Transcript Document

High efficiency
simultaneous
grinding and drying of
minerals and sludges
Presentation for:
15th Annual Conference on Markets for Industrial
Minerals Oct. 22, 2003
David Dungate, V-P Marketing
Dr. Sundar Narayan, V-P Research
First American Scientific Corporation, Delta, BC
Presentation Outline
• Introduction to First American Scientific
Corp. and the
KDS Micronex™ Grinder-Dryer
• Description of KDS Grinder-Dryer
• Pure Grinding Applications
Glass, Limestone, Gypsum, Gold Ore
• Grinding AND Drying Applications
Zeolite, Glacial Clay, Coal and Paper
Sludge
• Summary
About First American
• Founded in 1995, First American
Scientific Corporation (FASC) is industrial
equipment manufacturer and provider of
innovative systems that increase
profitability and reduce the
environmental impact of materials
processing.
• The KDS Micronex™, FASC’s patented
grinder-dryer, efficiently and
economically processes a wide variety of
raw materials and wastes into fine, dry
powders.
Introduction to the
KDS Micronex™ Technology
• KDS stands for Kinetic
Disintegration System. The KDS
Micronex™ is an high volume
grinder that dries WITHOUT
needing any heat input.
• No heat is needed because the
forces causing size reduction also
dry the material.
• KDS Technology uses LESS total
energy than conventional drying
and grinding combined.
Target Applications
• Soft rock minerals into fertilizers and
industrial feedstocks
– limestone, zeolite, phosphate rock, gypsum,
and clay
• Specialty applications
– glass, metallic mineral ores
• Biomass waste into fuel and fertilizer
– paper sludge, manures, biosolids, wood waste
and crop residues
• Agricultural and food waste processing
into animal feeds
– food processing waste, oyster shell, fish
bones, bread waste, seaweed
Description of the
KDS Micronex™ Technology
Materials that CANNOT be processed
include:
• Plastics
• Rubber (unless cryogenically cooled)
• Metals (metallic ores okay)
• Municipal Solid Waste (because it
contains the above materials)
Benefits of the KDS Micronex™
 Simplifying on-site grinding and drying
operations into a single compact, and
easy-to-operate system that has low
initial and operating costs
 Creating high-quality, dry, virtually
pathogen-free powders that have value
as industrial feedstocks, fuels, fertilizers
and animal feeds.
 Reducing transportation and disposal
costs by reducing moisture
The KDS MICRONEXTM Process Flow
Raw material is dropped
into the throat of the mill
The KDS MICRONEXTM Process Flow
An air-lock gate reduces dust
and eliminates blow-back
The KDS MICRONEXTM Process Flow
Material moves to the Torus
and is subjected to repeated
violent collisions with the
spinning rotor and strike plates
The KDS MICRONEXTM Process Flow
 Material is fractured and
pathogen destruction occurs
 Water vapor and water
droplets are released during
the fracturing process
The KDS MICRONEXTM Process Flow
Cyclone
The classifier allows finished
product to pass through to the
cyclone and forces oversize
particles to be reprocessed
The KDS MICRONEXTM Process Flow
Moisture
 Air containing moisture is
separated and removed from
the system.
 Processed solid material is
Product
output from the bottom of
the cyclone
KDS MICRONEX™
Physical Characteristics
•
•
•
•
•
•
18’ (h) x 14’ (l) x 7’ (w)
Footprint 1000 sq. ft.
Weight 9000 lbs.
Motors 250, 45, 2, 2, 2 HP
Electrical 480V, 800 Amp
High grade steel with some stainless
components
KDS Micronex™
Testing Site
KDS Micronex™
Process Process Results
Input
Output
KDS Micronex™ Applications
Container Glass
• KDS Micronex™ is the only
machine known to us that can
produce sub-micron glass powder,
in bulk quantities.
• Powdered glass can be used as a
replacement for silica fume
cement an brick manufacture or
as a filler for various other
coatings.
KDS Micronex™ Applications
Container Glass
Material
Feed
Rate
Power
(kW)
(kg/hr)
Broken
Bottles
543
Particle
Size, d
(microns)
150
15 % < 1
100 % < 45
KDS Micronex™ Applications
Limestone
• American limestone producer in
Washington State uses KDS Micronex™
machine for limestone milling.
• Powdered Limestone is used in cement
manufacturing and flue gas
desulfurization (FGD).
• Client reports that the KDS Micronex is
competitive with other size reduction
methods.
KDS Micronex™ Applications
Limestone
FASC Client's Production Figures
Material
Production
Rate
(kg/hr)
Power
(kW)
Particle
Size
(microns)
Limestone
3620
150
<75
KDS Micronex™ Applications
Limestone
Parameter
Horizontal
Ball Mill for
Limestone
KDS
Micronex
for
Limestone
Power
Consumption
35 kWhr/ton
35
kWhr/ton
KDS Micronex™ Applications
Gypsum
Gypsum plant in California used
KDS Micronex for gypsum grinding.
Material
Production
Rate
(kg/hr)
Power
(kW)
Particle
Size
(microns)
Gypsum
2265
112
75 (est)
KDS Micronex™ Applications
Gold Ore
• Patented process mechanically
separates gold and avoids the use of
toxic chemicals.
• Gold stays in KDS chamber when gold
ore (quartzite) is ground to 30 microns.
• Waste rock is conveyed out of KDS.
• Research under way to improve
operating efficiencies
KDS Micronex™ Applications
Zeolite, Glacial Clay, Coal
Material
Feed
Rate
Feed
Power
(kW)
(kg/hr)
MC
(%)
Zeolite
1116
13
Glacial Clay
1025
Coal
2100
Prodn
Rate
Out
MC
Particle
dia.
(kg/hr)
(%)
(micron)
130
1067
9
32
10
120
930
<1
45
23
150
1582
8
63
Zeolite is used in fast drying concrete mixtures
Glacial Clay is used in cosmetics, face creams.
KDS Micronex™ Applications
Paper Sludge
• Two kinds of Paper Sludge –
Primary/Secondary (P/S) Sludge
and De-inking Sludge
• P/S Sludge comes from wastewater
from paper pulp-making. Has
bacteria. MC = 80 %
• Deinking sludge results from
recycled paper manufacturing. It is
25% clay (kaolin). MC = 50 %
KDS Micronex™ Applications
Paper Sludge Comparison
• Both kinds contain burnable fiber,
but are too wet to burn on grate or
in dust burners.
• Both can be directly applied as
fertilizer, but this can lead to
respiratory problems and water
pollution.
• Paper Sludge is usually landfilled at
$17-35/mT + $0.1/mT/km
transportation cost.
KDS Micronex™ Applications
Paper Sludge Comparison
• Drying sludge reduces landfill
costs.
• Dried paper sludge can be used to
make sound-absorbing material,
cattle-bedding.
• Dried paper sludge is burnable in
grate or dust burner.
KDS Micronex™ Applications
Glacial Clay
Material
Feed
Rate
(kg/hr)
Feed
MC
(%)
Power
(kW)
Deinking
Sludge
1204
51
110
Prodn Out Drying
Rate
MC Energy
(kg/hr) (%) (kJ/kg)
797
26
975 kJ/kg is only 42 % of the latent heat of water!
Drum Dryer would need 3700 kJ/kg of water.
975
KDS Micronex™ Applications
Oyster Shells
• FASC has processed Oyster Shells
with excellent results.
• Fine, bone-dry powder is produced.
• Up to 3 TPH of possible.
KDS Micronex™ Applications
Summary
 Sub-micron glass powder can be
made cheaply in large quantities
 Limestone and gypsum can
effectively be ground to solution
grade
 KDS dries deinking sludge with 74 %
LESS energy than drum dryers
 Chemical-free gold extraction
system being commercialized
KDS Micronex™ Summary
 The KDS Micronex™ provides a simple,
compact, low cost and easy-to-operate
solution for fine grinding and drying.
 Proven applications include sludge drying,
grinding glass and soft-rock minerals and
preparing biomass fuels for power
production.
 The machine can quickly pay for itself, by
creating high-value end-products, reducing
processing and disposal costs.
For more information contact:
First American Scientific Corp.
Tel: +1-604-940-6220
Fax: +1-604-940-6221
Toll Free: 1-800-561-8656
Email: [email protected]
Web: www.fasc.net
Reduction System