Rapid action coater

Abstract

A new device and process for continuously applying coatings, such as resin and additives or polymers or the like, to minerals is disclosed. The device and apparatus differ substantially from standard batch coating processes currently used by industry. The apparatus uses a horizontal cylinder with an internal auger and a series of injection ports distributed along the cylinder. Minerals that are to be coated are pretreated and passed through the mixing cylinder using the auger (which may comprise one or more screws with variable pitch blades). As the mineral particles pass through the cylinder various coating materials are injected by the injection ports. The complete system is described, the method of use is explained and the control system which allows for different products is described.

1 . A continuous mixer for applying a coating material to particles comprising:
 a cylindrical conduit having a first end and a second end and having an inside and an outside;   an input aperture located at said first end of said conduit adapted to receive the particles for coating;   an output aperture at said second end of said conduit adapted to discharge coated particles;   auger means for continuously transporting the particles from said input aperture to said output aperture; and,   an injection port in communication with and adapted to inject the coating material from said outside of said conduit to said inside of said conduit whereby the particles, transported by said auger means, continuously pass under said injection port and whereby the particles are continuously coated with the coating material.   
     
     
         2 . A continuous mixer for applying a plurality of coating materials to particles comprising:
 a cylindrical conduit having a first end and a second end and having an inside and an outside;   an input aperture located at said first end of said conduit adapted to receive the particles for coating;   an output aperture at said second end of said conduit adapted to discharge coated particles;   auger means for continuously transporting the particles from said input aperture to said output aperture; and,   one or more injection ports, each one of said ports being in communication with a respective coating material and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said input aperture of said conduit and said output aperture of said conduit whereby the particles, transported by said auger means, continuously pass under said injection ports and whereby the particles are continuously coated with each of the plurality of required coating materials.   
     
     
         3 . The apparatus of  claim 2  wherein one of said injection ports is adapted to inject a quench solution onto the particles passing under said porting means. 
     
     
         4 . The apparatus of  claim 3  further comprising an air injection port located near said output aperture for injecting air onto the particles while the particles pass by said air injection port. 
     
     
         5 . The apparatus of  claim 1  wherein said auger means further comprises:
 a single screw auger having a plurality of paddles whose pitch is adjustable.   
     
     
         6 . The apparatus of  claim 2  wherein said auger means further comprises:
 a single screw auger having a plurality of paddles whose pitch is adjustable.   
     
     
         7 . The apparatus of  claim 1  wherein said auger means further comprises dual screw augers each auger having a plurality of paddles whose pitch is adjustable. 
     
     
         8 . The apparatus of  claim 2  wherein said auger means further comprises dual screw augers each auger having a plurality of paddles whose pitch is adjustable. 
     
     
         9 . A continuous mixer, capable of intermittent operation, for applying a coating material to particles comprising:
 a cylindrical conduit having a first end and a second end and having an inside and an outside;   an input aperture located at said first end of said conduit adapted to receive the particles for coating;   an output aperture at said second end of said conduit adapted to discharge coated particles;   auger means for intermittently transporting the particles from said input aperture to said output aperture; and,   an injection port in communication with and adapted to inject the coating material from said outside of said conduit to said inside of said conduit whereby the particles, transported by said auger means, pass under said injection port and whereby the particles are coated with the coating material   
     
     
         10 . The apparatus of  claim 8  for applying a plurality of coating materials and further comprising a plurality of additional injection ports, each being in communication with one of the plurality of coating materials and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said input aperture of said conduit and said output aperture of said conduit whereby the particles, transported by said auger means, pass under said injection ports and whereby the particles are coated with each of the plurality of coating materials. 
     
     
         11 . A continuous mixer for applying a coating material to particles comprising:
 a first cylindrical conduit having a first end and a second end and having an inside and an outside;   an input aperture located at said first end of said conduit adapted to receive the particles for coating;   an intermediate output aperture at said second end of said first conduit adapted to discharge the particles;   first auger means for continuously transporting the particles from said input aperture to said intermediate output aperture;   an injection port in communication with and adapted to inject the coating material from said outside of said conduit to said inside of said conduit located between said input aperture of said first conduit and said intermediate output aperture of said first conduit whereby the particles, transported by said auger means, continuously pass under said injection port and whereby the particles are continuously coated with the coating material being injected by said injection port;   a second cylindrical conduit having a first end and a second end and having an inside and an outside;   an intermediate input aperture located at said first end of said second conduit in communication with said intermediate output aperture of said first conduit   an output aperture at said second end of said second conduit adapted to discharge coated particles; and,   second auger means for continuously transporting the particles from said intermediate input aperture to said output aperture.   
     
     
         12 . The apparatus of  claim 11  where said injection port is translated to said second cylindrical conduit and is located between said input aperture of said second conduit and said output aperture of said second conduit whereby the particles, transported by said second auger means, continuously pass under said injection port and whereby the particles are continuously coated with the coating material being injected by said injection port. 
     
     
         13 . The apparatus of  claim 12  wherein said first segment acts a sand heater. 
     
     
         14 . A continuous mixer for applying a plurality of coating materials to particles comprising:
 a first cylindrical conduit having a first end and a second end and having an inside and an outside;   an input aperture located at said first end of said conduit adapted to receive the particles for coating;   an intermediate output aperture at said second end of said first conduit adapted to discharge the particles;   first auger means for continuously transporting the particles from said input aperture to said intermediate output aperture;   one or more injection ports, each one of said ports being in communication with a respective coating material and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said input aperture of said first conduit and said intermediate output aperture of said first conduit whereby the particles, transported by said first auger means, continuously pass under said injection ports and whereby the particles are continuously coated with each of the plurality of coating materials;   a second cylindrical conduit having a first end and a second end and having an inside and an outside;   an intermediate input aperture located at said first end of said second conduit in communication with said intermediate output aperture of said first conduit;   an output aperture at said second end of said second conduit adapted to discharge coated particles;   second auger means for continuously transporting the particles from said intermediate input aperture to said output aperture;   one or more injection ports, each one of said ports being in communication with a respective coating material and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said intermediate input aperture of said second conduit and said output aperture of said second conduit whereby the particles, transported by said second auger means, continuously pass under said injection ports and whereby the particles are continuously coated with each of the plurality of coating materials; and,   an output aperture at said second end of said conduit adapted to discharge the coated particles.   
     
     
         15 . The apparatus of  claim 14  further comprising air injection ports distributed between said intermediate input aperture and said output aperture on said second conduit for injecting air onto the particles while the particles pass said air injection ports. 
     
     
         16 . The apparatus of  claim 14  wherein said first and second auger means further comprise dual screw augers each auger having a plurality of paddles whose pitch is adjustable. 
     
     
         17 . A rapid action coater for continuously applying a plurality of coating materials to particles comprising:
 a storage silo adapted to store the particles to be coated;   a first particle flow control system for controlling the flow of particles from said storage silo to;   a particle heater adapted to heat the particles connected to;   a second particle flow control system for controlling the flow of heated particles from said heater to;   an input aperture said input aperture; said input aperture being part of   a cylindrical conduit having a first end and a second end and having an inside and an outside and wherein said input aperture is located at said first end of said conduit;   an output aperture located at said second end of said conduit;   auger means for continuously transporting the particles from said input aperture to said output aperture;   one or more injection ports, each one of said ports being in communication with a respective coating material and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said input aperture of said conduit and said output aperture of said conduit whereby the particles, transported by said auger means, continuously pass under said injection ports and whereby the particles are continuously coated with each of the plurality of coating materials being injected by said; and wherein said output aperture is adapted to discharge the coated particles to   a screener-shaker for final delivery of coated particles.   
     
     
         18 . The apparatus of  claim 17  further comprising air injection ports distributed from midway between said ends of said conduit and extending towards said output aperture for injecting air onto the particles while the particles pass by said air injection ports. 
     
     
         19 . A rapid action coater for continuously applying a plurality of coating materials to particles comprising:
 a storage silo adapted to store the particles to be coated;   a first particle flow control system for controlling the flow of particles from said storage silo to;   a particle heater adapted to heat the particles; connected to;   a second particle flow control system for controlling the flow of heated particles from said heater to;   an input aperture said input aperture; said input aperture being part of   a first cylindrical conduit having a first end and a second end and having an inside and an outside and wherein said input aperture is located at said first end of said conduit;   an intermediate output aperture located at said second end of said first conduit   first auger means for continuously transporting the particles from said input aperture to said intermediate output aperture;   one or more injection ports, each one of said ports being in communication with a respective coating material and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said input aperture of said first conduit and said intermediate output aperture of said first conduit whereby the particles, transported by said first auger means, continuously pass under said injection ports and whereby the particles are continuously coated with each of the plurality of coating materials;   a second cylindrical conduit having a first end and a second end and having an inside and an outside;   an intermediate input aperture located at said first end of said second conduit in communication with said intermediate output aperture of said first conduit;   an output aperture at said second end of said second conduit adapted to discharge coated particles;   second auger means for continuously transporting the particles from said intermediate input aperture to said output aperture;   one or more injection ports, each one of said ports being in communication with a respective coating material and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said intermediate input aperture of said second conduit and said output aperture of said second conduit whereby the particles, transported by said second auger means, continuously pass under said injection ports and whereby the particles are continuously coated with each of the plurality of coating materials; and, wherein said output aperture at said second end of said conduit is adapted to discharge the coated particles to   a screener-shaker for final delivery of coated particles.   
     
     
         20 . The apparatus of  claim 19  further comprising air injection ports distributed between said intermediate input aperture and said output aperture on said second conduit for injecting air onto the particles while the particles pass said air injection ports. 
     
     
         21 . The apparatus of  claim 19  wherein said first and second auger means further comprise dual screw augers each auger having a plurality of paddles whose pitch is adjustable. 
     
     
         22 . The apparatus of  claim 19  wherein said particle heater is combined into said first cylindrical conduit thereby removing the need for a second particle flow control system. 
     
     
         23 . A method for continuously coating particles with one or more ingredient coats in a continuous mixer having a controllable transfer speed and a plurality of coating ingredient injection points thereby producing a product with given specifications comprising:
 a) determining what product is required;   b) determining the required coating or coatings;   c) determining the transfer speed of the continuous mixer so that the coating or coatings will adhere as required by the product specifications to the particles;   d) determining the proper injection points that will inject which ingredient;   e) preparing the particles for coating;   f) passing the prepared particles through the continuous mixer;   g) injecting continuously the determined coating ingredients at the proper points in the continuous mixer; and   h) collecting the product.   
     
     
         24 . The method of  claim 23  wherein the following step is added between steps g) and h):
 g-1) cooling the product as required.   
     
     
         25 . A method for continuously coating particles with one or more ingredient coats in a continuous mixer having a controllable transfer speed and a plurality of coating ingredient injection points thereby producing a product with given specifications comprising:
 a) determining what product is required;   b) determining the required coating or coatings;   c) determining the transfer speed of the continuous mixer so that the coatings or coating will adhere as required by the product specifications to the particles;   d) determining the proper injection points that will inject which ingredient;   e) heating the particles for coating;   f) passing the prepared particles through the continuous mixer;   g) injecting continuously the determined coating ingredients at the proper points in the continuous mixer;   h) cooling the product as needed by the product specifications; and   i) collecting the product.   
     
     
         26 . A method for continuously coating particles with a resin coat and further encapsulating the coated particles with ingredients in a continuous mixer having a controllable transfer speed and a plurality of coating ingredient injection points thereby producing a product with given specifications comprising:
 a) determining what product is required;   b) determining the required resin coat;   c) determining what encapsulations are required;   d) determining the transfer speed of the continuous mixer so that the resin coat and encapsulations will adhere as required by the product specifications to the particles;   e) determining the proper injection points that will inject the encapsulation ingredient;   f) heating the particles for coating;   g) passing the prepared particles through the continuous mixer;   h) injecting continuously the required resin at the proper injection point;   i) injecting continuously the determined encapsulation ingredients at the proper points in the continuous mixer;   j) cooling the product; and   k) collecting the product.   
     
     
         27 . A method for continuously coating particles with a coat and further encapsulating the coated particles with premixed ingredients in a continuous mixer having a controllable transfer speed and a plurality of coating ingredient injection points thereby producing a product with given specifications comprising:
 a) determining what product is required;   b) determining the required coat;   c) determining what encapsulations are required,   d) determining the transfer speed of the continuous mixer so that the resin coat and encapsulations will adhere as required by the product specifications to the particles;   e) determining the proper injection points that will inject the premixed encapsulation ingredient;   f) preparing the premixed encapsulation ingredients;   g) heating the particles for coating;   h) passing the prepared particles through the continuous mixer;   i) injecting continuously the required resin at the proper injection point;   j) injecting continuously the determined encapsulation ingredients at the proper points in the continuous mixer; and   k) collecting the product.   
     
     
         28 . The method of  claim 26  wherein the following step is added between steps j) and k):
 j-1) cooling the product as required.   
     
     
         29 . A rapid action coater for continuously applying a plurality of coating materials to particles comprising:
 a storage silo adapted to store the particles to be coated;   a first particle flow control system for controlling the flow of particles from said storage silo to;   a particle heater adapted to heat the particles; connected to;   a second particle flow control system for controlling the flow of heated particles from said heater to;   an input aperture said input aperture; said input aperture being part of   a first cylindrical conduit having a first end and a second end and having an inside and an outside and wherein said input aperture is located at said first end of said conduit;   an intermediate output aperture located at said second end of said first conduit   first auger means for continuously transporting the particles from said input aperture to said intermediate output aperture;   one or more injection ports, each one of said ports being in communication with a respective coating material and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said input aperture of said first conduit and said intermediate output aperture of said first conduit whereby the particles, transported by said first auger means, continuously pass under said injection ports and whereby the particles are continuously coated with each of the plurality of coating materials;   a second cylindrical conduit having a first end and a second end and having an inside and an outside;   an intermediate input aperture located at said first end of said second conduit in communication with said intermediate output aperture of said first conduit;   an output aperture at said second end of said second conduit adapted to discharge coated particles;   second auger means for continuously transporting the particles from said intermediate input aperture to said output aperture;   one or more injection ports, each one of said ports being in communication with a respective coating material and each being adapted to inject its respective coating material from said outside of said conduit to said inside of said conduit, distributed between said intermediate input aperture of said second conduit and said output aperture of said second conduit whereby the particles, transported by said second auger means, continuously pass under said injection ports and whereby the particles are continuously coated with each of the plurality of coating materials; wherein said output aperture at said second end of said conduit is adapted to discharge the coated particles to   a screener-shaker for final delivery of coated particles;   air injection ports distributed between said intermediate input aperture and said output aperture on said second conduit for injecting air onto the particles while the particles pass said air injection ports; and   a control system wherein said control system controls all aspects of the rapid action coater such as rate of input of particles to be coated, preparation steps for the particles, selection of injection ports and respective coating material, rate of air injection and mixing speeds of the coating process based on chosen product requirements.