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PMT- J etmill GmbH. New Developments in Filler Micronization Jürgen Roth, Veronika Mayer. Ultrafine Grinding ’06, Falmouth, UK 12.-13. June 2006. Outline. Requirements of the Filler Industry Compound Reinforcement Comparison of Grinding Technologies Basics of Jetmilling
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PMT- Jetmill GmbH New Developments in Filler Micronization Jürgen Roth, Veronika Mayer Ultrafine Grinding ’06, Falmouth, UK 12.-13. June 2006
Outline • Requirements of the Filler Industry • Compound Reinforcement • Comparison of Grinding Technologies • Basics of Jetmilling • PMT Spiral Jet Mill • Some Application Results • Conclusions
Requirements of the Filler Industry The Future • Increasing Technical Demand from Compounders • Change from 'Extender Fillers' to 'Functional Fillers' • Importance of the Processing Stage to Enhance the Functional Properties of Minerals
Requirements of the Filler Industry Fillers are now High-Tech Products Compounders are looking for a Solution, not for a “Crushed Rock”
Requirements of the Filler Industry The Target - Finest Products • Finest Particle Sizes (d50) • Exact Top Cut (d97) • Improvement of the Functional Properties • Lower Specific Energy Consumption • Industrial Scale Size Output • Guaranteed Operational Reliability
Compound Reinforcement • Ec …. Modulus Compound • Em … Modulus Matrix • A … Aspect Ratio • B, C … Empirical Functions of Filler Modulus, Packing Fraction, Filler Loading • F ……. Filler Volume Fraction Nielson Equation Fillers with High Aspect Ratio Reinforce Better
Aspect Ratio (after W. Hohenberger) • A .......... Aspect Ratio • Os ......... Specific Surface • rF ........... Filler Density • d50, d84 ... PSD Values
Comparison of Grinding Technologies Opposed Jetmill Spiral Jetmill Impact - Jetmill • Best operational area Mohs 4 to 10or • cubic shape or • metal powders • Wearless and iron free grinding • Comminution by particle - particle collisions • Best operational area Mohs 1 to 4 with • laminar, layered or porous structure • Comminution by high velocity differences • high delamination effects • Lower particle collisions • Best operational area Mohs 4 to 10 • Big wear of the target plate • Not an iron free product
Suitable Minerals Soft to middle hard minerals Lamellar or porous structure • Graphite • Barite • Mica • Talc • Wollastonite • Zeolite • etc.
Spiral Jetmill Scheme • Injector Feed • Nozzles Around the Circumference • Spiral Stream Classifying
PMT Spiral Jetmill SJ Concentration of the Grinding Energy Higher Milling Chamber Special Feed Control System Coarse Product Outlet for Hard Grindable Materials Constant Loading
Advantages of PMT Jetmill System • Exact Top Cut (d97) 2. Coarse Product Outlet 3. Energy Consumption 4. Operational Reliability
Cumulative Mass Percent Passing 1. Exact Top Cut Particle Size Distribution after Sympatec Helos e.g.Graphite Equivalent Spherical Diameter [µm] Legend: d97[µm] d50[µm] rpm kWh/t Graphite Sample 1 8.4 3.38 9,700 2,060 GraphiteSample 2 12.9 5.16 6,700 1,190 Graphite Sample 3 20.9 8.12 3,700 485
1.Exact Top Cut e.g.Barite Particle Size Distribution after Sedigraph Cumulative Mass Percent Passing Equivalent Spherical Diameter [µm] Legend: d97[µm] d50[µm] rpm kWh/t Barite Sample 1 2.65 0.88 7,200 1,260 Barite Sample 2 6.40 1.74 3,200 240 Barite Sample 3 12.10 2.54 1,500 85
Dchgangs-% Äquivalenter Kugeldurchmesser [µm] 1. Exact Top Cut e.g.Mica Particle Size Distribution after Sedigraph Cumulative Mass Percent Passing 10 1 Equivalent Spherical Diameter [µm] Legend: d97[µm] d50[µm] rpm kWh/t Mica Sample 1 7.6 2.18 5,700 1,340 Mica Sample 2 11.2 3.00 4,200 810 Mica Sample 3 14.8 3.96 3,000 475 Mica Sample 4 23.1 6.22 2,200 290
Durchgangs-% Äquivalenter Kugeldurchmesser [µm] Legend: d97[µm] d50[µm] rpm kWh/t Talc Sample 1 3.9 1.01 6,800 1,250 Talc Sample 2 5.7 1.75 4,000 540 Talc Sample 3 9.0 2.81 2,700 290 Talc Sample 4 15.8 4.58 1,700 145 1. Exact Top Cut e.g.Talc Particle Size Distribution after Sedigraph Cumulative Mass Percent Passing Equivalent Spherical Diameter [µm]
2. Coarse Product Outlet e.g.Talc 1 ... Talc 2 ... Quartz Final Product Reject Product 3 ... Dolomite 4 ... Calzite 5 ... Chlorite 6 ... Muscovite 7 ... Feldspar 8 ... Montmorillonite
3. Energy Consumption Up to 30 % Less Energy
4. Operational Reliability Integrated Motor - Rotor - Unit • Circumferential Speed up to160 m/s • Exact Top Cut • Simple Disk Assembly • Specially Developed Rotor Shape • Only One Bearing System Maintenance Free and Operational Reliability
PMT Spiral- Jetmill SJ THE LATEST GENERATION • Up to 30% less Energy Consumption • Increase of the Grinding Efficiency due to the Closed Grinding- and Classifying Circuit • Easy Adjustment of Fineness by Regulation of Rotor Speed • Coarse Product Outlet
40 % Talc in PPh 4000 PMT Jetmill SJ Stirred Media Mill 3875 3750 ] 2 3625 3500 Modulus [N/mm Feed Material 3375 3250 3125 Filler Consulting 3000 1 2 3 4 5 6 7 8 9 10 20 30 40 50 Top Cut [µm] Application Results
40 % Mica in PPc 4000 3500 ] 2 3000 E-Modulus [N/mm 2500 2000 1500 1000 E-Modulus Spiral Jetmill Opposed Type Jetmill Aspect Ratio Vertical Ball Mill Table Roller Mill Stirred Media Mill Application Results
Vienna Kammern Graz PMT – Jetmill GmbH Powder Managed Together PMT – Jetmill GmbH Industriepark 1 A-8773 Kammern, AUSTRIA Tel: +43 3844 80350-0 Fax: +43 3844 80350-20 http:\\www.powder-maker.com jetmill@powder-maker.com