Abstract: One aspect is a microwave furnace including a conveyor for conveying a first material layer, and a second material layer carried on the first material layer, through the furnace. A microwave heating zone is configured for heating the second material layer with a microwave generator as the conveyer conveys the layers through the microwave heating zone. The second material layer consists of a metal-containing material. A direct heat zone is configured for heating the second material layer with a direct heat source as the conveyer conveys the layers through the direct heat zone. A discharge is provided for discharging the material layers out of the microwave furnace.

Abstract: One aspect is a method of recovering minerals. The method includes heating aggregated minerals with microwave energy. The aggregated minerals consists of at least a first and a second mineral bound together, the first and second minerals each having different differential thermal expansion rates such that fractures occur between the minerals of the aggregated minerals. The fractured minerals are subjected to microwave heating to induce fractures between and separation of the at least first and second minerals, and also to ultrasound energy causing further size reduction. The fractured and size-reduced minerals are heated with microwave energy. The fractured and size-reduced minerals consist of metal-containing materials, such that metal-containing materials are heated to at least the melting temperature of one of the metals in the metal-containing materials.

Abstract: One aspect is an ultrasonic crusher including a pipe system having at least one elutriator. A pump is configured to pump a slurry through the pipe system and the at least one elutriator. A first ultrasound sonotrode is configured proximate to the at least one elutriator.

Abstract: One aspect provides for the separating of two or more joined materials by heating with microwaves, thereby producing differential thermal expansion of the materials. The pieces to be treated are exposed to microwave energy, producing differing rates of heating, and therefore expansion, of the differing materials making up the treated pieces of material. The differential thermal expansion of the differing materials will cause sufficient strain to separate the differing materials. Separation can be enhanced in some cases by following microwave heating with rapid cooling of the treated material.

Abstract: One aspect is a method of recovering minerals. The method includes heating aggregated minerals with microwave energy. The aggregated minerals consists of at least a first and a second mineral bound together, the first and second minerals each having different differential thermal expansion rates such that fractures occur between the minerals of the aggregated minerals. The fractured minerals are subjected to microwave heating to induce fractures between and separation of the at least first and second minerals, and also to ultrasound energy causing further size reduction. The fractured and size-reduced minerals are heated with microwave energy. The fractured and size-reduced minerals consist of metal-containing materials, such that metal-containing materials are heated to at least the melting temperature of one of the metals in the metal-containing materials.

Abstract: One aspect is a method of recovering minerals. The method includes heating aggregated minerals with microwave energy. The aggregated minerals consists of at least a first and a second mineral bound together, the first and second minerals each having different differential thermal expansion rates such that fractures occur between the minerals of the aggregated minerals. The fractured minerals are subjected to microwave heating to induce fractures between and separation of the at least first and second minerals, and also to ultrasound energy causing further size reduction. The fractured and size-reduced minerals are heated with microwave energy. The fractured and size-reduced minerals consist of metal-containing materials, such that metal-containing materials are heated to at least the melting temperature of one of the metals in the metal-containing materials.

Abstract: One aspect provides for the separating of two or more joined materials by heating with microwaves, thereby producing differential thermal expansion of the materials. The pieces to be treated are exposed to microwave energy, producing differing rates of heating, and therefore expansion, of the differing materials making up the treated pieces of material. The differential thermal expansion of the differing materials will cause sufficient strain to separate the differing materials. Separation can be enhanced in some cases by following microwave heating with rapid cooling of the treated material.

Abstract: One aspect is a microwave furnace including a conveyor for conveying a first material layer, and a second material layer carried on the first material layer, through the furnace. A microwave heating zone is configured for heating the second material layer with a microwave generator as the conveyer conveys the layers through the microwave heating zone. The second material layer consists of a metal-containing material. A direct heat zone is configured for heating the second material layer with a direct heat source as the conveyer conveys the layers through the direct heat zone. A discharge is provided for discharging the material layers out of the microwave furnace.

Abstract: One aspect is a method of recovering minerals. The method includes heating aggregated minerals with microwave energy. The aggregated minerals consists of at least a first and a second mineral bound together, the first and second minerals each having different differential thermal expansion rates such that fractures occur between the minerals of the aggregated minerals. The fractured minerals are subjected to microwave heating to induce fractures between and separation of the at least first and second minerals, and also to ultrasound energy causing further size reduction. The fractured and size-reduced minerals are heated with microwave energy. The fractured and size-reduced minerals consist of metal-containing materials, such that metal-containing materials are heated to at least the melting temperature of one of the metals in the metal-containing materials.

Abstract: One aspect is an ultrasonic crusher including a pipe system having at least one elutriator. A pump is configured to pump a slurry through the pipe system and the at least one elutriator. A first ultrasound sonotrode is configured proximate to the at least one elutriator.