Method and system for heat treatment of particulate material

Abstract

A system (100) for heat treatment of particulate materials is disclosed. The system (100) includes: a first reaction section (12) for receiving particulate material at a top (12.1) such that the particulate material flows through the first reaction section (12) under gravity; a first heating system (14) arranged adjacent to and along the length of the first reaction section (12) to heat the particulate material flowing through the first reaction section (12) from outside the first reaction section (12), thereby activating the particulate material; and a compactor (16) for receiving and compacting the thermally activated particulate material from the first reaction section (12) to form agglomerates. A method for heat treatment of particulate materials is also disclosed.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to Australian Provisional Patent Application No. 2023903476, filed on October 30, 2023, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to the heat treatment of particulate materials. Specifically, this disclosure relates to heat treatment comprising activating and compacting the particulate materials to increase their tendency to undergo a target chemical reaction at elevated temperatures. Background Technology

[0004] Various methods for the heat treatment of particulate materials are known for different industries and for various purposes. Limiting examples include the direct reduction of fine iron ore particles in steelmaking and the calcination and clinkerization of raw meal for cement production. However, many (if not most) of these methods suffer from significant process and thermal inefficiencies. Furthermore, these methods are notorious for causing emissions of harmful gases, with the steel and cement industries contributing approximately 6-8% and 8% of global carbon dioxide (CO2) emissions, respectively.

[0005] With the growing demand for critical materials and the emphasis on decarbonization, there is a need for cross-industry approaches that can thermally process particulate materials in a way that is not only sustainable but also allows for the effective capture of unavoidable emissions and at least electrification options.

[0006] Any discussion of documents, actions, materials, devices, articles, etc. included in this specification shall not be construed as an admission that any or all of these matters form part of the prior art or are common general knowledge in the relevant field of this disclosure that existed prior to the priority date of each appended claim. Summary of the Invention

[0007] According to an aspect of this disclosure, a method for heat treatment of particulate materials is provided, the method comprising:

[0008] The particulate material is introduced into the vertical first reactor section. The particulate material is introduced into the first reactor section at the top, so that the particulate material flows through the first reactor section under the action of gravity.

[0009] The particulate material is heated from the outside of the first reactor section to activate it; and

[0010] Compacting thermally activated particulate materials to form agglomerates.

[0011] The method may include adding additional particulate material to the thermally activated particulate material prior to compaction. This additional particulate material may include, for example, materials such as flow aids, materials that do not require treatment in the first reactor section, or materials prepared in an oxidizing / reducing environment different from that of the first reactor section. Adding such additional material, compacting it together with those treated in the first reactor section, can advantageously influence the processing conditions. For example, adding such additional particles to the compaction system at a defined temperature can enhance control over the compaction process temperature, such as to mitigate or activate phase changes in the particles or chemical reactions within the agglomerates during agglomeration or later in the second reactor section described below. The additional material may be added at ambient temperature, at a temperature lower than that of the thermally activated particulate material from the first reactor section, or at a temperature higher than that of the thermally activated particulate material.

[0012] The method may also include:

[0013] The resulting agglomerates are introduced into the top of the vertical second reactor section to form a packed bed in the second reactor section;

[0014] Heating the aggregates in a packed or moving bed to initiate a target reaction within the aggregates as they move through the packed bed; and

[0015] The reacted agglomerates are discharged from the bottom of the second reactor section.

[0016] In the context of this disclosure, references to granular materials or granular feed materials may refer to one or any combination of the following: mined limestone or dolomite; synthetic calcium carbonate and magnesium carbonate; supplemental or alternative cementitious materials (SCM); raw meal or cement raw meal; metallic ores and / or concentrates; and biomass.

[0017] In the context of this disclosure, “activation” refers to at least partially metallizing, partially decomposing, gasifying, volatilizing, calcining, reducing and / or oxidizing at least a component of particulate material to form thermally activated particulate material, such that the thermally activated particulate material is in a solid state and exhibits a relatively increased tendency to carry out the target solid-state reaction at elevated temperatures.

[0018] In the context of this disclosure, "target reaction" refers to a physical and / or chemical process that produces a product, at least in part, through atomic transport processes between the component particles of the agglomerate.

[0019] As a non-limiting example, the particulate material processed according to any of the preceding paragraphs or the methods described below may be or include: raw meal or cement raw meal for manufacturing silicate cement clinker; limestone for manufacturing lime; a combination of limestone and kaolin clay for manufacturing SCM, the combination optionally including one or more additives; magnesite for manufacturing magnesia or other refractory materials; or a combination of SCM particles and silicate cement particles.

[0020] The reacted agglomerates can be dense or porous products.

[0021] Exhaust gas from the first reactor section can be discharged from an outlet located at the top of the first reactor section. The exhaust gas may contain gaseous products from the activation of particulate material. The exhaust gas can be separated by a separator to at least partially separate entrained solid particles, producing clean exhaust gas. The separated solid particles can be reintroduced into the first reactor section at the top. The separator may include one or more cyclone separators and / or filters in fluid flow connection to the outlet located in the first reactor section.

[0022] Heating the particulate material from outside the first reactor section can be achieved via a first heating system located adjacent to and along the length of the first reactor section. It should be understood that the activation of the particulate material can be exothermic, in which case the heat from the activation of the particulate material can contribute to the heating of the particulate material within the first reactor section.

[0023] Heating the agglomerates in the packed bed within the second reactor section may include one or more of the following: heating from outside the second reactor section; heating via a combustion reaction within the second reactor section; heating by injecting hot gas into the second reactor section and passing the hot gas through the packed bed of agglomerates; and an electrosmelting process. The second reactor section may include a second heating system arranged adjacent to and along the length of the second reactor section for heating the agglomerates in the packed bed from outside the second reactor section.

[0024] The first heating system and / or the second heating system may include electric heating elements, non-limiting examples of which include induction heating elements and resistance heating elements. One or both of the first and second heating systems may include an electric melting furnace. Where the first and / or second heating systems include electric heating elements, the electric heating elements may be powered by renewable energy and / or the power grid. Where the electric heating elements are powered by the power grid, the first and / or second heating systems may be used as a demand-side mechanism for balancing the power grid.

[0025] The first and / or second heating system may be a furnace section thermally connected to its associated reactor section, wherein heat is generated by the dissipation of electrical power within the material or by a combustion reaction, or by both combustion and electrical dissipation. The combustion reaction may be the combustion of an oxygen-fuel mixture using one or more syngas and oxygen sources (including but not limited to oxygen). The combustion reaction may serve to form gaseous products that constitute the flue gas of the furnace section. The furnace section may be thermally connected to its associated reactor section via a heat-conducting element. The heat-conducting element may be the wall of the associated reactor section.

[0026] Heating from the electrical power dissipation in the second reactor section can be achieved using an electric melting furnace configured to utilize the resistivity of a material (preferably a molten material), wherein such a molten material is prepared in the first reactor section or by material recirculation from the second reactor section, or by both.

[0027] Combustion reactions within the second reactor section can be achieved by introducing feed gas into the second reactor section. The feed gas comprises one or more of the following, or any combination thereof: one or more syngas; an oxygen source, including but not limited to oxygen or air; and a hydrogen source, including but not limited to hydrogen. Where the feed gas comprises a combination of one or more syngas and an oxygen source, the one or more syngas and oxygen sources can be introduced separately into the second reactor section, such that, upon mixing, oxygen fuel combustion heats the packed bed of agglomerates. Oxygen fuel combustion can be flameless. The feed gas can be introduced into the second reactor section at an elevated temperature.

[0028] It should be understood that the combustion reaction within the second reactor section and / or the target reaction can form gaseous products that serve as flue gas in the second reactor section.

[0029] The exhaust gas from the first reactor section, the furnace section flue gas, the second reactor section flue gas, and / or the exhaust gas from the pre-combustion capture process of the gasifier products may contain CO2 and / or H2O. Where the furnace section flue gas and / or the second reactor section flue gas and / or the exhaust gas from the first reactor section contain CO2, the method may include capturing CO2 from one or more of the furnace section flue gas, the second reactor section flue gas, and the first reactor section exhaust gas at a carbon capture facility. The carbon capture facility may include one or any combination of the following: cooling; gas cleaning; separation of H2O and / or other impurities; compression or liquefaction; and storage. The gas cleaning and separation processes may contain activated lime or dolomite, such as that produced using the activation process described below. The captured CO2 may be used in methanol, alternative aviation fuel, and / or hydrocarbon material production facilities.

[0030] CO2 released from the flue gas in the first reactor section may originate from a CO2-loaded adsorbent in a direct air capture facility, wherein heating releases CO2 and generates an adsorbent precursor, which is then processed by compaction and reaction in a second reactor section to form a product with a composition, particle size, shape, porosity, and specific surface area suitable for reuse in a direct air capture facility.

[0031] In cases where the captured CO2 is used in a methanol production facility, the oxygen source supplied to the furnace section and / or the second reactor section can be obtained from the methanol electrolyzer of the methanol production facility.

[0032] One or more syngases fed to the furnace section and / or the second reactor section may be formed at a gasification facility. Where the captured CO2 is used in a methanol production facility, the gasification facility may comprise the gasification of biomass and oxygen obtained from a methanol electrolyzer in the methanol production facility. The gasification products from the biomass and oxygen gasification may be cleaned to form one or more syngases. The gasification process can produce CO2. CO2 from the gasification process can be removed by a pre-combustion capture process or stage (such as an adsorbent-enhanced water-gas shift (SEWGS) process) and the hydrogen stream can be used for oxygen fuel combustion. The SEWGS adsorbent may contain activated lime or dolomite, such as that prepared using the activation process described below.

[0033] The captured CO2 may be injected at least partially into one or both of the furnace section and the second reactor section to regulate the temperature within the furnace section and / or the second reactor section.

[0034] The particle size distribution of the particulate material introduced into the first reactor section is preferably in the range of 150 μm to 350 μm.

[0035] The method may include fusing the particulate material to produce a particle size distribution in the range of 150 μm to 350 μm before introducing the particulate material into a first reactor section. The fusing of the particulate material may be performed using a cylindrical mill.

[0036] The particulate material can be homogenized before being introduced into the first reactor section.

[0037] The compaction of thermally activated granular materials to form agglomerates can be performed using a heat-resistant roller press. It should be understood that the agglomerates can be of any shape; non-limiting examples of cross-section or general agglomerate shapes include "pillow" shape, irregular shape, rectangular shape, square shape, circular shape, cylindrical shape, "cigar" shape, tablet shape, and polygonal shape. The size of the agglomerates is preferably in the range of 1 cm to 10 cm. As a non-limiting example, the agglomerates can be elongated and can generally be cylindrical or "cigar" shaped, having a width or diameter in the range of 1 cm to 3 cm and a length in the range of 3 cm to 6 cm. The pressure can be approximately 100 kN / cm.2 Compacted thermally activated particulate materials under linear pressure, and can be compacted at up to 200 kN / cm. 2 The thermally activated particulate material is compacted under pressure to form agglomerates.

[0038] The residence time of the particulate material in the first reactor section may be less than 60 seconds, preferably less than 40 seconds, and more preferably in the range of 20 to 30 seconds. The residence time of the agglomerates in the packed bed in the second reactor section may be less than 10 minutes, preferably about 5 minutes. However, it should be understood that the residence time of the agglomerates in the packed bed in the second reactor section depends at least in part on the particulate material, the temperature at which the agglomerates are heated in the second reactor section, and the size of the agglomerates, and therefore, in some cases the residence time may exceed 60 minutes.

[0039] The first reactor section and / or the second reactor section can be operated under positive gauge pressure.

[0040] The method may include cooling the reacted agglomerates discharged from the second reactor section to allow for handling and / or transport. Cooling of the agglomerates may be performed using equipment such as a grate cooler.

[0041] The method may include pulverizing the reacted agglomerates to form a powder product. Where the cooling of the agglomerates is carried out via a grate cooler, the grate cooler may include rotating pins, whereby the reacted agglomerates are pulverized.

[0042] The particulate material introduced into the first reactor section can be preheated.

[0043] According to another aspect of this disclosure, a system for heat treatment of particulate materials is provided, the system comprising:

[0044] A vertical first reactor section configured to receive particulate material at its apex, allowing the particulate material to flow through the first reactor section under gravity; and a first heating system adjacent to and arranged along the length of the first reactor section to heat the particulate material flowing through the reactor section from outside, thereby activating the particulate material; and

[0045] A compactor is used to receive and compact thermally activated particulate material from the first reactor section to form agglomerates.

[0046] The system may include a mechanism arranged to introduce additional particulate material into the thermally activated particulate material prior to compaction by a compactor. This mechanism may be an injection mechanism arranged to inject material directly into the compactor, or an injection mechanism arranged to inject additional material upstream of the compactor. This mechanism is generally arranged and capable of introducing additional material into the thermally activated material prior to compaction by a compactor. It should be understood that various mechanisms capable of introducing additional particulate material into the activated material, such as by spraying, coating, pumping, extrusion, deposition, etc., are all within the scope of this disclosure.

[0047] The system may include a vertical second reactor section, which is configured as follows:

[0048] It receives agglomerates from the compactor at its top, which form a packed bed within the second reactor section;

[0049] The aggregates in the packed bed are heated to initiate a target reaction within the aggregates as they move through the packed bed.

[0050] The reacted agglomerates can be discharged from the outlet located at the bottom of the second reactor section.

[0051] The second reactor section may include a discharge system configured to control the rate of movement of the agglomerates through the packed bed in the second reactor section.

[0052] The second reactor section may be configured to heat the agglomerates in the packed bed from outside the second reactor section, the heating being carried out by one or more of the following: operating a second heating system adjacent to and arranged along the length of the second reactor section; inducing a combustion reaction within the second reactor section; injecting hot gas into the second reactor section and passing the hot gas through the packed bed of agglomerates; and electromelting the agglomerates.

[0053] The first heating system and / or the second heating system may include one or more electric heating elements. The electric heating elements may be induction or resistance heating elements. The first heating system and / or the second heating system may include an electric melting furnace.

[0054] The first heating system and / or the second heating system may include a furnace section thermally connected to its associated reactor section, wherein heat is generated by a combustion reaction.

[0055] The combustion reaction can be the combustion of an oxygen-fuel mixture using one or more syngas and oxygen sources (including but not limited to oxygen). The combustion reaction can serve to form gaseous products that act as flue gas in the furnace section. The furnace section can be thermally connected to the associated reactor section via heat-conducting elements. These heat-conducting elements can be the walls of the associated reactor section.

[0056] The target reaction and / or combustion reaction can produce gases that serve as flue gas in the second reactor section.

[0057] The first reactor section and the second reactor section can be different reactors or, alternatively, sections of a monolithic reactor. The second reactor section can be fluidly connected to the first reactor section.

[0058] The first reactor section can be configured to discharge exhaust gas from an outlet located at the top of the first reactor section.

[0059] The activation of the particulate material can serve to generate exhaust gas in the first reactor section. The first and second reactor sections are sections of an integral reactor and / or are connected by fluid flow. The flue gas from the second reactor section can be discharged as exhaust gas or a part thereof from the outlet located at the top of the first reactor section.

[0060] In a configuration where the first reactor section is configured to discharge gas from an outlet located at the top of the first reactor section, the system may include a separator in fluid flow connection with the outlet located at the top of the first reactor section to receive the exhaust gas and at least partially separate entrained solid particles. The separator may be configured to reintroduce the separated solid particles into the first reactor section at the top. The separator may include one or more cyclone separators and / or filters.

[0061] Where the exhaust gas, second reactor section flue gas, furnace section flue gas, and / or pre-combustion captured gas contains CO2, the system may include a carbon capture facility for receiving, alone or in combination, any one or more of the exhaust gas, second reactor section flue gas, and / or furnace section flue gas. The carbon capture facility may include one or any combination of the following systems: cooling; gas cleaning; separation of H2O and / or other impurities; compression or liquefaction; and storage. CO2 from the gasification process may be removed by a pre-combustion capture system (such as an adsorbent-enhanced water-gas shift (SEWGS) system), and the hydrogen stream may be used for an oxygen fuel combustion system. The SEWGS system may contain activated lime or dolomite, such as that produced using the activation process described below. The captured CO2 can be used in methanol, alternative aviation fuel, and / or hydrocarbon material production facilities.

[0062] The system may include a gasification facility configured to produce one or more syngases for use in combustion reactions in either or both of the second reactor section and the furnace section. The gasification facility may include a gasifier configured to gasify the biomass feed using oxygen obtained from a methanol electrolyzer in a methanol production facility. The gasification facility may include gas cleaning operations to produce one or more syngases from the gasified biomass feed. CO2 from the gasification process may be removed by a pre-combustion capture system, such as an adsorbent-enhanced water-gas shift (SEWGS) system, and a hydrogen stream may be used in an oxygen-fuel combustion system. The SEWGS system may contain activated lime or dolomite, such as that produced using the activation process described below.

[0063] The system may include a preheater for preheating the particulate material before it is received by the first reactor section.

[0064] The system may include a melting and / or homogenizing facility for melting particulate material to produce a particle size distribution in the range of 150 μm to 350 μm and / or homogenizing the particulate material, after which the particulate material is introduced into a first reactor section. The melting and / or homogenizing facility may include a cylindrical mill.

[0065] The compactor can be one or more heat-resistant roller presses.

[0066] Where the first heating system and / or the second heating system includes one or more electric heating elements, the system may include a renewable energy facility for powering the electric heating elements. The renewable energy facility may receive electricity from renewable energy sources or may include renewable energy sources. The renewable energy facility may include an energy storage device, through which the electric heating elements are indirectly powered by renewable energy. The energy storage device may include a vanadium redox flow battery unit charged by renewable energy.

[0067] The system may include a cooling facility configured to cool the reacted agglomerates discharged from the second reactor section to allow for handling and / or transport. The cooling facility may include a grate cooler. The grate cooler may be a rotary grate cooler. The rotary grate cooler may include nails.

[0068] The system may include a pulverizer configured to pulverize reacted agglomerates to form a powder product. The pulverizer may be a rotary grate cooler including nails.

[0069] The system may include a preheater configured to preheat the particulate feed material before it is received in the reactor section.

[0070] The singular forms “a,” “a,” and “the” include plural referents unless the context clearly indicates otherwise.

[0071] Throughout the specification, the word “comprising” or variations thereof shall be understood to imply inclusion of the stated element, integer or step, or group of elements, integers or steps, but not to exclude any other element, integer or step, or group of elements, integers or steps.

[0072] It will be understood that the implementation scheme may include steps, features and / or integers indicated in the disclosure herein or the specification of this application, individually or collectively, and may include any and all combinations of two or more of the steps or features. Attached Figure Description

[0073] The implementation scheme will now be described by way of example only, with reference to the accompanying drawings, in which:

[0074] Figure 1 This is a schematic flowchart of a system for heat treatment of particulate materials;

[0075] Figure 2 yes Figure 1 A schematic cross-sectional side view of the vertical shaft furnace reactor of the system; and

[0076] Figure 3 This is a block flowchart of a method for heat treatment of particulate materials, which can be performed by the system shown in the previous figure. Detailed Implementation

[0077] In the accompanying drawings, reference numeral 100 generally denotes a system for the heat treatment of particulate materials. System 100 is shown as including a first reactor section 12 ( Figure 2 The first reactor section is configured to receive particulate material at its top 12.1, such that the particulate material flows through the first reactor section 12 under gravity; and the first heating system 14 ( Figure 2 The first heating system is arranged adjacent to and along the length of the first reactor section 12 to heat the particulate material flowing through the first reactor section 12 from the outside of the first reactor section 12, thereby activating the particulate material. The system 100 is also shown to include a compactor 16 for receiving and compacting the thermally activated particulate material from the first reactor section 12 to form agglomerates.

[0078] The system 100 and associated methods for heat treatment of particulate feed materials are further described herein with reference to exemplary embodiments. Figure 3 The particulate material is received as a product of an industrial or crushing process and is one of limestone, dolomite, magnesite, SCM mixture or cement raw material, typically a fine powder with an average particle size of less than about 40 μm.

[0079] refer to Figure 1The particulate material is conveyed from a storage facility (not shown) to a melting operation (as indicated by arrow A) including a cylindrical mill 18, where the particulate material is typically homogenized and fused at ambient temperature to increase the average particle size and achieve a desired particle size distribution, typically in the range of 150 μm to 200 μm, to exclude particles that are easily entrained in the gas stream, as well as undesirable larger and heavier particles, as will become apparent from the description below. Starting from the cylindrical mill 18, the particulate material passes through a preheater 20 and is then introduced into the first reactor section 12 of the vertical shaft reactor 10. The first reactor section 12 is configured to receive the particulate material through an inlet, such as that arranged at the top 12.1 of the reactor 10, as indicated by arrow B. Figure 2 As shown in the illustration. In this exemplary embodiment, the first reactor section 12 is Calix Flash Calciner technology developed and owned by Calix Pty Ltd.

[0080] The particulate feed material is introduced into the first reactor section 12 at the top 12.1, so that the particulate feed material flows through the first reactor section 12 under gravity to the bottom 12.2. The residence time of the particulate material in the first reactor section 12 is typically less than 60 seconds. However, it will be understood that this residence time can be affected at least in part by the length of the first reactor section 12 and the gas flow through the first reactor section, as further described below, and can be extended or shortened by providing a longer or shorter first reactor section 12, as may be done as needed.

[0081] exist Figure 2 As shown, the vertical shaft reactor 10 also includes a heating system 22 for the first reactor section 12, and this heating system 22 is configured as an electric heating element, such as an induction or resistance heating coil, arranged adjacent to and along the length of the first reactor section 12. The heating system 22 heats the particulate material flowing through the first reactor section 12 from outside the first reactor section 12. The heating system 22 heats the particulate material to temperatures up to approximately 1050°C to induce calcination of the particulate material. Therefore, the particulate material is activated to form thermally calcined particulate material and CO2 exhaust gas.

[0082] Due to the high effective specific surface area of ​​the particulate material and its preheating, rapid heating can occur in the first reactor section 12, allowing the particulate material to be calcined, a process commonly referred to as "flash calcination." This is further facilitated by the fusion operation 18 upstream of the shaft furnace reactor 10, thereby mitigating the agglomeration of the particulate material in the first reactor section 12 and its entrainment in the resulting exhaust gas. The system 100 is shown as including a separator 24, such as one or more cyclone separators and / or filters, which is in fluid flow connection with the exhaust gas outlet 26 arranged at the top 12.1 of the first reactor section 12. In this way, any solid particles entrained in the exhaust gas can be separated from the exhaust gas and reintroduced (indicated by arrow C) into the first reactor section 12, such as at the top 12.1, while the exhaust gas can be discharged, indicated by arrow D.

[0083] Using the heating system 22 in this manner also allows for at least partial electrification of the system 100 and enables the use of renewable energy sources in the process. Accordingly, the system 100 is shown as including a renewable electricity facility 200 for supplying power to the electric heating elements, by... Figure 1 Arrow E indicates this. It will be understood that the renewable power facility 200 may receive electricity from renewable energy sources or may itself include renewable energy source 210. The renewable power facility 200 may also include an energy storage device 220, through which the electric heating element can be powered directly or indirectly by renewable energy source 210. The energy storage device 220 preferably includes a vanadium redox flow battery unit as a desired battery technology for storing potentially fluctuating and intermittent renewable energy supplies. Alternatively or additionally, the electric heating element may be powered by the grid and thus act as a demand-side mechanism for balancing the grid.

[0084] It will be understood that the heating system 22 may also be a furnace section thermally connected to the first reactor section 12, wherein heat is generated by the combustion reaction and transferred to the first reactor section 12 via the walls of the first reactor section 12. Selecting the heating system 22 in this manner allows for consideration, for example, the type of particulate material being processed and the need for a low-emission process, as required.

[0085] Advantageously, by heating the particulate material from the outside of the first reactor section 12 as described above, contamination of the thermally activated particulate material through direct contact with the heating medium can be avoided, thereby allowing for the acquisition of high-purity thermally activated particulate material. If necessary, a gas (such as an inert gas) can also be introduced at F ( Figure 2A positive gauge pressure is introduced into reactor section 12 to maintain the positive gauge pressure within the first reactor section 12, which inhibits the entry of any harmful gases (e.g., oxygen from the air) into the first reactor section 12. The flow of particulate material under gravity in the first reactor section 12 thus implies net flow, taking into account the gas flow within the first reactor section 12. Furthermore, it will be understood that since activation of the particulate material does not require contact between particles, the flow of particulate material in the first reactor section 12 can be dilute.

[0086] The thermally activated particulate material is discharged from the vertical shaft reactor 10 via solid outlet 28 at the bottom end 12.1 of the first reactor section 12, indicated by arrow G. In this embodiment, the material is received by a compactor 16, such as one or more heat-resistant roller presses 30, at a temperature of approximately 700°C–800°C. The heat-resistant roller presses 30 operate at approximately 100 kN / cm². 2 The force is used to compact thermally activated particulate material to form agglomerates (which may be referred to as “clumps” or “thermal agglomerates”), preferably forming generally cylindrical or “cigar”-shaped agglomerates with a diameter of about 2 cm and a length of about 3-5 cm. It will be understood that the force used to compact the agglomerates can vary at least in part based on the size of the agglomerates, and this force can be adjusted to achieve any desired compressive strength, abrasion resistance, and / or porosity in the agglomerates. Surprisingly and surprisingly, the resulting nanoporosity achieved by calcining the particulate material to form thermally activated particulate material, along with its elevated temperature and relatively low Young's modulus, allows the activated particulate material to be effectively deformed and densified under a specified force, thereby forming dense agglomerates. It will be understood that this densification can enhance diffusion kinetics to increase the tendency of the agglomerates to undergo targeted reactions, such as sintering or clinkering at a suitable elevated temperature.

[0087] The agglomerates are then introduced into a vertical second reactor section 32 (a vertical kiln) to form a packed bed within the second reactor section 32. Syngas H and oxygen M are then injected into the second reactor section 32 at elevated temperatures and pass countercurrently through the packed bed of agglomerates. The "cigar" shape and size of the agglomerates enhance effective packing, mitigating or preventing the injection of high-pressure gases while suppressing harmful channeling through the packed bed.

[0088] The syngas and oxygen, separately introduced into the second reactor section 32, allow for flameless oxy-fuel combustion within the second reactor section 32, which heats the packed bed of agglomerates to a range of 1300°C to 1700°C. Therefore, as the agglomerates move through the packed bed, rapid sintering or clinkering is initiated, and CO2 flue gas is generated in the second reactor section 32 along with the oxy-fuel combustion. Consequently, the residence time of the agglomerates in the packed bed can be less than 10 minutes, preferably about 5 minutes, which is significantly shorter than the 35 minutes or longer required for clinkering or sintering in conventional rotary kiln processes.

[0089] The reacted aggregates in I( Figure 1 The solids are discharged from the solids outlet of the second reactor section 32 at point J, while the CO2 flue gas from the second reactor section 32 is discharged separately from the flue gas outlet of the second reactor section 32 at point J. It will be understood that the second reactor section 32 may include a discharge system configured to control the rate at which the reacted agglomerates are discharged from the second reactor section 32, thereby controlling the rate at which the agglomerates move through the packed bed.

[0090] Since both the exhaust gas from the first reactor section 12 and the flue gas from the second reactor section 32 contain CO2, the system 100 is shown as including a carbon capture facility 300, which includes cooling and gas cleaning 310 and liquefaction 320. The captured and liquefied CO2 can then be transported, for example, to a methanol production facility. Thus, unavoidable CO2 emissions from processes such as cement and lime production can be easily separated for use or storage. Furthermore, by allowing the exhaust gas from calcination in the first reactor section 12 to be emitted separately from the flue gas from the second reactor section 32 of sintering and clinker, the method provides a two-source approach, recognizing that the residual impurities in the respective gaseous product streams can be different, and thus allowing for the application of CO2 with different purity requirements and reduced gas cleaning expenditures.

[0091] The sustainability of this method can be further enhanced because the oxygen required for the combustion reaction in the second reactor section 32 can be obtained from the methanol electrolyzer of the methanol production facility, whose CO2 is supplied by system 100.

[0092] Furthermore, system 100 is shown to include a gasification facility 400, which includes a gasifier 410 and a gas cleaning operation 420, wherein biomass feed (indicated by arrow K) is gasified together with oxygen feed (indicated by arrow L) from a methanol electrolyzer in a methanol production facility. Therefore, the gasification products are cleaned in gas cleaning operation 420 to form syngas fed to the second reactor section 32.

[0093] Operating gasifier 410 to process biomass feed can generate CO2. CO2 from the gasification process can be removed by a pre-combustion capture process or stage, such as an adsorbent-enhanced water-gas shift (SEWGS) process. The SEWGS process produces a hydrogen stream, which can be used for oxy-fuel combustion. The SEWGS adsorbent may contain activated lime or activated dolomite, such as that prepared during the activation process of the first reactor section 10.

[0094] Finally, the reacted agglomerates formed in the second reactor section 32 are discharged from the second reactor section 32 and cooled at a cooling facility 34 near the second reactor section 32. In many industries, it is preferred to turn the reacted agglomerates into a powder product, and therefore the cooling facility 34 may include a rotary grate cooler with pins, such that the rotary grate cooler is configured not only to cool the reacted agglomerates discharged from the second reactor section 32, but also to pulverize the reacted agglomerates to produce such a powder product for processing and / or transport at N.

[0095] It will be understood that, if necessary, the temperature in the second reactor section 32 can be controlled by injecting CO2 gas from the carbon capture facility 300 into the second reactor section 32.

[0096] It will be further understood that the aforementioned system 100 and associated methods allow for various means of recovering heat throughout the process. As an example, waste heat obtained from cooling solid materials at cooling facility 34 can be recovered via path O( Figure 1 The material is recycled and used in the preheater 20 to preheat the particulate material.

[0097] In addition to possible equipment size considerations, the system 100 and associated methods described above allow for scaling up to increase their capacity, for example, by arranging multiple first reactor sections 10, second reactor sections 32, and / or compactors 16 in various configurations. As a non-limiting example, system 100 may include components that distribute fused and preheated particulate material from a single fusion and preheating facility 500 to multiple first reactor sections 12, each first reactor section 12 discharging thermally activated particulate material into a universal compactor 16 to form agglomerates, which are then introduced into a universal second reactor section 32 and from there discharged the reacted agglomerates into a cooling facility 34. Furthermore, it is contemplated that the first reactor sections 10 and the second reactor sections 32 need not be separate reactors and may be in the form of an integral reactor 600 and / or fluidly connected via the compactor 16.

[0098] The system 100 and associated methods illustrated above are not only compatible with electricity and alternative fuels, but also provide a feasible, flexible and / or economical way to sustainably process a variety of particulate materials.

[0099] It will be apparent to those skilled in the art that many variations and / or modifications can be made to the above embodiments without departing from the broad overall scope of this disclosure. Therefore, the present embodiments are considered illustrative rather than restrictive in all respects. Consequently, this disclosure extends to all functionally equivalent processing apparatuses, structures, methods, and uses within its scope. It will be further understood that the methods of this disclosure can be performed in a continuous, semi-continuous, or batch manner, and therefore, the steps of the provided methods need not necessarily be performed in the order or sequence described herein.

Claims

1. A method for heat-treating particulate materials, the method comprising: The particulate material is introduced into a vertical first reactor section, and the particulate material is introduced into the first reactor section at the top, so that the particulate material flows through the first reactor section under the action of gravity. The particulate material is heated from outside the first reactor section to activate it; and Compacting thermally activated particulate materials to form agglomerates.

2. The method according to claim 1, wherein, Additional particulate material is added to the thermally activated particulate material before compaction.

3. The method according to claim 1 or 2, further comprising: The resulting agglomerates are introduced into the top of a vertical second reactor section to form a packed bed in the second reactor section; Heating the agglomerates in the packed bed to induce a target reaction within the agglomerates as they move through the packed bed; and The reacted agglomerates are discharged from the bottom of the second reactor section.

4. The method according to claim 3, wherein the reacted agglomerate is a densified product or a porous product.

5. The method according to any one of the preceding claims, wherein exhaust gas from the first reactor section is discharged from an outlet disposed at the top of the first reactor section.

6. The method of claim 5, wherein the method comprises passing the exhaust gas through a separator to at least partially separate solid particles entrained in the exhaust gas to produce clean exhaust gas.

7. The method of claim 6, further comprising reintroducing the separated solid particles at the top into the first reactor section.

8. The method according to any one of the preceding claims, wherein heating the particulate material from outside the first reactor section is performed by a first heating system adjacent to and arranged along the length of the first reactor section.

9. The method of claim 8, wherein the first heating system comprises an electric heating element.

10. The method of claim 9, wherein the electric heating element is powered by a renewable energy source.

11. The method of claim 9, wherein the electric heating element is powered by the power grid.

12. The method of claim 11, wherein the first heating system serves as a demand-side mechanism for balancing the power grid.

13. The method of claim 8, wherein the first heating system is a furnace section thermally connected to the first reactor section, wherein the heat is generated by a combustion reaction.

14. The method of claim 13, wherein the combustion reaction in the furnace section thermally connected to the first reactor section is oxyfuel combustion, the oxyfuel combustion using one or more syngas and oxygen sources to form gaseous products as flue gas of the furnace section.

15. The method of claim 3, wherein heating the agglomerates in the packed bed in the second reactor section comprises one or more of the following: heating from outside the second reactor section; by combustion reaction within the second reactor section; by injecting hot gas into the second reactor section and passing the hot gas through the packed bed of agglomerates; and electromelting.

16. The method of claim 15, wherein heating the agglomerates in the packed bed of the second reactor section from outside the second reactor section is performed by a second heating system adjacent to and arranged along the length of the second reactor section.

17. The method of claim 16, wherein the second heating system comprises an electric heating element.

18. The method of claim 17, wherein the electric heating element is powered by a renewable energy source.

19. The method of claim 17, wherein the electric heating element is powered by the power grid.

20. The method according to any one of claims 16 to 19, wherein the second heating system comprises an electric melting furnace.

21. The method of claim 19, wherein the first heating system serves as a demand-side mechanism for balancing the power grid.

22. The method of claim 16, wherein the second heating system is a furnace section thermally connected to the second reactor section, wherein the heat is generated by a combustion reaction.

23. The method of claim 22, wherein the combustion reaction in the furnace section thermally connected to the second reactor section involves oxyfuel combustion, the oxyfuel combustion using one or more syngas and oxygen sources to form gaseous products as flue gas of the furnace section.

24. The method of claim 15, wherein heating the agglomerates in the packed bed is carried out by a combustion reaction in the second reactor section, the combustion reaction in the second reactor section being achieved by introducing a feed gas into the second reactor section, the feed gas comprising one or any combination thereof: one or more syngas; an oxygen source; and a hydrogen source.

25. The method of claim 24, wherein the feed gas comprises a combination of one or more syngas and oxygen sources, the one or more syngas and oxygen sources being separately introduced into the second reactor section such that, upon mixing, oxygen fuel combustion heats the packed bed of agglomerates and forms a gaseous product as flue gas of the second reactor section.

26. The method according to any one of claims 5 to 7, wherein the exhaust gas from the first furnace section contains CO2, and further comprising capturing CO2 in a carbon capture facility.

27. The method of claim 14 or 22, wherein the flue gas in the furnace section contains CO2, and further comprises capturing CO2 in a carbon capture facility.

28. The method of claim 25, wherein the flue gas in the second reactor section contains CO2, and further comprises capturing CO2 in a carbon capture facility.

29. The method according to any one of claims 14, 22 and 25, wherein the one or more syngases are formed by the gasification of biomass.

30. The method of claim 29, wherein the gasification of the biomass produces CO2, and further comprises capturing the CO2 in a carbon capture facility.

31. The method of claim 30, wherein the CO2 may be captured by a pre-combustion capture process.

32. The method of claim 31, wherein the pre-combustion process is an adsorbent-enhanced water-gas shift (SEWGS) process.

33. The method according to any one of claims 26 to 32, wherein the captured CO2 from the carbon capture facility is used in methanol, alternative aviation fuel and / or hydrocarbon material production facilities.

34. The method according to any one of the preceding claims, the method comprising homogenizing the particulate material and / or fusing the particulate material to produce a particle size distribution in the range of 150 μm to 350 μm, and then introducing the particulate material into the first reactor section.

35. The method according to any one of the preceding claims, the method comprising preheating the particulate material before introducing the particulate material into the first reactor section.

36. The method according to any one of the preceding claims, wherein at a maximum of 200 kN / cm 2 The thermally activated particulate material is compacted under linear pressure to form agglomerates.

37. The method of claim 33, wherein the linear pressure is about 100 kN / cm. 2 .

38. The method of claim 3, wherein the first reactor section and / or the second reactor section operate under positive gauge pressure.

39. The method of claim 3, wherein the method comprises cooling and / or crushing the reacted agglomerates discharged from the second reactor section to allow for processing and / or transport.

40. A system for heat treatment of particulate materials, the system comprising: A vertical first reactor section is configured to receive the particulate material at its top, such that the particulate material flows through the first reactor section under the influence of gravity. A first heating system, which is adjacent to the first reactor section and arranged along the length of the first reactor section, is used to heat the particulate material flowing through the reactor section from outside the reactor section, thereby activating the particulate material; as well as A compactor is used to receive and compact thermally activated particulate material from the first reactor section to form agglomerates.

41. The system of claim 40, further comprising an injection mechanism arranged to inject additional particulate material into the thermally activated particulate material prior to compaction by a compactor.

42. The system of claim 40 or 41, wherein the system includes a vertical second reactor section, the second reactor section being configured as follows: At its top, it receives agglomerates from the compactor, which form a packed bed within the second reactor section; and The agglomerates in the packed bed are heated to induce a target reaction within the agglomerates as they move through the packed bed.

43. The system of claim 42, wherein the reacted agglomerates are discharged from an outlet located at the bottom end of the second reactor section.

44. The system of claim 43, wherein the second reactor section includes a discharge system configured to control the rate of movement of the agglomerates through the packed bed in the second reactor section.

45. The system according to any one of claims 40 to 44, wherein the second reactor section is configured to heat the agglomerates in the packed bed from outside the second reactor section, the heating being performed by one or more of the following: operating a second heating system adjacent to and arranged along the length of the second reactor section; inducing a combustion reaction within the second reactor section; injecting hot gas into the second reactor section and passing the hot gas through the packed bed of agglomerates; and electromelting the agglomerates.

46. ​​The system according to any one of claims 40 to 45, wherein the first heating system comprises one or more electric heating elements.

47. The system according to any one of claims 42 to 46, wherein the second heating system is configured to heat the agglomerates in the packed bed from outside the second reactor section, the heating being carried out by the second heating system being arranged adjacent to and along the length of the second reactor section.

48. The system of claim 47, wherein the second heating system comprises one or more electric heating elements.

49. The system of claim 46 or 48, wherein the system includes renewable power facilities for supplying power to one or more electric heating elements.

50. The system according to any one of claims 40 to 45, wherein the first heating system comprises a furnace section thermally connected to the first reactor section, wherein heat is generated by a combustion reaction.

51. The system of claim 47, wherein the second heating system includes a furnace section thermally connected to the second reactor section, wherein heat is generated by a combustion reaction.

52. The system according to any one of claims 47 to 49, wherein the second heating system comprises an electric melting furnace.

53. The system according to claim 50 or 51, wherein the combustion reaction in the furnace section is the combustion of oxygen fuel using one or more syngas and oxygen sources, the combustion reaction forming gaseous products as flue gas in the furnace section.

54. The system of claim 53, wherein the second reactor section is configured to heat the agglomerates in the packed bed by a combustion reaction within the second reactor section, the combustion reaction being achieved by introducing a feed gas into the second reactor section, the feed gas comprising one or any combination thereof: one or more syngas; an oxygen source; and a hydrogen source.

55. The system of claim 54, wherein the target reaction and / or combustion reaction within the second reactor section produces a gas as flue gas of the second reactor section.

56. The system according to any one of the preceding claims, wherein the first reactor section is configured to discharge exhaust gas from an outlet disposed at the top of the first reactor section.

57. The system of claim 56, further comprising a separator in fluid flow connection with the outlet disposed at the top of the first reactor section to receive the exhaust gas and at least partially separate entrained solid particles.

58. The system of claim 57, wherein the separator is configured to reintroduce the separated solid particles into the first reactor section at the top of the first reactor section.

59. The system of claim 53, wherein the flue gas in the furnace section comprises CO2.

60. The system of claim 55, wherein the flue gas in the second reactor section comprises CO2.

61. The system according to any one of claims 56 to 58, wherein the exhaust gas comprises CO2.

62. The system of claim 49 or 50, wherein the system includes a gasification facility configured to produce one or more syngas from biomass.

63. The system of claim 62, wherein operating the gasification facility generates CO2.

64. The system of claim 63, wherein the gasification facility includes a pre-combustion capture stage to capture CO2.

65. The system of claim 64, wherein the pre-combustion stage is configured as an adsorbent-enhanced water-gas shift (SEWGS) process.

66. The system of claim 59 or 61, wherein the system includes a carbon capture facility for capturing CO2.

67. The system of claim 64 or 66, wherein the CO2 captured from the carbon capture facility is used in methanol, alternative aviation fuel and / or hydrocarbon material production facilities.

68. The system according to any one of claims 40 to 67, wherein the system includes a preheater for preheating the particulate material before it is received by the first reactor section.

69. The system according to any one of claims 40 to 68, wherein the system includes a melting and / or homogenizing facility for melting the particulate material to produce a particle size distribution in the range of 150 μm to 350 μm and / or homogenizing the particulate material, and then introducing the particulate material into the first reactor section.

70. The system of claim 69, wherein the fusion and / or homogenization facility comprises a cylindrical mill.

71. The system of claim 43, wherein the system includes a cooling facility configured to cool the reacted agglomerates discharged from the second reactor section to allow for processing and / or transport.

72. The system of claim 71, wherein the cooling facility comprises a grate cooler.

73. The system of claim 72, wherein the grate cooler is a rotary grate cooler.

74. The system according to any one of claims 71 to 73, wherein the system comprises a pulverizer configured to pulverize reacted agglomerates to form a powder product.

75. The system of claim 73, wherein the rotary grate cooler includes nails, and the rotary grate cooler crushes the reacted agglomerates to form a powder product.

76. The system of claim 40, wherein the first reactor section and the second reactor section are sections of an integral reactor.

77. The system according to any one of claims 40 to 76, wherein the second reactor section is in fluid flow connection with the first reactor section.

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