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http://www.castconsort.org

CENTER FOR ADVANCED SEPARATION TECHNOLOGIES TECHNOLOGY WORKSHOP MinExpo 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

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  1. CENTER FOR ADVANCED SEPARATION TECHNOLOGIESTECHNOLOGY WORKSHOPMinExpo 2004, Las VegasThursday, September 30 Richard Bajura and Roe-Hoan Yoon Co-DirectorsWest Virginia University and Virginia Tech http://www.castconsort.org

  2. Outline • Background • Roadmap • Funding • Organization • Success stories • Coal • Minerals • Environment • Basic research • Annual workshop • Summary

  3. Outline • Background • Roadmap • Funding • Organization • Success stories • Coal • Minerals • Environment • Basic research • Annual workshop • Summary

  4. Size-Size Solid-Solid Solid-Liquid Dense Media Vessel Dewatering Screens Coarse Raw Coal Screens Basket Centrifuges Dense Media Cyclone Medium Sieve Bends Screen-Bowl Centrifuges Coal Spirals Fine Classifying Cyclones Disc Filter Froth Flotation Separation Processes Used for Coal Ultrafine

  5. Outline • Background • Roadmap • Funding • Organization • Success stories • Coal • Minerals • Environment • Basic research • Annual workshop • Summary

  6. 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

  7. CAST Program % effort • Projects • Fundamental 50 • Applied 50 • R&D Areas • Coal 50 • Minerals 50

  8. Industrial Program • 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

  9. Identify National Priorities • Provide R&D Funding • Industry of the Future Program Government • Improved Efficiency • Trained Personnel • New Technologies • Sustainable mining CAST Industry Universities Synergy • Training • Basic Research • Long-term high-risk Research • Technology Development

  10. Outline • Background • Roadmap • Funding • Organization • Success stories • Coal • Minerals • Environment • Basic research • Annual workshop • Summary

  11. 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

  12. Funding Cycle

  13. Project Selection • Proposal submission • Six weeks • Follow the roadmap • Peer review • Paid reviewers • Technical Committee • DOE approval

  14. 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

  15. Outline • Background • Roadmap • Funding • Organization • Success stories • Coal • Minerals • Environment • Basic research • Annual workshop • Summary

  16. Organization

  17. 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

  18. Outline • Background • Roadmap • Funding • Organization • Success stories • Coal • Minerals • Environment • Basic research • Annual workshop • Summary

  19. 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)

  20. Then… …and Now Technology Application of Advanced Separation Technologies • Use of advanced separation technologies at Middle Fork • Recovered coal • Reuse of impoundment • No new impoundment • No new permits

  21. Pond recovery at Pinnacle MineWyoming County, WV • 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

  22. Novel Chalcopyrite Leaching Process

  23. 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 Amount of Ethylene Ferric Salt Chalcopyrite Silica (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 3.5 10 15 (ferric sulfate) 39.5 1.0 0 30 (ferric sulfate) 56.5 3.5 10 30 (ferric sulfate) 69.0

  24. Insoluble Impurities Trona Concentrate Trona Flotation Physical Processing Pilot plant testing in summer 2004 with industrial participants: • General Chemical, • EIMCO, • Roberts & Schafer. • 17.1 million tons per year • 90% of soda ash in the U.S. • $800 million per year Chemical Processing

  25. Flue gas Impinger solution (NETL)

  26. 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%.

  27. 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.

  28. 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.

  29. Bubble & Particle Velocity Measurement Using PIV Bubbles and Particles

  30. Results: RMS comparison of particle Levins and Glastonbury Liepe and Mockel

  31. Outline • Background • Roadmap • Funding • Organization • Success stories • Coal • Minerals • Environment • Basic research • Annual workshop • Summary

  32. 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

  33. Outline • Background • Roadmap • Funding • Organization • Success stories • Coal • Minerals • Environment • Basic research • Annual workshop • Summary

  34. 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

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