Vortex Milling

What is TORNADO – technology? 

This 11 types of air-vortex disintegration systems, their functionalization, activation and modification.
The new technologies of disintegration of materials developed in Scientific Research Institute TP under the conditional name "Tornado" cover a wide range of scopes – from materials science to molecular biology. The effect from introduction of technologies in the industry has great economic importance.

The new industrial technology of crushing gives the chance to receive a new class of products both in powder metallurgy, and in pharmacology and cosmetology, for polymers and ceramics, for the food and agricultural industry.

The direction of the production of biologically active substances from microalgae based on these products, means raw materials for pharmaceutical and cosmetic compositions, for food and feed.

2-3 metric tone capacity each hour, depending on hardness
The industrial production of homogeneous disperse mixtures (alloys) directly between the constituent components in the solid phase, avoiding the stage of their meltdown, became possible with the resonant-vortex installation "Tornado" in one step.

Note: Calculations of productivity are based on parameters of an air compressor of company Kaeser (Germany): 9-12 cubic meters / min, 9 atmospheres, air class 2/2, dew point - 40◦C. When greater productivity is needed, individual project of installation is required, on the basis of technical specifications. For questions on designing, please contact the technical department

TECHNOLOGY FEATURES

Mill is designed so that any particles of input material literally burst at the multiple intersections of zones of differential pressure in vortices and intervortex vacuum threads, on the border of the existence of which there is a super-high gradient (difference) of pressures (up to hundreds thousands  atmospheres). When it get into a zone of differential pressure, destruction of particles and of the material occurs, the mechanism of which may be compared to mechanism of destruction of the material sample in determining its tensile strength properties in mechanical tensile test rigs. That is, grinding is not due to the friction force, and other mechanics, but contingently by "air" and resonances, which gives the highest performance, speed of flow of raw materials and the low-cost efficiency and power consumption (no friction parts).
Photo of vortices (four) and discharge zones (dark) in the chamber "Tornado" Methods were developed for the following: metal-carbon, carbon-metal;intermetallic compounds; multi-component mixtures;carbides, metal carbides, binary carbides, multipartite ceramics, carbides, with the insertion of atoms;3D- mixtures, mixtures for plasma spraying and powder metallurgy;mixtures for super-strong multi-pole magnets and so on.

The VORTEX ("Tornado") for liquid environments

Release of colloidal solutions, emulsions, suspensions, concentrates, oils and mixtures thereof. 
Separation, gradient decontamination. Air Class 1/1, food stainless steel, the working chamber of super-hard alloys. 

Supply system of raw material (dosing device), ACS and resonance modes, the laser system of particle analysis in the flow, a set of resonators, spare processing chamber, GPS - module, touch control Fiesta, system of catching: cyclones for separation, scrubber on dispersed nanofluids (distilled water, alcohol or solvents, inert medium and so forth.). 

Price depending on the equipment. (Please ask for details) 
Warranty and included in her service - 2 years. 

The VORTEX equipment is designed in a way so that any particle of the input material gets literally torn by the repeated crossing of the differential pressure zones in the intervortex vacuum chamber, which produces ultra-high gradient (pressure drops) at the interface (up to hundreds of thousands of atmospheres). When the material is injected into such area of pressure differential, a rupture of the material’s structure and clusters occurs. Such mechanism can be compared to the mechanism of material’s sample destruction, which is done in order to determine its strength characteristics at tensile test plants. That is, the grinding occurs not due to the friction or any other mechanic force, but by “air” and resonances, which provide a high and efficient performance, great flow rate of raw material as well as inexpensive exploitation (no rubbing parts) with low power consumption. In the process of solid mixtures grinding within the working chamber of the "Tornado”, occurs an accelerated process of mass transfer and chemical interaction between the components with no thermal effects. The process can be influenced by reagents. In the formation of compact samples obtained from the activated micro powders by hot pressing, a further homogenization of the material in which the matrix of micro-heterogeneity of the solid solution amounts to about 0.2 weight%, The pressing temperature is reduced and the sample density is increased. The study of the process within the working chamber showed that one-step activation occurs, and almost at the same time, according to the scheme: dispersion -mechanical mixing-chemical interaction between which there are no clear boundaries. Examples of the mechanically activated micro powders: TiC+ZrC + diamond micro powders, compounds Al2O3 - Cr2O3, titanium carbide-nickel, oxides as modifier for resins, polyethylenes that increase the physico-chemical properties (Nano-dimension and ultra 0.1 to 1 micron)-TiO2, ZrO2, Cr2O3, Fe2O3, Fe3O4, CoO, NiO, CuO, ZrO2-Y2O3, BaTiO3, Li(Na)MO2, РЗЭ2Ti(Zr) 2O, Y3Al3O12; Ni70Al30; NiCr20Ti2,5Al; Si0, 8-Ge 0,2; Ni-Cr-B-Si-С; Sm Co 5, Ni45Co5Mn40Sn10; HF-Та-C,AlSi12, AlSi10Сu, AlZn10Si8Mg, and etc.

Compressor screw of compressed air of KAESER firm (Germany). 

The air 1/1 class, dew-point – 400C, 13 cubes / minute, pressure is 10 bars. 
Guarantee and service - 2 years. 

Particularly interesting is the application of the technology of producing micro and Nano-dispersed powders, the so-called pseudo alloys that are difficult or impossible to obtain by the traditional melting of the components. Therefore, pseudo alloys are acquired in other ways, in particular by sintering of the powder components. The physic-mechanical and operational properties of the pseudo alloys are superior to the traditional alloys of similar purpose. Often, a high level of specialized magnetic, nuclear (radiation), electric and other properties can be ensured only by pseudo alloys. The intensification of the operational impact and, above all, the temperature, leads to the need of developing high-temperature materials based on refractory metals – tungsten, tantalum, molybdenum and niobium. Thus, the technology of highly dispersed "Tornado" powders production has increased physical and mechanical properties of pseudo alloys W-Fe-Ni and Mo-Cu which are of special purpose. The parameters of the microstructure, defects of the crystalline structure and phase composition of the mechanically activated mixtures for the systems W- Ni-Fe and Mo-Cu were identified, as well as the optimal regimes of the mechanical activation of these systems. A positive result from the use of the Nano powders is the formation of a fine-grained structure of sintered materials. The industrial technology of production of electric-pseudo alloy Mo - Cu for gas-insulated switches, superior in its characteristics in contrast to all the world analogues. During the research, it was revealed that the mechanical activation is not limited to a simple increase of the free-surface, it is always accompanied by a change of the physical state, chemical properties and composition of the grinded material. Ultrafine grinding is accompanied by a change of defects of the crystalline structure, up to the complete amorphization of the substance. This creates an "aftereffect" due to the fact that the grinded material possesses "excess" energy that was accumulated during the grinding process. These processes facilitate the functionalization of homogeneous and also carbon structures, such as metal inoculation.

EQUIPMENT ASSEMBLING FOR PRODUCTION

• The turning table, the conveyor, loading capacity, a casing and working surfaces are made of stainless steel that conforms to requirements of the GMP standard
• Work with screwing up and slamming covers
• The machine is easy to configure and service
• The machine can be easily adjusted for different sizes of cans and lids. For setting of changing formative parts it takes 20 minutes
• Average amount - 4000 cans per hour

KDV-7 – automatic line for packaging in cans with their subsequent closing with functions of air cleaning, filling and packing of container. Average price is 50 000 €. 

This model is developed especially for automatic packing of products of pharmacological production, such as capsules, tablets, pills, dragee, etc. 

The machine is supplied with functions of careful cleaning of container, the exact account of a product and closing, and also system of monitoring. This equipment is made according to requirements of the GMP standard

Encapsulation equipment

The equipment of complete bio laboratory, including hardware - 580 000 € (Germany). Equipments: Chromatography, microscopes, analyzers, devices, qualifiers, separators, ware, sensors, hoods, means of protection, reactants and so forth. 

Price depending on details and callculated for 4 workplaces.

Extraction and granulation

Automatic machine of bottling of liquid dosage 

forms and extracts various containers.