Macroscopic Maceral Separation via Segmented Coal Processing
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Solution Overview
Problem
Existing methods such as iso-density gradient separation and electro-flotation have failed to effectively macroscopically separate coal macerals, hindering the comprehensive and efficient utilization of coal.
Innovation Solution
A process involving crushing and sieving raw coal into specific particle size ranges, followed by heavy medium cyclone (HMC) separation and froth flotation, using agents like 2-octanol and kerosene, to obtain vitrinite and inertinite concentrates, optimizing particle size ranges and separation densities for efficient maceral separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If iso-density gradient separation or electro-flotation is used, then coal macerals can be separated, but the separation is not effective at macroscopic level
Solution Approach 1:
The patent divides the coal processing into distinct size fractions through crushing and sieving, separating coal into different particle size ranges. Each fraction is then processed through appropriate separation methods (HMC for larger particles, froth flotation for finer particles), enabling effective macroscopic separation of macerals that cannot be achieved by single-method approaches.
Solution Approach 2:
The patent optimizes key parameters including particle size distribution (through controlled crushing and sieving), heavy medium density (adjusted for HMC separation), and flotation reagent dosages. These parameter optimizations enable the separation process to achieve macroscopic maceral separation effectiveness that overcomes the limitations of conventional methods.
2Manufacturing precision
If heavy medium cyclone separation is applied to all particle sizes, then separation can be performed, but fine particles cannot be effectively separated
Solution Approach 1:
The patent segments particles by size before separation, directing fine particles (<0.5mm) to froth flotation and coarser particles to HMC separation. This segmentation allows each separation method to operate in its optimal particle size range, achieving effective fine particle separation while maintaining overall process versatility.
Solution Approach 2:
The patent introduces size-based classification as an intermediary step between crushing and separation. This intermediary classification process sorts particles into appropriate size fractions, enabling the subsequent separation methods to handle particles within their effective ranges and achieve overall macroscopic maceral separation.
3Manufacturing precision
If froth flotation is used for all particle sizes, then separation can be performed, but larger particles are not effectively separated
Solution Approach 1:
The patent segments the coal feed into different particle size fractions, directing larger particles (>0.5mm) to HMC separation where they can be effectively separated based on density differences. This segmentation enables large particle separation effectiveness while maintaining process versatility through multi-method processing.
Solution Approach 2:
The patent changes the separation approach based on particle size parameters, using HMC with optimized heavy medium density for larger particles and froth flotation with optimized reagent dosages for finer particles. This parameter-based adaptation achieves effective large particle separation while maintaining overall process versatility.
4Manufacturing precision
If coal is not crushed to specific particle size ranges, then processing is simpler, but separation effectiveness is reduced
Solution Approach 1:
The patent performs preliminary crushing and sieving to achieve specific particle size distributions before separation. This preliminary size classification action enables subsequent separation methods to work effectively on appropriately sized particles, achieving macroscopic maceral separation effectiveness despite the added processing complexity.
Solution Approach 2:
The patent optimizes particle size parameters through controlled crushing and sieving, creating specific size distributions that maximize separation effectiveness. This parameter optimization justifies the additional processing complexity by enabling effective macroscopic separation that cannot be achieved with unprocessed coal.
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 enables the macroscopic separation of maceral concentrates, enhancing the hierarchical classification and utilization of coal, improving the economic efficiency and stability of coal processing by determining optimal particle size ranges and separation densities for HMC and froth flotation.
Implementation Method 1
subjecting the first coal sample to a heavy medium cyclone (HMC) separation process
Implementation Method 2
HMC separation process includes a concentration separation stage and a fine separation stage
Implementation Method 3
subjecting the second coal sample to a froth flotation process
Implementation Method 4
The froth flotation process uses a froth flotation agent including a foaming agent and a collector
Data Source
AI summary
Processes for macroscopically separating a maceral concentrate from raw coal are disclosed. In some embodiments, a process includes the following steps: crushing and sieving the raw coal to obtain a first coal sample and a second coal sample; subjecting the first coal sample to a heavy medium cyclone separation process; and subjecting the second coal sample to a froth flotation process. The first coal sample has a particle size within a first particle size range, and the second coal sample has a particle size within a second particle size range. In other embodiments, the froth flotation process uses a froth flotation agent including a foaming agent and a collector. The foaming agent includes at least one item selected from the group consisting of 2-octanol, terpenic oil, and polyethylene glycol (PEG). The collector includes at least one item selected from the group consisting of kerosene, diethyl phthalate (BET), and diesel.