Tar Binder for Coal Agglomeration Without Wastewater
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Solution Overview
Problem
Conventional coal coking methods using water as a binder result in contaminated wastewater production, freezing issues in cold temperatures, and energy inefficiencies, making the process technically demanding and inefficient.
Innovation Solution
Using tar produced during the coking process as a binder for coal, allowing for agglomeration of coal particles without stickiness or clumping, enabling the formation of stable coal cakes without external adhesion and eliminating the need for heating measures across a wide temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If water is used as a binder for ground coal, then the ground material can be compacted and solidified to form carbon cakes, but highly contaminated wastewater is produced which requires great technical effort to dispose of
Solution Approach 1:
The patent converts the harmful effect of tar (which normally causes sticking and clumping) into a beneficial binder that enables compactation without water. The tar is used in controlled amounts during the mixing phase to allow agglomeration, then evaporates during coking, leaving no harmful wastewater residue.
Solution Approach 2:
The patent changes the binder parameter from water to tar, and controls the tar content and mixing conditions to achieve the desired compactation behavior. The tar is mixed in specific amounts and under controlled conditions to enable temporary binding during compaction, then evaporates during the coking process without leaving harmful residues.
2Stability of the object's composition
If water is used as a binder for ground coal, then compactation can proceed, but the ground material can freeze in cold regions which eliminates the possibility of compacting and solidifying
Solution Approach 1:
The patent uses tar as a binder that remains effective across a wide temperature range including cold conditions. The tar provides binding properties without the freezing issue associated with water, enabling compactation and solidification even in cold regions where water-based binders would fail.
Solution Approach 2:
The patent changes the binder from water to tar, fundamentally altering the temperature dependence of the binding system. Tar maintains its binding properties in cold temperatures where water would freeze, thus eliminating the temperature limitation and enabling operation across a wide temperature range from -60°C to +60°C.
3Stability of the object's composition
If water is used as a binder for ground coal, then compactation can occur, but complex measures for heating the material to be ground become necessary
Solution Approach 1:
The patent eliminates the need for heating measures by using tar as a binder that functions effectively at ambient temperatures. The tar provides sufficient binding strength without requiring the ground material to be heated, thus eliminating the energy consumption associated with heating operations.
Solution Approach 2:
The patent changes the binder from water to tar, which fundamentally alters the thermal requirements of the process. Tar-based binding occurs effectively at ambient temperatures without requiring the heating that water-based systems necessitate, thereby eliminating energy consumption for heating the ground material.
4Productivity
If water is used as a binder for ground coal in direct coking, then the process can proceed, but the energy balance is worsened
Solution Approach 1:
The patent converts the energy-intensive water-based binding process into a more efficient tar-based system. The tar binder eliminates the need for heating operations and reduces the overall energy requirements of the coking process, improving the energy balance while maintaining productivity.
Solution Approach 2:
The patent changes the binder parameter from water to tar, which fundamentally improves the energy balance of the coking process. The tar-based system eliminates heating requirements and reduces energy consumption while maintaining the coking process productivity, achieving a more efficient overall process.
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 method produces a stable coal cake with uniform solidification and energy efficiency, avoiding wastewater and freezing issues, while utilizing waste tar for binding, resulting in a homogeneous charcoal block with enhanced stability and reduced processing effort.
Implementation Method 1
the binder formed as tar penetrating into the interior of agglomerate particles during the course of agglomeration
Implementation Method 2
the ground material and binder are mixed in such a ratio and over such a period of time that agglomerate particles are formed from the coal particles and the binder
Implementation Method 3
granulate particles 1 according to 1 form, which consist of coal particles 2 and the tar binder 3 holding the coal particles 2 together
Data Source
Figure 1~3
AI summary
The invention relates to a method for preparing coal for carbonisation, in which the coal is ground, the ground material is mixed with a binding agent, and a ballast (4) containing the ground material mixed with the binding agent (3) is produced. The produced ballast can be directly carbonised or alternatively further processed to a coal cake, wherein it is compressed in a mould (5) and consolidated to a block (7). According to the invention, the binding agent (3) is a binding agent that is liquid or solid over the possible temperature range, wherein tar in particular is used as the binding agent (3).