTAR
Specifications
1 ZERO Coarse particle contamination
EASY assembly, dis-assembly
Good maintainance
2
3
Simple Structure Has Been Adopted
BEFORE
AFTER
CFA 100 CFA 160 CFA 230 CFA 315
Specifications are subject to change without notice.
Throughput(kg/hr)
Air Flow(㎥/min)
Speed(rpm)
Dimensions(W×D×H)
Motor(kW)
10
4
7000
900×1300×1200
2.2
25
10
4500
1200×1700×1600
2.2
50
30
3000
1700×2400×2200
5.5
100
40
2300
2300×3300×3000
7.5 SEPA ALPHA
Model
Particle Size (μm)
6
5
8
7
4
3
2
1
00.1 1 10 100
Raw Material
Coarse Particle
Fine Particle
Raw Material
Coarse Particle
Fine Particle
Example:Inorganic Oxcide
After processing
SEPA ALPHA
Raw Materialdmin= 0.5μm, d50= 6.2μm, dMAX= 31.1μm
Fine Particle dmin= 0.5μm, d50= 2.9μm, dMAX= 9.0μm
Coarse Particledmin= 2.5μm, d50= 7.1μm, dMAX= 31.1μm
Frequency (%)
Particle size (μm)
10
8
6
4
2
0
Frequency
(%
)
0.100.1 1 10 100
d50=0.888μm
d50=6.529μm
After processing
Before processingReachable to
submicron range
Ashizawa's Proposal - #1
Raw materials that is supplied by DRYSTAR from a feeder is ground in DRYSTAR. The fine and coarse particles are separated by a classifier called SEPA ALPHA.Then, the fine particles are collected in the cyclone and the bag filter. After being classified, the coarse particles are returned to DRYSTAR and ground again.
System
SDA-L system is a closed circuit grinding system with a combination of a dry bead mill and a classifier.This system can efficiently produce fine with a sharp particle size with the energy of the minimum.
70
60
50
40
30
20
10
0
Par
ticle
Siz
e d
MA
X [μm] DRYSTAR
SDA-L System
0.0 0.5 1.0 1.5 2.0 2.5
Comparison of Electric Power Consumption Rates Required for Grinding
SDA-L System processes more effectively when targeting a finer particle size region
12
10
8
6
4
2
0
Raw Material
DRYSTAR Outlet
Coarse Particles
Fine Particles
1 10 100 10000.1
Particle Size Distribution After Grinding and Classifying
Grinding Classifying
10μm
d50=19.0μmdMAX=124.5μmd50=19.0μmdMAX=124.5μm
Raw Material
d50=5.3μmdMAX=22.0μmd50=5.3μmdMAX=22.0μm
Fine Particles
d50=2.7μmdMAX=6.5μmd50=2.7μmdMAX=6.5μm
Coarse Particles
d50=7.2μmdMAX=22.0μmd50=7.2μmdMAX=22.0μm
10μm
10μm
10μm
SDA-L
Feeder Cyclone
Bag FilterAir
Blower
Raw Materials
CFA
SDA
Coarse Particles
Fine Particles
DRYSTAR Outlet
Fre
que
ncy
(%)
Particle Size (μm)
When the maximum diameter for the particle size attained is more than 20 µm (above bisecting line in graph)
➡ is able to process using less electrical power.When the maximum diameter for the particle size attained is less than 20 µm (below bisecting line in graph)
➡ SDA-LSystem is able to process using less electrical power.
Effective Area for DRYSTAR
Effective Area for SDA-L
Electric Power Consumption Rate [kwh/kg]
DRYSTAR
SEPA ALPHA
DRYSTAR SEPA ALPHA
DRYSTAR
flow diagram
: Inorganic Material (Mohs Hardness 6)Case1
: Inorganic Material (Mohs Hardness 9)Case2
0
1
10
100
0.0 1.0 2.0 3.0 4.0
SDA5 + LMZ2LMZ2
Achieved in 30min.
Achieved in 90min.
“ECO-GRINDINGTMTM” is a new grinding system which saving energy by combining a dry bead mill and a wet bead mill.
Ashizawa's Proposal - #2
“ECO-GRINDINGTM” —
0
5
10
15
0.01 0.1 1 10 100 1000
Raw MaterialsSDA5φ5mm・62kWh/dry・tonLMZ2(After SDA5 grinding)φ0.5mm・970kWh/dry・tonLMZ2φ1mm・3880kWh/dry・ton
7~9
4~6
Quartz, Silica, Soft Ferrites, Hard Ferrites, Carrier Ferrites, Alumina, Silicone Nitride, Iron Oxide, Tungsten Oxide, Sodium Silicate
Gypsum, Magnesium Hydroxide, Aluminum Hydroxide, Barium Titanate, PZT, Powdered Green Tea, Rice Flour
Glass, Carbon, Black Silica, Blast Furnace Ash, Fly Ash, Burned Ash, Organogermanium
Mohs Hardness
Dry Process Wet Process
PumpPumpPump
Re-circulationTank
Tank forPre-mixing
Tank for Raw Materials
Tank for Product
NEXT Procedure
AdditivesSolid
Raw Materials
HL
HL
LL
LL
HL
LL
HL
M
M
M
LL
LMZSDA
CONTINUOUS DRY BEAD MILL
Feeder
Particle Size (μm)
Par
ticle
Siz
e d
50 (μ
m)
Fre
que
ncy
(%)
Particle Size Distribution Power Consumption for Grinding
Power Consumption[KwH/dry·kg]
73% Reduction in Power Consumption!
Proven Materials Used with
Materials
Less Than 4
Coarse GrindingSTARMILL
Fine GrindingDRYSTAR
DRYSTAR
flow diagram
ExampleExample : SiO2
Why does Ashizawa recommend ?■ Production efficiency comparison of the dry ball mill and dry beadmill
Comparison Between Dry Bead Mill and Jet Mill
©2010 Ashizawa Finetech Ltd.1910C2SDA_CFA(E)-4
(Model: SDA500)×1(Unit)
Your Partner for Fine Particle Technologies
https://www.ashizawa.com/english/ E-mail [email protected]
Headquarter
Osaka Branch TEL +81-6-6863-7117 FAX +81-6-6863-7010
TEL +81-47-453-8111 FAX +81-47-453-83781-4-2 Akanehama, narashino-shi, Chiba 275-8572 JAPAN
6-2-1 Sonehigashinocho, Toyonaka-shi, Osaka 561-0802 JAPAN
Ashizawa Finetech Ltd.
CONTINUOUS DRY BEAD MILL DRYSTAR
DRYSTAR
Performance comparison between and a ball mill Example of equipment comparison between and a ball mill
Dry bead mill can minimize contamination from beads compared to wet grinding.Therefore, dry grinding is effective as a pre-grinder for materials that require fine wet process grinding on a submicron or nano scale level.
0.001(1nm)
0.01 0.1 1 10 100 1000(1mm)
5000(μm)
Wet Bead Mill
Dry Bead Mill(DRYSTAR)
Attainable Particle Size for Grinding and Dispersing
Raw Material
After Dispersing
After Grinding
Raw Material
After Grinding
After Dispersing
Difference Between Wet Grinding and Dry Grinding
Wet Bead MillDry Bead Mill(DRYSTAR)
Bead Size
Shaft Sealing
Material Wear
Re-agglomeration
Particle Compounds
Mechanochemical Effect
φ1.5 to 8 mm
Easy(Oil Seal)
Low(1/10 of Wet Grinding)
More likely
Good
Large
φ0.03 to 2 mm
Precise(Mechanical Seal)
High
Less likely
Possible
Extremely Small
Grinding Media Grinding Principle Grinding Configuration
Grinding Force Particle Control Energy Costs Additional
Equipment
Beads(φ1.5 to 8 mm)
Beads’ Shear Force and Force of Impact
Surface Grinding Strong
Easy…Bead Diameter, Speed and Processing Flow
1/10 or Less of the Jet Mill Costs
Small Quantity Needed
Air(Humidity Control)
Impact of Product Itself
Bulk Grinding Weak
Difficult…Classifier and Air Pressure Require Adjustment
Extremely LargeLarge Quantity Needed
Jet Mill
Rotating Ball Mill1
Broad
Several µm
φ20 to 50 mm
Rather difficult
85 to 100 dB (A)
Slightly Large
Large
Difficult
Difficult
Chamber
Large-scale
Batch Method
Vibrating Ball Mill20
Slightly Broad
Several µm
φ10 to 20 mm, or Rods
Difficult
85 to 100 dB (A)
Public Disruption with Low Frequency
Rather Small
Easy
Easy
Chamber
Difficult
Continuous Pass
80
Sharp
1 to Several µm
φ1.5 to 8 mm
Easy
75 to 85 dB (A)
Same as a General Machine
Small
Easy
Easy
Agitator
Easy
Continuous Pass
Model
Installation Capacity
Particle Size Distribution
Attained Particle Size
Ball Size
Scaling Up
Noise
Vibration
Installation Area
Temp. Control
Product Collection
Wear
Maintenance
Grinding Method
16,000 L Ball Mill × 3(Units)
When using a production size machine, it is difficult to obtain the same results for a product as the testing sample on a ball mill. In addition, even if it is viable to manufacture a product that is equivalent to the testing sample, compared to dry bead mill , the equipment costs are roughly twice as much, the number of machines required is three times more, the installation area is roughly seven times larger and the amount of beads needed is roughly 60 times more. Hence, a ball mill is not really efficient nor realistic.
DRYSTAR
DRYSTAR
DRYSTAR
DRYSTAR
DRYSTAR
DRYSTAR
DRYSTAR