Abstract: Polymerization reactor systems providing real-time control of the average particle size of catalyst system components are disclosed. Methods for operating such polymerization reactor systems also are described.

Abstract: A method of enriching the iron content of low grade iron ore bearing materials has been developed which produces a high iron ore concentrate suitable for processing into pig iron and steel. The process includes reducing the low grade iron ore bearing materials to a fine particulate form and treating a water slurry of this material by applying a combination of ultrasonic treatments in a plurality of high and low intensity magnetic separation operations to remove interfering materials and concentrate magnetic and paramagnetic iron bearing materials into a high grade ore stock.

Abstract: A machine is employed for recovering heavy metals and precious or semi precious minerals, such as gold, copper, lead, diamonds, and garnets from placer, or hard rock ore. The machine employs a cylindrical, annular outer drum mounted for rotation at an inclination to the horizontal and including at least one spiral vane extending the length of its inner surface. A cylindrical, annular inner barrel is mounted within the drum and has an upper fragmentation section, an intermediate screened section, and a lower discharge section. A spray of water is directed into the inner barrel and a water spray bar is located in the annulus between the inner barrel and the outer drum. A fine sluice box is located to receive under one-quarter material input from a side trommel and a coarse sluice box located to receive discharge from the side trommel and discharge from the fine sluice box. The sluice box includes a plurality of landings, matting and screens upon which heavy materials, such as gold or precious stones, collect.

Abstract: A system for processing slag material from a steelmaking process includes reducing the average particle size of slag from a steelmaking process into finer particle size material by directing the slag against a surface at a velocity sufficient to cause the slag to break into smaller pieces, and separating the finer particle size material into at least an iron rich product and a silicate rich product based on the differences between these products in at least one or more properties including magnetic susceptibility, particle size, weight or specific gravity. Directing the slag against a surface to reduce the average slag particle size can better separate the dissimilar materials in the slag from each other, and result in less dust generation and less energy consumption compared to grinding the slag material.

Abstract: Polycrystalline silicon of the invention contains: (a) polycrystalline silicon fragments, wherein at least 90% of the fragments have a size from 10 to 40 mm, (b) <15 ppmw of silicon dust particles having particle sizes <400 ?m; (c) <14 ppmw of silicon dust particles having particle sizes <50 ?m; (d) <10 ppmw of silicon dust particles having particle sizes <10 ?m; (e) <3 ppmw of silicon dust particles having particle sizes <1 ?m; and (f) surface metal impurities in an amount ?0.1 ppbw and ?100 ppbw. A polycrystalline silicon production method of the invention includes fracturing polycrystalline silicon deposited on thin rods in a Siemens reactor into fragments; classifying the fragments by size; and treating the fragments with compressed air or dry ice to remove silicon dust from the fragments without wet chemical cleaning.

Abstract: A method of enriching the iron content of low-grade iron-bearing ore materials has been developed which produces a high iron ore concentrate suitable for processing into pig iron and steel. The process includes reducing the low-grade iron-bearing ore materials to a fine particulate form and treating a water slurry of this material by applying a combination of ultrasonic treatments in a plurality of high and low intensity magnetic separation operations to remove interfering materials and concentrate magnetic and paramagnetic iron-bearing materials into a high-grade ore stock.

Abstract: Materials in battery and electrochemical cells are separated in a form suitable for recycling by employing froth flotation techniques. Bulk materials, such as casings, are removed from converted battery scrap and the resultant pulp is subjected to froth flotation. Froth flotation agents, including frothers, collectors and/or depressants, are used to manipulate the hydrophilic and hydrophobic nature of the materials in the scrap. Hydrophobic materials are entrained in the air bubbles of the froth and float out of the froth flotation vessel while those that are hydrophilic remain in the vessel, thereby separating battery grid materials without resort to pyrometallurgical, energy intensive or other environmentally undesirable processes.

Abstract: A method for detecting tramp material in an inertia cone crusher having an outer crushing shell and an inner crushing shell is provided. The inner crushing shell is supported on a crushing head. The crushing head is rotatably connected to an unbalance bushing. The unbalance bushing has an unbalance weight for tilting the unbalance bushing when it is rotated, such that the crushing head will gyrate about a gyration axis, the inner crushing shell thereby approaching the outer crushing shell for crushing material in the crushing chamber formed therebetween. The method includes the steps of measuring at least one of a position and a motion of the crushing head; obtaining, based on the measurement, a gyration value; comparing the gyration value with a gyration reference value; and determining, based on the comparison, whether to issue a tramp material warning signal indicating the presence of tramp material in the crusher.

Abstract: The present invention discloses an advantageous and effective process for the concentration of iron ores, which can be fully dry or mixed, part of the process being dry, part wet. The invention thereby improves process efficiency as a whole by increasing recovery of concentrators and increasing the useful life of the mines.

Abstract: Polymerization reactor systems providing real-time control of the average particle size of catalyst system components are disclosed. Methods for operating such polymerization reactor systems also are described.

Abstract: Processing byproduct material from a direct reduction process of iron ore to reclaim iron and other materials from the byproduct. The systems and methods employ gravity separation tables to separate the iron from other byproduct material constituents. The byproduct material constituents may be size reduced, processed to remove dust, and sized prior to processing by the gravity separation.

Abstract: A toner producing apparatus including: a foreign matter separating unit including a foreign matter separating chamber for separating metallic foreign matters contained in raw powder material of toner from the raw powder material of toner by using gravity, a feeding pipe connected to the foreign matter separating chamber so as to feed the raw powder material of toner into the foreign matter separating chamber, and an exhausting pipe connected to the foreign matter separating chamber so as to exhaust the raw powder material of toner from the foreign matter separating chamber; and a pulverizing unit including a rotor, the pulverizing unit being connected to the exhausting pipe of the foreign matter separating unit.

Abstract: A method and system for processing biomass material from harvest to pelletizing includes a continuous shredding stage and grinding stage to reduce the size of the material. A fan pulls air through the shredder and the grinder to assist the movement of the biomass material through the shredder and the grinder. Due to the light weight of the biomass material, the material is transported between the shredding and grinding stages mechanically and pneumatically by a combination auger with air assist. The biomass material may include agricultural residues, such as corn stover. The process and equipment eliminates or minimizes damage to the carbohydrates in the biomass so as to maintain pre-grinding cellulose and hemi-cellulose levels.

Abstract: A method of protecting a roller crusher, having two rollers separated by a gap, from uncrushable objects is disclosed. The method comprises the steps of: detecting an uncrushable object in an in-feed stream of material, opening a gap between said rollers to a by-pass width, which is significantly larger than an operational width, such that said uncrushable object is permitted to pass through said gap, restricting an in-feed to said gap, such that material is fed to said gap at a restricted in-feed rate, determining that said uncrushable object has passed through said gap, reducing said gap to said operational width, and opening said in-feed to said gap, such that material is fed to said gap at an operational in-feed rate. A roller crusher having a protective system for protecting the roller crusher from uncrushable objects is also disclosed.

Abstract: The present invention discloses a method for recovering rare earth particulate material from an assembly comprising a rare earth magnet and comprises the steps of exposing the assembly to hydrogen gas to effect hydrogen decrepitation of the rare earth magnet to produce a rare earth particulate material, and separating the rare earth particulate material from the rest of the assembly. The invention also resides in an apparatus for separating rare earth particulate material from an assembly comprising a rare earth magnet. The apparatus comprises a reaction vessel having an opening which can be closed to form a gas-tight seal, a separator for separating the rare earth particulate material from the assembly, and a collector for collecting the rare earth particulate material. The reaction vessel is connected to a vacuum pump and a gas control system, and the gas control system controls the supply of hydrogen gas to the reaction vessel.

Abstract: A method of enriching the iron content of low grade iron ore bearing materials has been developed which produces a high iron ore concentrate suitable for processing into pig iron and steel. The process includes reducing the low grade iron ore bearing materials to a fine particulate form and treating a water slurry of this material by applying a combination of ultrasonic treatments in a plurality of high and low intensity magnetic separation operations to remove interfering materials and concentrate magnetic and paramagnetic iron bearing materials into a high grade ore stock.

Abstract: A system and methods for recycling lithium-containing battery materials are disclosed. More specifically, the system and method use a high energy ball mill for recrystallizing, reordering and/or reconstituting the lithium-ion containing battery material. In one embodiment, the system for recrystallizing the lithium-containing battery material restores it to its original state of functionality.

Abstract: A magnetic strap for preventing the undesired passage of articles through a sink drain hole and into a garbage disposal includes a strap member having a first end and a second end, with mating fastening members provided at the first end and the second end for selectively securing the first end to the second end so as to form a loop. A plurality of magnets are secured to the strap member, the magnets exhibiting sufficient strength to attract and trap ferrous objects by drawing the ferrous objects toward a sink flange where the ferrous objects are frictionally held to thereby prevent the ferrous objects from inadvertently slipping through the sink drain hole and into the garbage disposal.

Abstract: The present invention provides a process for dry grinding one or more mineral materials which include at least calcium carbonate. The process includes a) crushing the mineral material or materials in at least one crushing unit until a crushed material is obtained with a d95 of less than 10 cm, and dry grinding the material in at least one grinding unit (i) in the presence of at least one comb-type hydrophilic polymer containing at least polyalkylene oxide function grafted on to at least one unsaturated ethylene monomer, and (ii) in such a manner that the quantity of liquid in the grinding unit is less than 15% by dry weight of the material crushed in the crushing unit, wherein recovered material has a d50 of 0.5 to 500 microns.

Abstract: A process for producing the alumina fiber aggregate which, when examined by the electron microscope method, gives a frequency distribution regarding number of fibers, wherein the number of fibers having a fiber length of 50-200 ?m is 70% or more (including 100%), the number of fibers having a fiber length smaller than 50 ?m is 30% or less (including 0), the number of fibers of 50-100 ?m is 30-50%, the number of fibers longer than 100 ?m but not longer than 200 ?m is 30-50%, and the number of fibers longer than 200 ?m is 20% or less (including 0). The process including the steps of grinding cottony alumina-based fibers comprising 70-100% by mass of Al2O3 and 0-30% by mass of SiO2 while applying a pressure of 0.1-20 MPa thereto and then classifying the ground fibers.

Abstract: The present invention provides a process for dry grinding one or more mineral materials which include at least calcium carbonate. The process includes a) crushing the mineral material or materials in at least one crushing unit until a crushed material is obtained with a d95 of less than 10 cm, and dry grinding the material in at least one grinding unit (i) in the presence of at least one comb-type hydrophilic polymer containing at least polyalkylene oxide function grafted on to at least one unsaturated ethylene monomer, and (ii) in such a manner that the quantity of liquid in the grinding unit is less than 15% by dry weight of the material crushed in the crushing unit, wherein recovered material has a d50 of 0.5 to 500 microns.

Abstract: Processing waste materials to recover valuable metals, such as copper, from the materials. The disclosed methods employ processes that further refine the waste materials to concentrate the metallic material after the waste materials are initially processed. Processes include employing mechanical separation, air separation, sizing, and density separation.

Abstract: What is presented is a process for scrap metal processing for shredding and sorting recoverable material from a material stream that comprises a ferrous fraction, a non-ferrous fraction, a waste fraction and a less ferrous fraction that includes composite materials. The process comprises first shredding the material stream with a first shredder to a size that enables downstream processing. The shredded material stream is then conveyed to at least one drum separator to remove the non-ferrous fraction from the material stream and then conveyed to a first conveyor separator to further separate the ferrous fraction from the material stream. At the completion of these steps the remaining material stream to be handled by downstream processes represents 10% to 40% of the original material stream as compared to 70% to 75% of the material stream in the prior art.

Abstract: Classifying kits useful in separating gold, other precious metals, gems, collectable rocks, fossils, and archaeological artifacts from earth material. Classifying sieves and other parts of the classifying kits herein are configured to be used within a bucket and can readily be removable therefrom. Depending on the parts used and the goals of a user, the kits herein can be used with dry sifting methods or with water.

Abstract: A method for producing a ferro-alloy in an electric arc furnace is disclosed. The method comprises the steps of removing steel from a carbon-containing organic material, and charging the furnace with the carbon-containing organic material product.

Abstract: Processing waste materials to recover valuable metals, such as copper, from the materials. The disclosed systems and methods employ processes that further refine the waste materials to concentrate the metallic material after the waste materials are initially processed. Processes include employing air separation and screening. Processes also include employing a dynamic sensor and a vacuum pressure separator to separate metals from other materials. A central processing facility may process metal concentrate from multiple concentration facilities.

Abstract: A process for increasing the percentage of metal recovery from dross containing metal particles of different sizes having oxide and salt components adhered thereto. The process includes crushing and tumbling the dross to mechanically remove all of the oxide and salt components from the larger of the metal particles, separating the larger metal particles from the removed oxide and salt components and the smaller metal particles to provide a supply of larger metal particle concentrate, separating the removed oxide and salt components from the smaller metal particles, mechanically impacting the smaller metal particles to remove any additional oxide and salt components from the smaller metal particles, and separating the smaller metal particles from the additional oxide and salt components to provide a supply of smaller metal particle concentrate.

Abstract: Processing waste materials to recover valuable metals, such as copper, from the materials. The disclosed systems and methods employ processes that further refine the waste materials to concentrate the metallic material after the waste materials are initially processed. Processes include employing air separation and screening. Processes also include employing a dynamic sensor and a vacuum pressure separator to separate metals from other materials.

Abstract: A method and apparatus for grinding iron ore or iron ore concentrate is able to grind iron ore or iron ore concentrate economically. In the method and apparatus disclosed, the material is ground in circulation in a material bed roll mill, one fraction of the iron ore or iron ore concentrate ground in the material bed roll mill is recirculated to the material bed roll mill and the other fraction of the iron ore or iron ore concentrate is classified into oversize material and fines, and the oversize material is returned to the material bed roll mill.

Abstract: The invention relates to a method for comminution of material in a grinding mill, in which method the ground material from the mill is classified by means of particle sizes. After the classification of the ground material at least the part of the material having a particle size greater than the desired predetermined particle size is targeted to an electromagnetic energy treatment in at least one stage.

Abstract: The invention relates to a process for the comminution of composite materials, e.g. of electronics scrap, and also for the separation of the materials present therein, using a plurality of comminution stages and separation stages, with use of at least one hammer mill or rotor-impact mill (6), where, prior to the comminution of the material in the hammer mill or rotor-impact mill (6), a separation of previously comminuted composite material is achieved, into plastics on the one hand and composite material and also metals on the other hand.

Abstract: A method for recovering a catalyst for a fuel cell includes a collection step in which a catalyst is collected by attracting, using a magnetic force, a magnetic material contained in at least one of the catalyst and a carrier on which the catalyst is supported. A system for recovering a catalyst for a fuel cell includes a collection device that attracts, using a magnetic force, a magnetic material contained in at least one of a catalyst and a carrier on which the catalyst is supported.

Abstract: The recycling of metal materials is performed by efficiently recovering the metal materials from component materials of a process cartridge. To achieve this object, there is provided a method of recycling a process cartridge containing a toner, wherein in a crushing process of a process cartridge containing a recovered toner, a container shape of the process cartridge is subjected to disassembly treatment to an extent of main component parts, the toner is recovered by suction in a step of disassembly treatment, metal materials, such as ferrous materials and aluminum materials, in component materials of the process cartridge are subjected to separation treatment after the step of disassembly treatment, and each of the materials is subjected to melting treatment thereby to change the materials into forms capable of reuse as ferrous materials and aluminum materials.

Abstract: The present invention springs from the discovery that mild acids could be utilized to shear undesired metals away from desired precious metals that have been plated onto circuit board runners or contacts. This shearing action occurs at a high rate when metal scrap segments are immersed in mild acid and excited by application of an electromagnetic field at specific frequencies and power levels. These frequencies and power levels are based on the end metal desired and the metals contained in the scrap and the acid utilized. When mild acid saturated with copper sulfate and loaded with scrap metals is subjected to an electromagnetic field at the appropriate frequency and power levels copper and nickel molecules are sheared rapidly and absorbed into solution, leaving only the desired metal, such as gold, in a 99.5% pure flake which can be skimmed off the surface of the solution or filtered from the solution.

Abstract: A refrigerant gas is collected and a compressor is removed from a discarded refrigerator, a heat-insulating housing including a heat insulator is cut/processed and separated into a plurality of pieces, and the pieces are compressed/processed by compression rollers opposing each other so as to collect a gas contained in the heat insulator. In accordance with this method, substantially no gas contained in the heat insulator is diffused at the time of cutting the heat-insulating housing, and the gas can be collected at a high concentration because it is collected by being allowed to leak out at the time of compressing. Furthermore, by using the compression rollers, closed-cells in the heat insulator can be crushed easily, thereby collecting the gas completely and reliably. Thus, it is possible to collect a foaming gas contained in the heat insulator efficiently and disassemble a refrigerator at low cost without increasing the size of-equipment and an installation space.

Abstract: Pigment flakes having cores preferably composed of resins, polymers, thermoplastics, and/or thermosets with colorant (pigment and/or dyes) deposited thereon, coating applications thereof, and a method for making pigment flakes which includes providing a core material, compounding the core material, processing the core material into uniform forms such as films, wires, thread with rectangular cross sections and bead strings, providing colorant material, vaporizing the colorant material, exposing a surface of core material to the vaporized colorant material to form a layer of colorant on thereon, and fracturing the resultant colorant layered core material into flakes.

Abstract: A process, and associated apparatus, that separates the economic components of scrapped rubber tires while isolating and removing certain levels of contamination associated with these tires. The separation of the scrap tires contaminants is accomplished by shredding, washing, and rasping the tire product. The continual laboratory testing of the waste wash water and removal of the contaminates and particulates will produce an end-product of 3 to 100 mesh/crumb which will be virtually without contamination. The quality of the end-product is further enhanced by the associated quality apparatus that removes the steel and fiber products in addition to any contaminants.

Abstract: Process for production of three-dimensional objects by stereolithography in which a laser hardens particular areas of constantly succeeding layers of resin fluid. Prior to or during laser light action, the particles, which define physical or mechanical qualities of the object-to-be-produced, will be added into, and/or alternatively, will be produced within the resin fluid, leading to a resin-fluid-particle-mixture. The particles are integrated into the resin and/or compound with resin and/or other particles by means of laser light action or ultrasonic mixing.

Abstract: A method of forming a metal feedstock from wasted metal products is disclosed. The method includes the steps of crushing the metal products into pieces; magnetically separating sheet-shaped ferrous scraps and ferrous cast blocks from the crushed pieces; placing the cast blocks between the sheet-shaped scraps to make a sandwich structure; and pressing the sandwich structure to form a metal feedstock.

Abstract: The present invention, therefore, provides stage crushing method for recovering precious metals from slag produced by a coal burning furnace or boiler comprising: a plurality of crushing steps, wherein each crushing step produces slag particles having successively smaller particle diameter sizes, said crushing steps continued until a final desired particle diameter sized is obtained; wherein each of said crushing steps is followed by suspending said crushed slag particles in a liquid medium to form a slurry of light-weight particles and heavy weight-particles and allowing the crushed slag particles within the slurry to separate, based on weight of the particles, thereby forming a light-weight particle population and a heavy-weight particle population; wherein each suspending step is followed by removing said light-weight particles from said slurry, such that said slurry consists of substantially heavy-weight particles; and collecting said heavy-weight particles.

Abstract: An iron based product having at least a sufficient total ferrous content by weight to render the product commercially feasible wherein the product is derived by a process comprising the beneficiation of kish slag waste material having a relatively low ferrous material content before beneficiation. The resulting iron based product has a total ferrous content of substantially 90% by weight thereby making it both practical and economical for the reintroduction into iron and/or steel making processes utilizing an injection method or by briquetting at at least a portion of the resulting product. The beneficiation process involves the heating of the waste material to an extent at least sufficient for drying, separating the high sulphur slag from a remainder of the waste material and subsequently classifying the remainder of the waste material, once separated from the high sulphur slag by particle size.