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By Robert D. Hansen, Richard R. Klimpel

INTRODUCTION A very important factor in froth flotation is the use of surface-active chemicals to form a froth in which minerals or coals are retained, thus allowing for valuable component enrichment. In coal flotation reagents (frothers) specifically designed to provide an efficient froth are employed. It is this group of chemicals that will be the primary emphasis of this paper. Despite the importance of frothers, surprisingly little systematic scientific work has been performed with the goal of quantifying frother mechanisms and the influence of particles on froth stability. Based on direct experimental observations in both batch laboratory and continuous large-scale flotation cells, the use of a frother significantly increases first, the possibility of a particle- bubble contact, and second, the efficiency of sticking after such a contact. Thus, a major role of a frother is to significantly increase the rate of flotation. This rate modification by a surface-active agent occurs through several observable mechanisms including the formation of a froth of relatively consistent character (bubble size and bubble density) under a variety of operational conditions, an increase in the ability to disperse air in the flotation cell, a reduction in the rate of coalescence of individual bubbles in the cell, and a decrease in the rate of bubble rise to the pulp surface. It will not be the intention of this paper to exhaustively list all frother accomplishments related to research, development and use in coal flotation. Rather, the authors will attempt, based on their experience, to present a technology overview of the role of frothers in the chemistry of flotation as successfully practiced at the industrial level. A very useful framework for flotation is the concept suggested by Klimpel (1984, 1984a) of viewing flotation as a system consisting of three major components: chemistry, equipment and operating variables. This is illustrated in Figure 1. A major point of this figure is that flotation is a highly interactive system with many technical and economic combinations of component settings available to operators to achieve a given goal. Sometimes simultaneously changing various component settings will reinforce a particular attribute. Also various component settings can cancel or counteract each other if changes are not chosen wisely. Thus, coal flotation must be viewed by the plant operator as a complex system with the economic/technical optimization of a given flotation process being directly related to the operator's knowledge of how his particular flotation system behaves as a function of the major control variables he has at his disposal. Typical important component settings in coal flotation are collector dosage, frother type and dosage, air flow rate, feed rate, particle size, pulp density, and the surface oxidation conditions of the coal. Because of the above complexities, it is sometimes assumed (especially in laboratory studies) that the choice of frother type and dosage is not as crucial as some of the other factors such as collector type and dosage (e.g., Leja, 1982). Detailed plant level testing of all of the factors of Figure 1 performed in recent years, Klimpel (1980, 1980a, 1982, 1984, 1984a), Hansen (19861, Klimpel, Hansen and Meyer (1982), simply do not support this assumption. The above testing has shown rather clearly that certain frother chemical structures consistently exhibit predictable performance characteristics in both mineral and coal flotation. In addition, significant changes in both rate and recovery can be expected. In the remaining sections of this paper, the following topics will be covered: requirements of chemicals capable of use as frothers, types of chemicals used commercially as frothers, some general performance characteristics of existing commercial frothers, and recent work in developing new frother chemical structures.

Jan 1, 1986

By J H. Dressel, J. E. Williams

This paper presents a brief review of what coal gasification is, procedures that are available today and processes that may be available in the future. Examples are given as to how the process might be used in power plant applications, the effect on pollution level and power costs, and some thoughts on the added burden that might be placed on mining and coal preparation.

Jan 1, 1973

By Robert Sisselman

If we are lucky," says Hollis M. Dole, Assistant Secretary of the Interior, "coal, uranium and hydropower will provide us with maybe a third of the energy we require in 1985. The other two- thirds will have to be made available in liquid and gaseous form." Luck, however, may have run out, for if the facts and figures relating to supply and demand of natural gas over the next 20 years prove accurate, the United States may fall short in its attempts to bring the energy crisis under control. By the year 1990 the world will need to consume a minimum 150 quadrillion Btu of energy with gas requirements running as high as 42-43 trillion cu ft. By 1990, the U.S. alone will require 45-46 trillion cu ft. To meet anticipated demand, this country will have to overcome a deficiency of about 20 trillion cu ft since, by all pragmatic estimates, it will produce only 15-20 trillion cu ft of gas. The importation of natural gas into the U.S. will help but will not solve the problem. Adequate gas supplies will have to be supplied domestically. The Arctic, with its predicted huge reserves of gas, combined with imports of liquid natural gas (LNG) may provide as much as 15% of the 45-46 trillion figure, however, such reserves will not come into play as quickly as originally thought. The Alaskan gas fields, for instance, will provide a substantial supplement to domestic gas needs, but only after 1976.

Jan 10, 1972

By T. D. Brown

"A review of the current status of gasification technology shows that many engineering systems are immediately available for use in the gasification of coal. Widespread international experience can be brought to bear on the atmospheric pressure gasification of all Canadian coals.Unless a high ash content dictates the use of a fluid-bed gasifier, it appears that bituminous coals can be used in gravitating (fixed] bed systems and that the strongly caking coals are most suited to the high-pressure entrained-bed systems . Existing and developing technologies in fluid-bed gasification are attractive for reactive lignites and subbituminous coals.The Fischer-Tropsch based process is the only commercial embodiment of coal liquefaction; the use of Canadian coals in this process depends only on their gasification characteristics. Current developments in hydroliquefaction are directed toward carboniferous coals of medium or high rank. It is not clear that cretaceous coals of the same rank will give similar process yields and economics.IntroductionThe twin coal conversion processes of gasification and liquefaction have a history which dates back beyond the current energy shortages of the western world. Indeed, liquids and gas from coal were produced before this century.Coal gas produced from a coal carbonization process was originated before 1800, and the development of gasification of non-coking coals was patented by Siemens in 1860.This patent represented the first use of air and steam together in the gasmaking process. The pioneering development of coal gasification Using oxygen and steam was demonstrated by Lurgi in the late 1920s. This historical sequence was all carried out at atmospheric pressure, and it was not until the immediate pre-war (1939/45) years that operation of the coal gasification process at elevated pressure became a reality."

Jan 1, 1981

By Henry R. Linden

The demand for natural gas continues to increase at higher than anticipated rates, partly because of its widening price advantage over most other fossil fuels when the cost of air pollution control is included. However, there are clear indications that natural gas supply from the contiguous 48 states and continental shelves will not indefinitely keep up with this rapid growth in demand. Projections are presented which define the extent of potential deficiencies from the 1970's to the year 2000. Among the sources of supplemental gas - imported pipeline natural gas from Canada and Mexico, tanker import of liquefied natural gas, and synthetic pipeline gas from coal and oil shale - by far the most abundant at potentially competitive costs is pipeline gas from coal. The state of development and relative economics of the various coal gasification processes are reviewed. It is shown that synthetic pipeline gas could become a very substantial market for bituminous coal and lignite at current minemouth prices - 60-70 million' tons of coal for each trillion cubic feet of synthetic pipeline gas produced. This corresponds to only slightly more than the current annual increase is gas demand.

Jan 1, 1969

By R. D. Merer

The production of low- and medium-Btu gas from coal provides a more economic source of energy for most industrial users than pipeline-quality coal gas (SNG), although the latter has received more publicity. The paper reviews existing and advanced methods of coal gasification, with particular emphasis on the production of low- and medium Btu gas for industrial and utility use. Some of the ways in which coal gasification can be integrated into power cycles and industrial plant energy balances are discussed.

Jan 1, 1978

By E. R. Slatick

The northern and central Appalachian coal basin in the eastern United States has been the source of about two-thirds of the nation's coal output during the 20th century. This region includes parts of Pennsylvania, Ohio, Maryland, West Virginia, Virginia and eastern Kentucky. It covers about 130,000 km2 (50,000 sq miles) of the Appalachian coal basin and ranks as one of the world's most important coal production regions (Fig. 1). The coal industry's heyday in northern and central Appalachia has passed. This was due to competition from other fuels and low-sulfur coal produced in the West and because of the declining use of coking coal for steelmaking. Nevertheless, the region still plays a vital role in US coal production. It currently produces about 40% by weight of the nation's coal (its share is about one-half when measured by the energy content of the coal), contributes substantially to electricity generation and serves as the mainstay of US coal exports.

Jan 1, 1995

By J. C. Willett, J. R. Sanfilipo, S. M. Podwysocki, P. D. Warwick

The U.S. Geological Survey is concluding an assessment of the major coal regions of the country. In this program, the quantity and quality of coals that are expected to be mined during the next 30 years are characterized. For the Gulf Coast region, the evaluation includes reviews of the stratigraphic setting, coal resources, and the quality of the Cretaceous to Eocene coals in four coal-producing areas. The coal-bed methane potential for these areas will also be evaluated. The results of these efforts will be a series of digital maps, text, and tables that will be published in a CD-ROM format.

Jan 1, 2000

By H. E. Rutherford

Monterey Coal Company has begun a geologic monitoring program in order to better understand our in-mine geologic conditions and to apply the knowledge gained to our mining operations. Two methods are used to collect information. The first is a monthly examination of conditions throughout the mine using a rapid mapping technique. The second is the detailed mapping of specific events encountered during mining such as faults and roof falls. The data gathered from both methods is correlated with operational statistics to create a geologic/production database. From the database, a monthly evaluation of mining conditions is made. Also, the database has proved useful in such areas as forecasting roof conditions and examining how faulting has affected mining operations.

Jan 1, 1984

By M. Surracco, M. C. Tilocca

"Mineral comminution is often a costly process which also requires high level of energy. In the course of the studies carried out by the researchers of the Department of Civil-Environmental Engineering and Architecture at the University of Cagliari, aiming at the optimization of the reduction processes, it has been experimented, among of others, the effects of high-speed water jets on minerals grinding. As far as coal is concerned, some of the solutions initially adopted are presented in this paper, which essentially relied on the water jet power only, with secondary use of mechanical actions, to reach the most modern solutions that envisage the use of mechanical energy, normally used in traditional grinding machines, in synergy with hydraulic energy transferred by water jet.INTRODUCTION Mineral comminution can be rather expensive and demand a high-energy consumption, especially for fine sizes (Austin, 1979). Further interesting perspectives in this area may be offered by comminution means aided by high pressure water jets (Ciccu 2007), whose crushing potential is currently used for several operations such as cutting different materials, rock digging and industrial cleaning. The crushing action of water jets may induce a traction stress in materials where substances of a mineral nature, especially if characterised by permeable porosity, oppose a minor resistance (Griffith, 1920). The first solutions to this purpose essentially relied on the sole energy of water jets, with a secondary use of mechanical actions (Ciccu, 1993). Results were encouraging, despite the high values of specific energy for the low capacity of treatment. However, due to the difficulty in making the techniques mainly based on hydraulic energy practically applicable to solids comminution a solution was experimented, with some interesting results, consisting in the combination of mechanical energy, normally used in traditional grinding devices, with hydraulic energy transferred through water jets, in a synergic relationship (Ciccu, 1998; Tilocca, 2016)."

Jan 1, 2018

By Carl E. Bagge

It is easy for a coal spokesman to relate to the theme of this meeting--that the decade of the 1970's is pivotal for the mineral industries. For the coal operator, this period is crucial. The coal industry, according to most energy forecasters, must gear its production machinery to meet a sharp rise in the demand for coal--in this decade to sustain inevitable boosts in electricity output, and in the next to start supporting a big new domestic synthetic fuels industry that is already in the formative stage. The logic of that projection flows from a combination of hard circumstances--proved reserves of domestic fluid fuels are dwindling, the hope for bountiful and cheap nuclear power must be indefinitely deferred, and the threat of long-term fuel imports to the national interests is becoming starkly visible. Only coal, with its assets of abundance, security and versatility, offers the nation an adequate and immediate lift out of its current energy crisis. A hard-won expansion of coal production made the critical difference between local power load-shedding and major area blackouts in 1970, the year the energy crisis went public. Coal will have to play that same key role, not just through this pivotal decade but through the turn of the century. But the logic of fuel demand apparently does not always extend to supply. The coal industry has had a huge production job laid out for it by the energy statisticians, but up to now the energy policy-makers have not followed through with the aids and inducements that the coal operator urgently needs to do that job well and completely.

Jan 1, 1972

By B. J. Arnold, C. D. Harrison, R. A. Lohnes

More than 544 Mt (600 million st) of coal are handled annually for use by this country's coal fired power plants. Coal is transported in various ways: overland conveyors, railcars, trucks and barges. It can travel short distances or thousands of miles, picking up moisture, freezing or drying. When the coal is received at the power plant, environmental problems with fugitive dust and further handling problems can arise. To ensure that power plant availability is not jeopardized by coal handling problems, the Electric Power Research Institute's (EPRI) Coal Quality Development Center (CQDC) developed a research program aimed at addressing utility coal handling problems. The program has identified key areas, and is investigating the cost and cause of coal handling problems as well as the solutions to these problems. The ultimate goal of the program is to develop a "handleability index" that utilities can use in their coal specifications or hardware for a utility's sampling system to predict handleability and determine if a coal shipment should be accepted.

Jan 1, 1993

By B. P. Atkin, D. W. Brown

A handleability monitor was designed to provide a simple, rapid, on-site assessment of the whole or part consignment of a coal blend in its "as-received" condition. The monitor was evaluated at a number of coalhandling plants, which handle both metallurgical and power station coals from a variety of sources worldwide. The results can be used to predict which coals could routinely pass through a handling plant at line capacity without causing blockage or delay. Despite extensive analysis of the data, it was not possible to correlate the handleability index to the regular sample analysis of moisture, ash and size analyses of the coal blends.

Jan 1, 2002

By B. P. Atkin, D. W. Brown

The handleability monitor has been specifically designed to provide a simple, rapid and on-site assessment of the whole or part consignment of a coal blend in its ‘as-received’ condition. Evaluation has been carried out at a number of coal-handling plants, on both metallurgical and power station coals from a variety of sources world-wide. The results which are used to predict which coals could routinely pass through a handling plant at line capacity, without causing blockage or delay, have also been correlated with moisture, ash and size analyses of the coal to develop a predictive model of handleability.

Jan 1, 2000

By B. J. Arnold

Over 600 million tons of coal are handled annually for use by the country's coal-fired power plants. Coal is transported in various ways. overland conveyors. Railcars, trucks, and barges. It can travel short distances or thousands of miles, picking up moisture, freezing, or drying. When the coal is received at the power plant, environmental problems with fugitive dust and further handling problems can arise.

Jan 1, 1989

By Stanley Kesler

The first of two initial 650-mw units of the Paradise Steam Station, located on the banks of the Green River in the south-central portion of the western Kentucky coal basin, is scheduled for operation in late fall of 1962. This plant will be the eighth large-capacity, modern station built by TVA in a series starting with Johnsonville, operated first in 1951. During the subsequent ten years, unit sizes have increased from a capability of 125 mw to 650 mw at Paradise. This new unit will take its place in a power system that serves an area of about 80,000 sq miles with a present installed capacity of over 12,000 mw. Upon completion of the Paradise units and other additional hydro and steam units presently under construction, the system capacity will have reached over 15,000 mw. Projected load estimates indicate that this system will provide a margin of slightly under 10% of dependable capacity above peak demand at that time. One Paradise 650-mw unit at that time will represent approximately 4yc of the total system installed capacity.

Jan 10, 1962

By Stanley Kesler

The first of two initial 650-mw units of the Paradise Steam Station, located on the banks of the Green River in the south-central portion of the western Kentucky coal basin, is scheduled for operation in late fall of 1962. Location of the site is shown on the map of figure 1. This plant will be the eighth, large-capacity,, modern station built by TVA in a series starting with Johnsonville, operated first in 1951. During that period of 10 years,, unit sizes have increased from a capability of 125 mw to 500 mw at the recently completed Widows Creek Unit 7 addition and at Paradise to 650 mw. This new unit will take its place in a power system that serves an area of some 80,000; square miles with a present installed capacity of over 12,000 mw. Upon completion of the Paradise units and other additional hydro and steam units presently under construction, the system capacity will have reached over 15,000 mw. Projected load estimates indicate that this system will provide a margin' of slightly under 10 percent of dependable capacity above peak demand at that tire. One Paradise 650-mw unit at that time will represent approximately 4 percent of the total system installed capacity.

Jan 1, 1962

By J. J. Wallaert

The decreasing supplies of natural gas and low-sulfur crude oil available for electric power generation in the United States will unquestionably shift the emphasis to nuclear and coal fired steam power plants in the immediate future. Failure to do so will ensure our dependence on mid-east low sulfur crude oil comprising some 70% of the known world reserves, and imported liquid natural gas. By contrast, the United States has 43% of the known world reserves of anthracite, bituminous and semi-bituminous coal and 48% of all known coal reserves of the world including lignite. It is evident, therefore, that coal is alive and well and will continue to be a significant energy source for the production of electricity for many years. Of course, concern for our environment and the development of new technologies will ultimately curtail the utilization of coal for the generation of bulk power, but information released by the National Electric Reliability Council and the Federal Power Commission is worth repeating. In the year 1972 the total capacity of generating units in the United States was 379,552 Mw of which 149,974 Mw, or 39.5% of the total, was produced by coal fired steam turbines which consumed 344,700,000 tons of coal. New capacity additions planned or in construction show that in the year 1981 our total generating capacity will be 843,503 Mw, of which 257,995 Mw, or 30.6% of the total, if from coal only. Translating this increase into terms meaningful to the bulk material handling industry suggests that ten years from now the utility industry will require 590,000,000 tons of coal per year - a monumental task - if we are to sustain our current demand rate for power.

Jan 1, 1973

By Rick A. Croote

The objective of the Cerrejon Coal Project is to mine and export a minimum of 15 million metric tons per year of bituminous coal from the Guajira Pennisula in Colombia, South America. Major components of the project will include an open pit mine, 150 km railroad, marine terminal for storage and shipping, and accommodations for the support personnel. This paper primarily reviews the coal handling facilities at the mine and port which will include crushers, conveyors, silos, stacker/reclaimers, and a shiploader. Of special interest is the design concept for unloading bottom-dump railcars, a programmable controller control system with automatic stacking and reclaiming, a linear-type shiploader, and 2.4m wide conveyors running at 5 m/sec.

Jan 1, 1983

By William H. Lehr

In recent years, we have witnessed many innovations in the equipment used in handling bulk materials. Not too long ago, any sizeable stockpile of coal or iron ore was attended by one or more material handling bridges. More recently, large stockpiles have been built with mobile equipment of' the earth moving type with bulldozers and front end Loaders being utilized in reclaiming operations. The most recent stocking and reclaiming device is the rotary bucket wheel machine. The early bucket wheel machines built in the United States were developed for the strip mining of coal. We understand that the first American machine was built in the Midwest in 1944. This type of unit was developed in an effort to reduce the cost of removing overburden and to provide satisfactory spoil disposal. As the available coal reserves under shallow cover were exhausted, the cost of removing the deeper overburden with conventional equipment became too great for these operations to continue profitably. The first machine has now been followed by six or seven additional units, the largest of which can handle material at a rate of more than 7000 cubic yards per hour.

Jan 1, 1965