Method for the treatment of comminuted matter by electrical discharge

Abstract

A method for the treatment of matter by plasma action to produce a glassy product. A plurality of electrode structures are positioned to define a reaction zone associated with the inter-electrode space. The inter-electrode space is conditioned (as by preionizing) and a series of discrete electrical discharges are produced throughout the reaction zone. In a preferred embodiment, the reaction zone is subjected to a sequence of discrete electrical discharges in a time interval less than the residence time of material to be treated within the reaction zone.

Description

BACKGROUND OF THE INVENTION

The present invention relates generally to the treatment of matter by interaction with plasma and, in particular, to a method for bringing about structural changes in comminuted matter via discrete electrical discharges.

The relatively high energy levels available from plasma have recognized value in the processing of many particulate materials. Typical known methods of generating plasma have relied on the conversion of electric current into high temperature effluents of one kind or another which, by virtue of their high temperature and enthalpy, interact with the feedstocks, bringing about a higher rate of reaction than would take place at a low temperature. Most conventional methods of producing low temperature plasma, plasma torches ("plasmatrons"), for example, have not proven industrially useful for the treatment of tonnage quantities of particulate matter, in themselves.

The difficulties encountered in the treatment of particulate materials with low temperature plasmas are discussed in U.S. Pat. No. 4,361,441 issued Nov. 30, 1982 in the name of Jozef K. Tylko, the inventor herein, which patent is hereby incorporated by reference. The expression "low temperature plasma" as defined in the incorporated patent is an arbitrary reference to plasmas having an ion temperature below 100,000.degree. K. That convention is retained herein. Further, the term "particulate matter," as used herein, includes solid particles as well as fluids (gases or liquids), and combinations or mixtures thereof. "Comminuted matter", as that term is used herein, includes solid particulate matter.

As described in the incorporated patent, the industrial application of low temperature plasma technology has developed along two different routes. The first route (in which the volume of the arc discharge was not used for entrainment of feed stocks) chiefly utilized the point of impingement of the arc at the anode and behaved in this respect very much like electric arc furnaces. The second route, more relevant to the present invention, aims at the treatment of particles in the whole volume of the plasma produced-treatment "in flight." For this purpose, it was required to expand the plasma and this involves increasing its original volume. This is the development of Jozef K. Tylko, the inventor herein.

Two distinct methods for plasma expansion are discussed in the incorporated patent. It should be noted that both of these methods involve the establishment and maintenance of an expanded plasma volume. The more relevant of these methods to an understanding of the present invention is initially disclosed in British Patent Nos. 1,390,351-3. In this method, a plasma torch acting as a cathode was made to orbit in a circular path and at a small angle with the vertical, projecting the arc to a downstream annular electrode. A truncated conical plasma region was defined by the orbiting arc discharge. This method served well as a laboratory plasma furnace for studying many reactions. However, mechanical limitations resulting from the need to orbit the torch severely limited the industrial utility of this method.

The method of the incorporated patent addressed many of the limitations of the orbiting torch technology discussed above. In this methodology, an arc discharge was generated between stationary electrode structures, at least one of those structures being annular. As indicated in the incorporated patent, a primary requirement of the system was the establishment and maintenance of an expanded plasma within the reaction zone between the electrode structures. Early versions of the methodology of the incorporated patent also required utilization of a plasmatron. Later versions utilized a simple electrode structure as the central cathode while maintaining an annular ring structure for the anode, the annular anode being formed by multiple anode segments. Such a system is discussed in a thesis prepared by Steven Anthony Vrchota in partial fulfillment of the requirements of a degree of Masters of Science at the University of Minnesota dated April, 1991 and entitled Use of the Sustained Shock Wave Reactor for the Recovery of Metals From Electric Arc Furnace Dust.

The method of the incorporated patent allowed a heavier loading of matter to be treated while taking advantage of an apparently anomalous behavior of at least some matter in such plasmas. It was concluded that the presence of a dense suspension of particles in the plasma zone increased the effective energy flux causing rapid plasma-solid interactions. It was noted that these interactions need not be purely thermal and, indeed, that the method of the incorporated patent utilized these non-thermal (anomalous) phenomena.

As indicated above, the difficulty in these prior art methods is maintenance of the plasma-forming arc discharge. Generally, as the quantity of matter introduced into the expanded plasma increased, the likelihood of extinction of the arc increased. Extinction of the arc stops the processing, with many attendant problems. This difficulty was addressed in the incorporated patent by the utilization of a rapidly fluctuating potential difference between the cathode and the anode electrode structures while that discharge was circulating about the periphery of the annular electrode structure (anode). However, maintaining the plasma at industrially significant feedstock loading remained a problem. A pattern of least energy configuration would be established. Also, significant loading volumes remained a problem in themselves, in that not all particles were treated.

In summary, the method of the incorporated patent resolved the mechanical limitations in the prior art by orbiting the arc by non-mechanical means whereby rapid rates of "rotation" far greater than those possible by mechanical means were attained. Additionally, pulsation of the arc by rapid changes in the applied power established conditions which improved the ability to maintain the arc discharge while also utilizing non-thermal phenomena which enhance the plasma action on the matter being treated. However, the perceived need to maintain the arc discharge orbiting around the annular electrode structure significantly limited the industrial utility of the method. Also, significant loading volumes remained a problem. During operation, a pattern of least energy configuration was established. As a result, particles were not uniformly treated.

SUMMARY OF THE INVENTION

The present invention provides the advantages of the method of the incorporated patent while dispensing with the need to maintain an orbiting arc discharge. Instead, a series of discrete electrical discharges are utilized in a treatment or reaction zone defined by spaced electrode structures, the treatment zone containing large amounts of particles to be treated and the discharges acting on these particles "in flight." As described herein, these discharges may be sequential in time, but need not be sequential in space and may overlap in time and space and may be simultaneous. Thus, the criticality of maintaining a sequential orbiting discharge is eliminated.

As noted in the incorporated patent, the presence of a dense suspension of particles in the treatment zone increases the effective energy flux while utilizing non-thermal phenomena first recognized in the method of the incorporated patent. In particular, it is believed that these non-thermal phenomena are the result of the formation of "microfields" in which very high local potential differences and other associated fluctuating anomalies occur. These high local potential differences and associated anomalies appear to have a pronounced effect on the particles being treated, such as the imposition of electrical and mechanical stresses, assisting disruption and causing polarization, increased ionization, and interaction with solid state effects. Effects of this character are essentially primarily non-thermal and reside in the microscopic mechanisms of plasmas. As noted in the incorporated patent, they have been observed but have hitherto been dependent upon the establishment and maintenance of a sufficiently stable plasma for their economic utilization.

It is recognized that the model presented herein is highly simplified but does describe the basic mechanism which is believed to be operating within the present invention while pointing out the primary distinction between the present invention and the prior art--the necessity in the prior art of establishing and maintaining a stable expanded plasma. In a basic preferred embodiment in accordance with the present invention, a reactor is provided having spaced electrode structures defining a treatment zone. The treatment zone is preionized in any desired manner and discrete electrical discharges are produced throughout the treatment zone. The discrete electrical discharges are produced in a desired sequence and in a time interval less than, and preferably considerably less than, the transit time of the matter to be treated through the treatment zone. In a particularly preferred embodiment, and with any given electrode configuration, one or more of the electrode structures may alternatively function as anode or cathode. That is, the electrode structures, in accordance with the present invention may operate with a variable polarity. While this variable polarity, in itself, is an important feature of the present invention, it also highlights an essential difference between the present invention and the prior art. That is, an electrode utilized in the described prior art devices for the establishment and maintenance of an expanded plasma within the inter-electrode space must maintain its polarity for maintenance of the expanded plasma.

In particular, the present invention provides a method for the treatment of matter by electrical discharge including the steps of positioning the plurality of electrode structures to define a desired inter-electrode space or spaces, conditioning the inter-electrode space as by preionizing that space in any desired manner, introducing particulate matter to be treated to the inter-electrode space and producing a plurality of discrete electrical discharges in a desired sequence between said electrode structures. In accordance with this method, substantially the entire inter-electrode space is subjected to discrete electrical discharges within a time interval less than the expected residence time of a particle to be treated within the inter-electrode space. Accordingly, comminuted matter may be structurally changed by plasma action within the inter-electrode space, as described more fully below.

In a specific reactor embodiment, a conical treatment zone is established by a central cathode and a plurality of circularly disposed anodes longitudinally displaced from the central cathode. While superficially similar to the disclosed embodiment in the incorporated patent, the structure may be differentiated. In particular, an arc discharge need not "orbit" about an annular anode electrode structure. Instead, in accordance with the present invention, a series of discrete electric discharges may sequentially move along circularly disposed anode structures. Additionally, any or all of such circularly disposed electrode structures may function as a cathode--clearly differentiating the present invention from that of the incorporated patent.

Any number of distinct electrode configurations may be employed in accordance with the particular application. The reactor may be operated over a wide range of pressures (from below to above atmospheric pressure) and over a variety of regimes (reducing, oxidizing or neutral).

In accordance with the present invention, the reactor described above may be utilized to bring about structural changes in comminuted matter introduced into the treatment zone. In particular, comminuted matter is subjected to plasma action such that the crystalline inorganic content is converted to an industrially useful "glassy" product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic elevational view of a reactor according to the present invention;

FIG. 2 is a schematic illustration of a preferred electrode configuration in accordance with the present invention and their control;

FIG. 3 is a schematic diagram showing a preferred control circuit in accordance with the present invention;

FIG. 4 is a schematic diagram illustrating a modification to a portion of the circuit of FIG. 3;

FIGS. 5A-5F are schematic diagrams illustrating a sequence of discrete electrical discharges throughout a treatment zone defined by spaced electrode structures;

FIG. 6 is a table showing the on/off states of the power switches of FIG. 3 during part of an operating sequence.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a diagrammatic illustration of a reactor in accordance with the present invention which incorporates many elements know to the prior art and which may be utilized in the practice of the invention herein. In the reactor of FIG. 1, feedstock dispensers 10 are connected through electrostatic charging probes 11 to a modular head 12 which also receives gas for forming a plasma, coolant, and electrical supplies for the start-up electrode. Downstream of the plasma head 12 is a reaction chamber 13 and electrode assembly section 14. The remaining portions of the reactor FIG. 1 are application specific and are utilized, for example, if the reactor is to be used for energy recovery and include a combustion chamber 15 immediately below the electrode section 14 to which controlled quantities of air are injected, at 16, for example, to cause combustion of carbon value separated in the reactor chamber 13. A side duct 17 carries the resulting hot gases away for steam raising and electricity generation while the solid residues pass through a cooling chamber 18 to a collector 19.

The reactor illustrated in FIG. 1 is, in the general terms described, similar to that illustrated in FIG. 3 of the incorporated patent and has the same breadth of application as described in the incorporated patent.

Referring now to FIG. 2, there is shown an axial electrode structure 20 as may be contained in the modular head 12 of the reactor of FIG. 1 and a plurality of electrode structures 21-26 which may be circularly arranged about the longitudinal center axis of the electrode assembly section 14 of the reactor of FIG. 1. In the illustrated embodiment of FIG. 2, there are six electrode structures 21-26 which, in accordance with the present invention, may be simple rod shaped structures, graphitic or metallic, for example, to which a series of pulse charges are applied as described hereinafter. Similarly, in accordance with the present invention, the electrode 20 may be a simple rod structure similar to the electrodes 21-26. Each of the electrodes 20-26 is connected to a base current source 27 and a pulse current source 28 by associated switches 30 controlled via Switch Control 29. Preferred implementations of the switches 30 are discussed below with reference to FIGS. 3 and 4 and include control terminals, (represented by the terminal(s) 31 in FIG. 2) by which the potentials developed by base current source 27 and pulse current source 28 may be selectively applied between two or more of the electrodes 20-26, as described more fully below. The terminal(s) 31 may represent one or more control terminals as needed by a particular implementation. This is represented herein by the designation "terminal(s)". Terminal(s) 31 of Switch Control 29 are connected to the terminal(s) 31 associated with switches 30. Those connections are not shown for the sake of clarity but are within the skill of one ordinarily skilled in the art.

As described above, the central electrode 20 of FIG. 3 is axially arranged with regard to the electrodes 21-26 with the configuration of the electrodes 20-26 defining a treatment or reaction zone which coincides approximately with the interelectrode space. As will be appreciated by those skilled in the art, the electrodes 20-26, and particularly the electrodes 21-26, may be arranged in any desired configuration or arrangement to define or establish any desired inter-electrode space (or any treatment/reaction zone) between themselves or between themselves and the electrode 20. Nominally, in the implantation discussed herein, the electrode 20 may be referred to as a cathode while the electrodes 21-26 may function as anodes or, selectively as cathodes, as described below. Indeed, in some implentations of the present invention each electrode may function, selectively, as anode or cathode. Further, while six electrodes 21-26 are shown, any number of electrodes similarly constructed and electrically connected may be provided in accordance with the desired application. Those electrodes connected to function selectively as anode or cathode are sometimes referred to herein as variable polarity electrodes.

In operation, the switch 30 associated with electrode structure 20 is controlled, via its associated terminal(s) 31 and Switch Control 29, to connect the negative terminal of Base Current Source 27 to the electrode structure 20. Concurrently, one or more of the switches 30 associated with electrode structures 21-26 (and typically all of the electrode structures 21-26) are selectively controlled, via their associated control terminal(s) 31 and Switch Control 29, to connect the positive terminal of Base Current Source 29 to the selected ones of the electrode structures 21-26. The output of Base Current Source 29 is selected and controlled, in known manner, to establish a base current and thereby preionize the inter-electrode space. Of course, it is within the scope of the present invention to condition the inter-electrode space by preionizing in any known manner. This conditioning (by preionizing, for example) permits electrical discharges between selected electrode structures with practical potential differences. Such discharges are provided by selective application of pulses from Pulse Current Source 28 across the electrode structures 20-26 in a manner described more fully below. As will be apparent to those familiar with the art, sequential discharges between electrodes 20-26 will "condition" the inter-electrode space by maintaining an ionization level and may permit the base current to be discontinued during continued operation.

Any of the electrode structures 20-26 may function as a cathode with regard to the electrical discharges. Thus, it is apparent that selective control of the switches 30 allows the control of electrical discharges such that those discharges extend throughout the inter-electrode space. This is described with reference to FIG. 5. As described above, the interaction of these discharges with particulate matter to be treated within the treatment zone and, in particular, the effects of microfields within that zone, result in interaction with plasma (plasma action) without the necessity to establish and maintain an expanded plasma in the manner of the prior art. In the process described more fully below, this plasma action results in structural changes in the inorganic content of comminuted matter being treated.

FIG. 3 illustrates a preferred control circuit, and in particular, a preferred implementation of the switches 30 of FIG. 2. Throughout the several figures, like reference numerals are used to designate like elements. In the illustrated embodiment, the switches 30 are formed by one or more gate turn-off thyristors (GTO). It is to be understood, however, that other semiconducting power switches may be employed to implement the present invention, including bipolar junction transistors, MOSFET technology and other thyristors to provide current pulses. In the embodiment of FIG. 3, suitable switching control circuitry (represented at 29) is connected to the GTO control electrode, as described above, and as illustrated in FIG. 4 with respect to switch 30, in known manner. In the discussion of the present invention, the various thyristors are described as being "on" (conducting) or "off" (nonconducting) with control circuitry 29 applying appropriate control signals to the control electrode of the GTO to achieve that state. The switch 30 associated with each of the electrodes 20-26 is formed of three GTO's labeled "C" (for cathode), "P" (for pulse), and "B" (for base current). The positive output of the pulse current source 28 is connected to each of the GTO's labeled "P" while the positive output of base current source 27 is connected to each of the GTO's labeled "B" via magnetically linked inductors 32 which enhance current sharing, as will be understood by those skilled in the art.

In operation, and assuming a "conical" electrode configuration such as that shown in FIG. 2, the switch 30 associated with electrode 20 is controlled such that electrode 20 functions as a cathode. That is, the "C" GTO associated with electrode 20 is conducting and the associated "B" and "P" GTO are "off". The "C" GTO's associated with electrodes 21-26 are "off." Each of the "B" GTO's associated with electrodes 21-26 may be conducting such that current will flow between the "cathode" electrode 20 on one hand, and the "anode" electrodes 21-26 on the other. This current is selected to preionize the inter-electrode space and establish the conditions necessary for an arc discharge between the electrode 20 and the electrodes 21-26 at a practical potential difference. As noted above, preionization may, alternatively or in addition, be accomplished in any convenient manner.

With proper conditioning of the inter-electrode space (preionization established via Base Current Source 27 as described above, for example) an output from Pulse Current Source 28 will be applied to each of the "P" GTO's associated with electrodes 21-26. Under the control of Switch Control 29, one of the GTO's may be rendered "on" resulting in an arc discharge between its associated electrode 21-26 and the cathode electrode 20. It is apparent, that Switch Control 29 may be employed to establish a desired sequence of pulses (between the electrodes 21-26 and electrode 20) as will be described more fully below.

Terminals 35 are illustrated in FIGS. 3 and 4 in association with each of the electrodes 20-26. The terminals 35 may be employed in conjunction with a Current Detector 36 to detect the relative current between each or any of the electrodes 20-26 which are functioning as anode. Such current and associated voltage are representative of the loading of the feedstock being treated in the proximity to the relevant electrode. This information can be utilized for selection of firing order or other appropriate action which may depend on the relative loading conditions within the area or field of influence of a particular electrode. The connection between terminal 35 associated with each of the electrodes 20-26 is represented by the terminal 35 associated with Current Detector 36. The specific connections are not illustrated in FIG. 3 for the sake of clarity.

Referring now to FIG. 4, there is shown a modification to portions of the embodiment illustrated in FIG. 3 and, in particular, modifications to the switches 30 associated with each of the electrodes 20-26. As shown in FIG. 4, "C" GTO 40 corresponds to the "C" GTO of the switches 30 of FIG. 3 while "B" and "P" GTO's 41 and 42 correspond to the "B" and "P" GTO's, respectively. The terminals 43 and 44 may be connected to the negative and positive outputs of a Base Current Source such as that shown at 27 in FIG. 3, with the terminal 43 also being connected to the negative output of a Pulse Current Source such as that shown at 28 in FIG. 3. The terminal 45 in FIG. 4 may be connected to the positive output of a Pulse Current Source such as that shown at 28 in FIG. 3. The electrode 46 may represent any of the electrode structures 20-26 in FIG. 3.

To this point, the elements described in FIG. 4 correspond directly to those illustrated in FIG. 3 as does the connection of Current Detector 36 via terminal 35 and the control of the GTO's via Switch Control 29. In the modification of FIG. 4, the terminal 50 is adapted for connection to the negative output of an additional Pulse Current Source which may correspond in kind to that illustrated at 28 in FIG. 3, while the terminal 51 is adapted for connection to the positive output of that Pulse Current Source. The terminal 50 may also be connected to the negative output of a Base Current Source similar in kind to that illustrated at 27 in FIG. 3, while the negative output of that second Base Current Source is connected to the cathode electrode 20 in a manner which will be apparent to those familiar with the art. A second "C" GTO 52 is provided at terminal 50 while an additional "P" GTO 53 is provided at terminal 51. The GTO's 52 and 53 correspond in function to the GTO's 40 and 41 but are connected to second or additional Pulse Current Sources and Base Current Sources to provide a second set of pulses either as a supplement to the first set of pulses, as by being superimposed with them, or as a set of independent pulses.

Referring now to FIGS. 5A-5F, there is diagrammatically illustrated a series of circularly arranged electrodes corresponding to the arrangement of electrode structures 21-26 of FIG. 2. In FIGS. 5A-5F, dashed lines extending between the electrode structures 21-26 represent discrete electrical discharges established by the control systems described above, and particularly the control system of FIG. 3. Assuming a properly conditioned (preionized) inter-electrode space, each, and any, of the electrodes 21-26 may be selected to function as a cathode with others selectively functioning as anodes. For example, in FIG. 5A electrode structure 23 is functioning as a cathode while electrode structures 21, 26, and 25 are sequentially functioning as anodes. That is, discrete electrical discharge is first established (via Pulse Current Source 28) between electrode (cathode) 23 and electrodes (anode) 21. The next pulse from Pulse Current Source 28, is applied between electrode 23 as cathode and electrode 26 as anode under the control of switch control 29. Similarly, the next pulse is applied between the electrode 23 as cathode and electrode 25 as anode. Thereafter, the switch control 29 may be operative to select electrode structure 22 as cathode and electrode structures 24-26 as anodes with a series of discrete electrical discharges cycling between those electrodes as represented in FIG. 5B. Essentially, the sequential firing represented in each of the FIGS. 5A-5F do not exist at the same time although there may be some overlap. Further, by selectively switching the cathode and anode electrodes through the sequence selected by FIGS. 5A-5F the entire volume of the inter-electrode space is subjected to an electrical discharge. Thus, particles within that volume are subjected to a treatment in accordance with the present invention. Of course, any firing sequence may be employed including multiple discharges generated by multiple pulse and base current sources as described above with reference to FIG. 4. Further, the electrode 20 may be employed (as cathode or anode) within a reactor in accordance with the present invention, while the inter-electrode space may be modified by movement of one or more of electrodes. Indeed, electrode configuration can be easily changed to any desired configuration dependent upon the particular application and the requirements of that application. The electrode configuration and firing sequence and timing are selected such that substantially the entire inter-electrode space is subjected to discrete electrical discharges within a time interval less, and preferably considerably less, than the expected residence time of particles to be treated within the inter-electrode space. This may be accomplished by a selected sequence of discrete electrical discharges in a time interval less, and preferably considerably less, than the transit time of particulate matter to be treated through the reaction zone of the inter-electrode space.

The table of FIG. 6 represents the conduction/nonconduction (on=X, off=O) for the firing sequence represented in FIG. 5A. In the table, the first row indicates the particular electrode structure, while row two indicates the particular "C", "B", and "P" GTO's associated with each electrode. Rows 3-5 of the table represent the first, second, and third pulses delivered by Pulse Current Source 28. An inspection of the table shows that the "C" GTO associated with the electrode 23 is on throughout the three pulses while the "C" GTO associated with the other electrodes is off. The "P" GTO associated with electrode 23 is off, while the "B" GTO associated with the other electrodes are on. This provides a base current via Base Current Source 27 between the cathode of electrode 23 and the other electrodes which serve as anodes. Concurrently with the first pulse from Current Pulse Source 28, the "P" GTO associated with electrode 21 is conducting (on) thereby applying a potential between the electrode structures 21 and 23 resulting in a discrete electrical discharge as represented by the dash line between those electrode structures in FIG. 5A. A second pulse from Current Pulse Source 28 finds the "P" GTO associated with electrode structure 21 off, while the "P" GTO associated with electrode structure 26 on. Thus, a discharge is applied between electrode structures 23 and 26 as represented by the dashed line between those electrode structures in FIG. 5A. The bottom line shows the state of the GTO's during the third pulse in the sequence resulting in an electrical discharge between the cathode of electrode structure 23 and the anode 25. Thereafter, any of the electrode structures 21-26 may be employed as a cathode with its associated "C" GTO turned on and its associated "P" GTO turned off. The "C" and "B" GTO's of the other electrode structures are in the opposite condition while the "P" GTO of the electrode it is desired to function as an anode is turned on concurrently with a pulse from the Current Pulse Source 28. Electrode structure 20 is capable, in the illustrated implentation, of functioning as cathode or anode dependent on the state of its associate "C", "B" and "P" GTO's.

It is apparent from this description that each of the electrode structures 20-26 can function alternatively as cathode or anode thereby exhibiting a variable polarity. Further, the discharges may follow any desired sequence utilizing one of the electrodes as cathode while the selection of electrodes as cathode can similarly may follow any desired sequence. As noted above, the electrodes may be positioned in any desired configuration and may be moveable, in known manner, to modify that configuration during operation or initial set-up. For example, the electrode configuration described above establishes an essentially conical inter-electrode space when the central cathode 20 is considered. Other, non-conical, configurations are contemplated by the present invention. Also, it has been observed that resonance phenomena, naturally occurring or induced, interacting with the entrained particles improve their treatment. In addition, treatment zones may be "stacked" (multiple treatment zones positioned sequentially in the particle path) with different zones having the same or different electrode configurations. In order to smooth the operation of a reactor in accordance with the present invention, a magnetic field coil, with an adjustable power supply may be provided in a manner known to those skilled in the art. Finally, particulate matter to be treated, and gases for plasma formation and/or stabilization, may be introduced into the reaction zone in any known manner, in accordance with the teachings of the incorporated patent, for example. It is therefore to be understood, that any configuration of electrodes consistent with the treatment of particulate matter by plasma action through the utilization of discrete electrical discharges is within the scope of the present invention as described in the appended claims.

As described in co-pending application Ser. No. 08/249,153, filed May 25, 1994, which is co-owned with the present application, and which is hereby incorporated by reference, a reactor as described above may be employed in the treatment of waste and, particularly, the organic content of the matter being treated. In this treatment, fuel values may be released as thermal energy. In accordance with the present invention, the inorganic content of the matter being treated may be structurally altered to an industrially useful product. This may be accompanied by the concurrent treatment of organics (including the addition of waste particulates). However, the emphasis herein is on the treatment of comminuted matter to provide a "glassy" product.

While there is not a full explanation of the microscopic structure of glass, various hypotheses have been proposed which are based on experimentally observed premises. For example, the hypothesis of crystallites claims that as a melt cools, very small, joined together crystallites form which constitute the bulk of glass. This hypothesis of A. A. Lebediev et al. is related to the microcrystalline theory of liquids. A hypothesis of close-order structure has been proposed by Kobeko et al. which is similar to the quasi-crystalline hypothesis of liquids. Others include an aggregate hypothesis due to Berger et al., a polymerization hypothesis developed by Stevens et al., and a hypothesis of micro-heterogeneous structure developed by Poraj-Koszic et al. A crystalo-chemical or ionic hypothesis has at least three variants attributable to Goldschmidt, Zachariasen and Appien. Additionally, various standards, such as USA standard ASTMC162-47, provide a variety of different definitions.

As used herein, the terms "glass" and "glassy" are used to mean a material falling within one or more of the noted hypotheses or standards, or any other accepted hypothesis or standard. In particular, the present invention acts on suitable comminuted matter to bring about structural changes to provide a "glassy" product. Typically, the comminuted matter will become liquified while entrained in plasma, their microscopic architecture lose (completely or partially) any crystalline structure (periodicity or long range order), and they develop shear viscosity sufficiently large to retain their bulk (macroscopic shapes) for substantially long times. Upon exiting from the plasma treatment zone, the (now) molten and homogenized structures may be subjected to further treatment which may include outgassing, refining, quenching or any combination thereof. The "glassy" products develop a wide range of physico-chemical properties according to their original composition and their treatment in the reactor, including treatment following treatment in the plasma treatment zone. An example relating to glass manufacture is as follows:

Manufacture of Glass

Typical, raw, soda-lime glass can be manufactured in a small reactor in accordance with the present invention using the environmentally friendly and energy saving pelletization route. This involves preparation of comminuted feed in the form of small pellets. Pelletization is normally avoided since pellets become rapidly hygroscopic and highly aggressive. However, separate pellets falling through pulsating plasma are considerably better heated and homogenized, compared to the usual lengthy heating process based chiefly on reverberation. According to the present invention, two modifications are introduced to the otherwise known methods of pelletization. These are:

(i) drying the (highly hygroscopic) pellets by directing the hot offgases issuing from plasma effluents; and (ii) introducing small quantities of fumed silica onto the surfaces of the pellets, which reduces the sticking and scavenges certain amount of alkali vapors which are recirculated is of considerable advantage.

The pelletized feedstock used had the following approximate oxide composition:

______________________________________SiO.sub.2 73.5 (including 0.8% as fumed silica)Na.sub.2 O 13.1K.sub.2 O 0.3CaO 8.9MgO 2.3Al.sub.2 O.sub.3 2.0Fe.sub.2 O.sub.3 0.04______________________________________

When the above pelletized feed was processed in a nominal 40 kW, (laboratory scale) reactor, operating at 60,000 pulses per minute, a transparent, slightly yellowish glass was obtained containing numerous gas bubbles. The latter disappeared on prolonged heating. When carrying out a similar experiment using molybdenuminstead of graphite electrodes, a clear transparent product was obtained, the yellow tint being attributed to the graphite electrodes.

In addition to the production of traditional raw glasses, the method of the present invention may be employed for tonnage glass manufacture having an assured homogeneity coupled with an ability to form a wide range of glasses--including those having a high Al.sub.2 O.sub.3 content. Small units may be employed for the preparation of new compositions, for exploration of superconducting and/or semi-conducting glasses, for example. As will be appreciated by those familiar with the art, the method of the present invention may also be employed in the manufacture of cements, enamels, ceramic color, porcelains and metallurgical slags.

Obviously, many applications are possible beyond those indicated as are modifications to the processes described. For example, volatiles (mainly sodium and potassium salts) may be lost during the manufacture of raw glass. These may be replaced by introduction (or recirculation) as deemed appropriate. Also, as noted above, the method of the present invention has as its chief feature, the treatment of comminuted matter and, particularly, such matter having an inorganic content. However, matter having a significant carbon content (colliery spoils and fly ash, for example) may be treated advantageously in accordance with the present invention with the carbon content successfully oxidized and the remaining content contributing to a "glassy" product. An example relating to colliery spoil is as follows:

Utilization of Colliery Spoil (Coal Waste)

Most, if not all, deposits of coal are associated with two characteristic mineral waste, i.e., colliery spoil. The intrinsic spoil is derived from the inorganic content of the coal forming flora, while the extrinsic spoil is derived largely from the sediments settling on the bottoms of warm seas. While some of the extrinsic colliery spoil can be reduced by various beneficiating operations, the intrinsic spoil is there largely to stay. There is a varying amount of spoil associated with coal seams. In many cases, the removal of spoil is uneconomical or impractical or both. Such colliery spoils cannot be efficiently burned since they will simply smoulder, their temperature of combustion so low that a variety of often highly toxic hydrocarbons will be emitted. Very large amounts of such wastes are piled up undergoing slow auto-oxidation. Some of them may contain in excess of 50% wt. of maceral matter. In one of the experiments, colliery spoil containing 51.2% of macerals (i.e., equivalent to "coal organic minerals") was used with the remaining spoil content divided approximately as follows:

______________________________________ macerals: 51.2% intrinsic spoil: 17% extrinsic spoil: 31% moisture ad: 100%______________________________________

The feed has passed through 500.mu. sieve and was processed in 1 g/s. at a plasma power of 25 kW and pulsation of 55,000 pulses per minute. Commercial grade Argon was used sparingly (@ approximately 15 cfh) as a plasma forming gas in order to maximize the enthalpy of plasma effluents. On the other hand, large quantities of air were injected downstream of plasma zone, at two levels, to ensure full oxidation of the products and also to prevent the overheating of the lower part of the reactor. The solids accumulating in the collector were collected when cool and amounted to approximately 2 kg. They were olive greenish in color (due to some iron content) distinctly glassy, giving characteristic conchoidal fracture and retaining considerable internal stress. X-ray diffraction patterns showed characteristic glass structure with undulating fine ripple within which only very weak peaks of quartz and mullite could be identified.

Upon grinding and pulverizing of the above product, a number of tests and analyses were performed. The following results were obtained:

(i) Residual carbon analysis: no carbon detected. (ii) L.O.I. Test. No change in weight observed.

From the above two tests, it was confirmed that all combustibles were released as a result of treatment in the reactor.

(iii) Lea Pozzolanicity Test measuring Compressive Strength as MN/sq.m at 40% replacement, gave with 100% above product 37.2 MN/sq.m after 28 days at 18 deg.C. The same product gave after 7 days cure at 5 C deg. C. 41.9 MN/sq.m.

In some instances, it may be desirable to introduce carbon content. For example, waste oil may be employed with ash to provide a manageable feed material. In addition, fuel value is contributed by such addition with an attending release of thermal energy for recovery. It is therefore to be understood that the invention may be practiced otherwise than as specifically described.

Claims

1. A method of treating comminuted matter by electrical discharge to produce a glassy product comprising the steps of:

positioning a plurality of electrode structures to define a desired inter-electrode space;

introducing comminuted matter having an inorganic content into the inter-electrode space; and

producing a plurality of discrete electrical discharges in a desired sequence between individually controlled electrode structures.

2. The method of claim 1, further comprising the step of establishing a base current between at least some of said electrode structures.

3. The method of claim 2, further comprising the steps of detecting the base current and establishing said desired sequence in accordance with the detected base current.

4. A method of treating comminuted matter by electrical discharge to produce a glassy product comprising the steps of:

positioning a plurality of electrode structures to define a desired inter-electrode space;

preionizing the inter-electrode space;

passing comminuted matter to be treated through the interelectrode space; and

subjecting substantially the entire inter-electrode space to discrete electrical discharges within a time interval considerably less than the expected residence time of the matter to be treated within the inter-electrode space, said discrete electrical discharges being produced independently of each other in a desired sequence between said electrode structures.

5. The method of claim 4, wherein the comminuted matter has an inorganic content, the step of passing comprising the steps of passing particulate matter having an organic content through the inter-electrode space concurrently with said comminuted matter.