Patent ID: 9528700
Filing Date: 2016-12-27
CPC Classification: C04B,F23G,F23J,Y02W

Claim Text:
1. An apparatus, comprising: a single, dilute solids phase reactor having a top section, a central section, and a bottom section with an exit port, and a top particle output port, the top particle output port being located on or near the top section to provide for removal of exhaust gas and particles from the reactor, the exit port being located on or near the bottom for removal of particles other than those particles passing through said top particle output port; said reactor in communication with a solids return control device in communication with a mixer; a plurality of particle injection devices and a plurality of air injection devices situated at a plurality of heights on the reactor and arranged so particulate matter containing metal contaminant is injected into the reactor at a height above an adjacent air injection device; a particulate collection and cooling system connected to said solids return control device, said particulate collection and cooling system operates to separate gas from at least a portion of said particles exiting from the top particle output port of the reactor in stages, in series and at different temperatures, said particulate collection and cooling system comprising first, second and third particulate collection devices (PCD) a heat exchanger and a mixer, said first particulate collection device is in communication with said solids control return device and comprises an inlet, an exit port and an output port and operating in a first temperature range to remove at least a portion of the particles at a first temperature within said first temperature range through said exit port, said output port of said first particulate collection device is in communication with a second PCD operating in a second temperature range, and comprising an inlet, an exit port and output port, said output port is in communication with said heat exchanger, said exit port of said second particulate collection device is in communication with said mixer, and at least a portion of particles entering said second PCD are removed at a second temperature within said a second temperature range and below said first temperature through said particle output port and a remaining portion of the particles passing through the output port of said second PCD to said heat exchanger are cooled within said heat exchanger which is in communication with said third PCD, said third PCD comprising an inlet, a particulate exit port and gas exit port, whereby particles exiting said third PCD contain a level of metal contamination above the level of particles passing through the exit ports of said first and said second PCD.