Autoclave system and method

Abstract

An autoclave system comprises an autoclave vessel 210, for performing a leaching operation on sacrificial ceramic cores (not shown) and a storage vessel 220 for containing caustic leaching fluid 230. Interposed in a fluid flow path between the vessel 210 and the tank 220 is a heat exchange unit 240, comprising a body 250 containing a thermal exchange medium, in the form of water 260, and first and second thermal exchange conduits represented at 270 and 280. A thermal exchange medium inlet pipe 290a and a thermal exchange medium outlet pipe 290b are provided to the body so that the medium 260 can be replenished, preferably substantially continuously, to optimize thermal transfer efficiency.

Claims

1. A method of operating a leaching autoclave system, the method comprising discharging a leaching fluid and a pressurizing/venting fluid from an autoclave vessel to a common fluid storage tank in an external support system through a heat exchanger to reduce the temperature of the leaching fluid and the pressurizing/venting fluid, wherein the method comprises conveying the leaching fluid from the autoclave vessel to the common storage tank through a first conduit extending from the autoclave vessel to the common storage tank and conveying the pressurizing/venting fluid from the autoclave vessel to the common storage tank through a second conduit, separate from the first conduit and extending from the autoclave vessel to the common storage tank, the first conduit and the second conduit passing through and configured to convey fluids through the heat exchanger, wherein the method includes charging and discharging the autoclave vessel with the leaching fluid through a first thermal exchange section of the first conduit extending through the heat exchanger.

2. The method according to claim 1, wherein the first thermal exchange section is in thermal contact with a thermal transfer medium.

3. The method according to claim 1, wherein the first conduit includes the first thermal exchange section extending through the heat exchanger, and the method comprises passing the leaching fluid through the first thermal exchange section of the first conduit to reduce the temperature of the leaching fluid.

4. The method according claim 1, wherein the second conduit includes a second thermal exchange section extending through the heat exchanger, and the method comprises passing the pressurizing/venting fluid through the second thermal exchange section of the second conduit to reduce the temperature of the pressurizing/venting fluid.

5. The method according to claim 1, wherein the method comprises heating the leaching fluid in the heat exchanger prior to charging the autoclave vessel for a leaching operation.

Description

(1) A preferred embodiment of the present invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which:

(2) FIG. 1 shows schematically a previously considered leaching autoclave system;

(3) FIG. 2 shows schematically a leaching autoclave system according to an embodiment of the present invention;

(4) FIGS. 3a to 3d show, respectively: in perspective view, in perspective view with a body removed, in sectional view, and in part-cutaway perspective view from above, a heat exchanger for use in the system according to FIG. 2; and

(5) FIG. 4 shows schematically a leaching autoclave system in accordance with another embodiment of the present invention.

(6) Turning to FIG. 2, this shows generally at 200 an autoclave system according to an embodiment of the present invention. The system comprises an autoclave vessel 210, for performing a leaching operation on sacrificial ceramic cores (not shown) and a storage vessel 220 for containing caustic leaching fluid 230. Interposed in a fluid flow path between the vessel 210 and the tank 220 is a heat exchange unit 240.

(7) The heat exchange unit 240 comprises a body 250 containing a thermal exchange medium, in the form of water 260, and first and second thermal exchange conduits represented at 270 and 280. A thermal exchange medium inlet pipe 290a and a thermal exchange medium outlet pipe 290b are provided to the body so that the medium 260 can be replenished, preferably substantially continuously, to optimize thermal transfer efficiency.

(8) Pipe P1 conveys venting gas from the autoclave vessel 210 to the heat exchanger 240. The venting gas is cooled, and its pressure reduced, in the heat exchanger before being conveyed to the tank 220 by pipe P2.

(9) Used leaching fluid is discharged from the vessel 210 to the heat exchanger via pipe P3, where it is cooled and its pressure reduced before being returned to the tank 220 via pipe P4, at the end of a leaching cycle. The leaching or caustic fluid may typically comprise a base liquid such as an aqueous solution of a hydroxide, more typically sodium or potassium hydroxide.

(10) A further pipe, P5 conveys leaching fluid from the tank to charge the vessel 210 for the next leaching cycle.

(11) Turning now to FIGS. 3a to 3c, these show the heat exchanger unit 240 in more detail. The unit 240 comprises a substantially cylindrical body 300 of 316 Grade stainless steel, and head closure 310, constructed so that the unit is capable of withstanding super-atmospheric pressure. Inside the body are first and second thermal exchange conduits 270 and 280 in the form of substantially helical, coaxial, stainless steel alloy tubes (shown best in FIG. 3c). First and second inlets 320 and 330 are for connecting to pipes P1 and P3 respectively, and first and second outlets 340 and 350 are for connecting to pipes P2 and P4 respectively.

(12) Apertures 360a and 360b, shown in FIG. 3d, are provided respectively to the (water) inlet and outlet pipes 290a and 290b shown in FIG. 2.

(13) In use, during a leaching cycle the autoclave vessel 210 contains caustic leaching fluid at raised temperature and pressure. Typically the pressure inside the autoclave vessel may reach up to 30 bar and the temperature may reach 250C. The pressure is varied to cause the fluid in the tank to boil cyclically, so as to agitate the ceramic cores. At each periodic release of pressure the gas (typically air) inside the vessel is vented via pipe P1 to the heat exchanger 240. The hot, pressurized gas cools as it passes through the conduit 270, due to the conduit being surrounded by cooling fluid, so that when it reaches the tank 220 its energy has been substantially reduced (pressure and temperature have reduced).

(14) Similarly, at the end of a leaching cycle the used leaching fluid is discharged up to a maximum temperature of 250 C, and/or up to a maximum pressure of 30 barg, from the vessel 210 through pipe P3 to the heat exchanger 240, where it passes through the conduit 280, thereby cooling it before passing through pipe P4 to the storage tank 220. The temperature in the tank 220 typically ranges between ambient and 60 C.

(15) The use of the heat exchanger 240, as an intermediary between the autoclave vessel 210 and the storage tank 220 allows the latter to be kept at a modest size whilst still accommodating the returning leaching fluid and the pressurized venting gas.

(16) Suitable valves are used to replenish the heat exchange medium (ie water), through inlet 290a and outlet 290b pipes, preferably substantially continuously as it becomes heated through contact with the conduits 270 and 280, so as to maintain the efficiency of the cooling.

(17) FIG. 4 shows schematically another embodiment of the present invention. In this embodiment the heat exchanger 240 is used not only to cool the venting gas and the discharged leaching liquid, but is also used to pre-heat the leaching liquid from the tank at the next charging of the autoclave vessel 210.

(18) To achieve the pre-heating the heat exchanger is provided with an electric heating device (not shown), such as a heating blanket around an external surface of the body, that heats the exchange medium surrounding the conduits 270 and 280. As stated above, the heat exchange unit 240 is rated at super-atmospheric pressure, so as to allow heating to the desired temperature. The leaching fluid passes from the tank 220 along the same path as it does when discharging from the vessel 210 but in reverse, so that it travels first through pipe P4, then through the conduit 270 and then via pipe P3 to the vessel 210.

(19) There is no need for a separate charging pipe, and the arrows indicate a bi-directional flow in pipes P3 and P4.

(20) Pre-heating the leaching fluid in this way makes for increased efficiency, since less energy is required to heat the liquid while in the autoclave vessel in order to attain its operating temperature.

(21) In the above described embodiments both the leaching liquid and the pressurizing/venting gas are cooled in the heat exchanger. However, this does not have to be the case. Whilst the liquid and the gas should be conveyed separately between the autoclave vessel and the external support system, such as the tank, it may be sufficient to conduct only one through the heat exchanger. For example, it may be sufficient for only the leaching liquid to be conveyed through the thermal exchange conduit.

(22) It will be understood by the skilled person that where the heat exchanger is described as being located or interposed between the autoclave vessel and the storage tank, this need not mean that the heat exchanger must occupy physical space between the other two. Rather, the heat exchanger need only be positioned on a flow path between them. The physical juxtaposition of the three vessels may be chosen according to available space and to maximise efficiency.

(23) Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and/or shown in the drawings, whether or not particular emphasis has been placed thereon.