CONTINUOUS DRY BEAD MILL DDRYSSTAR · CONTINUOUS DRY BEAD MILL DRY BEAD MILL which is made by a...

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


Before Grinding

9

2.1

After 1PASS

BeforeGrinding

d50

200

52

（μm）

dMAX

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


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


Fine Particles


Coarse Particles


10μm

10μm

10μm

SDA-L

Feeder Cyclone

Bag FilterAir

Blower

Raw Materials

CFA

SDA

Coarse Particles

Fine Particles

DRYSTAR Outlet

Fre

que

ncy

(%)


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


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


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

CONTINUOUS DRY BEAD MILL DDRYSSTAR · CONTINUOUS DRY BEAD MILL DRY BEAD MILL which is made by a...

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