Universal chemical process equipment with radioisotope sources

Abstract

A universal chemical process apparatus (UCP) comprising a reaction vessel having a central longitudinal axis and a main chamber, the UCP comprising a first inlet port for a primary feedstock, a second inlet port for a fluidizing medium, and a third inlet port for one or more reactants. The UCP may also be used in a reactive radiochemical process apparatus (R 2 CP), this R 2 The CP includes a radioactive element extending along a longitudinal axis within the main chamber. In operation, a fluidized bed may be supported within the main chamber when a fluidizing medium and a feedstock are fed into the main chamber via the first and second inlet ports, R 2 The radioactive elements in the CP ionize the feedstocks and reactants, inducing chemical reactions and exposing them to ionizing radiation capable of sterilizing and decomposing all organic material within the radiation zone.

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 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 of the periodic table and are naturally radioactive to varying degrees. For the purposes of this document, radium, with atomic number 88, and promethium, which is technically a lanthanide but is also a naturally radioactive element with atomic number 61, are included in the actinides. Note that these elements are often found together in various ratios, complicating any subsequent separation process.

[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 said chemical. Note that the physical components of a dryer may also have other functions within a given system, provided that appropriate care is taken for proper operation.

[0007] Dry Chemistry: As used herein, the term "dry chemistry" refers to processes in which plasma rather than solution is generated. These produce fewer contaminants 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 performed in liquid baths and do not generate significant amounts of contaminants.

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

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

[0011] Field Enhancement: In the context of this document, the term "field enhancement" and its derivatives refer to the enhancement of some aspect of the reactions that take place within a particular device 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 within an internal reaction zone for the purpose of decomposing, sterilizing, or reacting materials. The Flash X-ray Irradiator is the predecessor technology to RXCP and is described in U.S. Patent No. 8,019,047, "Flash X-ray Irradiator" (hereinafter 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 fully 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 a 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, dried, or sometimes subjected to additional wet processing to extract the desired compounds or elements.

[0015] Fluidized Bed: A physical phenomenon that occurs when, under appropriate conditions, a fluid (liquid, gas, or plasma) entrains a quantity of granular solid medium (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 medium. This is typically accomplished by introducing a pressurized fluid, gas, or plasma through the granular medium. The resulting solid / fluid mixture possesses many of the properties and characteristics of ordinary 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 known as an 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] Ionizing radiation: radiation consisting of particles, x-rays, or gamma rays that have enough energy to cause ionization in the medium through which they pass.

[0020] Lanthanides: Chemical elements known as rare earth elements and occupying positions 57-71 of the periodic table, as well as scandium (atomic number 21), and yttrium (atomic number 39).

[0021] Leaching: A chemical process in which a raw material 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 subsequent processing steps.

[0022] 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 redox. Ligand selection is an important consideration in most reactions involving ligands.

[0023] Mobilization: A chemical process that liberates a desired element or compound from a complex within a mineral resource, allowing for further beneficiation.

[0024] 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).

[0025] Phosphogypsum: A by-product of the purification of fluoroapatite in the manufacture of fertilizer, phosphoric acid, and hydrofluoric acid. Chemically, it is a hydrate of calcium sulfate (CaSO4 2H2O). This material also contains recoverable amounts of rare earth elements (lanthanides) and some radioactive elements (actinides).

[0026] 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.

[0027] 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 a liquid and a gas. 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. This invention primarily relates to 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. This is also the simplest means to achieve total ionization, a necessary condition for many of the reactions contemplated by this invention.

[0028] 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 container, causing the compounds or elements of interest to sink to the bottom of the container, from which they can be removed by any of several well-known means.

[0029] 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.

[0030] Reactive X-ray Chemical Process Apparatus: A type of chemical process apparatus designed to enhance reaction conditions by using X-ray radiation to ionize present species 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.

[0031] 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.

[0032] Separation: A chemical or mechanical process or series of processes designed to separate chemically similar compounds.

[0033] Sedimentation (sedimentation): A process similar to precipitation in which the 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.

[0034] 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.

[0035] Stacks: Phosphogypsum is typically stored outdoors in very large piles called "stacks," which often cover tens of acres and can be hundreds of feet high.

[0036] Tailings: Material left over from the beneficiation process of a mining operation.

[0037] 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.

[0038] 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 amounts of strong acids, strong bases, amines, and biologicals. Wet processes are generally highly polluting and expensive to remediate. [Background technology]

[0039] 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.

[0040] 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, sedimentation, flotation, sedimentation, flocculation, thickening, mobilization, screening, and thickening. These processes are often referred to as "wet" processes.

[0041] These processes are often based on large-scale liquid chemical operations (such as large liquid baths, tanks, or ponds) that use toxic and highly polluting chemicals, such as strong acids (such as sulfuric acid, nitric acid, hydrochloric acid, and hydrofluoric acid), strong alkalis (such as caustic soda (NaOH), quicklime (CaO), ammonia (NH3), soda ash (Na2CO3), and limestone (CaCO3)), concentrated salts (such as potassium chloride), various amines, and others. While these chemicals can efficiently produce the desired chemical reactions, the liquids produced during the beneficiation process are highly contaminated and extremely difficult to dispose of in an environmentally responsible manner.

[0042] Due to environmental concerns associated with wet chemical processes, certain processing activities, such as rare earth processing, are no longer conducted or are rarely conducted in the United States. 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 because it proved too difficult and expensive to beneficiate rare earth-containing materials while complying with environmental regulations. China, with its large deposits of rare earth minerals 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 to avoid processing the material domestically and dealing with the toxic by-products of that activity.

[0043] The recognition that the United States needs to return to a position of self-sufficiency in this market is quite recent. However, the state-of-the-art in rare earth beneficiation remains wet chemical processes with the same environmental problems. Therefore, there is a great need for improved process technology, especially for rare earth minerals. Summary of the Invention

[0044] In a first aspect, the present disclosure provides a universal chemical process apparatus (UCP) comprising a reaction vessel having a longitudinal central axis and a main chamber, the UCP comprising a first inlet port for a primary feedstock, a second inlet port for a fluidizing medium, and a third inlet port for one or more reactants. The UCP also comprises a reactive radiochemical process apparatus (RCP) comprising a radioactive element disposed within the main chamber extending along the longitudinal axis. 2 In operation, when the fluidizing medium and raw material are fed into the main chamber through the first and second inlet ports, a fluidized bed is supported within the main chamber and R 2 The radioactive elements in CP ionize feedstocks and reactants, inducing chemical reactions and irradiating them with ionizing radiation capable of sterilizing and decomposing organic materials within the radiation zone; the processes can be used individually or in various combinations.

[0045] 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 radioactive element within the vessel operable to support a fluidized bed and to emit ionizing radiation into a radiation zone within the vessel.

[0046] Fluidized beds can be used for both typical fluidized bed reaction chemical processing and separation processes. Fluidized beds can be used separately or in combination with RXCPs, and RXCPs can be used separately or in combination with fluidized beds.

[0047] Numerous additional inventive aspects of the present disclosure are described in the detailed description that follows. [Brief explanation of the drawings]

[0048] [Figure 1] 1 is a cross-sectional view of an embodiment of a universal chemical process apparatus (UCP) according to the present disclosure. [Figure 2] 1 is a simplified cross-sectional schematic diagram of a UCP according to an embodiment of the present disclosure, illustrating an exemplary electrode configuration for an X-ray-free plasma-enhanced fluidized bed. FIG. [Figure 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] 1 is a simplified schematic cross-sectional view of a UCP according to an embodiment of the present disclosure, illustrating an exemplary placement of a catalyst within the UCP. [Figure 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 confined using electrostatic field enhancement. [Figure 7] 1 is a cross-sectional view of a UCP in which plasma generated within the UCP is confined using electromagnetic field enhancement, according to an embodiment of the present disclosure. [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 a UCP. [Figure 9] FIG. 1 is a schematic cross-sectional view showing the second stage of the 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 the third stage of the separation process according to the present disclosure using fluidized bed operation of the UCP. [Figure 11] 1 is a schematic cross-sectional view of a UCP according to an embodiment of the present disclosure having a heating / electrode element. [Figure 12] FIG. 1 is a longitudinal cross-sectional view of another embodiment of the RXCP / FXI portion of a UCP, designated R2CP, in which a centrally located radioisotope is used as the ionizing radiation source instead of a motorized electron gun. [Figure 13] FIG. 10 is another longitudinal cross-section of the R2CP, showing that the removable portion of the biological radiation shield is removable to allow replacement of the radioactive core element when necessary. [Figure 14]A cross-sectional view of a different configuration of R2CP is shown, where the radioactive elements are distributed non-uniformly around the outer surface of the reaction zone. When radiation penetrates the wall of the reaction zone, it generates additional X-rays and secondary electrons, similar to FXI, RXCP, and UCP. DETAILED DESCRIPTION OF THE INVENTION

[0049] As previously mentioned, current mining practice involves the use of "wet" processes such as leaching, flotation, precipitation, flocculation, and settling to perform mineral processing. These processes typically require large amounts 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 amounts 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, mineral processing operations often produce large amounts of contaminated process water, which cannot be irradiated without significant treatment. In short, separation and related processes carried out in mining are responsible for a significant portion of the toxic waste generated in mining, and replacing them with non-polluting alternatives would provide a much-needed solution.

[0050] The present disclosure provides methods 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 Irradiator (FXI) in some operational configurations. The UCP can include additional components for drying and electromagnetic field enhancement. Electromagnetic field enhancement involves using electric, electrostatic, and magnetic fields to drive chemical reactions within the UCP through a variety of operating modes. Thus, the UCP combines aspects of both fluidized bed, X-ray, or gamma irradiation, as well as other technologies, to achieve greater results and enable previously unavailable plasma-based processing strategies. In addition to being able to operate as a reactive chemical process, the fluidized bed can also perform separations on a purely mechanical basis by modifying operational control parameters. Individually, each component is capable of a specific range of operations. When combined, in addition to the individual operations, the disclosed methods and apparatus can unexpectedly reduce process steps and physical factory equipment as a direct result of combining multiple individual stages and operations, as described below. The present disclosure provides several exemplary processes that can be implemented with the UCP, all of which constitute enhancements over conventional approaches directly due to the unique structure of the UCP. In further embodiments, the present disclosure provides devices for chemical processing, decomposition, and sterilization using radioisotope sources.

[0051] FIG. 1 is a cross-sectional view of an embodiment of a UCP according to the present disclosure. The UCP 100 includes a generally cylindrical or columnar vessel 105, in this case with a vertical longitudinal central axis. The UCP can be oriented in various directions and may have a horizontal or inclined longitudinal axis, although a vertical orientation is preferred for most fluidized bed operations. The lower portion, or bottom 108, of the vessel 105 shown in FIG. 1 is provided with multiple inlet ports, which can be welded, molded, or attached to the vessel 105 as is well known in the art. In the illustrated embodiment, a feedstock inlet port 110 is coupled to the vessel bottom 108 and provides a conduit through which feedstock can be introduced into the vessel. Because feedstock typically has a larger diameter than other input materials, the diameter of the feedstock inlet port 110 is sized accordingly to accommodate the feedstock product. The feedstock may include a granular solid, liquid, gas, or plasma material intended to be processed in some manner within the vessel. For example, a 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 numerous 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 directly. The feedstock may also be supplied using other ports, such as reactant injector ports.

[0052] A fluidizing medium inlet port 112 is located adjacent to the feedstock inlet port at the bottom 108. The fluidizing medium is typically delivered into the vessel 105 through the fluidizing medium inlet port 112 at a pressure greater 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 gas, plasma, or liquid. A wide range of liquids and gases can be used depending on the desired process. As an example, if the material being processed (e.g., separated) could be adversely affected by the presence of oxygen, nitrogen or argon could be used as the fluidizing medium instead of compressed air. Various plasmas, which are effective in inducing additional reactions, can also be used. The choice of fluidizing medium depends on the desired end product. Preferably, the fluidizing medium port and injector are shielded from X-ray radiation. Shielding can be achieved 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. A shut-off 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 fluidizing medium when not needed.

[0053] In addition to the feedstock and fluidization medium, additional reactants for promoting one or more chemical reactions, heat transfer, catalysis, etc., can be introduced into the vessel through one or more reactant inlet ports 114 located in the bottom 108. Like 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 them constructed at least in part of a material 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 instead lead to a reactant injector 125 with multiple outlet nozzles (e.g., 127) located at various heights within the vessel. The shield 117 allows the reactants to be introduced without ionization until they enter the reaction chamber 135, ensuring uniform distribution throughout the reaction zone. In some embodiments (not shown), the raw material inlet port 112 is configured similarly to the reactant inlet port, allowing materials to be introduced into the center of the chamber 135, preferably with fewer nozzles, each with a larger diameter than the reactant inlet nozzle.

[0054] 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 UCP housing by an insulated feedthrough 208, which can be made from a ceramic material. The injector 205 is a shielded conduit that extends longitudinally within the UCP's main chamber 215. Reactants delivered through the reactant injector are discharged into the reaction zone within the main chamber through multiple nozzles (e.g., 212, 214, 216). FIG. 3 is a schematic cross-sectional view of an embodiment that includes a shielded injector 305 adapted for feedstock delivery, also extending longitudinally within the UCP's main chamber 315. In contrast to the embodiment shown in FIG. 2, materials delivered through the shielded injector 305 are discharged into the reaction zone within the UCP's main chamber through a single large nozzle 320.

[0055] In some embodiments, the UCP includes an electrode within the main chamber 135, adapted to generate a plasma or electromagnetic field within the main chamber or to sustain a plasma injected into the vessel. The plasma can be used to induce chemical reactions in fluidized beds and other plasma effects and applications. Figure 2 shows a rod-shaped electrode 220 extending through the reaction zone within the main chamber 135. The electrode is connected to a power source (not shown) through an insulated feedthrough 225, which may also be made from a ceramic material. The power source can be AC, DC, or RF, depending on the specific type of plasma, electromagnetic field, and bias desired. The electrode voltage can 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 insulator, as well as the electrode structure's geometry and spacing from walls or other grounded objects, such as catalysts.

[0056] It is desirable to prevent the plasma from touching the walls of the UCP reaction zone, which is referred to as "containment." This can be achieved 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, as shown in FIG. 6 (discussed below), using an electrode similar to electrode 220 shown in FIG. 2. In another embodiment, an external electromagnetic coil can be used to generate a magnetic field within 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.

[0057] Returning to Figure 1, ports 118 and 180 at the inlet and outlet ends of the UCP are connected to mass spectrometers. This allows for real-time analysis of the source material both before and after processing by the UCP. The fluidization medium and 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, as long as they have the appropriate porosity. Alternatively, the diffuser plate can have a uniform hole pattern to achieve the same effect. The diffuser plate 120 disperses and improves uniformity of the fluidization medium as it enters the vessel's main chamber 135 (referred to as the "separation zone" when a fluidized bed is operating to separate the source material), where separation and / or other processes occur. 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 via a recirculation loop (not shown in Figure 1), where it mixes with the incoming fluidization medium.

[0058] In some embodiments, the catalyst may be located above the diffuser plate. However, more generally, the catalyst can 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 center, near the top of the reaction zone, or entirely outside the reaction zone. The location depends on the degree of catalytic activity desired. The catalyst can take various forms, but for clarity, FIG. 4 shows it 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 within 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 method of introducing catalyst into the reaction generated in a UCP. Other forms of catalyst introduction include plates, trays, meshes, and 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.

[0059] In some embodiments, a specific category of catalysts known as electrocatalysts can be used in mineral processing. Electrocatalysts function on electrode surfaces, but most commonly, they can be incorporated into the electrode surface itself. Electrocatalysts can also be heterogeneous, such as platinized electrodes. This is achieved 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, thereby creating an electrocatalyst. Soluble homogeneous electrocatalysts aid in transferring electrons between the electrode and the reactants and / or facilitate intermediate chemical transformations described by overall half-reactions. While homogeneous electrocatalysts can be used for certain types of reactions, they may not be suitable for all reactions due to their potential physical instability and solubility. Electrocatalysis can be stimulated either by direct electrical connection or by interaction with an electric field within the reaction vessel.

[0060] The source material is entrained in a fluidizing medium within the main chamber 135, and the resulting combination of granular solids and fluids (including gases and plasmas) behaves like 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, source and reactant flow rates, and other factors (discussed below), are designed to cause the source-fluid mixture to behave like a fluid. In the illustrated embodiment, this is achieved by introducing a pressurized fluidizing medium through a particle medium at the bottom of a vessel of appropriate diameter. The granular solids / fluid combination, referred to as a fluidized bed, is a suspension and possesses many of the properties of a conventional fluid, such as the ability to flow freely under gravity or be pumped using fluidic techniques. This characteristic of a fluidized bed allows for horizontal operation. Recirculation pipe 138 receives pressurized fluidizing medium at the top of the chamber, applies pressure to the fluidizing medium via pump 161, 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, additional fluidizing medium entering through inlet port 112 can be shut off via a shut-off 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 maintain a constant pressure.

[0061] Within chamber 135, the upper surface of the bed is relatively horizontal but can be wave-like in nature, similar to hydrostatic behavior. The bed can be thought of as a heterogeneous mixture of fluid and granular solids that can be described by a single bulk density. In a fluidized bed, larger, denser particles tend to move downward within the bed, while smaller, lighter, denser particles tend to move upward, demonstrating fluid behavior according to Archimedes' principle. Varying the fluid ratio can alter the bed density (or, more precisely, the solid volume fraction of the suspension), 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 significantly contributes to the upward movement of the particles.

[0062] In a fluidized bed, contact between the solid particles and the fluidizing medium is significantly enhanced compared to a packed bed. This behavior in a fluidized combustion bed allows for enhanced heat transport within the system and between the particles and the fluidizing medium. The enhanced heat transfer achieves 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, dense materials tend to sink to the bottom of the bed. Note that very small, dense particles may migrate to the top of the bed, necessitating further separation. This is a simple gravity-induced process. For example, when air is used as the fluidizing medium, the upward flow through the bed essentially causes the material in the bed to float on the fluidizing medium. When material floats, this means there is sufficient pressure to fluidize the entire column, pushing lighter materials to the top of the column and causing the denser portions of the material to remain or move to lower positions in the column.

[0063] 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

[0064] Additionally, the introduction of the fluidizing medium into the main chamber 135 has the effect of generating gas bubbles, which form as a result of physical interaction with the raw material particles and pressure differentials. In physically small beds, the bubbles formed are small, sometimes microscopic. In large industrial beds with diameters of 10 to 15 feet, the bubbles can become quite large. The bubbles increase the mixing of the chemicals within the fluidized bed. A pressure relief valve 138 is provided at the top of the vessel to maintain a constant differential pressure environment within the bed. Pressure irradiation is preferably achieved by recirculation piping, especially when the fluidizing medium is reused. When certain gas bubbles or air molecules reach the upper region of the bed, the bed diameter increases, causing a sudden decrease in air velocity by nearly 10 times. This means that lighter (less dense) particles recirculate back into the turbulent flow region, eventually reaching a stable bed height based on particle size, density, and fluidizing medium pressure. Note that fluidized beds can be operated at atmospheric pressure, positive pressure, or partial vacuum.

[0065] Fluidized beds can be used to separate mixtures of various materials. As previously mentioned, the fluidizing medium can be a gas, liquid, granular solid, or a mixture of gases. The specific materials and fluidizing means are selected appropriately for the specific task. When batch processing is intended, fluidized bed processes can achieve high levels of separation by running the process for extended periods of time. However, when a continuous process, such as that typically found in industrial-scale applications, is desired, 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.

[0066] 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. Its 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, thoroughly mixing the component feed materials and effectively separating materials by density over a period of time. The lower and upper outputs 124, 128 can be connected to a mass spectrometer or other analytical equipment, allowing online analysis of the separated streams while the FB concentrator is in operation.

[0067] 8-10 illustrate 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 primarily comprising first and second components (components A and B) of different densities enters the main chamber 835 (separation zone) of the UCP through feedstock inlet 810, and a fluidized bed is maintained by supplying a fluidizing medium through 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 main chamber 835, it initially disperses in a generally random manner within the volume of the chamber.

[0068] By the second stage shown in Figure 9, the feed material has spread throughout the volume of the fluidized bed and has begun 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. At the second stage shown in Figure 9, the separation process is in its early or intermediate stages. A concentration gradient is beginning to form, but the components are not completely separated.

[0069] 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 and the other (i.e., region 925 is substantially devoid of component A, and region 920 is substantially devoid of component B). At this point, lower outlet port 140 and upper outlet port 142 are opened, allowing the separated outputs. A component-enriched fluid exits the vessel through lower output 840, and a component-enriched fluid exits the vessel through upper output 842. As noted above, the output streams from outlet ports 840 and 842, while significantly concentrated relative to the input feed, may not be sufficiently concentrated for desired purposes, and the outputs may be fed to a further UCP, fluidized-bed concentrator, or processing unit for further component separation or otherwise processing. 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 within the fluidized bed.

[0070] In one example, a UCP can be used to remove actinides from mineral source materials. The UCP can be operated (in one or more stages) in a fluidized bed mode to relatively separate actinides from raw materials such as uranium, radium, thorium, etc. This concentrated output material can be dried using a microwave oven or other drying device. The lighter material discharged from the fluidized bed can be fed to a UCP operated in an RXCP mode, where the material undergoes a chemical reaction in the presence of ammonia (NH). This step replaces conventional wet leaching in the presence of manganese oxide (MnO). 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 high-density output from the second fluidized bed stage is typically enriched in residual actinides, such as radium. This additional output can be dried for conventional, non-contaminating removal.

[0071] 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 stages in the fluidized bed, further improving cost, footprint, safety, and throughput.

[0072] One important application of fluidized beds is 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, such as the fluidized beds used in the production of polyethylene.

[0073] Historically, fluidized beds have been operated using granular solids, liquids, and gases. The inventors have realized that a fluidized bed can also be operated by using a plasma as the fluidizing medium in the bed or by having a plasma in the presence of another fluidizing medium in the bed. There are other examples of plasma processes in which a plasma is flowed into a chamber at a velocity to achieve a desired end result. One example is a plasma wind tunnel, which is used to simulate satellite re-entry into the atmosphere and the plasma conditions experienced by satellites in that situation, to verify whether the satellite will burn up upon re-entry. The present invention introduces the plasma, which behaves in many ways as a gas, into the chamber through an appropriate inlet port 114, and takes care to prevent the plasma charge from becoming grounded 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.

[0074] To maintain a plasma or electromagnetic field in the fluidized bed in the absence of x-rays, it may be desirable to include an insulated electrode to which a bias voltage can be applied. 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, with insulating means where the reactant injector enters the reactor to isolate it and maintain it above ground potential. Various electrode configurations are shown in Figure 5.

[0075] Returning again to FIG. 1, once the feed materials are separated by density, the lighter components are removed through an upper output port 140 (or multiple such ports) located at or near the top of the main chamber 135, while the heavier components are removed through a lower output port 142 (or multiple such ports) located toward the bottom of the main chamber above the diffuser plate 120. The height, particle size, and density of the ports determine the density of the removed material. The separated material is forced out of the fluidized bed through the output ports 140, 142 by 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.

[0076] 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 raw materials and then effectively separates the materials by density over time.

[0077] It should be noted that the UCP can operate alone as a fluidized bed or in combination with a reactive X-ray chemical process (RXCP) plasma-generated 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.

[0078] In Figure 1, the central portion of the UCP contains elements of a reactive X-ray chemical process apparatus (RXCP) capable of fully or partially ionizing (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 and enhance certain reactions. Additionally, the UCP may include a dryer to remove water or other undesirable liquid inclusions from the input or reaction products.

[0079] The basic process of the RXCP section begins with the complete or partial ionization of all or a portion of the source reactants introduced through the source inlet 110 and all other reactants introduced through one or more radiation-shielded reactant injectors 114, 116. This converts the source and reactants into a plasma. This is followed by the recombination of the resulting mixture of atomic species into their lowest energy state. The ionized source and reactants within the reactor are then placed in a plasma state. The resulting mixture of atomic species generates the output flow. The RXCP section uses a cylindrical cold field irradiation 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 irradiation cathode 150 and grid 155 together form an 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 a particular reaction. The radiation sources (R) described below 2 It should be noted that embodiments utilizing CP) can achieve similar current densities, photon energies, beam currents, and fluences.

[0080] During operation, the cathode 150 is charged using a power supply (not shown in FIG. 1 ) that meets the voltage, current, and, if used in pulsed mode, rise time and pulse repetition rate requirements. 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 places the tube in a standoff state (non-conducting state). When a control signal of ground potential is applied to the grid 155, the grid releases control over the cathode 160, causing the cathode to discharge. Electrons then travel from the cathode 150 to the anode 160. When they strike the anode 160, x-rays and secondary electrons are generated. The x-rays and secondary electrons are emitted isotropically 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 the region of the irradiation volume to provide some control over the desired transmission. 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 an important role because they dramatically increase the number of potential reactions. Each released secondary electron can in turn strike an atom within the anode, causing further x-ray emission and additional secondary electron irradiation. 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, sealed under high vacuum, and penetrate the biological radiation shield 165 and the vessel enclosure.

[0081] Instead of a cold cathode field-irradiated 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 nuclear radioisotope sources with appropriate gamma ray output and half-life. The entire UCP device is surrounded by radiation shielding 365 with a thickness proportional to the X-ray (or gamma ray) energy produced.

[0082] X-rays generated by the RXCP section enter the central portion of the main chamber 135, called the radiation zone 170, spatially bounded by a lower limit 185 and an upper limit 187 within the vessel. Within the radiation zone, preset compounds and atoms are partially or fully ionized into constituent ions of existing atomic species by the mixing of X-ray photons with secondary electrons generated by the gun and other collisional interactions within the reaction zone. Simultaneously and synchronously, secondary, tertiary, and additional reactants can be injected into the reaction space and fully ionized simultaneously or sequentially. The radiation zone contains intentionally high levels of turbulence, ensuring thorough mixing and interaction of all ions, electrons, atoms, and molecules. 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 alter this. The natural tendency of the system is to produce the lowest energy state compound. By adjusting various parameters, it is possible to determine exactly what molecules will emerge upon recombination (when the X-ray flux is stopped). 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; 2) the x-ray current; 3) the x-ray pulse duration (either in pulsed or continuous mode); 4) the ratio of the first and second (and subsequent, if any) reactants; 5) the flow rate of the reactants through the reactor and the particular chemicals selected as reactants; 6) the use of catalysts; etc.

[0083] 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 through a single reactant injector. Note that the injection ports can be large to allow for large volumes of reactants to flow into the radial zone 170, as desired in some fluidized bed applications (see FIG. 3). The number of injection ports can be reduced as needed.

[0084] To preserve the molecular structure of the reactants prior to injection, it is necessary to provide an X-ray shielded injection means. This prevents premature dissociation or premature partial or complete ionization of the injected reactants prior to the introduction of either or both the source material and the 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 lined 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 equipped with a nozzle (e.g., 127). Also included in Figure 1 is a plan view (non-cutaway view) of another shielded reactant injector (a UCP can contain 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.

[0085] Additional electrodes, either in the form of separate electrodes or electrically insulating shielded reactant injectors, can be included here for plasma support and field enhancement, or external magnetic coils can be provided for plasma confinement or field generation. It is also possible to support both conditions, but such configurations are functionally redundant.

[0086] Both the source material and the reactants enter the main chamber 135 and are exposed to 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 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.

[0087] The operation of the fluidized bed can be enhanced by one of several methods within the UCP. The first is to generate a plasma within the fluidized bed. This can be accomplished by one of several methods. One is to turn on the X-ray emitter in the RXCP. This generates high-energy ionizing radiation, enhancing 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 generates a plasma with lower energy than that generated using X-rays. The third method is to apply an RF signal, also via an insulated electrode. This generates a plasma with an energy intermediate between that generated by X-rays and DC. The choice of ionization method depends on the desired end result of the resulting reaction. In this regard, it should be noted that the high temperature of the plasma generated within the reaction chamber can be sufficient to trigger various reactions, even during the roasting process.

[0088] Because the plasmas contemplated by this invention are highly reactive, it is desirable to provide a means of directing the plasma away from the walls and the injector. There are three primary means for achieving this: (1) electrostatically (as shown in FIG. 6), which is the preferred embodiment; (2) electromagnetically (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 injection of various reactants and irradiation by both x-rays and secondary electrons.

[0089] FIG. 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, and 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, and 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. Note that other field configurations are possible. Additionally, note that one or more reactant injectors can be utilized as electrodes for generating the electrostatic field.

[0090] Figure 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, and 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, and 708 generate a magnetic field, represented 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. Note that other coil and electromagnetic field configurations are possible.

[0091] It is also desirable to be able to dry materials within the UCP. Figure 11 shows a cross-sectional view of an embodiment of a UCP with 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 interior 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 external to the interior volume of the UCP.

[0092] Prior to processing, an online analysis of the feedstock 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 of the chamber to confirm 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 Figure 1) provide an instrumented distribution and feedback system for controlling the precise 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 feed inlets, flow meters, and mass spectrometer, combining all information sources and utilizing artificial intelligence-based operations to ensure that 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 system's inputs and outputs.

[0093] The host computer is configured to compare mass spectrometer data generated from the raw material inputs and outputs with other data sources and compare the output data with a reference spectrum of the desired end product, among other data sources. 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 performs additional analytical iterations to determine whether the adjustments made have moved 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 iterations until the output stabilizes within set lower and upper limits. If the resulting output product is determined to be 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 predetermined ranges, indicating a safety issue.

[0094] As reactions occur within the main chamber 135, certain compounds precipitate and are removed from the system's output through one of the output ports. This process can be repeated one or more times, resulting in an effluent that is free of unwanted chemical and any biological components. For example, when UCP is used in water treatment, it breaks down complex organic compounds, such as pharmaceuticals or pesticides, that may be present.

[0095] The RXCP section of the UCP can operate as a flash X-ray irradiator (FXI). In FXI mode, high-intensity X-rays are typically applied to the reaction zone while the reactant supply is turned off. In this mode, raw materials are typically introduced through the raw material inlet port, while the remaining ports remain turned off. However, depending on the circumstances, it is possible to supply materials 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 complex molecules when they are exposed to intense X-ray irradiation that substantially exceeds the K-edge binding energies of the individual elements involved. This particular process is useful when organic components are present and need to be removed. Intense X-ray irradiation in FXI mode destroys any organic material, decomposing it into its constituent elements, which then reassemble into their lowest-energy 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, the components used to generate x-rays in either RXCP mode or FXI will be referred to in this application as RXCP.

[0096] To combine a fluidized bed with an RXCP, certain modifications are made, taking advantage of the fact that an RXCP typically incorporates a cylindrical process section. One possible modification is the addition of a perforated bottom plate with a supply connection 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 it is mounted horizontally. Depending on the specific 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 enhance separation efficiency. Note that the location of the inlet and outlet ports depends on whether the UCP is used in batch or continuous mode, and whether it is used horizontally or vertically. When operating a UCP as a fluidized bed in a horizontal position, the diffuser and catalyst must be repositioned to accommodate this orientation, since fluidized bed operation requires the diffuser to be located at the bottom of the fluidized bed. FXI function is achieved by turning off the reactant injection means and operating only the X-ray generation section of the UCP (i.e., the cathode, grid, and 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.

[0097] Regardless of the mode in which the UCP is used, 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 both electromagnetic and electrostatic field enhanced enhancement techniques, and any of the above can be run in a plasma or non-plasma environment as appropriate. Note 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. The R described below provides a detailed description of the R 2 CP can be used in place of RXCP in the above combinations.

[0098] Catalysts can be introduced into UCPs via the reactant feed to promote chemical reactions, or they can be permanently installed in the reaction zone. Catalysts are not consumed in catalytic reactions and therefore remain unchanged after the reaction. Many types of reactions often require only small amounts of catalyst. Furthermore, some reactions can only occur in the presence of a catalyst. The operation of both fluidized bed and RXCPs (and FXI) can be enhanced by the use of catalysts under certain circumstances. Generally, chemical reactions occur more quickly in the presence of a catalyst because the catalyst provides an alternative reaction pathway or mechanism with a lower activation energy than non-catalytic mechanisms. In catalytic mechanisms, the catalyst typically reacts to form an intermediate, which then regenerates the original catalyst within the process. Many materials can function 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 are considered electron acceptors (i.e., Lewis bases and Lewis acids, respectively). In plasma chemistry, the potential for excess electrons to be generated can sometimes eliminate the need for ligands. While this is not true for all reactions, it can be a significant cost-saving factor in some.

[0099] In the case of the fluidized bed portion of the UCP, the use of catalysts has been investigated, and the presence of a catalyst makes many reaction processes that take place in the fluidized bed possible. 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 existing ions immediately attempt to recombine into their lowest energy state, as described above. The introduction of a catalyst can modify this process, causing certain compounds to form preferentially over others.

[0100] Depending on the use of UCP, it is often useful to improve process results by pre-filtering the feedstocks and reactants to remove as many particulate reactants as possible to minimize the amount of material the reactor must process, and post-filtering to remove precipitates. 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 separation is preferred because it provides continuous, high-volume separation, there are numerous hardware suppliers, and hydrocyclone separators require less maintenance than basket filters. A major drawback of hydrocyclone separation is that it is not as effective at removing fine, microscopic contaminants as basket filters or other processes. Note 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.

[0101] Similarly, the RXCP section of the UCP is designed to produce a precipitate of some compounds in the output stream so that they can be separated and used for other purposes. Although many other means are possible, multi-stage basket filters with progressively finer pore sizes are an excellent way to achieve the desired cleanliness.

[0102] FIG. 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 provided to a 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 being input 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.

[0103] Similarly, fluidizing medium supply 512 delivers fluidizing medium through a supply line monitored by 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 fluidizing medium flow meter 514 and fluidizing medium inlet port 112 of UCP 100. Both fluidizing medium flow meter 514 and fluidizing medium control valve 518 are communicatively connected to host computer 550, with fluidizing medium flow meter 514 providing measurement signals to host computer 550 and reactant supply control valve 528 receiving command signals from the host computer and adjusting the supply of reactants according to the operating conditions of the UCP. Similarly, reactant supply 522 may include a tank or other vessel and delivers reactants through a supply line monitored by reactant flow meter 524, which measures the mass flow rate of the input reactant. A 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 coupled 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 according to the operating conditions of the UCP. In some embodiments, an additional reactant supply 532 supplies additional reactants (which may be different from the reactants from the reactant supply 522) to a secondary reactant supply line that connects to the feedstock supply line via the feedstock control valve 504. The feedstock and secondary reactants are thus supplied to the UCP 100 via the feedstock input line 110. The secondary reactant flow meter 534 measures the mass flow rate through the secondary reactant supply line and sends a measurement signal to the host computer 550. The raw material, fluidization medium and reactant supplies 502, 512, 522, 532 can comprise pipes rather than tanks in continuous mode.

[0104] The flow meter and control valve pairs 504 / 508, 514 / 518, and 524 / 528 can be, but are not required to be, implemented in separate devices. In some embodiments, both the metering and fluid regulation 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.

[0105] 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 ). 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). 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 pressure irradiation 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 exiting the main output port 145 may be the desired product of a reaction induced by an RXCP or FXI operation and may lead to a tank, pipe, or additional process component. When used in batch mode, a single reactor can be used to carry out various process steps in sequence by varying various feed and electrical parameters. When operated in continuous mode, there are fewer simultaneous operations and multiple UCPs can be coupled in sequence or otherwise to implement a particular process.

[0106] A host computer 550 is also communicatively connected to pressure illumination 138 for regulating the pressure within the UCP. Host computer 550 is configured to evaluate flow rate information received from the flow meters and information received from the mass spectrometer regarding the composition of input reactants (all reactants including raw materials) and output products and to control the flow of materials to the UCP via control valves 504, 514, 524. For example, the host computer may determine that a reaction is proceeding too quickly and issue commands to restrict the flow of input materials to slow the reaction rate.

[0107] A power supply 545 provides power to the cathode and grid of UCP 100. 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 grid 155 of the RXCP and switches the electron gun on and off. A radioisotope source is provided in the embodiment (R) described below. 2 When used as a CP, the power supply can be substantially simplified since the ionization source does not need to be electrically powered.

[0108] When the UCP is used to separate 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 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.

[0109] The UCPs described herein offer many synergies and advantages over stand-alone components and other types of chemical process equipment. The presence of an enhanced fluidized bed increases 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 UCPs, which allow multiple processes to be performed in a single system. Furthermore, it is possible to change processes without major rework (e.g., changing operation from exclusively in fluidized bed mode to fluidized bed mode with an 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 with individual stages.

[0110] UCPs also have 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.

[0111] With respect to the mining industry, and particularly rare earth element mining and recovery, the disclosed UCPs fulfill a long-felt need. The types of operations that UCPs can perform can eliminate the need for toxic and 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 significant. The combination of effective material separation using fluidized beds, removal of environmental toxins, and elimination using the RXCP's ability to reform or decompose hazardous by-products means that rare earth processing need not be an environmentally harmful 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 UCPs break the near-monopoly that small groups of countries have maintained over rare earth processing.

[0112] It should be 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, causing serious environmental problems. Essentially the same process for removing radioactive materials from phosphogypsum waste described herein (see Example 2 below) can be advantageously utilized in the oil and gas industry for essentially the same requirements: i.e., removing radioactive materials from process streams (see Example 3 below). This is because radium and radon, like phosphogypsum gas, are the two primary radioactive components that need to be remediated.

[0113] Radioisotope embodiment (R 2 CP) As mentioned above, the RXCP / FXI section of the UCP requires a power supply to provide energy to power the electron gun, which ultimately produces ionizing radiation. There are situations where it would be beneficial to operate a UCP in locations where available electrical power is limited or even non-existent. In such situations, a radioisotope source can be used as the energy source of ionizing radiation, instead of a power-driven electron gun, since radioisotopes naturally emit ionizing radiation at a known rate. Some radioisotopes not only produce directly ionizing gamma radiation, but also other energetic particles (e.g., alpha and beta), which can induce the secondary production of other forms of ionizing radiation, such as x-rays and secondary electrons. In the following sections, we will discuss radioisotope-based reactive chemical process devices (hereafter referred to as "R"). 2 CP,” which describes an embodiment of a Reactive Radioactive Chemical Processor (the 2 is a superscript and stands for “R-squared CP”).

[0114] R 2 CPs function similarly to FXI / RXCP / UCPs in that they also produce ionizing radiation, but in this case, rather than an electron gun, they use a radioisotope source that can be used to promote chemical reactions, induce decomposition and sterilization, and for other uses. More specifically, R 2 CPs can be used in modes similar to RXCP mode (which includes reactants to facilitate chemical reactions), FXI mode (which does not include reactants and is more used for digestion and sterilization), and can be used in UCPs with the ability to support a fluidized bed as well as other modes. 2 CP can be used in any and all of the following chemical reactions described for RXCP and FXI.

[0115] FIG. 12 shows the R 2 FIG. 1 is a longitudinal cross-sectional view of an embodiment of a CP. 2The CP includes a central pipe 1010 through which the medium and reactants flow. Within the central pipe 1010 is a streamlined, cylindrical radioactive element 1020 containing radioactive material. The streamlined, cylindrical radioactive element 1020 can be solid or formed as a hollow cylinder. Advantageously, for this application, spent nuclear fuel rods from a nuclear reactor can be used as the streamlined, cylindrical radioactive element 1020. This application therefore provides a solution to a major challenge for nuclear electric energy generation and the disposal of hazardous nuclear waste. Fuel rods no longer suitable for generating nuclear energy still contain sufficient radioactive material for the purposes of the UCP. The fuel rods 1020 (either new or used) can be in their original state, or chopped, crushed, or dissolved in acid (which is then neutralized). This facilitates casting the material as desired. The centrally located, streamlined, cylindrical radioactive element 1020 is sealed inside either a stainless steel or zirconium container. The centrally located, streamlined, cylindrical radioactive element 1020 container may be pointed to help stabilize the flow. The centrally located, streamlined, cylindrical radioactive element is connected to a central pipe 1010 and supported therefrom using a pair of three-point suspension fins 1024, 1028 (two of which are shown), whose fin-shaped cross-section also provides stability to the flow. Note that the support fins 1024, 1028 can be tilted to introduce turbulent flow conditions, which has the effect of increasing the duration of exposure. A biological radiation shield 1030 surrounds the central pipe 1010 and prevents radiation from leaking outside the device. The shield 1030 is preferably made of lead, but any suitable shielding material, such as concrete, steel, natural stone, or any other suitable material of appropriate atomic density, can be used. Flanges 1034, 1038 are located at both longitudinal ends of the central pipe and provide a platform for leak-proof connection to the piping system that delivers and removes materials from the reactor.

[0116] Regardless of how the centrally located, streamlined cylindrical radioactive element is formed, whether solid or hollow, centrally located or circling a reactant, the salient factor is that the amount of radioactive material and ionizing radiation it produces is sufficiently energetic for multiple ionizing events to produce the required degree of ionization and to provide sufficient levels of ionizing radiation. In some embodiments, the fuel rods 1020 can incorporate particles of cobalt-60, thorium-232, uranium-233, plutonium-239, cesium-137, and the like. Other radioactive isotopes are also known as R 2 Any material can be used as long as it has a sufficiently long half-life and can produce sufficiently high energy particles to achieve the many ionization events required by the CP process.

[0117] Figure 13 illustrates a variation of the embodiment shown in Figure 12. In this embodiment, R 2 The CP 1100 includes a removable shielding lid 1110 that, when closed, provides a radiation-tight environment. The lid is coupled to the source assembly components and includes a lifting ring 1115 that allows the assembly containing the centrally located, streamlined, cylindrical radioactive element 1120 to be removed and replaced with a new fuel rod. R 2 The spent fuel removed from CP1100 is then placed in a shielded container, which is in turn securely mounted onto a vehicle such as a truck, rail car or ship for transport from the site to a waste disposal site.

[0118] In a preferred embodiment, R 2 It should be noted that robotic equipment is used to connect, remove and replace fuel rods in the CP. For this purpose, the robotic equipment utilizes the lifting ring interlocking features and R 2 The use of robotic devices is not only due to safety concerns when handling radioactive materials, but also due to the need to maintain the CP. 2 CP is important because it is intended for use in remote locations where people are not present, or even extraterrestrial locations such as the Moon.

[0119] FIG. 14 shows the R 2 14 is a longitudinal cross-sectional view of another embodiment of the CP. 2 The CP 1200 comprises a central pipe 1210 having a thin-walled section similar to the FXI, RXCP, and UCP and conforming to the same design formulas. In this embodiment, radioactive material is not contained within the central pipe 1210. Rather, the thin-walled section of the central pipe 1210 is circumferentially surrounded by a jacket 1220 of radioactive material. The radioactive material contained in the jacket 1220 may be cast, machined, or in powder form. The jacket 1220 is, in turn, surrounded by a biological radiation shield 1230, which, as in other embodiments, may be made of lead or another suitable shielding material.

[0120] In all embodiments, the shielding is R 2 The radiation source contained within the CP is constructed to be sealed from the environment (in accordance with NRC regulations) and is designed to limit emitted radiation to background radiation levels.

[0121] It should be noted that, for both centrally located and circumferentially arranged radioisotope sources, the wall thickness of the material isolating the radioisotope source from the material being processed can be manipulated to reduce the level of gamma ray irradiation of the radioisotope source to a predetermined energy appropriate for the diameter of the central pipe and the density of the material being processed. This allows for a higher-energy gamma ray source to operate in the same energy range as the electron gun of an FXI / RXCP / UCP device. Also, thicker wall sections are typically required for the isolation wall, which are easier to machine in an FXI / RXCP / UCP device because the walls can be very thin. This adjustability allows for a wider range of isotope sources to be used. In the case of circumferentially arranged radioisotope sources, the wall thickness parameters are determined prior to fabrication based on the use of a particular preselected radioisotope source. In the embodiment shown in FIG. 4, the source is removable and a different source can be installed, allowing for a wider range of energy types for irradiation or for installing a different isotope source if one is available, replacing a previously installed source. For most applications, it is important to keep the energy of the irradiated gamma rays reaching the main chamber below 1.2 MeV, known as the pair production threshold. Irradiation above this level can induce radioactivity, an outcome that should be avoided in most applications.

[0122] R 2 A possible embodiment of CP is its use in space exploration, where it finds uses similar to those previously described, as well as for converting minerals in extraterrestrial natural objects into more useful chemicals or compounds, which may be for constructing structures in such extraterrestrial natural objects or for commercial implementation.

[0123] It should be 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, causing serious environmental problems. Essentially the same process for removing radioactive materials from phosphogypsum waste described herein (see Example 2 below) can be advantageously utilized in the oil and gas industry for essentially the same requirements: i.e., removing radioactive materials from process streams (see Example 3 below). This is because radium and radon, like phosphogypsum gas, are the two primary radioactive components that need to be remediated.

[0124] Example Reactions: To illustrate UCP operation, some example reactions are shown: 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 was ionized and reacted with purified oxygen to produce H2O2 in the following reaction:

number

[0125] This reaction can be adjusted to produce any desired concentration of H2O2. Note that above 20% concentration, H2O2 becomes increasingly unstable to the point that it may explode. For most concentrations above 10%, stabilizer chemicals are added to alleviate this problem.

[0126] Traditional methods for producing H2O2 involve the use of large quantities 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 byproduct.

[0127] 2. Production of phosphoric acid and hydrofluoric acid from fluoroapatite ore: The conventional wet chemical process for producing these products is as follows:

number

[0128] 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, where it is ionized and reacts with hydrogen sulfide gas and oxygen to produce the same end product. Care must be taken when setting the reactor operating parameters to maintain process stoichiometry. The reaction is as follows: To obtain the same end product using UCP, Ca5F(PO4)3 is mixed with water and flowed through a UCP reactor, where 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 process stoichiometry. The reaction is:

number

[0129] It should be noted that while H2SO4 is used as a liquid reactant (traditional process), the plasma process uses hydrogen sulfide and oxygen as gaseous reactants, which are more suitable for plasma processing. In a preferred embodiment, proper 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 additional process steps. The advantage that UCP brings to this process is the absence of toxic liquid waste, as unwanted byproducts are irradiated as gases and destroyed by pollution control devices in a pyrolysis unit at the process pump exhaust. This is an incinerator placed in series with the process pump exhaust and the building's air exhaust. 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.

[0130] 3. Separation of actinides from fluorapatite or phosphogypsum: Fluoroapatite rarely exists 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. Small amounts of other actinides are also frequently found. Therefore, at some point, the actinides must be separated from the fluoroapatite (or phosphogypsum) and lanthanides. Depending on the local conditions and regulations at the mine, this separation can occur before or after the fluoroapatite reaction described in #2 (above), but it is usually performed before the reaction to avoid generating large amounts of radioactive waste. It is desirable to remove the radioactive material (actinides) from fluoroapatite or phosphogypsum (byproducts of fertilizer, hydrofluoric acid, and phosphoric acid production) 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 UCP can completely eliminate the wet chemistry and associated contaminants. In this case, the UCP is used in fluidized-bed mode. Fluoroapatite 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, exiting 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 based on particle density. 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.

[0131] There are other methods for separating actinides and lanthanides from phosphogypsum or fluoroapatite using UCP. Typically, uranium, thorium, and radium are the predominant actinides found in fluoroapatite 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

[0132] 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.

[0133] 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 resulting ions are then recombined to their minimum energy state according to a process previously described in U.S. Patent No. 8,019,047, "Flash X-ray Irradiator." Hydrogen and oxygen ions also recombine back into water. The resulting water is now free of long-chain organic contaminants and is also sterilized. The reason a UCP system (in FXI or RXCP mode) can achieve this level of ionization and associated decomposition is because the X-rays (or R 2This is because the incident energy from both the gamma rays and the secondary electrons produced in the case of CPs 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 is true for all organic compounds, biologicals, petrochemicals, and pharmaceutical products. Note that to further remediate contamination, UCPs can be operated in RXCP mode and used to add hydrogen peroxide (H2O2) to contaminated water, as previously described.

[0134] Sufficient doses of X-rays or gamma rays are lethal to biological organisms in several ways, including, but not limited to, disrupting DNA by breaking molecular bonds, inducing genetic damage, and chemically altering key biological macromolecules, all of which lead to the death of the organism. During sterilization, the sample of interest is irradiated with high-energy X-rays, electrons, or gamma rays at sufficient fluence, leading to the formation of highly unstable free radicals, molecular ions, and secondary electrons, as well as X-rays. These radiations then react with nearby molecules, causing breakage and altering chemical bonds. DNA, in particular, is highly sensitive to the damaging effects of radiation, undergoing disruption, depolymerization, mutation, and structural changes when exposed to ionizing radiation. Failure to fully repair DNA damage results in the loss of genetic information and cell death. The sensitivity of a given biological organism to radiation is measured by its D value (D 10 value), given by the dose that reduces the microbial population by 10-fold.

[0135] 5. Removal of marine pollutants 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 positioned between the bows that can be lowered into the sea while the vessel is moving. The dredger directs contaminated water through pipes to a UCP operated in either FXI mode (the simplest form) or RXCP mode, which adds oxygen to form hydrogen peroxide. In FXI mode, radiation alone is used to break down 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 contaminants. Note that in either process mode, all fish passing through the reactor will likely die. This can be prevented by covering the inlet with a mesh to prevent fish from entering the unit. Note that this implementation may require periodic cleaning to remove fish and other material caught in the mesh, or a signal in the water ahead of the vessel to disperse the fish. Furthermore, note that oxygen is not the only additive that can be used in this application. Other gases, such as chlorine, can be successfully used to achieve similar results.

[0136] To implement this application, a generator and high-voltage power supply would be required on board the boat, in addition to the UPC or derivative. Additionally, if the boat's speed does not exceed a predetermined limit, a pump would be required to ensure sufficient water passes through the UCP or derivative. After passing through the irradiation device, the treated water is discarded back at the stern of the boat into the backwater. Note that this method of removing algal growth is not limited to surface floating. The dredger can be positioned at any desired depth, taking into account the vessel's speed 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.

[0137] Similarly, the same equipment is used in the case of oil and chemical spills. When toxic gases or flammable materials are involved, care should be taken to protect the ship's operators.

[0138] Typically, a large spill, such as in the ocean, a gulf, a large bay, or a strait, may require a faster, smaller vessel. This also increases the demand for power, as the illumination system must operate at higher illumination levels. 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 electric power industry for peak generation, can be used. The exhaust generates 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, more conventional motor and propeller systems are also included in low-speed maneuvers. The steering system propeller needs to be capable of feathering for high-speed operation.

[0139] 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 placed to prevent radiation from the irradiation system from hitting the operator. Note that when the system is not operating, 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.

[0140] R 2 When CP embodiments are used in marine applications, the weight from eliminating the electron guns, generators, and fuel supply is generally offset by the weight of the necessary added biological shielding required to make the vessel safe for a human operator. The loss of jet propulsion is compensated for by including larger conventional engines than would be required for slow speed operation and close-in maneuvers.

[0141] 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 or more ways to implement the present methods to those skilled in the art.

[0142] It should be further understood that like numerals in the figures represent like elements throughout the several figures, and that not every component or step described and illustrated with reference to the figures is required for every embodiment or configuration.

[0143] 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 either the term "comprise" or "comprising," when used herein, specifies the presence of stated features, elements, steps, operations, factors, and / or components, but does not exclude the presence or addition of one or more other features, elements, steps, operations, factors, components, and / or groups thereof.

[0144] 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.

[0145] Also, the phraseology and terminology used herein is 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.

[0146] 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 recitations in the following claims and the structures, functions, or steps equivalent to those recitations.

Claims

1. 1. A universal chemical process apparatus (UCP) comprising a reaction vessel having a longitudinal central axis and a main chamber, the UCP comprising: a first inlet port for a main ingredient leading to the main chamber; a second inlet port for fluidized medium leading to the main chamber; a third inlet port for one or more reactants entering the main reactor chamber; and Reactive radiochemical process equipment (R ２ CP), and ２ CP is, a radioactive element extending along the longitudinal axis within the main chamber; and an output for a product generated within the UCP. 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 via the first and second inlet ports; and The R ２ The UCP, wherein the radioactive element of the CP ionizes feedstocks and reactants, inducing chemical reactions and irradiating them with ionizing radiation capable of sterilizing and decomposing all organic materials within the radiation zone.

2. The UCP of claim 1 , wherein the radioactive element is centrally located in the main chamber and has a streamlined shape.

3. 10. The UCP of claim 1, wherein the radioactive element comprises spent fuel rods obtained from a nuclear facility.

4. 3. The UCP of claim 2, further comprising a removable shielding lid coupled to a wall of said main chamber that allows a centrally located, streamlined, cylindrical radioactive element to be removed from and replaced therein.

5. The UCP of claim 1 , wherein the radioactive element is formed as a jacket circumferentially surrounding a thin longitudinal section of the main chamber wall.

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

7. The UCP of claim 5 , wherein the catalyst is disposed on one of a screen, a plate, and a container within the main chamber.

8. In the work, ２ The UCP of claim 1 , wherein the fluidized bed is capable of being supported while the UCP irradiates ionizing radiation.

9. The UCP of claim 1 , wherein the first, second and third inlet ports are shielded against the ionizing radiation.

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

11. 11. The UCP of claim 10, further comprising a diffuser disposed at the bottom of the reactor downstream from the first feedstock inlet port and the second fluidization medium inlet port and operative to assist in uniformly distributing the fluidization medium and feedstock in the main chamber.

12. 6. The UCP of claim 5, wherein the thickness of the vertical section of the wall isolating the envelope from the main chamber is manipulated to reduce the energy level of gamma radiation emitted from the envelope to a predetermined energy appropriate for the diameter of the central pipe and the density of the material being processed.

13. 13. The UCP of claim 12, wherein the thickness of the longitudinal section of the wall is engineered such that the energy of the irradiated gamma rays is less than 1.2 MeV.

14. 1. A method of chemical processing comprising the steps of: configuring a reaction vessel for receiving the feedstock, the fluidization medium, and the reactants and for supporting a fluidized bed; and The method includes disposing a radioactive element within the vessel operable to emit ionizing radiation to a radiation zone within the vessel.

15. 15. The method of claim 14, wherein the radioactive element is located in the center of the reaction vessel and has a streamlined shape.

16. 15. The method of claim 14, wherein the radioactive elements comprise spent fuel rods obtained from a nuclear facility.

17. removing the fuel rods from the vessel via a removable shielding lid when the ionizing radiation is below a threshold level; and placing a fresh fuel rod into the vessel through the removable shield lid.

18. 15. The method of claim 14, wherein the reaction vessel comprises a wall surrounding an interior side of the chamber, and the radioactive element is formed as a jacket circumferentially surrounding a thin longitudinal section of the wall on the interior side of the chamber.

19. The method of claim 14 , wherein the radioactive element is operative to ionize feedstock and reactants within the radiation zone.

20. 15. The method of claim 14, wherein the fluidized bed is supported while the radioactive element emits ionizing radiation.

21. The method of claim 14 , wherein the reaction vessel is disposed in an extraterrestrial natural environment.

22. introducing a mineral material found in the extraterrestrial natural environment into the reaction vessel; and subjecting the mineral matter to a chemical reaction by exposing it to a reactant and to ionizing radiation produced by the radioactive element.

23. 20. The method of claim 18, wherein the thickness of the vertical section of the wall isolating the envelope from the main chamber is manipulated to reduce the energy level of gamma radiation emitted from the envelope to a predetermined energy appropriate for the diameter of the central pipe and the density of the material being processed.

24. A reactive radiochemical process apparatus (R) for inducing chemical reactions, decompositions and other modifications, comprising a reaction vessel having a longitudinal central axis and a main chamber. ２ CP), the device comprising: a first inlet port for a main ingredient leading to the main chamber; a second inlet port for fluidized medium leading to the main chamber; a radioactive element extending along the longitudinal axis within the main chamber; The R ２ The radioactive elements of the CP irradiate the raw materials and reactants with ionizing radiation capable of ionizing the raw materials and reactants, inducing chemical reactions, and sterilizing and decomposing all organic materials within the radiation zone. ２ C.P.

25. 25. The R of claim 24, wherein the radioactive element is located in the center of the reaction vessel and has a streamlined shape. ２ C.P.

26. 25. The radioactive element of claim 24, wherein the radioactive element comprises spent fuel rods obtained from a nuclear facility. ２ C.P.

27. 26. The R of claim 25, further comprising a removable shielding lid coupled to a wall of the main chamber that allows the centrally located, streamlined, cylindrical radioactive element to be removed from and replaced therein. ２ C.P.

28. 25. The radioactive element of claim 24, wherein the radioactive element is formed as a jacket circumferentially surrounding a thin longitudinal section of a wall within the chamber. ２ C.P.

29. 25. The R of claim 24, wherein the thickness of the longitudinal section of the wall isolating the envelope from the main chamber is manipulated to reduce the energy level of gamma radiation emitted from the envelope to a predetermined energy appropriate for the diameter of the central pipe and the density of the material being processed. ２ C.P.

30. 30. The R of claim 29, wherein the thickness of the longitudinal section of the wall is manipulated such that the energy of the irradiated gamma rays is less than 1.2 MeV. ２ C.P.

Images