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WO2024173980A1 - Traitement de matériau - Google Patents

Traitement de matériau Download PDF

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Publication number
WO2024173980A1
WO2024173980A1 PCT/AU2024/050119 AU2024050119W WO2024173980A1 WO 2024173980 A1 WO2024173980 A1 WO 2024173980A1 AU 2024050119 W AU2024050119 W AU 2024050119W WO 2024173980 A1 WO2024173980 A1 WO 2024173980A1
Authority
WO
WIPO (PCT)
Prior art keywords
working fluid
processing apparatus
reactor
material processing
gas
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/AU2024/050119
Other languages
English (en)
Inventor
Damien John DIGNEY
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.)
Calcining Investments Pty Ltd
Original Assignee
Calcining Investments 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
Priority claimed from AU2023900431A external-priority patent/AU2023900431A0/en
Application filed by Calcining Investments Pty Ltd filed Critical Calcining Investments Pty Ltd
Publication of WO2024173980A1 publication Critical patent/WO2024173980A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D45/00—Separating dispersed particles from gases or vapours by gravity, inertia, or centrifugal forces
    • B01D45/12—Separating dispersed particles from gases or vapours by gravity, inertia, or centrifugal forces by centrifugal forces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/1836—Heating and cooling the reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/46—Removing components of defined structure
    • B01D53/62—Carbon oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/96—Regeneration, reactivation or recycling of reactants
    • B01D53/965—Regeneration, reactivation or recycling of reactants including an electrochemical process step
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J6/00—Heat treatments such as Calcining; Fusing ; Pyrolysis
    • B01J6/001—Calcining
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    • B01J6/00—Heat treatments such as Calcining; Fusing ; Pyrolysis
    • B01J6/001—Calcining
    • B01J6/004—Calcining using hot gas streams in which the material is moved
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J8/006—Separating solid material from the gas/liquid stream by filtration
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    • B01J8/1854—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles with particles moving upwards while fluidised followed by a downward movement inside the reactor to form a loop
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    • B01J8/38—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed containing a rotatable device or being subject to rotation or to a circulatory movement, i.e. leaving a vessel and subsequently re-entering it
    • B01J8/384—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed containing a rotatable device or being subject to rotation or to a circulatory movement, i.e. leaving a vessel and subsequently re-entering it being subject to a circulatory movement only
    • B01J8/386—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed containing a rotatable device or being subject to rotation or to a circulatory movement, i.e. leaving a vessel and subsequently re-entering it being subject to a circulatory movement only internally, i.e. the particles rotate within the vessel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C19/00—Other disintegrating devices or methods
    • B02C19/06—Jet mills
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    • B01D2251/304—Alkali metal compounds of sodium
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    • B01D2251/404—Alkaline earth metal or magnesium compounds of calcium
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2257/50—Carbon oxides
    • B01D2257/504—Carbon dioxide
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    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/77—Liquid phase processes
    • B01D53/79—Injecting reactants
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    • B01J19/02—Apparatus characterised by being constructed of material selected for its chemically-resistant properties
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
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    • B02C19/06—Jet mills
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    • B04—CENTRIFUGAL APPARATUS OR MACHINES FOR CARRYING-OUT PHYSICAL OR CHEMICAL PROCESSES
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    • B04C5/04—Tangential inlets
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
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    • C22B1/10—Roasting processes in fluidised form
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    • C22B5/00—General methods of reducing to metals
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B15/00—Fluidised-bed furnaces; Other furnaces using or treating finely-divided materials in dispersion
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D17/00—Arrangements for using waste heat; Arrangements for using, or disposing of, waste gases
    • F27D17/10—Arrangements for using waste heat

Definitions

  • the present invention relates to an apparatus and method for processing a material, and in particular to a method and apparatus for processing a material by thermally treating and mechanically disrupting the material, for example to perform calcination of the material.
  • Calcination is the process of thermally treating a solid chemical compound, such as mixed carbonate ores, by raising the compound to a high temperature without melting under restricted supply of ambient oxygen, generally for the purpose of removing impurities or volatile substances and/or to incur thermal decomposition.
  • the process is typically performed in furnaces or reactors (sometimes referred to as kilns or calciners) of various designs including shaft furnaces, rotary kilns, multiple hearth furnaces, and fluidized bed reactors.
  • EP-2,116,294 describes the calcination of powdered or fine granular material by calcination in a calcination mill followed by post-calcination of hot in a reaction vessel, system exhaust gas is supplied as reaction gas to the reaction vessel as sole heat source.
  • US-9,469,884 describes system and method for the calcination of minerals.
  • the system comprises a vertically disposed reactor segment configured to impart horizontal forces on particles passing through the reactor segment in a vertical direction; an injector unit for receiving granular feedstock, the injector unit being disposed at a top portion of the reactor segment, whereby granules of the feedstock move through the reactor segment in a granular flow under at least one of a group consisting of a force of steam, gravitational force and a centrifugal force; a reactor heat exchange unit thermally coupled to a wall of the reactor segment for providing heat to the flowing granules inside the reactor segment through heat transfer through the wall of the reactor segment; one or more inlets formed in the reactor segment for introducing a superheated gas into the reactor segment to create conditions of a gas-solid multiphase system; and one or more exhaust openings formed in the retort segment such that gas products are at least partially flushed from the reactor segment under the flow of the superheated gas
  • prior art systems tend to be limited to disclosing methods/systems that are complex to manufacture, inefficient using an indirect heat source and high energy consumption using electricity without provision to supplementing its own energy requirements to run in a closed and continuous cycle.
  • an aspect of the present invention seeks to provide a material processing apparatus configured to process a material, the apparatus including: a working fluid conditioner configured to supply a conditioned working fluid; a reactor including: a working fluid inlet configured to receive a flow of conditioned working fluid from the working fluid conditioner; a material inlet configured to receive a supply of material; a reactor body configured to entrain material in the flow to thereby process the material, wherein the processing includes thermally treating and mechanically disrupting the material; and, a reactor outlet configured to supply processed material and used working fluid; and, a separator configured to separate processed material from the used working fluid.
  • the reactor body is configured to generate turbulence in the flow to at least one of: calcine the material; and, micronise the material.
  • the reactor body is cylindrical and configured to generate cyclonic flow.
  • the reactor body includes: a central chamber wherein: the material inlet is configured to deliver material into the central chamber; the reactor outlet is configured to receive processed material from the central chamber; an annular chamber radially outwardly of the central chamber, the working fluid inlet being configured to deliver working fluid into the annular chamber; and, a cylindrical wall separating the central and annular chambers, the wall including a number of openings to allow working fluid to enter the central chamber from the annular chamber, and wherein the working fluid is at least partially pressurised in the annular chamber.
  • the reactor body includes an elongate cylindrical body having a rifled inner wall configured to generate turbulence in the working fluid.
  • the reactor body is made of at least one of: stainless steel; and, ceramic materials.
  • the apparatus includes a plurality of reactors arranged in series so that a reactor outlet of one reactor is connected to the material inlet of a downstream reactor to thereby progressively process the material.
  • At least one of an operating temperature, a particle size distribution of the material supplied at the material inlet and a material residence time within the reactor varies across a combination of reactors of the plurality of reactors.
  • the combination of reactors may be any two or more reactors of the plurality of reactors.
  • At least some working fluid is recovered from the separator and returned to the working fluid conditioner and/or the reactor.
  • the working fluid conditioner is configured to at least one of heat and pressurise the working fluid.
  • the working fluid conditioner includes at least one of: a heater to heat the working fluid; and, a pressuriser to pressurise the working fluid.
  • the working fluid conditioner includes an engine configured to heat and pressurise the working fluid, wherein the engine is at least one of: a jet engine; a ramjet engine; and, a scramjet engine.
  • the working fluid conditioner is configured to heat the working fluid using at least one of: microwaves; electrical resistance heating; and, plasma heating.
  • the working fluid conditioner includes a reciprocating linear compression system.
  • the linear compression system includes multiple pairs of bladders, each pair being separated by a baffle configured to move in a reciprocating manner to alternatively compress and decompress the bladders.
  • the apparatus includes a heat exchanger downstream of the separator, the heat exchanger being configured to recover heat from the used working fluid.
  • the recovered heat is used to pre-heat working fluid supplied to the working fluid conditioner and/or the reactor.
  • the apparatus includes a compressor configured to pre-compress working fluid supplied to the working fluid conditioner and/or the reactor.
  • the separator includes at least one of: a gas medium filter; and, a cyclonic separator.
  • the apparatus includes a particle condenser downstream of the separator to condense the processed material.
  • the apparatus includes a capture arrangement configured to capture waste fluid.
  • the waste fluid includes at least one of: excess used working fluid; and, fluid emitted during processing of the material.
  • the capture arrangement includes a battery.
  • the battery is a CO2 sodium battery configured to absorb waste CO2 and generate hydrogen, which is used as a fuel for the working fluid conditioner.
  • the material is processed to at least one of: oxidise the material or a constituent thereof, reduce the material or a constituent thereof, remove impurities; remove volatile substances; thermally decompose the material; and, perform pyrolysis.
  • the material includes at least one of: limestone; clay; shale; gypsum; a metalliferous feedstock, by non-limiting example iron ore, magnesite ore, bauxite ore; and carbon containing materials.
  • the working fluid has a temperature of at least one of: 300 °C to 1800 °C; 400 °C to 1600 °C; 1000 °C to 1100 °C; 1350 °C to 1550 °C; 700 °C to 1000 °C; and, 400 °C to 900 °C.
  • the material is a particulate material having a size of at least one of: 1 pm to 1000 pm; 50 pm to 500 pm; and, 1 pm to 100 pm.
  • the working fluid includes at least one of: an inert gas; nitrogen; and, carbon dioxide.
  • the working fluid includes at least one of a reducing agent and an oxidising agent.
  • the working fluid may comprise hydrogen and/or carbon monoxide.
  • the working fluid may comprise a synthesis and/or natural gas.
  • the reactor includes an additional working fluid inlet configured to receive a separate flow of working fluid.
  • the separate flow of working fluid may be from the working fluid conditioner and/or an additional working fluid source.
  • the material inlet is further configured to receive a concurrent flow of working fluid.
  • the concurrent flow of working fluid may be from the working fluid conditioner and/or an additional working fluid source.
  • the additional working fluid source is a gasifier.
  • an aspect of the present invention seeks to provide a method of processing a material, the method including: supplying a conditioned working fluid; processing the material by thermally treating and mechanically disrupting the material using a reactor including: a working fluid inlet configured to receive a flow of conditioned working fluid from the working fluid conditioner; a material inlet configured to receive a supply of material; a reactor body configured to entrain material in the flow to thereby process the material; and, a reactor outlet configured to supply processed material and used working fluid; and, separating processed material from the used working fluid.
  • Figure 1 is a diagram of an example of the system design with milling apparatus, jet engines, air jet mills, a filter, heat exchangers, a cooler, a storage container, a compressor, a liquid C02 battery, gas tanks, ductwork and pipework reticulation;
  • Figure 2 is a schematic drawing of an example of a jet turbine engine including air intake, a fan, a multistage compressor, injectors, a combustion chamber, turbine, exhaust air and exhaust air outlet;
  • Figure 3 is a schematic drawing of an example of a ramjet engine including compressed air intake, a high pressure compressed air nozzle, a ramjet engine and exhaust air outlet;
  • Figure 4 is a schematic drawing of an example of a scramjet engine including compressed air intake, a high pressure compressed air nozzle, a ramjet engine and exhaust air outlet;
  • Figure 5 is a schematic drawing of an example of an air jet mill including an annular design, a working gas medium inlet pipe, a material conveyor pipe and an outlet classifying pipe;
  • Figure 6 is a 3D sectional drawing of an example of an air jet mill including an annular design with multiple chambers, a working gas medium inlet pipe, a material conveyor pipe and an outlet classifying pipe;
  • Figure 7 is a schematic drawing of an example of an air jet mill including an annular design with multiple chambers, a working gas medium inlet pipe, a material conveyor pipe and an outlet classifying pipe;
  • Figure 8 is a schematic drawing of an example of an alternate air jet mill including an annular design with multiple chambers, a working gas medium inlet pipe, a material conveyor pipe and a cyclonic action with outlet classifying pipe;
  • Figure 9 is a schematic diagram of an example of an apparatus for processing a material
  • Figure 10A is a schematic cross sectional side view of a first specific example of an apparatus for processing a material
  • Figure 10B is a schematic cross sectional side view of an example of the reactor of Figure 10A;
  • Figure 11 A is a schematic perspective view of a second specific example of an apparatus for processing a material
  • Figure 1 IB is a schematic side view of the apparatus of Figure 11 A;
  • Figure 11C is a schematic plan view of the apparatus of Figure 11 A;
  • Figure 12A is a schematic perspective view of the reactor of Figure 11 A;
  • Figure 12B is a schematic perspective exploded view of the reactor of Figure 12A;
  • Figure 12C is a schematic cross sectional side view of the reactor of Figure 12A;
  • Figure 13 A is a schematic perspective view of a specific example of a compressor
  • Figure 13B is a schematic plan view of the compressor of Figure 13 A;
  • Figure 13C is a schematic perspective close up view of an end of the compressor of Figure 13 A; and,
  • Figures 13D to 13F are schematic perspective view of the compressor of Figure 13 A at different stroke positions.
  • the material processing apparatus 900 includes a working fluid conditioner 910, which is configured to supply a conditioned working fluid.
  • the working fluid is a gaseous medium, and more particular an inert gaseous medium that does not react with the material itself, such as nitrogen, carbon dioxide, or the like.
  • the working fluid could include air, an oxidising and/or a reducing agent.
  • the nature of the processing being performed is hydrogen reduction
  • the working fluid can include hydrogen gas.
  • the working fluid could include carbon monoxide, such as from a natural or synthesis gas.
  • the processing being performed is preferably a solid state process.
  • the conditioning is typically performed to ensure the working fluid has desired temperature characteristics for thermally treating the material, as well as to ensure the working fluid is pressurised, so as to allow a pressurised flow of working fluid to be provided, which can be used for mechanically disrupting the material.
  • the apparatus further includes a reactor 920, which is used to process the material, having a reactor body 921, a working fluid inlet 922, a material inlet 923 and an outlet 924.
  • the working fluid inlet 921 is configured to receive a flow of conditioned working fluid from the working fluid conditioner 910, whilst the material inlet is configured to receive a supply of material.
  • the nature of the material and the form in which the material is provided will vary depending on the preferred implementation, but typically the material is a solid material, and is received in a particulate form, such as a powder, or similar.
  • the reactor body 921 is configured to entrain the material in the flow of working fluid to thereby process the material, specifically, to thermally treat and mechanically disrupt the material.
  • the heat treatment can be used for a variety of purposes, such as for reducing or oxidising the material or a constituent thereof, extracting volatile contaminants from the material, thermally decomposing the material, or performing pyrolysis.
  • the effect of the heat treatment will vary depending on the nature of the material and the particular temperature range selected.
  • the heat treatment can be used to calcine a material such as limestone, clay, shale, gypsum or the like.
  • the process can be used to purify a metalliferous feedstock including a metal ore, such as bauxite, iron ore, magnesium ore, or similar, to produce purified metals, or metal allows, such as stainless steel.
  • a metal ore such as bauxite, iron ore, magnesium ore, or similar
  • the heat treatment can also be used to pyrolise carbon containing materials, such as wood chip, or similar to produce activated carbon.
  • the mechanical disruption is typically used to fragment the material, and/or break open the surface of the material, so that heat is effectively applied to the entirety of the material. For example, this can be used to ensure volatiles are extracted from throughout the particles of material and not just from a surface region of the particle. This also allows the material to be processed more quickly that if mechanical disruption were not performed.
  • the apparatus further includes a separator 930, which is configured to separate processed material from the used working fluid.
  • a separator 930 can include a filter, cyclonic separator, or similar, which is used to extract processed materials, such as quick lime, clinker, metal, metal alloys, carbon, or the like depending on the nature of the material being processed.
  • the above described arrangement allows for the easy processing of materials, specifically using a combination of heat and mechanical disruption, which is performed in a reactor, to allow for continuous and rapid processing of material.
  • the reactor body is configured to generate turbulence in the flow to calcine the material and/or micronise the material. Specifically, generating turbulence enhances the mechanical disruption process, for example by causing particles to impact against one another and/or the reactor body, and can also lead to the generation of additional heat.
  • the reactor body is cylindrical and configured to generate cyclonic flow, and further examples of this will be described in more detail below.
  • the use of a cyclonic system is particularly beneficial as this can ensure that heavier particles are pushed to the outside of the reactor body, where they will tend to undergo additional mechanical disruption, whilst the reactor outlet can be provided towards a centre of the reactor body, so that only smaller particles of material are output from the reactor. This ensures that the particles of material undergo sufficient disruption before being output from the reactor.
  • the use of cyclonic flow can also increase the pressure of the working fluid, enhancing the effect of the mechanical disruption.
  • configuration of the reactor outlet can be used to control the reaction process, for example by controlling particle escape from the reactor body, so as to achieve a desired particle size and degree of thermal treatment.
  • the reactor outlet can be configured so that only a certain size of particle can be output, in turn ensuring a required degree of mechanical and thermal treatment is achieved.
  • the reactor body includes a central chamber with the material inlet being configured to deliver material into the central chamber and the reactor outlet being configured to receive processed material from the central chamber.
  • An annular chamber is provided radially outwardly of the central chamber, with the working fluid inlet being configured to deliver working fluid into the annular chamber.
  • a cylindrical wall separates the central and annular chambers, with the wall including a number of openings to allow working fluid to enter the central chamber from the annular chamber.
  • the working fluid is at least partially pressurised in the annular chamber, which in turn can ensure a higher flow velocity of working fluid in the central chamber. Additionally, appropriate configuration of the openings can help promote turbulence in the central chamber, to thereby enhance mechanical disruption of the material.
  • the reactor body can include an elongate cylindrical body having a rifled inner wall configured to generate turbulence in the working fluid.
  • flow can be partially cyclonic, but more typically is substantially axial along the length of the body, with eddies and vortices being formed by the rifling, so that particles are entrained in the eddies and vortices to ensure mechanical disruption and sufficient heating are performed.
  • the reactor body is typically made of stainless steel and/or ceramic materials, depending on the nature of the materials being processed and the temperature, pressure and type of the working fluid.
  • the apparatus can include a plurality of reactors arranged in series so that a reactor outlet of one reactor is connected to the material inlet of a downstream reactor to thereby progressively process the material.
  • This allows the size of particles to be progressively decreased through successive reactors, allowing operating parameters of the reactors, such as operating temperature and material residence time, through respective working fluid temperatures, pressures and flow rates, to be tailored to the particle size, thereby optimising the processing of the material.
  • each successive reactor may have different working fluid flow rates, temperature and pressures, to thereby optimise processing of the material.
  • Additional control over the reactor process can also be achieved by adjusting the design of the reactor outlet, the working fluid inlet and the material inlet, the shape and design of the reactor body, such as the shape of reactor chambers, and the size and shape of openings between the chambers.
  • At least some working fluid is recovered from the separator and returned to the working fluid conditioner.
  • This process may involve some processing of the working fluid, for example extracting contaminants introduced during processing of the material.
  • contaminants introduced during processing of the material For example, when volatiles are extracted from the material, these will be present in the used working fluid and may need to extracted prior to the working fluid being reused.
  • This can be achieved using any appropriate technique, such as condensing the working fluid or the contaminants therein.
  • the recovery process can be used so that there is a substantially closed loop of working fluid, with the working fluid only requiring minimal replenishment to account for losses during material process and/or processing of the working fluid. This therefore minimise the need for supplies of working fluid.
  • the working fluid conditioner is configured to at least one of heat and pressurise the working fluid. This can be achieved using any suitable technique and in one example, may involve using a heater to heat the working fluid and using a pressuriser to pressurise the working fluid.
  • apparatus can be used to both heat and pressurise the working fluid.
  • the working fluid conditioner can include an engine configured to heat and pressurise the working fluid, wherein the engine is a jet engine, a ramjet engine, a scramjet engine, or combination thereof.
  • the working fluid conditioner can heat the working fluid using microwaves, electrical resistance heating and/or plasma heating, or other suitable techniques.
  • the working fluid conditioner can include a compressor, for compressing the working fluid.
  • a reciprocating linear compression system can be used.
  • Such a system can include multiple pairs of bladders, each pair being separated by a baffle configured to move in a reciprocating manner to alternatively compress and decompress the bladders.
  • the apparatus includes a heat exchanger downstream of the separator, with the heat exchanger being configured to recover heat from the used working fluid.
  • the recovered heat can be used to pre-heat working fluid supplied to the working fluid conditioner, thereby reducing heating requirements for the working fluid conditioner. Additionally, and/or alternatively, the recovered heat could be used to pre-heat material, and/or pre-heat fuel for the working fluid conditioner, for example heating hydrogen or oxygen for a jet engine, or similar.
  • the apparatus can include a compressor configured to pre-compress working fluid supplied to the working fluid conditioner.
  • the separator includes a gas medium filter, although other suitable separators could be used.
  • the apparatus can include a particle condenser downstream of the separator to condense the processed material, allowing this to be used and/or stored as required.
  • the apparatus can include a capture arrangement configured to capture waste fluid.
  • the waste fluid can include excess used working fluid and/or fluid emitted during processing of the material. Depending on the nature of the waste fluid, this can be reused, stored or processed as needed.
  • the capture arrangement includes a battery, and specifically a CO2 sodium battery, which is configured to absorb waste CO2.
  • the battery can be configured to generate hydrogen, which is used as a fuel for the working fluid conditioner.
  • a specific example of the battery is described in co-pending application AU2023901956, the content of which is incorporated herein by cross reference.
  • the material processing apparatus can process the material to remove impurities, remove volatile substances, thermally decompose the material and/or perform pyrolysis.
  • this is not intended to be limiting, and other forms of processing could be performed.
  • the material processing apparatus can process the material to reduce and/or oxidise the material or a constituent thereof.
  • the working fluid can include an oxidising and/or reducing agent.
  • the working fluid can comprise a reducing agent as hydrogen, carbon monoxide and/or another reducing agent.
  • the working fluid can comprise a natural gas and/or a synthesis gas.
  • the reactor may include an additional working fluid inlet configured to receive a separate flow of working fluid.
  • This separate flow of working fluid may be from the working fluid conditioner as described above and/or can be from an additional working fluid source, such as a fluid storage facility or a gasifier.
  • the working fluid includes an inert gaseous medium and an oxidising and/or reducing agent
  • the inert gaseous medium may constitute or form part of the flow received at the fluid inlet of the reactor and the oxidising and/or reducing agent may: constitute or form part of the separate flow of working fluid received by the additional working fluid inlet; form part of the flow received by the fluid inlet; and/or constitute or form part of a concurrent flow of working fluid received at the material inlet with the material.
  • Examples of the materials that can be processed include limestone, clay, shale, gypsum, iron ore, magnesite ore, bauxite ore, iron ore, carbon containing materials, or the like.
  • Examples of the working fluid temperatures that can be used include 300 °C to 1800 °C, 400 °C to 1600 °C, 1000 °C to 1100 °C, 1350 °C to 1550 °C, 700 °C to 1000 °C, 400 °C to 900 °C, or the like, depending on the nature of the material and the processing being performed.
  • the material is a particulate material having a size of at least one of 1 pm to 1000 pm, 50 pm to 500 pm, 1 pm to 100 pm, or the like.
  • Examples of the working fluid can include an inert gas, nitrogen and/or carbon dioxide, although it will be appreciated that other working fluids could be used, such as air, or the like.
  • the apparatus can be used for performing calcination processes and specific examples of these include:
  • the apparatus 1000 includes a working fluid conditioner 1010, having a cylindrical body 1011 having a working fluid inlet 1012, that receives pressurised working fluid from a compressor (not shown).
  • the inlet may include a jet pump outlet 1012.1, which can be used to inject high pressure working fluid into the inlet to draw in additional working fluid from a working fluid source.
  • the jet pump can be an arrangement similar to that shown in Figures 3 and 4.
  • the conditioner 1010 includes a number of heating elements 1013, mounted within tubes 1014, having fins 1014.1, that extend laterally across the body 1011. In use, compressed working fluid is received via the inlet 1012 and passes over the fins, thereby allowing the working fluid to be heated using the heating elements 1013, before being output via an outlet 1015, into the working fluid inlet 1022, of the downstream reactor 1020.
  • the reactor is in the form of an elongate tubular body 1021, having a material inlet 1023, connected to a hopper 1040 containing particulate material.
  • the working fluid flows in through the inlet 1022, which has a narrower cross sectional area than the reactor body 1021, the working fluid accelerates, with the resulting flow providing a Venturi effect, thereby drawing material into the reactor, and entraining this within the fluid flow.
  • the reactor body 1021 includes a rifled inner surface, in this example formed from a helical baffle 1021.1 extending along the inner surface of the reactor body 1021, which induces turbulence in the working fluid flow. This acts to mechanically disrupt, and hence fragment the material particles, ensuring these are heated throughout, and thereby processing the particles as required.
  • the apparatus 1100 includes a working fluid conditioner 1110 and a recuperator 1150.
  • the recuperator receives a low temperature working fluid from a compressed air source via a recuperator inlet 1151, heating this using waste heat recovered from reactor 1120, before supplying heated working fluid via a recuperator outlet 1152 to the working fluid conditioner 1110, which is similar in form to the working fluid conditioner 1010 described above with respect to Figure 10A, which tops up the heat, supplying heated and compressed working fluid via a return pipe 1161 to a working fluid inlet 1122 of the reactor 1120.
  • working fluid and particles output from the reactor outlet 1124 could have a temperature of 1,200 °C, which preheats the incoming pressurised low temp CO2 working fluid.
  • the reactor further includes a material inlet 1123, which supplies material to the reactor vessel 1121, described further below with respect to Figures 12A to 12C.
  • the reactor includes an outlet 1124, which outputs used working fluid and processed material, which passes through an internal pipe of the recuperator 1150, thereby allowing waste heat to be recovered for heating new working fluid as described above.
  • the used working fluid and processed material are supplied to a separator 1130 including a cyclone 1131, which is used to separate the material and working fluid, with the working fluid being emitted via a filter 1133, whilst the processed material is deposited into a material collection vessel 1132.
  • the used working fluid can be collected and reused or recycled.
  • the reactor 1120 is shown in more detail in Figures 12A to 12C.
  • the reactor is via a generally flat cylindrical body 1121, including a working fluid inlet 1122, material inlet 1123 and outlet 1124.
  • the body 1121 is made of lower and upper plates 1221.1, 1221.2, held together via bolts and nuts 1221.3, 1221.4.
  • the plates are shaped to define an internal cavity, separated into central and outer chambers 1221.5, 1221.6 by a ring 1221.7, having a number of circumferentially spaced openings 1221.71 therein.
  • the working fluid inlet 1122 is in fluid communication with the outer annual chamber 1221.4, whilst the material inlet 1123 and outlet 1124 are in fluid communication with the central chamber.
  • sealing gaskets 1221.8 are provided between upper and lower plates 1221.1, 1221.2 and between each plate and the ring 1221.7.
  • working fluid is supplied into the outer chamber 1221.6, and further pressurised, before passing through the openings 1221.7 and into the central chamber 1221.5.
  • the working fluid mixes with material supplied via the material inlet 1123, heating and mechanically disrupting the material, before processed material and used working fluid is output via the outlet 1124.
  • the compressor includes a static frame 1371 having laterally extending static baffles 1371.1 held in position by elongate static beams 1371.2, and a moving frame 1372 including laterally extending movable baffles 1372.1, held in position by elongate movable beams 1372.2.
  • the movable frame 1372 is attached to actuators 1373, such as hydraulic rams, allowing the movable frame 1372 to be moved in a reciprocating linear fashion.
  • Pairs of bladders 1375.1, 1375.2 are provided between the static baffles 1371.1, with a movable baffle 1372.1 positioned between the bladders in each pair, so that the movable baffle can be used to compress each one of the bladders 1375.1, 1375.2, as the movable frame 1372 is moved between extents of the stroke, as shown in Figures 13D and 13F respectively.
  • Each bladder 1375.1, 1375.2 includes an inlet 1375.11, 1375.21 coupled to a supply manifold 1376, which supplies unpressurised working fluid, and an outlet 1375.12, 1375.22, coupled to an outlet manifold 1377, which supplies pressurised working fluid.
  • a supply manifold 1376 which supplies unpressurised working fluid
  • an outlet 1375.12, 1375.22 coupled to an outlet manifold 1377, which supplies pressurised working fluid.
  • the terms unpressurised and pressurised are relative, and the supply manifold could include partially pressurised fluid, which then undergoes further pressurisation.
  • valves such as butterfly valves, can be provided in the supply and outlet manifolds 1376, 1377, and/or the bladder inlets and outlets 1375.11, 1375.21, 1375.12, 1375.22, ensuring one way flow of fluid.
  • calcination of minerals involves the preparation of materials to be fed into a series of cyclone preheaters before entering a large horizontal rotary kiln.
  • Rotary kilns are generally slow rotating large diameter insulated pipes horizontally positioned.
  • Portland cement is manufactured by crushing up a meal (being mixed minerals including limestone and clay) to then be preheated and calcined to form clinker in the rotary kiln. Clinker is then cooled and micronized to powder form to make Portland cement.
  • limestone is calcined, it emits up to 50% of its weight in CO2 gases to form lime.
  • Natural gas, methane or coal is typically used to fire the rotary kilns to 1,500 °C.
  • the systems described above can be configured to address such problems by seek to provide a fast and compact flash calcination process using a working fluid conditioner in the form of a hydrogen fuelled jet engine, with recirculated CO2 used as the working gas medium and using compact air jet mills as reactors (acting as calciners) to replace large, expensive and inefficient rotary kilns.
  • the CO2 will be used as both the circular loop high temperature working gas medium and also serve as a fuel source for an electro-chemical reaction in a hydrogen battery.
  • the apparatus includes a mineral milling machine 28, a mineral powder transfer pump 29, mineral powder reticulation pipework 30, air jet mill material conveyor pipe inlet 15, annular air jet mill 31 and outlet classifying pipe 14.
  • Blending, milling and micronizing of mineral materials is processed in mineral milling machine 28 to prepare and blend crushed rock deposits to form a blended powder.
  • minerals Once minerals are micronized and blended in mineral milling machine 28, they are reticulated through pipework 30 to the air jet mill inlet 15 through mineral powder transfer pump 29.
  • Mineral powder transfer pump 29 can accurately dispense programmable micronized and blended powders using a batch process or alternatively and preferably, by a continuous process.
  • the volume and speed of discharge of blended micronized powders can be electronically controlled by a programmable logic controller (not shown).
  • annular air jet mill 31 of Figure 1 is further detailed in Figures 5,6,7 and 8.
  • Conventional air jet mills use a high pressure gas medium to enable particles to clash together to get an end desired result of blending multiple materials, pulverizing, micronizing and classifying materials.
  • Conventional air jet mills generally use a high pressure and high volume gas medium provided through pressurized and regulated eyeliner storage systems and / or from compressed air systems.
  • Conventional air jet mills generally have not been used for calcining high temperature mineral materials for a variety of reasons, such as cost prohibitive expensive materials required to withstand high temperatures and the expensive nature of using compressed air or a compressed gas medium.
  • Small scale air jet mills can consume over 1,000 cfm (Cubic Feet per Minute) to run just a small mill.
  • Modem material advancements in additive and subtractive manufacturing are enabling large complex parts to be made with exotic high temperature alloys.
  • an air jet mill operating as a reactor can be manufactured using high strength alloy materials to withstand temperatures up to 3,000 °c.
  • high temperature alloys include but are not limited to tungsten, silicon carbide, Tantalum, ceramics or composite combinations thereof.
  • the apparatus includes a material conveyor pipe inlet 15, and outlet classifying pipe 14, a working gas medium inlet pipe 13, an enclosed top circular housing 16, an enclosed base circular housing 17, an outer annular housing 11.
  • the apparatus includes a material conveyor pipe inlet 15, and outlet classifying pipe 14, a working gas medium inlet pipe 13, an enclosed base circular housing 17, an outer annular housing 11, an inner annular gas medium chamber 18, an inner gas medium injector ring 19, multiple gas medium injectors 20 and classifying channel 21.
  • Micronized and blended minerals enter through the material conveyor pipe inlet 15, preferably through a penetration of the enclosed top circular housing 16 in the close proximity of the classifying channel 21.
  • a high pressure and high temperature working gas medium enters inlet pipe 13 to pressurize the inner annular gas medium chamber 18.
  • Injector openings 20 are placed on acute angles through the inner gas medium injector ring 19 to restrict pressure and increase velocity of the pressurized working gas medium formed in the inner annular gas medium chamber 18.
  • Micronized and blended minerals enter material conveyor pipe inlet 15 in close proximity to classifying channel 21 with high pressure and temperature working gas medium, causing particles to clash with each other and become smaller. Micronized particles exposed to high temperature and high pressure working gas medium flash calcine in milliseconds within the air jet mill and once particle size is achieved, exit through outlet classifying pipe 14.
  • FIG. 8 A further alternate example of an annular air jet mill apparatus is referenced in Figure 8 showing a tapered cyclonic housing 26 to provide additional cyclonic action.
  • the classifier outlet pipe 25 extends into the cyclonic section to ensure only smaller particles of calcined material are output from the reactor.
  • such arrangements can be used to create a high temperature and high pressure working gas medium to power an air jet mill flash calciner using a hydrogen fuelled jet engine.
  • the apparatus includes an air intake 1, a fan 2, a multi stage compressor
  • injectors 4 combustion chamber 5
  • turbine 6 combustion exhaust gases 7 and exhaust air 8.
  • the air intake used is ambient air from the outside atmosphere made mainly of 80% nitrogen and 20% oxygen.
  • the air intake is delivered from a controlled source, preferably an inert gas such as carbon dioxide that has been captured from the calcination process of limestone.
  • Air intake 1 is drawn in by fan 2 through a multistage compressor 3 to increase pressure.
  • Injector 4 adds fuel to combustion chamber 5.
  • Hydrogen fuel and atmospheric air (20% oxygen) or pure oxygen are used to provide for combustion. If an inert working gas medium such as CO2 is used, both hydrogen and oxygen will be required through the injectors for combustion to occur given no oxygen is available when using a CO2 working gas medium.
  • turbines 6 accelerate combustion exhaust gases 7 and exhaust air 8.
  • exhaust gas pressures of between 1 and 30 bar are obtained.
  • exhaust gas temperatures of up to 3,000 °C are preferred.
  • atmospheric air intake is preferred, although in other examples an inert air intake is preferred.
  • an inert air CO2 intake is used to reclaim heat, for recirculation in calcining limestone and for ease of capturing carbon dioxide gas in the CO2 working gas medium.
  • the apparatus includes an air intake la, a high pressure compressed air jet nozzle 3a, a ramjet engine 9 and exhaust air outlet 8.
  • the ramjet engine typically receives air intake la provided by ambient air from the outside atmosphere derived mainly of 80% nitrogen and 20% oxygen.
  • a high pressure controlled source of working gas medium is supplied through a high pressure compressed air jet nozzle 3a, similar to an Exair Large Super air nozzle 1118/1119 as an example.
  • High pressure compressed air jet nozzle 3a uses a curved inlet and outlet body shape to enable the Coanda effect to draw in and accelerate air speed and volume la, therefore minimising the volume of compressed air required from the nozzle 3a.
  • the coanda effect is the tendency of a jet of air emerging from an orifice to follow and adjacent flat or curved surface and to entrain air from the surroundings so that a region of lower pressure develops.
  • a multiplier ratio of 1:25 can be achieved from the Exair large super air nozzle, reducing the volume of compressed air requirement of the ramjet.
  • the ramjet engine receives an inert air intake la provided by a controlled air compressor source and pipework, with supply of high pressure inert air through a high pressure compressed air jet nozzle 3a, similar to Exair Large Super air nozzle 1118/1119 as an example.
  • Gas medium exhaust air velocities of up to 3,000 kmph (kilometres per hour) are generally required for ramjet engines.
  • the apparatus includes an air intake la, a high pressure compressed air jet nozzle 3a, a scramjet engine 10 and exhaust air outlet 8.
  • the scramjet engine receives air intake la provided by ambient air from the outside atmosphere derived mainly of 80% nitrogen and 20% oxygen.
  • a high pressure controlled source of working gas medium is supplied through a high pressure compressed air jet nozzle 3a, similar to Exair Large Super air nozzle 1118/1119 as an example.
  • High pressure compressed air jet nozzle 3a uses a curved inlet and outlet body shape to enable the Coanda effect to draw in and accelerate air speed and volume la, therefore minimising the volume of compressed air requirement from 3a. Again, a multiplier ratio of 1 :25 can be achieved from the Exair large super air nozzle, reducing the volume of compressed air requirement of the scramjet.
  • the scramjet engine receives an inert air intake la provided by a controlled air compressor source and pipework, with supply of high pressure inert air through a high pressure compressed air jet nozzle 3a, similar to Exair Large Super air nozzle 1118/1119 as an example.
  • Gas medium exhaust air velocities of up to 5,000 kmph are generally required for scramjet engines.
  • the apparatus includes a mineral milling machine 28, a mineral powder transfer pump 29, mineral powder reticulation pipework 30, air jet mill material conveyor pipe inlet 15, annular air jet mill 31 and outlet classifying pipe 14.
  • a working gas medium inlet pipe 13 is supplied by jet engine 45.
  • Intake air 1 and la is supplied by pipework 40 from duct 39 and compressed by multi stage compressor 41.
  • Air Jet mill 31a discharges through outlet classifying pipe 14 through pipework 32 into gas medium filter 33.
  • Both inlet gas medium 1 and la, gas medium 42 are preheated through heat exchanger 36 and both are connected to a turbine with pipework 43.
  • Injectors 44 add fuel or fuels to the combustion chamber. If ambient air from atmosphere is being used, only hydrogen fuel is combusted. If an inert gas such as C02 is used, hydrogen and oxygen injectors are required.
  • the apparatus includes a series of air jet mills 31 connected in series by having the outlet classifying pipe 14 of one air jet mill connected to the material conveyor pipe inlet 15 of a downstream mill, to act as preheaters and micronizing of particles inherent in design with air mills through stages to minimise initial particle size milling requirements.
  • Each air jet mill may be powered by an individual jet engine running at different temperatures, pressures, particle sizes and output volumes and classifier outlets.
  • air jet mills in series may run off a singular or multiple alternating jet engines.
  • Gas medium filter 33 separates high temperature particles from high temperature gas, with high temperature gas circulating in a closed loop through fan 34 and pipework 35.
  • Pipework 35 reticulates high temperature gas to heat exchangers 36 to ensure maximum heat recovery to minimize fuel consumption for jet engines to power air jet mill calciners.
  • Pipework 47 connected between the particle condenser 49 and the gas medium filter 33 recovers any residual heat from the particle condenser 49.
  • the gas medium filter 33 delivers high temperature calcined and micronized particles through pipework 48 to the particle condenser 49.
  • the particle condenser 49 delivers low temperature calcined and micronized particles through pipework 50 to a particle storage silo 51.
  • cooled gas pipework 52 reticulates condensed cooled gas via pump 53 to compressor and compressed air storage 37.
  • the compressor and compressed air storage 37 would typically include carbon dioxide (CO2) captured in the working gas medium from the calcination of limestone.
  • CO2 carbon dioxide
  • air could be atmospheric, or another inert air suited to the preferred calcination process and material type.
  • maximum heat reclamation is obtained from closed loop continuous circulation of working gas medium from the gas medium filter 33 through the various heat exchangers that supply both low pressure air intake gas 1 and la and high pressure compressed gas 42 or high pressure compressed inert gas 42 from multi stage compressor 41.
  • the compressor and compressed air storage 37 supplies gas working medium to compressors 41, compressed working gas medium 42 and pump 55 to supply a controlled discharge of CO2 for dissolution into battery aqueous electrolyte 56.
  • a precooled CO2 working gas medium expelled in the limestone calcination process from a closed loop filter 33 is reticulated to a combined carbon capture utilization technology in the form of a Na-CO2 hybrid battery cell 70.
  • the filtered and cooled CO2 working gas medium from filter 33 and compressed in compressor 37 is used for chemical and electrochemical reactions in a Na-CO2 hybrid battery cell 70 to obtain hydrogen gas 62 and oxygen gas 64 as fuels for jet engine combustion requirements, for example, to calcine limestone in a closed loop.
  • the filtered and precooled CO2 working gas medium from storage and compressor 37 can be purged into an aqueous electrolyte solution of distilled water, seawater or NaOH solution 56. This can be used to form carbonic acid, FFCOslaq) through the hydration of C0 2 .
  • a cathode 59 is submerged in an aqueous electrolyte solution 56, whilst an anode 60, typically constructed of sodium metal, is submerged in an organic electrolyte solution 57.
  • a sodium super ionic conductor (NASICON) membrane 58 is typically placed between an organic electrolyte solution 57 and aqueous electrolyte solution 56, to allow ion transfer between the solutions.
  • typically a sodium super ionic conductor (NASICON) membrane 58 is placed between the organic electrolyte solution 57 containing a sodium metal anode 60 and the aqueous electrolyte solution 56 containing a cathode 59.
  • an electrical reaction between the anode and cathode provides electricity 61 to power an electrolysis process to provide hydrogen gas 62 and oxygen gas 64 from the Aqueous electrolyte 56.
  • a Na-CCh hybrid battery cell 70 generates hydrogen gas 62 and oxygen gas 64 from the CO2 generated in a calcination process from the captured working gas medium, with these optionally being captured and stored so that they can be used as an energy source for hydrogen gas jet engines through tank, valves and pipework reticulation 66, 67, 68 and 69.
  • Mineral powders are milled in mineral milling machine 28 to a predetermined particle size and reticulate through mineral powder transfer pump 29 and pipework 30 to enter air jet mill 31 material conveyor inlet pipe 15.
  • Air jet mill 31 shown in Figure 5 includes a material conveyor pipe inlet 15, and outlet classifying pipe 14, a working gas medium inlet pipe 13, an enclosed top circular housing 16, an enclosed base circular housing 17 and an outer annular housing 11. Further details of a sectional view of Figure 5 are shown in Figure 6 and 7, whereby the apparatus includes a material conveyor pipe inlet 15, and outlet classifying pipe 14, a working gas medium inlet pipe 13, an enclosed base circular housing 17, an outer annular housing 11, an inner annular gas medium chamber 18, an inner gas medium injector ring 19, multiple gas medium injectors 20 and classifying channel 21.
  • Micronized and blended minerals enter through the material conveyor pipe inlet 15, preferably through a penetration of the enclosed top circular housing 16 in the close proximity of the classifying channel 21.
  • a high pressure and high temperature working gas medium enters inlet pipe 13 to pressurize the inner annular gas medium chamber 18.
  • Injector openings 20 are placed on acute angles through the inner gas medium injector ring 19 to restrict pressure and increase velocity of the pressurized working gas medium formed in the inner annular gas medium chamber 18.
  • Micronized and blended minerals enter material conveyor pipe inlet 15 in close proximity to classifying channel 21 with high pressure and temperature working gas medium, causing particles to impact or clash with each other and become smaller. Micronized particles exposed to high temperature and high pressure working gas medium flash calcine in milliseconds within the air jet mill and once particle size is achieved, exit through outlet classifying pipe 14.
  • FIG. 8 A further alternate example of an annular air jet mill apparatus for use as a reactor is referenced in Figure 8 showing an additional cyclonic action.
  • Jet turbine engines (including a fan and compressor) or jet engines in the form of ramjet and scramjet (which exclude fan and compressor) use hydrogen fuels to provide a high temperature and high pressure gas medium suitable for flash calcining in an air jet mill. Jet turbine engines or jet engines are used to provide the pressure and temperature of the working gas medium for the calcination process with atmospheric gas or a controlled inert gas, depending the requirement to capture and or recover calcination gases generated during calcination. For example, calcining Kaolin clay to form metakaolin would not create the requirement to capture CO2, as Kaolin clay does not emit quantities of CO2 during calcination when compared to calcining limestone to manufacture Portland cement. In the calcination of iron ore, oxygen capture and recovery may be the preferred gas to capture.
  • the air jet mill 31 may be used in series or combination with other air jet mills 31.
  • the air jet mills may be supplied with high pressure and high temperature working gas medium with a singular or multiple jet turbine or jet engines.
  • Control over the calcination, working time between processes and particle size can be determined by modifying the design of the material conveyor pipe inlet 15, the outlet classifying pipe 14, a working gas medium inlet pipe 13, an enclosed base circular housing 17, an outer annular housing 11, an inner annular gas medium chamber 18, an inner gas medium injector ring 19, multiple gas medium injectors 20 and the classifying channel 21. Further control over the calcination, working time between processes can be determined by the pressure and temperature of exhaust working gas medium from the turbine jet engines or jet engines.
  • the intake gas working medium is ideally at very similar temperature to the calcining temperature with minimal heat loss to maintain efficiency through the heat exchangers 36 given the intake gas medium 1 and la is the largest volume of air requirement for the air jet mill 31.
  • FIG. 1 An example of an Na- CO2 hydrogen battery apparatus will be discussed with reference to Figure 1 where compressor and compressed air storage 37 supplies gas working medium to compressors 41, compressed working gas medium 42 and pump 55 to supply a controlled discharge of CO2 for dissolution into battery aqueous electrolyte 56.
  • a precooled CO2 working gas medium expelled in the limestone calcination process from a closed loop filter 33 is reticulated to a combined carbon capture utilization technology in the form of a Na- CO2 hybrid battery cell 70. In one example, this is used for chemical and electrochemical reactions to obtain hydrogen gas 62 and oxygen gas 64 as fuels for jet engine combustion requirements, for example as part of a process to calcine limestone in a closed loop.
  • a filtered and precooled CO2 working gas medium from storage and compressor 37 is purged into an aqueous electrolyte solution of distilled water, seawater or NaOH solution 56.
  • CO2 dissolution in an aqueous electrolyte solution 56 forms carbonic acid, fNCOslaq) through the hydration of CO2.
  • a cathode 59 is submerged in an aqueous Electrolyte solution 56 and an anode 60 is submerged in an organic electrolyte solution 57.
  • An anode constructed of Sodium metal 60 is submerged in an organic electrolyte solution 57, a Sodium super ionic conductor (NASICON) membrane 58 is placed between an organic electrolyte solution 57 and aqueous electrolyte solution 56 with the process creating electricity 61 for an electrolysis process to provide hydrogen gas 62 and oxygen gas 64 from the Aqueous electrolyte 56.
  • NAICON Sodium super ionic conductor
  • the Na-CCh hybrid battery cell 70 generates, and optionally captures and stores, hydrogen gas 62 and oxygen gas 64 from the CO2 generated in a calcination process from the captured working gas medium.
  • This can be used as an energy source for hydrogen gas jet engines through tank, valves and pipework reticulation 66, 67, 68 and 69.
  • the apparatus can provide a fast and compact flash calcination method in the form of reactors, such as air jet mills, which are powered by hydrogen jet turbine engines or jet engines including ramjet and scramjet capturing additional CO2 from a calcination process to supply CO2 to a form of Na-CC hybrid battery cell to create hydrogen and oxygen to then be used as fuel sources for the jet engines in a continuous closed loop cycle.
  • reactors such as air jet mills
  • ramjet and scramjet capturing additional CO2 from a calcination process to supply CO2 to a form of Na-CC hybrid battery cell to create hydrogen and oxygen to then be used as fuel sources for the jet engines in a continuous closed loop cycle.
  • an apparatus for flash calcining a material can include a jet engine using hydrogen and oxygen fuels for combustion with an inert CO2 gas working medium, an annular air jet mill acting as a reactor propelled by jet engine exhaust gases to flash calcine powdered materials.
  • a carbon capture system can be used for storage and utilization of CO2 from the air jet mill calcining process, with a CO2 utilization technology for the production of electrical energy, hydrogen and oxygen for use as jet engine fuels for the apparatus.
  • the apparatus can include one or more jet turbine engines, ramjet engines or scramjet engines, using hydrogen and oxygen fuels with an inert CO2 gas medium air intake.
  • a series of connected annular air jet mills are provided with material inlet pipes and outlet classifying pipes propelled by jet engine exhaust gases to flash calcine powdered materials with the inert CO2 working gas medium.
  • a closed calcining loop carbon capture system is employed for cooling, storage, pressurization and utilization of CO2 as a fuel, with a Na-CO2 hybrid battery cell being utilized for the production of hydrogen and oxygen derived from captured CO2 gas inputs from calcination for use as jet engine fuels for the apparatus.
  • the apparatus can include a high pressure and high temperature gas medium, annular air jet mills, a gas filter, a heat exchanger, a condenser, a compressor, CO2 storage, a C02 electrolysis battery and hydrogen and oxygen storage tanks.
  • the apparatus can include a compressor, such as a single stage for low pressures or multi stage for higher pressures.
  • the compressor may be integrated with a jet turbine engine, ramjet engine or scramjet engine, or could disconnected therefrom.
  • the jet turbine engine can include a multi staged compressor, with a combustion chamber downstream of the multi staged compressor.
  • the jet turbine engine can use hydrogen fuel and ambient gas intake, or alternatively hydrogen fuel and oxygen directly injected and controlled in a combustion chamber.
  • the hydrogen fuel and oxygen can be mixed in the combustion chamber with an inert gas provided from a source, such as a singular inert has source, which acts as a working medium.
  • the jet turbine engine includes a multi stage compressor, combustion chamber with hydrogen as a fuel source and atmospheric or inert intake gas to provide a high exhaust gas pressure between 3 and 20 bar and/or a high exhaust gas temperature between 100 °C and 3000 °C.
  • a ramjet engine includes a multi staged compressor, with a combustion chamber downstream of a multi staged compressor.
  • the ramjet engine uses hydrogen fuel and either ambient gas intake, or oxygen directly injected and controlled in a combustion chamber.
  • the hydrogen fuel and oxygen can be mixed with an inert gas supplied from a singular gas source.
  • the ramjet engine can provide high exhaust gas pressure greater than 5 bar and/or may provide a high exhaust gas temperature of up to 3000 °C.
  • a scramjet engine including a multi staged compressor and a combustion chamber downstream of a multi staged compressor.
  • the scramjet engine can use hydrogen fuel and ambient gas intake, or oxygen directly injected and controlled in a combustion chamber.
  • the hydrogen fuel and oxygen may be mixed with an inert gas from a singular inert gas source.
  • the scramjet engine can be configured to provide high or low exhaust gas pressure greater than 2 bar and/or a high exhaust gas temperature of up to 3000 °C.
  • the jet turbine, ramjet or scramjet engine is connected to an annular air jet mill, so as to provide high temperature and high pressure exhaust gas to the annular air jet mill.
  • the air jet mill typically comprises an annular chamber including a first section pressurized with high temperature gas medium, a second inner calcining section with a classifying section, an incoming material conveyor and a classifying outlet.
  • the incoming material conveyor conveys a material, such as a micronized material, into the second section so that the incoming material is sequentially exposed to high pressure and temperature gas medium supplied from the first pressurized section.
  • the first pressurized annular section includes multiple opening injectors into the second inner calcining section.
  • the second inner calcining section can include a pulverizing and classifying channel and/or zone, where calcining is performed.
  • an inner outlet is provided to discharge calcined material or powder, and specifically to discharge calcined material from the pulverizing and classifying zone.
  • the inner outlet can be configured to control particle size of discharged calcined material from the pulverizing and classifying zone, for example by controlling a time duration of particle exposure to heat and pressure.
  • an inner outlet of one air jet mill is used to discharge calcined material which is conveyed to the intake material conveyor of a downstream air jet mill.
  • a series of multiple air jet mills can be provided in this manner, by interconnecting intake material conveyors from outlet discharges. Pressures and temperatures of each air jet mill can be independently controlled by individual jet engines to thereby control material processing. In this arrangement, it will be appreciated that only a first one of the jet mills need receive raw materials and that the other air jet mills can be used as preheaters, particle pulverizes and/or classifiers.
  • a series of multiple air jet mills can be provided and interconnected, with pressure and temperature of intake gas mediums each independently controlled. This can be performed to provide particle size classification and duration of particles exposed to heat and pressure through various stages.
  • the series of multiple air jet mills can have pressures and temperatures independently controlled by individual jet engines with a common atmospheric air intake gas medium, achieved for example using a common distribution pipe to provide an intake ambient gas medium.
  • a common distribution pipe can be used to provide an intake ambient gas medium.
  • an inert intake gas medium can be used to supply an inert gas working medium.
  • Such a common distribution pipe can provide ambient ore inert intake gas medium directly to the engines, although alternatively this can be supplied via a heat exchanger before entry to jet engines, to pre-heat the air or gas.
  • the common distribution pipe can be used to provide an inert intake gas medium for jet engines from a controlled circular loop source, for example to recover filtered gas medium captured from a calcining process, with this optionally undergoing pre-heating (or pre-cooling) prior to being provided to the jet engines.
  • multiple distribution pipes can be used to provide circulation to heat exchangers from high temperature filtered gas medium from the air jet mill calcining process, allowing waste heat to be recovered.
  • a singular air jet mill or a series of multiple air jet mill preheaters combine to pulverize and calcine an inlet pre milled material, allowing this to be used in subsequent downstream for flash calcination.
  • a singular air jet mill or a series of multiple air jet mill preheaters combine to pulverize and calcine an inlet pre milled material and discharge powder materials to a filter apparatus to separate powder from high temperature gas medium, and optionally reclaim high temperature and high pressure working gas medium for use in heat exchangers. It will be appreciated that this can be performed as part of a substantially closed loop system, to provide working gas medium intake to common duct circulating supply to heat exchangers for jet turbine engines.
  • a filter apparatus is used to separate powder from the high temperature CO2 as a potential inert working gas medium.
  • the powder can be cooled by the filter apparatus, which in one example is a high temperature scrubber filter apparatus is used to cool powder from the high temperature working gas medium.
  • a powder storage apparatus can then be provided to receive and or cool powder from the high temperature filter apparatus.
  • a filter apparatus is used to separate powder from the high temperature gas, such as oxygen, so that the gas can act as a working gas medium.
  • the working gas medium can be transferred through heat exchangers or recuperators, allowing waste heat to be recovered.
  • a filter apparatus is used to separate powder from the high temperature C02 gas and circulate as a working gas heat transfer medium through heat exchangers or recuperators.
  • the filter apparatus can be used to separate powder from a high temperature working gas medium, for example separating powder from the high temperature CO2 working gas medium, and reclaiming high temperature and high pressure CO2 working gas medium in a closed loop sealed system to provide working gas medium intake to common duct supply for jet engines.
  • This can be used, for example, to separate powder from high temperature CO2 working gas medium expelled in the limestone calcination process, allowing the CO2 working gas medium to be cooled before being compressed and stored for use as a working gas medium intake to pipe supply for jet engines.
  • the heated CO2 working gas medium can be reticulated to a one or more heat exchangers, for example, using a fan in a closed recirculating loop, so that waste heat can be recovered and the CO2 cooled.
  • Pre-cooled CO2 working gas medium expelled for example during the limestone calcination process, can be reticulated to a carbon capture / sequestration / utilization technology, allowing the CO2 to be captured and/or reused.
  • this can be for performing chemical and electrochemical reactions in a hybrid battery, allowing hydrogen gas and oxygen gas to be obtained, which can in turn be used as fuels for jet engine combustion requirements.
  • This enables limestone calcination to be performed in a closed loop, with CO2 used as a working medium, and excess CO2 released in the process being used in the battery to generate hydrogen and oxygen to power the jet engines used in driving the calcining process.
  • Such hybrid batteries operate by having the filtered and precooled CO2 working gas purged into an aqueous electrolyte solution of distilled water, seawater or NaOH solution to forms carbonic acid, FhCOs/aq) through the hydration of CO2.
  • a cathode is submerged in an aqueous Electrolyte solution, whilst an anode, typically constructed of sodium, is submerged in an organic electrolyte solution.
  • a Sodium super ionic conductor (NASICON) membrane is placed between an organic electrolyte solution and aqueous electrolyte solution, allowing ion transfer between the solutions.
  • NAICON Sodium super ionic conductor
  • an electrical reaction between the anode and cathode provides electricity to consume for an electrolysis process, for example to provide hydrogen gas and oxygen gas from the aqueous electrolyte.
  • an electrolysis process for example to provide hydrogen gas and oxygen gas from the aqueous electrolyte.
  • the Na-CCh battery cell generates hydrogen gas and oxygen gas from the CO2 generated in a calcination process from the captured working gas medium, with this in turn being optionally used as an energy source for hydrogen gas jet engines through tank, valves and pipework reticulation.
  • the apparatus can be used to capture CO2 emitted from the calcination process of limestone and convert CO2 gas to hydrogen and/or oxygen gas for jet engine usage as a closes loop system.
  • working gas medium used in the air jet mill for calcining is CO2 captured from the calcining of limestone.
  • the working gas medium used in the air jet mill for calcining can be atmospheric air approximately 80% nitrogen and 20% oxygen, or could be another inert gas suitable for the material to which is being calcined.

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Abstract

La présente invention concerne un appareil et un procédé de traitement d'un matériau, et en particulier un procédé et un appareil de traitement d'un matériau par traitement thermique et rupture mécanique du matériau. L'appareil comprend un conditionneur de fluide de travail conçu pour fournir un fluide de travail conditionné ; un réacteur et un séparateur conçus pour séparer le matériau traité d'un fluide de travail usagé. Le réacteur comprend une entrée de fluide de travail conçue pour recevoir un écoulement de fluide de travail conditionné provenant du conditionneur de fluide de travail ; une entrée de matériau conçue pour recevoir une alimentation en matériau ; et un corps de réacteur conçu pour entraîner le matériau dans l'écoulement pour ainsi traiter le matériau ; et une sortie de réacteur conçue pour fournir le matériau traité et le fluide de travail usagé.
PCT/AU2024/050119 2023-02-20 2024-02-19 Traitement de matériau Ceased WO2024173980A1 (fr)

Applications Claiming Priority (4)

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AU2023900431 2023-02-20
AU2023900431A AU2023900431A0 (en) 2023-02-20 Hydrogen Jet Engine Calciner
AU2023902312A AU2023902312A0 (en) 2023-07-20 Material processing
AU2023902312 2023-07-20

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999031450A2 (fr) * 1997-12-12 1999-06-24 Thermo Power Corporation Echangeur thermique a lit de pluie et modes d'utilisation
EP1669137A1 (fr) * 2003-08-26 2006-06-14 KUROCHKA, Aleksandr Dispositif de concassage de materiaux
US7202389B1 (en) * 1999-11-11 2007-04-10 Nederlandse Organisatie Voor Toegepast Natuurwetenschappelijk Onderzoek Tno Flash-pyrolysis in a cyclone
EP2116294A1 (fr) * 2008-05-09 2009-11-11 Claudius Peters Technologies GmbH Procédé et installation de calcination
US9469884B2 (en) * 2006-03-31 2016-10-18 Calix Ltd System and method for the calcination of minerals
US20220134300A1 (en) * 2019-02-13 2022-05-05 Sabic Global Technologies B.V. Three-dimensional annular rotating fluidized bed fluid-solids contactor

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999031450A2 (fr) * 1997-12-12 1999-06-24 Thermo Power Corporation Echangeur thermique a lit de pluie et modes d'utilisation
US7202389B1 (en) * 1999-11-11 2007-04-10 Nederlandse Organisatie Voor Toegepast Natuurwetenschappelijk Onderzoek Tno Flash-pyrolysis in a cyclone
EP1669137A1 (fr) * 2003-08-26 2006-06-14 KUROCHKA, Aleksandr Dispositif de concassage de materiaux
US9469884B2 (en) * 2006-03-31 2016-10-18 Calix Ltd System and method for the calcination of minerals
EP2116294A1 (fr) * 2008-05-09 2009-11-11 Claudius Peters Technologies GmbH Procédé et installation de calcination
US20220134300A1 (en) * 2019-02-13 2022-05-05 Sabic Global Technologies B.V. Three-dimensional annular rotating fluidized bed fluid-solids contactor

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