Coal-Derived Hydrocarbon Particle Purification via Density Separation
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Solution Overview
Problem
Current coal processing methods are inefficient in handling and utilizing coal fines, leading to significant waste generation and environmental hazards, as they are often too wet, dirty, or fine to transport, and lack effective methods to separate pure hydrocarbon particles from mineral matter, resulting in reduced energy value and increased emissions.
Innovation Solution
Developing methods and systems to separate coal-derived solid mineral matter from carbonaceous matter, producing coal-derived solid hydrocarbon particles that are substantially free of inherent mineral matter, using froth flotation and milling processes to achieve particle sizes below 20 microns, allowing for the creation of pure coal-derived hydrocarbon particles suitable for various industrial applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional coal processing methods are used to handle coal fines, then processing cost increases, but energy content and value are reduced due to high mineral matter content
Solution Approach 1:
The patent applies density separation to extract and remove mineral matter from coal fines, isolating the hydrocarbon particles from the denser mineral components. This extraction process reduces mineral matter content from typical levels above 30% to below 10%, thereby increasing energy content without requiring expensive conventional processing of the entire coal matrix
Solution Approach 2:
The patent changes the physical state and density parameters of the coal slurry through controlled water addition and density separation processes. By adjusting the density of the slurry phase, the process selectively separates mineral matter from hydrocarbon particles based on their density differences, achieving purification at lower cost than conventional methods
2Ease of operation
If coal fines are removed and impounded as waste, then handling and transport problems are avoided, but significant waste generation and environmental hazards occur
Solution Approach 1:
The patent recovers valuable hydrocarbon particles from coal fines that would otherwise be discarded as waste. Through density separation, the process selectively removes mineral matter (which would be the waste portion) and recovers the hydrocarbon-rich particles for reuse as fuel or chemical feedstock, thereby eliminating waste generation while maintaining ease of handling
Solution Approach 2:
The patent converts the harmful aspect of coal fines (high mineral matter content making them unsuitable for direct use) into a benefit by using the density difference between mineral matter and hydrocarbons as the separation mechanism. The very property that makes coal fines difficult to handle (compositional heterogeneity) becomes the basis for their purification and valorization
3Quantity of substance
If density separation techniques are used to remove extraneous ash, then bulk mineral matter is reduced, but inherent mineral matter remains dispersed in the carbonaceous matrix
Solution Approach 1:
The patent applies sequential density separation steps that progressively separate mineral matter at different stages. The process segments the separation into multiple passes, each removing a portion of mineral matter, ultimately achieving complete separation of both extraneous and inherent mineral matter from the carbonaceous matrix
Solution Approach 2:
The patent employs excessive action by applying density separation beyond what is minimally required to remove only extraneous ash. The process continues with additional separation steps that thoroughly remove inherent mineral matter as well, ensuring complete purification even though this requires more processing than the minimum needed for bulk ash removal
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
The separation of coal-derived solid hydrocarbon particles from mineral matter enhances energy content, reduces emissions, and enables the use of coal fines in chemical and industrial applications, providing a cleaner burning fuel and increasing the value of coal products.
Implementation Method 1
The aqueous slurry is milled with milling media to reduce the particle size of the particles in the aqueous slurry to less than about 20 microns
Implementation Method 2
The milled aqueous slurry is floated to separate particles of composite coal from particles of mineral matter
Implementation Method 3
The floated milled aqueous slurry is passed through a filter press to mechanically remove water from the floated milled aqueous slurry
Data Source
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AI summary
The coal-derived solid hydrocarbon particles are discrete particles of coal-derived carbonaceous matter having a particle size less than about 10 µm that are substantially free of inherent or entrained mineral matter. The particles of have an average particle size in the range from 1 µm to 8 µm. The particles of coal-derived carbonaceous matter are milled to a size approximately the same as a size of coal-derived mineral matter inherent in the coal source to release inherent coal-derived mineral matter particles such that the particles of carbonaceous matter and the particles of mineral matter are discrete and separable solid particles. Following separation, less than 1.5 wt.% discrete coal-derived mineral matter particles are associated with the discrete particles of coal-derived carbonaceous matter. Particles of coal-derived solid hydrocarbon matter are blended with a gaseous or liquid hydrocarbon fuel to form a two-phase hydrocarbon fuel feedstock.