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The system is designed to be fully transportable on a standard 18-wheeler truck (Figure 1). The self-contained, portable system contains a submerged resistance bottom-pour electric furnace capable of reaching 3,800°F, with its own power supply, dust collection system, and cooling tower. Test melts drop out the bottom of the furnace to pots set underneath the truck’s carriage (Figure 2). After building the system, the next phase was to conduct test runs. Because we lack a ceramic engineer on our staff, we turned to Alfred University to establish data on chem- istry and fluxing agents. After a six- month test period and plenty of trial, error, and failure, we finally had an understanding of the dynamics of the system’s melting process. Over two years and 15 melt runs, the Melt Mizer system successfully melted waste and byproducts, such as sludge containing chromium, slag, and contami- nant soil. Despite these positive results, the client’s decision on what to do next always boils down to cost of remediation vs. revenue generated. So, our approach for the next design iteration was to review the chemistry and consistency of moisture content and par- ticle size to define temperature vs. resis- tivity, fluxing agent, and estimate future revenue to justify a test run. We worked with clients to provide data based on test samples to help them determine whether further pilot studies were justified. We expected the Melt Mizer would be useful to the ceramic, glass, and refractory industries. The next chal- lenge was to identify specific applica- tions that could benefit from using the Melt Mizer. With its high-temperature capability, it is an obvious fit for manufacturing ceramic fiber. We also participated in three pilot programs to evaluate the feasibility of using the Melt Mizer to process fly ash into rock- wool insulation or fine aggregate for sandblasting to remove rust or paint (similar, for example, to Black Beauty by Harsco Minerals International). Diversified Controls also sees a new and important role for Melt Mizer as Figure 1. Design of the Melt Mizer portable testing system. American Ceramic Society Bulletin, Vol. 101, No. 2 | www.ceramics.org 33 Fig. 2. Melt drops out the bottom-pour electric furnace into collection pots. a strategic player in environmental remediation applications. Presently we have established successful melt runs to remove chromium from toxic sludge waste and to separate iron and toxic waste from soil. Another possible appli- cation of Melt Mizer is to establish opti- mized methods of vitrification of waste streams. For example, the Melt Mizer could establish parameters for designing a production unit that vitrifies fly ash from utilities into large aggregates to reduce erosion along coastlines. A remaining challenge is to validate the environmental applications based on cost justification and regulatory man- dates. Our focus will be on the private sector to harness the capabilities of the Melt Mizer where applications make business sense. About the author Joseph Purcell is president of Diversified Controls & Systems (DC&S), a privately held company in Upstate New York. DC&S designs, man- ufactures, and services custom power supplies and custom control systems for manufacturing industries. Contact Purcell at dcsjp@aol.com or visit www.divconsys.com. n Credit: DC&S Credit: DC&SPDF Image | hydrogen as an alternative fuel
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CO2 Organic Rankine Cycle Experimenter Platform The supercritical CO2 phase change system is both a heat pump and organic rankine cycle which can be used for those purposes and as a supercritical extractor for advanced subcritical and supercritical extraction technology. Uses include producing nanoparticles, precious metal CO2 extraction, lithium battery recycling, and other applications... More Info
Heat Pumps CO2 ORC Heat Pump System Platform More Info
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