High efficiency simultaneous grinding and drying of minerals and sludges

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High efficiency simultaneous grinding and drying
of minerals and sludges

• Presentation for
• 15th Annual Conference on Markets for Industrial
  Minerals Oct. 22, 2003
• David Dungate, V-P Marketing
• Dr. Sundar Narayan, V-P Research
• First American Scientific Corporation, Delta, BC

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Presentation Outline

• Introduction to First American Scientific Corp.
  and the KDS Micronex Grinder-Dryer
• Description of KDS Grinder-Dryer
• Pure Grinding Applications
• Glass, Limestone, Gypsum, Gold Ore
• Grinding AND Drying Applications
• Zeolite, Glacial Clay, Coal and Paper Sludge
• Summary

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About First American

• Founded in 1995, First American Scientific
  Corporation (FASC) is industrial equipment
  manufacturer and provider of innovative systems
  that increase profitability and reduce the
  environmental impact of materials processing.
• The KDS Micronex, FASCs patented grinder-dryer,
  efficiently and economically processes a wide
  variety of raw materials and wastes into fine,
  dry powders.

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Introduction to theKDS Micronex Technology

• KDS stands for Kinetic Disintegration System.
  The KDS Micronex is an high volume grinder that
  dries WITHOUT needing any heat input.
• No heat is needed because the forces causing size
  reduction also dry the material.
• KDS Technology uses LESS total energy than
  conventional drying and grinding combined.

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Target Applications

• Soft rock minerals into fertilizers and
  industrial feedstocks
• limestone, zeolite, phosphate rock, gypsum, and
  clay
• Specialty applications
• glass, metallic mineral ores
• Biomass waste into fuel and fertilizer
• paper sludge, manures, biosolids, wood waste and
  crop residues
• Agricultural and food waste processing into
  animal feeds
• food processing waste, oyster shell, fish bones,
  bread waste, seaweed

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Description of theKDS Micronex Technology
Materials that CANNOT be processed include

• Plastics
• Rubber (unless cryogenically cooled)
• Metals (metallic ores okay)
• Municipal Solid Waste (because it contains the
  above materials)

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Benefits of the KDS Micronex

• Simplifying on-site grinding and drying
  operations into a single compact, and
  easy-to-operate system that has low initial and
  operating costs
• Creating high-quality, dry, virtually
  pathogen-free powders that have value as
  industrial feedstocks, fuels, fertilizers and
  animal feeds.
• Reducing transportation and disposal costs by
  reducing moisture

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The KDS MICRONEXTM Process Flow

• Raw material is dropped into the throat of the
  mill

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The KDS MICRONEXTM Process Flow

• An air-lock gate reduces dust and eliminates
  blow-back

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The KDS MICRONEXTM Process Flow

• Material moves to the Torus and is subjected to
  repeated violent collisions with the spinning
  rotor and strike plates

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The KDS MICRONEXTM Process Flow

• Material is fractured and pathogen destruction
  occurs
• Water vapor and water droplets are released
  during the fracturing process

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The KDS MICRONEXTM Process Flow

• The classifier allows finished product to pass
  through to the cyclone and forces oversize
  particles to be reprocessed

Cyclone
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The KDS MICRONEXTM Process Flow
Moisture

• Air containing moisture is separated and removed
  from the system.
• Processed solid material is output from the
  bottom of the cyclone

Product
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KDS MICRONEX Physical Characteristics

• 18 (h) x 14 (l) x 7 (w)
• Footprint 1000 sq. ft.
• Weight 9000 lbs.
• Motors 250, 45, 2, 2, 2 HP
• Electrical 480V, 800 Amp
• High grade steel with some stainless components

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KDS MicronexTesting Site
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KDS MicronexProcess Process Results
Input
Output
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KDS Micronex Applications Container Glass

• KDS Micronex is the only machine known to us
  that can produce sub-micron glass powder, in bulk
  quantities.
• Powdered glass can be used as a replacement for
  silica fume cement an brick manufacture or as a
  filler for various other coatings.

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KDS Micronex ApplicationsContainer Glass
Material Feed Rate (kg/hr) Power (kW) Particle Size, d (microns)
Broken Bottles 543 150 15 lt 1 100 lt 45
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KDS Micronex Applications Limestone

• American limestone producer in Washington State
  uses KDS Micronex machine for limestone milling.
• Powdered Limestone is used in cement
  manufacturing and flue gas desulfurization (FGD).
• Client reports that the KDS Micronex is
  competitive with other size reduction methods.

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KDS Micronex Applications Limestone
FASC Client's Production Figures
Material Production Rate (kg/hr) Power (kW) Particle Size (microns)
Limestone 3620 150 lt75
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KDS Micronex Applications Limestone
Parameter Horizontal Ball Mill for Limestone KDS Micronex for Limestone
Power Consumption 35 kWhr/ton 35 kWhr/ton
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KDS Micronex Applications Gypsum
Gypsum plant in California used KDS Micronex for
gypsum grinding.
Material Production Rate (kg/hr) Power (kW) Particle Size (microns)
Gypsum 2265 112 75 (est)
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KDS Micronex Applications Gold Ore

• Patented process mechanically separates gold and
  avoids the use of toxic chemicals.
• Gold stays in KDS chamber when gold ore
  (quartzite) is ground to 30 microns.
• Waste rock is conveyed out of KDS.
• Research under way to improve operating
  efficiencies

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KDS Micronex Applications Zeolite, Glacial
Clay, Coal
Material Feed Rate (kg/hr) Feed MC () Power (kW) Prodn Rate (kg/hr) Out MC () Particle dia. (micron)
Zeolite Glacial Clay Coal 1116 1025 2100 13 10 23 130 120 150 1067 930 1582 9 lt1 8 32 45 63
Zeolite is used in fast drying concrete
mixtures Glacial Clay is used in cosmetics, face
creams.
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KDS Micronex Applications Paper Sludge

• Two kinds of Paper Sludge Primary/Secondary
  (P/S) Sludge and De-inking Sludge
• P/S Sludge comes from wastewater from paper
  pulp-making. Has bacteria. MC 80
• Deinking sludge results from recycled paper
  manufacturing. It is 25 clay (kaolin). MC 50
  

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KDS Micronex Applications Paper Sludge
Comparison

• Both kinds contain burnable fiber, but are too
  wet to burn on grate or in dust burners.
• Both can be directly applied as fertilizer, but
  this can lead to respiratory problems and water
  pollution.
• Paper Sludge is usually landfilled at 17-35/mT
  0.1/mT/km transportation cost.

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KDS Micronex Applications Paper Sludge
Comparison

• Drying sludge reduces landfill costs.
• Dried paper sludge can be used to make
  sound-absorbing material, cattle-bedding.
• Dried paper sludge is burnable in grate or dust
  burner.

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KDS Micronex Applications Glacial Clay
Material Feed Rate (kg/hr) Feed MC () Power (kW) Prodn Rate (kg/hr) Out MC () Drying Energy (kJ/kg)
Deinking Sludge 1204 51 110 797 26 975
975 kJ/kg is only 42 of the latent heat of
water! Drum Dryer would need 3700 kJ/kg of water.
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KDS Micronex Applications Oyster Shells

• FASC has processed Oyster Shells with excellent
  results.
• Fine, bone-dry powder is produced.
• Up to 3 TPH of possible.

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KDS Micronex Applications Summary

• Sub-micron glass powder can be made cheaply in
  large quantities
• Limestone and gypsum can effectively be ground to
  solution grade
• KDS dries deinking sludge with 74 LESS energy
  than drum dryers
• Chemical-free gold extraction system being
  commercialized

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KDS Micronex Summary

• The KDS Micronex provides a simple, compact, low
  cost and easy-to-operate solution for fine
  grinding and drying.
• Proven applications include sludge drying,
  grinding glass and soft-rock minerals and
  preparing biomass fuels for power production.
• The machine can quickly pay for itself, by
  creating high-value end-products, reducing
  processing and disposal costs.

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For more information contact First American
Scientific Corp. Tel [phone] Fax
1-604-940-6221 Toll Free 1-800-561-8656 Email
help_at_fasc.net Web www.fasc.net