System and method for firing coal having a significant mineral content

Claim 2

A combustion system for mineralized coal, including, a source of coal having a significant content of iron pyrite (FeS 2 ) in its total mineral fraction, a classifier (beneficiator) connected to the source of coal to receive and divide the coal into a first stream of substantially pure coal and into a second stream of coal with a highly concentrated content of iron pyrite and other minerals, a furnace having two sets of burners arranged vertically one over the other, means connected between the classifier and the lower of the two sets of burners to receive and pulverize the first stream of coal supplied the burners, and means connected between the classifier and the upper of the two sets of burners to receive and pulverize the second stream of coal to an extremely small size (≦400 mesh) and supplied the burners, whereby the combustion generated by the coal of the first set of burners extends up through the furnace so that the coal of the second set of burners ejects into the hot temperatures and air-richer zone of the combustion and thereby roasts the iron pyrites to iron oxide.

Claim 3

The system of claim 1, including, means for supplying combustion air to the two sets of burners of the furnace so that the fuel-air ratio of the lower set of burners is fuel-rich and the fuel-air ratio of the second set of burners is air-rich.

Claim 4

A combustion furnace in which coal having a significant mineral content is burned, including, a combustion chamber having tube-lined walls through which tubes water is conducted to be vaporized into steam, a first set of burners mounted through the lower wall of the chamber, a second set of burners mounted through the upper wall of the chamber, a supply of coal having a high mineral content which has a significant ferrous disulfide (FeS 2 ) content, means connected to the supply for receiving the coal and dividing it into a first portion of relatively demineralized coal and a second portion of mineralized coal, a first mill connected to the dividing means to receive the first coal portion and pulverize it to a conventional size for combustion in the lower portion of the furnace chamber, means connecting the first mill to the first set of burners, a second mill connected to the dividing means to receive and pulverize the second coal portion to an extremely fine size, and means for connecting the second mill to the second set of burners for injecting the mineralized coal into an elevated portion of the combustion chamber, whereby the mineralized portion of the coal will be roasted to high-melting compounds which will not adhere to the walls of the furnace upon impact and the mineralized portion of the coal will be injected at such a fine size that the ash particles formed will be retained with the flue gas and be removed as fly ash.

Claim 5

A combustion furnace in which coal having a significant mineral content is burned, including, a combustion chamber having tube-lined walls through which tubes water is conducted to be vaporized into steam, a first set of burners mounted through the lower wall of the chamber, a second set of burners mounted through the upper wall of the chamber, a supply of coal having a high mineral content which has a significant ferrous disulfide (FeS 2 ) content, means connected to the supply for receiving the coal and dividing it into a first portion of relatively demineralized coal and a second portion of mineralized coal, a first mill connected to the dividing means to receive the first coal portion and pulverize it to a conventional size for combustion in the lower portion of the furnace chamber, means connecting the first mill to the first set of burners, a second mill connected to the dividing means to receive and pulverize the second coal portion to an extremely fine size, and means for connecting the second mill to the second set of burners for injecting the mineralized coal into an elevated portion of the combustion chamber, whereby the mineralized portion of the coal will be roasted to high-melting compounds which will not adhere to the walls of the furnace upon impact and the mineralized portion of the coal will be injected at such a fine size that the ash particles formed will be retained with the flue gas and be removed as fly ash.

Claim 6

A process for burning highly mineralized coal, including, dividing raw coal with a high mineral content into a first stream of relatively low mineral content and a second stream of relatively high mineral content including pyrites, pulverizing the first stream of coal to a conventional size for combustion in a furnace, supplying the first stream of pulverized coal to a combustion zone in the lower portion of a furnace, pulverizing the second stream of mineralized coal to an extremely fine size, and supplying the second stream of finely pulverized mineralized coal to the high-temperature upper portion of the combustion zone in the furnace, whereby the pyrites of the mineral is roasted to Fe 2 O 3 and/or Fe 3 O 4 and all of the mineral content is prevented from forming slag in the furnace.

Claim 7

A process for burning highly mineralized coal, including, dividing raw coal with a high mineral content into a first stream of relatively low mineral content and a second stream of relatively high mineral content including pyrites, pulverizing the first stream of coal to a conventional size for combustion in a furnace, supplying the first stream of pulverized coal to a combustion zone in the lower portion of a furnace, pulverizing the second stream of mineralized coal to an extremely fine size, and supplying the second stream of finely pulverized mineralized coal to the high-temperature upper portion of the combustion zone in the furnace, whereby the pyrites of the mineral is roasted to Fe 2 O 3 and/or Fe 3 O 4 and all of the mineral content is prevented from forming slag in the furnace.

Claim 8

The process of claim 4, wherein, air is supplied to the combustion zone so that the fuel-air ratio of the lower portion of the zone is fuel-rich and the fuel-air ratio of the upper portion of the zone is air-rich.