skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: DENSE MEDIA CYCLONE OPTIMIZATION

Abstract

The fieldwork associated with Task 1 (Baseline Assessment) was completed this quarter. Detailed cyclone inspections completed at all but one plant during maintenance shifts. Analysis of the test samples is also currently underway in Task 4 (Sample Analysis). A Draft Recommendation was prepared for the management at each test site in Task 2 (Circuit Modification). All required procurements were completed. Density tracers were manufactured and tested for quality control purposes. Special sampling tools were also purchased and/or fabricated for each plant site. The preliminary experimental data show that the partitioning performance for all seven HMC circuits was generally good. This was attributed to well-maintained cyclones and good operating practices. However, the density tracers detected that most circuits suffered from poor control of media cutpoint. These problems were attributed to poor x-ray calibration and improper manual density measurements. These conclusions will be validated after the analyses of the composite samples have been completed.

Authors:
Publication Date:
Research Org.:
National Energy Technology Lab., Pittsburgh, PA (US); National Energy Technology Lab., Morgantown, WV (US)
Sponsoring Org.:
US Department of Energy (US)
OSTI Identifier:
802858
Report Number(s):
FC26-01NT41061-02
TRN: US200223%%665
DOE Contract Number:
FC26-01NT41061
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 10 Sep 2001
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 01 COAL, LIGNITE, AND PEAT; CALIBRATION; MAINTENANCE; PERFORMANCE; QUALITY CONTROL; RECOMMENDATIONS; SAMPLING; HEAVY MEDIA SEPARATION; CYCLONE SEPARATORS; COAL PREPARATION; ORE PROCESSING

Citation Formats

Gerald H. Luttrell. DENSE MEDIA CYCLONE OPTIMIZATION. United States: N. p., 2001. Web. doi:10.2172/802858.
Gerald H. Luttrell. DENSE MEDIA CYCLONE OPTIMIZATION. United States. doi:10.2172/802858.
Gerald H. Luttrell. 2001. "DENSE MEDIA CYCLONE OPTIMIZATION". United States. doi:10.2172/802858. https://www.osti.gov/servlets/purl/802858.
@article{osti_802858,
title = {DENSE MEDIA CYCLONE OPTIMIZATION},
author = {Gerald H. Luttrell},
abstractNote = {The fieldwork associated with Task 1 (Baseline Assessment) was completed this quarter. Detailed cyclone inspections completed at all but one plant during maintenance shifts. Analysis of the test samples is also currently underway in Task 4 (Sample Analysis). A Draft Recommendation was prepared for the management at each test site in Task 2 (Circuit Modification). All required procurements were completed. Density tracers were manufactured and tested for quality control purposes. Special sampling tools were also purchased and/or fabricated for each plant site. The preliminary experimental data show that the partitioning performance for all seven HMC circuits was generally good. This was attributed to well-maintained cyclones and good operating practices. However, the density tracers detected that most circuits suffered from poor control of media cutpoint. These problems were attributed to poor x-ray calibration and improper manual density measurements. These conclusions will be validated after the analyses of the composite samples have been completed.},
doi = {10.2172/802858},
journal = {},
number = ,
volume = ,
place = {United States},
year = 2001,
month = 9
}

Technical Report:

Save / Share:
  • The project start date delayed by approximately 7 weeks due to contractual difficulties. Although the original start date was December 14, 2000, the Principal Investigator did not receive the Project Authorization Notice (PAN) from the Virginia Tech Office of Sponsored Programs until February 5, 2001. Therefore, the first project task (i. e., Project Planning) did not begin until February 2001. Activities completed as part of this effort included: (i) revision and updating of the Project Work Plan, (ii) preparation of equipment procurement documents for the Virginia Tech Purchasing Office, and (iii) initiation of preliminary site visits to several coal preparationmore » plants to discuss test work with industrial personnel. After a brief (2 month) contractual delay, project activities are now underway. There are currently no contractual issues or technical problems associated with this project. Project work activities are now expected to proceed in accordance with the proposed project schedule.« less
  • All work associated with Task 1 (Baseline Assessment) was successfully completed and preliminary corrections/recommendations were provided back to the management at each test site. Detailed float-sink tests were completed for Site No.1 and are currently underway for Sites No.2-No. 4. Unfortunately, the work associated with sample analyses (Task 4--Sample Analysis) has been delayed because of a backlog of coal samples at the commercial laboratory participating in this project. As a result, a no-cost project time extension may be necessary in order to complete the project. A decision will be made at the end of the next reporting period. Some ofmore » the work completed this quarter included (i) development of mass balance routines for data analysis, (ii) formulation of an expert system rule base, (iii) completion of statistical computations and mathematical curve fits for the density tracer test data. In addition, an ''O & M Checklist'' was prepared to provide plant operators with simple operating and maintenance guidelines that must be followed to obtain good HMC performance.« less
  • During the past quarter, float-sink analyses were completed for four of seven circuits evaluated in this project. According to the commercial laboratory, the analyses for the remaining three sites will be finished by mid February 2002. In addition, it was necessary to repeat several of the float-sink tests to resolve problems identified during the analysis of the experimental data. In terms of accomplishments, a website is being prepared to distribute project findings and software to the public. This site will include (i) an operators manual for HMC operation and maintenance (already available in hard copy), (ii) an expert system softwaremore » package for evaluating and optimizing HMC performance (in development), and (iii) a spreadsheet-based process model for plant designers (in development). Several technology transfer activities were also carried out including the publication of project results in proceedings and the training of plant operations via workshops.« less
  • The test data obtained from the Baseline Assessment that compares the performance of the density traces to that of different sizes of coal particles is now complete. The experimental results show that the tracer data can indeed be used to accurately predict HMC performance. The following conclusions were drawn: (i) the tracer curve is slightly sharper than curve for coarsest size fraction of coal (probably due to the greater resolution of the tracer technique), (ii) the Ep increases with decreasing coal particle size, and (iii) the Ep values are not excessively large for the well-maintained HMC circuits. The major problemsmore » discovered were associated with improper apex-to-vortex finder ratios and particle hang-up due to media segregation. Only one plant yielded test data that were typical of a fully optimized level of performance.« less
  • All project activities are now winding down. Follow-up tracer tests were conducted at several of the industrial test sites and analysis of the experimental data is currently underway. All required field work was completed during this quarter. In addition, the heavy medium cyclone simulation and expert system programs are nearly completed and user manuals are being prepared. Administrative activities (e.g., project documents, cost-sharing accounts, etc.) are being reviewed and prepared for final submission to DOE. All project reporting requirements are up to date. All financial expenditures are within approved limits.