US3272615A - Production of spheroidized particles - Google Patents

Production of spheroidized particles Download PDF

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Publication number
US3272615A
US3272615A US297635A US29763563A US3272615A US 3272615 A US3272615 A US 3272615A US 297635 A US297635 A US 297635A US 29763563 A US29763563 A US 29763563A US 3272615 A US3272615 A US 3272615A
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United States
Prior art keywords
particles
flame
passage
gas
zone
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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.)
Expired - Lifetime
Application number
US297635A
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English (en)
Inventor
Daniel J N Hoffman
Thomas B Beeton
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
South African Iron & Steel
SOUTH AFRICAN IRON AND STEEL INDUSTRIAL Corp Ltd
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South African Iron & Steel
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/50—Mixing liquids with solids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B01J2/02—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops
    • B01J2/04—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops in a gaseous medium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • B22F1/065—Spherical particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof

Definitions

  • This invention relates to the production of spheroidized particles, and more particularly spheroidized ferrosilicon particles.
  • a method of spheroidizing irregularly shaped particles includes the steps of passing a gas containing free oxygen in at least the proportion contained in air into an inner passage of a flame-producing nozzle; introducing a combustible gas through an annular passage in the nozzle surrounding the inner passage, thus producing a flame having a reducing zone at least towards its perimeter; feeding the irregularly shaped particles to be spheroidized into the inner passage; causing the particles to pass through the flame and its reducing zone thereby melting them at least at their surfaces; and allowing the thus spheroidized particles to enter a cooling zone.
  • oxidizing gas is blown into the center of the flame, and a combustible gas is supplied to produce a surrounding reducing zone at least towards the periphery of the flame. Particles to be spheroidized pass from the oxidizing center of the flame through the reducing zone upon leaving the flame and, as a result, too extensive oxidation of the particles is prevented. A so-called inverse flame is produced.
  • the flame characteristics can be improvide by mixing a small proportion of combustible gas with the oxidizing gas introduced into the inner passage of the flame-producing nozzle.
  • the irregularly shaped particles to be spheroidized are passed through a downwardly directed pencil-shaped flame.
  • irregularly shaped ferro-silicon particles containing from about to silicon, and preferably from about 12 to 17% silicon, are very suitable as the initial material.
  • Small amounts of other alloying constituents, such as, for example, copper or aluminum, which may have a beneficial effect on the spheroidizing, corrosion resistance, or other qualities of the particles, may be present or incorporated therein.
  • the initial material may, for example, be mechanically ground and then subjected to the spheroidizing treatment.
  • a method of spheroidizing irregularly shaped particles includes the steps of providing a high temperature flame; imparting a swirling motion to the irregularly shaped particles; passing the swirling particles through the flame; and allowing the particles to pass from the flame into a cooling zone.
  • a method of spheroidizing irregularly shaped particles includes the steps of discharging a gas containing free oxygen in at least the proportion contained in air from an inner passage of a flame-producing nozzle; discharging a combustible gas through an annular passage in the nozzle surrounding the inner passage, thus producing a flame having a reducing zone at least towards its perimeter; feeding the irregularly shaped particles to be spheroidized into the inner passage; imparting a swirling motion to particles issuing from the inner pass-age; causing the swirling particles to pass through the flame and its reducing zone thereby melting them at least at their surfaces; and allowing the particles to pass from the flame into a cooling zone.
  • a substantially circular swirling motion is imparted to the particles.
  • the swirling motion may conveniently be imparted to the particles by imparting a swirling motion to gas issuing from the flame-producing nozzle.
  • a swirling motion is imparted to combustible gas issuing from the annular passage of the nozzle.
  • the surrounding combustible gas transmits its swirling motion to the oxygen containing gas and the particles to be spheroidized which issue from the inner passage of the nozzle.
  • An inverse flame as described above is normally of the diffusion controlled type which tends to have an inner hollow zone in which no combustion occurs, the oxidizing zone of the flame surrounding the inner zone. As a result of their swirling motion, the particles to be spheroidized are thrown outwardly by centrifugal force from the cold inner zone into a hot zone of the flame.
  • the degree of swirl of particles should be regulated so as to be suificient to maintain them in the hot zone of the flame for an adaquate period of time.
  • some of the particles might miss the hot zone of the flame by falling more or less vertically downwards, if the degree of particle swirl is too low.
  • the degree of particle swirl is too great, some of the particles will pass too rapidly through the hot zone of the flame.
  • the amount of swirl imparted to gases and particles issuing from the inverse flarne-producing nozzle can be adjusted to some extent by spacing the mouth of the inner passage from the nozzle mouth and varying the distance between the mouth of the flame-producing nozzle and the mouth of the inner passage.
  • the oxygen containing gas issuing from the inner passage and the combustible gas issuing from the surrounding annular passage of the nozzle have closely similar exit velocities. This assists in maintaining a stable flame since it minimizes the formation of eddies at the interface of the two gases.
  • the additional envelope of reducing gas should be dis tributed very evenly all around the flame to ensure that the hot zone of the flame proper is completely surrounded by an essentially reducing zone of lower temperature.
  • the additional reducing gas should preferably issue from the nozzle at a high velocity. This materially assists in preventing fine particles of material undergoing spheroidizing from escaping from the flame too quickly.
  • a flameproducing nozzle for spheroidizing irregularly shaped particles includes an inner passage for discharging oxygen containing gas and irregularly shaped particles; an annular passage for discharging combustible material, the annular passage surrounding the inner passage; and a tangential inlet into the annular passage.
  • the flame-producing nozzle may include a supply passage for oxygen containing gas, communicating with the inner passage; and a particle feed passage located within the supply passage for oxygen containing gas and having an outlet directed towards the interior of the inner passage.
  • the supply passage for oxygen containing gas may be connected to the inner passage through a venturi tube, the outlet of the particle feed passage being located at or near the restricted zone of the venturi tube.
  • the outlet from the inner passage may be spaced from the mouth of the nozzle.
  • the flame-producing nozzle may include an additional annular passage for discharging reducing gas, the additional annular pasage surrounding the annular passage for combustible gas.
  • FIGURE 1 is a sectional view of a downwardly directed flame-producing nozzle according to the invention.
  • FIGURE 2 is a section on line IIII in FIGURE 1.
  • FIGURE 3 is a section on line IIIIII in FIGURE 1.
  • FIGURE 4 is a section on line IVIV in FIGURE 1.
  • Irregularly shaped particles of ferro-silicon alloy to be spheroidized are fed through feed hopper 1 into particle feed pipe 2, the outlet 3 of which is directed towards the interior of inner discharge tube 4.
  • Pre-heated air is introduced through inlet pipe 5 into supply tube 6 which surrounds particle feed pipe 2 and which communicates with inner discharge tube 4 through venturi tube 7.
  • outlet 3 of particle feed pipe 2 is located near the restricted zone 7a of venturi tube 7.
  • flow of air through venturi tube 7 induces a suction effect in particle feed pipe 2, the suction eifect assisting in introducing irregularly shaped particles into inner discharge tube 4.
  • feed pipe 2 carries a full load of irregularly shaped particles to be spheroidized.
  • Air is introduced from inlet 5 into supply tube 6 through vertical apertures 8 so that the air flows straight down supply tube 6 around particle feed pipe 2 without any substantial swirling action. It will be appreciated that irregularly shaped particles entering venturi tube 7 from particle feed pipe 2 are dispersed in air entering venturi tube 7 from supply tube 6. A mixture of pre heated air and irregularly shaped particles is discharged from outlet 9 of inner tube 4. Outlet 9 is spaced from nozzle mouth 10.
  • Coke oven gas or other suitable combustible fuel gas is introduced tangentially by means of inlet pipe 11 into chamber 12 which is located concentrically around inner discharge tube 4 and converges towards nozzle mouth 10.
  • the tangential introduction of the fuel gas causes it to pass down chamber 12 around inner tube 4 with a pronounced swirling motion to induce at or near nozzle mouth a swirl in the air stream issuing from central tube 4 as well as in irregularly shaped particles dispersed in the air stream.
  • the air and the fuel gas issuing from nozzle mouth 10 produces a pencil shaped, downwardly directed inverse flame 13 with an oxidizing zone 14 in which the highest temperature in the flame occurs, and a surrounding reducing zone 15 at least towards the periphery of flame 13.
  • Oxidizing zone 14 is located around a cold air-containing inner zone 20 in which no combustion occurs. Irregularly shaped particles issue from nozzle mouth 10 into cold inner zone 20 and as a result of their swirling motion, the particles are thrown out of inner zone 20 into the hot oxidizing zone 14 where they are melted at least at their surfaces before passing through reducing zone 15 and out of the flame.
  • the cold inner zone 20 extends down to the bottom of flame 13. If the degree of particle swirl is too low, some of the particles might miss the hot zone 14 of the flame by falling more or less vertically downwards. On the other hand, if the degree of particle swirl is too great, some of the particles will pass too rapidly through hot zone 14 of the flame.
  • the degree of swirl should be sufficient to maintain the particles in hot zone :14 of the flame for an adequate period of time to permit them to be melted at least at their surfaces.
  • the nozzle is so shaped and the air and the fuel gas introduced into the nozzle at such pressures that the air and the fuel gas are discharged at substantially similar exit velocities. This assists in maintaining a stable flame since it minimizes the formation of eddies at the interface between the air and the fuel gas.
  • the exit velocities can be adjusted within limits by raising and lowering outlet 9 of inner discharge tube 4 in relation to nozzle mouth 10. This can be effected by adjusting the position of upper nozzle portion A relative to lower nozzle portion B by adjusting the extent to which upper portion A is screwed into lower portion B at screw-threaded engagement 16.
  • the degree of particle swirl will depend on the exit velocity of combustible gas issuing from annular chamber 12.
  • the degree of swirl can be adjusted to some extent by adjustment of the position of outlet 9 of inner discharge tube 4 in relation to nozzle mouth 10.
  • the nozzle also includes annular chamber 17 in communication with outer annular discharge passage 18.
  • a reducing gas such as coke oven gas, introduced into chamber 17 through inlet 19, is discharged at a high velocity through outer discharge passage '18 to form an additional envelope 15a of reducing gas which completely envelopes flame 13.
  • the reducing envelope 15a is at a lower temperature than flame 13.
  • the high velocity of reducing envelope 15a helps to prevent the finer particles of material undergoing spheroidizing from escaping too quickly from the flame.
  • particle feed pipe 2 As can be seen from the drawings, particle feed pipe 2, supply tube 6, venturi tube 7, inner discharge tube 4, annular chamber 12 and outer annular passage 18 are all located coaxially.
  • Lower nozzle portion B is cooled by means of water introduced through pipe 21 into cooling jacket 22. Further cooling jackets may be provided if necessary.
  • the particles to be spheroidized Upon passing through flame 13, the particles to be spheroidized are melted at least at their surfaces and assume spheroidal shapes.
  • the flameproducing nozzle is mounted on the upper end of cooling chamber 23 and is arranged to direct flame 13 downwardly into chamber 23, which provides a cooling zone.
  • Annular inlet 24 is provided in the top of chamber 23 for directing a curtain of cooling medium down the inner periphery 25 of chamber 23. Cooling medium may also be introduced tangentially into chamber 23 at one or more levels along the height of chamber 23 through one or more peripheral inlets (not shown).
  • Solidified spheroidized particles may be discharged from chamber 2 3 into a suitable receptacle (not shown). Further cooling means, such as, for example, a heat exchanger, may be provided.
  • Cooling chamber 23 is advantageously provided with automatic pressure control means (not shown). This is of particular importance in cases Where the proper dispersion of the particles to be spheroidized in the air stream is dependent on the maintenance of a certain amount of suction on the particle feed pipe 2.
  • the spheroidized particles produced in accordance with the present invention are characterized by a particular regularity of shape and a great smoothness of surface, substantially Without angular corners.
  • the process is particularly suitable for the production of particles having a size distribution range below 200 mesh. Alloy particles and particularly ferro-silicon particles of a particle size range below 250 mesh, preferably below 270 mesh, can be spheroidized with good results.
  • any suitable gas containing free oxygen in at least the proportion contained in air may 'be discharged from inner passage 4.
  • a small proportion of combustible gas such as coke oven gas, producer gas, or water gas, may be mixed with the oxygen containing gas to improve the flame characteristics.
  • Any suitable combustible fuel gas other than coke oven gas may be discharged from annular passage 12.
  • any suitable reducing gas other than coke oven gas may be discharged from outer annular passage 18.
  • any suitable cooling chamber or other suitable cooling arrangement may be provided.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Nanotechnology (AREA)
  • Dispersion Chemistry (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Silicon Compounds (AREA)
US297635A 1962-08-01 1963-07-25 Production of spheroidized particles Expired - Lifetime US3272615A (en)

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Application Number Priority Date Filing Date Title
ZA623266 1962-08-01

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US (1) US3272615A (de)
AT (1) AT251546B (de)
DE (1) DE1254129B (de)
FR (1) FR1365684A (de)
GB (1) GB1051334A (de)
LU (1) LU44172A1 (de)

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2125566A1 (en) * 1971-02-19 1972-09-29 Knapsack Ag Ferrosilicon particles - rounded off by superficial melting in electric arc or plasma jet
US4028447A (en) * 1973-04-26 1977-06-07 Agway, Inc. Method of prilling material
US4238430A (en) * 1979-07-30 1980-12-09 United States Vacuumite Corporation Method for forming expanded cellular volcanic ash
US4264354A (en) * 1979-07-31 1981-04-28 Cheetham J J Method of making spherical dental alloy powders
EP0214441A2 (de) * 1985-09-03 1987-03-18 Societe Des Produits Nestle S.A. Trockner und Trocknungsverfahren
US4693739A (en) * 1984-06-21 1987-09-15 Nippon Sheet Glass Co., Ltd. Method for producing glass bubbles
US4816067A (en) * 1988-06-20 1989-03-28 Gte Products Corporation Process for producing fine spherical particles
FR2690638A1 (fr) * 1992-05-04 1993-11-05 Plasma Technik Sa Procédé et dispositif pour l'obtention de poudres à plusieurs composants et susceptibles d'être projetées.
US5558822A (en) * 1995-08-16 1996-09-24 Gas Research Institute Method for production of spheroidized particles
US5611833A (en) * 1992-08-26 1997-03-18 Mg Industries Method and apparatus for producing spheroidal glass particles
US5883029A (en) * 1994-04-25 1999-03-16 Minnesota Mining And Manufacturing Company Compositions comprising fused particulates and methods of making them
US6045913A (en) * 1995-11-01 2000-04-04 Minnesota Mining And Manufacturing Company At least partly fused particulates and methods of making them by flame fusion
US6254981B1 (en) 1995-11-02 2001-07-03 Minnesota Mining & Manufacturing Company Fused glassy particulates obtained by flame fusion
US20060112784A1 (en) * 2004-11-30 2006-06-01 Kao Corporation Apparatus for preparing inorganic spheroidized particle
EP1930071A1 (de) * 2006-12-06 2008-06-11 ECKA Granulate GmbH & Ko. KG Verfahren zur Herstellung von Partikeln aus fliessfähigem Material und Verdüsungsanlage dafür
US20100084777A1 (en) * 2008-10-02 2010-04-08 Parker Gerard E Pyrospherelator

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2451546A (en) * 1945-06-25 1948-10-19 Harold R Forton Method and apparatus for forming a powder from metals
US2530345A (en) * 1947-04-02 1950-11-14 Standard Oil Dev Co Preparation of a spheroidal fischer-tropsch catalyst
US2675295A (en) * 1949-05-12 1954-04-13 Daniels Joseph Process for rapidly and continuously performing a high temperature endothermic reaction between a solid and a gaseous reactant
US3015852A (en) * 1957-04-04 1962-01-09 South African Iron & Steel Process of spheroidizing irregularly shaped particles
US3041672A (en) * 1958-09-22 1962-07-03 Union Carbide Corp Making spheroidal powder
US3059860A (en) * 1959-11-17 1962-10-23 Hugo Boskamp Atomizing nozzle assembly
US3062638A (en) * 1961-05-03 1962-11-06 Union Carbide Corp Ultrafine metal powders
US3093315A (en) * 1959-03-23 1963-06-11 Tachiki Kenkichi Atomization apparatus

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2451546A (en) * 1945-06-25 1948-10-19 Harold R Forton Method and apparatus for forming a powder from metals
US2530345A (en) * 1947-04-02 1950-11-14 Standard Oil Dev Co Preparation of a spheroidal fischer-tropsch catalyst
US2675295A (en) * 1949-05-12 1954-04-13 Daniels Joseph Process for rapidly and continuously performing a high temperature endothermic reaction between a solid and a gaseous reactant
US3015852A (en) * 1957-04-04 1962-01-09 South African Iron & Steel Process of spheroidizing irregularly shaped particles
US3041672A (en) * 1958-09-22 1962-07-03 Union Carbide Corp Making spheroidal powder
US3093315A (en) * 1959-03-23 1963-06-11 Tachiki Kenkichi Atomization apparatus
US3059860A (en) * 1959-11-17 1962-10-23 Hugo Boskamp Atomizing nozzle assembly
US3062638A (en) * 1961-05-03 1962-11-06 Union Carbide Corp Ultrafine metal powders

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2125566A1 (en) * 1971-02-19 1972-09-29 Knapsack Ag Ferrosilicon particles - rounded off by superficial melting in electric arc or plasma jet
US4028447A (en) * 1973-04-26 1977-06-07 Agway, Inc. Method of prilling material
US4238430A (en) * 1979-07-30 1980-12-09 United States Vacuumite Corporation Method for forming expanded cellular volcanic ash
US4264354A (en) * 1979-07-31 1981-04-28 Cheetham J J Method of making spherical dental alloy powders
US4693739A (en) * 1984-06-21 1987-09-15 Nippon Sheet Glass Co., Ltd. Method for producing glass bubbles
EP0214441A2 (de) * 1985-09-03 1987-03-18 Societe Des Produits Nestle S.A. Trockner und Trocknungsverfahren
EP0214441A3 (en) * 1985-09-03 1988-03-30 Societe Des Produits Nestle S.A. Dryer and drying method
US4816067A (en) * 1988-06-20 1989-03-28 Gte Products Corporation Process for producing fine spherical particles
FR2690638A1 (fr) * 1992-05-04 1993-11-05 Plasma Technik Sa Procédé et dispositif pour l'obtention de poudres à plusieurs composants et susceptibles d'être projetées.
US5611833A (en) * 1992-08-26 1997-03-18 Mg Industries Method and apparatus for producing spheroidal glass particles
US5883029A (en) * 1994-04-25 1999-03-16 Minnesota Mining And Manufacturing Company Compositions comprising fused particulates and methods of making them
US5558822A (en) * 1995-08-16 1996-09-24 Gas Research Institute Method for production of spheroidized particles
US6045913A (en) * 1995-11-01 2000-04-04 Minnesota Mining And Manufacturing Company At least partly fused particulates and methods of making them by flame fusion
US6254981B1 (en) 1995-11-02 2001-07-03 Minnesota Mining & Manufacturing Company Fused glassy particulates obtained by flame fusion
US20060112784A1 (en) * 2004-11-30 2006-06-01 Kao Corporation Apparatus for preparing inorganic spheroidized particle
US7641824B2 (en) * 2004-11-30 2010-01-05 Kao Corporation Apparatus for preparing inorganic spheroidized particle
EP1930071A1 (de) * 2006-12-06 2008-06-11 ECKA Granulate GmbH & Ko. KG Verfahren zur Herstellung von Partikeln aus fliessfähigem Material und Verdüsungsanlage dafür
WO2008067868A1 (de) * 2006-12-06 2008-06-12 Ecka Granulate Gmbh & Co. Kg Verfahren zur herstellung von partikeln aus fliessfähigem material und verdüsungsanlage dafür
US20100084777A1 (en) * 2008-10-02 2010-04-08 Parker Gerard E Pyrospherelator
US8057203B2 (en) * 2008-10-02 2011-11-15 Gap Engineering LLC Pyrospherelator
US8343394B2 (en) 2008-10-02 2013-01-01 Gap Engineering LLC Pyrospherelator

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Publication number Publication date
AT251546B (de) 1967-01-10
LU44172A1 (de) 1963-10-07
GB1051334A (de) 1900-01-01
DE1254129B (de) 1967-11-16
FR1365684A (fr) 1964-07-03

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