Pyrolysis has been a useful procedure to treat waste-tire, which decomposes waste-tire at high temperature in the absence of oxygen. This thermal decomposition process generates pyrolysis oil, combustible gas, and char, which distribute in liquid phase, gas phase, and solid phase, respectively. Pyrolysis oil and combustible gas are fuels, while char is composed of carbon black and ash. Thus, char would be economically worth while to be treated before reuse. In this study, based on the resistivity difference between carbon black and ash, ash can be removed from char in the principle of electrostatic separation and thus increase the value of char. In this study, the objective was to separate ash from char by electrostatic separation process, different char including waste-tire pyrolytic char (raw char), low pressure re-pyrolytic char, ZnO-added char (12% ZnO mixed with 600 oC re-pyrolytic cahr) and man-made char (N600 carbon black mixed with 14.5% metallic oxide) were tested. The Electro-Static Separator (ESS) was designed and constructed with two types of discharge electrodes including a needle-plate electrode (NPE) and a needle-bar electrode (NBE) and two kinds of dust feeders to generate either fine or coarse particles. The results indicated that raw char had higher collection efficiency using the NBE system than the NPE system in the operating voltages of -7 kV to -15 kV because the surface area of the NBE system was less than the NPE system, thus led higher surface charge density for the NBE system than the NPE system, resulting in higher discharge current of the NBE system. In order to lower resistivity and reduce deposited pyrolysis oil on char, low pressure repyrolysis process was used. Because the removal efficiency of pyrolysis oil is proportional to repyrolysis temperature, more pyrolysis oil can be removed from the surface of char, resulting in more carbon blacks exposed on the char surface as conductive material. Thus, the collection efficiency of 600 oC repyrolytic char was less than that of 400 oC repyrolytic char. Furthermore, because particle charging quantity was proportional to particle size, fine char particles had less collection efficiency than coarse char particles. However, both raw char and repyrolytic char, the collection efficiency of carbon and ash had similar trends, suggesting that similar percentage of carbon and ash were collected on the plate and penetrated the ESS system. Therefore, the separation efficiency of carbon and ash were similar, same situation was observed for the ZnO-added char. In order to verify the feasibility of carbon and ash separation by electrostatic separation process, N660 carbon black mixing with 14.5% man-made ash (Al2O3, ZnO and CaO composed) to simulate man-made char, which was further used to proceed the electrostatic separation experiments in this study. The results indicated that the collection efficiency of man-made char increased with operating voltage, and the ash content seems to increase with voltage. Carbon black is a low resistivity material, which causing sparkover during the experiments, thus operating voltage cannot be regulated more than -8.25 kV. In order to verify the feasibility of carbon black and ash separation by the principle of electrostatic separation, this study applied non-linear regression to model the collection efficiency of man-made char, carbon black and ash, and further simulate the collection efficiency at higher electrical field strength. The simulated results indicated that the maximum collection efficiency of carbon and ash was approached around -10 kV/cm of carbon black and ash and their collection efficiencies were similar. The collection efficiency of ash was close to the ash content of man-made char (the collection efficiency of ash equal to the collected ash per mass of injected char), suggesting that most injected ash was collected by the ESS system. In addition, the ash content of penetration char was also simulated, the modeling results showed that the ash content of penetrated char were lower than 2%, while was relatively lower than the raw man-made char, and more than 75% injected char could penetrate the ESS system during the operation procedure. According to the modeling results, solid-solid separation technology could be more efficient if carbon and ash are independently separate particles, and lower resistivity materials would penetrate the ESS system and higher resistivity materials would be collected by the electrostatic separation process.

Thesis (MScEng (Process Engineering))--University of Stellenbosch, 2005. / 199 leaves single sided printed, preliminary pages i-vii and numbered pages 1-191. Includes bibliography, list of figures and tables. Digitized using a Hp Scanjet 8250 Scanner to pdf format (OCR). / ENGLISH ABSTRACT: This study provided scientific proof of the precipitation of iron and other metal species in the HAL circuit at the Mineral Separation Plant of Namakwa Sands. Iron and aluminium hydroxides were the most abundant precipitate complexes that formed in the HAL circuit. Sulphates formed bridges with the iron complexes. It was found that precipitation of iron in the HAL circuit was a function of the pH, ferric ion concentration and temperature of the process water. Experimental work provided abundant evidence that the precipitated iron hydroxide and other species adsorb to the surfaces of zircon and rutile mineral particles due to opposite zeta potentials of the mineral particles and iron hydroxide. These adsorbed species altered the electrostatic potential of the mineral surfaces, which reduced the electrostatic separation efficiency of these minerals. It was determined that an improvement of 7% could be expected if the precipitation and attachment of iron could be minimised. Based on the experimental results, conceptual processes were developed and iterative simulations were set up to determine the optimum solution that would maximise the removal of dissolved iron. This solution would ensure clean mineral surfaces free of any adsorbed precipitates. This process circuit was constructed in May to August 2004 at a total capital cost of R4.8m and removed 99.97% of the total dissolved iron prior to caustic addition. Prime zircon recoveries were increased by 3-7%. / AFRIKAANSE OPSOMMING: Hierdie studie het wetenskaplike bewyse gelewer dat yster en ander spesies neerslae vorm in die HAL proses van die Mineraal Skeidings Aanleg van Namakwa Sands. Yster- en aluminium hidroksiede was die vernaamste neerslag komplekse wat gevorm het in die HAL proses. Sulfaat spesies het verbindings gevorm met die yster komplekse. Die neerslag van yster was ‘n funksie van pH, ferric ioon konsentrasie en temperatuur van die proses water. Eksperimentele werk het genoegsame bewyse gelewer dat die yster hidroksied neerslag en ander spesies adsorbeer op die oppervlaktes van sirkoon en rutiel minerale weens teenoorgestelde zeta potensiale van die mineraal partikels en yster hidroksiede. Hierdie geadsorbeerde spesies het die elektrostatiese potentiaal van die mineraal oppervlaktes verander wat sodoende die elektrostatiese skeidingsvermoë van hierdie minerale verminder het. ‘n Verbetering van 7% in elektrostatiese skeiding van sirkoon en rutiel minerale kan verwag word indien die neerslag en adsorbsie van yster minimiseer word. Konseptuele prosesse, gebasseer op die eksperimentele resultate, is ontwikkel. Itteratiewe simulasies is opgestel om die optimum proses te bepaal wat sodoende die maksimum verwydering van die opgeloste yster sou verseker. Hierdie oplossing sou skoon mineraal oppervlaktes, vry van enige geadsorbeerde neerslae, verseker. Hierdie prosesaanleg was opgerig in Mei tot Augustus 2004 teen ‘n kapitaalkoste van R4.8m en dit het 99.97% van die totale opgeloste yster verwyder voordat natrium hidroksied bygevoeg is. Primêre sirkoon opbrengste het sodoende toegeneem met 3-7%.

An introduction to titanium minerals is provided along with a brief history of high tension roll (HTR) separation and its applications. Current HTR theory is critically reviewed and deficiencies in previous modelling work are identified. These problems are recognised as the likely reason why past models required empirical manipulation to reproduce observed separation behaviour. An updated theory of charge decay in a particle bed is developed for HTR applications. Particle bed interactions and their effects on electrostatic forces and discharge rates are examined, leading to a reviewed analysis of force balance. The theoretical contributions are incorporated into a new HTR model which takes a mechanistic approach to describing machine operation, as opposed to previous empirical-based work in the area. A simplified electrostatic field model is also developed. Atmospheric effects on separation behaviour are ignored in the modelling. Experimental separations are used to validate new model performance, where comparisons are specifically designed to test the theoretical developments on charge decay and force balance in a particle bed. The new model is also compared to the Dance (1992) HTR model, embedded in JKSimSand, the most recent HTR model with an empirical basis. An error analysis shows the new model performs as well as, or better, than JKSimSand in most respects. The fact that this is achieved with a mechanistic approach validates the new developments in particle bed charge decay and force theory, and sets the foundation for mechanistic HTR simulation.

Fundação de Amparo a Pesquisa no Estado do Rio Grande do Sul / The increasing industrial development results in a large consumption of products and materials. Among them, stand out the polymeric materials, due to their versatility and low cost, and electrical and electronic equipment (EEE), such as mobile phones and their batteries. In this scenario, an efficient and environmentally friendly recycling technology has a great importance. Therefore, this study presents an alternative to the mechanical recycling of these wastes. The separation of the polymeric mixtures was performed using the triboelectrostatic separation process. The components of lithium-ion batteries were recovered by a corona electrostatic separation process. In polymeric waste processing, the methodology employed was the characterization, washing, drying, comminution, secondary washing, secondary drying, tribocharging and electrostatic separation of the different polymeric blends (HDPE / PP, LDPE / PP and PET / PVC). The variables studied were the tribocharging mechanism, the relative humidity, the tribocharging residence time, the angle of the deflector, the distance of the static electrode, the electrode voltage and the rotation of the roll. In lithium ion batteries waste processing, the methodology employed was the characterization, comminution, drying, particle size separation and electrostatic separation. The selected parameters were the electrodes voltage, cylinder rotation, the distance of the static electrode and the angle of the deflector of the collector. For the polymeric waste processing the best results were: low relative humidity, tribocharging residence time of 5 minutes, angle of the deflector of 2.5 °, the distance of the static electrode of 3 cm, voltage of 30 kV and speed rotation 10 rpm. With these parameters, was obtained the recovery of 92.8% of PP (purity of 95.7%) and 95.9% of HDPE (purity of 93.1%). In the separation of PP and LDPE, was obtained a PP recovery of 90.2% (purity 93.8%) and a LDPE recovery of 94.2% (purity of 90.8%). Also, was achieved a recovery of 96.8% of PET (purity of 95.9%), and recovery of 95.9% for PVC (purity of 96.8%). For lithium ion batteries waste processing the best conditions were: rotation speed of 20 rpm, voltage of 25 kV, distance of the static electrode 6 cm and angle of the deflector 0 °. Through this process, was obtained a conductive fraction with 98.98% of metals content and a nonconductive fraction with 99.6% of polymer. The characterization of the batteries showed the batteries heterogeneity, being the electrostatic separation efficient to the different models tested. Therefore, the application of electrostatic separation is a promising method and efficient to recycling of polymer waste and lithium ion batteries waste. The studied process enabled a significant recovery of the components with a high purity. / O crescente desenvolvimento industrial acarreta em um grande consumo de produtos e materiais. Entre eles, destacam-se os materiais poliméricos, devido à sua versatilidade e baixo custo, e os equipamentos elétricos e eletrônicos (EEE), tais como os telefones celulares e suas baterias. Nesse cenário, tecnologias de reciclagem eficientes e ambientalmente aceitáveis tem uma grande importância. Diante disso, o presente trabalho apresenta uma alternativa para a reciclagem mecânica destes diferentes resíduos. A separação das misturas poliméricas foi realizada através do processo de separação triboeletrostática. Já os diferentes componentes das baterias de íon de lítio foram recuperados por um processo de separação eletrostática por efeito corona. No processamento dos resíduos poliméricos, a metodologia empregada consistiu na caracterização, lavagem, cominuição, lavagem e secagem secundária, tribocarregamento e separação eletrostática das diferentes misturas poliméricas (PEAD/PP, PEBD/PP e PET/PVC). As variáveis estudadas foram o mecanismo de tribocarregamento, a umidade relativa do ar, tempo de tribocarregamento, ângulo do defletor, distância do eletrodo de atração, tensão dos eletrodos e a rotação do rolo. No processamento das baterias de íon de lítio, realizaram-se a caracterização das baterias, cominuição, secagem, separação granulométrica e separação eletrostática. Os parâmetros selecionados foram a tensão dos eletrodos, rotação do rolo, distância do eletrodo de atração e o ângulo do defletor do coletor. Para o processamento dos resíduos poliméricos os melhores resultados foram: umidade relativa do ar de ± 42%, tempo de tribocarregamento de 5 minutos, ângulo do defletor de 2,5°, distância do eletrodo de atração de 3 cm, tensão de 30 kV e velocidade de rotação de 10 rpm. Com esses parâmetros, obteve-se a recuperação de 92,8% de PP (pureza de 95,7%) e 95,9% de PEAD (pureza de 93,1%). Na separação de PP e PEBD, obteve-se uma recuperação de PP de 90,2% (pureza de 93,8%), e uma recuperação de PEBD de 94,2% (pureza de 90,8%). Também, conseguiu-se uma recuperação de 96,8% de PET (pureza de 95,9%), e de 95,9% de PVC (pureza de 96,8%). Para a reciclagem de baterias de íon de lítio as melhores condições foram: velocidade de rotação de 20 rpm, tensão de 25 kV, distância do eletrodo de atração de 6 cm e ângulo do defletor de 0°. Através deste processamento, obteve-se uma fração condutora com 98,98% de metais e uma fração não condutora com 99,6% de polímeros. A caracterização das baterias demonstrou uma heterogeneidade desse tipo de resíduo, sendo o processo de separação eletrostática eficiente para os diferentes modelos testados. Sendo assim, a aplicação da separação eletrostática se mostrou um método eficiente e promissor para a reciclagem de resíduos poliméricos e de resíduos de baterias de íon de lítio. O processo estudado possibilitou a obtenção de uma expressiva recuperação dos componentes com uma alta pureza.

La démarche expérimentale menée dans cette thèse a eu comme objectif l'étude de la faisabilité de la séparation électrostatique d'une large gamme de mélanges de matériaux pulvérulents provenant du recyclage des déchets (Al, Cu, ABS, polycarbonate, polystyrène) ou de l'industrie agro-alimentaire (paille, copeaux de bois, semoule). Les recherches se sont focalisées sur des techniques faisant appel à trois mécanismes physiques différents pour la charge des matériaux : la décharge couronne, l'induction électrostatique et l'effet tribo-électrique. Deux nouvelles installations ont été conçues et réalisées, permettent de faciliter la compréhension des phénomènes physiques rencontrés lors de la séparation des particules sous-millimétriques, dont les trajectoires sont difficile à contrôler, en raison des importantes forces aérodynamiques en jeu. La première installation, le séparateur électrostatique multifonctions à électrode-convoyeur, donne la possibilité d'étudier un ou plusieurs des trois mécanismes de charge, en rapport avec les propriétés électriques des matériaux à traiter. La deuxième installation, le séparateur tribo-aéro-électrostatique à électrodes-disques-tournantes, utilise seulement l'effet tribo-électrique pour la charge des matériaux isolants dans un lit fluidisé. Le système de mesures simultanées et continues de la masse et de la charge électrique des produits collectés a facilité l'analyse des phénomènes. Les recherches ont permis de confirmer la séparabilité électrostatique des mélanges de matériaux pulvérulents, en faisant appel à la méthodologie des plans d'expériences pour identifier les facteurs influents et trouver le point de fonctionnement optimal. / The experimental approach undertaken in this thesis was aimed at the study of the feasibility of the electrostatic separation of a wide range mixtures of powdery materials originating from the recycling of waste electric and electronic equipment (Al, Cu, ABS, polycarbonate, polystyrene), or processed in the food industry (straw, wood chips, meal). Researches were focused on techniques using three different physical mechanisms for electrical charging of the materials: corona discharge, electrostatic induction and triboelectric effect. Two new installations have been designed end engineered to facilitate the understanding of the physical phenomena involved in the separation of powdery particles, the trajectories of which are difficult to control, as strongly affected by the aerodynamic forces. The first installation, the belt-type multifunction electrostatic separator, offers the possibility to study one or several of the three charging mechanisms, in relation with the electrical properties of the materials to be processed. The second installation, two-rotating-disks-type tribo-aero-electrostatic separator uses only the triboelectric effect for charging mixtures of insulating materials in a fluidized bed. A system of simultaneous and continuous measurement of mass and electric charge of collected products facilitated the investigation of the physical phenomena. These researches confirm the feasibility of the electrostatic separation of powdery materials, by taking advantage of the design of experiments methodology to identify the influential factors and find the optimum operation conditions.

La démarche expérimentale menée dans cette thèse CIFRE a eu comme objectif l’étude de la faisabilité de la séparation électrostatique d’une large gamme de mélanges de matériaux granulaires issus de déchets d’équipements électriques et électroniques (conducteur – isolant, conducteur – conducteur et isolant – isolant). Trois mécanismes physiques de charge électriques ont été mis en oeuvre : l’induction électrostatique, la décharge couronne et l’effet triboélectrique. Un dispositif de charge de laboratoire et deux séparateurs électrostatiques industriels ont été conçus et réalisés. Le dispositif de charge à cylindre(s) tournant(s) permet la charge triboélectrique de matériaux plastiques. Le prototype de séparateur industriel a d’abord été réalisé pour le traitement de mélanges granulaires conducteur – isolant puis a été adapté à la séparation isolant – isolant. Les trois mécanismes de charge peuvent y être utilisés. Ce prototype a permis la fabrication du premier séparateur électrostatique de série de la société CITF dédié à la séparation de déchets de câbles électriques. Des mesures de charge et de masse ainsi que des simulations et visualisations des trajectoires des particules par caméra rapide ont facilité l’analyse des phénomènes. La méthode des plans d’expérience a permis d’identifier les facteurs influents sur les processus de séparation et de définir leur point de fonctionnement optimal. L’influence d’une décharge à barrière diélectrique sur la charge triboélectrique et la séparation électrostatique de mélanges plastiques a été étudiée. Les travaux réalisés dans cette thèse ont confirmé la séparabilité électrostatique de mélanges de matériaux granulaires. / The experimental approach used in this thesis was aimed at the study of the feasibility of the electrostatic separation of a wide range of granular mixtures from waste electric and electronic equipment (conductive – insulator, conductive – conductive, insulator – insulator). Three physical mechanisms of electrical charging have been employed: electrostatic induction, corona discharge and triboelectric effect. A tribocharging device and two industrial electrostatic separators have been designed and engineered. The rotating cylinder tribocharging device allows the triboelectric charging of plastics. The industrial separator prototype was firstly built for processing conducting – insulator granular mixtures and then adapted for insulator – insulator separation. This prototype, which enables the use of all three electrical charging mechanisms, served as model for the CITF company first industrial electrostatic separator for the recycling of metals and plastics from electric cable wastes. Charge and mass measurement, as well as modelling and visualization of particle trajectories by a high-speed camera facilitated the investigations. Design of experiments method was used to define the influential factors and find the optimum operating conditions of the separation processes. Dielectric barrier discharge exposure of granular plastics may enhance the efficiency of the triboelectric charging of these materials and hence facilitate their electrostatic separation. These researches have confirmed the feasibility of the electrostatic separation of a wide variety of granular mixtures.

Plusieurs types de dispositifs mécaniques (à vibration, à cylindre tournant, à lit fluidisé) mettant en jeu l'effet triboélectrique sont actuellement utilisés pour charger électriquement les constituants des mélanges de matériaux isolants granulaires, en vue de leur séparation dans un champ électrique intense. La non-uniformité de la charge des granules à la sortie de ces dispositifs affecte l'efficacité de la séparation, d'où l'intérêt des recherches visant la mise au point de procédés électrostatiques nouveaux, notamment pour des applications dans le domaine du recyclage des déchets. L'utilisation simultanée de l'effet triboélectrique, de la force de Coulomb et de la force d'image électrique est la solution innovante selon laquelle ont été conçus les quatre dispositifs à lit fluidisés réalisés ou améliorés dans le cadre de cette thèse. L'évaluation des performances de ces dispositifs a été rendue possible par la mise en oeuvre de systèmes de mesure complexes, permettant l'enregistrement continu et simultané des charges et des masses des produits de la séparation. Ainsi, la méthode des plans d'expériences pour surfaces de réponse a pu être utilisée pour modéliser le processus de séparation et déterminer les valeurs optimales des variables de contrôle de chacun des dispositifs, tels que le niveau de la haute tension d'alimentation ou la vitesse de l'air de fluidisation. Les résultats obtenus sur les installations de laboratoire et sur un prototype préindustriel recommandent cette classe de procédés tribo-aéro-électrostatiques comme la solution de choix pour le recyclage des déchets granulaires d'équipements électriques et électroniques. / Several types of mechanical devices (vibratory trays, rotating drums, fluidized beds) make use of the triboelectric effect for electrically charge the constituents of insulating materials granular mixtures, in view of their separation in a high-intensity electric field. The non-uniformity of granule charge at the exit of these devices adversely affects the separation efficiency, justifying the researches aimed at the development of novel electrostatic processes, mainly for applications in the field of waste recycling. Simultaneous usage of the triboelectric effect, the Coulomb force and the electric image force is an innovative technical solution according to which four fluidized bed devices were built or improved within the framework of this thesis. The performances of these devices could be evaluated by setting up complex measurement systems that enable the continuous and simultaneous recording of the charges and masses of the separated products. Thus, the experimental design methodology could be used for modeling the separation process and identify the optimum values of the control variables of each device, such as the high voltage level of the speed of the fluidization air. The results obtained on laboratory devices as well on an semi-industrial pilot installation recommend this class of tribo-aero-electrostatic separation processes as the solution of choice for the selective sorting of plastics from waste electric and electronic equipment.