US3908912A - Coal beneficiating process - Google Patents

Coal beneficiating process Download PDF

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Publication number
US3908912A
US3908912A US506822A US50682274A US3908912A US 3908912 A US3908912 A US 3908912A US 506822 A US506822 A US 506822A US 50682274 A US50682274 A US 50682274A US 3908912 A US3908912 A US 3908912A
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United States
Prior art keywords
coal
middlings
fraction
feed
refuse
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Expired - Lifetime
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US506822A
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English (en)
Inventor
Stanton D Irons
Francis G Miller
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Bethlehem Steel Corp
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Bethlehem Steel Corp
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Priority to US506822A priority Critical patent/US3908912A/en
Priority to CA231,206A priority patent/CA1064883A/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
    • B03B9/00—General arrangement of separating plant, e.g. flow sheets
    • B03B9/005—General arrangement of separating plant, e.g. flow sheets specially adapted for coal

Definitions

  • PRobucr (VERY F/NE) rsxr FIIVE $1250 own cum mom/er (Fl/V58) COAL BENEFICIATING PROCESS BACKGROUND OF THE INVENTION
  • This invention relates to classifying, separating and assorting solids, and more particularly to coal beneficiating.
  • FIG. 1 is a schematic representation of our process showing beneficiation of a coal middlings fraction.
  • FIG. 2 is a diagrammatic illustration of an embodiment of our process.
  • the instant invention is directed to improvements in processing fine coal to remove sulfur and ash constituents while increasing yield by crushing middlings.
  • Presently in the industry there are many different systems used for reducing sulfur and 'ash in fine coal, but all feature common unit operations noted hereinbefore that are combined in various ways. Unit operations such as hydrocycloning, tabling, screening, crushing and those that use classifying cyclones and flotation are the most common.
  • the instant invention presents a unique combination of these components which, when working in a system, results in improved coal quality and increased yield. I
  • raw coal with a top size of several inches is initially separated in a high density separator to remove a refuse that contains no value.
  • the product stream from this first separation which contains all sizes of coal, middling and some refuse, is then sized to separate out a coarse fraction (from about 5 inches to about /2 inch) from the intermediate sized material (about /2 inch to about 28 mesh) and the fines (about 28 mesh to O).
  • the coarse material is then separated in a low density separator to recover a quality product (low sulfur) and a middling fraction.
  • Middling is crushed to liberate ash and sulfur constituents from coal, and this crushed material is combined with the undersize material from the first sizing operation. Com plete crushing, where needed, is obtained by recirculating oversize to the crusher feed.
  • the combined material is then screened to separate an intermediate size material from the fines.
  • the intermediate size material is next separated in a low density separator to recover a quality, low sulfur product and a middling. This middling is crushed and combined with the fines.
  • the total raw coal would normally be treated as described only if the low density fractions are low in sulfur.
  • the low density material is high in sulfur, all the material in the product stream from the first separator is crushed to a finer size.
  • Raw and crushed fines are treated in primary hydrocyclones which make an initial product separation. Because of the inefficiencies of hydrocyclone separations (coal lost to refuse and refuse misplaced to coal), auxiliary back-up systems are required. To cope with this inefficiency, we have found that good results can be achieved by (I) using secondary hydrocyclones to reclean the product (overflow), and (2) using tables to reject fine sulfur, to recover coal lost to refuse (underflow) and to recover a middling which can be crushed and retreated to increase yield.
  • the secondary hydrocyclone product (overflow) may still contain some misplaced fine, high-density sulfur components and to reject these fines, we use cyclones which classify by particle mass.
  • a raw coal feed in all size ranges is subjected to a high density separator to remove a high density refuse of, for example, mine rock.
  • the feed is then sized to separate a coarse fraction from the feed.
  • the coarse fraction is subjected to a low density separation to generate a coarse coal product which is recovered and a middlings fraction which is crushed and returned to the circuit.
  • the feed is now of intermediate size.
  • the feed now comprises a combination of the crushed middlings and the undersized fraction from the initial screenings and is now subjected to a second sizing step to separate the intermediate sizes from the fines.
  • the intermediates are separated in a low density separator to generate a coal product of intermediate size and an intermediate fraction comprising middlings and any refuse.
  • the middlings and any refuse that was liberated in the first crushing are crushed and returned to the circuit where they are combined with the undersized fraction from the second sizer, to form a feed which is generally fines.
  • the fines now proceed to a first hydrocyclone which performs first a combined density and size separation.
  • the overflow from the first hydrocyclone containing generally finer average size than the underflow, may be further classified in a second cyclone and the products of the second cyclone classification refined by flotation (for the overflow) and sizing (for the underflow).
  • the hydrocyclone step also generates an underflow which is subjected to concentrating tables to refine a coal product, refuse and middlings.
  • the first two that is the coal product and refuse, exit the circuit and the middlings are crushed and recycled.
  • a raw coal feed of a top size of about 5 inches and an ore content comprising, generally coal, middling and refuse is subjected to treatment in a jig to separate refuse having a specific gravity above about l.80 comprising mostly mine rock.
  • Feed material having a specific gravity less than about 1.80 is sent to a screen 14 as shown in line 12.
  • Screen 14 sizes the feed at about V2 inch (more or less) and the oversize travels by line 16 to heavy media vessel 18.
  • Heavy media vessel 18 separate the feed at a specific gravity of about 1.30 to produce a coarse coal product of about 5 inch to about /2 inch size and a similarly sized middlings fraction that has a specific gravity heavier than about 1.30 but lighter than about 1.80.
  • the middlings fraction is sent by line 20 to a crusher 22 and from there the crushed fraction is combined with the minus V2 inch size feed from screen 14.
  • the combined feed, now line 26 is screened on screen 28 at about 28 mesh.
  • the plus 28 mesh size fraction, from screen 28 travels by line 30 to heavy medium cyclone 32.
  • Heavy medium cyclone 32 separates the feed to yield an intermediate size coal product of about /2 inch to 28 mesh and an intermediate size middlings that has a specific gravity heavier than about 1.33.
  • the middlings fraction leaves cyclone 32 in line 34 and enters crusher 36.
  • Oversize material can be recycled as needed to the crusher 36 by line
  • Hydrocyclone 39 processes the fines fraction slurry 38 to separate an overflow fraction 40 comprising mainly 28 mesh to 0 fine coal and some misplaced 150 mesh to 0 very fine refuse from the underflow fraction 46 comprising mainly 28 mesh to 0 fine refuse and some misplaced 28 to 100 mesh fine coal.
  • Hydrocyclone 39 processes the fines fraction slurry 38 to separate an overflow fraction 40 comprising mainly 28 mesh to 0 fine coal and some misplaced 150 mesh to 0 very fine refuse from the underflow fraction 46 comprising mainly 28 mesh to 0 fine refuse and some misplaced 28 to 100 mesh fine coal.
  • the fine coal slurry 40 is retreated in a classifying cyclone 41 to separate an overflow fraction 42 comprising mainly 60 mesh to 0 coal and 200 mesh to O refuse from the underflow fraction 44 comprising mainly plus 60 mesh coal and 150 mesh to 0 refuse.
  • Slurry 42 is retreated to remove the contaminating refuse fines by a flotation stage 50 and separate a final fine coal product 52 from a fine refuse 51.
  • Classifying cyclone underflow 44 is processed on screen 60 which separates at about 150 mesh, and recovers a plus 150 mesh coal product 62 and rejects a 150 mesh to 0 refuse 61.
  • Underflow fraction 46 from hydrocyclone 39 is reprocessed in concentrating table to recover the misplaced 28 to 100 mesh coal fines as product 72 from a final refuse fraction 71.
  • Table 70 can also be set up to recover a plus 100 mesh middling fraction 73, which can be crushed in crusher to liberate additional coal values from refuse and by line 81 be reprocessed in the system beginning with hydrocyclone 39 or a similar system.
  • the new process provides an improved method for reducing the sulfur and ash content in coal, and increasing yield while producing a minimum of fine sizes.
  • the improvement features stage crushing of middlings, that are high in sulfur content, followed by reprocessing to 1) recover the low sulfur and low ash coal liberated during crushing, (2) reject high sulfur components, and (3) separate additional middlings that can be crushed to a finer size to further improve its quality and increase overall yield.
  • the system provides improved processing techniques for treating coal fines.
  • known components tables, hydrocyclones, classifying cyclones, fine screens presently used for processing fine coal
  • the 29% by weight A inch to 28 mesh middling fraction remaining was subjected to a second stage crushing to 14 mesh to produce a 14 mesh to 0 coal product having 1.77% by weight sulfur and 9.5% by weight ash content, an acceptable relatively high quality coal.
  • the remaining 13% by weight was 14 mesh to refuse.
  • the remaining increment which amounts to 5 29% of the coarse middlings feed in this first stage crushing step and which has a sulfur content of 2.51% by weight and an ash content of 29.0% by weight, is fed to a second stage crushing operation as intermediate (A inch to 28 mesh) middlings. Crushing the intermediate middlings to 14 mesh results in a coal product amounting to 16% of the intermediate middlings and having a sulfur content of 1.77% by weight and an ash content of 9.5% by weight. The remaining 13% is refuse. 5
  • a method for recovering high quality coal from a raw coal ore feed, which feed comprises a high middlings content comprising:
  • step (d) sizing the feed from step (d) at a finer mesh than the sizing of step (c) to recover an intermediate sized coal product which is separated from an intermediate sized middlings
  • step (f) separating the fines feed from step (f) to produce a fines product fraction and a refuse fraction
  • step (g) treating the product fraction from step (g) by a flotation step to recover coal
  • step (g) separating the refuse fraction from step (g) to produce three separate material fractions, including first sized coal values which are recovered, refuse which is discarded and middlings, and
  • step (i) crushing the middlings of step (i) and recycling the crushed material to step (g).
  • a method for recovering high quality coal from a raw coal ore feed, which feed comprises a high middlings content comprising:
  • step (c) crushing the coarse middlings from (c) to an intermediate size and combining same with intermediates from the sizing fraction of step (c) to provide a feed ranging in average size from intermediate to fine
  • step (d) sizing the feed from step (d) at a finer mesh than the sizing of step (c) to separate an intermediate fraction from a fines fraction and dividing the intermediate fraction at low density to recover an intermediate sized coal product which is separated from an intermediate sized middlings
  • step (e) crushing the intermediate sized middling from (e) to a fines size and combining same with the fines fraction of step (e) to provide a fines feed including coal, middlings and high density refuse,
  • step (f) separating the fines feed from step (f) by hydrocycloning to produce a first overflow and a first underflow fraction, the overflow fraction comprising various fine sizes of coal and finer refuse, the underflow fraction comprising various fine sizes of refuse and some fine coal,
  • step (g) classifying the overflow fraction from step (g) to separate, by mass, the light mass particles from the heavier mass particles, the light mass particles comprising very fine sized coal and ultrafine sized refuse, the heavier mass particles comprising fine sized coal and very fine sized refuse, and treating the light mass particles by a flotation step to recover coal and screening the heavier mass particles to recover coal,
  • step (g) separating the first underflow fraction from step (g) to produce three separate material fractions, including fine sized coal values which are recovered, refuse which is discarded and middlings, and

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  • Separation Of Solids By Using Liquids Or Pneumatic Power (AREA)
  • Solid Fuels And Fuel-Associated Substances (AREA)
US506822A 1974-09-17 1974-09-17 Coal beneficiating process Expired - Lifetime US3908912A (en)

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US506822A US3908912A (en) 1974-09-17 1974-09-17 Coal beneficiating process
CA231,206A CA1064883A (fr) 1974-09-17 1975-07-10 Traitement d'optimisation de la production et de la qualite du charbon

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Cited By (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2306015A1 (fr) * 1975-03-29 1976-10-29 Stamicarbon Procede de recuperation de materiaux utilisables a partir de dechets contenant des metaux et des non-metaux
DE2544538A1 (de) * 1975-10-04 1977-04-14 Schuster & Co F M N Vorrichtung zum einfuehren von faeden, garnen u.dgl. in eine spul- und changiereinrichtung einer spulmaschine
US4244530A (en) * 1979-12-17 1981-01-13 Consolidation Coal Company Integrated coal cleaning and slurry preparation process
US4338188A (en) * 1979-07-13 1982-07-06 Exxon Research & Engineering Co. Coal cleaning process
US4525173A (en) * 1982-05-19 1985-06-25 The British Petroleum Company P.L.C. Mineral slurries
US4526588A (en) * 1978-08-19 1985-07-02 Ruhrchemie Aktiengesellschaft Process for the production of a coal-water suspension which is suitable for use in coal gasification under elevated pressure
US4586660A (en) * 1984-04-30 1986-05-06 Stiller David W Process for separating anthracite coal from impurities
US4707162A (en) * 1983-08-19 1987-11-17 The British Petroleum Company P.L.C. Mineral slurries
US4826588A (en) * 1988-04-28 1989-05-02 The Dow Chemical Company Pyrite depressants useful in the separation of pyrite from coal
US4830740A (en) * 1988-04-19 1989-05-16 The Dow Chemical Company Pyrite depressants useful in the separation of pyrite from coal
WO1993007967A1 (fr) * 1991-10-15 1993-04-29 Genesis Research Corporation Procede d'epuration de charbon
US5277368A (en) * 1987-11-30 1994-01-11 Genesis Research Corporation Coal cleaning process
US5522510A (en) * 1993-06-14 1996-06-04 Virginia Tech Intellectual Properties, Inc. Apparatus for improved ash and sulfur rejection
US5794791A (en) * 1987-11-30 1998-08-18 Genesis Research Corporation Coal cleaning process
US5817230A (en) * 1997-08-29 1998-10-06 University Of Kentucky Research Foundation Method for improving the pozzolanic character of fly ash
US6533848B1 (en) 2000-03-13 2003-03-18 University Of Kentucky Research Foundation Technology and methodology for the production of high quality polymer filler and super-pozzolan from fly ash
US6599434B2 (en) 2001-11-06 2003-07-29 Norman B. Mullins Fine coal recovering process
US20050145732A1 (en) * 2000-02-25 2005-07-07 Oder Robin R. Method and apparatus for separating material
US20100056356A1 (en) * 2008-08-29 2010-03-04 Robl Thomas L Methodology and technology for the production of improved coal derived fly ash for the production of metal matrix composites
US20100287828A1 (en) * 2007-09-10 2010-11-18 Global Coal Solutions Pty Ltd Beneficiation of coal
US20120256022A1 (en) * 2008-10-16 2012-10-11 John Clarence Box Method of sorting mined, to be mined or stockpiled material to achieve an upgraded material with improved economic value
CN104475214A (zh) * 2014-11-13 2015-04-01 攀枝花钢城集团米易瑞地矿业有限公司 含风化矿钒钛磁铁矿预选工艺
CN105728156A (zh) * 2016-03-22 2016-07-06 中国矿业大学 一种超纯煤的制备工艺
CN105797831A (zh) * 2016-03-22 2016-07-27 中国矿业大学 一种炼焦末中煤的解离再选工艺
CN113245200A (zh) * 2021-06-16 2021-08-13 许泽胜 一种煤矸石选择性破碎制备砂石骨料的方法
CN114950713A (zh) * 2022-05-27 2022-08-30 徐州工程学院 可提高难选煤的精煤回收率的重介旋流器主再选选煤工艺
CN115318426A (zh) * 2022-07-19 2022-11-11 李少章 一种含硫煤矸石无害化处理及资源利用方法
USRE50392E1 (en) * 2010-06-02 2025-04-22 Technological Resources Pty Limited Separating mined material

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US2319394A (en) * 1940-04-05 1943-05-18 Chemical Construction Corp Beneficiation of low grade coal
US2330479A (en) * 1940-04-05 1943-09-28 Chemical Construction Corp Beneficiation of low grade coal
US2514958A (en) * 1947-12-26 1950-07-11 Republic Steel Corp Concentration of oolitic iron ores
US2656118A (en) * 1951-03-24 1953-10-20 Knowles Associates Disposal of slime-bearing water
US2842319A (en) * 1952-11-05 1958-07-08 Reerink Wilhelm Method of producing ultra-clean coal
US3023893A (en) * 1962-03-06 Process for separating particles of solid x
US3384310A (en) * 1966-02-16 1968-05-21 Cleveland Cliffs Iron Method of treating metalliferous ores
US3446349A (en) * 1966-03-16 1969-05-27 Bethlehem Steel Corp Apparatus and method for separating and recovering relatively coarse mineral particles and relatively fine mineral particles from a slurry containing said particles
US3638791A (en) * 1970-04-13 1972-02-01 Int Minerals & Chem Corp Method for treatment of heavy media
US3677475A (en) * 1970-10-02 1972-07-18 Int Minerals & Chem Corp Beneficiation of clay-containing sylvinite ore

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3023893A (en) * 1962-03-06 Process for separating particles of solid x
US2319394A (en) * 1940-04-05 1943-05-18 Chemical Construction Corp Beneficiation of low grade coal
US2330479A (en) * 1940-04-05 1943-09-28 Chemical Construction Corp Beneficiation of low grade coal
US2514958A (en) * 1947-12-26 1950-07-11 Republic Steel Corp Concentration of oolitic iron ores
US2656118A (en) * 1951-03-24 1953-10-20 Knowles Associates Disposal of slime-bearing water
US2842319A (en) * 1952-11-05 1958-07-08 Reerink Wilhelm Method of producing ultra-clean coal
US3384310A (en) * 1966-02-16 1968-05-21 Cleveland Cliffs Iron Method of treating metalliferous ores
US3446349A (en) * 1966-03-16 1969-05-27 Bethlehem Steel Corp Apparatus and method for separating and recovering relatively coarse mineral particles and relatively fine mineral particles from a slurry containing said particles
US3638791A (en) * 1970-04-13 1972-02-01 Int Minerals & Chem Corp Method for treatment of heavy media
US3677475A (en) * 1970-10-02 1972-07-18 Int Minerals & Chem Corp Beneficiation of clay-containing sylvinite ore

Cited By (36)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2306015A1 (fr) * 1975-03-29 1976-10-29 Stamicarbon Procede de recuperation de materiaux utilisables a partir de dechets contenant des metaux et des non-metaux
DE2544538A1 (de) * 1975-10-04 1977-04-14 Schuster & Co F M N Vorrichtung zum einfuehren von faeden, garnen u.dgl. in eine spul- und changiereinrichtung einer spulmaschine
US4526588A (en) * 1978-08-19 1985-07-02 Ruhrchemie Aktiengesellschaft Process for the production of a coal-water suspension which is suitable for use in coal gasification under elevated pressure
US4338188A (en) * 1979-07-13 1982-07-06 Exxon Research & Engineering Co. Coal cleaning process
US4348274A (en) * 1979-07-13 1982-09-07 Exxon Research & Engineering Co. Oil shale upgrading process
US4244530A (en) * 1979-12-17 1981-01-13 Consolidation Coal Company Integrated coal cleaning and slurry preparation process
US4525173A (en) * 1982-05-19 1985-06-25 The British Petroleum Company P.L.C. Mineral slurries
US4707162A (en) * 1983-08-19 1987-11-17 The British Petroleum Company P.L.C. Mineral slurries
US4586660A (en) * 1984-04-30 1986-05-06 Stiller David W Process for separating anthracite coal from impurities
US5314124A (en) * 1987-11-30 1994-05-24 Genesis Research Corporation Coal cleaning process
US5794791A (en) * 1987-11-30 1998-08-18 Genesis Research Corporation Coal cleaning process
US5348160A (en) * 1987-11-30 1994-09-20 Genesis Research Corporation Coal cleaning process
US5277368A (en) * 1987-11-30 1994-01-11 Genesis Research Corporation Coal cleaning process
US4830740A (en) * 1988-04-19 1989-05-16 The Dow Chemical Company Pyrite depressants useful in the separation of pyrite from coal
US4826588A (en) * 1988-04-28 1989-05-02 The Dow Chemical Company Pyrite depressants useful in the separation of pyrite from coal
WO1993007967A1 (fr) * 1991-10-15 1993-04-29 Genesis Research Corporation Procede d'epuration de charbon
US5522510A (en) * 1993-06-14 1996-06-04 Virginia Tech Intellectual Properties, Inc. Apparatus for improved ash and sulfur rejection
US5817230A (en) * 1997-08-29 1998-10-06 University Of Kentucky Research Foundation Method for improving the pozzolanic character of fly ash
US20050145732A1 (en) * 2000-02-25 2005-07-07 Oder Robin R. Method and apparatus for separating material
US7124968B2 (en) * 2000-02-25 2006-10-24 Exportech Company, Inc. Method and apparatus for separating material
US6533848B1 (en) 2000-03-13 2003-03-18 University Of Kentucky Research Foundation Technology and methodology for the production of high quality polymer filler and super-pozzolan from fly ash
US6599434B2 (en) 2001-11-06 2003-07-29 Norman B. Mullins Fine coal recovering process
US20100287828A1 (en) * 2007-09-10 2010-11-18 Global Coal Solutions Pty Ltd Beneficiation of coal
US8591607B2 (en) * 2007-09-10 2013-11-26 Global Coal Solutions Pty Ltd Beneficiation of coal
US20100056356A1 (en) * 2008-08-29 2010-03-04 Robl Thomas L Methodology and technology for the production of improved coal derived fly ash for the production of metal matrix composites
US20120256022A1 (en) * 2008-10-16 2012-10-11 John Clarence Box Method of sorting mined, to be mined or stockpiled material to achieve an upgraded material with improved economic value
US8931720B2 (en) * 2008-10-16 2015-01-13 Technological Resources Pty. Limited Method of sorting mined, to be mined or stockpiled material to achieve an upgraded material with improved economic value
AU2009304592B2 (en) * 2008-10-16 2015-10-08 Technological Resources Pty. Limited A method of sorting mined, to be mined or stockpiled material to achieve an upgraded material with improved economic value
USRE50392E1 (en) * 2010-06-02 2025-04-22 Technological Resources Pty Limited Separating mined material
CN104475214A (zh) * 2014-11-13 2015-04-01 攀枝花钢城集团米易瑞地矿业有限公司 含风化矿钒钛磁铁矿预选工艺
CN105797831A (zh) * 2016-03-22 2016-07-27 中国矿业大学 一种炼焦末中煤的解离再选工艺
RU2677339C1 (ru) * 2016-03-22 2019-01-16 Чайна Юниверсити Оф Майнинг Энд Текнолоджи Способ высвобождения и обогащения угольной мелочи, полученной от коксования
CN105728156A (zh) * 2016-03-22 2016-07-06 中国矿业大学 一种超纯煤的制备工艺
CN113245200A (zh) * 2021-06-16 2021-08-13 许泽胜 一种煤矸石选择性破碎制备砂石骨料的方法
CN114950713A (zh) * 2022-05-27 2022-08-30 徐州工程学院 可提高难选煤的精煤回收率的重介旋流器主再选选煤工艺
CN115318426A (zh) * 2022-07-19 2022-11-11 李少章 一种含硫煤矸石无害化处理及资源利用方法

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