# US 9,039,793 B2 · Separation system and method

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- Number: US 9,039,793 B2
- Document ID: US9039793B2
- Status: Granted
- Kind: B2
- Application number: 13/062,612
- Filed: 2009-10-14
- Published: 2011-09-22
- Granted: 2015-05-26
- Earliest claimed: 2008-10-15
- Assignees: Recycoal Switzerland S.A.
- Applicants: Liam Fitzgerald; Peter Lawson; Mike Lenagh
- Inventors: Liam Fitzgerald; Peter Lawson; Mike Lenagh
- Web page: https://patentgrep.com/patent/US9039793B2

## CPC

- B03B 5/34: Applications of hydrocyclones
- B03B 5/32: using centrifugal force
- B03B 5/44: Application of particular media therefor
- B03B 9/005: {specially adapted for coal}
- C10L 1/326: {Coal-water suspensions}
- B03B: SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
- C10L: FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS

## Abstract

A separation system and method for separating one or more solid fossil fuels from a contaminated source in a liquid medium, the system including primary separation means and secondary separation means, the primary and secondary separation means being arranged to operate with liquid media of differing specific gravities.

## Claims

### Claim 1

A method of separating coal from spoil/reject heaps containing coal, the method comprising:
a primary separation of:
(i) adding a portion from the spoil/reject heap containing coal to a liquid medium,
(ii) adjusting the specific gravity of the liquid medium carrying the portion from the spoil/reject heap containing coal to a first specific gravity by adding water and mineral dirt;
(iii) causing the liquid medium carrying the portion from the spoil/reject heap containing coal at the first specific gravity to undergo primary separation; and
a secondary separation of:
(iv) adjusting the specific gravity of the liquid medium carrying the portion from the spoil/reject heap containing coal from the first separator to a second specific gravity by adding water and mineral dirt in which the second specific gravity is lower than the first specific gravity; and
(v) causing the liquid medium carrying the portion from the spoil/reject heap containing coal at the second specific gravity to then undergo secondary separation thereby producing a clean coal product having at least 95% purity, wherein:
the first specific gravity is between about 1.25 to 1.35, and
the second specific gravity is between 1.15 to 1.249.

### Claim 2 (depends on 1)

A method according to claim 1, wherein the second specific gravity differs from the first specific gravity by at least from 0.001 to 0.1.

### Claim 3 (depends on 1)

A method as claimed in claim 1, wherein primary separation is undertaken in primary separation means.

### Claim 4 (depends on 3)

A method as claimed in claim 3, wherein the primary separation means comprises a primary cyclone.

### Claim 5 (depends on 4)

A method as claimed in claim 4, wherein the primary cyclone operates at between 10 and 20 psi.

### Claim 6 (depends on 4)

A method as claimed in claim 4, wherein the primary cyclone receives a feed material having particulates up to about 50 mm.

### Claim 7 (depends on 6)

A method as claimed in claim 6, wherein secondary separation is undertaken in secondary separation means.

### Claim 8 (depends on 7)

A method as claimed in claim 7, wherein the secondary separation means comprises a secondary cyclone.

### Claim 9 (depends on 8)

A method as claimed in claim 8, wherein the secondary cyclone operates at between 10 and 20 psi.

### Claim 10 (depends on 8)

A method as claimed in claim 8, wherein the secondary cyclone is adapted to receive a feed material having particulates up to about 50 mm.

### Claim 11 (depends on 1)

A method as claimed in claim 1, further comprising a preliminary separation step, wherein only water is added to the portion from the spoil/reject heap containing coal before step (i).

### Claim 12 (depends on 11)

A method as claimed in claim 11, wherein the preliminary separation is undertaken in preliminary separation means.

### Claim 13 (depends on 12)

A method as claimed in claim 12, wherein the preliminary separation means rotates, in use.

### Claim 14 (depends on 13)

A method as claimed in claim 13, wherein the preliminary separation means rotates about a longitudinal axis thereof, in use.

### Claim 15 (depends on 14)

A method as claimed in claim 14, wherein the preliminary separation means rotates at a rate of between about 4 and 50 rpm, in use.

### Claim 16 (depends on 12)

A method as claimed in claim 12, wherein the preliminary separation means may comprise a separating barrel.

### Claim 17 (depends on 12)

A method as claimed in claim 12, wherein the preliminary separation means is arranged on a slight incline.

### Claim 18 (depends on 17)

A method as claimed in claim 17, wherein a longitudinal axis of the preliminary separation means is arranged at between about 5 and 15 degrees to the horizontal.

### Claim 19 (depends on 1)

A method as claimed in claim 1, wherein the specific gravity of the liquid medium carrying the portion from the spoil/reject heap containing coal of step (ii) is adjusted to the first specific gravity by the addition consisting essentially of the water and the mineral dirt, wherein the mineral dirt of the first mixture is selected from the group consisting of mudstones, shales, coal, sandstone, and clay.

### Claim 20 (depends on 19)

A method as claimed in claim 19, wherein the specific gravity of the liquid medium carrying the portion from the spoil/reject heap containing coal from the first separator of step (iv) is adjusted to the second specific gravity by the addition consisting essentially of the water and the mineral dirt, wherein the mineral dirt of the second mixture is selected from the group consisting of mudstones, shales, coal, sandstone, and clay.