Rotary kiln and product

A rotary kiln includes: a cylindrical shell that includes a supply-side end portion and a discharge-side end portion at both ends in an axial direction of the shell, and a heat treatment chamber which is defined inside the shell and in which a heat treatment is performed on a process material; a supply-side holder that holds the supply-side end portion; a discharge-side holder that holds the discharge-side end portion; a supply-side rotary shaft that allows rotation of the supply-side holder; and a discharge-side rotary shaft that allows rotation of the discharge-side holder. The shell is rotated about its own axis by rotating at least one of the supply-side rotary shaft and the discharge-side rotary shaft.

INCORPORATION BY REFERENCE

The disclosure of Japanese Patent Application No. 2009-212478 filed on Sep. 14, 2009 including the specification, drawings and abstract is incorporated herein by reference in its entirety. The disclosure of Japanese Patent Application No. 2010-127748 filed on Jun. 3, 2010 including the specification, drawings and abstract is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a rotary kiln that performs a heat treatment on a process material while transferring the process material in an axial direction, and to a product manufactured by the rotary kiln.

2. Description of the Related Art

A rotary kiln includes a shell that rotates about its own axis (see Japanese Patent Application Publication No. 2008-128492 (JP-A-2008-128492), for example).FIG. 14is a perspective view of a rotary kiln disclosed in JP-A-2008-128492. As shown inFIG. 14, a rotary kiln100includes a shell101, a heating section102, and a platform103. A pair of front and rear rollers103ais disposed on the left side of the upper surface of the platform103. Also, a pair of front and rear rollers103bis disposed on the right side of the upper surface of the platform103. A pair of left and right tires101aand101bis disposed on the outer peripheral surface of the shell101. A gear101cis disposed on the right side of the tire101b. The heating section102covers the body portion of the shell101.

The tire101ais placed on the pair of rollers103a. Also, the tire101bis placed on the pair of rollers103b. When a rotational force is applied to the gear101c, the tire101arolls on the pair of rollers103a. Also, the tire101brolls on the pair of rollers103b. This allows the shell101to rotate about its own axis.

A process material is transferred inside the rotating shell101from the right side (supply side) to the left side (discharge side). At this time, the process material is heated by heat of the heating section102. In this way, the rotary kiln100performs a heat treatment on the process material.

In the case of the rotary kiln100according to the related art, it is necessary to mount the tires101aand101bon the outer peripheral surface of the shell101in order to allow rotation of the shell101while securely supporting a rotation axis thereof. In addition, it is necessary to mount the gear101con the outer peripheral surface of the shell101in order to transmit a rotational force.

Depending on the material of the shell101, however, it may be difficult to mount these members on the outer peripheral surface of the shell101. For example, in the case where the shell101is made of a ceramic and the tires101aand101band the gear101care made of a metal, it is necessary to mount the members on the outer peripheral surface of the shell101by tightening the members on the shell101. In this case, if the tightening force is loose, the members may slip with respect to the shell101. On the contrary, if the tightening force is large, the force that compresses the shell101from the radially outer side to the radially inner side may be strong. Thus, it may be difficult to mount the tires101aand101band the gear101cdepending on the material of the shell101. Thus, the rotary kiln according to the related art has low versatility for the material of the shell.

The shell101is designed to have a diameter set in accordance with the amount of production and the characteristics of the process material. For example, in the case where the amount of production of the process material is set to be much, the shell101is designed to have a large diameter. On the contrary, in the case where the amount of production of the process material is set to be little, the shell101is designed to have a small diameter.

In the case of the rotary kiln100according to the related art, however, a change in diameter of the shell101involves a change in dimensions of the tires101aand101b, the gear101c, the rollers103aand103b, and so forth. For example, an increase in diameter of the shell101involves an increase in diameter of the tires101aand101band the gear101c. An increase in diameter of the shell101also involves an increase in interval between the pair of rollers103aand interval between the pair of rollers103b. On the contrary, a decrease in diameter of the shell101involves a decrease in diameter of the tires101aand101band the gear101c. A decrease in diameter of the shell101also involves a decrease in interval between the pair of rollers103aand interval between the pair of rollers103b. Thus, the rotary kiln100according to the related art has low versatility for the diameter of the shell101.

SUMMARY OF THE INVENTION

The rotary kiln according to the present invention has been completed in view of the aforementioned issues. It is an object of the present invention to provide a rotary kiln with high versatility for the material and the diameter of a shell. It is another object of the present invention to provide a product manufactured by the rotary kiln.

(1) In order to address the aforementioned issues, a first aspect of the present invention provides a rotary kiln including: a cylindrical shell that includes a supply-side end portion and a discharge-side end portion at both ends in an axial direction of the shell, and a heat treatment chamber which is defined inside the shell and in which a heat treatment is performed on a process material; a supply-side holder that holds the supply-side end portion; a discharge-side holder that holds the discharge-side end portion; a supply-side rotary shaft that allows rotation of the supply-side holder; and a discharge-side rotary shaft that allows rotation of the discharge-side holder, in which the shell is rotated about an axis thereof by rotating at least one of the supply-side rotary shaft and the discharge-side rotary shaft.

According to the rotary kiln of the present invention, the supply-side rotary shaft and the discharge-side rotary shaft allow rotation of the shell while securely supporting a rotation axis thereof. A rotational force is transmitted to the shell from at least one of the supply-side rotary shaft and the discharge-side rotary shaft. Therefore, it is not necessary to dispose a member that allows rotation of the shell while securely supporting the rotation axis thereof (for example, the tires101a,101binFIG. 14) or a member that transmits a rotational force (for example, the gear101cinFIG. 14) on the outer peripheral surface of the shell. Thus, the shell can be rotated with the rotation axis thereof being securely supported regardless of the material of the shell. In addition, a rotational force can be transmitted to the shell regardless of the material of the shell. Thus, the rotary kiln according to the present invention provides high versatility for the material of the shell.

Also, according to the rotary kiln of the present invention, it is only necessary to change the supply-side holder and the discharge-side holder in order to change the diameter of the shell. That is, it is not necessary to change the supply-side rotary shaft and the discharge-side rotary shaft. Therefore, the rotary kiln according to the present invention provides high versatility for the diameter of the shell.

(2) According to a second aspect of the present invention, in the aforementioned configuration (1), it is preferable that the supply-side holder and the discharge-side holder are attached to the shell so as to be removable in the axial direction. According to this configuration, the shell can be removed from the supply-side holder and the discharge-side holder. This is convenient for inspection, repair, replacement, and so forth of the shell.

(3) According to a third aspect of the present invention, in the aforementioned configuration (2), it is preferable that the rotary kiln further includes: a supply-side support cart that includes the supply-side holder, the supply-side rotary shaft, and a bearing portion which rotatably supports the supply-side rotary shaft, and that is movable in the axial direction; and a discharge-side support cart that includes the discharge-side holder, the discharge-side rotary shaft, and a bearing portion which rotatably supports the discharge-side rotary shaft, and that is movable in the axial direction.

According to this configuration, the supply-side holder and the supply-side rotary shaft are disposed on the supply-side support cart. Also, the discharge-side holder and the discharge-side rotary shaft are disposed on the discharge-side support cart. Therefore, the supply-side holder and the discharge-side holder are easily movable. That is, the supply-side holder and the discharge-side holder can be easily attached to and removed from the shell.

(4) According to a fourth aspect of the present invention, in the aforementioned configuration (3), it is preferable that the supply-side rotary shaft is inserted into the shell from the supply-side end portion, and the rotary kiln further includes a supply part cart that includes a supply section inserted into the supply-side rotary shaft to supply the process material into the heat treatment chamber, and that is movable in the axial direction.

According to this configuration, the process material can be easily supplied into the shell. Moreover, the starting point of the heat treatment chamber can be located in the vicinity of the supply-side end portion. That is, the overall length of the heat treatment chamber in the axial direction can be set to be long. Also, according to this configuration, the supply section is disposed on the supply part cart. Therefore, the supply section is easily movable. That is, the supply section can be easily inserted into and taken out of the supply-side rotary shaft. This is convenient for inspection, repair, replacement, and so forth of the supply section.

(5) According to a fifth aspect of the present invention, in any one of the aforementioned configurations (2) to (4), it is preferable that the rotary kiln further includes a heating section that includes a heating chamber which is defined inside the heating section and through which the shell penetrates, and that is dividable along the shell.

This configuration provides a so-called externally heated rotary kiln. According to this configuration, a portion of the shell that is housed in the heating section can be exposed easily. This is convenient for inspection, repair, replacement, and so forth of the shell. This also allows access to the shell from a radial direction during replacement of the shell. This facilitates replacement work.

(5-1) In the aforementioned configuration (5), it is preferable that the heating section includes a lower divided portion and an upper divided portion that can be opened and closed to the lower divided portion, and a lower half portion and an upper half portion of the shell are respectively housed in the lower divided portion and the upper divided portion.

According to this configuration, the upper half portion of the shell is exposed by opening the upper divided portion. This is convenient for inspection, repair, replacement, and so forth of the shell. This also allows access to the shell from above during replacement of the shell. This facilitates replacement work.

(6) According to a sixth aspect of the present invention, in any one of the aforementioned configurations (1) to (5), it is preferable that the shell includes a supply-side heat insulation portion disposed radially inward of the supply-side end portion and a discharge-side heat insulation portion disposed radially inward of the discharge-side end portion.

According to this configuration, heat of the heat treatment chamber is not easily transmitted to the supply-side rotary shaft and the discharge-side rotary shaft. Therefore, a failure due to heat is not likely to occur in the supply-side rotary shaft and the discharge-side rotary shaft. Also, since heat is not easily transmitted to the supply-side rotary shaft and the discharge-side rotary shaft, the overall length of the heat treatment chamber in the axial direction can be set to be long.

(7) According to a seventh aspect of the present invention, in any one of the aforementioned configurations (1) to (6), it is preferable that the rotary kiln further includes a cooling section disposed inside the discharge-side rotary shaft to cool the discharge-side rotary shaft.

According to this configuration, the discharge-side rotary shaft can be cooled. Therefore, a failure due to heat is not likely to occur in the discharge-side rotary shaft. Also, since the temperature of the discharge-side rotary shaft is not likely to rise, the overall length of the heat treatment chamber in the axial direction can be set to be long.

(8) According to an eighth aspect of the present invention, in any one of the aforementioned configurations (1) to (7), it is preferable that the rotary kiln further includes a common drive section that transmits a drive force to the supply-side rotary shaft and the discharge-side rotary shaft.

According to this configuration, the number of parts is reduced compared to a case where a drive section exclusively for the supply-side rotary shaft and a drive section exclusively for the discharge-side rotary shaft are provided separately. Also, the drive section requires only a small installation space. Moreover, according to this configuration, it is easier to match the rotational speed of the supply-side rotary shaft and the rotational speed of the discharge-side rotary shaft with each other.

(9) According to a ninth aspect of the present invention, in any one of the aforementioned configurations (1) to (8), it is preferable that of a set of the supply-side holder and the supply-side end portion and a set of the discharge-side holder and the discharge-side end portion, one set of the holder and the end portion is coupled to each other so as not to be rotatable relative to each other, and the other set of the holder and the end portion is coupled so as to be rotatable relative to each other. According to this configuration, a torsional force is not likely to be applied to the shell even in the case where the rotational speed of the supply-side rotary shaft and the rotational speed of the discharge-side rotary shaft are different from each other.

(10) According to a tenth aspect of the present invention, in any one of the aforementioned configurations (1) to (9), it is preferable that the rotary kiln further includes a gas supply section that supplies an ambient gas to a space radially inward of the shell and a space radially outward of the shell.

According to this configuration, an ambient gas can be supplied in accordance with the characteristics of the process material and the material of the shell. In particular, combining this configuration and any one of the aforementioned configurations (2) to (5) facilitates replacement of the shell, so that the kind of the ambient gas can be changed in accordance with a change of the shell. In this way, this configuration allows the common use of the rotary kiln for a plurality of types of process materials and shells.

(11) According to an eleventh aspect of the present invention, in any one of the aforementioned configurations (1) to (10), it is preferable that the shell is made of carbon, and a battery material is manufactured by performing a heat treatment on the process material.

According to this configuration, the shell is made of carbon. Therefore, contamination of metal scale, which adversely affects the battery material, into the battery material can be suppressed. Thus, degradation in performance of the battery material can be suppressed. Also, the shell made of carbon provides excellent processability. Moreover, the shell made of carbon provides excellent heat shock resistance.

(12) In order to address the aforementioned issues, a twelfth aspect of the present invention provides a product manufactured by performing a heat treatment on the process material in the rotary kiln according to any one of the aforementioned configurations (1) to (10).

The product according to the present invention is manufactured by the rotary kiln according to the present invention. The rotary kiln according to the present invention provides high versatility for the material of the shell. Therefore, the material of the shell can be selected in accordance with the type of the product. Thus, it is possible to manufacture a desired product without using the shell which contains a component, contamination of which into the product is not preferable. For example, in the case where the product is a battery material, contamination of metal scale into the battery material is not preferable. In this case, contamination of metal scale into the battery material can be suppressed by using a shell made of a non-metallic material (for example, made of carbon).

According to the present invention, it is possible to provide a rotary kiln with high versatility for the material and the diameter of a shell. It is also possible to provide a product manufactured by the rotary kiln.

DETAILED DESCRIPTION OF THE EMBODIMENTS

A rotary kiln and a product according to an embodiment of the present invention will be described below.

First, the configuration of the rotary kiln according to the embodiment is described. In the drawings, the left side corresponds to the supply side (upstream side), and the right side corresponds to the discharge side (downstream side). For convenience of description, three fins56of a shell5are not shown in drawings other thanFIG. 10.FIG. 1is a perspective view of the rotary kiln according to the embodiment.FIG. 2is a transparent front view of the rotary kiln.

As shown inFIGS. 1 and 2, a rotary kiln1according to the embodiment includes a supply part cart2, a supply-side support cart3, a discharge-side support cart4, the shell5, a discharge chute6, a supply-side coupling tubular portion7, a heating section8, a platform90, and a drive section91.

The platform90has the shape of a plate. The platform90is placed on a site of a plant. The platform90includes a supply-side track portion900, a discharge-side track portion901, and a product extraction hole902. As shown inFIG. 2, the product extraction hole902is drilled in the platform90. The supply-side track portion900includes a pair of rails900a. The rails900aare made of steel, and extend in the left-right direction. Stoppers900bare respectively disposed at both ends of the rails900ain the left-right direction. The discharge-side track portion901includes a pair of rails901a. The rails901aare made of steel, and extend in the left-right direction. Stoppers901bare respectively disposed at both ends of the rails901ain the left-right direction.

As shown inFIG. 1, the drive section91includes a motor910, a shaft911, a supply-side drive sprocket912, and a discharge-side drive sprocket913. The motor910is disposed on the upper surface of the platform90. The shaft911is coupled to a rotary shaft of the motor910. The supply-side drive sprocket912is fixed at the left end of the shaft911. The discharge-side drive sprocket913is fixed at the right end of the shaft911.

FIG. 3is an exploded perspective view of a left portion of the rotary kiln according to the embodiment.FIG. 4is a cross-sectional view of the left portion taken in the left-right direction. As shown inFIGS. 3 and 4, the supply part cart2includes a lower stage portion20, four wheels21, four coupling pillars22, a middle stage portion23, four coupling rods24, an upper stage portion25, a pair of bearing portions26, a screw feeder27, a sealing portion28, and a supply hopper29. The screw feeder27is included in the supply section according to the present invention. The sealing portion28is included in the gas supply section according to the present invention.

The lower stage portion20is made of steel, and has the shape of a rectangular plate. A coupling plate200is disposed at the right end of the lower stage portion20. The four wheels21are disposed in the vicinity of the four corners of the lower stage portion20. The four wheels21can roll in the left-right direction on the pair of rails900a. That is, the supply part cart2is movable in the left-right direction along the pair of rails900a.

The middle stage portion23is made of steel, and has the shape of a rectangular plate. The middle stage portion23is disposed above the lower stage portion20. Each of the four coupling pillars22has the shape of a rectangular column. The four coupling pillars22are interposed between the lower stage portion20and the middle stage portion23.

The upper stage portion25is made of steel, and has the shape of a rectangular plate. The upper stage portion25is disposed above the middle stage portion23. Each of the four coupling rods24has the shape of a round bar. The four coupling rods24are interposed between the middle stage portion23and the upper stage portion25.

The pair of bearing portions26is disposed on the upper surface of the upper stage portion25. The pair of bearing portions26is arranged in the left-right direction at a predetermined interval between each other. The supply hopper29is made of steel, and has the shape of a cone tapered downward. The supply hopper29is disposed on the upper surface of the upper stage portion25. The supply hopper29is disposed on the right side of the pair of bearing portions26. A process material A is stored in the supply hopper29.

The screw feeder27includes a screw-housing cylindrical portion270and a screw271. The screw-housing cylindrical portion270is made of steel, and has the shape of a cylinder. The screw-housing cylindrical portion270is projected rightward from the lower end of the supply hopper29. The screw271is housed in the screw-housing cylindrical portion270. The screw271is driven by a drive force of a motor (not shown) to rotate about its own axis. A shaft portion271aof the screw271penetrates through the left wall of the supply hopper29. The penetrating end of the shaft portion271ais supported by the pair of bearing portions26so as to be rotatable about its own axis.

The sealing portion28is interposed between the left wall of the supply hopper29and the shaft portion271aof the screw271. The sealing portion28seals a gap between the left wall of the supply hopper29and the shaft portion271awhile permitting turning of the shaft portion271a. The configuration of the sealing portion28is the same as the configuration of a sealing portion35of the supply-side support cart3to be discussed later (seeFIG. 5). A nitrogen gas is supplied from the sealing portion28as indicated by an arrow Y1. The nitrogen gas is included in the ambient gas according to the present invention. The nitrogen gas is diffused inside the supply hopper29and inside the screw-housing cylindrical portion270.

The supply-side support cart3includes a lower stage portion30, four wheels31, an upper stage portion32, four coupling rods33, a pair of bearing portions34, the sealing portion35, a coupling plate36, a supply-side rotary shaft37, a supply-side holder38, a supply-side gear390, a supply-side pinion391, and a supply-side sprocket392. The sealing portion35is included in the gas supply section according to the present invention.

The lower stage portion30is made of steel, and has the shape of a rectangular plate. A coupling plate300is disposed at the left end of the lower stage portion30. The coupling plate300can be coupled to the coupling plate200via a bolt-nut mechanism. That is, the supply-side support cart3and the supply part cart2can be coupled to each other. The four wheels31are disposed in the vicinity of the four corners of the lower stage portion30. The four wheels31can roll in the left-right direction on the pair of rails900a. That is, the supply-side support cart3is movable in the left-right direction along the pair of rails900a.

The upper stage portion32is made of steel, and has the shape of a rectangular plate. The upper stage portion32is disposed above the lower stage portion30. Each of the four coupling rods33has the shape of a round bar. The four coupling rods33are interposed between the lower stage portion30and the upper stage portion32.

The pair of bearing portions34is disposed on the upper surface of the upper stage portion32. The pair of bearing portions34is arranged in the left-right direction at a predetermined interval between each other. The coupling plate36is made of steel, and has the shape of a rectangular plate. The coupling plate36is disposed at the right end of the upper stage portion32. A supply-side rotary shaft insertion hole360is drilled in the coupling plate36. The supply-side rotary shaft37is made of steel, and has the shape of a cylinder. The supply-side rotary shaft37is supported by the pair of bearing portions34so as to be rotatable about its own axis. The right end of the supply-side rotary shaft37is inserted into the supply-side rotary shaft insertion hole360.

FIG. 5is an enlarged view of a portion inside a circle V ofFIG. 4. As shown inFIG. 5, the sealing portion35is interposed between the supply-side rotary shaft37and the supply-side rotary shaft insertion hole360. The sealing portion35includes an inner annular portion350, an outer annular portion351, and a gas pipe352. The outer annular portion351is made of SUS (Stainless Used Steel)304, and has the shape of a bottomed cylinder (cup) opening leftward. The supply-side rotary shaft37is inserted through the right bottom wall of the outer annular portion351. The side peripheral wall of the outer annular portion351is fixed to the inner peripheral surface of the supply-side rotary shaft insertion hole360. The inner annular portion350is made of SUS304, and has the shape of a ring. The inner annular portion350seals the left opening of the outer annular portion351. The inner annular portion350is fixed to the outer annular portion351. The gas pipe352penetrates through the side peripheral wall of the outer annular portion351. A nitrogen gas is supplied from the gas pipe352to a space radially inward of the outer annular portion351as indicated by an arrow Y2. The nitrogen gas is diffused inside the supply-side coupling tubular portion7to be discussed later as indicated by an arrow Y3.

Returning toFIGS. 3 and 4, the supply-side holder38is made of steel, and has the shape of a bottomed cylinder (cup) opening rightward. The supply-side holder38is disposed on the right side of the coupling plate36. The supply-side rotary shaft37penetrates through the radially inner side of the supply-side holder38. The supply-side holder38is fixed to the outer peripheral surface at the right end of the supply-side rotary shaft37.

The supply-side gear390is made of steel, and has the shape of a circular plate. The supply-side gear390is fixed to the outer peripheral surface of the supply-side rotary shaft37. The supply-side gear390is disposed between the pair of bearing portions34. The supply-side pinion391is made of steel, and has the shape of a circular plate. The supply-side pinion391is meshed with the supply-side gear390. The supply-side sprocket392is made of steel, and has the shape of a circular plate. The supply-side sprocket392and the supply-side pinion391are fixed to an identical shaft. As indicated by dash-dotted lines inFIG. 1, a chain914is wound between the supply-side sprocket392and the supply-side drive sprocket912.

FIG. 6is an exploded perspective view of a right portion of the rotary kiln according to the embodiment.FIG. 7is a cross-sectional view of the right portion taken in the left-right direction. As shown inFIGS. 6 and 7, the discharge-side support cart4includes a lower stage portion40, four wheels41, an upper stage portion42, four coupling rods43, a pair of bearing portions44, a sealing portion45, a coupling plate46, a discharge-side rotary shaft47, a discharge-side holder48, a discharge-side gear490, a discharge-side pinion491, a discharge-side sprocket492, and a cooling pipe493. The sealing portion45is included in the gas supply section according to the present invention. The cooling pipe493is included in the cooling section according to the present invention.

The lower stage portion40is made of steel, and has the shape of a rectangular plate. The four wheels41are disposed in the vicinity of the four corners of the lower stage portion40. The four wheels41can roll in the left-right direction on the pair of rails901a. That is, the discharge-side support cart4is movable in the left-right direction along the pair of rails901a.

The upper stage portion42is made of steel, and has the shape of a rectangular plate. The upper stage portion42is disposed above the lower stage portion40. Each of the four coupling rods43has the shape of a round bar. The four coupling rods43are interposed between the lower stage portion40and the upper stage portion42.

The pair of bearing portions44is disposed on the upper surface of the upper stage portion42. The pair of bearing portions44is arranged in the left-right direction at a predetermined interval between each other. The coupling plate46is made of steel, and has the shape of a rectangular plate. The coupling plate46is disposed at the left end of the upper stage portion42. A discharge-side rotary shaft insertion hole460is drilled in the coupling plate46. The discharge-side rotary shaft47is made of steel, and has the shape of a cylinder. The discharge-side rotary shaft47is supported by the pair of bearing portions44so as to be rotatable about its own axis. The left end of the discharge-side rotary shaft47is inserted into the discharge-side rotary shaft insertion hole460.

The sealing portion45is interposed between the discharge-side rotary shaft47and the discharge-side rotary shaft insertion hole460. The configuration of the sealing portion45is the same as the configuration of the sealing portion35of the supply-side support cart3discussed earlier (seeFIG. 5). A nitrogen gas is supplied from the sealing portion45as indicated by an arrow Y4. The nitrogen gas is diffused inside the discharge chute6to be discussed later.

The discharge-side holder48is made of steel, and has the shape of a bottomed cylinder (cup) opening leftward. The discharge-side holder48is disposed on the left side of the coupling plate46. The discharge-side holder48is fixed to the left end of the discharge-side rotary shaft47.

The discharge-side gear490is made of steel, and has the shape of a circular plate. The discharge-side gear490is fixed to the outer peripheral surface of the discharge-side rotary shaft47. The discharge-side gear490is disposed between the pair of bearing portions44. The discharge-side pinion491is made of steel, and has the shape of a circular plate. The discharge-side pinion491is meshed with the discharge-side gear490. A thickness T1of the discharge-side gear490is larger than a thickness T2of the discharge-side pinion491. Therefore, the discharge-side pinion491and the discharge-side gear490can be meshed with each other even if the discharge-side gear490is displaced with respect to the discharge-side pinion491in the left-right direction. The discharge-side sprocket492is made of steel, and has the shape of a circular plate. The discharge-side sprocket492and the discharge-side pinion491are fixed to an identical shaft. As indicated by dash-dotted lines inFIG. 1, a chain915is wound between the discharge-side sprocket492and the discharge-side drive sprocket913.

FIG. 8is an enlarged view of a portion inside a circle VIII ofFIG. 7. The cooling pipe493is shown in cross section. As shown inFIG. 8, the cooling pipe493has the shape of a double cylinder, the left end of which is sealed. That is, the cooling pipe493includes an inner cylindrical portion493aand an outer cylindrical portion493b. Cooling water W is supplied from a water supply pipe494to the inner cylindrical portion493aas indicated by an arrow Y5inFIG. 7. The cooling water W flows leftward through a space radially inward of the inner cylindrical portion493a, and turns backward at the left end of the cooling pipe493. The cooling water W which has turned backward flows from the inner cylindrical portion493ainto the outer cylindrical portion493b. The cooling water W having flowed into the outer cylindrical portion493bflows rightward through a gap between the outer cylindrical portion493band the inner cylindrical portion493a, and is discharged from a water discharge pipe495to the outside as indicated by an arrow Y6inFIG. 7. The discharge-side rotary shaft47, the pair of bearing portions44, the discharge-side gear490, the sealing portion45, and so forth can be cooled by the cooling water W.

FIG. 9is a perspective view of a center portion of the rotary kiln according to the embodiment.FIG. 9shows an open state. As shown inFIG. 9, the heating section8includes a lower divided portion80D and an upper divided portion80U.

The lower divided portion80D includes an outer shell800D and a heat insulation material801D. The outer shell800D is made of steel, and has the shape of a rectangular box opening upward. The outer shell800D is fixed to the upper surface of the platform90via a pair of support blocks81. The heat insulation material801D is made of a ceramic fiber or a heat insulation brick with a predetermined thickness, and is fixed to the inner surface of the outer shell800D.

The upper divided portion80U includes an outer shell800U and a heat insulation material801U. The configuration of the upper divided portion80U is the same as the configuration of the lower divided portion80D. The upper divided portion80U and the lower divided portion80D are coupled to each other via a hinge portion (not shown). The upper divided portion80U can be opened and closed to the lower divided portion80D. As shown inFIG. 9, in the open state, the upper divided portion80U is disposed in rear of the lower divided portion80D such that they are arranged side by side. Meanwhile, as shown inFIGS. 4 and 7, in a closed state, the upper divided portion80U is disposed oppositely above the lower divided portion80D. In the closed state, a heating chamber82is defined by the heat insulation materials801D and801U. A heater (not shown) is disposed in the heating chamber82. Also, in the closed state, as shown inFIGS. 4 and 9, a supply-side shell insertion hole83is formed between an outer left portion of the heating section8and the heating chamber82. In addition, as shown inFIGS. 7 and 9, a discharge-side shell insertion hole84is formed between an outer right portion of the heating section8and the heating chamber82.

The shell5is made of carbon, and has the shape of a cylinder. The shell5penetrates through the heating section8in the left-right direction. That is, the left end of the shell5projects from the supply-side shell insertion hole83to the outside. Also, the right end of the shell5projects from the discharge-side shell insertion hole84to the outside. The body portion of the shell5is housed in the heating chamber82. The shell5is slightly inclined downward from the left to the right.

FIG. 10is a transparent exploded perspective view of the shell of the rotary kiln according to the embodiment. As shown inFIG. 10, the shell5includes a supply-side partition wall50, a discharge-side partition wall51, a heat treatment chamber52, three discharge holes53, five supply-side heat insulation plates54, nine discharge-side heat insulation plates55, the three fins56, a supply-side end portion57, and a discharge-side end portion58. The supply-side heat insulation plates54are included in the supply-side heat insulation portion according to the present invention. The discharge-side heat insulation plates55are included in the discharge-side heat insulation portion according to the present invention.

The supply-side partition wall50has the shape of a circular plate. The supply-side partition wall50is disposed in the vicinity of the left end of the shell5. A supply-side rotary shaft insertion hole500is drilled in the supply-side partition wall50. The discharge-side partition wall51has the shape of a circular plate. The discharge-side partition wall51is disposed in the vicinity of the right end of the shell5. The supply-side end portion57is disposed on the left side of the supply-side partition wall50. The discharge-side end portion58is disposed on the right side of the discharge-side partition wall51.

The heat treatment chamber52is defined between the supply-side partition wall50and the discharge-side partition wall51. As shown inFIGS. 4 and 7, the heat treatment chamber52is disposed radially inward of the heating chamber82. Returning toFIG. 10, the discharge holes53are disposed on the left side of the discharge-side partition wall51. The discharge holes53are in communication with the heat treatment chamber52. The three discharge holes53are disposed at intervals of 120° in the circumferential direction of the shell5.

The supply-side heat insulation plates54are made of a ceramic fiber or a ceramic board, and have the shape of a circular plate. A supply-side rotary shaft insertion hole540is drilled in each of the supply-side heat insulation plates54. The five supply-side heat insulation plates54are disposed in a stacked state on the left side of the supply-side partition wall50. That is, the five supply-side heat insulation plates54are housed inside the supply-side end portion57. The discharge-side heat insulation plates55are made of a ceramic fiber or a ceramic board, and have the shape of a circular plate. The nine discharge-side heat insulation plates55are disposed in a stacked state on the right side of the discharge-side partition wall51. That is, the nine discharge-side heat insulation plates55are housed inside the discharge-side end portion58.

The fins56have the shape of a rib. The fins56are disposed on the inner peripheral surface of the shell5. The fins56are disposed between the supply-side partition wall50and the three discharge holes53. The three fins56are disposed at intervals of 120° in the circumferential direction of the shell5.

As shown inFIG. 4, the left end of the shell5is housed in the supply-side holder38. The supply-side end portion57of the shell5and the supply-side holder38are bolted to each other. The supply-side rotary shaft37penetrates through the supply-side rotary shaft insertion holes540and500of the shell5from the left side. That is, the supply-side rotary shaft37penetrates through the supply-side end portion57from the left side. The opening at the penetrating end of the supply-side rotary shaft37is in communication with the heat treatment chamber52.

As shown inFIG. 7, the right end of the shell5is housed in the discharge-side holder48. The shell5and the discharge-side holder48are not fixed to each other. Therefore, the shell5is movable with respect to the discharge-side holder48in the left-right direction and in the circumferential direction.

As shown inFIG. 9, the supply-side coupling tubular portion7includes a lower divided portion70D and an upper divided portion70U. The lower divided portion70D is made of steel, and has the shape of a semi-rectangular cylinder opening upward. The lower divided portion70D is disposed at the left end of the lower divided portion80D of the heating section8. A flange divided portion700D is disposed at the left end of the lower divided portion70D.

The upper divided portion70U is made of steel, and has the shape of a semi-rectangular cylinder opening upward in an open state. The upper divided portion70U is disposed at the left end of the upper divided portion80U of the heating section8. A flange divided portion700U is disposed at the left end of the upper divided portion70U. A gas pipe701U is projected from the bottom wall of the upper divided portion70U in the open state. The gas pipe701U is included in the gas supply section according to the present invention.

The upper divided portion70U can be opened and closed to the lower divided portion70D. As shown inFIG. 9, in the open state, the upper divided portion70U is disposed in rear of the lower divided portion70D such that they are arranged side by side. Meanwhile, as shown inFIG. 4, in a closed state, the upper divided portion70U is disposed oppositely above the lower divided portion70D. In the closed state, the flange divided portions700D and700U are joined together to form a supply-side holder insertion hole71. The flange divided portions700D and700U are coupled to the coupling plate36of the supply-side support cart3via a bolt-nut mechanism. In the closed state, the left end of the shell5is housed inside the supply-side coupling tubular portion7. A nitrogen gas is supplied from the gas pipe701U into the supply-side coupling tubular portion7as indicated by an arrow Y7. The nitrogen gas is diffused inside the heating chamber82via the supply-side shell insertion hole83.

As shown inFIG. 9, the discharge chute6includes a lower divided portion60D and an upper divided portion60U. The lower divided portion60D is made of steel, and has the shape of a pyramid tapered downward. The lower divided portion60D is disposed at the right end of the lower divided portion80D of the heating section8. A flange divided portion600D is disposed at the right end of the lower divided portion60D. As shown inFIG. 7, the lower end of the lower divided portion60D is housed in the product extraction hole902. A protection plate601D made of carbon is disposed on the inner surface of the tapered portion of the lower divided portion60D.

Returning toFIG. 9, the upper divided portion60U is made of steel, and has the shape of a semi-rectangular cylinder opening upward in an open state. The upper divided portion60U is disposed at the right end of the upper divided portion80U of the heating section8. A flange divided portion600U is disposed at the right end of the upper divided portion60U.

The upper divided portion60U can be opened and closed to the lower divided portion60D. As shown inFIG. 9, in the open state, the upper divided portion60U is disposed in rear of the lower divided portion60D such that they are arranged side by side. Meanwhile, as shown inFIG. 7, in a closed state, the upper divided portion60U is disposed oppositely above the lower divided portion60D. In the closed state, the flange divided portions600D and600U are joined together to form a discharge-side holder insertion hole61. The flange divided portions600D and600U are coupled to the coupling plate46of the discharge-side support cart4via a bolt-nut mechanism. In the closed state, the right end of the shell5is housed inside the discharge chute6.

<Motion During Manufacture of Battery Material>

Next, the motion of the rotary kiln according to the embodiment during manufacture of a battery material will be described. The battery material is included in the “product” according to the present invention. First, as shown inFIG. 1, the motor910is driven. The drive force of the motor910is transmitted to the supply-side gear390via the shaft911, the supply-side drive sprocket912, the chain914, the supply-side sprocket392, and the supply-side pinion391in this order. In addition, the drive force of the motor910is transmitted to the discharge-side gear490via the shaft911, the discharge-side drive sprocket913, the chain915, the discharge-side sprocket492, and the discharge-side pinion491in this order. As shown inFIG. 2, the supply-side gear390is fixed to the supply-side rotary shaft37. The supply-side holder38is fixed to the supply-side rotary shaft37. The left end of the shell5is fixed to the supply-side holder38. Therefore, rotation of the supply-side gear390causes the shell5to rotate. Also, as shown inFIG. 2, the discharge-side gear490is fixed to the discharge-side rotary shaft47. The discharge-side holder48is fixed to the discharge-side rotary shaft47. Therefore, rotation of the discharge-side gear490causes the discharge-side holder48to rotate. In this way, the supply-side gear390causes the shell5to rotate about its own axis, and the discharge-side gear490causes the discharge-side holder48to rotate about its own axis.

Then, as shown inFIG. 4, the screw feeder27is driven. Then, the process material A is transferred from the supply hopper29to the heat treatment chamber52. Subsequently, as shown inFIG. 10, the process material A is moved rightward with the three fins56stirring the process material A inside the rotating shell5. The heat treatment chamber52is heated in a predetermined temperature pattern by the heating chamber82. Therefore, a predetermined heat treatment can be performed on the process material A by causing the process material A to pass through the heat treatment chamber52.

After that, as shown inFIG. 7, a battery material B which is obtained after the heat treatment is ejected from the discharge holes53of the rotating shell5. The ejected battery material B slides down inside the discharge chute6while colliding against the protection plate601D. The battery material B which has slid down is stored in a product housing portion (not shown) disposed below the discharge chute6. In this way, the battery material B is manufactured by performing a heat treatment on the process material A.

During manufacture of the battery material B, as shown inFIG. 4, a nitrogen gas is supplied from the sealing portion28(arrow Y1) to a space radially inward of the shell5. Also, a nitrogen gas is supplied from the sealing portion35(arrow Y2) to a space radially outward of the shell5. Also, a nitrogen gas is supplied from the gas pipe701U (arrow Y7) to a space radially outward of the shell5. Moreover, as shown inFIG. 7, a nitrogen gas is supplied from the sealing portion45(arrow Y4) to a space radially outward of the shell5. Thus, a nitrogen gas is supplied to a space radially inward of the shell5and a space radially outward of the shell5during manufacture of the battery material B. Moreover, as shown inFIG. 8, the discharge-side rotary shaft47is cooled by the cooling pipe493during manufacture of the battery material B.

<Motion During Replacement of Shell>

Next, the motion of the rotary kiln according to the embodiment during replacement of the shell will be described.FIG. 11is a transparent front view of the left portion of the rotary kiln according to the embodiment during replacement of the shell.FIG. 12is a transparent front view of the right portion of the rotary kiln according to the embodiment during replacement of the shell.

First, as shown inFIG. 4, the nuts are removed from the bolts to decouple the coupling plate36of the supply-side support cart3and the flange divided portions700U and700D. Also, as shown inFIG. 7, the nuts are removed from the bolts to decouple the coupling plate46of the discharge-side support cart4and the flange divided portions600U and600D. Moreover, as shown inFIG. 11, the bolts are removed to decouple the supply-side end portion57of the shell5and the supply-side holder38.

Then, the supply part cart2and the supply-side support cart3are moved leftward along the pair of rails900a. Then, the supply-side rotary shaft37and the supply-side holder38are taken out of the supply-side coupling tubular portion7. In addition, the discharge-side support cart4is moved rightward along the pair of rails901a. Then, the discharge-side rotary shaft47and the discharge-side holder48are taken out of the discharge chute6.

Subsequently, as shown inFIG. 9, the supply-side coupling tubular portion7, the heating section8, and the discharge chute6are brought from the closed state into the open state. Bringing the supply-side coupling tubular portion7, the heating section8, and the discharge chute6into the open state exposes the shell5. After that, the shell5is removed by a jack, a winch, a crane, or the like.

Thereafter, a new shell5is mounted on the heating section8, the supply-side coupling tubular portion7, the heating section8, and the discharge chute6are brought from the open state into the closed state, and the supply part cart2, the supply-side support cart3, and the discharge-side support cart4are brought back in position. Then, the bolts and the nuts are tightened. The shell5is thus replaced.

<Motion During Replacement of Screw Feeder>

Next, the motion of the rotary kiln according to the embodiment during replacement of the screw feeder will be described.FIG. 13is a transparent front view of the left portion of the rotary kiln according to the embodiment during replacement of the screw feeder.

First, as shown inFIG. 4, the nut is removed from the bolt to decouple the coupling plate200of the supply part cart2and the coupling plate300of the supply-side support cart3. Then, the supply part cart2is moved leftward along the pair of rails900a. Then, the screw feeder27is taken out of the supply-side rotary shaft37. Subsequently, the screw feeder27is removed. Thereafter, a new screw feeder27is mounted on the supply part cart2, and the supply part cart2is brought back in position. Then, the bolts and the nuts are tightened. The screw feeder27is thus replaced.

Next, the function and effect of the rotary kiln and the product according to the embodiment will be described. According to the rotary kiln1of the embodiment, the supply-side rotary shaft37and the discharge-side rotary shaft47allow rotation of the shell5while securely supporting the rotation axis thereof. Also, a rotational force is transmitted to the shell5from the supply-side rotary shaft37. Therefore, it is not necessary to dispose a member that allows rotation of the shell5while securely supporting the rotation axis thereof (for example, the tires101a,101binFIG. 14) or a member that transmits a rotational force (for example, the gear101cinFIG. 14) on the outer peripheral surface of the shell. Thus, the shell5can be rotated with the rotation axis thereof being securely supported regardless of the material of the shell5. In addition, a rotational force can be transmitted to the shell5regardless of the material of the shell5. Thus, the rotary kiln1according to the embodiment provides high versatility for the material of the shell5.

Also, according to the rotary kiln1of the embodiment, it is only necessary to change the supply-side holder38and the discharge-side holder48in order to change the diameter of the shell5. That is, it is not necessary to change the supply-side rotary shaft37and the discharge-side rotary shaft47. Therefore, the rotary kiln1according to the embodiment provides high versatility for the diameter of the shell5.

According to the rotary kiln1of the embodiment, the supply-side holder38and the discharge-side holder48are attached to the shell5so as to be removable in the left-right direction. That is, the shell5can be removed from the supply-side holder38and the discharge-side holder48. This is convenient for inspection, repair, replacement, and so forth of the shell5.

According to the rotary kiln1of the embodiment, the supply-side holder38and the supply-side rotary shaft37are disposed on the supply-side support cart3. Also, the discharge-side holder48and the discharge-side rotary shaft47are disposed on the discharge-side support cart4. Therefore, the supply-side holder38and the discharge-side holder48are easily movable. That is, the supply-side holder38and the discharge-side holder48can be easily attached to and removed from the shell5.

According to the rotary kiln1of the embodiment, the process material A can be easily supplied into the shell5. Moreover, the left end of the heat treatment chamber52can be located in the vicinity of the supply-side end portion57. That is, the overall length of the heat treatment chamber52in the left-right direction can be set to be long.

According to the rotary kiln1of the embodiment, the screw feeder27is disposed on the supply part cart2. Therefore, the screw feeder27is easily movable. That is, the screw feeder27can be easily inserted into and taken out of the supply-side rotary shaft37. This is convenient for inspection, repair, replacement, and so forth of the screw feeder27.

According to the rotary kiln1of the embodiment, the supply-side coupling tubular portion7, the heating section8, and the discharge chute6can be switched between the closed state and the open state. Therefore, a portion of the shell5that is housed in the supply-side coupling tubular portion7, the heating section8, and the discharge chute6can be exposed easily. This is convenient for inspection, repair, replacement, and so forth of the shell5. This also allows access to the shell5from above during replacement of the shell5. This facilitates replacement work.

According to the rotary kiln1of the embodiment, the supply-side heat insulation plates54are disposed radially inward of the supply-side end portion57. Also, the discharge-side heat insulation plates55are disposed radially inward of the discharge-side end portion58. Therefore, a failure due to heat is not likely to occur in the supply-side rotary shaft37and the discharge-side rotary shaft47. Also, since heat is not easily transmitted to the supply-side rotary shaft37and the discharge-side rotary shaft47, the overall length of the heat treatment chamber52in the left-right direction can be set to be long.

According to the rotary kiln1of the embodiment, the cooling pipe493is disposed inside the discharge-side rotary shaft47. Therefore, the discharge-side rotary shaft47, the pair of bearing portions44, the discharge-side gear490, the sealing portion45, and so forth can be cooled using the cooling water W. Thus, a failure due to heat is not likely to occur in the discharge-side rotary shaft47, the pair of bearing portions44, the discharge-side gear490, the sealing portion45, and so forth. Also, since the temperature of the discharge-side rotary shaft47is not likely to rise, the overall length of the heat treatment chamber52in the left-right direction can be set to be long.

According to the rotary kiln1of the embodiment, the drive section91for both the supply-side rotary shaft37and the discharge-side rotary shaft47is provided. Therefore, the number of parts is reduced compared to a case where a drive section exclusively for the supply-side rotary shaft37and a drive section exclusively for the discharge-side rotary shaft47are provided separately. Also, the drive section91requires only a small installation space. Moreover, it is easier to match the rotational speed of the supply-side rotary shaft37and the rotational speed of the discharge-side rotary shaft47with each other.

According to the rotary kiln1of the embodiment, the supply-side holder38and the supply-side end portion57are bolted to each other. Therefore, the supply-side holder38and the supply-side end portion57are not rotatable relative to each other. Meanwhile, the discharge-side end portion58is merely housed in the discharge-side holder48. Therefore, the discharge-side end portion58and the discharge-side holder48are rotatable relative to each other. Thus, a torsional force is not likely to be applied to the shell5even in the case where the rotational speed of the supply-side rotary shaft37and the rotational speed of the discharge-side rotary shaft47are different from each other.

According to the rotary kiln1of the embodiment, an ambient gas can be supplied in accordance with the characteristics of the process material A and the material of the shell5. That is, the kind of the ambient gas can be changed when the process material A or the shell5is changed. This allows the rotary kiln1to be commonly used for a plurality of types of process materials A and shells5.

The shell5of the rotary kiln1according to the embodiment is made of carbon. Therefore, contamination of metal scale, which adversely affects the battery material B, into the battery material B can be suppressed. Thus, degradation in performance of the battery material B can be suppressed. Also, the shell5made of carbon provides excellent processability. Therefore, as shown inFIG. 10, members such as the supply-side partition wall50, the discharge-side partition wall51, the discharge holes53, and the fins56can be easily provided in the shell5. These members can be provided in the shell5by cutting a carbon block or by bolting. Moreover, the shell5made of carbon provides excellent heat shock resistance.

Also, the heat treatment chamber52is disposed radially inward of the shell5. Therefore, a heat treatment involves a rise in temperature of the shell5. A rise in temperature of the shell5may cause oxidation of the shell5made of carbon.

In this respect, according to the rotary kiln1of the embodiment, a nitrogen gas is supplied from each of the sealing portion28ofFIG. 4(arrow Y1), the sealing portion35ofFIG. 5(arrow Y2), the gas pipe701U ofFIG. 4(arrow Y7), and the sealing portion45ofFIG. 7(arrow Y4). Therefore, oxidation of the inner peripheral surface and the outer peripheral surface of the shell5can be suppressed.

According to the rotary kiln1of the embodiment, as shown inFIG. 7, the protection plate601D made of carbon is disposed in the discharge chute6. Therefore, contamination of metal scale into the battery material B from the lower divided portion60D made of steel can be suppressed.

The rotary kiln1of the embodiment can adapt to increases and decreases in overall length of the shell5in the axial direction (left-right direction) due to heat of the heating section8or the like. That is, as shown inFIG. 5illustrating the sealing portion35, a slide margin in the axial direction is secured between the inner annular portion350and the outer annular portion351of the sealing portion45. Also, as shown inFIG. 7, the pair of bearing portions44is each a dry metal bearing that supports the discharge-side rotary shaft47so as to be slidable in the axial direction. Moreover, as shown inFIG. 6, the thickness T1of the discharge-side gear490is set to be larger than the thickness T2of the discharge-side pinion491. Therefore, the discharge-side pinion491and the discharge-side gear490can be meshed with each other even if the discharge-side gear490is displaced with respect to the discharge-side pinion491in the left-right direction. The rotary kiln1according to the embodiment can thus adapt to increases and decreases in overall length of the shell5in the axial direction.

In the case where the shell5has a double cylinder construction with an outer layer made of a metal and an inner layer made of carbon, the inner layer is generally bolted to the outer layer. With such a construction, a minute gap, that is, an air layer, is likely to be interposed between the inner layer and the outer layer. Therefore, heat is not easily conducted from the outer layer to the inner layer. In contrast, the shell5of the rotary kiln1according to the embodiment is a one-piece member made of carbon. Therefore, heat is easily conducted from the outer surface to the inner surface. Thus, the shell5provides excellent thermal conductivity.

The rotary kiln1according to the embodiment provides high versatility for the material of the shell5. Therefore, the material of the shell5can be selected in accordance with the type of the product (in the case of the embodiment, the battery material B). Thus, it is possible to manufacture a desired product without using the shell5which contains a component, contamination of which into the product is not preferable.

Other Embodiments

The rotary kiln and the product according to the embodiment of the present invention have been described above. However, the present invention should not be specifically limited to the embodiment described above. The present invention can also be implemented in various modified or improved forms that may occur to those skilled in the art.

For example, the mechanism for rotating the supply-side rotary shaft37and the discharge-side rotary shaft47is not specifically limited. As shown inFIG. 2, a tire may be provided on the supply-side rotary shaft37and the discharge-side rotary shaft47and rollers may be provided on the supply-side support cart3and the discharge-side support cart4so that the supply-side rotary shaft37and the discharge-side rotary shaft47can be rotated by rolling the tire on the rollers.

The type of the ambient gas is also not specifically limited. An inert gas (such as helium and argon) or a reducing gas (such as a carbon monoxide gas) may be used. The material of the shell5is also not specifically limited. A metal such as Ni (nickel), SUS, and Cu (copper), a ceramic such as SiC (silicon carbide), or carbon may be used. In particular, the rotary kiln according to the present invention is suitably embodied as the rotary kiln1having the shell5made of a material, on the outer peripheral surface of which it is difficult to dispose a member (such as a tire and a gear), such as a ceramic, carbon, and silica glass, for example. The rotary kiln according to the present invention is also suitably embodied as the rotary kiln1having the shell5made of a material that is too soft to dispose a member on the outer peripheral surface, such as Cu, for example.

As the process material A, LiFePO4and carbon powder, which are respectively a cathode material and a anode material for an ferric phosphate lithium-ion battery, may be used, for example. In this case, contamination of carbon of the shell5into the cathode material has little effect on the cathode material, compared to a case of contamination of metal scale into the cathode material. Also, contamination of carbon of the shell5into the anode material has little effect on the anode material because the anode material itself is made of carbon. Meanwhile, as the product, food, waste, chemicals, chemical raw materials, ceramic raw materials, carbon materials (nano carbon), and so forth may be used, for example, as well as the battery material B. The properties of the process material A and the product are also not specifically limited. For example, the process material A and the product may be powdery, particulate, massive, liquid, or foamed. The process material A and the product may be a contamination of two or more thereof. The particle shapes of the process material A and the product may be perfectly spherical, ovally spherical, polyhedral, or needle-shaped, or may be an irregular shape obtained by appropriately incorporating these shapes.