In modern coal preparation plants, solid-solid and solid-liquid separation processes used to treat fine coal are least efficient and most costly operations. For example, field studies indicate that the froth flotation process, which is normally used to treat minus (-0.2 mm) fine coal, often recovers less than 65 to 70% of the organic matter in this size range. Fine coal separation processes are also inherently less effective in removing pyrite than that of coarse coal separations. Moreover, while fines may represent 10% or less of the total run-of-mine feed, this size fraction often contains one-third or more of the total moisture in the delivered product. In order to address these issues, several multistage coal processing circuits were set up and experimentally tested to demonstrate the potential improvements in fine coal upgrading that may be realistically achievable using an "optimized" fine coal processing flowsheet. On the basis of results obtained from this research, engineering criteria was also developed that may be used to identify optimum circuit configurations for the processing different fine coal streams. In the current study, several fine coal cleaning alternatives were evaluated in laboratory, bench-scale and pilot-scale test programs. Fine coal processes compared in the first phase of this work included spirals, water-only cyclones, teeter-bed separators and froth flotation. The performance of each technology was compared based on separation efficiencies derived from combustible rejection versus ash rejection plots. The resulting data was used to identify size ranges most appropriate for the various alternative processes. As a follow-up to this effort, a second phase of pilot-scale and in-plant testing was conducted to identify new types of spiral circuit configurations that improve fine coal separations. The experimental data from this effort indicates that a four-stage spiral with second- and fourth-stage middlings recycle offered the best option for improved separation efficiency, clean coal yield and combustible recovery. The newly developed spiral circuitry was capable of increasing cumulative clean coal yield by 1.9 % at the same clean coal ash as compared to that of achieved using existing conventional compound spiral technology. Moreover, the experimental results also proved that slurry repluping after two turns is not effective in improving separation performance of spiral circuits. The third phase of work conducted in this study focused on the development of methods for improving the partitioning of pyrite within fine coal circuits. The investigation, which included both laboratory and pilot-scale test programs, indicated that density-based separations are generally effective in reducing sulfur due to the large density difference between pyrite and coal. On the other hand, the data also showed that sulfur rejections obtained in froth flotation are often poor due to the natural floatability of pyrite. Unfortunately, engineering analyses showed that pyrite removal from the flotation feed using density separators would be impractical due to the large volumetric flow of slurry that would need to be treated. On the other hand, further analyses indicated that the preferential partitioning of pyrite to the underflow streams of classifying cyclones and fine wire sieves could be exploited to concentrate pyrite into low-volume secondary streams that could be treated in a cost effective manner to remove pyrite prior to flotation. Therefore, on the basis of results obtained from this experimental study, a combined flotation-spiral circuitry was developed for enhanced ash and sulfur rejections from fine coal circuits. Finally, the fourth phase of work conducted as part of this investigation focused on evaluating a new mechanical, non-thermal dewatering process called Nano Drying Technology (NDT"). Experimental results obtained from bench-scale testing showed that the NDT" system can effectively dewater fine clean coal products from more than 30% surface moisture to single-digit moisture values. Test data obtained using a pilot-scale NDT" plant further validated this capability using a continuous prototype facility. It was also observed that, unlike existing fine coal dewatering processes, the performance of the NDT" system is not constrained by particle size. / Ph. D.

In modern coal preparation plants, solid-solid and solid-liquid separation processes used to treat fine coal are least efficient and most costly operations. For example, field studies indicate that the froth flotation process, which is normally used to treat minus (-0.2 mm) fine coal, often recovers less than 65 to 70% of the organic matter in this size range. Fine coal separation processes are also inherently less effective in removing pyrite than that of coarse coal separations. Moreover, while fines may represent 10% or less of the total run-of-mine feed, this size fraction often contains one-third or more of the total moisture in the delivered product. In order to address these issues, several multistage coal processing circuits were set up and experimentally tested to demonstrate the potential improvements in fine coal upgrading that may be realistically achievable using an "optimized" fine coal processing flowsheet. On the basis of results obtained from this research, engineering criteria was also developed that may be used to identify optimum circuit configurations for the processing different fine coal streams. In the current study, several fine coal cleaning alternatives were evaluated in laboratory, bench-scale and pilot-scale test programs. Fine coal processes compared in the first phase of this work included spirals, water-only cyclones, teeter-bed separators and froth flotation. The performance of each technology was compared based on separation efficiencies derived from combustible rejection versus ash rejection plots. The resulting data was used to identify size ranges most appropriate for the various alternative processes. As a follow-up to this effort, a second phase of pilot-scale and in-plant testing was conducted to identify new types of spiral circuit configurations that improve fine coal separations. The experimental data from this effort indicates that a four-stage spiral with second- and fourth-stage middlings recycle offered the best option for improved separation efficiency, clean coal yield and combustible recovery. The newly developed spiral circuitry was capable of increasing cumulative clean coal yield by 1.9% at the same clean coal ash as compared to that of achieved using existing conventional compound spiral technology. Moreover, the experimental results also proved that slurry repluping after two turns is not effective in improving separation performance of spiral circuits. The third phase of work conducted in this study focused on the development of methods for improving the partitioning of pyrite within fine coal circuits. The investigation, which included both laboratory and pilot-scale test programs, indicated that density-based separations are generally effective in reducing sulfur due to the large density difference between pyrite and coal. On the other hand, the data also showed that sulfur rejections obtained in froth flotation are often poor due to the natural floatability of pyrite. Unfortunately, engineering analyses showed that pyrite removal from the flotation feed using density separators would be impractical due to the large volumetric flow of slurry that would need to be treated. On the other hand, further analyses indicated that the preferential partitioning of pyrite to the underflow streams of classifying cyclones and fine wire sieves could be exploited to concentrate pyrite into low-volume secondary streams that could be treated in a cost effective manner to remove pyrite prior to flotation. Therefore, on the basis of results obtained from this experimental study, a combined flotation-spiral circuitry was developed for enhanced ash and sulfur rejections from fine coal circuits. Finally, the fourth phase of work conducted as part of this investigation focused on evaluating a new mechanical, non-thermal dewatering process called Nano Drying Technology (NDT™). Experimental results obtained from bench-scale testing showed that the NDT™ system can effectively dewater fine clean coal products from more than 30% surface moisture to single-digit moisture values. Test data obtained using a pilot-scale NDT™ plant further validated this capability using a continuous prototype facility. It was also observed that, unlike existing fine coal dewatering processes, the performance of the NDT™ system is not constrained by particle size. / Ph. D.

In order to produce coal containing less than 2% ash using a physical cleaning process, the coal must initially be ground to liberate the mineral matter. The result is a micronized feed material that cannot be efficiently treated using the commercial methods currently available. Therefore, an advanced physical cleaning technique for ultrafine coal, called"selective-shear coagulation", is presently being investigated. The process utilizes high shear conditions to overcome the strong electrostatic repulsive force between particles. The attractive hydrophobic interaction and van der Waals forces control the coagulation of the coal particles. The effects of various chemical parameters, such as pH and ion concentration, were studied. An optimum pH range was established for tap water and distilled water media. The presence of multivalent cations in the system increased coal recovery, but decreased selectivity. Physical parameters of the selective coagulation process, such as particle size, percent solids, and specific energy input, were studied. It was found that separation efficiency improved with decreasing particle size. An optimum feed percent solids was found by maximizing separation efficiency. In the case of distilled water, test results revealed that additional specific energy provided by mechanical agitation was required to induce coagulation after grinding. However, additional mixing was found unnecessary in the case of tap water. A continuous selective-shear coagulation process using an elutriation column as the separator was designed and characterized. A steady-state population balance model of the elutriation column was developed. The predictions were found to be in good agreement with experimental results. / Master of Science

Coal in the finer particle size ranges (below 1 mm) has always suffered from poor cleaning efficiencies. This problem has been exacerbated in recent years with the increased amount of high ash fines due to continuous mining machines and the mining of dirtier coal seams. In the present work, it is proposed to improve overall plant efficiencies by processing coarser coal in column flotation than is now commonly treated by that method. Column flotation for coarse coal is supported by actual lab and plant test data that result in a full-scale column plant installation. The fundamentals of coarse particle detachment from bubbles are reviewed and a new simplified model is developed which better handles cubical and rectangular coal particles. Much of the lower efficiency of fine coal cleaning is due to poor size separation of the fine-sized raw coal which results in misplaced high ash fines reporting to the coarser size streams. By sending coarser material to column flotation, the finest size separation that takes place in a plant can be as coarse as 0.5 mm or greater. The proper use of wash water in a flotation column then becomes the best mechanism for desliming of the high ash clays. This work quantifies the benefits of removing the high ash fines from the plant product and increasing overall plant yield by increasing the amount of near-gravity coarse material. The resulting yield gain is greater than that obtained from only the increased fine coal recovery. Methods of column operation for improved coarse coal recovery are also evaluated. / Ph. D.

Modern coal preparation facilities incorporate a wide array of solid-solid and solid-liquid separation processes for rejecting mineral matter to meet market specifications. The coarse mineral matter is typically placed into engineered refuse piles whereas the fine refuse is either stored in impoundments or co-disposed with the coarse refuse. The discharge water from the refuse material represents an environmental concern due to the potential release of trace elements, and the subsequent elevation of total dissolved solids and conductivity. The research findings reported in this dissertation addresses sustainable coal processing waste disposal through using strategies aimed at minimizing the environmental impacts. To provide an accurate and inexpensive method to assess the potential environmental effects of a given waste material, a conductivity screening-level test was modified to incorporate the impact of particle surface area. The test was used on various waste streams as well as the particle size and density fractions of each waste stream to identify environmentally sensitive components that can be separated from the bulk and isolated to prevent negative environmental impacts. The results were subsequently evaluated for long term mobility of trace elements under different disposal scenarios: (i) static leaching tests designed to simulate the quiescent conditions in a stable impoundment, and (ii) a dynamic test to simulate waste materials exposed to the atmosphere in variable wet/dry storage conditions. The results indicated that liberating, separating and isolating the highest density fractions (>2.68 SG) which represents less than 5% of the coal refuse materials results in significant abatement of total dissolved solids and conductivity. Required modifications of the coal processing plants were suggested to segregate and subsequently isolate the environmentally sensitive fractions from the remaining refuse material.