Hydrogravity system and process for reclaiming and purifying a solid, multiple domain feedstock

Abstract

The hydrogravity separation of a multiple component solid feedstock comprises granulating the feedstock to produce particles substantially of individual components having different densities. A dispersion mixer having a high shear and/or turbulent zone is utilized to disperse agglomerated particles and a quiescent hydrogravity tank is utilized to effect binary separation of one or more of the heaviest or one or more of the lightest feedstock components by utilizing an aqueous solution having a specific gravity intermediate of the various components. A high degree of purity is obtained by feeding particles of a selected component to a plurality of sequential dispersion mixers and hydrogravity separation tanks. In a similar manner, remaining thermoplastic particle components can be selectively removed and purified.

1 . A process for purifying a selected feedstock component, comprising the steps of: 
 a) mixing particles of a feedstock comprising a plurality of components, each component having a different specific gravity;    b) feeding said mixed feedstock component particles to a first hydrogravity tank containing a solution having a specific gravity intermediate to one or more heavier feedstock component particles and to one or more lighter feedstock component particles and causing said particles of at least one feedstock component to either sink or float;    c) removing selected specific gravity component particles from said hydrogravity tank;    d) mixing said removed selected component particles;    e) feeding said removed mixed selected component particles to another hydrogravity separation tank containing a solution having substantially the same specific gravity as said first tank solution; and    f) removing said selected component particles from said second hydrogravity tank.    
   
   
       2 . A process according to  claim 1 , wherein said feedstock comprises at least three components, and 
 wherein said selected specific gravity component particles are substantially of a single feedstock component.    
   
   
       3 . A process according to  claim 2 , wherein each particle comprises substantially a single component, and including mixing said selected component particles from said second hydrogravity tank and feeding to a third hydrogravity separation tank containing a solution having substantially the same specific gravity as said first tank solution.  
   
   
       4 . A process according to  claim 3 , wherein a mixer for mixing said feedstock component particles exists before each said hydrogravity separation tank; 
 wherein said feedstock component particles are fed into the side of each said hydrogravity separation tank, wherein the number of separation tanks is from about 2 to about 8, wherein the specific gravity of said at least one different feedstock component particles is at least 0.1 specific gravity units different than the specific gravity solution in each said tank, and    wherein each said hydrogravity solution is substantially free of a phosphorus containing compound.    
   
   
       5 . A process according to  claim 1 , wherein said hydrogravity solution is an aqueous solution.  
   
   
       6 . A process according to  claim 4 , wherein said hydrogravity solution is an aqueous solution.  
   
   
       7 . A process according to  claim 1 , wherein each said mixer has at least one substantially axial flow zone and at least one substantially radial flow zone.  
   
   
       8 . A process according to  claim 6 , wherein each said mixer has at least one substantially axial flow zones and at least one substantially radial flow zones.  
   
   
       9 . A process according to  claim 1 , wherein said feedstock comprises at least three different feedstock components including at least one plastic component and at least one metal component, or at least three different plastic components, or at least two different plastic components and a wood component, or at least two different plastic components and a cellulose component.  
   
   
       10 . A process according to  claim 6 , wherein said feedstock comprises at least three different feedstock components including at least one plastic component and at least one metal component, or at least three different plastic components, or at least two different plastic components and a wood component, or at least two different plastic components and a cellulose component.  
   
   
       11 . A process according to  claim 1 , wherein said feedstock components are derived from copper cables, aluminum cables, or combinations thereof.  
   
   
       12 . A process according to  claim 6 , wherein said feedstock components are derived from copper cables, aluminum cables, or combinations thereof.  
   
   
       13 . A process according to  claim 1 , including purifying said non-selected specific gravity feedstock component particles by feeding said particles to at least one of a tandem comprising a mixer and a subsequent hydrogravity tank having an aqueous solution of a specific gravity such that one of said remaining non-selected specific gravity feedstock component particles is separated.  
   
   
       14 . A process according to  claim 6 , including purifying said non-selected specific gravity feedstock component particles by feeding said particles to at least one of a tandem comprising a mixer and a subsequent hydrogravity tank having an aqueous solution of a specific gravity such that one of said remaining non-selected specific gravity feedstock component particles is separated.  
   
   
       15 . A hydrogravity process for reclaiming particles of a ground feedstock, comprising the steps of: 
 feeding particles of a ground feedstock containing a plurality of different components each having a different specific gravity to a first hydrogravity separation tank, said tank having substantially a phosphorus-free aqueous solution of a specific gravity greater or less than the specific gravity of at least one component of said feedstock particles;    removing particles of either at least one lighter specific gravity component or at least one heavier specific gravity component than the specific gravity of said aqueous solution;    subsequently feeding said selected removed lighter or heavier component particles to a second hydrogravity separation tank having substantially the same specific gravity of said substantially phosphorus-free aqueous solution as said first tank; and    purifying said selected removed component particles by separating said selected lighter or heavier component particles from any other different specific gravity component particles of said feedstock.    
   
   
       16 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 15 , including a mixer before at least one of said hydrogravity tanks for mixing said particles of said selected removed lighter or heavier feedstock components, 
 wherein said selected removed lighter or heavier component are particles of substantially a single feedstock component, and    wherein the amount of any phosphorus containing salt is less than about 3% by weight of said aqueous solution.    
   
   
       17 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 16 , including a mixer before each hydrogravity tank, mixing said particles of said selected component and feeding said particles into the side of each hydrogravity tank.  
   
   
       18 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 17 , wherein said feedstock comprises a total of at least three different feedstock components comprising at least one plastic component and at least one metal component, or at least three different plastic components, or at least two different plastic components and a wood component, or at least two different plastic components. and a cellulose component.  
   
   
       19 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 18 , including purifying said non-selected specific gravity component particles by feeding said particles to at least one of a tandem comprising a mixer and a subsequent hydrogravity tank having an aqueous solution of a specific gravity such that one of said remaining non-selected specific gravity feedstock component particles is separated.  
   
   
       20 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 19 , wherein said aqueous solution comprises a salt of an alkali metal, an alkaline earth metal, a transition metal from groups 3 through 15 of the Periodic Table other than phosphorus, and an anion comprising a halogen, oxygen or an oxygen-containing compound, hydroxide, carbonate, a nitrogen-containing compound, or a sulfur-containing compound; or wherein said aqueous solution is a drilling fluid, or a completion fluid, or an aqueous suspension.  
   
   
       21 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 17 , wherein said aqueous solution comprises potassium carbonate, zinc chloride, ferric chloride, ferrous chloride, calcium chloride, calcium bromide, calcium sulfate, zinc chloride, zinc bromide, zinc sulfate, zinc oxide, sodium hydroxide, sodium zincate, magnesium chloride, or a polytungstate complex, or mixtures thereof.  
   
   
       22 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 20 , wherein said aqueous solution comprises potassium carbonate, zinc chloride, ferric chloride, ferrous chloride, calcium chloride, calcium bromide, calcium sulfate, zinc chloride, zinc bromide, zinc sulfate, zinc oxide, sodium hydroxide, sodium zincate, magnesium chloride, or a polytungstate complex, or mixtures thereof.  
   
   
       23 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 19 , wherein each said mixer has at least two substantially axial flow zones and at least two substantially radial flow zones.  
   
   
       24 . A hydrogravity process for reclaiming particles of a ground feedstock according to  claim 15 , wherein said feedstock components are derived from copper cables, aluminum cables, or combinations thereof.  
   
   
       25 . A system for reclaiming particles of a ground feedstock comprising: 
 a) a first set of at least one mixer and a plurality of hydrogravity separation tanks each containing a substantially phosphorus-free aqueous solution having substantially the same specific gravity for separating particles of one component of said ground feedstock containing at least three different components, each aqueous solution having a specific gravity which is either. greater or less than the particles of a single selected component of said feedstock components, each said feedstock component having a different specific gravity;    said mixer located at least before one of said hydrogravity separation tanks for mixing said particles of said feedstock components before said components are fed to said at least one hydrogravity separation tank,    b) a second set of at least one mixer and a plurality of hydrogravity separation tanks for further separating a single selected remaining component of said feedstock components, said at least one mixer of said second set located before a hydrogravity separation tank for mixing said particles of said feedstock components before they are fed to at least one said second set hydrogravity separation tank, each said second set tank having a substantially phosphorus-free aqueous solution of substantially the same specific gravity but which is different than the specific gravity of said first aqueous solution, and is greater or less than only said single selected remaining component of said feedstock so that said second set aqueous solution is capable of separating said second selected component from the remaining feedstock components.    
   
   
       26 . A system according to  claim 25 , wherein in each said set of said mixers and said tanks, independently, the number of mixers and mixing tanks is each from about 3 to about 10.  
   
   
       27 . A system according to  claim 26 , wherein said solution, independently, in each said set of hydrogravity separation tanks is a phosphorus free compound comprising a salt of an alkali metal, an alkaline earth metal, a transition metal from groups 3 through 15 other than phosphorus of the Periodic Table, and an anion comprising a halogen, oxygen or an oxygen-containing compound, hydroxide, carbonate, a nitrogen-containing compound, or a sulfur-containing compound; or wherein said aqueous solution is a drilling fluid, or a completion fluid, or a suspension.  
   
   
       28 . A system according to  claim 27 , including in each set a mixer before each said hydrogravity separation tank, and wherein, independently, the number of mixers and tanks in each said set is at least two, and wherein the amount of any phosphorus containing compound is less than about 3% by weight of said aqueous solution of said first set and said second set.  
   
   
       29 . A system according to  claim 28 , wherein said hydrogravity aqueous solution comprises potassium carbonate, zinc chloride, ferric chloride, ferrous chloride, calcium chloride, calcium bromide, calcium sulfate, zinc chloride, zinc bromide, zinc sulfate, zinc oxide, sodium hydroxide, sodium zincate, magnesium chloride, or a polytungstate complex, or mixtures thereof.  
   
   
       30 . A system according to  claim 29 , wherein said feedstock comprises a total of at least three different feedstock components comprising at least one plastic component and at least one metal component, or at least three different plastic components, or at least two different plastic components and a wood component, or at least two different plastic components and a cellulose component.  
   
   
       31 . A system according to  claim 25 , wherein said feedstock is derived from copper wire cable, aluminum wire cable, or combinations thereof.  
   
   
       32 . A system according to  claim 30 , wherein said feedstock is derived from copper wire cable, aluminum wire cable, or combinations thereof.