Method and apparatus for separating clay from coal fines

Claim 1

An apparatus for use in the separation of clay from coal fines which comprises: a hopper including a bottom, a front wall, side walls and a rear wall, the side walls diverging upwardly, the rear wall having the top and extending upwardly from the bottom at an angle to horizontal of less than about 45 degrees, the rear wall including a central, rectangular wall portion and a pair of upwardly-widening triangular wall portions on either side of the rectangular wall portion, thereby defining a channel having the rectangular wall portion at the bottom; a first baffle mounted to said hopper and extending vertically downward toward the bottom of said hopper, said first baffle being positioned in a plane spaced horizontally from the front wall; a second, horizontal baffle mounted to said hopper; a conveyor positioned adjacent and extending along the rear wall of said hopper from approximately the bottom of said hopper to above the top of the rear wall of said hopper, said conveyor comprising a flight conveyor having numerous, transverse blade members, the blade members being complementary in shape with the central, rectangular wall portions of the rear wall and being received in the channel defined by the rear wall; drive means for driving said conveyor; feed means for feeding a water suspension of coal fines containing clay particles into said hopper between the front wall of said hopper and said baffle; an apron extending outwardly of said hopper from the rear wall of said hopper; and overflow means for receiving water suspension of clay and directing the suspension from said hopper, said overflow means including at least one overflow port located in one of the side walls of said hopper between said first baffle and the rear wall of said hopper, said second baffle extending directly below the overflow port, at least a portion of the overflow port being located below the top of the rear wall of said hopper, said first baffle extending upwardly at least as high as the bottom of the overflow port.

Claim 2

An apparatus for use in the separation of clay from coal fines which comprises: a hopper including a bottom, a front wall, side walls and a rear wall, the side walls diverging upwardly, the rear wall having the top and extending upwardly from the bottom at an angle to horizontal of less than about 45 degrees, the rear wall including a central, rectangular wall portion and a pair of upwardly-widening triangular wall portions on either side of the rectangular wall portion, thereby defining a channel having the rectangular wall portion at the bottom; a first baffle mounted to said hopper and extending vertically downward toward the bottom of said hopper, said first baffle being positioned in a plane spaced horizontally from the front wall; a second, horizontal baffle mounted to said hopper; a conveyor positioned adjacent and extending along the rear wall of said hopper from approximately the bottom of said hopper to above the top of the rear wall of said hopper, said conveyor comprising a flight conveyor having numerous, transverse blade members, the blade members being complementary in shape with the central, rectangular wall portions of the rear wall and being received in the channel defined by the rear wall; drive means for driving said conveyor; feed means for feeding a water suspension of coal fines containing clay particles into said hopper between the front wall of said hopper and said baffle; an apron extending outwardly of said hopper from the rear wall of said hopper; and overflow means for receiving water suspension of clay and directing the suspension from said hopper, said overflow means including at least one overflow port located in one of the side walls of said hopper between said first baffle and the rear wall of said hopper, said second baffle extending directly below the overflow port, at least a portion of the overflow port being located below the top of the rear wall of said hopper, said first baffle extending upwardly at least as high as the bottom of the overflow port.

Claim 5

A method for separating a mixture of clay particles and coal fines which comprises the steps of: a. providing a hopper apparatus including a hopper having a bottom and a downwardly extending baffle having a bottom edge spaced above the bottom of the hopper, the hopper including a front wall and including a rear wall extending upwardly from the bottom at an angle of less than about 45 degrees to horizontal; b. feeding an aqueous suspension of the mixture into the hopper apparatus between the front wall of the hopper and the baffle, whereby the aqueous suspension is forced downwardly toward the bottom of the hopper, the aqueous suspension being fed at a sufficiently slow rate to permit settling out of coal fines toward the bottom of the hopper while the clay particles remain suspended in the water; c. removing the settled out coal fines by a conveyor positioned adjacent the rear wall of the hopper; and d. removing the water and suspended clay particles from about the top of the hopper at a location between the baffle and the rear wall of the hopper.

Claim 6

A method for separating a mixture of clay particles and coal fines which comprises the steps of: a. providing a hopper apparatus including a hopper having a bottom and a downwardly extending baffle having a bottom edge spaced above the bottom of the hopper, the hopper including a front wall and including a rear wall extending upwardly from the bottom at an angle of less than about 45 degrees to horizontal; b. feeding an aqueous suspension of the mixture into the hopper apparatus between the front wall of the hopper and the baffle, whereby the aqueous suspension is forced downwardly toward the bottom of the hopper, the aqueous suspension being fed at a sufficiently slow rate to permit settling out of coal fines toward the bottom of the hopper while the clay particles remain suspended in the water; c. removing the settled out coal fines by a conveyor positioned adjacent the rear wall of the hopper; and d. removing the water and suspended clay particles from about the top of the hopper at a location between the baffle and the rear wall of the hopper.