Process for coking-calcining complete smelting charge aggregates

Claim 1

THE METHOD OF COKING-CALCINING MINERAL AGGREGATES COMPRISING A MIXTURE OF CARBONACEOUS MATERIAL AND A MATERIAL SELECTED FROM THE GROUP CONSISTING OF CAO-, ALUMINUM- AND PHOSPHATEBEARING MATERIALS, WHICH CONSISTS ON INTRODUCING A DOWNWARDLY MOVING COLUMN OF SAID AGGREGATES INTO A VERTICAL RETORT INDIRECTLY HEATING UNDER NON-OXIDIZING CONDITIONS THE UPPER SECTION OF SAID DOWNWARDLY MOVING COLUMN OF AGGREGATES TO A TEMPERATURE OF ABOUT 950* C. TO ABOUT 1100* C. TO EFFECT SUBSTANTIALLY COMPLETE REMOVAL OF THE VOLATILE COMPONENTS OF SAID AGGREGATES, SCRUBBING SAID VOLATILE COMPONENTS WITH AN AQUEOUS MEDIUM TO COOL SAID VOLATILE COMPONENTS AND REMOVE TAR THEREFROM, BURNING A PORTION OF THE SCRUBBED VOLATILE COMPONENTS TO PRODUCE HEAT FOR SAID INDIRECT HEATING OPERATION, RECYCLING A SUFFICIENT AMOUNT OF THE REMAINDER OF SAID SCRUBBED VOLATILE COMPONENTS THROUGH THE LOWER SECTION OF SAID COLUMN OF AGGREGATES TO COOL SAME TO A TEMPERATURE BELOW 200* C. AND DISCHARGING SAID COOLED AGGREGATES FROM THE BOTTOM OF SAID RETORT, SAID INDIRECT HEATING BEING APPLIED SUBSTANTIALLY THROUGHOUT SAID UPPER SECTION OF SAID RETORT UP TO ABOUT THE POINT OF ENTRY OF SAID AGGREGATES INTO SAID RETORT, SAID CARBONACEOUS MATERIAL IN THE INITIAL MINERAL AGGREGATES BEING EMPLOYED IN THE PROPORTIONS PROVIDING SUFFICIENT FUEL FOR SAID INDIRECT HEATING OPERATION AND ALSO SUFFICIENT RESIDUAL CARBON IN THE COKED-CALCINED PRODUCT FOR SUBSTANTIALLY COMPLETE REDUCTION OF SAID CAO-, ALUMINUM- AND PHOSPHATE-BEARING MATERIALS TO CALCIUM CARBIDE, FUSED ALUMINA AND PHOSPHORUS, RESPECTIVELY, AND SAID COOLING OPERATION BEING EXECUTED UNDER NON-OXIDIZING CONDITIONS.

Claim 2

THE METHOD OF COKING-CALCINING MINERAL AGGREGATES COMPRISING A MIXTURE OF CARBONACEOUS MATERIAL AND A MATERIAL SELECTED FROM THE GROUP CONSISTING OF CAO-, ALUMINUM- AND PHOSPHATEBEARING MATERIALS, WHICH CONSISTS ON INTRODUCING A DOWNWARDLY MOVING COLUMN OF SAID AGGREGATES INTO A VERTICAL RETORT INDIRECTLY HEATING UNDER NON-OXIDIZING CONDITIONS THE UPPER SECTION OF SAID DOWNWARDLY MOVING COLUMN OF AGGREGATES TO A TEMPERATURE OF ABOUT 950* C. TO ABOUT 1100* C. TO EFFECT SUBSTANTIALLY COMPLETE REMOVAL OF THE VOLATILE COMPONENTS OF SAID AGGREGATES, SCRUBBING SAID VOLATILE COMPONENTS WITH AN AQUEOUS MEDIUM TO COOL SAID VOLATILE COMPONENTS AND REMOVE TAR THEREFROM, BURNING A PORTION OF THE SCRUBBED VOLATILE COMPONENTS TO PRODUCE HEAT FOR SAID INDIRECT HEATING OPERATION, RECYCLING A SUFFICIENT AMOUNT OF THE REMAINDER OF SAID SCRUBBED VOLATILE COMPONENTS THROUGH THE LOWER SECTION OF SAID COLUMN OF AGGREGATES TO COOL SAME TO A TEMPERATURE BELOW 200* C. AND DISCHARGING SAID COOLED AGGREGATES FROM THE BOTTOM OF SAID RETORT, SAID INDIRECT HEATING BEING APPLIED SUBSTANTIALLY THROUGHOUT SAID UPPER SECTION OF SAID RETORT UP TO ABOUT THE POINT OF ENTRY OF SAID AGGREGATES INTO SAID RETORT, SAID CARBONACEOUS MATERIAL IN THE INITIAL MINERAL AGGREGATES BEING EMPLOYED IN THE PROPORTIONS PROVIDING SUFFICIENT FUEL FOR SAID INDIRECT HEATING OPERATION AND ALSO SUFFICIENT RESIDUAL CARBON IN THE COKED-CALCINED PRODUCT FOR SUBSTANTIALLY COMPLETE REDUCTION OF SAID CAO-, ALUMINUM- AND PHOSPHATE-BEARING MATERIALS TO CALCIUM CARBIDE, FUSED ALUMINA AND PHOSPHORUS, RESPECTIVELY, AND SAID COOLING OPERATION BEING EXECUTED UNDER NON-OXIDIZING CONDITIONS.