Multiple Output Stream Particle Beneficiation and Chemical Processing

摘要

A reactor (110) serves to combust residual carbon in fine particulate matter, remove a contaminant from fine particulate matter, or change the composition of fine particulate matter. The reactor output is processed by particle collection devices (115, 125, 140, 155, 175) and heat exchangers (135, 150, 165) to provide particle outputs (118, 124, 131, 144, 159) of different sizes. A contaminant, such as carbon or a metal, is combusted, vaporized, volatized, broken down, or substantially appears on one particle output (144) so that another particle output and the exhaust gas (142) are substantially contaminant-free. Different outputs can also be selectively mixed, as desired, to product a combined output (171). Fly ash and silica fume can be processed separately or together to reduce the amount of unburned carbon in both. Metals can also be removed from the fine particulate matter. Kaolin can also be processed to produce metakaolin.

主权项

1. An apparatus, comprising:
a single, dilute solids phase reactor having a top, a central section, and a bottom section with an exit port (118), and a top particle output port (121), the top particle output port being located on or near the top to provide for removal of exhaust gas and particles from the reactor, the port (118) 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 (120) 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 (120), 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 a first, second and third particulate collection devices (115, 125, 140) a heat exchanger (135) and a mixer (130), said first particulate collection device (115) is in communication with said solids control return device and comprising an inlet, an exit port (127) and an output port (129) 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 (127), said output port (129) in communication with a second particle collection device (PCD) (125) operating in a second temperature range, and comprising an inlet, an exit port (134) and output port (132), said output port (132) is in communication with said heat exchanger (135), said exit port (134) 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 (132) and a remaining portion of the particles passing through the output port (132) 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 said exit ports (127) and (134) of said first and said second PCD.