Chemical process equipment using X-rays

Abstract

A universal chemical process apparatus (UCP) including a reaction vessel having a main chamber with inlets for feed, fluidization medium, and reactants. The UCP further includes a reactive x-ray chemical process apparatus (RXCP) having a large area hollow cylindrical cold cathode in the main chamber, a grid centrally disposed relative to the cathode, and an anode centrally disposed relative to the cathode and grid. In operation, when activated, the cathode of the RXCP emits radiation to the anode, which then radiates x-rays into a radiation zone in the main chamber capable of ionizing the feed and reactants, inducing chemical reactions, and sterilizing and decomposing organic materials in the radiation zone, and a fluidized bed is supported in the main chamber as the fluidized medium and feed are fed. The RXCP and fluidized bed portions can be operated separately or in combination to achieve unexpected results.

Description

[Technical field]

[0001] The present disclosure relates to chemical engineering, and more particularly to methods and apparatus for inducing a wide variety of chemical reactions and processes at lower cost and with reduced or no pollution.

[0002] definition Acid mine waste: Also known as acid mine water, abbreviated as AMW in both cases. This is groundwater that has been contaminated by mine runoff or the acid beneficiation process in mining operations. This fluid is highly contaminated with a wide variety of chemicals and is a significant source of pollution.

[0003] Actinides: Chemical elements that occupy positions 89-103 in the periodic table and are naturally radioactive to various degrees. For the purposes of this document, radium, with atomic number 88, and promethium, which is theoretically a lanthanide but is also a naturally radioactive element with atomic number 61, are included in the actinides. Note that often these elements are found together in various ratios, complicating any subsequent separation processes.

[0004] Beneficiation: A process or set of processes that enhances the properties of mineral or metallurgical resources into products suitable for commercial and industrial purposes.

[0005] Enrichment: A chemical or mechanical process that increases the proportion of an element or compound in a medium by removing other undesirable elements or compounds in the medium.

[0006] Dryer: In the context of this document, the term "dryer" refers to a means of applying thermal energy to a chemical process to remove water or other undesirable liquid components from that chemical. It should be noted that the physical components of a dryer may also have other functions within a given system, so long as proper care is taken for proper operation.

[0007] Dry Chemistry: As used herein, the term "dry chemistry" refers to processes in which plasmas are generated rather than solutions. These produce fewer pollutants and are much easier to remediate. It can also be used to refer to other mineral beneficiation processes such as crushing, grinding, screening, and sorting, but these processes are not carried out in liquid baths and do not generate significant amounts of pollutants by their operations.

[0008] Electromagnetic Fields: For simplicity of explanation, when the term "electromagnetic fields" is used alone in this specification, it can mean either an electric field only (E), a magnetic field only (H), a static electric field only, or a combination of these.

[0009] Extraction: A chemical process or series of processes designed to separate a specific element or compound from the surrounding matrix.

[0010] Feedstock: A starting material input into a system that is intended to be altered (separated, chemically modified, decomposed, sterilized, etc.) by a process performed by the system. Feedstocks may include granular solids, liquids, gases, or plasmas.

[0011] Field Enhancement: In the context of this document, the term "field enhancement" and its derivatives refer to the intensification of some aspects of reactions that take place within certain devices in the presence of intentionally applied electric and magnetic fields.

[0012] Flash X-ray Irradiator: A cylindrical, large area X-ray source capable of producing extremely high radiation levels for the purpose of decomposing, sterilizing, or reacting materials within an internal reaction zone. The Flash X-ray Irradiator is the predecessor technology to RXCP and is described in U.S. Patent No. 8,019,047, entitled "Flash X-ray Irradiator" (hereafter the '047 patent or FXI). The '047 patent is incorporated herein by reference in its entirety for all purposes.

[0013] Flocculation: A chemical process in which a chemical coagulant is added to a bath to promote bonding between particles, creating larger aggregates that are easier to separate. The particles are removed from suspension in the form of flocs or flakes (synonymous technical terms). This process differs from precipitation in that prior to flocculation, the particles are merely suspended in the liquid in a stable dispersion, not completely dissolved in solution.

[0014] Flotation: A chemical process in which a solution containing one or more compounds or elements of interest is mixed with a chemical bath of specific pH and composition, causing the compounds or elements of interest to rise to the surface where they can be removed with a skimmer or similar device. After flotation, the compounds or elements of interest are washed and dried, or in some cases, subjected to additional wet processing to extract the desired compounds or elements.

[0015] Fluidized Bed: A physical phenomenon that occurs when, under the right conditions, a fluid (liquid, gas, or plasma) entrains a quantity of granular solid media (usually present in a holding vessel) to produce a granular solid / fluid mixture that behaves as a fluid, referred to as fluidization of the particulate media. This is usually accomplished by introducing a pressurized fluid, gas, or plasma through the particulate media. This resulting solid / fluid mixture has many of the properties and characteristics of normal fluids, including the ability to flow freely under gravity and to be pumpable using fluid-type techniques. Fluidized beds are used to facilitate chemical reactions and can also be used to separate materials based on density and particle size.

[0016] Fluidized Bed Thickener: A mechanical device that utilizes aspects of fluidized bed technology to achieve physical separation of feedstocks based on particle size, density, or pressure of the fluidizing medium. Also called FB thickener or FB separator.

[0017] Fluidizing medium: A granular solid, liquid, gas, or plasma that is injected into a fluidized bed and causes fluidization of the bed medium.

[0018] Fluorapatite: the ore from which some fertilizers, phosphoric acid, hydrofluoric acid, and phosphogypsum are derived. Its chemical formula is Ca5F(PO4)3. It is usually found in combination with hydroxyapatite [Ca5(PO4)3OH].

[0019] Lanthanides: Chemical elements known as the rare earth elements and occupying positions 57 through 71 in the periodic table, as well as scandium (atomic number 21), and yttrium (atomic number 39).

[0020] Leaching: A chemical process in which the feedstock is mixed with another chemical (usually, but not necessarily, a strong acid, base, bacteria, or salt) to mobilize a desired chemical, which then goes into solution and becomes available for use in subsequent processing steps.

[0021] Ligand: A ligand is an ion or molecule that binds to a central atom to form a coordination complex. The ligands in a complex determine the reactivity of the central atom, including the rate of ligand substitution, the reactivity of the ligand itself, and oxidation-reduction. Ligand selection is an important consideration in most reactions involving ligands.

[0022] Mobilization: A chemical process that liberates elements or compounds of interest from complexes within a mineral resource to allow for further beneficiation.

[0023] Modulation: Continuously adjusting the setting of an analog device, such as an analog valve (i.e. from fully closed to partially closed / open to fully open).

[0024] Phosphogypsum: A by-product of the purification of fluoroapatite in the manufacture of fertilizers, phosphoric acid, and hydrofluoric acid. Chemically, it is a hydrate of calcium sulfate (CaSO4·2H2O). The material also contains recoverable amounts of rare earth elements (lanthanides) and some radioactive elements (actinides).

[0025] Phosphoric Acid: The chemical H3PO4 is used in the production of some fertilizers and in many chemical reactions, as well as in the production of some foods, cosmetics, and toothpaste.

[0026] Plasma: Plasma is the fourth state of matter (besides solid, liquid, and gas). It is characterized by the removal of one or more electrons and exhibits properties of both liquids and gases. Plasma can be generated by a variety of means, including but not limited to DC excitation, RF (and microwave) excitation, and excitation by X-rays, gamma rays, and high energy secondary electrons. The present invention is primarily concerned with the use of X-rays as a means of ionization. X-rays are particularly useful because of their extremely high energy, allowing a single photon to be used multiple times in a particular reaction, including the generation of high energy secondary electrons, which themselves can also help stimulate a reaction if their energy is high enough. It is also the simplest means to achieve total ionization, a necessary condition for many reactions contemplated by the present invention.

[0027] Precipitation: A chemical process in which a solution containing one or more compounds or elements of interest is mixed with a chemical bath of a specific pH and composition in a vessel, causing the compounds or elements of interest to sink to the bottom of the vessel from where they can be removed by any of several well-known means.

[0028] Rare earth elements: A group of elements (atomic numbers 57-71) that includes the lanthanides, scandium, with atomic number 21, and yttrium, with atomic number 39.

[0029] Reactive X-ray Chemical Process Apparatus: A type of chemical process apparatus designed to enhance reaction conditions by using X-ray radiation to ionize species present and promote reactions in a plasma environment. This process apparatus is disclosed in U.S. Patent No. 9,406,478, entitled "Method and Apparatus for Inducing Chemical Reactions by X-ray Irradiation" (hereinafter the '478 patent and / or RXCP). The '478 patent is incorporated herein by reference in its entirety for all purposes.

[0030] Screening: The mechanical separation of granular material into size classes using screens. A screen is a surface with a uniform, closely spaced pattern of holes that allow particles smaller than the hole size to pass through. Screening can be performed using gravity, vibration, density, or electrostatic techniques.

[0031] Separation: A chemical or mechanical process, or set of processes, designed to separate chemically similar compounds.

[0032] Sedimentation (sedimentation): A process similar to precipitation in which a compound or element of interest sinks (usually by gravity) from a mixture in a container over time, without the use of additional chemicals. The compound or element of interest can then be collected from the container by known means.

[0033] Sieving: A subset of screening, a laboratory procedure in which precision screens are used to separate materials based on particle size. The American Society for the Testing of Materials (ASTM) defines screen sizes. These are usually expressed in "mesh", i.e., 200 mesh, 50 mesh, etc.

[0034] Stacks: Phosphogypsum is usually stored outdoors in very large piles called "stacks," which often cover tens of acres and can be hundreds of feet high.

[0035] Tailings: Material left over from the beneficiation process in mining operations.

[0036] Thickening: As the name suggests, thickening is the process of increasing the viscosity of a solution, liquid, slurry, etc. Some chemical processes work well with low viscosities while others require high viscosities. Thickening provides a reliable method of controlling the viscosity of a substance at various stages of processing.

[0037] Wet Chemistry: As used herein, the term "wet chemistry" refers to chemical processes carried out in liquid media and conditions. When used to treat mineral ores, tailings, wastes, and by-products, it generally refers to processes that utilize large quantities of strong acids, strong bases, amines, and biologicals. Wet processes are generally highly polluting and expensive to remediate. [Background technology]

[0038] Many industrial applications require reacting different chemicals and sometimes separating them based on chemistry, particle size or density. These processes are traditionally carried out using wet chemistry and often involve toxic and polluting chemicals, generating contaminated waste streams and by-products in addition to the desired end product.

[0039] For example, in the mining industry, to extract useful mineral resources from ores, mining operations use a variety of beneficiation processes to chemically and mechanically separate desired minerals and elements from other minerals and elements present in the ore. These processes include, but are not limited to, leaching, stripping, precipitation, settling, flotation, sedimentation, flocculation, thickening, mobilization, screening, and thickening. These processes are often referred to as "wet" processes.

[0040] These processes are often based on large-scale liquid chemical operations (such as large liquid baths, tanks, or ponds) that use strong acids (such as sulfuric acid, nitric acid, hydrochloric acid, hydrofluoric acid), strong alkalis (such as caustic soda (NaOH), quicklime (CaO), ammonia (NH3), soda ash (Na2CO3), limestone (CaCO3)), concentrated salts (such as potassium chloride), various amines, and other toxic and highly polluting chemicals. While these chemicals can efficiently produce the desired chemical reactions, the liquids become highly polluted during the beneficiation process and are very difficult to dispose of in an environmentally responsible manner.

[0041] Certain processing activities, such as rare earth processing, are no longer conducted or are rarely conducted in the United States due to environmental issues associated with wet chemical processes. Despite the critical importance of rare earth minerals to high-tech manufacturing, the United States largely abandoned its global dominance in mining and rare earth processing in the 1980s, as it proved too difficult and expensive to beneficiate rare earth-containing material while complying with environmental regulations. China, which has many rare earth mineral deposits and fewer environmental regulations, has since become the largest processor of rare earth elements. Globally, many companies with significant rare earth resources send their mined ore to China or one or two other countries for processing in order to avoid processing the material domestically and dealing with the toxic by-products of that activity.

[0042] The recognition that the United States needs to return to a position of self-sufficiency in this market is only recent. However, the state of the art in rare earth beneficiation remains wet chemical processes with the same environmental problems. Thus, there is a great need for improved process technology, especially for rare earth minerals. Summary of the Invention

[0043] In a first aspect, the disclosure provides a universal chemical process apparatus (UCP) comprising a reaction vessel having a longitudinal central axis and a main chamber. The UCP comprises a first inlet port for a main feedstock leading to the main chamber, a second inlet port for a fluidized medium leading to the main chamber, a third inlet port for one or more reactants leading to the main reactor chamber, and a reactive x-ray chemical process apparatus (RXCP). The RXCP includes a hollow-cooled cathode extending along a longitudinal axis within the main chamber, a grid concentrically and more centrally disposed relative to the cathode within the main chamber, and an anode concentrically and more centrally disposed relative to both the cathode and the grid. In operation, a fluidized bed can be supported within the main chamber when the fluidized medium and feedstock are fed to the main chamber via the first and second inlet ports. When powered on, the RXCP's cathode is bombarded with electrons which fire towards the anode and emit X-rays into a radiation zone in the vessel's main central chamber; the X-rays ionize the feedstocks and reactants, inducing chemical reactions and enabling the sterilization and decomposition of organic material in the radiation zone; the processes can be used individually or in various combinations.

[0044] In another aspect, the present disclosure provides a method of chemical processing including configuring a reaction vessel for receiving a feedstock, a fluidization medium, and a reactant, and disposing a reactive X-ray chemical process apparatus (RXCP) within the vessel operative to support a fluidized bed and to emit X-rays into a radiation zone within the vessel.

[0045] The fluidized bed can be used for both typical fluidized bed reaction chemical processing and separation processes. The fluidized bed can be used separately or in combination with the RXCP, and the RXCP can be used separately or in combination with the fluidized bed.

[0046] Numerous additional inventive aspects of the present disclosure are described in the detailed description that follows. [Brief description of the drawings]

[0047] [Figure 1]FIG. 1 is a cross-sectional view of an embodiment of a universal chemical process apparatus (UCP) according to the present disclosure. [Diagram 2] FIG. 1 is a simplified schematic cross-sectional view of a UCP according to an embodiment of the present disclosure, showing an exemplary electrode configuration for an x-ray-free plasma-enhanced fluidized bed. [Diagram 3] FIG. 1 is a simplified schematic cross-sectional view of a UCP plan according to an embodiment of the present disclosure, showing an exemplary reactant injector modified for use as a feed injector for fluidized bed operation. [Figure 4] FIG. 1 is a simplified schematic cross-sectional view of a UCP according to an embodiment of the present disclosure, illustrating an exemplary arrangement of a catalyst within the UCP. [Diagram 5] FIG. 1 is a schematic diagram illustrating an embodiment of a system including a UCP and a control system according to the present disclosure. [Figure 6] 1 is a cross-sectional view of a UCP according to an embodiment of the present disclosure, in which a plasma generated within the UCP is contained using electrostatic field enhancement. [Figure 7] 1 is a cross-sectional view of a UCP according to an embodiment of the present disclosure, in which a plasma generated within the UCP is contained using electromagnetic field enhancement. [Figure 8] FIG. 1 is a schematic cross-sectional view showing the first stage of a separation process according to the present disclosure using fluidized bed operation of the UCP. [Figure 9] FIG. 1 is a schematic cross-sectional view showing a second stage of a separation process according to the present disclosure using fluidized bed operation of the UCP. [Figure 10] FIG. 1 is a schematic cross-sectional view showing a third stage of a separation process according to the present disclosure using fluidized bed operation of the UCP. [Figure 11] FIG. 1 is a schematic cross-sectional view of a UCP according to an embodiment of the present disclosure having a heating / electrode element. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] As previously mentioned, current mining practice involves the use of "wet" processes such as leaching, flotation, precipitation, flocculation, and settling. These processes typically require large quantities of strong acids (typically sulfuric acid (H2SO4), nitric acid (HNO3), hydrochloric acid (HCl), hydrofluoric acid (HF), etc.), strong alkalis (caustic soda (NaOH), quicklime (CaO), ammonia (NH3), soda ash (Na2CO3), limestone (CaCO3), etc.), bacteria, or other salt solutions. At the end of these processes, large quantities of these chemicals remain contaminated with a wide variety of toxic chemicals, posing a significant pollution threat. Remediating this waste is costly and increases the overall cost of the resulting product. Additionally, beneficiation operations often produce large quantities of contaminated process water that cannot be released without significant treatment. In essence, separation and related processes carried out in mining are responsible for a significant portion of the toxic waste generated in the mining industry, and replacing them with non-polluting alternatives would be a much-needed solution.

[0049] The present disclosure provides a method and apparatus for chemical processing. In a preferred embodiment, the apparatus for chemical processing, referred to as a Universal Chemical Processor (UCP), includes a fluidized bed reactor integrated into a Reactive X-ray Chemical Processor (RXCP). The RXCP can operate as a Flash X-ray Exposure Instrument (FXI) in some operational configurations. The UCP can include additional components for drying and electromagnetic field enhancement. Electromagnetic field enhancement includes using electric, electrostatic and magnetic fields to drive chemical reactions within the UCP through a wide variety of operating modes. Thus, the UCP combines aspects of both the fluidized bed, the X-ray exposure, and other techniques to achieve greater results and allows for plasma-based processing schemes that were not previously available. Besides being able to operate as a reactive chemical process apparatus, the fluidized bed can also perform separations on a purely mechanical basis by changing the operational control parameters. Individually, each component is capable of a certain range of operations. When combined, in addition to the individual operations, the method and apparatus of the present disclosure can unexpectedly reduce process steps and physical factory equipment as a direct result of combining multiple individual stages and operations, as described below. This disclosure provides several exemplary processes that can be implemented with the UCP, all of which constitute direct enhancements over conventional approaches due to the unique structure of the UCP.

[0050] FIG. 1 is a cross-sectional view of an embodiment of a UCP according to the present disclosure. The UCP 100 comprises a generally cylindrical or columnar vessel 105, in this case with a vertical longitudinal central axis. The UCP can be oriented in a variety of orientations and can have a horizontal or inclined longitudinal axis, but in most cases of fluidized bed operation, a vertical orientation is preferred. The lower portion, or bottom 108, of the vessel 105 shown in FIG. 1 is provided with a number of inlet ports that can be welded, molded, or attached to the vessel 105 as is known in the art. In the illustrated embodiment, a feedstock inlet port 110 is coupled to the bottom 108 of the vessel and provides a conduit through which the feedstock is pumped into the vessel. The feedstock is typically larger in diameter than the other input materials, so the diameter of the feedstock inlet port 110 is correspondingly sized to accommodate the feedstock product. The feedstock includes granular solids, liquids, gases, or plasma materials that are intended to be processed in some way within the vessel. For example, the feedstock may be introduced into the vessel to undergo one or more chemical reactions to separate components of the feedstock fluid for reactive chemical processes, catalytic cracking, combustion, heat or mass transfer, product separation, or interface modification (e.g., application of a coating to a solid article). In one advantageous embodiment, the feedstock is phosphogypsum from a waste storage stack, which is a by-product of fertilizer production and may contain a number of contaminants, such as rare earth elements and radioactive elements. The feedstock may be delivered to the feedstock inlet port 110 continuously or in batches (referred to as batch mode), and the contaminants may be separated and further processed or used as is. The feedstock may also be supplied using other ports, such as reactant injector ports.

[0051] Adjacent to the feedstock inlet port at the bottom 108 is a fluidizing medium inlet port 112. The fluidizing medium is delivered into the vessel 105 through the fluidizing medium inlet port 112, typically at a pressure higher than atmospheric pressure. The fluidizing medium is introduced under pressure into the bottom of the reactor. The fluidizing medium can include a homogeneous gas, such as compressed air, or a homogeneous liquid, such as water. Alternatively, the fluidizing medium can include a mixture of gases, plasmas, or liquids. A wide range of liquids and gases can be used, depending on the process of interest. As an example, nitrogen or argon can be used as the fluidizing medium instead of compressed air, where the material being processed (e.g., separated) may be adversely affected by the presence of oxygen. Various plasmas can also be used, which have the effect of causing additional reactions. The choice of fluidizing medium depends on the desired end product. Preferably, the fluidizing medium port and the injector are shielded from X-ray radiation. Shielding can be accomplished by forming the inlet port using concentric pipes layered with a packing material composed at least in part of a material resistant to X-ray radiation, such as lead. An isolation valve (not shown in FIG. 1 for clarity) may be coupled to the fluidizing medium inlet port 112 to open or close or regulate the flow of the fluidizing medium when not needed.

[0052] In addition to the feedstock and fluidization medium, additional reactants for facilitating one or more chemical reactions, heat transfer, catalysis, etc., can be introduced into the vessel through one or more reactant inlet ports 114 located at the bottom 108. As with the fluidization medium ports, the reactant inlet ports 114 are preferably shielded against X-ray radiation. In one embodiment, the reactant inlet ports are surrounded by a shield 117, which may be formed of concentric pipes with filler between the concentric pipes constructed at least in part of a material that is resistant to X-ray radiation, such as lead. The outer pipe should be made of a material that does not react with other materials present in the reaction zone, such as 316 steel or titanium. In the illustrated embodiment, unlike the feedstock and fluidization medium inlet ports 110, 112, the reactant inlet ports do not deliver reactants to the bottom of the vessel, but rather lead to a reactant injector 125 with multiple outlet nozzles (e.g., 127) located at various heights in the vessel. The shield 117 allows the reactants to be introduced without being ionized until they enter the reaction chamber 135, where they are introduced uniformly into the reaction zone. In some embodiments (not shown), the feedstock inlet port 112 is configured similarly to the reactant inlet port to allow materials to be introduced into the center of the chamber 135, preferably with fewer nozzles, each nozzle having a larger diameter than the reactant inlet nozzle.

[0053] FIG. 2 is a schematic cross-sectional view of an embodiment of a UCP, showing an insulated reactant inlet injector 205, which can be coupled to the housing of the UCP by an insulated feedthrough 208, which can be made of a ceramic material. The injector 205 is a shielded conduit that extends vertically within the main chamber 215 of the UCP. Reactants transported through the reactant injector are discharged into the reaction zone in the main chamber through multiple nozzles (e.g., 212, 214, 216). FIG. 3 is a schematic cross-sectional view of an embodiment including a shielded injector 305 adapted for feedstock delivery, also extending vertically within the main chamber 315 of the UCP. In contrast to the embodiment shown in FIG. 2, materials transported through the shielded injector 305 are discharged into the reaction zone in the main chamber of the UCP through a single large nozzle 320.

[0054] In some embodiments, the UCP includes an electrode in the main chamber 135 adapted to generate a plasma or electromagnetic field in the main chamber or to maintain a plasma injected into the vessel. The plasma can be used to induce chemical reactions in fluidized beds and other effects and applications of plasma. In FIG. 2, a rod-shaped electrode 220 is shown extending through the reaction zone in the main chamber 135. The electrode is connected to a power source (not shown) through an insulating feedthrough 225, which may also be made from a ceramic material. The power source may be AC, DC, or RF, depending on the particular type of plasma, electromagnetic field, and bias desired. The voltage of the electrode may range from 2-20 volts up to several kilovolts, depending on various factors such as the density of the plasma, the composition and density of the feedstock and reactants in the reaction zone, and the pressure of the plasma. To successfully implement plasma or field enhancement, it is important to pay attention to the voltage rating of the insulators, as well as the geometry of the electrode structure and its spacing from other grounded objects such as walls or catalysts.

[0055] It is desirable to keep the plasma from touching the walls of the UCP reaction zone, which is referred to as "containment." This can be accomplished using either electrostatic or electromagnetic means. In a preferred electrostatic embodiment, the plasma can be generated without the use of X-rays by an internal electrostatic field using an electrode similar to electrode 220 shown in FIG. 2, as shown in FIG. 6 (discussed below). In another embodiment, an external electromagnetic coil can be used to generate a magnetic field in the RXCP reaction zone region, as shown in FIG. 7 (discussed below). There are numerous configurations of both electrostatic and electromagnetic fields that will provide the desired separation of the plasma from the chamber walls. These will be apparent to those skilled in the art.

[0056] Returning to FIG. 1, ports 118, 180 at the inlet and outlet ends of the UCP are connected to a mass spectrometer. This allows for real-time analysis of the source material both before and after processing by the UCP. The fluidization medium and the source material fed into the vessel are mixed and flowed through a diffuser plate 120 located above but near the bottom of the vessel. The diffuser plate 120 can be made from a variety of radiation-resistant materials, so long as they have the appropriate porosity. Alternatively, the diffuser plate can have a uniform pattern of holes to achieve the same effect. The diffuser plate 120 has the effect of dispersing and enhancing the uniformity of the fluidization medium as it enters the vessel's main chamber 135 (referred to as the "separation zone" if a fluidized bed is operating to separate the source material) where separation and / or other processes take place. A recirculation pipe 138 receives the fluidization medium from the top of the chamber, runs it through a recirculation pump, and reapplies it to the bottom of the chamber through a recirculation loop (not shown in FIG. 1) to mix it with the incoming fluidization medium.

[0057] In some embodiments, the catalyst may be located above the diffuser plate. More generally, however, the catalyst may be located in various locations within the reaction zone, with different locations resulting in different chemical outcomes. For example, as shown in FIG. 4, it may be desirable to have the catalyst at the beginning of the reaction zone, but the catalyst may also be located in the middle, near the top of the reaction zone, or all the way outside the reaction zone. The location will vary depending on the degree of catalysis desired. The catalyst can take a variety of forms, but for clarity, is shown in FIG. 4 implemented as one or more screens. In this exemplary embodiment, two catalyst screens 404, 408 are located above the diffuser plate 410 and below the lower limit of the reaction zone 414 in the main chamber of the UCP (the reaction zone is described with reference to the RXCP section of the UCP below). Note that while two screens 404, 408 are depicted, there may be a single screen, or multiple similar screens. Screen implementation is one common way to introduce catalyst to the reaction generated in the UCP. Other forms of catalyst introduction include plates, trays, meshes, as well as various types of porous containers. In some embodiments, the diffuser plate 410 can be used to carry the catalyst. Other forms of catalyst introduction will be apparent to those skilled in the art.

[0058] In some embodiments, a particular category of catalysts known as electrocatalysts can be used in the beneficiation process. Electrocatalysts function on the electrode surface, but most commonly can be incorporated into the electrode surface itself. Electrocatalysts can be heterogeneous, such as platinized electrodes. This is accomplished by attaching the catalyst to an electrically insulating structure (not shown) and providing an electrically insulating electrical feedthrough that allows a voltage or signal to bias the catalyst, thus creating an electrocatalyst. Soluble homogeneous electrocatalysts help transfer electrons between the electrodes and reactants and / or facilitate intermediate chemical transformations described by overall half-reactions. Homogeneous electrocatalysts can be used for certain types of reactions, but are not suitable for all reactions, as they may be physically unstable and soluble. Electrocatalysis can be stimulated by either a direct electrical connection or by interaction with an electric field within the reaction vessel.

[0059] The source material is entrained in the fluidizing medium in the main chamber 135, and the resulting combination of granular solids and fluids (including gases and plasmas) behaves as a fluid (i.e., fluidizes) under certain controlled conditions. Fluidization occurs when various factors and parameters, such as vessel dimensions, pressure drop across the bed, average particle density, feed and reactant flow rates, and other factors (discussed below), are sized to cause the mixture of feed and fluid to behave as a fluid. In the illustrated embodiment, this is accomplished by introducing a pressurized fluidizing medium through a particle medium at the bottom of a vessel of suitable diameter. The granular solids / fluids combined medium, referred to as a fluidized bed, is in suspension and has many of the properties of a normal fluid, such as the ability to flow freely under gravity or be pumpable using fluid-type techniques. This feature of the fluidized bed allows for horizontal operation. The recirculation pipe 138 receives pressurized fluidizing medium at the top of the chamber, applies pressure to the fluidizing medium via pump 161 medium, and re-applies pressure to the fluidizing medium at the bottom of the chamber at re-inlet port 163, mixing it with the incoming fluidizing medium. As mentioned above, the additional fluidizing medium entering from inlet port 112 can be shut off via a shutoff valve (not shown in FIG. 1) if necessary. However, additional fluidizing medium is typically required to offset volume losses in the FB concentrator as product is removed and to keep the pressure constant.

[0060] In chamber 135, the upper surface of the bed is relatively horizontal, but may be wave-like in nature, which resembles hydrostatic behavior. The bed may be considered to be a heterogeneous mixture of fluid and granular solids that can be represented by a single bulk density. In a fluidized bed, larger and denser particles tend to move downwards in the bed, while smaller and lighter denser particles tend to move upwards, demonstrating fluid behavior according to Archimedes' principle. By varying the proportion of fluid, the density of the bed (or more precisely, the solids volume fraction of the suspension) can be altered, thereby allowing objects with different densities compared to the average density of the bed to sink or float. The upward force of the fluidizing medium contributes significantly to the upward movement of the particles.

[0061] In a fluidized bed, the contact between the solid particles and the fluidizing medium is greatly enhanced compared to a packed bed. This behavior in a fluidized combustion bed allows for a high degree of heat transport inside the system and between the particles and the fluidizing medium. The enhanced heat transfer allows for thermal uniformity similar to that of a well-mixed gas, allowing the fluidized bed to have a large heat capacity while maintaining a uniform temperature field. As mentioned above, in a fluidized bed, the denser material tends to sink to the bottom of the FB. Note that very small dense particles can migrate to the top of the FB. This necessitates further separation efforts. This is due to a simple gravity-induced process. For example, when air is used as the fluidizing medium, the upward flow through the bed of material will cause the material in the bed to essentially float on the fluidizing medium. When the material floats, it means that there is enough pressure to fluidize the entire column, pushing the lighter material to the top of the column and the denser portion of the material to stay or move to a lower position in the column.

[0062] The fluidization condition can be expressed by the following equation (1), where the product of the apparent pressure drop and the cross-sectional area of ​​the bed is equal to the force of the weight of the granular solid particles (minus the buoyancy of the granular solid in the fluid).

number

[0063] Additionally, the introduction of the fluidizing medium into the main chamber 135 has the effect of generating bubbles that form as a result of physical interaction with the particles of the source material and pressure differentials. In physically small beds, the bubbles that form are small and sometimes microscopic. In large industrial beds that can be as large as 10 to 15 feet in diameter, the bubbles can become quite large. The bubbles increase the mixing of the chemicals in the fluidized bed. A means for releasing pressure (e.g., a relief valve) 138 is provided at the top of the vessel to ensure that a constant differential pressure environment is maintained within the bed. Pressure release is preferably accomplished by recirculation piping means, especially if the fluidizing medium is reused. When a particular air bubble or air molecule reaches the upper region of the bed, the velocity of the air suddenly decreases by nearly a factor of 10 due to the increase in the diameter of the bed. This means that the lighter (less dense) particles will recirculate back into the turbulent region, eventually reaching a stable bed height based on particle size, density, and pressure of the fluidizing medium. It should be noted that fluidized beds can be operated at atmospheric pressure, positive pressure, or partial vacuum.

[0064] Fluidized beds can be used to separate mixtures of different materials, and as mentioned above, the fluidizing medium can be a gas, liquid, granular solid, or a mixture of gases. The particular materials and fluidizing means are appropriately selected depending on the particular task. If batch processing is intended, the fluidized bed process can achieve high levels of separation by running the process for extended periods of time. However, if a continuous process is desired, as is typically found in industrial scale applications, the fluidized bed can be modified to include a means for continuously introducing the materials to be processed and a means for removing separated materials of different densities. Multiple stages, including multiple fluidized beds in separate vessels, may be required to achieve the desired degree of processing and / or separation.

[0065] The separation process performed by the fluidized bed is intended to replace the flotation, sedimentation, partial precipitation, and sedimentation processes typically found in industrial, mining, and laboratory chemical processes. The most important advantage is that separation occurs without the use of large amounts of toxic and environmentally harmful chemicals. Separation proceeds due to the properties of the fluidized bed, thoroughly mixing the component feed materials and effectively separating the materials by density over a period of time. The lower output 124 and upper output 128 can be connected to a mass spectrometer or other analytical equipment, allowing on-line analysis of the separated streams to be performed while the FB concentrator is in operation.

[0066] 8-10 show an exemplary sequence of steps in a separation process according to the present disclosure using the FB concentrator function of a UCP. In FIG. 8, a feedstock containing primarily first and second components (components A and B) of different densities enters the main chamber 835 (separation zone) of the UCP through a feedstock inlet 810, and a fluidized bed is maintained by supplying a fluidizing medium through a fluidizing medium inlet 812. In the illustrated example, component A is denser than component B. As shown in FIG. 8, when the feedstock material enters the main chamber 835, it initially spreads in a generally random manner within the volume of the chamber.

[0067] By the second stage shown in Figure 9, the feed material has spread throughout the volume of the fluidized bed and begins to separate into a first partially separated mixture 820 located toward the bottom of the main chamber where the higher density component (A) is more concentrated relative to the feed, and a second region 825 located toward the top of the main chamber where the lower density component (B) is more concentrated relative to the feed. In the second stage shown in Figure 9, the separation process is in an early or intermediate stage. A concentration gradient is beginning to form, but the components are not completely separated.

[0068] In the third stage shown in FIG. 10, components A and B have more completely separated, with regions 820 and 825 containing substantially one component or the other (i.e., there is very little component A in region 925 and very little component B in region 920). At this point, the lower and upper outlet ports 140 and 142 are opened to allow for the separation outputs. Fluid enriched in component A exits the vessel through lower output 840, and fluid enriched in component B exits the vessel through upper output 842. As noted above, the output streams of outlet ports 840, 842, while significantly concentrated compared to the input feed, may not be concentrated enough for the desired purpose, and the output may be input to a further UCP, fluidized bed concentrator, or processing device for further separation or otherwise processing of the components. Additionally, as noted above, the fluidizing medium is recirculated via recirculation pipe 838 and pump 846 to maintain the volume and pressure of the fluidizing medium in the fluidized bed.

[0069] In one embodiment, the UCP may be used to remove actinides from mineral source materials. The UCP may be operated (in one or more stages) in a fluidized bed mode for the relative separation of actinides from sources such as uranium, radium, thorium, etc. This concentrated output material may be dried using a microwave oven or other drying device. The lighter material discharged from the fluidized bed may be fed to a UCP operated in RXCP mode, where the material undergoes a chemical reaction in the presence of ammonia (NH3). This step replaces the conventional wet leaching in the presence of manganese oxide (MnO2). The reaction products in the RXCP mode are output to a further fluidized bed stage, where the products are again separated according to density. The dense output from the second fluidized bed stage is typically enriched in residual actinides such as radium. This additional output may be dried for conventional non-contaminating removal.

[0070] The fluidized bed separation process can be enhanced by the use of screening, both before and after the fluidized bed operation. Screening involves the mechanical separation of particulate material into size classes using screens. Screening can reduce the number of fluidized bed stages, further improving cost, footprint, safety, and throughput.

[0071] One important application is that fluidized beds can be used in the beneficiation of lanthanides and actinides as a means of separating materials based on their density. Because basic fluidized bed separations do not involve chemical reactions, fluidized beds can be implemented in a simpler manner than those typically found in the chemical industry, for example, the fluidized beds used in the production of polyethylene.

[0072] Historically, fluidized beds have been operated using granular solids, liquids, and gases. It has occurred to the inventors that it is possible to operate a fluidized bed by using a plasma as the fluidizing medium in the bed, or even by having a plasma with another fluidizing medium present in the bed. There are also examples of other plasma processes where the plasma is flowed into the chamber at a rate to achieve a desired end result. One example is the plasma wind tunnel, which is used to simulate the re-entry of a satellite into the atmosphere and the plasma conditions it would experience in that situation, to verify whether the satellite would burn up upon re-entry. The present invention allows the plasma, which behaves in many ways as a gas, to be introduced into the chamber through a suitable inlet port 114, and takes care not to ground the charge of the plasma by providing insulating means to isolate the plasma from the ground. Once inside the reactor, the plasma behaves like a gas, but also like an RXCP mode. This effect significantly increases the reaction rate and reduces the residence time in the reactor.

[0073] It may be desirable to include an insulated electrode to which a bias voltage can be applied to maintain a plasma or electromagnetic field in the fluidized bed in the absence of x-rays. This can be accomplished by placing a separate electrode in the reaction zone 170, or by using the outer shell of the reactant injector as the electrode and providing insulating means where the reactant injector enters the reactor to isolate it and keep it above ground potential. Various electrode configurations are shown in Figure 5.

[0074] Returning again to FIG. 1, once the feed material is separated by density, the light components are removed through an upper output port 140 (or multiple such ports) located at or near the top of the main chamber 135, and the heavy components are removed through a lower output port 142 (or multiple such ports) located towards the bottom of the main chamber above the diffuser plate 120. The height of the ports, the particle size and the density determine the density of the material removed. The separated material is pushed out of the fluidized bed through the output ports 140, 142 by the internal pressure within the bed. The output ports 140, 142 are connected to subsequent parts of the process which can vary widely depending on the material being processed. Additionally, a main output port 145 is located at the top of the reactor for non-FB processes such as chemical manufacturing.

[0075] The fluidized bed of the present disclosure is intended to replace the flotation, sedimentation, partial precipitation, and sedimentation processes typically found in industrial, mining, and laboratory chemical processes. The most significant advantage is that separation occurs without the use of large amounts of toxic and environmentally harmful chemicals. Separation proceeds due to the properties of the fluidized bed, which thoroughly mixes the component feed materials and then effectively separates the materials by density over time.

[0076] It should be noted that the UCP can operate alone as a fluidized bed or in combination with a Reactive X-ray Chemical Processor (RXCP) plasma generation process, field enhancement and drying. The fluidized bed, plasma generation and field enhancement can be used simultaneously or sequentially within the UCP vessel in various combinations, in the same unit in a batch processing environment or in separate units in a continuous processing environment.

[0077] In FIG. 1, the central portion of the UCP includes elements of a reactive X-ray chemical process apparatus (RXCP) that can fully or partially ionize (to any desired state) chemical reactants introduced into the vessel. A stand-alone reactive X-ray chemical process apparatus (RXCP) is disclosed in commonly owned and assigned U.S. Patent No. 9,406,478, entitled "Method and Apparatus for Inducing Chemical Reactions by X-ray Irradiation." These capabilities are further enhanced by the addition of sources of both electromagnetic and electrostatic fields, which provide the ability to conduct reactions under the influence of these fields, enhancing certain reactions. Additionally, the UCP can include a dryer to remove water or other undesirable liquid inclusions from the input or reaction products.

[0078] The basic process of the RXCP section begins with full or partial ionization of all or a portion of the feed reactants input through the feed inlet 110 and all other reactants input through one or more radiation shielded reactant injectors 114, 116. This turns the feed and reactants into a plasma. This is followed by recombination of the resulting mixture of atomic species into their lowest energy state. The ionized feed and reactants in the reactor become a plasma. The resulting mixture of atomic species produces the output flow. The RXCP section uses a cylindrical cold field emission hollow cathode 150, hollow grid 155, and hollow anode 160 transmission type X-ray source in combination with a reactant measurement, control, and injection system (not shown in FIG. 1) located in the central region of the device. The cold field emission cathode 150 and grid 155 together constitute the electron gun. The construction of a transmission X-ray tube begins with a hollow cathode 150, which contains a coaxially oriented hollow grid 155, which contains a coaxially oriented hollow anode 160, all aligned with their central axes. The electron gun of the RXCP has a theoretical maximum current density of approximately 80,000 Amperes / cm in pulsed mode. 2 can be achieved, which ultimately allows for high levels of exposure due to the high fluence generated by the large number of electrons used to generate the x-ray beam. In practical applications, the cathode 150 is not loaded to the theoretical maximum, but rather at a value less than that. For example, the RXCP section of a UCP can achieve high x-ray photon energies, typically between 0.025 and 5 MeV, and high beam currents, typically in the range of kiloamperes to several megaamperes. The RXCP section can operate at lower current levels depending on the fluence requirements of the particular reaction.

[0079] During operation, the cathode 150 is charged using a power supply (not shown in FIG. 1) that meets the requirements for voltage, current, and, if used in pulsed mode, rise time and pulse repetition rate. A bias resistor (also not shown) is connected between the cathode 150 and the grid 155 and is used to generate a voltage on the grid 155, which normally puts the tube in a stand-off state (non-conducting state). When a control signal of ground potential is applied to the grid 155, the grid releases control of the cathode 160, which discharges. Electrons then travel from the cathode 150 to the anode 160. When they impinge on the anode 160, x-rays and secondary electrons are generated. The x-rays and secondary electrons are isotropically emitted from the x-ray emitting (inner) surface of the anode 160. Due to the relatively thin walls of the hollow anode 160, a significant portion (approximately 50%) of the generated x-rays and secondary electrons propagate to the central region of the hollow anode. The penetration depth of the incident electrons is controlled by the balance between the cathode voltage and the thickness of the anode 160. The anode 160 typically has thin-walled sections in areas of the irradiation volume to provide some control over the desired trans-irradiation. The thickness of the anode wall section is a function of the diameter of the interior space, the cathode voltage, and the atomic number (Z) of the anode. Secondary electrons emitted from the anode play a key role because they dramatically increase the number of potential reactions. Each released secondary electron can in turn strike an atom in the anode, causing further x-ray emission and the emission of additional secondary electrons. This cascading effect of secondary electrons helps ensure that a realistic energy balance can be achieved. The cathode voltage is supplied through a cathode electrically insulating vacuum feedthrough 162, and the grid voltage is supplied through a grid electrically insulating vacuum feedthrough 164. Both feedthroughs 162 and 164 are electrically insulated and sealed with high vacuum, and penetrate the biological radiation shield 165 and the vessel housing.

[0080] Instead of the cold cathode field emission X-ray source, other radiation sources can be used. An alternative is to use multiple conventional X-ray sources. It is also possible to use a nuclear radioisotope source with a suitable hollow cylindrical shape, suitable gamma ray output, and half-life. The entire UCP device is surrounded by a radiation shield 365 with a thickness proportional to the X-ray (or gamma ray) energy generated.

[0081] The X-rays produced by the RXCP section enter the central part of the main chamber 135, called the radiation zone 170, spatially bounded by a lower limit 185 and an upper limit 187 in the vessel. Within the radiation zone, the preset compounds and atoms are partially or fully ionized into constituent molecules into ions of the atomic species present, by the mixing of the X-ray photons with the secondary electrons formed by the gun, and other collision interactions within the reaction zone. Simultaneously and synchronously with this, secondary, tertiary, and additional reactants can be injected into the reaction space and fully ionized simultaneously or sequentially. There is deliberately large turbulence in the radiation zone, ensuring that every ion, electron, atom, and molecule is thoroughly mixed and interacted with. It is possible, and often necessary, to include a catalyst in the radiation zone to enhance certain properties of the reaction. In most cases, this will be the compound with the lowest energy state, unless special measures are taken to change this. The natural tendency of the system is to produce compounds with the lowest energy state. By adjusting various parameters, it is possible to determine exactly what molecules will emerge once recombination has occurred (by stopping the X-ray flux). Several adjustable parameters are used to control the type of reaction and the rate at which chemical reactions occur, including: 1) the x-ray voltage; the x-ray current; the x-ray pulse duration (either in pulsed or continuous mode); the ratio of the first and second (and subsequent, if any) reactants; the flow rate of the reactants through the reactor, as well as the particular chemicals selected as reactants; the use of catalysts, etc.

[0082] Reactants are introduced into the main chamber through shielded reactant injector(s) 125 and enter the reaction zone of the main chamber 135 through shielded reactant injector(s) 125. Multiple reactant injectors can be used, or multiple reactant species can be introduced from a single reactant injector. Note that the injection ports can be large to allow large volumes of reactants to flow into the radiating zone 170 (see FIG. 3), as desired in some fluidized bed applications. The number of injection ports can be small, if desired.

[0083] To preserve the molecular structure of the reactants prior to injection, it is necessary to provide an injection means that is X-ray shielded. This prevents premature dissociation or premature partial or complete ionization of the injected reactants prior to the introduction of source material and / or reactants into the irradiation volume 170. The requirement for a shielded injection means is preferably met by implementing the reactant conduit 125 using concentric pipes with an X-ray radiation shielding material 117, typically lead or other high atomic number elements, thereby filling the gaps between the concentric pipes. The pipes are stainless steel or other non-reactive material that is compatible with and unaffected by the radiation environment within the source and reactants introduced via inlets 110, 114 or the irradiation volume 170. The reactant inlet port 114 leads to the shielded reactant injector 125, which is a generally cylindrical conduit with a nozzle (e.g., 127). FIG. 1 also includes a plan view (non-cutaway view) of another shielded reactant injector (UCPs can include one, two, or more shielded reactant injectors) showing the distribution of nozzles arranged around the injector conduit, with the number of reactant injectors depending on the requirements of the intended reaction.

[0084] Additional electrodes, either in the form of separate electrodes or in the form of electrically insulating shielded reactant injectors, may be included here for plasma support and field enhancement, or external magnetic coils may be provided for plasma confinement or field generation. It is also possible to support both conditions, but such configurations are functionally redundant.

[0085] Both the source material and reactants enter the main chamber 135 and are exposed to the X-rays and secondary electrons. If a fluidized bed is also present, the fluid phase of the fluidized bed is also present and exposed to the X-rays. The reactants can vary widely, including liquids, gases, plasmas, and in some cases, granular solids. The amount of each reactant and key raw material is metered using mass flow controllers developed by the semiconductor industry. These controllers allow for the delivery of very precise amounts of material, literally with atomic precision. This allows for very precise control of the stoichiometry of the reaction.

[0086] The work of the fluidized bed can be enhanced by one of several means in the UCP. The first is to generate a plasma in the fluidized bed. This can be achieved by one of several means. One is to turn on the X-ray emitter of the RXCP. This will cause high energy radiation to ionize and enhance the reaction characteristics. The second method is to apply a high voltage DC signal to an insulated electrode (which can also function as a heater or dryer). This will generate a plasma with lower energy than that generated using X-rays. The third method is to apply an RF signal, also through an insulated electrode. This will generate a plasma with an energy intermediate between that generated by X-rays and that generated by DC. The choice of ionization means depends on the desired end result to be obtained from the resulting reaction. In this regard, it should be noted that the high temperature of the plasma generated in the reaction chamber can be sufficient to cause various reactions even by the roasting process.

[0087] Because the plasmas contemplated in this invention are highly reactive, it is desirable to provide a means of keeping the plasma away from the walls and the injector. There are three main means for accomplishing this: (1) electrostatic (as shown in FIG. 6), which is the preferred embodiment; (2) electromagnetic (as shown in FIG. 7), which may be used in some circumstances; and (3) using a physical insulating barrier (not shown). Starting with the latter, a physical insulating barrier involves placing an insulating, non-reactive dielectric insert in the reaction zone that confines the plasma to a specific region while allowing the injection of various reactants and irradiation by both x-rays and secondary electrons.

[0088] 6 is a simplified cross-sectional view of an embodiment of a UCP employing electrostatic plasma confinement, often referred to as field confinement or field enhancement, which is the preferred embodiment. In the illustrated embodiment, three equidistant electrodes 602, 604, 606 are positioned within the inner wall 610 of the RXCP within the working zone of the main chamber, but just outside the reaction zone. The electrodes 602, 604, 606 are configured to generate a uniform, generally cylindrical or spherical field within which the plasma reaction occurs, referred to as the plasma confinement region 615. It should be noted that other field configurations are possible. Additionally, it should be noted that one or more reactant injectors can be utilized as electrodes for electrostatic field generation.

[0089] 7 is a simplified cross-sectional view of an embodiment of a UCP employing electromagnetic plasma confinement. In the illustrated embodiment, four electromagnetic coils 702, 704, 706, 708 are positioned around the reaction zone. The activation voltage / current can be either direct current (DC) or alternating current (AC). When activated, the electromagnetic coils 702, 704, 706, 708 generate a magnetic field, indicated by field lines 712. The magnetic field confines the plasma generated within the reaction zone by deflecting charged particles (i.e., current) moving out of the confinement region back into the confinement zone 715. It should be noted that other coil and electromagnetic field configurations are possible.

[0090] It is also desirable to be able to dry materials within the UCP. Figure 11 is a cross-sectional view of an embodiment of a UCP having a dryer element. The axial cross-sectional view shown shows several concentric cylindrical elements, from outermost to innermost, a shield housing 165, a cathode 150, a grid 155, an anode 160, and a dryer element 910. The dryer element may include a generally cylindrical serpentine resistive heating element mounted on electrical insulators 914, 918 just inside the inner wall of the hollow anode 160. The dryer element 910 may also be used as an electrode for initiating and sustaining a plasma by connecting the dryer element to a switching means outside the interior volume of the UCP.

[0091] Prior to processing, an online analysis of the feed is performed via the mass spectrometer inlet port 118. After passing through the reactor, a second online chemical analysis is obtained by sampling the effluent at a second mass spectrometer inlet 180 at the top end of the chamber to ensure that the reactants have reacted to the desired state. Note that additional reactants can be added in the correct ratio to achieve the desired reaction and concentration. Mass flow meters (not shown in FIG. 1) provide an instrumented distribution and feedback system to control the exact amount of reactant fed to the system. Controlling these factors, along with the x-ray voltage and current, allows the system to be tuned to produce a wide range of chemical outputs. A host computer (not shown) with suitable processing, memory, and communication resources is connected to the feeds, flow meters, and mass spectrometer, combining all the information sources and utilizing artificial intelligence based operations to ensure that the reactor parameters are always optimized for the desired output product. The operation of the mass flow controllers is controlled by the host computer using inputs from residual gas analyzers and other analytical instruments connected to the system that monitor the inputs and outputs of the system.

[0092] The host computer is configured to compare mass spectrometer data generated from the feed inputs and outputs with other data sources, among other data sources, and compare the output data with a reference spectrum of the desired end product. Based on this analysis, the host computer determines whether to increase, decrease, or maintain the same flow rates of reactants. Once these adjustments are made, the host computer iterates additional analyses to determine whether the adjustments made have brought the end product closer to or further from the desired end result product. Based on these iterations, further adjustments can be made. The host computer continues iterating until the output stabilizes within set lower and upper limits. If it is determined that the resulting output product is too far out of specification for the host computer to correct, it will stop the chemical process and issue a notification to an operator. The host computer also monitors other critical functions for safety purposes, and will shut down the system if any of the monitored parameters fall outside of predetermined ranges, indicating a safety hazard.

[0093] As reactions occur within the main chamber 135, certain compounds precipitate and are removed from the output of the system via one of the output ports. This process is repeated one or more times, resulting in an effluent that is free of unwanted chemical components and any biological components. For example, when UCPs are used in water treatment, complex organic compounds such as pharmaceuticals or pesticides that are present are broken down.

[0094] The RXCP section of the UCP can be operated as a flash X-ray irradiator (FXI). In FXI mode, typically high intensity X-rays are applied to the reaction zone with the reactant feed turned off. In this mode, feedstock is typically introduced through the feedstock inlet port, while the remaining ports remain turned off. However, in some circumstances, it is also possible to feed material in FXI mode using other inlet ports. Depending on the material present in the reaction (radiation) zone, decomposition and crosslinking are typical reactions that can occur in this mode. In this context, decomposition refers to what happens to a complex molecule when it is subjected to intense X-ray irradiation that substantially exceeds the K-edge binding energy of the individual elements involved. This particular process is useful when an organic component is present and one wishes to remove it. Intense X-ray irradiation in FXI mode destroys any organic matter, breaking it down into its constituent elements, which then recombine into their lowest energy state forms. Furthermore, it is well known that ionizing radiation (X-rays) can initiate crosslinking reactions in polymers, etc. By setting the correct operating parameters, FXI easily achieves this operating environment. A detailed description of these and other processes is provided in commonly owned and assigned U.S. Patent No. 8,019,047. For ease of reference, in this application, the components used to generate x-rays in either RXCP mode or FXI will be referred to as RXCP.

[0095] To combine a fluidized bed with an RXCP, certain modifications are made, taking advantage of the fact that the RXCP typically incorporates a cylindrical process section. One possible modification is the addition of a perforated bottom plate with feed connections for the fluidization means and inlet and outlet ports on the side of the reaction zone if the UCP is mounted vertically, or a perforated bottom plate if horizontal. Depending on the specification composition of the material to be separated, it may be desirable to incorporate a screening step outside the UCP, either before or after the fluidized bed step, to increase the separation efficiency. It should be noted that the location of the inlet and outlet ports depends on whether the UCP is used in batch or continuous mode, or horizontally or vertically. When operating the UCP as a fluidized bed in a horizontal position, the diffuser and catalyst must be repositioned to accommodate this orientation, since the fluidized bed operation requires the diffuser to be located at the bottom of the fluidized bed. The FXI function is achieved by turning off the reactant injection means and running only the X-ray generating section of the UCP (i.e., cathode, grid, anode). For the purposes of this application, vertical mode in batch processing is the preferred embodiment, although horizontal operation in continuous mode is practical and can be used in industrial scale processes.

[0096] Regardless of which mode the UCP is used in, certain commonalities have been identified, such as the ability to operate in multiple continuous modes, including but not limited to: i) Fluidized Bed (FB) only; ii) RXCP only; iii) Flash X-ray only; (iv) Full UC, including any of: FB+RXCP, v) FB+RXCP+FXI, vi) FB+Dry, vii) FB+RXCP+Dry, viiii) FB+RXCP+Field Enhanced, ix) RXCP+Dry, and x) RXCP+Field Enhanced. All of the above modes of operation can be run in either continuous or batch mode. All of the above modes can be run using enhancement techniques, both electromagnetic and electrostatic field enhancement, and any of the above can be run in a plasma or non-plasma environment as appropriate. It should be noted again that the UCP mode includes FXI functionality by simply turning off the reactants. Other FXI operations also occur during this mode. Various combinations of achievable processes will be apparent to those skilled in the art.

[0097] Catalysts can be introduced into the UCP via the reactant feed to facilitate chemical reactions, or they can be permanently attached to the reaction zone. Catalysts are not consumed in catalytic reactions and therefore remain unchanged after the reaction. For many types of reactions, it is often the case that only small amounts of catalyst are required. Furthermore, some reactions can only occur in the presence of a catalyst. Fluidized bed and RXCP (and FXI) operation can both be enhanced by the use of catalysts under certain circumstances. In general, chemical reactions occur faster in the presence of a catalyst because the catalyst provides an alternative reaction pathway or mechanism with a lower activation energy than a non-catalytic mechanism. In catalytic mechanisms, the catalyst usually reacts to form an intermediate, which is then regenerated in the process to the original catalyst. Many materials can act as catalysts, ranging from inorganic compounds such as titania (titanium dioxide (TiO2)) or manganese dioxide (MnO2) to complex organic compounds such as Wilkinson's catalyst, RhCl(PPh3)3. As an illustrative example, Wilkinson's catalyst loses one triphenylphosphine ligand before entering the true catalytic cycle. Generally, ligands are considered electron donors and metals as electron acceptors (i.e. Lewis bases and Lewis acids, respectively). In plasma chemistry, the use of ligands may be obviated due to the potential for the generation of surplus electrons. This is not true for all reactions, but for some it can be a significant cost-saving factor.

[0098] In the case of the fluidized bed part of the UCP, the use of catalysts has been investigated, and a number of reaction processes carried out in the fluidized bed are made possible by the presence of a catalyst. In the case of the RXCP section of the UCP, the introduction of a catalyst can be a crucial additional element in making the reaction possible. The operating principle of RXCP (and FXI) is that following the ionization step in these processes, the ions present immediately try to recombine into their lowest energy state as described above. By introducing a catalyst, it is possible to modify this process and preferentially form some compounds over others.

[0099] Depending on the use of UCP, it is often useful to perform pre-reaction filtration of the feed and reactants to remove as many particulate reactants as possible to minimize the amount of material the reactor must process, and post-filtration to remove precipitates to improve process results. This can be done by any of a number of well-known methods, including but not limited to fluidized bed separation according to the present disclosure, screening, hydrocyclone separation, centrifugation, basket filters, or several other methods. Hydrocyclone is a suitable method for continuous, large volume separation, there are many suppliers of hardware, and hydrocyclone separators require less maintenance than basket filters. A major disadvantage of hydrocyclone separation is that it is not as effective at removing fine and microscopic contaminants as basket filters or other processes. It is noted that removing as much material as possible before the RXCP section of the UCP process reduces the amount of energy required to run the process.

[0100] Similarly, the RXCP section of the UCP is designed to produce a precipitate of some compounds in the output stream so that these can be separated and used for other purposes.Multi-stage basket filters with progressively finer pore sizes are an excellent way to achieve the desired cleanliness, although many other means are possible.

[0101] 5 is a schematic diagram illustrating an embodiment of a system including a UCP and a control system according to the present disclosure. In system 500, multiple controlled inputs are fed to the UCP, and both inputs and outputs are monitored and controlled by a host computer 550. A feedstock supply 502, such as a tank or other vessel, delivers feedstock material through a feed line that is monitored by a feedstock flow meter 504, which measures the mass flow rate of the feedstock material fed through the feedstock supply line. The output from the feedstock flow meter is delivered (via a wired or wireless connection) to the host computer 550. A feedstock supply control valve 508 is disposed on the feedstock supply line between the flow meter 504 and the feedstock inlet port 110 of the UCP 100. The feedstock control valve is communicatively connected to the host computer and receives control signals to open, close, or adjust the valve depending on the operation of the UCP as determined by an algorithm executed by the host computer 550.

[0102] Similarly, the fluidizing medium supply 512 delivers the fluidizing medium through a supply line monitored by a fluidizing medium flow meter 514, which measures the mass flow rate of the fluidizing medium through the fluidizing medium supply line. The fluidizing medium supply may include a pressurized liquid and / or gas tank. A fluidizing medium control valve 518 is disposed between the fluidizing medium flow meter 514 and the fluidizing medium inlet port 112 of the UCP 100. The fluidizing medium flow meter 514 and the fluidizing medium control valve 518 are both communicatively connected to a host computer 550, with the fluidizing medium flow meter 514 providing measurement signals to the host computer 550 and the reactant supply control valve 528 receiving command signals from the host computer and adjusting the supply of reactants depending on the operating conditions of the UCP. Similarly, the reactant supply 522 may also include a tank or other vessel and delivers the reactants through a supply line monitored by a reactant flow meter 524, which measures the mass flow rate of the input reactant. The reactant supply control valve 528 is disposed between the reactant flow meter 524 and the reactant inlet port 114 of the UCP 100. Both the reactant flow meter 524 and the reactant supply control valve 528 are communicatively connected to a host computer 550, with the reactant flow meter 524 providing signals indicative of the mass flow rate of the reactants to the host computer 550 and the reactant supply control valve 528 receiving command signals from the host computer to adjust the supply of the reactants depending on the operating conditions of the UCP. In some embodiments, the additional reactant supply 532 supplies further reactants (which may be different from the reactant supply 522) to a secondary reactant supply line that connects to the feed supply line via the feed control valve 504. The feed and secondary reactants are thus supplied to the UCP 100 via the feed input line 504. The secondary reactant flow meter 534 measures the mass flow rate through the secondary reactant supply line and transmits a measurement signal to the host computer 550. The feedstock, fluidization medium and reactant supplies 502, 512, 522, 532, in continuous mode, can comprise pipes rather than tanks.

[0103] The flow meter and control valve pairs 504 / 508, 514 / 518, and 524 / 528 can be implemented in separate devices, but this is not necessary. In some embodiments, both the metering and flow regulating functions can be performed by a single device using semiconductor technology well known in the art. The UCP also includes a recirculation loop for the fluidizing medium (not shown in FIG. 5), through which a pump recirculates liquid from the top of the main reactor / concentrator chamber to the bottom.

[0104] The UCP 100 includes a first analytical output 118 that provides a sample of the input material provided at the proximal end of the UCP 100 to a first mass spectrometer (not shown in FIG. 2). The output from the first mass spectrometer is provided to a host computer 250. At the distal end of the UCP is a second analytical output 180 that provides a sample of the output product to a second mass spectrometer (also not shown). The output from the second mass spectrometer is also provided to a host computer 550. The distal end of the UCP also includes a main output port 145 for products of reactions and other processes occurring within the UCP and a pressure relief vent 138. An output flow meter 540 measures the flow rate of the output product and sends a measurement signal to the host computer 550. The material discharged from the main output port 145 may be the product of interest of a reaction induced by a RXCP or FXI operation and may lead to a tank, a pipe, or additional process components. When used in batch mode, a single reactor may be used to perform various process steps in sequence by varying various feed and electrical parameters. When operated in continuous mode, there may be less simultaneous operations and multiple UCPs may be coupled in sequence or otherwise to implement a particular process.

[0105] A host computer 550 is also communicatively connected to the pressure release 138 to regulate the pressure in the UCP. The host computer 550 is configured to evaluate flow rate information received from the flow meters, as well as information received from the mass spectrometer regarding the composition of the input reactants (all reactants including feedstocks) and output products, and control the flow of materials to the UCP via the control valves 504, 514, 524. For example, the host computer may determine that a reaction is proceeding too quickly and execute commands to restrict the flow of input materials to slow the reaction rate.

[0106] A power supply 545 provides power to the cathode and grid of UCP 100. A host computer 550 also provides control signals to operate various components of the RXCP section of UCP 100 and receives electrical signals to monitor the status of the UCP. For example, host computer 550 controls the operation of the RXCP grid 155 to switch the electron gun on and off.

[0107] When the UCP is used for separation of raw materials, typically but not necessarily in fluidized bed operation, the heavier components are discharged through the lower output port 140 and the lighter components are discharged through the upper output port 142 (not shown in FIG. 2). Flow meters (not shown) may also be located at the lower and upper separation output ports 140, 142 to provide mass flow data of the separated streams to the host computer 550. Due to the independent nature of the control systems, any feature or combination of features is possible in the UCP, but the FXI and RXCP functions are mutually exclusive and excluded.

[0108] The UCP described herein offers many synergies and advantages over stand-alone components and other types of chemical process equipment. The presence of the enhanced fluidized bed increases the mixing and contact of reactants, catalysts, and feedstocks, resulting in higher throughput per stage and more complete reactions compared to traditional separate reactors and process equipment. This is due to the increased versatility of the UCP to carry out multiple processes in a single system. Furthermore, it is possible to change processes without major rework (e.g., changing operation from only fluidized bed mode to fluidized bed mode with RXCP). In other words, the ability to support multiple operating modes in a single unit means that a single plant can produce multiple products and change process parameters and configurations more easily than individual stages.

[0109] The UCP also has a more compact design and smaller footprint than conventional reactors of similar functionality. This compact design allows for a simpler electrical system with better adjustments. The aforementioned advantages may lead to a more universal design requiring fewer variations, reducing manufacturing costs and achieving greater economies of scale. The UCP concept presented herein represents an unexpected means of achieving process flexibility previously unattainable in conventional chemical processing plants.

[0110] With respect to the mining industry, and rare earth element mining and recovery in particular, the UCPs of the present disclosure fill a long felt need. The types of operations that the UCPs can perform can eliminate the need for toxic and highly polluting wet chemical processes that have been used for hundreds of years. The impacts on the environment and civilians living in the vicinity of these mining operations are immediate and severe. The combination of effective material separation using fluidized beds, removal of environmental toxins, and elimination using the RXCPs' ability to reform or decompose hazardous by-products means that rare earth processing does not need to be an environmentally hazardous activity due to the generation of large amounts of toxic liquid waste, and can be carried out cost-effectively in locations and jurisdictions where it was previously infeasible. For the United States, this represents a national security benefit, as the UCPs break the near monopoly that a small group of countries maintains over rare earth processing.

[0111] It is noted that the technology of the present invention may also benefit other mining industries. For example, the oil and gas production industry generates significant amounts of radioactive waste by-products, which pose serious environmental problems. Essentially the same process for removing radioactive material from phosphogypsum waste as described herein (see Example 2 below) can be advantageously utilized in the oil and gas industry for essentially the same requirements, i.e., removal of radioactive material from process streams (see Example 3 below). This is because radium and radon, as well as phosphogypsum gas, are the two primary radioactive components that need to be remediated.

[0112] Example Reactions: To illustrate UCP operation, some example reactions are given: 1. Hydrogen peroxide production: Purified water was used as the main raw material to produce hydrogen peroxide (H2O2) in the UCP. In the RXCP mode, it is ionized and reacts with purified oxygen to produce H2O2 in the following reaction:

number

[0113] This reaction can be adjusted to produce any concentration of H2O2 desired. Note that above 20% concentration, H2O2 becomes increasingly unstable to the point that it can explode. For most concentrations above 10%, stabilizer chemicals are added to alleviate this problem.

[0114] Traditional methods of producing H2O2 involve the use of large amounts of ammonia, sulfuric acid, 2-ethylanthraquinone, ammonium persulfate, etc., all of which are toxic and considered environmental pollutants. The UCP / RXCP process eliminates all of these substances, and the downstream pollutants they create. Only water, oxygen, and electricity are required to make H2O2. Optionally, if energy is available, the incoming waste stream can be electrolyzed to produce the required amount of oxygen, with hydrogen as the only by-product.

[0115] 2. Production of phosphoric and hydrofluoric acids from fluoroapatite ores: The conventional wet chemical process for producing these products is:

number

[0116] From this equation, we can see that Ca5F(PO4)3 (fluorinated apatite) reacts with sulfuric acid (H2SO4) and water to produce phosphoric acid, hydrofluoric acid, and phosphogypsum. Phosphogypsum ((CaSO4·2H2O) is a by-product of this process and is a hydrate of calcium sulfate). The end product of this reaction is then subjected to further separation steps to isolate the individual compounds. To obtain the same end product using a plasma-based process, Ca5F(PO4)3 is mixed with water and flowed through an RXCP or UCP reactor. There it is ionized and reacts with hydrogen sulfide gas and oxygen to produce the same end product. Care must be taken in setting the reactor operating parameters to maintain the stoichiometry of the process. The reaction is as follows:To obtain the same end product using UCP, Ca5F(PO4)3 is mixed with water and flowed through an UCP reactor. There it is ionized and reacts with hydrogen sulfide gas to produce the same end product. Care must be taken when setting the operating parameters of the UCP reactor to maintain the stoichiometry of the process. The reaction is:

number

[0117] It should be noted that whereas H2SO4 is used as a liquid reactant (conventional process), the plasma process uses hydrogen sulfide and oxygen as gaseous reactants that are more suitable for plasma processes. In the preferred embodiment, the correct selection of operating conditions allows for the removal of phosphoric acid as a liquid, phosphogypsum as a solid (precipitate), and HF as a gas. This eliminates the need for further process steps. The advantage that UCP brings to this process is that there is no toxic liquid waste, since the unwanted by-products are released as a gas and can be destroyed by a pollution control device in a pyrolysis unit at the exhaust of the process pump. This is an incinerator placed in series with the exhaust of the process pump and the exhaust from the building to the atmosphere. The use of plasma technology is standard in modern semiconductor processing. It should be noted that there are other plasma-based approaches to achieve the same end product.

[0118] 3. Separation of actinides from fluorapatite or phosphogypsum: Fluoroapatite is rarely found alone. It is usually found in combination with hydroxyapatite [Ca5(PO4)3OH], various rare earth elements (lanthanides), and radioactive minerals (actinides), typically uranium, radium, and thorium. Other actinides are frequently found in small amounts. Thus, at some point, the actinides must be separated from the fluoroapatite (or phosphogypsum) and the lanthanides. Depending on the local conditions and regulations at the mine, this separation can be done before or after the fluoroapatite reaction described in #2 (above), but is usually done before the reaction so as not to generate large amounts of radioactive waste. It is desirable to remove the radioactive materials (actinides) from fluoroapatite or phosphogypsum (by-products of fertilizer, hydrofluoric acid, and phosphoric acid manufacturing) so that these products and the residual phosphogypsum can be safely used for other purposes. Existing wet chemical processes generate large amounts of toxic contaminants. In some cases, if the actinides are not chemically bound to the phosphogypsum, the use of the UCP can completely eliminate the wet chemistry and associated contaminants. In this case, the UCP is used in a fluidized bed mode. The fluoride apatite or phosphogypsum (in this particular case, the feedstock) is introduced as a dry powder and fluidized (usually) with air. This causes a portion of the feedstock to rise to the top of the column, while the actinides sink to the bottom of the column and exit the column through outlet port 140 for the phosphogypsum and outlet port 142 for the actinides, respectively. When the UCP is used in this mode, separation is performed based on the density of the particles. If the compounds are chemically bound, it is appropriate to use a reactive plasma step prior to the physical separation step to completely separate the radioactive material from the feedstock.

[0119] There are other methods for separating actinides and lanthanides from phosphogypsum or fluorapatite using UCP. Typically, uranium, thorium, and radium are the predominant actinides contained in fluorapatite and therefore phosphogypsum. One such method involves reacting the actinides (as hydrates) with water and NO (nitric oxide, as a gas) or HCL (as a gas) to produce the following:

number

number

[0120] The particular reaction chosen will depend on the raw materials available, which may be used as is or with some degree of pre-treatment to tailor both the mechanical and electrical properties of these materials.

[0121] 4. Removal of pharmaceutical contaminants and other organic and biological contaminants: A major contamination problem facing many countries is the presence of pharmaceutical contaminants and other organic chemical contaminants in water. In this process, for example, with water that has contaminating chemicals (or organic contaminants), the UCP is operated in FXI mode. Here, the contaminated water is exposed to a high dose of X-rays. This has the effect of both ionizing the water and simultaneously breaking all bonds of the organic contaminants (including pharmaceutical contaminants). All the resulting ions are then recombined to their minimum energy state according to a process previously described in U.S. Pat. No. 8,019,047, "Flash X-ray Irradiator." Hydrogen and oxygen ions are also recombined back into the water. The resulting water is now free of long-chain organic contamination and is also sterilized. The reason that a UCP system (in FXI or RXCP mode) can achieve this level of ionization and associated decomposition is because the incident energy from both the X-rays and the secondary electrons that are generated is often many times the K-shell energy level, which is the energy level at which K-shell electrons (and all others) are dropped from atoms. This applies to all organic compounds, biologicals, petrochemicals and pharmaceutical products. Note that to further remediate contamination, the UCP can be operated in RXCP mode and used to add hydrogen peroxide (H2O2) to the contaminated water, as previously described.

[0122] X-rays in sufficient doses are lethal to biological organisms in several ways, including but not limited to, disintegration of DNA by breaking molecular bonds, induction of genetic damage, and chemical changes of major biological macromolecules, any of which leads to the death of the organism. During sterilization processing, the sample of interest is irradiated with high energy X-rays, electrons, or gamma rays at a sufficient fluence, leading to the formation of X-rays as well as highly unstable free radicals, molecular ions, and secondary electrons. These radiations then react with nearby molecules, breaking them and changing their chemical bonds. DNA in particular is highly sensitive to the damaging effects of radiation, and is disrupted, depolymerized, mutated, and altered in structure when exposed to ionizing radiation. Failure to fully repair DNA damage leads to loss of genetic information and cell death. The sensitivity of a given biological organism to radiation is measured by its D value (D 10 The dose that reduces the microbial population by a factor of 10 is called the dose-dependent dose.

[0123] 5. Removal of marine contaminants such as oil and chemical spills, bacterial and algal overgrowth: In this application, the system is mounted on a boat, hovercraft or other type of marine vehicle, preferably a catamaran, with a large dredger placed between the bows and capable of being lowered into the sea while the vessel is moving. The dredger directs the contaminated water through a pipe to a UCP operated either in FXI mode (the simplest form) or in RXCP mode, where oxygen is added to form hydrogen peroxide. In FXI mode, only radiation is used to break down the organic matter and kill any bacteria or other algae that may be present. In RXCP mode, both radiation and oxidation are used to remediate or remove the contaminants. It is noted that in either process mode, any fish passing through the reactor will likely die. This can be prevented by covering the inlet with a mesh to block the fish from entering the unit. It is noted that this implementation may require periodic cleaning to remove the fish and other material caught in the mesh, or a signal to be sent in the water ahead of the vessel to disperse the fish. It is further noted that oxygen is not the only additive that can be used in this application. Other gases, such as chlorine, can be used successfully to obtain similar results.

[0124] To implement this application, a generator and high voltage power supply would need to be on board the boat in addition to the UPC or derivative. Additionally, if the speed of the boat does not exceed a certain limit, a pump would need to be provided to ensure that enough water passes through the UCP or derivative. Once past the irradiation device, the treated water is dumped back aft of the stern back into the backwater. It should be noted that this method of removing algal growth is not limited to floating on the surface. The dredger can be placed at a desired depth, taking into due consideration the speed of the vessel through the water and appropriate precautions to prevent entanglement with underwater obstacles. Onboard sonar can be used to prevent the dredger from entangling with underwater obstacles.

[0125] Similarly, in the case of oil and chemical spills the same equipment is used. Where toxic gases or flammable materials are involved, care should be taken to protect the ship's operator.

[0126] Typically, a large spill, such as in the ocean, bay, large gulf or strait, may require a faster, smaller vessel. This also increases the power demand as the illumination system needs to operate at a higher illumination level. In this case, a small jet engine (typically the size used for large commercial jets) coupled to a generator such as those used by the electrical industry for peak generation can be used. The exhaust creates thrust to move the boat at high speed, and the generator can produce power in the megawatt range. This type of motor generator is commercially available from several suppliers. Smaller conventional motor and propeller systems are also included in low speed maneuvers. The maneuvering system propeller needs to be capable of feathering for high speed operation.

[0127] Radiation protection for the operator of the irradiation vessel must be provided. This can be in the form of lead or other high atomic number shielding material arranged to prevent radiation from the irradiation system from hitting the operator. Note that when the system is not in operation, there is no radiation risk to the operator and crew. Alternatively, the marine vehicle can be remotely operated, placing the operator at a safe distance from the radiation generated by the UCP.

[0128] It should be noted that the implementation of other lighting systems integrated into the boat is possible and practical.

[0129] It should be understood that the structural and functional details disclosed herein should not be construed as limitations on the systems and methods, but are provided as representative embodiments or configurations to teach one of ordinary skill in the art one or more ways to implement the present methods.

[0130] It should be further understood that like numerals in the drawings represent like elements throughout the several drawings, and that not all components or steps described and illustrated with reference to the drawings are required for all embodiments or configurations.

[0131] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprise" or "comprising," as used herein, specify the presence of stated features, elements, steps, operations, factors, and / or components, but do not exclude the presence or addition of one or more other features, elements, steps, operations, factors, components, and / or groups thereof.

[0132] Orientation terms are used herein for convenience and reference purposes only and should not be construed as limiting, although it is recognized that these terms may be used by an observer, and therefore no limitation is implied or inferred.

[0133] Also, the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," "having," "containing," "involving," and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

[0134] The above subject matter is provided by way of example only and should not be construed as limiting. Various modifications and changes to the subject matter described herein can be made without following the illustrated and described embodiments and application examples, and without departing from the true spirit and scope of the invention encompassed by this disclosure, as defined by the set of descriptions in the following claims, and structures and functions or steps equivalent to these descriptions.

Claims

1. 1. A universal chemical process apparatus (UCP) comprising a reaction vessel having a longitudinal central axis and a main chamber, said UCP comprising: a first inlet port for a primary ingredient leading to the primary chamber; a second inlet port for fluidizing medium leading to the main chamber; a third inlet port for one or more reactants into the main reactor chamber; 1. A reactive x-ray chemical process apparatus (RXCP), comprising: a cold cathode extending along the longitudinal central axis within the main chamber; a grid positioned concentrically and more centrally relative to the cathode within the main chamber; an anode concentrically and more centrally positioned relative to both the cathode and the grid; an RXCP including: Equipped with In operation, a fluidized bed may be supported within the main chamber when a fluidizing medium and a feedstock are supplied to the main chamber through the first inlet port and the second inlet port; and When powered on, the cathode of the RXCP emits electrons toward the anode, which, upon impact with the electrons, emits X-rays into an irradiation zone within the main chamber of the vessel, and the X-rays ionize raw materials and reactants, induce chemical reactions, and can sterilize and decompose organic materials within the irradiation zone.

2. The UCP of claim 1 further comprising a catalytic material disposed within the main chamber.

3. The UCP of claim 2 , wherein the catalytic material is disposed on one of a screen, a plate, and a container within the main chamber.

4. 10. The UCP of claim 1, wherein in operation, the fluidized bed can be supported while the RXCP is powered on.

5. 10. The UCP of claim 1, wherein in operation, the fluidized bed can be supported while the RXCP is powered off.

6. 10. The UCP of claim 1, wherein in operation, the RXCP is capable of functioning in a flash x-ray exposure (FXI) mode when the supply of reactants other than the primary feedstock through the first inlet port is turned off.

7. The UCP of claim 1 , wherein the first inlet port, the second inlet port, and the third inlet port are shielded against X-ray radiation.

8. 2. The UCP of claim 1, wherein the first inlet port and the second inlet port deliver a feedstock and a fluidizing medium, respectively, to a bottom of the reactor vessel upstream of the radiating zone.

9. 10. The UCP of claim 8, further comprising a diffuser disposed at the bottom of the reactor downstream from the first inlet port and the second inlet port and operative to help uniformly distribute the fluidizing medium and feedstock throughout the main chamber.

10. A UCP as described in claim 8, further comprising a lower output port at a first height within the main chamber and an upper output port at a second height within the main chamber, the second height being higher than the first height, and wherein during fluidized bed operation, chemical species separate by density, with heavier components being output from the main chamber through the lower output port and lighter components being output from the upper output port.

11. 2. The UCP of claim 1, wherein the first inlet port leads to a shielded injector conduit having an outlet centrally located within the main chamber.

12. The UCP of claim 7, wherein the third inlet port leads to a shielded conduit having a nozzle that opens to release reactants directly into the main chamber.

13. The UCP of claim 1 , further comprising at least one electrode located within the main chamber and configured to induce or sustain a plasma within the main chamber.

14. The UCP of claim 10 further comprising a main outlet port for outputting products of a chemical reaction occurring within the main chamber.

15. 10. The UCP of claim 1, further comprising a dryer disposed in the main chamber and adapted to remove water or other undesirable liquid inclusions from reactants and products.

16. 1. A marine vehicle adapted for treating marine pollutants at a polluted site, said marine vehicle comprising: means for propelling said marine vehicle; An on-board generator; a high voltage power supply coupled to the on-board generator; The UCP of claim 1 coupled to the high voltage power supply; a dredger for collecting water at the contaminated site; Equipped with A marine vehicle, wherein the dredger is coupled to a feedstock inlet of the UCP, the UCP is operated to decompose organic components present in the contaminated feedstock and to kill bacteria and algae, and a non-polluted output from the UCP is discharged outside the marine vehicle and returned to the water at the contaminated site.

17. 17. The marine vehicle of claim 16, wherein the means for propelling comprises a jet engine providing high speed propulsion.

18. 17. The marine vehicle of claim 16, wherein said means for propelling further comprises a separate low speed engine adapted for operating said marine vehicle at low speeds.

19. 17. The marine vehicle of claim 16, wherein the UCP is operated in FXI mode to decompose organic components, including oil compounds and associated chemical waste, and to kill bacteria and algae.

20. 17. The marine vehicle of claim 16, wherein the UCP is operated in RXCP mode to decompose organic components, including oil compounds and associated chemical waste, and to kill bacteria and algae.

21. 17. The marine vehicle of claim 16, further comprising radiation shielding disposed around the UCP to protect personnel on the marine vehicle from radiation while the UCP is operating in RXCP or FXI mode.

22. 1. A universal chemical process apparatus (UCP) comprising a reaction vessel having a longitudinal central axis and a main chamber, said UCP comprising: a first inlet port for a primary ingredient leading to the primary chamber; a second inlet port for fluidizing medium leading to the main chamber; a third inlet port for one or more reactants into the main reactor chamber; a reactive chemical process apparatus (RCP) including a radiation source adapted to emit X-rays into the main chamber; Equipped with In operation, a fluidized bed may be supported in the main chamber when a fluidizing medium and a feedstock are fed into the main chamber through the first inlet port and the second inlet port; When powered on, the radiation source of the RCP emits X-rays into a radiation zone within the main chamber of the vessel, and the X-rays can ionize raw materials and reactants, induce chemical reactions, and sterilize and decompose organic materials within the radiation zone.

23. 23. The UCP of claim 22, wherein the radiation source comprises a radioisotope.

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