Description:
FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
A REFINING SYSTEM

PARASON MACHINERY (INDIA) PRIVATE LIMITED

AN INDIAN COMPANY HAVING ADDRESS AT
GOLDEN DREAMS, E-27, 4TH FLOOR CHIKALTHANA, MIDC, AURANGABAD, MAHARASHTRA INDIA, 431006

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE SUBJECT MATTER AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD OF THE INVENTION
[001] The present invention relates to refining systems, specifically to an advanced refining system designed for applications in the pulp and paper industry. More particularly, the invention pertains to the "Refining System," which improves material retention time without adversely affecting efficiency with fiber treatment uniformity.
BACKGROUND OF THE INVENTION
[002] In the pulp and paper industry, refining systems are essential for processing raw materials into usable pulp. The quality and consistency of pulp directly affect the overall quality of paper products. Traditional refining systems suffer from inefficiencies such as uneven fiber distribution. These issues result in reduced productivity, increased operational costs, and higher energy usage, making it challenging to meet the evolving demands of the industry.
[003] Conventional refiners face limitations in uniformly treating fibers due to choking and reduced retention time in the refining zone formed between the stator and rotor. Uneven fiber distribution across refining bars or refining systems leads to inconsistent fiber treatment, affecting the quality of the final paper product. Traditional systems often require multiple refiners to achieve adequate refining, increasing energy usage and maintenance costs. In these refiners, each stator and rotor are arranged opposite to form a refining zone. The surfaces of the stator and rotor have openings through which fibrous material is introduced or removed. These openings are arranged opposite each other in an offset manner. Some refiners opted to have one outlet opening and multiple inlet opening or single outlet and single inlet openings. However, the shape and size of each opening is similar, which severely affects the final paper product due to the chocking of the material between the openings, partial refining of the processed material, and less retention time of the raw material between the refining zone .
[004] The need for an innovative solution that addresses these inefficiencies has become critical in light of growing sustainability concerns and rising operational costs in the industry. The conical refining system has been designed to tackle these challenges by introducing advanced features that not only improve the quality of fiber treatment but also significantly reduce energy consumption and maintenance efforts. By offering a high-throughput, energy-efficient, and cost-effective refining process, the conical system provides a transformative solution for modern refining applications in the pulp and paper industry.
SUMMARY OF THE INVENTION
[005] The present invention provides a refining system, namely the conical refining system, which includes a conical tackle with advanced features to improve the efficiency of the refining process.
[006] The present disclosure provides a refining system comprising a conical rotor configured for rotation around an axis and driven by a motor, and a conical stator that is fixed in place relative to the rotor. Wherein the plurality of refining plates are configured with each other in order to formulate the rotor , while the plurality of refining plates are configured with each other to formulate the stator, creating a refining zone in the form of a refining gap (106) between them.
[007] The rotor is designed with multiple evenly spaced inlet openings that facilitate the entry of feedstock into the refining gap, while the stator features outlet openings that allow the refined feedstock to exit after passing through the gap. Further, the inlet openings are designed to have even surfaced without area reduction, and the outlet openings are configured with teeth along their inner edges to enhance the shearing action during the refinement process or divergent positioning to improve material retention time. Additionally, the stator and rotor are securely attached via a fixing mechanism to the main frame of the refiner, ensuring proper alignment and stability during operation.
[008] In yet another embodiment, the present disclosure provides a refining system wherein the fixing means comprises various securing components to ensure proper alignment and stability during operation. These include a plurality of clamps that are utilized to hold the rotor and stator tightly together, resisting any forces that might cause misalignment during operation. The fixing mechanism further includes male and female sockets that provide a secure joint connection between the rotor and stator, allowing for easy assembly and disassembly while maintaining stability. Furthermore, alignment pins fit into corresponding holes in both the rotor and stator (to ensure precise positioning and prevent any rotational misalignment, ensuring efficient and stable operation of the refiner.
[009] In yet another embodiment, the present disclosure provides a refining system, further comprising bars and grooves surrounding the inlet openings and outlet openings on both the rotor and stator, respectively, to enhance the refining process.
[0010] In an embodiment, the present disclosure provides a refining system, , wherein the inlet openings are arranged in an inward slanted pattern and outlet openings on stator are arranged in an outward slanted pattern, to facilitate enhanced retention time of refined material flow into the refining gap .
[0011] In yet another embodiment, the present invention provides a refining system, wherein the outlet openings in the stator are designed with trapezoidal or divergent shapes to optimize choking and enhance the retention time of refined material.
[0012] In still another embodiment, the present invention provides a refining system, wherein the outlet openings (are configured in a concentric circular narrowing shape to ensure smooth material flow with minimized turbulence.
[0013] In an another embodiment, the present invention provides a refining system, wherein the outlet openings are configured in elongated and oriented diagonally to reduce weight and improve portability.
[0014] In yet another embodiment, the present invention provides a refining system, wherein the diagonal and curved outlet openings on the stator extend fully from one edge of the stator to the other, facilitating weight reduction and enhancing the structural efficiency of the refiner.
[0015] In still another embodiment, the present invention provides a refining system, wherein the rotor inlet openings and stator outlet openings are designed to align during rotor rotation, allowing for the continuous and efficient flow of feedstock through the refining gap.
[0016] In yet another embodiment, the present invention provides a refining system, wherein the shape and size of the inlet openings are different from the shape and size of the outlet openings wherein the outlet openings are configured to facilitate smooth discharge of refined material and prevent clogging, thereby optimizing the refining process.
[0017] In still another embodiment, the present invention provides a refining system, wherein the stator ) has a plurality of outlet openings, wherein the outlet openings are designed as: slanted openings with teeth along their inner edges, creating additional mechanical shearing and cutting action as the feedstock passes through; or circular openings with protruding teeth along their inner edges, enhancing the refining process by increasing contact surface area and introducing greater turbulence for improved material breakdown.
[0018] The present disclosure provides a method for refining feedstock using a refining system. The method begins by introducing feedstock into the conical rotor through multiple evenly spaced inlet openings and inlet end. The rotor is driven by a motor and rotates around an axis, causing the feedstock to move into the refining gap between the rotating refining plates on the rotor and the stationary refining plates on the stator. As the feedstock passes through the refining gap, it undergoes shearing and mechanical action, enhanced by the presence of teeth along the inner edges of both the inlet openings and the outlet openings, which improve the cutting and shearing effects during the refinement process. Once the refining is complete, the refined feedstock is discharged from the refining gap through the outlet openings in the stator and outlet end positioned opposite of said inlet end. The method ensures that the rotor and stator remain securely aligned during operation by using a fixing means that prevents vibration or misalignment, thereby maintaining optimal refining efficiency.
[0019] In one embodiment, the present disclosure provides a method for controlling feedstock flow in a refining system. The method involves introducing the feedstock into the rotor through slanted or circular inlet openings that are specifically designed to evenly distribute the feedstock across the refining plates as the rotor spins and inlet end of said refining system. The slanted or circular openings direct the feedstock towards the refining plates in a manner that ensures uniform flow, reducing turbulence and promoting efficient refining. The refined material is then discharged through corresponding outlet openings in the stator and the outlet end, where slanted or trapezoidal or divergent shapes facilitate smooth and efficient discharge without clogging.
[0020] In yet another embodiment, the present disclosure provides a method of enhancing shearing in said refining system. This method includes creating mechanical interaction with teeth located along the inner edges of both the inlet and outlet openings. As the feedstock passes through the refining gap, these teeth interact with the material, increasing mechanical shearing and cutting action, further breaking down the feedstock. Additionally, the slanted configuration of the openings extends the duration of feedstock contact with the refining plates, which enhances the mechanical action and achieves finer refinement.
[0021] In another embodiment, the method for enhancing shearing in said refining system further involves using slanted or circular inlet openings to introduce feedstock in a manner that reduces energy consumption. The slanted or circular design of these openings ensures smooth and even feedstock flow, promoting efficient processing while minimizing energy requirements.
OBJECTIVES OF THE INVENTION
[0022] The primary objective of this invention is to provide an efficient refining system that addresses the limitations of traditional systems. The disclosed refining system aims to improve fiber treatment, minimize energy consumption, and reduce maintenance costs.
[0023] Another objective of the invention is to ensure uniform fiber treatment using flow-through technology that evenly distributes the fiber slurry across refining bars, enhancing pulp quality and reducing the need for additional refining stages.
[0024] Further, the objective is to optimize the design and arrangement of the inlet and outlet openings, the invention ensures even distribution of the feedstock across the refining plates, leading to consistent fiber treatment and improved quality of the final paper product.
[0025] In still another objective, the present disclosure provides a refining system wherein the outlet openings (in the stator are designed with concentric circular, slanted openings with teeth, trapezoidal, elongated diagonal, and circular openings with teeth, divergent opening, to create a more controlled and streamlined flow of feedstock, prevents choking of the material between the openings and optimize the mechanical interaction with the refining plates.
[0026] In yet another objective, the refining system features diagonal and curved outlet openings on the stator that extend fully from one edge of the stator to the other. This design facilitates weight reduction while enhancing the structural efficiency of the refiner.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
[0027] Aspects and features of the various embodiments will be more apparent by describing examples with reference to the accompanying drawings, in which:
[0028] Figure 1: illustrating a simplified diagram a refining system according to the present disclosure;
[0029] Figure 2a-2b: illustrating a typical construction of rotor segments and stator segments used for said refining system of the type illustrated in FIG. 1;
[0030] Figure 3a: illustrating another embodiment of said refining system according to the present disclosure;
[0031] Figure 3b: illustrating a typical construction of rotor segments and stator segments used for said refining system;
[0032] Figure 4-5: illustrating examples of stator segments according to some aspects of the present disclosure;
[0033] Figure 6a: illustrating examples of stator edges according to some aspects of the present disclosure
[0034] Figure 6b: illustrating examples of stator edges according to some aspects of the present disclosure
[0035] REFERENCE NUMERALS
Numerals References
100 Refining System
101 Stator
102 Rotor
103 Inlet openings
104 Outlet openings
105 Fixing means
106 Refining gap
107 Refining plates
108 Refining plates
109 Inlet
110 Outlet
111 Inlet end
112 Outlet end
200 Refining System
201 Stator
202 Rotor
203 Inlet openings
204 Outlet openings
204a Projections
205 Fixing means
300 Refining System
301 Stator
302 Rotor
303 Inlet openings
304 Outlet openings
305 Fitting
306 Refining gap
307 Refining plates
308 Refining plates
309 Inlet
310 Outlet
311 Inlet end
312 Outlet end
313 Refining surface
314 Bar
315 Groove
400 Refining System
401 Stator
402 Rotor
403 Inlet openings
404 Outlet openings
500 Refining System
501 Stator
502 Rotor
503 Inlet openings
504 Outlet openings
504a Projections
600 Refining System
601 Stator
602 Rotor

603 a Bars on rotor
603 b Bars on stator
604 Rotor edge

605 Stator edge

606 Gap

607 winding path of the raw material
608 Gap

608a External point
608b Internal point
608c Surface
608d Surface
D Angle of divergence
T Thickness
LD Length of divergence
[0036] DETAILED DESCRIPTION OF THE INVENTION
[0037] The present invention relates to a refining system designed for refining raw materials such as wood pulp, cellulose, virgin or recycled raw material, or other materials required for making paper. The invention addresses various challenges associated with conventional refining systems, including uneven fiber treatment, high energy usage, and maintenance costs. The refining system features a rotor and stator with strategically designed openings to ensure controlled and uniform entry and exit of feedstock, maximizing the material retention time and maintaining even distribution and pressure during the refining process. The invention also includes a robust fixing means to maintain the stability and alignment of the refiner's components, enhancing the overall efficiency and performance of the refining process.
[0038] In an embodiment as illustrated in figure 1, presents an illustration of a refining system (100), which consists of a conical rotor (102) and a conical stator (101). The rotor (102) rotates around an axis, driven by a motor connected through a shaft. The rotor (101) is formulated by means of the configuration of the same or similar types of refining plates (107) with the abrasive surface or plurality of bars and grooves, which spin with it, while the stator (101) configured with a plurality of stationary refining plates (108) . A refining gap (106) exists between the rotor (102) and the stator (101).
[0039] In this refining system (100), feedstock, such as wood pulp or cellulose or recycled raw material or other required for making paper, enters the rotor (102) and moves into the refining gap (106) through numerous evenly spaced inlet openings (103) in the rotor plates (107) and from an inlet (109) . As the feedstock passes over both the rotor (102) and stator (101) comprising a plurality of a refiner plate (107, 108) with the plethora of the bars and grooves positioned to process the fed raw material into the refined output to be dispersed form said outlet openings (104) of said stator (101) and the outlet (110) from said outlet end (112) that allow the refined feedstock to exit the refining system (100). Additionally, the surfaces surrounding these openings on the stator (101) and said rotor (102) contain various bars and grooves that design in accordance with the refining pattern required to be achieved by means of said refining system (100).
[0040] The fixing means (105) in the refining system (100) is designed to securely hold the stator (101) and the rotor (102) of the refining system (100) in place during operation. This mechanism ensures that the rotor (102) and stator (101) remain properly aligned, allowing for efficient refining of the feedstock. The fixing (105) means may consist of various components such as brackets, bolts, clamps, and male and female sockets or joint means that provide stability and facilitate easy assembly and disassembly. These joint means ensure a secure connection between different parts of the refining system (100) , preventing any movement that could disrupt the refining process. By maintaining the integrity of the assembly, the fixing means plays a crucial role in the overall functionality and performance of the refining system (100).
[0041] The fixing means (105) in the refining system (100) consists of several key components that work together to ensure the stability and alignment of the refiner's parts during operation. These components may include:
[0042] Brackets: These structural supports attach the rotor (102) and the stator (101) to the main frame of the refining system (100). help to maintain the correct positioning of the components and resist any forces that may cause misalignment.
[0043] Clamps: Clamps are used to hold components tightly together, ensuring that they do not shift during operation. They can be especially useful for securing the rotor (102) and stator (101) in place.
[0044] Male and Female Sockets: These joint means provide a way to connect different parts of the refining system (100) easily. The male socket fits into the female socket, creating a secure and stable connection that can also allow for quick assembly or disassembly when maintenance is required.
[0045] Alignment Pins: These small cylindrical components help align the rotor (102) and stator (101) precisely. They fit into corresponding holes in the components to ensure that everything is positioned correctly.
[0046] Together, these components of the fixing means (105) ensure that the refining system (100) operates smoothly and effectively, maintaining the necessary alignment and stability throughout the refining system (100) .
[0047] The rotor (102) is connected to the main frame of the refining system (102) via fixing means (105) that secure it longitudinally. This connection ensures that the rotor (102) remains properly aligned and rotatably stable during the operation. Similarly, the stator (101) is also connected to the main frame using fixing means (105), which provides additional support and stability.
[0048] Further, Figure 1 highlights the specific points where the rotor (102) and stator (101) are attached to the main frame of the refining system (100) . These connection points are critical as they ensure that both components are securely held in place. The rotor (102) is depicted as being connected longitudinally, meaning that its length is aligned with the direction of operation. This type of connection allows for efficient rotation and minimizes the risk of misalignment during the refining process. The stator (101) is shown to be fixed in place using similar fixing means (105). This connection provides a stationary counterpart to the rotating rotor (102), which is essential for the refining action. The stator's (101) stability helps maintain the necessary gap (106) between the rotor (102) and stator (101), ensuring optimal performance. The fixing means (105) are emphasized in the diagram as essential components that provide structural integrity to the refining system (100). They prevent any movement or vibration that could lead to wear, damage, or inefficiencies in the refining process.
[0049] In another embodiment, illustrated in Figure 2, the structure of the rotor (202) and stator (201) is shown separately. The stator (201) is the stationary component of the refining system (200). In this embodiment, it is denoted by the reference numeral (201). The stator (201) holds the stationary refining plates and is responsible for remaining fixed while the rotor (202) rotates. It has outlet openings (204) of said stator (201) designed in the vertical and/or horizontal and/or inclined slots to treat the refining material with choking possibility in the circular openings. Further, said opening (204) includes the projections (204a) to increase the refining area or perform the secondary refining during the travel of processed material from said opening (204). Wherein the introduction of said projections (204a) within said outlet opening (204) produces the resistance to pass the material from said opening (204) which results in an increase in the force or pressure required to cross the projections (204a) of said opening (204) that produces the reaction forces on following material to detect less resistance path towards the configuration of the bars and ribs between said gap (206) to increase the material retention time and gradually enhances the refining quality without release of the partially processed material. The rotor, labelled as (202), is the rotating part of the refining system (200). Driven by a motor, the rotor (202) spins around a central axis, and its surface is equipped with inlet openings (203) configured without any projections (204) and comprising the plane surface that allow the feedstock to enter the refining gap (106) with a higher rate to insure sufficiency of material availability for refining. Further, the arrangement of these openings is such that they ensure an even distribution of material as the rotor (202) spins, allowing the feedstock to move efficiently toward the refining plates.
[0050] During refining, the raw material enters through the inlet openings (203) and inlet end (109) and experiences a controlled pressure, ensuring that it is evenly distributed as it enters the refining gap (106). The refining gap (106), formed between the stator (201) and rotor (202), wherein the opening (204) with said projections (204a) ensures that the material is retained for a sufficient period within said gap (106), allowing thorough processing and seeps out smoothly through the outlet openings (204) without blocking or choking.
[0051] Further, the outlet openings (204) in the stator (201), allow the refined material to exit the refining system (200) after passing through the refining gap (106). These openings (204) are positioned in such a way that the feedstock exits uniformly after the refining process is completed. The projections (204a) on the stator openings (204) are a set of grooves and ridges (teeth-like structures) or formulated in threaded pattern or labyrinth grooves. These projections (204a) are designed to enhance the refining process by increase in turbulence to pass the process material in order to increase the material retention time in said refining gap (106) and providing additional mechanical action of refining. The arrangement of these projections (204a) is typically in parallel lines, inclined, vertical or horizontal or patterns that radiate outward, creating turbulence in the material as it passes through the gap (106), which leads to more efficient refining. The projections (204a) along the inner edges of the outlet openings (204) increase the contact surface area and introduce additional mechanical action of refining. This enhanced shearing and cutting action helps to break down larger clumps of feedstock into smaller, more manageable pieces before they exit the refining gap (106). By fragmenting the material effectively, the risk of blockages caused by larger chunks of feedstock is minimized.
[0052] The projections (204a) along the inner edges of the outlet openings (204) create localized turbulence as the material passes through the outlet openings (204). This turbulence ensures that the material is kept in motion, preventing it from settling and potentially causing clogs. The continuous movement of the material helps to maintain a smooth and uninterrupted flow through the outlet openings (204).
[0053] The design of the projections (204a) along the inner edges or throughout of the outlet openings (204) ensures that the material is evenly distributed across the outlet openings (204). This uniform flow prevents the accumulation of material in any specific area, reducing the likelihood of choke points forming. The even distribution of material also helps to maintain consistent pressure and flow rate throughout the refining process.
[0054] Moreover, the shape and arrangement of the outlet openings (204) with said projections (204a) are designed to create a controlled flow of material. The projections (204a) act as flow restrictors within said opening (204), providing resistance to the material’s movement. This resistance ensures that the material is processed for a sufficient duration within the refining gap (106) before being expelled.
[0055] As illustrated in Figure 2, the inlet openings (203) in the rotor (202) are arranged in an evenly spaced pattern around its surface. This pattern ensures that the feedstock is introduced uniformly across the refining plates as the rotor (202) spins. Similarly, the outlet openings (204) in the stator (201) are similarly spaced and aligned with the feedstock’s flow, ensuring that the refined material exits efficiently without clogging or backflow. In one of the preferred embodiments said opening (204) of said stator (201) and said opening (203) of said rotor (203) are configured co-axially in order to produce a streamlined refining effect with generation uniform pressure region along said openings (204, 203) that assist choked free pressurized exit of the processed material after spending sufficient time in refining gap (106). The gap (106), formed between the stator (201) and rotor (202), is critical for processing the raw material efficiently.
[0056] The slanted arrangement of the openings in both the rotor (202) and the stator (201) serves multiple important purposes in the operation of the refining system. The slanted openings help create a more controlled and streamlined flow of the feedstock as it enters through the rotor (inlet openings (203)) and exits through the stator (outlet openings (204)). This arrangement maximizes turbulence by ensuring that the material flows smoothly along the rotor (202) and the stator (201). The coaxial angled positioning of the openings (203, 204) helps guide the feedstock more efficiently through the refining gap (106), optimizing the mechanical interaction with the rotor (202) and the stator (201). By slanting the openings (203, 204), more of the rotor (202) and stator (201) surfaces are exposed for refining. This means that the feedstock is in contact with the rotor (202) and the stator (201) for a longer duration, allowing for a more thorough and uniform refining process. The slant helps the feedstock flow along the entire length of the plates rather than passing through too quickly.
[0057] The slanted openings (203, 204) ensure that the feedstock is distributed evenly across the surface of the rotor (202) and stator (201). This uniform distribution prevents clumping or uneven wear on the refining plates, leading to more consistent refining results and prolonged equipment life. The angle at which the openings are slanted helps prevent material from clogging the passages. The slant encourages continuous movement of the material, preventing blockages and ensuring that the refining process remains uninterrupted. This is particularly important in high-speed operations, where a build-up of material could reduce efficiency or even damage the equipment.
[0058] The slanted arrangement contributes to better shearing and cutting action. As the feedstock moves through the slanted openings (203, 204), it encounters the projections (204a) on the rotor (202) and the stator (201) at an angle, which improves the refining action on the material. This results in finer and uniform refining, particularly for materials like wood pulp, or cellulose, or recycled material.
[0059] In an embodiment as illustrated in Figure 2b, the slotted opening (203, 204) can be replaced with a circular openings(204) on the stator (201) and circular opening (203) on said rotor (202), wherein said circular opening (204) may be equipped with projections (204a) along their inner edges. These projections (204a) enhance the refining process by creating additional mechanical shearing and cutting action as the feedstock passes through the circular openings. The projections (204a) increase the contact surface area and introduce a greater degree of turbulence, which improves the material breakdown and allows for finer refinement in accordance with said slotted opening (204) illustrated in figure no. 02a.
[0060] Compared to standard circular openings (203) provided on the rotor (202), the addition of projections (204a) allows for more aggressive shearing, especially beneficial for tougher or more fibrous materials. This design provides a hybrid approach, combining the uniform flow benefits of circular openings (203, 204) with the enhanced mechanical action of the projections (204a), resulting in finer and more consistent product quality.
[0061]
[0062] In another embodiment, as illustrated in Figure 3a, the straight inlet openings (303) on the rotor (302) are arranged slanted and large size, designed to allow higher inlet material flow and guide the feedstock into the refining gap efficiently at sufficient quantity. These openings (303) are evenly spaced to ensure uniform material distribution. Further, the divergent outlet openings (304) on the stator (301) are tapered, and designed in a manner that gradually decreases from the refining gap (306) to the external surface (301a) of the stator (301) and differently shaped than the inlet openings (302) to increase material retention time in the refining gap (306) and enhance the refining effect on the material surrounding to the opening (303, 304) by means of uniform pressure zone generated due to reaction force produced due to material force at the exit of small opening (304) corresponding to said surface (304a) to ensure only the processed material to exit smoothly. The divergent outlet openings (304) prevent clogging and ensure the efficient discharge of the refined feedstock. The distinct shapes with coaxial arrangements of the inlet (303) and outlet openings (304) optimize material flow and the overall refining process.
[0063] Particularly, the outlet openings (304) on the stator indeed appear to have a divergent or trapezoidal shape with an angle of divergence (D). This divergent or trapezoidal design of the outlet openings (304) allows for a smaller exit and wider inlet for the refined material to allow more material to enter into the opening (304) from the surface (301b) and travel along the gradual reducing wall (301c) towards the exit at the surface (301a) opposite to said gap (306), as the area of said wall (304a) from the surface (301b) to said surface (301a) reduces divergently at said angle (D) to raise the pressure within said opening (304) to resist the easy exit from said opening (304) at the surface (301a) which results into building the back pressure or reaction force on the backflow approaching to said opening (304) to force to flow towards corresponding refining surface (313) or next opening (304) or outlet (310) and this action of flowing towards corresponding surface forces the backflow material to pass through the configuration of bars (314) and groove (315) to get processed if processed partially or incompletely to achieve desired refining effect. In one of the embodiments said angle of divergence (D) can be greater than 1° and less than 90° and preferably can be in the range of 1.5° to 20°. However, if said openings (304) positioned in series consecutive one after another then the length of divergence (LD) to position corresponding openings (304) at least two times the thickness (T) of said opening (T) in order to produce the sufficient backpressure to achieve the intended result from said refining system (300).
[0064] Furthermore, this shape is particularly effective in high-volume operations, helping to manage the discharge efficiently.
[0065] In an embodiment as illustrated in Figure 3b, the inlet openings (303) on the rotor (302) are designed as circular openings, while the outlet openings (304) on the stator (301) are designed as concentric circular openings with the diameter on the surface (301b) with the configuration of said bars (314) and grooves (315) is larger than the diameter of said opening (304) on the surface (301a) opposite to configuration of said bars (314) and grooves (315). In one of the embodiments the diameter on the surface (301b) may be in the range 5% to 30% larger than the diameter of said opening (304) on the surface (301a) and preferably the diameter on the surface (301b) required to be at least 10% larger than the diameter of said opening (304) on the surface (301a) in order to generate sufficient and effective back pressure. The different shapes of the openings (303, 304) allow the feedstock to enter the refining gap in a controlled and uniform manner with sufficient retention time. The circular shape of the inlet openings (303) ensures smooth material flow with minimized turbulence at the inlet, maintaining an even distribution of the feedstock across the refining surface. The concentric circular shape of the outlet openings (304) facilitates an efficient exit of the refined feedstock. Whereas in the case of the material with higher consistency or the choking possibility or the specific application requirement the circular shaped openings (303, 304) with said divergent configuration of wall (304a) can be altered in different shapes which include but not limited to slotted opening (203), slotted opening with projections (204a), square or rectangular shaped opening, elliptical or curved openings, etc.
[0066] The circular and concentric circular shapes of the openings (303, 304) maintain balanced pressure distribution, making them ideal for consistent processing. They provide a direct entry into the gap, resulting in a gentle shearing process, which is beneficial for materials requiring less aggressive treatment. The uniform introduction of material across the refining surface prolongs the life of the refining plates and increases energy efficiency by reducing additional guiding forces.
[0067] To prevent choking and ensure thorough processing, the refining gap (306) formed between the stator (301) and rotor (302) retains the material for a sufficient period. Controlled pressure within the refining gap (306) is achieved through the rotor's (302) rotational speed and the strategic design of the openings (303, 304). The inlet openings (303) allow material to enter at a high rate, preventing sudden surges and clogging. The concentric circular and divergent trapezoidal shape of the outlet openings (304) ensures pressurized exit of the material by creating a continuous high-pressure flow with an enhanced refining effect.
[0068] In an embodiment as illustrated in Figure 4, the outlet opening labelled as (404) on the stator (401) appears to be an elongated, diagonal slot, curved slot, aerofoil slot, or channel-shaped. The shape of this opening is a long narrow rectangle oriented at an angle within the stator component. In one of the preferred embodiments the shape of said opening (404) can be aerofoil shaped with gradually increasing the cross-sectional area. The outlet opening (404) extends from near the top of the stator (401) towards the bottom-right, cutting diagonally across the shaded area of the stator (401) gradually narrowing from the end (404b) to the end (404c) in order to allow gradual outlet of the exit material while building sufficient pressure on the backflow material to generate the resistance in the exit of the processed material which results in the retention time of the fed material. This single outlet opening (404) of the stator (401) removes material from the stator (401) core, resulting in reduced reduce the machining cost of drilling multiple slots, holes or other shapes with maintaining the strength of said stator (401) and rotor (402) plate in order to operate in high loading and very fine refining compatible conditions with higher efficacy and efficiency. Further, in case the increased retention time and refining effect are required the cross-sectional wall (404a) not shown in the figure can be modified with a divergent shape as per the refining system (300) or with projections (204) in accordance with the refining system (200) or the serrations, threading or the labyrinth grooves can be provided. In one of the preferred embodiments said opening (404) can be furnished on the refining surface (413) adjacent to the outlet end (210, 310) of the refining system to expel only process material input from the inlet end (209, 309) after passing through substantial refining surface (413) with the plurality of bars (414) and grooves (415). However, the formulation of said opening (404) within the refining surface (413) assists in generation the of effective back pressure to enhance the refining efficacy.
[0069] In an embodiment as illustrated in Figure 5, the outlet opening labelled as (504) on the stator (501) instead on the elongated opening (404) with the same or similar configuration, position and formulation. Wherein said opening (404) can be of shape which include but not limits to curved shaped, kidney shaped with the larger exit, semi-circular or quarter circular, aerofoil shaped, etc with gradually increasing in the cross-sectional area. Further, the opening appears to be visible with curves or bends. The opening appears to extend fully from one edge of the stator's inner surface to the other, terminating within the body of the stator. This curved or aerofoil or kidney-shaped opening (504) was designed with a similar configuration of wall and end as of said opening (404) in order to perform more outlet centralized refining to increase more refining time and refining surface (513) space as compare to said refining system (400) to suits in high retention, high refining to process the harder or high consistency or recycled type of material with less machining cost and higher refining strength. The rotor inlet opening may be similar in shape or circular or slotted or any other shaped to the inlet openings designed or positioned at adjacent to the inlet end (209, 309) to offer larger refining surface and time to perform alleviated reefing effect. as illustrated in Figures 4 and 5, aligned with the outlet openings (404, 504) so that the inlet can flow from inlet end and an opening (403, 503) of said rotor and when the rotor (402, 502) rotates, the inlet raw material from the inlet opening (403, 503) proceed towards the outlet opening (404, 504) within the refining gap over the refining surface to exit as the processed output from the outlet opening (404, 504) without generation of unprocessed or partially processed output. . The technical advantages of the proposed structure offer several significant technical advantages. At its core is an advanced refining technology that utilizes a conical tackle design. This innovative system incorporates cutting-edge flow-through methods, ensuring an even distribution of fibers with higher retention time without choking. By spreading stock uniformly across refining bars, it achieves consistent fiber treatment and maintains high product quality throughout the process.

[0070] In an embodiment as illustrated in Figure 6a; a refining system (600) typically consists of a stator (601) and a rotor (602) wherein the stator (601) are configured with plurality of same or similar type of stators (601) by maintaining the gap (608) between configuration of corresponding stator (601) in order to allow processed material to flow from the gap (608) between said stators (601) to increase material discharge from said refining system (600) to enhance the efficiency of said refining system (600). Further, each of said stator (601) and rotor (602) are equipped with bars (603b) on the stator side and bars (603a) on the rotor (602) side. These components define a refining zone (606), which is a narrow gap (606) between the stator (601) and rotor (602), where raw material (pulp) undergoes mechanical treatment. The stator (601) is a stationary component, shown with bars (603b) on its inner circumference. The rotor (602) is the rotating component, also fitted with bars (603a) on its outer circumference projected towards the stator (601) configuration. The refining space (or gap) (606) between the bars (603a) on the rotor (602) and the bars (603b) on the stator (601). This is where plurality of forces which include but not limits to shear forces, beating forces, etc. act on the raw material. The raw material (pulp) flows into the refining gap (606) and is forced through the gap (606) by the rotation of the rotor (602). Further, the refined or processed raw materials exist from the gap (608) formed between corresponding sectors (601) from the edges (605). In this design, the flow path or winding path (607) is deliberately curved, inclined, slanted or extended to divert the pulp’s straight flow to curved, inclined, slanted or extended path to increase the flow resistance to increase in residence (retention) time in the refining gap (606). Wherein by prolonging the time the raw material stays in contact with the bars (603a, 603b), more fiber fibrillation and mechanical and refining action occur, leading to improved refining quality and output strength . Longer retention in the refining zone or gap (106) means more contact between fibers of raw material and the bars (603a, 603b), enhancing fiber fibrillation. Prolonged refining can lead to better tensile strength, tear resistance, and controlled fiber cutting or fibrillation. A well-designed flow or winding path (607) of the raw material due to the slanted or inclined edges (605) ensures that mechanical energy is applied effectively, rather than letting pulp exit too quickly.
[0071] As the rotor (602) spins at high speed, it creates a pumping effect that draws the raw material into the refining gap (606). The bars (603a) on the rotor (602) cross against the bars (603b) on the stator (601), shearing and refining the fibers of the raw material.
[0072] Patterns like grooves or dams on the bars (603a, 603b) enhance turbulence, mixing, and shear forces within the refining gap (606). Located on the stator (601), these inclined outlet gap (608) between said sectors (601) guide the refined raw material of pulp out of the refining system (600), such that the flow material moved in a inclined path or winding path (607) as shown in corresponding detail view. Unlike straight or radial outlets, inclined outlet openings (608) introduce a tangential or swirling component to the exiting flow. These edges near the outlet openings (608) on the stator (601) help direct the flow of raw material along a winding path (607). The rotor (602) may also have inclined edges (604) that work in tandem with the stator’s (601) inclined edges (605) to influence the flow path. Because of the inclined edges (604, 605) of the outlet openings (608), the raw material does not simply exit in a straight line. Instead, it follows a longer, inclined path, effectively increasing the residence time in the refining gap (606). The inclination of the edges (605) of the outlet openings (608) and partially deflect or swirl the path (607) of processed material, preventing an immediate exit. As the processed material path (607) swirls and lingers, it spends more time in the gap (606) where the bars (603a) and bars (603b) interact with the fibers. More passes between the rotor (602) and stator (601) bars (603a, 603b) lead to better refining control, whether the goal is fibrillation or other modifications. By extending the flow path (607), the inclined outlet openings (608) and inclined edges (604, 605) ensure the raw material remains in the refining gap (606) longer. This increased retention time translates to improved mechanical treatment of fibers, thereby enhancing paper strength characteristics (e.g., tensile strength, tear resistance) and allowing for more precise control over fiber properties.
[0073] In another embodiment said gap or opening (608) and edges (604, 605) of said stator (601) designed in a manner an external point (608a) and an internal point (608b) will be axially inline in order to ensure that there will be no straight opening (608) from said gap (606) and articulate the curved path (607) to ensure effective retention of processed material within the gap (606).
[0074] In an embodiment as illustrated in Figure 6b; the external point (608a) and the internal point (608b) of the gap (608) curved in order to facilitate smooth surface at the entry and exit of the flow from the path (607) to eliminate the sharp corners at the points (608a, 608b) and avoid stress concentration at the edges (604, 605) and/or said points (608a, 608b). Whereas the surface (608c) adjacent to the external point (608a) and surface (608d) adjacent to the internal point (608b) made in tangentially coaxial to form an indirect trajectory of path (607) and seal the direct rout of exit from the gap (606) to ensure the higher material retention time in the gap (606) to alleviate the refining quality.
[0075] By combining these elements—mechanical shear in the bar crossings, extended flow path (607) due to the curved geometry, and controlled exit through curved outlet openings (604)—the refiner achieves a higher refining efficiency and optimal fiber treatment for improved paper properties.
[0076] Energy efficiency is another key benefit of this structure. The design dramatically reduces power consumption, using up to 30% less electricity compared to conventional systems. This remarkable efficiency is achieved through innovative features that minimize energy losses without compromising performance. Despite the lower energy input, the system maintains excellent refining capabilities, striking an optimal balance between efficiency and effectiveness.
[0077] Moreover, the proposed embodiments allows for higher power handling, making the system capable of managing increased installed power. Such versatility makes it suitable for a wide range of refining applications, with particular effectiveness in low-consistency refining processes. This flexibility ensures that the system can meet diverse industrial needs while maintaining high performance standards.
[0078] From an operational perspective, the proposed structure offers significant cost benefits. By reducing the number of refiners needed in the system, it substantially lowers maintenance requirements and associated costs. The design's inherent durability and efficiency contribute to decreased lifecycle costs, providing long-term savings for industrial users. These factors combine to make the system a highly cost-effective solution, particularly well-suited for large-scale industrial.
[0079] The embodiment described herein, along with its various features and advantages, is explained with reference to non-limiting examples in the following descriptions. Descriptions of well-known components and processing techniques are omitted to avoid unnecessarily obscuring the embodiment; the examples provided are intended merely to illustrate ways in which the embodiments may be practiced and to further enable those skilled in the art to implement the disclosed embodiments. Accordingly, these examples should not be construed as limiting the scope of the embodiments.
[0080] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not limitation. Those skilled in the art will recognize that the embodiments can be practiced with modifications within the spirit and scope of the described embodiments.
[0081] Throughout this specification, the term “comprise” and its variations, such as “comprises” or “comprising,” imply the inclusion of a stated element, integer, step, or group of elements, integers, or steps, but do not exclude any other elements, integers, or steps.
[0082] The expressions “at least” or “at least one” suggest the inclusion of one or more elements, ingredients, or quantities, as necessary to achieve one or more of the desired objectives or results in the disclosed embodiments.
[0083] Any discussion of documents, acts, materials, devices, articles, or similar items included in this specification is solely for the purpose of providing context for the disclosure and should not be interpreted as an admission that any or all of these matters are part of the prior art or were common general knowledge in the relevant field before the priority date of this application.
[0084] While considerable emphasis has been placed on the components and parts of the preferred embodiment, it should be appreciated that many embodiments can be developed, and numerous modifications can be made to the preferred embodiments without departing from the principles of the disclosure. These and other changes, as well as other embodiments of the disclosure, will be apparent to those skilled in the art from the information provided herein. Thus, it is to be distinctly understood that the foregoing descriptive material is illustrative of the disclosure and not a limitation.
Dated this 07th day of February 2025

Shailendra Om Khojare,
IN/PA-4041
Applicants Patent Agent

, Claims:

CLAIM
We Claim:
1. A refiner system (100, 200, 300, 400, 500, 600) comprising:
a rotor (102, 202, 302, 402,502, 602) configured for rotation around an axis, driven by a motor;
a stator (101, 201, 301, 401, 501, 601) fixed in place relative to the rotor;
refining plates (107) configured to the rotor (102, 202, 302, 402,502,602) and stationary refining plates (108) on the stator (101, 201, 301, 401, 501, 601), creating a refining gap (106, 306, 606) in between.
wherein, the rotor (102, 202, 302, 402, 502, 602) comprising multiple evenly spaced inlet openings (103, 203, 303, 403,503) that facilitate the entry of feedstock into the refining gap (106, 306, 606);
wherein, the stator (101, 201, 301, 401, 501, 601) comprising outlet openings (104, 204, 304, 404, 504) that permit refined feedstock to exit after passing through the refining gap (106, 206, 606);
wherein the stator (101, 201, 301, 401, 501, 601) and rotor (102, 202, 302, 402,502,602) are securely attached via a fixing means to a main frame of the refiner, ensuring proper alignment during operation;
wherein, the outlet openings (104, 204, 304, 404, 504, 604) are configured with projections (204a, 504a) along the inner edges of the outlet openings (104, 204, 304, 404, 504, 604) to enhance shearing action during refining or formulated with the divergent angle (D) to increase the material retention time in said gap (106, 306, 606).
2. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1, wherein the fixing means comprises
a plurality of clamps that hold the rotor (102, 202, 302, 402, 502, 602) and the stator (101, 201, 301, 401, 501, 601) tightly together to resist any forces that may cause misalignment during operation;
at least a male and female sockets that provide a secure joint connection between rotor (102, 202, 302, 402, 502, 602) and stator (101, 201, 301, 401, 501, 601), allowing for easy assembly and disassembly while maintaining stability; or
a plurality of alignment pins that fit into corresponding holes in both the rotor (102, 202, 302, 402, 502, 602) and stator (101, 201, 301, 401, 501, 601) to ensure precise positioning and prevent any rotational misalignment.
3. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1, comprising the bars (314, 603a, 603b) and grooves (315) surrounding the inlet openings (103, 203, 303, 403, 503) and outlet openings (104, 204, 304, 404, 504) on both the rotor (102, 202, 302, 402, 502, 602) and stator (101, 201, 301, 401, 501, 601), respectively .
4. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1, wherein the inlet openings (103, 203, 303, 403, 503) are arranged in straight erect pattern and the outlet openings (104, 204, 304, 404, 504, 604) on stator (101, 201, 301, 401, 501, 601) are arranged with an divergent or gradually narrowing configuration, to allow sufficient material entry into said refining gap (106, 306, 606) and facilitate enhanced retention time of processing material into the refining gap (106, 306, 606).
5. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1, wherein the outlet openings (304, 404, 504) in the stator (101, 201, 301, 401, 501, 601), are designed with trapezoidal or divergent shapes gradually narrowing from a surface (301b) to surface (301a).
6. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1; wherein the outlet openings (404, 504) configured in elongated aerofoil shaped and oriented diagonally to reduce weight and improve portability.
7. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1; wherein the inlet openings (103, 203, 303) and outlet openings (104, 204, 304) are co-axially in design to align during rotor rotation, allowing for continuous and efficient flow of feedstock through the refining gap (106, 306, 606).
8. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1;wherein the shape and size of the inlet openings (103, 203, 303, 403, 503) are different from the shape and size of the outlet openings (104, 204, 304, 404, 504, ), wherein the outlet openings (104, 204, 304, 404, 504, 604) are configured to facilitate smooth discharge of refined material and prevent clogging, thereby optimizing the refining process.
9. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1; wherein said angle of divergence (D) is required to be at least 1.5°.
10. The refiner system (100, 200, 300, 400, 500, 600) as claimed in claim 1; wherein the length of divergence (LD) to position corresponding openings (104, 204, 304) at least two times the thickness (T) of said opening (104, 204, 304).
11. A method for refining feedstock using a refiner system (100, 200, 300, 400, 500, 600) comprising:
rotating a rotor (102, 202, 302, 402, 502, 602) around an axis, wherein the rotor is driven by a motor;
maintaining a stator (101, 201, 301, 401, 501, 601) in a fixed position relative to the rotor (102, 202, 302, 402, 502, 602);
introducing feedstock into a refining gap (106, 306, 606) formed between refining plates (107, 307) attached to the rotor and stationary refining plates (108, 308) attached to the stator (101, 201, 301, 401, 501, 601), wherein the feedstock enters through multiple evenly spaced inlet openings (103, 203, 303, 403, 503) on the rotor (102, 202, 302, 402, 502, 602)
refining the feedstock as it passes through the refining gap (106, 306, 606);
discharging the refined feedstock through outlet openings (104, 204, 304, 404, 504) on the stator (101, 201, 301, 401, 501, 601), wherein the outlet openings (104, 204, 304, 404, 504) are configured with projections (204a) or inclined divergently at an angle (D) along their inner edges increase retention time to enhance the refining efficacy.
12. The method for refining feedstock using refiner system (100, 200, 300, 400, 500, 600) as claim in claim 11; comprising:
introducing the feedstock into the rotor through straight inlet openings (103, 203, 303, 403, 503) that are designed to distribute the feedstock evenly across the refining plates (107, 307, 108, 308) in said refining gap (106, 306, 606) as the rotor (102, 202, 302, 402, 502, 602) spins;
the slanted or circular openings direct the feedstock towards the refining plates (107, 307, 108, 308) configured with plurality of bars (314, 603a, 603b) and the grooves (315), ensures uniform refining of fed material; and
allowing the refined material to exit through corresponding outlet openings (104, 204, 304, 404, 504) in the stator (101, 201, 301, 401, 501, 601), where slanted or trapezoidal or divergent shapes with projections (204a) or without projections (204a) facilitate smooth and efficient material discharge without clogging.
Dated this 07th day of February 2025 Shailendra Om Khojare,
IN/PA-4041
Applicants Patent Agent