U.S. patent application number 09/742739 was filed with the patent office on 2001-11-22 for concentric electrode dc arc systems and their use in processing waste materials.
Invention is credited to Hamilton, Richard A., Titus, Charles S., Wittle, J. Kenneth.
Application Number | 20010043638 09/742739 |
Document ID | / |
Family ID | 24391761 |
Filed Date | 2001-11-22 |
United States Patent
Application |
20010043638 |
Kind Code |
A1 |
Wittle, J. Kenneth ; et
al. |
November 22, 2001 |
Concentric electrode DC arc systems and their use in processing
waste materials
Abstract
An electrode assembly comprising concentric tubular electrodes
is provided for high temperature processing of materials. The
electrode assembly is connected with a power supply that includes
switching means for alternatively operating the electrode assembly
in a transferred mode of operation, in a non-transferred mode of
operation, or according to a controlled sequence of non-transferred
and transferred modes of operation. The power supply system
includes variable inductors, such as leakage-coupled reactors, for
controlling the electrical power supplied to the electrodes for
producing a DC arc. The electrode assembly can be incorporated into
an arc furnace for processing waste material in the furnace. The
electrode assembly is also suitable for use in the practice of
in-situ vitrification and remediation of contaminated soil. During
in-situ vitrification, the electrode assembly may also be operated
in the non-transferred mode, while being withdrawn from holes in
the earth, to produce vitrified columns of soil. The vitrified
columns of soil can be coalesced with similar adjacent columns of
soil in order to form a composite or unitary subterranean mass or
barrier for contaminated material in a selected area. Multiple
electrode assemblies can be employed to treat contamination located
within a large area. An AC potential can be applied to adjacent
electrode assemblies in order to promote coalescence of the
adjacent columns of treated soil to form a composite or unitary
mass.
Inventors: |
Wittle, J. Kenneth; (Chester
Springs, PA) ; Hamilton, Richard A.; (Aston, PA)
; Titus, Charles S.; (Newtown Square, PA) |
Correspondence
Address: |
DANN DORFMAN HERRELL & SKILLMAN
SUITE 720
1601 MARKET STREET
PHILADELPHIA
PA
19103-2307
US
|
Family ID: |
24391761 |
Appl. No.: |
09/742739 |
Filed: |
December 21, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09742739 |
Dec 21, 2000 |
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09597497 |
Jun 20, 2000 |
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09597497 |
Jun 20, 2000 |
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08749916 |
Nov 14, 1996 |
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08749916 |
Nov 14, 1996 |
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08266209 |
Jun 27, 1994 |
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5673285 |
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Current U.S.
Class: |
373/60 ; 175/11;
205/743; 373/108; 373/82 |
Current CPC
Class: |
F27D 2099/006 20130101;
F27D 2099/0058 20130101; F27B 3/085 20130101; F27B 3/12 20130101;
C03B 5/025 20130101; F27D 99/0006 20130101; F27D 11/08 20130101;
H05B 7/109 20130101; F27D 1/0006 20130101; F23G 5/10 20130101; C03B
5/005 20130101; F27D 2003/161 20130101; H05B 7/06 20130101; F27D
2099/0023 20130101; F23G 2900/51001 20130101; F23G 2202/20
20130101 |
Class at
Publication: |
373/60 ; 373/82;
373/108; 205/743; 175/11 |
International
Class: |
F27D 003/00; H05B
007/18; H05B 003/02; C02F 001/461; E21B 007/14 |
Claims
We claim:
1. A method for treating waste material located in soil, the method
comprising the steps of: forming a hole in the soil, inserting a
first electrode and a second electrode into the hole, initiating a
non-transferred electric arc between said first electrode and said
second electrode, and heating the soil with said non-transferred
arc.
2. The method of claim 1, comprising the steps of: withdrawing said
first and second electrodes within the hole, and maintaining said
non-transferred arc between said first and second electrodes during
said withdrawing step.
3. The method of claim 2, comprising the step of: adding filler
material to the hole during said withdrawing step.
4. The method of claim 1 wherein said initiating step comprises:
placing said first and second electrodes in contact with the bottom
of the hole; applying a DC voltage between said first and second
electrodes so that an electrical current is established in the soil
at the bottom of the hole, and withdrawing said first and second
electrodes from contact with the bottom of the hole.
5. The method of claim 4, comprising the step of: placing an
electrically conductive material at the bottom of the hole to
increase the conductivity of the soil at the bottom of the hole
prior to placing said first and second electrodes in contact with
the bottom of the hole.
6. The method of claim 1 wherein said initiating step comprises:
applying a DC voltage between said first and second electrodes, and
locating electrically conductive particulate material between said
first and second electrodes such that electrical conduction is
established within said electrically conductive particulate
material.
7. A method for treating waste material located in soil, the method
comprising the steps of: forming a first hole in the soil, forming
a second hole in the soil adjacent to said first hole, inserting a
first electrode assembly having a first electrode and a second
electrode into the first hole, inserting a second electrode
assembly having a third electrode and a fourth electrode into the
second hole, initiating a first non-transferred electric arc
between said first and second electrodes of said first electrode
assembly, initiating a second non-transferred electric arc between
said third and fourth electrodes of said second electrode assembly,
heating the soil surrounding said first hole with said first
non-transferred electric arc, and heating the soil surrounding said
second hole with said second non-transferred electric arc.
8. The method of claim 7, comprising steps of: withdrawing said
first electrode assembly within said first hole while maintaining
said first non-transferred arc, withdrawing said second electrode
assembly within said second hole while maintaining said second
non-transferred arc.
9. The method of claim 8, comprising steps of: applying an
electrical voltage between a selected one of said first and second
electrodes and a selected one of said third and fourth electrodes,
whereby an electrical current is established in the soil between
said first and second holes.
10. The method of claim 7, comprising steps of: applying an
electrical voltage between a selected one of said first and second
electrodes and a selected one of said third and fourth electrodes,
whereby an electrical current is established in the soil between
said first and second holes.
11. An apparatus for treating waste material located in soil, the
apparatus comprising: a first electrode assembly having first and
second electrodes adapted for insertion into a first hole in the
soil, first electrical supply means for applying a first voltage
between said first and second electrodes, a second electrode
assembly having third and fourth electrodes adapted for insertion
into a second hole in the soil, second electrical supply means for
applying a second voltage between said third and fourth electrodes,
and third electrical supply means isolated from said first and
second electrical supply means for applying a third voltage between
a selected one of said first and second electrodes and a selected
one of said third and fourth electrodes.
12. The apparatus of claim 11 wherein said first voltage and said
second voltage are DC voltages.
13. The apparatus of claim 12 wherein said third voltage is an AC
voltage.
14. The apparatus of claim 13, comprising hoisting means for
inserting and for withdrawing said first and second electrode
assemblies within said first and second holes respectively.
15. The apparatus of claim 12 wherein: said first electrode
comprises a cylinder having an axial cavity, and said second
electrode comprises a cylindrical rod positioned coaxially within
said axial cavity of said first electrode.
16. The apparatus of claim 15 comprising means for injecting
electrically conductive particulate material between said first
electrode and said second electrode.
17. A method of igniting an electric arc between a pair of
concentric electrodes which is formed by an inner electrode and an
outer electrode surrounding the inner electrode and providing a
cavity therebetween, the method comprising: injecting conductive
particulate material into the cavity; and applying an electrical
voltage across the inner and outer electrodes.
18. The method of claim 17 wherein said injecting step comprises
injecting the particulate material into said cavity in connection
with a compressed gas.
19. The method of claim 18, further comprising injecting said
particulate material through a bore within one of said electrodes
and into said cavity.
20. The method of claim 19 wherein said particulate material is
injected through a bore within said inner electrode.
21. The method of claim 18 wherein said transmitting step comprises
transmitting said quantity of particulate material through an
electrically insulating conduit.
22. A power supply circuit for providing a DC arc between two
electrodes, comprising: a three-phase AC power source for providing
a three-phase AC current; transformer means having primary windings
and secondary windings, said primary windings receiving said AC
current and said secondary windings producing a transformed current
in response thereto, and at least one of said primary windings and
said secondary windings comprising a variable inductor; rectifier
means connected with said secondary windings and with the
electrodes for rectifying said transformed current and supplying a
DC current to the electrodes.
23. A power supply circuit for providing a DC arc between two
electrodes, comprising: a three-phase AC power source for providing
an AC current; transformer means having primary windings and
secondary windings, said primary windings receiving said AC current
and said secondary windings providing a transformed three-phase AC
current; first, second, and third variable inductors connected in
series with respective phases of said secondary windings for
variably controlling said transformed current; rectifier means
connected with said first, second, and third variable inductors for
receiving said transformed current and supplying a DC current to
the electrodes.
24. The power supply circuit of claim 23 wherein at least one of
said variable inductors comprises: a first magnetic core having
windings thereon for producing a first magnetic field, a second
magnetic core adjacent to said first magnetic core and having
windings thereon for producing a second magnetic field, and
interconnecting means for interconnecting the windings upon said
first and second magnetic cores.
25. The power supply circuit of claim 24 wherein said
interconnecting means includes switching means for selecting the
relative polarity of said first and second magnetic fields.
26. An arc furnace, comprising: a DC power supply having first and
second terminals for providing supplying electrical power; a
furnace enclosure having a conductive hearth therein connected with
one of said terminals of said power supply, said furnace enclosure
being adapted to receive material to be heated in the furnace on
the hearth; an electrode assembly positioned adjacent the material
on the hearth in the furnace enclosure, said electrode assembly
comprising first and second electrodes, one of said first and
second electrodes being connected to said second terminal of said
power supply; first switching means for selectively connecting said
second electrode with said first terminal of said power supply for
providing a non-transferred arc between said first and second
electrodes; and second switching means for selectively connecting
said second electrode with said second terminal of said power
supply for providing a transferred arc between said electrode
assembly and said hearth.
27. A method of operating a DC arc furnace, comprising: placing
material to be treated into a furnace enclosure having conductive
hearth within the furnace, the material being received by the
hearth; providing DC electrical power from a power source having
first and second terminals; connecting said hearth with said first
terminal; positioning an electrode assembly having first and second
electrodes adjacent the material on the hearth; producing a
non-transferred arc between said first and second electrodes by
connecting the first electrode with the first terminal of said
power supply and connecting the second electrode with the second
terminal of said power supply; heating the material on the hearth
with the non-transferred arc; and subsequently producing a
transferred arc between the electrode assembly and the heated
material on the hearth by disconnecting the first electrode from
the first terminal of said power supply and connecting the first
electrode with the second terminal of said power supply.
28. The method of claim 27 wherein said step of producing a
non-transferred electric arc includes injecting particulate
material into a gap between the first and second electrodes.
29. The method of claim 27 wherein said heating step comprises:
detecting the presence of any electrical current passing between
said hearth and said power supply to determine when the current
reaches a predetermined level, and producing the transferred arc in
response to detecting the predetermined level of current.
30. The method of claim 25 wherein said step of producing a
non-transferred arc comprises contacting the surface of the
material on the hearth with said first and second electrodes.
31. The method of claim 25 wherein said first and second electrodes
comprises elongated cylinders and said step of producing a
non-transferred arc comprises positioning respective ends of said
first and second electrodes in relative proximity.
32. A method of making a construction foundation, comprising:
forming a hole in soil; placing an electrode assembly within the
hole; operating the electrode assembly within the hole to produce a
subterranean mass of vitrified material in the hole; removing the
electrode assembly from the hole; and placing a piling into the
hole to be supported by said vitrified material.
33. The method of claim 32 wherein said forming step comprises
placing a cylindrical sheath into the hole and said operating step
comprises suspending said electrode assembly in the hole within
said sheath.
34. The method of claim 33, comprising: connecting a power supply
with said sheath and with an electrode in the soil adjacent the
hole; and applying an electrical potential from said power supply
between said sheath and the electrode in the soil for vitrifying
the soil adjacent the sheath.
35. An electrode assembly, comprising: a first electrode comprising
a hollow cylinder having an upper end and a lower end; a second
electrode comprising a cylinder having an upper end and a lower end
and positioned coaxially within said first electrode, said first
and second electrodes having an annular cavity therebetween; and
one of said first and second electrodes having a conduit formed
therein for transporting conductive material into said annular
cavity.
36. The electrode assembly of claim 35 wherein each of said first
and second electrodes comprises two separable segments
corresponding to the upper end and the lower end of each electrode,
whereby the lower end of each electrode is replaceable upon
deterioration.
37. The electrode assembly of claim 35 comprising clamping means
for retaining said first and second electrodes in coaxial
alignment.
38. The electrode assembly of claim 37 wherein the upper end of
said second electrode extends axially outward of the upper end of
said first electrode and wherein said clamping means comprises;
first holding means for retaining the upper end of said first
electrode; second holding means for retaining the upper end of said
second electrode; and a rigid insulator connected between said
first and second holding means for positioning said first and
second holding means to retain said first and second electrodes in
alignment and electrically isolated.
39. The electrode assembly of claim 38 wherein said first and
second holding means comprise electrical connection means for
connecting said first and second electrodes with a source of
electricity.
40. The electrode assembly of claim 38 wherein said first and
second holding means comprise respective first and second annular
clamps, and wherein said insulator comprises a disc positioned
between said first and second annular clamps and encircling the
upper end of said second electrode.
41. The electrode assembly of claim 40 wherein said first and
second annular clamps include conduits for circulating coolant
therein.
42. An electrode assembly comprising: a first tubular electrode
having an interior surface; a second electrode positioned coaxially
within said first electrode to provide a cavity between said first
and second electrodes; and constricting means connected with said
second electrode and extending within said cavity to form a
constriction within said cavity.
43. The electrode assembly of claim 40 wherein said constricting
means comprises an inwardly-projecting taper formed on the interior
surface of said first electrode.
44. The electrode assembly of claim 40 wherein a portion of said
second electrode extends outside of one end of said first
electrode.
45. The electrode assembly of claim 42 comprising: first clamping
means for retaining said one end of said first electrode second
clamping means for retaining said second electrode in coaxial
alignment with said first electrode; and a rigid insulator
connected between said first and second clamping means and
encircling said extending portion of said second electrode.
46. The electrode assembly of claim 43 comprising injection means
for injecting a compressed gas into said annular cavity.
47. The electrode assembly of claim 44 wherein said injection means
includes a conduit formed within said insulator.
48. An arc furnace for processing material, comprising: a
conductive shell; a conductive hearth having a central portion for
holding the material, said hearth being positioned within the shell
and insulated from the shell; an electrode assembly for producing
an electric arc and translatable within the shell for being
positioned over the central portion of the hearth; and a
ferromagnetic plate member supported in the shell beneath the
hearth and electrically insulated from said shell and from said
hearth, the plate member being positioned relative to said hearth
and said electrode assembly for maintaining said electric arc
directed to the central portion of the hearth.
49. A method of forming an underground structure in the earth
beneath a selected area, comprising the steps of: forming a first
plurality of holes adjacent to one another in the earth; forming a
second plurality of holes adjacent to one another in the earth, the
second plurality of holes having a horizontal directional component
to extend beneath the selected area; and producing a volume of
vitreous material associated with said first and second pluralities
of holes and causing the volumes of material to coalesce to form a
vitreous barrier beneath the selected area.
50. A method of forming an underground structure in the earth
beneath a selected area, comprising the steps of: forming a first
plurality of holes adjacent to one another to define the selected
area in the earth and defining the perimeter of the selected area;
forming a second plurality of holes in the earth adjacent to one
another in an array within the perimeter of the selected area;
producing a molten pool of vitreous material substantially at the
bottom of each of said second plurality of holes and causing each
pool to coalesce with similar pools in adjacent ones of said second
plurality of holes to form a horizontal barrier beneath the
selected area; producing a column of vitreous material within each
of said first plurality of holes and coalesced with adjacent ones
of said first plurality of holes; and joining each of said columns
with said bottom barrier to form a barrier beneath the selected
area.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to systems for high
temperature processing of materials. In particular, the invention
relates to an electrode apparatus and associated systems for
operating the electrode apparatus to process waste materials with a
DC arc.
BACKGROUND OF THE INVENTION
[0002] The safe disposal of waste materials, particularly hazardous
waste materials, is an area of increasing social concern. The
manifold benefits of advances in chemistry, medicine, and nuclear
technology have been accompanied by the accumulation of large
quantities of toxic, infectious and/or radioactive waste materials
as well as otherwise inert materials which have been contaminated
by such undesirable agents. In some areas, subterranean
contamination of the soil by such agents threatens the safety of
underground water supplies and other natural resources.
[0003] DC arc furnaces have been employed to melt ferrous metals.
The use of such furnaces to process waste materials offers several
advantages in the disposal of such materials relative to other
available disposal technologies such as incineration. These
advantages include the ability to separate and recover useful
materials from the waste, reduced gaseous emissions, and a more
complete breakdown of the waste material into non-hazardous
components or into pure elements. Such advantages are described in
U.S. Pat. No. 4,431,612 issued Feb. 14, 1984 and in U.S. Pat. No.
3,812,620 issued May. 28, 1974, both of which are incorporated by
reference herein.
[0004] Several of the particular advantages described in the
aforementioned patents result from the effects of a DC plasma or
arc that is rooted at one end to an electrode and at the other end
to a conductive pool of molten material within a conductive hearth.
Such an electric arc is referred to as a "transferred" arc, in
that, electrical current is transferred between the electrode
assembly and the waste material. Another known type of DC arc
processing utilizes a "non-transferred" arc wherein an arc is
established between two electrodes in the vicinity of the material
to be treated so that thermal energy is transferred from the arc to
the material primarily by radiation. A transferred arc provides
more effective transfer of thermal energy to the waste material and
enhanced chemical breakdown of the waste material relative to a
non-transferred arc.
[0005] In order to establish a transferred arc in accordance with
the known methods, it is necessary either (i) to establish a
conductive molten pool or "heel" within the hearth prior to adding
waste materials to the hearth or (ii) to limit the use of such
apparatus to the treatment of waste materials having a sufficient
bulk conductivity to establish arcing between the electrode and the
conductive material in the pool. The requirement of initially
forming a conductive layer in the pool prior to adding
heterogeneous waste material can cause difficulties in practice,
particularly if the furnace is operated on a batch basis. The
alternative requirement of restricting the use of a DC arc to the
treatment of electrically conductive waste materials severely
limits the usefulness of DC arc processing of waste since many
waste materials are not sufficiently conductive to establish a
transferred DC arc.
[0006] It would be desirable to provide a waste treatment system
capable of treating a wide range of waste materials using a
transferred DC arc regardless of the electric conductivity of such
materials. It would also be desirable to provide such a system in
which it is not necessary to form a conductive pool within a hearth
prior to the addition of such waste materials. In the processing of
material on a batch basis, it would be desirable to provide a
system in which it is not necessary to remove any non-conductive
surface layer(s) after processing each batch.
[0007] A more fundamental limitation of prior systems for
destroying waste material in an arc furnace is that such materials
must be transported from their respective sites of origin to the
furnace in order to be processed. In order to remediate
contamination at certain remote sites, it would be prohibitively
expensive, hazardous, and/or otherwise impractical to remove the
waste material from the contaminated site for transportation to a
processing facility such as a furnace. Such contaminated sites
include nuclear waste reprocessing and storage facilities, chemical
weapons repositories, and other locations wherein undesirable or
hazardous materials have been stored or otherwise located
underground.
[0008] Many such buried waste facilities have proven inadequate to
confine their respective waste materials to the originally-intended
sites as a result of unstable geology or inadequate containment
means. It would be desirable to provide a system that is capable of
treating such contaminated sites in order to alleviate the
contamination therein without having to remove and to transport
large volumes of contaminated soil. It would also be desirable to
provide a system for forming stable subterranean barriers to
contain such underground contamination and to prevent migration of
contaminants beyond the intended site or beyond the current
boundaries of such underground contamination at sites that have
already been compromised.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following detailed description of the preferred
embodiments of the present invention will be better understood when
read in conjunction with the appended drawings, in which:
[0010] FIGS. 1A-B are partially schematic diagrams of an electrode
assembly for treating waste material;
[0011] FIGS. 2A-C are diagrams of alternative arrangements for
initiating an electric arc between two electrodes of the electrode
assembly of FIGS. 1A-B;
[0012] FIG. 3 is a partial cross-sectional view of an arc furnace
employing the electrode assembly of FIGS. 1A-B;
[0013] FIG. 4 is a partial cross-sectional view of a clamping
structure for supporting the electrode assembly within the furnace
of FIG. 3;
[0014] FIG. 5 is a diagram of a combined plumbing and electrical
system for connecting the clamping structure of FIG. 4 with cooling
water and electrical power;
[0015] FIG. 6A-B are schematic diagrams of alternative DC
electrical power supply systems for supplying electrical power to
an electrode assembly;
[0016] FIG. 7 is a diagram of adjustable leakage-coupled inductors
for use in the power supply systems of FIGS. 6A-B;
[0017] FIGS. 8A-B are partial cross-sectional views of the
electrode assembly of FIGS. 1A-B employed in the practice of
vitrifying contaminated soil at a site of contamination;
[0018] FIG. 9 is a partially schematic diagram of a system for
operating a plurality of electrode assemblies at a remote site to
produce a subterranean barrier;
[0019] FIGS. 10A-B are cross-sectional views of alternative
subterranean barrier structures that can be constructed using the
system of FIG. 9;
[0020] FIGS. 11A-B are partial cross-sectional views of the
electrode assembly of FIGS. 1A-B employed in the practice of
forming a subterranean support for piling construction; and
[0021] FIG. 12 is a partial cross sectional view of an alternative
system for forming a subterranean support for piling
construction.
ELECTRODE ASSEMBLY
[0022] In FIG. 1A there is shown an electrode assembly 20. The
electrode assembly 20 comprises a pair of concentric tubular
electrodes 22 and 24, which are formed of a conductive material,
preferably graphite. The outer electrode 22 is preferably in the
form of a hollow cylinder. The inner electrode 24 is preferably in
the form of a solid cylinder positioned coaxially relative to
electrode 22. The electrode assembly 20 is positioned above a
hearth, such as a graphite hearth 26, containing material to be
processed. Such material may include, for example, heterogeneous
waste material 21 that is to be processed. An electrical switching
and power supply network 31 is connected with the electrode
assembly 20 and the hearth 26 to provide sufficient electrical
power for processing the heterogeneous waste material 21. The
network 31 includes switches 36 and 38 for configuring the relative
electrical polarities of the electrode 22, electrode 24, and the
hearth 26 so that pyrolysis may be carried out in a non-transferred
mode, in a transferred mode, or according to a controlled sequence
of non-transferred and transferred modes of operation.
[0023] The electrical switching and power supply network 31
includes a power supply, such as DC power supply 30, having a
positive terminal 34 and a negative terminal 32. The DC power
supply may be a conventional power supply such as a
thyristor-controlled power supply or, alternatively, may be of a
type described hereinafter in connection with FIGS. 6A-B. The
positive terminal 34 of the power supply 30 is connected to one
terminal of a series inductor 33. The other terminal of series
inductor 33 is connected to the inner electrode 24 of the electrode
assembly 20 via switch 38 and conductor 40. The positive terminal
34 of the power supply 30 is connected to the hearth 26 through an
ammeter 42. A contactor or switch 38 is connected to terminal 34
for connecting and disconnecting electrode 24 to the positive
terminal 34 via conductor 40. A contactor or switch 36 is connected
between conductor 40 and conductor 35 for connecting and
disconnecting electrode 24 with the negative terminal 32 via
inductor 33.
[0024] In order to operate the electrode assembly 20 in the
non-transferred mode, switch 38 is initially closed and switch 36
is initially open so that a DC voltage is established between the
inner conductor 24 and the outer conductor 22. Then, an arc 28 can
be initiated and sustained between the inner electrode 24 and the
outer electrode 22. The arc 28 produces radiant energy which is
absorbed by the heterogeneous waste material 21 and converted into
heat. Such direct radiant transfer of energy from the arc to the
waste material differs substantially from the manner in which
thermal energy is obtained during operation of a conventional
plasma torch. A plasma torch, in contrast to the electrode assembly
of the present invention, utilizes an electric arc that is internal
to the torch apparatus. In order to transfer thermal energy from
the internal arc of a plasma torch to the material to be processed,
a flow of gas must be maintained within the torch such that the gas
is heated by the arc and then expelled from the torch. As can
readily be appreciated, no such flow of gas is required in order to
treat waste material using a non-transferred DC arc in accordance
with the present invention. The radiant transfer of energy from the
arc 28 to the waste material 21 can be augmented with convective
heat transfer by passage of an inert gas, such as argon or
nitrogen, through the annular cavity between electrodes 24 and 22
and toward the waste material 21 in the hearth 26, if desired. The
heat transferred to the waste material is sufficient to destroy or
render inert the undesirable chemical constituents of the waste
material 21. If the waste material includes such materials as
silicates or metal oxides, then the waste material can be converted
into a molten vitreous residue.
[0025] In order to operate the electrode assembly in the
transferred mode, switch 36 is initially closed and switch 38 is
initially open. In such a configuration, both the inner electrode
24 and the outer electrode 22 are maintained at the negative
voltage provided at terminal 32 of the power supply 30 while the
hearth 26 is maintained at the positive voltage presented by
terminal 34 of the power supply 30. An electric arc 28a is then
established between the electrode assembly 20 and the waste
material 21 by lowering the electrode assembly 20 into contact with
the waste material 21. If the waste material 21 is sufficiently
electrically conductive, then electrical current will begin to flow
through the waste material between the electrode assembly 20 and
the hearth 26.
[0026] The series inductor 33, along with any parasitic impedances,
determines the rate at which transient DC current is established
within the waste material. When a steady-state has been reached,
the electrode assembly is withdrawn from the surface of the waste
material 21 in the vertical direction to establish the arc 28a. The
transferred mode of operation provides more efficient transfer of
energy to the waste material 21 than is provided in the
non-transferred mode of operation. Additionally, the transferred
mode of operation also provides physical mechanisms, such as Joule
heating and promotion of electrokinetic chemical reactions, that
contribute to enhanced decomposition and/or pyrolization of the
waste material 21. As noted above, it is necessary for the waste
material 21 to be sufficiently electrically conductive in order to
initiate the transferred arc 28a by contacting the electrode
assembly 20 to the waste material 21. This conductivity requirement
has heretofore limited the benefits of transferred arc
decomposition to the processing of waste material having sufficient
electrical conductivity to establish and maintain conduction
between an electrode and a hearth.
[0027] In order to process material having insufficient electrical
conductivity for contact initiation of a transferred arc, the
electrode assembly 20 can be initially operated in a
non-transferred mode and then switched to a transferred mode of
operation. The detailed procedure by which such sequential
operation is performed depends, in part, upon the composition of
the waste material to be treated and, in particular, upon the
conductivity of the constituents of the waste material at elevated
temperatures. It has been observed that certain materials that are
poor conductors at room temperature, such as soils or waste
materials containing metal oxides, become sufficiently conductive
to establish a transferred arc after having been heated and/or
melted by the non-transferred arc 28. A procedure for treating such
materials may be carried out as follows. Beginning with switch 36
open and switch 38 closed, a non-transferred arc 28 can be
established between the inner electrode 24 and the outer electrode
22. The waste material 21 is then heated by the non-transferred arc
28. When the waste material 21 has been heated to reach a
sufficiently conductive condition, switch 38 can be opened and
switch 36 can be closed. The sudden change in the polarity of the
electrode 24 caused by opening switch 38 and closing switch 36,
combined with the increased conductivity of the heated waste
material 21, favor the formation of a transferred arc 28a. The
transferred arc may extend from within the waste material at one
end of the arc 28a to either one of the electrodes 22 or 24 at the
other end of the arc 28a. Pyrolitic transformation and/or
decomposition of the waste material 21 can then continue in the
transferred mode.
[0028] The point in time at which the heated waste material 21 has
become sufficiently conductive to permit switching from
non-transferred to transferred operation can be determined by
monitoring the ammeter 42 connected between the hearth 26 and the
positive terminal 34 of the power supply 30. During the initial
phase of the sequential procedure, when the electrode assembly 20
is operating in the non-transferred mode, the electrode assembly 20
is lowered to position the arc 28 within a close proximity to the
surface of the waste material 21. As the waste material 21 becomes
conductive, momentary transferred arcing will spontaneously occur
from time to time. Such spontaneous transferred arcing will cause
the ammeter 42 to register momentary bursts of electrical current
supplied from the positive terminal 34 to the hearth 26. When such
momentary increases in current are registered by the ammeter 42,
switch 38 can be opened and switch 36 can be closed under either
manual or automatic control in order to begin sustained operation
of the electrode assembly 20 in the transferred mode.
[0029] During the initial non-transferred phase of the sequential
procedure, the heterogeneous waste material 21 will often melt and
coalesce, as shown in FIG. 1B, into two or more layers, such as
molten layers 21a and 21b, depending upon the relative density of
the constituent components of the waste material 21. If the layers
21a and 21b are sufficiently conductive, the electrode assembly 20
can be switched into the transferred mode as has been described.
More often, however, the conductive metallic constituents of the
waste material 21, such as metals, tend to settle into the lower
layer 21b while the less conductive constituents, such as
refractory oxides and/or organic compounds, tend to accumulate in
the upper layer 21a. The presence of the less conductive
constituents within the upper layer 21a can inhibit the formation
of a transferred arc. In order to establish a transferred arc
between the electrode assembly 20 and the molten waste material in
such circumstances, the electrode assembly 20 can be lowered into
the upper layer 21a of the molten waste material 21. As the
electrode assembly 20 is submerged beneath the surface of layer
21a, the central portion 23 of the non-conductive layer 21a is
vaporized by the non-transferred arc. The electrode assembly 20 can
continue to be lowered until spontaneous transferred arcing occurs
between the negative outer electrode 22 and the conducting layer or
layers 21b in contact with the hearth 26. Then, the electrode
assembly can be switched into the transferred mode.
[0030] An alternative procedure for treatment of a
marginally-conductive bulk waste material having conductive and
non-conductive constituents can be carried out as follows. The
electrode assembly 20 is initially placed in contact with the waste
material 21 while switch 36 is initially open and switch 38 is
initially closed. Electrical current then flows from the inner
electrode 24, through the marginally-conductive waste material 21,
and to the outer electrode 22. The resulting Joule heating, or
I.sup.2R heating, of the waste material 21 causes the waste
material to melt and subsequently to vaporize within the vicinity
of the electrode assembly 20 forming a void 23, as indicated in
FIG. 1B by dashed lines. Also, as the waste material vaporizes, a
non-transferred arc can be initiated between the electrodes 22 and
24. As such melting and vaporization proceed, the electrode
assembly 20 is lowered into the void 23 so that a transferred arc
may be established as previously described. Alternatively, the
electrode assembly may be maintained at its original position if
the upper layer 21a molten waste material becomes sufficiently
conductive to establish a transferred arc.
[0031] In order to operate the electrode assembly 20 in the
non-transferred mode for sustained non-transferred operation, or
during the initial phase of sequential operation, it is necessary
to establish a non-transferred arc between the two electrodes 22
and 24. A non-transferred arc may be ignited or struck by
establishing a voltage between the inner electrode and the outer
electrode and then touching the proximal end of the electrode
assembly 20 to the surface of the waste material 21. If the
separation distance between the electrodes 22 and 24 is small
relative to the depth of the waste material, then the effective
resistance of a conduction path between the two electrodes will be
less than the resistance of a path through the waste material from
the electrodes to the hearth. Thus, a non-transferred arc may be
initiated by contacting the electrodes to the waste material even
if the waste material is not conductive enough to establish
sufficient conduction for transferred arc initiation.
[0032] If the surface of the waste material 21 is not sufficiently
conductive to initiate a non-transferred arc by contacting the
waste material, then other means for striking a non-transferred arc
are necessary. A preferred arrangement for striking a
non-transferred arc in such a circumstance is shown in FIG. 2A. The
arrangement of FIG. 2A allows an electrically-conductive fine
particulate material to be injected into the annular cavity between
the inner and outer electrodes in order to promote formation of a
non-transferred arc.
[0033] Referring to FIG. 2A, the inner electrode 24 preferably
includes a disposable lower portion 24b that is removably attached
to a upper portion 24a, such as by a threaded connection 27.
Similarly, the outer electrode 22 preferably includes a disposable
lower portion 22b that is removably attached to an upper portion
22a by a threaded connection 29. Since each of the electrodes
includes such separable segments, the lower portion of each
electrode may be replaced whenever replacement becomes desirable
due to, for example, deterioration.
[0034] An axial bore 46a is formed within the upper portion 24a of
the inner electrode 24. The lower end of the axial bore 46a
intersects with an angled bore 46b leading to an orifice 47 between
the angled bore 46b and the annular cavity 37 between the inner
electrode 24 and the outer electrode 22.
[0035] The bores 46a and 46b within the inner electrode 24 permit
the introduction of fine particulate material into the annular
cavity as follows. A hopper 49 is provided for containing a
quantity of fine particulate material, such as graphite powder 50.
The lower end of the hopper 49 is connected to a mixing tee 62 via
a valve 58. When a non-transferred arc is to be struck, the valve
58 is momentarily opened and then closed in order to deposit a
fixed quantity of graphite powder into the mixing tee 62. When
valve 58 has been closed, and valve 60 is opened, a solenoidal
valve 56 is opened so that the mixing tee 62 is connected to a
supply of inert gas 52, such as nitrogen, via a regulated gas line
64, to connect the mixing tee 62 to a pipe 66 and to cause the
deposited charge of particulate material to be forcibly swept into
the pipe 66 under pressure provided by the inert gas 52. A length
of tubing 70 is connected at one end to the pipe 66 to receive the
charge of particular material. The other end of tubing 70 is
connected to a tubing adapter 48 that is threaded into the axial
bore 46a.
[0036] When valve 60 is opened, the charge of particulate material
is thus transmitted through tubing 70 and adapter 48 into the axial
bore 46a. The charge of particulate matter then travels through
bore 46b to be expelled into the annular cavity via an orifice 47.
The electrode assembly can be disconnected from the power supply
prior to injecting the conductive fine particulate into the annular
cavity. When this material has been injected into the annular
cavity, the electrode assembly can then be energized after a
sufficient period of time has passed for the particulate material
to be located substantially at the tip of the electrode assembly.
If the electrode assembly has been energized, the resulting
particulate matter introduced into the annular cavity promotes the
formation of a non-transferred arc between the inner electrode 24
and the outer electrode 22. The injected particulate material
drifts downward within the annular cavity, reaching a stable
position at the lower tip of the electrode assembly 20. The
downward drift of the injected particulate suspension may be
enhanced by leaving valves 56 and 60 open for a period of time
subsequent to injection of the charge in order to, in effect, blow
the non-transferred arc into a position at the tip of the electrode
assembly. Since the inner electrode 24 is switchable from a
positive polarity to a negative polarity relative to the outer
electrode 22 during the sequential mode of operation, it is
desirable to provide electrical isolation between the inner
electrode 24 and the several components of the arc ignition system,
such as the hopper 49 and the gas cylinder 52. Such electrical
isolation may be obtained by providing flexible tubing 70 in the
form of an electrically insulating material. It is also desirable
to prevent a conductive path from forming within the tubing 70 due
to any adhesion of the particulate material to the interior wall of
the flexible tubing 70. For this reason, it is preferable that the
flexible tubing 70 be made of a non-adherent material, such as
reinforced silicone or polytetrafluoroethylene, so that adhesion
between the particulate material and the interior surface of the
flexible tubing 70 is minimized. It is also preferable that the
tubing 70 be flexible so that the tubing 70 remains attached to the
connector 48 when the electrode assembly 70 is raised and
lowered.
[0037] An alternative method of striking a non-transferred arc is
illustrated in FIG. 2B. The upper ends of electrodes 22 and 24 are
held within respective annular clamps 72 and 74. The annular clamp
74 is angularly translatable relative to clamp 72, such as by a
suitable pivoting means (not shown). The inner electrode 24 can be
positioned at an angle within the axial cavity of electrode 22,
such that the tip of electrode 24 is in contact with or in
sufficient proximity to the inner periphery of electrode 22 to
establish DC conduction between the inner and outer electrodes. In
this arrangement, the formation of a non-transferred arc is readily
initiated.
[0038] Another alternative arrangement for striking a
non-transferred arc is illustrated in FIG. 2C. In this
configuration, the upper ends of electrodes 22 and 24 are held
within annular clamps 72 and 74, respectively. The annular clamps
72 and 74 are secured to a disc of insulating material 78 so that
the electrode 24 is held coaxially within the electrode 22. The
interior surface of the outer electrode 22 includes an
inwardly-projecting tapered portion 25 so that the annular cavity
between the inner electrode 24 and the tapered portion 25 of outer
electrode 22 is constricted to a relatively small gap at the upper
end of the outer electrode 22. The constriction of the annular
cavity caused by the taper 25 allows a non-transferred arc to be
initiated between the inner electrode 24 and the tapered portion 24
of outer electrode 22 at a relatively lower voltage than would be
possible for a uniformly wide annular separation between the
electrodes 24 and 22.
[0039] In order to position the non-transferred arc at the lower
tip of the electrode assembly, pressurized gas is supplied via
tubing 75 to an internal passageway 76 within the insulating disc
78. The internal passageway 76 terminates in an orifice 79 located
on the interior surface of the insulating disc 78 so that
pressurized gas supplied via tubing 75 causes a pressure
differential within the annular cavity 77 located between the inner
electrode 24 and the insulating disc 78. The resulting pressure
differential within the annular cavity 77 causes the gas to flow
through the gap between the inner electrode 24 and the outer
electrode 22, thus urging the non-transferred arc toward the tip of
the electrode assembly 20. In general, a wide variety of geometric
irregularities may be formed between the outer surface of the inner
electrode and the inner surface of the outer electrode in order to
promote the formation of a non-transferred arc in an equivalent
manner to that described in connection with FIG. 2C. Still other
provisions for striking the non-transferred arc, such as connecting
the electrodes 22 and 24 to a high voltage sparking circuit that is
isolated from the DC power supply, are possible within the scope of
the invention.
DC ARC FURNACE
[0040] The electrode assembly 20 in accordance with the foregoing
description is suitable for operation within a DC arc furnace, such
as the furnace 80 shown in FIG. 3. The upper end of electrode
assembly 20 is attached to a clamping assembly generally designated
114 that is suspended within housing 80a. The electrode assembly 20
extends downward within the housing 80a from the clamping assembly
114 and into a processing chamber generally designated 80b. An
exterior shell 82 surrounds the processing chamber 80b. The shell
82 is preferably made of an electrically-conductive material, such
as a steel. The interior of the steel shell 82 is preferably lined
with several thermally and electrically insulating materials. Such
insulating linings include, for example, a bed of granular
material, such as silica or granite chips 90, filling the lower
portion of the shell 82, a refractory ceramic or clay material 84
lining the midsection of the shell, a refractory facing 88 forming
the interior surface of the furnace, and a refractory vault 104
lining the upper portion of the shell.
[0041] A gas conduit 99a extends from a source of inert gas (not
shown) through the shell 82 and into the granular bed 90. The
conduit 99a is connected to a perforated tubular ring 99b that is
located within the granular bed 90. Prior to operating the furnace,
an inert purge gas can be introduced through conduit 99a into the
ring 99b. The purge gas will then percolate through the
perforations of ring 99b and through the granite bed 90. When the
interstitial spaces within the granular bed 90 are sufficiently
pressurized by the purge gas, the purge gas will then diffuse into
the interior of the furnace through fissures, pores, and the like
within the refractory material 84 and the refractory material 88.
An exhaust port 99c extends from the interior of the processing
chamber to an appropriate external ventilation system for venting
any gases generated during waste treatment while maintaining the
desired non-oxidizing atmosphere within the furnace. In this
manner, the proportion of oxygen within the furnace can be
decreased in order to inhibit oxidation of the graphitic material,
such as the electrodes, during operation of the furnace in the
treatment of waste material.
[0042] A hearth 26 is located in the lower portion of the shell 82.
The hearth 26 is supported upon a layer of refractory material 92
resting upon a supporting plate 94 that is embedded within the
granular bed 90. Electrical contact is made to the hearth 26 via
graphite pegs 96 and 96', respectively, that are embedded in holes
within the hearth 26. The graphite pegs 96 and 96' are connected to
conductive straps 98 and 98' which are preferably flexible to allow
for thermal expansion of the hearth. The conductive straps 98 and
98' are connected to conductors 100 and 100', respectively, which
lead to the exterior of the shell 82 through insulating bushings
102 and 102', respectively.
[0043] In addition to providing mechanical support for the layer of
refractory material 92 and the hearth 26, the supporting plate 94
may be made of a ferromagnetic material in order to provide
enhanced magnetic control and stabilization of the DC arc. Such
magnetic control is desirable to attract and to maintain a
non-transferred arc at or near the tip of the electrode assembly
and to maintain transferred arcs in an area beneath the electrode
assembly and near the center of the hearth. In the absence of such
control, the arc may tend to drift upward within the electrode
assembly during non-transferred operation or to wander during
transferred operation. Upward drift of the non-transferred arc
undesirably decreases the efficiency of heat transfer from the arc
to the waste material. Positional instability of the transferred
arc can contribute to uneven heating of the waste material and
premature erosion of the hearth.
[0044] The presence of the ferromagnetic plate 94 beneath the
hearth causes an attractive force to be exerted upon the arc, thus
stabilizing the arc. This attractive force is generated due to the
interaction of the arc current with the magnetic field of induced
currents within the plate. In order to maximize the stabilizing
influence of the magnetic plate upon the arc, the plate should be
positioned as close as possible to the bottom of the hearth.
[0045] The proximity with which the magnetic plate may be
positioned relative to the bottom of the hearth is limited by the
necessity of retaining the magnetic characteristics of the material
used to form the plate. If the plate is heated to a temperature
above the Curie temperature of the plate, the electromagnetic
stabilization beneficial effect of the plate is adversely
influenced. The magnetic plate is preferably positioned at a
distance below the bottom of the hearth that is sufficient to
maintain the plate below the Curie temperature. In order to satisfy
this thermal condition, while positioning the plate as close as
possible to the bottom of the hearth, one or more layers of
thermally insulating material, such as the refractory material 92,
are preferably interposed between the bottom of the hearth and the
magnetic plate. The required thickness of the refractory material
92 or other thermally insulating layer is determined by the
conductivity of the insulating layer, the desired hearth
temperature, and the Curie temperature of the plate according to
well-known principles of thermal equilibrium.
[0046] The surface area of the magnetic plate may be smaller than
the bottom of the hearth in order to provide a concentration of the
induced magnetic flux near the center of the hearth. For example, a
round magnetic plate with a diameter of 30 inches positioned
beneath a 48 inch diameter hearth would be sufficient to centrally
position an arc beneath an electrode assembly having a 14 inch
outer diameter. The plan surface of the magnetic plate is
preferably of the same shape and size, or even larger than, the
bottom surface of the hearth in order to provide a suitable
mechanical base for the hearth and the intervening layer of thermal
insulation.
[0047] The upper limit of suitable ferromagnetic plate size can be
determined by the size of the furnace shell and the
thermally-dependent dielectric characteristics of the insulating
material, such as the granite chips, surrounding the plate. Since a
high DC potential exists between the hearth and the shell, it is
important to maintain electrical isolation between the hearth and
the shell. During operation of the arc, the insulating material in
contact with the hearth, such as the refractory layer 92, may
become electrically conductive as the temperature is increased. If
the ferromagnetic plate extends laterally from beneath the
refractory material 92 to within a sufficient proximity of the
shell, a conductive path may be established from the hearth,
through the refractory material 92, and then through the
ferromagnetic plate to the shell. Such a conductive path would
cause an undesirable short-circuit between the hearth and the
shell. The size of the ferromagnetic plate should therefore be
selected to leave sufficient insulating material between the
ferromagnetic plate and the shell so that such a short circuit will
not occur. For a furnace shell having an inner diameter of 72
inches, the diameter of the ferromagnetic plate should be
approximately 60 inches or less, so that the circumferential edge
of the plate is separated from the shell by at least 6 inches of
granite chips. The necessary size of the ferromagnetic plate and
the separation between the plate and the shell can thus be
determined by those skilled in the art on the basis of the
particular operating conditions and materials used in various
embodiments of the invention in accordance with the principles made
apparent herein.
[0048] The ferromagnetic plate may also have a central perforation
or hole therein (not shown) in order to further stabilize the arc.
It is believed that such a central hole provides enhanced
stabilization by eliminating eddy currents within the plate that
would otherwise intersect the vertical axis defined by the
electrode assembly and along which axis the arc is desired to be
maintained.
[0049] A material feeding aperture generally designated 95 is
located in the side of the processing chamber 80b. The aperture 95
opens into the processing chamber 80b from a feed chamber 91 in
which waste material to be processed is inserted. Isolation gate
91a is opened as waste material within the feed chamber 91 is
pushed into the processing chamber 80b via the aperture 95 by a
hydraulic pushing mechanism 94. For continuous processing of waste
material, a loading airlock or isolation gate 93 is connected with
the feed chamber 91, so that additional waste material may be
introduced into the feed chamber 91 from time to time while
maintaining an airtight environment within the furnace.
[0050] For continuous removal of molten material from the
processing chamber 80b, a conduit 86 is provided. The conduit 86
leads from the lower portion of the interior of the hearth 26 to an
isolated discharge chamber generally designated 97. Located within
the isolated discharge chamber 97 is a receptacle 89 for receiving
molten waste material from the conduit 86. The conduit 86 is
preferably heated to prevent the molten slag material from
solidifying as it is drained from the hearth 26 to a slag
receptacle 89. The conduit 86 may be heated by, for example,
graphite heating elements within a ceramic muffle surrounding the
conduit. The graphite heating elements can be connected with an
adjustable voltage AC source. Since the atmosphere in the furnace
chamber is non-oxidizing, the graphite heating elements are thus
protected from oxidation. The isolated discharge chamber 97
includes isolation gates allowing the receptacle 89 to be replaced
from time to time, while maintaining an airtight environment within
the processing chamber 80b.
[0051] An additional conduit 86a can be provided for removal of
relatively dense molten materials from the lower portion of the
hearth 26. The conduit 86 allows such material to be discharged
into a collection receptacle 89a that is housed within an isolation
enclosure 97a. A motor driven shaft (not shown) is provided within
the conduit 86a for locating a removable plug (not shown) at the
end of the conduit 86a within the hearth 26 in a known manner.
[0052] Alternative mechanisms for loading and discharging material
from the hearth are possible within the scope of the invention. For
example, an alternative arc furnace may be constructed, wherein the
processing chamber may be separable from the electrode housing so
that molten waste material may be removed from the hearth by
tipping the processing chamber.
[0053] The housing 80a includes several flanged tubular segments
108a, 108b and 108c defining an airtight cylinder, providing
housing 80a, positioned above the processing chamber 80b. The
electrode assembly 20 may be translated along the vertical axis of
the cylinder forming housing 80a. Other ports may be formed in the
electrode housing 80a or in the processing chamber 80b for
introducing and/or removing gases into and/or from the furnace to
maintain an appropriate ambient environment within the chamber. The
tubular segments 108a, 108b and 108c may be individually detachable
from the furnace 80 to provide access to the electrode assembly 20
or the clamping assembly 114 for maintenance or repair. The tubular
segments may be raised or lowered by a hoisting mechanism generally
designated 87 mounted above the housing 80a, so that such access
may be made at any location within the electrode housing 80a.
[0054] The clamping assembly 114 is suspended within the electrode
housing 80a by a cable 112. The cable 112 is connected via pulleys
105a, 105b, 105c and through a conduit 107 to a winch 106. The
winch 106 is preferably sealed relative to the atmosphere external
to the electrode housing 80a, so that no potentially toxic gases
are vented via the conduit 107. The winch 106 can be operated to
raise or lower the clamping assembly 114 within the electrode
housing 80a. Vertically mounted guide rails, such as rails 110 and
110', are positioned, e.g. at 120.degree. intervals, within the
interior periphery of the electrode housing 80a. The clamping
assembly 114 includes rollers, such as roller 120, that ride upon
the guide rails to maintain the vertical alignment of the electrode
assembly 20 within the processing chamber as it is raised and
lowered.
[0055] The clamping assembly 114 is shown in greater detail in FIG.
4. The outer electrode 22 is securely held within a water cooled
clamp 72. The water cooled clamp 72 is connected to a source of
cooling water via connector 142 and hose 148. Cooling water
received into clamp 72 via connector 142 is discharged via a
similar connector 146 to hose 150. The respective cooling water
supply and discharge hoses 148 and 150 also serve as conduits for
electrical cables 35a and 35b, respectively.
[0056] The clamp 72 is secured, such as by bolts (not shown), to
the underside of an insulating disc 124. The insulating disc 124
has a central hole in which the inner electrode 24 is positioned.
The inner electrode 24 is secured within a water cooled clamp 74.
The clamp 74 is fastened to the upper surface of an insulating disc
126, for example by bolts (not shown). Several insulating discs 128
are sandwiched between discs 124 and 126 to provide sufficient
insulation between the clamps 72 and 74 while maintaining coaxial
alignment of the electrodes 24 and 22. Guide wheel mounts, such as
mount 122, are held in place between discs 124 and 126 by tie rods,
such as tie rod 132. The tie rods have threaded ends and are
secured to the bottom surface of disc 124 by nuts. The tie rods
extend vertically through disc 124, guide wheel mounts 122, disc
126, and through an upper insulating disc 130. Nuts are threaded
onto the upper ends of tie rods 132 so that the clamping assembly
114 is held together by a compressive force exerted by the tie
rods. Struts 156 are secured to the upper end of the tie rods 132.
The struts 156 extend angularly upward and inward and are attached
to a hub 158 from which the clamping assembly 114 is suspended.
[0057] The electricity and cooling water may be supplied to the
clamps 72 and 74 through a system such as shown in FIG. 5. Hoses
148 and 150 from clamp 72 are connected with respective couplers
162a and 162b. The couplers 162a and 162b each have an internal
electrical terminal for connecting respective electrical cables 32a
and 32b with conduits 163a and 163b. Conduits 163a and 163b are
extended through the top of the electrode housing via respective
bushings 164a and 164b. The conduits 163a and 163b are connected to
conductor 35 of the electrical supply network at terminals mounted
upon the bushings 164a and 164b.
[0058] The cooling water circuit for clamp 72 operates as follows.
Cooling water is provided via pipe 160. A portion of the cooling
water from pipe 160 is diverted at tee 170 to flow into an
electrical isolating coupler 172. The coupler 172 is a hose coupler
having an internal graphite lining that is grounded in order to
isolate the cooling water supply plumbing from any electrical
currents which may be conducted within the cooling water itself.
The graphite lining of the coupler 172 also protects the upstream
plumbing from electrolytic damage that would occur from such
conduction within the cooling water. The cooling water flows
through the coupler 172 and into a length of insulating hose 174
that provides further electrical isolation of the plumbing supply.
An electrical isolating coupler 176 receives the cooling water from
hose 174. The coupler 176 is connected to conduit 163a which passes
into the electrode housing 80a via feed-through or bushing 164a.
Conduit 163a connects to hose 148 via coupler 162a. Hose 148
supplies cooling water to the clamp 72. Cooling water from clamp 72
returns to coupler 162b via hose 150 and is passed through coupler
162b into conduit 163b which passes out of the top of the electrode
housing 80a via feed-through 164b. The return water is passed
through an electrical isolating coupler 182 connected to a length
of insulating hose 184 and then into a grounded electrical
isolating coupler 186. From the coupler 186, the return water
passes via a tee 188 to drain pipe 190.
[0059] The cooling water circuit for the clamp 74 is similar to
that provided for the clamp 72. Cooling water from supply line 160
passes through tee 170 and into grounded coupler 192, through
insulated hose 194 and coupler 196 into feed-through 198. From
feed-through 198 the cooling water passes through coupler 166a and
into hose 152 which leads to clamp 74. Water returned from clamp 74
arrives via hose 154 and through coupler 166b into feed-through
200. From feed-through 200, the returned water from clamp 74 passes
through coupler 202 into insulating hose 204 and into grounded
coupler 206 from which the returned water passes through tee 188
and into drain pipe 190.
POWER SUPPLY SYSTEM
[0060] During operation of a DC arc, the arc is susceptible to a
variety of transient phenomena. For example, in the decomposition
of hazardous wastes, gases may be expelled from the waste that can
alter the composition of the ionization path between the electrode
assembly and the waste material. In the latter case, the effective
electrical resistance of the arc may be increased or decreased. If
the DC arc is extinguished, it may be re-initiated according to the
procedures discussed previously herein. However, it is desirable to
provide a power supply system that is capable of providing a
controllable constant current to the electrode assembly during arc
transients and supply such current over a relatively broad range of
current. Such control of the current is particularly important in
initiating an electric arc by contacting the electrode to
conductive material. During such contact, it is desirable to limit
the available current so that a short-circuit condition does not
overload the components of the DC power system.
[0061] Several suitable transient-resistant DC power supplies are
disclosed in U.S. Pat. No. 4,461,010, issued Jul. 17, 1984, and
such disclosure is incorporated herein by reference. The '010
patent discloses several circuits wherein a linear reactor is
placed in series with the secondary terminals of a three-phase
transformer. The linear reactor is connected in series to a
three-phase diode rectifier, which provides a DC voltage and
current to an arc furnace. In the last-mentioned arrangement in the
'010 patent, the power to the DC arc may be mechanically adjusted
according to the separation distance between the arcing electrodes.
In the practice of the present invention, it has been found
desirable to provide a range of control of the power to the DC arc
in order to facilitate consistent DC arc power independent of the
length of the arc.
[0062] It has also been found desirable to be able to adjust the
power to the arc, where the arc in the furnace may be constant
length. The ability to maintain a consistent power level to an arc
of variable length is particularly desirable for operating the arc
in the transferred mode, wherein the level and composition of the
treated waste material varies during treatment. In contrast, in
operation with constant arc length, it is particularly desirable
during any non-transferred mode of operation, to maximize the power
transferred to the waste material, so that any insulating layer,
which may have been formed at the surface of the waste material,
may be made molten and/or vaporized prior to establishing a
transferred arc.
[0063] To facilitate the above power requirements, there is shown
in FIG. 6A a DC power supply circuit 30a that is capable of
providing variable electrical power to a constant length arc while
maintaining a constant current supply to the arc during transient
conditions. In FIG. 6A, A three-phase AC power source 208 is
connected by conductors 210a, 210b and 210c to the primary
terminals of a three-phase transformer 212. The secondary terminals
of transformer 212 are each connected in series by conductors 214a,
214b and 214c to variable reactors 216a, 216b and 216c,
respectively. The variable reactors are connected, in turn, to a
three-phase rectifier 220, which is preferably a diode rectifier
providing a positive DC output at terminal 224a and a negative DC
output at terminal 226a.
[0064] In order to provide effective control of the power to the DC
arc over a wide operating range, it is desirable that the variable
reactors 216a, 216b and 216c provide a variable inductance over a
relatively large range of inductance values. Such a large range of
variable inductance is attainable by utilizing adjustable reactors
of the type wherein the leakage inductance between two movable
coils may be varied. An arrangement for providing a suitably large
range of variable inductance for the variable reactor 240 is shown
in FIG. 7. In this arrangement, the variable reactor 240 includes
cores 242 and 244, which comprise solid laminated magnetic cores.
Switches 250a, 250b, 252a and 252b are connected as shown so that
the coil 246 or core 242 may be electrically configured to have a
positive or a negative mutual inductance. When switches 250a and
250b are closed and switches 252a and 252b are open, the flux
linkage between the magnetic cores 242 and 244 will be additive.
When switches 250a and 250b are open and switches 252a and 252b are
closed, the current within coil 248 is reversed with respect to the
current within coil 246, which causes an opposing flux linkage
effect between the magnetic cores 242 and 244. The ability to
select and vary the additive or opposing effects of the mutual
inductance for the variable reactors facilitates varying the
resistance over a wider range than available in prior hard wired
configurations.
[0065] It is also possible to provide such variable coupling
between the primary and secondary coils of the three-phase
transformer in the power supply system, thus eliminating the need
for separate variable reactors in series with the secondary
windings of the three-phase transformer. This latter alternative is
shown in FIG. 6B, wherein the power supply system 30b includes a
three-phase power supply 208 connected to the primary windings of a
variable leakage-coupled transformer generally designated 254. The
primary and secondary windings within the transformer 254 may be
variably coupled, as described in connection with the series
reactors shown in FIGS. 7a and 7b. When configurations of the type
disclosed in FIGS. 7A or 7B are utilized for the windings of the
variable transformer, the windings upon each of the movable cores
are connected to respective individual terminals so that each pair
of movable cores provides one primary leg and one secondary leg of
the transformer 254 as shown in FIG. 6B. The secondary terminals of
transformer 254 are connected to a three-phase rectifier generally
designated 220, as shown in FIG. 6B, so that a positive DC voltage
is provided at terminal 224b and a negative DC voltage is provided
at terminal 226b.
IN SITU VITRIFICATION OF CONTAMINATED SOILS
[0066] The electrode arrangements and the power supply systems,
according to the foregoing description, can also be used
independently of a DC arc furnace system for in situ vitrification
and remediation of contaminated soils. A dual mode electrode
pyrolysis system may be assembled and operated in situ at a
contamination site, as indicated in FIG. 8A.
[0067] A borehole generally designated 272 is formed within the
ground 270 at a site of soil contamination. The borehole may be
formed by any of the drilling techniques well-known in the art and
obviously have a diameter larger than that of the electrode
assembly 20. The borehole 272 extends into the ground 270 to a
depth commensurate with the depth of soil contamination. A suitable
support structure 274 is located above the borehole 272 for
supporting electrode assembly 275 within the borehole. The support
structure 274 may be coextensive with a drilling derrick or other
apparatus used to form the borehole 272. Alternatively, the support
274 may be a transportable structure adapted to transport the
electrode assembly to a site. The support 274 also is preferably
adapted to support associated array of electrical connections for
operation of the electrode, which may be configured as shown and
described in regard to electrode 20 in FIG. 3.
[0068] The support structure is preferably provided with suitable
means for raising and lowering the electrode assembly 275 within
the borehole 272. A cable 112 is connected to the electrode
clamping assembly 277 and passes over a pulley 276 to a winch 278.
Electrical supply means for supplying electric power and for supply
means for supplying cooling water to the assembly may be provided
in a conventional manner within a utility structure 280, such as a
trailer or other temporary structure, that can be transported to
the remediation site.
[0069] For the remediation of soils containing toxic contaminants,
the electrode support structure 274 may preferably include a
substantially airtight shell that is connected to the utility
housing 280 by a conduit system 282. In such an application, the
utility housing 280 can include well-known equipment for reducing
noxious components of any gaseous emissions. One advantage of
performing in situ soil vitrification in accordance with the
present invention is that vitrification of contaminated soils and
pyrolysis of toxic contaminants can be conducted at subsurface
depths sufficient to allow condensation of noxious gases as they
rise from the bottom of the borehole 272 and come into contact with
the relatively cool walls of the borehole while existing the
hole.
[0070] After the borehole has been formed and the support structure
has been assembled at the site, the electrode assembly 275 is
lowered into the borehole 272 as shown in FIG. 8A. Preferably, a
non-transferred arc is struck and the arc is positioned at the
lower tip of the electrode assembly as has been described in
connection with FIGS. 2A-2C. If the soil at the bottom of the
borehole is not sufficiently conductive for contact arc initiation,
a starter material, which includes conductive constituents, may be
introduced into the borehole prior to or during insertion of the
electrode assembly into the borehole. The non-transferred arc can
then be struck by contacting the tip of the electrode assembly with
the conductive starter material.
[0071] In operation, after the non-transferred arc has been
established at the tip of the electrode assembly, a volume of soil
286 in the vicinity of the tip of the electrode assembly 275 may be
heated to form a molten pool at the bottom of the borehole 272.
Once the pool of molten material has been established, the
electrode assembly 275 is slowly raised in the borehole 272 toward
ground level by the winch 278 while the non-transferred arc is
maintained between the electrodes of the electrode assembly. As can
be seen in FIG. 8B, the raising of the operating electrode assembly
20 in the vertical direction toward ground level causes the soil
adjacent to the borehole to melt and to converge into the borehole,
thus forming a vitrified column 290 within the original
borehole.
[0072] Depending upon the nature and composition of the soil 270,
the vitrified column 290 may not adequately fill the borehole, so
that it may be desirable to deposit additional filler material into
the borehole 272 by dropping it through the annular cavity 288
between the inner and outer electrodes of the electrode assembly
20. Such filler material may be introduced into the annular cavity
28 in a manner similar to the particulate injection procedure
discussed in connection with FIG. 2A. Of course, the filler
material may be introduced into the borehole 272 in a variety of
ways depending on the configuration of the borehole and the
configuration of the electrode assembly. It should also be
appreciated that the filler material may include various agents for
altering the physical and/or chemical properties of the soil, such
as its melting temperature, the viscosity of the molten soil, the
conductivity of the melt, and the like.
[0073] For treatment of relatively isolated or limited areas of
soil contamination, a single vitrified column formed within a
borehole may suffice to remediate such limited areas of
contamination. However, if the contamination is spread over a
relatively large area, then in situ vitrification in accordance
with the invention may be carried out by simultaneously operating
electrodes in a plurality of adjacent boreholes in the contaminated
area. By selecting a sufficiently close spacing between adjacent
boreholes, the individual vitrified columns formed within adjacent
boreholes may coalesce to form a composite subterranean mass of
vitrified material over the area between the boreholes. To reduce
the time required for such remediation in a relative large area, a
system of a plurality of electrodes operating in adjacent boreholes
to simultaneously vitrify the soil is shown in FIG. 9.
[0074] In the arrangement of FIG. 9, it is desired to solidify the
contaminated soil associated with each borehole or to create a
subterranean vitrified mass or barrier around the area of
contaminated soil to prevent migration of the contaminants through
the barrier. Alternatively, such a subterranean barrier may be
formed to surround an area of non-contaminated soil, in order to
prevent migration of contaminants into the area of non-contaminated
soil.
[0075] As shown in FIG. 9, adjacent boreholes generally designated
302a, 302b and 302c are formed in the ground 301. Electrode
assemblies 303a, 303b and 303c are inserted into respective
boreholes 302a, 302b and 302c in a manner as described in regard to
FIG.8A. Each of the electrode assemblies 303a-c is associated with
an independent DC power supply 300a-c, respectively. The power
supplies 300a-c are each connected with their respective electrode
assemblies through switching networks that allow each electrode
assembly to be operated in transferred and non-transferred modes as
described previously in connection with FIGS. 1A-B.
[0076] After the electrode assemblies 303a-c are lowered into their
respective boreholes 302a-c, their associated switches 308a-c and
306a-c are closed for preferably non-transferred operation of each
of the electrode assemblies. Non-transferred operation is
maintained for a sufficient amount of time to form a molten pool at
the bottom of each of the boreholes 302a-c. The electrode
assemblies 20a-c are then slowly withdrawn from the boreholes
302a-c while maintaining non-transferred operation in order to
produce adjacent columns of vitrified material.
[0077] Depending on the distance of separation between the
boreholes 302a-c, the individual columns may coalesce as the
electrode assemblies are slowly withdrawn. Such coalescence of
adjacent columns of molten material can be enhanced by operating
the electrode assemblies 303a-c in the transferred mode.
[0078] The transferred mode of operation may be established by
configuring the power supplies 300a-c such that the DC polarity of
each electrode is reversed with respect to each adjacent electrode.
Alternatively, a plurality of electrodes in adjacent boreholes may
be operated in a DC non-transferred mode while AC potentials are
applied between the outer electrodes of adjacent electrode
assemblies so that material within each borehole is heated
primarily by the non-transferred arc while material between
adjacent boreholes is heated by the transferred AC current between
electrode assemblies.
[0079] It should be appreciated that after the electrode assemblies
303a-c are lowered into the boreholes and have begun operating in a
non-transferred mode for a sufficient period of time, the soil
separating the boreholes may become heated and sufficiently
conductive to allow transferred operation. Additionally, conductive
material may be added to the molten pools in the boreholes to
enhance conductivity between adjacent boreholes. When conduction
has been established between adjacent boreholes, a transition to
transferred operation may be made as follows. Switches 308a, 306b
and 308c are opened and switches 310a, 310b and 310c are closed so
that the inner and outer electrodes of electrode assemblies 303a
and 303c are connected with a positive DC potential while the inner
and outer electrodes of electrode assembly 303b are connected with
a negative potential. A transferred arc will then be established
between the interior surface of each borehole and the tip of each
electrode assembly 303a, 303b and 303c. The transferred mode of
operation established within each borehole will enhance the
tendency of the vitrified material 304 formed in the boreholes to
coalesce into a unitary or composite mass across the area treated
by the system.
[0080] After transferred mode of arc operation has been established
in each of the boreholes, the electrode assemblies are maintained
in a transferred mode while being slowly raised within their
respective boreholes. As indicated in FIG. 9, the above described
operation of the system has been found to result in the coalescence
of the fused columns formed within each of the boreholes to form a
solid mass of vitrified material, designated 304.
[0081] As previously mentioned, an alternative method of promoting
coalescence of adjacent columns of molten soil is carried out by
maintaining a non-transferred DC mode of operation within each
borehole while establishing an AC potential between the outer
electrodes of the electrode assemblies within adjacent boreholes.
In this arrangement, an AC power supply system 306 may be connected
to the outer electrodes of each of the electrode assemblies 303a-c.
As shown in FIG. 9, three-phase AC power is supplied from an AC
power source 308 to the primary terminals of a three-phase to
two-phase transformer assembly, such as a Scott-T connected
transformer bank 310. The secondary terminals of the transformer
310 provide one two-phase AC potential between conductors 312a and
312b and another two-phase AC potential between conductors 312b and
312c. Conductors 312a, 312b and 312c are connected with the outer
electrodes of electrode assemblies 303a-c, respectively, through
switches 314a-c, respectively. The switches 314a-c are initially
held open while the electrode assemblies 303a-c are lowered into
their respective boreholes and the electrode assemblies are started
in a DC non-transferred mode of operation, as previously described.
After the electrodes 303a-c have begun to operate in a DC
non-transferred mode, the switches 314a-c may be closed to
establish AC conduction between adjacent boreholes in order to
promote coalescence of the material therebetween.
[0082] The principles of operating the plurality of adjacent
electrodes for in situ vitrification described in connection with
FIG. 9 can be extended to an arbitrarily large number of electrodes
and electrode configurations other than the concentric electrode
configuration shown, may be employed, as would be apparent to those
skilled in the art having read the disclosure herein. The ability
to create an arbitrarily long subterranean barrier of fused
vitrified columns facilitates the construction of subterranean
containment. Also, subterranean contaminants can be formed to
encircle contaminated areas and to prevent migration or leaching
beyond the barriers by such subterranean containments. A
subterranean containment is indicated as having been formed in FIG.
10A. As shown in FIG. 10A, contaminated soil is located beneath an
area 320 of the surface. A plurality of boreholes 322a are
indicated as having been drilled into the ground 318 about the
perimeter of contaminated area 320. Electrode assemblies (not
shown) may be operated within the perimeter boreholes 322a in order
to form vertical barriers, such as walls 324 and 324' of fused,
vitrified soil columns. These fused columns prevent contaminants
from migrating beyond the boundary defined by the columns. The
depth of the boreholes 322a preferably extends into the ground 318
below the depth at which the contamination has been determined to
extend. The boreholes 322a may extend significantly deep relative
to the contamination to reach a suitably stable subterranean
geological formation capable of preventing the contaminating
material from migrating outward beneath the vertical barriers 324,
324'.
[0083] Alternatively, an additional set of boreholes 322b may be
formed within the area 320 in an array such that the entire area
320 is perforated by boreholes extending into the ground 318.
Electrode systems (not shown) may be operated within the interior
boreholes 322b so that molten pools of material at the bottom of
the boreholes 322b may be fused together to form a bottom barrier
326. The bottom barrier designated 326 may be formed before, after
or during the formation of the vertical barriers 324 and 324', so
that the vertical barriers 324, 324' are fused with the bottom
barrier 326, thus forming a subterranean containment structure in
the shape of a vessel. If it is desired to completely transform the
contaminants within the soil into a complete vitrified mass, rather
than simply containing the contaminated area, the electrodes
inserted into the interior boreholes 322b may be operated during
the entire withdrawal operation that the soil is fused into a
single solid vitrified block.
[0084] In the event that it is desired to reduce the number of
boreholes in forming an underground containment for contaminated
soil, an alternative borehole strategy may be employed, such as
indicated in FIG. 10B. In this arrangement, boreholes 322a are
drilled into the soil 318 about the periphery of the contaminated
area in order to form peripheral barrier walls 324 and 324'
surrounding the contaminated area. A bottom 334 connecting the
peripheral barrier walls may be formed by employing a series of
boreholes 330 drilled on a slant into the ground 318 beginning at a
location outside of the perimeter of the contaminated area. The
boreholes 330 are drilled in such a way as to have a horizontal
extending component, so that the holes extend diagonally down
beneath the barrier walls. Electrodes may then be inserted into the
diagonally extending boreholes 330 and operated as previously
described to form the bottom barrier 334 of the containment, which,
when completed, is in the form of a vessel.
[0085] It is should be appreciated that the methods of producing a
vitrified subterranean formation, such those disclosed above, will
find wide use in various applications in addition to containment of
waste material. For example, such methods can be employed in the
construction industry to provide a sound footing or foundation
pilings at locations where the soil is not mechanically competent
or sufficiently stable to provide suitable footing for supporting
structures.
[0086] In regard to a construction application for the invention,
there is shown in FIG. 11A a region of soil 400 into which a
borehole 402 is formed. An electrode assembly 404, in accordance
with the invention, is inserted into the borehole 402 and is
suspended therein by a suitable support member 406. The support
member 406 includes means for supplying electrical power and
cooling water to the electrode assembly 404 as previously described
above in regard to other embodiments of the invention. The support
member 406 is connected with a suitable hoist (not shown) for
raising and/or lowering the electrode assembly 404 within the
borehole.
[0087] The electrode assembly 404 is lowered into the borehole 402
until it is adjacent to the bottom of the borehole 402. Then the
electrode assembly 404 is energized to vitrify the soil at or near
the bottom of the borehole forming a vitrified mass 408. The
electrode assembly 404 may be raised within the borehole 402 during
formation of the vitrified mass 408 in order to increase the
vertical extent of the vitrified material. Additional materials,
such as clay or other glass-forming substances, can be introduced
into the borehole prior to, or during, the vitrification process
404. The use of such additional materials is particularly desirable
for practicing the method in soil which is unsuitable for forming a
mechanically competent base for supporting pilings.
[0088] After the vitrified mass 408 has been formed at or near the
bottom of the borehole 402, the electrode assembly 404 is removed
from the borehole. Then, as shown in FIG. 11B, a piling 414 is
driven into the borehole until it contacts and adequately anchored
to the vitrified mass 408. If the piling 414 has a diameter that is
smaller than the original borehole, filler material 412 can be
introduced into the annular space 410 between the exterior of the
piling 414 and the interior of the borehole in order to provide
lateral support for the piling 414.
[0089] In loose soil, or in soil that is otherwise not suitable for
maintaining a vertical borehole, it may be desirable to provide a
mechanical support column during formation of the vitrified mass at
the bottom of the hole. Referring now to FIG. 12, there is shown a
region of soil 416 in which a borehole 418 has been formed. A
mechanical support, such as a metallic sheath 420, is inserted into
the borehole in order to provide a working shaft for electrode
assembly 422. The metallic sheath 420 may comprise one or more
connected tubular segments that can be raised or lowered within the
borehole using standard techniques known in the drilling art. The
electrode assembly 422 is suspended within the metallic sheath 420
and is supplied with electrical power and cooling water through a
conduit in support member 424.
[0090] After the electrode assembly 422 has been positioned
adjacent to the bottom of the borehole, the electrode assembly is
operated to vitrify the soil at or near the bottom of the borehole.
Additional glass-forming material, such as clay, can be added to
the borehole prior to, or during, the vitrification process. After
vitrification is accomplished, the electrode assembly is removed
from the hole. The metallic sheath may also be removed from the
hole. A piling (not shown) can then be driven into the hole.
Alternatively, the metallic sheath may remain in the hole in order
to provide further lateral support for the piling.
[0091] If additional lateral support is desired, the metallic
sheath 420 can be used to vitrify the surrounding exterior of the
borehole. If such vitrification is desired, one terminal of the
power supply 428 is connected to the metallic sheath 420. The other
terminal of the power supply is connected, by an earth electrode
430, to the adjacent soil 416. When power is supplied to this
connection, the soil in the vicinity of the metallic sheath is
vitrified. If desired, additional glass forming material can be
inserted into the annular space 429 between the metallic sheath and
the interior of the borehole prior to operating the power supply
428.
[0092] To provide an extensive subterranean support for piling
construction, multiple vitrification systems can be operated to
form an extensive support arrangement in accordance with the
principles discussed in connection with FIG. 9 and FIGS. 10A and
10B. In embodiments wherein metallic supporting sheaths are
employed, an electrical potential can be applied across adjacent
metallic sheaths in order to vitrify the soil therebetween.
[0093] In summary in regard to the inventive concepts herein, the
terms and expressions, which have been employed, are used as terms
of description and not of limitation. There is no intention in the
use of such terms and expressions of excluding any equivalents of
the features shown and described, or portions thereof. From the
above description, it will be appreciated that the invention herein
may be embodied in a large variety of forms different from the ones
specifically shown and described without departing from the scope
and spirit of the inventive concepts as defined by the appended
claims.
* * * * *