Partnership with FLS on Testing & Analysis

Testing is available through our partnership with FLSmidth. Capabilities and Unit Operations at FLS Whitehall R&D include the following:

  • Pyroprocessing:
    • Rotary Systems (Kiln, Dryers)
    • Gas Suspension System (Calciners, Dryers)
    • Fluidized Beds (Dryers, Inert Bed)
    • Packed Bed
    • Combustion Chambers
  • Crushing/Milling
    • Ball and Vertical Mills
    • Classifier
    • Crushers (Jaw, Roll, “Abon”)
    • Bond Testing (Ball, Abrasion, Impact)
  • Chemical Assays
  • Physical Properties
  • Gaseous Emissions

Available Unit Operations

  • 0.3m x 4.6m Rotary Kiln
    • Refractory Lined
    • Capacity: 15-35 kg/h
    • 1450°C Maximum
    • Solids Residence Time: 0.5-3 hours
    • Fuel: gas, liquid, solid
    • Adjustable Speed/Slope
    • Onboard Air or Fuel Injection
  • 0.9m x 15.2m Rotary Kiln
    • Refractory lined
    • Capacity: 100-250 kg/h
    • 1450°C maximum
    • Solids residence time: 0.5-5 hours
    • Fuel: gas, liquid, solid
    • Adjustable speed
    • Onboard air or fuel injection
    • Sub- or super- stochiometric firing
    • Precalciner & cyclone preheating
    • Bag filter, wet scrubber, & ID fan
  • 0.46m x 3.7m Rotary Dryer
    • Stainless steel
    • Capacity: 100-250 kg/h
    • Maximum inlet temperature: 1200°C
    • Solids residence time: 10-45 minutes
    • Fuel: gas, liquid, solid
    • Bag filter & ID fan
  • 0.15m Flash Dryer
    • Stainless steel
    • Capacity: 25-100 kg/h
    • Maximum gas outlet: 700°C
    • Gas residence time: 0.5-1 seconds
    • Collection cyclone
    • Bag filter
    • Fuel: gas, liquid, solid
  • 0.3m x 1m Batch Rotary Kiln
    • Refractory lined
    • Capacity: 5-15 kg
    • Maximum: 1450°C
    • Fuel: gas
    • Atmosphere: oxidizing or reducing
    • Online sampling
  • 0.075m Flash Calciner
    • Stainless steel
    • Capacity: 2-10 kg/h
    • Maximum 1150°C
    • Gas residence time: < 1 sec.
    • Multi-stage fuel injection
    • Fuel: Propane
    • Bag filter & ID Fan
  • 0.15m Flash Calciner
    • Refractory Lined
    • Capacity: 10-25 kg/h
    • Maximum: 1550°C
    • Gas residence time: 1.5-2.5 sec.
    • Multistage fuel injection
    • Fuel: gas, liquid, solid
    • Collection cyclone, bag filter, & ID fan
  • 0.35m 3-Stage Flash Calciner
    • Refractory Lined
    • 2 Preheat cyclones
    • Capacity: 100-250 kg/h
    • Maximum: 1450°C
    • Gas residence time: <1.5s
    • Multistage fuel injection
    • Fuel: gas, liquid, solid
    • Bag filter, wet scrubber, ID fan
  • 0.61m Flash Calciner
    • Refractory Lined
    • Up to 3 preheat cyclones
    • Capacity: 200-500 kg/h
    • Maximum: 1450°C
    • Gas residence time: < 1.5 sec.
    • Multistage Fuel Injection
    • Fuel: gas, liquid, solid
    • Bag filter, wet scrubber, ID Fan

Material Preparation Unit Operations

  • Packed Bed Preheater
  • 1m x 1.5m Dry Grinding Ball Mill
    • Single compartment
    • Open- or closed-circuit operation
    • Capacity: 100-300 kg/h
    • Dynamic classifier
    • Bag filter, ID fan
  • Low-Speed Sizer (Abon)
  • Hammer Mill Dryer
  • Agglomeration
    • Disc pellitizers
      • 0.3m: 2-10 kg/h
      • 1m: 25-100 kg/h
    • Extruder
      • 50-150 kg/h
      • 5 die options
    • Pin pelletizer
      • 25-100 kg/h

Analytical/Laboratory

  • Physical Analyses
    • Bulk density
    • Angle of repose (AOR)
    • Specific gravity
    • Moisture & drying rate
    • Particle size: Sieve, “Air Jet”, & laser
    • specific surface area (BET, Blaine)
    • Lime hydration reactivity (ASTM & GOST)
    • Limestone strength
    • Bond ball mill grindability
    • Bond crushability
    • Unconfirmed compressive strength
    • Abrasion index
    • Furnace sticking tests
    • Fluidization analysis
  • Chemical Analyses
    • Elemental
      • Atomic Absorption
      • X-Ray Fluorescence (fused bead, pressed pellet, or powder)
    • Lithium acid and water solubility
    • Vanadium water solubility
    • Sulfur speciation and removal
    • Organic and inorganic carbon
    • Available CaO (ASTM & GOST)
    • Nickel speciation
    • Iron speciation
    • Chrome metallization
    • Total phosphorus and reactivity
    • Laboratory emissions analysis (including FTIR)
  • Lab Furnaces
    • Tube furnaces (1250°C max.), 2x
    • Muffle furnace (1200°C), programmable
    • Fast heat-up furnace (1400°C max.), programmable
    • Smelting furnace (1700°C max.)
    • Electric rotary tube furnace (3-zone, 1450°C max.)