System and method for powder processing

Abstract

The present invention may comprise processes, methods, and systems for powder processing aimed at and characterized in reduction of adsorbed gases, vapors, particulates, and moisture through high-temperature vacuum out-gassing by disintegrating the powder bulk or flow into separate particles. Heat may be transferred to powder particles in vacuum by multiple interactions during intimate contact with heated metal balls within a tube or other container serving as a reaction vessel.

1 . An apparatus for flowing a particulated material through a mass of a solid material, comprising:
 a reaction vessel with an exterior surface and an interior space;   a plurality of metal spheres packed into the interior space of the reaction vessel, packed to a volumetric proportion of about 50% to about 60% between an upper inlet of the reaction vessel and a lower outlet of the reaction vessel;   wherein the reaction vessel is compressed with the plurality of packed metal spheres inside the interior space of the reaction vessel to a volumetric proportion of about 70% to about 80% such that the plurality of metal spheres does not flow in relation to the interior space of the reaction vessel;   an upper inlet in fluid communication with the reaction vessel; and   a lower outlet in fluid communication with the reaction vessel and the upper inlet.   
     
     
         2 . The apparatus of  claim 1  wherein the reaction vessel is sealed under vacuum. 
     
     
         3 . The apparatus of  claim 1 , wherein the plurality of metal spheres comprises nubs. 
     
     
         4 . The apparatus of  claim 2 , wherein a vibrating agitator directly engages a vertical shell of the reaction vessel while a vacuum connector is in pressure communication with the interior space of the reaction vessel and in pressure communication with a vacuum pump. 
     
     
         5 . The apparatus of  claim 4 , wherein a feed pipe feeds metal powder to enter into the vertical shell of the reaction vessel through a top closure assembly. 
     
     
         6 . The apparatus of  claim 5 , wherein a top vacuum pump is connected to the feed pipe via an upper vacuum connector. 
     
     
         7 . The apparatus of  claim 6 , further comprising an upper shutoff valve in fluid communication with the feed pipe. 
     
     
         8 . The apparatus of  claim 4 , further comprising a purge conduit for purging out gases or to feed gases or other substances into the reaction vessel. 
     
     
         9 . A method for processing flowing material, comprising:
 adding a plurality of metal spheres packed into an interior space of a reaction vessel, packed to a volumetric proportion of about 50% to about 60% between an upper inlet of the reaction vessel and a lower outlet of the reaction vessel;   compressing the reaction vessel in a direction towards the interior space of the reaction vessel, wherein the metal spheres obtain contact surfaces with other metal spheres and contact surfaces with an interior surface of the interior space of the reaction vessel and provide due to these contact surfaces thermal conductivity for heat transfer from the exterior of the reaction vessel;   submitting the reaction vessel to an interior vacuum;   transferring heat from an exterior of the reaction vessel towards the interior space of the reaction vessel;   transferring heat from the exterior of the reaction vessel to the plurality of metal spheres;   flowing powder material into the reaction vessel under gravity and vibration;   flowing powder material through the interior of the reaction vessel under gravity and vibration in intimate contact with the plurality of heated metal spheres;   wherein the flowing powder material is dispersed into an array of separated particles;   wherein the flowing metal powder particles are urged to move under the gravity and vibration along the serpentine paths between the compressed balls, defined by the metal powder cascading to the bottom of the reaction vessel;   wherein the separated particles are heated from multiple contacts with the heated spheres;   wherein the heated particles are outgassed in the vacuum of the reaction vessel through physical and chemical desorption from the particles' surfaces; and   removing the powder material particles out of the lower outlet of the reaction vessel into the evacuated bottom container that is then backfilled with inert gas.   
     
     
         10 . The method of  claim 9 , wherein the plurality of metal spheres are steel spheres. 
     
     
         11 . The method of  claim 9 , wherein the plurality of metal spheres is made nubbed to increase the conductivity and the contact areas with the flowing powder. 
     
     
         12 . The method of  claim 9 , wherein the metal spheres are compressed to a volumetric proportion of about 70% to about 80% such that the plurality of the metal spheres does not flow in relation to the interior space of the reaction vessel and to maintain both the conductivity and the flow of powder particles through the plurality of packed spheres. 
     
     
         13 . The method of  claim 9 , wherein the total volume of the flowing powder material placed into the reaction vessel is between about 16% to about 25% of the volume of the heated spheres compressed within the reaction vessel. 
     
     
         14 . The method of  claim 9 , wherein the external heater of the reaction vessel heats the plurality of compressed spheres and the powder from about 400 degrees Fahrenheit to about 1,200 degrees Fahrenheit (about 204 degrees Celsius to about 649 degrees Celsius) through the multiple interactions of the particles with the plurality of heated balls. 
     
     
         15 . The method of  claim 9 , wherein for highly contaminated powders the process is repeated by installing the receiving bottom container with powder return flow into an inlet of the reaction vessel for recycling the processed powder for additional processing. 
     
     
         16 . The method of  claim 9 , wherein the compressing the reaction vessel in a direction towards the interior space of the reaction vessel is performed by HIP (Hot Isostatic Pressing) at a low temperature of from about 900 degrees Fahrenheit to about 1,200 degrees Fahrenheit (from about 482.22 degrees Celsius to about 648.89 degrees Celsius) so that contact surfaces are formed between the balls and the outer layer of the balls, the balls indented with the inner surface of the tube from the compression so that the wall “embraces” the outer layer of the balls. 
     
     
         17 . The method of  claim 7 , wherein the HIP cycle is followed by the removal of the upper lid of the reaction vessel and the densified system of the metal balls is further processed either in a HIP cycle or in a vacuum sintering furnace at a temperature of from about 2,000 degrees Fahrenheit to about 2,200 degrees Fahrenheit (from about 1.09 degrees Celsius to about 1,204 degrees Celsius) to provide diffusion bonding between the balls.