WO1992015715A1 - Procede et appareil destines a extraire des substances minerales de valeur de materiaux particulaires - Google Patents

Procede et appareil destines a extraire des substances minerales de valeur de materiaux particulaires Download PDF

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Publication number
WO1992015715A1
WO1992015715A1 PCT/PL1991/000003 PL9100003W WO9215715A1 WO 1992015715 A1 WO1992015715 A1 WO 1992015715A1 PL 9100003 W PL9100003 W PL 9100003W WO 9215715 A1 WO9215715 A1 WO 9215715A1
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WIPO (PCT)
Prior art keywords
chamber
mineral
fraction
inlet
air
Prior art date
Application number
PCT/PL1991/000003
Other languages
English (en)
Inventor
Juliusz Boleslaw Czaja
Jerzy Leslaw Romanowski
Original Assignee
Avny Industries Corporation Spólka Z O.O.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Avny Industries Corporation Spólka Z O.O. filed Critical Avny Industries Corporation Spólka Z O.O.
Priority to AU74945/91A priority Critical patent/AU7494591A/en
Priority to PCT/PL1991/000003 priority patent/WO1992015715A1/fr
Priority to MX9200853A priority patent/MX9200853A/es
Priority to ZA921400A priority patent/ZA921400B/xx
Priority to IL101090A priority patent/IL101090A0/xx
Publication of WO1992015715A1 publication Critical patent/WO1992015715A1/fr

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Classifications

    • 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
    • C22B4/00—Electrothermal treatment of ores or metallurgical products for obtaining metals or alloys
    • C22B4/005—Electrothermal treatment of ores or metallurgical products for obtaining metals or alloys using plasma jets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
    • B03B9/00—General arrangement of separating plant, e.g. flow sheets
    • B03B9/04—General arrangement of separating plant, e.g. flow sheets specially adapted for furnace residues, smeltings, or foundry slags
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
    • B07B4/00—Separating solids from solids by subjecting their mixture to gas currents
    • B07B4/02—Separating solids from solids by subjecting their mixture to gas currents while the mixtures fall
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
    • B07B9/00—Combinations of apparatus for screening or sifting or for separating solids from solids using gas currents; General arrangement of plant, e.g. flow sheets
    • 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
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/02—Working-up flue dust
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

Definitions

  • the present invention relates in general to methods and apparatus for extracting mineral values from mineral containing particulate material. More particularly, it relates to methods and apparatus for extracting essentially pure mineral values from particulate raw materials including such waste materials as fly ash, slag and the like as well as recovering other valuable by-products.
  • the present invention has been developed in response to the above-noted shortcomings of the prior art.
  • the invention provides economically advantageous methods having exceptional environmental and commercial attributes for treating mineral containing particulate material to extract essentially pure mineral values therefrom and apparatus for use in such methods.
  • the methods of this invention also provide for the extraction and recovery of valuable by-products from the raw material which have commercially advantageous utility as, for example, building materials, fillers, binders and the like. Accordingly, the methods of the present invention provide for the utilization of essentially all of the raw material particulates providing substantial environmental benefits.
  • the methods of the present invention may comprise either single stage or multiple stage processes. More specifically, a method of the present invention may include a two-stage recovery system for treating a raw material stock which incorporates both physical and chemical separation techniques or the method may comprise only one or the other of these two stages in order to accomplish the desired extraction and recovery of mineral content from the raw material stock as well as to provide other valuable by-products from the process residuals.
  • the raw material stock for use herein may be derived from fly ash, flue dust, industrial slag, foundry or metallurgical processing residues such as those from the ferro-chrome or the galvanization process, mining residues such as those from ore concentration flotation processes, sea sand and other like waste materials having desired compositions.
  • one of the processing stages comprises a pneumo-gravitational separation technique to separate out the mineral content such as metal and metal oxide concentrates from the raw material stock.
  • Another stage of the process comprises a chemo-thermal treatment of a raw material stock or, in a preferred embodiment, an effluent stream derived from the pneumo-gravitational separation stage utilizing plasma separation techniques to extract essentially pure mineral
  • the method of the present invention includes the stage of introducing mineral containing particulate material having a radial particle size of less than about 0.1 mm. into a pneumo-gravitational separation apparatus to be described hereinafter having a flotation chamber with at least one inlet port and multiple outlet ports formed therein.
  • Means are provided such as a fan, a blower or similar device to introduce air into the chamber and to cause an air flotation stream to flow from at least one of the inlet ports to at least one of the outlet ports and the particulate material is contacted with this air flotation stream at a predetermined air flow velocity.
  • the air flow velocity must be sufficient to cause the particulate material introduced into the chamber through at least one inlet port positioned a predetermined longitudinal distance from the location of air introduction into the chamber and at a predetermined angle relative to the axial air flow path through the chamber to separate into a mineral value fraction which precipitates out from the air flotation stream.
  • This mineral value fraction precipitates out from the stream in response to gravitational settling of the fraction from the stream based on the weight of the mineral values in the fraction leaving an unprecipitated residual granular fraction in the flotation stream.
  • the unprecipitated residual granular fraction from the flotation stream is collected for further treatment in order to produce valuable building materials including advantageous cement-like compositions or binding compositions and the like.
  • the precipitated fractions which are collected contain such materials as aluminum oxide (alumina) , titanium oxide, chromium and iron salts, as well as elemental forms of such minerals and a variety of other compounds and elemental constituents derived from the diversity of particulate raw materials which may be treated by the methods of this invention.
  • the flotation chamber of the pneumo-gravitational separator may be rectangular, square, circular or any other appropriate shape in cross-section and the assembly is structured so that air for the air flow stream is introduced at an inlet port at one end of the chamber and flows through the chamber to an outlet port positioned at the other end of the chamber.
  • a separate inlet port is provided for introducing the particulates into the chamber and is positioned a distance from the outlet end of the chamber sufficient to provide optimum separation of the mineral values in the treated particulates as will be discussed in greater detail hereinafter.
  • SUBSTITUTESHEET Furthermore, it is preferred to wet the particles with a sulfuric acid solution prior to introduction into the chamber in order to react the active particles with the acid whereby the density of the particles increase and these heavier particles have less likelihood to clog or agglomerate within the chamber as they are blown therein.
  • the particulates should be introduced into the chamber at an angle ranging from 12° to 75° relative to the axial direction of laminar air flow through the chamber from one end to the other and the air flow velocity in the chamber should be maintained in a range of from about 2 meters/second for lighter weight particles up to about 25 meters/second for heavier particles such as
  • means are provided for tilting the chamber in order to enable adjustment of the angle presented between the essentially horizontal direction of the laminar flow of air in the chamber and the longitudinal axis of the chamber.
  • This angular adjustment controls the time and distance the particles will fall before being contacted by the air stream and is set, preferably, in a range of from about -60° to about 0° (horizontal) to accommodate lighter weight particles by increasing the time and distance before the particles are engaged by the air flow and from about +60° to about 0° (horizontal) to accommodate heavier weight particles by decreasing the time and distance before the particles are engaged by the air flow.
  • the mineral value fractions in particulate form are introduced into a reaction chamber of a plasma reactor.
  • the average radial size of the mineral value particles to be treated is less than about 0.1 mm.
  • a stream of plasma gas is also introduced into the reaction chamber and the gas is ionized to produce a plasma arc in a reaction zone formed in the reactor between a cathode and a multi-segmented anode wherein the temperature is raised to a level of about 10,000° K.
  • the reactor is structured and dimensioned in a manner such that the plasma arc is caused to rapidly revolve about the segmented anode and the particulate fractions are subjected to this motion whereby the particles are caused to pass through the plasma in a desired spiral flow.
  • the anode employed in the reactor includes from six to ten segments and, most preferably, eight segments in order to achieve plasma rotation preferably greater than about 15,000 revolutions per minute (RPM) and, most preferably, in a range of about 15,000 - 30,000 RPM.
  • the plasma reactor of this invention is constructed to produce a rotating plasma arc discharge between two stationary electrode structures. When a voltage of sufficient magnitude is impressed across the electrode pair (i.e., the cathode and anode), a plasma
  • the anode is a segmented annular ring with each of the anode segments electrically isolated from the others.
  • Each anode segment is electrically connected to a region of constant potential or ground through a pair of solenoid coils arranged on either side of the anode segment at a 90" angle.
  • the axis of each such solenoid coil is parallel to a line drawn from the center of the reaction chamber to the anode segment to which it is connected.
  • a plasma discharge from the cathode to a particular anode segment and then to ground thus energizes the corresponding pair of solenoid coils.
  • the magnetic field thus produced tends to rotate the plasma arc to the adjacent anode segment. The process is then repeated which results in a rapidly rotating plasma arc.
  • a coaxial solenoid coil encircles the periphery of the reaction zone and is coaxial with the path from cathode and anode.
  • the coaxial coil produces a second magnetic field to further increase the rotational velocity of the plasma arc by converting radial velocity of the plasma arc to circumferential velocity.
  • Appropriate plasma gases for use in generating the plasma arc depend on the composition of the particulate raw material being treated but include various oxidizing gases such atmospheric air or oxygen, reducing gases such as hydrogen and inert gases such as argon or other noble gases.
  • the reactor of this invention is further structured and dimensioned to provide a cooling zone so that as the liquid exits from the plasma reaction zone, it passes
  • SUBSTITUTE SHEET through various declining temperature gradients during which time the desired mineral values in essentially pure elemental or compound form cool and agglomerate into relatively dense particulate form.
  • the heated residuals in the originally fed particles either crystallize and form dust-like particles of low relative density in the cooling zone or evaporate and form gases in such zone as a result of the plasma treatment and the subsequent cooling.
  • the reactor construction includes a countercurrent flow zone into which the liquid, dust and gas materials pass as they exit from the cooling zone.
  • these materials are subjected to a countercurrent flow of air in a manner and utilizing apparatus to be described in detail hereinafter such that the desired liquid mineral values pass through the countercurrent air flow and are collected in their essentially pure particulate form while the residual dust-like and gaseous components are removed from the desired mineral values by virtue of the countercurrent flow of air and are separately collected.
  • essentially pure mineral values having purity levels exceeding 95% are extracted from the raw material treated therein.
  • the residual dust-like and gaseous components separated from the collected mineral values may be further processed to provide other desirable essentially pure fractions.
  • the collected residuals may be utilized in certain instances as valuable by-products of the process.
  • SUBSTITUTE SHEET and titanium oxide from mineral containing raw materials preferably waste materials such as fly ash, flue dust, industrial slag, foundry or metallurgical processing residues, mining residues, sea sand and the like.
  • Another object of this invention is to provide an economically feasible and environmentally advantageous method for extracting essentially pure mineral fractions in a commercially successful manner.
  • a further object of this invention is to provide methods for extracting commercially advantageous by-products in addition to essentially pure mineral fractions from raw materials, preferably waste materials such as fly ash, flue dust, industrial slag, foundry or metallurgical processing residues, mining residues, sea sand and the like.
  • a still further object is to provide a method for the recovery of aluminum oxide, and titanium oxide, iron, chromium, nickel, cobalt, lead, zinc, copper, zirconium and other elemental mineral values and other valuable by-products from waste raw materials derived from foundries; power plants, waste disposal facilities, environmental pollution abatement sources such as sea bed cleansing programs and the like in a manner such that the initial environmental concerns relative to the raw materials are eliminated and essentially no additional environmental pollution problems are presented as a result of the practice of the method.
  • a more specific object is to provide a single stage method for extracting mineral values from mineral containing particulate raw materials by introducing and treating the raw materials in a pneumo-gravitational separation apparatus.
  • a companion object is to provide the pneumo-gravitational separation apparatus for performing such extraction process.
  • SOBSHTCTBSHEET Another specific object is to provide a single stage method for extracting mineral values from mineral containing particulate raw materials by introducing and treating the raw materials in a chemo-thermal reactor utilizing plasma separation techniques.
  • a companion object is to provide the chemo-thermal reactor for performing such extraction process.
  • a still further specific object is to provide a multiple stage method for extracting mineral values from mineral containing particulate raw materials by subjecting the raw materials to pneumo-gravitational separation in a first stage followed by a second stage separation in a chemo-thermal reactor utilizing plasma separation techniques.
  • FIG. 1 is a schematic flow diagram illustrating the method of the present invention employed to extract mineral values from a dry fly ash raw material source
  • FIG. 2 is a schematic flow diagram similar to FIG. 1 illustrating the method of the present invention employed to process a galvanization residue raw material source;
  • FIG. 3 is a schematic flow diagram illustrating the method of the present invention for processing a metallurgical slag waste material from a ferro-chrome treatment process;
  • FIG. 4 is a schematic flow diagram illustrating the method of the present invention for processing sea sand;
  • FIG. 5 is a schematic side view of a preferred apparatus for performing the pneumo-gravitational separation step in the method of the present invention
  • FIG. 6 is a schematic side view of a preferred plasma reactor apparatus for performing the chemo-thermal separation step in the method of the present invention
  • FIG. 7 is a schematic top view projecting downwardly from the cathode to the multi-segmented anode assembly in the plasma reactor apparatus of FIG. 6;
  • FIG. 8 is a detailed schematic view of the cathode and segmented anode arrangement of FIG. 7 with broken cross-sections of parts thereof.
  • FIGS. 1-4 are schematic flow diagrams showing various embodiments of the methods of the present invention including process options depending on the composition of the raw material source and its physical condition, its inherent mineral content and other like considerations.
  • the embodiment of this invention depicted in FIG. 1 utilizes a freshly produced, dry fly ash derived from the combustion of power plant coal.
  • the fresh ash employed herein was soft enough to be used as dust without grinding into particulate form.
  • an ash had been utilized which had been obtained from a reserve pile or mountain which has been collected over an extended period up to a period of years, it would have been necessary to grind the raw material ash into an appropriate particle size in order to provide adequate results in the method of the present invention.
  • composition of the dry fly ash utilized in this method may vary somewhat depending on the fuel burned.
  • the main elements in the fly ash are silicon and aluminum and the minor elements therein include calcium, iron, titanium and magnesium. Trace amounts of lead, mercury, silver, manganese and chromium may also be
  • a fly ash employed in the method normally contains the following compounds present in amounts (on a weight basis) as follows:
  • This fly ash sample was introduced into a flotation chamber of a pneumo-gravitational separation device of the type illustrated in FIG. 5. As the fly ash was being introduced into the chamber, it was treated with 1 liter of 5% sulfuric acid solution and the ash reacted with the acid to form a sulfate particle fraction of higher density to promote settling out of the active particles on further processing.
  • the particles were contacted by a laminar air flotation stream flowing through the chamber from an inlet port at one end thereof to an outlet port at the other end thereof.
  • SOBSi ⁇ TE SHEET air velocity was about 2 meters/second and as the particles were blown through the chamber, the higher weight particles including Al-O- and Ti 0 2 precipitated out of the flotation stream as a result of gravitational settling while the lighter weight particles essentially remained suspended in the flotation stream.
  • the particulate mineral value fraction which precipitated out of the flotation stream weighed 3.08 Kg and had the following composition on a weight percent basis:
  • This precipitated particulate fraction was collected and transported for further processing in a chemo-thermal separation stage to extract higher purity mineral values from the product obtained from the pneumo-gravitational separation stage.
  • the precipitated particulate fraction from the pneumo-gravitational separation stage was introduced into a plasma reactor of the type illustrated in FIG. 6 wherein a plasma having a temperature of about 10,000°K was generated employing air as the plasma generating gas and the plasma arc was caused to rotate about an eight segmented anode at a rate of about 30,000 RPM which resulted in the separation of a mineral value fraction having a weight of 2.53 Kg based on the original 3.08 Kg sample of particulate material introduced into the reaction chamber.
  • This separate fraction had a composition on a weight percentage basis of: A1 2 0 3 95.0% Ti 0 2 2.7%
  • a 97.7% pure fraction of A1_0 3 and Ti 0- are obtained from this two stage process by melting the A1_0- and Ti 0- in the plasma and collecting the unseparated, agglomerated particles which settle to the bottom of the reactor chamber of the reactor device of FIG. 6.
  • the remaining .55 Kg residual fraction from the original 3.08 Kg sample introduced into the reactor is removed from the reactor as described in regard to the device depicted in FIG. 6.
  • the predominant portion of magnesium, iron and silicates in the 3.08 Kg sample were melted in the plasma and crystallized forming dust-like particles which were blown out of the reactor.
  • the sulfates evaporated in the plasma forming a gas.
  • FIG. 2 illustrates another embodiment of this invention wherein a metallurgical slag derived from a foundry producing ferro-chrome products was employed as the particulate raw material.
  • slag derived from mining operations has also been employed as the mineral containing particulate for use in the methods of this invention.
  • a sample of metallurgical slag from a foundry blast-furnace was collected from a reserve pile or mountain of slag.
  • the slag sample was screened to remove over size particulates and then the resulting particulates were subjected to a magnetic separation technique whereby magnetic particles having average radial particle size of greater than 250 mm were separated from the remainder of the raw particulate material stock.
  • This separated fraction with 250 mm or greater radial size contained 75% (by weight) iron and 25% (by weight) chromium compositions.
  • a 10 Kg sample of the remaining smaller particle size raw material had the following composition on a weight percentage basis:
  • SUBSTITUTE SHEET This 10 Kg sample was then subjected to a crushing or grinding operation wherein the particles were reduced in size to an average radial particle size of about .1 mm to about 2 mm. These ground particles were introduced into a flotation chamber of a pneumo-gravitational separation device of the type illustrated in Fig. 5. In the pneumo-gravitational separation device, the particles were contacted by a laminar air flotation stream flowing through the chamber from an inlet port at one end thereof to an outlet port at the other end thereof. The air velocity was about 10 meters/second and as the particles were blown through the chamber, the particles precipitated out in a first and a second fraction based on particle weight.
  • the first fraction contained the heavier weight particles while the second fraction contained the lighter weight particles.
  • the first particulate mineral value fraction which precipitated out weighed 5.75 Kg and was collected and subjected to known magnetic separation techniques in order to separate an iron and chromium rich portion weighing
  • the 2.48 Kg second portion had the following composition on a weight percent basis: A1 2 ° 3 6.05%
  • SUBSTITUTESHEET collected from the chemo-thermal reaction stage as described in regard to the removal of residuals from the reactor of Fig. 6 weighed 6.5 Kg and was employed for producing valuable by-products such as a Portland Cement-type product.
  • the residue obtained from the galvanization process for producing high quality steel was utilized as the mineral value containing raw material for use in practicing the method.
  • a waste residue or sediment was collected having a composition including chromates, sulfate and chloride salts, ferric and ferrous compounds as well as silicates.
  • the sediment included a high percentage (greater than 50% by weight) of chromium salts.
  • this residue was subjected to hot air treatment in order to dry the material. Then, the dried material was ground into particles having an average radial size not in excess of 2 mm. This particulate material was transported to and introduced as a 10 Kg sample into a pneumo-gravitational separator of the type illustrated in FIG. 5 and which was operated as described in reference thereto.
  • the air velocity of the laminar air flow in the flotation chamber was 5 meters/sec. and a 4.5 Kg particulate fraction precipitated out from the flotation stream while the remaining 5.5 Kg fraction remained suspended in the flotation stream.
  • the precipitated particulate fraction from the pneumo-gravitational separation stage was introduced into a plasma reactor of the type illustrated in FIG. 6 wherein a plasma having a temperature of about 10,000°K was generated employing methane as a reducing plasma gas and the plasma arc was caused to rotate about an eight segmented anode at a rate of about 30,000 RPM which resulted in the separation of essentially pure elemental chromium and chromium salts as well as elemental iron.
  • This mixture of chrome and iron materials was subjected to an electromagnetic separation step in order to extract the essentially pure chromium materials from the essentially pure iron.
  • the embodiment of this invention depicted in Fig. 4 utilizes sand dredged from the bottom of a body of water such as an ocean, sea or lake as the raw material mineral value source.
  • the sand for use herein which will be referred to as "sea sand" is collected from a location in close proximity to a mining operation or an industrial plant which disposes wastes into the body of water.
  • a 10 Kg sample of particulate sea sand was employed as the raw material mineral value source.
  • the sea sand sample had a mineral value content which was present in the form of the
  • the 10 Kg sea sand sample was initially introduced into a magnetic separator having a weak magnetic field of up to about 5 Kilogaus in order to separate a highly magnetic fraction of predominantly ferrous materials from the non-magnetic and less magnetic components of the sample.
  • the highly magnetic fraction thus separated weighed 2.8 Kg and contained 97% Ilmenite and 3% of such mineral containing compositions as Garnet, Amphibole, Epidote and Tourmaline.
  • This magnetic fraction was then introduced in particulate form into a plasma reactor of the type illustrated in FIG. 6 and this particulate material was subjected to the chemo-thermal processing technique as described in regard to the operation of such reactor whereby 98.6% pure iron and 99.4% pure Ti 0 2 was extracted from the treated Ilmenite rich fraction.
  • the remaining non-magnetic and less magnetic fraction weighing 7.2 Kg was transported from the magnetic separator and was subjected to an electrostatic separation process with the positive potential up to 50 kV. This electrostatic separation caused the treated fraction to separate into two portions.
  • the first portion constituting the conductive materials weighed 2.9 Kg and the second portion constituting the dielectric and non-conductive materials weighed 4.3 Kg.
  • the first conductive portion included such mineral containing materials as Garnet, Amphibole, Epidote, Tourmaline and Rutile and was further treated in order to separate "semi-magnetic" materials therein from the non-magnetic fraction by subjecting the 2.9 Kg sample to magnetic separation in a strong magnetic field of up to 16 Kilogaus.
  • the separated semi-magnetic material represented the residue from the process weighing 1.6 Kg.
  • the remaining separated material weighing 1.3 Kg was collected and cleaned by a subsequent electrostatic separation treatment whereby any remaining dielectric materials were removed as residue and the conductive materials weighing 7 Kg and constituting a 96% Rutile concentrate along with 4% impurities predominantly including Garnet as well as Zircon, Amphibole, Epidote and Tourmaline was collected for further processing in a plasma reactor of the type illustrated in FIG. 6 which was operated in accordance with details provided relative thereto.
  • the resulting composition extracted as a result of such chemo-thermal processing in the plasma reactor contained 99.8% pure Ti 0_.
  • the 4.3 Kg dielectric and non-conductive second portion referenced above was collected and subjected to magnetic separation in a strong magnetic field of up to 16 Kilogaus resulting in two additional fractions being separated.
  • One such fraction included the magnetic minerals in the portion and weighed 0.5 Kg.
  • This magnetic material fraction comprised 98% Monazite along with 4% impurities such as zircon, Garnet, Amphibole, Epidote and Tourmaline. This 98% Monazite fraction was collected and treated in the plasma reactor in order to obtain 99.3% pure lanthanum oxides.
  • this fraction weighing 4.15 Kg was transported for further electrostatic separation whereby a Zircon concentrate was obtained as the dielectric output of the electrostatic separation with the conductive residue separated therefrom.
  • the Zircon concentrate weighed 2.1 Kg which contained 97% Zr Si 0. and 3% impurities comprising mainly Rutile and small quantities of other materials such as Garnet, Amphibole, Epidote and Tourmaline.
  • This Zircon concentrate was also treated in a chemo-thermal processing stage by introducing the particles into a plasma reactor of the type described and illustrated in FIG. 6 in order to obtain 99.5% pure Zi 0 2 and 99.8% pure Si 0 2 .
  • the conductive material weighing 2.05 Kg was separated and represented the residue from the process. This residue was combined with the residue from the prior stages for disposal.
  • a pneumo-gravitational separation apparatus 50 is schematically illustrated which is suitable for use in extracting mineral values from mineral containing particulate raw materials introduced therein.
  • the apparatus 50 has a longitudinally extending housing 52 which is rectangular in lateral cross-section.
  • the housing 52 includes a flotation chamber 54 therein and has an inlet port 56 with an adjustable chute 58 such as a vibrating conveyor or the like depending therefrom and extending into the chamber 54 for introducing the particulate materials into the chamber 54 at a desired angle of entry.
  • Another inlet port 60 is provided in
  • SUBSTITUTESHEET ISAEP housing 52 for allowing air to be introduced into the chamber 54 via operation of a fan or blower 62 fixedly positioned proximal to a first end 64 of the housing 52.
  • the housing 52 also includes at least one outlet port, which as illustrated is represented by ports 66 and 68 which are positioned to enable recovery of precipitated mineral value fractions resulting from treatment of the particulate raw materials input into the chamber 54.
  • An outlet port 70 is provided at a second end 72 of the housing 52 distal from the first end 64 for enabling recovery of an unprecipitated fraction of residual mineral containing particulate materials from the treatment of the particulate raw materials.
  • the inlet port 56 is positioned longitudinally from the outlet end 72 of the chamber 54 a distance determined by the formula:
  • L is the longitudinal distance of the inlet port through which the particles are introduced into the chamber from the end of the chamber through which the particles exit from the chamber;
  • C is a constant which is calculated on the basis of Reynold's No. and, in the case of a laminar flow of air in the chamber, has been determined to be 18;
  • V is the velocity of gas (e.g., air) flowing through the chamber;
  • m is the dynamic viscosity y of the gas;
  • F is the cross-sectional area of the chamber;
  • d is the average diameter of the particles being * f c introduced into the chamber through the inlet port; is the specific weight of the particles and H is the height of the chamber.
  • chute 58 is structured to vibrate or oscillate in a manner such that the particles exiting therefrom and entering chamber 54 will be shaken sufficiently to avoid agglomeration of the particles.
  • Legs 76 and 78 are provided for supporting housing 52 in a stable condition removed from the floor 80.
  • Standard control mechanisms 82 and 84 for adjusting the height of the legs 76 and 78 are positioned on the legs 76 and 78, respectively. These mechanisms 82 and 84 are independently operable to raise or lower the housing 52 in order to tilt the flotation chamber 54 in the housing 52, if desired, and to thereby adjust the angle (angles ) between the fixed horizontal axis 74 and the longitudinal axis of the chamber.
  • the distance which the particles entering the chamber 54 must fall before coming into contact with the flow of air may be adjusted as required to accommodate various weight raw material particles.
  • this angular adjustment should range from about -60° to 0° (horizontal) for lighter weight mineral value particles and from about +60° to 0° (horizontal) for heavier weight mineral value particles.
  • FIG. 6 there is shown schematically a plasma reactor 100 suitable for processing particulate raw
  • the reactor 100 includes a plasma head 102 having a plasma gun or torch 104 vertically mounted therein.
  • the plasma gun 104 is structured and dimensioned for introduction of a suitable plasma gas for purposes of establishing a downwardly directed, central plasma arc or stream 105 extending from a cathode 106 to a multi-segmented annular anode assembly 108 positioned in a reaction chamber 110 downstream of the head section 102.
  • the plasma head 102 has channels 116 formed therein which extend upwardly and are in communication with dispensing equipment or metering devices (not shown) for introducing particulate mineral containing raw materials into the reaction chamber 110.
  • a cylindrical cooling chamber 112 Positioned downstream of the reaction chamber 110 is a cylindrical cooling chamber 112 which leads vertically downward to a conical section 114 wherein a countercurrent flow of air is introduced through an inlet port 138 for purposes of blowing certain residual cooled materials descending from the chamber 110 out through an outlet port 140 as will be described in detail below.
  • the particles are introduced into the chamber 110, they are contacted by the plasma arc 105 and the particles are heated to a high temperature in an environment wherein the plasma arc 105 is revolving or circulating as shown by arrow A in FIGS. 7 and 8 at greater speeds than can be attained with previous methods and devices.
  • FIG. 7 is a schematic illustration of a particular embodiment of the plasma reactor of the present invention looking downwardly from the cathode 106 toward the anode
  • the reaction zone 118 normally contains a gas suitable for plasma formation when a sufficient voltage from an external source (not shown) is applied between the anode 108 and cathode 106.
  • the path of the plasma arc 105 from cathode 106 to anode 108 will be referred to herein as the axis of the reaction zone.
  • the plasma arc 105 is directed from the cathode 106 to a segmented annular anode 108 having eight separate segments electrically insulated from one another to which the plasma arc is sequentially directed resulting in a rotating plasma arc.
  • a segmented anode having up to six segments has previously been described in U.S. Patent No. 4,361,441 which is hereby incorporated by reference into the present disclosure.
  • sequential activation of the anode segments causes the arc to move in a circular fashion at a velocity up to about 6,000 RPM according to the frequency at which the separate segments are activated. Electrical switching means are used to effect the sequential activation of the anode segments.
  • the '441 apparatus also uses a rotating magnetic field which, owing to the charged nature of plasma, causes the arc to experience a force perpendicular to the applied magnetic field and the velocity of the arc.
  • An array of solenoid coils arranged around the periphery of the plasma arc path and sequentially energized by an external source is used to generate the rotating magnetic field.
  • the present invention also employs a segmented anode 108. However, unlike the '441 apparatus, the present invention employs no electrical switching circuitry to cause the plasma arc to jump from one anode
  • the annular segmented anode 108 has a plurality of solenoid coils 120 arranged around its periphery.
  • Each coil 120 is wrapped around a low reluctance annular core 122 with its axis oriented perpendicular to the axis of the reaction zone 118.
  • the total number of coils 120 equals twice the number of anode segments.
  • FIGS 7 and 8 show an eight-segmented anode with the segments separated by insulating material 124. For simplicity, however, only four coils 120 are shown in FIG. 7, designated 120a, 120a 1 , 120b, and 120b'.
  • Anode segment 108a is electrically connected to coils 120a and 120a' while anode segment 108b is electrically connected to coils 120b and 120b'.
  • Coils 120a and 120b are wrapped around the same portion 126 of core 122 in opposite directions.
  • Coils 120a' and 120b' are similarly wrapped around the opposite core portion 122.
  • Each of the coils 120 is also connected to an electrical ground, designated 130.
  • each anode segment is maintained at a constant electrical potential by two paths to ground in which is interposed a solenoid coil 120 located on the periphery of the reaction zone 118 and oriented so that its longitudinal axis is parallel to a line drawn from the center of the annular anode 108 to
  • a plasma arc discharge 105 takes place between the cathode 106 and a particular anode segment, an electrical current flows between the anode segment and ground which thus energizes the two solenoid coils associated with that segment (e.g., coils 120a and 120a').
  • the purpose of the coils 120 is to generate a magnetic field oriented radially and pointed toward (or away from) the anode segment conducting the plasma discharge.
  • the pair of coils 120a and 120b arranged on opposite sides of the periphery of the arc's path when energized produce a radially oriented magnetic field vector B,.
  • the magnetic field B 1 therefore causes the plasma arc 105 to experience a circumferentially directed force at right angles to B 1 which is proportional to the arc's axial velocity along the path from cathode to anode.
  • the plasma reactor 100 of the present invention thus operates as follows. All of the anode segments are connected to ground (or other constant potential) through separate pathways each of which includes a solenoid coil 120.
  • a plasma discharge occurs between the cathode 106 and one of the anode segments 108 when the breakdown potential of the gas within the reaction chamber is reached and a conductive plasma pathway is formed. If no other forces were present, the resulting plasma discharge would either remain stationary or jump from anode segment to anode segment at random.
  • the magnetic field B- forces the arc circumferentially and causes it to jump to the adjacent anode segment. That anode segment in turn energizes another pair of solenoid coils which further rotates the plasma arc to another adjacent anode segment and so on. In this manner, the plasma arc is made to rotate continuously at a rate independent of any electrical switching frequency.
  • the present invention employs another solenoid 132 wrapped around the periphery of the reaction zone 118 and coaxial with the axis of the reaction zone 118.
  • the coaxial solenoid 132 when energized by an external power source thus causes another magnetic field B 2 directed axially along the plasma arc path as depicted in FIG. 8.
  • the field B 2 therefore causes any charged particles moving with a radial or circumferential velocity component to experience a force directed perpendicularly to that velocity component.
  • the plasma arc is given a radial velocity component by the segments of the annular anode being arranged near the periphery of the arc path which tends to cause the plasma arc to bend radially outward.
  • the magnetic field B 2 thus converts the radially directed linear momentum of the charged particles into angular momentum and causes the arc to rotate. Furthermore, the resulting circumferential velocity component of the rotating plasma arc (caused by both magnetic fields B., and B 2 ) is acted upon by the field B 2 which tends to draw the arc radially inward. This provides the centripetal force necessary to maintain rapid rotation.
  • SDBS ⁇ TCTE SHEET thus, in the practice of the method of the present invention, atmospheric air or oxygen has been employed as the plasma gas to produce essentially pure aluminum oxide and titanium oxide from a precipitated particulate fraction derived from the pneumo-gravitational separation of fly ash.
  • the temperature generated in the reaction chamber 110 of the plasma reactor 100 was about 10,000° K and the arc was caused to revolve or rotate about an eight segmented anode 108 at a velocity of about 16,000 RPM.
  • the particulates were introduced into the top of the vertically aligned reactor chamber 110 through channels 116 at a rate such that they descended in a spiral through the plasma arc.
  • the desired mineral values therein such as, aluminum oxide and titanium oxide
  • the remaining constituents of the introduced particles such as magnesium either crystallize or evaporate.
  • the treated materials exit from the reaction chamber 110 through anode 108, they enter cylindrical cooling chamber 112 and descend through temperature gradients therein as the melted mineral values agglomerate into relatively dense particles, the crystallized residuals form dust-like particles and the evaporated components form gases.
  • a product guide or collector plate 134 which is positioned centrally within the chamber 112 for purposes of causing the relatively denser agglomerated mineral value particles such as aluminum oxide and titanium oxide to separate out from the other descending materials. Furthermore, plate 134 acts to direct or guide the separated mineral value particles in a proper downward direction through conical section 114 to enable collection thereof at the bottom end 136 of the conical section 114.
  • a countercurrent flow or swirl of air is directed from an inlet port 138 upwardly to an outlet port 140 in order to cause the dust-like particles and the gases accompanying the agglomerated minerals to separate out from the agglomerates and to be blown out of the reactor 100 through outlet pipe or tube 141 associated with outlet port 140.
  • angle X essentially defines the angle of entry of air into the conical section 114 of the reactor 100.
  • the angle X should be about 15°.
  • the appropriate dimension of angle X for any particular treatment depends on a variety of factors including the speed or velocity of the air being introduced through port 138, the specific weight or density of the material being treated and the angle of the cone (angle Y as illustrated) .
  • angle X may be increased as high as 90° (i.e., air will be introduced from the bottom of the cone) for very high density materials.
  • angle Y The preferred angle of the cone (angle Y) is about 30°.
  • angle X should range from about 0° to about 37° and angle Y should range from about 10° to about 30°.
  • angle X should range from about 5° to about 30° and angle Y should range from about 15° to about 40°.
  • angle Y should range from about 15° to about 40°.
  • angle X should range from about 0° to about 15° and angle Y should range from about 30° to about 40°.
  • angle X should range from about 0° to about 30° and angle Y should range from about 20° to about 40°.
  • the conical section 114 of the reactor is provided as an interchangeable part so that variously configured piece parts may be installed onto the body of the reactor 100 as desired.
  • Another important feature in the construction of the conical section 114 of the reactor 100 is the positioning of the port 138 and its accompanying air inlet 142.
  • the mid-point of the port 138 should be a height h, above the bottom end 136 of the conical section 114 of about 1/4 of the total height h 5 of the section 114.
  • the height h for any embodiment of the section 114 may be calculated as a function of the cone angle Y employing the equation:
  • d is the diameter of the cone 114 at the horizontal top edge 148 of the section 114.
  • the diameter d of the cone 114 may be calculated from the further equation:
  • a further important feature in the construction of the reactor 100 is the provision of an appropriately angled wall section 150 positioned horizontal bottom edge 152 of the cylindrical cooling chamber 112 and the horizontal top edge 148 of the conical section 114.
  • the wall 150 circumferentially interconnects and seals the chamber 112 and the cone section 114.
  • the wall 150 is positioned at an angle Z relative to the horizontal top edge 148 of the conical section 114 such that the air introduced into the section 114 through inlet port 138 at angle X will be directed by wall 150 in a desired upward direction in order to contact the descending materials exiting from the cooling chamber 112 and to cause the relatively lower density materials therein such as the dust-like particles and the gases to ascend through a centrally located tube or funnel arrangement 154 to contact the descending particles and to direct the lower density materials to the outlet port 140 where they exit through outlet pipe 141 and are collected as residuals of the method of this invention.
  • angle Z may range from about 35° to 60°, and most preferably should be about 45°. However, angle Z may be varied as desired to achieve optimum aerodynamic conditions within the conical section 114 for guiding and directing the air introduced at port 138 to the outlet port 140 either in a direct air flow pattern or in a swirling, spiraling or revolving flow stream.
  • a ventilation device (not shown) may be associated with outlet pipe 141 to assist in the collection of residual materials.
  • the velocity of the air being introduced into the conical section 114 is a further important factor to be considered in regard to the operation of the reactor 100 of this invention.
  • the velocity of the air being introduced into section 114 through port 138 should be in the range of about 1 to 20 meters/second.
  • the speed of air is regulated depending on the density of the mineral values being extracted with higher speeds generally being employed for the heaviest or most dense particles such as ferro-chrome, while lower speeds are employed for less dense materials.
  • air velocity of about 1.7 meters/second should be introduced into the conical section 114 through port 138.
  • an electromagnet 156 annularly encircling the lower section of the cylindrical cooling chamber 112 may be desirable for certain applications of the reactor 100. Specifically, in order to perform certain separation treatments on the plasma treated materials derived from metallurgical slag or foundries, operation of this electromagnet 156 may be of value in separating the mineral values from the residuals. However, for processing fly ash particulates, such eletromagnetic operation normally is not required.

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Abstract

Procédé en deux phases destiné à extraire des substances minérales de valeur de matériaux particulaires contenant des minéraux comprenant une phase de séparation pneumo-gravitationnelle dans laquelle les substances minérales de valeur sont précipitées à partir d'un courant d'air de flottation et les particules précipitées sont ensuite traitées par séparation thermo-chimique dans un réacteur au plasma. Les substances minérales de valeur qui en résultent sont recueillies sous une forme essentiellement pure.
PCT/PL1991/000003 1991-02-27 1991-02-27 Procede et appareil destines a extraire des substances minerales de valeur de materiaux particulaires WO1992015715A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
AU74945/91A AU7494591A (en) 1991-02-27 1991-02-27 Methods and apparatus for extracting mineral values from particulate materials
PCT/PL1991/000003 WO1992015715A1 (fr) 1991-02-27 1991-02-27 Procede et appareil destines a extraire des substances minerales de valeur de materiaux particulaires
MX9200853A MX9200853A (es) 1991-02-27 1991-02-27 Metodos y aparatos para la extraccion de valores minerales de materiales en particulas.
ZA921400A ZA921400B (en) 1991-02-27 1992-02-26 Methods and apparatus for extracting mineral values from particulate materials
IL101090A IL101090A0 (en) 1991-02-27 1992-02-27 Methods and apparatus for extracting mineral values from particulate materials

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Application Number Priority Date Filing Date Title
PCT/PL1991/000003 WO1992015715A1 (fr) 1991-02-27 1991-02-27 Procede et appareil destines a extraire des substances minerales de valeur de materiaux particulaires

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CN114769007A (zh) * 2022-03-08 2022-07-22 中国矿业大学 一种复配-改性制备低阶煤浮选药剂的方法

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114769007A (zh) * 2022-03-08 2022-07-22 中国矿业大学 一种复配-改性制备低阶煤浮选药剂的方法
CN114769007B (zh) * 2022-03-08 2024-05-28 中国矿业大学 一种复配-改性制备低阶煤浮选药剂的方法

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IL101090A0 (en) 1992-11-15

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