DE10230814A1 - Synthetic fuel comprising coal dust, water and a reactive organic compound and a method for producing such synthetic fuel - Google Patents

Abstract

The present invention relates to a synthetic fuel made from coal dust, water and an organic chemical reactive with the coal dust to form a chemical bond with the coal dust when compacted to give a product which Coal is very similar. Surprisingly, the product according to the invention in some cases provides a higher BTU value than coal alone (up to 5 to 1000 BTUs per ton more than coal), does not produce the waste ash of inorganic chemicals (and many organic chemicals such as tar) in the Device of the user and can solve a moisture problem of coal dust and even gives an increased green strength.

Description

FIELD OF THE INVENTION

The present invention relates to a synthetic fuel, too referred to as synthetic coal. These fuels are suitable for providing higher BTU levels for fuel users, most often electrical utilities. The The fuels involved also meet all the requirements of Heading 29 of the Internal Tax Code.

BACKGROUND OF THE INVENTION

Coal has been a commercially important fuel since the early 19th century. Appropriately processed, coal is and is an excellent, high BTU supplier relatively cheap due to the fact that it is readily available in the United States. Coal is relatively abundant in the environment, but its chemical The composition varies from deposit to deposit and from state to state.

From the earliest days of the U.S. coal mine industry (to the present day) Days) has the crushing of the coal, which is carried out by miners on the miner's head coal dust is achieved (or more recently within the mine itself) as a waste product generated. On average, about 5% of the total coal extracted does not become such usable waste. This dust is not wanted by traditional coal customers cannot be shipped without expensive containment equipment and, unlike that, can Slag waste from metal processing not as a hill of slag waste of the type be stored, which surrounds steel, iron or smelting plants. Coal dust is a very fine powder, and a pile of such dust is easily made by even small ones Distributed wind speeds.

Another method had to be found in the 19th century to get the waste control, and the method then chosen remains the method of choice in the 21st Century. For more than 100 years, the process of removing coal dust has been the most Creation of sometimes natural, more often artificial water lakes in which the coal dust was unloaded. The moisture in the water coagulates the dust and prevents it Blow away. Over time, these lakes have become known as coal "lagoons" - it will estimated that there are over 1,000 square miles of such lagoons in America, some of which most are close to mining communities. You are concentrated in Coal mine areas and particularly in the states of Ohio, W. Virginia, Alabama, Pennsylvania, Virginia and to a certain extent Wyoming and the Dakotas.

Lagoons are essentially dead, unused space for fish and recreation is hostile, and ugly reminders of America's past. Coal dust itself also very harmful to humans. It is the trigger of black Lung disease, dirty living and working conditions and is toxic to people, animals and Fish.

A few decades ago it was first realized that the existing coal lagoons in Rivers, streams and city water supplies seep through, and that such seepage mostly could not be stopped. Also drying out lagoons, a much more common one Phenomenon once considered possible now often results in "black dust" storms, which damage existing structures and machinery and the quality of life in Mining communities affect.

In response to the above, senators from the most affected states changed, with considerable support from senators from other countries where citizens have worked, to establish an environmental movement, the Internal Tax Code in the late 90's Years. The law now provides a tax loan of around $ 25 to around $ 28 each Tonne for companies using synthetic fuel products Develop and sell coal dust. This amount is significant as it is in addition to the Sales price for the product is what such companies charge their customers can if the synthetic fuel product they are developing with natural coal is comparable. Section 29 of the Internal Tax Code was particularly relevant in this regard directed at the dust found in coal lagoons, however, is also interpreted to trap dust generated in coal mine manufacturing facilities that are in operation. The tax loan will expire in 2008 unless found is that it works to score the serious environmental problems for which it had been passed. To date, about 12 manufacturing processes are through the IRS been certified to produce new synthetic fuel products using coal dust manufacture.

It is estimated that several million dollars in research funds from large and small Companies have been issued which have been mentioned since the above Tax law changes have been made. The tax law has therefore an increased interest in the Development of a method for providing a suitable, commercial synthetic fuel is provided and powered using coal dust. Lots Companies have chosen tar as the ingredient to fix the dust or tie, however, this is unsatisfactory for most businesses. Tar works just as a simple adhesive, has a very low melting temperature and remains flawed when providing bond strength. It seems that plants are one desire organic binder which adds BTUs to the coal dust, wherein no ashes remain after a burn, and factories want a strongly bound one Product (which looks similar to coal) and burns and how coal can be stored.

By synthetic fuel or synthetic coal we mean a fuel that is made from Coal dust or very fine material is produced.

The use of an organic binder composition for coal dust, which forms a useful fuel when in the coal dust in a small amount blended and compacted has long been a goal of inventors, but is never been successfully achieved. Generally are organic Binder compositions have been found which have numerous disadvantages: for example, they do not provide the binding power of suitable inorganic binders, they do not worry that the coal dust can dry, which is often very damp, and fail very much often to provide the necessary bond or green strength. Many inorganic Binders, such as tar, have very low melting temperatures and on hot days they decompose the synthetic fuel and can render it useless. To date most commercial synthetic fuels using coal dust either an inorganic binder, usually a smectic clay, or a petroleum derivative, such as asphalt and tar. Many of these binders have been selected, though often, unlike organics, no (and often a reduced) BTU profit generated when the fuel was burned, however, increased the amount considerably Ash waste, which itself had to be stored or otherwise treated.

In the prior art, which is relevant to the present invention, there are following patents.

U.S. Patent No. 44,000, issued in 1861 to a New York inventor from Brooklyn during the civil war, describes a synthetic coal that is made from coal dust and Wheat and corn starches are made, probably obtained from flour that was used in the past New York grocery was available.

U.S. Patent No. 1,121,325 shows briquetting coal dust by mixing drier Coal and starch, heating with oil and steam, compacting and then drying the Mix product.

U.S. Patent No. 1,851,689, issued in 1932, shows asphalt and carbohydrate pastes, such as corn starch, as an emulsion binder for coal briquettes, which are described or are made from finely powdered soft coal.

U.S. Patent No. 5,009,671 discloses that synthetic fuel can be made from Coal dust mixed with starch, molasses and water.

US Patent No. 5,916,826 discloses briquetting carbon fines using of binders produced by liquefying biomass with rapid pyrolysis of Tar and petroleum asphalt added to the mixture.

U.S. Patent No. 6,013,116 describes a briquetting binder composition for Binding of metal oxides or fine coal, comprising 95% asphalt and one Natriumcarbonatpumpflüssigkeit.

Other illustrative patents show a wide variety of binders for Coal dust: U.S. Patent No. 3,898,076 (paraffin wax); U.S. Patent No. 5,221,290 (smectic clay) including bentonite; U.S. Patent No. 4,659,374 (Pech and Lignosulfanate), U.S. Patent No. 5,698,007 (water-soluble polymers and alkalis) and U.S. Patent No. 6,071,325 (organic Binders including water-soluble polymers including guar gum and starches).

It is also known commercially, injectable clays, cement, fly ash and To use bag house dust as a binder for coal dust, including mixtures thereof Ingredients with starch.

SUMMARY OF THE INVENTION

The present invention relates to a synthetic fuel made from Coal dust, water and defined organic chemicals associated with the coal dust are reactive, is made to bond between the coal dust when compacting to provide a product that is very similar to, but chemically like coal is different. The product according to the invention surprisingly represents in some cases a higher BTU value than coal alone (up to 5 to 1000 BTU per ton more versus coal), does not produce the waste ash from inorganic chemicals (and many organic chemicals, such as tar) when setting up users, and if that organic chemical is selected as a "water-absorbent" reactive polymer, not only does a moisture problem of coal dust be solved, but there is even one increased green strength.

DETAILED DESCRIPTION OF THE INVENTION

The aim of the present invention is to provide a highly suitable synthetic To provide fuel that contains at least 90% coal dust. This invention provides also surprisingly a synthetic fuel with a higher BTU Content as natural coal and uses coal dust as its main ingredient, which is still a waste product of ever increasing environmental risk and concern has been.

Such a fuel is advantageous, among other reasons, because (1) more coal per Volume unit can be shipped; (2) the fuel is particularly effective for Electricity facilities; (3) facilities fuel as an immediate replacement for coal in can use the same level in their operations; (4) Taking a tax advantage IRS law can be achieved using the fuel, and (5) end user one experience greater freedom (e.g. there is less moisture with synthetic coal than with linked to natural coal).

The invention has been found particularly useful in providing Fuel for electricity facilities. The fuel surprisingly shows frequently has a higher BTU content than coal from the same mine and is therefore of benefit of a higher value for the same price. It is particularly advantageous to have one synthetic coal fuel ready to be added to the power plant systems as a replacement to have for natural coal. Such a synthetic fuel can simply be called a Fuel supply without the need for special handling equipment in be integrated into the facility.

In a preferred embodiment, the present invention relates to a synthetic fuel using defined ingredients.

• a) wenigstens etwa 90 Gew.-% Kohlenstaub, wobei etwa 90% der Teilchengröße desselben 50 µm oder weniger ist;
• b) von etwa 0,5 bis 8,0 Gew.-%, auf der Basis des Gewichts des Kohlenstaubs, eine oder mehrere organische Chemikalie(n), die mit dem Kohlenstaub reaktionsfähig ist bzw. sind; und
• c) Wasser.

One embodiment of the invention is a composition which comprises:

• a) at least about 90% by weight of coal dust, about 90% of its particle size being 50 µm or less;
• b) from about 0.5 to 8.0% by weight, based on the weight of the coal dust, one or more organic chemical (s) that are reactive with the coal dust; and
• c) water.

In the inventive embodiments, element (a), coal dust, is either a Waste from current coal production at or near a mine or is being obtained from a waste deposit, like a coal lagoon. Naturally occurring coal dust can Contain impurities - when calculating the above percentages, only the Coal content of the two types of coal dust, either of which is used in this invention can be used, used.

According to the present invention, the composition preferably comprises about at least 90% coal dust, although the invention is effective for lower levels of dust. These are intended to be covered by the use of the word. Mixtures of coal dust can be used. The product preferably contains approximately 95 wt% coal dust or more.

The preferred type of coal dust for the invention is where most of the dust are quite fine particles, d. H. about 90% of the particles in the dust are 50 µm or less. However, it should be understood that dust with a less fine consistency, containing essentially larger amounts of larger particle sizes, also suitable will produce synthetic fuel according to this invention.

Element (b), reactive organic chemicals useful in this invention are any organic compounds that are reactive with coal dust, and include functionalized starches, monosaccharides, disaccharides, polysaccharides, copolymers from sodium acrylates and acrylamide and mixtures thereof, as follows described.

By reactive is meant that the organic chemical is capable of either one chemical bond, bond by hydrogen bond, bond on van the Waal forces or other forms of bonding with the coal dust. Because coal is mainly carbon, surprisingly a very unreactive element in many Cases, it is believed that the organic chemical is actually primarily associated with the small amounts of contaminants found in coal dust can react to the unexpectedly strong binding forces obtained by this invention form, although a carbon bond is not entirely scientific Possibility can be excluded.

Preferred additives for this invention include functionalized starches their salts and their esters.

Starch is a carbohydrate polymer with organic repeating units. Strengthen vary greatly in the number of repeat units in the polymer, resulting in a large one Extent depends on the source of strength. Starch is usually composed of about 25% amylose and 75% amylopectin. Amylose is used by scientists as one Mixture of linear and slightly branched molecules considered, whereas amylopectin is considered a densely branched, high molecular weight molecule. In some Cereal starches can have as little amylose content as 0-1% as in waxy ones Barley, waxy sorghum and waxy corn, and can be as high as 50 to 70% in some corn hybrids. Starch is often described as a repeat polymer Glucose units linked together via glycoside bonds.

Starch is a polysaccharide obtained from plants, including wheat, corn, Potato, tapioca and rice are common commercial sources. Without the functionalizing Modifications discussed herein is starch a white, semi-crystalline, tasteless powder, often in granular form. If starch with hot water is sufficient Amount mixed, such as at a temperature of 65 ° C or higher, can be irreversible Gelatinization occur. A large number of pure starches are available including those commonly used as commercial, powdered, pearly, laundry, technical and edible starches are labeled.

The starch for this invention must be functionalized to have units that are reactive with coal. Based on the disclosure provided herein, a Those skilled in the art will be able to easily formulate functional strengths and select which are suitable for your invention.

Examples of suitable modifications to functionalize the starches Use in this invention include cross-linking, substitution of functional groups on the Polymer chain, oxidizing and acid thinning.

The starch is preferably modified by well known oxidation processes. The code of Federal Regulations, which is hereby incorporated by reference, describes in Modified starches intended for industrial applications. For example, 21 CRF 172,892 describes a modification of starch for food use, while 21 CFR 178.3520 the modification of starch for industrial applications covers.

Functionalized starch-based polymers suitable for this invention include preferably reaction polyols obtained from a reaction using of catalysts, of starch with dibasic acids and hydrogen donors Compounds dissolved in a water slurry; the slurry will then be high Subjected to temperatures and pressures, resulting in a low viscosity polymer in an aqueous Solution results. A molecular rearrangement takes place, and the functionalized Starch polymer that is formed is very different from natural starch in terms of Structure. The polymer can be further reacted with acids, bases and crosslinking agents.

A water based solution and dispersion of a polysaccharide with a Dextrose equivalent between 0 and 100, which also contains inorganic salts and / or organic dissolved May contain substances. The polysaccharide itself can also be chemically modified. Preferred types of these products include the commercial products (Polysaccharide resins) from Lorama Chemicals Inc.

A particularly preferred, functionalized starch additive is selected from the Lorama range Polysaccharide resins (CAS # 65996-63-6) of the group consisting of JK270, JA250-3, ECO plus ANECO. These resins are an aqueous solution of a polysaccharide with a Dextrose equivalent between 0.1 and 100 where the polysaccharide has been chemically modified.

Even more preferred additives for this invention are copolymers of sodium acrylates and Acrylamides. These are made by well known reaction methods which are in the Literature are described, and are commercially available products. Such Compositions usually contain small amounts of contaminants such as acrylamide, Acrylic acid and 1-propenamide. Such copolymers can also be in an aqueous solution.

Ciba Specialty Water Treatment Chemicals offers a range of for sale Homopolymers, copolymers and terpolymers based on acrylate, acrylamide and Sodium acrylate, which are very suitable for this invention. The most preferred copolymer in this series is Cibas Magnafloc 155 (CAS # 25085-02-3).

A particularly preferred organic composition is a mixture in a wide range Range of functionalized starch and copolymer proportions Sodium acrylate and acrylamide. Generally there are use of these types of chemicals surprising results in a bond between the same and the coal dust what due to their nature ensures that the synthetic fuel at any high Ambient temperature can be stored without reducing the green strength.

Element (c) is water.

It should be understood that synthetic coal is in many cases different materials may include, however, the preferred embodiment is where the above three Components of more than 90% of the synthetic fuel up to 100% of the synthetic Form fuel.

The compounds of this invention are believed to work by organic additive on the coal dust particles is chemisorbed when the organic Connections to coal dust and water. It is also believed that the additives add a negatively charged layer on the coal dust through each Form carbon particles. It is also believed that the additives, when mixed with the coal dust be burned, not just provide energy from their own nature as an organic Product, but also cause the coal dust itself to burn more completely and leaves less residue. It is also believed that the additive itself with the Water in the mixture can react to form a flammable substance, which too added to the BTUs generated when it burns. It is believed that this synergy is responsible for the increase in the BTU content of the product according to the invention, which is shown in the experimental results described below.

• a) Mischen von wenigstens etwa 90 Gew.-% Kohlenstaub, von denen 90 Gew.-% der Teilchengröße 50 µm oder weniger ist, und Wasser mit einer oder mehreren organischen reaktionsfähigen Chemikalie(n), um eine Zusammensetzung zu bilden; und
• b) Kompaktieren der Zusammensetzung;

wodurch die synthetische Brennstoffzusammensetzung gebildet wird. In another embodiment, the invention is directed to a method of making a synthetic fuel which comprises a method of making a synthetic fuel composition which comprises:

• a) mixing at least about 90% by weight of coal dust, 90% by weight of the particle size of which is 50 µm or less, and water with one or more organic reactive chemical (s) to form a composition; and
• b) compacting the composition;

whereby the synthetic fuel composition is formed.

According to the present invention, there are several approaches to the manufacture of the synthetic fuel available. For example, one could either disadvantageous (i.e. Coal dust with impurities) or beneficial natural coal dust with the disperse the organic additive of this invention in water. Alternatively, you can Coal dust and the additive are premixed and added to the coal dust and dispersed become. The resulting mixture is then compacted using a large one Width of known compacting, extrusion or other devices.

There are a total of 12 synthetic coal plants through the Internal Tax Code Service approved under heading 29 with a total annual capacity of up to 15 Million tons. Even with the relatively small levels of organic Coal dust chemicals required by this invention become up to 1 to 2 Millions of tons of such additives are needed every year to meet demand.

MCN Energy Group has recently opened 6 "Coal Fines" plants using manufacturing equipment that can produce synthetic coal in accordance with the present invention. The compaction briquetting devices in these MCN plants make coal dust briquettes ago using Kompaktierungskräften of up to 10 tons per square inch. ²

Each of the MCN plants has an estimated annual capacity of one million tons synthetic coal briquettes, however, the actual production rates could be much higher and cannot be accurately estimated until several months of operating experience won. The facilities are located in Monongalia County (2 facilities), West Virginia, McDowell County, West Virginia, Knox County, Kentucky and Harrison County, Ohio.

The following examples are provided to illustrate our invention. Other Embodiments of the invention will become apparent to those skilled in the art the description and practice of the invention disclosed herein. It is intends that the description and examples be considered as exemplary only, the true scope and spirit of the invention being indicated by the claims.

EXAMPLES example 1 method

A sample was made. The sample mixed 1 lb. Ciba Magnafloc 155 at 2000 pounds ground, clean Pond Creek coal which has been ground to a particle size where about 90% of the particles are 50 µm or less. The Magnafloc 155 was made with water mixed until fully hydrated - the withdrawal time is 3 to 10 minutes. To after extraction, it was added to the coal dust and mixed completely. The Mixture was then compacted using a 2 ton press.

The sample prepared above was compared to clean Pond Creek coal base coal, ie raw, untreated coal, and the following results were obtained:

Example 2

An analysis of the synthetic fuel sample was carried out with a load of 5% to the amount of coal dust with a small amount of water.

The process mixed the starting coal with a binder to make a synthetic one Manufacture fuel product. Technical information was then obtained from a Series of tests of synthetic fuel and raw coal and binder, described below.

aim

The goal of performing analytical tests, which are summarized herein, was to determine whether the method used to manufacture the synthetic fuel the chemical structure is considerable when performing certain types of analysis has changed. The tests performed on the samples were selected based on their Ability to determine differences in chemical structure, and in proportion frequent use of the tests.

ways of working

Portions of raw coal, organic chemical and synthetic Fuel product was obtained and prepared for analysis. A number of tests have been done with performed on the samples, including a Fourier-transformed infrared analysis (FTIR), a thermogravimetric analysis (TGA), an ASTM short analysis and one Calorific value determination.

The inventive product sample was compared to an analysis from a simple one Mixture of starting coal and binder (obtained from a mass-weighted Average of results for starting coal and binder) and was done to Identify similarities and differences. Considerable changes would indicate that a chemical interaction among the compounds as a result of Manufacturing process has taken place.

Tests used A. FTIR analysis

Fourier-transformed infrared spectroscopy (FTIR) is a non-descrutive analysis which determines the content of functional groups in coals. Get "functional groups" chemical species linked to aromatic carbon ring structural sites, where chemical reactions usually take place. They close different ones Types of hydrogen (i.e. hydroxylic, aromatic and aliphatic hydrogen), Vibrations due to the absorption of infrared radiation by functional groups characteristic absorption bands (reference 1).

For extremely complex molecular structures, such as coal, a detailed quantitative is Analysis using FTIR difficult due to the overlap of peaks. however provides a comparison of spectra valuable information and can structural Show differences between the samples.

A sample is embedded in potassium bromide (KBr) pellets for FTIR analysis. Light in the infrared frequency range (400-4000 cm ^-1 ) is passed through the pellet. The sample absorbs specific light frequencies depending on the type and amount of chemical bonds present. A list of absorption peaks as key functional groups that are commonly found in coals is given in Table 1 (based on Reference 1).

For FTIR analysis of raw and synthetic samples Fuel spectra, all spectra have been normalized for comparison purposes and are an average off sixteen individual scans of the samples used to create them.

In general, the FTIR spectral range from 4,000 to about 1,800 cm ^{-1 identifies} strong triple bonds and also hydrogen stretching vibrations. The range from about 1,800 to about 1,400 cm ^-1 corresponds to aromatic structures and double bond structures. Wavenumbers from 1,000 to 400 cm ^-1 identify single bond structures, including numerous types of aromatic substitution bonds.

A comparison of the spectra for the synthetic fuel product with those determined for a corresponding simple mixture of the starting carbon and the binder was obtained. Changes in the absorption peak ranges for the fuel products, which are key chemical functional groups, relative to the corresponding simple mixtures, indicate the degree to which the coal dust had been changed as a result of the organic chemical manufacturing process. Computer-measured areas of key samples are normal and depend on sample homogeneity and sample preparation. Previous statistical analysis of multiple coal samples indicate that generally peak area differences greater than 20% represent a significant change in the functional groups displayed. As shown in Table 2, the product sample shows a considerable variation in the FTIR measured peak areas relative to the starting materials for the hydroxyl groups, aromatic CH, aromatic rings, cyclic CH ₂ , CO bonds, alkenes, aldehydes, polycyclic aromatic framework structures, aromatic substitution , Ketones and carbonyl groups.

This immediate measurement of a chemical structure indicates that chemical Changes in these functional groups found in the product are significant are different relative to the starting carbon material.

B. TGA analysis

A thermo-gravimetric analysis (TGA) measures the temperature and the speed at which pyrolysis products develop. The temperature required to break chemical bonds and then release volatile fractions of coal is determined by the strengths and types of bonds present. Volatile components that are attached to carbon macromolecules through weak chemical bonds develop at low temperatures. Components that are held with stronger bonds that require more energy to break develop at higher temperatures. Differences in the TGA curves (obtained under identical conditions) between a simple mixture of all ingredients and the corresponding product would indicate that changes in the chemical bonding of the volatile components to the macromolecular carbon structure have occurred. Table 1 Absorption bands of functional groups that are common in coal

Table 2 Comparison of the FTIR results of starting coal and fuel product according to the invention

The TGA tests presented here were carried out under inert conditions, under Using nitrogen as a carrier gas and with a heating rate of 15 ° C / minute of Room temperature to 700 ° C, and pyrolysis rate curves for the invention Product or the original coal were obtained. Pyrolysis weight loss rate curves for the simple mixture of starting coal / binder and the fuel product were compared. The maximum speed of pyrolysis is considerably lower for the fuel product as it is intended for a simple mixture of the starting ingredients what suggests increasing chemical crosslinking in the fuel product. Quantitative differences in peak and high temperature pyrolysis rates (668 ° C) for the coal / binder mixture and the fuel product are in Table 3 given. The accuracy of weight loss determination for thermogravimetric The analyzer used for these tests is 1%. Variations from sample to sample can be 2 to 3% for non-homogeneous materials such as coal.

Differences in peak pyrolysis mass loss rates of 21% are strong evidence of a significant chemical change in the synthetic fuel product relative to the starting materials. Table 3 Pyrolysis rates of feed materials and fuel product

D. Brief analysis and calorific value

A brief analysis of the raw materials and the synthetic fuel is in Table 4 shown. These tests were carried out according to a standard ASTM procedure (Reference 7). For comparison purposes of the fuel structure, the results are in one shown dry, ash-free base. The measurement errors in the reported results must be within the permitted limits to meet the ASTM requirements. Therefore are the allowed error range results used here to be a conservative To provide information on whether the measured differences are statistically significant.

A comparison of the dry, ash-free results for the fuel product with the simple mixture of ingredients shows that the differences between volatile and solid Carbon content outside the statistical error limits are (± 0.5% for volatile and solid Carbon). Therefore, these results provide additional evidence of a chemical Change ready to support FTIR and TGA results. The difference in that The calorific value is within the statistical error limits (± 107 BTU / lb for the calorific value).

The brief analysis shows that ash and sulfur levels are somewhat higher for the fuel product than for the starting materials. However, it is thought that this is not a result of a chemical change, but possibly due to mineral inclusion. Table 4 Test results for starting ingredients and fuel product (as the basis obtained)

discussion of the results

Independent tests using samples of raw materials (coal and binder) and Fuel products made with 5% binder have shown that significant chemical changes occur during the manufacture of the synthetic fuel product.

Chemical changes were suggested by FTIR analysis, which showed a change in hydroxyl groups, aromatic CH, aromatic rings, cyclic CH ₂ , CO bonds, alkenes, aldehydes, polycyclic aromatic framework structure, aromatic substitution, ketones and carbonyl groups. TGA tests showed significant differences in the characteristics of the peak pyrolysis rate. A brief analysis showed statistically significant differences in the levels of solid carbon and volatile substances.

These differences indicate that the chemical structure of the synthetic Fuel product is significantly different from the starting carbon materials from which it is made is made.

Example 3 method

Two additional samples were made. The first sample mixed a pound of Lorama Starch JK270 with 2000 pounds of coal dust using the method of Example 1. A second sample was made using a mixture of 1/2 pound Ciba Magnafloc 155 and 1/2 pound Lorama starch JK270 with a similar amount Coal dust like for the first sample.

Similar tests as described above were carried out.

Sample 1

The FTIR spectrum for the additive was recorded. A comparison of the spectra for that Fuel product with those required for an appropriate simple mix of Starting coal and the additive were determined, was created. Computer-measured areas the key absorption peaks were listed and for the fuel product / simple Compared mixture.

A comparison of the spectra of the samples showed a considerable variation in FTIR measured peak areas relative to the starting materials at the spectral locations with aromatic CH, carbon-oxygen bond, carbonyl, ketones, Carboxyl groups, thiophenes, heterocycles, branched and cyclic alkanes, aliphatic ethers, aromatic substitution bond and the polycyclic aromatic framework structure are connected. This direct measurement of the chemical structure indicates that it is functional Groups with a different concentration in the product compared to the Starting materials are available. A difference in peak area deviations of 38% for all Peaks were determined. An average peak area deviation of 38% Evidence ready for a substantial chemical change in the product of Sample 1 relative to the starting materials.

Sample 2

The FTIR spectrum for the 50/50 mixture was determined. A comparison of the spectra for the fuel product with those who are looking for a simple mixture of the appropriate Starting coal and the additive were determined, was created. computer Surveyed Range of key absorption peaks were listed and for that Fuel product / simple blend compared.

A comparison of the spectra of the samples for Sample 2 showed a considerable variation of the FTIR-measured peak areas relative to the starting materials at the spectral sites associated with cyclic CH ₂ , carbon-oxygen bond, alkenes, aldehydes, carbonyl, ketones and the polycyclic aromatic Scaffold structure are connected. This direct measurement of the chemical structure indicates that these functional groups are present at a different concentration in the product compared to the starting materials. An average of 20% peak area deviation for all peaks was determined. An average peak deviation of 20% provides evidence of a significant chemical change in the synthetic fuel product of Sample 2 relative to the starting materials, with supporting evidence from additional test studies.

TGA analysis

TGA tests were performed on both samples under inert conditions, under Use of nitrogen as a carrier gas and a heating rate of 15 ° C / min. from room temperature to approx. 700 ° C (reference 7). Considerable differences in the Pyrolysis characteristics of the two fuel product samples relative to the starting materials showed a modified cross-linking of the carbon-containing structure.

Brief analysis and calorific value

A comparison of the short analyzes of the starting coal dust and the two synthetic fuel products was created. These tests were carried out according to ASTM Standard procedure. For the purpose of comparing the fuel structure, the Results presented on a dry, ash-free basis. The measurement error in the Results presented were within the allowed limits to meet the ASTM requirements fulfill. Therefore, the allowed margin of error provided a conservative hint whether the measured differences are statistically significant.

A good correlation between the ash and sulfur levels for that Starting material and the synthetic fuel product suggests that probably none significant procedural or sampling errors have occurred in collecting these samples. This suggests that these samples are representative and therefore suitable for this analysis.

discussion of the results

Independent tests were performed on samples of the raw materials (Kentucky Coal, and the additives of sample 1 and sample 2) mixed with coal dust. Fuel products were manufactured with different proportions of the additives. Based on before statistical analysis performed showed a value greater than 25% at the average FTIR peak range deviation indicates that a significant chemical Change between the synthetic fuel product and the raw material has taken place. If the average peak area change is between 15-25%, then help results from other types of tests, such as a TGA or a short analysis determine whether the displayed deviations of the FTIR analysis are significant chemical Represent change or some kind of sample variation.

It was believed that test results from the sample from Example 1 made with the additive from Example 1 suggested that significant chemical changes occurred during the manufacture of the fuel product. An FTIR analysis of the fuel product sample from Example 1 and the corresponding starting materials shows considerable variations at spectral sites associated with cyclic CH ₂ , carbon-oxygen bond, alkenes, aldehydes, carbonyl, ketones, carboxyl groups, thiophenes, heterocycles, branched and cyclic Alkanes, aliphatic ethers, aromatic substitution bonds and polycyclic aromatic framework structure are connected. The short analysis test results for this fuel product show considerable differences in the amount of volatile substances and solid carbon relative to the starting materials.

It was considered that test results from Sample 1 show that considerable chemical changes have occurred during the manufacture of the fuel product. An FTIR analysis of the sample 1 fuel product sample and the corresponding Starting materials indicate significant variations in spectral locations that match aromatic CH, carbon-oxygen bond, carbonyl, ketones, carboxyl groups, Thiophenes, heterocycles, branched and cyclic alkanes, aliphatic ethers, aromatic Substitution bond and polycyclic aromatic framework structure are connected.

The test results of Sample 2 were believed to suggest that significant chemical changes occur during the manufacture of the fuel product. An FTIR analysis of the fuel product sample of sample 2 and the corresponding starting materials indicates that variations in the FTIR-measured peak areas relative to the starting materials take place at spectral locations which are associated with cyclic CH ₂ , carbon-oxygen bond, alkenes, aldehydes, carbonyl , Ketones and polycyclic aromatic framework structure. The TGA test results for this fuel product show significant differences in the characteristics of the peak pyrolysis rate. These differences, obtained from different analytical tests, show that the chemical structure of the fuel product of Sample 2 is considerably different from the starting materials from which it is made.

In summary, the results of the analytical tests show that with starting materials and fuel products that have undergone considerable chemical Changes in the manufacture of these synthetic fuel products have taken place. A good correlation between the ash and sulfur contents for the starting material and all synthetic fuel products suggest that the samples of the fuel product are representative of the starting materials from which they were made, and are therefore suitable for this analysis.

Claims (14)

1. A synthetic fuel composition comprising: a) at least about 90% by weight of coal dust; b) from about 0.5 to 80% by weight, based on the weight of the coal dust, one or more organic chemical (s) that are reactive with the coal dust, and c) water. 2. Fuel composition according to claim 1, characterized in that the Coal dust is available from a coal manufacturing facility at or near a coal mine. 3. Fuel composition according to claim 1, characterized in that the Coal dust from anthracite coal. 4. Fuel composition according to claims 1, characterized in that the organic chemical a copolymer of one or more sodium acrylates and Is acrylamides. 5. The fuel composition of claim 1 which has been compacted. 6. Fuel composition according to claim 1, characterized in that one or more organic chemicals are selected or are selected from the group consisting of: a) functionalized strengths, and b) copolymers of sodium acrylates and acrylamides, and c) mixtures thereof. 7. Fuel composition according to claim 1, characterized in that the organic chemical is a copolymer of sodium acrylate and acrylamide. 8. Synthetic fuel composition according to claim 1, characterized in that the organic additive is selected from the group consisting of polysaccharide resins, Copolymers of sodium acrylate and acrylamide and mixtures thereof. 9. A synthetic fuel composition according to claim 1, characterized in that at least about 90% of the particle sizes of the coal dust are 50 µm or less. 10. Synthetic fuel component, which comprises: a) at least about 90% by weight of coal dust; b) about 0.5 to 8% by weight, based on the weight of the coal dust, one or more functionalized starch (s); and c) water. 11. A synthetic fuel composition according to claim 10, characterized in that that the functionalized starch is selected from the group consisting of Lorama Strengths JK270, JA250, JA250-3, ECOPlus and ECO. 12. A method of making a synthetic fuel composition which comprises: a) mixing at least about 90 weight percent coal dust with water and with one or more organic chemical (s) that are reactive with the coal dust to form a composition; and b) compacting the composition; whereby the synthetic fuel composition is formed. 13. The method according to claim 12, characterized in that at least about 90 wt .-% the particle sizes of the coal dust are 50 µm or less. 14. A method of making a synthetic fuel composition according to Claim 12, characterized in that a compacting is provided by a Mixing drum.