Wet Coal Processing with Superabsorbent Polymers
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Solution Overview
Problem
Existing methods for implementing superabsorbent polymers (SAPs) in pulverized coal combustion (PCC) systems are inefficient and cost-prohibitive, leading to ineffective use in coal processing due to impractical usage ranges and lack of practical systems for efficient SAP implementation.
Innovation Solution
A method involving the measurement of moisture content in wet coal mixes using sensors, followed by the precise addition of superabsorbent polymers like sodium poly-acrylate to the coal mix before milling, ensuring effective drying and processing, thereby optimizing coal combustion and electricity generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If superabsorbent polymers are added to wet coal mixes without moisture measurement and control, then moisture absorption capacity is increased, but SAP usage becomes inefficient and cost-prohibitive
Solution Approach 1:
The system employs moisture sensors to continuously measure the moisture content of coal mixes and provides feedback control for SAP addition. The controller adjusts SAP dosage based on real-time moisture measurements, ensuring optimal absorption capacity while preventing excessive SAP usage and maintaining cost-effective processing efficiency
Solution Approach 2:
The invention dynamically adjusts the dosage parameter of SAP based on measured moisture content variations. By changing the SAP addition rate according to actual moisture levels rather than using fixed high doses, the system achieves efficient moisture absorption while maintaining productivity and cost-effectiveness
2Quantity of substance
If high amounts of SAP are used to treat wet coal, then moisture content is reduced, but processing costs increase significantly
Solution Approach 1:
Moisture sensors provide continuous feedback on coal moisture content, enabling the controller to adjust SAP dosage precisely to achieve target moisture levels. This prevents over-dosing with SAP, reducing material costs while maintaining effective moisture content reduction
Solution Approach 2:
Instead of applying excessive SAP to all coal regardless of moisture needs, the system applies partial doses only when and where moisture content exceeds thresholds. This targeted approach reduces SAP consumption and processing costs while achieving necessary moisture reduction
3Ease of operation
If moisture content in coal is not controlled, then coal can be processed freely, but transportation and processing problems occur due to excessive moisture
Solution Approach 1:
The system performs preliminary moisture measurement and SAP treatment before coal enters transportation and processing stages. By pre-controlling moisture content through monitored SAP addition, the coal is prepared in advance to prevent blockages, hang-ups, and clogging during subsequent transportation and processing operations
Solution Approach 2:
SAP acts as an intermediary substance that modifies the moisture characteristics of coal. The moisture sensors monitor this transformation process, ensuring SAP adequately binds excess moisture to transform wet, problematic coal into free-flowing, reliable material for transportation and processing
4Productivity
If moisture sensors and automated control systems are implemented, then SAP usage is optimized, but system complexity increases
Solution Approach 1:
The system is designed to be relatively self-regulating, where moisture sensors automatically detect moisture levels and the controller autonomously adjusts SAP dosage without requiring constant operator intervention. This self-service capability optimizes SAP usage efficiency while minimizing the operational complexity burden
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 approach allows for efficient processing and increased electricity generation by reducing moisture-related issues, enabling higher coal fines incorporation and improved combustion efficiency with controlled SAP usage, making the process more cost-effective and practical.
Implementation Method 1
Water-absorbing polymers, which are classified as hydrogels when mixed, absorb aqueous solutions through hydrogen bonding with water molecules
Implementation Method 2
absorb aqueous solutions through hydrogen bonding with water molecules
Implementation Method 3
measuring the amount of moisture of the wet coal mix in the stream of wet coal mix
Data Source
AI summary
A method of wet coal processing for electrical power generation comprises the providing a stream of a wet coal mix for an electrical power generation system having a boiler, such as metering coal product onto a conveyor; measuring the amount of moisture of the wet coal mix in the stream, such as with a moisture sensor on the conveyor; determining an amount of drying material to be added to the wet coal mix; adding the determined amount of drying material, such as one or more super absorbent polymers, added to the wet coal mix; Milling the treated wet coal mix; Transporting the milled treated wet coal mix to the boiler of the electrical power generation system for combustion. The method may utilize treated coal wash residual product and teaches a process for treating coal wash residual product.