CA2807744A1 - Composite products and manufacturing method - Google Patents
Composite products and manufacturing method Download PDFInfo
- Publication number
- CA2807744A1 CA2807744A1 CA2807744A CA2807744A CA2807744A1 CA 2807744 A1 CA2807744 A1 CA 2807744A1 CA 2807744 A CA2807744 A CA 2807744A CA 2807744 A CA2807744 A CA 2807744A CA 2807744 A1 CA2807744 A1 CA 2807744A1
- Authority
- CA
- Canada
- Prior art keywords
- product
- metal
- binder
- carbon
- polymeric material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 60
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 239000000463 material Substances 0.000 claims abstract description 218
- 239000000047 product Substances 0.000 claims abstract description 204
- 238000000034 method Methods 0.000 claims abstract description 89
- 239000011230 binding agent Substances 0.000 claims abstract description 72
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 59
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 58
- 238000010438 heat treatment Methods 0.000 claims abstract description 14
- 238000002156 mixing Methods 0.000 claims abstract description 11
- 239000012467 final product Substances 0.000 claims abstract description 9
- 239000011874 heated mixture Substances 0.000 claims abstract description 7
- 229910052751 metal Inorganic materials 0.000 claims description 56
- 239000002184 metal Substances 0.000 claims description 56
- 238000009628 steelmaking Methods 0.000 claims description 26
- 239000002245 particle Substances 0.000 claims description 19
- 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
- -1 polyethylene Polymers 0.000 claims description 12
- 239000005060 rubber Substances 0.000 claims description 9
- 238000012545 processing Methods 0.000 claims description 8
- 239000002028 Biomass Substances 0.000 claims description 7
- 239000004698 Polyethylene Substances 0.000 claims description 6
- 239000004743 Polypropylene Substances 0.000 claims description 6
- 239000006185 dispersion Substances 0.000 claims description 6
- 239000000428 dust Substances 0.000 claims description 6
- 239000010881 fly ash Substances 0.000 claims description 6
- 239000011368 organic material Substances 0.000 claims description 6
- 239000000123 paper Substances 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 6
- 229920001155 polypropylene Polymers 0.000 claims description 6
- 239000006227 byproduct Substances 0.000 claims description 5
- 239000003245 coal Substances 0.000 claims description 4
- 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
- 241000282887 Suidae Species 0.000 claims description 2
- 239000008187 granular material Substances 0.000 claims description 2
- 229920001903 high density polyethylene Polymers 0.000 claims description 2
- 239000004700 high-density polyethylene Substances 0.000 claims description 2
- 239000008188 pellet Substances 0.000 claims description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 38
- 229910052742 iron Inorganic materials 0.000 description 19
- 238000010891 electric arc Methods 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
- 241000196324 Embryophyta Species 0.000 description 8
- 230000008901 benefit Effects 0.000 description 8
- 239000000446 fuel Substances 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
- 239000002803 fossil fuel Substances 0.000 description 5
- 239000007789 gas Substances 0.000 description 5
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 4
- 239000004568 cement Substances 0.000 description 4
- 238000005538 encapsulation Methods 0.000 description 4
- 239000003517 fume Substances 0.000 description 4
- 239000006057 Non-nutritive feed additive 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
- 230000000694 effects Effects 0.000 description 3
- 238000009845 electric arc furnace steelmaking Methods 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
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 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
- JGFZNNIVVJXRND-UHFFFAOYSA-N N,N-Diisopropylethylamine (DIPEA) Chemical compound CCN(C(C)C)C(C)C JGFZNNIVVJXRND-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
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 229910001092 metal group alloy Inorganic materials 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 239000002861 polymer material Substances 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
- 235000009421 Myristica fragrans Nutrition 0.000 description 1
- 244000270834 Myristica fragrans Species 0.000 description 1
- 235000011941 Tilia x europaea Nutrition 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
- 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
- 239000007788 liquid Substances 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 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
- 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)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
- Processing Of Solid Wastes (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Vertical, Hearth, Or Arc Furnaces (AREA)
- Processes Of Treating Macromolecular Substances (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Powder Metallurgy (AREA)
- Laminated Bodies (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
r = = CA 02807744 2013-02-07 =
Received 08/06/2012 COMPOSITE PRODUCTS AND MANUFACTURING METHOD
The present invention relates to composite products and to a method of manufacturing the products.
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, 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 400 C, typically at least 600 C.
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.
= 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.
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.
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 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, AMENDED SHEET 2781536_2 (GHMatters) P83863 PCT 8t06/12 e = , CA 02807744 2013-02-07 Received 08/06/2012 with the heatihg 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 product in the form of (a) a polymeric material binder and a metal-bearing material or (b) the 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, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product.
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 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 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' 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 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.
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 AMENDED SHEET 2761538_2 (GHMatters) P83863 PCT 8/06112 = 1PEA/AU
=
Received 08/06/2012 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 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 io polymeric material binder so that there is a uniform dispersion of the metal-bearing material 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.
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 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 150-175 C.
The method may comprise selecting the metal-bearing material and the 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 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.
The metal-bearing material and the carbon-bearing material may be in a particulate form.
=
2761536_2 (GHMatters) P83863 PCT 8/06/12 = CA 02807744 2013-02-Received 08/06/2012 By way of particular example that i relevant to steelmaking methods, the metal-bearing material may be in the form of iron-bearing particles.
The iron-bearing particles may be in the form of fines.
By way of particular example, the iron-bearing particles may be in the form of mill scale fines or baghouse dust or other by-products from a steelmaking plant or an ironmaking plant.
io 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 major dimension of less than 6 mm.
In a wider context of metal-bearing particles for use in high temperature is methods in metallurgical furnaces, the term "fines" is understood herein to mean particles that have a major dimension of less than 6 mm.
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 20 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 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.
25 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 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, 30 the specified conditions may include particular materials handling requirements for the product.
The polymeric material binder may be a recycled polymeric material.
=
35 The polymeric material binder may be a recycled polyethylene such as a low density polyethylene or a high density polypropylene or a recycled polypropylene.
AMENDED SHEET =1PEA/AU
2761536 2 (GHMatters) P83863.PCT 8106/12 Received 08/06/2012.
Received 08/06/2012 COMPOSITE PRODUCTS AND MANUFACTURING METHOD
The present invention relates to composite products and to a method of manufacturing the products.
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, 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 400 C, typically at least 600 C.
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.
= 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.
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.
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 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, AMENDED SHEET 2781536_2 (GHMatters) P83863 PCT 8t06/12 e = , CA 02807744 2013-02-07 Received 08/06/2012 with the heatihg 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 product in the form of (a) a polymeric material binder and a metal-bearing material or (b) the 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, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product.
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 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 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' 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 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.
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 AMENDED SHEET 2761538_2 (GHMatters) P83863 PCT 8/06112 = 1PEA/AU
=
Received 08/06/2012 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 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 io polymeric material binder so that there is a uniform dispersion of the metal-bearing material 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.
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 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 150-175 C.
The method may comprise selecting the metal-bearing material and the 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 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.
The metal-bearing material and the carbon-bearing material may be in a particulate form.
=
2761536_2 (GHMatters) P83863 PCT 8/06/12 = CA 02807744 2013-02-Received 08/06/2012 By way of particular example that i relevant to steelmaking methods, the metal-bearing material may be in the form of iron-bearing particles.
The iron-bearing particles may be in the form of fines.
By way of particular example, the iron-bearing particles may be in the form of mill scale fines or baghouse dust or other by-products from a steelmaking plant or an ironmaking plant.
io 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 major dimension of less than 6 mm.
In a wider context of metal-bearing particles for use in high temperature is methods in metallurgical furnaces, the term "fines" is understood herein to mean particles that have a major dimension of less than 6 mm.
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 20 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 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.
25 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 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, 30 the specified conditions may include particular materials handling requirements for the product.
The polymeric material binder may be a recycled polymeric material.
=
35 The polymeric material binder may be a recycled polyethylene such as a low density polyethylene or a high density polypropylene or a recycled polypropylene.
AMENDED SHEET =1PEA/AU
2761536 2 (GHMatters) P83863.PCT 8106/12 Received 08/06/2012.
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 =
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 shape.
=
The forming step may be any one of an extrusion step, a moulding step o (including injection moulding), and a briquetting or other type,of pressing step.
, =
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:
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 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 final product shape may be any suitable shape and any suitable size.
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 = metallurgical furnace in which the product is to be used.
The product may be in the form of pellets.
=
The product may be in the form of granules.
The product may be in the form of larger products that can be described as blocks, pigs, patties, plugs and pucks.
The larger product may have a major dimension of at least 10 cm.
= AMENDED SHEET
2761536_2 (GHMatters) P83863 PCT 8106/12 IPEA/AU
=
=
Received 08/06/2012 -=
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 shape.
=
The forming step may be any one of an extrusion step, a moulding step o (including injection moulding), and a briquetting or other type,of pressing step.
, =
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:
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 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 final product shape may be any suitable shape and any suitable size.
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 = metallurgical furnace in which the product is to be used.
The product may be in the form of pellets.
=
The product may be in the form of granules.
The product may be in the form of larger products that can be described as blocks, pigs, patties, plugs and pucks.
The larger product may have a major dimension of at least 10 cm.
= AMENDED SHEET
2761536_2 (GHMatters) P83863 PCT 8106/12 IPEA/AU
=
=
Received 08/06/2012 -=
The larger product may have a major dimension of at least 15 cm.
The larger product may be at least 1 kg.
The larger product may be at least 2 kg.
The larger product may be at least 3 kg.
.
The larger product may be less than 10 kg.
=
In any given situation, the factors affecting the shape and the size of the product may include the following factors.
= The product should have sufficient strength and toughness to be able to be handled 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.
= 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 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 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 4.2 material.
2761536_2 (GHMatters) P83863 PCT EV06112 =
=
PCT/AU2011/000960 =
Received 08/06/2012 = =
The product described in the preaeding paragraph may include =other materials, such as materials that are sources of carbon other than the polymeric material binder.
5 = 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.
The product described in the preceding paragraph may include other lo materials, such as a metal-bearing material.
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.
15 The product may be a porous product.
L 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 20 transported. For example, this is particularly the case with products that include biomass as the carbon-bearing material of the product.
The product may comprise an outer covering of the polymeric material.
25 The covering may make the product non-porous.
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.
30 In any given situation, the relative amounts of the polymeric binder material, = 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.
The polymeric material binder may comprise greater than 10 wt.% of the product.
AMENDED SHEETIPEA/AU
2761536_2 (GHMatten) P83863 PCT 8/06/12 = = CA 02807744 2013-02-07 = =
=
Received 08/06/2012 The polymeric material binder may comprise greater than 15 wt.% of the product.
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.
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.
=
The polymeric material binder may be a recycled polyethylene such, as a low density polyethylene or a high density polyethylene or a recycled polypropylene.
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.
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, 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 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.
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.
AMENDED SHEET
2761536_2 (GHMatters) P83863 PCT 8/06/12 =
Received 08/06/2012 The product may be any suitable size and shape. The product shape and 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 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".
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 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 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.
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.
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 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 2761536_2 (GHMatters) P83863 PCT 8/06112 Received 08/06/2012 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 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 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.
= io =
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 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 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 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.
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.
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.
AMENDED. SHEETIPEA/AU
2761536_2 (GHMatters) P83863 PCT 8/06112 = = =
Received 08/06/2012 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 WO of a sample composition of the product of the present invention in an electric arc steelmaking furnace of the applicant.
io 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 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 Coke fines Recycled LDPE
Processing Aid = Composition by Element Iron (-75 wt.% Fe in mill scale) Carbon (-85 wt.% C in LDPE / -85 wt.% C in coke) Oxygen (-25 wt.% 0 in mill scale) Hydrogen (-15 wt.% H in polymer) 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 ofthe product was monitored via - cameras and standard data recording of chemistry and method operating parameters.
25 The heat balance for the addition is set out below.
=
AMENDED SHEET = 1PEA/AU =
2761536_2 (GHMatters) P83863.PCT 8/06112 =
Received 08/06/2012 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 = 510kg x 0.44kWhr/kg = 225 kWhr Balance 3,096 - (1,360 + 225) =+1,511 kWhr 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.
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 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 = water for 1 week.
= The product patties settled at the bath/slag interface and started reacting within the *
= furnace.
= i = 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.
= There was very little fume generation compared to plastic and rubber alternative products.
2761536_2 (GHMatters) P83663 PCT 6106112 =
= CA 02807744 2013-02-07 Received 08/06/2012 = Charge reaction ¨ no noticeable change adding 100kg, 200kg and 300kg/heat in bottom bucket 1.
The results of the trial indicate significant business opportunities based on the s composite product of the present invention.
In particular, the applicant realised from the trial that a compoSite product of 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 io than the steelmaking industry, with these applications including 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 engineered fuels.
In addition, the applicant realised from the trial that a composite product of the is 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 20 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 25 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 ' 30 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 35 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.
AMENDED SHEET 2761536_2 (GHMatters) P83863 PCT 8106112 = =
Received 08/06/2012 Based on the trial, the applicant believes that if the composite product patties 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.
5 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 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 ' io reaction and shielded the reactants within the product.
There should be a large thermal 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 400 C) = and reaction products leaving the surface of the briquette. For example, this should insulate 15 the product patties from the surrounding high temperature steel and slag (1500 ¨ 1750 C) and allow the product patties to last longer.
=
Fuel is released at a controlled rate as only that exposed at the surface reacts.
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 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 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 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.
2761536_2 (GHMatters) P83863 PCT 8/06/12 Received 08/06/2012 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 s 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 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.
10 =
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:
15 = 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 20 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.
25 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.
=
= 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 115 C and vaporises -350 C).
= The carbon and hydrogen components of the polymeric material binder may assist in combustion/reduction based methods.
=
AMENDED SHEET
IPEA/AU
27615.38_2 (GHMatters) P83863.PCT 8/06/12 = =
Received 08/06/2012 = The use of the polymeric material acting as a binder could be applied to any = suitable high temperature method and not only, high temperature methods in metallurgical fu.maces.
= 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-, bearing material and the other product type being based on a carbon-bearing material.
io = 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 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.
= 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.
' = The use of the product under and within a scrap charge for an electric arc steelmaking method facilitates close contact heating qf the scrap charge and potentially improved heat transfer and efficient use of energy.
= 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.
Many modifications may be made to the present invention described above without departing from the spirit and scope of the invention.
2761536_2 (GHMatters) P83863 PCT 8106112
The larger product may be at least 1 kg.
The larger product may be at least 2 kg.
The larger product may be at least 3 kg.
.
The larger product may be less than 10 kg.
=
In any given situation, the factors affecting the shape and the size of the product may include the following factors.
= The product should have sufficient strength and toughness to be able to be handled 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.
= 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 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 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 4.2 material.
2761536_2 (GHMatters) P83863 PCT EV06112 =
=
PCT/AU2011/000960 =
Received 08/06/2012 = =
The product described in the preaeding paragraph may include =other materials, such as materials that are sources of carbon other than the polymeric material binder.
5 = 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.
The product described in the preceding paragraph may include other lo materials, such as a metal-bearing material.
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.
15 The product may be a porous product.
L 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 20 transported. For example, this is particularly the case with products that include biomass as the carbon-bearing material of the product.
The product may comprise an outer covering of the polymeric material.
25 The covering may make the product non-porous.
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.
30 In any given situation, the relative amounts of the polymeric binder material, = 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.
The polymeric material binder may comprise greater than 10 wt.% of the product.
AMENDED SHEETIPEA/AU
2761536_2 (GHMatten) P83863 PCT 8/06/12 = = CA 02807744 2013-02-07 = =
=
Received 08/06/2012 The polymeric material binder may comprise greater than 15 wt.% of the product.
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.
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.
=
The polymeric material binder may be a recycled polyethylene such, as a low density polyethylene or a high density polyethylene or a recycled polypropylene.
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.
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, 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 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.
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.
AMENDED SHEET
2761536_2 (GHMatters) P83863 PCT 8/06/12 =
Received 08/06/2012 The product may be any suitable size and shape. The product shape and 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 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".
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 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 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.
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.
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 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 2761536_2 (GHMatters) P83863 PCT 8/06112 Received 08/06/2012 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 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 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.
= io =
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 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 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 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.
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.
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.
AMENDED. SHEETIPEA/AU
2761536_2 (GHMatters) P83863 PCT 8/06112 = = =
Received 08/06/2012 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 WO of a sample composition of the product of the present invention in an electric arc steelmaking furnace of the applicant.
io 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 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 Coke fines Recycled LDPE
Processing Aid = Composition by Element Iron (-75 wt.% Fe in mill scale) Carbon (-85 wt.% C in LDPE / -85 wt.% C in coke) Oxygen (-25 wt.% 0 in mill scale) Hydrogen (-15 wt.% H in polymer) 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 ofthe product was monitored via - cameras and standard data recording of chemistry and method operating parameters.
25 The heat balance for the addition is set out below.
=
AMENDED SHEET = 1PEA/AU =
2761536_2 (GHMatters) P83863.PCT 8/06112 =
Received 08/06/2012 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 = 510kg x 0.44kWhr/kg = 225 kWhr Balance 3,096 - (1,360 + 225) =+1,511 kWhr 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.
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 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 = water for 1 week.
= The product patties settled at the bath/slag interface and started reacting within the *
= furnace.
= i = 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.
= There was very little fume generation compared to plastic and rubber alternative products.
2761536_2 (GHMatters) P83663 PCT 6106112 =
= CA 02807744 2013-02-07 Received 08/06/2012 = Charge reaction ¨ no noticeable change adding 100kg, 200kg and 300kg/heat in bottom bucket 1.
The results of the trial indicate significant business opportunities based on the s composite product of the present invention.
In particular, the applicant realised from the trial that a compoSite product of 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 io than the steelmaking industry, with these applications including 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 engineered fuels.
In addition, the applicant realised from the trial that a composite product of the is 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 20 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 25 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 ' 30 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 35 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.
AMENDED SHEET 2761536_2 (GHMatters) P83863 PCT 8106112 = =
Received 08/06/2012 Based on the trial, the applicant believes that if the composite product patties 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.
5 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 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 ' io reaction and shielded the reactants within the product.
There should be a large thermal 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 400 C) = and reaction products leaving the surface of the briquette. For example, this should insulate 15 the product patties from the surrounding high temperature steel and slag (1500 ¨ 1750 C) and allow the product patties to last longer.
=
Fuel is released at a controlled rate as only that exposed at the surface reacts.
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 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 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 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.
2761536_2 (GHMatters) P83863 PCT 8/06/12 Received 08/06/2012 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 s 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 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.
10 =
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:
15 = 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 20 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.
25 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.
=
= 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 115 C and vaporises -350 C).
= The carbon and hydrogen components of the polymeric material binder may assist in combustion/reduction based methods.
=
AMENDED SHEET
IPEA/AU
27615.38_2 (GHMatters) P83863.PCT 8/06/12 = =
Received 08/06/2012 = The use of the polymeric material acting as a binder could be applied to any = suitable high temperature method and not only, high temperature methods in metallurgical fu.maces.
= 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-, bearing material and the other product type being based on a carbon-bearing material.
io = 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 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.
= 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.
' = The use of the product under and within a scrap charge for an electric arc steelmaking method facilitates close contact heating qf the scrap charge and potentially improved heat transfer and efficient use of energy.
= 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.
Many modifications may be made to the present invention described above without departing from the spirit and scope of the invention.
2761536_2 (GHMatters) P83863 PCT 8106112
Claims (31)
1. A method of manufacturing a composite product in the form of (a) a polymeric material binder and a metal-bearing material or (b) the 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, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product.
2. The method of manufacturing the composite product that comprises the polymeric material binder and the metal-containing material defined in claim 1 includes mixing other materials, such as materials that are sources of carbon other than the polymeric material binder, with the metal-bearing material and the polymeric material
3. The method defined in claim 2 wherein the other sources of carbon comprise any one or more of biomass, flyash, rubber, paper, coke fines, char fines, coal fines, toner from printers and photocopying machines, and any other suitable organic material.
4. The method defined in any one of the preceding claims comprises controlling the method and the selection of the metal-bearing material (when present), the carbon-bearing material (when present), and the polymeric material binder to produce a product having a required porosity.
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 metal-bearing material and the polymeric material binder so that there is a uniform dispersion of the metal-bearing material through the product.
7. The method defined in any one of claims 1 to 6 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.
8. 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.
9. The method defined in any one of the preceding claims comprises selecting the metal-bearing material and the carbon-bearing material so that these materials remain as solids during the heating step.
10. The method defined in any one of the preceding claims 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.
11. The method defined in any one of the preceding claims wherein the polymeric binder material is a recycled polymeric material, such as a recycled polyethylene such as a low density polyethylene or a high density polypropylene or a recycled polypropylene.
12. The method defined in any one of the preceding claims wherein the carbon-bearing material is in the form of biomass, flyash, rubber, paper, coke fines, char fines, coal fines, used toner from printers and photocopying machines, and any other suitable organic material.
13. The method defined in any one of the preceding claims includes forming the heated mixture into the composite product by extruding the heated mixture.
14. A composite product comprises a metal-bearing material and a polymeric material that acts as a binder for the metal-bearing material.
15. The product defined in claim 14 comprises other materials, such as materials that are sources of carbon other than the polymeric material binder.
16. A composite product comprises a carbon-bearing material and a polymeric material that acts as a binder for the carbon-bearing material.
17. The product defined in claim 16 comprises other materials, such as a metal-bearing material.
18. The product defined in any one of claims 14 to 17 comprises a continuous network of the polymeric material and a uniform dispersion of the metal-bearing material or the carbon-bearing material.
19. The product defined in any one of claims 14 to 18 being a non-porous product and hence being at least substantially waterproof.
20. The product defined in any one of claims 14 to 19 comprising an outer covering of the polymeric. material.
21. The product defined in any one of claims 14 to 20 wherein the polymeric material comprises greater than 10 wt.% of the product.
22. The product defined in any one of claims 14 to 21 wherein the polymeric material comprises less than 50 wt.% of the product.
23. The product defined in any one of claims 14 to 22 wherein the polymeric material is a recycled polyethylene such as a low density polyethylene or a high density polyethylene or a recycled polypropylene.
24.
material is in the form of mill scale fines and/or baghouse dust or other by-products from a The product defined in any one of claims 14 to 23 wherein metal-bearing steelmaking plant.
material is in the form of mill scale fines and/or baghouse dust or other by-products from a The product defined in any one of claims 14 to 23 wherein metal-bearing steelmaking plant.
25. The product defined in any one of claims 14 to 24 wherein the carbon-bearing material is in the form of particles of biomass, flyash, rubber, paper, coke fines, char fines, used toner from printers and photocopying machines, and any other suitable organic materials.
26. The product defined in any one of claims 14 to 25 being made completely from recycled materials, with each of the polymeric binder material and the metal-bearing material (when present) and the carbon-bearing material (when present) being recycled materials.
27. The product defined in any one of claims 14 to 26 in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks.
28.
of at least 10 cm.
The product defined in any one of claims 14 to 27 having a major dimension
of at least 10 cm.
The product defined in any one of claims 14 to 27 having a major dimension
29. The product defined in any one of claims 14 to 28 being at least 1 kg.
30. A method for producing a molten Metal that comprises supplying the composite product defined in any one of claims 14 to 29 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 12 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 furnace
31. A method for producing a molten metal that comprises supplying the composite product defined in any one of claims 14 to 29 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 12 to 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.
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|---|---|---|---|
| AU2010903554A AU2010903554A0 (en) | 2010-08-09 | Composite Products and Manufacturing Method | |
| AU2010903554 | 2010-08-09 | ||
| PCT/AU2011/000960 WO2012019216A1 (en) | 2010-08-09 | 2011-08-01 | Composite products and manufacturing method |
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| Publication Number | Publication Date |
|---|---|
| CA2807744A1 true CA2807744A1 (en) | 2012-02-16 |
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| US (2) | US20130228044A1 (en) |
| EP (1) | EP2603617A4 (en) |
| JP (1) | JP2013533366A (en) |
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| CA (1) | CA2807744A1 (en) |
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| MX (1) | MX2013001590A (en) |
| WO (1) | WO2012019216A1 (en) |
| ZA (1) | ZA201301145B (en) |
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| WO2013014318A1 (en) * | 2011-07-26 | 2013-01-31 | Universitat De Barcelona | Inertization of electric-arc furnace dust by means of the stabilizing integration thereof in a construction material |
| ES2499840B1 (en) * | 2011-09-06 | 2015-08-17 | Nicolás GRINGAUS URRUTIA | SPOON WITH FLEXIBLE EDGES |
| JP6171390B2 (en) * | 2013-02-18 | 2017-08-02 | 日立化成株式会社 | Powder mixture |
| US20150165701A1 (en) * | 2013-12-18 | 2015-06-18 | Gaudreau Environnement Inc. | Method of Manufacturing Paving Slabs |
| 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 |
| RU2664330C1 (en) * | 2018-04-05 | 2018-08-16 | федеральное государственное бюджетное образовательное учреждение высшего образования "Кузбасский государственный технический университет имени Т.Ф. Горбачева" (КузГТУ) | Composite fuel |
| DE102020206095A1 (en) * | 2020-05-14 | 2021-11-18 | Bernegger Gmbh | Methods of preparing waste material |
| IT202100031460A1 (en) | 2021-12-15 | 2023-06-15 | Pipex Energy S R L | METHOD FOR PRODUCING A FERROUS ALLOY IN A METALLURGICAL FURNACE. |
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| GB901789A (en) * | 1959-02-20 | 1962-07-25 | Stamicarbon | Improvements relating to agglomerated fuels and the production thereof |
| US4236897A (en) * | 1978-09-18 | 1980-12-02 | Johnston Ian F | Fuel pellets |
| US4659374A (en) * | 1985-06-14 | 1987-04-21 | Dow Corning Corporation | Mixed binder systems for agglomerates |
| US20010016244A1 (en) * | 1994-02-09 | 2001-08-23 | Preston Lynn E. | Process of recycling waste polymeric material and an article utilizing the same |
| US5554207A (en) * | 1994-11-25 | 1996-09-10 | Usx Corporation | Process of recycling iron oxides and plastics in steelmaking |
| BE1010378A6 (en) * | 1996-06-21 | 1998-07-07 | Centre Rech Metallurgique | Method of recycling iron and steel manufacturing waste |
| CA2180882A1 (en) * | 1996-07-10 | 1998-01-11 | Vic De Zen | Substructure for composite products and products formed therewith |
| US6165238A (en) | 1999-06-14 | 2000-12-26 | Cq Inc. | Fuel pellet and method for its production |
| JP2001049357A (en) * | 1999-08-03 | 2001-02-20 | Kiriu Mach Mfg Co Ltd | Fuel briquette for cupola and production thereof |
| TW445202B (en) * | 1999-11-02 | 2001-07-11 | Nippon Kokan Kk | Molded lump and its production method thereof |
| JP2001348626A (en) * | 2000-06-09 | 2001-12-18 | Daido Steel Co Ltd | Raw material for melting metallic material |
| JP2002161318A (en) * | 2000-09-14 | 2002-06-04 | Nippon Steel Corp | Method for controlling growth of deposit layer in rotary hearth furnace and agglomerate of metallic oxide therefor |
| JP2002235122A (en) * | 2001-02-06 | 2002-08-23 | Tetsugen Corp | Method for producing powder agglomerate using waste plastics as binder |
| JP2004052002A (en) * | 2002-07-16 | 2004-02-19 | Mitsui Bussan Raw Materials Development Corp | Method of reducing metal oxide, and resin solid material used in this method and forming equipment |
| US20090235577A1 (en) * | 2003-12-17 | 2009-09-24 | Kela Energy, Llc | Methods For Binding Particulate Solids And Particulate Solid Compositions |
| US7700038B2 (en) * | 2005-03-21 | 2010-04-20 | Ati Properties, Inc. | Formed articles including master alloy, and methods of making and using the same |
| US7632330B2 (en) * | 2006-03-13 | 2009-12-15 | Michigan Technological University | Production of iron using environmentally-benign renewable or recycled reducing agents |
| CN101443465B (en) * | 2006-03-13 | 2013-10-16 | 密歇根理工大学 | Production of iron using environmentally-benign renewable or recycled reducing agent |
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- 2011-08-01 BR BR112013003261A patent/BR112013003261A2/en not_active Application Discontinuation
- 2011-08-01 JP JP2013523433A patent/JP2013533366A/en active Pending
- 2011-08-01 CA CA2807744A patent/CA2807744A1/en not_active Abandoned
- 2011-08-01 US US13/814,933 patent/US20130228044A1/en not_active Abandoned
- 2011-08-01 WO PCT/AU2011/000960 patent/WO2012019216A1/en active Application Filing
- 2011-08-01 EP EP11815892.2A patent/EP2603617A4/en not_active Withdrawn
- 2011-08-01 AU AU2011288959A patent/AU2011288959B2/en active Active
- 2011-08-01 CN CN201180048790.5A patent/CN103429768B/en not_active Expired - Fee Related
- 2011-08-01 EA EA201390205A patent/EA026994B1/en not_active IP Right Cessation
- 2011-08-01 KR KR1020137005260A patent/KR20130103716A/en not_active Application Discontinuation
-
2013
- 2013-02-08 ZA ZA2013/01145A patent/ZA201301145B/en unknown
-
2015
- 2015-11-24 US US14/950,375 patent/US20160281013A9/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| EP2603617A1 (en) | 2013-06-19 |
| AU2011288959A1 (en) | 2013-03-14 |
| WO2012019216A1 (en) | 2012-02-16 |
| US20160075959A1 (en) | 2016-03-17 |
| ZA201301145B (en) | 2014-06-25 |
| US20160281013A9 (en) | 2016-09-29 |
| EP2603617A4 (en) | 2016-02-24 |
| CN103429768B (en) | 2017-03-15 |
| KR20130103716A (en) | 2013-09-24 |
| EA026994B1 (en) | 2017-06-30 |
| JP2013533366A (en) | 2013-08-22 |
| BR112013003261A2 (en) | 2016-06-14 |
| CN103429768A (en) | 2013-12-04 |
| EA201390205A1 (en) | 2013-08-30 |
| US20130228044A1 (en) | 2013-09-05 |
| AU2011288959B2 (en) | 2015-07-30 |
| MX2013001590A (en) | 2013-10-28 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request |
Effective date: 20160708 |
|
| FZDE | Discontinued |
Effective date: 20190801 |