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By Price E. R.

The coal industry was beset with work stoppages and strikes throughout the year, and there was some loss in markets to oil and gas. These conditions, along with the mild decline in industrial activity, the steel strike, and the reduction in exports, contributed to an unfavorable year for the industry. All coal mines are working three days a week at the time of writing, and in estimating production for the year, it will be assumed that the mines will continue to work on that basis through December. Total production of bituminous coal in 1949 is estimated at 420 million tons, which is 179,518,229 tons under the production in 1948. Anthracite production is expected to reach 39,400,000 tons as compared with 57,139,948 tolls in 1948, a loss of 17,739,948 tons. Coal stocks, as of January 1, 1949, were 69,373,000 tons but at the end of the year will have dropped to approximately 22 million tons. Regardless of the difficulties during the current year, the industry has made substantial

Jan 1, 1950

By F. Freme

Coal production in the United States increased in2004 by 36 Mt (39.7 million st) to end the year at 1 Gt(1.11 billion st), according to the U.S. Energy Information Administration (EIA). This was a 3.7-percent in-crease from 2003’s 971.6 Mt (1.07 billion st) (Table 1).(All percentage change calculations are done at the short-tons level.) Although U.S. coal consumption rose in 2004, not all coal-consuming sectors had increased consumption for the year. Coal consumption increased in the electric power sectors by 1 percent and declined slightly in the other industrial sector, while coking coal consumption dropped by 2.4 percent. U.S. coal exports rose for the second consecutive year, while coal imports again increased to record levels. Coal stocks declined during the year, as electric generators used their stockpiles to helpmeet increased demands and missed shipments. Coal producers used their stockpiles to supplement their production levels.

Jan 1, 2005

By D. R. Mitchell

Accent is on mechanization, more preparation plants - Competition from other fuels remains biggest problem.

Jan 2, 1953

The North American Coal Corp. Increasing demand for coal, stimulated by the national energy shortage, and complicating and often conflicting, demands by government and ecology groups for better land reclamation methods continued to propel advances in surface mining technology during 1974. To meet current demands for coal (estimated at more than 700 million t for 1975 and 1.5 billion t in 19851, equipment manufacturers and coal operators concentrated on increasing the productivity of all surface mining equipment. The trend towards larger equipment, particularly in overburden removal, loading, and haulage machinery, prevailed during the year, notwithstanding the perennial debate over the economics and practicality of using large, inflexible equipment. Increasingly, the industry called on computers to monitor productivity and help design more efficient production systems

Jan 2, 1975

By C. F. Hardy, D. R. Mitchell

Bolts held up roofs as mining machines went on to set new records, but rising labor costs still plagued operators.

Jan 2, 1951

By George R. Eadie

As 1972 slipped through our grasp, coal industry adjustments to health and safety laws, environmental restrictions, rising costs and higher production targets left many mine operators groping for a new grip. The industry adopted a defensive attitude in 1972 as it faced the onslaught of inspectors. With rigid demands for improving safety and instituting environmental programs, the industry worked hard and watched production figures stagger upward while operating costs zoomed. In an effort to determine how to meet the goals that were established for fewer ignitions, fewer accidents, less respirable dust, lower noise levels, fewer law violations, better reclamation, less pollution, lower costs and higher production, industry representatives attended numerous technical meetings.

Jan 2, 1973

By Marke Wong

? Vietnam?s economy is growing so fast that gross domestic product (GDP) growth remained above 8% in 2005 and exports are rising steadily at 25% per year. ? Demand for electricity is expected to increase 18% per year through 2010 requiring an additional estimated 7,547 MW before 2010 ? Domestic coal demand is expected to be over 45 Mt by 2010. ? The Quang Ninhcoal deposits are estimated at 6.5-7 billion tons (350m) Vietnam News Agency. Saturday, May, 6, 2006. ? National resources are now estimated at 10 billion tonnes; not including a relative new coal bed discovery estimated at 210 billion tonnesin the Red River Basin.

May 1, 2006

With the dawning of a new century came the beginning of a new era in the coal industry. Instead of the traditional practice of only buying and selling produced coal in the United States, a coal futures market was established. The New York Mercantile Exchange began trading coal futures in July 2001. But, even in this new era, many of the old is-sues that have beset the coal industry still remain, as was evident in2001. Coal production increased to are cord level during 2001, according to preliminary data from the US Energy Information Administration(EIA). Production in 2001 rose by4% to 1.01 Gt (1.12 billion st), compared with 2000 (Table 1). This barely surpassed the previous record level of 1 Gt (1.11 billion st)set in 1998. Coal consumption remained unchanged. The additional production was used to replenish the depleted stockpiles that had resulted after two years of declining coal production and increasing coal consumption.

Jan 1, 2002

By Suresh P. Babu, Joseph W. Leonard, Richard Muter, D. P. Sen

OUTLOOK FOR COAL UTILIZATION In 1975, about 650 million tons of bituminous coal and lignite mined in the United States was used to meet 55% of the primary energy input for electric power generation and 26% of the total industrial consumption.1 Even though this amounts to only 21% of the total energy requirements, it is believed that with the declining natural gas resources and uncertainty of liquid fuel imports, coal will assume a more dominant role in suppplying our future energy needs. A regional breakdown of the coal reserves of the United States along with their characteristics is shown in Table I. At present the United Stares Energy Research and Development Administration (ERDA) and the US Bureau of Mines (USBM) are financing extensive research programs in advanced mining methods and energy conversion processes. The increased demand for wal which may result from these research programs may also create large-scale environmental protection problems. As more and more coal is mined the production of undesirable coal fines and dust also increases proportionally. The USBM and the Environmental Protection Agency (EPA) research in this field includes development in the areas of instrumentation for qualitative and quantitative analysis of wal dust, protective devices, and dust collectors. Dust control by water sprays, steam, and foam are also being investigated. Other aspects of safety in mining include developing methane drainage techniques prior to coal mining, fire and explosion prevention, and neutralization and disposal of acid mine waters. It is the belief of coal technologists that when the emphasis shifts to coal as the primary source of energy. the existing methods of mining and preparation of coal must be improved considerably to supply large quantities of quality coal for energy conversion. It is the objective of the present large-scale research financed by ERDA to produce substitute fuels from coal. Large-scale gasification pilot plants are being constructed by Bituminous Coal Research, Consolidation Coal Co., Institute of Gas Technology, and the Pittsburgh Energy Research Center to produce coal gas of natural gas standards at 1,000 psig. The processes being adopted by these pilot plants are oriented towards recovering most of the sulfur from coal by absorbing H2S and its subsequent conversion to elemental sulfur. The environmental protection standards will be strictly followed in using the results of these pilot plants to construct large-scale coal gasification plants in the latter part of the 1970's. With the increasing awareness of the need for air pollution control, considerable research is being done to minimize sulfur dioxide emission from thermal power plants. Utilization of limestone and dolomite scrubbing systems and caustic treatment of stack gases have proved to reduce sulfur and nitric oxide emissions by about 90 to 96%.3 Currently, about 22 scrubbers are in use in the United States to reduce sulfur in stack gas emission. In the long-term, it appears that optimal combinations will be developed involving both advanced coal preparation technology and wet scrubbing. The sulfur compounds are converted either to elemental sulfur of sulfuric acid. Besides the sulfur compounds, the major byproduct of the coal utilization industry is the large amount of coal ash. The Coal Research Bureau at West Virginia University has developed a practical use for coal ash as a structural material. The coal industry will undergo revolutionary changes when coal becomes the primary source of energy. New coal mining and preparation processes will be introduced to meet the ever-increasing per capita energy requirements. 2. BENEFICATION Introduction Coal preparation, like the beneficiation of ores, is also aimed at the separation of values from associated waste. Even though the unit operations involved when enriching ores and coal are similar, there are certain characteristics unique to coal preparation. Unlike the scattered and concentrated veins of underground minera1 ores, coal is distributed uniformly and very much in abundance in the coal mines. Coal occurs as the metamorphosed sedimentary deposits of vegetable matter, while metal and mineral deposits occur in great varieties of forms, structures, and origin-from igneous to sedimentary and metamorphic. The mined coal, being much more friable than mineral ores, is subjected to less intensive size reduction operations. Ores are usually ground to a very fine size for subsequent concentration, while coal is crushed to a coarser size, since considerably less liberation is needed to achieve the desired degree of separation. Since mineral matter is to a great extent discretely distributed in coal, concentration is mainly achieved by taking advantage of differences in specific gravity between clean coal and associated waste. In general, about 90% of coal is concentrated using specific gravity separation and about 10% by froth flotation. In contrast, these operations are frequently reversed in the beneficiation of ores. In coal preparation almost all fractions separated during various stages are made use of. while large amounts of gangue material are rejected in the concentration of ores. Hence, coal generally has a much lower ratio of concentration than ores. Since ore deposits are frequently more variable and mineralogically complex than coal, beneficiation of ore may require more plant flexibility and point-to-point quality control. This characteristic difference between the mineral ores and coal is attributed to the generally used one-step processing in coal as compared to the multiple-step processing of ores. Dewatering to enhance the energy content of coal is usually considered a major unit operation. Even though thickening and filtration are common for dewatering ore concentrates and cleaned coal, vibrating centrifuges and disk filters find unique application in the coal industry for achieving these types of solid-fluid separation. In coal preparation, thermal drying is carried out in separate units at the mine. While ore concentrates are usually dried at the smelter. Although the drying of ores is seldom considered dangerous, volatile matter and combustible dust are reasons why the thermal drying of coal can be hazardous. Open air storage of ores and mined coal results in partial oxidation. Unlike the oxidation of ores, the oxidation of the pyritic and carbonaceous constituents of coal together with the heat of condensation of moisture contribute to spontaneous heating and the subsequent combustion of coal in storage. Among the other significant difference between concentration of ores and coal are the weight and capacity of processing equipment. Coal processing employs less cumbersome, higher capacity units while the beneficiation of ores usually requires much more massive and frequently lower capacity equipment. Properties of Coal Which Influence Design The widely varying and heterogeneous composition of coal, due to metamorphism, determines the preparation design and uses of the resulting products. Petrography serves as a useful system of classification to identify the coal types present and their distribution. Early

Jan 1, 1985

By H. W. Ahrenholz

Seven weeks of 1971 were devoted to a nationwide coal walkout resulting in lost production of some 70 million tons and leaving 1971 coal production at about 550 million tons. Compounding the problem, consumption of coal in 1971 by electric utilities rose by about 5% to 336 million tons. In the mean- time, numerous contracts were awarded for coal R&D including $24.8 million given by the Office of Coal Research to Bituminous Coal Research for the construction of a coal-to-gas pilot plant using the BIGAS process. Exports declined mainly due to Japan's decrease in steel production and to that country's increase in coal imports from Canada and Australia. The advances in equipment design and mining procedures made 1971 a noteworthy year. Introduction of the variable pitch I dipper, the trend toward wheeled vehicles, the greater use of scrapers in reclamation and battery-operated vehicles and oscil-mining, and the increased activity in the areas of ventilation and dust control were given widespread approval. There were also strides made in computerization, longwall mining, roof bolting, rock dusting, mine haulage and methane detection.

Jan 2, 1972

By B. Tönjes

In the course of the last decade, the concept of sustainability has turned from a catchword into a vision - a vision to which politics and industry feel increasingly committed. In terms of the energy industry, the key criteria for sustainable development are supply security, economic efficiency and social responsibility. Coal is able to meet all these criteria if it is produced in conformity with high safety standards through the use of modern mining technology and converted into electricity with the aid of environmentally friendly methods. Among the fossil energy resources, coal will, according to the vast majority of global energy scenarios, continue to be the most important input energy in power generation for the foreseeable future. Coal is therefore today, and will in future continue to be, an important element in ensuring sustainable energy and raw material supply, worldwide, in Europe and also in Germany.

Jan 1, 2005

By R. F. Stewart, A. W. Hall

A method has been developed for continuously measuring the moisture content of coal. The method is based on the thermalization of fast neutrons by hydrogen in the coal. Neutrons from a small radio-isotope source penetrate the coal, are scattered by hydrogen, and measured by a thermal neutron detector. The number of thermal neutrons counted can be directly correlated with the moisture content of coal. In a pilot-scale system, moisture was measured continuously within 0.2% in coal moving at rates up to 20 tph. The method is adaptable in industry for continuously measuring the moisture content of coal at high tonnage flow rates. Such an application would permit continuous recording of moisture in coal without sampling and facilitate quality control. An automatic and continuous method of measuring the moisture content of coal is needed by the coal industry. Automatic control of the coal quality would reduce the cost of coal preparation, improve the product, and thus indirectly increase the use of coal. Moisture in coal can be determined by several methods, but the time required to obtain samples and analyze them by existing methods makes it difficult, if not impossible, to control the quality of the product. Both producers and consumers need a method for continuous and instantaneous measurement of moisture content without sampling in order to regulate process equipment and keep the moisture content of coal within specifications. At the Morgantown, W. Va., Coal Research Center we are developing a nuclear method for continuous measurement of moisture in coal. This method is based on the thermalization of fast neutrons by hydrogen in the water and organic matter of coal. Neutrons from a small radioisotope source penetrate the coal, are scattered by hydrogen, and are measured by a thermal neutron detector. The number of thermal neutrons counted can be directly correlated with the moisture content of coal. Design of a moisture meter based on neutron thermalization depends on many variables, any or all of which can affect the sensitivity of the meter. These factors include those related to the nuclear aspect; type and size of neutron flux and source, type of detecting device, and background count; and those related to the coal being tested: rank, particle size, and ash content. A survey was initiated to eliminate the relatively insignificant factors and to ascertain the magnitude of the major effects. Such information was necessary to fully evaluate the technique and to establish design criteria. Coal contains a relatively large amount of hydrogen in the organic coal substance and the water of hy-dration of the shaly material as well as in the moisture. To apply this concept of moisture measurement to coal requires that the organic substance in coal from any one seam of a particular mine be uniform in hydrogen content. The difference in total hydrogen content of wet and dry coal is relatively small, so that a moisture measurement based on this concept requires a measurement between two large numbers to a high degree of precision. Thus, it was necessary to develop a highly precise instrumentation system for continuous measurement and to obtain a physical arrangement permitting measurement of moving coal with a minimum effect from density variation. EXPERIMENT WITH TRAYS OF COAL Tests were conducted with metal trays containing SO to 100 lbs of coal to develop an instrument system of high precision. A scaling system with a maximum instrument error of 0.2% was used to test different types of thermal neutron detectors. The most suitable type of detector was a boron-10-lined proportional counter tube. While this type of detector showed satisfactory stability, extensive testing disclosed a long-term count reduction probably due to some type of deterioration in the detector. However, development of an electronic system using dual detectors eliminated this deterioration as a serious problem. (The second detector would be used to measure a reference drum of dry coal — the difference in count rate between the wet coal and dry reference coal being a direct measure of moisture content.) Table I, column 1, shows typical results with a 1-curie plutonium-beryllium neutron source and a thermal neutron detector beneath a tray of coal and illustrates the precision of measurement. Consecutive measurements (indicated in Table 1, columns 2-5) of thermal neutrons at various times and positions be-

Jan 1, 1968

By C. F. Cockrell, H. E. Shafer, J. W. Leonard

A significant technological development is discussed for the processing of certain power plant flyashes that are a problem because they contain a high water-soluble mineral content and yield inferior flyash-based brick. This development is based on the addition of hydrochloric acid to the flyash-bottom ash-sodium silicate blends used for the production of flyash-based structures. Favorable changes are evi-dent in sodium silicate consumption, where about half the amount used for making brick from normal flyash is required, processing costs, and strength and appearance of the resulting freshly formed green and fired structural products. In some high cost in-stances (above the $30 or less per thousand brick estimated for normal flyash), hydrochloric acid additions can replace or reduce other costly additives normally required for problem flyashes. This results in savings of as much as $9 per thousand brick. These developments offer promising possibilities for utilizing problem flyashes as well as flyashes which may come into contact with water soluble sulfur as a result of the eventual application of certain experimental air pollution control processes. Much of the research datal-6 accrued through work by the Coal Research Bureau of West Virginia University for the Department of Interior's Office of Coal Research on converting waste power coal ash to valuable brick and other structural products, can be categorized as follows: (1) general ash-to-brick tech- nology; (2) specific ash-to-brick optimization; (3) pilot plant progress; (4) production cost estimates. A summary of the progress on bench-scale experiments indicates that coal ash can yield two types of brick. An acceptable brick is obtained by mixing 73.6% fly-ash, 23.5% bottom ash and 2.9% sodium silicate solution (dry basis). Depending on the flyash and bottom ash used, optimum brick can be manufactured by mixing 72-77% flyash, 20-25% bottom ash and 2.3-3.0% sodium silicate (dry basis) with Na2O : SiO2 ratio varied according to the composition of the flyash used. These blends are thoroughly mixed and mechanically formed into green brick shapes at pressures ranging from 1000 to the more usual 3000 lb per sq in. The green shapes then are dried and fired at temperatures ranging from 1975-2150°F using clay brick cycles that are shorter than standard. Other findings reported to date indicate that when making optimum brick, it is necessary to carefully control the top size of the moisture-releasing bottom ash so that it falls between 8 and 30 mesh, depending on the flyash used. Moreover, the chemical composition of bottom ash and flyash have been found to be of little significance with the exception of a few problem flyashes which are the subject of this paper. Finally, the pilot plant, which was previously reported under construction, is now in operation. This will indicate, among other things, the cost of brick production, which was earlier estimated for non-problem flyashes at $30 or less per thousand brick. The foregoing bench-scale technology is applicable to all the initially tested ashes as well as to the majority of ashes examined during the course of research. However, a few of the ashes yield green and fired products that may be structurally inferior or unacceptable, necessitating excessive and diverse reagent addition, and/or may be coated with unsightly surface deposits. These problem ashes generally originate in certain areas of Illinois, western Ken-

Jan 1, 1969

By R. D. Saltsman

This paper deals with the evolution of a test procedure devised to totalize a coal's ignitibility, its degree of caking, and its coke reactivity and the development of a method for assigning proper combustion indices to stoker coals. The application of this type of work to stoker design is also discussed. It is believed that this work may be the prelude to understanding the effect of various petrographic constituents on the combustion characteristics of a coal or a blend of coals. The inadequacy of our knowledge of the coal combustion process has long been recognized. This was expressed very well by Spicer and Finney.1 "The control of combustion processes in industry and the design of the equipment necessary for efficient burning to take place have always been very much branches of an industrial art rather than of an exact science. This has been especially true of the utilization of coal, a substance so heterogeneous and complex in character that all too little is known about its chemical and physical composition." During the past several years one branch of coal utilization, that of high temperature carbonization, has made significant advances from being an art into being an exact science. This has been accomplished by the development of petrographic techniques for identifying, measuring, and determining the thermal properties of the organic materials which affect the carbonization of coal and the correlation of this information with a pre-existing standard of coke quality, the stability index. The success in using petrographic analysis for predicting the coking properties of coals and their blends suggested that petrographic techniques might be applied to the combustion process for predicting the combustion characteristics of coals. Certainly the different organic entities2 influence the combustion characteristics of a coal as they influence its coking properties. If it were possible to predict combustion characteristics from an analysis of a coal's petrographic composition, it would seem logical that an intelligent investigation could then be made into methods of altering stoker coals to improve their combustion characteristics. The successful application of petrographic analysis in the field of high temperature carbonization was made possible by the pre-existence of the stability index, which is a numerical value of coke quality. The quality of combustion is determined by the sum of the effects of the ignitibility, the caking, and the coke reactivity characteristics of a coal. While the literature is filled with papers reporting the correlation of various analyses to the ignitibility, or to the caking, or to the coke reactivity characteristics of coals, none of these earlier studies could be related to one index. The lack of a single index for combustion quality precluded the application of petrographic techniques for predicting combustion characteristics. SELECTION OF THE COMBUSTION TEST EQUIPMENT The primary prerequisite of any test developed to evaluate the relative performance of stoker coals must reflect the three characteristics of the coal burning process: 1) ignitibility, 2) degree of caking, and 3) coke reactivity. The widespread variations in these combustion characteristics of the available stoker coals are well known. The ignitibility, which has been defined as that characteristic which determines the ease with which the fuel may be brought to a condition of self-supporting active oxidation, varies from where a coal is deemed to be flashy to the opposite extreme of being fireproof. The ignitibility of a coal influences its ability to pick-up from hold fire, greatly affects the degree of bed stability during swing loads, and is a factor in determining the average burning rate obtainable on a given grate. The caking characteristic affects the degree of bed porosity during the devolatilization period, and coals are classified on a scale varying from free burning to highly caking. Caking is not synonymous with bed swelling since a bed may swell two to three times its normal depth during the period of devolatilization yet remain very porous, allowing an efficient and high rate of combustion to take place. Caking is melting

Jan 1, 1964

By Marshall Pease, R. J. Brandon

A UTILITY that has a large consumption of coal must insure an adequate and sound supply of fuel. The Detroit Edison Co., which has an annual coal consumption of about four million tons and spends approximately $32 million a year for coal, including freight charges, has developed a program for fuel procurement and for evaluation and selection of fuel for reliable and efficient plant operation. Fuel Procurement Coal Purchasing Division: The Fuel Supply Div. of the Purchasing Dept. combines all of the procurement functions in one group, which must maintain adequate stocks of fuel. In addition to its usual purchasing duties, the division also governs transportation, follow-up, invoice and freight bill, in cooperation with the Accounting Dept. The Fuel Div. is comprised of the fuel agent, an assistant fuel agent, a coal buyer and five coal clerks, who follow the movement of each car, initially approve freight bills and invoices, and file claims whenever there is a shortage of one ton or more. The fuel agent reports directly to the purchasing agent of the Company, and all major programs are planned jointly with the chief purchasing officer. The apparent individuality of the fuel section is necessary because of the tremendous volume of coal cars handled each day, sometimes as many as 500, which must be handled promptly to complete the fastest possible move from the mines to the plants. Determining Annual Coal Volume: Through the combined studies of a Production Dept. Load Committee and the Controller's office, accurate predictions of coal requirements for any given year are provided the Fuel Dept. from 12 to 15 months in advance. This is divided into the requirements of all individual power plants and central heating plants. This in turn determines the quantity and quality for plants whose specific fuels vary with the type of equipment installed. In the Detroit area, which has a high industrial load, early estimates of annual coal consumption usually are resolved at the end of the year within 4 or 5 pct of the original plan. Operating in a highly developed industrial area eases the task of estimating primary output; and, with the residential demands increasing in a steady and fairly well-defined pattern, the overall coal schedules are not subject to radical changes during any given year. Selecting Suppliers: At any time, but especially during or before an emergency, the coal supply factor must be made secure. This is particularly true in the procurement of utility fuel. There are always extreme quantities of so-called "bargain" coal available during the buyers' markets, such as recently prevailed. These opportunistic offerings may be considered a means of averaging down overall price, rather than as a steady and dependable supply source. Coal is purchased on contract from mine operators and sales agents who have proved reliable. They are not opportunists who desert for higher dollars in times of duress; they do not fail to fulfill contracts when markets rise or overship when markets dip. The progressive operator today who is willing to expend capital to improve quality and service deserves much more consideration than a matching of short-term pennies. When a company has a high volume of annual needs, all phases of the mine supply must be considered. The mine must be able to produce the quality required at a fair price and be able to sell oversizes of coal in enough volume to screen sufficient nut and slack. It must crush coal and sell mine run at prices in line with competitive nut and slack and be willing to do so when there is no demand for prepared sizes. Determining Price: The public utility is in direct competition with any of its customers who can, if savings are guaranteed, generate their own power. Today, to a greater extent than ever before, private industry must do a better overall job than Government-controlled operations. The price of coal must be realistically balanced with the price paid by almost all industries and the railroads as well. The supply-demand ratio in coal is not difficult to discern. There is access at all times to Govern-

Jan 1, 1952

By Michael Perch, Charles C. Russell

The fact that coal is a complex organic material and heterogeneous in composition has made its study extremely difficult, particularly in regard to obtaining a fundamental concept of the processes involved in the formation of coke. It has been stated1 recently that coals are natural polymers and that in a complex reaction such as occurs during carbonization the differences between coals are quantitative and not qualitative. Such being the case, it would be expected, therefore, that a series of coals subjected to exactly the same conditions of coking would produce results that should be related quantitatively to the chemical analyses of the individual coals. In the past, however, this fact was not generally recognized and consequently many empirical test methods were devised for testing coals. The interpretation of the results obtained depended upon comparing a set of data with other data on coals of known characteristics. The testing procedure had to be conducted in precisely the same manner each time and not the least requirement in making the interpretation was experience. The test methods varied from those utilizing a gram of coal to the plant-scale tests in which one or more ovens were charged with the test coal. The aim had been principally to find some simple, inexpensive means by which the coke-making and other properties of coal could be predicted. It is not necessary to emphasize the importance of these endeavors, for anyone acquainted with the problems involved in the selection of coals for making coke is well aware of the time and expense involved in making a series of definitive tests. Several attempts have been made to derive formulas for such predictions. The relations of both ultimate and proximate analyses to coke physical properties and byproduct yields have been studied. Lowry and co-workers1 correlated statistically the U. S. Bureau of Mines-American Gas Association assay test results with coal analyses, using 90 coals and coal blends. Parry,² Spooner,3 and Gabinskii and Krym4 made similar correlations. Lowry concluded that there were definite relationships between the proximate analyses of the coals and the yields and properties of the products. Although this statistical study was made on test results from carbonizing coal in a cylindrical steel retort, the conclusions are important and provided one of the first steps in the simplification of this complex subject. Studies should be made of other references on this subject just cited. Studies of the coking process reported in the literature frequently were confined to a small number of coals, and very few have included coals from various ranks. It would seem logical, however, that a program for studying factors involved in the formation of coke should be based on a number of coals selected from each of the various classes or types of coking coal. The possible use of the scheme of classifi-

Jan 1, 1950

By R. J. Wagner, G. H. Gronhovd, A. J. Wittmier

The paper describes the results of a series of full-scale boiler tests run to determine the ash fouling characteristics of a North Dakota lignite as a function of sodium content of the coal. Four levels of sodium were investigated and rate of fouling was determined both by boiler performance and by specially constructed probe equipment. Discussed is information on chemical and physical properties of the ash deposits. The vast lignite deposits in North Dakota are becoming increasingly important as a source of low-cost fuel for power generation. A new 200-megawatt lignite-burning plant located near Stanton, N.D., was placed in operation early in 1966. Another 172-mega-watt unit in the same area is scheduled for operation late in 1966, and plans have recently been announced for a 212-megawatt unit to be in operation by 1970. If these plants show good performance, western North Dakota could become a major power production center for a large geographic area in the upper midwest. One of the problems associated with the use of lignite in power boilers is its tendency to form troublesome ash deposits on boiler tube surfaces. This problem varies considerably from one lignite-fired boiler to another and is dependent upon such factors as source of lignite, boiler design, load factor, tube metal temperatures, and soot-blowing practices. This report presents data on sodium content* variation in a North Dakota mine, describes the results of a series of tests performed to determine the relationship between ash fouling tendencies and the sodium content, and tells how the mining company and electric utility have coordinated their operations to reduce the ash fouling problem. GENERAL BACKGROUND Until recent years it was generally assumed that North Dakota lignite from a given mine had qualities peculiar to that mine, but that within the mine, the lignite was quite uniform. In 1959, the Otter Tail Power Co. installed a 53.5-megawatt lignite-burning unit at its Hoot Lake plant, Fergus Falls, Minn. Shortly after the unit was put into operation, it was noted that at certain times under high load conditions, ash fouling problems were quite severe, but not consistent or predictable. Each time fouling occurred in the unit the position of the loading shovel at the mine was noted. Within two years it became apparent that there were certain areas in the Knife River Coal Mining Co. mine at Beulah, N.D., where the lignite apparently had a high fouling tendency for the Hoot Lake unit. Results from analyses of the coal did not show large differences in moisture percentage, ash percentage, heating value, or ash fusion temperature between the highly troublesome and less troublesome coals. After three years of operation, the troublesome areas had been quite well defined and the mining company started a procedure of bypassing these areas when load conditions at the plant were high and then returning to the troublesome areas to load the lignite during the summer months when peak loads were lower. It was noted that the lignite from the areas which caused severe fouling under high load conditions produced much less fouling at the lower summer loads. However, bypassing certain areas in the strip pit caused the mining company to disrupt their continuous loading schedule, which in turn upset their continuous stripping schedule and made for less efficient mining operation. Meanwhile, at the Hoot Lake plant, the number of soot blowers on No. 2 boiler had been increased from 30 to 55, and a very rigorous blowing schedule had been adopted resulting in soot blowers operating at least some part of 21 hrs per day. Fouling problems continued, with a resulting reduction in plant economy and reliability. During this period the Federal Bureau of Mines Coal Research Laboratory at Grand Forks, N.D., had initiated various research programs relating to the study of lignite ash and ash fouling problems. One project was a survey in which full seam samples were obtained from various locations in all the major

Jan 1, 1968

By S. J. Aresco, A. A. Orning

This paper presents a scheme for determination of precision for the various steps in coal sampling, sample preparation, and analysis. It also gives resulting data on 100 American coals from various coal fields covering all ranks from lignite to low-volatile bituminous. The variances of the various steps of the process are studied as a function of the coal preparation, the top size of coal as sampled, and the ash content. To understand the variables that control the overall precision of coal sampling, sample reduction and analysis, there is need for measurement of the variances due to successive steps of the process. The purpose of the present paper is to study these variances as a function of the coal preparation, the top size of the coal as sampled, and the ash content. The sampling data included are from 100 individual preparation plants from various coal fields in the United States and cover all ranks of coal from lignite to low-volatile bituminous; various types of preparation; deep, strip and auger mines; and, in many instances, mixtures from two or more coal beds or types of mines. The collection of data is continuing, but sufficient work has been done to draw some important conclusions. Since the work was done in conjunction with the Bureau of Mines sampling of coal, the time that could be spent at any one preparation plant was limited. This, in turn, limited the number of samples that could be taken for each coal. For this reason, the results from various plants were pooled in blocks. Two major blocking categories were "raw" and "washed!' The raw coals had no preparation other than crushing and/or screening. The washed coals were prepared further by some combination of wet or dry mechanical cleaning. The categories were further divided ac-

Jan 1, 1965

By G. A. Vissac

MoIstuRe in coal must be considered as an impurity, just the same as ash, from the standpoint of utilization of the coal. Being incombustible, it reduces directly the heating value of the coal, and in addition absorbs heat for its evaporation. Its presence means useless expenditures in handling and transportation. In coke plants, extra moisture reduces capacity and may cause damage to brick work and equipment. Accordingly, the removal of extra moisture can be considered just as important as the removal of other impurities, such as ashes, in the modern coal preparation plant. Moisture, which can be removed by heating the coal up to a temperature of 100°C, may be retained in various forms: 1. As a film, on the surface of each coal particle, and in the interstices between particles, retained by capillary forces. 2. Or "occluded" inside the coal particles. This occluded moisture may be either free moisture (as in a sponge), or hygroscopic moisture which varies with atmospheric conditions, (also called "regain"). These latter forms of moisture are particularly common in "young" coals (subbituminous and lignites); bloom coals (seam outcrops); fusain; and carbonized products. In our study of coal drying, we shall consider only the removal of free moisture, exclusive from hygroscopic moisture. Dewatering If we reserve the name of drying to the removal of water by evaporation, we must consider the initial phase of the mechanical removal of free moisture as a distinct operation covered by the term dewatering. In all cases the free water carried over the surface of the coal particles or in their interstices, or in their pores, is retained by capillary forces. Dewater-ing is accomplished by breaking or counteracting these capillary forces; removal of as much water as possible by dewatering methods is usually advisable, as the cost of these operations is generally much less than by evaporation. The most common methods of me-chanical dewatering are: 1. "Pressure piling," which reduces the interstitial spaces, accomplished in dewatering bins or over dewatering screens. 2. Or dynamic methods, such as used in centrifuges or over vibrating screens. We shall only mention the " preferential wetting" method, in which surface water can be displaced by hydrocarbons, as offering possibilities, but which, to our knowledge, has not reached yet a practical development. But we must point out that the capillary forces retaining water on the coal surfaces, decrease considerably with increased temperatures. This is the principle used in all modern dishwashing machines; by using very hot water, dishes are extracted almost dry. In line with this development, we favor the type of dryers including a dewatering section; as the coal enters the dryer and is gradually brought up to higher temperatures, its dewatering ability is increased and advantage can be taken of this conditioning, resulting in increased drying efficiencies and reductions in drying costs. Heat Drying In the final phase, the remaining moisture must be evaporated. Coal and water must be brought up to the chosen temperature of evaporation, and heat must be supplied to fill the requirements of the latent heat of evaporation of the water to be removed. Accordingly, drying becomes largely a problem of heat transfer, and drying methods can be classified accordingly, namely: 1. Radiant transfer. 2. Transfer by surface contact and conduction. 3. Transfer by hot gas contact. The first method is not applicable to coal drying; the second method is used in the old type rotary dryer. The third method, the most commonly used in modern coal dryers, will be the only one considered here; and, of course, we shall deal with continuous types of dryers only. The mechanism of complete drying is really very complex-—several phases are involved: 1. The constant rate period. 2. The uniform falling rate period. 3. The varying falling rate period. As most of our practical coal drying problems deal with wet coals (over 6 pct of moisture), and do not require complete drying (under 1.5 pct), we shall deal with the first condition only, namely the constant rate drying. Dryer Calculations Instead of presenting the algebraic formulas, we believe a concrete example will provide a clearer illustration. Assume a feed of wet coal at the rate

Jan 1, 1950

By G. A. Vissac

O. R. LYONS *—I wish to thank Mr. Vissac for his compliment. I hope that his paper is not only well received, but that it will serve to bring forth more papers on the subject of thermal drying. One of the primary purposes of the work performed by Battelle for Bituminous Coal Research in investigating the thermal drying of coal was to stimulate other investigators and to get them to contribute their knowledge in the form of papers such as this one. We at Battelle and the personnel of Bituminous Coal Research are very gratified that Mr. Vissac and other persons have responded in this matter of the thermal drying of coal. I wish to state that I think that Mr. Vissac's paper is a very clear and easily understood description of a method of calculating the design requirements for a screen type drier, and I think that it would be exceedingly valuable to operators and to those who intend to purchase any type of thermal drier and use it in the future, if the manufacturers or operators who have such information for other types of driers would provide the same type of information for the other makes of driers now on the market. 1 also wish to point out—an idea that is new to me, and I know is new to most of the operators of driers in the United States-—the idea of recovering the heat that is normally lost in the coal and in the exhaust gases. This heat is not being recovered at most (of the thermal drying operations in the United States, and the possibility of recovering it should be called to the attention of every single one of those operators. I know many of them have never given any thought to the matter, but they will be interested once they realize the ease with which it could be done and the savings that could be realized. I also wish to compliment Mr. Vissac for presenting the method of analysis that he uses to determine the difficulty of drying any particular coal. It is a very simple method, and yet it seems to me that it should be a very effective, very efficient method for determining the difficulty of drying for his particular problems. C. Y. HEINER*—I do not know that I can add anything very illuminating to what Mr. Vissac has said. I think anything that Mr. Vissac said in regard to coal drying is a contribution because, to my personal knowledge, he has studied the matter carefully for many years and made many valuable contributions. I am not too familiar with coal drying problems in the east, but I know in the west we have not made enough coal drying studies. I think coal operators too often just take the coal as it is and make more or less the best of it. There are relatively few washing plants in the west now, and so the problem has not come to the front as much as it probably will in the future. In this connection, it seems to me that this matter of drying the raw coal, as Mr. Vissac brings up, is an extremely important one. We have not a continuous miner ourselves, yet, but we expect to get some this year, and we think the percentage of fine coal-—that is, minus 3/16 in.—will double. We have about 20 pct minus 3/16 in. in the 8 in. by 0 size now, and we think we will likely have 40 pct, which will have a surface moisture of the order of 8 pct. To wash it satisfactorily, we will have to dry the raw coal first in order to screen it, and after that, I suppose, there will have to be dry cleaning of some sort. We have not really used dry cleaning on fines in the west yet to my knowledge, but it is a matter that has to be faced by the industry, and I am very hopeful that Mr. Vissac's study will assist us in that connection. W. L. McMORRIS*-In my company we are preparing largely metallurgical coal for a great number of byproduct coke plants. The most outstanding thing to me about the requirements of moisture in the finished product is that there is a different requirement for almost every coke plant. Each operator has a different set of factors on which he establishes his coking costs where they involve moisture. For our corporation operations in Birmingham, my company does not produce the coal, but in Birmingham they are getting away with moistures very much higher than our plant at Clairton, Pa., would tolerate. The moisture that we have to produce for the plants along the lakefront where they are subject to much more severe weather is something else again. We have not tackled heat drying, primarily because our customers do not know what heat drying will do to the coking characteristics of the coal. If the temperature of drying can be held down

Jan 1, 1950