Appendix 2 - 1969 MIRL - Bering River.pdf

M.I.R.L.

REPORT PJO. 21

WASHABILITY CHARACTERISTICS OF

LOW-VOLATILE BITUMINOUS COAL FROM

BERING RIVER FIELD, ALASKA

by

P. DHARMA RAO

Mineral Industry Research Laboratory University of A lmka

College, A lmko 99701

FEBRUARY 1969

M.I.R.L.

Report N o . 21

WASHABILITY Ct.1ARACTERISTICS OF

LOW-VOLATI LE BITUMINOUS COAL FROM

BERING RIVER FIELD, ALASKA

by

P. Dharrna Rao

Mineral industry Research Laboratory University of Alaska

College, Alaska 99701

February 1969

ACKNOWLEDGMENTS

The author wishes to express his gratitude to Cortella Coal

Corporation for supplying the coal samples used i n this study.

Thanks are due to Dr. Donald J. Cook, Head, Department of Mineral Engineering and Earl H. Beisfline, Dean, Coilege of

Earth Sciences and Mineral Industry for their guidance and direction.

ABSTRACT

Two samples of low-volatile bituminous coal from Bering River

Coal Field were s i ted to 0.525" x 3, 3 x 6 , 6 x 10, 10 x 20, and

20 x 35 mesh and their washability characteristics studied at specific gravities ranging from 1.29 to 1.55. The results showed that the coals can be up-graded to an ash content as low as 2% wi th conventional cyclone heavy media process. A product containing less than 1% ash can be obtained from these coals with surprisingly high yields, ranging from 50 to 95% depending on the ash content desired i n the washed coal, and the characteristics of the row coal.

The experimental work proves the technical feasibility of pre-paration of the coal for metallurgical use and as low ash carbon raw mater ial , Further Pilot Plant testing would be required i n the fields of preparation and ut i l izat ion in order to design the f inal for os-certaining the economic feasibility.

TABLE OF CONTENTS

Page - ACKNOWLEDGMENTS . . . . . . . . . . . . . i

... ABSTRACT. . . . . . . . . . . . . . 1 1 1

TABLE OF CONTENTS . . . . . . . . . . , , . . iv

LlST OF TABLES . . . , . . . . , . . . . . . . v

LlST OF FIGURES . . . . . . . . . . . . . . . v i i

SAMPLING AND SAMPLE PREPARATION

Sample Location . . . . , . . . , , . . . 2 Sample Preparation. . . . . . . . , DISCUSSION OF RESULTS

Washability Charucteristics . , , . . . , 4 Coking Choracteristics , , , , , , , 6

MARKET POTENTIAL . . . . ,

As Raw Material for Metal lurgical Coke As Low Ash Coal . . . . . , CarbonElectrodeRawMa:erial . . . , . . . 8 Foreign Market . . . . . . . . , . . . 8 Miscellaneous Potential Markets . . , . , . . 9

CONCLUSIONS A N D RECOMMENDATIONS . . . . , . 10

Conclusions . . . . . . . , Recommendations

REFERENCES

LIST OF TABLES

Table Page - Size Analysis and Ash Distribution for Leeper Creek

No. 1 Raw Coal, Bering River Field . . , . . 14

Size Analysis and Ash Distribution for Leeper Creek No. 2 Raw Coal, Bering River Field . . . , . 15

Sink-Float Kesults of 0.525" x 3 Mesh Size Coal, Leeper Creek No. 1, Bering River F ie ld

Sink-Float Results of 3 x 6 Mesh Size Coal, Leeper Creek No. 1, Bering River Field

Sink-Float Results of 6 x 10 Mesh S i re Coal, Leeper Creek No. 1, Bering River Field. . , Sink-Float Results of 10 x 20 Mesh Size Coal, Leeper Creek No. 1, Bering River Field

Sink-Float Kesults of 20 x 35 Mesh Size Coal, Leeper Creek No. 1, Bering River Field

Sink-Float Results of 0.525" x 35 Mesh Size Coal, Leeper Creek No. 1, Bering River Field

Sink-Float Results of 0.525" x 3 Mesh Size Coal, Leeper Creek No. 2, Bering River Field . . . , 28

Sink-Float Results of 3 x 6 Mesh Size Coal, Leeper Creek No. 2, Bering River Field. . . . . . , 30

Sink-Float Results of 6 x 10 Mesh Size Coal, Leeper Creek No. 2, Bering River Field. . . . . , . 32

Sink-Float Results of 10 x 20 Mesh Size Coal, Leeper Creek No. 2, Bering River Field

Sink-Flwt Results of 20 x 35 Mesh Size Coai, Lceper Creek No. 2, Bering River Field. . . , . . . 36

LIST OF TABLES (Cont.)

Table - Page - 14 Sink-Float Results of 0.525" x 35 Mesh Size Coal, Leeper Creek No. 2, Bering River Field

15 Proximate Analysis of Raw Coal and 1.29 S p . G .

Float Samples. . . . . . . . . , , . 40

LIST OF FIGURES

Figure - Page - 1 Washability Characteristics of 0.525" x 3 Mesh Size

Coal, Leeper Creek No. 1, Bering River Field . . 17

2 Washability Characteristics of 3 x 6 Mesh Size Coal, Leeper Creek No. 1, Bering River Field

3 Washability Characteristics of 6 x 10 Mesh Size Coal, Leeper Creek No. 1 , Bering River Field

4 Washability Characteristics of 10 x 20 Mesh Size Coal, Leeper Creek No. 1, Bering River Field . . 23

5 Washability Characteristics of 20 x 35 Mesh Size Coal, Leeper Creek No. 1, Bering River F ie ld . . 25

6 Washability Characteristics of 0.525" x 35 Mesh Size Coal, Leeper Creek No. 1, Bering Rivela Field . . 27

7 Washability Characteristics of 0.525" x 3 Mesl-i Size Coal, Leeper Creek No. 2, Bering River Field . . 29

8 Washability Characteristics of 3 x 6 Mesh Size Coal, Leeper Creek No. 2, Bering River Field . . , , 31

9 Washability Characteristics of 6 x 10 Mesh Size Coal, Leeper Creek No . 2, Bering River Field

10 Washability Characteristics of 10 x 20 Mesh Size Coal, Leeper Creek No. 2, Bering River Field . . 35

1 1 Washability Characteristics of 20 x 35 Mesh Size Coal, Leeper Creek No. 2, Bering River Field . . 37

12 Washability Characteristics of 0.525" x 35 Mesh Size Coal, Leeper Creek No. 2, Bering River Field . . 39 vi i l NTRODUCTION

Ccwl bearing formations in Bering River Coal Field are known to extend in an almost continuous belt in excess of a SO square mile area.") The coal varies i n rank from low-volatile bituminous to semi-anthracite and anthracite. Although the field has been pros-pected on surface and under-ground, no commerical exploifation has been done. Accurate estimotes of the reserves are not available due to complex structure of the region and lock of thorough subsurface exploration.

Cortella Coal Corporation of Cordova has recently launched a dril l ing prqram with a view of assessing the quality and extent reserves for foreign markets. Two of the samples obtained during their exploration program were sent to the Mineral Industry Research Labo-ratory for washability studies. The samples investigated represent a very limited portion of the Bering River Coal Field and the results, therefore, do not reflect the characteristics of the entire deposit.

SAMPLING AND SAMPLE PREPARATION

Sample Location

The sample designated as Leeper Creek No. 1 was a dr i l l sample at 800 foot level from Section 21, T175, R7E, NE 1/4 of

Cordova (B-1 ) Quadrangle. The sample designated as Leeper Creek

No. 2 was collected in a seemingly unweathered portion of a stripped seam at a depth of 14 feet from Section 15, T17S, R17E, SW 1/4, adjacent to the common corners of Sections 21, 22, 15, and 16 of

Cordova (B-1) Quadrangle.

Sample Preparation

The samples received were mostly minus 1" wifh a small por-tion coarser than 1/21'. The samples were screened o n 0.525" screen and the oversize was crushed to pass the screen. Twenty of soch of the samples were screened on 3, 6, 10, 20, 35, and 200mesh

Tyler screens. The size distribution and analysis of the sized fractions i s presented i n Tables 1 and 2. For the size fractions used in wash-.

abi l i ty studies, the reported ash value i s calculated by reassembling al l the gmvimetric fractions. The ash content of 35 x 200 and -200 mesh fractions were, however, obtained by direct analysis.

WASHABILITY STUD1 ES

The sized 0.525" x 3, 3 x 6, 6 x 10, 10 x 20, and 20 x 35 mesh fractions were used i n washability studies. Separations were made at 1.290, 1.300, 1 ,325, 1.375, 1.400, 1.450, 1.500 and

1.550 specific gravities, using mixtures of carbon tetrachloride and benzene as heavy liquid. Since the quantity of sinks obtained at

1.55 Sp.G. was small, no separations were made a t higher specific gravities, The washability data of the varioussized fractions are presented in Tables 3 to 8 for Leeper Creek No. 1, and Tables 9 to

14 for Leeper Creek No. 2. Figures 1 to 14 show washability curves for Leeper Creek No. 1 and No, 2.

Raw coal samples and 1.29 Sp. G. floats of composite 0.525" x 35 mesh products were analyzed for ash, sulfur, volat i le matter, heating value and free swelling index.

DISCUSSION OF RESULTS

Washabi i i ty Characteristics

The results show that the coals can be wnshed to an ash content as low as 2% using conventional heavy media cyclone process. Figure

6 shows the washability characteristics of recombined 0.525" x 35 mesh

Leeper Creek No. 1 coal. I t may be noted from the curves that the yield of clean coal, containing 2% ash, w i l l be 90% (cumulative float ash curve). The sinks w i l l analyze 32.836 ash (cumulative sink ash curve). The highest ash i n any single particle w i l l be 10% (elementary ash curve). The coal w i l l have to be washed at a theoretical gravity of 1,364 (specific gravity curve). 'The + 0.025 Sp. G. near gravity -material w i l l be 6.5% (+ 0.025 Sp. G. distribution curve). However, -in a product containing 1% ash the predicted results would be: 64% yield of clean coal, 12.3% ash in sinks, separating gravity 1.297 with t 0.025 near gravity material in excess of 80%. - Figure 12 shows the washabi l i t y characteristics nf combined

0.525" x 35 mesh Leeper Creek No. 2 coal. For clean coal con-taining 1% ash, the curves show 96.4% yield, 33% a h in sinks,

1.336 separating gravity at + 0.025 near gravity material of 2.6%. - These coals seem to offer additional possibility of amenability to the production of ultra clean coal containing less than 1% ash. The en t

Ire esh theoretical yield and ash content that can be expected at 1.29 Sp.G, separation for 0,525" x 35 mesh coal w i l l be:

Coal - Ash, % - Yield, %

Leeper Creek No. 1 0.83 53.25 Leeper Creek No. 2 0.74 64.83

I t would be of interest to note that the coals can be considered as unique in their amenability to production of ultra clean coal at a size as coarse as 0.525" coupled with high yields.

The washability data show a slight but insignificant reduction in near gravity material with decrease in size coal. There is, however, a very significant decrease in ash content for smaller sire floats. The

1.29 Sp,G. floats for Leeper Creek No. 1 gave 0.95% ash for 0.525" x 3 mesh fraction and the ash content decreased to 0.63% for 20 x 35 mesh coal. Leeper Creek No. 2, however, gave 0.84% ash for

0.525" x 3 mesh fraction and the ash decreased to 0.65% for 20 x 35 mesh coal. I t is, therefore, possible to obtain a lower overall ash content in clean coal when the raw coal i s washed at a finer size.

Although no testing was done for minus 35 mesh coal, flotation could yield a clean coal with much lower ash than attainable by heavy media process.

Coking Characteristics

Table 15 shows the proximate analysis of raw coal and 1.29

5p.G. floats. Both coals fall in low-volatile bituminous rank. Leeper

Creek No. 1 coal gave a free swelling index of 24 cornpared to an index of 2 for Leeper Creek No. 2. In both cases, the free swelling was higher for 1.29 Sp.G. floats giving 33 for Leeper Creek No. 1 and 3 for Leeper Creek N o , 2 showing that washing can improve the swelling characteristics, The improvement will probably be less pronounced when washed at a higher specific gravity.

MARKET POTENTIAL

As Raw Material for Metallurgical Coke

From the foregoing study it i s concluded that the coals tested can readily be washed to meet the specification of o n~etal lurgical coal and can possibly make an excellent blending coal. Additional p i lo t plant coking tests would be required for a characterization of the resultant coke.

As Low Ash Coal

The possibility of preparation of ultra clean coal from the

Bering River cools, could open new markets as low ash coal, ( * j 5 ) Battelle Memorial Institute. under conhoct from the Of f ice of Cool Research, has completed a study on the potential market for low ash cool, prepared by Spencer Solvent Process. (314) Their finding would apply equally wel l i n the present context. A brief review of potential markets for low ash coal i s given below. N o attempt i s made to establish the cornmerical feasibility of preparation of \ow ash coal from the coals tested nor the suitability of such low ash coal for the markets reviewed herein. Only p i lot plant testing i n both the above fields can establish the economic feasibil ity for such potential markets.

Carbon Electrode Raw Material: Largest potential market for low ash coal appears to be as o raw material i n the manufacture of carbon electrodes and graphite, for the aluminum industry i n particular.

This requirement is presently met by coke. The ever increasing demand for carbon f i l ler material by the aluminum industry and decreasing quantities of residual stock produced by the refineries represenh a step in the direction of possible potential market for low ash coal to f i l l the gap. Considering the total poten-t ia l market for carbon fi l ler material as potential market for low ash coal, the fononger estimated by Battalle Mernoriol ~nr t i tv te(~)are:

1970 2,150,000 Tons 1975 3,680,000 Tons 1980 3,220,000 Tons

The possible reaction of producers of petroleum coke and the possibility of reduced prices of their products due to competition of coal has not been determined.

Foreign Market: Low ash coal may be considered very favor-ably by the pollution conscious foreign buyers. Further, lower shipping costs on Btu basis for low ash coal could make i t more attroc-tive. The foreign market might thus constitute one of the largest single outlet for low ash cool.

Miscellaneous Potential Markefs: Looking into the long range future, the markets for low ash coal* could be gas turbine fuel, electr ic power generalion, carbon black manufacture, blends wi th diesel oi l for locomotives, low ash metallurgical coke, magneto-hydrodynamic power generation, and fuel cells. Some of these possi-bilit ies, although proven technically feasible, need to be evaluated from the aspect of the economics of ut i l izat ion i n each potential market.

CONCLUSIONS AND RECOMMENDATIONS

Conclusions

The couls studied can be washed to obtain a product containing as low as 2.0% ash using conventional cyclone heavy media process.

Further reduction to less than 1% i s possible with recoveries as high as

50 to 95%. A review of l iterature indicates potential markets for such low ash coal. Pilot Plant studies o f preparation and ut i l izat ion are required for an evaluation of economics. Float fractions obtained at

1.29 Sp. G. showed defini te improvement in free swelling index over the raw coals which would be advantageous i n marketing washed coals for metallurgical use.

Recommendations

The following are recommendations for further research on the ut i l izat ion of Bering River coals:

1. Bench scale coking tests be conducted with washed coals to determine the resultant coke and tests wi th blends with other coals i f further improvement i s needed,

2. Pilot Plant tests using heavy media cyclone and flotation process to determine limits of reduction in ash for use as low ash coal.

3. Tests to be conducted on re pared low ash coal for use in the manufacture of carbon electrodes for the production of aluminum and i n other potential markets. Only such testing can determine the economics of ut i l ization of these coals for such applications.

REFERENCES

1. Barnes, F. F., "Coal Resources of Alaska," Geological Survey Bulletin 1242-8, 1967.

2. Campbell, R. J. Jr,, Hilton, R. J., and Boyd, C. L., "Coal as a Source of Electrode Carbon in Aluminum Production, " Bureau of Mines Report of Investigations 5191, February 1956.

3. Kloepper, D. L., et.al, "Solvent Processing of Coal to Produce De-Ashed Product, " Research and Development Reporl No. 9, submitted by Spencer Chemical Division to Of f ice of Coal Research, U .S. Dept. of Interior.

4, Nelson, H. W., Hein, G. M., and Hazard, H. R., "Assessment of Potential Markets for Low-Ash Coal, " Report sub-mitted by Bottelle Memorial Institute to O f f i ce of Coal Research, U . S . Dept. of Interior, December 1964.

5. Sanner, W. S. , "The Preparation of Low-Ash-Content Anthrocite," Preprint, Presented at AlME Annual Meeting, February 1968.

TABLE 1

SIZE ANALYSIS AND ASH DISTRIBUTION FOR

LEEPER CREEK NO. 1 RAW COAL, BER1NG RIVER FIE LD

, . Screen Size, Mesh Passing Retoined

20 35

35 200

200 Pan

Reassembled Products Cumulative Retained W t . , % Ash,% P

Wt., % Ash, % Curnu! ative Passing W t . , % Ash,%

TABLE 2

SIZE ANALYSIS A N D ASH DISTRIBUTION FOR

LEEPER CREEK NO. 2 RAW COAL, BERING RIVER FIELD

Screen Size, Mesh Passing Retained

0,525" 3

3 6

6 10

10 20

20 35

35 200

200 Pan

Total

Reassembled Products Cumulative Retained Wt., % Ash, O/b Wt., Oio Ash, % - -

Cumulative Passing Wt., % Ash, % - -

TABLE 3

Total

SINK-FLOAT RESULTS OF 0.525" x 3 MESH SIZE COAL, LEEPER CREEK NO. 1, BERING RIVER FIELD

(25.59% of Raw Coal)

Actual Produck Cumulative Float Cumulative Sink - +0.025 Sp. G.

Wt., % Ash, % - - Wt., % Ash, % Wt., 5% Ash, % Material, %

FIGURE 1 - WASHABILITY CHARACTERISTICS OF 0.525" x 3 MESH SIZE COAL, LEEPER CREEK NO. 1, BERING RIVER FIELD

FIGURE 2 - WASHABILITY CHARACTERISTICS OF 3 x 6 MESH SIZE COAL, FIGURE 3 - WASHABI LlTY CHARACTERISTICS OF 6 x 10 MESH SIZE COAL, TABLE 6

SINK-FLOAT RESULTS OF 10 x 20 MESH SIZE COAL, LEEPER CREEK NO. 1 , BERING RIVER FIELD

(1 1.75% of Raw Coal)

Specific Gravity Sink Float - -

Actual Products Cumulative Float Cumuiative Sink . - - - - . . - - . . . . - W t . , % Ash,% W t . , % Ash,% Wt. , % A s h , %

4.025 Sp. G. -

Material, %

FIGURE 4 - WASHABILITY CHARACTERISTICS OF 10 x 20 MESH SIZE COAL, TABLE 7

SINK-FLOAT RESULTS OF 20 x 35 MESH SIZE COAL, LEEPER CREEK NO. 1, BERING RIVER FIELD

(7.75% of Raw Coo I)

Sg;ric G;:;:? Actual Products Cumulative Float Cumulative Sink - +0.025 Sp. G

- - Wt., % Ash, % W t . , % Ash,% Wt., % Ash, % Material, %

1 .550 10.56 48.57 100.00 8.15 10.56 48.57 -

Total 100.00 8.15

FIGURE 5 - WASHABILITY CHARACTERISTICS OF 20 x 35 MESH SIZE COAL, TABLE 8

SINK-FLOAT RESULTS OF 0.525" x 35 MESH SIZE COAL, LEE PER CREEK NO. 1, BERING RIVER FIELD

(89.71% of Raw Coal)

Total

Actual Products Cumulative Float Cumulative Sink - - - .

W t . , % Ash,% Wt.,% Ash,% Wt., % Ash, O/b

53.25 0.83 53.25 0.83 'fOO.00 5-10

a. 025 Sp. G. - Mater ia I, %

FIGURE 6 - WASHABILITY CHARACTERISTICS OF 0.525" x 35 MESH SIZE COAL, Total

TABLE 9

SINK-F LOAT RESULTS OF 0.525" x 3 MESH SIZE COAL, LEEPER CREEK NO. 2, BERING RIVER FlELD

(17.53% of Raw Coal)

Actual Products Cumulative Float Cumulative Sink Wt . ,% Ash, % W t . , Ash,% Wt . , O/b Ash, 9'0

63.98 0.84 63.98 0.84 100.00 2.05

N.025 Sp.G. -

TABLE 10

SINK-FLOAT RESULTS OF 3 x 6 MESH SIZE COAL, LEEPER CREEK NO. 2, BERtNG RIVER FIELD

(23.09% of Raw Coal)

Actual Products CumuJat ive Float Cumulative Sink W t . , % Ash,% Wt., % Ash, % W t . , % Ash,%

4.025 Sp. G. -

Material. %

TABLE 11

SINK-FLOAT RESULTS OF 6 x 10 MESH SIZE COAL, LEE PER CREEK NO. 2, BERING RIVER FIELD

(21.03% of Raw Coal)

Specific Gravity Sink Float - -

Total

Actual Products Cumulative Float Cumulative Sink Wt, ,% Ash,% W t . , % Ash,% W t . , % Ash,% tO.025 Sp. G. -

FIGURE 10 - WASHABILITY CHARACTERISTICS OF 10 x 20 MESH SlZF COAL, LEEPER CREEK NO. 2, BERING RIVER FIELD

TABLE 13

SINK-FLOAT RESULTS OF 20 x 35 MESH SIZE COAL, LEFPER CREEK NO. 2, BERING RIVER FIELD

(10.66% of Raw Coal)

S;;:ic G;viy Actual Products Cumulative Float Cumulative Sink M.025 Sp. G. - - - Wt., % Ash, % Wt., % Ash, % - - W t . , % Ash, % - Material, %

I -

Total 100.00 4.22

TABLE 14

SINK-FLOAT RESULTS OF 0.525" x 35 MESH SIZE COAL, LEEPER CREEK NO. 2, BERING RIVER FIELD

(87.47% of Raw Coa 1)

Tota 1

Actual Products Cumulative Float Cumulative Sink Wt., % ~ s h , % Wt., % Ash, % Wt., % Ash,%

-tO. 025 Sp. G. - Material . %

FIGURE 12 - WASHABILITY CHARACTERISTICS OF 0.525" x 35 MESH SIZE COAL, LEEPER CREEK NO. 2, BERING RIVER FIELD

TABLE 15

PROXIMATE ANALYSIS OF RAW COAL

AND 1.29 SP.G. FLOAT SAMPLES

Bed VoIatile Fixed Heating Free Moisture* Ash Sulfur Matter Carbon Value SweI l ing

Coal Basis % % % ?& % Btu l ndex

Raw Cml 1 1.45 6.00 1.22 14.66 77.89 1 4,586 Leeper Creek 2 - 6-09 1.24 14.88 79-03 14,801 No. I 3 - - 1.32 15.85 84.15 15,759 23

4 - - - - - 15,690

P Raw Coal 1 1 -71 2-72 0.78 13.96 81.61 15,041 o Leeper Creek 2 - 2.77 0.79 14.20 83.03 15,303 No. 2 3 - - 0.82 14.61 85.39 1 5,739 2

4 - - - - - 15,680

0,525" x 35 Mesh 1 1.86 0.82 0.70 14.91 82.41 15,346 1.29Sp.G. Floats 2 - 0.83 0.71 15.19 83.98 15,637 Leeper Creek 3 - - 0.72 15.32 84.68 15,768 34 No. I 4 - - - - - 15,735

0.525" x 35 Mesh 1 1.66 0.73 0.70 14.15 83.46 15,401

1.29 Sp. G. Ffwts 2 - 0.74 0.71 14.39 84.87 15,661

Leeper Creek 3 - - 0.72 14.49 85.51 , 15,777

No. 2 4 - - - - - 15,750

*Equil ibrated Bed Moisture 1. Bed moisture basis 3. Moisfure and ash free basis

2. Dry basis 4. Moist ash free basis