Thesis (M.S.)--Virginia Polytechnic Institute and State University, 1994. / Vita. Abstract. Includes bibliographical references (leaves 75-77). Also available via the Internet.

The potential for improved selectivity has made column flotation cells a popular choice for upgrading fine coal. Unfortunately, recent production data from full-scale column plants indicate that many industrial installations have failed to meet original expectations in terms of clean coal recovery. Theoretical studies performed using a simple dispersion model showed that this inherent shortcoming could be largely minimized by reconfiguring the columns to operate in series as a cell-to-cell circuit. Follow-up field data showed that this low-cost modification increased flotation recovery as predicted by the dispersion model. This study presents the key findings obtained from the field investigation and provides generic guidelines for designing multi-stage column circuits. / Master of Science

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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.

Field assessments were performed to establish the performance capabilities of a new flotation technology for fine coal upgrading, known as StackCell flotation. Flotation release analysis was performed on all samples to determine the amount of hydrophilic material present in the streams around the flotation cell. Data from this work supported recommendations from the equipment manufacturer that the wash water distribution system should be changed to a drip pan and that the design of the slurry-air distributor from the mixing chamber should be altered. The experimental data showed that as froth depth, rotor speed, and wash water rate changed, the performance of the cell followed expected trends with respect to product quality, but diverged from expected trends with respect to carbon recovery and yield. Other work performed includes the development of a new carbon partitioning test, which uses a blender to provide a high shear environment and uses oil to partition the slurry into a carbon rich oil phase and an ash rich pulp phase. This test is capable of producing results comparable to those of a traditional release analysis. Lastly, a spreadsheet program was developed that can aid users in designing drip pans. This program is capable of producing custom designs or unit cell designs. A study of the effect that plate thickness has on flow rate was performed in order to develop a model for flow through an orifice plate. The results of this work showed that plate thickness has little to no effect on the flow rate. / 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.

The coalburg seam coal is an example of difficult to float bituminous coal. Laboratory tests conducted on coalburg flotation feed sample revealed recovery values around 28% with 15% product ash when using fuel oil as collector under natural pH conditions. A detailed study showed that increasing pH from natural value of 5.6 to 7.5 provided a significant improvement in recovery of approximately 32 absolute percentage points. The improvement is believed to be result of the release of humic acids from the surface and the dispersion of clay particles thereby leaving a more hydrophobic surface. Based on the tests conducted with various commercially available collectors, oleic acid was selected as a model collector for oxidized coals. Conventional flotation tests found an increase in combustible recovery of 10 absolute percentage points above the pH improvement using 4:1 blend of fuel oil and oleic acid. The problem of higher ash in conventional cell product due to entrainment was minimized by the use of wash water in a flotation column. A flotation concentrate containing less than 7.5% ash was produced while recovering around 75% of the combustible material. Further testing using fatty acids-fuel oil blend also showed evidence of a near 200% increase in flotation rate.