ALKANOLAMINE- FATTY ACID CONDENSATE CONDITIONER FOR FLOTATION OF COAL AND A FLOTATION PROCESS THEREFOR

Abstract: The froth flotation of coal in the presence of a con­ densate of an alkanolamine with at least about 0.8 equiva­ lent of a fatty acid improves the separation of carbonaceous solids possessing relatively high heat value from ash and other inert mineral matter. Flotation in the presence of this condensate is particularly effective to enhance the recovery of oxidized bituminous coal.

Description: ALIsANOLAMItE-TALL OIL FATTY ACID CONDv ATE CONDITIONER FOR FLOTATION OF COAL This invention relates to the froth flotation of coal-containing ashes, coal sludge or coal-containing residues to recover coal containing a lower percentage of impurities. In particular, this invention relates to the use of a condensation pr.oduct of an alkanolamine and a fatty acid as a conditioner for the flotation of finely -divided coal. The natural process of "coalification" inherently deposits some non-combustible mineral matter in association with the combustible carbonaceous solids. Large fragments of non-combustible material can be removed by screening or other gravity concentration techniques, but other cleaning methods more efficiently remove fine material intimately associated with the carbonaceous solids. Froth flotation of coal is used in the art to beneficiate finely-divided raw coal. Bituminous coals generally possess a natural hydrophobicity, which results in the coal being floatable in the presence of a frother, such as methyl isobutyl carbinol, desirably with a relatively mild collector, such as kerosene. However, anthracite coals, as well as coals of all grades in which the surface has been at least partially oxidized, float poorly in such a medium, resulting in the loss of significant amounts of combustible material in the tail from the flotation. The loading of the oil-type collector is generally 0.05 to 1 kilogram Ser 1000 kg of coal feed for bituminous coals of intermediate or low rank, with the loading being relatively greater for the flotation of lignite and anthracite coals. However, good recovery of oxidized coals or lignite coals can only be effected at such high loadings of the oil-type collector that significant amounts of inert material are floated along with the combustible materials. Sun suggests in Trans. AIME, 199:396 -401 (1954), that fatty amines can be utilized as co-collectors in the flotation of oxidized coals to effect enhanced recovery. However, even these amine collectors float substantial amounts of ash along with the coal and effect only partial recovery of combustible material. The present invention is a froth flotation process for beneficiating coal characterized by: (a) classifying the coal to separate particles of flotation size; and (b) floating the sized coal in a frothing aqueous medium comprising a fuel oil collector and an effec tive amount of a condensation product, or an acid derivative of the condensation product, of an alka nolamine corresponding to the formula I EMI3.1 wherein R1 is a ss-hydroxyalkyl group or inertly-substituted ss-hvdroxyalkyl group having 2 to 5 carbon atoms; and R2 and R3 are independently R1, hydrogen, an alkyl group of from 1 to 4 carbon atoms or a monovalent group corresponding to the formula EMI3.2 wherein y is 2 or 3 and R4 and R5 are independently R1, hydrogen or an alkyl of from 1 to 4 carbon atoms; condensed with a fatty acid or fatty acid ester in a molar ratio of at least 0.8 mole fatty acid or fatty acid ester per mole of the alkanolamine. The present invention also includes a composition of matter comprising the reaction product of: (1) a condensation product of diethanolamine and a C10-C24 fatty acid condensed in a mole ratio of 1:2; and (2) one-half equimolar amount of a C1-C4 mono carboxylic acid or mixtures thereof, based on the moles condensate. The alkanolamine utilized as a component of the condensation product in the practice of this invention is an unsubstituted or N-alkyl substituted monoethanolamine; diethanolamlne; triethanolamine; hydroxyethylethylenediamine; N,N'-di(hydroxyethyl)ethylenediamine; N,N-di(hydroxyethyl) ethylenediamine; N,N,N'-tri(hydroxyethyl)ethylenediamine; N,N,N1,N1 -tetra(hydroxyethyl )ethylenediamine; and like compounds in which the ethylene moiety is replaced by a propylene group and/or the hydroxyethyl group its replaced by a ss-hydroxyalkyl group having from 3 to 5 carbon atoms. For reasons of economics the hydroxyalkyl group is desirably a hydroxyethyl, 1-methyl (hydroxyethyl) or l-ethyl(hydroxyethyl) group. However, the above-identified unsubstituted alkanolamines bearing only hydroxyethyl and ethylene moieties are preferred. Diethanolamine, triethanolamine and di-, tri- or tetra (hydroxyethyl )ethylenediamine are especially preferred alkanolamines, with diethanolamine being the most preferred. The alkanolamine can be a single compound or a mixture of operable alkanolamines, with the latter being preferred for economic reasons. These alkanolamines are available comnc-r- cially or can be readily prepared by the reactions of alkylene oxides with ammonia or an alkylenediamine in a manner known to the art. The fatty acid condensed with the alkanolamine can operably be a fatty acid having a saturated or unsaturated alkyl group. The fatty acid can suitably bear hydroxyl substituents on its alkyl portion, but such substitution does not impart any substantial advantage. Fatty acids such as oleic, lauric, linoleic, palmitic, stearic, myristic, mixtures thereof and other like fatty acids are operable. The esters corresponding to the fatty acids, such as glycerides, are also operable, but less preferred. For reasons of economy, it is preferred to use crude mixtures of fatty acids with minor amounts of rosin acids, lignin and unsaponifiable material, such as tall oil, coconut oil, palm oil, palm kernel oil, cottonseed oil, linseed oil, olive oil, peanut oil and fish oil. Tall oil and tall oil heads are especially preferred mixtures of fatty acids. Tall oil and tall oil heads are well-known compositions described in the Kirk-Othmer, Encyclopedia of Chemical Technology, 2nd Ed., Vol. 19, pp. 614-629 (1969). The fatty acid or corresponding ester and the alkanolamine can be readily reacted-by mixing these reactants and heating until the desired degree of condensation has taken place as indicated by the water distilled overhead or infrared spectrophotometric analysis of the condensation product. Generally, a reaction temperature of from about 1200C to about 2500C is operable. The reaction is termed a condensation herein to distinguish it from the formation of the ammonium salt of the acid at lower temperatures. Depending on the alkanolamine, the condensation product may be an. ester, an amide or both. Although it is desirable that the condensation reaction is substantially complete to make most efficient use of the reactants, the condensation product is operable, but less effective, as a conditioner for coal in the presence of a substantial amount of unreacted fatty acid and the uncondensed alkanolammonium salt of the acid. The term "conditioner" indicates that the condensation product is primarily effective to enhance the hydrophobicity of the coal surface. However, the use of the descriptive term tconditioner is not intended to exclude the possibility that this condensation product acts as a co-collector with the fuel oil. The efficacy of the instant condensation product is greatest when the reactants are condensed in a specific range of mole ratios. At least a stoichiometric amount of the fatty acid or its equivalent (i:e., fatty ester) is desirably condensed with the alkanolamine, although a less than equimolar amount is operable. The molar ratio of fatty acid or fatty ester to the alkanolamine is at least 0.8, and preferably from about 1.5:1 to about 5:1, more preferably about 2:1 to about 3:1. However, to avoid waste of fatty acid, the number of moles of fatty acid and ester in the condensate should not exceed the number of moles of alkanolamine multiplied by the average number of reactive sites on a molecule of the alkanolamine The term reactive sites" refers to the exchangeable hydrogen substituents on the amine group and the reactive hydroxyl substituents on the hydroxyalkyl group, which will react with the fatty acid or fatty acid ester to produce amides and esters respectively. Acid derivatives of the above-described condensation products are operable, as well as the condensates themselves, in the instant flotation process. These derivatives are prepared by adding an inorganic or organic acid to the condensate so as to reduce the pH of the resulting mixture. The derivative may be either salt, partial salt or an acid complex. The organic acid derivatives are generally more readily dispersed in the aqueous flotation medium than are the parent compounds. These derivatives may exhibit greater activity or less activity than their parent compounds, but this relationship is not fully understood. Common inorganic acids which can be used to prepare the acid derivatives include phosphoric, nitric, boric, hydrochloric, hydrobromic and sulfuric acids. These inorganic acid derivatives are operable, but not preferred. Organic acids which can be used include aliphatic mono-, di-, or tricarboxylic acids; lower alkyl carboxylic acids; mono- or dihydroxy lower alkyl carboxylic acids; amino-substituted carboxylic acids and unsaturated aliphatic carboxylic acids. Representative examples of these organic acids are formic, acetic, hydroxyacetic, propionic, butyric, isovaleric, lactic, gluconic, aminoacetic, malonic, succinic, adipic, malic, tartaric, glutaric, fumaric, citric, salicylic, benzoic and naphthenic acids. Fatty acids are operable, but not preferred. Acetic acid, and other lower alkyl organic carboxylic acids, especially the C1 to C4 organic acids, are preferred for this purpose. In one especially preferred embodiment, 0.5 mole of acetic or propionic acid is added per mole of a condensate prepared from 1 eliva- lent of diethanolamine condensed with two equivalents of tall oil fatty acid. Titration with a base, as well as infrared and proton magnetic resonance spectroscopy of the resulting acetic or propionic acid derivative of this condensate indicate that an acid complex is formed and not a salt. The loading of condensation product in the flotation medium which effects the greatest recovery of combustible carbonaceous matter with a tolerable amount of inert matter is affected by the size, grade, degree of oxidation and inert matter content of the coal feed, as well as the loading of frother and other adjuvants. The term "effective amount of a condensation product" is used herein to denote the amount of said product required to increase the recovery of coal by froth flotation in the presence of fuel oil and a frother. Generally, where the condensation product is employed with only fuel oil, the condensate is advantageously employed in a ratio of from about 0.001 to about 1.0, preferably about 0.002 to about 0.2 kilogram of condensate per 1000 kg of coal flotation feed. The instant condensation product can be utilized in conjunction with co-collectors or other adjuvants, such as activators, conditioning reagents, dispersing reagents, frothing reagents and depressing reagents. Fuel oil is employed in the flotation medium as a collector. Representative fuel oils include diesel oil, kerosene, Bunker C fuel oil and mixtures thereof. The fuel oil can generally be advantageously employed in a ratio of from about 0.02 to about 2.5 kilograms fuel oil per 1000 kg of coal flotation feed. The optimal loading of fuel oil in the flotation medium is influenced by numerous factors, such as the size, degree of oxidation and grade of the coal to be floated and the loading of condensate and frother. Therefore, the loading of the fuel oil should be optimized empirically to effect the greatest selectivity and recovery during flotation. In one preferred embodiment the conditioner is charged to the flotation medium dispersed in part or all of the fuel oil charge. A frothing agent should be present in the flotation medium to promote formation of a froth. Conventional frothers, such as pine oil, cresol, C4 to C8 alkanols containing one or two tertiaryl or one quaternary carbon atom, e.g., isomers of amyl alcohol, are suitable for this purpose. However, methyl isobutyl carbinol and polypropylene glycol alkyl or phenyl ethers are preferred as frothers, with polypropylend glycol methyl ethers having a weight average molecular weight between about 200 and about 600 being most preferred. The optimal loading of frother in the flotation medium its influenced by a number of factors, most important of which is the rank and degree of oxidation of the coal Generally, a ratio of from about 0.05 to about 0.5 kilogram frother per 1000 kg of coal feed is advantageous. The coal to be floated by the instant process can suitably be anthracite, bituminous or subbituminous. This process is preferably employed to float coal which cannot be floated with conventional frothers alone and is particularly effective in the flotation of bituminous coal of intermediate or low grade, where the surface of the coal is oxidized to an extent which significantly impedes the flotation of the coal using conventional agents. The size of the coal particles to be separated by flotation is important as generally particles larger than about 28 mesh (U.S. Sieve Size) are difficult to float. In typical operations,;coal particles larger than 28 mesh, advantageously larger than 100 mesh, are separated from both the inert material mined therewith and more finely divided coal by gravimetric separation tech piques However, if a substantial fraction of the coal in the flotation feed comprises particles larger than 28 mesh, it is desirable that he feed be comminuted further prior to flotation. The sized coal flotation feed optionally is first washed and then mixed with sufficient water to prepare an aqueous slurry having a solids concentrate which promotes rapid flotation. Generally, a solids concentration between about 2 to about 20 weight percent solids, more preferably from about 5 to about 10 weight percent, is preferred. The aqueous coal slurry is advantageously conditioned with the condensation product, a frother, fuel oil and any other adjuvants by mixing with the slurry in a manner known to the art. Generally for difficult to float coal, it is advantageous to contact with mixing the coal slurry with the conditioner and fuel oil for a period of time prior to flotation, so as to effect intimate contact of the conditioner and fuel oil with substantially all of the coal. -Where the aqueous coal slurry is prepared in a container distinct from the flotation cell and then is conveyed to the flotation through conduits, the desired intimate contact can conveniently be attained by introducing the conditioner and fuel oil to the slurry upstream from the flotation cell. The frother, however, should be introduced to the slurry shortly before or during flotation to provide maximum frothing. The coal is operably floated at the natural pH of the coal in the aqueous slurry, which can vary from about 3.0 to about 9.5 depending upon the composition of the feed. However, a pH adjusting composition is optionally used as necessary to adjust-and maintain the pH of the aqueous coal slurry prior to and during flotation to a value from about 4 to about 8, preferably about 4 to about 7, which normally promotes the greatest coal recovery. If the coal is acidic in character, the pH adjusting composition can operably be an alkaline material, such as soda ash, lime, ammonia, potassium hydroxide or magnesium hydroxide, with sodium hydroxide being preferred. If the aqueous coal slurry is g alkaline in character, a carboxylic acid such as acetic acid, or a mineral acid such as sulfuric acid or hydrochloric acid are operable to adjust the pH. The conditioned and pH-adjusted aqueous coal slurry is aerated in a conventional flotation machine or bank of rougher cells to float the coal. Any suitable rougher flotation unit can be employed. The practice of the process of the instant invention can be used alone to beneficiate coal. Alternatively, the process can be used in conjunction with secondary flotations following the instant process to effect even greater beneficiation of the coal. In the following examples, unless otherwise indicated, all parts and percentages are by weight. Example 1 In a series of similar flotation runs that differ principally in the frother used and presence or absence of an alkanolamine/fatty acid condensation product, a 200 gram charge of comninuted coal is diluted with deionized water to a slurry of 6.67 percent solids. The coal is a low grade, bituminous coal having a highly oxidized surface as indicated by the high oxygen content (14.3 percent) of the coal as determined by elemental analysis techniques. The fraction of the coal feed consisting of particles larger than 25 mesh is separated before dilution, comminuted and then recombined with the remainder of the coal. The comminuted coal feed is more than 90 percent particles smaller than 80 mesh. The coal as charged to the slurry contains about 14.7 percent ash. This aqueous coal slurry is introduced into a flotation machine having a three-liter cell. The pH of the slurry is determined to be about 4. The coal slurry is agitated for about seven minutes to thoroughly wet the coal, at which time a refined kerosene is added to the slurry to effect a loading of about 2.5 kilograms of kerosene per 1000 kg of coal feed. In two flotation runs embodying the instant process, a condensate prepared from a molar ratio of 1 part diethanolamine (DEA) to 2 parts tall oil fatty acid (TOFA) is introduced with the kero-sene into the aqueous coal slurry in a loading of about 6.125 kilogram of condensate per 1000 kg of coal feed. The tall oil fatty acid reactant, according to analysis by conventional methods contains 39 percent rosin acids, 29.3 percent oleic acid, 23 percent linoleic acid, 3.7 percent conjugated linoleic acid, 1.8 percent stearic acid and about 3.2 percent other acids and components. DIO control flotation runs not embodying the present invention are also made in which kerosene is the collector added to the slurry. After the kerosene is added to the slurry, the slurry is agitated for one minute to condition the coal. A frothing agent is then added to the slurry to effect a loading of 0.2 kilogram frother per 1000 kg of coal feed. Methyl isobutyl carbinol (MIBC) and a polypropylene glycol methyl ether having a weight average molecular weight of about 400 (D-1012) are each employed as frothers in separate runs. The aqueous coal slurry is conditioned by agitation for one minute, after which aeration of the medium is initiated and continued for four minutes. A frothy concentrate is collected during aeration. The collected concentrate is first dried in an oven and then weighed. The percent recovery of coal by flotation is determined from the weight of coal in the concentrate divided by the weight of coal (i.e., total weight less weight of ash) in the 200 gram charge. A one-gram sample of the concentrate is completely burned and the ash content of the concentrate is determined from the weight of the material remaining after combustion. Table I tabulates the identity of the conditioner and frothing agent for each run as well as the percent recovery of coal and ash content in the concentrate. The results of a comparative flotation, in which a prior art fatty amine co-collector, dodecylamine hydrochloride (DDA HC1), is used in place of the DEA/TOFA condensate in a flotation otherwise identical to that set out above, is also included in Table I. TABLE I Coal Ash Run Conditioner Frother Recovery Content A DEA/TOFA PPGr/lE 72% 9.0% A1 None 1I 36% 9.1% B DEA/TOFA MIBC 53% 10.3% B2 None " 13% 7.5% C3 DDA HCl PPGME 53% 11.8% 1Comparative A. 2Comparative B. 3Comparative C. The data in Table I show that the presence of condensation products of DEA with TOFA in the flotation medium greatly enhances the recovery of oxidized coal, relative to flotation systems utilizing only kerosene. Further, the DEA/TOFA conditioner in Run A exhibits both enhanced coal recovery and less ash co-flotation than the prior art fatty amine utilized in Comparative C. Example 2 A series of runs are performed in the same manner as Example 1, with the exception of minor differences disclosed hereinafter. -After the pH of the aqueous coal slurry is measured, it is adjusted in two separate runs to pH values of 7 and 9, respectively, by the addition of sodium hydroxide. The pH of the coal slurry in a third run is measured, but not adjusted. The coal in each of the three slurries is then floated in the presence of DEA/TOFA, kerosene and PPGME frother in the manner and at the loadings set out in Example 1. The results and identifying parameters for each run are tabulated in Table II. TABLE II Coal Run Slurry pH Recovery C 4.0 72% D 7.0 67% E 9.0 47% The data in Table II demonstrate the effect of slurry pH on the recovery of clean coal by flotation of this particular oxidized bituminous coal. Example 3 Seven flotation runs are performed in the same manner as Example 1, except for the condensation product employed as a conditioner. The condensation product is prepared in each case by condensing the tall oil fatty acid of Example 1 with an alkanolamine selected from diethanolamine (DEA), triethanolamine (TEA) and a mixture of hydroxyethyl-substituted ethylene diamines (HEEDA). The HEEDA mixture consists of about-l0 percent aminoethylethanolamine, about 75 percent di(hydroxyethyl)ethylenediamine, about 12 percent tri(hydroxyethyl)ethylenediamine and about 3 percent tetra(hydroxyethyl)ethylenediamine. The alkanolamine (AA) and tall oil fatty acid (TOFA) are condensed in the molar ratio tabulated hereinafter. The coal in each of the three slurries is floated with 0.125 kilogram of the condensation product per 1000 kg of coal feed, along with kerosene and PPGME frother in the manner and at the loadings set out in Example 1. The results and identifying parameters for each run are tabulated in Table III. TABLE III % % Ratio Coal Ash Run Conditioner AA:TOFA Recovery Content F DEA/TOFA 1:2.5 62 8.3 G " 1:2 63 8.2 H " 1:1 56 9.2 J TEA/TOFA 1:3 60 8.8 K HEEDA/TOFA 1:4 66 8.7 L " 1:3 64 8.9 M " 1:2 57 10.0 Example 4 Fourteen flotation runs are performed in the general manner of Example 1, with the exception that different coals are employed. Seven different raw coals, having the ash contents tabulated hereinafter, are each floated in a pair of runs in which a 1:2 condensate of DEA/TOFh is employed in only one of the pair, the other run acting as a control. The coal in each case is introduced as sn aqueous slurry into a flotation machine. The pH of the slurry is measured and then PPGME frother, kero sense and the DEA/TOFA condensate are introduced into the slurry at the loadings of kilograms per 1000 kg of coal feed specified in Table IV. After flotation is complete, the concentrate is recovered and t-he ash content and recovery of coal determined in the manner previously described. TABLE IV %Ash %Ash DEA/TOFA Kerosene FROTHER in in %Coal Coal pH (kg/1000 kg) (kg/1000 kg) (kg/1000 kg) Feed Conc. Recov. N 8.4 0.018 0.35 0.1 28.3 9.4 90.2 Comparative D " none 0.37 " " 9.7 79.0 O 4.9 0.075 0.68 0.1 14.0 6.2 73.0 Comparative E " none 0.75 " " 6.3 59.7 P 8.2 0.09 1.75 0.2 30.2 14.9 85.0 Comparative F " none 1.85 " " 15.0 75.0 Q 6.5 0.075 0.68 0.1 22.7 9.5 90.0 Comparative G " none 0.75 " " 7.9 80.4 R 8.8 0.037 0.34 0.1 38.8 10.7 83.3 Comparative H " none 0.75 " " 10.5 80.9 S 3.4 0.019 1.65 0.2 17.6 11.3 83.7 Comparative I " none 1.85 0.15 " 11.9 60.6 T 9.0 0.075 0.68 0.1 22.4 7.7 83.3 Comparative J " none 0.75 " " 6.9 69.2 The data tabulated demonstrate that the condensation product of DEA with TOFA enhances the recovery of clean coal from each of the raw coals tested. Further, this enhancement is manifested despite the fact that a relatively smaller loading of kerosene is employed in the runs with the condensate than in the control runs. Example 5 In the general manner of Example 1, five flotation runs are performed using an 8 percent dispersion of a 1:2 condensate of DEA/TOFA or an acetic acid-or propionic acid derivative thereof in 4f1 diesel oil as the conditioner collector. These acid derivatives consist of 0.5 mole of acetic or propionic acid for each mole of the condensate. These derivatives are believed to be hydrogen bonded acid complexes of the condensate, inasmuch as the acetic acid introduced is titratable stoich iometrically with 0.085 normal KOII. Infrared and proton magnetic resonance spectroscopic analysis also indicate that an acid complex with hydrogen bonding is present. In each run, 200 grams of coal containing 14.4 percent ash in 3 liters of water is introduced into a flotation machine and conditioned for 7 minutes. The pH of the slurry is adjusted to the values tabulated in Table V with a 1 normal aqueous solution of NaOH or HCl. The slurry is agitated while *1 diesel oil containing the conditioner is charged to the slurry to effect a loading equivalent to about 1.5 kilograms of diesel oil per 1000 kg of coal feed and 0.12 kilogram of the condensate per 1000 kg of coal. A small amount (0.04 cm3) of a conventional frother (D-1012) is added to the slurry and the slurry agitated for 10 seconds. The results and iden tidying parameters for each run are tabulated in Table V. TABLE V Coal Ash Run Conditioner PH RecoverY Content U DEA/TOFA 5.1 88.0 9.8 Ascetic Acid Deriva- 5.0 88.0 10.2 tive of DEA/TOFA Propionic Ac,d W Derivative of 5.0 87.9 9.7 DEA/TOFA X DEA/TOFA 8.0 79.3 9.3 Acetic Acid Deriva- 8.0 80.7 9.3 tive of DEA/TOFA The condensation products of alkanolamines and higher organic acids are known. U.S. Patent 2,173,909, Kritchevsky, September 26, 1939, discloses that fatty alkanolamides can be employed in ore flotation, particularly in a slightly acidic medium. U.S. Patent 2,609,931, Rodman, September 9, 1952, teaches that mono fatty airide derivatives of N,N-dihydroxyalkylethylenediammine are useful filtering agents; the acetate salt of these compounds is alleged in column 6, lines 43-47 to be particularly useful in some applications. U.S. Patent 2,993,919, Findley, July 25, 1961, describes the use of acid salts of mixtures of fatty alkanolamides and diethanolamine in ore flotation. The condenbation products of diethanolamine and fatty acids are known in the art, but generally an excess of at least an equimolar amount of diethanclamine relative to fatty acid is employed in preparing these condensates. The term "condensation product" is employed herein to distinguish this product from the ammonium salt of the fatty acid produced at lower redaction temperatures. The condensation product in the subject novel composition is prepared using a ratio of from about 1.8 to 2.2 moles of fatty acid for each mole of diethanolamine. The claimed composition is prepared by adding the water-soluble lower alkanoic acids, i.e., formic, acetic, propionic or butyric acids or a mixture thereof to the above-described condensation product at a temperature which does not effect substantial additional condensation. The temperature during addition of this lower alkanoic acid is operably from about 1000 to about 1000C, preferably from about 200C to about 500C. Substantially all of this lower alkanoic acid added to the composition can be titrated wIth an alkali metal hydroxide, which sug gests that a hydrogen-bonded acid complex is formed and not a salt. Analysis of infrared and proton magnetic resonance spectroscopy supports the theory that the resulting composition is an acid complex, but this structural elucidation is not definitive and the instant composition is not limited thereby. The C1-C4 alkalmic acid derivative of the diethanolamine/fatty acid condensate is charged to tile flotation medium dispersed in fuel oil. Preferably, the alkanoic acid derivative comprises from about 0.1 to about 70, more preferably from 0.25 to 50 volume percent of the total fuel oil dispersion. This fuel oil disper sion is believed to be a novel composition. Likewise, a composition of the alkanoic acid derivative and frothing agent and optionally further comprising fuel oil is believed novel. Example 6 A 1:2 condensate of DEI/TOFA and an acetic acid derivative thereof is employed in a coal flotation plant. The acetic acid derivative consists of 0.5 mole of acetic acid for each mole of condensate. The conditioner is added to 1 diesel oil in a quantity sufficient to effect an increase of 10 percent in volume. The mix ture of conditioner and &num;1 diesel oil is introduced at a rate of 200 cubic centimeters per minute to the tank used to collect the smaller than 100 mesh coal prior to introduction to the four banks of Daniel flotation cells. In one instance, diesel oil alone is introduced for purposes of comparison. The pH of the coal slurry in the collecting tank is determined for each run. To each bank of cells at the air port of the first of the four cells in the bank, is introduced 67 cubic centimeters per minute of a polypropyiene glycol methyl ether frother having a weight average molecular weight of about 400. For each run, a sample of the coal feed is recovered as it is introduced to the first cell of a bank of cells. Samples of the material recovered by froth flotation are taken from near the end of the second cell in each bank of four cells. Tail materials are sampled at the overflow weir above the sand gate. The samples of coal feed, floated material and tail material in each instance are dried and then weighed. One-gram samples of the coal feed, the floated material (or concentrate) and the tail material are then each burned and the weight of the unburned ash determined. The difference in the weight of each of the fractions before and after ;-ombustion is assumed to be the weight of coal present in each fraction The percentage of the ash-free or "clean" coal recovered is then calculated by the formula: Percent Clean Coal = 100 x C(F-T) F(C-T) where: C = 100 (Percent Ash in Concentrate) F = 100-(Percent Ash in Feed Material) T = 100- (Percent Ash in Tail Material) The results and identifying parameters are tabulated in Table VI. TABLE VI % Clean % Ash % Ash in Coal Run Conditioner pH in Feed Concentrate Recovered Acetic Acid Z Derivative of 6.9 47.8 13.8 38.0 DEA/TOFA zz DEA/TOLA 6.8 50.1 13.8 -21.1 * None 6.7 42.7 11.5 10.6 *Comparative K The data compiled in Table VI indicate that the claimed acetic acid derivative of the DEA/TOFA con dens ate is much more effective in floating certain coals in a coininercial floating operation than diesel oil alone or diesel oil containing the DEA/TOFA condensate but not acetic acid.

Claims: 1. A froth flotation process for beneficiating coal characterized by: (a) classifying the coal to separate particles of flotation size; and (b) floating the sized coal in a frothing aqueous medium comprising a fuel oil collector and an effec tive amount of a condensation product, or an acid derivative of the condensation product, of an alka nolamine corresponding to the formula I EMI23.1 wherein R1 is a p-hydroxyalkyl group or inertly-substituted g-hydroxyalkyl group having 2 to 5 carbon atoms; and R2 and R3 are independently R1, hydrogen, an alkyl group of from 1 to 4 carbon atoms or a monovalent group corresponding to the formula EMI24.1 where in y is 2 or 3 and R4 and R5 are independently R1, hydrogen or an alkyl of from 1 to 4 carbon atoms; condensed with a fatty acid or fatty acid ester in a molar ratio of at least 0.8 mole fatty acid or fatty acid ester per mole of the alkanolamine. 2. The process as in Claim 1 wherein the coal is a bituminous coal having an oxidized surface. 3. The process as in Claim 1 wherein the ss-hydroxyalkyl group is ss-hydroxyetnyl. 4. The process as in Claim 1 wherein R2 is p-hydroxyethyl or hydrogen, and R3 is a univalent group corresponding to the formula EMI24.2 where in R4 and R5 are each ss-hydroxyethyl or hydrogen, with the proviso that at least one of R2 and R4 is I3-hydroxyethyl. 5. The process as in Claim 1 wherein the molar ratio of fatty acid and ester to alkanolamine in the condensation product is from 1.5:1 to 5:1. 6. The process as in Claim 1 wherein the coal is floated in the presence of a Cl-c4 monocarboxylic acid derivative of the condensate. 7. The process as in Claim 6 wherein the coal is floated in the presence of an acetic or propionic acid cope, the condensate in which 0.5 mole of acetic or propionic acid is present for each mole of condensate. 8. The process as in Claim 1 wherein the frothing aqueous medium contains an effective amount of a conventional frothing agent. 9. A composition of matter comprising the reaction product of: (1) a condensation product of diethanolamine and a C10-C24 fatty acid condensed in a mole ratio of 1:2, and (2) one-half the equimolar amount of a C1-C4 mono-carboxylic acid or mixture thereof, based on the moles of condensate. 10. The composition as described in Claim 9 wherein the fatty acid is a tall oil fatty acid or a mixture of tall oil fatty acids. 11. The composition as described in Claim 9 wherein component (2) is acetic acid. 12. The composition of Claim 9 which further comprises fuel oil in such an amount that said reaction product constitutes 0.1 to 70 volume percent of the total volume. 13. The composition of Claim 9 which further comprises an effective amount of a frothing agent.

Inventors: HANSEN, ROBERT DOUGLAS, HEFNER JR., ROBERT EUGENE, MEYER, CLARENCE WILFRED
Applicants: THE DOW CHEMICAL COMPANY
Application year: 1980
Main classification: B03D1
IPC codes: C10L9, B03D1