Title: High efficiency simultaneous grinding and drying of minerals and sludges
1High 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
2Presentation 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
3About 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.
4Introduction 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.
5Target 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
6Description 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)
7Benefits 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
8The KDS MICRONEXTM Process Flow
- Raw material is dropped into the throat of the
mill
9The KDS MICRONEXTM Process Flow
- An air-lock gate reduces dust and eliminates
blow-back
10The KDS MICRONEXTM Process Flow
- Material moves to the Torus and is subjected to
repeated violent collisions with the spinning
rotor and strike plates
11The KDS MICRONEXTM Process Flow
- Material is fractured and pathogen destruction
occurs - Water vapor and water droplets are released
during the fracturing process
12The KDS MICRONEXTM Process Flow
- The classifier allows finished product to pass
through to the cyclone and forces oversize
particles to be reprocessed
Cyclone
13The 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
14KDS 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
15KDS MicronexTesting Site
16KDS MicronexProcess Process Results
Input
Output
17KDS 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.
18KDS Micronex ApplicationsContainer Glass
Material Feed Rate (kg/hr) Power (kW) Particle Size, d (microns)
Broken Bottles 543 150 15 lt 1 100 lt 45
19KDS 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.
20KDS Micronex Applications Limestone
FASC Client's Production Figures
Material Production Rate (kg/hr) Power (kW) Particle Size (microns)
Limestone 3620 150 lt75
21KDS Micronex Applications Limestone
Parameter Horizontal Ball Mill for Limestone KDS Micronex for Limestone
Power Consumption 35 kWhr/ton 35 kWhr/ton
22KDS 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)
23KDS 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
24KDS 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.
25KDS 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
26KDS 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.
27KDS 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.
28KDS 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.
29KDS Micronex Applications Oyster Shells
- FASC has processed Oyster Shells with excellent
results. - Fine, bone-dry powder is produced.
- Up to 3 TPH of possible.
30KDS 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
31KDS 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.
32For more information contact First American
Scientific Corp. Tel 1-604-940-6220 Fax
1-604-940-6221 Toll Free 1-800-561-8656 Email
help_at_fasc.net Web www.fasc.net