Bio-oil Agglomeration Mill for Coal Ash Separation
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Solution Overview
Problem
Current methods for separating solids with lyophobic and lyophilic components, such as coal ash, are inefficient in reducing ash content and require significant energy and equipment, as they often fail to effectively liberate and separate these components due to limitations in comminution and agglomeration processes.
Innovation Solution
A process utilizing a high-speed, high-shear mill with positive transport capability, where a mixture of coal, aqueous solvent, and bio-oil or bio-diesel is comminuted to form agglomerates or flocs, allowing for simultaneous comminution and agglomeration, thereby reducing energy and equipment needs, and enabling effective separation of lyophobic and lyophilic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional comminution and agglomeration processes are used to separate solids with lyophobic and lyophilic components, then separation is achieved, but significant energy and equipment are required and ash content reduction is inefficient
Solution Approach 1:
The patent combines comminution and agglomeration operations into a single integrated process step, where both functions are performed simultaneously in one piece of equipment rather than as separate sequential operations. This merging reduces the total energy required and eliminates the need for multiple pieces of equipment, directly addressing the contradiction between energy loss and productivity.
Solution Approach 2:
The invention introduces specific parameter changes by using high-speed, high-shear mixing conditions combined with specific reagent dosing rates and pH control to achieve effective separation. By optimizing these parameters, the process achieves efficient ash content reduction with lower energy consumption compared to conventional methods.
2Device complexity
If conventional separation methods are used, then equipment is available, but the process requires significant equipment and is complex
Solution Approach 1:
The patent merges comminution and agglomeration functions into a single piece of equipment, reducing the total number of equipment items required from multiple separate units to one integrated device. This directly reduces device complexity while maintaining or improving separation efficiency through the combined actions performed simultaneously.
Solution Approach 2:
The invention makes a single piece of equipment perform multiple functions - both comminution and agglomeration - thereby reducing the overall equipment requirements. This multi-functionality approach allows one device to replace what would traditionally require several separate pieces of equipment, simplifying the process configuration.
3Manufacturing precision
If conventional comminution processes are used, then processing is achieved, but effective liberation of lyophobic and lyophilic components is not realized
Solution Approach 1:
The patent achieves effective component liberation by changing key process parameters including using high-speed, high-shear mixing conditions, controlling pH levels, and optimizing reagent dosing rates. These parameter changes enable thorough liberation of lyophobic and lyophilic components while maintaining high processing efficiency.
Solution Approach 2:
The invention introduces chemical reagents as intermediaries that facilitate the separation process by modifying surface properties of particles, enabling effective liberation and subsequent agglomeration of different components. These intermediaries enhance the effectiveness of component separation without requiring excessive mechanical processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process efficiently liberates ash in particulate form, reduces ash content, and enhances coal recovery by forming stable agglomerates or flocs, which can be separated using a mesh screen or flotation, resulting in improved ash liberation and reduced energy consumption.
Implementation Method 1
a second liquid which is immiscible with the first liquid and which will wet the lyophobic component to form agglomerates or flocs of the lyophobic component
Implementation Method 2
form agglomerates or flocs of the lyophobic component
Implementation Method 3
form agglomerates or flocs of the lyophobic component
Implementation Method 4
comminuting a mixture of coal, aqueous solvent, such as water, and bio-oil, bio-diesel or combinations thereof, to liberate at least a portion of the ash and coal in particulate form
Implementation Method 5
high speed, high shear mill
Data Source
AI summary
A process for separating a solid having two or more components, at least one of which is lyophobic and at least one of which is lyophilic. The process comprises, in a single step, comminuting a mixture of the solid in a first liquid to which one of the components is lyophilic and to which the other component is lyophobic and in a second liquid which is immiscible with the first liquid and which will wet the lyophobic component to form agglomerates or floes of the lyophobic component and the second liquid in a mill having positive transport capability such that the mill causes the mixture to be transported therethrough. The second liquid comprises a bio-oil, bio-diesel or combination thereof. The agglomerates are then separated from the mixture. This process may be used for beneficiating a coal containing ash.