Abstract: An apparatus connects first and second conduits that convey a flow of gas. The apparatus includes a first flange element fixed to the first conduit, and a second flange element fixed to the second conduit. The flange elements are coupled together to permit fluid communication in an internal environment between the first and second conduits. At least one port is intermediate the flange elements to deliver a flow of purge gas therebetween. The at least one port may be located within a purge gas channel arranged in one of the flange elements. A pressure gradient of the flow of purge gas may substantially prevent at least one of fluid egress from the internal environment and fluid ingress from an external environment. Purge gas distribution systems and related methods are also described.

Abstract: A burner is provided for a pulverous feed material. The burner has a structure that integrates the burner with a reaction vessel, and has an opening that communicates with the interior of the reaction vessel. The burner also has a gas supply channel to supply reaction gas through the opening into the reaction vessel, and a feed supply for delivering pulverous material to the reaction vessel. The burner also has a fluidic control system having at least one port capable of directing a stream of fluid at an angle to the direction of flow of the reaction gas so as to modify the flow of the reaction gas. In addition, components are provided to modify the swirl intensity and turbulence intensity of the reaction gas independently of the exit velocity.

Abstract: A method is disclosed for controlling retention time in a reactor, such as an autoclave, having a plurality of compartments separated by dividers with underflow openings. A retention time of the reaction mixture is calculated and compared with an optimal retention time, and the volumes of the reaction mixture in the compartments are adjusted while maintaining the flow rate of the reaction mixture, so as to change the retention time to a value which is closer to the optimal retention time. The reactor may include a level sensor in the last compartment for generating volume data; a control valve for controlling the liquid level in the last compartment; and a controller which receives volume data from the level sensor and controls operation of the control valve.

Abstract: A chill mold is used to cool molten material to form a casting. A support holds the chill mold so that a bottom of the chill mold is elevated. A baffle is arranged to divert a generally horizontal flow of cooling air upwardly to impinge the bottom of the chill mold. A plurality of chill molds may be aligned generally in a row, and at least one fan may be arranged at an end of the row to direct the flow of cooling air underneath the chill molds. The size and the vertical position of the baffles may be varied along the row, so as to generally equalize convective cooling rates among the chill molds in the row.

Abstract: An uptake apparatus is arranged to extract a stream of off-gas containing carbon monoxide from a process vessel. At least one gas conditioning train receives and conditions the stream. An outlet expels at least a portion of the stream. A portion of the stream is separated to form a recycle stream. An eductor apparatus combines the stream with the recycle stream, to decrease the temperature and increase the static pressure of the stream. The stream is maintained at a positive gauge pressure.

Abstract: A chute receives contaminant gas-laden dust from a dust collector. At least one gas injector provides an upward flow of purge gas in the chute to release contaminant gas entrained with the dust. Downstream areas are maintained at positive pressure relative to upstream areas. A purge hopper arranged below the chute collects the dust. Dust handling apparatuses allow the upward flow of the purge and contaminant gases. Movable flaps in the dust handling apparatuses include perforations that may be capped to vary the gas flow rate. A dust discharge apparatus discharges washed dust from the purge hopper.

Abstract: A burner for a flash smelting furnace. The burner includes an injector having a sleeve for delivering pulverous feed material to the furnace and having a central lance within the sleeve to supply compressed air for dispersing the pulverous feed material in the reaction shaft of the furnace. The central lance has an annular slot at its tip for creating a substantially continuous air curtain.

Abstract: A process for direct reduction of iron oxide in a shaft furnace. The furnace has a pre-reduction zone near its uppermost portion, a metallization zone below the pre-reduction zone, an intermediate zone which separates the pre-reduction zone from the metallization zone and which includes a restriction to inhibit rich fuel gas from passing from the pre-reduction zone to the metallization zone, and a cooling zone below the metallization zone at the lowest portion of the furnace.

Abstract: A methanol indirect combustion combined-cycle power generation apparatus and method. A liquid methanol input stream is evaporated to provide a gaseous methanol stream which is converted to syngas that is combusted in a gas turbine assembly to drive a first electrical generator and produce an exhaust gas. Heat from the exhaust gas of the gas turbine assembly is used to produce first and second steam streams. The first steam stream drives a first steam turbine and provides the heat required for converting the gaseous methanol stream to the syngas combustion stream. The second steam stream drives a second steam turbine and provides the heat required for evaporating the liquid methanol input stream. A second electrical generator is driven using at least one of the first and second steam turbines.

Abstract: A method for removing elemental sulfur from a hot gas stream, such as an autoclave vent gas, while simultaneously cooling the gas stream. The method results in conversion of sulfur in the hot gas stream to the form of solid, non-sticky sulfur allotropes such as rhombic sulfur while avoiding formation of sticky sulfur allotropes such as monoclinic sulfur, thereby avoiding scaling and fouling of plant equipment. According the method, the hot gas stream is contacted with an aqueous medium containing a particulate material inside a quench vessel having a first inlet for the hot gas stream, a second inlet for the aqueous medium, and an outlet for removing a sulfur-containing liquid fraction from the vessel. At least a portion of the sulfur contained in the hot gas stream, along with other condensable materials, becomes incorporated into the aqueous medium and is subsequently drained from the vessel.

Abstract: By appropriately designing a flash tube, spraying of abrasive slurry on the vessel walls and impinging the multiphase jet on bottom of the vessel are minimized. By appropriately designing a flash vessel, once the flash tube has been designed, a slurry pool is provided having a volume that is sufficient to dissipate the flash tube exit jet momentum and the mass of entrained carryover products exiting from the vapor outlet is minimized.

Abstract: Diagnostic methods and systems are used to determine operating condition and performance of a cooling element in a metallurgical reactor during operation of the reactor. The system can include sensing means, processing means and display means. The sensing means is located in or approximate the cooling element for sensing operating conditions of the cooling element. The processing means is in communication with the sensing means for receiving data corresponding to the sensed operating conditions and for processing the data to determine a relative condition indicator of the cooling element. The display means is in communication with the processing means and displays the relative condition indicator to a user of the diagnostic system. The display means can display a first, second or third state representative of the relative health indicator.

Abstract: Process and facility for treating an aqueous solution containing substantial concentrations of a variety of contaminants, including solids, semi-solids, colloids, complexes, oligomers, polyvalents, organics and monovalents, and which tend to form gels and scale precipitates when their concentration levels are increased during treatment of the aqueous solution, the process comprising the steps of: a) feeding the aqueous solution to an ultrafiltration (UF) plant and recovering therefrom an UF permeate reduced in such suspended solids, semi-solids and colloids; b) feeding the UF permeate obtained from step (a) to a nanofiltration (NF) plant and recovering therefrom an NF permeate reduced in such complexes, oligomers, polyvalents and organics; and feeding the NF permeate obtained from step (b) to a first reverse osmosis (RO) plant and recovering therefrom an RO permeate reduced in such monovalents. The process and facility may be used for treating process water from wet process phosphate acid production.

Abstract: A control system for a combined power generation and metallurgical plant facility integrates generator-side and load-side control to provide coordinated operation of the two processes. The power generation facility includes one or more generator units and the metallurgical plant facility includes one or more controllable loads. Operating characteristics of the one or more loads are fed back to the one or generator units through a master controller to determine input control parameters for the one or more generator units. Similarly control signals and operating characteristics of the one or more generators are fed forward to the one or more loads through the master controller to determine input control parameters for the one or more loads. Using feed-forward as well as feed-back loops to exchange generator output and load set-point information, power balance between the generator units and controlled loads is maintained within an operating envelope.

Abstract: Systems and methods for measuring the level of a plurality of phases of a conductive or semi-conductive mixture in a vessel. The systems and method include a vessel configured to hold the mixture, a plurality of antennas configured to transmit electromagnetic and/or eddy current signals into the mixture to impinge upon the plurality of phases and to receive corresponding signals reflected from the plurality of phases, a transmitter module configured to generate electromagnetic and/or eddy current signals in communication with the plurality of antennas, a receiver module configured to receive electromagnetic and/or eddy current signals in communication with the plurality of antennas, a control module in communication with the transmitter module and the receiver module configured to control their operation, and a signal analysis module in communication with the receiver module configured to process the reflected signals to determine the levels of the plurality of phases within the vessel.

Abstract: A system, method and controller for managing and controlling a micro-grid network. The system includes a plurality of energy resources including at least one dispatchable energy resource and at least one intermittent energy resource, wherein the at least one of the energy resources is an energy storage element and at least one of the intermittent energy resources is responsive to environmental conditions to generate power, a controller configured to record operational constraints of the energy resources, obtain an environmental condition prediction and generate a component control signal based on the environmental condition prediction and the operational constraints corresponding to the energy resources. The controller is further configured to receive a network disturbance signal and generate a dynamic control signal based on such disturbances.

Abstract: A membrane treatment plant having at least two stages (53), (69), (75) arranged serially is disclosed. Each stage (53), (69), (75) comprises at least four membrane units (55) arranged in parallel, with each membrane unit (55) having an inlet (57), a feed/concentrate outlet (59) and a permeate outlet (61). Each stage (53), (69), (75) has a common inlet header (51), (67), or (73) and a common outlet header (65), (71), or (77), with the common outlet header (65) (71) of an upstream stage connecting to has the common inlet header (67) (73) respectively of an immediately downstream stage. Each membrane unit (55) has an inlet flow control valve (93) connecting between its inlet (57) and the common inlet header of the stage in which it is located, and an outlet flow control valve (63) connecting between its outlet (59) and the common outlet header of the stage in which it is located.

Abstract: A power generation plant and a method of generating electric energy from recovered heat during an industrial process that uses steam as a means of transferring energy. The method comprises: a) generating a first saturated steam in a first heat exchanger heated by a first source of recovered heat; b) feeding the first saturated steam into a first steam turbine generator, where the first steam turbine generator outputs exhaust steam; c) removing moisture from the exhaust steam with a moisture separator; d) superheating the moisture reduced exhaust steam from step c) in a main heat exchanger with a heat source; and e) feeding the superheated exhaust steam into a second steam turbine generator. The power generation plant comprises a first source of saturated steam, a first steam turbine generator, a moisture separator, a second source of saturated steam, a heat exchanger and a second steam turbine generator.

Abstract: A burner for a flash smelting furnace. The burner includes a distributor for receiving pulverous feed material from a plurality of feed pipes. The distributor has at least one curved deflector that directs the feed stream in an evenly distributed annulus into the sleeve of the burner.

Abstract: A burner for a flash smelting furnace. The burner includes an injector having a sleeve for delivering pulverous feed material to the furnace and having a central lance within the sleeve to supply compressed air for dispersing the pulverous feed material in the reaction shaft of the furnace. The central lance has an annular slot at its tip for creating a substantially continuous air curtain.