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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 MarketingDr. Sundar Narayan, V-P ResearchFirst American Scientific Corporation, Delta, BC
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
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™, FASC’s patented grinder-dryer, efficiently and economically processes a wide variety of raw materials and wastes into fine, dry powders.
• 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.
Introduction to theKDS Micronex™ Technology
• 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
Target Applications
• Plastics
• Rubber (unless cryogenically cooled)
• Metals (metallic ores okay)
• Municipal Solid Waste (because it contains the above materials)
Description of theKDS Micronex™ TechnologyMaterials that CANNOT be processed include:
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
Material moves to the Torus and is subjected to repeated violent collisions with the spinning rotor and strike plates
The KDS MICRONEXTM Process Flow
Material is fractured and pathogen destruction occurs
Water vapor and water droplets are released during the fracturing process
The KDS MICRONEXTM Process Flow
The classifier allows finished product to pass through to the cyclone and forces oversize particles to be reprocessed
The KDS MICRONEXTM Process Flow
Cyclone
Air containing moisture is separated and removed from the system.
Processed solid material is output from the bottom of the cyclone
The KDS MICRONEXTM Process FlowP
rod
uct
Moisture
• 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
KDS MICRONEX™ Physical Characteristics
• 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.
KDS Micronex™ Applications Container Glass
Material
Feed Rate(kg/hr)
Power(kW)
ParticleSize, d(microns)
BrokenBottles
543 150 15 % < 1
100 % < 45
KDS Micronex™ ApplicationsContainer Glass
• 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.
KDS Micronex™ Applications Limestone
Material Production Rate(kg/hr)
Power(kW)
ParticleSize
(microns)
Limestone
3620 150 <75
FASC Client's Production Figures
KDS Micronex™ Applications Limestone
Parameter Horizontal Ball Mill for Limestone
KDS Micronex
for Limestone
Power Consumption
35 kWhr/ton
35 kWhr/ton
KDS Micronex™ Applications Limestone
Gypsum plant in California used KDS Micronex for gypsum grinding.
Material Production Rate(kg/hr)
Power(kW)
ParticleSize
(microns)
Gypsum 2265 112 75 (est)
KDS Micronex™ Applications Gypsum
• 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
KDS Micronex™ Applications Gold Ore
Material Feed Rate(kg/hr)
Feed MC (%)
Power(kW)
ProdnRate(kg/hr)
OutMC (%)
Particle dia. (micron
)
Zeolite
Glacial
Clay
Coal
1116
1025
2100
13
10
23
130
120
150
1067
930
1582
9
<1
8
32
45
63
Zeolite is used in fast drying concrete mixtures
Glacial Clay is used in cosmetics, face creams.
KDS Micronex™ Applications Zeolite, Glacial Clay, Coal
• 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 %
KDS Micronex™ Applications Paper Sludge
• 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.
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.
KDS Micronex™ Applications Paper Sludge Comparison
Material Feed Rate(kg/hr)
Feed MC (%)
Power(kW)
ProdnRate(kg/hr)
OutMC (%)
Drying Energ
y (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.
KDS Micronex™ Applications Glacial Clay
• FASC has processed Oyster Shells with excellent results.
• Fine, bone-dry powder is produced.
• Up to 3 TPH of possible.
KDS Micronex™ Applications Oyster Shells
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
KDS Micronex™ Applications 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.
KDS Micronex™ Summary
Reduction System
For more information contact:
First American Scientific Corp. Tel: +1-604-940-6220Fax: +1-604-940-6221Toll Free: 1-800-561-8656Email: [email protected]: www.fasc.net