# US 2014/0191450 A1 · Apparatus and method for the thermal extraction of metals

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- Number: US 2014/0191450 A1
- Document ID: US20140191450A1
- Status: Published application
- Kind: A1
- Application number: 14/101,540
- Filed: 2013-12-10
- Published: 2014-07-10
- Earliest claimed: 2011-07-05
- Assignees: Global Metal Technologies LLC
- Applicants: Global Metal Technologies LLC
- Inventors: Vaughn K. Boyman; Joseph A. Diaz; Gerald Engdahl; Thomas E. Stephens; Christopher E. Gordon
- Web page: https://patentgrep.com/patent/US20140191450A1

## CPC

- B02C 19/18: Use of auxiliary physical effects, e.g. ultrasonic waves or irradiation, for disintegrating
- C22B 4/08: Apparatus ({C22B4/005 takes precedence; } electric heating elements H05B)
- C22B 7/001: {Dry processes}
- C22B 11/046: {from manufactured products, e.g. from printed circuit boards, from photographic films, paper or baths}
- F27B 14/06: heated electrically, e.g. induction crucible furnaces with or without any other source of heat (F27B14/04 takes precedence)
- F27D 3/10: Charging directly from hoppers or shoots
- F27D 3/1509: {Tapping equipment}
- F27D 11/06: Induction heating, i.e. in which the material being heated, or its container or elements embodied therein, form the secondary of a transformer
- H05H 1/3484: {Convergent-divergent nozzles}
- Y02P 10/20: Recycling
- Y02P 10/25: Process efficiency
- B02C: CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN ({household tools and machines for pulverising foodstuffs, e.g. coffee and spice mills A47J42/00; pharmaceutical mortars A61J3/02; mechanical processing of refuse and garbage B03B9/06; dressing mould materials by grinding B22C5/04}; obtaining metallic powder by crushing, grinding or milling B22F9/04; {recovery of plastics by disintegrating B29B17/00; crushing raw materials in starch making C08B30/02; beaters for papermaking D21D1/02; crushing devices specially for transport in mines E21F13/002; slag crushing devices F23J1/00; fuel milling devices in combustion apparatus F23K1/00; household devices for crushing coal F24B15/02; ice disintegrating devices F25C5/02})
- C22B: PRODUCTION AND REFINING OF METALS (electrolytic C25); PRETREATMENT OF RAW MATERIALS
- F27B: FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27D: DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- H05H: PLASMA TECHNIQUE (apparatus or processes specially adapted for producing X-rays H05G2/00); PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

An apparatus and methods for removing metal from complex materials.

## Claims

### Claim 1

An apparatus for processing complex material comprising:
a chamber having a first opening for accommodating entry of a plasma torch where said plasma torch operates in a non-transfer mode;
where said torch has an active end and an inactive end;
where said torch is operatively located through the first opening in an orientation with the active end extending into the chamber and away from the first opening and the inactive end is secured in the chamber proximate to the first opening;
where said chamber further comprises a second opening near the first opening for entry of complex material and carrier gas having a constrained path into the chamber, the second opening being proximate to the first opening; the path of the complex material and carrier gas being along the same axis in relation to the major axis of the plasma torch;
where said chamber is surrounded by a secondary heating system.

### Claim 2 (depends on 1)

The apparatus of claim 1 comprises a: secondary melt system; gas treatment system; off-gas system; or combinations thereof.

### Claim 3

An apparatus for processing complex material where the apparatus is adapted to receive components that are subject to wear, are consumable, or both, said apparatus comprising:
a chamber having a first opening for accommodating entry of a plasma torch where said plasma torch operates in a non-transfer mode;
where said torch has an active end and an inactive end;
where said torch is operatively located through the first opening in an orientation with the active end extending into the chamber and away from the first opening and the inactive end is secured in the chamber proximate to the first opening;
where said chamber further comprises a second opening near the first opening for entry of complex material and carrier gas having a constrained path into the chamber, the second opening being proximate to the first opening; the path of the complex material and carrier gas being along the same axis in relation to the major axis of the plasma torch;
where said chamber is surrounded by a secondary heating system.

### Claim 4 (depends on 3)

The apparatus of claim 3 where the chamber is a component subject to wear or is a consumable part.

### Claim 5 (depends on 4)

The apparatus of claim 4 where the chamber is replaced with a second chamber.

### Claim 6 (depends on 3)

The apparatus of claim 3 where the reactor temperature is monitored by at least one thermocouple; where the thermocouple is subject to wear or is a consumable part.

### Claim 7 (depends on 6)

The apparatus of claim 6 where the at least one thermocouple is replaced by a second thermocouple.

### Claim 8 (depends on 3)

The apparatus of claim 3 where the chamber is insulated by, at least, a graphite insulation blanket or refectory lining; where the graphite insulation blanket and the refractory lining is subject to wear and is a consumable part.

### Claim 9 (depends on 8)

The apparatus of claim 8 where at least a first graphite insulation blanket is replaced with a second graphite insulation blanket, and/or a first refractory lining is replaced by a second refractory lining.

### Claim 10 (depends on 3)

The apparatus of claim 3 where the torch comprises at least an electrode, a gas ring, insulator ring, or nozzle that is subject to wear or is a consumable part.

### Claim 11 (depends on 10)

The apparatus of claim 10 where at least a first electrode is replaced by a second electrode, a first gas ring is replaced by a second gas ring, a first insulator ring is replace by a second insulator ring, and/ or a first nozzle is replace by a second nozzle.

### Claim 12

A method to replace components that are subject to wear or include consumable components, where said apparatus comprises:
a chamber having a first opening for accommodating entry of a plasma torch where said plasma torch operates in a non-transfer mode;
where said torch has an active end and an inactive end;
where said torch is operatively located through the first opening in an orientation with the active end extending into the chamber and away from the first opening and the inactive end is secured in the chamber proximate to the first opening;
where said chamber further comprises a second opening near the first opening for entry of complex material and carrier gas having a constrained path into the chamber, the second opening being proximate to the first opening; the path of the complex material and carrier gas being along the same axis in relation to the major axis of the plasma torch;
where said chamber is surrounded by a secondary heating system;
where the chamber is a component subject to wear or is a consumable part;
where the chamber is insulated by, at least, a graphic insulation blanket or refectory lining;
where the graphite insulation blanket and the refractory lining is subject to wear and is a consumable part;
where the torch comprises at least an electrode, a gas ring, insulator ring, or nozzle that is subject to wear or is a consumable part;
were the method comprises:
replacing a first chamber with a second chamber;
replacing, at least, a first graphite insulation blanket is with a second graphite insulation blanket, and/or a first refractory lining is by a second refractory lining; or
replacing, at least, a first electrode is by a second electrode, a first gas ring by a second gas ring, a first insulator ring by a second insulator ring, and/ or a first nozzle by a second nozzle.

### Claim 13

An apparatus for processing complex material comprising:
a chamber having a first opening for accommodating entry of a plasma torch where said plasma torch operates in a non-transfer mode;
where said torch has an active end and an inactive end;
where said torch is operatively located through the first opening in an orientation with the active end extending into the chamber and away from the first opening and the inactive end is secured in the chamber proximate to the first opening;
where said chamber further comprises a second opening near the first opening for entry of complex material and carrier gas having a constrained path into the chamber, the second opening being proximate to the first opening; the path of the complex material and carrier gas being along the same axis in relation to the major axis of the plasma torch.

### Claim 14 (depends on 13)

The apparatus of claim 13 where the chamber is surrounded by a secondary heating system.

### Claim 15 (depends on 13)

The apparatus of claim 13 comprises a: secondary melt system; gas treatment system; off-gas system; or combinations thereof.

### Claim 16

An apparatus for processing complex material where the apparatus is adapted to receive parts that are subject to wear or include a consumable component that is employed during operation of said apparatus, said apparatus comprising:
a chamber having a first opening for accommodating entry of a plasma torch where said plasma torch operates in a non-transfer mode;
where said torch has an active end and an inactive end;
where said torch is operatively located through the first opening in an orientation with the active end extending into the chamber and away from the first opening and the inactive end is secured in the chamber proximate to the first opening;
where said chamber further comprises a second opening near the first opening for entry of complex material and carrier gas having a constrained path into the chamber, the second opening being proximate to the first opening; the path of the complex material and carrier gas being along the same axis in relation to the major axis of the plasma torch.

### Claim 17 (depends on 16)

The apparatus of claim 16 where the chamber is a component subject to wear or is a consumable part.

### Claim 18 (depends on 17)

The apparatus of claim 17 where the chamber is replaced with a second chamber.

### Claim 19 (depends on 16)

The apparatus of claim 16 where the reactor temperature is monitored by at least one thermocouple; where the thermocouple is subject to wear or is a consumable part.

### Claim 20 (depends on 19)

The apparatus of claim 19 where the at least one thermocouple is replaced by a second thermocouple.

### Claim 21 (depends on 16)

The apparatus of claim 16 where the chamber is insulated by, at least, a graphic insulation blanket or refectory lining; where the graphite insulation blanket and the refractory lining is subject to wear and is a consumable part.

### Claim 22 (depends on 21)

The apparatus of claim 21 where at least a first graphite insulation blanket is replaced with a second graphite insulation blanket, and/or a first refractory lining is replaced by a second refractory lining.

### Claim 23 (depends on 16)

The apparatus of claim 16 where the torch comprises at least an electrode, a gas ring, insulator ring, or nozzle that is subject to wear or is a consumable part.

### Claim 24 (depends on 23)

The apparatus of claim 23 where at least a first electrode is replaced by a second electrode, a first gas ring is replaced by a second gas ring, a first insulator ring is replace by a second insulator ring, and/or a first nozzle is replace by a second nozzle.

### Claim 25

A method to replace components that are subject to wear or include consumable components, where said apparatus comprises:
a chamber having a first opening for accommodating entry of a plasma torch where said plasma torch operates in a non-transfer mode;
where said torch has an active end and an inactive end;
where said torch is operatively located through the first opening in an orientation with the active end extending into the chamber and away from the first opening and the inactive end is secured in the chamber proximate to the first opening;
where said chamber further comprises a second opening near the first opening for entry of complex material and carrier gas having a constrained path into the chamber, the second opening being proximate to the first opening; the path of the complex material and carrier gas being along the same axis in relation to the major axis of the plasma torch;
where the chamber is a component subject to wear or is a consumable part;
where the chamber is insulated by, at least, a graphic insulation blanket or refectory lining;
where the graphite insulation blanket and the refractory lining is subject to wear and is a consumable part;
where the torch comprises at least an electrode, a gas ring, insulator ring, or nozzle that is subject to wear or is a consumable part;
were the method comprises:
replacing a first chamber with a second chamber;
replacing, at least, a first graphite insulation blanket is with a second graphite insulation blanket, and/or a first refractory lining is by a second refractory lining; or
replacing, at least, a first electrode is by a second electrode, a first gas ring by a second gas ring, a first insulator ring by a second insulator ring, and/or a first nozzle by a second nozzle.

### Claim 26

An apparatus for processing complex material comprising:
a chamber having a first opening for accommodating entry of a plasma torch;
where said torch has an active end and an inactive end;
where said torch is operatively located through the first opening in an orientation with the active end extending into the chamber and away from the first opening and the inactive end is secured in the chamber proximate to the first opening;
where said chamber further comprises a second opening of complex material into the chamber.

### Claim 27 (depends on 26)

The apparatus of claim 26 where the plasma torch creates inductively coupled plasma, wave heat plasma, arc discharge plasma, or AC/DC plasma in transfer or non-transfer mode.

### Claim 28 (depends on 26)

The apparatus of claim 26 where the chamber is surrounded by a secondary heating system.

### Claim 29 (depends on 26)

The apparatus of claim 26 comprises a: secondary melt system; gas treatment system; off-gas system; or combinations thereof.