METHODS AND APPARATUS FOR USE IN PROCESSING AND TREATING PARTICULATE MATERIAL

Abstract: A method is described which is particularly suitable for converting otherwise waste particulate material, such as fly ash from power stations, into a product having controlled dimensions, and in a form suitable for use in many applications, for example as a filler, extender, pigment, additive, and bulking or viscosity agent. The method includes the step of subjecting the particulate material in a slurry to vibration at an ultrasonic frequency.

Description: METHODS AND APPARATUS FOR USE IN PROCESSING AND TREATING PARTICULATE MATERIAL This invention relates to methods and apparatus for use in processing and treating particulate material. A process to be described below may be used, for example, to produce particulate material of required dimensions, and in the recovery of specific materials, for example, metals. A further method to be described below is concerned with coating particulate material. In a particular arrangement to be described below, as an example, material contained in a slurry pulp is subjected to vibrations at ultrasonic frequencies and then given a centrifugal treatment in a cyclone in order to enable particles of a required size to be separated out. A magnetic separator may be used to separate out magnetisable materials. Arrangements illustrative of the invention will now be described, by way of example, with reference to Figures 1 to 9 of the accompanying drawings which show in block schematic diagrammatic form various arrangements of apparatus and their method of operation. Referring to Fig. 1 of the drawings, there is shown diagrammatically a silo 1 from which ash particles, which might be fly ash or bottom ash obtained by burning coal in a power station, are fed under the influence of gravity via a conduit 2. Near to the lower end of the conduit 2, the ash is mixed with water obtained via a 1 2 pipe 3, and the mixture is passed into a slurry tank 4 where it is agitated. Mixture from near to the bottom of the slurry tank 4 is fed, as indicated at 5, to a pump 6, which pumps the mixture to continuous flow chambers 7 and 8, in which the mixture is subjected to vibrations at ultrasonic frequencies. The ultrasonic vibrations are delivered to the mixture via horns, diagrammatically indicated at 9, and the mixture is passed via a conduit 11 to a hydro-cyclone 12 for separation into particles of differing sizes. In the particular example, particles of less than 5 microns are withdrawn via conduit 13 and particles which are larger than 5 microns are returned from the bottom of the hydro- cyclone 12 to the slurry tank 4 to be recycled and reprocessed. Or the separation (classification) of particles may be preferably performed dry after the drying stage as described hereinafter, by using pneumatic type cyclones and air classifiers. Typically particles are subjected to air attrition to deagglomerate particles which become agglomerated in the drying and calcining stages as a result of alkalis that may be present in the slurry before classification. Particles can be classified into grades at sizes as small as less than 2 microns. The mixture is passed in a continuous flow between the chambers 7 and 8 via a conduit 10. The ultrasonic horns 9 are energised by electro-mechanical generators 14, which are supplied with power from a source 15. It will be appreciated that, instead of two separate flow chambers 7 and 8, it is possible to employ a single flow chamber having a plurality of ultrasonic vibrators along its length, and that the means to convey the vibrations to the particulate material may be other than a horn. For example, it is possible for rods to extend from generators, such as those shown diagrammatically at 14, into the moving particulate material, in order to cause the material to be vibrated. Other forms of transducer, for example a plurality of frusto-conical transducer elements, arranged in line, and through which the material passes successively may be employed. The applicants have found that, in one particular arrangement the use of ultrasonic vibrations in the range of 15 to 30 kHz, generated by piezo-electric crystals and transmitted and focused in the slurry pulp by titanium disruptor horns 9, has proved particularly advantageous in producing "cavitation". Cavitation causes the formation and implosion of microscopic vapour bubbles, and results in a shearing and tearing action (of the particle chemical or physical bonding) , thus causing a greater number of free ultra fine fine particles in the slurry pulp. In the arrangement mentioned above, the action is concentrated in a particular region as a result of the design of a transducer horn and of transducer probes, and the slurry pulp which is under treatment in the chambers 7, 8, is maintained at a pressure between 100 and 200 pounds per square inch. The particles of the desired size, which are obtained from the hydro-cyclone 12, are fed via the conduit 13 to a gravity-type unit (not shown) , such as an oscillating centrifuge or flotation column, for the recovery of liberated by-products, including metal, and the main product is fed to a holding tank for treatment such as dewatering and drying (if necessary) and storage before being delivered to users. In another arrangement to be described with reference to Fig. 2, in which similar components are identified by means of the same reference numerals, a single flow chamber 7a, which is a tubular ultrasonic irradiator, is illustrated having a plurality of ultrasonic vibrators, such as horns 9, along its length, and the output from the chamber 7a is passed via a sump 16 and a pump 17, via the conduit 11, to the hydrocyclone 12. The power applied to the horns 9 is, in a particular method, between 1 and 5 kw, at a frequency of around 20KHz. The sonicated slurry pulp output from the hydrocyclone 12 is passed via a conduit 13 to a second stage 2 illustrated with reference to Fig. 3. Instead of the fly ash being delivered to the silo 1, it may, if wet, be delivered directly to stage 2 (Fig. 3) . In a particular method, the fly ash is conveyed to the slurry tank/attrition mill 4 shown in Figs. 1 and 2 with recycled and make-up water for a period of 30 to 90 minutes. A dispersant, for example stearic acid, is added continuously in small amounts, e.g. 500 to 1000 parts per million. The pump 6 may be a screw/gear type non-resonating pump. The slurry pulp is pumped, as indicated in Figs . 1 and 2, via conduit 11 to the hydrocyclone 12 for classification at around 45 microns. The underflow, that is the plus 45 micron fraction, may either be recycled for further sonication, or fed to a vacuum type filter, such as that shown in Fig. 6, the overflow, being the minus 45 micron fraction, being gravity fed into a gravity separator, such as a centrifuge or sonic sluice, the heavy fraction being fed to a storage container, and the light fraction being fed to the arrangement of Fig. 4. Referring to Fig. 3, the sonicated slurry from stage 1 (Fig. 1 or Fig. 2) is shown passing via a sonic sluice 20. The heavy fraction is fed directly to a container 21. The remainder is passed to a first low intensity magnetic separator 22, operating at between 1,000 and 1,500 gauss, from which a magnetic fraction 1 is fed to a container 23. The remainder of the material is fed from the separator 22 to a high intensity magnetic separator 24 operating at between 5000 to 10,000 gauss and the magnetic fraction which is obtained from the separator 24 is stored in a container 25. From the separator 24 a light fraction of non-magnetic pulp is fed via a conduit 26 to a third stage which includes a thickener 27 from which thickened pulp is passed via a conduit 28 to a fourth stage to be described with reference to Fig. 5. Decanted effluent from the thickener 27 is passed via a conduit 29 and a filter plant 30 to the conduit 28. Referring to Fig. 5, the thickened pulp and filtered effluent in the conduit 28 is shown being fed to a slurry tank 32, whose output is passed via a pump 33 and a conduit 34 to a bank of hydrocyclones consisting of a single hydrocyclone 36, a pair of hydrocyclones 37 and four hydrocyclones 38. A sump and a pump 39 and 40 are provided to feed the material between the hydrocyclones 36 and 37, and a pump and sump 41 and 42 are provided to feed the material between the 'hydrocyclones 37 and 38. Coarse and medium fractions are obtained via conduits 43 and 44 from the hydrocyclones 36 and 37 respectively, and from the hydrocyclones 38 there are obtained via conduits 45 and 46 fine and ultrafine grades of material respectively. These classified grades of material are passed to a vacuum filter (which may be of the rotary drum, filter press or other type of vacuum filtering equipment) stage illustrated diagrammatically in Fig. 6, where the classified grades of pulp are shown being fed separately to respective vacuum filters 50, 51, 52 and 53, from which the vacuumed solutions are fed via a conduit 54 to a filter plant. The filtered cake is shown diagrammatically being passed via respective paths 55, 56, 57 and 58 and decarbonizers and dryers, or burners/calciners, indicated at 59, where any organic _ 7 material is burnt off, to a final stage shown in Fig. 8 in which the dried graded material is shown being fed via respective silos to bags 61-64 for the coarse, medium, fine and ultrafine material. It is possible alternatively or additionally for organic material to be burnt off at some other stage in the process, for example during the passage of the material from the silo 1 into a calciner, such as a rotary kiln type, where the exothermic energy generated from the carbon and the iron oxides that are precipitated from the flue with the ash and the temperature of the ash itself, being 100°C to 300°C, is sufficient to power a generator to produce energy to the extent of 0.5 to 2 megawatts per 2 to 4 tonnes of throughput, depending on the carbon and iron oxide content, where the carbon content can vary from 6% to in excess of 20% and the iron oxide content from 5% to 15% . Further, a supplementary feed, such as natural gas or coal dust or waste can be made to make up to a desired GJ/h energy balance to achieve a consistent energy source to the generator. The resultant fly ash being ideally suited for sale to the cement replacement concrete industry or as a feed to the process plant as described in this application. Alternatively, depending on the fly ash which is being processed it may be desirable to convert, with controlled heating and oxidisation conditions, the magnetite (Fe 3 0 4 ) and or hematite (Fe 2 0 3 ) in the ash into highly magnetic gamma ferric oxide (FeO) , which is more magnetic than magnetite and hematitite to aid in the magnetic separation, or for the purpose of subsequently calcining the ash. In summary, it will be understood that by using the process described above, ash particles may be vigorously scrubbed or polished during their passage through the chambers 7 and 8, enabling surface salts to be removed and dissolved in the aqueous medium. During the ultrasonic treatment of a slurry containing ash in the chambers 7, 7a, and 8, the surfaces of the ash particles are cleaned, and/or partially disintegrated, preferably retaining their spheriodal shape, causing heavy metals, that had become locked in the ash particles as a result of fusion while the material was being burnt in the furnace, to be released. It is, moreover, possible to pre-treat the material in a slurry tank to reduce it to a pulp with a density, by weight, of between 15% to 50% of its original density. After treatment, magnetic separators may be used to remove certain metallic oxides. For example, a low intensity magnetic separator may be used to remove iron oxides and paramagnetic metals may be removed using a high intensity separator. A centrifuge may be used to capture non-magnetic particles appearing in the conduit 13. Water that is removed is pumped through a filtering step for recycling, or simply discharged. It will be understood that the resultant product may be separated out from the hydro-cyclone 12 (Fig. 1 and 9 Fig. 2) at varying particle sizes, for example at 5, 10, 20, 30 or 45 microns, for use in particular respective applications, for example as a mineral filler, extender, or pigment, a replacement for Portland cement, or a fine concrete additive. Fly ash or bottom ash produced and treated in the ways described above may be used as a filler, an extender, a pigment extender, a pigment, an additive, a replacement, a bulking agent or a viscosity agent (improver) in industrial products such as paint, coatings, plastics, resins, paper, rubber, ceramics, sealants, adhesives, concrete and other building products . The invention also provides methods of treating particulate material, for example fly ash produced and treated in one of the above mentioned ways . It is possible to coat the surface of fly ash or bottom ash particles produced and treated in the ways described above with pigments and chemicals such as titanium dioxide, iron oxides, synthetic and natural stearic acid, barium sulphate, precipitated calcium carbonate, calcium hydroxide and magnesium carbonate using ultrasonic and sonochemical techniques. In one coating operation, fly ash particles produced by the processes described above, which were of .01 microns to 100 microns in diameter, were introduced with the coating material, which was a Ti0 2 pigment, into a chamber and treated by ultrasonic vibrations at a frequency between 15 and 40kHz for between 1 and 120 seconds . Other mineral materials, for example sand, may be coated using a similar ultrasonic process. It will be seen that it is possible to eliminate or at the least reduce the use of solvents in paints by employing fly ash, beneficiated as described above by the removal, in particular, of materials that may be deleterious to paint, for example unburned carbon and metallic elements. It is believed that the reduced need for, or the elimination of, a solvent results from the fact that the beneficiated fly ash, having a low specific gravity (1.8 to 2.3 g/cm 3 ) and spherical shape, and therefore low bulk density (0.8 to 1.1 g/cm 3 ), lowers the viscosity of a mixture in which it is incorporated. Further, the low surface area of beneficiated fly ash being spherical, results in low oil demand and therefore less vehicle/binder . The coating of the beneficiated fly ash particles, in the way described using ultrasonic vibrations, improves the brightness of any mixture in which the coated particles are incorporated. It will be appreciated that the particles may be coated by methods employing other means than ultrasonic vibrations . A particular paint formulation, for example, employs 55-62.5% of beneficiated fly ash (i.e. treated using one of the processes described above) , 10% water, 20% Ti0 2 pigment and 7V 2 - 15% of a vehicle (binder/resin) e.g. oligomer. These components were emulsified sonically. Reference will now be made to Fig. 9, in which there is shown a complete system, which is similar to, but has variations with respect to the previously described system. In Fig. 9, there is shown a storage silo 71 to which fly ash is delivered directly from a power plant by a pneumatic system, by road, or by rail. The fly ash is passed from the silo 71 via a conduit 72 to a slurry tank 73 where, by the addition of hot make-up water, as indicated at 74, and recycled water from later stages in the system, as indicated at 75, the mixture is given a pulp density of 20% to 50% solids by weight. The slurry tank 73 is fitted with an overflow weir, indicated at 76 allowing for 2% to 5% of the slurry pulp, depending on the fly ash being treated, to overflow into the weir 76 for the removal of hydrophobic material, such as partially oxidised coal, (unburned carbon) , and hollow spheres (cenospheres) known as "floaters", which are removed via a conduit. Slurry pulp is gravity fed or pumped from the bottom of the slurry tank 73 via a conduit 78, at a rate to equal 98% to 95% of the feed to the slurry tank, to vibrating screens 79 fitted with one or more 50 μ to 75 μm sieves for the removal of a substantial amount of the unburned carbon, (partially oxidised coal) and oversize ash particles. The oversize 10 12 fraction is stockpiled for further treatment, sold as a recycled fuel source, and partially used in a later stage of the system. The undersize fraction of the slurry pulp is fed via a conduit 81 to a low intensity (500 to 1500 gauss) magnetic separator 82 for the removal of a magnetic ash fraction and discrete magnetic particles, mainly magnetite (iron oxide) , which are further stockpiled for further benefication, or used or sold as a feed stock for pure ion oxide pigment production, which may be used later in the process to coat the ash. The unmagnetised fraction of the slurry pulp that is not removed by magnetic force is fed via a conduit 83 to a gravity belt type thickener 84, where it is thickened to a pulp density of 60 to 70% solids by weight. Other types of thickener than a gravity belt thickener may, of course, be used. The thickened pulp is then conveyed via a conduit 85 and a positive displacement type pump 86, through a heat exchanger 87 to raise the slurry temperature to between 100°C to 300°C. The water that is removed from the thickener 84 is returned via conduit 88 to the slurry tank 73. Slurry pulp from the heat exchanger 87 is fed by a tubular connection 89 to an attrition scrubber 91 in order to provide autogenous scrubbing of particles in the slurry to dislodge elements which have become fused to the surface of the spheres during combustion and thus to condition the particles to be more amenable to treatment in subsequent stages. Slurry pulp from the scrubber 91 is fed to a positive displacement pump and thence to a flow cell 93 which is fitted with ultra sonic irradiators (resonators, transducers) and is referred to as a sonicator. Power input to the sonicator 93 from a generator 94 can be between 1,000 to 10,000 kW, the sonicator frequency being typically 20 kHz. Slurry pulp being subjected to cavitation caused by the sonic irradiation in the sonicator 94 is deagglomerated and pleurospheres, (spheres encapsulated within spheres) , are cracked releasing the encapsulated spheres, resulting in substantial size reduction and therefore a substantial increase in the amount of the fine and ultra fine particles, (0.1 to 10 μm particle sizes). Further, chemical leaching reactions of the alkali salts and other amorphous elements are initiated. Pulp exiting the sonicator 93 is fed by a pump (not shown) to a reactor 95, which in the particular embodiment has a tube reactor consisting of coiled high pressure steel tubing being 60 cm to 180 cm in diameter and of lengths from 100 metres to 2,000 metres, depending on the desired throughput volumes and residence times required for the dissolution of alkali salts and other amorphous elements. Pressures of between 3 bar to 50 bar may be required, depending on the fly ash being treated, which can be protected from the effect of excess pressure being developed by the installation of pressure relief valves. Additional heating of the slurry pulp may be necessary and may be achieved by the installation of a heat exchanger which involves passing sections of the coiled tube of the reactor 95 through a jacket containing heating oil or steam to obtain the desired temperatures, which may vary from 100 to 300 degrees centigrade. The dissolution of alkali salts and other elements volatised during the combustion step and deposited on the surfaces of the ash particles by condensation on cooling is completed in this stage. Leach reagents may be added, in addition to water, to the slurry pulp at this stage. Pulp exiting the reactor 95 is gravity fed into a slurry tank 96 for the adjustment of the pulp density by means of the addition of water. Density is adjusted to 20% to 33% solids by weight. Pulp from the slurry tank 96 is fed via a pump 97 through additional magnetic separators 98 and 99, the first separator 98 being a low intensity (500 to 1500 gauss) magnetic separator, and the second separator 98 in series being a high intensity magnetic separator (5000 to 10000 gauss) for the removal of magnetic and para magnetic particles released as a result of the sonic irradiation in the sonicator 93 and having been made discrete as a result of being released from entrapment on the spherical particle surface by the steps of attrition scrubbing and leaching of the alkali salts in the scrubber 91 and the leach reactor 95. Slurry pulp is then fed into a slurry tank 101 connected to a pump 102 to feed a filtering and ion exchange system 103-105. The system 103 to 105 includes columns containing the oversize activated carbon separated from the slurry pulp by the vibrating screens 79. A vessel containing activated resins may be included in series in order to remove by adsorption additional elements which will be in the leach solution as a result of prior treatment. A precipitation tank 106 may be included after the filtering stage 103-105 for the precipitation of alkali salts. Loaded resins and activated carbon may subsequently be treated for the recovery of adsorbed elements as by-products and alkali salts may be recovered as additional by-products . Filtered slurry from columns 103-105 is then fed into a solid-liquid precipitation separation and washing system 106 to achieve a clean vitreous spherical filter cake which is conveyed to a classification circuit. Solution is recycled to the tank 73 via conduit 75. Filter cake from the system 106 is reslurried in a slurry tank 107 of the classification circuit to a pulp density of 25% to 30% solids by weight for feeding by pumping through a series of classifiers. The classifiers may, for example, be either hydrocyclones or strainers. Particles are classified into medium, fine and ultra fine sizes, the total slurry being classified first, where a separation at between 25 and 30 μm is achieved, the over size being fed to a solid liquid separator and the undersize being fed to a secondary system for the separation of particles at 10 μm. The resultant oversize particles are fed to a second solid liquid separator and the undersize particles are fed to a third system for separation at 3 μm to 5 μm, the oversize and the undersize being fed to separate solid-liquid separators. The solid liquid separators are typically filter presses, rotary drum filters or centrifuges . In the classification circuit, the slurry is pumped via a pump 108 from the slurry tank 107 to a first classifier including a solid/liquid separator backwash tank 109, which provides an output for material of greater diameter than 10 μm solid/liquid to a press or vacuum filter 111. An output from the filter 111 is fed to drying and calcining units 112 to 114 and thence to a first bagging unit 115. Filtered water is returned to the tank 109 via a pump 116. Material having a dimension less than 10 μm is fed from the tank 109 to a further slurry tank 117 from which it is pumped via a pump 118 to a second solid/liquid separator backwash tank 119. Particles having a size between 5μm and 10 μm are passed to a press or vacuum filter 120 from the tank 119 and thence to a second bagging unit 121 via the drying and calcining unit 113. Filtered water is returned to the tank 119 via a pump 123 and particles up to 5 μm in size are passed to a press or vacuum filter 124 from the tank 119 and thence via the drying and calcining unit 114 to a bagging unit 126. Input and output strainers 127 and 128 of appropriate dimensions are employed at the respective inputs and outputs of the tanks 109 and 119. Or the separation (classification) of particles may 17 be preferably performed dry after the drying stage as described hereinafter, by using pneumatic type cyclones and air classifiers. Typically particles are subjected to air attrition to deagglomerate particles which become agglomerated in the drying and calcining stages as a result of alkalis that may be present in the slurry before classification. Particles can be classified into grades at sizes as small as less than 2 microns. Classified pulp is fed through a dryer and calciner system in series in order to burn off the organic material and to oxidise occluded magnetite, if it has not been completely removed in the preceding stages . The separated product from the drying and calcining units may be cooled and stored in silos connected to the bagging system. Each grade may be bagged or stored in silos for bulk transport to the market, or it may be further treated and then bagged or stored. Certain classified and separated grades may be coated with different coating agents to improve the brightness and other physical characteristics of the particles. Milk of lime, calcium hydroxide and calcium oxide in solution may be precipitated from solution in a further treatment by the bubbling of carbon dioxide through a solution in the presence of the vitreous ash spheres, which have activated surfaces as result of the heat treatment, (calcining) , as a precipitated calcium carbonate (PCC) . The tank used in this further treatment may be sonicated accelerating the bonding of the PCC to the spherical particle surface. Other coating agents may be used in coating the spherical ash particles, which have been treated in the preceding stages, using sonochemistry, such as titanium dioxide, iron oxide or other agents . It will be appreciated that, although particular items of apparatus have been identified in describing the examples shown in the drawing, it is possible to employ various alternative items of apparatus able to perform the same or similar functions in carrying out the steps of the process. The methods described above for treating fly ash may be used to achieve deagglomeration, to remove surface salts and other matter on the surface of particulate material during and after combustion and to reduce particle size, as well as to provide coatings on particulate material. Although the invention has been illustrated with reference to particular arrangements, by way of example, it will be appreciated that variations and modifications thereof, as well as other arrangements may be employed within the scope of the protection sought. It will, of course, be understood that although a hydrocyclone has been described as a separator or filter, any other well known separator or filter may be used. It will also be appreciated that, although in the particular arrangements described as examples in illustration of the invention, the final product has been graded or 10 19 classified into particular sizes, it may be preferred that for some applications the product should be a mixture of many different sizes.

Claims: CLAIMS 1. A method for use in treating particulate material including the steps of mixing the material with a fluid to form a slurry, subjecting the material in the slurry to vibration at an ultrasonic frequency, and separating out from the slurry the material so treated. 2. A method as claimed in claim 1 in which the vibration is in a frequency band extending between 15 and 30 kHz. 3. A method as claimed in either claim 1 or claim 2 which includes the step of classifying the material to be subjected to vibration into a particular size range before it is subjected to vibration at the ultrasonic frequency . 4. A method as claimed in any one of the preceding claims which includes the step of classifying the material into particular size ranges after it has been subjected to vibration at the ultrasonic frequency. 5. A method as claimed in any one of the preceding claims which includes the step of separating magnetic fractions and particles from the slurry before it is subjected to the vibration at an ultrasonic frequency. 6. A method as claimed in any one of the preceding claims in which the step of classifying the material into a particular size range is carried out by means of a vibrating screen. 7. A method as claimed in any one of the preceding claims in which the material is passed through an attrition scrubber before it s subjected to vibration at the ultrasonic frequency. 8. A method as claimed in any one of the preceding claims in which the material separated out from the slurry is subjected to a step of drying and calcining. 9. Apparatus for use in treating particulate material, including means for mixing the material with a fluid to form a slurry, means for subjecting the material in the slurry to a vibration at an ultrasonic frequency and means for separating out from the slurry the material so treated. 10. Particulate material which has been treated by a method as claimed in any one of claims 1 to 8.

Inventors: NELLMAPIUS JOHN HUGO, WATT JOHN H, NELLMAPIUS, JOHN, HUGO, WATT, JOHN, H.
Applicants: NELLMAPIUS JOHN HUGO, WATT JOHN H, NELLMAPIUS, JOHN, HUGO, WATT, JOHN, H.
Application year: 1997
Main classification: B03B1
IPC codes: B01J19, B03B1, B03B5, B03B9