Abstract: The present specification discloses a pyrometallurgical system for maintaining a material in a molten state, the system comprising a vessel for molten material, the vessel conceptually dividable into a number of substantially uniform cells. A mechanical stirrer is provided for each such cell and is centered within the cell. The stirrers are sized and driven at a rate so as to promote a uniform temperature and composition of the molten material and improved heat transfer between, and blending of, various constituents of molten material, while producing minimal erosion of the conventional refractory lining of the vessel. Preferably, adjacent pairs of stirrers are driven with opposite rotational senses, thereby assuring reinforcing flow patterns at the cell boundaries. Heating means (e.g., power electrodes) are provided at locations which do not substantially interfere with the flow patterns generated by the array of mechanical stirrers.

Abstract: Disclosed is a pyrometallurgical reactor for entraining a low density particulate solid (e.g., coal) in a high density liquid (e.g., slag) in order to promote and accelerate reactions dependent upon contact between the solid and the liquid. The present disclosure develops interrelationship between the dimensions and rotation rate of a mechanical stirrer and the dimensions of the reactor vessel in order to achieve, simultaneously, good entrainment of the particulate solid which is delivered to the surface of the liquid, minimal entrainment of gasses along with the particulate solid, and minimal erosion of the vessel walls.

Abstract: Disclosed is a pyrometallurgical system and method for optimizing the interfacial contact in a two liquid system for promoting a reaction dependent upon such interfacial contact. Results are presented which indicate that, while the reaction rate initially increases rapidly with a mixing of the two liquids, excessive mixing produces little additional benefit in the reaction rate, can lead to damage of vessel walls, and can lead to a great increase in the "settling out" time of one liquid from the other (or even a complete emulsification). The specification identifies key parameters in the design of a suitable stirrer blade assembly and presents an analysis intended to yield an optimized blade design.