Description:FORM 2
THE PATENT ACT 1970
(39 OF 1970)
&
The Patent Rules, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

1 TITLE OF THE INVENTION :
AN INTEGRATED SYSTEM FOR COOLING HOT PRODUCTS INCLUDING REDUCTION ROASTED PRODUCTS AND HOT GASES AND SIMULTANEOUS CLEANING AND BURNING OF COMBUSTIBLE GASES.



2 APPLICANT (S)

Name : JSW STEEL LIMITED.

Nationality : An Indian Company incorporated under the Companies Act, 1956.

Address : JSW CENTRE,
BANDRA KURLA COMPLEX,
BANDRA(EAST),
MUMBAI-400051,
MAHARASHTRA,INDIA.




3 PREAMBLE TO THE DESCRIPTION

COMPLETE

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION:
The present invention relates to the field of mineral processing especially cooling of reduction roasted iron ore fines / slime/iron ore tailings. More particularly, the present invention is directedto provide an integrated systemfor cooling iron ore fines or slime/iron ore tailing after reductionroasting along with cleaning and burning of combustible gases from a bubbling fluidized bed reactor.

BACKGROUND OF THE INVENTION:
A fluidized bed is essentially a fine particulate solid in gas suspension, where at a certain condition, the bed behaves like a fluid. A perforated plate is used to support the bed of particles as the gas is passed from the bottom. Based on the pressure, velocity and flow rate of gas, the operation could be stationary, bubbling or floating. The continuous operation of such an apparatus requires appropriate adjustment of gas and solid flow to maintain the bubbling behaviour.
The principle of fluidization has been used in several unit processes like catalysis, granulation of fine particles, coating of particles and drying of fine particles. The high efficiency of heat and mass transfer makes this technique extremely useful for energy intensive mineral processing such as reduction roasting. In a typical operation, preheated solid particles and mixture of CO and N2 is fed from the top and bottom respectively. The exothermic reductionreactions form magnetite and the solid mixture is transported to a chamber for cooling. The hot gas passing through the bed contains fine dust and is toxic due to presence of unreacted CO/H2. It is vital to clean and cool the hot gas and solids before burning, due to environmental concerns. Once the gas is cooled and cleaned using a scrubbing system, it could be burnt using an external burner.
Present invention describes a system wherein the cooling of high temperature solids and cleaning and burning of combustible gases is simplified by reducing engineering complexity.

Prior art:
An example of mineral processing to produce iron concentrates using a fluidised bed can be found in CN114438310A for instance in paragraphs [0010]-[0015]or inEP0543429A1, CN107460307A, EP0206066B1.
The typical multistage fluidised bed system with a product cooler is known fromCN107460307A wherein the hot solids flow from the fluidised bed into the cooling chamber while the gases are cleaned separately in a cyclone separator. The mentioned method uses dry approach for gas cleaning and cooling of solids the intended operation being in bubbling regime of fluidisation.
The EP0543429A1 describes a fluidised bed cooler intended for operation at higher superficial velocities and relatively less dense granular particles. This allows for transport of solids through the gas into a high temperature separation system such as a cyclone. The cooling however, takes place in a separate chamber at the exit of cyclone separator. This can lead to difficulty in continuous operation owing to fine particle size leading to high pressures required for the fluidising gas. Moreover, the overall consumption of fluidising gas in such a system might be too high.
The CN204388653 discloses a fluidized bed cooling system. The said system involves an air blowing chamber and a cooling chamber.
The IN272931A1 discloses a product cooler for a fluidised bed reactor/combustor which consists of direct cooling using a fluidised chamber followed by indirect cooling via tubular heat exchanger with flow of liquid coolant such as water.
Most of the above mentioned works use a separate unit for gas cleaning and product cooling. These involve separate components each satisfying individual requirements of the process adding to the engineering complexity. The proposed design combines two unit processes into a single unit without compromising safety. The system proposed herein provides uninterrupted flow of solids out of the cooling chamber unlike conventional systems that are prone to choking.Finally, the system allows for safe cleaning and combustion of hazardous gases.

OBJECTIVE OF THE INVENTION:
The basic objective of the present invention is to develop an integrated system for cooling the reduction roasted iron bearing fine materials, with flexibility of cooling wider particle size range in a single apparatus/setup.
A further object of the present invention is directed to said integrated cooling systemwhich would be capable of simultaneous cleaning and combusting the gases coming along with the solid particles from fluidised bed reactor.

SUMMARY OF THE INVENTION:
The basic aspect of the present invention is directed to an integrated system for cooling hot products including reduction roasted products and hot gases including fluidized bed reactor comprising:

a vertically extending tubular inlet chamber;

said vertically extending tubular inlet chamber having a closed lower end and an open upper end , therebetween said closed lower end and open upper end having a hot feed inlet for the feeding in of hot solids and /or gases therein;

a primary water inlet into said vertically extending inlet chamber disposed above said hot feed inlet for maintaining water level in said tubular inlet chamber ;

a secondary water inlet disposed above said primary water inlet for a secondary water flow inlet into said vertically extending tubular inlet chamber;

at said closed lower end of said vertically extending tubular inlet chamber, the same is operatively connected to an extending tubular outlet chamber;

said extending tubular outlet chamber having a closed lower end operatively communicating with the vertically extending tubular inlet chamber and internally housing a coaxially disposed rotary screw member to remove water-solid mixture entering the said tubular inlet chamber through the said tubular outlet chamber;

hot gases are blocked by the water and solid content in said tubular outlet and are released only after passage through the secondary water flow through the open outlet of said vertically extending tubular inlet chamber.

A further aspect of the present invention is directed to said integrated system wherein said rotary screw member in said tubular outlet chamber is operatively connected to an electric motor through bearing housing whereby the screw is driven by said electric motor.
A still further aspect of the present invention is directed to said integrated system comprising at the top closed end of said tubular outlet chamber having a motor support for holding the electric motor on the axis and the other end of the rotary screw connected to a rotary joint.
A still further aspect of the present invention is directed to said integrated system wherein the bottom of cooling inlet chamber allows flow of solids slurry preferably through a declined bottom of outlet chamber towards the screw so that rotary movement of screw minimizes the material accumulation inside the inlet and outlet chamber ensuring smooth and steady operation.
A still further aspect of the present invention is directed to said integrated system wherein outlet of said screw conveying mechanism is located lower than the water level of slurry to ensure easier discharge of slurry due to hydrodynamic pressure and the level of slurry is maintained lower than the solid inlet to avoid backflow into fluidised chamber.
A still further aspect of the present invention is directed to said integrated system comprising said inlet and outlet chambers configured in a V-shape where the hot solids from the fluidized bed reactor is quenched with water in a vertical inlet chamber and the solid forms a slurry and gets cooled to 40oC which is conveyed to an inclined outlet chamber.
A still further aspect of the present invention is directed to said integrated system wherein the slurry formed in cooling inlet chamber is discharged through an outlet of inclined outlet chamber propagated therethrough by said screw conveyor at a rate of 65 kg/h at a temperature of 40oC.
A still further aspect of the present invention is directed to said integrated system adapted to cool reduction roasted hot solids from temperature of 550oC to 40oC by water quenching and simultaneous scrubbing of hot gas resulting in eliminating the fine particulates floating in the gas stream.
The bottom of cooling chamber allows flow of solids preferably through a declined bottom towards the screw. Rotational movement of screw minimizes the material accumulation inside the inlet and outlet chamber ensuring smooth and steady operation.
The outlet of said conveying mechanism is located lower than the water level of slurry toensure easier discharge of slurry due to hydrodynamic pressure. The level of slurry is maintained lower than the solid inlet to avoid backflow into fluidised chamber.
A further aspect of the present invention is directed to the said system wherein the gas entering the cooler is handled within a vertical uptake wherein said vertical uptake is mounted above the inlet chamber (welded or flanged mode of connection). The inlet hot gas moves through the vertical uptake due to natural draft. The said gas may contain fine dust particles, and hazardous gases such as CO with temperatures between 300 – 600oC.
The said inlet hot gas is cleaned and cooled by secondary water inlet preferably spray nozzles situated inside the vertical uptake perpendicular to the movement of gas and axis of vertical uptake. The said vertical uptake allows water from spray nozzles to trickle down into the pool of slurry at bottom. Upon cleaning, the exit gases like CO/H2/CH4 are combusted using a LPG gas burner. The LPG gas burner uses atmospheric air for combustion.
Above and other aspects and advantages of this invention are illustrated hereunder in details with reference to the following accompanying non limiting drawings and example.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

Fig. 1. illustrates the integrated system with a cooling unit for water quenching of reduction roasted products and simultaneous cleaning and burning of gases according to a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO ACCOMPANYING DRAWING:
The accompanying figure together with the detailed description below forms part of the specification and serves to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention.
The present invention is now discussed in more detail referring to the drawing that accompanys the present application. In the accompanying drawing, like and/or corresponding elements are referredby like reference numbers. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts.Before describing in detail embodiments that are in accordance with the invention, it should be observed that the embodiments represent primarily a cooler unit.
Accompanying Figure 1 illustrates the cooler ‘A’ which quenches the roasted material. It comprises of an inlet 9 through which the inlet hot gas and solids enter the inlet chamber 8. A primary water inlet 10 is attached to the vertical uptake 13 above which a secondary water inlet 11 is attached.Cooler ‘A’ consists of an outlet chamber 5 to which the screw 4 is attached. The screw 4 is attached to the electric motor 1 through the bearing housing 3. The bearing housing 3 is bolted to the top cover 3.1. The screw 4 is driven by an electric motor 1. The motor support 2 holds the electric motor on the axis. The other end of screw 4 is connected to a rotary joint 6. The entire tubular assembly is supported on a support frame 7.

Example 1:
The water from the primary water inlet(10) is kept at a flow rate of 15 L/min. This ensures the water level in the cooler (A). The water from the secondary water inlet (11) is maintained at 2 LPM. The cooling of the hot solid and gas is done by feeding 65kg/hr of hot solid and up to 6 Nm3/h of gas at temperature of 550oC each. The water from the primary water inlet (1) and the existing water level in the inlet chamber (8), cools down the solid to temperature of 40oC. The electric motor (1) to which the screw (4) is attached is set at 15 rpm. This removes the water – solid mixture from the outlet chamber (5) though a discarge outlet(14). The hot gas moves through the vertical uptake (13) as it cannot pass through the cooling zone at the bottom. The hot gas is cooled using water from thesecondary water inlet(11). The gas exiting the inlet chamber (8) is combusted using a LPG gas burner (12) with a flow rate of1litre per minute.
Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention and not limiting. Although the present invention has been described in detail with reference to the embodiments, those of ordinary skill in the art should understand that modifications or equivalent replacements of the technical solutions of the present invention shall not depart from the spirit and scope of the technical solutions of the present invention, which shall all be covered by the present invention within the scope of the claims.
, Claims:We Claim:
1. An integrated system for cooling hot products including reduction roasted products and hot gases including fluidized bed reactor comprising :

a vertically extending tubular inlet chamber;

said vertically extending tubular inlet chamber having a closed lower end and an open upper end , therebetween said closed lower end and open upper end having a hot feed inlet for the feeding in of hot solids and /or gases therein;

a primary water inlet into said vertically extending inlet chamber disposed above said hot feed inlet for maintaining water level in said tubular inlet chamber ;

a secondary water inlet disposed above said primary water inlet for a secondary water flow inlet into said vertically extending tubular inlet chamber;

at said closed lower end of said vertically extending tubular inlet chamber, the same is operatively connected to an extending tubular outlet chamber;

said extending tubular outlet chamber having a closed lower end operatively communicating with the vertically extending tubular inlet chamber and internally housing a coaxially disposed rotary screw member to remove water-solid mixture entering the said tubular inlet chamber through the said tubular outlet chamber;

hot gases are blocked by the water and solid content in said tubular outlet and are released only after passage through the secondary water flow through the open outlet of said vertically extending tubular inlet chamber.

2. The integrated system as claimed in claim 1 wherein said rotary screw member in said tubular outlet chamber is operatively connected to an electric motor through bearing housing whereby the screw is driven by said electric motor.
3. The integrated system as claimed in anyone of claims 1 or 2 comprising at the top closed end of said tubular outlet chamber having a motor support for holding the electric motor on the axis and the other end of the rotary screw connected to a rotary joint.
4. The integrated system as claimed in anyone of claims 1 to 3 comprising a vertical uptake being mounted above the inlet chamber wherein the hot gas entering the cooler is handled within said vertical uptake,
said inlet hot gas moves through the vertical uptake due to natural draft and is cleaned and cooled by said secondary water inlet preferably spray nozzles situated inside the vertical uptake perpendicular to the movement of gas and axis of vertical uptake, wherein said vertical uptake allows water from spray nozzles to trickle down into the pool of slurry at bottom and upon cleaning, the exit gases like CO/H2/CH4 vented out at top of vertical uptake are combusted using a LPG gas burner disposed at top of said vetical uptake, said LPG gas burner using atmospheric air for combustion.
5. The system as claimed in anyone of claims 1 to 4 whereinthe bottom of cooling inlet chamber allows flow of solids slurry preferably through a declined bottom of outlet chamber towards the screw so thatrotary movement of screw minimizes the material accumulation inside the inlet and outlet chamber ensuring smooth and steady operation.
6. The system as claimed in anyone of claims 1 to 5 whereinoutlet of said screw conveying mechanism is located lower than the water level of slurry toensure easier discharge of slurry due to hydrodynamic pressure and the level of slurry is maintained lower than the solid inlet to avoid backflow into fluidised chamber.
7. The system as claimed in anyone of claims 1 to 6comprising said V-shaped cooling chamber where the hot solids from the fluidized bed reactor is quenched with water in a vertical chamber and the solid forms a slurry and gets cooled to 40oC.
8. The system as claimed in anyone of claims 1 to 7whereinthe slurry formed in cooling inlet chamber is dischargedthrough an outlet of inclined outlet chamber propagated therethrough by said screw conveyor at a rate of 65 kg/h at a temperature of 40oC.
9. The system as claimed in anyone of claims 1 to 8 adapted to cool reduction roasted hot solids from temperature of 550oC to 40oC by water quenching and simultaneous scrubbing of hot gas resulting in eliminating the fine particulates floating in the gas stream.
Dated this the 11th day of March, 2024
Anjan sen
Of Anjan Sen & Associates
(Applicant’s Agent)
IN/PA-199