US2371619A - Process of and apparatus for facilitating and controlling chemical reactions and physical treatments - Google Patents

Description

March 20, 1945. J. c. HARTLEY 2,371,619 PROCESS OF AND APPARATUS FOR FACILITATING AND CONTROLLING CHEMICAL REACTIONS AND PHYSICAL.TREATMENTS Filed June 5, 1940 6 Sheets-Sheet l INVENTOR f/wfs CHART/.5)!

Z @QQZ KZW ATTORNEYS March 20, 1945. .1, c. HARTLEY 2,371,619

PROCESS OF AND APPARATUS FOR FACILITATING AND CONTROLLING CHEMICAL REACTIONS AND PHYSICAL TREATMENTS Filed June 3, 1940 6 Sheets-Sheet 2 INVENTOR JI4NJ C HARTLEY BY 7 ww ww w ATTORNEYS March 20, 1945.

J. C. HARTLEY PROCESS OF AND APPARATUS FOR FACILITATING AND CONTROLLING CHEMICAL REACTIONS AND PHYSICAL TREATMENTS Filed June 5, 1940 6 Sheets-Sheet 3 p/eapucr INVENTOR fines C. #42725) 2,371,619 PROCESS OF AND APPARATUS FOR FACILITATING AND CONTROLLING INVENTOR .fwfa CHARTLfX BY 9 Q 6 Sheets-Sheet 4 J. C. HARTLEY Filed June 3,

6 wzm CHEMICAL REACTIONS AND PHYSICAL TREATMENTS March 20, 1945.

6 Sheets-Sheet 5 J. C. HARTLEY Filed June 3, 1940 CHEMICAL REACTIONS AND PHYSICAL TREATMENTS PROCESS OF AND APPARATUS FOR FACILITATING AND CONTROLLING March 20, 1945.

ymvw E o n .N m Wm. WC W im @W M! B /22 HO 2 2 2w 4% p g M y 2 m w fl March 20, 1945. J. c. HARTLEY PROCESS OF AND APPARATUS FOR FACILITATING AND CONTROLLING CHEMICAL REACTIONS AND PHYSICAL TREATMENTS 6 Sheets-Sheet 6 Filed June 3, 1940 V/ I u/ M 2 H 0 I I 2/ n H. n: M w W 2 2 2/ HI i I 4 208 INVENTOR Iva-1s 6. HARHEY /8 2/6 ATTORNEYS Patented Mar. 20, 1945 2 371 519 PROCESS OF AND APPARATUS FOR FACILI- TATING AND CONTROLLING CHEMICAL REACTIONS AND PHYSICAL TREATMENTS James C. Hartley, Nor-walk, Conn., assignor, by mesne assignments, to Minerals and Metals Corporation, New York, N. Y., a corporation oi Delaware Application June3, 1940, Serial No. 333,560

' 4 Claims. 2&6-21) This invention relates to processes of and apparatus for facilitating and controlling chemical reactions or physical treatments in which one or more solids in a comparatively finely divided coninsure a rapid, uniform, emcient and effective carrying out of the desired chemical reaction or physical treatment and an end product of superior quality.

dition are involved. 5 An important feature of the present invention In various chemical processes and in various is the manipulation and control of a fluid or processes of efiecting physical treatments of mafluids, preferably but not necessarily a gas or in which at least some of the materials vapor, to obtain the desired facilitation and conwhich react or which are to be acted upon are trol of a chemical reaction or a physical treatsolids in a comparatively finely divided condition, ment in which a solid or solids, in a comparatively difilculty is usually experienced in securing unifinely divided condition, is or are involved, the form, rapid and complete chemical reaction fluid in substantially all cases having a plurality hro hout the mass of the finely divided solid of functions. If, for example, the fluid employed or uniform and rapid physical treatment of all in practicing the process be one of the reagents of the individual particles of the mass. This is of a chemical reaction, the invention contem- Particularly t f chemical processes which inplates utilizing the fluid both to take part in the volve either the reaction of a solid in finely direaction and to provide or to assist in providing vided form with a fluid reagent or the reaction th desired physical conditions favoring the reof two intimately commingled solids in finely diaction, such as temperature control, agitation of vided form, promoted usually by providing temthe finely divided material to expose the particles perature and pressure conditions favorable to the to reaction or treatment or to insure catalytic reaction, and some form of agitation. contact in those cases where the finely divided Among the chemical reactions or physical solid is a catalyst, movement of the finely divided treatments, to the facilitation and control of material progressively through the reaction zone, which the present invention will lend itself, are and movement of the particles of the material reduction reactions which involve either the reinto wiping, rubbing or impacted contact with duction of finely divided ores by means of solid each other to keep their surfaces in proper reacreducing agents, such as carbon, or the reduction tive condition and to eifect mechanical separaof finely divided ores with fluid reducing agents, tion of extraneous matter. If the reagents of a such as carbon monoxide gas or hydrogen or hychemical reaction both be finely divided solids, drocarbons, catalytic processes in which the cataintimately commingled, the invention contemlyst is in a finely divided state, for example, the plates employing the fluid both to create or to catalytic cracking of hydrocarbons to form gasoaid in creating physical conditions favorable to line either in the presence of hydrogen or in the the reaction and also to effect agitation and adpresence of other gases, regenerative processes in vancing movement of the particles to insure reacwhich finely divided catalyst or other contact tive contact of the reagents, their exposure to the masses containing foreign deposits, such as carphysical conditions and their movement through bonaceous deposits formed during catalytic conthe reaction zone. version of hydrocarbon oils, are treated with a If, as another example, the reaction involve regenerating agent to oxidize or otherwise remerely the physical treatment of the material as, move said deposits, partial reduction processes for example, when performing a preliminary such as those sometimes employed as steps in ore roasting or other physical beneficiating treatment beneficiating processes, and impregnation or coatof an ore preparatory to reduction or when coating processes, such, for example, as processes of ing or impregnating an ore with carbon or other impregnating or coating finely divided ores with elements or compounds, whether or not the carcarbon preparatory to reduction. Other chemibon be produced by decomposition of a hydrocarcal reactions and physical treatments, to the fabon or other compound by the ore itself, the incilitation and control of which the invention can vention contemplates employing the fluid to proreadily be applied, will suggest themselves to those duce physical conditions favorable to the desired skilled in the art. treatment, to act as a carrier for the carbon or A eneral object of the present invention is to other means used in effecting some physical treatprovide a process of, and apparatus for, facilitatments and to insure the agitation and advancing ing and controlling chemical reactions or physical movement of the finely divided solid through the treatments, in which solids in a comparatively treatment zone. The invention also contemplates finely divided condition are involved, which will l6 employing the fluid in a classifying capacity to insure selective treatment. To this end the fluid will he so directed that the smaller and lighter particles of a finely divided solid will be carried more quickly through the reaction zone while the larger and heavier particles will remain longer in the reaction zone and thus be subjected to a more extensive treatment.

Another important feature of the invention is the introduction of the fluid into the zone of reaction or treatment in a. pluraliiaj of individual streams of the fluid, each designed to perform the multiple functions hereinabove referred to, and the arrangement and control of these individual streams so that close control may be maintained of the various conditions which determine the eiliciency and the eil'ectiveness of the operations being carried out. More particularly the invention aims to cause the individual streams of a group of streams of the fluid to flow through a loose mass of the finely divided solid with such force and in such direction in respect to the gravi. tational pull on the solid particles that the particles of the solid, as they are disturbed by the fluid from the positions toward which gravity tends to pull them, will gradually travel across the group of streams and be acted upon in eventual succession by each of the streams of said up. v

A particular object of the invention is to make possible both agitation of a finely divided material. in order to insure treatment of or reactive contact with all particles thereof, and its progression through the zone of reaction or treatment in cases where the reactions or treatments take place at temperatures above those at which the parts of mechanical agitators lose their resiliency or elasticity.

As hereinabove suggested, among the chemical reactions or physical treatments, to the facilitation and control of which the present invention will contribute, are reduction reactions involving the reduction of finely divided ores. For the pun pose merely of illustrating one of its many uses. the invention will be specifically described and shown as applied to the reduction of finely divided ores such, for example, as finely divided point of the metal, of finely divided metallic oxides or other ores;

Figure 2 is a transverse section on the line 2-2 of Figure 1;

Figure 3 is a sectional detail on the line 33 of Figure 4 illustrating the face construction of a one side of one of the blocks which are preferably used in forming the grate or hearth having the slots or jet orifices of the present invention;

Figure 4 is a section on the line 4-4 of Figure 3;

Figure 5 is a section on the line 5-5 of Figure 4;

Figure 6 is a vertical section through another form of apparatus in which the finely divided material to be treated or which is to take part in the reaction or treatment passes in succession through a series of reaction chambers arranged one above the other and each embodying structural features of the present invention and in each of which the material is separately treated;

Figure 7 is a section on the line 1-1 of Figure 6;

Figure 8 is a vertical section through still another form of apparatus in which provision is made for treating or eifecting reactions with a finely divided material in a series of reaction chambers arranged one above the other, this apparatus having provision for passing the treating fluid or fluid to be treated in succession through the reaction chambers;

Figure 9 is a section on the line 9-9 of Figure 8;

Figure 10 is a vertical section through still another form of apparatus in which provision is made for the use of two diflcrent treating fluids or fluids to be treated, one entering the treating or reaction chamber from above and the other n'om below, this view also showing a series of ren action chambers through which the finely divided magnetite ores or iron sands, and particularly to the reduction of such ores at temperatures below the fusing point of the metal or of the gangue. It will be understood, of course, that there is no intention, in thus specifically describing one of the many uses of the invention, to limit it either to the described use or to use in the particular held in which the described use lies. General reference will he made hereinafter to some of the other uses of the invention and to adaptation of the apparatus to such uses.

It will be understood that the novel process of the present invention can be carried out with many diilerent arrangements of apparatus and that many diilerent arrangements of apparatus will be required for meeting the varying conditions presented by the different uses to which the invention may be put. Illustrative forms of apparatus embodying structural characteristics useful in practicing the novel process of the present invention are shown in the accompanying drawings, in which:

Figure 1 is a longitudinal section through one form of apparatus embodying structural features of the present invention'and useful in practicing the novel process thereof, the illustrative apparatus being particularly suited for effectingthe reduction, at temperatures below the melting material may pass in succession;

Figure 11 is a section on the line I l--l l of F ure 10;

Figure 12 shows an modification of the invention in which the fluid employed is introduced into the reaction chamber in individual, definitely directed streams, not only through slots or jets in the material supporting grate but also through slots or jets in the side walls of the reaction chamber; and

Figure 13 is a section on the line l'I-ll of Figure 12.

Referring now to the illustrative embodiment of the invention which is shown in Figures 1 and 2 of the drawings, the slotted grate or hearth 2, for supporting the finely divided material to be treated or which is to take part in the reaction or treatment, is located in a reaction or treating chamber 4 which may have its wall formed of any suitable heat-resisting metal alloy. The reaction chamber 4 is located in a heating chamber 6 having walls 8 of suitable heat-resisting, and preferably also heat-insulating, material or refractory. The reaction or treating chamber 4 is shown as suspended in the heating chamber 6 by rods or bolts Iii which extend through cross bars l2 beneath the chamber 4 and through cross bars l4 extending across the top wall of the heating chamber 8. The rods or bolts III are preferably headed at the lower ends and provided with nuts H5 at their threaded upper ends.

For convenience the chamber 4 and similar chambers in other illustrated embodiments will be referred to hereinafter as a "reaction chamher" but it will be understood that the apparatus and the process are not restricted to the control of chemical reactions and that the finely divided material may undergo or take part in a physical treatment in the apparatus and by the process to equal advantage.

The grate 2 of the apparatus shown in Figures 1 and 2 is provided with inclined slots or jet orifices I 8 which may be of the sectional shape shown in Figure 5, the slots or jet orifices l8 bein preferably all inclined in the same general direction so that the fluid streams jetting from them are substantially parallel, the illustrated arrangement being such that the progressing action of the fluid jets or streams upon the finely divided material upon the grate 2 is from right to .left in Figure 1. Practical dimensions for the jet orifices or slots l8 may vary somewhat with the material to be treated, but successful agitation, progression and reduction of finely divided and concentrated magnetite ores, ground substantially to 100 mesh size, has been effected with slots or jet orifices of 0.010" smaller dimension at their jet ends and of 0.1875" corresponding dimension at their intake ends. Contemplated commercial jet dimensions for reduction of finely divided iron ores are 0.03125" smaller dimension and 6" larger dimension at the jet end and 0.1875" smaller dimension at the intake end.

These jets or slots [8 may be of varying larger dimension or length across the grate but, as shown in Figure 2 of the drawings, better control of the operation can usually be obtained by not making the larger dimension or the extent of the slot across the grate too great and, instead, dividing the reaction chamber into a plurality of longitudinally extending compartments so that each compartment will have therein a succession of slots or jet orifices of the desired jet thickness and of not too great extent across the grate.

A convenient way of providing the grate 2 with slots or jet orifices of the character shown particularly in Figure 5 is to form the grate or each of which has on one side a smooth face and on its opposite side a face having a recess molded or milled into it, which will form with the smooth face of the adjacent section a slot or jet orifice of the desired form. The blocks 20; in one side of each of which a slot or jet recess is molded or milled and the opposite side of which forms the remaining wall of a slot or jet recessed into an adjacent block, may be of any suitable material, such as a heat-resisting alloy or a refractory, and the blocks may be clamped or tied together in any suitable manner to allow for expansion and contraction under the varying temperature conditions to which they are subjected, the particular manner of effecting such clamping not being herein shown. As shown. however, in Figures '7, 9, 11 and 17, the slots 18 stop somewhat short of the side edges of the blocks 20, it being found in practice that it is not necessary to extend the slots or jet orifices entirely to the side walls of the reaction compartment.

The gas or other-fluid to be forced through the slots or jets 18 in the grate or hearth 2 is caused to flow into the reaction chamber 4 from conduits or jet manifolds located below the grate 2 and preferably from a plurality of separate manifolds 22, each serving a different section of the grate or hearth 2 along the length thereof. By providing a plurality of separate manifolds, each serving a section of the grate or hearth 2, for introducing the gas or other fluid that is to pass up through the slots or jet orifices l8, better control ofthe distribution of the gas or fluid can be had and also any desired variation in pressure or temperature along different sections of the grate or hearth can be obtained, each manifold 22 serving a plurality of jet orifices ll.

As herein shown, the reaction chamber 4 is divided into a plurality of longitudinally extending reaction compartments 23 by partitions 24 and each of these compartments has its own grate or hearth 2 and has beneath the grate a series of manifolds 22, each arranged to direct the gas or other fluid through the jet orifices l8 of a particular section of the grate or hearth 2. In other words, each manifold 22 directs the gas or other fluid through a group of slots or jets l8, thus providing, for that particular group, the same pressure, the same temperature and the same kind and quality of gas in each slot or jet of the group.

Extending across the bottom of the reaction compartment 4 are other manifolds 26 having penings 2'! into each of the correspondingly located jet manifolds 22 of the grates or hearths 2 of the different longitudinal compartments 23 of the reaction chamber 4 which are defined by the partitions 24. Each manifold 26 will preferably be tapered from its intake, as shown in Figure 2, to insure uniform .distribution of the gas or other fluid to the series of manifolds 22 served by it.

The manifolds 26 are connected by tubes 28 with a longitudinally extending manifold 30 from the source of gas or other fluid supply. The manifold 30 is preferably located inside the heating chamber 6 for reasons shortly to appear. The manifold 30, the connecting tubes 28, the manifolds 26 and the manifolds 22 being all exposed to the heat of the heating chamber 5, the gas or other fiuid passing therethrough will be preheated before it passes up through the slots or jets l8. If the gas be formed in a gas producer or be put through areforming device in hearth 2 of a plurality of sections or blocks 20, 7 which it is heated as an incident to the reforming operation, it may have substantial preheating before it enters the manifold 30. In any event, it will usually be raised to the desired temperature for the reaction or other treatment to take place in the reaction compartment 4 before it is caused to pass up through the slots or jets N3 in the grate 2. The manifold 30, like the manifolds 26 preferably tapers from its intake, as shown by the shade lines in Figure 2, so as to insure uniform distribution of the gas or other fluid to the manifolds 26.

The pulverized concentrated ore or other finely divided solid to be treated or to take part in the treatment in the chamber 4 may be introduced or charged into the reaction chamber 4 in any suitable manner. As herein shown, it is so introduced into the chamber 4 through chutes 32 that it is deposited upon the right hand end of the grate or hearth 2. there being a separate chute 32 for each longitudinal compartment defined by the division walls 24. The chutes 32 may be fed from a hopper 34 by any suitable feed control device, such as star feeder 36, which will deliver the material to be treated to the hearth or grate 2 in such measured quantities, in respect to the rate of travel of the material across the hearth or grate 2, as to maintain a constant supply for a continuous operation or, in other words, the rate of feed of material through the chutes 32 to the respective grates or hearths 2 of the respective compartments in the reaction chamber 4 will be commensurate with the rate of treatment of the material on the grates or hearths 2.

If the material treated in the reaction chamber 4 be a finely divided concentrated iron oxide such as the magnetite oxide of iron, F8304, to be reduced as it travels through the chamber 4, it will be apparent that, as the material is caused to travel along the grate or hearth 2 from the right hand end toward the left hand end, assuming uniform feed of material through the chute 32 to the right hand end of the grate or hearth, the thickness of the layer of material on different sections of the grate 2 may vary somewhat and that the specific gravity of the particles may also vary, due to the reduction which takes place as the material travels from the right hand end of the grate or hearth 2 toward the left hand end. The resistance to passage of the gas through the layer of finely divided material upon the hearth 2 will, in such cases, usually be greater at the right hand end of the hearth 2 than at the left hand end where the oxide is substantially completely reduced. In providing for discharge of the gaseous products of reduction from the reaction chamber and from the individual compartments thereof, consideration is therefore taken of these differences in resistance to gas fiow through the charge and the chamber is so shaped that the stack or exhaust 38 is located nearer the right hand end of the chamber, the left hand part of the chamber 4 being provided with a long gradually sloping upper wall 39, extending from the left hand side wall 40 of the chamber 4 to the stack, and the right hand end of the chamber 4 being provided with a more steeply sloping upper wall 42, extending from the right hand side wall 44 of the chamber 4 to the stack 38.

In order further to insure the desired direction and distribution of flow of the gas or gases throughout the reaction zone as they pass up through the slots or jets l8 of the grate 2 and on to the stack 38, each of the compartments defined by the partition walls 24 may be provided with baflles 45, 48 and 50, defining draft channels between the grate 2 and the common draft zone above the partitions 24.

From the foregoing description, it will be seen that, in the embodiment of the invention illustrated in Figures 1 and 2, a perforate grate or hearth 2 is provided, having therein slots or let orifices it of such shape, inclination and arrangement that, when the charge of finely divided solid material, such as a magnetite ore to be reduced, is introduced into one of the compartments of the reaction chamber 4 and deposited on the right hand end of the grate or hearth 2, the gas, which, in the case of a reduction operation, may be either a reducing gas or a gas for producing reducing conditions for a charge comprising an ore mixed with a reducing agent, when forced up through the jet orifices It, will cause the particles of the ore to be projected upward away from the surface of the grate 2, with a slight trajectory toward the left hand end of the grate. The particles projected upward by one jet will thus be thrown into the field of operation of one or more of the succeeding jets and thus gradually be caused to progress from the right hand end of the grate or hearth 2 toward the left hand end. In practice it has been found that to secure thorough commingling of the solid particles with the fluid the component of force in the direction across the hearth should. as above indicated, be less than the vertical component or, in other words, that the inclination of the slots to the hearth should be, as shown in the drawings, greater than It will be obvious that the extent of the traiectory of a particle projected from the hearth 2 by one of the jets will vary somewhat with the size, weight, or specific gravity of the particle and that it may fall back either into the field of operation of the immediately succeeding jet or it may, in its trajectory, pass over several succeeding jets before coming down sufficiently to be reprojected. It will thus be seen that the heavier and larger particles will usually travel more slowly across the grate or hearth 2 andthus be subjected to a more extended treatment in the reaction chamber, and to more agitation, a result which, in substantially all cases, will be desirable, particularly when reducing metal oxides.

As shown in Figure l of the drawings, there is preferably provided in the connections 28 between the manifold 30 and the manifolds 26, but

terfiy or other control valves 29 by which the pressure and rate of flow of the gas in the different manifolds 26 may be varied to vary the jet action along different sections of the grate or hearth 2. The valves 29 may be operated by shaft extensions to handles 3| on the outside of wall 8 of the chamber 5, as shown in Figure 2. In this manner the agitating and propelling force of the gas issuing from the jet orifices It can be varied and, therefore, the time that it takes the ore, or other material to be treated, to travel across the different sections of the hearth 2 may thus be varied together with the amount of agitation.

As the material to be treated reaches the left hand end of the hearth 2, in the apparatus shown in Figure 1, it may be discharged into a discharge chute or hopper 52, common to the longitudinal compartments 23 of the reaction chamber '4. At its lower end the chute or hopper 52 communicates with a horizontal conduit 54 in which a screw conveyor 55 serves both to insure a. gas sealing efi'ect'and to convey the product. without exposure to the air to the desired location. The conveyor 56 may discharge the product, such as sponge iron, into a spout 58 leading either to a cooling and packaging device or to a compacting and extruding or other metal working apparatus, such, for example, as that disclosed in the co-pending application of Herman A. Brassert and James C. Hartley, Serial No. 323,076, filed March 9, 1940.

Heat for heating the chamber 6 may be provided from any suitable source, such as the gaseous products of combustion from a gas producer or a gas reformer, introduced into the chamber 6 through the flue 64. If, for example, the gas used in the reaction in the chamber 4 be a reducing gas, either supplied from a gas producer for the ore or other material which is about to be charged into the reaction chamber 4 through the chutes 32.

In the modified form of apparatus shown in Figures 6 and 7 of the drawings, provision is made for the finely divided solid to be treated or to take part in a reaction or treatment in a series of reaction chambers in each of which the solid will be acted upon in much the same manner as in the reaction chamber 4 of the apparatus shown in Figures 1 and 2.

In the apparatus illustrated in Figures 6 and 7, reaction chambers 68, I and I2 are located, one above the other, in a heating chamber 14. serving substantially the same purpose as the heating chamber 8 in the form of the invention illustrated in Figures 1 and 2. In each of the reaction chambers 88, I0 and 12 is a grate or hearth 2, of the same construction as the corresponding grate in Figures 1 and 2, and beneath the grates 2 are manifolds 22, in turn connected to manifolds 26, the manifolds 28 being connected to an outside manifold, not shown,

in the same manner as the corresponding manifolds are connected to the manifold 30 in the form of apparatus shown in Figures 1 and 2.

The material to be treated, which, for example, may be an ore to be reduced or may be a powdered catalyst employed to facilitate a chemical reaction, such as the cracking and reforming of hydrocarbon oils, is first introduced into the topmost reaction chamber 88 in any suitable manner as, for example, through a chute 18, controlled by a gate valve operated by means of a rod 18 extending through the wall 80 of the chamber 14. The chute 16 is located so that it discharges the finely divided solid material upon the right hand end of the grate or hearth 2 of the reaction chamber 88, theslots or jet orifices I8 in the grate 2 of this chamber inclining to the left so that the movement of the material is toward the left hand end of the grate.

At the material reaches the left hand end of the grate 2 in the reaction chamber 68, it is discharged into a chute or conduit 82, having therein astar feeder 84 which permits transfer to the reaction chamber 10 of the material which has been treated in the reaction chamber 88, and deposit thereof upon the left hand end of the grate 2 in the chamber 10, without permitting the gaseous products of the reaction in chamber I0 to enter the chamber 68. In the same manner the material deposited upon the grate or hearth 2 of the reaction chamber I0 will be moved from the left hand end thereof, by reason of the inclination of the jet orifices or slots I8 in the grate 2 of this chamber, and will be discharged eventually into a chute or conduit 88 which connects this chamber with the chamber 12 and which is provided with a star feeder 88 to permit the material to be discharged from the chute 88 into the chamber 12 and deposited upon the right hand end of the grate 2 of said chamber 12, without allowing the gaseous products of the reaction in the chamber 12 to enter the chamber 10. The material deposited upon the right hand end of the grate or hearth 2 in reaction chamber 12, will, by reason of the inclination of the jet orifices or slots I8 in the grate 2 of said chamber I2, be gradually moved to the left hand end of the grate and discharged into a chute or conduit 90, which may deliver the material to a screw conveyor 92 to be conveyed to the point of use.

Burners 94 may supply heat to the heating chamber I4, as shown in Figure 6. To permit inspection of the operations going on in the various reaction chambers and thereby to permit accurate control of the speed of reaction and of the other physical conditions desirable for securing the best results, sight tubes 88 may be provided, as shown.

As more fully shown in Figure 7, the reaction chambers 68. I0 and 12 may be divided into a .pluraiity of longitudinally extending compartments by partition walls 98 which perform the same function as the partition walls 24 in the form of the invention shown in Figures 1 and 2. The gaseous products of the reactions in the reaction chambers 88, 10 and I2 may be discharged through exhaust openings I00, I02 and I04 into a stack or stacks I08.

In the illustrative embodiment of apparatus embodying structural features of the present invention, and useful in practicing the novel process thereof, which is shown in Figures 8 and 9, provision is made for passing the finely divided solid through a series of reaction chambers in which it is acted on in successive stages by the same gas or other fluid, the gaseous products of the reaction in the lowermost reaction chamber passing in succession through the reaction chambers located above it.

In the embodiment shown in Figures 8 and 9, the finely divided solid to be treated, or to take part in the reaction or treatment, enters first the uppermost reaction chamber I08, being introduced thereinto in any-suitable manner, as, for example, through chute IIO. After it has been moved across the grate or hearth 2 by the gas forced up through the Jet orifices I8 in the hearth 2 from the manifolds 22, it falls into a chute 2 connected with the reaction chamber H4. The chute I I2 is provided with a star feeder I I6, which makes possible transfer of the material that has been treated on the hearth 2 of the chamber I08 to the chamber II4, without permitting the gaseous products of the reaction in the chamber II4 to enter the chamber I08 other than by way of the jet orifices I8 of the hearth 2 of said chamber I08. The chamber I I4, like the chamber I08, is provided with a hearth 2, the orifices I8 of which are so inclined to the surface thereof I08 and m, is provided with a grate 2, the jet orifices III of which are so inclined that they cause the material deposited upon the left hand end of the grate 2 of the chamber I22 to be gradually moved to the right hand end of the said grate and discharged into the chute I24 for the end product. Beneath the grate or hearth 2 of the reaction chamber I22 are manifolds 22 connected to a manifold I28 which, in turn, is connected to a manifold I28 supplied from any suitable source of gas or other fluid supply.

From the foregoing description it will be seen that gas is introduced into the manifolds I28 for eventual use in all of the reaction chambers I08, H4 and I22, these chambers being preferably divided into compartments by partition members I30. The gas is delivered from the manifold I28 into the manifolds 22 beneath the grate or hearth 2 of the lowermost reaction chamber I22. After passing up through the jet orifices I8 of the grate or hearth 2 of the chamber I22 and effecting the agitation, treatment and feeding of the material,

on the hearth 2 of the chamber I22, the gaseous products of this treatment or reaction, together probably with some unchanged gas, pass into a manifold I32 formed by a partition member I84 between the chamber I22 and the manifolds 22 of the reaction chamber II4. This partition member I34 is preferably so inclined as to form a manifold I32 shaped to insure substantially even distribution of the gas, which enters the wide end of the manifold I32 through the opening I88, equally among the manifolds 22 beneath the hearth 2 of the reaction chamber II4. In the same manner the gases which have passed up through the jet orifices I8 of the hearth 2 of the chamber H4 and have done their work on the material resting upon this hearth, together with the gaseous products of the reaction in this chamber, pass beyond the partition member I88 into the manifold I40 which supplies the manifolds 22 beneath the grate or hearth 2 of the reaction chamber I08. The partition member I38, like the partition member I34, so inclined as to provide a manifold I40 that will insure substantially uniform distribution of the gas to the manifolds 22 of the reaction chamber I08.

The gaseous products of the reaction in the chamber I08 may pass out through the stack I42. The reaction chambers I08, H4 and I22 and the manifolds I28 and I23 are preferably exposed to the heat in a heating chamber I44 which may be supplied by heat in any suitable manner, as, for example, by burners I48, shown conventionally in the lower part thereof.

In the form of apparatus embodying the present invention and designed to practice the novel process thereof, which is illustrated in Figures 10 and 11 of the drawings, provision is made for the introduction into the reaction chambers of two different gases, or of the same gas, both above and below the material to be treated and to this end perforate grates are provided both in the bottom and in the top of each reaction chamber. As shown in Figure 10, a series of reaction chambers of the type Just described are arranged one above the other so that the finely divided material, first treated, or taking part in the reaction or treatment, in the topmost reaction chamber may be delivered in succession to the reaction chambers below it to receive further treatment in each. The reaction chambers herein shown, I48, I50 and IE2, are located in a common heating chamber I54 enclosed within walls of suitable material I58 and provided with a stack I58 for the exhaust gases with which the heating is effected.

Each of the reaction chambers I48, I50 and I52 is provided with a bottom grate 2 of the same character as the grate 2 in the form of apparatus shown in Figure 1, each of the grates 2 having below it manifolds 22, in turn connected with manifolds 26, the manifolds 26 being connected by tubes 28 to an outside manifold, not shown, which in turn is connected to any suitable source of supply of. gas or other fluid to be delivered to the manifolds 22 beneath the grates 2 of the respective chambers I48, I50 and I52.

As hereinabove suggested, each of the reaction chambers I48, I50 and I52 has its top wall formed by a grate 2' similar in construction to the grate 2 but discharging its Jets through jet openings I8 downwardly and in the same general direction along the chamber as the jets I8' in the grates 2. Above the upper grates 2' are located manifolds 22' of the same general construction as the manifolds 22 for the lower grates 2, these manifolds 22' connecting with manifolds 28' which in turn are connected by tubes 28' to a manifold, not shown, outside the heating chamber I54 and itself connected to any suitable source of gas or other fluid supply.

The form of the apparatus illustrated in Fi ures 10 and 11 is particularly useful when it is desired not only to treat a finely divided solid in the reaction chambers, I48, I50 and I52, but at the same time to cause a reaction between two different gases employed in eifecting the ultimate reaction in the reaction chamber, which gases also assist in creating the physical conditions essential to the reaction, such as agitation of the solid, turbulence of the gases and entrained particles of the solid and eventual movement of the solid along the grates toward the discharge end thereof.

As shown in Figure 10, the finely divided solid to be treated, or to participate in the treatment or reaction, may be introduced into the uppermost reaction chamber I48 in any suitable manner, as, for example, through a chute I connected to any suitable source of supply of the material to be treated, the charge of material being delivered upon the left hand end of the lower grate 2 of chamber I48 and the Jet orifices I8 in the grate 2 of said chamber bein so inclined that the gases jetting therefrom tend to move the material gradually toward the right hand end of the grate. If, for example, the material to be treated be a powdered ore, the gas forced through the jet orifices of the lower grate 2 be a gas which assists in the reduction of the ore and the products of the reduction operation form a combustible gas which it is desired to burn in the reaction chamber to produce the necessary heat, then air to supply the oxygen for combustion may be introduced through the jet orifices I8 of the upper grate 2'. In this manner not only will combustion to supply the necessary heat for the reaction be provided for in the reaction chamber I48, or in either of the succeeding reaction chambers I50 and I52, but the air for the combustion will be so introduced into the reaction chambers that it will assist in the movement of the material toward the discharge end of the grate 2 and at the same time assist in creating a turbulence in the chamber that will insure a thorough commingling and interaction of the particles of the reagents.

As herein shown, a chute I62, provided with a star feeder I84, provides for transfer of the material discharged from the right hand end of the grate 2 of the chamber I48 into the chamber I50 and a chute I88, provided with a star feeder I88, provides for transfer of the material discharged from the left hand end of the grate 2 of the reaction chamber I50 into the reaction chamber I52. The gaseous products of the reaction in the lowermost reaction chamber I52 pass up through the flue I10 into the upper end of the heating chamber I54 and out through the stack I58 together with theproducts of combustion from any heating means for said heating chamber. The gaseous products from the reaction in the reaction chamber I50 pass up through the flue I12 into the upper part of the heating chamber I54 and also pass out through the stack I58. The gaseous products from the reaction in the reaction chamber I48 may pass directly into the heating chamber I54 and then on to the stack I58.

As shown in Figure 11 of the drawings, each of the reaction chambers I48, I50 and I52 may be divided into longitudinally extending compartments by partitions I14 similar to the partitions 24 in the form of apparatus shown in Figures 1 and 2 of the drawings. Peep tubes I16, for observing the reactions taking place in the reaction chambers I48, I50 and I52, may be provided as desired.

In the embodiment of the invention illustrated in Figures 12 and 13, provision is made for introducing a gas or other fluid through slots or jet orifices in the side wall or walls of the individual reaction compartments in the reaction chamber, the illustrative embodiment of this form of the invention showing provision for the introduction of a gas or other fluid both through the side walls of the individual reaction compartments and through their bottom grates or hearths. In Figures 12 and 13, this modification is shown as applied to the uppermost reaction chamber of the form of the invention illustrated in Figures 8 and 9, in which the gases that issue from the jets I8 in the grates 2 are distributed to the jet manifolds 22 by a manifold I40, into which the gaseous products of the reaction in chamber H4 and any unreacted gas or gases surviving the reaction enter.

If, for example, reduction reactions are taking place in the reaction chambers H4 and I22 of the apparatus shown in Figures 8 and 9 and the ore to be reduced is to be brought to the reduction temperature and possibly roasted in the reaction chamber I08 before delivery to reaction chamber II4, without substantial reduction taking place in chamber I08, then an oxygen containing gas, to support the combustion of the gaseous products of the reduction which come to chamber I08 from the lower chambers I I4 and I22, can advantageously be introduced into the compartments in chamber I08 in which the preheating and/or roasting is taking place and preferably in such manner that there will be a thorough commingling with the gases to be burned and with the particles of the ore to be preheated and/or roasted. To this end, in the modified form of the topmost reaction chamber I08 of Figures 8 and 9 which is illustrated in Figures 16 and 17, instead of simple partition members I30 dividing the topmost reaction chamber into aplurality of compartments, the partitions are constituted by manifolds 206 separated by a dividing wall 208 and having a common top or cover 2| 0,'

the side walls of the reaction compartments 2I2 being constituted by grates 2 having slots or let orifices I8 communicating with the manifolds 206 and of the same typeand having substantially the same inclination to the surfaces of the grates 2I4 as do the slots or jet orifices I8 in the bottom grate 2. The manifolds 206, which supply gas to the orifices I8 of the side grates 2I4, in turn receive their gas or other fiuid from manifolds 2 I6 connected to any suitable outside source of gas supply.

If, as above suggested, the compartment I08 is to be utilized for heating and/or roasting an ore to be reduced in the compartments H4 and I22, then the manifolds 2"; can be supplied with preheated air which, as it passes through the slots or jet orifices I8 in the side grates 2I4, will mix with the gaseous products of reduction from chambers H4 and I22 and any unused reducing gases which enter the chamber I08 through the lower grates 2 and thus effect combustion of the combustible parts of these gases to supply at least a part of the heat required for preheating and/or roasting the ore preparatory to its delivery to the reduction chamber II4.

As above pointed out, the inclination of the slots or jet orifices I8 in the side grates 2I4 to the plane of the grate is such that the air entering the reaction compartments 2I2 through the side grate orifices tends not only to increase the turbulence in these reaction compartments, but also assists in effecting progression of the ore particles, or the particles of any other finely divided solid which is being treated, from left to right toward the discharge end of the grate 2. The invention, therefore, not only contemplates the use of a gas or other fluid, introduced through slots or jet orifices in a supporting grate, to effect the agitation and the progression over the supporting grate of a finely divided solid which is to be treated or which is to participate in a reaction or treatment in a reaction chamber, but it also contemplates the introduction of a gas or other fiuid through the side wall or walls of the reaction compartment in a similar manner for effecting such agitation and progression, either alone or in cooperation with the gas introduced through the bottom grate.

The mode of operation of the various forms of apparatus hereinabove described has been set forth to a considerable extent in connection with the detailed description thereof but may be briefly recapitulated. using for illustration the operation of the apparatus in the reduction of a finely divided and concentrated iron ore such as a magnetite ore. In practicing the novel process of the present invention to reduce finely ground and concentrated magnetite ores with the form of apparatus illustrated in Figures 1 and 2, the concentrated and finely divided ore is delivered in a preheated condition to, or is preheated in, a hopper, only the discharge end 34 of which is shown in Figures 1 and 2. Between the hopper and the individual chutes 32, which lead to the reaction compartments defined by the partition members 24, is a star feeder 36, having, as shown, a series of compartments 3! which feed successive measured quantities of ore from the hopper into the chutes 32, without at any time providing a continuous gas passage between the hopper and the chutes through which gas from the reaction chamber 4 might escape into the hopper.

The finely divided ore, traveling down the chutes 32, is delivered to the right hand ends of the grates 2 of the individual reaction compartments 23 in the reaction chamber 4 which are defined by the partition members 24. As soon as the ore is deposited upon or approximately reaches the surface of the grate or hearth 2 of the reaction compartment 23 it comes into the field of action of the jets of reduction gas issuing from the slots or jet orifices I8 above the manifold 22 at the extreme right. The gas supplied to the manifolds 22 may be a reduction gas supplying the entire reducing agent for reducing the magnetite ore or the ore may be coated or impregnated with carbon or have finely divided carbon intimately admixed therewith, in which case the reducing agent need not be supplied entirely or even at all by the gas supplied to the manifolds 22. For the purpose of this description, however, we will assume that the ore is a plain magnetite oxide of iron that has been subjected to a beneficiating treatment so that it contains few, if any, impurities and that the entire amount of reducing agent required is to be furnished by the gas supplied to the manifolds 22. Suitable gases for this urpose are either carbon monoxide or hydrogen or a mixture of the two such as is found in water gas, or the gas may be a hydrocarbon stabilized by reforming. Preferably the reducing gas supplied to the manifolds 22 will be one which is not likely to decompose and deposit carbon in the slots or jet orifices I8 at the temperatures employed for the reduction reaction.

It is both desirable and important that the reduction of the magnetite oxide take place at a temperature below the melting point of the iron and below the melting point of any associated impurities. It is also important, if the reducing agent comprise carbon monoxide, that the reaction be carried out at a temperature above that at which freshly reduced iron readily decomposes carbon monoxide. The reaction is, therefore, preferably carried out at a temperature above 1200 F. and preferably not much above 1800 F.

Preferably most of the heat for the reduction operation will be supplied by preheating the ore and by preheating the reduction gases. The ore may be preheated in any well known manner, for example, by utilizing the waste gases from the heating chamber 6, as hereinabove suggested. As also hereinabove suggested, the reducing gases, if they are delivered from a gas reformer which has utilized heat in the reforming operation, may contain a considerable amount of heat when they enter the manifold 30. As shown in Figure 1, the manifold 30 is located in the heat- 1 ing chamber 6 and will, therefore, supply some additional heat to the gases as they travel through it. Moreover, the connections 28 between the manifold 30 and the manifolds 28 are shown as extending for a considerable distance through the heat in the heating chamber 5 and the manifolds 26 and 22 are also shown as exposed to the heat in the chamber 5. In this manner the gases entering the manifold 22 can be brought to the desired reaction temperature and any loss of heat growing out of the endothermic nature of the reduction reaction in reducing magnetic oxides with CO and H may be made up by conduction through the walls of the reaction chamber 4 from the heating agent in chamber 6.

Assuming that the gas entering the manifolds 22 is a mixture of CO and H in suitable proportions and that it has been heated to a temperature of 1800" F. and that the magnetic oxide delivered from the chutes 32 upon the grates or hearths 2 has been preheated to substantially the same temperature, the gas will be forced through the manifolds 22 and through the Jet orifices l8 with sufficient force to keep the particles of magnetic oxide constantly agitated and thoroughly commingled with the gas and with each other and the orifices l8 will so direct these jets that as the oxide particles are lifted from the hearth 2 they will be projected partly in the desired direction of movement across the hearth toward the discharge end thereof, thus bringing them into the field of operation of one or more succeeding jets of reducing gas, This agitation and progression of the particles, which take place simultaneously in the reducing atmosphere provided by the gases, will result in the removal of the oxygen from the oxide by combination with the C0 and H, the constant agitation insuring both exposure to the reducing gas of all sides of the particles, a rubbing or impacting action of the particles against each other and against the hearth to effect the removal of any film of carbon dioxide or water vapor that may form there-' on and also to effect the removal or the cracking open of any reduced metal which might form a. contiguous and impervious skin on a particle as well as the removal of any mechanically connected impurities. The overall result is the production of conditions most favorable to the compelte reduction.

As the particles are gradually progressed along the grate 2 toward the left hand end thereof, it will be apparent that their size will probably decrease somewhat, owing both to the reduction andto the rubbing of the particles against each other, and it will also be apparent that their specific gravity will increase by reason of the separation of the oxygen from the iron. If, by reason of the change in the character of the particles or for any other reason it is found to be desirable to vary the force of the jets along different parts of the path of travel of the ore or other material across the hearth, this can be done by adjusting one or more of the butterfly valves 29 in the tubes 28 leading from the manifold 30 to the manifolds 26. Inspection of the operation upon the hearth 2 may be made through inspection tubes or vision ports 39.

As the reduced oxide or sponge iron reaches the left hand end of the grate 2 of Figure 1 it is discharged into a chute or hopper 52 common to all of the compartments 23. The hopper 52 at its discharge end communicates with a screw,

conveyor 56 which is arranged to deliver the reduced iron, without exposure to the air, either to suitable cooling and packaging apparatus or to compacting and extruding or other metal working apparatus, such as that disclosed in the copending application of Herman A. Brassert and James C. Hartley, Serial No. 323,076, filed March 9,}940. The gaseous products of the reduction reaction will pass out through the stack 38 and may be utilized in any manner to conserve their heat content or they may be regenerated to renew the supply of reducing reagent. By reason of the intimate commingling of the reducing gases with the ore to be reduced, resulting from the agitation and progression effected by the fluid reducing agent itself, the gaseous products of the reducing reaction will not contain as large a proportion of combustible constituents as do the gaseous products of many of the reduction reactions of the prior art.

Although it has been found in practice that a constant fiow-impelling pressure on the fluid delivered to the jet orifices I8 produces satisfactory agitation of the finely divided solid together with the desired progression thereof over the grate or hearth 2, the invention also contemplates the possibility of utilizing a, pulsating flow of the fluid to meet special conditions.

It will be understood that the grate or hearth 2, not being subjected to mechanical movement, may be made of any material capable of static resistance to deterioration under the physical and chemical conditions incident to the particular use to which the apparatus is being put. Moreover, although the jet orifices II in the grade or hearth 2 have been herein shown in the form of slots. and slots have some practical advantages, it will be understood that there is no intention to limit the invention to jet orifices of the particular forms or arrangements herein shown and described for illustrative purposes.

It will also be understood that the invention is not restricted to the illustrated means for supplying heat to the reaction or treatment chambers and that any of the well-known methods of supplying either the main or the makeup heat for the reaction or treatment may be employed where practicable.

This application, as to common subject matter, is a continuation in part of application Serial No'. 323,076, filed March 9, 1940. From.the application just identified in which, as filed, the present applicant, through inadvertence and mistake, and without fraudulent intent, appeared as joint applicant, the subject-matter common to this application and to said application Serial No. 323,- 076, as filed, and of which common subject matter the present applicant is sole inventor, will be divided.

What is claimed as new is:

1. Apparatus for use in bringing about a change in the chemical composition of a finely divided ore by reaction with a fluid reagent, comprising a plurality of substantially horizontally arranged hearths arranged in parallel for supporting the finely divided ore, each of said hearth being provided with a succession of jet orifices in the form of parallel closely-spaced narrow slits, said slits constituting the reduced immediate outlets of fluid-conducting slots of substantial crosssection extending approximately through said hearth, each of said slots having its greater crosssectional dimension transverse to the direction of movement of the finely divided ore across the hearth, and each having its fluid discharge directing walls inclined to the surface of the hearth, in the direction of movement of the ore thereacross, at an angle greater than 45, means, including means for supplying fluid reagent under the required pressure, for causing said fluid reagent, which is to be brought into reactive relation to the finely divided ore, to jet from each of said jet orifices with a, force which is substantially constant at the respective orifices and is suflicient to carry the fluid entirely through the mass of ore above each orifice and to project upwardly and also to carry into the field of action of a succeeding jet the particles of the ore encountered thereby in its travel through said mass, and means for maintaining in said fluid reagent and in said ore mass a temperature above the minimum reaction temperature for the desired reaction, but

fold and in which transversely extending manifolds are provided to supply the same pressure and quality of fluid to each of the group manifolds in corresponding locations beneath the respective hearths.

3; Apparatus for facilitating and controlling a chemical reaction or a physical treatment, in which a finely divided solid and a fluid are brought into interacting relation to each other,

comprising a plurality of hearths arranged one above the other forreceiving and supporting the finely divided solid in succession and conduits connecting the discharge end of each upper hearth with the receiving end of the hearth below it, each of said hearths being provided with a series of jet orifices inclined toward the discharge end and having defined locations in the hearth in respect to each other and in respect to the supporting surface of said hearth, a housing enclosing said hearths, means, including means for supplying fluid under the required pressure, for causing the fluid which is to be brought into interacting relation to the finely divided solid, to jet from said orifices with a force sufiicient to project from said hearth particles of the solid encountered thereby, and means in the conduit between successive hearths for intermittently feeding the material received from an upper hearth to the one beneath it, said means being below the fusion or sintering temperatures of any constructed to out off fluid flow through the conduit, said hearths being so constructed and arranged that the fluid flows in succession through the jet orifices of a lower hearth, through the material on said hearth and then through the jet orifices of the hearth above.

4. Apparatus for use in bringing about a change in the chemical composition of a finely divided ore by reaction with a fluid reagent, comprising a plurality of hearths arranged one above the other for receiving and supporting the finely divided ore in succession, and conduits connecting the discharge end of each upper hearth with the receiving end of the hearth below it, each of said hearths being provided with a series of jet orifices inclined toward the discharge end thereof and having definite locations in the hearth in respect to each other, and in respect to the supporting surface ofsaid hearth, a, housing enclosing said hearths and means, including means for supplying fluid under the required pressure separately to each hearth, for causing the fluid which is to be brought into interacting relation to the finely divided ore, to jet from said orifices with a. force sufficient to project from said hearth particles of the ore encountered thereby, and means in each conduit between successive hearths for intermittently feeding the material fed from the upper hearth to the one beneath it, said means being constructed to cut oil fluid fiow through the conduit.

JAMES C. HARTLEY.

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