APPARATUS AND METHOD FOR SEPARATING A SLAG MATERIAL FROM A COLLECTOR MATERIAL

Abstract

A process for separating a fusion mix sample comprising a slag material and a collector material using a separator. The separator comprising a plurality of impact members configured to rotate. The process comprising the steps of providing a solid fusion mix sample and loading the solid sample into the separator. Dislodging the slag material from the solid fusion mix sample by rotating the impact members and contacting the rotating impact members and the solid fusion mix sample. Separating into a first fraction substantially comprising the collector material and a second fraction substantially comprising slag material.

Claims

1. A process for separating a fusion mix sample comprising a slag material and a collector material using a separator comprising a plurality of impact members configured to rotate around a center axis of the separator, the process comprising at least the steps of: providing a solid fusion mix sample and loading the solid sample into the separator; dislodging slag material from the solid fusion mix sample by rotating the impact members and contacting the rotating impact members and the solid fusion mix sample to provide a collector material and a slag material; separating by specific gravity using a gas flow and optionally centripetal forces on the loosened slag to provide a high-density fraction substantially comprising the collector material and a low-density fraction substantially comprising slag material.

2. The process according to claim 1, wherein slag material is dislodged from the solid fusion mix sample by rotating the impact members around the center axis, said center axis being oriented at an angle between 15 to 85 degree with respect to vertical.

3. The process according to claim 1 or claim 2, wherein the high-density fraction comprises collector material which has a purity of 99 w/w % or more, such as 99.9 w/w % or more.

4. The process according to any previous claims, additionally comprising the step of: providing a liquid fusion mix sample comprising collector material and slag material; separating, while in the liquid state, the collector material from a portion of the slag material by removing a portion of the upper layer of the liquid fusion mix sample; cooling the remaining liquid fusion mix sample to provide a solid fusion mix sample.

5. The process according to claim 4, wherein the liquid fusion mix sample has a volume V.sub.1 comprised of the volume of collector material V.sub.c and the volume of slag material V.sub.s, and wherein the step of separating is achieved by pouring the liquid fusion mix sample into a container having a top opening and a volume V.sub.2, V.sub.2 being larger than V.sub.c but smaller than V.sub.1.

6. An apparatus for separating a solid fusion mix material into a collector material and a slag material, the apparatus having a separating unit, the separating unit defining a central axis, and comprising a separation chamber having an inner surface and having a top portion and a bottom portion arranged with respect to the central axis an inlet configured to allow entry of a solid fusion mix material, an impact member configured to rotate around the central axis by rotating means and adapted to contact a solid fusion mix material in the separation chamber while rotating, to dislodge slag material and thereby separate the solid fusion mix material into a slag material and a collector material; and at least one outlet allowing extraction of separated slag material and/or collector material from the separating chamber.

7. The apparatus according to claim 6 further comprising a casting unit comprising: a container for accommodating a liquid fusion mix material, the container having a base with a side wall extending from the base, the side wall defining a top opening into the container; cooling means for solidifying a liquid fusion mix material in the container; and moving means adapted to move the container between at least a loading position and an unloading position.

8. The apparatus according to claim 6 or 7, wherein central axis is oriented at an angle between 15 degrees to 85 degrees with respect to vertical.

9. The apparatus according to claim 6 to claim 8, wherein the bottom portion of the separation chamber has a tapered shape, preferably a conical shape or half spherical shape.

10. The apparatus according to claim 6 to claim 9, wherein the impact member comprising an impact head, a link piece, and a rotating element, said link piece being attached to the impact head in one end and to a rotating member in the other end, and wherein the link piece is flexible and optionally wherein the link piece is a string, chain, wire or cable.

11. The apparatus according to claim 6 to claim 10, wherein the separating unit comprising a first outlet for removing slag material and a second outlet for removing collector material.

12. The apparatus according to claim 6 to claim 11, wherein the first outlet is located in the top portion of the separator.

13. The apparatus according to claim 6 to claim 12, wherein the second outlet is located in the bottom portion of the separator.

14. The apparatus according to claim 6 to claim 13, wherein the separating unit comprising suction means configured to extract the particles and/or dusts of slag material from the separating chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0058] The invention will be described in more details below by means of non-limiting examples of presently preferred embodiments and with reference to the schematic drawings, in which:

[0059] FIG. 1 shows a schematic cross-sectional view of an apparatus for separating a collector material from a slag material comprising a separating unit and casting unit according to an embodiment of the invention;

[0060] FIG. 2 shows a schematic cross-sectional view of a separating unit during intended use according to an embodiment of the invention;

[0061] FIG. 3 shows a schematic cross-sectional view of a separating unit during unloading according to an embodiment of the invention;

[0062] FIG. 4 shows a schematic cross-sectional view of a casting unit according to an embodiment of the invention;

[0063] FIG. 5 shows a schematic cross-sectional view of a casting unit according to another embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0064] FIG. 1 shows a schematic view of an apparatus 1 for separating a collector material from a slag material. The apparatus 1 has a separating unit 100 and a casting unit 200. The separating unit 100 comprising a separation chamber 101 having an inner surface 110 and having a top portion 111 and a bottom portion 112 arranged with respect to a central axis 2. The central axis 2 is inclined at an angle of 35° with respect to vertical, but may alternatively be oriented at any angle between 15° to 85° with respect to vertical. A lid 115 is located on the top portion 111 of the separation chamber 101. An inlet 102 for entry of a solid fusion mix material 3 is located in the lid 115. An impact member 103 is configured to rotate around the central axis 2. It is driven by rotating means (not shown) and is adapted to contact a solid fusion mix material 3 if present in the separation chamber 101. When the impact member 103 contacts the solid fusion mix material 3 while rotating, slag material located on the surface of the solid fusion mix material 3 will be dislodged. An outlet 104 allows extraction of separated slag material from the separating chamber 101. The outlet 104 is located in the lid 115 near the periphery. The inlet 102 and outlet 104 is located in opposite sides of the lid 115. When the separating unit 100 is arranged for intended use, the lid 115 is located on the separating chamber 101 such that the outlet 104 is below the inlet 102. The lid 115 additionally comprises two air inlets 116. The air inlets 116 allows for compressed air to be purged into the separation chamber 101 for cleaning the separating unit between separation. In the shown embodiment the casting unit 200 is located adjacent the separating unit 100. The casting unit comprises a container 201 suitable for accommodating a liquid fusion mix material. The container has a base 207 with an inner and outer side wall 220 and 221 extending from the base 207. The side walls defining a top opening 240 into the container 201. The container 201 is attached to a moveable arm 203. The arm 203 is moveably attached to a base 202 to allow the container 201 to move between at least a loading position and an unloading position.

[0065] Turning now to FIG. 2 showing a separating unit 100 during intended use, wherein the separation chamber 101 accommodates a solid fusion mix sample 3. The separating unit 100 may be configured for separating different sized fusion mix samples 3 by changing the size of the components in the separating unit 100. The impact member 103 has two impact heads 107 each mounted on link pieces 105. The link pieces 105 are attached to a rotating element 106 and extends in a radial direction from the rotating element 106. Alternatively the impact member 103 may comprise 3 or 4 impact heads balanced around the center axis 2. The rotating element 106 is driven by a motor located in the base 108. The motor preferably has a variable speed drive (VSD), which allows for various rotation speeds of the impact member 103 within a single separation cycle. Variable rotational speeds provides an optimized separation process. High speeds may be applied at the start of separation but after a set time the speed may be reduced to ensure minimal wear on the rest of the system and to further reduce risk of any collector material from being dislodged once most of the slag material covering it is removed. The speed can then be increased again just before release of the collector material to ensure all slag is forced out the chute outlet 104. The link pieces 105 are made from high wearing steel to withstand contact with material in the separation chamber 101. The link pieces 105 may further be configured to swivel on itself upon impact with solid fusion mix samples 3. The direction of rotation may be reversed during separation. This may be beneficial if material is stuck somewhere in the separation chamber 101. In combination with a variation of the speed of the rotation this provides improved separation. The length of the link piece 105 is flexible whereby the distance between the distal end 109 of the impact heads 107 and the inner surface 110 of the separation chamber 101 can be varied. This allows the separating unit 100 to be configured to different sized samples. At its maximum length the impact heads 107 are spaced from the inner surface 110 of the separation chamber 101 by a small gap. By increasing the length of the link piece 105, the momentum of the impact heads 107 increase during rotation. When larger samples are to be separated, the length of the link piece 105 may be reduced to make the impact member 103 more robust. During a typical separation cycle, the length of the link piece 105 is reduced after initial impact between the impact heads 107 and the solid fusion mix sample 3 in order to only impact the fusion mix sample and less so to push the separated slag material around. The effect is a much more efficient separation.

[0066] As the impact member 103 rotates it come into contact with the solid fusion mix sample 3. The slag material 5 located on the surface of the solid fusion mix sample is dislodged by the contact with the impact heads 107 and eventually provide a separated collector material 4.

[0067] The size of the inlet 102 is configured to only allow samples of such a size that the impact members 103 are not unintentionally damaged during separation. The inlet 102 is located in lid 115 preferably in the upper portion of the separation chamber. This ensures that separated slag is not send back up the inlet 104. As illustrated in the FIG. 2 the outlet 104 is located closer to the periphery of the separation chamber than the inlet 102.

[0068] The height of the separation chamber 101 i.e. from the floor of the separator to the underside of the lid 115 is set to allow for enough space for the solid fusion mix sample to tumble freely.

[0069] The lid 115 is removably fastened to the separation chamber 101 by fastening means in the form of quick release clamps. This allows for easy access to the separator chamber for inspection/maintenance. Additionally the lid 115 comprises the inlet 102, outlet 104 and air inlets 116. In the embodiment shown in FIG. 2 the lid 115 additionally comprise a second outlet in the form of a door 118 for easy removal of the separated collector material. The door is controlled by an actuator (not shown) located in or on the lid 115.

[0070] The bottom of the separation chamber 101 has a tapered shape similar to a half spherical shape to guide the fusion mix sample 3 towards the impact member 103. The first outlet 104 may comprise suction means (not shown) to aid the removal of dislodged slag material from the separation chamber 101.

[0071] Turning now FIG. 3 showing a separating unit 100 during unloading. The second outlet in the form of a door 118 is located in the separation chamber wall. The door 118 is moveably connected to the separation chamber by means of a hinge 119 and controlled by an actuator (not shown). After a full separation cycle the collector material 4 is substantially free from slag material 5 and has a substantial round shape due to the repeating contacts with the impact member 103. The embodiment of the separation unit 100 has air inlets 116 located in the separation chamber wall. It may be positioned to form swirling air flow along the inner periphery of the separation chamber. Optionally the swirling air flow may be directed against or parallel with the rotational direction of the impact member 103. In the embodiment shown, the air inlet 116 is positioned substantially opposite of the first material outlet 104. The inlet 102 may comprise a sensor (not shown) to sense if a sample enters the separation unit 100. A controller (not shown), may upon receiving the sensed signal, close the inlet opening (and the outlets), and initiate separation by starting the motor driving the rotating element 106. Sensors may be located near the outlets 104 and/or 118 to measure if the outlets are in an open or closed position. Additionally the sensor near the outlet 104 may sense if dislodged slag flows through the open outlet 104. The separation may stop after a specific time or when no slag material flows though the outlet 104.

[0072] Turning now to FIG. 4 showing one embodiment of a casting unit 200. The casting unit 200 comprises container 201 defined by an inner wall 221. The container 201 which is adapted for receiving molten fusion mix to be cast into a desired shape. In the embodiment shown, the fusion mix is cast into a cone-shape. It may be any shape, such as square, cylinder, round, etc. It is preferred that there are no thin sections that can easily be dislodged from the primary mass of collector material during separation, which could then potentially be carried away with the slag fragments. The inner wall 221 together with the outer wall 220 define a cavity 205 for flowing a cooling fluid. An inlet 210 and outlet 211 allows cooled fluid to flow into and out of the cavity 205. A liquid such a water or heat transfer oil is preferred for cooling. The flow of cooling fluid is controlled by flow control valves (not shown) comprising sensors to flow or stop the supply of cooling fluid. The sensor may measure a parameter indicating the flow or temperature of the cooling fluid which can be used to optimize the forced cooling.

[0073] The container 201 has a top opening 240 for pouring molten fusion mix into the vessel. The vessel 201 is made from a material which can withstand the temperature of molten fusion mix, such as cast iron or a steal alloy. The vessel 201 has a side opening 230 in the inner wall 221 and outer wall 220. The opening 230 functions as a chute for allowing an excess amount of slag to discharge from the container 201. The collector material in the liquid fusion mix has a larger density than the slag material. The collector material will therefore settle towards to bottom of the container 201 while the excess amount of slag material will be discharged. By removing an excess amount of slag and force cooling with a cooling fluid, the fusion mix will be cast much faster and allows for an overall faster process. A moveable arm 203 is in one end connected to the outer wall 220 of the vessel 201 and in the opposite end moveably connected to a base 202. The container 201 may therefore move in relation to the base 202. In the shown embodiment the base 202 has a rotatable pin 245 which is fixed to a hole in the moveable arm 203. The pin is coupled to a motor in the base 202 (not shown) allowing it to rotate. By rotating the pin, the vessel 201 may be moved from a loading position shown in FIG. 4 to an unloading position shown in FIG. 5. In FIG. 5 the vessel 201 is rotated around the base 202 such that the opening 240 is oriented in a substantially downwards direction for unloading the cast fusion mix sample. In the unloading position the container 201 is positioned relative to the separator so that the solid sample material can fall freely from the container 201 into the inlet 102 of the separator unit 100. A temperature sensor (not shown) located in the container 201 may indicate when the fusion mix sample is sufficiently cooled. This information may automatically initiate the movement of the vessel 201 and discharge the cast fusion mix sample into separation unit 100.

LIST OF REFERENCE NUMBERS

[0074] Apparatus 1

[0075] Central Axis 2

[0076] Solid fusion mix sample 3

[0077] Slag material 4

[0078] Collector material 5

[0079] Separation unit 100

[0080] Separation 101

[0081] Material Inlet 102

[0082] Impact 103

[0083] Outlet 104

[0084] Link piece 105

[0085] Rotating element 106

[0086] Impact head 107

[0087] Separation unit base 108

[0088] distal end of the impact heads 109

[0089] Inner surface 110

[0090] Top portion 111

[0091] Bottom portion 112

[0092] Lid 115

[0093] Air inlet 116

[0094] Collector material outlet door 118

[0095] Hinge 119

[0096] Casting unit 200

[0097] Container 201

[0098] Base 202

[0099] Movable arm 203

[0100] Cavity 205

[0101] Container base 207

[0102] Outer wall 220

[0103] Inner wall 221

[0104] Side opening 230

[0105] Top opening 240

[0106] Rotatable pin 245