91�� Research - Thermal Processing

Waste Treatment and Recycling

hazen-research-admin — Mon, 10 Jun 2013 20:57:48 +0000

Potentially applicable thermal treatment technologies include thermal desorption, pyrolysis, and thermal oxidation. On occasion, vitrification may be warranted to stabilize nonvolatile metals or radionuclides that remain in the ash or residue from other waste treatment processes. Many factors, including the site cleanup criteria, the contaminant types and concentrations, and the chemical and physical characteristics of the material, impact the selection of an effective contaminant elimination or stabilization technology of the contaminated material.

91�� can design and perform hazardous waste treatability studies for most applications. Our experience includes thermal treatment of soils, sediments, and sludges containing pesticides, polychlorinated biphenyls (PCBs), dioxins and furans, petroleum fuels, and a number of other organic contaminants. We have also successfully treated samples containing inorganic contaminants such as arsenic, lead, mercury, and low-level radionuclides. All treatability studies are performed in compliance with the terms and conditions stipulated by our federal and state approvals and licenses.

Occasionally, processes can be devised to recover or use valuable materials while dealing with hazardous waste components. When possible, recycling presents an attractive alternative to waste destruction. As a result of completing numerous recycling projects, 91�� has developed substantial expertise in recognizing ways to restore certain waste components to marketable forms.

Recent waste treatment and recycling activities include:

Waste vitrification in a rotary kiln
Thermal desorption of volatile metals and volatile and semivolatile organic compounds
Pyrolysis of automobile shredder residue
Smelting of spent automobile catalyst
Recovery of tin from bronze scrap
Thermal oxidation of spent catalyst
Pyrolysis of nylon-6 to recover its monomer
Injection smelting of electronic scrap

Introduction Copy:

Increased environmental awareness and regulatory pressure have provided the impetus for research and development related to both the remediation of existing environmental problems and the prevention of pollution within operating facilities.

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Flowsheet Development

Laboratory Investigations

Consulting and Field Services

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Thermal Processing

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Thermal Processing

Thermal Process Development

hazen-research-admin — Mon, 10 Jun 2013 20:54:40 +0000

91�� is able to help clients continue process development by incorporating the knowledge and experience gained from the bench or laboratory scale and translating it to larger continuous operations. Often, new processes must be demonstrated on a semicommercial or pilot plant scale to secure detailed design criteria necessary for commercial implementation. Demonstration plants may integrate several complex unit operations to accurately portray commercial operating requirements, such as internally recycling process streams. 91�� has a variety of pilot-scale equipment (rotary kilns, fluidized-bed reactors, and multiple hearth kilns), and has successfully demonstrated a process with similar results to a commercial equivalent.

91�� has played a key role in developing many commercial processes. For example, a new process for producing iron carbide was developed in 91��'s thermal processing laboratories. The process, which is licensed by Iron Carbide Holdings, Inc. (Lakewood, Colorado), uses fluidized-bed technology to reduce and carburize the iron contained in an oxide ore to form Fe3C, an ideal electric arc furnace feed material. 91�� uses this two-inch-diameter fluidized-bed reactor system to evaluate the process amenability of iron ore samples on behalf of Iron Carbide Holdings.

Introduction Copy:

Our process engineering expertise and excellent craftsmen and shop facilities have enabled us to successfully design, construct, and operate a series of demonstration plants on behalf of clients in the mineral, chemical, and environmental industries.

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Process Development

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Thermal Processing

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Thermal Processing

Materials Processing

hazen-research-admin — Mon, 10 Jun 2013 20:52:09 +0000

In some cases, established thermal processing techniques can alter or refine materials to enhance their suitability for specialized applications. However, where existing technology falls short, new extraction, refining, synthesis, or treatment techniques must be developed to produce materials with the requisite physical characteristics.

91��'s proficiency at serving the materials processing sector extends from preliminary feasibility analyses and laboratory-scale investigations to detailed process development programs. For example, we are accomplished in a variety of diffusion-oriented processes such as vapor deposition and other surface modification techniques. We can use these methods to enhance (or diminish) corrosion resistance, hardness, thermal conductivity, electrical conductivity, and other properties. With respect to materials synthesis, our experience and facilities enable us to advance a process concept from a laboratory curiosity to a demonstration-scale reality.

A related consideration is the behavior of materials in harsh operating environments such as furnaces, heat exchangers, reactors, pressure vessels, etc. Our engineers have extensive experience in the design, construction, and operation of thermal processing systems. The knowledge gained through years of experience in fabricating pilot systems to operate under highly aggressive conditions uniquely qualifies us to evaluate the applicability of engineering materials for service in high-temperature, oxidizing, or corrosive environments.

Recent projects have focused on:

Iron carbide process development
Metal carbide synthesis
Electric arc furnace refractory erosion
Nickel-based alloy high-temperature oxidation
High-temperature agglomeration
Fluidized-bed chemical vapor deposition

Introduction Copy:

Technological advances have increased the demand for specialty metals, ceramics, polymers, and composite materials to meet stringent specifications for composition, purity, structure, and other properties.

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Thermal Processing

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Thermal Processing

Pyrometallurgy

hazen-research-admin — Mon, 10 Jun 2013 20:46:12 +0000

In most instances, both phases are molten (such as the matte and slag in a conventional copper smelting operation). The gas phase may also be used to advantage, either as a means of separating valuable volatile constituents or for removing unwanted volatile impurities. These separation techniques form the basis of thermal smelting and refining operations.

There are no universally applicable pyrometallurgical technologies. Most industrial processes are commodity-specific, because they were developed to deal with the unique physical and chemical properties associated with a particular metal and its naturally occurring impurities. Thus, pyrometallurgical process development demands a keen understanding of thermochemistry, kinetics, reactor design, and materials and refractory selection. 91�� has these capabilities and can utilize them to our clients’ advantage.

Our laboratory and pilot plant programs employ a full range of pyrometallurgical methods. We have completed projects on reduction and matte smelting, drossing, and selective volatilization (fuming). Our experience includes evaluating exotic slag chemistries and using molten salts. Additionally, we have considerable expertise in developing methods of treating slag, flue dust, scrubber sludge, and other metallurgical streams.

Thermodynamic analysis and process modeling can aid concept development and parameter selection. Our recent pyrometallurgical experience includes:

Indium recovery from lead smelter dusts
Chloride drossing of lead–tin–bismuth bullion
Copper matte smelting and injection smelting
Recovery of platinum group metals
Ferronickel refining
Refractory metal recovery and refining
Magnesium reduction

Introduction Copy:

The basic premise of most pyrometallurgical operations is simple: high-temperature chemistry is employed to segregate valuable metals in one phase while rejecting gangue and impurities in another phase.

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Thermal Processing

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Thermal Processing

Endothermic Processes

hazen-research-admin — Mon, 10 Jun 2013 20:44:46 +0000

Drying and calcination are endothermic processes that require heat to evaporate bulk moisture or decompose chemical compounds. Combustion processes involve exothermic oxidation or "burning" of the feed material. Roasting processes use elevated temperature and controlled furnace atmospheres to effect desired chemical reactions in the furnace charge; roasting reactions may be either endothermic or exothermic. Although many furnace technologies exist, current industrial practice favors the rotary kiln and the fluidized-bed reactor for these applications.

91�� can assist its clients in this area, because we understand that furnace design relies not only on an accurate definition of process operating conditions, but also on the physical characteristics of the feed materials, product specifications, gas handling requirements, and other important considerations. We can develop a well-planned program to ascertain the technical feasibility of a potential processing method, examine areas of technological uncertainty, and establish the economic viability of the venture. Once process parameters have been adequately defined, pilot-scale confirmation can generate the process design criteria needed for commercial implementation.

91�� has an excellent assortment of equipment, including rotary kilns and fluidized-bed reactors for laboratory and pilot-scale studies. Our equipment inventory contains most conventional configurations, including both indirectly and directly heated furnaces. Our fluidized-bed studies have included evaluations of classical bubbling-bed, circulating-bed, and high-pressure reactor applications. We maintain an array of other pilot-scale equipment, including a multiple-hearth furnace, Holoflite® dryers, spray dryers, and an indirectly heated screw kiln. We can also custom design and manufacture laboratory and pilot-scale furnaces for special applications.

Since opening its doors in 1961, 91�� has completed projects over an exceptionally wide range of thermal processing applications. Some of our recent studies have involved:

Roasting of refractory and carbonaceous gold ores
Sulfation roasting of cobalt–copper–nickel concentrate
Reduction roasting of nickel laterites
Manganese carbonate calcination
Zirconium sulfate calcination
Selective chlorination of metals
Antimony and arsenic fuming
Combustion of coal, oil shale, refuse-derived fuel, and other fuels
Combustion of municipal solid waste for energy recovery

Introduction Copy:

Assessing the appropriate furnace technology for a given application is not a trivial exercise.

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Thermal Processing

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Thermal Processing

hazen-research-admin — Mon, 03 Jun 2013 21:45:31 +0000

91�� Research’s Thermal Processing department assists in the development of new and existing thermal process flowsheets for engineering, mining, chemical, waste treatment, and various other clients worldwide. The corporate experience of 91�� Research covers the gamut of thermal processing applications.

Our staff includes experienced chemical engineers, metallurgical engineers, mechanical engineers, and process technicians whose expertise allows us to fully evaluate all essential process considerations including critical materials handling issues such as the feed, product recovery, and offgas handling systems.

We maintain an extensive collection of process equipment for programs ranging in scope from preliminary laboratory concept evaluation to pilot-scale demonstration plants leading to commercial plant design. Because we are not committed to any particular technology or affiliated with equipment vendors, 91�� is able to guarantee an unbiased evaluation of every application. 91�� is known for its thoroughness and the reliability of its results, and customers often come to 91��’s Thermal Processing team to de-risk the scaleup of their thermal processes.

Examples of Thermal Processes at 91��:

Combustion
Oxidation
Reduction
Drying
Calcining
Roasting
Pyrolysis
Activation
Sulfating
Purification
Decontamination
Mineralization
Thermal Destruction
Thermal Oxidation
Volume Reduction
Carbonation
Carbonizing
Denitration
Decomposition
Steam Reformation

Some of our recent projects involve:

Roasting of double refractory high sulfide and carbonaceous gold ores
Sulfation roasting of cobalt–copper–nickel concentrate
Reduction roasting of nickel laterites
Manganese carbonate calcination
Zirconium sulfate calcination
Selective chlorination of metals
Antimony and arsenic fuming
Combustion of coal, oil shale, refuse-derived fuel, and other fuels
Combustion of municipal solid waste for energy recovery
Treatment of mixed waste streams that contain high nitric acid concentrations from nuclear fuels reprocessing plants
Cesium calcination
Reduction roasting of manganese oxides to recover silver
Carbon activation
Graphite purification
Rare earth sulfation
Carbon pyrolysis and activation from various feedstocks

An incomplete list of our onsite thermal processing equipment follows:

Thermal Analytical Equipment

Netzsch Simultaneous Thermal Analyzer
Multiple Sized Muffle Furnaces
Cold Flow Unit

Fluidized Beds

4 in. Fluidized-Bed Reactor
6 in. Fluidized-Bed Reactor (various configurations)
8 in. Fluidized-Bed Reactor (various configurations)
12 in. Fluidized-Bed Reactor
15 in. Refractory-Lined Fluidized-Bed Reactor
24 in. Refractory-Lined Fluidized-Bed Reactor

Rotary Kilns

2-7 in. High Temperature Furnace (various configurations and materials of construction)
4 in. Rotary Batch Kiln (quartz)
7 in. Rotary Batch Kiln (quartz)
7 in. Continuous Rotary Kiln
15 in. Direct-Fired Refractory-Lined Rotary Kiln
24 in. Indirectly Heated Rotary Kiln
24 in. Direct-Fired Refractory-Lined Rotary Kiln
60 in. Direct-Fired Refractory-Lined Sectional Kiln

Screw Kilns and Holo-Flites

2 in. Screw Kiln - Electric
5 in. Screw Kiln - Gas
8 in. Screw Kiln - Electric
3 in. Holo-Flite Processor
7 in. Holo-Flite Processor

Other Available Thermal Processing Equipment

24 in. Top Blown Rotary Converter
36 in. Multiple Hearth Furnace
63 in. Spray Dryer
36 kW Induction Furnace
3 ft³ Harper Box Furnace

Thermal processing technologies have retained their industrial prominence for several reasons. Many chemical reactions that are not thermodynamically feasible under ambient conditions occur spontaneously at elevated temperatures. Thermal processing also provides definite kinetic advantages, often-rendering reaction and transport rates so rapid that they are merely of academic importance. Other advantages include efficient separation and improved yield, inherently superior energy efficiency, and the relatively high throughput per unit volume of most thermal reactors. Critics decry thermal processing for air pollution emissions, but this argument is refuted by the ready availability of commercially proven gas collection and cleaning technologies.

Introduction Copy:

91��’s Thermal Processing Department offers a wide variety of Process Development Services for Business and Industry

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Thermal Processing

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91���� Research - Thermal Processing

Waste Treatment and Recycling

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Thermal Process Development

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Materials Processing

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Pyrometallurgy

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Endothermic Processes

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Thermal Processing

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91�� Research - Thermal Processing

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