Technical Field
[0001] This invention relates to a countercurrent direct-heating heat exchanger. More specifically,
this invention relates to a countercurrent direct-heating heat exchanger that exchanges
heat by making a heating target fluid and a heating medium contact each other directly
while flowing the heating target fluid into the heat exchanger from an upper part
thereof and flowing the heating target fluid out of the heat exchanger from a lower
part thereof, and simultaneously, flowing the heating medium into the heat exchanger
from a lower part thereof and flowing the heating medium out of the heat exchanger
from an upper part thereof.
Background Art
[0002] High-temperature and pressure sulfuric acid leaching, which is high pressure acid
leaching (HPAL) using sulfuric acid, is known as hydrometallurgy to recover a valuable
metal such as nickel or cobalt, etc. from a low-grade nickel oxide ore represented
by a limonite ore, etc.
[0003] Hydrometallurgy by means of high-temperature and pressure sulfuric acid leaching
includes a pretreatment step and a high-temperature and pressure sulfuric acid leaching
step. In the pretreatment step, a nickel oxide ore is crushed and classified to manufacture
an ore slurry. In the high-temperature and pressure sulfuric acid leaching step, the
ore slurry is charged into an autoclave and then leaching process is performed under
a leaching condition such as a temperature or a pressure selected, as necessary.
[0004] To maintain a high leaching rate, a temperature from about 200 to about 300°C is
generally selected as a condition for leaching in the autoclave. Meanwhile, the ore
slurry manufactured in the pretreatment step is placed at a temperature substantially
the same as an outside air temperature. Hence, charging the ore slurry at this temperature
as it is into the autoclave not only reduces a temperature in the autoclave to reduce
a leaching rate but also causes an unstable temperature condition to make it difficult
to produce stable leaching reaction. A responsive method having been employed is to
make the temperature of the ore slurry approach a temperature in the autoclave by
preheating the ore slurry and then charge the preheated ore slurry into the autoclave.
[0005] A countercurrent direct-heating heat exchanger is used as a preheating facility for
an ore slurry (patent literature 1). The countercurrent direct-heating heat exchanger
exchanges heat by making a heating target fluid (ore slurry) and a heating medium
(water vapor) contact each other directly while flowing the heating target fluid into
the heat exchanger from an upper part thereof and flowing the heating target fluid
out of the heat exchanger from a lower part thereof, and simultaneously, flowing the
heating medium into the heat exchanger from a lower part thereof and flowing the heating
medium out of the heat exchanger from an upper part thereof.
Prior Art Literature
Patent Literature
[0006] Patent Literature 1: Japanese Patent Application Publication No.
2010-25455
Summary of Invention
Problem to be Solved by Invention
[0007] Using the countercurrent direct-heating heat exchanger for hearing an ore slurry
may cause wear of the side wall of a container of the countercurrent direct-heating
heat exchanger by the ore slurry.
[0008] In view of the foregoing circumstances, this invention is intended to provide a countercurrent
direct-heating heat exchanger capable of suppressing wear of a container caused by
a heating target fluid.
Means of Solving Problem
[0009] A countercurrent direct-heating heat exchanger according to a first invention includes:
a container; a supply pipe through which a heating target fluid is supplied into the
container; an inlet provided at an end portion of the supply pipe; a flow guide connected
to the inlet and guiding the heating target fluid to flow in a vertically downward
direction; and an umbrella-shape distribution plate having a top arranged vertically
below the flow guide. The flow guide includes: a cylindrical body; and a partitioning
member that partitions the interior of the cylindrical body into a plurality of flow
paths extending along the center axis of the cylindrical body.
[0010] The countercurrent direct-heating heat exchanger according to a second invention
is characterized in that, in the first invention, a slit is formed at the cylindrical
body, the partitioning member includes an insertion plate, and the insertion plate
is inserted into the slit and the slit and the inserted insertion plate are welded.
[0011] The countercurrent direct-heating heat exchanger according to a third invention is
characterized in that, in the first or second invention, the flow guide includes a
blocking member arranged on the center axis of the flow guide and blocking the flow
of the heating target fluid.
[0012] The countercurrent direct-heating heat exchanger according to a fourth invention
is characterized in that, in the first, second, or third invention, the umbrella-shape
distribution plate is covered by a sacrificial member at the top and the vicinity
of the top.
[0013] The countercurrent direct-heating heat exchanger according to a fifth invention is
characterized in that, in the first, second, third, or fourth invention, the flow
guide is connected in a removable manner to the inlet.
[0014] The countercurrent direct-heating heat exchanger according to a sixth invention is
characterized in that, in the first, second, third, fourth, or fifth invention, a
distance between an opening of the flow guide and the top of the umbrella-shape distribution
plate is from 1. 1 to 1.3 times the diameter of the flow guide.
[0015] The countercurrent direct-heating heat exchanger according to a seventh invention
is characterized in that, in the first, second, third, fourth, fifth, or sixth invention,
the supply pipe is arranged substantially horizontally.
[0016] The countercurrent direct-heating heat exchanger according to an eighth invention
is characterized in that, in the first, second, third, fourth, fifth, sixth, or seventh
invention, the heating target fluid is a slurry.
Advantageous Effects of Invention
[0017] According to the first invention, the flow guide can suppress deflection of the heating
target fluid. Thus, the heating target fluid flows down to the top or the vicinity
of the top of the umbrella-shape distribution plate and is distributed uniformly in
all directions of the umbrella-shape distribution plate. As a result, the amount of
the heating target fluid to contact the side wall of the container is not increased
locally to allow suppression of the wear of the container caused by the heating target
fluid.
[0018] According to the second invention, the tight joint by welding between the cylindrical
body and the partitioning member can function to stand against resistance produced
by the flow of the heating target fluid to reduce the probability of damage of the
flow guide.
[0019] According to the third invention, the flow velocity of the heating target fluid vertically
below the blocking member is restricted. As a result, collision of the heating target
fluid with the top of the umbrella-shape distribution plate can be weakened to allow
reduction in damage of the umbrella-shape distribution plate.
[0020] According to the fourth invention, the sacrificial member receives impact caused
by flowing down of the heating target fluid. In this way, wear of the umbrella-shape
distribution plate can be suppressed.
[0021] According to the fifth invention, as the flow guide is removable, the flow guide
can be exchanged or repaired easily.
[0022] According to the sixth invention, the distance between the flow guide and the umbrella-shape
distribution plate is 1. 1 times the diameter of the flow guide or more. This causes
the heating target fluid to flow smoothly to weaken rubbing between the heating target
fluid and the umbrella-shape distribution plate. Thus, wear of the umbrella-shape
distribution plate can be suppressed. The distance between the flow guide and the
umbrella-shape distribution plate does not exceed 1.3 times the diameter of the flow
guide. Thus, a direction in which the heating target fluid flows down from the flow
guide is unlikely to be changed by the flow of a heating medium.
[0023] According to the seventh invention, even if the heating target fluid flows in the
supply pipe in the horizontal direction, the flow guide can still guide the heating
target fluid to flow in a vertically downward direction.
[0024] According to the eighth invention, even if the heating target fluid is a slurry,
wear of the container caused by the heating target fluid can still be suppressed.
Brief Description of Drawings
[0025]
Fig. 1 is a longitudinal sectional view of a countercurrent direct-heating heat exchanger
A according to an embodiment of this invention.
Fig. 2 is a sectional view taken along an arrow line II-II of Fig. 1
Fig. 3 is a sectional view taken along an arrow line III-III of Fig. 1. Hatching shows
an umbrella-shape distribution plate 20.
Fig. 4 is a sectional view taken along an arrow line IV-IV of Fig. 1. Hatching shows
an annular flow guide plate 30.
Fig. 5 is an enlarged view showing an inlet 12 and its vicinity in the absence of
a flow guide 40.
Fig. 6A is a longitudinal sectional view of the flow guide 40. Fig. 6B is a plan view
of the flow guide 40.
Fig. 7 is a perspective view of the flow guide 40.
Fig. 8 is an enlarged view of the flow guide 40 and its vicinity.
Fig. 9A is a transverse sectional view of the flow guide 40 according to a different
embodiment. Fig. 9B is a transverse sectional view of the flow guide 40 according
to a still different embodiment.
Fig. 10A shows a simulation result about the concentration distribution of a slurry.
Fig. 10B is a simulation result about the flow velocity distribution of the slurry.
Fig. 11 is an entire process drawing of hydrometallurgy.
Embodiment for Carrying Out Invention
[0026] An embodiment of this invention will be described next by referring to the drawings.
(Hydrometallurgy)
[0027] A countercurrent direct-heating heat exchanger A according to an embodiment of this
invention is used for hydrometallurgy to obtain nickel-cobalt mixed sulfide from a
nickel oxide ore using high-temperature and pressure sulfuric acid leaching. As shown
in Fig. 11, the hydrometallurgy includes a pretreatment step (101), a high-temperature
and pressure sulfuric acid leaching step (102), a solid-liquid separating step (103),
a neutralizing step (104), a dezincification step (105), a sulfurizing step (106),
and a detoxifying step (107).
[0028] An ore to be used as a nickel oxide ore as a raw material is mainly what is called
a laterite ore such as a limonite ore and a saprolite ore, for example. A nickel content
in the laterite ore is generally from 0.5 to 3.0% by mass. The laterite ore contains
nickel in the form of hydroxide or a siliceous magnesia (magnesium silicate) ore.
An iron content in the laterite ore is from 10 to 50% by mass. The laterite ore contains
iron mainly in the form of trivalent hydroxide (goethite, FeOOH) and partially in
the form of divalent iron as a magnesium silicate ore.
[0029] In the pretreatment step (101), the nickel oxide ore is crushed, classified into
an average particle size of 2 mm or less, and then slurried to manufacture an ore
slurry. Redundant water in the ore slurry is removed using a solid-liquid separating
device such as a thickener to concentrate the ore slurry so as to obtain a predetermined
concentration of a solid in the ore slurry. In the high-temperature and pressure sulfuric
acid leaching step (102), sulfuric acid is added to the ore slurry obtained in the
pretreatment step (101). Then, the ore slurry is agitated under a temperature condition
from 200 to 300°C for high-temperature and pressure acid leaching, thereby obtaining
a leached slurry. In the solid-liquid separating step (103), the leached slurry obtained
in the high-temperature and pressure sulfuric acid leaching step (102) is separated
into a solid and a liquid to obtain a leachate containing nickel and cobalt (hereinafter
called a "crude nickel sulfate solution") and a leaching residue.
[0030] In the neutralizing step (104), the crude nickel sulfate solution obtained in the
solid-liquid separating step (103) is neutralized. In the dezincification step (105),
hydrogen sulfide gas is added to the crude nickel sulfate solution neutralized in
the neutralizing step (104) to remove zinc as a precipitate of zinc sulfide. In the
sulfurizing step (106), hydrogen sulfide gas is added to final solution resulting
from the dezincification obtained in the dezincification step (105) to obtain nickel-cobalt
mixed sulfide and nickel barren solution. In the detoxifying step (107), the leaching
residue generated in the solid-liquid separating step (103) and the nickel barren
solution generated in the sulfurizing step (106) are detoxified.
[0031] A solid concentration in the ore slurry (weight ratio of a solid (ore) in the slurry)
manufactured in the pretreatment step (101) depends largely on the properties of the
nickel oxide ore as a raw material. Although not particularly limited, the concentration
of a solid in the ore slurry is controlled in such a manner that the solid represents
from 20 to 50% by mass. If a concentration in the ore slurry is less than 20% by mass,
a large facility should be prepared for obtaining given time of stay during leaching
and the amount of acid to be added should be increased for adjusting a residual acid
concentration. Additionally, a nickel concentration in a resultant leachate is reduced.
By contrast, if a solid concentration in the ore slurry exceeds 50% by mass, the scale
of a facility can be reduced. However, such a solid concentration increases the viscosity
of the ore slurry to make it difficult to carry the ore slurry due to blockage of
a carrier pipe or large energy required for carrying the ore slurry.
[0032] The high-temperature and pressure sulfuric acid leaching step (102) includes two
sub-steps (a preheating step and a leaching step). In the preheating step, the ore
slurry at a temperature about an outside air temperature carried from the pretreatment
step (101) is preheated to make the temperature of the ore slurry approach a temperature
in an autoclave to be used in the leaching step. In the leaching step, the ore slurry
carried from the preheating step is charged into the autoclave. Then, leaching is
performed by adding sulfuric acid to the ore slurry and blowing high-pressure air
and high-pressure water vapor into the autoclave.
[0033] The countercurrent direct-heating heat exchanger A of this embodiment is used for
heating the ore slurry in the preheating step. If necessary, two or more countercurrent
direct-heating heat exchangers A are connected in series and the ore slurry is heated
in stages.
[0034] To maintain a moisture content in the ore slurry, the countercurrent direct-heating
heat exchanger A uses water vapor as a heating medium. Water vapor to be used may
be generated by using a common method such as a boiler. For ejection of a leached
slurry from the autoclave, pressure is reduced in stages using a pressure reducing
container. Water vapor generated in this pressure reducing container may be collected
and used as a heating medium in the countercurrent direct-heating heat exchanger A.
(Countercurrent Direct-Heating Heat Exchanger A)
[0035] The countercurrent direct-heating heat exchanger A according to this embodiment will
be described next.
[0036] The countercurrent direct-heating heat exchanger A is a heat exchanger that exchanges
heat by flowing a heating target fluid 1 and a heating medium 2 in opposite directions
and making the heating target fluid 1 and the heating medium 2 contact each other
directly. In this embodiment, the heating target fluid 1 is an ore slurry 1 obtained
in the pretreatment step (101) of the foregoing hydrometallurgy and the heating medium
2 is water vapor 2.
[0037] As shown in Fig. 1, the countercurrent direct-heating heat exchanger A includes a
substantially circular cylindrical container 10. The container 10 is arranged vertically
in such a manner that the center axis of the container 10 extends in the vertical
direction.
[0038] The container 10 is provided with a supply pipe 11 arranged substantially horizontally
at an upper part of the container 10. A heating target fluid inlet 12 is provided
at an end portion of the supply pipe 11 to be pointed vertically downwardly. A flow
guide 40 is connected to the heating target fluid inlet 12. The container 10 is provided
with a heating target fluid outlet 13 arranged at a lower part, more specifically,
at the bottom of the container 10. The ore slurry 1 as the heating target fluid 1
is supplied into the container 10 through the supply pipe 11, passes through the heating
target fluid inlet 12, and flows down from an opening (lower end) of the flow guide
40. Then, the ore slurry 1 flows down in the container 10 and is ejected to the outside
of the container 10 from the heating target fluid outlet 13.
[0039] Solid arrows of Fig. 1 show a flow of the ore slurry 1. The heating target fluid
inlet 12 corresponds to an "inlet" recited in the appended claims. The heating target
fluid inlet 12 will simply be called an inlet 12.
[0040] The container 10 is provided with a heating medium inlet 14 arranged at a lower side
wall of the container 10. The container 10 is provided with a heating medium outlet
15 arranged at an upper part, more specifically, at the top of the container 10. The
water vapor 2 as the heating medium 2 is supplied from the heating medium inlet 14
into the container 10. The supplied water vapor 2 moves up in the container 10 and
is then ejected to the outside of the container 10 from the heating medium outlet
15. Dashed arrows of Fig. 1 show a flow of the water vapor 2.
[0041] The container 10 is provided with a plurality of umbrella-shape distribution plates
20 and a plurality of annular flow guide plates 30. The umbrella-shape distribution
plates 20 and the annular flow guide plates 30 are arranged alternately, one above
the other, with the respective centers being substantially aligned with each other.
These umbrella-shape distribution plates 20 and these annular flow guide plates 30
each have a tilted surface. The ore slurry 1 supplied into the container 10 flows
down along the respective tilted surfaces of the umbrella-shape distribution plates
20 and those of the annular flow guide plates 30 to drop down from downstream edge
portions of the tilted surfaces. By making this flow repeatedly, the ore slurry 1
flows down in the container 10. Meanwhile, the water vapor 2 supplied into the container
10 moves up in the container 10 while passing through between the umbrella-shape distribution
plates 20 and the annular flow guide plates 30 in a zigzag manner.
[0042] As shown in Fig. 2, in a plan view, the supply pipe 11 is arranged to extend in the
direction of the diameter of the container 10 from the side wall to a substantially
central point of the container 10. The inlet 12 is formed at an end portion of the
supply pipe 11. The inlet 12 is arranged at a substantially central point of the container
10 in a plan view. Thus, the flow guide 40 is also arranged at a substantially central
point of the container 10 in a plan view. The supply pipe 11 is supported by a beam
11a extending linearly from the end portion of the supply pipe 11 to the side wall
of the container 10.
[0043] As shown in Figs. 1 and 3, the umbrella-shape distribution plate 20 is a tilted plate
having an umbrella shape (conical shape). The umbrella-shape distribution plate 20
is arranged in such a manner that the top of the umbrella-shape distribution plate
20 is pointed upwardly and the top (center) substantially agrees with the center of
the container 10 in a plan view. The top of the umbrella-shape distribution plate
20 is arranged vertically below the flow guide 40. Thus, the ore slurry 1 is supplied
from the flow guide 40 to the top of the umbrella-shape distribution plate 20 in a
top layer, distributed radially along the tilted surface of the umbrella-shape distribution
plate 20, and drops down in a skirt-like manner from a downstream edge portion 21.
The downstream edge portion 21 of the umbrella-shape distribution plate 20 is an edge
where the side surface and the bottom surface of a cone contact each other.
[0044] The umbrella-shape distribution plate 20 in the top layer is covered by a sacrificial
member 22 at the top and the vicinity of the top. The sacrificial member 22 may be
formed by hardfacing or using a material having a strength such as a steel sheet.
[0045] As shown in Figs. 1 and 4, the annular flow guide plate 30 is an annular tilted plate
having a slope descending from the outer peripheral edge toward the inner peripheral
edge of the annular flow guide plate 30. The outer diameter of the annular flow guide
plate 30 is substantially the same as the inner diameter of the container 10. The
outer peripheral edge of the annular flow guide plate 30 contacts the inner wall of
the container 10. The annular flow guide plate 30 is arranged in such a manner that
the center of the annular flow guide plate 30 (the respective centers of the outer
periphery and the inner periphery) substantially agrees with the center of the container
10 in a plan view. After dropping down from the umbrella-shape distribution plate
20 to the annular flow guide plate 30, the ore slurry 1 flows down along the tilted
surface toward the center of the annular flow guide plate 30 and then drops down in
a skirt-like manner from a downstream edge portion 31. The downstream edge portion
31 of the annular flow guide plate 30 is the inner peripheral edge thereof.
(Heat Exchange by Countercurrent Direct-Heating Heat Exchanger A)
[0046] Heat exchange by the countercurrent direct-heating heat exchanger A will be described
next.
[0047] The ore slurry 1 is supplied into the container 10 from the flow guide 40. The ore
slurry 1 supplied into the container 10 first flows down radially along the tilted
surface of the umbrella-shape distribution plate 20 in the top layer and then drops
down in a skirt-like manner from the downstream edge portion 21. After dropping down
from the umbrella-shape distribution plate 20 to the annular flow guide plate 30,
the ore slurry 1 flows down along the tilted surface toward the center of the annular
flow guide plate 30 and then drops down in a skirt-like manner from the downstream
edge portion 31. Then, the ore slurry 1 drops down to the umbrella-shape distribution
plate 20 in a subsequent layer. In this way, the ore slurry 1 flows down along the
respective tilted surfaces of the umbrella-shape distribution plate 20 and the annular
flow guide plate 30 alternately and is then ejected to the outside of the container
10 from the heating target fluid outlet 13 at the lower part of the container 10.
[0048] The water vapor 2 is supplied into the container 10 from the heating medium inlet
14 at the lower part of the container 10, moves up while passing through between the
umbrella-shape distribution plate 20 and the annular flow guide plate 30 in a zigzag
manner, and is then ejected to the outside of the container 10 from the heating medium
outlet 15 at the upper part of the container 10. During this flow, the water vapor
2 contacts the ore slurry 1 directly by flowing along the ore slurry 1 while the ore
slurry 1 flows down along the respective tilted surfaces of the umbrella-shape distribution
plate 20 and the annular flow guide plate 30. The water vapor 2 also contacts the
ore slurry 1 directly by passing through the ore slurry 1 while the ore slurry 1 drops
down from the downstream edge portions 21 and 31 of the umbrella-shape distribution
plate 20 and the annular flow guide plate 30 respectively. In this way, heat is exchanged
between the ore slurry 1 and the water vapor 2.
[0049] As described above, the countercurrent direct-heating heat exchanger A exchanges
heat by making the ore slurry 1 and the water vapor 2 contact each other directly
while flowing the ore slurry 1 into the heat exchanger A from an upper part thereof
and flowing the ore slurry 1 out of the heat exchanger A from a lower part thereof,
and simultaneously, flowing the water vapor 2 into the heat exchanger A from a lower
part thereof and flowing the water vapor 2 out of the heat exchanger A from an upper
part thereof.
[0050] The ore slurry 1 is distributed radially along the umbrella-shape distribution plate
20. This increases an area of contact between the ore slurry 1 and the water vapor
2 to increase heat exchange efficiency. Further, the flow of the water vapor 2 is
guided along the annular flow guide plate 30 and the water vapor 2 flows along the
ore slurry 1 while the ore slurry 1 flows down along the tilted surface of the umbrella-shape
distribution plate 20. This also increases an area of contact between the ore slurry
1 and the water vapor 2 to increase heat exchange efficiency.
(Flow Guide 40)
[0051] The flow guide 40 forming a characteristic part of this embodiment will be described
in detail next.
[0052] Fig. 5 is an enlarged view showing the inlet 12 and its vicinity in the absence of
the flow guide 40. Alternate long and two short dashes lines O in Fig. 5 show a vertical
line passing through the center of the inlet 12.
[0053] In the absence of the flow guide 40, the ore slurry 1 flows in a substantially horizontal
direction in the supply pipe 11 and then flows down from the inlet 12. The ore slurry
1 is under the force of gravity while flowing down from the inlet 12, so that the
ore slurry 1 flows in a direction downward from the horizontal direction.
[0054] Meanwhile, the ore slurry 1 still has momentum in the horizontal direction generated
during the flow of the ore slurry 1 in the supply pipe 11. Hence, a direction in which
the ore slurry 1 flows down from the inlet 12 is tilted from a vertically downward
direction. The ore slurry 1 is tilted in a direction in which the supply pipe 11 extends
(leftward direction of Fig. 5). In this description, a phenomenon where such a tilt
of the flow direction of the ore slurry 1 from the vertically downward direction occurs
when the ore slurry 1 flows down from the inlet 12 is called "deflection."
[0055] On the occurrence of the deflection, a part of the ore slurry 1 flowing along the
tilted surface of the umbrella-shape distribution plate 20 and flowing in the direction
of the deflection (direction in which the supply pipe 11 extends) has greater momentum
than a part of the ore slurry 1 flowing in a different direction. This part of the
ore slurry 1 having greater momentum drops down from the downstream edge portion 21
of the umbrella-shape distribution plate 20 and then contacts the side wall of the
container 10. Hence, a part of the side wall of the container 10 located in the direction
of the deflection (part w of Fig. 1) is to contact the ore slurry 1 of a greater amount
than a different part of the side wall. Specifically, the amount of the ore slurry
1 to contact the side wall of the container 10 is increased locally. As a result,
the part of the side wall of the container 10 (part w) is more likely to be worn out
by the ore slurry 1 than a different part.
[0056] On the occurrence of the deflection, the ore slurry 1 is not distributed uniformly
in all directions of the umbrella-shape distribution plate 20 to cause imbalance.
As a result, heat exchange efficiency is reduced.
[0057] A deflection angle θ (an angle formed between a direction in which the ore slurry
1 flows and a vertical line O) changes in a manner that depends on the flow rate of
the ore slurry 1, a slurry specific gravity, or a solid concentration. These parameters
change during operation of the countercurrent direct-heating heat exchanger A. Thus,
the deflection angle θ changes during the operation to change a position where the
ore slurry 1 having flowed down from the inlet 12 collides with the umbrella-shape
distribution plate 20. Apart of the umbrella-shape distribution plate 20 to collide
with the ore slurry 1 having flowed down from the inlet 12 is likely to be damaged.
If the deflection angle θ changes during the operation, flowing down of the ore slurry
1 may cause impact on a wide range of the umbrella-shape distribution plate 20. It
is difficult to protect the umbrella-shape distribution plate 20 from such impact.
[0058] To solve the foregoing problem, the flow guide 40 is attached to the inlet 12. The
flow guide 40 has the function of guiding the ore slurry 1 to flow in a vertically
downward direction.
[0059] As shown in Figs. 6A, 6B, and 7, the flow guide 40 is constructed of a cylindrical
body 41, a partitioning member 42, and a blocking member 43.
[0060] The cylindrical body 41 is a member having a circular cylindrical shape and includes
a flange 41f at an upper end portion thereof. The flange 41f and a flange 12f of the
inlet 12 are coupled with a bolt, a nut, etc., thereby attaching the flow guide 40
to the inlet 12.
[0061] The cylindrical body 41 is formed with four slits 41s each extending from the lower
end toward a point near the vertical center of the cylindrical body 41. The slits
41s are formed at regular intervals (at intervals of 90 degrees) in the peripheral
direction of the cylindrical body 41.
[0062] The partitioning member 42 is constructed of a pipe 42a of a small diameter, and
eight partitioning plates 42b joined to the outer periphery of the pipe 42a. The partitioning
plates 42b are arranged at regular intervals (at intervals of 45 degrees) in the peripheral
direction of the pipe 42a. In a plan view of the partitioning member 42, the eight
partitioning plates 42b are arranged in a radial pattern about the pipe 42a. The pipe
42a is arranged in such a manner that the center axis of the pipe 42a agrees with
a center axis O of the flow guide 40. The partitioning plates 42b are flat plates
and arranged to extend along the center axis O.
[0063] Four of the eight partitioning plates 42b have outer edge portions protruding from
their lower ends toward their vertically central points. These protruding portions
are called insertion plates 42c. The partitioning plates 42b with the insertion plates
42c and the partitioning plates 42b without the insertion plates 42c are arranged
alternately. Specifically, the insertion plates 42c are arranged at intervals of 90
degrees in the peripheral direction of the pipe 42a.
[0064] The blocking member 43 is a member having a circular plate shape and has a diameter
substantially the same as the outer diameter of the pipe 42a. The blocking member
43 is arranged on the center axis O of the flow guide 40 and joined to the upper end
of the pipe 42a. The upper end of the pipe 42a is sealed by the blocking member 43.
The flow of the ore slurry 1 is blocked in a part in which the blocking member 43
is arranged. Thus, the flow of the ore slurry 1 is blocked at the center axis O and
its vicinity of the flow guide 40.
[0065] As shown in Fig. 7, the flow guide 40 is assembled by the following procedure. First,
the partitioning member 42 is inserted from a lower opening of the cylindrical body
41. At this time, the insertion plates 42c of the partitioning member 42 are inserted
into the slits 41s of the cylindrical body 41. Then, the slits 41s and the insertion
plates 42c are welded.
[0066] By assembling the flow guide 40 in this way, the cylindrical body 41 and the partitioning
member 42 are tightly joined by welding. If the ore slurry 1 passes through in the
flow guide 40, resistance (friction or impact) acts between the ore slurry 1 and the
partitioning member 42 to produce force of pressing the partitioning member 42 downwardly.
Meanwhile, the tight joint between the cylindrical body 41 and the partitioning member
42 can function to stand against the downwardly acting force produced by the flow
of the ore slurry 1, reducing the probability of damage of the flow guide 40.
[0067] The foregoing method is not a limited method of assembling the flow guide 40. A configuration
of inserting the insertion plates 42c into the slits 41s may not be employed. The
flow guide 40 may be assembled simply by welding the inner surface of the cylindrical
body 41 and the outer edge portions of the partitioning plates 42b. Alternatively,
the cylindrical body 41 and the partitioning member 42 may be fixed by a different
method such as fastening with a screw.
[0068] As shown in Fig. 6B, the interior of the cylindrical body 41 is partitioned into
eight flow paths 44 by the partitioning member 42. Both the pipe 42a and the partitioning
plates 42b are arranged to extend along the center axis O, so that each flow path
44 extends along the center axis O.
[0069] The ore slurry 1 flows in a distributed manner through the plurality of flow paths
44 extending along the center axis O of the flow guide 40. This makes it possible
to guide the ore slurry 1 to flow in a direction along the center axis O of the flow
guide 40.
[0070] As shown in Fig. 8, the flow guide 40 is arranged in such a manner that the center
axis O of the flow guide 40 substantially agrees with the vertical line passing through
the center of the inlet 12. The inlet 12 is arranged at the substantially central
point of the container 10, so that the center axis O of the flow guide 40 also substantially
agrees with the center axis of the container 10. Thus, after the ore slurry 1 passes
through the flow guide 40, the ore slurry 1 flows vertically downwardly along the
center axis of the container 10. Even if the ore slurry 1 flows in the supply pipe
11 in the horizontal direction, the flow guide 40 can still guide the ore slurry 1
to flow in a vertically downward direction. In this way, the flow guide 40 can suppress
the deflection of the ore slurry 1.
[0071] The deflection of the ore slurry 1 can be suppressed. Thus, the ore slurry 1 flows
down to the top or the vicinity of the top of the umbrella-shape distribution plate
20 in the top layer and is distributed uniformly in all directions of the umbrella-shape
distribution plate 20. This prevents the momentum of the ore slurry 1 flowing along
the tilted surface of the umbrella-shape distribution plate 20 from increasing locally.
The amount of the ore slurry 1 to contact the side wall of the container 10 is not
increased locally to allow suppression of the wear of the container 10 caused by the
ore slurry 1.
[0072] The ore slurry 1 is distributed uniformly in all directions of the umbrella-shape
distribution plate 20. This increases the heat exchange efficiency of the countercurrent
direct-heating heat exchanger A.
[0073] Even if the flow rate of the ore slurry 1, a slurry specific gravity, or a solid
concentration changes, a direction in which the ore slurry 1 flows can still be maintained
in a vertically downward direction. Thus, the ore slurry 1 always collides with the
top or the vicinity of the top of the umbrella-shape distribution plate 20 and this
position does not change. Covering the top and the vicinity of the top of the umbrella-shape
distribution plate 20 in the top layer with the sacrificial member 22 makes the sacrificial
member 22 receive impact caused by flowing down of the ore slurry 1. In this way,
wear of the umbrella-shape distribution plate 20 can be suppressed. As a result, the
lifetime of the umbrella-shape distribution plate 20 can be extended.
[0074] The blocking member 43 is provided on the center axis O of the flow guide 40. The
top of the umbrella-shape distribution plate 20 is arranged vertically below the blocking
member 43. By the presence of the blocking member 43, the flow rate (flow velocity)
of the ore slurry 1 vertically below the blocking member 43 can be restricted. As
a result, collision of the ore slurry 1 with the top of the umbrella-shape distribution
plate 20 in the top layer can be weakened to allow reduction in damage of the umbrella-shape
distribution plate 20.
[0075] The flow guide 40 causes the ore slurry 1 to pass through, so that the flow guide
40 is worn out easily. After long-time use of the flow guide 40, the flow guide 40
should be exchanged or repaired. The flow guide 40 is attached to the inlet 12 at
the flange 41f as described above, so that the flow guide 40 is removable. As the
flow guide 40 is removable, even if the flow guide 40 is worn out, the flow guide
40 can be exchanged or repaired easily.
[0076] A distance H between the opening at the lower end of the flow guide 40 and the top
of the umbrella-shape distribution plate 20 in the top layer is preferably from 1.
1 to 1.3 times a diameter D of the flow guide 40.
[0077] If the distance H is less than 1.1 times the diameter D, the ore slurry 1 is accumulated
at an exit of the flow guide 40. In this case, the ore slurry 1 rubs vigorously against
the umbrella-shape distribution plate 20. As a result, the umbrella-shape distribution
plate 20 becomes likely to be worn out easily. Further, by the presence of the accumulated
ore slurry 1, the ore slurry 1 in the flow guide 40 is decelerated to cause the risk
of blockage of the flow guide 40 by the ore slurry 1. If the distance H is 1.1 times
the diameter D or more, the ore slurry 1 is caused to flow smoothly to weaken rubbing
between the ore slurry 1 and the umbrella-shape distribution plate 20. Thus, wear
of the umbrella-shape distribution plate 20 can be suppressed.
[0078] If the distance H exceeds 1.3 times the diameter D, the ore slurry 1 having flowed
down from the flow guide 40 is disturbed by the flow of the water vapor 2 to cause
the risk of failing to maintain uniform distribution at the umbrella-shape distribution
plate 20. Additionally, if the ore slurry 1 of a large amount exceeding the capability
of the flow guide 40 to guide a flow is supplied, the ore slurry 1 may collide with
the side wall of the container 10 directly without abutting on the umbrella-shape
distribution plate 20. If the distance H does not exceed 1.3 times the diameter D,
a direction in which the ore slurry 1 flows down from the flow guide 40 is unlikely
to be changed by the flow of the water vapor 2. Further, the ore slurry 1 does not
collide with the side wall of the container 10 directly.
[0079] An opening surface of the flow guide 40 is perpendicular to the center axis O. Thus,
even if pressure in the flow guide 40 is higher than outside pressure, the ore slurry
1 can still be prevented from flying outwardly.
[Other Embodiments]
(Flow Guide 40)
[0080] As shown in Fig. 9A, the partitioning member 42 may be formed by tying a plurality
of small-diameter pipes 42d together. The cross section of the small-diameter pipe
42d is not limited to a circular shape but may be a polygonal shape.
[0081] As shown in Fig. 9B, the partitioning member 42 may be formed by combining a plurality
of partitioning plates 42e in a radial pattern. The number of the flow paths 44 in
the cylindrical body 41 is not limited to eight but is required to be two or more.
If the partitioning member 42 formed by combining the partitioning plates 42e in a
cross shape is used, four flow paths 44 are formed.
[0082] Adjacent flow paths 44 may be partitioned completely by the partitioning member 42.
The partitioning member 42 may include a communication part for making communication
between the adjacent flow paths 44.
[0083] The blocking member 43 is required to be arranged on the center axis O of the flow
guide 40. If the blocking member 43 having a circular plate shape is used, the upper
part of the flow guide 40 is not a limited place for arrangement of the blocking member
43 but the blocking member 43 may be arranged at a lower part or a vertically central
part of the flow guide 40.
[0084] The shape of the blocking member 43 is not limited to a circular plate shape but
various shapes are applicable. The blocking member 43 may have a circular columnar
shape or a conical shape. For example, the conical blocking member 43 is assembled
into the partitioning member 42 with the top of the blocking member 43 pointed upwardly.
This causes the ore slurry 1 to flow along a tilted surface of the blocking member
43. In this way, collision of the ore slurry 1 with the blocking member 43 and resultant
dispersion of the ore slurry 1 can be suppressed.
(Heating Target Fluid 1)
[0085] The heating target fluid 1 is not particularly limited but is required to be a heating
target having flowability. For example, the heating target fluid 1 may be liquid with
flowability in the form of a slurry containing a solid component. The liquid with
flowability in the form of a slurry may be a slurry (ore slurry) containing an ore.
The ore slurry may be a slurry containing a nickel oxide ore obtained in the pretreatment
step (101) of the hydrometallurgy, for example. Even if the heating target fluid 1
is a slurry, wear of the container 10 caused by the heating target fluid 1 can still
be suppressed.
(Heating Medium 2)
[0086] The heating medium 2 is not particularly limited but is required to be a medium to
supply heat to the heating target fluid 1. The heating medium 2 may be gas such as
water vapor at a higher temperature than the heating target fluid 1.
Examples
(Simulation)
[0087] The supply pipe 11, the flow guide 40, and the umbrella-shape distribution plate
20 in the top layer were reproduced on a computer and the behavior of a slurry was
simulated. The shape of the flow guide 40 shown in Figs. 6A and 6B was employed. Fig.
10A shows the concentration distribution of the slurry. Fig. 10B shows the flow velocity
distribution of the slurry.
[0088] As understood from Fig. 10A, the concentration of the slurry is uniform and the slurry
is distributed uniformly in all directions of the umbrella-shape distribution plate
20. As understood from Fig. 10B, the flow velocity of the slurry flowing down from
the flow guide 40 is lower at the center and its vicinity than at an external point.
This results from effect brought by the blocking member 43. The flow velocity of the
slurry is found to be restricted at the top of the umbrella-shape distribution plate
20.
(Working Example 1)
[0089] In the preheating step of the foregoing hydrometallurgy, an ore slurry was heated
using a countercurrent direct-heating heat exchanger. The countercurrent direct-heating
heat exchanger has the same basic configuration as the countercurrent direct-heating
heat exchanger A shown in Fig. 1.
[0090] The side wall of the container 10 of the countercurrent direct-heating heat exchanger
is made of titanium of a thickness of 9 mm on an inner side and carbon steel of a
thickness of 23.5 mm on an outer side. The side wall has a total thickness of 32.5
mm.
[0091] The flow guide 40 shown in Figs. 6A and 6B was attached to the inlet 12. The ore
slurry 1 was supplied to the countercurrent direct-heating heat exchanger and operation
was started.
[0092] The state of the interior of the countercurrent direct-heating heat exchanger was
checked one year after start of the operation and no thickness reduction of the side
wall of the container 10 was found. The state of the interior of the countercurrent
direct-heating heat exchanger was checked two years after start of the operation and
no thickness reduction of the side wall of the container 10 was found.
(Comparative Example 1)
[0093] The flow guide 40 used in Working Example 1 was replaced by a short pipe. The short
pipe has dimensions similar to those of the cylindrical body 41 of the flow guide
40. The other conditions are the same as those of Working Example 1.
[0094] The state of the interior of the countercurrent direct-heating heat exchanger was
checked one year after start of the operation and thickness reduction of the side
wall of the container 10 was found. The state of the interior of the countercurrent
direct-heating heat exchanger was checked two years after start of the operation and
a pin hole appeared in the side wall of the container 10 due to further development
of the thickness reduction.
[0095] As described above, Working Example 1 was found to be capable of suppressing wear
of the side wall of the container 10. This is considered to be realized by the uniform
flow of the ore slurry 1 in all directions of the umbrella-shape distribution plate
20 as a result of provision of the flow guide 40.
Reference Sings List
[0096]
- A
- Countercurrent direct-heating heat exchanger
- 1
- Ore slurry
- 2
- Water vapor
- 10
- Container
- 11
- Supply pipe
- 12
- Inlet
- 20
- Umbrella-shape distribution plate
- 22
- Sacrificial member
- 30
- Annular flow guide plate
- 40
- Flow guide
- 41
- Cylindrical body
- 42
- Partitioning member
- 43
- Blocking member