Apparatus and method for the thermal extraction of metals

Abstract

An apparatus and methods for removing metal from complex materials.

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.   
     
     
         2 . The apparatus of  claim 1  comprises a: secondary melt system; gas treatment system; off-gas system; or combinations thereof. 
     
     
         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.   
     
     
         4 . The apparatus of  claim 3  where the chamber is a component subject to wear or is a consumable part. 
     
     
         5 . The apparatus of  claim 4  where the chamber is replaced with a second chamber. 
     
     
         6 . 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. 
     
     
         7 . The apparatus of  claim 6  where the at least one thermocouple is replaced by a second thermocouple. 
     
     
         8 . 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. 
     
     
         9 . 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. 
     
     
         10 . 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. 
     
     
         11 . 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. 
     
     
         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.   
     
     
         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.   
     
     
         14 . The apparatus of  claim 13  where the chamber is surrounded by a secondary heating system. 
     
     
         15 . The apparatus of  claim 13  comprises a: secondary melt system; gas treatment system; off-gas system; or combinations thereof. 
     
     
         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.   
     
     
         17 . The apparatus of  claim 16  where the chamber is a component subject to wear or is a consumable part. 
     
     
         18 . The apparatus of  claim 17  where the chamber is replaced with a second chamber. 
     
     
         19 . 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. 
     
     
         20 . The apparatus of  claim 19  where the at least one thermocouple is replaced by a second thermocouple. 
     
     
         21 . 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. 
     
     
         22 . 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. 
     
     
         23 . 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. 
     
     
         24 . 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. 
     
     
         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.   
     
     
         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.   
     
     
         27 . 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. 
     
     
         28 . The apparatus of  claim 26  where the chamber is surrounded by a secondary heating system. 
     
     
         29 . The apparatus of  claim 26  comprises a: secondary melt system; gas treatment system; off-gas system; or combinations thereof.