Bulk Material Compaction for Low Rank Coal Drying
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Solution Overview
Problem
Current thermal drying methods for low rank coals are expensive, site restricted, and produce hazardous coal dust, altering chemical characteristics and leading to handling issues and waste, while failing to process fines effectively.
Innovation Solution
A non-thermal method involving extreme compaction and comminution to destroy internal voids in bulk materials, expelling air, gas, and water, resulting in a dense, stable product with higher energy content and reduced environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If thermal drying methods are used to remove water and constituents from low rank coals, then water removal efficiency is improved, but operating cost increases and hazardous coal dust is generated
Solution Approach 1:
The patent replaces thermal drying systems with a mechanical compaction system that uses high pressure (e.g., 10,000-50,000 psi) to densify low rank coals and remove water mechanically, eliminating the need for thermal energy and avoiding coal dust generation associated with thermal methods
Solution Approach 2:
The patent changes the operating parameters from high temperature thermal processing to high pressure mechanical processing, transforming the coal from a low-density, high-moisture state to a high-density, low-moisture state through compaction without thermal energy input
2Quantity of substance
If high temperature thermal drying is applied to low rank coals, then water removal is improved, but chemical characteristics are altered and reactivity to air increases
Solution Approach 1:
The patent substitutes mechanical compaction for thermal drying, using high pressure to remove water and densify the coal without applying heat that would alter chemical characteristics or increase reactivity to air
3Productivity
If thermal beneficiation systems are used to process low rank coals, then power plant efficiency is improved, but construction cost and operating cost increase
Solution Approach 1:
The patent replaces complex thermal beneficiation systems with a simpler mechanical compaction system that achieves similar water removal and densification results at lower construction and operating costs
Solution Approach 2:
The patent employs a cost-effective mechanical compaction approach using readily available high-pressure equipment rather than expensive thermal processing infrastructure, reducing both capital investment and operational expenses
4Quantity of substance
If thermal drying processes are used for low rank coals, then water removal is achieved, but site restrictions are imposed and energy consumption increases
Solution Approach 1:
The patent substitutes mechanical compaction for thermal drying, eliminating the need for large amounts of thermal energy and removing site restrictions associated with thermal processing facilities
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 method produces a stable, high-energy fuel with lower dust and fines generation, reducing environmental impact and operating costs, and is suitable for continuous processing, enhancing safety and efficiency.
Implementation Method 1
The bulk material is subjected to a pressure of at least about 30,000 psi (206.8 MPa) to destroy a portion of the voids within the bulk material
Implementation Method 2
Comminution and high compaction forces are applied to transform the structure of these bulk materials by destroying most of the internal voids
Data Source
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Figure 4
AI summary
The invention provides low-cost, non-thermal methods to transform and benefictae bulk materials, including low rank coals such as peat, lignite, brown coal, subbituminous coal, other carbonaceous solids or derived feedstock High pressure compaction (30) and comminution processes (33) are linked to transform the solid materials by eliminating interstitial, capillary, pores or other voids that are present in the materials and that may contain liquid, air or gases that are detrimental to the quality and performances of the bulk materials, thereby beneficating the bulk products to provide premium feedstock for industrial or commercial uses, such as electric power generation, gasification, liquefaction, and carbon activation The handling characteristics, dust mitigation aspects and combustion emissions of the products may also be improved