Center for Advanced Separation Technologies CAST CENTER FOR ADVANCED SEPARATION TECHNOLOGIES TECHNOLOGY WORKSHOP MinExpo 2004, Las Vegas Thursday, September

Center for Advanced Separation Technologies CASTCAST

CENTER FOR ADVANCED SEPARATION TECHNOLOGIES

TECHNOLOGY WORKSHOPMinExpo 2004, Las Vegas

Thursday, September 30

Richard Bajura and Roe-Hoan Yoon Co-Directors

West Virginia University and Virginia Tech

http://www.castconsort.org


Outline

Background Roadmap Funding Organization Success stories

Coal Minerals Environment Basic research

Annual workshop Summary


Outline





Separation Processes Used for Coal

Ultr

afin

e

SieveBends

Dense Media

Cyclone

BasketCentrifuges

Dense Media Vessel

DewateringScreens

Raw CoalScreens

Coal Spirals Screen-BowlCentrifuges

ClassifyingCyclones

Med

ium

Solid-Solid Solid-LiquidSize-SizeC

oars

eF

ine

Froth Flotation Disc Filter


Committed(Funded)

Caution(Partially Funded)

Critical for Future(Unfunded)

Products

December 23, 1998 Science & Technology Roadmap

1999 2008

Solid Fuels and FeedstocksTechnology Roadmap (Draft)

Fine Particle Separation Subsy stemComponentIntegration

Dewatering andMaterials Handling

Solid/Liquid Separation

Physical Separations

Carbonization, Dewatering, & Thermal Stabilization

Smart Systems/AI

SystemsIntegration

POC-ScaleIndustry Test

Densification

Carbonization CompositeFormulations

FeedstockTesting

SystemsStudies

Efficient Gathering &Delivery Systems

Multiple ProcessEvaluation/Selection

Advanced Process Development POC-ScaleIndustry Test

Carbon/Polymer Processes(Feedstock Development)

Product Upgrading &Industrial Trials

SmartSystems/AI

Non-Intrusive Diagnostics

Contaminated Soil Remediation &Waste Water Treatment Value-Added By-Products

Adv. Extraction(Remote Mining)

Advanced Separations &Mine Remediation

Total Carbon Recovery,Clean Product,

Remediated Pond Sites,No New Ponds

Compliant Fuels &Vision 21 Feedstocks

Products

Low-Cost/Greene r Fue ls andReduced G HG Em issions,

Industrial Waste, &Landfil l Requ ire ments

Domestic CokeFrom Coal

High-Value CarbonProducts and Chemicals

Near-Zero Wastes

Sustainable MiningOperations

CARBON RESOURCERECOVERY

POLLUTANTREDUCTION

BIOMASS/WASTEUTILIZATION

ADVANCEDCARBON

PRODUCTS

ADVANCEDSEPARATIONS

SCIENCE


Committed(Funded)

Caution(Partially Funded)

Critical for Future(Unfunded)

Products

January 25, 1999 Science & Technology Roadmap

1999 2008

Solid Fuels and FeedstocksTechnology Roadmap -- Advanced Separations Science

ProductsADVANCED

MINERAL EXTRACTION

SOILREMEDIATION

RECYCLING

WATERCLEAN UP

CROSSCUTTINGSEPARATION

SCIENCE

Model-Based

Process ControlSystems

Non-Intrusive

Diagnostics

IsotopeRemoval

Tail ings Rem ediation Tail ings Min im ization

Non-Intrusive Diagnostics Advanced Extraction

Contaminant Association

Analysis

Process Flowsheet Developm ent

Hydrocarbon Removal Heavy Metal Removal

Waste Paper PulpDe-inking

Advanced Munic ipalWaste Sorting

Ele ctronics Scrap

Utilization

Coal Combustion

By-products UpgradingCoal Combustion

By-products Util ization

Adsorptive Bubb le S eparation Coal Derived Absorb ents

Watershed Management

Particl e Hydrodynamic sModeling

Solid/Liqu id/GasBoundary Layer Studies

Onlin e Sensor Developm ent Smart Systems/AI

Sustainable Min ingOperations

Near-Zero Wastes

Recovery of Value-AddedProducts, Redu ced Waste,Higher Ene rgy Effic iency,

Reduced G HG Em issions

Lower-cost Clean Up Technologies, Fewer

Contaminated Sites

Optimum SeparationProcesse s Using

Real-Time Control

Purer-water Te chnology

Reduced G roundwater

Pollution

Advanced Partic leSeparations

Groundwater Decontamination

(Hydrocarbons)


Outline





Roadmap Development

Workshop in Charleston, WV, August 14-15, 2002 53 participants, mostly from

industry. 67-page roadmap developed.

Identified research priorities in the following areas: Physical separation Chemical biological separation Environmental control

Published Hardcopies Website:

• www.castconsort.org


CAST Program

T e ch n ica lC o m m ittee

A dv iso ryB oa rd

P hys ica lS ep ara tion

C he m ica l/B i lo log ica lS ep ara tion

E nv iro nm e nta lC o ntro l

In du stryA ffi lia tes

C oo rp ora tiveR & D

In dus tria lP ro gram

D ire c to r 'sO ffice

% effort Projects

Fundamental 50 Applied 50

R&D Areas Coal 50 Minerals 50


Affiliate Program No annual membership fee Access to non-proprietary technical information

• research reports, technical papers, theses, and dissertations Free registration to Annual Technical Workshop

Cooperative R&D Program Identify specific industrial problems.

• short-term Solve the problems using the center expertise. Share costs among interested companies. Cost-share from participating universities

• Use allocated funds

Industrial Program


Synergy

UniversitiesUniversities

GovernmentGovernment

IndustryIndustry

CASTCAST

• Identify National Priorities• Provide R&D Funding• Industry of the Future Program

• Improved Efficiency• Trained Personnel• New Technologies• Sustainable mining

• Training• Basic Research• Long-term high-risk Research • Technology Development


Outline





Funding 2001

CAST I: $1.75 million for 2 years • Year 1 $0.75 million• Year 2 $1 million

VT and WVU 2002

CAST II $8.8 million for 3 years• Year 1 $1.8 million• Year 2 $3 million• Year 3 $3 million

2004 CAST III Funding Request

• FY05, -06, and -07• Modular Approach

– Mining $3 million for FY05– Mercury $1 million for FY05

• $12 million proposal due October 5, 2004


Funding Cycle

J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D

2001 2002 2003 2004

Roadmap Development

RFP Preparation/Distribution

Proposal Writing

Proposal Review

Proposal Selection

Project R&D Work

Annual Workshops

6-Monthly Reports

PROJECT ACTIVITY

CAST I YR1Project Funding Cycle

CAST I YR2/CASTII YR1Project Funding Cycles

CAST II YR2Project Funding Cycle

KEY:

CAST I & CAST II PROJECT ACTIVITY

$0.75M $1.00M $1.8M $3.00M $3.00M

J A S O N DJ A S O N D J F M A M J J A S O N DJ F M A M J J A S O N D J F M A M J J A S O N DJ F M A M J J A S O N D J F M A M J J A S O N DJ F M A M J J A S O N D

2001 2002 2003 2004

Roadmap Development

RFP Preparation/Distribution

Proposal Writing

Proposal Review

Proposal Selection

Project R&D Work

Annual Workshops

6-Monthly Reports

PROJECT ACTIVITY

CAST I YR1Project Funding Cycle

CAST I YR2/CASTII YR1Project Funding Cycles

CAST II YR2Project Funding Cycle

KEY:

CAST I & CAST II PROJECT ACTIVITY

$0.75M $1.00M $1.8M $3.00M $3.00M


Project Selection

Proposal submission Six weeks Follow the roadmap

Peer review Paid reviewers

Technical Committee DOE approval


Projects Funded

A total 41 projects funded Mostly $70-100K per annum 2-3 year projects

Type of separations research Solid-solid 17 Solid-liquid 18 Chemical/biological 10 Modeling, control/sensor 5 Environment 4

Mineral type Coal 15 Base metal 10 Industrial mineral 9 Basic research 7


Outline





Organization

T e ch n ica lC o m m ittee

A dv iso ryB oa rd

W V UV T

C h ar te rM em be rs

U tahN e va daN e w M ex icoM on ta naK e n tu cky

M em be rs

U n iv e rs i tyM em be rs

C o rp ora tio ns G orv en m e ntA ge n cies

O th e rs

A ff i lia teM em be rs

D irec to r&

S u pp or t S ta ff

V T C E


Industry Advisory Board

Richard Lawson, Chairman, Energy, Environment and Security Group, Ltd.

Bart Hyita, Vice President, Operation, CONSOL Energy

David Peugh, Vice President, Arch Minerals

John Marsden, Vice President, Phelps Dodge Mining Company

Edward Dowling, Vice President, Cleveland Cliffs


Outline





Impoundments

3 billion tons of fine coal In 713 impoundments Mostly in Central Appalachia.

Main cause Lack of appropriate Separation Technologies

• Solid-Solid (Fine particles)• Solid-Liquid (Dewatering)


Application of Advanced Separation Technologies

Use of advanced separation technologies at Middle Fork Recovered coal Reuse of impoundment

• No new impoundment

• No new permits

Then…

…and NowTechnology


Pilot-scale tests Moisture reduction

• From 29% to 16% Throughput

• 2-3 times higher 200 tons/hr plant to be built by Beard

Technologies by March 2005

Pond recovery at Pinnacle MineWyoming County, WV


Novel Chalcopyrite Leaching Process


Amount of Ethylene Ferric Salt ChalcopyriteSilica (g/L) (%) Glycol (ml/L) (g/L) Dissolution 0 10 10 (ferric chloride) 27.0

3.5 10 10 (ferric chloride) 88.6 1.0 0 15 (ferric chloride) 56.3

1.0 0 15 (ferric sulfate) 17.2




Ferric Ion as Oxidant in Leaching of Chalcopyrite

Conditions: 2.5 g/L chalcopyrite (-74 x 37 )0.5 N H2SO4, 75oC, 24 hr-leaching


Trona FlotationGREEN RIVER FORMATIONGREEN RIVER FORMATION

•17.1 million tons per year• 90% of soda ash in the U.S.• $800 million per year

Trona Concentrate Insoluble Impurities

Pilot plant testing in summer 2004 with industrial participants:

• General Chemical, • EIMCO, • Roberts & Schafer.

Chemical Chemical ProcessingProcessing

Physical Physical ProcessingProcessing


0.0 0.1 0.2 0.3 0.4 0.5

1

2

3

4

5 Sample 00S3, ppt range

Dif

fere

nti

al C

urr

ent,A

Potential V.vs.SCE

Sample+Au +200pptHg +400pptHg +600pptHg +800pptHg

-200 0 200 400 600 8000

1

2

3

4 Sample 00S3,123 ppt Hg

Dif

fere

nti

al C

urr

ent,A

Potential V.vs.SCE

Flue gas Impinger solution (NETL)


Gold Filters for Mercury Removal from Flue GasDr. Kumar Ganesan

Results of research shows that gold filters can remove Hg from flue gases with an efficiency of up to high as 95%.

Hg Concentration vs Time

050

100150200250300350400450500

0.5

1.5 3 5 7 9 11 13 15 17 19 21 23 25 27

Time(min)

Hg

Co

nc

en

tra

tio

n (

ug

/m3)


Non-Cyanide Leaching of Gold

Cyanide in band for gold leaching in Montana. Alkaline sulfide leaching system is being developed.

thermodynamic model optimization

Lab tests showed 82% recovery of the gold.


Flotation Modeling

R&D Project: Develop a universal flotation

model that can be used to design and optimize industrial flotation plants.

Accomplishments: Basic modeling equations have

been developed from first principles.

Engineering firm plans to use the model as the basis for an advanced flotation control system.


Bubble & Particle Velocity Measurement Using PIV

Bubbles and ParticlesBubbles and Particles


Results: RMS comparison of particle

32

9794312 330

f

fii

**i dRe.U

Levins and Glastonbury

Liepe and Mockel

1

1 2

2

2

aT

)b(

U

U i


Outline





Annual Workshops Progress report to industry Information exchange

Between universities and industry Between universities

Promote industry participation Venue

Industry centers• Charleston, WV; Denver, CO; Phoenix, AZ, etc.

Universities Publication

Internet Special volumes

• Coal Preparation, International Journal• International Journal of Mineral Processing• Mineral Engineering


Outline





Summary CAST was formed in 2000 between WVU and VT. Joined by five other universities:

UK MT UU UNR NMT

Different expertise at different universities. Synergy Addresses local interest Wide geographical areas

Promotes industrial participation Industrial Affiliate Program Cooperative Research Program

Success stories and promising technologies Coal, minerals, environment, basic research

Documents

Center for Advanced Separation Technologies CAST CENTER FOR ADVANCED SEPARATION TECHNOLOGIES TECHNOLOGY WORKSHOP MinExpo 2004, Las Vegas Thursday, September