US20220348837A1 - Processing of low rank coal - Google Patents
Processing of low rank coal Download PDFInfo
- Publication number
- US20220348837A1 US20220348837A1 US17/862,008 US202217862008A US2022348837A1 US 20220348837 A1 US20220348837 A1 US 20220348837A1 US 202217862008 A US202217862008 A US 202217862008A US 2022348837 A1 US2022348837 A1 US 2022348837A1
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- US
- United States
- Prior art keywords
- coal
- binder
- vessel
- less
- fuel composition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- 239000003245 coal Substances 0.000 title claims abstract description 114
- 239000000203 mixture Substances 0.000 claims abstract description 84
- 239000011230 binding agent Substances 0.000 claims abstract description 51
- 239000000446 fuel Substances 0.000 claims abstract description 50
- 239000011164 primary particle Substances 0.000 claims abstract description 14
- 238000000034 method Methods 0.000 claims abstract description 12
- 238000007493 shaping process Methods 0.000 claims description 2
- 239000002817 coal dust Substances 0.000 description 30
- 229920003023 plastic Polymers 0.000 description 22
- 239000004033 plastic Substances 0.000 description 22
- 239000003077 lignite Substances 0.000 description 12
- 239000000428 dust Substances 0.000 description 10
- 238000010438 heat treatment Methods 0.000 description 9
- 238000013019 agitation Methods 0.000 description 8
- -1 polyethylene Polymers 0.000 description 7
- 239000011159 matrix material Substances 0.000 description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 239000000460 chlorine Substances 0.000 description 4
- 229910052801 chlorine Inorganic materials 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 230000009467 reduction Effects 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 3
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 3
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 3
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 description 3
- 239000005020 polyethylene terephthalate Substances 0.000 description 3
- 238000010298 pulverizing process Methods 0.000 description 3
- 229910052717 sulfur Inorganic materials 0.000 description 3
- 239000011593 sulfur Substances 0.000 description 3
- 239000003039 volatile agent Substances 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- 238000005054 agglomeration Methods 0.000 description 2
- 230000002776 aggregation Effects 0.000 description 2
- 230000004075 alteration Effects 0.000 description 2
- 239000006227 byproduct Substances 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 125000004435 hydrogen atom Chemical class [H]* 0.000 description 2
- 229920001684 low density polyethylene Polymers 0.000 description 2
- 239000004702 low-density polyethylene Substances 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 230000000116 mitigating effect Effects 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 239000004417 polycarbonate Substances 0.000 description 2
- 229920000515 polycarbonate Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000004449 solid propellant Substances 0.000 description 2
- 230000009466 transformation Effects 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- XQUPVDVFXZDTLT-UHFFFAOYSA-N 1-[4-[[4-(2,5-dioxopyrrol-1-yl)phenyl]methyl]phenyl]pyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C(C=C1)=CC=C1CC1=CC=C(N2C(C=CC2=O)=O)C=C1 XQUPVDVFXZDTLT-UHFFFAOYSA-N 0.000 description 1
- PEEHTFAAVSWFBL-UHFFFAOYSA-N Maleimide Chemical compound O=C1NC(=O)C=C1 PEEHTFAAVSWFBL-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004696 Poly ether ether ketone Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004697 Polyetherimide Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- RHZUVFJBSILHOK-UHFFFAOYSA-N anthracen-1-ylmethanolate Chemical compound C1=CC=C2C=C3C(C[O-])=CC=CC3=CC2=C1 RHZUVFJBSILHOK-UHFFFAOYSA-N 0.000 description 1
- 239000003830 anthracite Substances 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000002802 bituminous coal Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000002864 coal component Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical class O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 231100001261 hazardous Toxicity 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229920001179 medium density polyethylene Polymers 0.000 description 1
- 239000004701 medium-density polyethylene Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000000386 microscopy Methods 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 229920003192 poly(bis maleimide) Polymers 0.000 description 1
- 229920000747 poly(lactic acid) Polymers 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920002530 polyetherether ketone Polymers 0.000 description 1
- 229920001601 polyetherimide Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000004626 polylactic acid Substances 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000003476 subbituminous coal Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10F—DRYING OR WORKING-UP OF PEAT
- C10F5/00—Drying or de-watering peat
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/06—Methods of shaping, e.g. pelletizing or briquetting
- C10L5/10—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders
- C10L5/14—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders with organic binders
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
- C10B53/08—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form in the form of briquettes, lumps and the like
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10F—DRYING OR WORKING-UP OF PEAT
- C10F7/00—Working-up peat
- C10F7/02—Disintegrating peat
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10F—DRYING OR WORKING-UP OF PEAT
- C10F7/00—Working-up peat
- C10F7/08—Working-up peat by extrusion combined with cutting
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/04—Raw material of mineral origin to be used; Pretreatment thereof
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/06—Methods of shaping, e.g. pelletizing or briquetting
- C10L5/10—Methods of shaping, e.g. pelletizing or briquetting with the aid of binders, e.g. pretreated binders
- C10L5/22—Methods of applying the binder to the other compounding ingredients; Apparatus therefor
-
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- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/34—Other details of the shaped fuels, e.g. briquettes
- C10L5/36—Shape
- C10L5/366—Powders
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L9/00—Treating solid fuels to improve their combustion
- C10L9/08—Treating solid fuels to improve their combustion by heat treatments, e.g. calcining
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L9/00—Treating solid fuels to improve their combustion
- C10L9/10—Treating solid fuels to improve their combustion by using additives
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2230/00—Function and purpose of a components of a fuel or the composition as a whole
- C10L2230/22—Function and purpose of a components of a fuel or the composition as a whole for improving fuel economy or fuel efficiency
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2250/00—Structural features of fuel components or fuel compositions, either in solid, liquid or gaseous state
- C10L2250/04—Additive or component is a polymer
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/02—Combustion or pyrolysis
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/06—Heat exchange, direct or indirect
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/08—Drying or removing water
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/22—Impregnation or immersion of a fuel component or a fuel as a whole
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/24—Mixing, stirring of fuel components
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/28—Cutting, disintegrating, shredding or grinding
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/30—Pressing, compressing or compacting
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L2290/00—Fuel preparation or upgrading, processes or apparatus therefore, comprising specific process steps or apparatus units
- C10L2290/46—Compressors or pumps
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/02—Solid fuels such as briquettes consisting mainly of carbonaceous materials of mineral or non-mineral origin
- C10L5/34—Other details of the shaped fuels, e.g. briquettes
- C10L5/36—Shape
- C10L5/363—Pellets or granulates
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel
Definitions
- This disclosure relates to processing of low rank coal, such as lignite.
- Low rank coal e.g., lignite
- “hard” coal e.g., bituminous, sub-bituminous, anthracite.
- Lignite the lowest rank coal, typically has a moisture content in a range of 30-60 wt % and a heat content in a range of 4,000-8,300 BTU/lb.
- sub-bituminous coal typically has a moisture content in a range of 10-45 wt % and an energy content in a range of 8,500-13,000 BTU/lb
- bituminous coal typically has a moisture content in a range of 2-15 wt % and a heat content in a range of 11,000-15,000 BTU/lb. Due to its high moisture content and brittle nature, processing of low rank coal requires significant energy input and results in the creation of coal fines (e.g., dust), which presents a combustion hazard and is of little use.
- Certain aspects of the subject matter described can be implemented as a method or preparing a fuel composition.
- the method includes placing coal having a heat content between about 3,000 BTU/lb and about 9,000 BTU/lb and a moisture content between about 20 wt % and about 60 wt % in a vessel.
- the coal is exposed to heat and a pressure less than atmospheric pressure within the vessel, thereby reducing a primary particle size of the coal, such that an average primary particle size of the coal is less than 1 millimeter.
- a binder is introduced to the vessel, such that the coal combines with the binder to yield a mixture.
- the mixture is shaped to yield a fuel composition.
- the coal is exposed to heat before combining the coal and the binder. In some embodiments, exposing the coal to heat includes heating the coal by conduction. In some embodiments, exposing the coal to heat includes contacting the coal with a heated surface. In some embodiments, the heated surface includes a rotating blade.
- the coal is agitated in the vessel. In some embodiments, agitating the coal includes intermittently agitating the coal in the vessel.
- exposing the coal to the pressure less than atmospheric pressure within the vessel includes intermittently reducing the pressure in the vessel.
- the mixture is heated by conduction.
- the binder includes a plastic substantially free of chlorine.
- heating the mixture includes increasing the malleability of the plastic.
- heating the mixture includes melting or softening the plastic.
- the fuel composition includes the coal distributed in a plastic matrix.
- shaping the fuel composition includes cutting, shredding, or milling the mixture to form discrete portions of the fuel composition.
- the mixture is extruded to yield an extruded fuel product before cutting, shredding, or milling the mixture of coal and binder.
- the extruded fuel product includes the coal distributed in a plastic matrix.
- the fuel composition includes about 5 wt % to about 50 wt % of the binder.
- the mixture is heated to a temperature between 100° C. and 250° C., between 110° C. and 240° C., 120° C. and 230° C., between 130° C. and 220° C., or between 140° C. and 210° C.
- the coal placed in the vessel is uncrushed.
- the fuel composition includes coal having a heat content between about 4,000 BTU/lb and about 8,300 BTU/lb and a binder including plastic.
- the fuel composition includes less than 5 wt % coal dust having an average primary particle size of 75 micrometers or smaller.
- the coal includes lignite.
- the binder is in the form of a plastic matrix. In some embodiments, the coal is bound in the plastic matrix.
- the fuel composition includes about 5 wt % to about 50 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 40 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 30 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 25 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 20 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 15 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 10 wt % of the binder. In some embodiments, the fuel composition includes about 10 wt % of the binder.
- the fuel composition is in the form of a solid inhomogeneous mixture.
- the plastic includes polyethylene. In some embodiments, the fuel composition includes polyethylene terephthalate. In some embodiments, the plastic is free of chlorine.
- the fuel composition has a moisture content between about 1 wt % and about 3 wt % or between about 2 wt % and about 3 wt %.
- a heat content of the fuel composition is at least about 9,000 BTU/lb. In some embodiments, a heat content of the fuel composition is at least about 10,000 BTU/lb. In some embodiments, a heat content of the fuel composition is between about 10,000 BTU/lb and about 11,000 BTU/lb. In some embodiments, a heat content of the fuel composition is at least about 1.5, 1.6, 1.7, 1.8, 1.9, or 1.95 times greater than the heat content of the coal.
- Low rank coal is a coal typically having a heat content (for example, higher heating value (HHV)) between about 4,000 BTU/lb and about 8,300 BTU/lb and a moisture content between about 20 wt % and about 60 wt % or between about 40 wt % and about 50 wt %.
- low rank coal has a fixed carbon content between about 30 wt % and about 70 wt %.
- low rank coal has an ash content of less than about 10 wt %.
- low rank coal has a volatiles content between about 5 wt % and about 50 wt %.
- One example of low rank coal is lignite.
- pulverizing the low rank coal in order to reduce moisture content can produce coal dust and can pose handling, logistics and transport challenges, including due to the creation of dust.
- pulverizing the low rank coal in order to reduce moisture content can produce coal dust and can convert the low rank coal into a non-transportable form (e.g., a hazardous powder). Therefore, after reducing the moisture content of the low rank coal, the low rank coal needs to be re-packaged and/or processed into a transportable form.
- the methods described in this disclosure can be implemented to complete the steps of removing moisture content from low rank coal and re-packaging the low rank coal with reduced moisture content into a transportable form in a single batch process.
- One example advantage of the methods described herein is that the energy content of the coal is increased on a per weight basis, while also displacing a certain percentage of coal with a waste material that otherwise would not be beneficially used, thus allowing for a near-term reduction of the amount of coal needed by the operator due to the higher energy content and reducing the negative environmental impact of coal combustion emissions and the total demand for coal.
- low rank coal is combined with a binder to yield a fuel composition including a binder.
- Suitable binders include one or more plastics, such as low, medium, and high-density polyethylene.
- a suitable binder include polyethylene terephthalate, polystyrene, polyester, polyamides, acrylonitrile butadiene styrene, polyethylene/acrylonitrile butadiene styrene, polycarbonate, polycarbonate/acrylonitrile butadiene styrene, polyurethanes, maleimide/bismaleimide, melamine formaldehyde, phenol formaldehydes, polyepoxide, polyetheretherketone, polyetherimide, polyimide, polylactic acid, polymethyl methacrylate, polytetrafluoroethylene, urea-formaldehyde, and polypropylene.
- the fuel composition typically includes between 5 wt % and 50 wt % of the binder (e.g., between 5 wt % and 40 wt %, between 5 wt % and 30 wt %, between 5 wt % and 25 wt %, between 5 wt % and 20 wt %, between 5 wt % and 15 wt %, or between 5 wt % and 10 wt %).
- the fuel composition includes about 10 wt % of the binder.
- the binder is typically free of chlorine. In some embodiments, the binder is substantially free of chlorine-containing plastics, such as polyvinyl chloride.
- the fuel composition is in the form of a solid, inhomogeneous mixture (e.g., a plastic matrix, with the coal bound in the plastic matrix).
- the binder can be reclaimed from municipal waste or recycling.
- the binder can be used as is or cut or shredded before it is combined with the coal.
- Processing low rank coal includes placing coal having a heat content between about 4,000 BTU/lb and about 8,300 BTU/lb in a vessel.
- the coal can be uncrushed (e.g., straight from a mine) or crushed.
- the binder is combined with the coal before heating.
- the coal is heated prior to addition of the binder.
- the coal (or coal-binder mixture) can be sealed in the vessel.
- the coal (or coal-binder mixture) is heated by conduction.
- Heating the coal (or coal-binder mixture) by conduction includes contacting the coal (or coal-binder mixture) with a heated surface. Heating the coal (or coal-binder mixture) can occur without providing heated gas (e.g., air) to the vessel.
- the heated surface includes one or more blades configured to rotate in the vessel.
- the coal (or coal-binder mixture) can be heated to a temperature up to about 250° C. In some examples, the coal (or coal-binder mixture) is heated to a temperature between 100° C. and 250° C., between 110° C. and 240° C., between 120° C. and 230° C., between 130° C.
- heated fluid e.g., in the form of steam or air
- heated fluid is not provided to the vessel.
- the blade(s) When the coal (or coal-binder mixture) is heated by a blade configured to rotate in the vessel, the blade(s) can be rotated at a speed between about 1 and about 10 rotations per minute.
- the blade(s) can be rotated intermittently, such that the blade is stationary at times and in motion at other times.
- the intermittent rotation can occur in a pattern (e.g., periodically) or occur randomly.
- the coal (or coal-binder mixture) can be agitated (e.g., by rotation of the blade(s)).
- the agitation can occur intermittently (e.g., during rotation of the blade(s)).
- the agitation is intermittently performed in intervals of about 1 minute separated by pauses in agitation of about 1 minute to about 3 minutes.
- the blade(s) protrude radially outward from and are coupled to a central rod.
- the central rod is rotated, for example, by a motor, to rotate the blade(s), resulting in agitation of the coal within the vessel.
- the methods provided herein can produce fines and/or dust during processing, the fines and/or dust are largely stabilized once the processing has been completed to significantly reduce the amount of fines and/or dust by-product that are produced by the system.
- the fines and/or dust can be stabilized by either densifying the fines and/or dust into a solid fuel product and/or by adding plastic to bind the fines and/or dust together to form the solid fuel product.
- the pattern, duration, and extent of agitation can be selected to reduce or minimize pulverization of the coal, and thereby reduce or minimize the amount of fines and/or dust by-product produced from the coal.
- the blade(s) are rotated at a speed that is less than 25 revolutions per minute (rpm), less than 20 rpm, less than 15 rpm, less than 10 rpm, or less than 5 rpm. In some embodiments, the blade(s) are rotated at a speed between 2 rpm and 25 rpm. In some embodiments, the speed at which the blade(s) are rotated is varied. In some embodiments, the speed at which the blade(s) are rotated is varied between 1 rpm and 25 rpm. In some embodiments, the blades are not rotated at all, or not rotated for a desired time duration (e.g., 1 min to 5 mins).
- the speed at which the blade(s) are rotated alternates between gradually decreasing and gradually increasing.
- the time duration(s) of no rotation of the blade(s) is between 1 minute and 3 minutes.
- the blade(s) are rotated around a longitudinal axis defined by the central rod, such that an outermost tip of the blade(s) has a maximum tangential velocity of about 20 inches per second (in/s) or about 15 in/s.
- the blade(s) are rotated around the longitudinal axis defined by the central rod, such that the outermost tip of the blade(s) has a tangential velocity between 5 in/s and 15 in/s.
- the pressure in the vessel can be reduced to below atmospheric pressure (vacuum).
- vacuum can encompass any pressure that is less than atmospheric pressure (1 atmosphere).
- Reducing the pressure in the vessel can occur intermittently. The intermittent pressure reduction can occur in a pattern (e.g., periodically) or occur randomly. That is, the pressure may be reduced, then allowed to increase (e.g., to atmospheric pressure), and then reduced again.
- the pressure in the vessel can be reduced to a pressure between 10 torr and 150 torr, between 50 torr and 150 torr, or between 50 torr and 100 torr. With reduced pressure in the vessel, the coal may be heated to a temperature between about 30° C. and about 100° C.
- Reducing the pressure in the vessel e.g., to about 50 torr
- heating to a lower temperature e.g., 40° C.
- a greater pressure e.g., atmospheric pressure
- a greater temperature e.g. 140° C.
- Reducing the pressure promotes thermal transformation, removal of moisture (e.g., in the form of water vapor), and also promotes removal of oxygen, thereby mitigating and/or preventing ignition of the coal.
- Pressure reduction in the vessel can be carried out by using, for example, a vacuum pump.
- Reducing pressure in the vessel can involve using the vacuum pump to evacuate vapor from an interior of the vessel.
- an outlet of a vapor space of the vessel is connected to the vacuum pump, and during operation, the vacuum pump pulls vapor from the vapor space of the vessel.
- the outlet of the vapor space of the vessel that is connected to the vacuum pump is located a predetermined distance away from a processing zone of the vessel that includes the rotating blade(s).
- the outlet is located at least one radius away from an outermost tip of the rotating blade(s), in which the radius is defined as the distance between the central rod and the outermost tip of the rotating blade(s).
- the radius is twelve inches
- the outlet is located at least twelve inches away from the outermost tip of the rotating blade(s). In this example, this also means that the outlet is located at least 24 inches away from the central rod.
- the outlet is located at least one radius away from the outermost tip of the rotating blade(s) and also above the rotating blade(s) with respect to gravity.
- the orientation of the outlet and the distance away from the processing zone (the rotating blade(s)) can mitigate and/or prevent coal dust from being evacuated with the vapor by the vacuum pump.
- the intermittent agitation can also mitigate and/or prevent coal dust from being evacuated with the vapor by the vacuum pump. For example, by pausing the agitation intermittently, coal dust can be allowed to settle via gravity to mitigate and/or prevent coal dust from being evacuated with the vapor by the vacuum pump.
- a knockout pot is included between the outlet and the vacuum pump for collecting water.
- a filter is included between the outlet and the vacuum pump for mitigating and/or preventing particulates from reaching the vacuum pump.
- the filter is downstream of the knockout pot.
- the filter is a single stage filter.
- the filter is a multi-stage filter, such as a dual stage filter or a 3-stage filter.
- the filter is a multi-stage filter having a 1 st stage filter defining openings with a maximum dimension between 30 micrometers and 50 micrometers, a 2 nd stage filter defining openings with a maximum dimension between 10 micrometers and 20 micrometers, and a 3 rd stage filter defining openings with a maximum dimension between 2 micrometers and 10 micrometers.
- the coal (or coal-binder mixture) is introduced to a single vessel, and processed by a low speed, mid to high torque mechanical blending while being exposed to heat (i.e., contacting heated surfaces).
- Heat and/or vacuum exposure within the vessel can cause the coal to be reduced in size without requiring a time and/or energy-intensive process of mechanically reducing the coal (for example, by smashing or rigorous agitation using substantial force, and/or investing several hours of time to process).
- the coal is pulverized into fines and/or dust within a short time (e.g., between 5-30 minutes) of being exposure to heat and vacuum within the vessel.
- the coal is reduced to having an average primary particle size of less than 1 millimeter within a predetermined time.
- a “primary particle size” refers to the longest linear dimension, e.g., a maximum length or a maximum diameter, of a primary particle.
- a “primary particle” is an individual single particle, not an agglomeration of two or more particles.
- a primary particle can be visually identified by microscopy and distinguished from agglomerations of two or more primary particles based on size, shape, or both.
- the coal is reduced to having an average primary particle size between 1 micrometer and 1 millimeter, between 1 micrometer and 500 micrometers, or between 1 micrometer and 100 micrometers. In some embodiments, the coal is reduced to having an average primary particle size of about or less than 100 micrometers (e.g., or about or less than 90 micrometers, 80 micrometers, 70 micrometers, 60 micrometers, 50 micrometers, 40 micrometers, 30 micrometers, 20 micrometers, 10 micrometers, 9 micrometers, 8 micrometers, 7 micrometers, 6 micrometers, 5 micrometers, 3 micrometers, or 1 micrometer).
- 100 micrometers e.g., or about or less than 90 micrometers, 80 micrometers, 70 micrometers, 60 micrometers, 50 micrometers, 40 micrometers, 30 micrometers, 20 micrometers, 10 micrometers, 9 micrometers, 8 micrometers, 7 micrometers, 6 micrometers, 5 micrometers, 3 micrometers, or 1 micrometer
- the predetermined time for achieving the desired average primary particle size is about or no more than 5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, 30 minutes, 1 hour, 2 hours, or about or no more than 3 hours of being exposed to heat and/or vacuum within the vessel.
- the heat exposure causes the binder to melt or soften.
- the coal is pre-heated (e.g., 10 to 20 minutes) before addition of the binder.
- the coal-binder mixture is processed until the binder reaches a temperature of at least 180° C. (e.g., sufficient to melt or soften the plastic).
- the melted or softened plastic can serve as a binder for the coal that has been reduced in size from being exposed to heat and vacuum within the vessel.
- the coal or coal-binder mixture (both of which can be considered a fuel composition) can be mechanically forced through an extrusion die to yield a shaped fuel composition.
- the shaped fuel composition can be cut, shredded, or milled to form discrete portions of the fuel composition.
- the discrete portions can include pellets or briquettes.
- the coal-binder mixture does not undergo extrusion (which can be energy-intensive) and is simply cut, shredded, or milled to form discrete portions of the fuel composition.
- the fuel composition has a moisture content of less than 3 wt %, less than 2 wt %, or less than 1 wt %, and a heat content of at least about 1.5, 1.6, 1.7, 1.8, 1.9, or 1.95 times greater than the heat content of the unprocessed coal (e.g., at least about 9,000 BTU/lb, at least about 10,000 BTU/lb, or between about 10,000 BTU/lb and about 11,000 BTU/lb).
- the fuel composition has a fixed carbon content between about 40 wt % and about 70 wt % or between about 50 wt % and about 60 wt %.
- the fuel composition has an ash content between about 5 wt % and 20 wt % or between about 10 wt % and about 20 wt %. In some embodiments, the fuel composition has a volatiles content between about 40 wt % and about 70 wt %, between about 40 wt % and about 60 wt %, or between about 40 wt % and about 50 wt %.
- the fuel composition after the fuel composition has been formed, it is substantially free of coal dust (for example, the composition is substantially free of coal particulates having an average size of 75 micrometers or smaller).
- the term “substantially free” can refer to the composition containing less than 1 wt. % (e.g., less than 0.5 wt. %, less than 0.1 wt. %, less than 0.01 wt. % or less than 0.001 wt. %) of a material.
- the fuel composition after the fuel composition has been formed, it comprises less than 20 wt % coal dust, less than 15 wt % coal dust, less than 10 wt % coal dust, less than 5 wt % coal dust, less than 4 wt % coal dust, less than 3 wt % coal dust, less than 2 wt % coal dust, less than 1 wt % coal dust, less than 0.5 wt % coal dust, or less than 0.1 wt % coal dust. In some embodiments, after the fuel composition has been formed, it is substantially free of coal dust.
- the fuel composition after the fuel composition has been formed, it releases less than 20 wt % coal dust, less than 15 wt % coal dust, less than 10 wt % coal dust, less than 5 wt % coal dust, less than 4 wt % coal dust, less than 3 wt % coal dust, less than 2 wt % coal dust, less than 1 wt % coal dust, less than 0.5 wt % coal dust, or less than 0.1 wt % coal dust.
- the methods described herein can be implemented to convert unprocessed, uncrushed low rank coal into the fuel composition provided herein within 1 hour, within 55 minutes, within 50 minutes, within 45 minutes, within 40 minutes, within 35 minutes, within 30 minutes, within 25 minutes, or within 20 minutes.
- Uncrushed lignite coal taken directly from a Mississippi mine showed typical characteristics: 43.22 wt % moisture, 26.4 wt % volatiles, HHV of 5922 BTU/lb, 0.012 wt % sulfur, and 6.63 wt % ash.
- the composition of the uncrushed and unprocessed lignite coal is provided in Table 1.
- the coal was exposed to heat ranging from 140-208° C. for a duration of approximately 60 minutes.
- the mechanism of heat transfer was conduction.
- Slow speed (up to 25 rpm), high torque mechanical blades were used to promote intermittent contact with the lignite, and a careful balance was maintained to reduce creation of coal dust.
- the mechanical blades were rotated intermittently, and the rotation speed varied between 0 rpm and 25 rpm with gradual increases and decreases.
- the rotation of the mechanical blades was paused (that is, no rotation) for time durations of between 1 minute and 2 minutes.
- the coal was kept in a vessel at all times, with intermittent exposure to vacuum.
- the vacuum was introduced (1) to remove oxygen and, thus, reduces the likelihood of ignition of the coal and (2) to promote thermal transformation.
- the pressure within the processing chamber, at various points during processing, was kept at 150 torr or less.
- the combination of heat and slow speed intermittent mechanical processing facilitated a natural breakdown of the coal.
- 10 wt % plastic (a blend of high-density polyethylene, low-density polyethylene, and polyethylene terephthalate) was combined with the coal after the coal had been preheated, by introducing the plastic between the 10 and 20 minute time intervals.
- Samples 1 and 2 were the resulting fuel compositions after the coal was processed and combined with the plastic. In Sample 1, the coal and plastic mixture was extruded. In Sample 2, the coal and plastic mixture was not extruded.
- Processing of the lignite resulted in a moisture reduction from 43.22 wt % to less than 3 wt % (2.46 wt % and 1.43 wt % for Samples 1 and 2, respectively) and an increase in energy content from 5,922 BTU/lb to 10,649 and 10,285 BTU/lb (HHV) for Samples 1 and 2, respectively.
- the compositions of Samples 1 and 2 are provided in Table 2.
- the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise.
- the term “or” is used to refer to a nonexclusive “or” unless otherwise indicated.
- the statement “at least one of A and B” has the same meaning as “A, B, or A and B.”
- the phraseology or terminology employed in this disclosure, and not otherwise defined is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.
- the term “about” or “approximately” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.
- the term “substantially” refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.
- a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited.
- a range of “between 0.1% and about 5%” or “between 0.1% and 5%” should be interpreted to include about 0.1% to about 5%, as well as the individual values (for example, 1%, 2%, 3%, and 4%) and the sub-ranges (for example, between 0.1% and 0.5%, between 1.1% and 2.2%, and between 3.3% and 4.4%) within the indicated range.
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Abstract
A method of preparing a fuel composition includes placing coal having a heat content between about 3,000 BTU/lb and about 9,000 BTU/lb and a moisture content between about 20 wt % and about 60 wt % in a vessel. The coal is exposed to heat and a pressure less than atmospheric pressure within the vessel, thereby reducing the coal, such that an average primary particle size of the coal is less than 1 millimeter. A binder is introduced to the vessel, such that the coal combines with the binder to yield a mixture. The mixture is shaped to yield a fuel composition.
Description
- This application is a continuation of U.S. application Ser. No. 17/150,904, filed Jan. 15, 2021, which claims the benefit of priority to U.S. Provisional Application No. 62/961,552 filed on Jan. 15, 2020, and entitled “PROCESSING OF LOW RANK COAL,” the contents of which are hereby incorporated by reference.
- This disclosure relates to processing of low rank coal, such as lignite.
- Low rank coal (e.g., lignite) is softer, is more CO2 intensive, and has a higher moisture content and lower fuel value than “hard” coal (e.g., bituminous, sub-bituminous, anthracite). Lignite, the lowest rank coal, typically has a moisture content in a range of 30-60 wt % and a heat content in a range of 4,000-8,300 BTU/lb. In contrast, sub-bituminous coal typically has a moisture content in a range of 10-45 wt % and an energy content in a range of 8,500-13,000 BTU/lb, and bituminous coal typically has a moisture content in a range of 2-15 wt % and a heat content in a range of 11,000-15,000 BTU/lb. Due to its high moisture content and brittle nature, processing of low rank coal requires significant energy input and results in the creation of coal fines (e.g., dust), which presents a combustion hazard and is of little use.
- Certain aspects of the subject matter described can be implemented as a method or preparing a fuel composition. The method includes placing coal having a heat content between about 3,000 BTU/lb and about 9,000 BTU/lb and a moisture content between about 20 wt % and about 60 wt % in a vessel. The coal is exposed to heat and a pressure less than atmospheric pressure within the vessel, thereby reducing a primary particle size of the coal, such that an average primary particle size of the coal is less than 1 millimeter. A binder is introduced to the vessel, such that the coal combines with the binder to yield a mixture. The mixture is shaped to yield a fuel composition.
- This, and other aspects, can include one or more of the following features.
- In some embodiments, the coal is exposed to heat before combining the coal and the binder. In some embodiments, exposing the coal to heat includes heating the coal by conduction. In some embodiments, exposing the coal to heat includes contacting the coal with a heated surface. In some embodiments, the heated surface includes a rotating blade.
- In some embodiments, the coal is agitated in the vessel. In some embodiments, agitating the coal includes intermittently agitating the coal in the vessel.
- In some embodiments, exposing the coal to the pressure less than atmospheric pressure within the vessel includes intermittently reducing the pressure in the vessel.
- In some embodiments, the mixture is heated by conduction. In some embodiments, the binder includes a plastic substantially free of chlorine. In some embodiments, heating the mixture includes increasing the malleability of the plastic. In some embodiments, heating the mixture includes melting or softening the plastic.
- In some embodiments, the fuel composition includes the coal distributed in a plastic matrix.
- In some embodiments, shaping the fuel composition includes cutting, shredding, or milling the mixture to form discrete portions of the fuel composition. In some embodiments, the mixture is extruded to yield an extruded fuel product before cutting, shredding, or milling the mixture of coal and binder. In some embodiments, the extruded fuel product includes the coal distributed in a plastic matrix.
- In some embodiments, the fuel composition includes about 5 wt % to about 50 wt % of the binder.
- In some embodiments, the mixture is heated to a temperature between 100° C. and 250° C., between 110° C. and 240° C., 120° C. and 230° C., between 130° C. and 220° C., or between 140° C. and 210° C.
- In some embodiments, the coal placed in the vessel is uncrushed.
- Certain aspects of the subject matter described can be implemented as a fuel composition. The fuel composition includes coal having a heat content between about 4,000 BTU/lb and about 8,300 BTU/lb and a binder including plastic. The fuel composition includes less than 5 wt % coal dust having an average primary particle size of 75 micrometers or smaller.
- This, and other aspects, can include one or more of the following features.
- In some embodiments, the coal includes lignite.
- In some embodiments, the binder is in the form of a plastic matrix. In some embodiments, the coal is bound in the plastic matrix.
- In some embodiments, the fuel composition includes about 5 wt % to about 50 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 40 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 30 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 25 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 20 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 15 wt % of the binder. In some embodiments, the fuel composition includes about 5 wt % to about 10 wt % of the binder. In some embodiments, the fuel composition includes about 10 wt % of the binder.
- In some embodiments, the fuel composition is in the form of a solid inhomogeneous mixture.
- In some embodiments, the plastic includes polyethylene. In some embodiments, the fuel composition includes polyethylene terephthalate. In some embodiments, the plastic is free of chlorine.
- In some embodiments, the fuel composition has a moisture content between about 1 wt % and about 3 wt % or between about 2 wt % and about 3 wt %.
- In some embodiments, a heat content of the fuel composition is at least about 9,000 BTU/lb. In some embodiments, a heat content of the fuel composition is at least about 10,000 BTU/lb. In some embodiments, a heat content of the fuel composition is between about 10,000 BTU/lb and about 11,000 BTU/lb. In some embodiments, a heat content of the fuel composition is at least about 1.5, 1.6, 1.7, 1.8, 1.9, or 1.95 times greater than the heat content of the coal.
- “Low rank coal” is a coal typically having a heat content (for example, higher heating value (HHV)) between about 4,000 BTU/lb and about 8,300 BTU/lb and a moisture content between about 20 wt % and about 60 wt % or between about 40 wt % and about 50 wt %. In some embodiments, low rank coal has a fixed carbon content between about 30 wt % and about 70 wt %. In some embodiments, low rank coal has an ash content of less than about 10 wt %. In some embodiments, low rank coal has a volatiles content between about 5 wt % and about 50 wt %. One example of low rank coal is lignite.
- Transportation of unprocessed low rank coal can be considered inefficient due to its high moisture content. In effect, paying to transport unprocessed low rank coal can be considered wastefully paying for transport of a resource that can be about half water by weight. Thus, it can be beneficial to remove moisture content from low rank coal before transportation. Methods to remove the moisture in lignite have been employed but entail specific challenges. One such challenge is that lignite must often be crushed or pulverized as a separate step, prior to effective moisture removal. For example, in order to remove moisture content from low rank coal, the low rank coal needs to be reduced in size (e.g., pulverized) so that the water trapped in the low rank coal can escape. However, pulverizing the low rank coal in order to reduce moisture content can produce coal dust and can pose handling, logistics and transport challenges, including due to the creation of dust. For example, pulverizing the low rank coal in order to reduce moisture content can produce coal dust and can convert the low rank coal into a non-transportable form (e.g., a hazardous powder). Therefore, after reducing the moisture content of the low rank coal, the low rank coal needs to be re-packaged and/or processed into a transportable form.
- The methods described in this disclosure can be implemented to complete the steps of removing moisture content from low rank coal and re-packaging the low rank coal with reduced moisture content into a transportable form in a single batch process. One example advantage of the methods described herein is that the energy content of the coal is increased on a per weight basis, while also displacing a certain percentage of coal with a waste material that otherwise would not be beneficially used, thus allowing for a near-term reduction of the amount of coal needed by the operator due to the higher energy content and reducing the negative environmental impact of coal combustion emissions and the total demand for coal. As described in this disclosure, in some embodiments, low rank coal is combined with a binder to yield a fuel composition including a binder.
- Suitable binders include one or more plastics, such as low, medium, and high-density polyethylene. Some additional examples of a suitable binder include polyethylene terephthalate, polystyrene, polyester, polyamides, acrylonitrile butadiene styrene, polyethylene/acrylonitrile butadiene styrene, polycarbonate, polycarbonate/acrylonitrile butadiene styrene, polyurethanes, maleimide/bismaleimide, melamine formaldehyde, phenol formaldehydes, polyepoxide, polyetheretherketone, polyetherimide, polyimide, polylactic acid, polymethyl methacrylate, polytetrafluoroethylene, urea-formaldehyde, and polypropylene. The fuel composition typically includes between 5 wt % and 50 wt % of the binder (e.g., between 5 wt % and 40 wt %, between 5 wt % and 30 wt %, between 5 wt % and 25 wt %, between 5 wt % and 20 wt %, between 5 wt % and 15 wt %, or between 5 wt % and 10 wt %). In one example, the fuel composition includes about 10 wt % of the binder. The binder is typically free of chlorine. In some embodiments, the binder is substantially free of chlorine-containing plastics, such as polyvinyl chloride. The fuel composition is in the form of a solid, inhomogeneous mixture (e.g., a plastic matrix, with the coal bound in the plastic matrix). The binder can be reclaimed from municipal waste or recycling. The binder can be used as is or cut or shredded before it is combined with the coal.
- Processing low rank coal includes placing coal having a heat content between about 4,000 BTU/lb and about 8,300 BTU/lb in a vessel. The coal can be uncrushed (e.g., straight from a mine) or crushed. In some cases (e.g., when the coal is crushed), the binder is combined with the coal before heating. In other cases (e.g., when the coal is uncrushed), the coal is heated prior to addition of the binder. The coal (or coal-binder mixture) can be sealed in the vessel.
- The coal (or coal-binder mixture) is heated by conduction. Heating the coal (or coal-binder mixture) by conduction includes contacting the coal (or coal-binder mixture) with a heated surface. Heating the coal (or coal-binder mixture) can occur without providing heated gas (e.g., air) to the vessel. In one example, the heated surface includes one or more blades configured to rotate in the vessel. The coal (or coal-binder mixture) can be heated to a temperature up to about 250° C. In some examples, the coal (or coal-binder mixture) is heated to a temperature between 100° C. and 250° C., between 110° C. and 240° C., between 120° C. and 230° C., between 130° C. and 220° C., or between 140° C. and 210° C. The heat provided is insufficient to pyrolyze the coal. Moreover, in some embodiments, heated fluid (e.g., in the form of steam or air) is not provided to the vessel.
- When the coal (or coal-binder mixture) is heated by a blade configured to rotate in the vessel, the blade(s) can be rotated at a speed between about 1 and about 10 rotations per minute. The blade(s) can be rotated intermittently, such that the blade is stationary at times and in motion at other times. The intermittent rotation can occur in a pattern (e.g., periodically) or occur randomly. The coal (or coal-binder mixture) can be agitated (e.g., by rotation of the blade(s)). The agitation can occur intermittently (e.g., during rotation of the blade(s)). In some embodiments, the agitation is intermittently performed in intervals of about 1 minute separated by pauses in agitation of about 1 minute to about 3 minutes. In some embodiments, the blade(s) protrude radially outward from and are coupled to a central rod. In some embodiments, the central rod is rotated, for example, by a motor, to rotate the blade(s), resulting in agitation of the coal within the vessel. While the methods provided herein can produce fines and/or dust during processing, the fines and/or dust are largely stabilized once the processing has been completed to significantly reduce the amount of fines and/or dust by-product that are produced by the system. For example, during processing, the fines and/or dust can be stabilized by either densifying the fines and/or dust into a solid fuel product and/or by adding plastic to bind the fines and/or dust together to form the solid fuel product. The pattern, duration, and extent of agitation can be selected to reduce or minimize pulverization of the coal, and thereby reduce or minimize the amount of fines and/or dust by-product produced from the coal.
- In some embodiments, the blade(s) are rotated at a speed that is less than 25 revolutions per minute (rpm), less than 20 rpm, less than 15 rpm, less than 10 rpm, or less than 5 rpm. In some embodiments, the blade(s) are rotated at a speed between 2 rpm and 25 rpm. In some embodiments, the speed at which the blade(s) are rotated is varied. In some embodiments, the speed at which the blade(s) are rotated is varied between 1 rpm and 25 rpm. In some embodiments, the blades are not rotated at all, or not rotated for a desired time duration (e.g., 1 min to 5 mins). In some embodiments, the speed at which the blade(s) are rotated alternates between gradually decreasing and gradually increasing. In some embodiments, the time duration(s) of no rotation of the blade(s) is between 1 minute and 3 minutes. In some embodiments, the blade(s) are rotated around a longitudinal axis defined by the central rod, such that an outermost tip of the blade(s) has a maximum tangential velocity of about 20 inches per second (in/s) or about 15 in/s. In some embodiments, the blade(s) are rotated around the longitudinal axis defined by the central rod, such that the outermost tip of the blade(s) has a tangential velocity between 5 in/s and 15 in/s.
- The pressure in the vessel can be reduced to below atmospheric pressure (vacuum). As used in this disclosure, the term “vacuum” can encompass any pressure that is less than atmospheric pressure (1 atmosphere). Reducing the pressure in the vessel can occur intermittently. The intermittent pressure reduction can occur in a pattern (e.g., periodically) or occur randomly. That is, the pressure may be reduced, then allowed to increase (e.g., to atmospheric pressure), and then reduced again. The pressure in the vessel can be reduced to a pressure between 10 torr and 150 torr, between 50 torr and 150 torr, or between 50 torr and 100 torr. With reduced pressure in the vessel, the coal may be heated to a temperature between about 30° C. and about 100° C. Reducing the pressure in the vessel (e.g., to about 50 torr) and heating to a lower temperature (e.g., 40° C.) may yield the same results as heating at a greater pressure (e.g., atmospheric pressure) and a greater temperature (e.g., 140° C.). Reducing the pressure promotes thermal transformation, removal of moisture (e.g., in the form of water vapor), and also promotes removal of oxygen, thereby mitigating and/or preventing ignition of the coal.
- Pressure reduction in the vessel can be carried out by using, for example, a vacuum pump. Reducing pressure in the vessel can involve using the vacuum pump to evacuate vapor from an interior of the vessel. For example, an outlet of a vapor space of the vessel is connected to the vacuum pump, and during operation, the vacuum pump pulls vapor from the vapor space of the vessel. The outlet of the vapor space of the vessel that is connected to the vacuum pump is located a predetermined distance away from a processing zone of the vessel that includes the rotating blade(s). In some embodiments, the outlet is located at least one radius away from an outermost tip of the rotating blade(s), in which the radius is defined as the distance between the central rod and the outermost tip of the rotating blade(s). For example, for mixing blade(s) that radially protrude twelve inches from the central rod, the radius is twelve inches, and the outlet is located at least twelve inches away from the outermost tip of the rotating blade(s). In this example, this also means that the outlet is located at least 24 inches away from the central rod. In some embodiments, the outlet is located at least one radius away from the outermost tip of the rotating blade(s) and also above the rotating blade(s) with respect to gravity. The orientation of the outlet and the distance away from the processing zone (the rotating blade(s)) can mitigate and/or prevent coal dust from being evacuated with the vapor by the vacuum pump. The intermittent agitation can also mitigate and/or prevent coal dust from being evacuated with the vapor by the vacuum pump. For example, by pausing the agitation intermittently, coal dust can be allowed to settle via gravity to mitigate and/or prevent coal dust from being evacuated with the vapor by the vacuum pump.
- In some embodiments, a knockout pot is included between the outlet and the vacuum pump for collecting water. In some embodiments, a filter is included between the outlet and the vacuum pump for mitigating and/or preventing particulates from reaching the vacuum pump. In some embodiments, the filter is downstream of the knockout pot. In some embodiments, the filter is a single stage filter. In some embodiments, the filter is a multi-stage filter, such as a dual stage filter or a 3-stage filter. For example, the filter is a multi-stage filter having a 1st stage filter defining openings with a maximum dimension between 30 micrometers and 50 micrometers, a 2nd stage filter defining openings with a maximum dimension between 10 micrometers and 20 micrometers, and a 3rd stage filter defining openings with a maximum dimension between 2 micrometers and 10 micrometers.
- Thus, the coal (or coal-binder mixture) is introduced to a single vessel, and processed by a low speed, mid to high torque mechanical blending while being exposed to heat (i.e., contacting heated surfaces). Heat and/or vacuum exposure within the vessel can cause the coal to be reduced in size without requiring a time and/or energy-intensive process of mechanically reducing the coal (for example, by smashing or rigorous agitation using substantial force, and/or investing several hours of time to process). In some cases, the coal is pulverized into fines and/or dust within a short time (e.g., between 5-30 minutes) of being exposure to heat and vacuum within the vessel. In some embodiments, the coal is reduced to having an average primary particle size of less than 1 millimeter within a predetermined time. As used herein, a “primary particle size” refers to the longest linear dimension, e.g., a maximum length or a maximum diameter, of a primary particle. As used herein, a “primary particle” is an individual single particle, not an agglomeration of two or more particles. In some embodiments, a primary particle can be visually identified by microscopy and distinguished from agglomerations of two or more primary particles based on size, shape, or both.
- In some embodiments, the coal is reduced to having an average primary particle size between 1 micrometer and 1 millimeter, between 1 micrometer and 500 micrometers, or between 1 micrometer and 100 micrometers. In some embodiments, the coal is reduced to having an average primary particle size of about or less than 100 micrometers (e.g., or about or less than 90 micrometers, 80 micrometers, 70 micrometers, 60 micrometers, 50 micrometers, 40 micrometers, 30 micrometers, 20 micrometers, 10 micrometers, 9 micrometers, 8 micrometers, 7 micrometers, 6 micrometers, 5 micrometers, 3 micrometers, or 1 micrometer).
- In some embodiments, the predetermined time for achieving the desired average primary particle size is about or no more than 5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, 30 minutes, 1 hour, 2 hours, or about or no more than 3 hours of being exposed to heat and/or vacuum within the vessel.
- In cases in which binder is included, the heat exposure causes the binder to melt or soften. In some cases, the coal is pre-heated (e.g., 10 to 20 minutes) before addition of the binder. After addition of the binder, the coal-binder mixture is processed until the binder reaches a temperature of at least 180° C. (e.g., sufficient to melt or soften the plastic). The melted or softened plastic can serve as a binder for the coal that has been reduced in size from being exposed to heat and vacuum within the vessel. The coal or coal-binder mixture (both of which can be considered a fuel composition) can be mechanically forced through an extrusion die to yield a shaped fuel composition. The shaped fuel composition can be cut, shredded, or milled to form discrete portions of the fuel composition. In some cases, the discrete portions can include pellets or briquettes. In some cases, the coal-binder mixture does not undergo extrusion (which can be energy-intensive) and is simply cut, shredded, or milled to form discrete portions of the fuel composition.
- The fuel composition has a moisture content of less than 3 wt %, less than 2 wt %, or less than 1 wt %, and a heat content of at least about 1.5, 1.6, 1.7, 1.8, 1.9, or 1.95 times greater than the heat content of the unprocessed coal (e.g., at least about 9,000 BTU/lb, at least about 10,000 BTU/lb, or between about 10,000 BTU/lb and about 11,000 BTU/lb). In some embodiments, the fuel composition has a fixed carbon content between about 40 wt % and about 70 wt % or between about 50 wt % and about 60 wt %. In some embodiments, the fuel composition has an ash content between about 5 wt % and 20 wt % or between about 10 wt % and about 20 wt %. In some embodiments, the fuel composition has a volatiles content between about 40 wt % and about 70 wt %, between about 40 wt % and about 60 wt %, or between about 40 wt % and about 50 wt %.
- In some embodiments, after the fuel composition has been formed, it is substantially free of coal dust (for example, the composition is substantially free of coal particulates having an average size of 75 micrometers or smaller). The term “substantially free” can refer to the composition containing less than 1 wt. % (e.g., less than 0.5 wt. %, less than 0.1 wt. %, less than 0.01 wt. % or less than 0.001 wt. %) of a material. In some embodiments, after the fuel composition has been formed, it comprises less than 20 wt % coal dust, less than 15 wt % coal dust, less than 10 wt % coal dust, less than 5 wt % coal dust, less than 4 wt % coal dust, less than 3 wt % coal dust, less than 2 wt % coal dust, less than 1 wt % coal dust, less than 0.5 wt % coal dust, or less than 0.1 wt % coal dust. In some embodiments, after the fuel composition has been formed, it is substantially free of coal dust. In some embodiments, after the fuel composition has been formed, it releases less than 20 wt % coal dust, less than 15 wt % coal dust, less than 10 wt % coal dust, less than 5 wt % coal dust, less than 4 wt % coal dust, less than 3 wt % coal dust, less than 2 wt % coal dust, less than 1 wt % coal dust, less than 0.5 wt % coal dust, or less than 0.1 wt % coal dust.
- The methods described herein can be implemented to convert unprocessed, uncrushed low rank coal into the fuel composition provided herein within 1 hour, within 55 minutes, within 50 minutes, within 45 minutes, within 40 minutes, within 35 minutes, within 30 minutes, within 25 minutes, or within 20 minutes.
- Uncrushed lignite coal taken directly from a Mississippi mine showed typical characteristics: 43.22 wt % moisture, 26.4 wt % volatiles, HHV of 5922 BTU/lb, 0.012 wt % sulfur, and 6.63 wt % ash. The composition of the uncrushed and unprocessed lignite coal is provided in Table 1.
-
TABLE 1 Composition of uncrushed lignite coal Component Amount (wt %) Moisture 43.22 Carbon 34.96 Hydrogen 2.71 Nitrogen 0.65 Sulfur 0.012 Ash 6.63 Oxygen 11.82 - The coal was exposed to heat ranging from 140-208° C. for a duration of approximately 60 minutes. The mechanism of heat transfer was conduction. Slow speed (up to 25 rpm), high torque mechanical blades were used to promote intermittent contact with the lignite, and a careful balance was maintained to reduce creation of coal dust. The mechanical blades were rotated intermittently, and the rotation speed varied between 0 rpm and 25 rpm with gradual increases and decreases. The rotation of the mechanical blades was paused (that is, no rotation) for time durations of between 1 minute and 2 minutes. The coal was kept in a vessel at all times, with intermittent exposure to vacuum. The vacuum was introduced (1) to remove oxygen and, thus, reduces the likelihood of ignition of the coal and (2) to promote thermal transformation. The pressure within the processing chamber, at various points during processing, was kept at 150 torr or less. The combination of heat and slow speed intermittent mechanical processing facilitated a natural breakdown of the coal.
- 10 wt % plastic (a blend of high-density polyethylene, low-density polyethylene, and polyethylene terephthalate) was combined with the coal after the coal had been preheated, by introducing the plastic between the 10 and 20 minute time intervals. Samples 1 and 2 were the resulting fuel compositions after the coal was processed and combined with the plastic. In Sample 1, the coal and plastic mixture was extruded. In Sample 2, the coal and plastic mixture was not extruded. Processing of the lignite resulted in a moisture reduction from 43.22 wt % to less than 3 wt % (2.46 wt % and 1.43 wt % for Samples 1 and 2, respectively) and an increase in energy content from 5,922 BTU/lb to 10,649 and 10,285 BTU/lb (HHV) for Samples 1 and 2, respectively. The compositions of Samples 1 and 2 are provided in Table 2.
-
TABLE 2 Composition of Samples 1 and 2 Sample 1 Sample 2 (extruded) (not extruded) Component Amount (wt %) Moisture 2.46 1.43 Carbon 58.95 58.23 Hydrogen 5.02 4.83 Nitrogen 0.97 1.01 Sulfur 0.352 0.412 Ash 13.64 14.76 Oxygen 18.61 19.33 - As used in this disclosure, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed in this disclosure, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.
- As used in this disclosure, the term “about” or “approximately” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.
- As used in this disclosure, the term “substantially” refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.
- Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “between 0.1% and about 5%” or “between 0.1% and 5%” should be interpreted to include about 0.1% to about 5%, as well as the individual values (for example, 1%, 2%, 3%, and 4%) and the sub-ranges (for example, between 0.1% and 0.5%, between 1.1% and 2.2%, and between 3.3% and 4.4%) within the indicated range. The statements “X to Y” and “between X and Y” have the same meanings as “about X to about Y” and “between about X and about Y”, unless indicated otherwise. Likewise, the statement “X, Y, or Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.
- The details of one or more embodiments of the subject matter of this disclosure are set forth in the accompanying drawings and the description. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
- Although this disclosure contains many specific embodiment details, these should not be construed as limitations on the scope of the subject matter or on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are described in this disclosure in the context of separate embodiments can also be implemented, in combination, in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments, separately, or in any suitable sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
- Particular embodiments of the subject matter have been described. Other embodiments, alterations, and permutations of the described embodiments are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results.
- Accordingly, the previously described example embodiments do not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.
Claims (1)
1. A method of preparing a fuel composition, the method comprising:
placing coal having a heat content between about 3,000 BTU/lb and about 9,000 BTU/lb and a moisture content in a range between about 20 wt % and about 60 wt % in a vessel;
exposing the coal to heat and a pressure less than atmospheric pressure within the vessel, thereby reducing the coal, such that an average primary particle size of the coal is less than 1 millimeter;
introducing a binder to the vessel, such that the coal combines with the binder to yield a mixture; and
shaping the mixture to yield a fuel composition.
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US17/150,904 US11407954B2 (en) | 2020-01-15 | 2021-01-15 | Processing of low rank coal |
US17/862,008 US20220348837A1 (en) | 2020-01-15 | 2022-07-11 | Processing of low rank coal |
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US4725337A (en) * | 1984-12-03 | 1988-02-16 | Western Energy Company | Method for drying low rank coals |
US6165238A (en) * | 1999-06-14 | 2000-12-26 | Cq Inc. | Fuel pellet and method for its production |
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US852025A (en) | 1906-07-03 | 1907-04-30 | George J Mashek | Process of preparing pulverulent materials for molding or briqueting. |
US1734992A (en) | 1927-07-18 | 1929-11-12 | Ruth Hull Barrows | Process and apparatus for drying and pulverizing coal |
JPS5962696A (en) | 1982-10-01 | 1984-04-10 | Hitachi Ltd | Improvement of coal |
JP3941131B2 (en) | 1996-05-21 | 2007-07-04 | 宇部興産株式会社 | Modified coal production method, CWM and production method thereof, and H2 and CO production method |
WO2000000575A1 (en) | 1998-06-30 | 2000-01-06 | Duquesne Energy, Inc. | Coal-based pelletized fuel composition and method of manufacturing same |
US8579999B2 (en) | 2004-10-12 | 2013-11-12 | Great River Energy | Method of enhancing the quality of high-moisture materials using system heat sources |
WO2006135340A1 (en) * | 2005-06-17 | 2006-12-21 | Calrex Investments Pte Ltd | Method and apparatus for treating coal |
CN102037105B (en) | 2008-04-15 | 2013-12-25 | 拉里·亨特 | Coal enhancement process |
KR101090750B1 (en) | 2009-07-31 | 2011-12-08 | 한국에너지기술연구원 | Drying Apparatus by Heated Disc and Rotating Blade |
MY178469A (en) * | 2014-10-30 | 2020-10-14 | EcoGensus LLC | Solid fuel composition formed from mixed solid waste |
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2021
- 2021-01-15 CN CN202180015138.7A patent/CN115427543A/en active Pending
- 2021-01-15 BR BR112022014039A patent/BR112022014039A2/en not_active Application Discontinuation
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- 2021-01-15 EP EP21741123.0A patent/EP4090720A4/en not_active Withdrawn
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US4249909A (en) * | 1979-05-30 | 1981-02-10 | Hydrocarbon Research, Inc. | Drying and passivating wet coals and lignite |
US4725337A (en) * | 1984-12-03 | 1988-02-16 | Western Energy Company | Method for drying low rank coals |
US6165238A (en) * | 1999-06-14 | 2000-12-26 | Cq Inc. | Fuel pellet and method for its production |
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