PRE-BURNING, DRY PROCESS METHODOLOGY AND SYSTEMS FOR ENHANCING METALLURGICAL SOLID FUEL PROPERTIES

• US 20090038213A1
• Filed: 08/06/2008
• Published: 02/12/2009
• Est. Priority Date: 12/12/2003
• Status: Active Grant

• Current Assignee: JY Capital Investment, LLC
• Original Assignee: Coaltek, Inc.
• Inventors: Wang, Ru T., Ginther, Neil E., Weinberg, Jerry L., Aten, Jed A.
• Granted Patent: US 8,579,998 B2
• Time in Patent Office: Days
• US Class Current: 44/620
• CPC Class Codes: C10B 57/10 Drying
• CPC Class Codes: C10L 9/00 Treating solid fuels to improve their combustion
• CPC Class Codes: C10L 9/08 by heat treatments, e.g. calcining
• CPC Class Codes: F23K 1/00 Preparation of lump or pulverulent fuel in readiness for delivery to combustion apparatus
• CPC Class Codes: F26B 3/347 Electromagnetic heating, e.g. induction heating or heating using microwave energy
• CPC Class Codes: Y02P 20/129 Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
• CPC Class Codes: Y10S 44/903 Method including measuring, testing or automatic control
• CPC Class Codes: Y10S 44/904 Method involving electric or wave energy

Abstract

Measurements are taken of moisture, BTU/lb (British Thermal Units per pound), ash, forms of sulfur, volatile material, grindability, and absorption properties of any of a wide variety of mine-run solid fuels. Using that information, a dry electromagnetic process technology has been developed that can be controlled and monitored to selectively alter and enhance metallurgical solid fuel properties. Specific changes include altering the mechanical structure and chemical composition of solid fuels such as coal, coal coke or petroleum coke, increasing the BTU/lb to optimum levels, decreasing all forms of sulfur, and decreasing ash, while maintaining the BTU/lb of the fuels. A new family of solid fuel designer coals not found in nature can be produced via these methods and apparatus.

Claims

1. A method for processing raw solid-fuel, comprising:

measuring one or more properties selected from the following for a raw solid-fuel;

percent moisture, BTU/lb, percent ash, percent total sulfur, percent of each of various forms of sulfur, percent volatile material, percent fixed carbon, Hardgrove grindability index, trace minerals amounts by weight, and response of the fuel and its individual constituents to electromagnetic radiation;

determining the fuel properties desired from the solid-fuel after processing;

based on the measured raw solid-fuel properties, selecting at least one of the duration, the frequency and the power of electromagnetic radiation exposure that will result in the solid fuel having the desired fuel properties and a solid fuel temperature during treatment not exceeding about 100 degrees Celsius; and

processing the solid-fuel by exposing it to the selected electromagnetic radiation.

2. The method of claim 1, wherein the solid fuel temperature during treatment is about 70 degrees Celsius to about 100 degrees Celsius.

3. The method of claim 1, wherein a plurality of power levels are employed in a pre-determined sequence to obtain a targeted release of different components from the solid-fuel.

4. The method of claim 1, wherein the solid fuel is coal.

5. The method of claim 4, wherein the solid fuel is not in the form of a slurry.

6. The method of claim 4, wherein the solid fuel is crushed or screened to limit the solid fuel to particles having a diameter of about 8 inches or less.

7. The method of claim 1, wherein the selected electromagnetic radiation to which the solid fuel is exposed is microwave energy.

8. The method of claim 7, further comprising pre-heating the raw solid-fuel before exposing it to the microwave energy, wherein the pre-heat and microwave energy are applied to process the solid-fuel to control a targeted property of the solid fuel.

9. The method of claim 7, wherein the targeted property is the release of moisture.

10. The method of claim 8, wherein pre-heating the raw solid-fuel includes pre-heating the air in a chamber into which the solid-fuel is disposed.

11. The method of claim 8, wherein pre-heating includes use of microwave energy.

12. The method of claim 1, wherein the solid fuel is processed in a chamber, the method comprising flowing air through the chamber during processing.

13. The method of claim 12, wherein the air is supplied at a sufficient flow rate to carry away moisture-laden gas.

14. The method of claim 1, wherein the electromagnetic radiation processing can increase the BTU/pound of the solid fuel by at least 200 BTU/pound.

15. The method of claim 1, wherein the solid-fuel is processed in a chamber, the method further comprising flowing inert gas through the chamber during processing.

16. The method of claim 1, wherein the solid-fuel property used in selecting the electromagnetic radiation is moisture.

17. The method of claim 1, wherein the electromagnetic-radiation processing can selectively reduce the percent moisture in the solid fuel from at least about one percent up to ninety-eight percent.

18. The method of claim 1, wherein the electromagnetic radiation is applied to promote release of at least some of the ash.

19. The method of claim 1, wherein the electromagnetic radiation is applied to the solid fuel to obtain a release of sulfur from the solid fuel.

20. The method of claim 1, wherein the electromagnetic radiation processing reduces the percent pyrite in the solid fuel by at least about three percent.