Continuous gravity assisted ultrasonic coal cleaner

An improved system and method for separating combustible organic particles from noncombustible inorganic particles in coal, in preparation for combustion. The coal is size-reduced and size-graded to small pieces which are then supplied to input ends of water-immersed descending slides having ultrasonic transducers for vibratory separation of inorganic and organic particles. The slides have different longitudinal lengths with angles of declination configured to achieve time-differential exposure to the ultrasonic vibratory energy, with smaller coal pieces being subjected to shorter time ultrasonic vibratory exposure. In one preferred form, longitudinally spaced turbidity sensors along the slide provide signals used to control selected ultrasonic transducers upon substantially complete cleaning of the coal pieces.

BACKGROUND OF THE INVENTION

This invention relates generally to an improved system and method for cleaning of coal. More specifically, this invention relates to improved separation of carbon-based or organic combustible particles or matter comprising vegetation and the like, from suspended and substantially noncombustible inorganic particles or matter, such as clay particles and the like.

Coal deposits are generally defined as carbonized vegetation matter which, due to the effects of heat and pressure over a prolonged period of time, becomes compressed into a rock-like dark material which is combustible to provide a common fuel source used widely in various industrial applications, such as electrical generation plants and the like. In use, the coal is mined from the earth, and typically reduced in size as by grinding for subsequent combustion within a large firebox or the like. In a typical electrical generation facility, the heat generated by the combusted coal is used to heat water sufficiently to provide a source of steam used to drive appropriate steam-powered generators.

In a raw or as-mined state, coal deposits normally include a minor proportion of noncombustible inorganic matter, particularly such as clay particles, ash, sand, rock fragments, and the like, which are mixed into the carbon-based organic matter. This inorganic matter occurs naturally in the course of primordial formation of the coal deposits, due to sporadic flooding and other natural phenomena which inherently combines such inorganic matter with the organic matter. Upon subsequent coal combustion, this entrained or embedded inorganic matter is substantially noncombustible, and thereby melts within the firebox to rob heat from the combusted organic coal particles. While such inorganic particles can be removed from post-combustion flue gases by means of electrostatic precipitation or the like, there is nevertheless a significant reduction in the total combustion output energy of the combusted organic coal particles.

Mercury particulate and the resultant flue gas contaminant represent an especially problematic inorganic constituent in some mined coals. In recent years, governmental regulations have applied pressure to the coal industry to effectively remove such mercury particulate from mined coal, prior to combustion in a firebox.

In the past, a variety of systems and methods have been proposed for separating the noncombustible inorganic matter or particles from the combustible organic carbon-based coal matter or particles. Such systems and methods have generally comprised initial crushing of mined coal to a relatively small and preferably powder-like constituency, followed by passing the small powder-like coal through a vibratory conveyor for recovering separated inorganic minerals from the otherwise combustible carbon-based coal component. More recently, improved systems and methods have used ultrasonic vibration. See, e.g., U.S. Pat. No. 4,741,839 which discloses a ground coal powder delivered as a water-borne slurry along a descending vibrator tray activated by multiple ultrasonic transducers used to separate the inorganic matter from the carbon-based organic matter. Different densities of the physically separated but still inter-mixed inorganic particles vs. organic particles permits subsequent settling and/or centrifugal separation to recover the valuable organic matter for drying, and subsequent combustion, as well as removal of an undesired inorganic component.

The descending ultrasonically vibrated conveyor, however, requires pre-crushing or pre-grinding of mined coal chunks substantially into a powder form to provide the requisite water-borne slurry. Such grinding of the mined coal chunks to a powder form is a mechanically intensive process, with the incumbent wear and maintenance/replacement of components.

There exists, therefore, a significant need for an improved ultrasonic system and method for separating mined coal into noncombustible inorganic matter and combustible organic matter, prior to supplying the comparatively softer organic matter to a firebox for combustion, while substantially reducing and/or eliminating the maintenance-intensive process of pre-crushing or pre-grinding the mined coal in preparation for ultrasonic separation. The present invention fulfills these needs and provides further related advantages.

SUMMARY OF THE INVENTION

In accordance with the invention, an improved system and method are provided for separating combustible organic particles from noncombustible inorganic particles in coal, preparatory to combustion. The coal is size-reduced and size-graded to pieces which are then supplied to input ends of water-immersed descending slides having ultrasonic transducers for vibratory separation of inorganic and organic particles. The slides have different longitudinal lengths and are optionally angularly adjustable for selected time-differential exposure to the ultrasonic vibratory energy, with smaller coal pieces being subjected to shorter time ultrasonic vibratory exposure. In one preferred form, longitudinally spaced turbidity sensors along the slide provide signals used to deactivate or otherwise regulate or control selected ultrasonic transducers upon substantially complete cleaning of the coal pieces.

Mined coal is initially crushed or ground to smaller pieces, preferably on the order of about 0.5 inch or less, and then supplied to the upper input ends of the descending slides. Each slide has a longitudinal length which differs according to the sizes of the coal pieces inputted thereto, with smaller-sized pieces being supplied to a shorter-length slide, and vice versa. A preferred embodiment utilizes three different descending slides of different longitudinal lengths, with each slide comprising a chute having a closed geometry defined by top, bottom and a pair of side walls. Each chute is angularly adjustable for selection of a unique or specific declination angle, typically ranging from about 30 to about 85 from a horizontal plane, and tapers downwardly with a diverging or expanding geometry. Coal jamming in each chute is prevented and/or relieved by upward backflushing, either by a high flow through the entire slide/chute assembly, or by use of one or more upwardly angled high-flow flushing jets.

Water is supplied to each slide chute in a counter-current or upward direction opposite to the gravity-falling coal pieces therein, or alternately in a forward-current or downward direction therein. Operation of the ultrasonic transducers provides ultrasonic vibratory energy which effectively separates the inorganic and organic constituents. Thereafter, the cleaned coal is dried and ready for combustion in a firebox or the like.

The water used to clean the coal pieces travels with the fluidized particulate, primarily inorganic particulate, to a treatment step for cleaning and, in the preferred form, recycling. One such treatment step includes a cyclone for separating any residual powder-like coal fines from the inorganic particles.

In accordance with one aspect of the invention, each slide further includes at least one and preferably a plurality of turbidity sensors mounted at longitudinally spaced positions along the descending slide. These turbidity sensors provide water clarity signals representative of local water turbidity, wherein these signals are used for automatic or manual modulation control or deactivation of selected ultrasonic transducers in the event that the turbidity sensor signal indicate substantially complete cleaning of the coal pieces. In this regard, the separated noncombustible inorganic matter or particles tends to obscure and cloud the water in the immediate vicinity of the separation event. The multiple turbidity sensors provide longitudinally spaced differential readings which, if continuing to increase along the slide length, indicate that inorganic/organic matter separation is still occurring. In the event that successive turbidity sensors do not detect increases in water turbidity indicative of on-going separation of the inorganic/organic matter, then the resultant signals indicate that subsequent, or one or more of the ultrasonic transducers can be reduced in power or otherwise turned off to save energy. Alternately, in the event that the turbidity signal or signals indicate relatively low water turbidity, the ultrasonic transducers can be modulated for increased power to increase cleaning of the coal pieces.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates generally to an improved production system and method for separating combustible organic matter or particles from noncombustible inorganic matter, such as clay particles and the like, from coal preparatory to combustion of the coal in a suitable firebox. As shown generally inFIGS. 1 and 2, raw mined coal referred to generally by the reference numeral10is initially crushed or ground by means of a conventional crusher12or the like, and then size-graded as indicated by reference numeral13into multiple different sizes10′ such as the illustrative small, medium and large. The size-graded coal pieces10′ (FIG. 2) are then conveyed to the upper ends of suitable descending slides14,16and18(as shown inFIG. 1) for water-washing in the presence of ultrasonic energy provided by multiple ultrasonic transducers20(FIG. 2). The cleaned coal22is discharged from the lower ends of the slides14,16and18for transport as by means of an auger (not shown) or the like for suitable drying in a dryer24(FIG. 1), followed by combustion in a firebox26or the like.

FIG. 2shows the water circulation process applicable to each of the descending slides14,16and18. In particular, water from a suitable water supply28is initially stored in a water tank30or the like. This water from the tank30is pumped as indicated by reference numeral32to a intake supply manifold33associated with each of the slides14,16and18(as will be described herein in more detail) to clean, in association with the ultrasonic transducers20, the coal pieces10′. Prior to pumping to the slides14,16and18, the water can be degassed (not shown) for improved ultrasonic separation of the inorganic constituent. The cleaned coal22is discharged from the lower end of the associated slide14,16or18, whereas the now-dirty water comprising primarily the fluidized inorganic particulate (with some powder-like entrained coal fines) is discharged separately via a discharge manifold34to an appropriate treatment step36. Persons skilled in the art will recognize and appreciate that this treatment step36and associated equipment may take different forms, such as a cyclone, settling pond, filtration unit, and/or a suitable chemical treatment unit, or the like. In any case, the treatment step36and associated equipment separates residual powder-like coal fines and particulate37from the predominantly inorganic particulate38from the water for separate output as indicated inFIG. 2by lines40,41and42. As shown, the cleaned water43can be recycled via line42to the storage tank30.

As further illustrated inFIG. 2, water from the storage tank30may also be supplied to a high flow flush pumping apparatus indicated by reference numeral44. This high flow flush pumping apparatus44beneficially supplies a flushing water flow46(FIG. 7) to the slide14,16,18in its entirety, or alternately to one or more upwardly angled flush flow nozzles48disposed at or near the lower end of each descending slide14,16and18. The nozzles48each provide a counter-current and high pressure localized water stream that acts to mix and stir the water and coal pieces within each descending slide sufficiently to prevent jamming therein. Undesirable jamming is further reduced by forming each of the descending slides14,16and18to have a slightly expanding or diverging cross sectional size and shape in a downward direction, as shown inFIGS. 1 and 2.

FIGS. 3-4show an exemplary descending slide14,16or18in more detail, relative to the ultrasonic transducers20and the water supply equipment. In a preferred embodiment, each slide comprises a chute or chute-like construction having a closed geometry defined by top, bottom and a pair of side walls. As shown inFIG. 2by reference numeral45, the descending slide14,16or18is angularly oriented at a desired, adjustable descending or declination angle according to the size of inputted coal pieces10′, the desired coal mass flow rate, and the amount of anticipated inorganic matter to be cleaned from the inputted coal pieces10′. Such adjustment and selection of the particular slide angle, in combination with the longitudinal slide length, determines the practical time-exposure to ultrasonic vibration energy. That is, where more cleaning of the inputted coal pieces10′ is desired, the declination angle of the descending slide will be decreased. In a typical orientation, the declination angle of the descending slide will be set within a range of from about 45 to about 80 from a horizontal plane. In a most preferred form of the invention, the specific declination angle for each of the chutes/slides14,16and18will be optimized and then fixed for maximum removal of inorganic particles from the material being processed. Manual or automatic adjustment of the specific declination angles may also be employed to account for short term and long term variations in the fuel supply. The sorting process13will deliver the smaller size-graded coal pieces to the shorter slide14, whereas progressively larger-sized coal pieces will be delivered to the longer slides16and18, respectively.

In this regard, in one preferred form of the invention, the grinding or crushing step12(FIG. 1) reduces the sizes of inputted coal chunks from a raw mined state typically comprising chunks up to about 6 inches in size, to a useful size applicable to the cleaning system and method of the present invention. In a preferred form, the crushing equipment12reduces the sizes of the mined coal pieces10to about 0.5 inches or less, thereby minimizing the average distance between embedded inorganic particles and the surface of the associated coal piece10′. Thereafter, the ground or crushed coal pieces10′ are size-graded for supplying respectively to the different-length and/or different-angled slides14,16and18, as shown in the exemplary drawings. In this regard, small powder-like coal pieces10′ will be supplied to the smallest slide14, with larger-sized coal pieces10′ supplied to the largest, longest slide18, and intermediate-sized pieces supplied to the intermediate slide16. Optionally, this crushing step12may include preliminary coal exposure to a cryogenic temperature, such as by exposure to a liquid nitrogen bath (not shown) to increase the presence of microscopic cracks and crevices in the coal chunks, for subsequent improved ultrasonic separation of embedded inorganic particulate.

A controller50regulates operation of the system and method. As viewed inFIG. 3, the controller50operates the pumping system32via an adjustable speed drive52or the like to drive a water flow pump53used to supply a flow of clean water to the associated descending slide14,16or18. The specific flow rates are a function of the scale of the process, the cross-sectional areas of the chute-like slides14,16and18, the specific number of the chute-like slides in service, whether the application is a forward-current or a counter-current design, and the specific characteristics of the coal being processed.FIG. 3shows this water supply from the pump53to an intake manifold33disposed at or near a lower end of the descending slide for counter-current water flow in a generally upward direction within the slide, opposite to the downward gravity-induced flow of the coal pieces10′ through the slide. During this counter-current water-coal flow through the descending slide, the controller50activates multiple ultrasonic transducers20disposed in close association with the slide.FIG. 3shows an exemplary total of 16 different ultrasonic transducers disposed in longitudinally spaced rows of 8 each along the upper and lower sides of each descending slide14,16or18, wherein persons skilled in the art will recognize and appreciate that this arrangement and number of ultrasonic transducers is representative and may be subject to different arrangements and/or different numbers according to the characteristics of the coal being cleaned and the specific geometries and/or numbers of the chute-like slides. The controller50is operable to activate these transducers20to produce ultrasonic vibratory energy at a specific and variable frequency chosen for best cleaning of the coal pieces10′, with a typical ultrasonic frequency ranging from about 20 kilohertz to about 80 kilohertz, and more preferably about 40 kilohertz. Accordingly, as the coal pieces10′ travel downwardly along the descending slide14,16or18, the coal is progressively cleaned, whereas the upward traveling or counter-current water flow becomes progressively dirtier. This now-dirty water flow exits from near the upper end of the descending slide14,16or18via the discharge manifold34for suitable treatment and cleaning (as viewed inFIG. 2).

The ultrasonic transducers20are frequency selected to the characteristics of the inorganic particles, such as clay, within the coal pieces10′. The ultrasonic vibration energy is believed to produce pressure waves of sufficient magnitude to cause multiple cavitation sites within the coal pieces resulting in a cavitation bubble that collapses substantially immediately. The result is that these cavitation sites in the water form adjacent to the inorganic particles to provide the impetus to effectively expel the inorganic particles through the interstices and microscopic channels of the coal pieces for separation. In this regard, the cavitation sites are believed to nucleate from the boundary between the organic vs. the inorganic particles within the coal10′.

Persons skilled in the art will recognize and appreciate that the ultrasonic transducers20have a conventional known construction. Exemplary ultrasonic transducers20are available from Crest Ultrasonic Corporation, Trenton, N.J., in immersible arrangements.

If and when needed, the controller50additionally operates the high flow pumping system44(FIG. 2) by actuating a high flow pump54(FIG. 3) to supply the flush nozzles48at or near the bottom of each descending slide14,16or18, for effectively providing a high pressure water jet or jets into the slide interior in an upwardly angled or counter-current direction to achieve thorough mixing of the coal pieces10within the supplied water. This water jet or jets beneficially prevent the gravity-falling coal pieces10from jamming or otherwise obstructing the lower outlet end of the descending slide. Such jamming is further deterred by forming each descending slide14,16or18to have a downwardly expanding or diverging shape which becomes progressively larger in cross section toward the lower end thereof.FIG. 3shows a counter-current embodiment wherein the pumps53and54both supply water to the nozzles48, whereasFIG. 5shows a forward-current embodiment wherein the high flow pump54supplies the flushing water flow to the nozzles48.

In accordance with one further aspect of the invention, each of the descending slides14,16and18is also provided with at least one and preferably multiple turbidity sensors56mounted at longitudinally spaced positions along the descending lengths thereof. These turbidity sensors56provide water turbidity or water clarity readings linked to the controller50, wherein the controller50responds to these turbidity-indicative readings to control the ultrasonic transducers20in accordance therewith. That is, the turbidity readings, such as turbidity readings provided by two consecutive turbidity sensors56indicate progressively dirtier water, or progressive decrease in water clarity, then the controller50can be operated to modulate or control the remaining ultrasonic transducers20to continue cleaning inorganic particles from the coal pieces10′. However, in the event that the turbidity reading or readings as provided, e.g., by consecutive turbidity sensors56, indicates a minimal or no change in water dirtiness, then the controller50can be operated to modulate or turn off subsequent ultrasonic transducers20as unnecessary energy usage. As a further alternative, depending upon the characteristics of the coal being cleaned, a turbidity reading may result in controller operation to increase power to subsequent ultrasonic transducers20. Alternatively, selected ones of the ultrasonic transducers20can be manually modulated or turned off by a system operator in response to the signals from the turbidity sensor or sensors56.

WhileFIG. 3shows two turbidity sensors56, persons skilled in the art will recognize and appreciate that additional turbidity sensors56may be used, as desired. Persons skilled in the art will also understand that the construction and operation of such turbidity sensors56are conventional. Exemplary turbidity sensors56are available from HACH Company, Loveland, Colo., under model designation Solitax.

FIGS. 5-6illustrate an alternative preferred form of the invention, differing fromFIGS. 3-4in that the water supplied to each descending slide14,16or18is provided in a forward-current direction at or near the upstream end of the slide, along with the coal pieces10. That is, the clean water is pumped to the intake manifold33disposed at or near the upstream end of the slide14,16or18, and dirty water is removed from the slide for cleaning via the discharge manifold34disposed at or near the side lower or downstream end. All other aspects of the cleaning system and method, inclusive of the ultrasonic transducers20, the controller50, and the turbidity sensors56, remain the same. Moreover,FIG. 5shows the flush nozzle48mounted at or near the lower or downstream end of the descending slide14,16or18for flush-flow (FIG. 7) to prevent undesired jamming. Persons skilled in the art will understand that additional and/or alternative locations for the flush nozzle or nozzles48may be employed.

Persons skilled in the art will recognize and appreciate that the use of multiple descending slides14,16and18as shown can be provided in any desired multiple number, and/or that the multiple descending slides can be replaced by a single descending slide that is laterally angled to provide steeper vs. shallower slide paths for the size-graded coal pieces in varying time-exposure to the ultrasonic vibratory energy produced by the multiple ultrasonic transducers.

In accordance with further aspects of the invention, it will be understood that various salts and/or wetting agents may be added to the water for enhancing the ability of the water to soak through microscopic cracks, channels and crevices in the coal pieces to improve ultrasonic separation of inorganic particulate from the combustible organic constituent.

A variety of further modifications and improvements in and to the improved system and method of the present invention will be apparent to those skilled in the art. Accordingly, no limitation on the invention is intended by way of the foregoing description, except as set forth in the appended claims.