System for conveying and processing aggregate materials

Claim 2

A conveying and processing system for aggregate material comprising: a conveying pipe; a means for conveying aggregate material as a homogeneous pseudo-gas in said conveying pipe, said means conveying said aggregate material in said pipe by creating a zero velocity boundary layer of gas around the interior surface of said conveying pipe and a high speed, smooth gas flow in a remainder of said conveying pipe and by mixing said aggregate material into said high speed, smooth gas flow at a predetermined volumetric ratio of gas to aggregate material; and a cyclone coupled to an end of said conveying pipe for receiving the aggregate material and for separating moisture in said conveying pipe from the aggregate material.

Claim 3

A conveying and processing system according to Claim 1 further comprising a self-feeder feeding the aggregate material into an input of said means for conveying aggregate material.

Claim 4

A conveying and processing system according to Claims 1 or 2, wherein said gas is hot, dry air.

Claim 5

A conveying and processing system according to Claim 3 further comprising a booster for restoring said zero velocity boundary layer provided in said conveying pipe between said means for conveying and said cyclone.

Claim 6

A conveying and processing system according to Claim 4, wherein said booster comprises an air chamber surrounding and communicating with said conveying pipe and a means for injecting hot, dry air into said air chamber.

Claim 7

A conveying and processing system according to Claim 4, wherein said booster comprises another cyclone for receiving the aggregate material and for separating moisture in said conveying pipe from said aggregate material; and another means for conveying aggregate material as a homogeneous pseudo-gas in said conveying pipe coupled to the aggregate material output of said another cyclone.

Claim 8

A conveying and processing system according to any one of Claims 3 to 5 further comprising a cleaner and classifier coupled to the output of said first mentioned cyclone for cleaning said aggregate material and for classifying said aggregate material by volume and mass.

Claim 9

A conveying and processing system according to Claim 7, wherein said cleaner and classifier comprises: another means for conveying aggregate material as a homogeneous pseudo-gas in an output pipe coupled to the output of said cyclone, said another means for conveying said aggregate material conveying said aggregate material in said output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing said aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry gas to aggregate material; a classifying chamber comprising at least a first and second hopper placed longitudinally in said classifying chamber, said output pipe of said another means for conveying aggregate material firing said aggregate material into said classifying chamber at an upward angle whereby the greater mass and larger pieces of said aggregate material travel farther falling into said second hopper and smaller mass, smaller volumer pieces of aggregate material travel a lesser distance falling into said first hopper; and a bag house coupled to said classifying chamber for sucking out dust and very fine particles in the atmosphere of said classifying chamber.

Claim 10

A conveying and processing system according to Claim 8, wherein said classifying chamber further comprises at least one air knife for further affecting classification of said aggregate material.

Claim 11

A conveying and processing system according to Claim 8 or 9, wherein the large particles from said second hopper of said classifying chamber are crushed in an autogeneous crusher.

Claim 12

A conveying and processing system according to Claim 10, wherein said autogeneous crusher comprises a pair of another means for conveying aggregate material as a homogeneous pseudo-gas in an output pipe, said means for conveying said aggregate material conveying said aggregate material in said output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing said aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry inert gas to aggregate material; a crushing chamber wherein said output pipes of said pair of another means for conveying aggregate material fire said aggregate material in two intersecting streams of said aggregate material; and another cleaner and classifier for separating that portion of said crushed aggregate material which is smaller than some predetermined size and for feeding the remainder of said crushed aggregate material back to the inputs of said pair of another means for conveying aggregate material coupled to output of the crushing chamber.

Claim 13

A conveying and processing system according to Claim 11, wherein said output pipes of said pair of another means for conveying aggregate material are arranged and configured such that said stream of aggregate material from one output pipe does not hit the other output pipe and further comprising at least two impinging plates provided in said crushing chamber, one of said impinging plates being provided transversely to flow of material from one output pipe and the other impinging plate being provided transversely to the flow of material from the other output pipe.

Claim 14

A conveying and processing system according to Claim 11 or 12, wherein each of said pair of another means for conveying aggregate material comprises.: an auger barrel with a material input adjacent one end thereof; an air chamber surrounding another end thereof; a means for injecting low pressure, hot, dry inert gas into said air chamber; an auger shaft extending from said one end to said other end in said auger barrel; a means for rotating said auger shaft; at least one and one-half flights provided on an end of said auger shaft; and a plurality of auger flights provided on said auger shaft from a location subjacent said material input to a position on said auger shaft which is some predetermined distance from said at least one and one-half auger flights whereby a space is created in said auger barrel between an end of said plurality of auger flights and a beginning of said one and one-half auger flights wherein said aggregate material is pressed and rubbed together to facilitate crushing of said aggregate material.

Claim 15

A conveying and processing system according to any one of Claims 10 to 13 further comprising a pelletizer for forming said aggregate material into solid pellets.

Claim 16

A conveying and processing system according to Claim 14, wherein said pelletizer comprises: a pellet form; and a means for conveying aggregate material as a homogeneous pseudo-gas for spraying and compacting said aggregate material in said pellet form, said means for conveying said aggregate material conveying said aggregate material in an output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing said aggregate material in said high speed, smooth, hot, dry inert gas flow at predetermined volumetric ratio of hot, dry inert gas to the aggregate material.

Claim 17

A conveying and processing system according to Claim 14, wherein said pelletizer comprises: an auger barrel having an aggregate material input adjacent one end of said auger barrel, the other end of said auger barrel being open; a cooling means provided around said other end of said auger barrel; an auger shaft extending a full length of said auger barrel; a means for rotating said auger shaft; a plurality of dual lead pitch auger flights provided on said auger shaft from a point subjacent said material input to a point some predetermined distance from said other end of said auger barrel whereby said aggregate material is compacted into a pellet in a space within said auger barrel from said end of said barrel to said position wherein said plurality of auger flights ends; and a means for cutting said pellet into a plurality of pellets provided adjacent said other end of said auger barrel.

Claim 18

A conveying and processing system according to Claim 16, wherein said means for cutting said pellet comprises a longitudinally oscillating and rotating flying knife.

Claim 19

A cleaner and classifier for use in a conveying and processing system for aggregate material comprising: a means for conveying aggregate material as a homogeneous pseudo-gas in an output pipe, said means for conveying said aggregate material conveying said aggregate material in said output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry gas to aggregate material; a classifying chambercomprising at least a first and a second hopper placed longitudinally in said classifying chamber, said output pipe of said means for conveying aggregate material firing said aggregate material into said classifying chamber at an upward angle whereby the greater mass and larger pieces of said aggregate material travel farther falling into said second hopper and smaller mass, smaller volume pieces of aggregate material travel a lesser distance falling into said first hopper; and a bag house coupled to said classifying chamber for sucking out dust and very fine particles in the atmosphere of said classifying chamber.

Claim 20

A cleaner and classifier for use in a conveying and processing system for aggregate material comprising: a means for conveying aggregate material as a homogeneous pseudo-gas in an output pipe, said means for conveying said aggregate material conveying said aggregate material in said output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry gas to aggregate material; a classifying chambercomprising at least a first and a second hopper placed longitudinally in said classifying chamber, said output pipe of said means for conveying aggregate material firing said aggregate material into said classifying chamber at an upward angle whereby the greater mass and larger pieces of said aggregate material travel farther falling into said second hopper and smaller mass, smaller volume pieces of aggregate material travel a lesser distance falling into said first hopper; and a bag house coupled to said classifying chamber for sucking out dust and very fine particles in the atmosphere of said classifying chamber.

Claim 21

A cleaner and classifier according to Claim 18, wherein said classifying chamber further comprises at least one air knife for further affecting classification of said aggregate material.

Claim 22

An autogeneous crusher for use in a conveying and processing system for aggregate material comprising; a pair of means for conveying aggregate material as a homogeneous pseudo-gas in an output pipe, said means for conveying said aggregate material conveying said aggregate material in said output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing said aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry inert gas to aggregate material; a crushing chamber wherein said output pipes of said pair of means for conveying aggregate material fires said aggregate material into intersecting streams of said aggregate material; and a cleaner and classifier for separating that portion of said crushed aggregate material which is smaller than some predetermined size and for feeding the remainder of said crushed aggregate material back to the inputs of said pair of means for conveying aggregate material coupled to the output of the crushing chamber.

Claim 23

An autogeneous crusher for use in a conveying and processing system for aggregate material comprising; a pair of means for conveying aggregate material as a homogeneous pseudo-gas in an output pipe, said means for conveying said aggregate material conveying said aggregate material in said output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing said aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry inert gas to aggregate material; a crushing chamber wherein said output pipes of said pair of means for conveying aggregate material fires said aggregate material into intersecting streams of said aggregate material; and a cleaner and classifier for separating that portion of said crushed aggregate material which is smaller than some predetermined size and for feeding the remainder of said crushed aggregate material back to the inputs of said pair of means for conveying aggregate material coupled to the output of the crushing chamber.

Claim 24

An autogenous crusher according to Claim 20, wherein said cleaner and classifier comprises: another means for conveying aggregate material as a homogeneous pseudo-gas in another output pipe coupled to the output of said crushing chamber, said another means for conveying said aggregate material conveying said aggregate material in said another output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing said aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry inert gas to aggregate material; a classifying chamber comprising at least a first and a second hopper placed longitudinally in said classifying chamber, said output pipe of said another means for conveying aggregate material firing said aggregate material into said classifying chamber and at an upward angle whereby the greater mass and larger pieces of said aggregate material travel farther falling into said second hopper and smaller mass, smaller volume pieces of aggregate material travel a lesser distance falling into said first hopper; and a bag house coupled to said classifying chamber for sucking out dust and very fine particles in the atmosphere of said classifying chamber.

Claim 25

An autogenous crusher according to Claim 21, wherein said output pipes of said pair of another means for conveying aggregate material are arranged and configured such that said stream of aggregate material from one output pipe does not hit the other output pipe and further comprising at least two impinging plates provided in said crushing chamber, one of said impinging plates being provided transversely to the flow of material from one output pipe and the other impinging plate being provided transversely to the flow of material from the other output pipe.

Claim 26

Anautogenous crusher according to Claim 22, wherein each of said pair of means for conveying aggregate material comprises: an auger barrel with a material input adjacent one end thereof; an air chamber surrounding another end thereof; a means for injecting low pressure, hot, dry inert gas into said air chamber; an auger shaft extending from said one end to said other end in said auger barrel; a means for rotating said auger shaft; at least one and one-half auger flights provided on an end of said auger shaft; and a plurality of auger flights provided on said auger shaft from a location subjacent said material input to a position on said auger shaft which is some predetermined distance from said at least one and one-half auger flights whereby a space is created in said auger barrel between an end of said plurality of auger flights and a beginning of said one and one-half auger flights wherein said aggregate material is pressed and rubbed together to facilitate crushing of said aggregate material.

Claim 27

A pelletizer for use in a conveying and processing system for aggregate material comprising: a pellet form; and a means for conveying aggregate material as a homogeneous pseudo-gas for spraying and compacting said aggregate material in said pellet form, said means for conveying said aggregate material conveying said aggregate material in an output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing said aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry inert gas to the aggregate material.

Claim 28

A pelletizer for use in a conveying and processing system for aggregate material comprising: a pellet form; and a means for conveying aggregate material as a homogeneous pseudo-gas for spraying and compacting said aggregate material in said pellet form, said means for conveying said aggregate material conveying said aggregate material in an output pipe by creating a zero velocity boundary layer of hot, dry inert gas around an interior surface of said output pipe and a high speed, smooth, hot, dry inert gas flow in a remainder of said output pipe and by mixing said aggregate material into said high speed, smooth, hot, dry inert gas flow at a predetermined volumetric ratio of hot, dry inert gas to the aggregate material.

Claim 29

A pelletizer for use in a conveying and processing system for aggregate material comprising: an auger barrel having an aggregate material input adjacent one end of said auger barrel, the other end of said auger barrel being open; ` a cooling means provided around said other end of said auger barrel; an auger shaft extending a full length of said auger barrel; a means for rotating said auger shaft; a plurality of dual lead pitch auger flights provided on said auger shaft from a point subjacent said material input to a point some predetermined distance from said other end of said auger barrel whereby said aggregate material is compacted into a pellet in a space within said auger barrel from said end of said barrel to said position wherein said plurality of auger flights ends; and a means for cutting said pellet into a plurality of pellets provided adjacent said other end of said auger barrel.

Claim 30

A pelletizer for use in a conveying and processing system for aggregate material comprising: an auger barrel having an aggregate material input adjacent one end of said auger barrel, the other end of said auger barrel being open; ` a cooling means provided around said other end of said auger barrel; an auger shaft extending a full length of said auger barrel; a means for rotating said auger shaft; a plurality of dual lead pitch auger flights provided on said auger shaft from a point subjacent said material input to a point some predetermined distance from said other end of said auger barrel whereby said aggregate material is compacted into a pellet in a space within said auger barrel from said end of said barrel to said position wherein said plurality of auger flights ends; and a means for cutting said pellet into a plurality of pellets provided adjacent said other end of said auger barrel.

Claim 31

A pelletizer according to Claim 25, wherein said means for cutting said pellet comprises a longitudinally oscillating and rotating flying knife.