AU2011288959B2 - Composite products and manufacturing method - Google Patents
Composite products and manufacturing method Download PDFInfo
- Publication number
- AU2011288959B2 AU2011288959B2 AU2011288959A AU2011288959A AU2011288959B2 AU 2011288959 B2 AU2011288959 B2 AU 2011288959B2 AU 2011288959 A AU2011288959 A AU 2011288959A AU 2011288959 A AU2011288959 A AU 2011288959A AU 2011288959 B2 AU2011288959 B2 AU 2011288959B2
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- Prior art keywords
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- polymeric material
- binder
- carbon
- composite product
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- 239000002131 composite material Substances 0.000 title claims abstract description 70
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 239000000047 product Substances 0.000 claims abstract description 198
- 239000000463 material Substances 0.000 claims abstract description 197
- 238000000034 method Methods 0.000 claims abstract description 88
- 239000011230 binding agent Substances 0.000 claims abstract description 73
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 56
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 55
- 238000010438 heat treatment Methods 0.000 claims abstract description 21
- 239000012467 final product Substances 0.000 claims abstract description 18
- 238000002156 mixing Methods 0.000 claims abstract description 12
- 239000011874 heated mixture Substances 0.000 claims abstract description 10
- 229910052751 metal Inorganic materials 0.000 claims description 43
- 239000002184 metal Substances 0.000 claims description 43
- 239000000571 coke Substances 0.000 claims description 17
- 229920001684 low density polyethylene Polymers 0.000 claims description 14
- 239000004702 low-density polyethylene Substances 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 12
- 239000005060 rubber Substances 0.000 claims description 9
- -1 polypropylene Polymers 0.000 claims description 8
- 238000012545 processing Methods 0.000 claims description 8
- 241000282887 Suidae Species 0.000 claims description 6
- 239000008187 granular material Substances 0.000 claims description 6
- 239000008188 pellet Substances 0.000 claims description 6
- 239000004743 Polypropylene Substances 0.000 claims description 5
- 239000003245 coal Substances 0.000 claims description 5
- 239000006185 dispersion Substances 0.000 claims description 5
- 229920001155 polypropylene Polymers 0.000 claims description 5
- 238000004090 dissolution Methods 0.000 claims description 4
- 230000015556 catabolic process Effects 0.000 claims description 3
- 239000007787 solid Substances 0.000 claims description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 32
- 238000009628 steelmaking Methods 0.000 description 23
- 229910052742 iron Inorganic materials 0.000 description 16
- 238000010891 electric arc Methods 0.000 description 15
- 239000002245 particle Substances 0.000 description 15
- 238000006243 chemical reaction Methods 0.000 description 13
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 13
- 239000000446 fuel Substances 0.000 description 9
- 230000008901 benefit Effects 0.000 description 8
- 238000005007 materials handling Methods 0.000 description 8
- 230000008569 process Effects 0.000 description 7
- 229910000831 Steel Inorganic materials 0.000 description 6
- 235000013980 iron oxide Nutrition 0.000 description 6
- 239000010959 steel Substances 0.000 description 6
- 238000002485 combustion reaction Methods 0.000 description 5
- 239000000945 filler Substances 0.000 description 5
- 239000007789 gas Substances 0.000 description 5
- 239000002028 Biomass Substances 0.000 description 4
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 4
- 239000004568 cement Substances 0.000 description 4
- 239000000428 dust Substances 0.000 description 4
- 238000005538 encapsulation Methods 0.000 description 4
- 239000002803 fossil fuel Substances 0.000 description 4
- 239000003517 fume Substances 0.000 description 4
- 239000006057 Non-nutritive feed additive Substances 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 239000004566 building material Substances 0.000 description 3
- 239000006227 byproduct Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000009845 electric arc furnace steelmaking Methods 0.000 description 3
- 239000010881 fly ash Substances 0.000 description 3
- 230000020169 heat generation Effects 0.000 description 3
- 238000001192 hot extrusion Methods 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 238000005065 mining Methods 0.000 description 3
- 239000011368 organic material Substances 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 239000000123 paper Substances 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 238000012827 research and development Methods 0.000 description 3
- 239000002893 slag Substances 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 238000009844 basic oxygen steelmaking Methods 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 239000010459 dolomite Substances 0.000 description 2
- 229910000514 dolomite Inorganic materials 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 229910001385 heavy metal Inorganic materials 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 238000002386 leaching Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 229910001092 metal group alloy Inorganic materials 0.000 description 2
- 239000004484 Briquette Substances 0.000 description 1
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 1
- 229910001021 Ferroalloy Inorganic materials 0.000 description 1
- 235000011941 Tilia x europaea Nutrition 0.000 description 1
- MOVRNJGDXREIBM-UHFFFAOYSA-N aid-1 Chemical compound O=C1NC(=O)C(C)=CN1C1OC(COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C(NC(=O)C(C)=C2)=O)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C(NC(=O)C(C)=C2)=O)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C(NC(=O)C(C)=C2)=O)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)COP(O)(=O)OC2C(OC(C2)N2C3=C(C(NC(N)=N3)=O)N=C2)CO)C(O)C1 MOVRNJGDXREIBM-UHFFFAOYSA-N 0.000 description 1
- 239000000292 calcium oxide Substances 0.000 description 1
- 235000012255 calcium oxide Nutrition 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 1
- 230000002045 lasting effect Effects 0.000 description 1
- 239000004571 lime Substances 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 235000014380 magnesium carbonate Nutrition 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- CSJDCSCTVDEHRN-UHFFFAOYSA-N methane;molecular oxygen Chemical compound C.O=O CSJDCSCTVDEHRN-UHFFFAOYSA-N 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920005596 polymer binder Polymers 0.000 description 1
- 239000002491 polymer binding agent Substances 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 239000012925 reference material Substances 0.000 description 1
- 238000011042 selective layering Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/06—Methods of shaping, e.g. pelletizing or briquetting
- C10L5/10—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders
- C10L5/14—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders with organic binders
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/34—Other details of the shaped fuels, e.g. briquettes
- C10L5/36—Shape
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/34—Other details of the shaped fuels, e.g. briquettes
- C10L5/36—Shape
- C10L5/361—Briquettes
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/34—Other details of the shaped fuels, e.g. briquettes
- C10L5/36—Shape
- C10L5/363—Pellets or granulates
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/40—Solid fuels essentially based on materials of non-mineral origin
- C10L5/406—Solid fuels essentially based on materials of non-mineral origin on plastic
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B1/00—Preliminary treatment of ores or scrap
- C22B1/14—Agglomerating; Briquetting; Binding; Granulating
- C22B1/24—Binding; Briquetting ; Granulating
- C22B1/242—Binding; Briquetting ; Granulating with binders
- C22B1/244—Binding; Briquetting ; Granulating with binders organic
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2200/00—Components of fuel compositions
- C10L2200/04—Organic compounds
- C10L2200/0461—Fractions defined by their origin
- C10L2200/0469—Renewables or materials of biological origin
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/06—Heat exchange, direct or indirect
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/24—Mixing, stirring of fuel components
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/32—Molding or moulds
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Environmental & Geological Engineering (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Geology (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Engineering & Computer Science (AREA)
- Metallurgy (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
- Vertical, Hearth, Or Arc Furnaces (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Processing Of Solid Wastes (AREA)
- Laminated Bodies (AREA)
- Powder Metallurgy (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Processes Of Treating Macromolecular Substances (AREA)
Abstract
A composite product and a method of manufacturing the composite product are disclosed. The composite product includes (a) a polymeric material binder and a metal- bearing material or (b) the polymeric material binder and a carbon-bearing material. The 5 method includes heating and mixing the components of the composite product and thereafter forming the heated mixture into a final product shape, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product.
Description
- 1 COMPOSITE PRODUCTS AND MANUFACTURING METHOD The present invention relates to composite products and to a method of manufacturing the products. 5 The present invention relates particularly, although by no means exclusively, to composite products that are made from recycled products. The present invention relates particularly, although by no means exclusively, 10 to composite products that are suitable for use in high temperature methods. The term "high temperature methods" is understood herein to mean methods that operate at temperatures greater than 4000C, typically at least 6000C. 15 Examples of high temperature methods are methods that are carried out in metallurgical furnaces such as steelmaking furnaces. In these methods the composite products of the present invention are intended to provide any one or more of metal bearing units and a source of energy. 20 Other examples of high temperature methods are methods that are carried out in power stations and kilns, such as cement making kilns, that require heat to be generated by fossil or engineered fuels. In these methods the composite products of the present invention are intended to provide a source of energy as a replacement of fossil fuels. 25 The present invention is not confined to composite products that are suitable for use in high temperature methods. By way of example, the composite products of the present invention are suitable for use as building materials or as protective materials for building and wear resistant materials (e.g. for wear resistance or corrosion resistance), such as alternatives to timber products and steel products. 30 The present invention is based on the use of a polymeric material as a binder to hold together particles of a metal-bearing material and/or a carbon-bearing material in a composite product that comprises (a) the polymeric material and the metal-bearing material or (b) the polymeric material and the carbon-bearing material or (c) the polymeric material 35 and the metal-bearing material and the carbon-bearing material. The present invention is also based on manufacturing these composite products by a combination of heating and mixing the components of the composite product, 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -2 with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the products. The present invention provides a method of manufacturing a composite 5 product in the form of a polymeric material binder and a carbon-bearing material that comprises heating and mixing the components of the composite product and thereafter forming the heated mixture into a final product shape in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product. 10 The present invention also provides a composite product in the form of a polymeric material binder and a metal-bearing material comprising heating and mixing the components of the composite product and thereafter forming the heated mixture into a final product shape in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks, with the 15 heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product, and wherein the metal-bearing material is in the form of mill scale fines or baghouse dust or other by-products from a steelmaking plant or an ironmaking plant. 20 The heating and mixing steps may be carried out in the order described in the preceding paragraph or in the reverse order or simultaneously. The term "metal-bearing material" is understood herein to mean any material that can be processed in a high temperature method such as a high temperature 25 metallurgical method carried out in a metallurgical furnace to produce a metal product. The term "metal" is understood herein to include metal alloys. Steelmaking, particularly electric arc steelmaking, is one metallurgical method of particular interest to the applicant. Other metallurgical methods include, by way of example, basic oxygen steelmaking and ironmaking methods. The present invention is not confined to high temperature 30 metallurgical methods. The metal-bearing material may be a recycled material. The method of manufacturing the composite product that comprises the polymeric material binder and the metal-containing material may include mixing other materials, such as materials that are sources of carbon other than the polymeric material 35 binder, with the metal-bearing material and the polymeric material. The other sources of carbon may comprise any one or more of biomass, flyash, rubber, paper, coke fines, char fines, coal fines, toner from printers and photocopying 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -3 machines, and any other suitable organic material. It is noted that, typically, in addition to containing carbon in the form of carbon black, toner contains metal-containing particles (iron oxides) and polymeric material. The other sources of carbon may be recycled materials. The other sources of carbon may be virgin materials. 5 The other materials may include burnt lime, dolomite, and magnesite. The method may comprise controlling the method and the selection of the metal-bearing material (when present), the carbon-bearing material (when present), and the 10 polymeric material binder to produce a product having a required porosity. There may be situations in which it is desirable that the product be non-porous. There may be other situations where the preferred chemical reactions in the high temperature method, such as a high temperature metallurgical method, may make it desirable for the product to have a level of porosity. For example, it may be desirable for chemical reactions to take place within the 15 product within the furnace, in which case a level of porosity to facilitate escape of volatilised reaction products may be desirable. The method may comprise mixing the metal-bearing material and the polymeric material binder so that there is a uniform dispersion of the metal-bearing material 20 through the product. The method may comprise mixing the carbon-bearing material and the polymeric material binder so that there is a uniform dispersion of the carbon-bearing material through the product. 25 The method may comprise heating the mixture of the components of the product at a temperature that is sufficiently high to completely melt the polymeric material binder. The temperature may be any suitable temperature having regard to the particular selection of the polymeric material binder, the other components of the mixture, and the 30 requirements of the particular method of forming the composite product. By way of example, in the case of a polymeric material binder in the form of low density polyethylene, typically the temperature is of the order of 150-1750C. The method may comprise selecting the metal-bearing material and the 35 carbon-bearing material so that these materials remain as solids during the heating step. The method may comprise controlling the method and the selection of the metal-bearing material (when present), the carbon-bearing material (when present), and the 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -4 polymeric material binder to produce a product having a required density. For example, when the product is a feed material for a steelmaking process it may be preferred that the product have a density that allows the product to float on a molten metal pool that forms in the process. 5 The carbon-bearing material may be in a particulate form. In the context of iron-bearing particles for use in making steel in an electric arc steelmaking furnace, the term "fines" is understood herein to mean particles that have a 10 major dimension of less than 6 mm. In a wider context of metal-bearing particles for use in high temperature methods in metallurgical furnaces, the term "fines" is understood herein to mean particles that have a major dimension of less than 6 mm. 15 The use of the polymeric material as a binder for metal-containing or carbon containing materials in the composite product of the present invention is not confined to composite products for high temperature methods carried out in metallurgical furnaces and extends to high temperature methods generally that require the composite product of the 20 invention. In this context, the present invention is not confined to fines and extends to metal bearing and to carbon-bearing materials that have a major dimension of greater than 6 mm. The polymeric material binder may be any suitable material. An important requirement of the polymeric material binder is that it be capable of acting as a binder of the 25 other components of the composite product under the specified materials handling and operational conditions for the product. By way of example, the specified conditions may include storage for prolonged periods in the outside atmosphere. By way of further example, the specified conditions may include particular materials handling requirements for the product. 30 The polymeric material binder may be a recycled polymeric material. The polymeric material binder may be a recycled polyethylene such as a low density polyethylene or a high density polypropylene or a recycled polypropylene. 35 The carbon-bearing material may be in the form of biomass, flyash, rubber, paper, coke fines, char fines, coal fines, used toner from printers and photocopying 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -5 machines, and any other suitable organic material. The carbon-bearing material may recycled materials. The carbon-bearing material may be virgin materials. The method may include any suitable forming step for forming a final product 5 shape. The forming step may be any one of an extrusion step, a moulding step (including injection moulding), and a briquetting or other type of pressing step. 10 By way of example, the forming step may include forming the heated mixture into the composite product by extruding the heated mixture. The extrudate may be in the final product shape. 15 Alternatively, it may be necessary to cut the extrudate to form the final product shape. For example, the forming step may include forming a continuous extrudate and thereafter cutting the extrudate as it emerges from the extruder into the final product shape. In a situation in which the extrudate emerges from the extruder as a 20 continuous "rope" (of small or large cross-section), the method may include cutting the rope into smaller lengths, whereby the smaller lengths of the extrudate form the product. The shape and size of the final product shape may be determined having regard to the materials handling and process requirements for the metallurgical method and 25 metallurgical furnace in which the product is to be used. The final product may have a major dimension of at least 10 cm. The final product may have a major dimension of at least 15 cm. 30 The final product may be at least 1 kg. The final product may be at least 2 kg. 35 The final product may be at least 3 kg. The final product may be less than 10 kg. 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -6 In any given situation, the factors affecting the shape and the size of the final product may include the following factors. The product should have sufficient strength and toughness to be able to be handled 5 within a high temperature processing plant such as a metallurgical plant and to be charged into a high temperature furnace such as a metallurgical furnace in the plant without significant breakdown of the product into smaller sized products, with generation of fines outside and/or inside the furnace. 10 * The product should be sufficiently large and have required mechanical properties such as strength to withstand the high temperature and reactive conditions in the high temperature furnace such as the metallurgical furnace to facilitate controlled dissolution of the product in the furnace over a required time period. Depending on the high temperature method, this time period may be a relatively short time period 15 or a longer time period. The required dissolution rate may vary depending on the chemical reaction requirements of the high temperature method and the overall time period of the method. For example, in some methods it may be important to have combustion of combustible components in the product as soon as possible. In other situations, it may be important to have relatively slow dissolution of the 20 product so that there is consumption of the product during the whole operating period of the method. The present invention also provides a composite product that comprises a metal-bearing material and a polymeric material that acts as a binder for the metal-bearing 25 material. The product described in the preceding paragraph may include other materials, such as materials that are sources of carbon other than the polymeric material binder. 30 The present invention also provides a composite product that comprises a carbon-bearing material and a polymeric material that acts as a binder for the carbon bearing material. 35 The product described in the preceding paragraph may include other materials, such as a metal-bearing material. 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -7 The product may comprise a continuous network of the polymeric material and a uniform dispersion of the metal-bearing material or the carbon-bearing material. The product may be a porous product. 5 The product may be a non-porous product and hence be at least substantially waterproof. This is an advantageous feature in situations where any one or more of the components of the product is susceptible to taking up moisture while being stockpiled or transported. For example, this is particularly the case with products that include biomass as 10 the carbon-bearing material of the product. The product may comprise an outer covering of the polymeric material. The covering may make the product non-porous. 15 In addition or alternatively, the covering may thereby encapsulate fines in the product and minimise the release of the fines during materials handling and transportation. In any given situation, the relative amounts of the polymeric binder material, 20 the metal-bearing material (when present), the carbon-bearing material (when present) and other materials will be a function of factors such as the binder requirements for the composite products, the requirement for metal-bearing materials in an end-use application for the products, and the energy requirements for the products in the end-use application. 25 The polymeric material binder may comprise greater than 10 wt.% of the product. The polymeric material binder may comprise greater than 15 wt.% of the product. 30 The polymeric material binder may comprise less than 50 wt.% of the product. The polymeric material binder may comprise less than 45 wt.% of the product. 35 The polymeric material binder may have a vaporisation temperature lower than the temperature of a molten bath in the metallurgical furnace. The polymeric material binder may be a recycled polymeric material. 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -8 The polymeric material binder may be a recycled polyethylene such as a low density polyethylene or a high density polyethylene or a recycled polypropylene. 5 The metal-bearing material may be in the form of iron-bearing particles. The iron-bearing particles may be in the form of fines. The iron-bearing particles may be in the form of iron oxide particles. 10 The iron-bearing particles may be in the form of mill scale fines and/or baghouse dust or other by-products from a steelmaking plant. The carbon-bearing material may be in the form of particles of biomass, 15 flyash, rubber, paper, coke fines, char fines, used toner from printers and photocopying machines, and any other suitable organic materials. The carbon-bearing material may recycled materials. The carbon-bearing material may be virgin materials. The product may be made completely from recycled materials, with each of 20 the polymeric binder material and the metal-bearing material (when present) and the carbon bearing material (when present) being recycled materials. The recycled materials may be obtained from any suitable source. 25 By way of example, the metal-bearing units may be in the form of mill scale fines, the polymeric binder material binder in the form of recycled polyethylene, and the carbon-bearing units may be in the form of coke fines or recycled rubber. The product may be any suitable size and shape. The product shape and 30 size may be as described above. The product may be suitable for use in a high temperature method. The product may be suitable for use as a source of energy as a replacement 35 for fossil fuels in power stations and kilns, such as cement making kilns, and other applications that require heat to be generated by fossil fuels. When used as a source of energy, the product may be described as an "engineered fuel". 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -9 The product may be suitable for use as building materials or as protective materials for building materials (e.g. for wear resistance or corrosion resistance)or as protective materials for mining consumables (e.g. for wear resistance on mining consumable parts for mineral processing or mining extraction equipment), such as alternatives to timber 5 products and steel products. The present invention also provides a high temperature method that comprises supplying the above-described composite product that contains metal-bearing units and carbon-bearing units and a polymeric material binder as a feed material for the 10 method. The high temperature method may be a method for producing a molten metal (which term includes a metal alloy, including a ferroalloy) in a metallurgical furnace. 15 The method may be a method of producing steel. The steelmaking method may be an electric arc steelmaking method. The steelmaking method may be a basic oxygen steelmaking method. 20 The method may be a method of producing iron. The present invention is based on a realisation of the applicant during the course of a research and development project that it is possible to produce a composite 25 product that comprises metal bearing units, more particularly, iron-bearing units in the form of mill scale fines and a polymeric material binder in the form of recycled low density polyethylene that is well-suited in terms of materials handling, chemistry, and processing properties for use in an electric arc furnace steelmaking method. In particular, the applicant found in the course of the project that the polymeric material acted as an effective binder for 30 the iron-bearing fines in the composite product and provided a source of energy. The present invention is also based on a realisation of the applicant during the course of the project that it is possible to produce a composite product that comprises carbon-bearing units in the form of coke fines and a polymeric material binder in the form of 35 recycled low density polyethylene that is well-suited in terms of materials handling, chemistry, and processing properties for use in an electric arc furnace steelmaking method. 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -10 The present invention is also based on a realisation of the applicant during the course of the project that hot forming, for example by hot extrusion, of mixtures of the above-described metal-bearing units and/or carbon-bearing units and polymeric material binder at temperatures at which at least part of the polymeric material binder had melted and 5 the other components of the mixture remained as solids is an effective method of producing composite products with the required materials handling, chemistry, and processing properties for use in an electric arc furnace steelmaking method. The present invention is also based on a realisation of the applicant during 10 the course of the project that the metal-bearing based composite product and the carbon unit based composite product of the invention has wider end-uses than steelmaking. In particular, the applicant has realised that the carbon unit-based composite product of the invention has applications as a replacement for fossil fuels in power stations and kilns, such as cement making kilns, and other applications that require heat to be generated by fossil or 15 engineered fuels. The research and development project included laboratory work on a wide range of products having 10-45 wt.% of a polymeric material in the form of low density polyethylene in accordance with the present invention. 20 The laboratory work included work on composite products comprising metal bearing, specifically iron-bearing, material in the form of mill scale and the polymeric material in the above ranges. The laboratory work found almost 100% reduction of the iron oxide in these products to molten iron. 25 The laboratory work also included work on composite products comprising carbon-bearing material in the form of coke fines and the polymeric material in the above ranges. 30 One example of the product had a composition of 24 wt.% low density polyethylene binder, 1 wt.% processing aid, 75 wt.% coke fines and other carbon-containing material. The research and development project also included a 1 tonne trial of a 35 sample composition of the product of the present invention in an electric arc steelmaking furnace of the applicant. 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 - 11 The sample product for the trial was extruded successfully on a standard commercial hot extruder. The continuous "rope" that was produced by the extruder was formed into 5 large "pattie" shapes, of the order of 3 kg. The sample product had a composition of 24 wt.% low density polyethylene, 1 wt.% processing aid, 7 wt.% coke, and 68 wt.% mill scale. Composition by Material Mill scale 68 Coke fines 7 Recycled LDPE 24 Processing Aid 1 10 Composition by Element Iron (-75 wt.% Fe in mill scale) 51 Carbon (-85 wt.% C in LDPE / -85 wt.% C in coke) 26 Oxygen (-25 wt.% 0 in mill scale) 17 Hydrogen (-15 wt.% H in polymer) 4 The 1 tonne of the product patties was charged into a hot heel of the electric arc furnace. The effect of the addition of the charge of the product was monitored via cameras and standard data recording of chemistry and method operating parameters. 15 The heat balance for the addition is set out below. Product 1,000kg = 680kg FeO (510kg Fe) + 240kg LDPE + 70kg Coke Heat In 240kg LDPE x 12.9 kWhr/kg = 3,096 kWhr Heat Out Iron oxide reduction = 2kWhr/kg* x 680kg = 1,360 kWhr Iron melting = 51 0kg x 0.44kWhr/kg = 225 kWhr Balance 3,096 - (1,360 + 225) = +1,511 kWhr 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -12 It is noted that the above heat balance is based on theoretical data from standard reference materials and data obtained from an electric arc steelmaking plant of the applicant in NSW, Australia. 5 Some key findings of the trial are as follows. * The product patties were a source of energy. * The product patties were magnetic - therefore, the patties could be handled using a 10 standard furnace scrap magnet crane - -500kg/load. * The product patties were tough - no breakage with regular blocks. * The product patties were waterproof - no noticeable weight increase submerged in 15 water for 1 week. * The product patties settled at the bath/slag interface and started reacting within the furnace. 20 * The product patties remained intact and reacted at a controlled rate for extended period with some patties lasting > 15 minutes. * The product patties produced strong heat generation. 25 * There was very little fume generation compared to plastic and rubber alternative products. * Charge reaction - no noticeable change adding 100kg, 200kg and 300kg/heat in bottom bucket 1. 30 The results of the trial indicate significant business opportunities based on the composite product of the present invention. In particular, the applicant realised from the trial that a composite product of 35 the present invention that is based on a polymeric material binder that holds together carbon-bearing material could be a significant source of energy that has wider applications than the steelmaking industry, with these applications including as a replacement for fossil 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -13 fuels in power stations and kilns, such as cement making kilns, and other applications that require heat to be generated by fossil or engineered fuels. In addition, the applicant realised from the trial that a composite product of the 5 present invention makes it possible to introduce different ratios of steelmaking feed materials and sources of energy in a charge bucket to an electric arc furnace. Hence, depending on the requirements, there may be more or less of each of the iron-bearing materials and other steelmaking feed materials and the polymeric material (as a binder and a source of energy) in a charge bucket. Hence, the composite product of the present invention provides an io opportunity for flexibility in the supply of feed materials to a steelmaking process and, in particular, an opportunity to optimise energy utilisation. Another key benefit of the sample product patties, which is a benefit that should facilitate use of the composite product of the invention in electric arc furnaces and 15 other high temperature methods is that there is a controlled and metered rate of reaction and heat generation because of the physical and chemical composition of the product patties. The controlled rate of fuel release leads to complete combustion and utilisation of heat in a furnace rather than in the offgas system. Therefore, there is a lower risk of high gas duct temperatures and bag house trips as well as unburnt fuel or fume in the off-gas duct leading 20 to explosions. In the 1 tonne trial it was observed that the sample product patties (~3kg each) took longer than 10 minutes to combust when added to the hot heel of the furnace. This was a key observation and significant benefit and should allow the sample product patties to be used like "burners" under scrap charge at a controlled rate during meltdown rather than reacting too fast immediately after charging and causing fume and flame to exit 25 the furnace. In comparison, when a small amount of plastic film bound together or pieces of rubber tyre was added to the furnace it reacted and was burnt within a few minutes. The sample product patties were observed to ignite and sustain a strong flame for a long period. Based on the trial, the applicant believes that if the composite product patties 30 are located under the scrap in an electric arc furnace, the product patties will potentially provide preheating and reduce the power on time and electrical energy consumption. The slower rate of combustion of the product patties was controlled in the trial due to the composite nature of the composite product. The reaction of the polymer material 35 binder or filler materials (mill scale and coke fines) with oxygen was limited to the surface of the product patties due to the low porosity caused by the binder. Therefore, there was very little gas penetration into the product patties. The low porosity limited the surface area for reaction and shielded the reactants within the product. There should be a large thermal 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -14 gradient from the inside to the surface of the product with reaction taking place on or near to the surface. There would also be some insulation effect from the gas/fume/flame layer formed by the fuming and ignition of the polymer at relatively low temperature (250 to 4000C) and reaction products leaving the surface of the briquette. For example, this should insulate 5 the product patties from the surrounding high temperature steel and slag (1500 - 17500C) and allow the product patties to last longer. Fuel is released at a controlled rate as only that exposed at the surface reacts. 10 The composite matrix structure of the product patties means that the iron oxide shields the polymer binder and controls the reaction rate. If the filler material has low combustibility, then the rate of supply of a "fuel" to the surface where it can contact oxygen is lower. That is why the iron oxide (mill scale) products would potentially last longer in liquid 15 metal slag than briquettes that contain combustible filler like coke or graphite. The same shielding effect could be achieved by using other filler materials with low rate of combustion (lime, dolomite, baghouse dust, etc.). The products also slow down the reaction compared to if the fine materials 20 were added individually. For example, both mill scale and coke fines can react quickly or violently through a carbon oxygen reaction when introduced to a liquid steel bath due to the high surface area of these materials. It follows from the above discussion that the rate of reaction could be 25 controlled by varying the composition of the product patties to increase or decrease the filler and binder materials. This could be applied to many pyrometallurgical applications or other high temperature applications. For example, the applications include mini-blast furnaces or alternate iron making processes or incineration processes or power generation processes. 30 In the context of the electric arc steelmaking industry, the trial indicated that the composite product of the present invention provides opportunities for scrap replacement, the use of waste products and by-products produced in steelmaking plants and in other industries, the use of feed materials in the form of fines that otherwise would not be suitable for use in electric arc steelmaking furnaces, the use of recycled materials as the polymer 35 material binder and as a source of energy, and the opportunity for selective layering of charges in an electric arc furnace to optimise heat generation and other reactions. The opportunities translate into environmental and financial benefits. 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -15 The present invention has the following features and advantages, which are described to a large extent in the context of the use of the composite product of the invention in a steelmaking application but also apply to other end-uses of the product: 5 * The polymeric material binder produces a very tough and in many instances a water-proof product, meaning less product breakdown and longer shelf life in materials handling. * There are additional advantages when the product has a covering of the polymeric 10 material that encapsulates fines and larger size particles in the product. Encapsulation of the fines and larger size particles in the polymeric material may make it possible to store the product outside without appreciable moisture pick-up. Also, more generally, encapsulation provides protection against moisture pick up/hydration when the product is exposed to atmosphere in any storage situation. 15 In addition, encapsulation of the fines and larger size particles in the polymeric material may prevent or at least minimise leaching of compounds from the product. For example, encapsulation of electric arc furnace dust containing heavy metals in a composite product of the invention to prevent leaching of heavy metals may be an advantage in handling, storage and transportation of the product. 20 * The polymeric material acts as a "clean" binder to carry fines into a high temperature method. The fines are consumed in the furnace and the polymeric material binder exits system as a gas (for example, low density polyethylene melts at 1150C and vaporises ~3500C). 25 * The carbon and hydrogen components of the polymeric material binder may assist in combustion/reduction based methods. * The use of the polymeric material acting as a binder could be applied to any 30 suitable high temperature method and not only high temperature methods in metallurgical furnaces. * The hot extrusion process is suitable for large scale and economically viable production of both product types, namely one product type being based on metal 35 bearing material and the other product type being based on a carbon-bearing material. 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15 -16 * Size control for the polymeric material binder is potentially less stringent due to melting during extrusion process. * The use of recycled polymeric materials as the binder may attract environmental 5 benefit as many polymeric materials would be otherwise sent to landfill. * Hot extrusion technology is potentially applicable to any industry requiring the recovery, transport and processing of fines, including metal-bearing and carbon bearing fines. 10 * The product is magnetic when it contains iron-bearing units. * The use of the product in an electric arc steelmaking method was energy positive in overall terms. 15 * The use of the product under and within a scrap charge for an electric arc steelmaking method facilitates close contact heating of the scrap charge and potentially improved heat transfer and efficient use of energy. 20 * The use of a hot extruder makes it possible to use feed materials with higher moisture contents due to heating in the extruder. * The invention makes it possible to use feed materials in the form of fines. 25 Many modifications may be made to the present invention described above without departing from the spirit and scope of the invention. 6151104_1 (GHMatters) P83863.AU.1 GRM 28/01/15
Claims (18)
1. A method of manufacturing a composite product for use in methods carried out in metallurgical furnaces at high temperatures of at least 4000C, the composite product 5 being in the form of a recycled polymeric material binder that acts as a binder and a carbon bearing material selected from any one or more than one of rubber, coke fines, char fines, and coal fines, with the amount of the polymeric material comprising greater than 10 wt.% of the product, the method of manufacturing the composite product comprising heating and mixing the components of the composite product and thereafter forming the heated mixture io into a final product shape in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product.
2. A method of manufacturing a composite product for use in methods carried 15 out in metallurgical furnaces at high temperatures of at least 4000C, the composite product being in the form of a recycled polymeric material binder that acts as a binder and a carbon bearing material selected from any one or more than one of rubber, coke fines, char fines, and coal fines, with the amount of the polymeric material comprising greater than 10 wt.% of the product, the method of manufacturing the composite product comprising mixing and 20 heating the components of the composite product and thereafter forming the heated mixture into a final product shape in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product. 25
3. A method of manufacturing a composite product for use in methods carried out in metallurgical furnaces at high temperatures of at least 4000C, the composite product being in the form of a recycled polymeric material binder that acts as a binder and a carbon bearing material selected from any one or more than one of rubber, coke fines, char fines, and coal fines, with the amount of the polymeric material comprising greater than 10 wt.% of 30 the product, the method of manufacturing the composite product comprising heating and mixing the components of the composite product simultaneously and thereafter forming the heated mixture into a final product shape in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product. 35 6574308_1 (GHMatters) P83863.AU.1 -18
4. The method defined in any one of the preceding claims comprises controlling the method and the selection of the carbon-bearing material and the polymeric material binder to produce a product having a required porosity.
5 5. The method defined in claim 4 wherein the product is a non-porous product.
6. The method defined in any one of the preceding claims comprises mixing the carbon-bearing material and the polymeric material binder so that there is a uniform dispersion of the carbon-bearing material through the product. 10
7. The method defined in any one of the preceding claims comprises heating the mixture of the components of the product at a temperature that is sufficiently high to completely melt the polymeric material binder. 15
8. The method defined in any one of the preceding claims comprises selecting the carbon-bearing material so that these materials remain as solids during the heating step.
9. The method defined in any one of the preceding claims wherein the recycled polymeric material is a recycled low density polyethylene or a recycled high density 20 polypropylene or a recycled polypropylene.
10. The method defined in any one of the preceding claims includes forming the heated mixture into the composite product by extruding the heated mixture. 25
11. A composite product in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks comprises a carbon-bearing material and a polymeric material that acts as a binder for the carbon-bearing material produced in the method defined in any one of the preceding claims. 30
12. The product defined in claim 11 comprises a continuous network of the polymeric material and a uniform dispersion of the carbon-bearing material.
13. The product defined in claim 11 or claim 12 being a non-porous product and hence being at least substantially waterproof. 35
14. The product defined in any one of claims 11 to 13 comprising an outer covering of the polymeric material. 6574308_1 (GHMatters) P83863.AU.1 -19
15. The product defined in any one of claims 11 to 14 wherein the polymeric material comprises less than 50 wt.% of the product.
16. The product defined in any one of claims 11 to 15 being made completely 5 from recycled materials, with each of the polymeric binder material and the carbon-bearing material being recycled materials.
17. A method for producing a molten metal that comprises supplying the composite product defined in any one of claims 11 to 16 as a feed material for the method claims, with io the composite product being formed by the method defined in any one of claims 1 to 10 with sufficient strength and toughness to be able to be handled within a high temperature processing plant for carrying out the method of producing the molten metal and to be charged into a high temperature furnace in the plant without significant breakdown of the product into smaller sized products, with generation of fines outside and/or inside the 15 furnace.
18. A method for producing a molten metal that comprises supplying the composite product defined in any one of claims 11 to 16 as a feed material for the method claims, with the composite product being formed by the method defined in any one of claims 1 to 10 to 20 be sufficiently large and have required mechanical properties such as strength to withstand high temperature and reactive conditions in a high temperature furnace in a high temperature processing plant for carrying out the method to facilitate controlled dissolution of the product in the furnace over a required time period. 6574308_1 (GHMatters) P83863.AU.1
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US9789070B2 (en) | 2015-07-28 | 2017-10-17 | Elc Management Llc | Sheet packs for treating facial or body surfaces |
WO2017059497A1 (en) * | 2015-10-08 | 2017-04-13 | Biocoal Group Pty Ltd | Processing waste materials |
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DE102020206095A1 (en) * | 2020-05-14 | 2021-11-18 | Bernegger Gmbh | Methods of preparing waste material |
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- 2011-08-01 KR KR1020137005260A patent/KR20130103716A/en not_active Application Discontinuation
- 2011-08-01 BR BR112013003261A patent/BR112013003261A2/en not_active Application Discontinuation
- 2011-08-01 WO PCT/AU2011/000960 patent/WO2012019216A1/en active Application Filing
- 2011-08-01 AU AU2011288959A patent/AU2011288959B2/en active Active
- 2011-08-01 JP JP2013523433A patent/JP2013533366A/en active Pending
- 2011-08-01 CN CN201180048790.5A patent/CN103429768B/en not_active Expired - Fee Related
- 2011-08-01 MX MX2013001590A patent/MX2013001590A/en not_active Application Discontinuation
- 2011-08-01 EP EP11815892.2A patent/EP2603617A4/en not_active Withdrawn
- 2011-08-01 US US13/814,933 patent/US20130228044A1/en not_active Abandoned
-
2013
- 2013-02-08 ZA ZA2013/01145A patent/ZA201301145B/en unknown
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2015
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Also Published As
Publication number | Publication date |
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CN103429768B (en) | 2017-03-15 |
AU2011288959A1 (en) | 2013-03-14 |
CA2807744A1 (en) | 2012-02-16 |
EP2603617A1 (en) | 2013-06-19 |
BR112013003261A2 (en) | 2016-06-14 |
ZA201301145B (en) | 2014-06-25 |
KR20130103716A (en) | 2013-09-24 |
MX2013001590A (en) | 2013-10-28 |
CN103429768A (en) | 2013-12-04 |
US20160075959A1 (en) | 2016-03-17 |
JP2013533366A (en) | 2013-08-22 |
EA026994B1 (en) | 2017-06-30 |
EA201390205A1 (en) | 2013-08-30 |
US20160281013A9 (en) | 2016-09-29 |
EP2603617A4 (en) | 2016-02-24 |
WO2012019216A1 (en) | 2012-02-16 |
US20130228044A1 (en) | 2013-09-05 |
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