Cooled conveyor for decoating systems
10883774 ยท 2021-01-05
Assignee
Inventors
Cpc classification
B01D45/16
PERFORMING OPERATIONS; TRANSPORTING
F27D3/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02P10/20
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F27D17/004
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F28F5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F27D17/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F27D3/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D45/16
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A decoating system includes a dust cyclone and cooled conveyor. The dust cyclone is configured to receive an exhaust gas from a decoating kiln, filter organic particulate matter from the exhaust gas as dust, and discharge the dust at a discharge temperature. The cooled conveyor is configured to receive the dust from the dust cyclone and cool the dust to a dust processing temperature that is less than the spontaneous reaction temperature.
Claims
1. A decoating system comprising: a dust cyclone configured to: receive an exhaust gas from a decoating kiln; filter organic particulate matter from the exhaust gas as dust; and discharge the dust at a cyclone discharge temperature; and a cooled conveyor comprising a screw rotatably positioned in a trough, wherein at least one of the screw or the trough is internally cooled with a coolant, and wherein the cooled conveyor is configured to: receive the dust from the dust cyclone; and cool the dust to a dust processing temperature that is less than the cyclone discharge temperature.
2. The decoating system of claim 1, wherein the cyclone discharge temperature is from about 250 C. to about 400 C., and wherein the dust processing temperature from about 50 C. to about 150 C.
3. The decoating system of claim 2, wherein the dust processing temperature is less than an ignition temperature of the dust.
4. The decoating system of claim 1, wherein both the screw and the trough of the cooled conveyor are internally or externally cooled with the coolant.
5. The decoating system of claim 1, wherein the screw comprises a hollow body and at least one helical flight extending from the hollow body, and wherein the screw is configured to receive the coolant within the hollow body to cool an outer surface of the hollow body that contacts the dust during operation.
6. The decoating system of claim 5, wherein the helical flight is a hollow helical flight in fluid communication with the hollow body, and wherein the screw is configured to receive the coolant within the hollow helical flight to cool an outer surface of the hollow helical flight that contacts the dust during operation.
7. The decoating system of claim 1, wherein the trough defines internal or external passages configured to receive the coolant within the internal passages to cool a surface of the trough that contacts the dust during operation.
8. The decoating system of claim 1, wherein the cooled conveyor is a first cooled conveyor, wherein the decoating system comprises a plurality of cooled conveyors, and wherein each cooled conveyor or the plurality of cooled conveyors comprises a screw rotatably positioned in a trough.
9. The decoating system of claim 1, wherein the screw is a first screw, and wherein the cooled conveyor comprises a plurality of screws rotatably positioned in the trough.
10. The decoating system of claim 1, further comprising an introducer configured to inject a cooling material into the dust within the cooled conveyor.
11. A decoating system comprising: a dust cyclone configured to: receive an exhaust gas from a decoating kiln; filter organic particulate matter from the exhaust gas as dust; and discharge the dust at a cyclone discharge temperature; and a cooled conveyor configured to: receive the dust from the dust cyclone; and cool the dust to a dust processing temperature that is less than the cyclone discharge temperature.
12. The decoating system of claim 11, wherein the cyclone discharge temperature is from about 250 C. to about 400 C., and wherein the dust processing temperature from about 50 C. to about 150 C.
13. The decoating system of claim 12, wherein the dust processing temperature is less than an ignition temperature of the dust.
14. The decoating system of claim 11, wherein the cooled conveyor comprises a trough, and wherein the trough is internally or externally cooled with a coolant.
15. The decoating system of claim 11, wherein the cooled conveyor comprises at least one of a screw conveyor, a troughed belt conveyor, a bucket conveyor, a pneumatic conveyor, or a vibrating conveyor.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.
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DETAILED DESCRIPTION
(8) The subject matter of examples of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
(9)
(10) During a decoating process using the decoating system 100, metal scrap 101 is fed into the kiln 102. Heated gas 115 is injected into the kiln 102 to raise the temperature within the kiln 102 and vaporize and/or thermally crack the organic contaminants without melting the scrap metal. In many cases, the oxygen concentration within the decoating system 100 is maintained at a low level (such as from about 6% to about 8% oxygen) such that the organic coatings do not ignite. For example, within the decoating system, the atmosphere may be 7% oxygen such that the organic compounds do not ignite even though they are at elevated temperatures due to the decoating process. The decoated scrap metal 103 is removed from the kiln 102 for further processing and ultimately processing into new aluminum products. As the scrap progresses through the kiln 102, it is heated by the gases, thereby cooling said gases. This thermal profile results in certain organic compounds that had previously vaporized to re-condense onto the surface of particulate matter.
(11) Exhaust gas containing the vaporized organic compounds and particulate matter exits the kiln 102 through a duct 114, which connects the kiln 102 to the cyclone 104 (or other suitable solid/gas separator). Within the cyclone 104, larger particulates containing condensed organic compounds are removed from the exhaust gas as dust and ultimately discharged from the cyclone 104 for disposal. The particulate matter is composed of various metallic and non-metallic solids as well as carbonaceous material. From the cyclone 104, the exhaust gas is directed into the afterburner 106. The afterburner 106 incinerates the remaining organic compounds within the exhaust gas, and discharges a heated gas into a duct 116 that ultimately leads to the exhaust system 112 (e.g., a baghouse), the atmosphere or back into the kiln 102. The afterburner 106 may include a hot air burner 119 or other suitable device for heating the gas. The temperature of the heated gas within the duct 116 is greater than the temperature of the exhaust gas from the kiln 102 within the duct 114. For example, in various cases, the temperature of the exhaust gas within the duct 114 is generally from about 250 C. to about 400 C., while the temperature of the heated gas within the duct 116 is generally from about 700 C. to about 900 C. Some of the heated gas is optionally recirculated back to the kiln 102 through a recirculation duct 118. In various examples, cooling devices 113 (such as water sprayers) are provided to cool a temperature of the heated gas from the afterburner 106 before the gas is recirculated back to the kiln 102.
(12) As illustrated in
(13) Traditionally, dust discharged from the cyclone 104 is collected with a bin or hopper. The dust discharged from the cyclone 104 and retained within the hopper is susceptible to combustion and the formation of fires because the dust exits the cyclone at a relatively high temperature and it can contain low temperature ignition compounds and catalyzing materials and compounds. This is exacerbated by the dust particles being loosely packed, the rate of air ingress into a pile of dust is relatively high (i.e., more air can infiltrate a pile of dust such that more dust is in contact with air), and the rate of heat conduction away from a local reaction site is relatively low. These dust fires are very difficult to extinguish, even with water or fire extinguishers. Moreover, if water were used to wet the dust to make a slurry mixture of the water and dust, the mixture may be costly to dispose of due to the content of the slurry mixture as well as the volume of the material. The process may further be costly to implement because of the quantity of water needed on a daily basis, and the mixture may present potential safety and environmental issues.
(14) As illustrated in
(15) In various examples, the cooled conveyor may be any of suitable type of conveyor configured to receive dust from the cyclone 104 and reduce the temperature of the dust from the cyclone temperature to a dust processing temperature, as described in detail below. In the examples shown in
(16) Referring to
(17) While the conveyor 124 illustrates one screw 126 within the trough 128, the number of screws 126 within the trough 128 should not be considered limiting on the current disclosure. For example, in some examples, multiple screws 126 may be provided within the trough 128 (see
(18) In some examples, the decoating system 100 optionally includes sprayers or other injectors at various locations along the conveyor 124 that are configured to inject a reduced amount of water or other liquid or solid coolant into the dust in the conveyor 124. In such examples, the water is injected in an amount sufficient to help, in combination with the cooled conveyor 124, reduce the dust from the discharge temperature to the dust processing temperature, but not enough to create a slurry mixture with the dust.
(19) In various examples, the decoating system 100 includes an introducer that is configured to inject predetermined amounts of a cooling material into the conveyor 124 along with the dust to further help cool the dust. In various examples, the cooling material may be inert materials, although they need not be. For example, in some cases, the cooling material that may be injected into the conveyor 124 with the dust includes materials that are inert or not inert. For example, the cooling materials includes, but is not limited to, various salts, sodium bicarbonate, sand, rock dust, metal shot, crushed stone, dross dust, cement kiln dust, lime, drop dust, sand, and various other suitable materials that may help cool the dust. In examples where the cooling material is injected into the conveyor 124 with the dust, the cooling material may optionally be separated from the dust downstream with a separator, depending on additional processing of the cooled dust (if any).
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(22) Similar to the screw 226, during operation of the screw 326, a coolant at a lower temperature than the dust is introduced into the hollow body 328 as indicated by arrow 332 is then directed through the screw 326 as indicated by arrow 334. From the hollow body 328, the coolant is directed to the hollow flights 330. As the coolant flows through the hollow body 328 and the screw 326 advances the dust, the temperature of the coolant in the flights 330 and/or the hollow body 328 increases due to contact with the dust, and the temperature of the dust decreases. The heated coolant is then directed from the flights 330 and the hollow body 228 as indicated by arrow 324. Similar to the screw 226, the heated coolant from the screw 326 may be subsequently cooled through a heat exchanger and recirculated back to the screw 326.
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(25) A collection of exemplary examples, including at least some explicitly enumerated as ECs (Example Combinations), providing additional description of a variety of example types in accordance with the concepts described herein are provided below. These examples are not meant to be mutually exclusive, exhaustive, or restrictive; and the invention is not limited to these example examples but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.
(26) EC 1. A decoating system comprising: a dust cyclone configured to: receive an exhaust gas from a decoating kiln; filter organic particulate matter from the exhaust gas as dust; and discharge the dust at a cyclone discharge temperature; and a cooled conveyor comprising a screw rotatably positioned in a trough, wherein at least one of the screw or the trough is internally cooled with a coolant, and wherein the cooled conveyor is configured to: receive the dust from the dust cyclone; and cool the dust to a dust processing temperature that is less than the cyclone discharge temperature.
(27) EC 2. The decoating system of any of the preceding or subsequent example combinations, wherein the cyclone discharge temperature is from about 250 C. to about 400 C., and wherein the dust processing temperature from about 50 C. to about 150 C.
(28) EC 3. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than about 120 C.
(29) EC 4. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than about 100 C.
(30) EC 5. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than about 80 C.
(31) EC 6. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is about 50 C.
(32) EC 7. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than an ignition temperature of the dust.
(33) EC 8. The decoating system of any of the preceding or subsequent example combinations, wherein the ignition temperature is from about 175 C. to about 300 C.
(34) EC 9. The decoating system of any of the preceding or subsequent example combinations, wherein both the screw and the trough of the cooled conveyor are internally or externally cooled with the coolant.
(35) EC 10. The decoating system of any of the preceding or subsequent example combinations, wherein the coolant is a fluid.
(36) EC 11. The decoating system of any of the preceding or subsequent example combinations, wherein the coolant is at least one of water-based, glycol-based, petrochemical-based, biologically-based and/or molten salt-based coolants, water, ethylene glycol, or oil.
(37) EC 12. The decoating system of any of the preceding or subsequent example combinations, wherein the screw comprises a hollow body and at least one helical flight extending from the hollow body, and wherein the screw is configured to receive the coolant within the hollow body to cool an outer surface of the hollow body that contacts the dust during operation.
(38) EC 13. The decoating system of any of the preceding or subsequent example combinations, wherein the helical flight is a hollow helical flight in fluid communication with the hollow body, and wherein the screw is configured to receive the coolant within the hollow helical flight to cool an outer surface of the hollow helical flight that contacts the dust during operation.
(39) EC 14. The decoating system of any of the preceding or subsequent example combinations, wherein the trough defines internal passages configured to receive the coolant within the internal passages to cool a surface of the trough that contacts the dust during operation.
(40) EC 15. The decoating system of any of the preceding or subsequent example combinations, wherein the cooled conveyor is a first cooled conveyor, wherein the decoating system comprises a plurality of cooled conveyors, and wherein each cooled conveyor or the plurality of cooled conveyors comprises a screw rotatably positioned in a trough.
(41) EC 16. The decoating system of any of the preceding or subsequent example combinations, wherein the screw is a first screw, and wherein the cooled conveyor comprises a plurality of screws rotatably positioned in the trough.
(42) EC 17. The decoating system of any of the preceding or subsequent example combinations, further comprising an introducer configured to inject a cooling material into the dust within the cooled conveyor.
(43) EC 18. The decoating system of any of the preceding or subsequent example combinations, wherein the cooling material comprises at least one of rock dust, metal shot, crushed stone, dross dust, cement kiln dust, lime, salt, sodium bicarbonate, sand, and drop dust.
(44) EC 19. A method of cooling dust containing organic particulate matter from a dust cyclone of a decoating system comprising: extracting the dust from the dust cyclone of the decoating system and into a cooled conveyor comprising a screw rotatably positioned in a trough, wherein at least one of the screw or the trough is internally cooled with a coolant; and advancing the dust along the trough with the screw and cooling the dust from a cyclone discharge temperature to a dust processing temperature with the cooled conveyor.
(45) EC 20. The method of any of the preceding or subsequent example combinations, wherein the cyclone discharge temperature is from about 250 C. to about 400 C., and wherein the dust processing temperature is from about 50 C. to about 150 C.
(46) EC 21. The method of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than an ignition temperature of the dust.
(47) EC 22. The method of any of the preceding or subsequent example combinations, wherein the ignition temperature is from about 175 C. to about 300 C.
(48) EC 23. The method of any of the preceding or subsequent example combinations, wherein the coolant is a fluid.
(49) EC 24. The method of any of the preceding or subsequent example combinations, wherein the coolant comprises at least one of water-based, glycol-based, petrochemical-based, biologically-based and/or molten salt-based coolants, water, ethylene glycol, or oil.
(50) EC 25. The method of any of the preceding or subsequent example combinations, wherein cooling the dust further comprises: circulating the coolant through a hollow body of the screw and cooling an external surface of the hollow body; and contacting the external surface of the hollow body with the dust.
(51) EC 26. The method of any of the preceding or subsequent example combinations, wherein cooling the dust further comprises: circulating the coolant through a hollow helical flight of the screw in fluid communication with the hollow body and cooling an external surface of the hollow helical flight; and contacting the external surface of the hollow helical flight with the dust.
(52) EC 27. The method of any of the preceding or subsequent example combinations, wherein cooling the dust further comprises: circulating the coolant through an internal or external passage of the trough to cool a surface of the trough; and contacting the cooled surface of the trough with the dust.
(53) EC 28. The method of any of the preceding or subsequent example combinations, further comprising injecting with an introducer a cooling material into the dust in the cooled conveyor.
(54) EC 29. The method of any of the preceding or subsequent example combinations, wherein the cooling material comprises at least one of rock dust, cement kiln dust, metal shot, crushed stone, dross dust, lime salt, sodium bicarbonate, sand, or drop dust.
(55) EC 30. The method of any of the preceding or subsequent example combinations, wherein the cooling material comprises an inert material.
(56) EC 31. A decoating system comprising: a dust cyclone configured to: receive an exhaust gas from a decoating kiln; filter organic particulate matter from the exhaust gas as dust; and discharge the dust at a cyclone discharge temperature; and a cooled conveyor configured to: receive the dust from the dust cyclone; and cool the dust to a dust processing temperature that is less than the cyclone discharge temperature.
(57) EC 32. The decoating system of any of the preceding or subsequent example combinations, wherein the cyclone discharge temperature is from about 250 C. to about 400 C., and wherein the dust processing temperature from about 50 C. to about 150 C.
(58) EC 33. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than about 120 C.
(59) EC 34. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than about 100 C.
(60) EC 35. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than about 80 C.
(61) EC 36. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is about 50 C.
(62) EC 37. The decoating system of any of the preceding or subsequent example combinations, wherein the dust processing temperature is less than an ignition temperature of the dust.
(63) EC 38. The decoating system of any of the preceding or subsequent example combinations, wherein the ignition temperature is from about 175 C. to about 300 C.
(64) EC 39. The decoating system of any of the preceding or subsequent example combinations, wherein the cooled conveyor comprises a trough, and wherein the trough is internally or externally cooled with a coolant.
(65) EC 40. The decoating system of any of the preceding or subsequent example combinations, wherein the cooled conveyor comprises at least one of a screw conveyor, a troughed belt conveyor, a bucket conveyor, a pneumatic conveyor, or a vibrating conveyor.
(66) The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described example(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims that follow.