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Browsing by Author "Keles, Serhat"

Now showing 1 - 5 of 5
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    Analytical and Numerical Techniques for the Optimal Design of Mineral Separation Circuits
    Noble, Christopher Aaron (Virginia Tech, 2013-06-13)
    The design of mineral processing circuits is a complex, open-ended process.  While several tools and methodologies are available, extensive data collection accompanied with trial-and-error simulation are often the predominant technical measures utilized throughout the process.  Unfortunately, this approach often produces sub-optimal solutions, while squandering time and financial resources.  This work proposes several new and refined methodologies intended to assist during all stages of circuit design.  First, an algorithm has been developed to automatically determine circuit analytical solutions from a user-defined circuit configuration.  This analytical solution may then be used to rank circuits by traditional derivative-based linear circuit analysis or one of several newly proposed objective functions, including a yield indicator (the yield score) or a value-based indicator (the moment of inertia). Second, this work presents a four-reactor flotation model which considers both process kinetics and machine carrying capacity.  The simulator is suitable for scaling laboratory data to predict full-scale performance.  By first using circuit analysis to reduce the number of design alternatives, experimental and simulation efforts may be focused to those configurations which have the best likelihood of enhanced performance while meeting secondary process objectives.  Finally, this work verifies the circuit analysis methodology through a virtual experimental analysis of 17 circuit configurations.  A hypothetical electrostatic separator was implemented into a dynamic physics-based discrete element modeling environment.  The virtual experiment was used to quantify the selectivity of each circuit configuration, and the final results validate the initial circuit analysis projections.
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    Fine Coal Dewatering Using Hyperbaric Centrifugation
    Keles, Serhat (Virginia Tech, 2010-05-05)
    The solid-solid separation processes employed by modern coal preparation plants require large amounts of process water that must be removed from the surfaces of particles using mechanical dewatering equipment. Unfortunately, the existing processes that are used to dewater fine particles are inefficient in terms of moisture reduction and/or solids recovery. Many coal preparation plants are forced to discard fine coal particles because of the inability of existing technologies to reduce the moisture content of this product to an acceptable level. In light of this problem, a new ultrafine dewatering process called hyperbaric filter centrifugation (HFC) has been developed. This novel method combines centrifugation and pressure filtration within a single process to substantially reduce moistures over what can be achieved using conventional dewatering systems. In the current study, steady-state and dynamic dewatering models were developed in order to be able to simulate the behavior of the HFC technology. The steady-state model, which was based on grain-size properties, used empirical expressions to predict product moistures. On the other hand, the dynamic model was based on fundamental theories of filtration and centrifugation. Although the dynamic model provided a better understanding of the working principles of the process, the steady-state grain model produced more accurate equilibrium moisture predictions. Therefore, the steady-state model was used to further investigate the effects of several parameters on cake moistures. As such, the steady-state model was useful for scale up and design purposes. The steady-state dewatering model was also used to perform an economical analysis of potential applications of the HFC technology. The model was used to investigate a variety of new circuit designs that have the potential to be commercially applied in the coal industry. The results clearly showed that this new technology would allow coal companies to process difficult-to-dewater ultrafines using the HFC process, while coarser solids would be more appropriately dewatered using conventional technologies such as vacuum filters or screenbowl centrifuges. This "split dewatering" concept would provide substantially higher profitability due to lower moistures and higher recoveries of ultrafine solids than could be achieved using a single dewatering process. Laboratory- and pilot-scale versions of this technology has been constructed and tested at the facilities of Mining & Minerals Engineering Department of Virginia Tech. Results of this testing program showed that 30-50% lower moisture values than the ones obtained using conventional mechanical dewatering processes could be achieved with the HFC technology. Based on these promising results, a pilot-scale prototype unit, which was tested successfully at several commercial U.S. coal plants, was also constructed by Decanter Machine, Inc. Finally, the process of developing of this novel technology was successfully completed with the sale of the first full-scale commercial unit by Decanter Machine, Inc. to a major U.S. coal producer.
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    Identification, Characterization, and Speciation of Rare Earth Elements in Coal Refuse
    Russell, Alexandra Dawn (Virginia Tech, 2021-06-24)
    Rare earth elements are the 14 lanthanides on the periodic table, plus yttrium and scandium. These elements play a critical role in modern-day technologies such as liquid-crystal displays, GPS systems, and fiber optic cables. A majority of the mining of these elements is from China; however, due to decreasing reserves a need for alternative processes for extracting and processing rare earth elements (REEs) is becoming increasingly important. Special focus has been placed upon the identification of REEs within coal refuse, but the phase designation and speciation is not fully understood. This investigation focuses on the characterization, speciation, and morphology of REEs within fine and coarse coal refuse. During this study, physical and chemical characterization was conducted on coal refuse samples to understand characteristics, which influence REE phase designation. Experimental methods were chosen to specifically evaluate REE content and speciation across four key characteristics: size distribution, density, seam location, and thermal decomposition. Characterization of the refuse material was conducted in two campaigns: (1) an exploratory campaign, which focused on size distribution, and physical imaging of REEs within fine refuse, and (2) a detailed campaign, which utilized sequential chemical extraction methods alongside calcination to understand the phases in which REEs are present in coarse refuse. The results show that REEs within fine coal refuse are smaller than ten microns and found with phosphorus. In general, as size decreased REE content increased, likely due to increased clay content. Further conclusion could not be drawn from simple microscopic analysis. Consequently, detailed chemical characterization was conducted to fully understand REE speciation. The tests showed that a majority of REEs within coarse refuse were within insoluble species. A calcination treatment was found to greatly increase the recovery of REEs from the metal oxide fraction, thus increasing the overall soluble species contained within the coarse refuse material.
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    New Methodologies for the Characterization and Separation of Rare Earth Elements Present in Coal
    Kiser, Michael James (Virginia Tech, 2015-11-24)
    Three phases of work were performed for this study. First a new form of liberation analysis was created and applied to two coal samples from separate formations. This new method of liberation analysis attempts to remove sources of error found in the traditional form of liberation analysis. This new method is capable of producing results comparable to multiple iterations of the traditional liberation analysis while using only one head sample. The new method relies on the mathematical reconstruction of the data to produce the resulting liberation profile. This allows the user to easily expand the method to include more liberation profiles without greatly increasing the amount of head weight needed. The results of this phase confirm that the products of each liberation profile reconstitute the correct feed ash. The second phase of work focused on the evaluation and concentration of rare earth elements (REEs) present in the refuse streams of coal processing plants found in the eastern United States. Twenty plants were sampled for the fleet study. Samples of these plants' refuse streams were collected and their REE and ash contents were determined. Coal from the Eagle seam, Fire Clay seam, and Fire Clay Rider were collected and tested during the concentration phase. Samples of a waste coal from the Pittsburgh seam and a coal combustion by prodcut were also provided by a third party. The separation methods investigated include multi-gravity separation, electrostatic separation, and selective oil agglomeration. Partition curves from x-ray sorting devices were also applied to REE float-sink data as well. The results of this work show that REEs tend to partition with low ash material when viewing the results on an ash basis. Finally, the third phase of this work involved the application of x-ray sorting technology on different coals. This work showed that the x-ray sorting technology in question is capable of effectively treating prescreened feed with a size range of 2" x 1/4". The work also shows that the x-ray sorting technology also has applications in the power generation field, where it can be used to eliminate elements of environmental concern.
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    Vibration Enhanced Flooded Bed Dust Scrubber with Liquid-Coated Mesh Screen
    Uluer, Mahmud Esad (Virginia Tech, 2023-10-18)
    Respirable coal mine dust (RCMD) is one of the biggest occupational health hazards. Dusty mining environments can cause life-threatening respiratory health problems for coal miners known as black lung. Over the last 20 years, the flooded bed dust scrubber (FBS) has been employed as an integral component of dust control strategies for underground continuous mining operations. These units have been shown to be effective and robust in mining environments; however, several technical challenges and knowledge gaps limit their performance and efficiency. Despite the capability of the FBS, there are numerous technical challenges that limit its performance and efficiency. In particular, the static panel filter, instrumental in most scrubber designs, is fundamentally limited in collection efficiency and causes numerous operational challenges including rapid clogging. Furthermore, the current design of the filter panel is not capable of evenly wetting the entire surface area. This allows dust-laden air to pass through the filter media and decreases the cleaning capability of the FBS. In this research, both a lab-scale and a full-scale vibration-enhanced FBS with a liquid-coated filter panel were designed, manufactured, and tested. The results confirmed that a vibration-induced filter panel enhances dust collection performance and reduces mesh clogging. In addition, laboratory-scale mesh clogging tests showed that a hydrophilic mesh provided superior clogging mitigation and better performance. Typical results from bench-scale tests showed notable improvements in dust collection efficiencies by over 6% in wet condition and over 7% in dry condition while reducing mass accumulation in the filter by almost 10% in wet condition and over 40% in dry condition. The prototype testing was less conclusive, with deviations between the static mesh and vibrating mesh depending on the mesh density and operating conditions. Nevertheless, with the highest mesh density tested (30-layer), the vibrating mesh notably outperformed the static mesh with superior collection efficiency and reduced airflow loss. The system was further analyzed to investigate the size-by-size recovery of dust particles to various endpoints in the scrubber, under both vibrating and static conditions. Results show that while a majority of the particles are recovered into the demister sump, nearly a quarter of the dust mass is recovered upstream of the screen. In addition, the data confirm that vibration prompts notable improvements to collection efficiency, particularly in the finest size class (- 2.5 micron).