Abstract: A method of making a foamed glass composite, including crushing a vitreous precursor material, such as waste glass, frit, metallurgical slag or the like, sizing the crushed vitreous precursor to segregate an amount of crushed particles of a predetermined size and pelletizing the crushed particles. The pellets are preheated and passed through a high-temperature flame to foam the pellets. The foamed pellets are air-quenched to a temperature below their dilatometric softening point and then cooling to room temperature. The foamed pellets are then mixed with Portland cement and water to form a composite material. The flame temperature is at least about 1300° C. and the pellets are preheated to within no more than about 25° C. of their dilatometric softening point. The pellets have a volume of between about 0.05 and about 1 cubic centimeter and reside in the flame for between about 0.5 to about 10 seconds.

Abstract: A method for burning raw materials by which method the raw material and a secondary fuel are separately introduced to one and the same rotary kiln in which the raw material as well as the secondary fuel are heated by gases formed by burning of a primary fuel in the rotary kiln so that the secondary fuel is converted to gases and solid matter in the form of combustion residues such as ashes and coke. The secondary fuel during the process of conversion to gases and solid matter is kept separate from the introduced raw material, which may ensure that the secondary fuel and hence the locally reducing zones and major areas with reducing conditions are brought into minimum contact with the raw material.

Abstract: This application concerns methods and apparatus for use in industrial waste recovery operations such as recovery of non-consumed chemicals in industrial processes, with recovery of quick lime in a wood pulp process being an example. In some embodiments, methods comprise baking lime sludge in a kiln and controlling a temperature in a calcining zone of the kiln to be above about 2250° F. to vaporize sodium contained in the lime sludge. Interaction of the vaporized sodium with SOx can deter accumulation of one or both of CaCO3 and CaSO4 on one or more inner surfaces of the kiln. In some embodiments, lime sludge can be rinsed to generate a filtrate comprising dissolved NaOH, and the filtrate can charge a scrubber for removing SOx from an exhaust from the kiln. Embodiments of co-fired burners for heating such kilns by burning petroleum coke and natural gas are also disclosed.

Abstract: An apparatus and method for recovering heat radiating from the outer surface of a rotary kiln includes an enclosure formed as a stationary housing that has an axially extending opening and closure flaps on circumferential ends of the housing extending towards the shell to form a chamber and an exhaust fan, arranged to draw a flow of air into the housing, which flow of air recovers heat from the kiln shell and is discharged from the chamber for heat recovery therefrom.

Abstract: An improved method and apparatus for charging, preheating and refining steel. The charging apparatus has a skirted charging section for introducing charge materials, a dynamic gas seal adjacent the charging section and a preheater, the preheater for preheating the charged materials, a connector adjacent the preheater and removably insertable into an electric arc furnace for feeding charged materials into a furnace bath for melting and refining metallic charge therein, and a vibrating conveyor which extends throughout the charging apparatus. The charging apparatus is positioned on rails to be movable by a hydraulic cylinder between a charging position wherein the connector is fully inserted into the furnace, a retracted position where the connector is partially inserted into the furnace and a disconnected position where the connector is fully removed from the furnace.

Abstract: A method and apparatus is described for environmentally sound usage of combustible hazardous waste as supplemental fuel in operating rotary cement kilns. The apparatus comprises an open port in the rotary vessel at a point where during cement kiln operation the in-process mineral material is in a calcining state and where kiln gas temperatures are sufficient to decompose volatile components of the waste fuel. A drop tube extending from the port into the kiln is provided to prevent in-process mineral from escaping through the port during rotation of the rotary vessel. Combustible solids are delivered through the port under the force of gravity and air is continuously drawn into the rotary vessel through the open port during kiln operation. The apparatus and method allow efficient usage of combustible solid waste as a supplemental fuel for cement kiln operation.

Abstract: A method and apparatus for supplying lime sludge to a rotary kiln guides the flow of the lime sludge into the kiln, and the flow of flue gases out of the kiln, in distinct paths so that contact between the lime sludge entering the kiln and flue gases exiting the kiln is substantially prevented. This is typically accomplished by providing a general horizontal tubular duct interiorly of the kiln first end and extending into a substantially vertical flue gas conduit with an annular chamber defined between an outer surface of the tubular duct and an inner surface of an inlet to the first end of the rotary kiln. The lime sludge is introduced into the annular chamber. Spiral feeding blades are preferably provided on the outer surface of the tubular duct and the duct rotates with the rotary kiln so that the spiral feeding blades engage the lime sludge and move it toward the kiln. The lime sludge is preferably dried before it is fed into the annular chamber.

Abstract: The carbonizing furnace of the present invention is capable of effectively making a large amount of carbides and reducing manufacturing cost and maintenance cost. The carbonizing furnace includes a furnace proper being formed into a cylindrical shape, the furnace proper having a first end section, to which a combustible raw material is supplied, and a second end section, from which a carbide is discharged; a spiral member for conveying the raw material from the first end section to the second end thereof; and a burner for burning the raw material to make the carbide, the burner burns the raw material in the second end section whereby the raw material is carbonized therein, wherein a surface of the raw material is coated with an inorganic binder.

Abstract: Contaminants are removed from particulate material in an inclined, rotating drum which has an inlet for contaminated material at its upper end, an outlet at its upper end for vaporized contaminants, an inlet for air that is located between the upper end and the lower end, and an outlet for clean particulate material at its lower end. Contaminated particulate material is admitted to the upper end of the drum and conveyed under the influence of gravity and the rotation of the drum to its lower end. A combustion chamber at the lower end of the drum is provided with an air inlet, a fuel burner and an outlet for combustion products. Fuel is burned in the combustion chamber with excess air supplied so that the temperature of the products of combustion is high enough to volatilize the contaminants in the particulate material, but not so high as to incinerate them. A fire tube within the drum conveys the combustion products from the combustion chamber to the upper end of the drum.

Abstract: A drum mixer having a combined heating-mixing zone which receives aggregate from both ends. The drum mixer includes a rotatable drum having an inlet end and a discharge end. Within the drum, a drying zone extends from the inlet end to a combustion zone and a mixing zone extends from the combustion zone to the discharge end. A cylindrical, tubular combustion housing is mounted in the combustion zone to define the heating-mixing zone between the drum and the combustion housing. The inner periphery of the combustion housing defines a combustion chamber into which the flame of a burner assembly is directed. The heating-mixing zone communicates with the drying zone, the combustion chamber, and the mixing zone. Aggregate is introduced into the drying zone and is urged toward the combustion zone as the drum is rotated.

Abstract: An apparatus is disclosed for the separation and extraction of a waste material into a solid, a liquid, and a gas phase utilizing a rotating drum that is sealed from the atmosphere. The exterior of the drum is heated and the waste material flows through the interior of the drum where the liquid components are vaporized and the solids are dried. The drum includes a oxidizing section where the hot dried solids, after the majority of the liquids have been vaporized, are mixed with gas containing oxygen for oxidizing the remaining particles of oxidizable material in the solids. Hot exhaust gases flow through the interior of the drum in a counter current direction of the flow of the solids to maintain an inert atmosphere in the heating section where the vaporization takes place and to prevent the condensables from flowing back over the solids and condensing. The vapors flow through a chamber that contains a hot oil spray for removing solids from the vapors, and then flow to a condenser.

Abstract: A drum mixer is provided with a rotatable cylinder in which aggregates, reclaimed asphalt pavement and liquid asphalt are mixed to produce an asphaltic composition. The drum cylinder includes a first region, in which virgin aggregate is heated and dried by heat radiation and the stream of hot gases produced by a burner flame flowing in countercurrent flow to the aggregate itself to establish a highly beneficial heat transfer relationship. A second region doubles as combustion and mixing zones. In the mixing zone the reclaimed asphalt pavement and liquid asphalt is added and mixed with the aggregates. The combustion zone is formed along the center of the mixing zone by an elongated combustion assembly disposed along the central axis thereof. The combustion assembly and chamber extend from the discharge end of the drum through the mixing zone to the heating and drying zone to segregate the hot gases from the asphalt, thereby preventing degradation of the final product.

Abstract: An apparatus and method for remediating soils and other materials contaminated with organic compounds comprising dual volatilizing zones and radiant heat. The material is treated in the volatilizing zones to substantially volatilize the organic compounds contained within the material.

Abstract: An apparatus for delivering material to the interior of a kiln to be burned therein which includes a feeding mechanism which rotates with the kiln within a stationary transfer means or drum, means for delivering material to be burned to the interior of the transfer drum, said feeding mechanism including means for collecting material from the transfer drum as it rotates and said feeding mechanism including means for compressing, shredding in some applications and delivering the material to the interior of the kiln.

Abstract: An asphalt drum drying and mixing plant capable of using recycled pavement aggregate material includes two interacting drums, each being heated to different temperatures. A first drum is a parallel flow drying and mixing drum. The recycled material is introduced at the intake or feed end of this first drum and dried and heated to a comparatively low temperature in a first region of the first drum. A burner of relatively lower heat generation capacity furnishes heated gases. The recycled material is protected by supplying the gases through a cylindrical combustion chamber within which the fuel is completely burned such that no luminous gases enter the drum and contact the recycled material. A second, adjacent region of the parallel flow drum is the mixing region. The recycled material is transferred to the mixing region with the close control over the temperature at which the material enters the mixing region.

Abstract: A process and apparatus for the preparation of green briquettes for the production of silicon or silicon carbide or ferrosilicon in electric pit furnaces, quartz sand, a carbon carrier and a bituminous binder being mixed together, the mixture being shaped into blanks from which the green briquettes are formed by heat treatment. The process is performed with the use of blanks which are free from melted bituminous caking coal and whose specific weight is made greater than the bulk density of quartz sand by adjustment of the proportions of the mixture and by compacting. The blanks are introduced for the heat treatment into a heated rotating drum furnace whose lower part is filled with quartz sand to an extent such that the heat treatment proceeds in a dip bed of quartz sand.

Abstract: An apparatus for heat treating contaminated particulate material and more particularly, an apparatus for reclaiming foundry sand. The apparatus includes a heated, inclined rotary drum and an auger projects into the upstream end of the drum and serves to feed material to the drum. The auger includes a spiral flight carried by a hollow shaft and a blower is connected to the outer end of the hollow shaft so that air is supplied through the shaft into the drum. A seal is provided between the non-rotating auger housing and the drum, and the seal includes an annular bearing plate mounted on the end of the drum while a sealing ring is connected to the auger housing and is biased against the plate to provide a seal. The excess air in the heated drum burns off the organic contaminates from the particulate material and calcines the mineral contaminates.

Abstract: A system including a method and apparatus for treating waste containing organic contaminants which includes a direct fired, countercurrent, rotary kiln providing a soaking zone having an oxidizing atmosphere through which the materials being treated are passed after the unwanted organics are removed, and a secondary combustion chamber for oxidizing gases containing vaporized or pyrolyzed organics in which the organics are burned and are subjected to high temperatures for a holding time sufficient to effect destruction of the organic contaminants. The system includes means to minimize off-gas so as to make possible a reduction in size of the equipment employed.

Abstract: A rotary kiln device for incinerating combustible materials such as municipal and commercial waste materials. The kiln is a co-current gas-material flow apparatus. The kiln is divided by means of a dam into a drying zone and a combustible zone. Waste material is retained within the drying zone sufficiently long so that that moisture contained in the material is driven off. Air for combustion is supplied directly to the combustion zone, bypassing the drying zone so that self-sustaining combustion may take place.

Abstract: A method of removing hazardous flammable hydrocarbons from soils comprises introducing the contaminated soil into a rotatable drum open at only one end, introducing flame and hot gases of combustion in the drum while rotating it to substantially expose the soil to the hot gases thereby heating the soil to a temperature sufficient to substantially vaporize all of the contaminant flammable hydrocarbons therein, and continuing to introduce the flame and hot gases whereby the vaporized hydrocarbon is burned in the drum with the exhaust gases of combustion then directed to atmosphere from the open port. The uncontaminated soil is then recovered from the drum.

Abstract: A system including a method and apparatus for treating waste containing organic contaminants which includes a direct fired, countercurrent, rotary kiln providing a soaking zone having an oxidizing atmosphere through which the materials being treated are passed after the unwanted organics are removed, and a secondary combustion chamber for oxidizing gases containing vaporized or pyrolyzed organics in which the organics are burned and are subjected to high temperatures for a holding time sufficient to effect destruction of the organic contaminants. The system includes means to minimize off-gas so as to make possible a reduction in size of the equipment employed.

Abstract: A furnace for the selective incineration or carbonization, by a process of distillation to remove its volatile components, of waste materials, the furnace consisting of an elongated, slightly inclined, rotatable cylindrical kiln, waste material being introduced into its upper end, moved along the length thereof in the form of a tumbling bed at its lower portion by rotation thereof either at higher rates to produce higher turbulence of the material as is useful in the incineration mode of operation, or at lower rates for less turbulence of the material as is useful in the carbonization mode. Air is introduced into the kiln either in large amounts supplying ample oxygen for full combustion as is useful in the incineration mode, or in sub-stoichiometric amounts as is necessary in the carbonization mode.

Abstract: The present invention deals with a chute for a kiln intake housing of a rotary tubular kiln or the like, the chute having a lining composed of a refractory material and a double-walled, inwardly facing collar disposed at the lower end thereof, the collar functioning to support the lower end of the refractory lining within its metal jacket and the collar being equipped with a special coolant circulating device. The inner end of the collar is composed of support segments which are connected to each other and to a holding means, the interior space of the collar being subdivided as required in order to provide for an induced circulation of a coolant.

Abstract: A port assembly for delivering fluid through a shell of a horizontal rotating reactor, such as a rotary kiln, is disclosed for purging from the port particulate material which enters port piping when no fluid is passing through the port. The port assembly comprises a cylindrical nozzle disposed in a port pipe, or port sleeve. The nozzle defines a nozzle orifice for discharging fluid into the reactor. A base member having a sloping surface is provided adjacent the nozzle with the sloping surface and nozzle cooperating to define a fluid distribution cavity with a thickness constantly varying from its circumference toward its center. The base member is sized as to define a fluid supply passage with facing surfaces of the port sleeve. Rest tabs along the circumference of the base member separate the base member from the nozzle while permitting communication between the fluid supply passage and fluid distribution cavity.

Abstract: A port assembly for delivering fluid through a shell of a rotary kiln is disclosed with structures for screening and excluding particulate matter from the port during operation of the kiln. The port assembly comprises a cylindrical nozzle defining a nozzle orifice to deliver fluid to the interior of a kiln. A base member secured to one side of the nozzle is provided with a platform extending partly through the nozzle orifice and cooperates with the nozzle to define an annular chamber. Facing surfaces of the base member and nozzle define a fluid distribution cavity for providing fluid to the annular chamber for ultimate distribution into the kiln. An annular shoulder surrounding the platform within the fluid distribution cavity cooperates with a facing surface of the nozzle to define a particle barrier gap.

Abstract: An arrangement for storing and distributing a fluid on board a rotary reactor such as a rotary kiln. The application discloses a rotary reduction kiln for reducing a metallic oxide such as iron oxide to a lower state of oxidation. A liquid hydrocarbon is used as a reductant in the reduction process for the metallic oxide. The kiln includes a cylindrical chamber adapted to receive the charge of material which is being subjected to the reduction process. A plurality of rows of nozzles are mounted on and supported by the kiln in hydraulic communication with the interior of the reduction chamber. Flow of hydrocarbon liquid to each row of nozzles is controlled by a corresponding flow control valve in accordance with the position of the corresponding row of nozzles relative to the charge of material in the kiln. A plurality of hydro-pneumatic accumulators having the hydraulic sections thereof connected to a common manifold are mounted on and rotatable with the kiln.

Abstract: Flow control valves are mounted with corresponding axial rows of nozzles about the periphery of a rotary kiln. A metering cylinder is mounted on the kiln and rotates therewith. A piston member is moveable in the metering cylinder in alternately opposite directions to deliver a predetermined measured volume of a liquid hydrocarbon such as fuel oil from said cylinder equally in each direction of movement of said piston member. A first hydraulic circuit interconnects each of said liquid flow control valves with a liquid fuel supply and with one end of said metering cylinder on one side of said piston member, and a second hydraulic circuit interconnects each of said liquid flow control valves with an opposite end of said metering cylinder on an opposite side of said piston member and with a plurality of nozzles in the row of nozzles corresponding to the given flow control valve.

Abstract: A flexible cam system characterized by the use of flexible guide tracks provided with balance weights attached thereto. The guide tracks are connected to a supporting frame through regulating drive mechanisms provided therefor and mounted on opposite sides of the frame. The drive mechanisms are connected respectively with one end of each of said guide tracks rigidly, and with the other end thereof, movably, through guide rollers fixed thereto.

Abstract: Temperature control is often a problem in direct-fired rotary kilns for the pyrolysis of carbonaceous materials wherein at least part of the thermal energy for pyrolysis is obtained by in situ combustion of the pyrolysis gases. The present process and apparatus provides a means by which temperature control, and particularly reduction in intensity of the fireball at the burner end of the kiln and/or moving the fireball away from the burner hood. This is accomplished by (1) controlling the velocity of any burner gases and the velocity of the in situ air (or other oxygen-containing gas) and (2) the distribution of the in situ air at the burner end of the kiln, such that a Craya-Curtet number of at least 0.2, and preferably at least 0.4, is obtained.

Abstract: Apparatus for controlling the delivery of fuel and air to a rotary reduction kiln wherein both the fuel and air flow through the same fluid distribution nozzle. Separate fuel and air valves control the flow through the nozzles. Two separate means are provided about the kiln for operating each valve as the kiln rotates. Each of these means is individually adjustable to a first position where the valve setting is sequentially altered as the kiln rotates and to a second position where the valve setting is unaltered as the kiln rotates.

Abstract: A rotating kiln having two rotating cylindrical chambers, these chambers having colinear axes which slope below the horizontal from the upper or loading end of the first chamber. The material to be processed into lightweight aggregate is introduced to the kiln at the upper end of the first chamber which is of narrower diameter than the second chamber. The lower end of the first chamber unites with the upper end of the second chamber providing an annular inner face for the second chamber.

Abstract: A rotating kiln having two rotating cylindrical chambers, these chambers having colinear axes which slope below the horizontal from the upper or loading end of the first chamber. The material to be processed into light-weight aggregate is introduced to the kiln at the upper end of the first chamber which is of narrower diameter than the second chamber. The lower end of the first chamber unites with the upper end of the second chamber providing an annular inner face for the second chamber.