Coal Cleaning Using Resonance Disintegration for Mercury and Sulfur Reduction Prior to Combustion

Abstract

Coal-cleaning processes have been utilized to increase the heating value of coal by extracting ash-forming minerals in the coal. These processes involve the crushing or grinding of raw coal followed by physical separation processes, taking advantage of the density difference between carbonaceous particles and mineral particles. In addition to the desired increase in the heating value of coal, a significant reduction of the sulfur content of the coal fed to a combustion unit is effected by the removal of pyrite and other sulfides found in the mineral matter.WRI is assisting PulseWave to develop an alternate, more efficient method of liberating and separating the undesirable mineral matter from the carbonaceous matter in coal. The approach is based on PulseWave's patented resonance disintegration technology that reduces that particle size of materials by application of destructive resonance, shock waves, and vortex generating forces.Illinois #5 coal, a Wyodak coal, and a Pittsburgh #8 coal were processed using the resonance disintegration apparatus then subjected to conventional density separations. Initial microscopic results indicate that up to 90% of the pyrite could be liberated from the coal in the machine, but limitations in the density separations reduced overall effectiveness of contaminant removal. Approximately 30-80% of the pyritic sulfur and 30-50% of the mercury was removed from the coal. The three coals (both with and without the pyritic phase separated out) were tested in WRI's 250,000 Btu/hr Combustion Test Facility, designed to replicate a coal-fired utility boiler. The flue gases were characterized for elemental, particle bound, and total mercury in addition to sulfur. The results indicated that pre-combustion cleaning could reduce a large fraction of the mercury emissions.iv