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WO1992020469A1 - Procede de transformation des materiaux residuels de creuset - Google Patents

Procede de transformation des materiaux residuels de creuset Download PDF

Info

Publication number
WO1992020469A1
WO1992020469A1 PCT/AU1992/000220 AU9200220W WO9220469A1 WO 1992020469 A1 WO1992020469 A1 WO 1992020469A1 AU 9200220 W AU9200220 W AU 9200220W WO 9220469 A1 WO9220469 A1 WO 9220469A1
Authority
WO
WIPO (PCT)
Prior art keywords
spl
ash
additives
mixture
pot liner
Prior art date
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.)
Ceased
Application number
PCT/AU1992/000220
Other languages
English (en)
Inventor
Robin Branson
Eric Raymond Vance
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.)
QUBATOR Pty Ltd
Original Assignee
QUBATOR Pty Ltd
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 QUBATOR Pty Ltd filed Critical QUBATOR Pty Ltd
Priority to AU16935/92A priority Critical patent/AU653815B2/en
Publication of WO1992020469A1 publication Critical patent/WO1992020469A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G7/00—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals
    • F23G7/003—Incinerators or other apparatus for consuming industrial waste, e.g. chemicals for used articles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/1325—Hazardous waste other than combustion residues
    • 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
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

Definitions

  • the present invention relates to a process by which environmentally hazardous industrial waste material comprising predominantly but not exclusively spent pot liner (SPL) or similar waste material is combined with other substances to produce a ceramic material, of markedly reduced hazard to the environment, which preferably is manufactured into commercially valuable products but which at least constitutes a suitable medium for the permanent disposal of SPL.
  • SPL is produced from aluminium smelters as a waste product.
  • US Pat No. 4,763,585 deals specifically with the problem of agglomeration in fluidised bed combustion by means of a physical coating over the sticky particles which cause the problem.
  • a principal purpose of this invention is to immobilise the toxic components of the hazardous waste (SPL) in a ceramic material.
  • the fluorides contained in SPL are formed into a compound which is sufficiently insoluble in water to render the ceramic material containing tne compound non-hazardous.
  • the ceramic material is therefore a suitable medium for the permanent disposal of SPL.
  • Another effect of the process of this invention is that the cyanides contained in SPL are pyrolysed into harmless species.
  • the process of the invention may incorporate waste material from other manufacturing processes, such as dead burnt calcium sulphate but is not limited to doing so.
  • the process of the invention preferably produces materials which have a commercial value, independent of any value which may be attributed to the permanent disposal of SPL.
  • the present invention provides a process for the treatment of spent pot liner (SPL) or chemically similar material comprising: crushing raw SPL to a size suitable for combustion; combusting the crushed SPL material for a period and at a temperature sufficient to pyrolyse cyanides in said material into environmentally harmless species and to oxidise the graphite content of the material, thereby producing a substantially carbon free ash; mixing and milling the ash with additives comprising chemically reactive compounds selected to immobilise fluorine and other materials required to produce a desired ceramic material; heating the mixture for a sufficient period and at a temperature required to cause chemical combination of the reactive compounds in the mixture to produce a heat treated ceramic material.
  • SPL spent pot liner
  • ceramics may be produced by the process of the present invention for a wide variety of applications including refractory lining, civil engineering construction, wear surfaces, industrial components and domestic ceramic artefacts.
  • the heat treated solids may be crushed, milled and screened to provide a suitable grog which is then mixed by conventional means with suitable additives such as binders, pressed into a final shape and sintered.
  • suitable additives such as binders
  • One example of the process of the present invention employed raw SPL crushed by conventional means and burnt in a muffle furnace to produce a substantially carbon free ash. The resultant SPL ash was mixed with additives, milled, pressed into briquettes and heated. The briquettes were then crushed and screened to produce a grog with the fractions of different particle sizes required for optimum packing density when forming the final product.
  • the grog fractions were mixed in specified proportions with a binder and water and pressed into blocks and dried.
  • the blocks were sintered in a muffle f rnace.
  • Raw, untreated SPL was crushed to 2mm and spread evenly to a depth of 25mm on inconel trays measuring 1500mm by 700mm by 45mm. The trays were loaded 4 at a time into a muffle furnace.
  • the furnace temperature was ramped to 600 C at a rate of 200°C/hour and held at this temperature for 32 hours. It may not have been necessary to combust the SPL for 32 hours but the combustion time was extended to minimise the carbon content.
  • Each batch was milled separately using a 450mm diameter hammer mill ⁇ ch that approximately 95% of the material passed through a 100 mesh screen ie. - 150 microns.
  • the milled mixture was pressed dry, without binders or other additives, into briquettes using a single roll press applying approximately 15 tonnes pressure/briquette. If all that is required is to produce a grog then it will not be necessary to form briquettes. It is believed good enough to feed the powder through a roll press to produce cake for heating. Heat Treatment
  • the briquettes were piled approximately 100mm high onto the inconel trays mentioned above, which had been lined with Kao board approx. 20mm thick, and loaded into the muffle furnace. The furnace was ramped at 300°C/hour to a temperature of 1050°C and held at this temperature for
  • the heat treated briquettes were crushed in a roll crusher, milled in the hammer mill mentioned above and screened to obtain the following fractions of different material sizes for each batch, as determined by a screen analysis:
  • the broadest process of the invention produces a material which may be subjected to ancillary process to achieve additional useful results such as the improvement of the ceramic body and the retrieval of re-usable elements or compounds.
  • One example is given: Removal of Sodium by Leaching
  • Sodium in a ceramic may inhibit its use for certain purposes. This method of removing sodium from the calcined briquettes or sintered material is possible because the fluorides have been fixed so only sodium will come out in solution.
  • the grog was leached for 24 hours in de-ionised water at the rate of 51t/kg of material and then dried in preparation for further processing.
  • Sodium may be recovered by conventional evaporation of the leachate.
  • samples of SPL crushed to an average particle size of 20mm were combusted in a muffle furnace at between 600-700°C and then milled to a powder.
  • the powder was mixed with calcium sulphate and alumina in the approximate proportions 30% by weight - SPL; 60% by weight - calcium sulphate; 10% by weight alumina and heat treated at 800°C at atmospheric pressure for 3 hours.
  • the formed shapes from the resulting heat treated mixture were sintered in air at atmospheric pressure at 1150°C for 1 hour using a heating rate of 3°C per minute to achieve the steady state temperature.
  • the invention can be readily operated with an SPL ash to additive ratio in the range of 1:1 to 1:5.
  • the sulphates act like a flux or catalyst in the process of fixing the fluorides. Sulphates, or a substitute for them, are highly beneficial to the process. Simple experimentation can determine the optimum proportions of calcium, sulphates, alumina and/or other additives to achieve a desired result. For example, clay was substituted for alumina in a mixture of SPL ash and calcium sulphate corresponding to Batch 2. The mixture was pressed into briquettes which were heated at 1050°C for 2 hours. The resulting ceramic was similar to that produced by using alumina but with apparently useful distinguishing characteristics. It may, for example, be possible to incorporate sodium into refractory aluminium sodium silicate which is conducive to producing a better quality ceramic.
  • a muffle furnace has been used to date for combusting the raw SPL whereas a rotating furnace may reduce the residence time of the charge without having to substantially raise the temperature.
  • the principal objective at the initial stage is to achieve a substantially carbon free ash. Subsequent heat treatment will remove any residual cyanides.
  • the present invention facilitates a complete disposal strategy for SPL and other similar hazardous materials.
  • the output from the process must, therefore, be a product which does not depend exclusively for its disposal on being the input to another industrial process.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Dispersion Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

Procédé permettant de transformer des matériaux résiduels de creuset pour qu'il adopte une forme dans laquelle il n'est plus dangereux pour l'environnement et de préférence pour qu'il soit utilisé d'un point de vue commercial lorsqu'on le transforme en un matériau céramique pour un traitement thermique associé à des additifs: dans ce procédé les cyanures sont transformés en des espèces ne présentant aucun danger pour l'environnement et les fluorures sont chimiquement liés dans le matériau céramique.
PCT/AU1992/000220 1991-05-16 1992-05-15 Procede de transformation des materiaux residuels de creuset Ceased WO1992020469A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU16935/92A AU653815B2 (en) 1991-05-16 1992-05-15 Process for converting spent pot liner

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPK616791 1991-05-16
AUPK6167 1991-05-16

Publications (1)

Publication Number Publication Date
WO1992020469A1 true WO1992020469A1 (fr) 1992-11-26

Family

ID=3775405

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU1992/000220 Ceased WO1992020469A1 (fr) 1991-05-16 1992-05-15 Procede de transformation des materiaux residuels de creuset

Country Status (1)

Country Link
WO (1) WO1992020469A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2756198A1 (fr) * 1996-11-26 1998-05-29 Pechiney Aluminium Procede d'insolubilisation et de consolidation de brasques usees provenant des cuves d'electrolyse hall-heroult
WO2004035238A1 (fr) * 2002-10-18 2004-04-29 Regain Technologies Pty Ltd Traitement de sous-produits de fusion
CN112939614A (zh) * 2021-03-24 2021-06-11 湖南国发控股有限公司 一种电解铝大修渣协同陶瓷化的处理方法
CN113426796A (zh) * 2021-02-08 2021-09-24 吴正建 一种电解铝大修渣和大修渣浸出液再生循环利用方法及回收物的应用方法
CN113511881A (zh) * 2021-03-24 2021-10-19 湖南国发控股有限公司 一种利用大修渣制备发泡陶瓷的配方及方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0117761A2 (fr) * 1983-03-01 1984-09-05 Alcan International Limited Traitement de matériau de revêtement usagé provenant de cellules de réduction d'aluminium
US4956158A (en) * 1988-03-29 1990-09-11 Aluminum Company Of America Stabilization of fluorides of spent potlining by chemical dispersion
US5024822A (en) * 1988-03-29 1991-06-18 Aluminum Company Of America Stabilization of fluorides of spent potlining by chemical dispersion
AU7539491A (en) * 1990-04-24 1991-11-07 Alcan Australia Limited Process for treating spent potliner material from an aluminium smelter process and products therefrom

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0117761A2 (fr) * 1983-03-01 1984-09-05 Alcan International Limited Traitement de matériau de revêtement usagé provenant de cellules de réduction d'aluminium
US4956158A (en) * 1988-03-29 1990-09-11 Aluminum Company Of America Stabilization of fluorides of spent potlining by chemical dispersion
US5024822A (en) * 1988-03-29 1991-06-18 Aluminum Company Of America Stabilization of fluorides of spent potlining by chemical dispersion
AU7539491A (en) * 1990-04-24 1991-11-07 Alcan Australia Limited Process for treating spent potliner material from an aluminium smelter process and products therefrom

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2756198A1 (fr) * 1996-11-26 1998-05-29 Pechiney Aluminium Procede d'insolubilisation et de consolidation de brasques usees provenant des cuves d'electrolyse hall-heroult
WO1998023551A1 (fr) * 1996-11-26 1998-06-04 Aluminium Pechiney Procede d'insolubilisation et de consolidation de brasques usees provenant des cuves d'electrolyse hall-heroult
US5947888A (en) * 1996-11-26 1999-09-07 Aluminium Pechiney Process for insolubilizing and consolidating spent linings from hall-heroult electrolysis cells
WO2004035238A1 (fr) * 2002-10-18 2004-04-29 Regain Technologies Pty Ltd Traitement de sous-produits de fusion
US7594952B2 (en) 2002-10-18 2009-09-29 Regain Technologies Pty Ltd Treatment of smelting by-products
CN113426796A (zh) * 2021-02-08 2021-09-24 吴正建 一种电解铝大修渣和大修渣浸出液再生循环利用方法及回收物的应用方法
CN112939614A (zh) * 2021-03-24 2021-06-11 湖南国发控股有限公司 一种电解铝大修渣协同陶瓷化的处理方法
CN113511881A (zh) * 2021-03-24 2021-10-19 湖南国发控股有限公司 一种利用大修渣制备发泡陶瓷的配方及方法
CN113511881B (zh) * 2021-03-24 2024-02-02 湖南国发控股有限公司 一种利用大修渣制备发泡陶瓷的配方及方法

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