Abstract
A machine for the heating of granular material at high temperature, wherein a vessel is divided into compartments by vessel dams and vibrated in a direction perpendicular or Cross Axis to the vessel longitudinal axis. The vessel is vibrated by counter rotating rotary vibrators to create a Cross Axis vibration causing a circular cascading movement of the granular material within the vessel. The vessel is surrounded by a furnace heated by electric power or a combustible gas.
Claims
1. A calciner for heating a granular material, the calciner comprising: a. an elongated vessel having a feed chute proximate a front plate, a discharge chute proximate an end plate, and a longitudinal axis extending from the front plate to the end plate; b. a plurality of vessel dams substantially equally spaced along the longitudinal axis, each of the plurality of vessel dams having an upper portion and a lower portion, each of the upper portion and the lower portion oriented substantially orthogonal to the longitudinal axis, the upper portion having an upwardly inclined edge, the vessel dams shaped and located such that passage of the granular material from the feed chute to the discharge chute along the longitudinal axis is blocked by the lower portion of the vessel dams and the granular material must traverse each of the vessel dams by passing above the upwardly inclined edge of the upper portion; c. a platform on which the vessel is mounted; d. two rotary vibrators attached to the platform and spaced apart along the longitudinal axis, wherein one of the rotary vibrators is configured to have a direction of rotation counter to a direction of rotation of the other of the rotary vibrators, the direction of rotation of each of the rotary vibrators being perpendicular to the longitudinal axis of the vessel; and e. a furnace which surrounds the vessel.
2. A method for moving a granular material through a vessel, the method comprising: a. providing: i. an elongated vessel having a feed chute proximate a front plate, a discharge chute proximate an end plate, and a longitudinal axis extending from the front plate to the end plate; ii. a plurality of vessel dams substantially equally spaced along the longitudinal axis, each of the plurality of vessel dams having an upper portion and a lower portion, each of the upper portion and the lower portion oriented substantially orthogonal to the longitudinal axis, the upper portion having an upwardly inclined edge, the vessel dams shaped and located such that passage of the granular material from the feed chute to the discharge chute along the longitudinal axis is blocked by the lower portion of the vessel dams and the granular material must traverse each of the vessel dams by passing above the upwardly inclined edge of the upper portion; iii. a platform on which the vessel is mounted; and iv. two rotary vibrators attached to the platform and spaced apart along the longitudinal axis; b. adding granular material to the vessel through the feed chute; c. vibrating the vessel by rotating the two rotary vibrators such that one of the rotary vibrators has a direction of rotation counter to a direction of rotation of the other of the rotary vibrators, and the direction of rotation of each of the rotary vibrators is perpendicular to the longitudinal axis of the vessel, thereby causing the granular material to pass through the vessel along the longitudinal axis and traverse the vessel dams; and d. discharging the granular material through the discharge chute.
3. The calciner according to claim 1, further comprising: a plurality of drain openings in a bottom of the vessel, each of the plurality of drain openings located near one of the plurality of vessel dams; a plurality of gravity drain ports, each located beneath one of the plurality of drain openings, each of the plurality of gravity drain ports including vertically offset shelves protruding from opposing sidewalls of the gravity drain ports, the shelves partially overlapping in a horizontal direction; and a drain trough located beneath the plurality of gravity drain ports, each of the gravity drain ports opening thereto.
4. The calciner according to claim 1, further comprising: a vessel cover extending along the vessel between the front plate and the end plate; the vessel including a first region having a first cross-sectional profile defined by an internal surface of the first region of the vessel and an internal surface of the vessel cover when the vessel cover is in a closed position, and a second region having a second cross-sectional profile defined by an internal surface of the second region of the vessel and an internal surface of the vessel cover when the vessel cover is in a closed position, the first and second cross-sectional profiles each having an orthogonal orientation to the longitudinal axis, wherein the first cross-sectional profile has a first area greater than a second area of the second cross-sectional profile; a first set of the plurality of vessel dams located in the first region and a second set of the plurality of vessel dams located in the second region; and a vessel transition dam adjoining the first region and the second region, oriented substantially parallel to the plurality of vessel dams, and shaped and positioned such that the granular material passing from the first region to the second region along the longitudinal axis must traverse the vessel transition dam.
5. The calciner according to claim 1, further comprising: a vessel cover extending along the vessel between the front plate and the end plate; a cross-sectional profile defined by an internal surface of the vessel and an internal surface of the vessel cover when the vessel cover is in a closed position, the cross-sectional profile having an orthogonal orientation to the longitudinal axis; the plurality of vessel dams mounted to the internal surface of the vessel, offset from the vessel cover, and having an outer shape smaller than the cross-sectional profile.
6. The calciner according to claim 1, wherein the platform is substantially horizontal and the elongated vessel is inclined upwardly away from the platform in a direction orthogonal to the longitudinal axis.
7. The calciner according to claim 6, wherein the elongated vessel is inclined upwardly at an angle of between 20 degrees and 40 degrees.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1 Prior Art, is a side elevation diagram of a conventional rotary calciner;
(2) FIG. 2 Prior Art, is a cross section diagram of a conventional rotary calciner;
(3) FIG. 3 Prior Art, is a side elevation diagram of a conventional vibrating vessel describing plug flow motion;
(4) FIG. 4 is a section view showing the counter rotation of two rotary vibrators and the resulting linear motion;
(5) FIG. 5 shows a section view of vibration induced motion principle of the invention which reorients the direction of vibration in a Cross Flow manner demonstrating the cascading material motion path;
(6) FIG. 6 is a perspective view of the primary elements of the present invention;
(7) FIG. 7 is a perspective view of the present invention showing the inventions commercial features;
(8) FIG. 8 is a section view cut from FIG. 7 of the present invention;
(9) FIG. 9 is a perspective view taken from FIG. 7, showing the feed end and the wire brush seal to enclose the feed furnace opening of the furnace housing;
(10) FIG. 10 is a reverse perspective view of FIG. 9 showing the vessel front plate and the front plate opening;
(11) FIG. 11A is a section view of the vessel dam in relation to the vessel and the drain trough: FIG. 11B is a section view of an alternative design vessel dam in relation to the vessel and the drain trough:
(12) FIG. 12 is a side elevation view taken from FIG. 7 showing the vessel expansion slide 29;
(13) FIG. 13 is a section view taken from FIG. 12 showing the interior details of the vessel expansion slide 29;
(14) FIG. 14 is an enlarged perspective view of the discharge end taken from FIG. 7 showing details of the vessel discharge and the vessel drain method;
(15) FIG. 15 is a perspective view taken from FIG. 14 showing an enlarged perspective view of the gravity drain port 50;
(16) FIG. 16 is a section view taken from FIG. 15 showing a section view of the gravity drain port 50;
(17) FIG. 17 is a section view taken of FIG. 14 of the preferred vessel during the normal operation of the invention showing a full bed of granular material;
(18) FIGS. 18A and 18B is a section view taken from FIG. 17 showing the vessel and the relationship to the vessel drain trough 48 the drain spout 51 and the discharge chute 16;
(19) FIG. 19 is a section view of the preferred vessel 13 showing a decreased level bed of material in the process of being drained from the vessel;
(20) FIGS. 20A and 20B is a view taken from FIG. 19 showing a section view of the vessel;
(21) FIG. 21 is a plan view of an alternate processing vessel arrangement which shows the ability of having multiple cross section areas within a single vessel;
(22) FIG. 22 is a section view of FIG. 21 that shows two joined cross section vessel areas with one of a reduced area;
(23) FIG. 23 is a section view of FIG. 21 showing the reduced area vessel section
(24) TABLE-US-00002 LIST OF PARTS No. Part Description 1 Rotary calciner 2 Cylindrical tube 3 Steel tire 4 Steel trunnion wheel 5 Ring gear 6 Pinion gear 7 Motor reducer 8 Furnace 9 Gas burner 10 Feeder 11 Discharge breeching 12 Granular material 13 Vessel 14 Feed chute 15 Vessel dam 16 Discharge chute 17 Vibration isolator 18 Vibrator mount 19 Motor 20 Eccentric weight 21 Rotary vibrator 22 Furnace top half 23 Furnace bottom 24 Right support leg 25 Left support leg 26 Vessel cover 27 Platform 28 Furnace leg brush seal 29 Vessel expansion slide 30 Furnace support brace 31 Isolator column 32 Structural base 33 Lifting jack 34 Pivot block 35 Furnace hinge 36 Vessel front plate 37 Vessel front plate opening 38 Feed brush seal 39 Discharge brush seal 40 Split ball joint swivel bearing 41 Swivel bearing housing 42 Housing bolt 43 Shaft 44 Spacer block 45 Linear bearing 46 Vessel end plate 47 End plate opening 48 Drain trough 49 Drain opening 50 Gravity drain port 51 Drain spout 52 Drain spout closure valve 53 Alternate vessel dam 54 Alternate vessel dam openings 55 Vessel transition dam 56 Reduced area vessel 57 Reduced area vessel dam
DETAILED DESCRIPTION OF PRIOR ART
(25) Referring to FIGS. 1 and 2 both Prior Art as it relates to the method of operation and the mechanical embodiments of conventional rotary calciners.
(26) The Prior Art consists of a rotary calciner 1 comprised of a cylindrical tube 2 supported by steel tires 3 and rests on steel trunnion rollers 4. A ring gear 5 is circumferentially attached to the cylindrical tube 2 and is meshed with a pinion gear 6. The pinion gear 6 is driven by a motor reducer 7 causing the rotation of the cylindrical tube 2. Surrounding the cylindrical tube 2 is a furnace 8 which can be electrically heated or by the combustion of a gaseous fuel through a gas burner 9. Granular material 12 is fed to the rotary calciner by a feeder 10 and leaves the calciner through discharge breeching 11.
(27) Referring to FIG. 2 Prior Art shows a section view of the Prior Art calciner with the granular material 12 tumbling in a cascading motion. The granular material 12 migrates down the cylindrical tube 2 being heated by radiation heat transfer to achieve the desired material properties.
(28) Referring to FIG. 3 Prior Art, it shows the method of operation for conventional vibrating equipment and their dependency on the material transport phenomena known as plug flow and shows an elevation view of a conventional Plug Flow vibrating bed. A vessel 13 with a feed chute 14, a discharge chute 16 and a vessel dam 15 to maintain a level bed of granular material 12. Two counter rotating rotary vibrators 21 mounted on a vibrator mount 18 provide a linear path of vibration parallel to the long axis of the vessel 13. The assembly is supported by a plurality of vibration isolators 17. The orientation of the vibrators 21 creates vibration along the long axis of the vessel and imparts energy into the granular material 12 to cause the Plug Flow motion of the granular material 12 from the feed to the vessel dam 15. The granular material 12 flows over the vessel dam 15 and into the discharge chute 16.
(29) Referring to FIG. 4 Prior Art which shows a vibrator mount 18 supporting two counter rotating rotary vibrators 21. The two rotary vibrators 21 each having a motor 19 to which eccentric weights 20 are attached to each end of the motor 19. The motors 19 are rotated in opposite directions of each other one being clockwise and the other counter clockwise.
DETAILED DESCRIPTION OF THE INVENTION
(30) Referring to FIG. 5, which demonstrates the Cross Axis vibration principle of the present invention, the circular shaped vessel 13 and vessel cover 26 are supported by platform 27. Vibrator mounts 18 connected to platform 27 support two rotary vibrators 21 (refer to FIG. 6). The two rotary vibrators 21 are rotated in opposite directions of each other, one being clockwise and the other counter-clockwise. The entire vibrating assembly is mounted on a plurality of vibration isolators 17.
(31) FIG. 6 shows a perspective view of an embodiment of a Cross Axis vibrating bed. A vessel 13 with a vessel front plate 36, a vessel end plate 46, an end plate opening 47, a feed chute 14, a discharge chute 16 and a plurality of vessel dams 15 is configured to contain a bed of granular material 12. The vessel 13 is supported by a plurality of vessel legs 25 attached to the platform 27. Two counter rotating rotary vibrators 21 are mounted on a vibrator mount 18 attached to the platform 27 and provide a linear path of vibration perpendicular, or Cross Axis to the long axis of the vessel 13. The vessel 13 is slightly sloped from the feed to the discharge to aid in transport of the granular material. The assembly is supported by a plurality of vibration isolators 17.
(32) FIG. 7 is a perspective view of the commercial features of the present invention and shows a vessel 13 fabricated from heat resistant material which is supported by a plurality of support legs 24 and 25 along the vessel 13 length. Within the vessel 13 are located a plurality of vessel dams 15 which are spaced a distance equal to the effective radius of the vessel 13. The vessel 13 contains and transports granular material 12. The vessel 13 is covered with a vessel cover 26.
(33) The front of the vessel 13 is closed by the vessel front plate 36 to which is mounted the feed chute 14. The opposite end of the vessel 13 is closed off by the vessel end plate 46 which includes the vessel end plate opening 47 through which the granular material discharges to the discharge chute 16. Located behind and beneath the discharge chute 16 is the drain spout 51 which is part of the vessel drain design feature. Attached to the furnace bottom half 23 and the furnace top half 22 is the discharge brush seal 39 to reduce radiant heat losses.
(34) The vessel 13 and the support legs 24 and 25 are connected to a horizontal platform 27 through vessel expansion slides 29 which are further described in FIG. 12. Two counter-rotating rotary vibrators 21 are mounted to the underside of the horizontal platform 27 attached at an angle between 45 and 60 degrees from the horizontal, determined by test work examining the granular material motion properties.
(35) The horizontal platform 27 is supported by a plurality of vibration isolators 17. The vibration isolators 17 are supported on isolator columns 31 attached to the structural base 32.
(36) An electrically heated or natural gas fired furnace constructed as furnace top half 22 and the furnace bottom half 23 surround the vibrating vessel 13 for the purpose of providing the required heat to the vessel 13. The furnace hinge 35 allows the furnace top half 22 to be lifted to the raised position for maintenance. The weight of the furnace is supported by the furnace support brace 30 which connects with the structural base 32. The support legs 24 and 25 of the vessel 13 pass through openings in the furnace bottom half 23. The support legs 24 and 25 of the vessel 13 are attached to vessel expansion slides 29 to allow for the linear expansion of the vessel during heating.
(37) Drain openings 49 allow the draining of the granular material from the vessel 13 and is explained in more detail in FIG. 14 through FIG. 20.
(38) The entire machine is supported at the discharge end of the structural base 32 by a pivot block 34. A lifting jack 33 supporting the feed end is located at the front end of the structural base 32 and used to impart an adjustable downward slope of 3 to 6 from the feed end to the discharge end to aid in material movement.
(39) FIG. 8 shows a section view taken from FIG. 7 showing vessel 13 with granular material 12, vessel dam 15, vessel cover 26, right support leg 24, left support leg 25, horizontal platform 27, rotary vibrators 21, and the vibrator mount 18 with a plurality of vibration isolators 17. The vibration isolators 17 are supported by isolator columns 31 which are attached to the structural base 32. The support legs 24 and 25 are attached to the vibrating platform 27 by a vessel expansion slide 29. The leg brush seals 28 reduce radiant heat losses from the furnace bottom half 23 where the right support leg 24 and the left support leg 25 pass through openings in the furnace bottom half 23.
(40) The furnace top half 22 and furnace bottom half 23 are connected by the furnace hinge 35. The furnace bottom half 23 is supported by furnace support brace 30 which is connected to the structural base 32. The structural base 32 is fixed to a foundation through a pivot block 34 mounted near the discharge end of the invention.
(41) A vessel end plate 46 with the vessel end plate opening 47 allows the granular material 12 to exit from the vessel 13.
(42) At the bottom of vessel 13 is located the drain openings 49 that occur near each vessel dam 15. Granular material 12 flows through the drain openings 49 into the gravity drain ports 50 and into the drain trough 48 as part of the method to drain the vessel 13 of all granular material 12 for maintenance.
(43) FIG. 9 shows a perspective of the feed zone of vessel 13 showing the vessel dam 15 and feed chute 14 as it passes through the front of the furnace bottom half 23. The feed chute 14 is attached to the vessel front plate 36. Attached to the furnace bottom half 23 and the furnace top half 22 are feed brush seals 38 which minimize radiation heat losses.
(44) FIG. 10 shows a reverse view of the vessel 13 of FIG. 9, including vessel dam 15, vessel cover 26, vessel front plate 36, and the vessel front plate opening 37, which permits the flow of granular material 12 from the feed chute 14 and into the vessel 13.
(45) FIG. 11a shows a cross section of the preferred profile of the vessel 13 and the vessel dam 15 attached to the vessel 13. The lower region of the dam embodies a raised edge so as to prevent granular material 12 from spilling over the lower region edge.
(46) FIG. 11b shows a cross section of the preferred profile of the vessel 13 with an alternative vessel dam 53 that embodies a full profile plate and provides alternative vessel dam openings 54 located at the desired material discharge level which permits the granular material 12 to escape to the next compartment. The provision of a full profile plate permits the welding of the top of the dam 15 to the vessel cover 26 providing a stronger assembly, although, at the sacrifice of visibility down the length of the vessel 13.
(47) FIG. 12 shows an elevation view of the vessel expansion slide 29 attached to support legs 24 and 25 which is attached to the swivel bearing housing 41. Within the swivel bearing housing 41 is positioned a split ball joint swivel bearing 40. The swivel bearing housing 41 is separated at the bottom by a flanged slot through which a housing bolt 42 passes. The swivel bearing housing 41, when squeezed by housing bolt 42, compresses the split ball joint swivel bearing 40 upon the shaft 43 which passes through the swivel bearing housing 41, fixing it firmly onto shaft 43. This assembly provides three degrees of freedom about the shaft 43 providing alignment flexibility during the assembly of the vessel expansion slide 29. Each end of the shaft 43 pass through linear bearings 45 allowing the vessel 13 and support legs 24 and 25 to move in a horizontal linear direction along the length of the horizontal platform 27 as the vessel 13 length increases due to the vessel 13 linear expansion caused by heating.
(48) Referring to FIG. 13, a section view of the vessel expansion slide 29 is shown, including swivel bearing housing 41, housing bolt 42, and shaft 43. A spacer block 44 is located beneath each linear bearing 45 to provide adequate clearance between the swivel bearing housing 41 and the horizontal platform 27.
(49) FIG. 14 is a perspective view showing the vessel end plate 46 and the end plate opening 47, which is the material passage for discharge chute 16. Also shown are a plurality of drain openings 49 located at the bottom of the vessel 13 near each vessel dam 15. Below each drain opening 49 is a gravity drain port 50 which is attached to the underside of vessel 13 and oriented so the drain opening 49 is a passage through which granular material can flow through the gravity drain port 50 into the drain trough 48 and to the drain spout 51. Drain spout 51 may be closed by the drain spout closure valve 52.
(50) FIG. 15 shows an enlarged perspective view of the gravity drain port 50. The gravity drain port 50 is comprised of four vertical sides and two horizontal opposed shelves. Granular material 12 can flow down though the staggered horizontal shelves by the vibration, but is not able to flow upwards through the shelves due to the presence of the two horizontal opposed shelves in the gravity drain port 50.
(51) FIG. 16 shows a section view of the gravity drain port 50, clearly revealing the opposed horizontal shelves.
(52) FIG. 17 is a cross-sectional view along line 17-17 of FIG. 14 and shows the preferred profile of vessel 13, vessel cover 26, vessel dam 15, drain opening 49, gravity drain port 50, and the drain trough 48 during normal operation with a full bed of granular material 12.
(53) FIGS. 18A and 18B are sectional views along line 18-18 of of FIG. 17 showing the vessel 13, vessel dam 15, vessel cover 26, vessel end plate 46, vessel end plate opening 47, discharge chute 16, drain trough 48, drain opening 49, gravity drain port 50, drain spout 51, and the drain spout closure valve 52. The view is shown in the primary operation of the vessel 13 processing granular material 12 as flowing over the plurality of vessel dam 15 and flowing through the end plate opening 47 and out the discharge chute 16. Granular material 12 is trapped inside the drain trough 48 since the drain spout closure valve 52 is in the closed position. Also shown is discharge brush seal 39, attached to the furnace top half 22 and the furnace bottom half 23, which reduces radiation heat loss.
(54) FIG. 19 is cross section along line 19-19 of FIG. 14 showing the operation of draining the vessel 13. Shown are vessel dam 15, vessel cover 26, drain opening 49, gravity drain port 50, and the drain trough 48, as well as a reduced level of granular material 12.
(55) FIGS. 20A and 20B are sectional views along line 20-20 of FIG. 19, showing the draining of granular material 12 from the vessel 13. The shown level and volume of granular material 12 are lower than as shown in FIGS. 18A & 18B due to the draining. Also shown are the vessel 13, vessel cover 26, vessel dam 15, vessel end plate 46, vessel end plate opening 47, discharge chute 16, drain trough 48, drain opening 49, gravity drain port 50, and drain spout 51. Drain spout closure valve 52 is shown in the opened position allowing granular material 12 to flow from the drain trough 48 through the drain spout 51, which empties the granular material 12 from vessel 13.
(56) FIG. 21 shows a plan view of a vessel arrangement of varying section profiles. Vessel 13, with a profile area of one diameter proceeds to a position where, required by process specifics, a profile area reduction is preferred. At this point a vessel transition dam 55 is provided to transfer the material from vessel 13 to reduced area vessel 56 of a diameter smaller than the diameter of the preceding vessel 13. Beyond this position a reduced vessel dam 57 aligned to the top of the vessel dam 55 maintains a consistent granular material 12 level.
(57) FIG. 22 shows a cross section of the larger profile area vessel 13, vessel dam 15 and the vessel transition dam 55.
(58) FIG. 23 shows a cross section of the reduced area vessel 56 and reduced area vessel dam 57.
