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WO2025068187A1 - Atomized powder production plant - Google Patents

Atomized powder production plant Download PDF

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Publication number
WO2025068187A1
WO2025068187A1 PCT/EP2024/076788 EP2024076788W WO2025068187A1 WO 2025068187 A1 WO2025068187 A1 WO 2025068187A1 EP 2024076788 W EP2024076788 W EP 2024076788W WO 2025068187 A1 WO2025068187 A1 WO 2025068187A1
Authority
WO
WIPO (PCT)
Prior art keywords
slip
plant
heating
heat exchange
hot
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2024/076788
Other languages
French (fr)
Inventor
Luca MANZINI
Marco MANFREDINI
Giacomo GALLI
Nicolas BELLINA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gruppo Concorde SpA
Original Assignee
Gruppo Concorde SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gruppo Concorde SpA filed Critical Gruppo Concorde SpA
Publication of WO2025068187A1 publication Critical patent/WO2025068187A1/en
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D1/00—Evaporating
    • B01D1/16—Evaporating by spraying
    • B01D1/18—Evaporating by spraying to obtain dry solids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D1/00—Evaporating
    • B01D1/0082—Regulation; Control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B01J2/02—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops
    • B01J2/04—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops in a gaseous medium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B21/00—Arrangements or duct systems, e.g. in combination with pallet boxes, for supplying and controlling air or gases for drying solid materials or objects
    • F26B21/06—Controlling, e.g. regulating, parameters of gas supply
    • F26B21/10—Temperature; Pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B23/00—Heating arrangements
    • F26B23/001—Heating arrangements using waste heat
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B3/00—Drying solid materials or objects by processes involving the application of heat
    • F26B3/02—Drying solid materials or objects by processes involving the application of heat by convection, i.e. heat being conveyed from a heat source to the materials or objects to be dried by a gas or vapour, e.g. air
    • F26B3/10—Drying solid materials or objects by processes involving the application of heat by convection, i.e. heat being conveyed from a heat source to the materials or objects to be dried by a gas or vapour, e.g. air the gas or vapour carrying the materials or objects to be dried with it
    • F26B3/12—Drying solid materials or objects by processes involving the application of heat by convection, i.e. heat being conveyed from a heat source to the materials or objects to be dried by a gas or vapour, e.g. air the gas or vapour carrying the materials or objects to be dried with it in the form of a spray, i.e. sprayed or dispersed emulsions or suspensions

Definitions

  • the present invention relates to the field of ceramic products manufacturing and the like; more specifically the object of the invention is a plant for the production of atomized powder, that is, a fine, homogeneous powder, ready for pressing.
  • ICE cogeneration units include an engine, an alternator for converting the mechanical energy generated by the engine into electrical energy, a cooling circuit, for instance a water-based cooling circuit, for cooling the engine, and an exhaust gas collector.
  • Cogeneration units are particularly suitable for use in the ceramic manufacturing industry.
  • ICE cogeneration units are suitable for use in atomized powder production plants because the electricity generated is used to power the manufacturing facility while the exhaust gases generated by the engine can be used in the slip atomization process, thus reducing the consumption of gaseous fuel, such as natural gas, during the process.
  • gaseous fuel such as natural gas
  • the technical noun "slip” indicates a viscous liquid obtained by mixing and grinding water and variable raw materials.
  • raw materials include clays, feldspars, quartz, and kaolins.
  • the gaseous fuel is used to heat the drying air used during the atomization process.
  • the slip after having been sieved, is fed into an atomizer, powered by gaseous fuel, where it is spray-dried so as to obtain atomized powder, i.e. a fine, homogeneous powder ready for pressing.
  • the sieving operation is carried out so that the slip does not clog the nozzles, from which it will be sprayed during spray-drying.
  • the heat stored in the cooling circuit can be used to meet the hot water needs of the production facility and/or to preheat the drying air used by the atomizer, further reducing gaseous fuel consumption.
  • drying air is run through an air-fluid, e.g., air- water, exchanger in order to exchange thermal energy with the fluid circulating inside the cooling circuit, heating up before being conveyed to the atomizer.
  • an air-fluid e.g., air- water
  • Air- or water-cooled radiators are used to ensure that the correct temperature of water and oil is kept inside the engine.
  • An object of the present invention is to provide an atomized powder production plant with low gaseous fuel consumption.
  • a further object of the invention is to provide an atomized powder production facility that has a reduced risk of derating of the ICE unit.
  • a further object of the invention is to provide an atomized powder production facility, whose maintenance and cleaning is easy and practicable without incurring production stoppages.
  • the plant includes at least one atomizer, a slip feeding unit feeding the atomizer, a slip supply unit suitable to generate a flow of slip to be atomized, and a first heat exchange device, provided with an inlet and an outlet for the slip, suitable to fluidly couple the slip supply unit and the slip feeding unit.
  • the plant also includes a slip heating circuit operatively connected with the first heat exchange device for transferring heat to the slip, an ICE (internal combustion engine) cogeneration unit, provided with a cooling circuit for cooling the engine, and a second heat exchange device suitable to exchange heat between the cooling circuit and the heating circuit. Therefore, unlike the prior art atomized powder production plants, the slip entering the atomizer is preheated.
  • the plant allows further use of the heat stored in the engine cooling circuit. In this way, the temperature of the fluid circulating in it is kept sufficiently low even in summer, thus reducing the risk of derating of the ICE cogeneration unit.
  • the first heat exchange device is of the indirect type.
  • the second heat exchange device is of the indirect type.
  • Indirect heat exchange refers to heat exchange between fluids that are separated by a material so that they do not mix with each other.
  • the first heat exchange device includes a spiral heat exchanger.
  • the spiral heat exchanger is particularly suitable for use in systems where at least one of the incoming fluids, in this case slip, is particularly dense or viscous.
  • the spiral heat exchanger has a liquid inlet and a liquid outlet, respectively connected to a hot portion and a cold portion of the cooling circuit. The hot portion extends from the second heat exchange device to the liquid inlet, while the cold portion extends from the liquid outlet to the second heat exchange device.
  • the spiral heat exchanger also has the slip inlet, connected to the slip supply unit via a slip inlet pipe, and the slip outlet, connected to the slip feeding unit via a slip outlet pipe.
  • the plant includes a bypass pipe, along which a remotely controlled bypass valve is provided to bypass, if necessary, the spiral heat exchanger by directly fluidly coupling the slip supply unit and slip feeding unit.
  • the plant further includes two exclusion valves arranged along the slip inlet pipe and the slip outlet pipe respectively for excluding the spiral heat exchanger. In this way, it is possible to bypass the spiral heat exchanger, when necessary, to carry out maintenance and cleaning of the heat exchanger without interrupting the slip flow toward the atomizer and, therefore, without slowing down the production.
  • the plant includes a cleaning water inlet branch and a cleaning water outlet branch for equicurrent washing the spiral heat exchanger.
  • a remotely controlled inlet valve and a remotely controlled outlet valve are provided along the cleaning water inlet branch and the cleaning water outlet branch, respectively.
  • the cleaning water inlet branch is coupled to the slip inlet pipe downstream of the exclusion valve along the slip inlet pipe, and, at the same time, the cleaning water outlet branch is coupled to the slip outlet pipe upstream of the exclusion valve along the slip outlet pipe.
  • the plant also includes a remotely controlled washing system for washing the bypass pipe so that slip does not settle along the bypass pipe.
  • the plant includes a monitoring and control unit UMC, that allows the plant to be monitored and controlled remotely, ensuring the proper operation thereof. In this way, the plant is particularly safe.
  • UMC monitoring and control unit
  • the slip feeding unit may include one or more tanks for containing slip, and a pumping system for making the slip circulate up to the atomizer.
  • the slip supply unit may include one or more tanks for containing slip, and a pumping system for making the slip circulate up to the slip feeding unit.
  • an ICE or endothermic engine, is a driving machine for converting the thermal energy of a gaseous flow into mechanical work, made available to the drive shaft.
  • the ICE cogeneration unit is provided with a cooling circuit for cooling the engine; preferably the cooling circuit is a water-based cooling circuit.
  • the cogeneration unit includes an alternator for converting the mechanical energy generated by the ICE into electrical energy, and preferably also an exhaust gas collector.
  • the electrical energy produced is used to power the slip feeding unit and/or the slip supply unit.
  • Fig. 1 schematically shows a first embodiment of an atomized powder production plant according to the invention in a first operational situation
  • Fig. 2 schematically shows the atomized powder production plant of Fig. 1 in a second operational situation
  • FIG. 3 schematically shows a further version of the atomized powder production plant of Fig. 1 in the second operational situation
  • Fig. 4 schematically shows a further version, with additional elements, of the atomized powder production plant of Fig. 1 in the first operational situation;
  • Fig. 5 schematically shows the atomized powder production plant of Fig. 1 in a third operational situation.
  • Fig. 6 schematically shows a second embodiment of an atomized powder production plant according to the invention in the first operational situation
  • Fig. 7 schematically shows the atomized powder production plant of Fig. 6 in the second operational situation
  • Fig. 8 schematically shows a further version of the atomized powder production plant of Fig. 6 in the second operational situation
  • Fig. 9 schematically shows a further version, with additional elements, of the atomized powder production plant of Fig. 6 in the second operational situation;
  • Fig. 10 schematically shows the atomized powder production plant of Fig. 6 in the third operational situation
  • Fig. 11 is a diagram showing a comparison between the gaseous fuel consumption of an atomized powder production plant according to the invention and that of the prior art plants.
  • An atomized powder production plant includes an atomizer 22.
  • the atomizer 22 is of the type known to those skilled in the art, and is gaseous fueled.
  • the slip is spray-dried in the atomizer 22 so as to obtain the so-called atomized powder, that is, a fine, homogeneous powder ready for pressing.
  • Slip is a viscous liquid obtained by mixing and grinding water and variable raw materials.
  • raw materials include clays, feldspars, quartz, and kaolins.
  • the plant 10 also includes a slip feeding unit 21 connected to the atomizer 22.
  • the slip feeding unit 21 includes one or more tanks for containing slip, and a pumping system for making the slip circulate up to the atomizer 22.
  • the plant 10 further includes a slip supply unit 20 suitable to generate a flow of slip to be atomized.
  • the slip supply unit 20 includes one or more tanks for containing slip, and a pumping system for making the slip circulate up to the slip feeding unit 21.
  • the plant 10 further includes an ICE cogeneration unit C provided with a cooling circuit CR for cooling the engine.
  • the ICE cogeneration unit is of the type known to those skilled in the art.
  • the cooling circuit CR is a water-based cooling circuit.
  • the cogeneration unit C also includes an alternator for converting the mechanical energy generated by the ICE into electrical energy, and an exhaust gas collector.
  • the electrical energy produced is used to power the slip feeding unit 21 and/or the slip supply unit 20. Otherwise, exhaust gases are used during the slip atomization process, according to a mode known to those skilled in the art.
  • the plant 10 also includes a heating circuit 11, in which a first heating liquid circulates, and a second heat exchange device 12 that allows heat exchange between the heating circuit 11 and the cooling circuit CR.
  • the second heat exchange device 12 is of the indirect type, and may include, for example, a plate heat exchanger.
  • the first heating liquid may be water.
  • the plant 10 also includes a first heat exchange device 13, for example of the indirect type.
  • the first heat exchange device 13 is provided with an inlet 16 and an outlet 17 for the slip, suitable to fluidly couple the slip supply unit 20 and the slip feeding unit 21.
  • the heat exchange device 13 is operationally connected with the heating circuit 11; in this way, the first heat exchange device 13 enables heat transfer from the first heating liquid to the slip flow to be atomized.
  • the heating circuit 11 includes a hot portion I la, within which the first hot heating liquid circulates, and a cold portion 1 lb, within which the first cold heating liquid circulates.
  • the plant 10 includes a first pump 32 provided along the heating circuit 11 and suitable to make the first heating liquid circulate along the heating circuit 11.
  • the first pump 32 is connected to a monitoring and control unit UMC.
  • the first heat exchange device 13 includes an indirect-type exchanger, such as a spiral heat exchanger 13’.
  • a spiral heat exchanger is a type of heat exchanger that uses two spiral-shaped channels, basically concentric to each other, for transferring heat from one fluid to another without any physical contact between the two fluids. The fluids, after having entered the spiral heat exchanger, circulate in opposite directions along the two channels.
  • the spiral heat exchanger 13’ is particularly suitable for use in systems where at least one of the incoming fluids, in this case slip, is particularly dense or viscous.
  • the spiral heat exchanger 13’ can be surrounded by an openable protective cage.
  • the spiral heat exchanger 13' is provided with a liquid inlet 14, a liquid outlet 15, the inlet 16 and the outlet 17 for the slip.
  • the hot portion I la of the heating circuit 11 extends from the second heat exchange device 12 to the liquid inlet 14, whilst the cold portion 11b extends from the liquid outlet 15 to the second heat exchange device 12.
  • the inlet 16 and the outlet 17 are respectively connected with a slip inlet pipe 18 and a slip outlet pipe 19.
  • slip outlet pipe 19 connects the spiral heat exchanger 13' with the slip feeding unit 21.
  • the slip inlet pipe 18 connects the spiral heat exchanger 13’ with the slip supply unit 20.
  • slip supplied by the slip supply unit 20 will be referred to as cold slip, while the slip exiting the spiral heat exchanger 13' will be referred to as hot slip.
  • the slip feeding unit 21 also include a sieve device to sieve the slip before it is sent to the atomizer 22; in the second case, it will be the slip supply unit 20 that will include a sieve device to sieve the cold slip.
  • the slip inlet pipe 18 includes a first temperature sensor 23 provided near the slip inlet 16.
  • the slip outlet pipe 19 includes a second temperature sensor 24 provided near the slip outlet 17.
  • each temperature sensor 23,24 is connected to the monitoring and control unit UMC that can be managed by an operator.
  • the temperature sensors 23,24 are of the contact type and are adhered to the slip inlet pipe 18 and the slip outlet pipe 19, respectively.
  • the hot portion I la and the cold portion 11b may also include, respectively, a third temperature sensor 33 and a fourth temperature sensor 34, both connected to the monitoring and control unit UMC.
  • the slip inlet pipe 18 includes a first pressure sensor 25, provided near the slip inlet 16, and the slip outlet pipe 19 includes a second pressure sensor 26 provided near the slip outlet 17.
  • the pressure sensors 25,26 are connected to the monitoring and control unit UMC.
  • the plant 10 includes a motorized three-way valve 29 connecting the hot portion I la and the cold portion 1 lb of the heating circuit 11.
  • the three-way valve 29 is controlled, depending on the temperature measured by the second temperature sensor 24, by a feedback controlled by the monitoring and control unit UMC.
  • an inverter coupled to the pump 32 can be provided instead of, or together with, the three-way valve 29.
  • the inverter is also controlled by the monitoring and control unit UMC depending on the temperature measured by the second temperature sensor 24.
  • the plant 10 also includes a slip bypass pipe 27 to bypass, if necessary, the spiral heat exchanger 13'.
  • the slip bypass pipe 27, if necessary, directly fluidly couples the slip supply unit 20 and the slip feeding unit 21.
  • slip bypass pipe 27 is coupled to the slip inlet pipe 18 and the slip outlet pipe 19 via a bypass valve 28.
  • bypass valve 28 is remotely controlled by the monitoring and control unit UMC.
  • two exclusion valves 35, 42 are provided along the slip inlet pipe 18 and the slip outlet pipe 19, respectively, for excluding the spiral heat exchanger 13'.
  • the exclusion valves 35, 42 are remotely controlled by the monitoring and control unit UMC.
  • the plant 10 includes, in detail, a cleaning water inlet branch 41 and a cleaning water outlet branch 41' for equi current washing the spiral heat exchanger 13', if necessary.
  • a remotely controlled inlet valve 31 and a remotely controlled outlet valve 31' are provided along the cleaning water inlet branch 41 and the cleaning water outlet branch 41', respectively.
  • both the inlet valve 31 and the outlet valve 31' are remotely controlled by the monitoring and control unit UMC.
  • the plant 10 includes two block valves 43, 44 for blocking the first heating liquid.
  • the first block valve 43 for blocking the first heating liquid is provided along the hot portion I la of the heating circuit 11, whilst the second block valve 44 for blocking the first heating liquid is provided along the cold portion 1 lb.
  • the first heating liquid block valves 43, 44 are remotely controlled by the monitoring and control unit UMC.
  • the cleaning water inlet branch 41 is coupled to the slip inlet pipe 18 downstream of the exclusion valve 35 along the slip inlet pipe 18, and, at the same time, the cleaning water outlet branch 41' is coupled to the slip outlet pipe 19 upstream of the exclusion valve 42 along the slip outlet pipe 19.
  • bypass pipe 27 is fluidly coupled to the slip inlet pipe 18 upstream of the exclusion valve 35 along the slip inlet pipe 18 and, at the same time, is fluidly coupled to the slip outlet pipe 19 downstream of the exclusion valve 42 along the slip outlet pipe 19.
  • the plant 10 described above does not exclude the possibility of using the heat stored in the cooling circuit CR, also to meet the hot water needs of the production facility and/or to preheat the drying air used by the atomizer 22 during the spray drying process.
  • a first distribution manifold 37 may be provided along the cold portion 1 lb, and a second distribution manifold 38 may be provided along the hot portion I la, so as to keep part of the first circulating heating liquid for satisfying the hot water needs of the production facility and/or for preheating the drying air used by the atomizer 22 through respective hot branches 39a, 40a and cold branches 39b, 40b.
  • the first distribution manifold 37 is provided between the pump 32 and the second heat exchange device 12.
  • the plant 10 includes a washing system for washing the slip bypass pipe 27.
  • the washing system can be controlled by the monitoring and control unit UMC.
  • the monitoring and control unit UMC may include a physical storage device, such as an external hard disk, or be connected to a cloud storage.
  • a third heat exchange device 30 is provided, arranged along the heating circuit 11.
  • the third heat exchange device 30 is of the indirect type, and may include, for example, a plate heat exchanger.
  • the heating circuit 11 is divided into two heating sub-circuits 11’, 11”, the first heating sub-circuit 11 ’ extending between the third heat exchange device 30 and the spiral heat exchanger 13’, and the second heating sub-circuit 11” extending between the second heat exchange device 12 and the third heat exchange device 30.
  • the first heating liquid circulates within the first heating sub-circuit 11’, while a second heating liquid circulates within the second heating sub-circuit 11”.
  • the first heating liquid and the second heating liquid are water.
  • the plant 10 includes two pumps 32, 36, arranged along the second heating sub-circuit 11” and the first heating sub-circuit 11’, respectively.
  • the two pumps 32, 36 are connected to the monitoring and control unit UMC.
  • Both heating sub-circuits 11’, 11” include first and second hot sub-portions l l’a, l l”a and cold sub-portions 11’b, l l”b, respectively.
  • the first hot sub-portion l l’a of the first heating sub-circuit 11’ extends from the third heat exchange device 30 to the liquid inlet 14, whilst the first cold sub-portion 11’b extends from the liquid outlet 15 to the third heat exchange device 30.
  • the three-way valve 29 connects the second hot sub-portion l l”a and the second cold sub-portion 1 l”b of the second heating sub-circuit 11”.
  • the third temperature sensor 33 and the fourth temperature sensor 34 are provided along the first hot subportion l l’a and the first cold sub-portion 1 l’b, respectively.
  • first heating liquid block valves 43, 44 are also arranged along the first hot sub-portion l l’a and the first cold sub-portion 1 l’b, respectively.
  • the plant 10 does not exclude the possibility of using the heat stored in the cooling circuit CR, also to meet the hot water needs of the production facility and/or to preheat the drying air used by the atomizer 22 during the spray drying process.
  • a first distribution manifold 37 may be provided along the second cold sub-portion 1 l”b and a second distribution manifold 38 may be provided along the second hot sub-portion 1 l”a, so as to keep part of the second circulating heating liquid for satisfying the hot water needs of the production facility and/or for preheating the drying air used by the atomizer 22 through respective hot branches 39a, 40a and cold branches 39b, 40b.
  • the first distribution manifold 37 is provided between the pump 32 and the second heat exchange device 12.
  • an inverter coupled to pump 36 can be provided instead of, or together with, the three-way valve 29.
  • the inverter is also controlled by the monitoring and control unit UMC depending on the temperature measured by the second temperature sensor 24.
  • the plant 10 includes a washing system for washing the slip bypass pipe 27.
  • the washing system can be controlled by the monitoring and control unit UMC.
  • the first heating liquid that is cold and circulates within the cold portion 1 lb of the heating circuit 11, enters the second heat exchange device 12 and exchanges thermal energy with the fluid circulating in the cooling circuit CR, thus heating up.
  • the first heating liquid that has heated up i.e., the first hot heating liquid, coming from the second heat exchange device 12 and circulating in the hot portion I la, and the cold slip, coming from the slip supply unit 20 and circulating within the slip inlet pipe 18, enter the spiral heat exchanger 13' through the liquid inlet 14 and the slip inlet 16, respectively.
  • the first heating liquid that has cooled i.e., the first cold heating liquid
  • the slip that has heated up, i.e., the hot slip
  • the second heating liquid that is cold and circulates in the second cold sub-portion l l”b, enters the second heat exchange device 12 and exchanges thermal energy with the fluid circulating in the cooling circuit CR, thus heating up.
  • the second heating liquid that has heated up i.e., the second hot heating liquid, coming from the second heat exchange device 12 and circulating in the second hot sub-portion l l”a, enters the third heat exchange device 30, where it transfers the thermal energy, that has stored during the heat exchange that has occurred within the second heat exchange device 12, to the first heating liquid, that is cold and comes from the first cold sub-portion 1 l’b.
  • the first heating liquid that has heated up i.e., the first hot heating liquid, coming from the third heat exchange device 30 and circulating in the first hot subportion l l’a, and the cold slip, coming from the slip supply unit 20 and circulating within the slip inlet pipe 18, enter the spiral heat exchanger 13’ through the liquid inlet 14 and the slip inlet 16, respectively.
  • the first heating liquid that has cooled i.e., the first cold heating liquid, exits the spiral heat exchanger 13’ through the liquid outlet 15 and circulates toward the third heat exchange device 30, while the slip that has heated up, i.e., the hot slip, exits the spiral heat exchanger 13’ through the slip outlet 17.
  • the hot slip flows in the slip outlet pipe 19 up to the slip feeding unit 21, which, in turn, feeds the hot slip to the atomizer 22.
  • the temperature of the hot slip detected by the second temperature sensor 24, is too high. This situation may occur, for example, when the temperature of the hot slip exiting the spiral heat exchanger 13’ is higher than the threshold parameters, for example higher than the maximum operative temperature of the slip feeding unit 21.
  • the monitoring and control unit UMC detects that the temperature of the hot slips is higher than the threshold parameters, and acts on the three-way valve 29 so as to reduce the flow of the first hot heating liquid entering the spiral heat exchanger 13’, thus reducing the temperature of the hot slip exiting it.
  • the monitoring and control unit UMC acts on the three-way valve 29 so as to reduce the flow of second hot heating liquid entering the third heat exchange device 30, thereby reducing the temperature of the first heating liquid entering the spiral heat exchanger 13’, thus reducing the temperature of the hot slip exiting it.
  • the thermal energy absorbed by the slip is less than that absorbed normally. In detail, this decrease can be verified by monitoring the temperatures measured by the temperature sensors 23, 24, 33, 34 and reported by the monitoring and control unit UMC.
  • the monitoring and control unit UMC signals the operator that the pressure difference detected by the pressure sensors 25, 26 is excessive, and the operator, through the same monitoring and control unit UMC, opens the slip bypass valve 28 and closes the exclusion valves 35,42.
  • the slip circulates directly from the slip supply unit 20 to the slip feeding unit 21, avoiding the spiral heat exchanger 13', and, in this way, the necessary cleaning and/or maintenance of the spiral heat exchanger 13’ can be carried out without slowing down the production.
  • the operator opens, through the monitoring and control unit UMC, the inlet valve 31 and the outlet valve 31’, so that cleaning water circulates in the spiral heat exchanger 13’, cleaning it and removing any clogging residue.
  • the operator through the monitoring and control unit UMC, closes the inlet valve 31, the outlet valve 31’, and the first heating liquid block valves 43, 44, so as to isolate the spiral heat exchanger 13’.
  • the monitoring and control unit UMC operates the washing system so as to prevent slip from settling along the slip bypass pipe 27.
  • the monitoring and control unit UMC includes a physical storage device or is connected to a cloud storage, it is possible, for example, to generate (and to store) a database, where to record the maintenance and/or cleaning operations carried out on the spiral heat exchanger 13’ coupled to the temperature values detected by the temperature sensors 23, 24, 33, 34 and/or the pressure difference detected by the pressure sensors 25, 26.
  • the atomized powder production plant 10 achieves all the intended objects, solving the drawbacks of the prior art plants.
  • the plant 10 reduces the risk of derating the ICE cogeneration unit C.
  • the plant 10 allows further use of the heat stored in the cooling circuit CR, keeping the temperature of the fluid circulating within it sufficiently low even in summer.
  • the plant 10 reduces the consumption of gaseous fuel during the atomization process.
  • the slip is heated inside the spiral heat exchanger 13’ up to a temperature of about 80°C before being sent to the atomizer 22.
  • the slip entering the atomizer 22 has a temperature about 25-30°C higher; in this way, cooler drying air can be used during the atomization process, thus reducing the gaseous fuel consumption.
  • the component of the plant 10 that is most affected by wear and/or in need of cleaning is the spiral heat exchanger 13’.
  • the plant 10 allows, if necessary, to bypass the spiral heat exchanger 13' without interrupting the flow of slip toward the atomizer 22 and, thus, without slowing down the production.
  • the plant 10 is particularly safe because the monitoring and control unit UMC allows to monitor and to control remotely the plant 10, ensuring the proper operation thereof.
  • the materials can be chosen appropriately according to the requirements and in accordance with the state of the art available, to the extent that they are compatible with the specific use and the respective components for which they are intended.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Microbiology (AREA)
  • Organic Chemistry (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)

Abstract

An atomized powder production plant (10) includes at least one atomizer (22), a slip feeding unit (21) feeding the atomizer (22), a slip supply unit (20) suitable to generate a flow of slip to be atomized, and a first heat exchange device (13) provided with an inlet (16) and an outlet (17) for the slip, suitable to fluidly couple the slip supply unit (20) and the slip feeding unit (21). The plant (10) also includes a slip heating circuit (11) operatively connected with the first heat exchange device (13) for transferring heat to the slip, an ICE (Internal Combustion Engine) cogeneration unit (C), provided with a cooling circuit (CR) for cooling the engine, and a second heat exchange device (12) suitable to exchange heat between the cooling circuit (CR) and the heating circuit.

Description

ATOMIZED POWDER PRODUCTION PLANT
Description
Technical Field
[0001] The present invention relates to the field of ceramic products manufacturing and the like; more specifically the object of the invention is a plant for the production of atomized powder, that is, a fine, homogeneous powder, ready for pressing.
State of the Art
[0002] The use of cogeneration units is well known for producing, at the same time, electricity and heat.
[0003] In particular, the use of gas turbine- or ICE (internal combustion engine)- based cogeneration units is well known within the ceramic manufacturing industry.
[0004] ICE cogeneration units include an engine, an alternator for converting the mechanical energy generated by the engine into electrical energy, a cooling circuit, for instance a water-based cooling circuit, for cooling the engine, and an exhaust gas collector.
[0005] Cogeneration units are particularly suitable for use in the ceramic manufacturing industry.
[0006] In particular, ICE cogeneration units are suitable for use in atomized powder production plants because the electricity generated is used to power the manufacturing facility while the exhaust gases generated by the engine can be used in the slip atomization process, thus reducing the consumption of gaseous fuel, such as natural gas, during the process.
[0007] The technical noun "slip" indicates a viscous liquid obtained by mixing and grinding water and variable raw materials. In the case of ceramic products made of porcelain stoneware, raw materials include clays, feldspars, quartz, and kaolins.
[0008] Specifically, the gaseous fuel is used to heat the drying air used during the atomization process. [0009] In fact, during the atomized powder production process, the slip, after having been sieved, is fed into an atomizer, powered by gaseous fuel, where it is spray-dried so as to obtain atomized powder, i.e. a fine, homogeneous powder ready for pressing.
[0010] The sieving operation, in particular, is carried out so that the slip does not clog the nozzles, from which it will be sprayed during spray-drying.
[0011] Furthermore, the heat stored in the cooling circuit can be used to meet the hot water needs of the production facility and/or to preheat the drying air used by the atomizer, further reducing gaseous fuel consumption.
[0012] Specifically in the case of drying air preheating, the drying air is run through an air-fluid, e.g., air- water, exchanger in order to exchange thermal energy with the fluid circulating inside the cooling circuit, heating up before being conveyed to the atomizer.
[0013] However, the amount of gaseous fuel still required for slip atomization remains high.
[0014] This also promotes engine cooling by preventing the temperature of the fluid circulating in the cooling circuit from being too high, thus losing the ability to cool the engine.
[0015] Air- or water-cooled radiators are used to ensure that the correct temperature of water and oil is kept inside the engine.
[0016] However, this solution may be ineffective in summer.
[0017] In fact, in the warmer months it may happen that, due to high ambient temperatures (and also the resulting low hot water demand), the cooling circuit is unable to cool the engine sufficiently.
[0018] In other words, in summer it may happen that the temperature of the fluid circulating in the cooling circuit cannot be kept low enough.
[0019] This results in a lower production capacity of the cogeneration unit, causing the so-called derating of the ICE cogeneration unit. [0020] Therefore, it is desirable to provide a solution to further reduce the consumption of gaseous fuel during the slip atomization process.
[0021] It would also be desirable to provide a solution that is able to reduce the risk of derating of the ICE cogeneration unit.
[0022] It would be furthermore desirable to provide a solution, whose maintenance and cleaning is easy and practicable without incurring production stoppages.
Summary
[0023] An object of the present invention is to provide an atomized powder production plant with low gaseous fuel consumption.
[0024] A further object of the invention is to provide an atomized powder production facility that has a reduced risk of derating of the ICE unit.
[0025] A further object of the invention is to provide an atomized powder production facility, whose maintenance and cleaning is easy and practicable without incurring production stoppages.
[0026] These and additional purposes that will be apparent to the industry technician are achieved by an atomized production plant according to the attached claims.
[0027] Specifically, the plant includes at least one atomizer, a slip feeding unit feeding the atomizer, a slip supply unit suitable to generate a flow of slip to be atomized, and a first heat exchange device, provided with an inlet and an outlet for the slip, suitable to fluidly couple the slip supply unit and the slip feeding unit. The plant also includes a slip heating circuit operatively connected with the first heat exchange device for transferring heat to the slip, an ICE (internal combustion engine) cogeneration unit, provided with a cooling circuit for cooling the engine, and a second heat exchange device suitable to exchange heat between the cooling circuit and the heating circuit. Therefore, unlike the prior art atomized powder production plants, the slip entering the atomizer is preheated. In this way, cooler drying air can be used during the atomization process, thus reducing the gaseous fuel consumption. In addition, the plant allows further use of the heat stored in the engine cooling circuit. In this way, the temperature of the fluid circulating in it is kept sufficiently low even in summer, thus reducing the risk of derating of the ICE cogeneration unit.
[0028] Preferably, the first heat exchange device is of the indirect type.
[0029] Preferably, the second heat exchange device is of the indirect type.
[0030] Indirect heat exchange refers to heat exchange between fluids that are separated by a material so that they do not mix with each other.
[0031] Preferably, the first heat exchange device includes a spiral heat exchanger. In fact, the spiral heat exchanger is particularly suitable for use in systems where at least one of the incoming fluids, in this case slip, is particularly dense or viscous. The spiral heat exchanger has a liquid inlet and a liquid outlet, respectively connected to a hot portion and a cold portion of the cooling circuit. The hot portion extends from the second heat exchange device to the liquid inlet, while the cold portion extends from the liquid outlet to the second heat exchange device. The spiral heat exchanger also has the slip inlet, connected to the slip supply unit via a slip inlet pipe, and the slip outlet, connected to the slip feeding unit via a slip outlet pipe.
[0032] Preferably, the plant includes a bypass pipe, along which a remotely controlled bypass valve is provided to bypass, if necessary, the spiral heat exchanger by directly fluidly coupling the slip supply unit and slip feeding unit. The plant further includes two exclusion valves arranged along the slip inlet pipe and the slip outlet pipe respectively for excluding the spiral heat exchanger. In this way, it is possible to bypass the spiral heat exchanger, when necessary, to carry out maintenance and cleaning of the heat exchanger without interrupting the slip flow toward the atomizer and, therefore, without slowing down the production.
[0033] Preferably, the plant includes a cleaning water inlet branch and a cleaning water outlet branch for equicurrent washing the spiral heat exchanger. In addition, a remotely controlled inlet valve and a remotely controlled outlet valve are provided along the cleaning water inlet branch and the cleaning water outlet branch, respectively. In addition, the cleaning water inlet branch is coupled to the slip inlet pipe downstream of the exclusion valve along the slip inlet pipe, and, at the same time, the cleaning water outlet branch is coupled to the slip outlet pipe upstream of the exclusion valve along the slip outlet pipe. In this way, maintenance and cleaning operations are simplified. Even more preferably, the plant also includes a remotely controlled washing system for washing the bypass pipe so that slip does not settle along the bypass pipe.
[0034] Preferably, the plant includes a monitoring and control unit UMC, that allows the plant to be monitored and controlled remotely, ensuring the proper operation thereof. In this way, the plant is particularly safe.
[0035] For example, the slip feeding unit may include one or more tanks for containing slip, and a pumping system for making the slip circulate up to the atomizer.
[0036] For example, the slip supply unit may include one or more tanks for containing slip, and a pumping system for making the slip circulate up to the slip feeding unit.
[0037] For example, an ICE, or endothermic engine, is a driving machine for converting the thermal energy of a gaseous flow into mechanical work, made available to the drive shaft.
[0038] For example, the ICE cogeneration unit is provided with a cooling circuit for cooling the engine; preferably the cooling circuit is a water-based cooling circuit.
[0039] For example, the cogeneration unit includes an alternator for converting the mechanical energy generated by the ICE into electrical energy, and preferably also an exhaust gas collector.
[0040] For example, the electrical energy produced is used to power the slip feeding unit and/or the slip supply unit.
Brief description of the drawing
[0041] The invention will be better understood and implemented with reference to the attached drawing, illustrating two non-limiting embodiments, given just by way of example; in the drawing: Fig. 1 schematically shows a first embodiment of an atomized powder production plant according to the invention in a first operational situation; Fig. 2 schematically shows the atomized powder production plant of Fig. 1 in a second operational situation;
Fig. 3 schematically shows a further version of the atomized powder production plant of Fig. 1 in the second operational situation;
Fig. 4 schematically shows a further version, with additional elements, of the atomized powder production plant of Fig. 1 in the first operational situation;
Fig. 5 schematically shows the atomized powder production plant of Fig. 1 in a third operational situation.
Fig. 6 schematically shows a second embodiment of an atomized powder production plant according to the invention in the first operational situation;
Fig. 7 schematically shows the atomized powder production plant of Fig. 6 in the second operational situation;
Fig. 8 schematically shows a further version of the atomized powder production plant of Fig. 6 in the second operational situation;
Fig. 9 schematically shows a further version, with additional elements, of the atomized powder production plant of Fig. 6 in the second operational situation;
Fig. 10 schematically shows the atomized powder production plant of Fig. 6 in the third operational situation;
Fig. 11 is a diagram showing a comparison between the gaseous fuel consumption of an atomized powder production plant according to the invention and that of the prior art plants.
Detailed description of embodiments
[0042] An atomized powder production plant, generically indicated with the reference number 10, includes an atomizer 22.
[0043] Specifically, the atomizer 22 is of the type known to those skilled in the art, and is gaseous fueled. [0044] The slip is spray-dried in the atomizer 22 so as to obtain the so-called atomized powder, that is, a fine, homogeneous powder ready for pressing.
[0045] Slip is a viscous liquid obtained by mixing and grinding water and variable raw materials.
[0046] Specifically, in the case of ceramic products made of porcelain stoneware, raw materials include clays, feldspars, quartz, and kaolins.
[0047] As shown in the attached Figs. 1-10, the plant 10 also includes a slip feeding unit 21 connected to the atomizer 22.
[0048] Just by way of example, the slip feeding unit 21 includes one or more tanks for containing slip, and a pumping system for making the slip circulate up to the atomizer 22.
[0049] The plant 10 further includes a slip supply unit 20 suitable to generate a flow of slip to be atomized.
[0050] In a non-limiting example of embodiment of the invention, the slip supply unit 20 includes one or more tanks for containing slip, and a pumping system for making the slip circulate up to the slip feeding unit 21.
[0051] The plant 10 further includes an ICE cogeneration unit C provided with a cooling circuit CR for cooling the engine.
[0052] In particular, the ICE cogeneration unit is of the type known to those skilled in the art.
[0053] Just by way of example, the cooling circuit CR is a water-based cooling circuit.
[0054] The cogeneration unit C also includes an alternator for converting the mechanical energy generated by the ICE into electrical energy, and an exhaust gas collector. [0055] By way of example, the electrical energy produced is used to power the slip feeding unit 21 and/or the slip supply unit 20. Otherwise, exhaust gases are used during the slip atomization process, according to a mode known to those skilled in the art.
[0056] The plant 10 also includes a heating circuit 11, in which a first heating liquid circulates, and a second heat exchange device 12 that allows heat exchange between the heating circuit 11 and the cooling circuit CR.
[0057] By way of example, the second heat exchange device 12 is of the indirect type, and may include, for example, a plate heat exchanger.
[0058] By way of non-limiting example, the first heating liquid may be water.
[0059] As shown in the attached Figs. 1-10, the plant 10 also includes a first heat exchange device 13, for example of the indirect type.
[0060] The first heat exchange device 13 is provided with an inlet 16 and an outlet 17 for the slip, suitable to fluidly couple the slip supply unit 20 and the slip feeding unit 21.
[0061] Furthermore, the heat exchange device 13 is operationally connected with the heating circuit 11; in this way, the first heat exchange device 13 enables heat transfer from the first heating liquid to the slip flow to be atomized.
[0062] In more detail, with reference to Figs. 1-5 showing a first embodiment of the plant 10, the heating circuit 11 includes a hot portion I la, within which the first hot heating liquid circulates, and a cold portion 1 lb, within which the first cold heating liquid circulates.
[0063] Specifically, the plant 10 includes a first pump 32 provided along the heating circuit 11 and suitable to make the first heating liquid circulate along the heating circuit 11.
[0064] Even more specifically, the first pump 32 is connected to a monitoring and control unit UMC.
[0065] Furthermore, the first heat exchange device 13 includes an indirect-type exchanger, such as a spiral heat exchanger 13’. [0066] Generically speaking, a spiral heat exchanger is a type of heat exchanger that uses two spiral-shaped channels, basically concentric to each other, for transferring heat from one fluid to another without any physical contact between the two fluids. The fluids, after having entered the spiral heat exchanger, circulate in opposite directions along the two channels.
[0067] The spiral heat exchanger 13’ is particularly suitable for use in systems where at least one of the incoming fluids, in this case slip, is particularly dense or viscous.
[0068] Optionally, the spiral heat exchanger 13’ can be surrounded by an openable protective cage.
[0069] The spiral heat exchanger 13' is provided with a liquid inlet 14, a liquid outlet 15, the inlet 16 and the outlet 17 for the slip.
[0070] Specifically, the hot portion I la of the heating circuit 11 extends from the second heat exchange device 12 to the liquid inlet 14, whilst the cold portion 11b extends from the liquid outlet 15 to the second heat exchange device 12.
[0071] The inlet 16 and the outlet 17 are respectively connected with a slip inlet pipe 18 and a slip outlet pipe 19.
[0072] Specifically, the slip outlet pipe 19 connects the spiral heat exchanger 13' with the slip feeding unit 21.
[0073] The slip inlet pipe 18 connects the spiral heat exchanger 13’ with the slip supply unit 20.
[0074] Hereafter, the slip supplied by the slip supply unit 20 will be referred to as cold slip, while the slip exiting the spiral heat exchanger 13' will be referred to as hot slip.
[0075] Furthermore, it is important to remember that the slip undergoes a sieving operation before being sent to the atomizer 22 so as not to clog the nozzles thereof.
[0076] This operation can be carried out at the slip feeding unit 21 or at the slip supply unit 20. [0077] In the first case, the slip feeding unit 21 also include a sieve device to sieve the slip before it is sent to the atomizer 22; in the second case, it will be the slip supply unit 20 that will include a sieve device to sieve the cold slip.
[0078] In the non-limiting example of embodiment illustrated in Figs. 1-5, the slip inlet pipe 18 includes a first temperature sensor 23 provided near the slip inlet 16.
[0079] At the same time, the slip outlet pipe 19 includes a second temperature sensor 24 provided near the slip outlet 17.
[0080] Specifically, each temperature sensor 23,24 is connected to the monitoring and control unit UMC that can be managed by an operator.
[0081] Even more specifically, the temperature sensors 23,24 are of the contact type and are adhered to the slip inlet pipe 18 and the slip outlet pipe 19, respectively.
[0082] Similarly, the hot portion I la and the cold portion 11b may also include, respectively, a third temperature sensor 33 and a fourth temperature sensor 34, both connected to the monitoring and control unit UMC.
[0083] Optionally, as shown in the attached Figs. 1-5, the slip inlet pipe 18 includes a first pressure sensor 25, provided near the slip inlet 16, and the slip outlet pipe 19 includes a second pressure sensor 26 provided near the slip outlet 17.
[0084] In detail, the pressure sensors 25,26 are connected to the monitoring and control unit UMC.
[0085] Furthermore, in the example of embodiment illustrated in Figs. 1-5, the plant 10 includes a motorized three-way valve 29 connecting the hot portion I la and the cold portion 1 lb of the heating circuit 11.
[0086] Specifically, the three-way valve 29 is controlled, depending on the temperature measured by the second temperature sensor 24, by a feedback controlled by the monitoring and control unit UMC.
[0087] In an alternative version, not shown in the attached figures, an inverter coupled to the pump 32 can be provided instead of, or together with, the three-way valve 29. [0088] The inverter is also controlled by the monitoring and control unit UMC depending on the temperature measured by the second temperature sensor 24.
[0089] As shown in Figs. 1-5, the plant 10 also includes a slip bypass pipe 27 to bypass, if necessary, the spiral heat exchanger 13'. In other words, the slip bypass pipe 27, if necessary, directly fluidly couples the slip supply unit 20 and the slip feeding unit 21.
[0090] In the versions illustrated in Figs. 1,2,4 and 5, the slip bypass pipe 27 is coupled to the slip inlet pipe 18 and the slip outlet pipe 19 via a bypass valve 28.
[0091] In more detail, the bypass valve 28 is remotely controlled by the monitoring and control unit UMC.
[0092] At the same time, two exclusion valves 35, 42 are provided along the slip inlet pipe 18 and the slip outlet pipe 19, respectively, for excluding the spiral heat exchanger 13'.
[0093] In particular, the exclusion valves 35, 42 are remotely controlled by the monitoring and control unit UMC.
[0094] With reference to the attached Figs. 1-5, the plant 10 includes, in detail, a cleaning water inlet branch 41 and a cleaning water outlet branch 41' for equi current washing the spiral heat exchanger 13', if necessary.
[0095] Even more in detail, a remotely controlled inlet valve 31 and a remotely controlled outlet valve 31' are provided along the cleaning water inlet branch 41 and the cleaning water outlet branch 41', respectively.
[0096] In the non-limiting example of embodiment described herein, both the inlet valve 31 and the outlet valve 31' are remotely controlled by the monitoring and control unit UMC.
[0097] At the same time, the plant 10 includes two block valves 43, 44 for blocking the first heating liquid. [0098] The first block valve 43 for blocking the first heating liquid is provided along the hot portion I la of the heating circuit 11, whilst the second block valve 44 for blocking the first heating liquid is provided along the cold portion 1 lb.
[0099] In particular, the first heating liquid block valves 43, 44 are remotely controlled by the monitoring and control unit UMC.
[0100] In addition, the cleaning water inlet branch 41 is coupled to the slip inlet pipe 18 downstream of the exclusion valve 35 along the slip inlet pipe 18, and, at the same time, the cleaning water outlet branch 41' is coupled to the slip outlet pipe 19 upstream of the exclusion valve 42 along the slip outlet pipe 19.
[0101] Otherwise, as shown in Figs. 1, 2, 4, and 5, the bypass pipe 27 is fluidly coupled to the slip inlet pipe 18 upstream of the exclusion valve 35 along the slip inlet pipe 18 and, at the same time, is fluidly coupled to the slip outlet pipe 19 downstream of the exclusion valve 42 along the slip outlet pipe 19.
[0102] In the version shown in Fig. 3, the bypass pipe 27 directly couples the slip supply unit 20 and the slip feeding unit 21 without being connected to either the slip inlet pipe 18 or the slip outlet pipe 19.
[0103] It should also be noted that the plant 10 described above does not exclude the possibility of using the heat stored in the cooling circuit CR, also to meet the hot water needs of the production facility and/or to preheat the drying air used by the atomizer 22 during the spray drying process.
[0104] In particular, as shown in the version of Fig. 4, a first distribution manifold 37 may be provided along the cold portion 1 lb, and a second distribution manifold 38 may be provided along the hot portion I la, so as to keep part of the first circulating heating liquid for satisfying the hot water needs of the production facility and/or for preheating the drying air used by the atomizer 22 through respective hot branches 39a, 40a and cold branches 39b, 40b.
[0105] Even more specifically, the first distribution manifold 37 is provided between the pump 32 and the second heat exchange device 12. [0106] In a further embodiment, not illustrated in Figs. 1-5, the plant 10 includes a washing system for washing the slip bypass pipe 27.
[0107] In particular, the washing system can be controlled by the monitoring and control unit UMC.
[0108] Lastly, the monitoring and control unit UMC may include a physical storage device, such as an external hard disk, or be connected to a cloud storage.
[0109] Now, with reference to the attached Figs. 6-10, in a second embodiment of the plant 10, in addition to what described above, a third heat exchange device 30 is provided, arranged along the heating circuit 11.
[0110] By way of example, the third heat exchange device 30 is of the indirect type, and may include, for example, a plate heat exchanger.
[oni] In this way, the heating circuit 11 is divided into two heating sub-circuits 11’, 11”, the first heating sub-circuit 11 ’ extending between the third heat exchange device 30 and the spiral heat exchanger 13’, and the second heating sub-circuit 11” extending between the second heat exchange device 12 and the third heat exchange device 30.
[0112] The two heating sub-circuits 11’, 11” are physically disjointed.
[0113] In detail, the first heating liquid circulates within the first heating sub-circuit 11’, while a second heating liquid circulates within the second heating sub-circuit 11”.
[0114] Even more in detail, the first heating liquid and the second heating liquid are water.
[0115] Specifically, the plant 10 includes two pumps 32, 36, arranged along the second heating sub-circuit 11” and the first heating sub-circuit 11’, respectively.
[0116] Even more specifically, the two pumps 32, 36 are connected to the monitoring and control unit UMC.
[0117] Both heating sub-circuits 11’, 11” include first and second hot sub-portions l l’a, l l”a and cold sub-portions 11’b, l l”b, respectively. [0118] In detail, the first hot sub-portion l l’a of the first heating sub-circuit 11’ extends from the third heat exchange device 30 to the liquid inlet 14, whilst the first cold sub-portion 11’b extends from the liquid outlet 15 to the third heat exchange device 30.
[0119] In more detail, in the non-limiting embodiment of Figs. 6-10, the three-way valve 29 connects the second hot sub-portion l l”a and the second cold sub-portion 1 l”b of the second heating sub-circuit 11”.
[0120] In addition, as shown in Figs. 6-10, in this embodiment the third temperature sensor 33 and the fourth temperature sensor 34 are provided along the first hot subportion l l’a and the first cold sub-portion 1 l’b, respectively.
[0121] Similarly, the first heating liquid block valves 43, 44 are also arranged along the first hot sub-portion l l’a and the first cold sub-portion 1 l’b, respectively.
[0122] It should be noted that also in this embodiment the plant 10 does not exclude the possibility of using the heat stored in the cooling circuit CR, also to meet the hot water needs of the production facility and/or to preheat the drying air used by the atomizer 22 during the spray drying process.
[0123] In detail, as shown in the version of Fig. 9, a first distribution manifold 37 may be provided along the second cold sub-portion 1 l”b and a second distribution manifold 38 may be provided along the second hot sub-portion 1 l”a, so as to keep part of the second circulating heating liquid for satisfying the hot water needs of the production facility and/or for preheating the drying air used by the atomizer 22 through respective hot branches 39a, 40a and cold branches 39b, 40b.
[0124] Even more in detail, the first distribution manifold 37 is provided between the pump 32 and the second heat exchange device 12.
[0125] Furthermore, in an alternative version not shown in Figs. 6-10, an inverter coupled to pump 36 can be provided instead of, or together with, the three-way valve 29.
[0126] The inverter is also controlled by the monitoring and control unit UMC depending on the temperature measured by the second temperature sensor 24. [0127] In a further embodiment, not illustrated in the attached Figs. 6-10, the plant 10 includes a washing system for washing the slip bypass pipe 27.
[0128] In particular, the washing system can be controlled by the monitoring and control unit UMC.
[0129] The operation of plant 10 is described below.
[0130] Firstly, reference should be made to a first operational situation where the bypass valve 28, the inlet valve 31 and the outlet valve 31' are closed, whilst the two excluding valves 34, 35 and the first heating liquid block valves 43, 44 are open and, therefore, both the first heating liquid and the slip are free to circulate within the spiral heat exchanger 13'.
[0131] Thus, with reference to the first embodiment schematized in Figs. 1-5, and with particular reference to Figs. 1 and 4, the first heating liquid, that is cold and circulates within the cold portion 1 lb of the heating circuit 11, enters the second heat exchange device 12 and exchanges thermal energy with the fluid circulating in the cooling circuit CR, thus heating up.
[0132] The first heating liquid that has heated up, i.e., the first hot heating liquid, coming from the second heat exchange device 12 and circulating in the hot portion I la, and the cold slip, coming from the slip supply unit 20 and circulating within the slip inlet pipe 18, enter the spiral heat exchanger 13' through the liquid inlet 14 and the slip inlet 16, respectively.
[0133] Within the spiral heat exchanger 13’, the thermal energy, that has been stored in the first hot heating liquid because of the heat exchange that has occurred within the second heat exchange device 12, is transferred to the cold slip; as a result, the heating liquid cools while the slip heats up.
[0134] The first heating liquid that has cooled, i.e., the first cold heating liquid, exits the spiral heat exchanger 13’ through the liquid outlet 15 and flows towards the second heat exchange device 12, whilst the slip, that has heated up, i.e., the hot slip, exits the spiral heat exchanger 13’ through the slip outlet 17. [0135] With reference to the second embodiment of the plant 10 of Figs. 6-10, i.e., if the plant 10 is equipped with the third heat exchange device 30, there is an additional intermediate step.
[0136] In fact, with particular reference to Fig. 6, the second heating liquid, that is cold and circulates in the second cold sub-portion l l”b, enters the second heat exchange device 12 and exchanges thermal energy with the fluid circulating in the cooling circuit CR, thus heating up.
[0137] The second heating liquid that has heated up, i.e., the second hot heating liquid, coming from the second heat exchange device 12 and circulating in the second hot sub-portion l l”a, enters the third heat exchange device 30, where it transfers the thermal energy, that has stored during the heat exchange that has occurred within the second heat exchange device 12, to the first heating liquid, that is cold and comes from the first cold sub-portion 1 l’b.
[0138] The first heating liquid that has heated up, i.e., the first hot heating liquid, coming from the third heat exchange device 30 and circulating in the first hot subportion l l’a, and the cold slip, coming from the slip supply unit 20 and circulating within the slip inlet pipe 18, enter the spiral heat exchanger 13’ through the liquid inlet 14 and the slip inlet 16, respectively.
[0139] Within the spiral heat exchanger 13’, almost all the thermal energy, that has been stored in the first hot heating liquid because of the heat exchange that has occurred within the third heat exchange device 30, is transferred to the cold slip; as a result, the heating liquid cools while the slip heats up.
[0140] The first heating liquid that has cooled, i.e., the first cold heating liquid, exits the spiral heat exchanger 13’ through the liquid outlet 15 and circulates toward the third heat exchange device 30, while the slip that has heated up, i.e., the hot slip, exits the spiral heat exchanger 13’ through the slip outlet 17.
[0141] At this point, regardless of the embodiment considered, the hot slip flows in the slip outlet pipe 19 up to the slip feeding unit 21, which, in turn, feeds the hot slip to the atomizer 22. [0142] Let’s assume that the temperature of the hot slip, detected by the second temperature sensor 24, is too high. This situation may occur, for example, when the temperature of the hot slip exiting the spiral heat exchanger 13’ is higher than the threshold parameters, for example higher than the maximum operative temperature of the slip feeding unit 21.
[0143] In this situation, with reference to the first embodiment of the invention, and in particular to Figs. 1 and 4, the monitoring and control unit UMC detects that the temperature of the hot slips is higher than the threshold parameters, and acts on the three-way valve 29 so as to reduce the flow of the first hot heating liquid entering the spiral heat exchanger 13’, thus reducing the temperature of the hot slip exiting it.
[0144] In the same situation, with reference to the second embodiment of the invention, and in particular to Fig. 6, the monitoring and control unit UMC acts on the three-way valve 29 so as to reduce the flow of second hot heating liquid entering the third heat exchange device 30, thereby reducing the temperature of the first heating liquid entering the spiral heat exchanger 13’, thus reducing the temperature of the hot slip exiting it.
[0145] Now, let’s assume that the pressure detected by the second pressure sensor 26 is significantly lower than that detected by the first pressure sensor 25. This situation usually occurs when the spiral heat exchanger 13’ is damaged or clogged, that is, when maintenance and/or cleaning of the spiral heat exchanger 13’ are necessary.
[0146] Moreover, in this situation the thermal energy absorbed by the slip is less than that absorbed normally. In detail, this decrease can be verified by monitoring the temperatures measured by the temperature sensors 23, 24, 33, 34 and reported by the monitoring and control unit UMC.
[0147] In this case, as shown in Figs. 2, 3, 5, 7, 8, 9 and 10, the monitoring and control unit UMC signals the operator that the pressure difference detected by the pressure sensors 25, 26 is excessive, and the operator, through the same monitoring and control unit UMC, opens the slip bypass valve 28 and closes the exclusion valves 35,42. [0148] In this way, regardless of the embodiment of the invention, the slip circulates directly from the slip supply unit 20 to the slip feeding unit 21, avoiding the spiral heat exchanger 13', and, in this way, the necessary cleaning and/or maintenance of the spiral heat exchanger 13’ can be carried out without slowing down the production.
[0149] In detail, as shown in Figs. 5 and 10, the operator opens, through the monitoring and control unit UMC, the inlet valve 31 and the outlet valve 31’, so that cleaning water circulates in the spiral heat exchanger 13’, cleaning it and removing any clogging residue.
[0150] In addition, cleaning the channels of the spiral heat exchanger 13' makes it easier to detect any damage and to assess the need to carry out maintenance operations on the spiral heat exchanger 13’.
[0151] Specifically, if the spiral heat exchanger 13’ needs to be maintained, the operator, through the monitoring and control unit UMC, closes the inlet valve 31, the outlet valve 31’, and the first heating liquid block valves 43, 44, so as to isolate the spiral heat exchanger 13’.
[0152] Once cleaning and/or maintenance have been carried out, the operator, through the monitoring and control unit UMC, opens the first heating liquid block valves 43, 44.
[0153] Furthermore, if the plant 10 includes a washing system for the slip bypass pipe 27 that is controlled by the monitoring and control unit UMC, the monitoring and control unit UMC operates the washing system so as to prevent slip from settling along the slip bypass pipe 27.
[0154] Lastly, if the monitoring and control unit UMC includes a physical storage device or is connected to a cloud storage, it is possible, for example, to generate (and to store) a database, where to record the maintenance and/or cleaning operations carried out on the spiral heat exchanger 13’ coupled to the temperature values detected by the temperature sensors 23, 24, 33, 34 and/or the pressure difference detected by the pressure sensors 25, 26. [0155] In view of what described above, it is clearly apparent that the atomized powder production plant 10 achieves all the intended objects, solving the drawbacks of the prior art plants.
[0156] In particular, the plant 10 reduces the risk of derating the ICE cogeneration unit C.
[0157] In fact, the plant 10 allows further use of the heat stored in the cooling circuit CR, keeping the temperature of the fluid circulating within it sufficiently low even in summer.
[0158] In addition, the plant 10 reduces the consumption of gaseous fuel during the atomization process.
[0159] In fact, the slip is heated inside the spiral heat exchanger 13’ up to a temperature of about 80°C before being sent to the atomizer 22.
[0160] Therefore, compared with the prior art plants, the slip entering the atomizer 22 has a temperature about 25-30°C higher; in this way, cooler drying air can be used during the atomization process, thus reducing the gaseous fuel consumption.
[0161] This reduction has been verified by experimental tests (23 are shown) conducted after the installation of the plant 10 (and an associated measurement system), as shown in the diagram of Fig. 11.
[0162] In particular, there is evidence of a decrease in gaseous fuel consumption (specifically, natural gas) ranging between 6% and 9%, with an average value of about 7%, compared to a prior art plant.
[0163] It is important to highlight that the reduction in gaseous fuel consumption is "free", because the thermal energy generated by the ICE cogeneration unit C, that would otherwise be wasted, is used.
[0164] In addition, maintenance and cleaning of the plant 10 are particularly easy and feasible without slowing down the production.
[0165] In fact, the component of the plant 10 that is most affected by wear and/or in need of cleaning is the spiral heat exchanger 13’. [0166] However, the plant 10 allows, if necessary, to bypass the spiral heat exchanger 13' without interrupting the flow of slip toward the atomizer 22 and, thus, without slowing down the production.
[0167] In addition, the plant 10 is particularly safe because the monitoring and control unit UMC allows to monitor and to control remotely the plant 10, ensuring the proper operation thereof.
[0168] In practice, the materials can be chosen appropriately according to the requirements and in accordance with the state of the art available, to the extent that they are compatible with the specific use and the respective components for which they are intended.
[0169] It is understood that what is illustrated purely represents possible non-limiting embodiments of the invention, which may vary in forms and arrangements without departing from the scope of the concept on which the invention is based. Any reference numerals in the appended claims are provided for the sole purpose of facilitating the reading thereof in the light of the description above and the accompanying drawings and do not in any way limit the scope of protection.

Claims

Claims
1. An atomized powder production plant (10), comprising
- at least one atomizer (22),
- a slip feeding unit (21) feeding the atomizer (22),
- a slip supply unit (20) suitable to generate a flow of slip to be atomized, and
- a first heat exchange device (13), provided with an inlet (16) and an outlet (17) for the slip, suitable to fluidly couple the slip supply unit (20) and the slip feeding unit (21), wherein the plant (10) further includes
- a slip heating circuit (11), in which a first heating liquid circulates, the heating circuit (11) being operatively connected with the first heat exchange device (13) for transferring heat from the first heating liquid to the slip,
- an internal combustion engine cogeneration unit (C), provided with a cooling circuit (CR) for cooling the engine, and
- a second heat exchange device (12) suitable to exchange heat between the cooling circuit (CR) and the heating circuit (11).
2. The plant (10) of claim 1, wherein the first heat exchange device (13) comprises a spiral heat exchanger (13') having a liquid inlet (14) and a liquid outlet (15), the heating circuit (11) comprising a hot portion (I la), extending from the second heat exchange device (12) to the liquid inlet (14), and a cold portion (1 lb), extending from the liquid outlet (15) to the second heat exchange device (12), the spiral heat exchanger (13') further comprising the inlet (16), connected to the slip supply unit (20) via a slip inlet pipe (18), and the outlet (17), connected to the slip feeding unit (21) via a slip outlet pipe (19).
3. The plant (10) of claim 2, wherein the slip inlet pipe (18) comprises a first pressure sensor (25) arranged close to the inlet (16), and wherein the slip outlet pipe (19) comprises a second pressure sensor (26) arranged close to the outlet (17).
4. The plant (10) of claim 2 or 3, comprising a bypass pipe (27), along which a bypass valve (28) is provided to bypass, if necessary, the spiral heat exchanger (13') by directly fluidly coupling the slip supply unit (20) and the slip feeding unit (21), the plant (10) further comprising two exclusion valves (35,42) arranged along the slip inlet pipe (18) and the slip outlet pipe (19) respectively for excluding the spiral heat exchanger (13'), wherein the bypass valve (28) and the exclusion valves (35,42) can be remotely controlled by a monitoring and control unit (UMC).
5. The plant (10) of claim 4, wherein the bypass pipe (27) is fluidly coupled to the slip inlet pipe (18) upstream of the exclusion valve (35) along the slip inlet pipe
(18) and, at the same time, is fluidly coupled to the slip outlet pipe (19) downstream of the exclusion valve (42) along the slip outlet pipe (19).
6. The plant (10) of claim 5 comprising a cleaning water inlet branch (41) and a cleaning water outlet branch (41') for equi current washing the spiral heat exchanger (13'), wherein an inlet valve (31) and an outlet valve (31') are provided, remotely controlled by the monitoring and control unit (UMC) and arranged along the cleaning water inlet branch (41) and the cleaning water outlet branch (41') respectively, the cleaning water inlet branch (41) being fluidly coupled to the slip inlet pipe (18) downstream of the exclusion valve (35) along the slip inlet pipe (18) and, at the same time, the cleaning water outlet branch (41') being fluidly coupled to the slip outlet pipe
(19) upstream of the exclusion valve (42) along the slip outlet pipe (19).
7. The plant (10) of any one of claims 4 to 6, wherein the slip outlet pipe (19) comprises a second temperature sensor (24) arranged close to the outlet (17), the plant (10) further comprising a motorized three-way valve (29) connecting the hot portion (I la) and the cold portion (1 lb), the three-way valve (29) being controlled, depending on the temperature measured by the second temperature sensor (24), by a feedback controlled by the monitoring and control unit (UMC).
8. The plant (10) of to any one of claims 4 to 7, comprising first heating liquid block valves (43,44), a first heating liquid block valve (43) being arranged along the hot portion (I la) and a second heating liquid block valve (44) being arranged along the cold portion (11b), wherein the first heating liquid block valves (43,44) are remotely controlled by the monitoring and control unit (UMC).
9. The plant (10) of any one of claims 1 to 8, comprising a first distribution manifold (37) along the cold portion (11b) and a second distribution manifold (38) along the hot portion (I la), so as to keep part of the first circulating heating liquid for satisfying the hot water needs of the production plant and/or for preheating the drying air used by the atomizer (22) through respective hot (39a, 40a) and cold (39b, 40b) branches.
10. The plant (10) of to any one of claims 2 to 6, further comprising a third heat exchange device (30), the heating circuit (11) being thus divided into a first heating sub-circuit (I T), comprising a first hot sub-portion (1 l'a) and a first cold sub-portion (l l'b), which extends between the spiral heat exchanger (13') and the third heat exchange device (30) and in which the first heating liquid circulates, and a second heating sub-circuit (11"), comprising a second hot sub-portion (H"a) and a second cold sub-portion (H"b), which extends between the second heat exchange device (12) and the third heat exchange device (30) and in which a second heating liquid circulates, the first heating sub-circuit (11") and the second heating sub-circuit (11") being physically disjointed and operatively connected to the third heat exchange device (30) for transferring heat from the second heating liquid to the first heating liquid.
11. The plant (10) of claim 10 when dependent on any one of claims 4 to 6, wherein the slip outlet pipe (19) comprises a second temperature sensor (24) arranged close to the outlet (17), the plant (10) further comprising a motorized three-way valve (29) connecting the second hot sub-portion (H"a) and the second cold sub-portion (11 "b), the three-way valve (29) being controlled, depending on the temperature measured by the second temperature sensor (24), by a feedback controlled by the monitoring and control unit (UMC).
12. The plant (10) of claim 11 or claim 10 when dependent on any one of claims 4 to 6, comprising block valves (43,44) for the first heating liquid, a first block valve (43) for the first heating liquid being arranged along the first hot sub-portion (1 l'a) and a second block valve (44) for the first heating liquid being arranged along the first cold sub-portion (l l'b), wherein the block valves (43,44) for the first heating liquid are remotely controlled by the monitoring and control unit (UMC).
13. The plant (10) of any any one of claims 10 to 12, comprising a first distribution manifold (37) along the second cold sub-portion (l l"b) and a second distribution manifold (38) along the second hot sub-portion (11 "a), so as to keep part of the second circulating heating liquid for satisfying the hot water needs of the production plant and/or for preheating the drying air used the atomizer (22) through respective hot (39a, 40a) and cold (39b, 40b) branches.
PCT/EP2024/076788 2023-09-25 2024-09-24 Atomized powder production plant Pending WO2025068187A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT102023000019746A IT202300019746A1 (en) 2023-09-25 2023-09-25 ATOMIZATION PRODUCTION PLANT
IT102023000019746 2023-09-25

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WO2025068187A1 true WO2025068187A1 (en) 2025-04-03

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1987000765A1 (en) * 1985-08-01 1987-02-12 Georgia Kaolin Company, Inc. Energy conserving process for drying a clay slurry
US5223088A (en) * 1991-02-15 1993-06-29 Niro A/S Apparatus for producing concentrated aqueous slurries and spray dried particulate products
WO2010063341A1 (en) * 2008-12-02 2010-06-10 Rolls-Royce Plc Desalination method

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1987000765A1 (en) * 1985-08-01 1987-02-12 Georgia Kaolin Company, Inc. Energy conserving process for drying a clay slurry
US5223088A (en) * 1991-02-15 1993-06-29 Niro A/S Apparatus for producing concentrated aqueous slurries and spray dried particulate products
WO2010063341A1 (en) * 2008-12-02 2010-06-10 Rolls-Royce Plc Desalination method

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