This application is a U.S. National Phase application of PCT Application NO. PCT/EP2020/073597 filed on Aug. 24, 2020, which is incorporated by reference herein in its entirety.
Subject-matter of the invention is a screen plate for a separating device for mechanically classifying bulk material, more particularly polycrystalline silicon chunk.
Polycrystalline silicon (polysilicon) is produced typically by the Siemens process—a chemical vapor deposition process. In a bell-shaped reactor (Siemens reactor), thin filament rods (thin rods) of silicon are heated by direct passage of current, and a reaction gas comprising a silicon-containing component (e.g., monosilane or halosilane) and hydrogen is introduced. The surface temperature of the filament rods is typically more than 1000° C. At these temperatures, the silicon-containing component of the reaction gas is decomposed, and elemental silicon deposits from the gas phase in the form of polysilicon on the rod surface, increasing the rod diameter. When a mandated diameter has been reached, deposition is halted and the silicon rods obtained are uninstalled.
Polysilicon is the starting material in the production of monocrystalline silicon, which is produced for example by means of Czochralski process (crucible pulling). Additionally, polysilicon is needed for the production of multicrystalline silicon, using a block casting process, for example. Both processes require the polysilicon rods to be crushed to form individual chunks. These chunks are classified by size, typically in separating devices. The separating devices generally comprise screening machines which sort the polysilicon chunk mechanically into different size classes—that is, they classify it.
Polysilicon may additionally be produced in the form of granules in a fluidized bed reactor. This is accomplished by fluidization of silicon seed particles using a gas flow in a fluidized bed, which is heated using a heating device. The addition of a silicon-containing reaction gas brings about a deposition reaction on the hot particle surface, with elemental silicon being deposited on the seed particles and an increase in the diameter.
The polysilicon granules as well are typically divided by a screening unit into two or more fractions (classifying). The smallest fraction (screen undersize) may subsequently be processed into seed particles in a milling unit, and supplied to the reactor. The target fraction (product fraction) is typically packed and transported to the customer.
Screening machines serve generally to separate solids according to particle size. A distinction may be made in terms of motion characteristics between planar vibratory screening machines and shaker screening machines. The screening machines are usually driven electromagnetically or by means of imbalance motors or imbalance gearing. The motion of the screen tray conveys the charge material in the screen longitudinal direction and facilitates passage of the screening undersize through the screen openings. In contrast to planar vibratory screening machines, shaker screening machines feature vertical as well as horizontal screen acceleration.
Multideck screening machines are able to fractionate a number of particle sizes at the same time. The drive principle for multideck planar screening machines is based on two imbalance motors which operate in opposite directions to generate a linear vibration, with the fractionation material moving linearly over a horizontal separation surface. A m modular system may be used to assembly a multiplicity of screen decks into a screen stack. It is possible accordingly to produce different particle sizes in a single machine without any need to change screen decks.
Classification is typically accomplished using, alternatively, perforated screens, bar screens or profile screen plates with elevations and valleys and possibly V-shaped openings on one side.
Classification using perforated screens, of the kind described in CN207605973U, for example, are subject to possible blocking during operation, and, depending on the size of the charged material and the throughput, any blockages must be removed at regular intervals, leading to plant and production downtime. In the case of classification using bar screens (cf. EP 2 730 510 A1), the geometrical arrangement of the bars may result in blocking and clogging of fractionation material, with the possible consequence of losses in yield when the target product is separated off.
WO 2016/202473 A1 describes a profiled screen plate having a V-shaped profile, which has enlarging openings on a takeoff side. The valleys and peaks, which taper to a point, may however give rise to blocking of product fraction (blocked bulk material may also be referred to as stuck particles) in the product flow and in the opening region. This may lead to a deterioration in the classified material, since the undersize fraction, to be separated off, passes via the stuck fraction into the target fraction. To prevent this, it is again necessary to remove the stuck fraction regularly, resulting in longer downtime.
WO 2018/108334 A1 represents an improvement to the screen plate described in WO 2016/202473 A1. In this case the openings on the takeoff side have additional widening. The screen plate, however, is fairly poor at separating coarse/product fraction and fine fraction (precision of separation). As a result of the screen geometry, large particles may push the undersize in front of them and prevent the undersize being separated off.
The object to be achieved by the invention arose from the above-described problems.
The object is achieved by means of a screen plate for a separating device for classifying bulk material, comprising a profile region which has a profile having depressions and elevations extending in the direction of a takeoff side, where the profile is describable by a circle arc of a first circle K1 and by a circle arc of the second circle K2, and the circles K1 and K2 are disposed adjacent to one another, (and can be juxtaposed in alternation as often as desired) where the circle arc of the first circle K1 with a radius r1 describes the elevations and the circle arc of the second circle K2 with a radius r2 describes the depressions,
with each depression in a takeoff region undergoing transition into an opening which expands in the direction of the takeoff side, where the opening has an opening edge with a width corresponding to the length of the radius r2 to 2*r2. The width preferably corresponds to the radius r2.
It has emerged that this rounded profile allows the undersize fraction (fines to be separated off) even more effectively to separate from the product fraction. As a result of the profiled region, larger amounts of the undersize fraction collect in the rounded depressions. Larger chunks are transported over the undersize fraction on the screen plate into the depressions, generally without coming into contact with the undersize fraction. This results in a high quality of separation. The profile prevents larger chunks remaining stuck in the depressions by jamming. In particular, the broadened opening edge also on the one hand prevents the jamming of large chunks, and on the other hand ensures unhindered separation of the undersize fraction if a larger chunk becomes jammed.
The screen plate of the invention is more particularly an onward development of the screen plate described in WO 2018/108334 A1.
The circles K1 and K2 may contact one another at a point T0, or are joined to one another by a common tangent, with the tangent touching the circle K1 at the point T1 and the circle K2 at a point T2. Correspondingly, the profile is described by the tangent, optionally with the circle arcs. The circles K1 and K2 are preferably disposed adjacent to one another with the proviso that the depressions and the profile always expand upwardly (cf.
The two circles K1 and K2 may in principle be joined to one another by a higher-order function, a hyperbole or an ellipse arch as well, albeit with the proviso that the depressions of the profile always expand upwardly.
The bulk material may comprise polysilicon chunk material, such as comminuted polysilicon rods from the Siemens process. The bulk material may also comprise polysilicon granules. The bulk material is applied to the screen plate generally in a charging region, which is opposite the takeoff region.
The opening edge has a concave extent, thus arching into the interior of the screen plate or in the direction of the feed region, and has a depth t, with t being subject to 0<t≤5*r2, preferably r2 to 5*r2, more preferably r2 to 4*r2, more particularly 2*r2 to 3*r2. (cf.
According to another embodiment, the opening edge has a rectangular extent and has a depth t, with t being subject to 0<t≤5*r2, preferably r2 to 5*r2, more preferably r2 to 4*r2, more particularly 2*r2 to 3*r2. (cf.
For removal of bulk material of small particle size (also referred to as undersize), the profile of the screen plate may preferably have the two configurations described below. Bulk material of small particle size is intended here to refer to a portion of the charged amount of bulk material that is to be separated off by means of the screen plate. The bulk material of small particle size hence corresponds to the fraction to be separated off.
The profile of the screen plate for removing undersize is preferably subject to r2<r1, where 0<r2/r1<1, preferably 0.2<r2/r1<0.4. Furthermore, r1+r2=e, where e corresponds to the distance between the circle center point M1 of K1 and the circle center point M2 of K2, and where the circles K1 and K2 contact one another at a point T0, at which the circle arcs described in the profile merge.
Furthermore, 0°<α<65°, preferably 0°<α<25°, more preferably 5°<α<20°, where α is an angle which defines the position of M2 relative to M1 in a cartesian coordinate system, if M1 and M2 are vertices of a right-angled triangle and e corresponds to the hypotenuse of the triangle (cf.
According to a further embodiment for the removal of undersize, the screen plate is subject to r2<r1, where 0<r2/r1<1, preferably 0.2<r2/r1<0.4. Additionally, r1+r2>e, where e is the distance between the circle center point M1 of K1 and M2 of K2, and the circles K1 and K2 do not contact one another.
Additionally, −65°<α<65°, preferably −25°<α<10°, more preferably −10°<α<5°, where α is an angle which defines the position of M2 relative to M1 in a cartesian coordinate system, if M1 and M2 are vertices of a right-angled triangle and e corresponds to the hypotenuse of the triangle, where the circle arc (or the circles K1 and K2) are joined to one another by a joint tangent through the points T1 of K1 and T2 of K2 (cf.
For the removal of bulk material of large particle size (also referred to as oversize), the profile of the screen plate may preferably have the two configurations described below. Bulk material of large particle size is intended here to refer to a portion of the charged amount of bulk material that is to be separated off by means of the screen plate. The bulk material of large particle size therefore corresponds to the fraction to be separated off. Oversize may lead to clogging of individual depressions or to damage to the screen plate.
The profile of the screen plate for removing oversize is preferably subject to r2>r1, where 0<r1/r2<1, preferably 0.2<r1/r2<0.4.
Additionally, r1+r2=e, where e corresponds to the distance between the circle center point M1 of K1 and the circle center point M2 of K2, and K1 and K2 contact one another at a point T0 at which the circle arcs merge. Furthermore, −65°<α<0°, preferably −20°<α<0°, where α is an angle which defines the position of M2 relative to M1 in a cartesian coordinate system, if M1 and M2 are vertices of a right-angled triangle and e corresponds to the hypotenuse of the triangle (cf.
According to a further embodiment for removing oversize, the screen plate is subject to r2>r1, where 0<r1/r2<1, preferably 0.2<r1/r2<0.4.
Additionally, r1+r2>e, where e corresponds to the distance between the circle point M1 of K1 and the circle center point M2 of K2, and the circles K1 and K2 do not contact one another. Furthermore, −65°<α<65°, preferably −20°<α<0°, where α is an angle which defines the position of M2 relative to M1 in a cartesian coordinate system, if M1 and M2 are vertices of a right-angled triangle and e corresponds to the hypotenuse of the triangle, with the circle arcs being joined to one another by a common tangent through the points T1 of K1 and T2 of K2 (cf.
The screen plate is preferably made of a material selected from the group of plastic, ceramic, glass, diamond, amorphous carbon, silicon, metal, and combinations thereof.
The screen plate, or at least the part of the screen plate that comes into contact with the bulk material, may be lined or coated with a material selected from the group of plastic, ceramic, glass, diamond, amorphous carbon, silicon, and combinations thereof.
More particularly the screen plate may have a coating of titanium nitride, titanium carbide, silicon nitride, silicon carbide, aluminum titanium nitride or DLC (diamondlike carbon).
The plastic may be for example PVC (polyvinyl chloride), PP (polypropylene), PE (polyethylene), PU (polyurethane), PFA (perfluoroalkyl polymer), PVDF (polyvinylidene fluoride), and PTFE (polytetrafluoroethylene).
The screen plate preferably consists of a cemented carbide.
A further aspect of the invention concerns a separating device for classifying bulk material, comprising at least one of the screen plates described, and at least one separating element disposed beneath the takeoff region of the screen plate and having a separating edge.
The length of the separating element preferably corresponds to the length of the takeoff side of the screen plate. The distance of the separating element from the takeoff region is preferably variable.
The purpose of the separating element is to separate undersize or oversize from the target fraction. The separating element is preferably static and does not vibrate with the screen plate.
The separating element preferably has a triangular side profile, more particularly the side profile of an acute-angled triangle.
The separating edge of the separating element preferably has the same profile as the screen plate. The separating edge may also have a straight-line configuration, so that when viewed straight on the separating element has the contour of a rectangle.
The separating element is preferably swivelable by an angle δ. At relatively high transport speeds in particular, this may be an advantage, since in that case there is a greater difference in the drop curves of large and small chunks, and the fine fraction can be separated off more effectively with a swiveled separating edge. As a result of the swivel, there are far fewer chunks which rebound from the separating element and possibly enter the target product.
Typical values for the screen plate 10B are as follows: r1=5 mm; r2=25 mm; t=25 mm, e=50 mm; and α=45°. The angle δ of the separating element 30A may be 90°.
Undersize Removal
The polysilicon material supplied in a bag by a polysilicon manufacturer may generally include smaller chunks and an undersize fraction (undersize). The undersize, more particularly having particle sizes smaller than 4 mm, has an adverse effect on the pulling operation during the production of monocrystalline silicon, and for that reason must be removed prior to use. For the test, polysilicon of chunk size 2 (CS 2) was used.
The size class of polysilicon chunks is defined as the longest distance between two points on the surface of the silicon chunk (corresponding to the maximum length):
The polysilicon material used for the test (CS 2) was screened using an analytical screen (according to DIN ISO 3310-2) with a nominal hole size W=4 mm (square hole) and was made available for the tests. The undersize fraction removed (undersize) was collected and weighed.
10 kg of the test material (without undersize fraction <4 mm) were applied to a conveying unit. The test material is charged preferably via a hopper. The container to be filled is positioned at the end of the screen section above the first conveying unit, allowing the test material to be readily conveyed into the container.
The undersize fraction separated off in advance is used for this test. Upon filling of the conveying unit, 2 g of undersize fraction is added per 2 kg of test material, resulting in the addition overall of around 10 g of undersize fraction.
The conveying rate was set prior to the test run at 3 kg±0.5 kg per minute. The undersize fraction removed was collected and weighed. The experiments were performed five times per setting.
Test 1:
The conveying unit used comprised a screen plate with a convex opening edge (according to
Test 2:
The conveying unit used comprised a screen plate with a rectangular opening edge (according to
Test 3:
The conveying unit used comprised a screen plate with a convex opening edge (according to
Test 4:
The conveying unit used comprised a screen plate with a convex opening edge (according to
Table 1 shows the average results in comparison to the results from WO 2018/108334 A1.
Oversize Removal
The polysilicon material supplied in bags by the polysilicon manufacturer must not contain excessively sized chunks (oversize). The oversize may result in clogging and damage and must therefore be removed prior to use. The test was carried out using CS 2.
All of the oversize chunks were removed manually from the polysilicon material (CS 2) used for the test. The oversize material removed was retained and weighed.
10 kg of the test material without oversize were applied to the conveying unit. Charging took place by a hopper. The container to be filled is positioned at the end of the screening section over the first conveying unit, allowing the test material to be conveyed into the container.
Upon filling of the conveying unit, 100 g of the removed oversize are added per 2 kg of test material, resulting in the overall addition of 500 g of oversize.
The conveying rate was set ahead of the test run at 15 kg±1 kg per minute. The oversize removed was collected and weighed. The tests were performed five times per setting.
Test 1:
The conveying unit used comprised a screen plate with a convex opening edge (according to
Test 2:
A separating device in twofold series was used, according to
Test 3:
A separating device in fourfold series was used, according to
Test 4:
The conveying unit used comprised a screen plate with a convex opening edge (according to
Table 2 shows the average results for the oversize removal:
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/EP2020/073597 | 8/24/2020 | WO |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2022/042815 | 3/3/2022 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
6360895 | Riggenmann | Mar 2002 | B1 |
20180185882 | Bergmann | Jul 2018 | A1 |
Number | Date | Country |
---|---|---|
1302237 | Jul 2001 | CN |
207605973 | Jul 2018 | CN |
102016225248 | Jun 2018 | DE |
1079939 | Mar 2001 | EP |
2730510 | May 2014 | EP |
6588937 | Oct 2019 | JP |
9726495 | Jul 1997 | WO |
WO-9726495 | Jul 1997 | WO |
0121329 | Mar 2001 | WO |
WO-0121329 | Mar 2001 | WO |
2016202473 | Dec 2016 | WO |
2018108334 | Jun 2018 | WO |
WO-2018108334 | Jun 2018 | WO |
Number | Date | Country | |
---|---|---|---|
20230311165 A1 | Oct 2023 | US |