WO2011093741A1 - Device for the simultaneous production of high-melting metallic and non-metallic materials and sublimates - Google Patents

Abstract

The invention relates to the production of high-melting metallic and non-metallic materials and sublimates. The device comprises a reactor separator, side gates with channels, a granulator, and heat exchange devices of the first, second and third stages. The reactor separator is in the form of a cylindrical chamber with a hollow rod electrode having heat exchange elements, a channel for the egress of exhaust gases and sublimates, and an electromagnetic coil. The heat exchange device of the first stage is in the form of a drum mixer for simultaneously drying and heating the raw charge material to a temperature greater than 100°C using hot clinker entering from the granulator. The heat exchange device of the second stage has a hollow housing that surrounds the cylindrical chamber of the reactor. The heat exchange device of the third stage is in the form of a plasmatron and thermal calciner. The technical result is that of eliminating loss by radiation, maximizing the use of energy from exothermic reactions, minimizing the use of energy resources necessary for clinker formation, and significantly enhancing the productivity of the reactor and the quality of cement clinkers.

Description

 Device for the simultaneous production of refractory, metallic and non-metallic materials and sublimates

 The invention relates to electric arc plasma separator reactors for the simultaneous production of refractory, metallic and non-metallic materials and sublimates, mainly special types of artificial binder clinkers having a high degree of melt viscosity and related non-ferrous metals, and can be used in cement, chemical industry and metallurgy.

 The invention can significantly reduce energy consumption due to drying and heating of the raw material mixture, using the heat of the clinker and the reactor itself, maximizing the efficiency of all equipment, dramatically increasing the performance of the separator reactor and the quality of fused clinkers, eliminating the cyclic nature of work.

 The alleged invention relates to devices for the simultaneous production of refractory, metallic and non-metallic materials and sublimates, mainly special types of artificial binder clinkers, for example cement clinker, having a high degree of melt viscosity and related metal alloys, and can be used in the cement industry.

A device for melting a material, mainly cement clinker, containing a chamber, solid horizontal rod electrodes, openings for introducing waste and steam, an opening for discharging exhaust gases is known. RF patent il 57060 C2, H 05 B7 / 00 dated 15.12. 1998. The disadvantages of this device are the low resource of the plasmatron (erosion of the electrodes), low productivity of the unit when using industrial waste, the cyclical nature of the work and the high consumption of energy resources. Known plasma reactor for melting a material, mainly cement clinker, comprising a cylindrical chamber, hollow rod electrodes passing into the chamber through its upper cover, holes for introducing reagents in the chamber vault and outlet in the hearth, two electromagnetic coils covering the chamber and located one above the other by its height. Patent N ° 2213792, С22В 9/22, F 27 В 14/04 of 10/10/2003. The disadvantage of this method is the rapid wear of the electrodes and the need to stop the unit to replace them.

 Known plasma reactor for melting a material, mainly cement clinker, including a water-cooled cylindrical chamber, rod hollow graphite electrodes passing into the chamber through the top cover, four side feeders and one upper feeder for introducing the raw material charge, an electromagnetic coil, a longitudinal, hollow, internally cooled raw material, a partition that divides the camera into two equal parts and has horizontal slit openings for the exit of the material and create an additional garrison the same hole and an opening for the arc, located above the surface of the melt rotating in the horizontal plane to evacuate solid raw materials from under the electrodes and move it to the arc burning zone, openings for outputting the finished material. Patent N_2277598, C22B 9/22, F27B 14/04 dated 1 1.1 January 2004. The disadvantage of this invention is the low reliability of the partition.

The closest in technical essence and the achieved result is a plasma thermal decarbonizer reactor-separator for simultaneous production of a melt of refractory non-metallic materials and metallic materials and sublimates, containing a cylindrical chamber, rod hollow electrodes, a channel for evacuating exhaust gases and sublimates, an electromagnetic coil, side feeders with channels for entering part of the heated raw material and / or creating a skull on the lining in the form of conical slopes at the boundary of the melt mirror, a granulator for cooling and granulating the melt of refractory non-metallic materials with clinker production, heat exchangers of the first and second stages for heat transfer and return to the production process.

 Patent RU 2 354 724 C2 of January 16, 2007. The disadvantages of this invention are the technological difficulties of the cooled clinker and heated raw materials at the first stage of heat transfer, as well as the reduction in quality of the resulting finished clinker.

 The basis of the present invention is the elimination of heat loss to the environment, the maximum use of the energy of exothermic reactions, the minimum energy consumption necessary for clinker formation, a significant increase in the productivity of the device for the simultaneous production of refractory, metallic and non-metallic materials and sublimates and the quality of cement clinkers.

According to the invention, the problem is solved in that a device for simultaneously producing a melt of refractory metallic and nonmetallic materials and sublimates, containing a channel for supplying fire-liquid slag located in the upper cover of the reactor chamber, a channel for evacuating exhaust gases and sublimates, an electromagnetic coil that creates rotation the melt in the horizontal plane for the evacuation of raw materials from under the electrodes and moving it to the arc burning zone and controlled by a special power source that changes frequency and magnitude of alternating current, side feeders with channels for introducing part of the heated raw material and / or creating a skull on the lining in the form of conical slopes at the boundary of the melt mirror, a channel for outputting melts of refractory non-metallic materials located in the side wall at a distance of 1/3 of the height from the camera vault. Also containing a granulator for cooling and granulating the melt of refractory non-metallic materials, openings for the output of melts of related metal materials located in the bottom of the chamber, three heat exchangers of the first, second and third stages for transferring and returning heat to the production process, the heat exchange device of the first stage being made in the form two-chamber drum mixer for simultaneous drying and heating of the feed mixture to t 1 10-150 ° C with hot clinker coming from the granulator and further transfers heated charge into the heat exchanger of the second stage, and the heat exchanger of the second stage is made in the form of a hollow body, covering the cylindrical chamber of the reactor and heating the raw material charge to t 360-400 ° C, the heat exchanger of the third stage is made in the form of a hollow graphite electrode, in the inner channel of which there are inclined overflow shelves or a conveying screw, the temperature of the raw material mixture at this stage is heated to t 800-900 ° C, as well as additional small electrodes immersed in the melt and installed nies in the side walls of the cylindrical chamber at a distance of 3/4 from the chamber vault.

 A device for the simultaneous production of refractory metallic and nonmetallic materials and sublimates includes a second-stage heat exchanger 1, which is a cylindrical chamber around the reactor vessel and consisting of an internal bearing part I, an external part of the lined body c and a filler b (raw material charge) of the cavity, which during continuous operation of the feeders 2 and 3 moves from the upper horizontal part of the housing to the heat exchanger 1.

The heat exchanger 1 of the second stage covers a cylindrical chamber around the outer continuous reactor vessel to transfer heat from the reactor vessel a with a temperature of 600 ° С to the raw material charge, channel 4 for evacuating the exhaust gases and sublimates, openings 5 in the bottom for removing molten metal materials from the chamber . Channel 8, for output of a lighter binder (refractory non-metallic materials, for example, clinker), made in the form of a coil of currents of variable frequency and controlled by a special power source that allows you to change the frequency of the alternating current from 10 Hz to ultra-high frequencies depending on the task to obtain the specified quality of the final product (clinker ) The electromagnetic coil 6 creates a rotation of the melt in a horizontal plane to evacuate the raw materials from under the heat exchanger of the third stage of the plasma torch-thermo decarbonizer 7 with a conveying screw, through which plasma-forming and transporting gas (argon, nitrogen, carbon dioxide) is supplied and moving it to the arc burning zone, in where the temperature of the raw material charge increases to 800-900 ° C, while the raw material mixture passes through the stage of thermal shock when it passes from the plasma torch-thermal decarbonizer, getting into the plasma melt, seven side feed lei 9 (1 ', 2', 3 ', 4', 5 ', 6', 7 ') with channels for introducing part of the heated raw material charge into the cavity of the heat exchanger 1 of the second stage, the raw material charge in the combustion zone of the reactor and creating a skull 10 on the lining in the form of conical slopes at the boundary of the melt mirror and, if necessary, when reversing the feeders, feeding heated material through a plasma torch-thermal decarbonizer to the reactor chamber 1 1. The clinker melt granulator is mounted under the reactor to cool and granulate the melt of refractory non-metallic materials made in the form of a rotating t an arc 12, cooled by water from the inside, a rotary drum mixer 13, which is a first-stage heat exchanger, for transporting and transferring heat from a pre-granulated clinker with a temperature of 1000-1200 ° С to a raw material charge with simultaneous drying and heating of a raw material charge to a temperature above 1 10 ° С, which is supplied through the feeder 14 to the cavity of the heat exchanger 1 of the second stage, the fire-liquid slag with a temperature of more than 1800 ° C is fed by the feeder through the graphite channel 15, located in the upper cover of the chamber, two rods 16, at with the help of which the reactor starts, the additional small electrodes 17 perform the function of the main electrodes at the time of replacement of the latter.

A device for the simultaneous production of refractory metallic and non-metallic materials and sublimates works as follows. The reactor is powered through a third-stage heat exchanger of the plasmatron-thermode decarbonizer 7 with a feed mixture heated to 360-400 ° C. The raw material charge is initially heated in a first-stage heat exchanger, which is a continuous double-chamber drum mixer 13, containing a shell with loading and unloading holes for heating the raw material charge and simultaneously cooling the clinker and serves to transfer heat from the clinker with a temperature of 1000-1200 ° С in the raw material charge with a temperature of 5-20 ° C, the mixture is heated to t 1 10-150 ° C. Clinker is obtained in the reactor from a clinker melt, which is poured onto a granulator 12 for heat recovery and granulation. The granulator 12 is made in the form of a rotating water-cooled plate inside, when hit on which the melt by centrifugal force is thrown onto stationary plates, while it is cooled and crushed. Then, the selected mixture heated to t 1 10-150 ° C is continuously fed by the feeder 14 into the cavity of the cylindrical chamber around the reactor vessel, which serves as the heat exchanger 1 of the second stage. The raw material mixture enters the hollow body through feeders 2 and 3, cools the walls of the reactor, and at the same time it heats up to t 360-400 ° С and side feeders 9 (Γ, 2 ', 3', 4 ', 5', 6 ', 7 ') is introduced through channels located in the walls of the body at an angle of 90 ° on one horizontal plane relative to each other, into the reactor on the melt surface to create a skull lining of the material itself at the boundary of the melt mirror, resulting in a skull 10 in the form of conical slopes on melt mirror, thereby thermochemical corrosion of the lining is excluded. When reversing feeders 9 (Γ, 2 ', 3', 4 ', 5', 6 ', 7') the raw material charge is heated to t 360-400 ° C using feeder 18, through a plasma torch-thermal decarbonizer 7 is fed into the reactor chamber, while the temperature of the mixture reaches 800-900 ° C. The raw material charge heated to t 800 - 900 ° С, which is introduced, contains in the calculated amount chemical compounds that provide artificial binders, for example, cement clinker, during their melting.

 When using waste materials, for example, chemical plants, as well as metallurgical industry waste in the form of liquid-liquid slag, they contain a certain amount of non-ferrous metals. Flame-liquid slag with a temperature above 1800 ° C is fed by a feeder through a graphite channel 15 located in the wall of the reactor chamber. At the same time, additional heat is supplied, sharply reducing energy costs and increasing the productivity of the reactor and the quality of cement clinkers.

When the melt rises above the coil 6, voltage is applied to its winding. The walls of the chamber are made of non-magnetic material. The electromagnetic field generated as a result of the passage of current through the coil acts on the melt, which in the liquid state becomes conductive. Due to this, the melt rotates in the horizontal plane to evacuate solid raw materials from under the plasma torch-thermal decarbonizer and move it in one direction to the arc burning zone and to channel 8 to remove lighter binder (refractory non-metallic materials). As a result of mixing the melt due to the rotating magnetic field generated by the three-phase coil, the melt is homogenized. Channel 8 is made in the form of a coil controlled by an additional power source that changes the frequency from 10 Hz to ultra-high frequencies. In this case, the influence of a magnetic field of variable frequency has a modifying effect on the formation monomineral phases of aluminates and calcium ferrites, which can dramatically improve the quality of artificial binders (clinker) and obtain new types of cementitious cements. When melting the mixture to obtain a cement clinker, which contains a small amount of rare metals, some of them whose melting point is slightly higher than the clinker melt (except for tungsten and molybdenum) are deposited in the bottom of the chamber above holes 5 and are periodically released into the molds. The deposition of metals is due to the fact that their density is at least two times higher than the clinker melt.

 Pairs of easily combustible rare metals (for example, lithium), together with carbon dioxide released as a result of decarbonization of the carbonate components of the clinker charge, are evacuated by the vacuum created in channel 4, into special separation devices where metal oxide pairs are condensed, and carbon dioxide can be used for receiving dry ice. Sublimates of metal oxides are transferred for further processing to obtain a conditioned product. Thus, the proposed device due to its compactness, the use of a continuous production process, heating the raw material charge moving in the cavity of the housing and cooling the walls of the reactor, cooling the clinker with the same raw material charge, minimizes energy consumption, significantly increases the productivity of the reactor, and improves the quality clinker, and along with this allows to obtain by-products in the form of their melt and sublimates.

Claims

Claim 1. A device for the simultaneous production of refractory, metallic and nonmetallic materials and sublimates, comprising a reactor-separator made in the form of a cylindrical chamber with a rod hollow electrode with heat exchange elements, a channel for evacuating exhaust gases and sublimates and an electromagnetic coil to create a melt rotation in a horizontal plane for the evacuation of raw materials from under the electrode and moving it to the arc burning zone, side feeders with channels for introducing part of the heated raw material and / or a skull on the lining in the form of conical slopes at the boundary of the melt mirror, made in the bottom of the chamber, channels for outputting melts of refractory non-metallic and metallic materials, a granulator for cooling and granulating the melt of refractory non-metallic materials to produce clinker, a first-stage heat exchanger for simultaneous drying and heating the feed mixture to a temperature above 100 ° C with a hot clinker coming from a granulator, a second-stage heat exchange device for further transfer to a third raw material charge and made in the form of a hollow body covering the cylindrical chamber of the reactor, characterized in that it further comprises a third-stage heat exchanger made in the form of a plasma torch-thermal decarbonizer equipped with bulk regiments or a conveying screw for passing the raw material charge when supplying a plasma-forming gas for accelerated decarbonization and maximum heat transfer between the electric arc and the raw material charge, the temperature of which reaches 800-900 ° C, and the heat exchange device ystvo first stage is designed as a two-chamber mixer drum. 2. The device according to claim 1., Characterized in that it further comprises an electromagnetic coil controlled by an additional source power supply that changes the frequency of the alternating current from 10 Hz to ultra-high frequencies, which allows controlling quality; clinker.