Integration of thickener underflow into thermal dryer circuit. Final report
A large number of coal preparation plants in the United States are troubled with coal fines and associated plant operation problems. As part of their process, these plants use thermal dryers for producing product coal, cyclones for first-stage recovery of coal fines, and wet scrubbers for the second-stage removal of coal fines carry-over from the dryer exhaust gas. The first challenge for these plants is to recover the clean ultra-fine coal captured in the scrubbers rather than to dispose of it in settling ponds. The second challenge is to mitigate the over-dry fine coal dusting problems in the dryer product. Prior to the completion of this program, the difficulties of the first challenge involving the recovery and use of fine clean coal from the thermal dryer scrubber effluent had not been solved. The second challenge, controlling fine coal dusting, was previously met by applying a solution of surfactants and process water to the over-dry coal fraction. As a result of the demonstration provided by the performance of this program, the implementation of a simple process improvement, involving the use of a thickener in combination with a belt press, simultaneously solved both challenges: the de-dusting and the dryer scrubber effluent recovery issues. The objective of this project was to: (1) Use a clean coal thickener with a squeeze belt press to recover the ultra-fine coal in dryer scrubber effluent; (2) Demonstrate that the coal-water mixture (CWM) produced from scrubber sludge of a thermal dryer can be used as a dust suppressant. The thickener/belt press system has increased the production of JWRI Mine Number 4 by approximately 0.7%. This production increase was accomplished by recovering and re-using 3 metric tons/hr (3.3 tons/hr) of coal fines that were previously sent to holding ponds, returning this as a 50% CWM to de-dust the 430 metric tons/hr (470 tons/hr) of existing dryer production.
- Research Organization:
- TECOGEN, Inc., Waltham, MA (United States)
- Sponsoring Organization:
- USDOE Assistant Secretary for Fossil Energy, Washington, DC (United States)
- DOE Contract Number:
- AC22-93PC93156
- OSTI ID:
- 589905
- Report Number(s):
- DOE/PC/93156-T1; ON: DE98050581; TRN: 98:001841
- Resource Relation:
- Other Information: PBD: [1998]
- Country of Publication:
- United States
- Language:
- English
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