Patent Application
20110073529
Embodiments of the disclosure may generally relate to the separation of usable metals from boiler grit.
It is not uncommon for industrial factories, plants, and mills to burn combustible materials onsite to either create electricity for the factory/plant or to supply heat for water and ambient temperature regulation. Typical combustible materials burned onsite at an industrial location may include wood, coal, oil, refuse, etc., but generally will be the cheapest and most readily-available burnable material. Recently, industrial locations have been using pre-shredded automotive tires as a source of combustible materials, since tires can be obtained quite inexpensively, and burning tires serves to reduce the amount of landfill intake.
Tires today, however, are manufactured to include numerous steel belts (i.e., “radials”), which are used to reinforce the area under the tread, to provide puncture resistance, and to help the read surface remain planar so that it makes the best contact with the road. The combustion process at an industrial location rarely reaches temperatures sufficient to melt or incinerate the radials. Therefore, after the burning process, charred steel radials will generally remain in the boiler grit, or burnt residue, along with a substantial amount of dirt and rock. Having no apparent value of use, the boiler grit, including the charred radials, is then typically shipped at a cost by the industrial location to a local landfill for disposal, or on site.
As can be readily appreciated, however, the charred steel radials may have potential value in the scrap metal industry. If properly recovered from the boiler grit and cleaned for recycling purposes, the charred radials may be sold as valuable scrap metal. Furthermore, because of the burning process, the charred radials are generally free from any tire residue which steel mills or scrap metal yards often refuse to accept.
What is needed, therefore, is an efficient system and method of removing charred steel radials from the boiler grit resulting from burning tires at industrial locations.
Embodiments of the disclosure may provide a system for removing ferrous materials from furnace boiler grit. The system may include a hopper configured to receive the boiler grit derived from burning tires, and having a vibratory feeder coupled thereto, wherein the vibratory feeder has a conveyor configured to transport the boiler grit away from the hopper, a grating coupled to the hopper and having a plurality of slats configured to prevent the admission of large objects into the hopper, wherein the grating is disposed at an incline relative to the hopper, such that the large objects fall off the grating, and a magnetic separator having a magnet configured to attract ferrous materials in the boiler grit, thereby separating the ferrous materials from a remaining non-ferrous residue. The system may also include a residue collection module configured to collect the remaining non-ferrous residue, a non-ferrous material conveyor configured to transport the remaining non-ferrous residue away from the system, a metal collection module configured to collect the ferrous material, and a ferrous material conveyor communicably coupled to the metal collection module and configured to transport the ferrous material away from the system.
Embodiments of the disclosure may further provide a method of removing ferrous materials from boiler grit. The method may include receiving the boiler grit in a hopper, wherein the boiler grit includes charred steel radials derived from burning tires, transporting the boiler grit away from the hopper toward a magnetic separator via a conveyor, and separating the charred steel radials from the boiler grit using the magnetic separator, thereby leaving a non-ferrous residue. The method may also include collecting the non-ferrous residue in a residue collection module located adjacent to the conveyor, conveying the non-ferrous residue away from the system via a non-ferrous material conveyor communicably coupled to the residue collection module, collecting the ferrous materials in a metal collection module located adjacent to the magnetic separator, and conveying the ferrous material away from the system with a ferrous material conveyor communicably coupled to the metal collection module.
Embodiments of the disclosure may further provide a system for removing ferrous materials from a boiler grit having ferrous and non-ferrous materials. The exemplary system may include a hopper configured to receive the boiler grit, and having a vibratory feeder coupled thereto, wherein the vibratory feeder has a conveyor capable of transporting the boiler grit away from the hopper, a magnetic separator having a magnet designed to attract the ferrous materials in the boiler grit, thereby separating the ferrous materials from the non-ferrous materials and leaving a non-ferrous residue, a first material transportation vehicle located adjacent to the conveyor and configured to collect the non-ferrous residue for transport away from the system, and a second material transportation vehicle located adjacent to the magnetic separator and configured to collect the ferrous material for transport away from the system.
The present disclosure is best understood from the following detailed description when read with the accompanying Figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure, however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, ° the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.
Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Further, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope.
Combustion chambers, such as a boiler located at industrial locations, may produce the boiler grit 104 as a result of locally burning a combustible material, such as coal or wood, to produce electricity or heat for the location. In at least one embodiment, the industrial location burns worn and/or pre-shredded automotive or industrial tires having steel radials. Thus, the boiler grit 104 from the tires may include a significant amount of recyclable ferrous material, including the charred remains of the steel radials, which may be removed and cleaned via embodiments of the system 100 herein disclosed. Moreover, because of the prior burning process, the ferrous material may be substantially clean of tire residue, which steel mills and recycling centers will typically reject.
The boiler grit 104 may be introduced to the hopper 102 via a grating 106 coupled to the hopper 102 at its top. The grating 106 may include a plurality of longitudinal slats, or otherwise crisscrossed slats, that provide an area for the boiler grit 104 to fall into the hopper 102, while preventing the admission of larger objects, such as rocks and other unwanted residue. Thus, the grating 106 may serve to filter the boiler grit 104 to remove large objects that may obstruct various moving parts used in the system 100. In at least one exemplary embodiment, the grating 106 may be disposed at an incline relative to the hopper 102, whereby larger objects may “roll” or otherwise fall off the grating 106 and onto either an adjacent receptacle (not shown) or the ground for subsequent removal or usage. In another exemplary embodiment, the grating 106 may be configured to be self-cleaning so as to prevent clogging. For example, the grating 106 may be an actuated grating designed to dispose of caught objects.
In an exemplary embodiment, the hopper 102 may include a gravity hopper or a slant hopper, as is known in the art. In at least one embodiment, the hopper 102 may include three interior sides which are each angled at about 45 degrees and one side that is substantially vertical, thereby causing the contents of the hopper 102 to funnel towards an outlet located at the bottom via gravitational forces. In another exemplary embodiment, the hopper 102 may include four interior sides which are all angled toward an outlet located at a centralized-bottom location, and configured to funnel the contents thereto.
A commercially-available vibratory feeder 108 may be coupled to the bottom of the hopper 102 at its outlet. The vibratory feeder 108 may be powered by a motor 110 and configured to vibrate the boiler grit 104 towards the bottom of the hopper 102. As follows, the vibratory feeder 108 may also serve to vibrate the boiler grit 104 in the hopper 102 so as to break up any chunks of boiler grit 104 and pre-separating the metal from the dirt and rock. Furthermore, the vibratory feeder 108 may feed the boiler grit 104 onto an adjacent conveyor 112. In at least one embodiment, the conveyor 112 may be an integral part of the vibratory feeder 108 and be designed to receive the boiler grit 104 and transport it aided by vibrational energy in the direction of arrow A. In one embodiment, the conveyor 112 may be slightly declined relative to ground so as to allow gravitational forces to contribute to the movement in direction A. In another embodiment, the conveyor 112 may include a belt-conveying system, as is known in the art, and the vibratory feeder 108 may be designed to feed the boiler grit 104 onto the conveyor 112 by means of an auger positioned in or near the lower portion of the hopper 102, for example. In this exemplary embodiment, a motor may power the conveyor 112 to transport the boiler grit 104 in the direction of arrow A.
The boiler grit 104 transported in direction A may be transported by the conveyor 112 toward a crossbelt magnetic separator 114. In an exemplary embodiment, a leveling device (not illustrated) may be employed over the conveyor 112 to “rake” the boiler grit 104 to a substantially leveled height. Raking the incoming boiler grit 104 to a level height may allow the crossbelt magnetic separator 114 to continuously receive an equal amount of boiler grit 104 thereby avoiding the clogging of the system 100. The crossbelt magnetic separator 114 may be configured to remove a substantial portion of the ferrous content from the boiler grit 104. In particular, the crossbelt magnetic separator 114 may be designed to remove the pieces of charred steel radials that once comprised the radial belts of a tire.
As best seen in
Still referring to
Thus, in at least one embodiment, the crossbelt magnetic separator 114 may be disposed co-linearly with the conveyor 112, as illustrated in
In another exemplary embodiment, the conveyor belt 204 does not include cleats 206. Instead, the crossbelt magnetic separator 114 may include a scraper 220 designed to scrape the surface of the conveyor belt 204, and thereby remove any remaining ferrous materials 208 that remained attached thereto after moving out of the range of the magnetic field.
In yet another exemplary embodiment, the magnet 202 may be disposed across a substantial portion of the crossbelt magnetic separator 114 and the conveyor belt 204 may be configured to rotate in a direction opposite the direction B. Thus, the magnetic field produced by the magnet 202 may attract the ferrous material 208 onto the surface of the conveyor belt 204 and transport the ferrous material 208 on the underside of the crossbelt magnetic separator 114 in direction C. Underneath the crossbelt magnetic separator 114, the ferrous material 208 may remain magnetically attracted to the surface of the conveyor belt 204 until passing outside the range of the magnetic field of the magnet 202, at which point the ferrous material 208 may fall into the metal collection module 218, as described above. While not necessary, a scraper 220, as also described above, may be employed in this embodiment to assist in the removal of any ferrous material 208 stuck or otherwise attached to the conveyor belt 204 outside of the range of the magnetic field.
Referring now to
Although the angular disposition of the stationary internal magnet 304 is illustrated to a specific angle, it can be appreciated that any number of angular configurations may be employed. Indeed, depending on the concentration of the ferrous material in the boiler grit 104, and its overall weight, the angular configuration of the internal magnet 304 may be altered or adjusted to suit the specific application to attract the greatest amount of material 208.
In an exemplary embodiment, a leveling device (not illustrated) may be employed over the conveyor 112 to “rake” the boiler grit 104 to a substantially leveled height. Raking the incoming boiler grit 104 to a level height may allow the crossbelt magnetic separator 114 to continuously receive an equal amount of boiler grit 104 thereby avoiding the clogging of the system 100. In exemplary operation, as the boiler grit 104 moves in direction A on the conveyor 112, the boiler grit 104 eventually encounters the magnetic field generated by the internal magnet 304, whereby the ferrous material 208 is attracted to the outer drum surface 306, separating it from the remaining rock, dirt, and other non-ferrous residue 210. At the discharge end 212 of the conveyor 112, the non-ferrous residue 210 may fall off into a residue collection module 214. The ferrous material 208, however, may be magnetically attracted to the outer drum surface 306 until the ferrous material 208 passes through the magnetic field, at which point it is discharged to the rear of the outer drum surface 306 and allowed to fall into a metal collection module 218.
Referring once more to
Moreover, the non-ferrous material conveyor 116 may also be replaced with any type of receptacle or module to fit the particular application. For example, the combination of the residue collection module 214 and non-ferrous material conveyor 116 may be replaced with a material transportation vehicle, like a dump truck, for collecting the non-ferrous material 210 for shipping to another location. In at least one embodiment, once collected, the non-ferrous material 210 may be re-processed by running it through the system 100 multiple times in order to remove all traces of ferrous material 108. Also, the non-ferrous material 210 may be further processed by removing larger rocks and eventually sold as road base material.
The ferrous material conveyor 118 may be communicably coupled to the metal collection module 218. As illustrated, the ferrous material conveyor 118 may be configured to transport the ferrous material 208 up an incline and away from the system 100 in direction F. At the discharge end 122 of the ferrous material conveyor 118, the ferrous material 208 may fall into a metal collection bin 124. Similar to the non-ferrous material conveyor 116, however, it is not necessary that the ferrous material conveyor 118 be arranged at an incline of any specific angular configuration. Instead, the conveyor 118 may be disposed parallel to the ground, or even at a decline with respect to the ground, depending on the location of the collection bin 124.
Moreover, the combination of the metal collection module 218 and ferrous material conveyor 118 may be replaced with a material transportation vehicle, such as a dump truck for directly collecting the ferrous material 208 for ease of shipping to another location. In another exemplary embodiment, the metal collection bin 124 may include the bucket of a dump truck designed to receive the ferrous material 208 and facilitate easy transportation for recycling purposes. However, in each exemplary embodiment, the ferrous material 208 in the metal collection bin 124 may instead be repeatedly processed to assure a cleaner product for scrap metal yards, therefore, the material transport vehicle may include a conveying system configured to return the processed material back to the hopper 102.
Referring now to
The hopper 402, in at least one embodiment, may include a feeder, or conveyor 112, as an integral part of the hopper 402. While not illustrated herein, the hopper 402 may also include a vibratory feeder coupled to the bottom of the hopper 402 to facilitate improved transport of the boiler grit 104 via vibrational forces through the conveyor 112. In another embodiment, the conveyor 112 may include a belt-conveying system designed to feed the boiler grit 104 in the direction A.
The boiler grit 104 transported in direction A may eventually fall off the conveyor 112 and into a material collection module 404 communicably coupled to a material conveyor 406. The material conveyor 406 may include a belt-conveying system having a belt 408 configured to convey the boiler grit 104 in direction G for processing. In at least one embodiment, the belt 408 may include ribs (not shown) designed to more easily transfer the boiler grit 104 up an incline.
As the boiler grit 104 travels in direction G, it eventually passes under a crossbelt magnetic separator 410 suspended or otherwise disposed above the material conveyor 406. In at least one embodiment, as illustrated, the crossbelt magnetic separator 410 may be suspended by cables 411 attached to a support structure 413.
As best seen in
In exemplary operation, as the boiler grit 104 moves in direction G on the material conveyor 406, the magnetic forces emanating from the magnet 412 of the crossbelt magnetic separator 410 may attract the ferrous material 208 onto the surface of the conveyor belt 414, thereby separating it from the rock, dirt, and other non-ferrous residue 210 remaining in the boiler grit 104. At the discharge end 416 of the material conveyor 406, the non-ferrous residue 210 may fall off into a residue collection module 418.
The ferrous material 208, however, may be magnetically-transported in direction H (
As can be appreciated, it is not necessary that the material conveyor 406 or the ferrous material conveyor 424 be arranged at an incline of any specific angular configuration. Instead, both the conveyor 406 and the ferrous material conveyor 424 may be disposed at any inclined angle, parallel to the ground, or even at a decline, depending on the location of the adjacent receptacles 418,428, respectively.
Moreover, as with prior embodiments disclosed herein, the combination material conveyor 406 and residue collection module 418 may be replaced with a dump truck for collecting the non-ferrous material 210 for shipping to another location. In at least one embodiment, for example, the non-ferrous material 210 may be further processed to remove larger rocks and eventually sold as road base material.
Likewise, the combination of the ferrous material conveyor 424 and the metal collection bin 428 may be replaced with a dump truck for directly collecting the ferrous material 208 from the crossbelt magnetic separator 410 for ease of shipping to another location. In another exemplary embodiment, the metal collection bin 428 may include the bucket of a dump truck designed to receive the ferrous material 208 and facilitate easy transportation for recycling. However, in each exemplary embodiment, the ferrous material 208 in the metal collection bin 124 may instead be repeatedly processed to ensure a cleaner product for scrap metal yards.
Referring now to
Referring now to
Preceding the receipt of the boiler grit 104 by the hopper 102,402, the boiler grit 104 may optionally be pre-processed either onsite at the industrial location (not shown), or adjacent to the hopper 102,402. Part of the pre-processing may include amassing the boiler grit 104 into a localized pile, as at step 604. Instead of being in a pile, the boiler grit 104 may be simply spread out so as to more-easily locate the ferrous material 208 therein. Once in a pile or spread out, the boiler grit 104 may have a magnet suspended overhead to attract the ferrous material 208 and roughly separate it from the non-ferrous material 210, as at step 606. The ferrous material 208 may then be deposited in either an adjacent transport vehicle or other transport device, as at step 608. Once collected in a transport vehicle, the ferrous material 208 may then be transported to the hopper 102,402 for processing, as at step 610. The remaining boiler grit 104 from the pile may also be transported to the hopper 102,402 for processing.
Once received into the hopper 102,402 (step 602), the boiler grit 104, including the ferrous material 208 separated out by the magnet (step 606), may be transported away from the hopper toward a magnet separator 114,410 via a conveyor 112, as at step 612. The magnet separator 114,410 may be configured to separate the ferrous materials 208 in the boiler grit 104 from the non-ferrous materials 210, as at step 614.
The non-ferrous residue 210 may then be collected into a residue collection module 214 located adjacent to the conveyor 112, as at step 616. Once collected into the residue collection module 214, the non-ferrous materials 210 may be conveyed away from the system 100,400 via a non-ferrous material conveyor 116, as at step 618. The ferrous materials 208 are also collected in a metal collection module 124, as at step 620. The collected ferrous materials 208 may then be conveyed away from the system with a ferrous material conveyor 118, as at step 622.
Optionally, the method may include re-processing the collected ferrous material 208 or the non-ferrous material 210 by passing the material through the system 100,400 once again, as at step 624. As can be appreciated, processing the materials 208,210 multiple times may result in a substantially clean material 208,210 that may be subsequently sold or used.
The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the detailed description that follows. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.
