Abstract: The invention provides a method by which high moisture low rank coal or other carbonaceous material may be transformed into a high-energy, water resistant product. The raw feed is comminuted then mechanically compacted by a roller press with rolls of a specified profile to mobilize the inherent moisture and collapse most of the interstitial pore space. The mobilized moisture is then removed by low-temperature drying and the material is sized and shaped to form a product that is resistant to re-absorption of water or other liquids. The present invention will promote the use of low rank coal for liquefaction and gasification.

Abstract: Modified solid fuel manufacturing method and modified solid fuels manufactured using the manufacturing method. When solid fuels are manufactured by crushing low grade coal, mixing the crushed low grade coal with solvent oil to prepare a slurry, heating the slurry to at least the boiling point of water to evaporate moisture included in the slurry, separating the solvent oil from the slurry to produce charcoal dust and compression compacting said charcoal dust, by heating the slurry to at least the boiling point of water, the non-volatile components included in the low grade coal are extracted with the solvent oil, the outer surface of the low grade coal and the internal surfaces of the pores are coated with the extracted non-volatile components, and the content of heavy oil added from the outside will be less than 0.5 mass %, relative to the solid fuel after drying.

Abstract: A process for upgrading brown coal having a first water content including subjecting the brown coal to a conditioning step which includes heating the brown coal to a first temperature to produce a conditioned brown coal having a second water content which is lower than the first water content; attritioning the conditioned brown coal to enable water to be released from the microstructure of the brown coal and thereby producing an admixture of the brown coal and released water; forming aggregates of the admixture; drying the aggregates to produce upgraded brown coal having a third water content which is lower than the second water content.

Abstract: Modified solid fuel manufacturing method and modified solid fuels manufactured using the manufacturing method. When solid fuels are manufactured by crushing low grade coal, mixing the crushed low grade coal with solvent oil to prepare a slurry, heating the slurry to at least the boiling point of water to evaporate moisture included in the slurry, separating the solvent oil from the slurry to produce charcoal dust and compression compacting said charcoal dust, by heating the slurry to at least the boiling point of water, the non-volatile components included in the low grade coal are extracted with the solvent oil, the outer surface of the low grade coal and the internal surfaces of the pores are coated with the extracted non-volatile components, and the content of heavy oil added from the outside will be less than 0.5 mass % relative to the solid fuel after drying.

Abstract: Described is a method for producing a fuel containing carbon, wherein the fuel is formed by compressing raw material containing a carbon and adding an additive that promotes thermal utilization of the fuel at a specified amount. The additive contains a chemical compound made of the elements calcium and/or magnesium and having or not having carbon. In a first method step, the raw material containing carbon is pressed and in this way a pressed article is produced. Then the additive is fed to at least one area of said pressed fuel article.

Abstract: A method of treating untreated low calorific coal containing moisture and organic volatiles includes feeding untreated coal to a dryer, and drying the coal. The dried coal is subjected to a pyrolyzing step where oxygen-deficient gases are brought into contact with the coal, thereby lowering the volatile content of the coal and producing a stream of pyrolysis effluent gases. The pyrolysis effluent gases are subjected to a separation process to separate lean fuel gases from liquids and tars, wherein the separation process removes less than about 20 percent of the pyrolysis effluent gases as the liquids and tars, with the remainder being the lean fuel gases. The lean fuel gases are returned to the dryer combustor, the pyrolyzer combustor, or the pyrolyzer.

Abstract: The inventive technology includes methods and apparatus for the generation and application of segregated catalytic additives for the pre-combustion treatment of carbonaceous fuel and/or feedstocks. The application of such segregated additives results in the reduction of environmentally harmful emissions during combustion as well as gasification processes. Specifically, pre-combustion treatment of carbonaceous materials with the inventive additives results in the reduction of NOx and/or mercury emissions by least 20% and 40% respectively.

Abstract: The invention provides a method by which high moisture low rank coal or other carbonaceous material may be transformed into a high-energy, water resistant product. The raw feed is comminuted then mechanically compacted by a roller press with rolls of a specified profile to mobilize the inherent moisture and collapse most of the interstitial pore space. The mobilized moisture is then removed by low-temperature drying and the material is sized and shaped to form a product that is resistant to re-absorption of water or other liquids. The present invention will promote the use of low rank coal for liquefaction and gasification.

Abstract: A coal reforming system includes a drying furnace for drying low-grade coal, a carbonizing furnace for carbonizing the dried low-grade coal, hot air generating furnaces for supplying hot air to the drying furnace or the carbonizing furnace, and a carbonizing gas circulation line for supplying a carbonizing gas, which is generated in the carbonizing furnace, as a fuel for the hot air generating furnaces while the temperature thereof is maintained.

Abstract: A process for upgrading brown coal having a first water content including subjecting the brown coal to a conditioning step which includes heating the brown coal to a first temperature to produce a conditioned brown coal having a second water content which is lower than the first water content; attritioning the conditioned brown coal to enable water to be released from the microstructure of the brown coal and thereby producing an admixture of the brown coal and released water; forming aggregates of the admixture; drying the aggregates to produce upgraded brown coal having a third water content which is lower than the second water content.

Abstract: The present invention relates generally to processes for preparing agglomerated particulate low-rank coal feedstocks of a particle size suitable for reaction in a fluidized-bed reactor and certain other gasification reactors and, in particular, for coal gasification and combustion applications. The present invention also relates to integrated coal gasification and combustion processes including preparing and utilizing such agglomerated particulate low-rank coal feedstocks.

Abstract: The present invention relates generally to processes for preparing agglomerated particulate low-rank coal feedstocks of a particle size suitable for reaction in certain gasification reactors and, in particular, for coal gasification. The present invention also relates to integrated coal gasification processes including preparing and utilizing such agglomerated particulate low-rank coal feedstocks.

Abstract: The present invention relates generally to processes for preparing agglomerated particulate low-rank coal feedstocks of a particle size suitable for reaction in a fluidized-bed reactor and certain other gasification reactors and, in particular, for coal gasification and combustion applications. The present invention also relates to an integrated coal hydromethanation process including preparing and utilizing such agglomerated particulate low-rank coal feedstocks.

Abstract: The present invention provides methods of transforming low rank coals into high quality metallurgical coke, and the coke products produced by such methods.

Abstract: The invention provides methods of reducing the energy required to remove moisture from biomass, carbonaceous materials and mixtures of the same. The method significantly reduces the energy requirements by removing moisture as a liquid and by transferring the moisture to the surface of the material where it is more easily and efficiently evaporated.

Abstract: In embodiments of the present invention improved capabilities are described for a system and method for briquetting solid fuel before or after treatment with electromagnetic energy. In the system and method, solid fuel is transported through a continuous feed solid fuel treatment facility, treated using electromagnetic energy, and briquetted after treatment.

Abstract: The invention relates to the use of engineered fuel feedstocks to control the emission of sulfur-based, chlorine-based, nitrogen-based, or mercury-based pollutants, such as SO2, SO3, H2SO4, NO, NO2, HCl, and Hg that are generated during the combustion of fossil fuels, such as coal. Disclosed are novel engineered fuel feedstocks, feedstocks produced by the described processes, methods of making the fuel feedstocks, methods of producing energy from the fuel feedstocks, and methods of generating electricity from the fuel feedstocks.

Abstract: Provided is a manufacturing method for a briquetted solid fuel that can reduce the briquetting cost while maintaining the strength of the briquetted product. A mixed oil that includes a heavy oil and a solvent oil, and a porous coal are mixed to obtain a slurry. The slurry is dewatered by heating to obtain a dewatered slurry. Solvent oil is separated from the dewatered slurry to obtain a cake, the cake is heated, and solvent oil is further separated from the cake to obtain a modified coal. Moisture is added to the modified coal to obtain a moist modified coal with a moisture content of 3 wt % to 10 wt %, and then the moist modified coal is briquetted under pressure.

Abstract: The present invention provides a process for burning coal instead of oil comprising the stages of coal gasification, gas combustion and optionally gas purification, utilization of residual heat of flue gas and flue gas discharge. The present invention further provides an apparatus for burning coal instead of oil. By present invention, the fuel cost for an oil-burning apparatus can be reduced by about four-fifths, so the resources of oil and natural gas can be saved either. Furthermore, the present invention has the advantages such as good reliability, high heat efficiency, high level of automation, high return on investment and good environmental benefits.

Abstract: Provided are a modified solid fuel manufacturing method that reduces manufacturing costs and environmental impact while also realizing higher strength such as for transport, and modified solid fuels manufactured using the manufacturing method. When solid fuels are manufactured by crushing low grade coal, mixing the crushed low grade coal with solvent oil to prepare a slurry, heating the slurry to at least the boiling point of water to evaporate moisture included in the slurry, separating the solvent oil from the slurry to produce charcoal dust and compression compacting said charcoal dust, by heating the slurry to at least the boiling point of water, the non-volatile components included in the low grade coal are extracted with the solvent oil, the outer surface of the low grade coal and the internal surfaces of the pores are coated with the extracted non-volatile components, and the content of heavy oil added from the outside will be less than 0.

Abstract: The invention provides low-cost, non-thermal methods to transform and beneficiate bulk materials, including low rank coals such as peat, lignite, brown coal, subbituminous coal, other carbonaceous solids or derived feedstock. High pressure compaction and comminution processes are linked to transform the solid materials by eliminating interstitial, capillary, pores, or other voids that are present in the materials and that may contain liquid, air or gases that are detrimental to the quality and performance of the bulk materials, thereby beneficiating the bulk products to provide premium feedstock for industrial or commercial uses, such as electric power generation, gasification, liquefaction, and carbon activation. The handling characteristics, dust mitigation aspects and combustion emissions of the products may also be improved.

Abstract: An improved process for the production of smokeless (low CO2—CO emitting) boiler fuels which have been obtained by careful temperature control and the addition of waste, trash or other carbonaceous material during carbonization of various coal materials such as tar sands, bituminous coal, peat lignite, and oil shale.

Abstract: A process for upgrading brown coal is disclosed, including providing at least two converging surfaces defining a nip, wherein at least one of the surfaces is rollable in a direction toward the nip; feeding the brown coal to the nip where, by the rolling action of the rollable surface, the brown coal is subjected to shearing stresses, causing attritioning of the microporous structure of the brown coal and the release of water contained in the micropores; and continuing the shearing attritioning until the brown coal forms into a plastic mass. Processes for the production of char are also disclosed utilizing as feed material pellets formed from the upgraded brown coal produced by the above process, as well as a process for recovering metal from a metal containing material.

Abstract: Methods of controlling the bulk density, permeability, moisture retention and thermal properties of bulk materials are provided by selectively sizing the bulk material. Preferably, the bulk material is sized into successively smaller particle size fractions, with the largest fraction placed into a confined area. The next smaller size fraction is then added until the largest sized fraction begins to dilate. The next successive smaller size fraction is added until the mixture beams to dilate, with the process being continued until the smallest size fraction is used. Methods of decreasing the density of bulk materials are also provided.

Abstract: A process for upgrading brown coal is disclosed, including providing at least two converging surfaces defining a nip, wherein at least one of the surfaces is rollable in a direction toward the nip; feeding the brown coal to the nip where, by the rolling action of the rollable surface, the brown coal is subjected to shearing stresses, causing attritioning of the microporous structure of the brown coal and the release of water contained in the micropores; and continuing the shearing attritioning until the brown coal forms into a plastic mass. Processes for the production of char are also disclosed utilizing as feed material pellets formed from the upgraded brown coal produced by the above process, as well as a process for recovering metal from a metal containing material.

Abstract: Process for treating coal to enhance its rank, wherein the temperature of the material is gradually increased in a controlled set of atmospheres, to allow for the reduction of surface and inherent moisture and the controlled reduction of volatile matter while maintaining the coal's natural structural integrity. The process reduces the time, capitalization, and production costs required to produce coal of enhanced rank, thus substantially increasing the cost effectiveness and production rate over prior processes.

Abstract: Process for treating coal to enhance its rank, wherein the temperature of the material is gradually increased in a controlled set of atmospheres, to allow for the reduction of surface and inherent moisture and the controlled reduction of volatile matter while maintaining the coal's natural structural integrity. The process reduces the time, capitalization, and production costs required to produce coal of enhanced rank, thus substantially increasing the cost effectiveness and production rate over prior processes.

Abstract: As one of the coal reforming treatment steps constituting a coal reforming process, an oxidation treatment step is carried out on a circular grate. For this purpose, there is used a coal reforming apparatus comprising a circular grate, the circular grate being separated into a plurality of zones which include fixed bed zones and mixing zones for fluidizing the coal properly between adjacent fixed bed zones.

Abstract: A method and composition are disclosed to reduce the oxidative deterioration of bulk materials. Preferred embodiments of bulk materials include solid fuel materials, such as coal, and bulk food products. The method includes sizing a bulk material so that it has a porosity of 40% or less. This relatively low porosity reduces the surface area of the bulk material available to the ambient environment for oxidation. The method of sizing the bulk material may be combined with the step of contacting the bulk material with an inert gas or a heat transfer medium.

Abstract: Disclosed is a method to reduce oxidative deterioration of bulk materials. Preferred embodiments of bulk materials include solid fuel materials, such as coal, and bulk food products. The method includes contacting a bulk material with a heat transfer medium to reduce the temperature of the bulk material below ambient temperature, and preferably below about 10.degree. C. In this manner, the rate of oxidation is sufficiently low so that significant losses, such as the loss of thermal values in of fuel material, are avoided. The heat transfer medium can be solid or fluid and in a preferred embodiment is liquid carbon dioxide or liquid nitrogen.

Abstract: A combustible carbonaceous composition and method of making a charcoal briquette wherein a finely divided carbonaceous material is combined with an activated carbon and/or an activated graphite (which may be formed in-situ during pyrolysis of the composition by reacting a humic-containing ore with a low VOC-containing carbon and/or graphite). The combustible carbonaceous composition is present in the briquette composition in an amount of about 65% to about 99.9% by weight; a binder is included in the composition in an amount of about 1% to about 15% by weight when forming a charcoal briquette or an igniter log; and the activated carbon and/or activated graphite is present in an amount of about 0.1% to about 20% by weight. The activated carbon and/or activated graphite absorbs most of the VOCs entitled from the combustible carbonaceous material, thereby preventing the VOCs from escaping to the atmosphere.

Abstract: A compressed briquette or other solid shape, object, or article useful as a coke substitute in blast furnaces disclosed as being manufactured so as to comprise a reaction product of fine carbonaceous material (such as coke breeze, coke fines, or petroleum coke), a reactive tar, and polymeric binder.

Abstract: Disclosed is a method to reduce oxidative deterioration of bulk materials. Preferred embodiments of bulk materials include solid fuel materials, such as coal, and bulk food products. The method includes contacting a bulk material with a heat transfer medium to reduce the temperature of the bulk material below ambient temperature, and preferably below about 10.degree. C. In this manner, the rate of oxidation is sufficiently low so that significant losses, such as the loss of thermal values in of fuel material, are avoided. The heat transfer medium can be solid or fluid and in a preferred embodiment is liquid carbon dioxide or liquid nitrogen.

Abstract: A method and a solid fuel product, such as briquettes and pellets, comprising carbon fines, in the form of heretofore discardable coke breeze and/or coal fines and/or revert materials, bound together chemically into smaller pieces to substantially prevent degradation and which constitutes a source of high heat without creating significant pollution or smoke.

Abstract: The invention disclosed relates to a method for drying low-quality solid carbonaceous fuels such as lignite and sub-bituminous coal to reduce the moisture content substantially to zero, and to minimize re-adsorption of moisture during storage and transporation. The method involves drying the solid fuel in a mildly reducing atmosphere at a temperature in the range of 150.degree.to 300.degree. C., preferably 200.degree.to 210.degree. C. The mildly reducing atmosphere may be provided by a gaseous lower-alkane e.g. propane and methane. In some cases, the coal may beneficiated by agglomeration with small amounts of oil.

Abstract: A process for upgrading a low rank coal and a heavy oil to produce an improved coal product and an improved oil product. First, the low rank coal is dewatered to reduce its moisture content to less than about 4 percent in order to render the low rank coal more oleophilic. Next, the dewatered low rank coal is mixed with a quantity of the heavy oil of between about 15 and 40 percent of the dry weight of the low rank coal so that the heavy oil substantially contacts the low rank coal in order to produce a mixture. The mixture is then heated to a temperature less than the mild thermal cracking limit of the mixture in order to separate hydrocarbons from the mixture and to produce the improved coal product. The hydrocarbons separated from the mixture during the heating step are then collected in order to produce the improved oil product.

Abstract: A method and a solid fuel product, such as briquettes and pellets, comprising carbon fines, in the form of heretofore discardable coke breeze and/or coal fines and/or revert materials, bound together chemically into smaller pieces to substantially prevent degradation and which constitutes a source of high heat without creating significant pollution or smoke.

Abstract: A method and a solid fuel product, such as briquettes and pellets, comprising carbon fines, in the form of heretofore discardable coke breeze and/or coal fines and/or revert materials, bound together chemically into smaller pieces to substantially prevent degradation and which constitutes a source of high heat without creating significant pollution or smoke.

Abstract: A solid fuel containing a recycled residue from anaerobic fermentation or anaerobic digestion of an organic material. The solid fuel can also contain a volatile solid fossil fuel. The residue is preferably derived from an anaerobic digestion process of municipal solid waste, raw sewage sludge, biomass feedstock, industrial waste, agricultural waste or mixtures thereof. The volatile solid fossil fuel preferably contains a coal constituent of lignite, anthracite coal, meta-anthracite coal, bituminous coal and/or sub-bituminous coal. Regardless of whether the solid fuel contains only recycled residue or recycled residue bound with a volatile solid fossil fuel, the solid fuel can be formed into pellets or energy cubes.

Abstract: The invention relates to a method and apparatus of forming pellets and in particular spherical binderless pellets from lower rank coals. The method includes the steps of feeding a pelletizing means 10, with a lower rank feedstock, 1; rotating the coal in said pelletizing means, 10, to form pellets in the absence of any binder, wherein the pellets are formed by compaction and layering of coal fines. The moisture content of the lower rank coal is at a level so as to at least substantially fill the voids within the coal.

Abstract: The present invention provides a process for producing a coal-water mixture using a reaction mixture obtained by subjecting a low-rank coal of high water content to a hydrothermal treatment in the presence of carbon monoxide and water at a temperature not higher than the critical temperature of water. The above hydrothermal treatment makes the walls of pores present in the coal hydrophobic and densifies the coal matrix, whereby the coal after the treatment has a lower equilibrium moisture content. Hence, it becomes possible to produce a coal-water mixture containing a high concentration of coal and having good stability and fluidity, from a low-rank coal of high water content which has been unusable as a material for a coal-water mixture. Further, in the production of a coal-water mixture from the above reaction mixture, the amount of surfactant used can be reduced because the liquid phase of the reaction mixture contains a large amount of humic acid having surface activity.

Abstract: A method is disclosed for bonding particles into briquettes wherein the particles to be briquetted are mixed with a phenolaldehyde resin and polyisocyanate in the presence of a catalyst, and the resulting mixture is briquetted. A phenolic-urethane polymer is formed to bond the particles and coat the briquette formed of said particles. Apparatus for carrying out the method is also disclosed.

Abstract: A selectively-sized, raw, low-rank coal is processed to produce a low ash and relative water-free agglomerate with an enhanced heating value and a hardness sufficient to produce a non-decrepitating, shippable fuel. The low-rank coal is treated, under high shear conditions, in the first stage to cause ash reduction and subsequent surface modification which is necessary to facilitate agglomerate formation. In the second stage the treated low-rank coal is contacted with bridging and binding oils under low shear conditions to produce agglomerates of selected size. The bridging and binding oils may be coal or petroleum derived. The process incorporates a thermal deoiling step whereby the bridging oil may be completely or partially recovered from the agglomerate; whereas, partial recovery of the bridging oil functions to leave as an agglomerate binder, the heavy constituents of the bridging oil. The recovered oil is suitable for recycling to the agglomeration step or can serve as a value-added product.

Abstract: A low-rank coal oil agglomeration process. High mineral content, a high ash content subbituminous coals are effectively agglomerated with a bridging oil which is partially water soluble and capable of entering the pore structure, and usually coal derived.

Abstract: Self-ignition of low rank coal is inhibited by application of a permanganate salt, such as potassium permanganate, together with a phosphorus compound, such as a phosphoric or polyphosphoric acid. The inhibitors are applied in aqueous solution following drying of the particulate coal. The combination treatment is much more effective than the use of a permanganate salt alone.

Abstract: Densified coal pellets of improved physical properties and enhanced calorific value are produced by a process which includes subjecting coal to a shearing-attritioning step followed by extrusion and drying steps, characterised by incorporating an additive into the coal that is subject to the said shearing-attritioning step, said additive being chosen from one or more of the group consisting of: alkali metal hydroxides, alkaline earth metal hydroxides, ammonium hydroxide, alkali metal carbonates, alkaline earth carbonates, oxides of base metals, oxides of transition metals, and small molecule carbonyl compounds.