Omnis Advanced Technologies, LLC

Omnis Mineral Technologies, LLC

Earth Technologies USA Limited

James S Swensen

Simon K Hodson

Jonathan K Hodson

Douglas Edward Grunder

Nathan A Chapman

Paul R Samario

John G Gritt

Michael R Hodson

David S Gibbel

Stephen P Gibbel

Coal fines are processed by flotation separation to separate coal particles from ash-forming mineral content particles. Coal fines are mixed water under high shear mixing conditions to form an aqueous slurry of coal fines containing between 15 wt. % and 55 wt. % coal fines. The aqueous slurry is introduced into a coal flotation cell to separate coal particles from ash-forming mineral content particles by flotation separation, wherein the coal fines have a particle size less than 100 μm, and more preferably less than 50 μm. Bubbles are generated in the coal flotation cell having a bubble size and bubble quantity selected to float the coal particles and to form a coal-froth containing at least 15 wt. % solid particles. The solid particles include coal particles and ash-forming mineral content particles. The coal-froth is collected for further processing.

Flotation separation of fine coal particles from ash-forming particles

A continuous process for converting metal compound particles into a mixture of elemental metals. Metal compound particles and a reductant are introduced into an ultra-high temperature reaction zone having a temperature greater than 2,700° C. and an oxygen content less than 3 vol. %. The metal compound particles have particle sizes of d90 500 μm. The metal compound particles have a residence time less than 1 minute in the ultra-high temperature reaction zone sufficient to mix with and react with the reductant to reduce the metal compound particles to form a mixture of elemental metals. The mixture of elemental metals is removed from the ultra-high temperature reaction zone. One or more elemental metals are separated or concentrated from the mixture of elemental metals within one or more separation zones based on differential size and density of the one or more elemental metals and the remaining mixture of elemental metals.

Ultra-high temperature continuous reduction of metal compound particles with subsequent selective separation

A continuous hydrocarbon pyrolysis process to produce hydrogen gas and carbon includes exposing a hydrocarbon feedstock to an oxygen depleted combustion gas within a hydrocarbon pyrolysis zone. A valveless pulse combustor produces the combustion gas at a temperature greater than 2,400° C. The hydrocarbon feedstock and combustion gas have a residence time within the hydrocarbon pyrolysis zone less than 30 seconds to cause pyrolysis of the hydrocarbon feedstock and produce gas comprising hydrogen and solid particles comprising carbon. The gas and solid particles exit the hydrocarbon pyrolysis zone at a temperature greater than 1,200° C. A heat exchanger cools the gas and solid particles to a temperature less than 200° C. A gas absorber removes unwanted gas molecules from the gas and produce Hcontaining gas having an Hconcentration greater than 80 vol. % H. The Hcontaining gas is continuously introduced to a Hconsuming facility.

Ultra-high temperature pyrolysis separation of hydrogen and carbon

A process for comminuting particles of heterogeneous material. The particles of heterogeneous material are fragmented and broken into smaller particle size by breaking them against each other. Heterogeneous material means two or more different solid materials or phases in the same solid. The component materials may have different specific gravity and/or hardness. In the process, a slurry of particles of heterogeneous material is pumped through an agitated mixture of impingement media, wherein the impingement media has a size greater than a size of the particles, wherein adjacent impingement media interact to create impingement zones through which the particles pass and impinge each other to cause the particles to fracture and break into smaller particles. The impingement media may be from 5 to 10 times larger than the particles. The impingement media may be harder than the particles. The heterogeneous material may be coal.

Inter-particle impingement fracture of heterogeneous material

A process for fracturing and devolatilizing coal particles rapidly exposes coal particles to a high temperature, oxygen-depleted work zone for a sufficient time period to cause volatile matter within the coal particles to vaporize and fracture the coal particles. The work zone has a temperature in the range from 600&#xb0; C. to 2000&#xb0; C. The coal particles are exposed to the high temperature, oxygen-depleted work zone for a time period less than 1 seconds, and preferably less than 0.3 second. The vaporized volatile matter is condensed and recovered as microcarbon particles.

Thermal fracture and microcarbon separation of coal particles

A gaseous combustible fuel includes a gaseous hydrocarbon fuel feedstock and solid fuel particles suspended in the gaseous hydrocarbon fuel feedstock. The solid fuel particles have a sufficiently small particle size so that they remain suspended during transportation. The hydrocarbon fuel feedstock may include natural gas, ethane, propane, butane, and gaseous derivatives and mixtures thereof. The solid fuel particles may include coal-derived solid carbonaceous matter. Other examples of solid fuel particles include biomass, refined bioproducts, and combustible polymer particles. The gaseous combustible fuel has an energy density at atmospheric pressure which is at least 25% greater than the volumetric energy density of the gaseous hydrocarbon fuel feedstock. Improvements in volumetric energy density of 50%, 100%, and even 500% are disclosed. The gaseous combustible fuel may be pressurized to a pressure in the range from 2 to 100 atmospheres.

Gaseous combustible fuel containing suspended solid fuel particles

The coal-derived solid hydrocarbon particles are discrete particles of coal-derived carbonaceous matter having a particle size less than about 10 &#x3bc;m that are substantially free of inherent or entrained mineral matter. The particles of have an average particle size in the range from 1 &#x3bc;m to 8 &#x3bc;m. The particles of coal-derived carbonaceous matter are milled to a size approximately the same as a size of coal-derived mineral matter inherent in the coal source to release inherent coal-derived mineral matter particles such that the particles of carbonaceous matter and the particles of mineral matter are discrete and separable solid particles. Following separation, less than 1.5 wt. % discrete coal-derived mineral matter particles are associated with the discrete particles of coal-derived carbonaceous matter. Particles of coal-derived solid hydrocarbon matter are blended with a gaseous or liquid hydrocarbon fuel to form a two-phase hydrocarbon fuel feedstock.

Coal-derived solid hydrocarbon particles

A method of preparing agglomerates of ultra-fine coal particles includes mixing a film forming agglomeration aid (FFAA) with a quantity of ultra-fine coal particles to form ultra-fine coal particles coated with the FFAA. The FFAA has a lower surface energy relative to a surface of the ultra-fine coal particles. The FFAA is mixed with the ultra-fine coal particles in an amount less than 3% by weight of the ultra-fine coal particles on a dry basis. Agglomerates of the ultra-fine coal particles coated with the film forming agglomeration aid are formed using vibration, pelleting, and/or briquetting. The agglomerates have a size of at least 2 mm. The ultra-fine coal particles have a particle size less than 100 &#x3bc;m. The agglomerate has a tumbler test friability less than 3%. The drop shatter friability is also less than 3%.

Agglomeration of ultra-fine coal particles

A transportable and combustible gaseous suspension includes solid fuel particles suspended in a gaseous carrier. The solid fuel particles have a sufficiently small particle size so that they remain suspended during transportation. The gaseous carrier may include reactive and inert gases. The solid fuel particles may include coal-derived solid carbonaceous matter. Other examples of solid fuel particles include biomass, refined bioproducts, and combustible polymer particles. The combustible gaseous suspension can be tailored to have an energy density at atmospheric pressure which is comparable to conventional gaseous hydrocarbon fuels. The gaseous combustible fuel may be pressurized to a pressure in the range from 2 to 100 atmospheres.

Transportable combustible gaseous suspension of solid fuel particles

Coal-derived mineral matter is used to capture or remove combustion gas emissions from flue gas or exhaust gas. The coal-derived mineral matter may be obtained by separating it from coal particles, such as by use of a flotation separation process. Coal-derived mineral matter may also be present in fine coal refuse. In the method of removing combustion gas emissions from flue gas, an aqueous suspension of coal-derived mineral matter particles is contacted with the combustion gas emissions for sufficient time to cause the combustion gas emissions to react with the aqueous suspension and form an enhanced aqueous suspension. The combustion gas emissions may comprise NOx, SOx, CO, or mixtures thereof. An aqueous suspension of coal-derived mineral matter particles containing enhanced amounts of soluble and insoluble sulfate, sulfite, nitrate, nitrite, or carbonate reaction compounds formed by reaction of the aqueous suspension of the coal-derived mineral matter particles with combustion gas emissions.

Combustion gas removal from flue gas using coal derived mineral matter

Coal-derived mineral matter particles are an effective soil amendment. Coal-derived mineral matter particles added to soil increase the silt and clay fractions of the soil and improve the soil texture. The fine coal-derived mineral matter particles also increase mineral and essential nutrient availability for plant growth. Improved soil texture also increases water holding capacity and cation-exchange capacity (CEC) of the soil. The mineral matter particles typically have a size less than 50 &#x3bc;m and an average size of 10 &#x3bc;m or less. In some non-limiting embodiments, the mineral matter particles mixed with the soil are present in the mixture in an amount ranging from 5 to 30 wt. %. The coal-derived mineral matter particles contain a plurality of essential nutrients necessary for healthy plant growth selected from B, Ca, Cl, Cu, Fe, Mg, Mn, Mo, N, P, K, S, and Zn.

Coal-derived mineral matter as a soil amendment

Fine coal particles are dewatered by mechanically removing water from the coal particles by vibration assisted vacuum dewatering to form a coal particle filter cake. The filter cake typically has a water content less than 35% by weight, suitable for extrusion to form discrete, non-tacky pellets. The vibration assisted vacuum dewatering may operate at a vibration frequency in the range from about 1 Hz to about 500 Hz. The vibration frequency may be adjusted during the dewatering process. In some embodiments, the vibration frequency is increased as the moisture content of the coal particle filter cake is decreased. Washing the filter cake during dewatering removes soluble contaminants. Various vibration assisted vacuum dewatering devices may be used, including a vibration assisted rotary vacuum dewatering drum, a vibration assisted vacuum disk filter, and a vibration assisted vacuum conveyor system.

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Santa Barbara, CA, United States of America

James S Swensen