US20110030270A1 - Methods for removing impurities from coal including neutralization of a leaching solution - Google Patents

Methods for removing impurities from coal including neutralization of a leaching solution Download PDF

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US20110030270A1
US20110030270A1 US12/538,423 US53842309A US2011030270A1 US 20110030270 A1 US20110030270 A1 US 20110030270A1 US 53842309 A US53842309 A US 53842309A US 2011030270 A1 US2011030270 A1 US 2011030270A1
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Prior art keywords
leaching solution
coal
solution
products
precipitate
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US12/538,423
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Chandrashekhar Sonwane
Samuel D. Draper
Lawrence B. Kool
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General Electric Co
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General Electric Co
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Priority to US12/538,423 priority Critical patent/US20110030270A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DRAPER, SAMUEL D., KOOL, LAWRENCE B., SONWANE, CHANDRASHEKHAR
Priority to DE102010036803A priority patent/DE102010036803A1/en
Priority to JP2010176841A priority patent/JP2011038100A/en
Priority to CH01280/10A priority patent/CH701637A2/en
Priority to CN2010102605693A priority patent/CN101993755A/en
Publication of US20110030270A1 publication Critical patent/US20110030270A1/en
Abandoned legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B37/00Compounds having molecular sieve properties but not having base-exchange properties
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B37/00Compounds having molecular sieve properties but not having base-exchange properties
    • C01B37/02Crystalline silica-polymorphs, e.g. silicalites dealuminated aluminosilicate zeolites

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  • This disclosure generally relates to methods for removing impurities from coal, and more particularly relates to methods for removing impurities from coal which include neutralization of a leaching solution.
  • Clean coal such as ultra clean coal
  • coal including impurities may be treated with a first leaching solution such as hydrofluoric acid (“HF”) in a first reactor to produce a first reaction slurry.
  • a first leaching solution such as hydrofluoric acid (“HF”)
  • HF hydrofluoric acid
  • the first reaction slurry may be transported to a filter (e.g., drum filter) to produce filtered, wet coal.
  • the filtered, wet coal may then be transported to a second reactor for treatment with a second leaching solution such as a nitrate solution to produce a second reaction slurry.
  • the second reaction slurry may then be transported to a filter for filtering.
  • the resulting ultra clean coal may then be water washed and transported to a dryer for drying.
  • the moles of HF required for the first reaction are significantly lower than the moles of HF used.
  • the unreacted HF remains in the liquid and may even remain in the coal (e.g., in the areas of pre-existing moisture and in etched pores in the coal created from the HF reacting with ash impurities) after the coal is filtered.
  • HF is known to be extremely toxic and to corrode glass. HF typically has an occupational exposure level of 2 ppm. The PPO's needed include rubber gloves, face mask or safety glasses, apron, and good ventilation. If HF is inhaled or ingested, the result may be fatal. HF is readily absorbed through the skin and skin contact may also be fatal. HF also acts as a systemic poison, causes severe burns, and is a possible metic. In addition, the reaction with HF may be delayed. Thus, any contact with HF, even if minor, requires immediate medical attention.
  • This disclosure provides a method for removing at least one impurity from coal.
  • the method comprises providing coal having a plurality of impurities and contacting the coal with a first leaching solution.
  • the first leaching solution reacts with at least one of the impurities to produce one or more first products soluble in the first leaching solution.
  • the method further comprises adding a neutralizing composition to the first leaching solution.
  • the neutralizing composition reacts with the first leaching solution to form a precipitate.
  • the method further comprises separating at least a portion of the first leaching solution from the coal and the precipitate and contacting the coal and the precipitate with a second leaching solution.
  • the second leaching solution reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively, the second products and the third products being soluble in the second leaching solution.
  • the method further comprises separating at least a portion of the second leaching solution from the coal.
  • the present disclosure also provides another method for removing at least one impurity from coal.
  • the method comprises providing coal having a plurality of impurities and contacting the coal with a first leaching solution.
  • the first leaching solution reacts with at least one of the impurities to produce one or more first products soluble in the first leaching solution.
  • the method further comprises separating at least a portion of the first leaching solution from the coal as an unreacted first leaching solution.
  • the method further comprises adding a neutralizing composition to the unreacted first leaching solution.
  • the neutralizing composition reacts with the unreacted first leaching solution to form a precipitate.
  • the method further comprises separating at least a portion of the unreacted first leaching solution from the precipitate and contacting the coal and the precipitate with a second leaching solution.
  • the second leaching solution reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively, the second products and the third products being soluble in the second leaching solution.
  • the method further comprises separating at least a portion of the second leaching solution from the coal.
  • FIG. 1 illustrates a method 10 for removing at least one impurity from coal in accordance with an embodiment of the present invention.
  • FIG. 2 illustrates a method 50 for removing at least one impurity from coal in accordance with another embodiment of the present invention.
  • this disclosure encompasses methods for removing at least one impurity from coal.
  • the method of the present disclosure may be used to produce ultra clean coal.
  • the term “ultra clean coal” refers to coal having a reduced ash content (e.g., below about 0.2%) and/or a substantially reduced sulfur content such that the coal may be fed directly into processes such as gas turbine processes and provide advantages such as improved thermal efficiency, for example.
  • ash refers to both the non-combustible components in the coal before combustion and the non-combustible byproducts resulting from combustion of the coal. Embodiments of the method for removing at least one impurity from coal are described below and illustrated in FIGS. 1 and 2 .
  • any system e.g., gas turbine systems such as coal fired gas turbine systems, pulverized coal power plants, and integrated gasification combined cycle systems
  • the coal e.g., ultra clean coal
  • FIG. 1 illustrates an embodiment of the method 10 for removing impurities from coal of the present disclosure.
  • the method 10 first provides coal 12 comprising a plurality of impurities.
  • Embodiments of method 10 may provide coal 12 in the form of anthracite coal, bituminous coal, subbituminous coal, lignite coal, or combinations thereof.
  • the impurities include, but are not limited to, oxides of aluminum, iron, potassium, calcium, sodium, and other metals, minerals, inorganic and organic sulfur compounds, alkalis, ash, or combinations thereof.
  • the impurities may be present in the coal 12 in an amount ranging from about 2 wt. % to about 50 wt. %. In other embodiments, the impurities may be present in the coal 12 in an amount ranging from about 3 wt. % to about 8 wt. %. In still other embodiments, the impurities may be present in the coal 12 in an amount ranging from about 5 wt. % to about 7 wt. %.
  • the method 10 contacts the coal 12 with a first leaching solution 14 in a first reactor 16 . At least one of the impurities reacts with the first leaching solution 14 to produce one or more first products soluble in the first leaching solution.
  • the first leaching solution 14 may comprise an acid solution.
  • the first leaching solution 14 may include, but is not limited to, first reactants such as a hydrofluoric acid, a nitric acid, a hydrochloric acid, a hydrofluorosilicic acid, a combination thereof, or other strong acids that dissolve oxides.
  • the first leaching solution 14 has a first reactant concentration ranging from about 3 M to about 10 M. In other embodiments, the first leaching solution 14 has a first reactant concentration ranging from about 3 M to about 6 M. In still other embodiments, the first leaching solution 14 has a first reactant concentration ranging from about 4 M to about 6 M.
  • the weight ratio of first leaching solution 14 to coal 12 added to the first reactor 16 ranges from about 10:1 to about 10:5. Unless otherwise indicated, all ratios are weight to weight ratios. In other particular embodiments, the weight ratio of first leaching solution 14 to coal 12 added to the first reactor 16 ranges from about 10:2 to about 10:4. In still other particular embodiments, the weight ratio of first leaching solution 14 to coal 12 added to the first reactor 16 ranges from about 10:2.5 to about 10:3.5.
  • the first leaching solution 14 comprises a hydrofluoric acid solution having a hydrofluoric acid concentration ranging from about 3 M to about 10 M. In other embodiments, the first leaching solution 14 comprises a hydrofluoric acid solution having a hydrofluoric acid concentration ranging from about 3 M to about 6 M. In still other embodiments, the first leaching solution 14 comprises a hydrofluoric acid solution having a hydrofluoric acid concentration ranging from about 4 M to about 6 M. In particular embodiments, the weight ratio of hydrofluoric acid solution 14 to coal 12 added to the first reactor 16 ranges from about 10:1 to about 10:5.
  • the weight ratio of hydrofluoric acid solution 14 to coal 12 added to the first reactor 16 ranges from about 10:2 to about 10:4. In still other particular embodiments, the weight ratio of hydrofluoric acid solution 14 to coal 12 added to the first reactor 16 ranges from about 10:2.5 to about 10:3.5.
  • the coal 12 is in contact with the first leaching solution 14 for about 1 hours to about 10 hours in the first reactor 16 . In other particular embodiments, the coal 12 is in contact with the first leaching solution 14 for about 3 hours to about 5 hours in the first reactor 16 . In still other particular embodiments, the coal 12 is in contact with the first leaching solution 14 for about 4 hours to about 5 hours in the first reactor 16 .
  • the coal 12 is in contact with the first leaching solution 14 at a temperature ranging from about 70° F. to about 200° F. in the first reactor 16 . In other particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a temperature ranging from about 110° F. to about 170° F. in the first reactor 16 . In still other particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a temperature ranging from about 140° F. to about 160° F. in the first reactor 16 .
  • the coal 12 is in contact with the first leaching solution 14 at a pressure ranging from about 14 psia to about 1000 psia in the first reactor 16 . In other particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a pressure ranging from about 14 psia to about 42 psia in the first reactor 16 . In still other particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a pressure ranging from about 14 psia to about 20 psia in the first reactor 16 .
  • the one or more first products comprises one or more fluorides, hydroxyl fluorides, hydroxides, or combinations thereof.
  • the fluorides may be selected from silicon fluoride, aluminum fluoride, iron fluoride, calcium fluoride, potassium fluoride, or combinations thereof.
  • the method 10 further comprises adding a neutralizing composition 18 to the first leaching solution 14 such that neutralizing composition reacts with the first leaching solution to form a precipitate.
  • a neutralizing composition 18 By adding the neutralizing composition 18 to the first leaching solution 14 , any unreacted first reactant (i.e. excess first reactant that has not reacted with at least one of the impurities) in the first leaching solution is neutralized.
  • the neutralizing composition 18 comprises a neutralizing reactant including a calcium hydroxide, sodium hydroxide, any other alkali, or combinations thereof.
  • the first leaching solution comprises a hydrofluoric acid solution
  • the neutralizing composition comprises calcium hydroxide
  • the precipitate comprises a calcium fluoride
  • the one or more third products comprise calcium ions, nitrate ions, or combinations thereof.
  • the neutralizing composition 18 is added to the first leaching solution 14 after the coal 12 has been in contact with the first leaching solution for about 1 hours to about 10 hours in the first reactor 16 . In other particular embodiments, the neutralizing composition 18 is added to the first leaching solution 14 after the coal 12 has been in contact with the first leaching solution for about 3 hours to about 5 hours in the first reactor 16 . In still other particular embodiments, the neutralizing composition 18 is added to the first leaching solution 14 after the coal 12 has been in contact with the first leaching solution for about 4 hours to about 5 hours in the first reactor 16 .
  • the neutralizing composition 18 has a neutralizing reactant concentration ranging from about 1 M to about 10 M. In other embodiments, the neutralizing composition 18 has a neutralizing reactant concentration ranging from about 1 M to about 4 M. In still other embodiments, the neutralizing composition 18 has a neutralizing reactant concentration ranging from about 2 M to about 3 M.
  • the method 10 further comprises separating at least a portion of the first leaching solution 14 from the coal 12 and the precipitate.
  • separating at least a portion of the first leaching solution 14 from the coal 12 at least a portion of the first products are also separated from the coal because they are soluble in the first leaching solution.
  • substantially all of the first leaching solution 14 including substantially all of the first products may be separated from the coal 12 and the precipitate.
  • the first leaching solution 14 , the coal 12 , and the precipitate are transported from the first reactor 16 as a slurry 20 to a drum filter 22 .
  • the drum filter 22 filters the slurry 20 to separate the coal and the precipitate as wet coal 26 from the first leaching solution 24 .
  • the wet coal 26 is then fed to a second reactor 30 where the coal 12 and the precipitate are contacted with a second leaching solution 28 .
  • the second leaching solution 28 reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively.
  • the second products and the third products are soluble in the second leaching solution 28 .
  • the second leaching solution 28 may comprise a nitrate solution.
  • the second leaching solution 28 comprises a second reactant including, but not limited to nitric acid, aluminum nitrate, ferric nitrate, fluoronitrate, other nitrates, hydroxide, hydroxyl fluoride, hydroxynitrate ions thereof, or combinations thereof.
  • the one or more second products comprises nitrate ions, sulfate ions, iron ions, hydroxyfluorides, oxides, fluoronitrate, or combinations thereof.
  • the one or more third products comprise calcium ions or combination thereof.
  • the second leaching solution 28 has a second reactant concentration ranging from about 0.1 M to about 5 M. In other particular embodiments, the second leaching solution 28 has a second reactant concentration ranging from about 0.1 M to about 0.4 M. In still other particular embodiments, the second leaching solution 28 has a second reactant concentration ranging from about 0.3 M to about 0.4 M.
  • the weight ratio of second leaching solution 28 to wet coal 26 added to the second reactor 30 ranges from about 10:1 to about 10:5. In other embodiments, the weight ratio of second leaching solution 28 to wet coal 26 added to the second reactor 30 ranges from about 10:2 to about 10:4. In still other embodiments, the weight ratio of second leaching solution 28 to wet coal 26 added to the second reactant reactor 30 ranges from about 10:2.5 to about 10:3.5.
  • the second leaching solution 28 comprises a nitric acid solution having a nitric acid concentration ranging from about 0.1 M to about 5 M. In other particular embodiments, the second leaching solution 28 comprises a nitric acid solution having a nitric acid concentration ranging from about 0.1 M to about 0.4 M. In still other particular embodiments, the second leaching solution 28 comprises a nitric acid solution having a nitric acid concentration ranging from about 0.2 M to about 0.3 M. In certain embodiments, the weight ratio of nitric acid solution 28 to wet coal 26 added to the second reactor 30 ranges from about 10:1 to about 10:5.
  • the weight ratio of nitric acid solution 28 to wet coal 26 added to the second reactor 30 ranges from about 10:2 to about 10:4. In still other embodiments, the weight ratio of nitric acid solution to 28 to wet coal 26 added to the second reactor 30 ranges from about 10:2.5 to about 10:3.5.
  • the second leaching solution 28 is in contact with the coal and the precipitate for about 20 hours to about 30 hours in the second reactor 30 . In other particular embodiments, the second leaching solution 28 is in contact with the coal and the precipitate for about 22 hours to about 26 hours in the second reactor 30 .
  • the second leaching solution 28 is in contact with the coal and precipitate at a temperature ranging from about 70° F. to about 190° F. in the second reactor 30 . In other particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a temperature ranging from about 150° F. to about 1.90° F. in the second reactor 30 . In still other particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a temperature ranging from about 140° F. to about 160° F. in the second reactor 30 .
  • the second leaching solution 28 is in contact with the coal and precipitate at a pressure ranging from about 14.4 psia to about 100 psia in the second reactor 30 . In other particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a pressure ranging from about 14.4 psia to about 43 psia in the second reactor 30 . In still other particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a pressure ranging from about 14.4 psia to about 28 psia in the second reactor 30 .
  • the method 10 further comprises separating at least a portion of the second leaching solution 28 from the coal.
  • separating at least a portion of the second leaching solution 28 from the coal at least a portion of the second products and at least a portion of the third products are also separated from the coal because they are soluble in the second leaching solution.
  • substantially all of the second leaching solution 28 including substantially all of the second products and substantially all of the third products may be separated from the coal.
  • the second leaching solution 28 and the coal are transported from the second reactor 30 as a slurry 32 to a drum filter 34 .
  • the drum filter 34 filters the slurry 32 to separate wet coal 38 from the second leaching solution 36 .
  • the method 10 may further comprise washing the wet coal 38 with water in a water wash apparatus 40 to remove any residual reactants or products from the coal.
  • the water-washed coal 42 may be transferred to a coal dryer (not shown) over a conveyer belt (not shown), which will further act as a filter to remove water from the coal.
  • Ash may be present in particular embodiments of the water-washed coal 42 in an amount less than about 0.2% by weight. In certain embodiments of the method 10 , ash is present in the water-washed coal 42 in an amount ranging from about 0.01% by weight to about 0.5% by weight. In other embodiments of the method 10 , ash is present in the water-washed coal 42 in an amount ranging from about 0.01% by weight to about. 0.2% by weight.
  • the method further comprises agitating the first leaching solution in the first reactor, agitating the second leaching solution in the second reactor, or both.
  • FIG. 2 illustrates an another embodiment of a method 50 for removing impurities from coal. Like elements in FIGS. 1 and 2 are numbered with like numerals.
  • the neutralizing composition 18 is added to an unreacted first leaching solution 54 rather than to the first reactor 16 as in the method 10 illustrated in FIG. 1 .
  • the first leaching solution 12 and the coal 14 are transported from the first reactor 16 as a slurry 52 to the drum filter 22 .
  • the drum filter 22 fillers the slurry 52 to separate an unreacted first leaching solution 54 and from wet coal 56 .
  • the neutralizing composition 18 is added to the unreacted first leaching solution 54 and the neutralizing composition reacts with the unreacted first leaching solution to form a precipitate.
  • At least a portion of the unreacted first leaching solution 54 is separated by a filter apparatus 58 from the precipitate 60 as a neutralized first leaching solution 62 .
  • the precipitate 60 is then contacted with the second leaching solution 28 in the nitrate reactor, along with the wet coal 56 .
  • the second leaching solution 28 reacts with at least one of the impurities and the precipitate 60 to form one or more second products and one or more third products, respectively.
  • the second products and the third products are soluble in the second leaching solution 28 .
  • the methods may be carried out in one reaction chamber in a batch process to avoid using multiple reactors, multiple filters, and conveying equipment (e.g., pumps and conveyer belts) an associated costs and space requirements.
  • conveying equipment e.g., pumps and conveyer belts
  • exposure of coal outside of the reactor is reduced, thus h

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Abstract

A method for removing at least one impurity from coal is provided. The method comprises providing coal having a plurality of impurities and contacting the coal with a first leaching solution. The first leaching solution reacts with at least one of the impurities to produce one or more first products soluble in the first leaching solution. The method further comprises adding a neutralizing composition to the first leaching solution. The neutralizing composition reacts with the first leaching solution to form a precipitate. The method further comprises separating at least a portion of the first leaching solution from the coal and the precipitate and contacting the coal and the precipitate with a second leaching solution. The second leaching solution reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively, the second products and the third products being soluble in the second leaching solution. The method further comprises separating at least a portion of the second leaching solution from the coal.

Description

    TECHNICAL FIELD
  • This disclosure generally relates to methods for removing impurities from coal, and more particularly relates to methods for removing impurities from coal which include neutralization of a leaching solution.
  • BACKGROUND OF THE INVENTION
  • Clean coal, such as ultra clean coal, may be provided by treatment of coal including impurities to remove the impurities. For instance, coal including impurities may be treated with a first leaching solution such as hydrofluoric acid (“HF”) in a first reactor to produce a first reaction slurry. The first reaction slurry may be transported to a filter (e.g., drum filter) to produce filtered, wet coal. The filtered, wet coal may then be transported to a second reactor for treatment with a second leaching solution such as a nitrate solution to produce a second reaction slurry. The second reaction slurry may then be transported to a filter for filtering. The resulting ultra clean coal may then be water washed and transported to a dryer for drying.
  • Typically, the moles of HF required for the first reaction are significantly lower than the moles of HF used. Thus, the unreacted HF remains in the liquid and may even remain in the coal (e.g., in the areas of pre-existing moisture and in etched pores in the coal created from the HF reacting with ash impurities) after the coal is filtered.
  • HF is known to be extremely toxic and to corrode glass. HF typically has an occupational exposure level of 2 ppm. The PPO's needed include rubber gloves, face mask or safety glasses, apron, and good ventilation. If HF is inhaled or ingested, the result may be fatal. HF is readily absorbed through the skin and skin contact may also be fatal. HF also acts as a systemic poison, causes severe burns, and is a possible mutigen. In addition, the reaction with HF may be delayed. Thus, any contact with HF, even if minor, requires immediate medical attention.
  • SUMMARY OF THE INVENTION
  • This disclosure provides a method for removing at least one impurity from coal. The method comprises providing coal having a plurality of impurities and contacting the coal with a first leaching solution. The first leaching solution reacts with at least one of the impurities to produce one or more first products soluble in the first leaching solution. The method further comprises adding a neutralizing composition to the first leaching solution. The neutralizing composition reacts with the first leaching solution to form a precipitate. The method further comprises separating at least a portion of the first leaching solution from the coal and the precipitate and contacting the coal and the precipitate with a second leaching solution. The second leaching solution reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively, the second products and the third products being soluble in the second leaching solution. The method further comprises separating at least a portion of the second leaching solution from the coal.
  • The present disclosure also provides another method for removing at least one impurity from coal. The method comprises providing coal having a plurality of impurities and contacting the coal with a first leaching solution. The first leaching solution reacts with at least one of the impurities to produce one or more first products soluble in the first leaching solution. The method further comprises separating at least a portion of the first leaching solution from the coal as an unreacted first leaching solution. The method further comprises adding a neutralizing composition to the unreacted first leaching solution. The neutralizing composition reacts with the unreacted first leaching solution to form a precipitate. The method further comprises separating at least a portion of the unreacted first leaching solution from the precipitate and contacting the coal and the precipitate with a second leaching solution. The second leaching solution reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively, the second products and the third products being soluble in the second leaching solution. The method further comprises separating at least a portion of the second leaching solution from the coal.
  • Other aspects, features, and advantages of this invention will be apparent from the following detailed description, drawings, and claims.
  • BRIEF DESCRIPTION OF DRAWINGS
  • FIG. 1 illustrates a method 10 for removing at least one impurity from coal in accordance with an embodiment of the present invention.
  • FIG. 2 illustrates a method 50 for removing at least one impurity from coal in accordance with another embodiment of the present invention.
  • DETAILED DESCRIPTION OF EMBODIMENTS
  • As summarized above, this disclosure encompasses methods for removing at least one impurity from coal. Thus, the method of the present disclosure may be used to produce ultra clean coal. As used herein, the term “ultra clean coal” refers to coal having a reduced ash content (e.g., below about 0.2%) and/or a substantially reduced sulfur content such that the coal may be fed directly into processes such as gas turbine processes and provide advantages such as improved thermal efficiency, for example. As used herein, “ash” refers to both the non-combustible components in the coal before combustion and the non-combustible byproducts resulting from combustion of the coal. Embodiments of the method for removing at least one impurity from coal are described below and illustrated in FIGS. 1 and 2. It should be understood that any system (e.g., gas turbine systems such as coal fired gas turbine systems, pulverized coal power plants, and integrated gasification combined cycle systems) may use the coal (e.g., ultra clean coal) provided by embodiments of the methods of the present disclosure.
  • FIG. 1 illustrates an embodiment of the method 10 for removing impurities from coal of the present disclosure. The method 10 first provides coal 12 comprising a plurality of impurities. Embodiments of method 10 may provide coal 12 in the form of anthracite coal, bituminous coal, subbituminous coal, lignite coal, or combinations thereof.
  • In some embodiments, the impurities include, but are not limited to, oxides of aluminum, iron, potassium, calcium, sodium, and other metals, minerals, inorganic and organic sulfur compounds, alkalis, ash, or combinations thereof. In certain embodiments, the impurities may be present in the coal 12 in an amount ranging from about 2 wt. % to about 50 wt. %. In other embodiments, the impurities may be present in the coal 12 in an amount ranging from about 3 wt. % to about 8 wt. %. In still other embodiments, the impurities may be present in the coal 12 in an amount ranging from about 5 wt. % to about 7 wt. %.
  • TABLE 1
    Examples of ranges of chemical composition for fly ash produced from
    different coal types (expressed as percent by weight).
    Component Bituminous Subbituminous Lignite
    SiO2 20-60 40-60 15-45
    Al2O3 5-35 20-30 10-25
    Fe2O3 10-40  4-10  4-15
    CaO  1-12  5-30 15-40
    MgO 0-5 1-6  3-10
    SO3 0-4 0-2  0-10
    Na2O 0-4 0-2 0-6
    K2O 0-3 0-4 0-4
    LOI 0-15 0-3 0-5
    Source: http://www.tfhrc.gov
  • The method 10 contacts the coal 12 with a first leaching solution 14 in a first reactor 16. At least one of the impurities reacts with the first leaching solution 14 to produce one or more first products soluble in the first leaching solution. In certain embodiments, the first leaching solution 14 may comprise an acid solution. In some embodiments, the first leaching solution 14 may include, but is not limited to, first reactants such as a hydrofluoric acid, a nitric acid, a hydrochloric acid, a hydrofluorosilicic acid, a combination thereof, or other strong acids that dissolve oxides.
  • An example of a reaction of the first leaching solution 14 with at least one impurity is given below in Formula (I):

  • SiO2+4HF→SiF4+2H2O  (I).
  • In certain embodiments, the first leaching solution 14 has a first reactant concentration ranging from about 3 M to about 10 M. In other embodiments, the first leaching solution 14 has a first reactant concentration ranging from about 3 M to about 6 M. In still other embodiments, the first leaching solution 14 has a first reactant concentration ranging from about 4 M to about 6 M.
  • In particular embodiments, the weight ratio of first leaching solution 14 to coal 12 added to the first reactor 16 ranges from about 10:1 to about 10:5. Unless otherwise indicated, all ratios are weight to weight ratios. In other particular embodiments, the weight ratio of first leaching solution 14 to coal 12 added to the first reactor 16 ranges from about 10:2 to about 10:4. In still other particular embodiments, the weight ratio of first leaching solution 14 to coal 12 added to the first reactor 16 ranges from about 10:2.5 to about 10:3.5.
  • In certain embodiments, the first leaching solution 14 comprises a hydrofluoric acid solution having a hydrofluoric acid concentration ranging from about 3 M to about 10 M. In other embodiments, the first leaching solution 14 comprises a hydrofluoric acid solution having a hydrofluoric acid concentration ranging from about 3 M to about 6 M. In still other embodiments, the first leaching solution 14 comprises a hydrofluoric acid solution having a hydrofluoric acid concentration ranging from about 4 M to about 6 M. In particular embodiments, the weight ratio of hydrofluoric acid solution 14 to coal 12 added to the first reactor 16 ranges from about 10:1 to about 10:5. In other particular embodiments, the weight ratio of hydrofluoric acid solution 14 to coal 12 added to the first reactor 16 ranges from about 10:2 to about 10:4. In still other particular embodiments, the weight ratio of hydrofluoric acid solution 14 to coal 12 added to the first reactor 16 ranges from about 10:2.5 to about 10:3.5.
  • In particular embodiments, the coal 12 is in contact with the first leaching solution 14 for about 1 hours to about 10 hours in the first reactor 16. In other particular embodiments, the coal 12 is in contact with the first leaching solution 14 for about 3 hours to about 5 hours in the first reactor 16. In still other particular embodiments, the coal 12 is in contact with the first leaching solution 14 for about 4 hours to about 5 hours in the first reactor 16.
  • In particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a temperature ranging from about 70° F. to about 200° F. in the first reactor 16. In other particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a temperature ranging from about 110° F. to about 170° F. in the first reactor 16. In still other particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a temperature ranging from about 140° F. to about 160° F. in the first reactor 16.
  • In particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a pressure ranging from about 14 psia to about 1000 psia in the first reactor 16. In other particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a pressure ranging from about 14 psia to about 42 psia in the first reactor 16. In still other particular embodiments, the coal 12 is in contact with the first leaching solution 14 at a pressure ranging from about 14 psia to about 20 psia in the first reactor 16.
  • In certain embodiments, the one or more first products comprises one or more fluorides, hydroxyl fluorides, hydroxides, or combinations thereof. In embodiments where the first products comprise one or more fluorides, the fluorides may be selected from silicon fluoride, aluminum fluoride, iron fluoride, calcium fluoride, potassium fluoride, or combinations thereof.
  • The method 10 further comprises adding a neutralizing composition 18 to the first leaching solution 14 such that neutralizing composition reacts with the first leaching solution to form a precipitate. By adding the neutralizing composition 18 to the first leaching solution 14, any unreacted first reactant (i.e. excess first reactant that has not reacted with at least one of the impurities) in the first leaching solution is neutralized.
  • In some embodiments, the neutralizing composition 18 comprises a neutralizing reactant including a calcium hydroxide, sodium hydroxide, any other alkali, or combinations thereof. In certain embodiments, the first leaching solution comprises a hydrofluoric acid solution, the neutralizing composition comprises calcium hydroxide, the precipitate comprises a calcium fluoride, and the one or more third products comprise calcium ions, nitrate ions, or combinations thereof.
  • In certain embodiments, the neutralizing composition 18 is added to the first leaching solution 14 after the coal 12 has been in contact with the first leaching solution for about 1 hours to about 10 hours in the first reactor 16. In other particular embodiments, the neutralizing composition 18 is added to the first leaching solution 14 after the coal 12 has been in contact with the first leaching solution for about 3 hours to about 5 hours in the first reactor 16. In still other particular embodiments, the neutralizing composition 18 is added to the first leaching solution 14 after the coal 12 has been in contact with the first leaching solution for about 4 hours to about 5 hours in the first reactor 16.
  • In certain embodiments, the neutralizing composition 18 has a neutralizing reactant concentration ranging from about 1 M to about 10 M. In other embodiments, the neutralizing composition 18 has a neutralizing reactant concentration ranging from about 1 M to about 4 M. In still other embodiments, the neutralizing composition 18 has a neutralizing reactant concentration ranging from about 2 M to about 3 M.
  • The method 10 further comprises separating at least a portion of the first leaching solution 14 from the coal 12 and the precipitate. By separating at least a portion of the first leaching solution 14 from the coal 12, at least a portion of the first products are also separated from the coal because they are soluble in the first leaching solution. Thus, in particular embodiments, substantially all of the first leaching solution 14 including substantially all of the first products may be separated from the coal 12 and the precipitate. In the method 10 illustrated in FIG. 1, the first leaching solution 14, the coal 12, and the precipitate, are transported from the first reactor 16 as a slurry 20 to a drum filter 22. The drum filter 22 filters the slurry 20 to separate the coal and the precipitate as wet coal 26 from the first leaching solution 24.
  • The wet coal 26 is then fed to a second reactor 30 where the coal 12 and the precipitate are contacted with a second leaching solution 28. The second leaching solution 28 reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively. The second products and the third products are soluble in the second leaching solution 28. In certain embodiments, the second leaching solution 28 may comprise a nitrate solution.
  • Examples of reactions of the second leaching solution 28 with at least one impurity are given below in Formulas (II) and (III):

  • FeS2+14Fe(NO3)3+8H2O→2SO4 2−+16H++15Fe2++42NO3−  (II)

  • SiF4+2(Al,Fe)(NO3)3+2H2O→SiO2(s)+2(Al,Fe)F2 ++4H++6NO3   (III).
  • In certain embodiments, the second leaching solution 28 comprises a second reactant including, but not limited to nitric acid, aluminum nitrate, ferric nitrate, fluoronitrate, other nitrates, hydroxide, hydroxyl fluoride, hydroxynitrate ions thereof, or combinations thereof. In some embodiments of the method, the one or more second products comprises nitrate ions, sulfate ions, iron ions, hydroxyfluorides, oxides, fluoronitrate, or combinations thereof. In particular embodiments, the one or more third products comprise calcium ions or combination thereof.
  • In particular embodiments, the second leaching solution 28 has a second reactant concentration ranging from about 0.1 M to about 5 M. In other particular embodiments, the second leaching solution 28 has a second reactant concentration ranging from about 0.1 M to about 0.4 M. In still other particular embodiments, the second leaching solution 28 has a second reactant concentration ranging from about 0.3 M to about 0.4 M.
  • In certain embodiments, the weight ratio of second leaching solution 28 to wet coal 26 added to the second reactor 30 ranges from about 10:1 to about 10:5. In other embodiments, the weight ratio of second leaching solution 28 to wet coal 26 added to the second reactor 30 ranges from about 10:2 to about 10:4. In still other embodiments, the weight ratio of second leaching solution 28 to wet coal 26 added to the second reactant reactor 30 ranges from about 10:2.5 to about 10:3.5.
  • In particular embodiments, the second leaching solution 28 comprises a nitric acid solution having a nitric acid concentration ranging from about 0.1 M to about 5 M. In other particular embodiments, the second leaching solution 28 comprises a nitric acid solution having a nitric acid concentration ranging from about 0.1 M to about 0.4 M. In still other particular embodiments, the second leaching solution 28 comprises a nitric acid solution having a nitric acid concentration ranging from about 0.2 M to about 0.3 M. In certain embodiments, the weight ratio of nitric acid solution 28 to wet coal 26 added to the second reactor 30 ranges from about 10:1 to about 10:5. In other embodiments, the weight ratio of nitric acid solution 28 to wet coal 26 added to the second reactor 30 ranges from about 10:2 to about 10:4. In still other embodiments, the weight ratio of nitric acid solution to 28 to wet coal 26 added to the second reactor 30 ranges from about 10:2.5 to about 10:3.5.
  • According to certain embodiments of the present disclosure, the second leaching solution 28 is in contact with the coal and the precipitate for about 20 hours to about 30 hours in the second reactor 30. In other particular embodiments, the second leaching solution 28 is in contact with the coal and the precipitate for about 22 hours to about 26 hours in the second reactor 30.
  • In particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a temperature ranging from about 70° F. to about 190° F. in the second reactor 30. In other particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a temperature ranging from about 150° F. to about 1.90° F. in the second reactor 30. In still other particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a temperature ranging from about 140° F. to about 160° F. in the second reactor 30.
  • In particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a pressure ranging from about 14.4 psia to about 100 psia in the second reactor 30. In other particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a pressure ranging from about 14.4 psia to about 43 psia in the second reactor 30. In still other particular embodiments, the second leaching solution 28 is in contact with the coal and precipitate at a pressure ranging from about 14.4 psia to about 28 psia in the second reactor 30.
  • The method 10 further comprises separating at least a portion of the second leaching solution 28 from the coal. By separating at least a portion of the second leaching solution 28 from the coal, at least a portion of the second products and at least a portion of the third products are also separated from the coal because they are soluble in the second leaching solution. Thus, in particular embodiments, substantially all of the second leaching solution 28 including substantially all of the second products and substantially all of the third products may be separated from the coal. In the method 10 illustrated in FIG. 1, the second leaching solution 28 and the coal are transported from the second reactor 30 as a slurry 32 to a drum filter 34. The drum filter 34 filters the slurry 32 to separate wet coal 38 from the second leaching solution 36.
  • The method 10 may further comprise washing the wet coal 38 with water in a water wash apparatus 40 to remove any residual reactants or products from the coal. The water-washed coal 42 may be transferred to a coal dryer (not shown) over a conveyer belt (not shown), which will further act as a filter to remove water from the coal.
  • Ash may be present in particular embodiments of the water-washed coal 42 in an amount less than about 0.2% by weight. In certain embodiments of the method 10, ash is present in the water-washed coal 42 in an amount ranging from about 0.01% by weight to about 0.5% by weight. In other embodiments of the method 10, ash is present in the water-washed coal 42 in an amount ranging from about 0.01% by weight to about. 0.2% by weight.
  • In particular embodiments, the method further comprises agitating the first leaching solution in the first reactor, agitating the second leaching solution in the second reactor, or both.
  • FIG. 2 illustrates an another embodiment of a method 50 for removing impurities from coal. Like elements in FIGS. 1 and 2 are numbered with like numerals.
  • As illustrated in FIG. 2, the neutralizing composition 18 is added to an unreacted first leaching solution 54 rather than to the first reactor 16 as in the method 10 illustrated in FIG. 1. Thus, in this embodiment, the first leaching solution 12 and the coal 14 are transported from the first reactor 16 as a slurry 52 to the drum filter 22. The drum filter 22 fillers the slurry 52 to separate an unreacted first leaching solution 54 and from wet coal 56. The neutralizing composition 18 is added to the unreacted first leaching solution 54 and the neutralizing composition reacts with the unreacted first leaching solution to form a precipitate.
  • At least a portion of the unreacted first leaching solution 54 is separated by a filter apparatus 58 from the precipitate 60 as a neutralized first leaching solution 62. The precipitate 60 is then contacted with the second leaching solution 28 in the nitrate reactor, along with the wet coal 56. The second leaching solution 28 reacts with at least one of the impurities and the precipitate 60 to form one or more second products and one or more third products, respectively. The second products and the third products are soluble in the second leaching solution 28.
  • In alternate embodiments (not shown), the methods may be carried out in one reaction chamber in a batch process to avoid using multiple reactors, multiple filters, and conveying equipment (e.g., pumps and conveyer belts) an associated costs and space requirements. In addition, exposure of coal outside of the reactor is reduced, thus h
  • By adding a neutralizing composition to the first leaching solution either in the first reactor or into an unreacted first leaching solution separated from the coal and then contacting the produced precipitate with the second leaching solution, excess unreacted reactant, such as hydrofluoric acid, is reduced or eliminated from the remainder of the process and the resulting coal. Thus, the potential for exposure to hazardous chemicals, such as hydrofluoric acid or other acids used, as it is neutralized rather than transported to the second reactor along with the coal. In addition, the reactors volumes may be lower and the process can be carried out in a continuous manner instead of in a batch or semi-batch process.
  • it should be apparent that the foregoing relates only to the preferred embodiments of the present application and that numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the generally spirit and scope of the invention as defined by the following claims and the equivalents thereof.

Claims (20)

1. A method for removing at least one impurity from coal, the method comprising:
providing coal having a plurality of impurities;
contacting the coal with a first leaching solution, wherein the first leaching solution reacts with at least one of the impurities to produce one or more first products soluble in the first leaching solution;
adding a neutralizing composition to the first leaching solution, wherein the neutralizing composition reacts with the first leaching solution to form a precipitate;
separating at least a portion of the first leaching solution from the coal and the precipitate; and
contacting the coal and the precipitate with a second leaching solution, wherein the second leaching solution reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively, the second products and the third products being soluble in the second leaching solution; and
separating at least a portion of the second leaching solution from the coal.
2. The method of claim 1, wherein the neutralizing composition comprises calcium hydroxide, sodium hydroxide, or combinations thereof.
3. The method of claim 1, wherein the neutralizing composition has a neutralizing reactant concentration ranging from about 1 M to about 10 M.
4. The method of claim 1, wherein the first leaching solution comprises a hydrofluoric acid solution, the neutralizing composition comprises calcium hydroxide, the precipitate comprises a calcium fluoride, and the one or more third products comprise calcium ions, nitrate ions, or combinations thereof.
5. The method of claim 1, wherein the first leaching solution comprises a hydrofluoric acid solution, a nitric acid solution, a hydrochloric acid solution, a hydrofluorosilicic acid solution, or combinations thereof.
6. The method of claim 1, wherein the first leaching solution comprises a hydrofluoric acid solution having a hydrofluoric acid concentration ranging from about 3 M to about 10 M.
7. The method of claim 1, wherein the neutralizing composition reacts with the first leaching solution to neutralize substantially all of the first leaching solution.
8. The method of claim 1, wherein the second leaching solution comprises nitric acid, aluminum nitrate, ferric nitrate, fluoronitrate, hydroxide, hydroxyl fluoride, hydroxynitrate, ions thereof, or combinations thereof.
9. The method of claim 1, wherein the second leaching solution comprises a nitric acid solution having a nitric acid concentration ranging from about 0.1 M to about 5 M.
10. The method of claim 1, wherein the method is carried out in a batch reactor chamber.
11. A method for removing at least one impurity from coal, the method comprising:
providing coal having a plurality of impurities;
contacting the coal with a first leaching solution, wherein the first leaching solution reacts with at least one of the impurities to produce one or more first products soluble in the first leaching solution;
separating at least a portion of the first leaching solution from the coal as an unreacted first leaching solution;
adding a neutralizing composition to the unreacted first leaching solution, wherein the neutralizing composition reacts with the unreacted first leaching solution to form a precipitate;
separating at least a portion of the unreacted first leaching solution from the precipitate;
contacting the coal and the precipitate with a second leaching solution, wherein the second leaching solution reacts with at least one of the impurities and the precipitate to form one or more second products and one or more third products, respectively, the second products and the third products being soluble in the second leaching solution; and
separating at least a portion of the second leaching solution from the coal.
12. The method of claim 11, wherein the neutralizing composition comprises calcium hydroxide, sodium hydroxide, or combinations thereof.
13. The method of claim 11, wherein the neutralizing composition has a neutralizing reactant concentration ranging from about 1 M to about 10 M.
14. The method of claim 11, wherein the first leaching solution comprise a hydrofluoric acid solution, the neutralizing composition comprises calcium hydroxide, the precipitate comprises a calcium fluoride, and the one or more third products comprise calcium ions, nitrate ions, or combinations thereof.
15. The method of claim 11, wherein the first leaching solution comprises a hydrofluoric acid solution, a nitric acid solution, a hydrochloric acid solution, a hydrofluorosilicic acid solution, or combinations thereof.
16. The method of claim 11, wherein the first leaching solution comprises a hydrofluoric acid solution having a hydrofluoric acid concentration ranging from about 3 M to about 10 M.
17. The method of claim 11, wherein the neutralizing composition reacts with the unreacted first leaching solution to neutralize substantially all of the unreacted first leaching solution.
18. The method of claim 11 wherein the second leaching solution comprises nitric acid, aluminum nitrate, ferric nitrate, fluoronitrate, hydroxide, hydroxyl fluoride, hydroxynitrate, ions thereof, or combinations thereof.
19. The method of claim 11, wherein the second leaching solution comprises a nitric acid solution having a nitric acid concentration ranging from about 0.1 Mto about 5 M.
20. The method of claim 11, wherein the method is carried out in a batch reactor chamber.
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JP2010176841A JP2011038100A (en) 2009-08-10 2010-08-06 Method for removing impurity from coal including neutralization of leaching solution
CH01280/10A CH701637A2 (en) 2009-08-10 2010-08-09 A method for removing impurities from coal with neutralization of a leach solution.
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