Patent Application
20140197254
The present invention relates to rotary mills. More particularly, the invention relates to an automated system for reliably discharging rotary mills.
Rotary mills, also known as ball mills, pebbles mills, rod mills, or tumble mills, are well known in the art. A traditional rotary mill includes a horizontal rotating cylinder that rotates about a central axis. The cylinder includes grinding media that is generally spherical, cylindrical, or another uniform shape. Solid target materials are placed, as a dry solid or along with a liquid medium, into the cylinder for milling. The cylinder is rotated, causing the grinding media to tumble along with the target material, with the grinding media abrading and impacting the target solids. Continued rotation of the cylinder results in a milled product in the form of dry fine particles or particles suspended in liquid media.
Upon completion of the milling process, the product is discharged from the cylinder. The cylinder includes an opening with a solid cover that can be manually removed and replaced with a discharge grate, which will retain the grinding media but allow the product to pass through.
In the case of dry product, the product can become trapped between grinding media when the cylinder is stationary. Thus, to discharge the product, the cylinder can be rotated with the discharge grate open to discharge the solid product. In the case of a wet product, the cylinder can remain stationary if the liquid suspending the product is low-viscosity to flow past the media due to gravity. In the case of non-Newtonian or high-viscosity liquids, the cylinder can be rotated to discharge the product, similar to dry product.
In another form, the grinding media and product can be dumped from the cylinder without the use of a grate, and subsequently separated by a grate, filter, or vibrating sifter.
The rotary mill also includes a discharge housing that surrounds the rotating cylinder to define an annular space between the cylinder and the housing. The housing also includes a collection hopper at the bottom. When the product is discharged, as described above, the product will enter the annular space and fall into the hopper.
However, the above discharge process can result in dirty conditions, with dust becoming adhered to the inner surface of the housing as well as the outside of the cylinder. Retrieval of the product from the discharge housing can also result in dust entered the surrounding air. These conditions can reduce the amount of product recovered, as well as lead to cross-contamination issues and cleaning problems. In the case of liquid product, the operator must make and break a piped connection to the discharge housing, exposing the milled product and solvent vapors to the surrounding area during this connection.
Accordingly, there is a need for a discharge system that can reliably deliver the milled product from the cylinder while limiting loss of product and exposure of the product to adjacent areas and operators.
A rotary milling system is provided comprising: a rotatable cylinder defining a cavity and a central longitudinal axis; a discharge grate provided on a sidewall of the cylinder and defining an opening to allow milled product to pass therethrough; a discharge housing surrounding the discharge grate and defining a cavity therein; a flap disposed within the discharge housing and moveable between a closed position covering the opening of the discharge grate and an open position away from the opening; a conveying pipe in fluid communication with the housing; and a negative pressure producing vacuum member operatively associated with the conveying pipe to create a negative pressure within the conveying pipe.
In another form, the system further comprises a rotary union connected with the conveying pipe.
In another form, the system further comprises a secondary pipe connected to the rotary union, wherein the rotary union couples the secondary pipe and the conveying pipe and the secondary pipe is disposed between the negative pressure producing vacuum member and the conveying pipe.
In another form, the system further comprises a separator tank operatively coupled to the conveying pipe, wherein the vacuum member is in fluid communication with the separator tank.
In another form, the flap includes an elastomer face for creating a seal between the valve and the opening of the discharge grate when the flap is in the closed position.
In another form, the flap is pivotable relative to the discharge grate.
In another form, the system further comprises an actuator for moving the flap between an open and closed position.
In another form, the actuator is pneumatically operated.
In another form, the system further comprises a transmission portion coupled to the cylinder for rotating the cylinder.
In another form, the discharge housing includes a check valve for regulating the pressure in the system.
In another form, the system further comprises a dust filter located upstream of the vacuum member.
In another form, the system further comprises first and second trunion members for supporting the cylinder for rotation about the central axis.
In another form, the conveying pipe extends into and through the first trunion member.
In yet another form, a method for discharging milled product from a rotary mill is provided comprising: rotating a cylinder in which a plurality of grinding media and milled product are disposed; moving a flap away from a discharge grate provided on the cylinder, wherein the flap and discharge grate are surrounded by a discharge housing; discharging the milled product through the discharge grate into the discharge housing; and applying a negative pressure to a conveying pipe that is in fluid communication with the discharge housing to convey the product out of the housing and through the conveying pipe.
In another form, the method further comprises rotating the cylinder with the flap in an open position.
In another form, the method further comprises opening a check valve in the housing to provide sufficient airflow through the conveying pipe.
In another form, the milled product is disposed within a liquid medium.
Referring now to the drawings,
With further reference to
The grinding media 28 may be any suitably hard material, such as carbon steel, stainless steel, tungsten carbide, alumina, zirconia, porcelain, or the like. The grinding media can have different sizing as necessary. For example, in one form, the grinding media can be between ¼ inches in diameter to 1 inch in diameter. Of course, it could also be as small ⅛ inch or as large as 3 inches in diameter. The grinding media 28 is preferably a uniform size; however, the media size used in a particular operation could be different, where some of the media could be, for example, 1 inch in diameter with others being 2 inches in diameter. These sizes are merely exemplary and it will be appreciated that various other sizes of the grinding media could also be used.
The cylinder 12 also includes a first trunion 30 and a second trunion 32 extending outwardly from the end walls 24 and 25, respectively, along the central axis A. The trunions 30 and 32 support the cylinder 12 for rotating. More specifically, the system 10 includes a pair of vertical support members 34a, 34b each having a base 36a, 36b for contacting a support surface such as a floor and a bearing 38a, 38b for engaging and supporting the trunions 30 and 32 for rotation therein.
The cylinder 12 further includes a loading opening 40 extending through the sidewall 22 for delivering grinding media 28 or the product to be milled. An access hatch or loading cover 42 can be mounted over the opening 40 for sealing the opening 40 in a manner known in the art. The loading opening 40 can be diametrically opposed from the discharge grate 14 on the opposite side of the cylinder 12. However, other locations of the loading opening 40 in the sidewall 22 could also be used.
Turning to
Referring back
With reference to
The housing 18 can further include first and second access hatches 56 and 58 that can provide access into the housing cavity 54, if necessary. The access hatches 56 and 58 can be gasketed and bolted in a manner known in the art to provide a dust-tight seal between the housing cavity 54 and the air surrounding the housing 18.
With reference to
An actuator 64 can be connected to the axle 60 outside of the housing 12 to rotate the axle 60 and thus, pivot the flap 16. The actuator 64 can be manually operated to open and close the flap 16 or it could be automatically operated. In the case of manual operation, an operator can be positioned adjacent the housing 18 with limited interaction with the dust produced by the milled solid. In the case of automated operation, the operator can be positioned remotely to open and the close the flap 16 likewise limiting interaction with the milled product. In one form, the actuator 64 can be in the form of a vane actuator, as shown in
An automated actuator 64 can be pneumatically activated in a manner known in the art. The pneumatic pressure can be provided by a supply line 66 (shown in
With reference to
The housing 18 can include a check valve 84 mounted to the side of the housing 18 generally opposite the interface between the housing 18 and the pipe 20. The check valve 84 can be in the form of a poppet valve, and can operate as a vacuum breaker or to allow air into the cavity 52 to provide for sufficient conveying velocity of the milled product out of the housing 18 through the pipe 20. The check valve 20 can be configured and sized to allow for different desired air pressure within the cavity 52 in a manner known in the art.
With reference again to
The tank 88 can include different components depending on whether the milled product is a solid discharge, such as dry fine particles, or liquid discharge, where the particles are suspended in the liquid.
With reference to
With reference to
As shown in
Having described the general structure of the system 10, the function of the rotary milling system 10 described above will now be described in further detail.
With the cylinder 12 in a stationary position and the flap 16 in the closed position over the grate 14, the loading cover 42 can be opened to allow access into the cavity 26 of the cylinder 12. The desired product to be milled can be deposited into the cavity 26 for subsequent milling by the system 10. This process can be performed for both dry milling and liquid milling. Additionally, grinding media 28 can be deposited into the cavity 26 or removed from the cavity 26 depending on the needs of the user.
Once the desired amount of product and grinding media 28 are present in the cavity 26 of the cylinder 12, the loading cover 42 can be replaced on the cylinder 12 to create a seal and limit milled product from exiting the cavity 26 during the milling process. Similarly, the flap 16 is in the closed position over the discharge grate 14 in a sealed configuration to likewise limit milled product from exiting the cavity during the milling process.
With reference to
To assist in lifting the grinding media during operation, the cylinder 12 can include a plurality of longitudinally running ribs 12a within the cavity 26 of the cylinder 12. These ribs 12a can be seen in
As stated above, the solid product to be milled can be processed in a dry milling operation or a wet milling operation. In the dry milling operation, the solids are milled in a dry state and subsequently discharged dry. In the wet milling operations, the solids are milled in a liquid medium and the milled product is discharged as a liquid suspension or dispersion. Both processes are performed in the same general manner described above, with the cylinder 12 rotating at a selected speed to cause the grinding media 28 to be lifted and then fall or tumble to abrade the product.
During the rotation of the cylinder 12, the housing 18 and conveying pipe 20 will rotate about the central axis of the cylinder 12. Because the conveying pipe 20 extends to couple with the trunion 32 and into the rotary union 80, the pipe 20 remains in fluid communication with the housing 18 mounted to the cylinder 12 and the secondary pipe 86 leading to the separator tank 88.
At the conclusion of the rotation of the cylinder 12 during the milling process, the cylinder 12 will contain the product as either a dry solid in a fine particle form, or as a wet solid in a liquid medium. Depending on the type of milling operation (dry or wet), the product may require additional rotation of the cylinder 12.
In the case of dry milling, the product may become trapped between individual members of the grinding media 28. The cylinder 12 can be further rotated to loosen and free the product from the grinding media 28, if necessary.
In the case of liquid milling, if the liquid has a low viscosity, the liquid medium and the solid product contained in the liquid can generally flow through the grinding media 28 toward the bottom of the cylinder 12 without requiring additional rotation. If the liquid is non-Newtonian or has a high viscosity, the cylinder 12 may require additional rotation, similar to dry milling.
If the particular milling process used does not generally require additional rotation of the cylinder 12 to discharge the product, the cylinder 12 can be rotatably positioned such that the discharge grate 14 is at the bottom of the cylinder 12. The flap 16 can be opened via the actuator 64 allowing the product to flow through the grate 14 and into the cavity 54 of the housing 18. The actuator 64 can be operated automatically or manually. In either case, the product can pass through the grate 14 without exposing the operator or the surrounding environment to the milled product or solvent vapors. Rather, the product remains substantially contained within the housing 18.
If the cylinder 12 is required to rotate to discharge the milled product, for reasons described above, the flap 16 can remain in the open position allowing the milled product to pass through the grate 14. The milled product will remain contained within the system 10 during this rotation. As described above, the flap 16 can be automatically opened via a pneumatic connection. The air delivery line 66 to produce the pneumatic connection will rotate along with the cylinder 12 during the rotation.
While the milled product is being discharged through the grate 14 and into the cavity 54 of the housing 18, the conveying pipe 20 can convey the milled product to the separator tank 88. More specifically, a vacuum or negative pressure can be applied to the conveying pipe 88 from the blower or vacuum 91 mounted to the tank 88. The vacuum will be applied through the secondary pipe 86, the rotary union 80, and the conveying pipe 20 to pull the milled product from the housing cavity 54. This vacuuming of the milled product from the housing 18 allows for the housing 18 to be substantially smaller than the total volume of product that is discharged.
In the case of dry solids, the vacuum is used to create an air stream where the solids are suspended in the air stream. In the case of liquid discharge, a slight vacuum is drawn to motivate fluid flow.
The vacuum applied through the conveying pipe 20 can occur with the cylinder 12 and housing 18 either stationary or rotating. Because the conveying pipe 20 and housing 18 rotate along with the cylinder 12, and the conveying pipe 20 is coupled to the rotary union 80, the negative pressure to retrieve the discharging product is not dependent on the cylinder 12 rotating or remaining stationary.
In the event the pressure in the housing cavity 54 or conveying pipe 20 is ineffective to retrieve the milled product, the check valve 84 can open to regulate the pressure in the system 10. In the case of dry discharge, the check valve 84 is in the form of a poppet that will allow sufficient air flow to maintain sufficient velocity to keep the solids suspended in the air stream created by the vacuum. An air bleed 98 can be provided on the opposite trunion to allow air or for gas purging. In the case of liquid discharge, the check valve 84 is in the form of a vacuum breaker.
The use of a vacuum or negative pressure on the system 10, in addition to retrieving the product during the discharging process, can also be used to clean the system. The conveying pipe 20 and secondary pipe 86 can have a generally circular cross-section to limit the amount of build-up of product between the cylinder 12 and the tank 88.
Moreover, the use of negative pressure or a vacuum through the system 10 also limits instances of product escaping past a seal and into the surrounding area or into contact with an operator. Rather, the negative pressure will continue to pull product back into the system 10 in the event of a leak in one of the seals, in contrast to a system that forces air through a passageway that would push product out of a leaking seal or joint and into the surrounding area.
Additionally, to prevent build-up of product within the conveying pipe 20, rotary union 80, and secondary pipe 86, these components can be made from tri-clamp sanitary connections that retain little product, and can be broken down and easily cleaned.
The use of negative pressure to pull the product toward the separator tank 88 also allows the system 10 to be generally free from other conveying mechanisms, such as augers or the like, that can become easily contaminated and dirty after repeated use.
At the conclusion of the retrieval process, the flap 16 can be closed, manually or automatically, to allow for another milling operation. The milled product can be retrieved from the separator tank 88 in a manner known in the art.
As a person skilled in the art will readily appreciate, the above description is meant as an illustration of implementation of the principles this invention. This description is not intended to limit the scope or application of this invention in that the invention is susceptible to modification, variation, and change, without departing from the spirit of this invention, as defined in the following claims.
