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Hosokawa Alpine Aktiengesellschaft, Augsburg, Germany
Minerals & Metals Division
Mr. Dietmar Alber
IM 22
VANCOUVER
1-3 April 2014
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Ultrafine Micronisation
of
Hard Minerals
for
the Ceramic and IT Industry
Dietmar Alber, Hosokawa Alpine, Augsburg, Germany
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- Production facilities in 5 countries
- 12 R&D and testing centres world-wide
- 1500 Employees
Hosokawa Worldwide
Hosokawa Micron
Powder Systems
Hosokawa Alpine
Corporate Headquarters
Osaka, Japan
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Hosokawa Micron Powder Systems
Location: Summit,
NJ USA
Founded: 1923
� Powder & Particle Divisions:Mills, Classifiers, Mixers and Dryers for Applications in the Minerals & Metals, Chemicals, Pharma and Food.
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� Powder & Particle Divisions:Mills, Granulators and Classifiers for Applications in the Minerals- & Metals, Chemicals, Pharma, Food and Feed Industries and the Inline-Recycling.
� Blown Film Division:Blown Film Lines: Extruder, Film Die Heads, Film Winders, Film Orientation Lines
Location: Augsburg
Founded: 1898
Employees: 620
Hosokawa Alpine Aktiengesellschaft
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• Micronisation of high purity quartz
• Micronisation of zircon opacifier
• Processing of special grades for
the ceramic industry
• Processing of silica powder for
LCD display screens
Agenda
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Agenda
Micronisation of high purity quartz
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Definition:
- High Purity Quartz (HPQ)
- Ultra High Purity Quartz
- Official definition is not fixed
- range from 99.30 % to 99.9992 % SiO2
- standard SiO2 products hardly reach 99.50 %
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Applications of HPQ:
- semiconductors
- high temperature lamp tubes
- telecommunication
- optics
- microelectronics
- Solar silicon applications
The market for really ultra high purity silica with
contamination levels < 30 ppm is relatively small
and according to IM Magazine report from
Jan 2012 a maximum of 100.000 tpa
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Processing of High Purity Quartz/Silica
Avoid contamination as far as possible during processing
• Autogen grinding
• Jet milling
• Benefication processes
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Impurities are ranging from 10 to 7000 ppm
Depending of the application one has to look
which impurities come into the product by
processing and how much is already in the
feed
Impurities
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What impurities are added during processing?
- Fe203
- Al2O3
- SiO2
- TiO2
- ZrO2
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What impurities are added during processing?
- Fe203 any increase is a no go
- Al2O3
- SiO2
- TiO2
- ZrO2
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What impurities are added during processing?
- Fe203 any increase is a no go
- Al2O3
- SiO2
- TiO2
- ZrO2
In sum a contamination of maximum 300 ppm
is possible today
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silica lining
and
silica grinding media
AUTOGEN GRINDING in Ball Mills
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Jet Milling system AFG for Silica
Multi-Wheel Classifier
Head
for very fine products
For minimized contamination of the raw material
ALPINE Fluidized Bed Jet Mill AFG
with
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Jet Milling system AFG for Silica
Wear Protection is a must !
Multi-Wheel Classifier
Head
in ceramic design
Milling section
in ceramic design
with
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Jet Milling system AFG for Silica
Typical Flow Sheet:
400 AFG with load cellsStandard plant design AFG
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Jet Milling system AFG for Silica
Plant Examples:
800/3 AFG
• Feed material: 97 % < 100 µm
• Fineness: d97 = 10 µm
• Capacity: approx. 400 kg/h
400/4 AFG
• Feed material: 97 % < 100 µm
• Fineness: d97 = 7 µm
• Capacity: approx. 20 kg/h .
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Agenda
Micronisation of zircon opacifier
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Definition: zircon opacifier
Origine from purified zricon sand (ZrSi04) used direct as
glaze opazifier in the white ceramic ware at a fineness
of typically 100 % < 6 µm and a average particle size of
0,8 – 1,2 µm
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Ball Mill / Classifying system for Opacifier grade
Typical Flow Sheet
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Super Orion SO-SF Ball Mills with ceramic lining
+
fully wear protected
ultrafine classifier
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Optimized parameters at dry running ball mills
For ultrafine micronisation of hard minerals
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Processing paramters of dry running ball mills
• ball mill revolution /r.p.m.)
• L/D ratio of the ball mill drum
• selections of grinding media
• sizing of the grinding media
• number of grinding chambers
• selection of mill lining
• mill discharge system (airswept, overflow, slotwall, etc)
• ball mill filling level
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High capacity and heavy wear
protection
ATP – multi wheel
315/6 ATP/GS
d50 = 0,8 µm
Aluminiumoxide
ceramic
version
315/3 ATP
Aluminiumoxide
ceramic lining
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Preconditions for processing of ultra fine hard
industrial minerals at a fineness of < d50 = 0,8 –
3,0 µm in closed ball mill - / classifying circuits
• optimized ball mill parameters
• economical ultra fine wear protected classifiers
• use of grinding aid
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Agenda
Processing of special grades for
the ceramic industry
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The key word here is
One Plant - Two Products
What does this phrase mean?
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Master-tailored powders
for Sanitary, Tile and
Porcelain Industries
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ceramic body ceramic glazes
Up to date dry processing
of
silica for ceramic
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µm
%conventional
wet
conventional
dry
tailor
made
µm
%
µm
%
Deve
lop
me
nt
of
PS
D
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Today’s requirements of
Ceramic Industry
Glaze:
1 µm max. 13 %
3 - 4 µm ≈≈≈≈ 50 %
20 µm ≈≈≈≈ 99,8 %
Body:
1 µm max. 3 %
15 - 18 µm ≈≈≈≈ 50 %
80 µm ≈≈≈≈ 99,8 %
0
20
40
60
80
100
120
0 10 20 30 40 50µm
%
0
20
40
60
80
100
120
0 20 40 60 80 100µm
%
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Advantages of narrow PSD
Ceramic Body:
• wide sinter intervals
• thinner bodies
• less scrap (deformation)
Ceramic Glaze:
• less fines ⇒⇒⇒⇒ less cohesion & adhesion
• even pigment and glaze distribution
• smooth surface
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S.O. + ASP + ATP
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Example of Production Capacities
Plant: 265/500 S.O. + 630 ASP + 500 ATP
Products: Feldspar Quartz
20 - 63 µm 6,4 t/h 5,3 t/h
0 - 20 µm 0,9 t/h 0,7 t/h
Power consumption: 295 kWh
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Ball Mill
0
20
40
60
80
100
0 20 40 60 80 100 120
µm
%
Ball Mill
Particle size distributions
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0
20
40
60
80
100
0 20 40 60 80 100 120
µm
%
ASP fines
Ball Mill
Particle size distributions
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0
20
40
60
80
100
0 20 40 60 80 100 120
µm
%
Glaze
Ball Mill
Body
Particle size distributions
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Silica plant for specialty and standard powders
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Dry processing of standard PSD grades
gritt 100 – 800 µm
gritt 75 – 630 µm
various fractioning 100-300; 100-500
powder D97 = 75 µm
powder D97 = 63 µm
powder D97 = 45 µm
porcelain powder D97 = 20 µm
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Flexible silica production plant
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Super Orion Ball Mill
With conventional gear rim - pinion drive
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Al2O3 lining
and
Al2O3 grinding media
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Wear protected 800 ASP Classifier
1
2
3
2 = Bull ring
3 = Guide vane Ring
1 = Classifier wheel
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Allgaier & Mogensen Screens for gritting
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- Optical sorting
- High intensive magnetic separation
- Magnetic separation
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Agenda
Processing of silica powder for
LCD display screens
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Design of steep Particle Size Distributions
Products for LCD & plasma display screens:
- very steep PSD within the limits of:
99 % < 90 µm
and
35 % < 45 µm
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Steep PSD for LCD screens
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
1000010000
1
2
3
4
5
Datum: 12.03.12
10
Maschine: ALPINE process
20
25
30
40
Material: silica
45
50
60
65
70
75
Firma: Step PSD80
85
90
95
97
99
99,5
99,899,9
99,99
99,999
99,9999
AlpineKörnungsnetz
(RRS Diagramm)
1 10 100 1000 10000
Korngröße d in µm
Du
rch
gan
g D
in
%
1 PSD LCD screen
2
3
4
5
6
7
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Steep vs Standard PSD
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
1000010000
1
2
3
4
5
Datum: 12.03.12
10
Maschine: ALPINE process
20
25
30
40
Material: silica
45
50
60
65
70
75
Firma: Step PSD80
85
90
95
97
99
99,5
99,899,9
99,99
99,999
99,9999
AlpineKörnungsnetz
(RRS Diagramm)
1 10 100 1000 10000
Korngröße d in µm
Du
rch
gan
g D
in
%
1 PSD LCD screen
2
3 standard silica
4
5
6
7
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Production of steep PSD:
- very steep PSD within the limits of:
99 % < 90 µm and 35 % < 45 µm
Requires: - high yield of above fraction > 50 % !!!
- processing know how of micronisation
in ball mill separator loops
- high efficient air separators
- contamination poor processing machines
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Hosokawa Alpine Aktiengesellschaft, Augsburg, Germany
Minerals & Metals Division
Thank you very much for your attention!
IM 22