United States
                    Environmental Protection
                    Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
                    Research and Development
 EPA/600/S7-85/032 Apr. 1986
&EPA         Project  Summary
                    Economic Evaluation of  Oil
                    Agglomeration for  Recovery  of
                    Fine Coal  Refuse
                    L Larkin and J. D. Maxwell
                      In this project economics of an oil-
                    agglomeration process with and with-
                    out an oil recovery system were evalu-
                    ated for recovering coal fines from a
                    fine refuse stream of 105 ton/hr* from
                    a coal preparation plant. The two base
                    case  processes studied  are an  oil-
                    agglomeration process in which heptane
                    is used  and recovered and an  oil-
                    agglomeration process in which fuel oil
                    is used and blended with the product.
                    The economics for both processes were
                    estimated with  and without a pond
                    credit (savings in coal preparation plant
                    investment resulting from the smaller
                    waste disposal pond needed for the oil-
                    agglomeration process). The total capi-
                    tal investments for the recovery and
                    nonrecovery processes without a pond
                    credit are $21 million and $13 million,
                    respectively. With the use of the pond
                    credit, the total capital investment for
                    the recovery process is $9 million, and a
                    capital investment credit of $0.2 million
                    is received for the nonrecovery process.
                    The first-year annual revenue require-
                    ments for the recovery and nonrecovery
                    processes are $6.4 million (0.86 $/106
                    Btu) and $8.0 million (1.10 $/10s Btu)
                    with a pond credit and $8.5 million
                    (1.15 $/10e  Btu)  and $10.3 million
                    (1.42 $/108 Btu) without a pond credit,
                    respectively. These costs compare quite
                    favorably with an eastern bituminous
                    coal which  has a  heating value  of
                    11.000 Btu/lb and cost of 1.85 $/10B
                    Btu (40.70 $/ton).  Both the recovery
                    and the nonrecovery processes appear
                    to be economically feasible, but the
                    •Readers more familiar with metric units may use the
                    conversion factors at the back of this Summary.
recovery process is more cost-effective
for recovering fine  coal from refuse
streams.
  This Project Summary was developed
by EPA's Air and Energy Engineering
Research Laboratory. Research Triangle
Park, NC. to announce key findings of
the research project that is fully docu-
mented in a separate report of the same
title (see Project  Report ordering in-
formation at back).

Introduction
  In this report, the economics of an oil-
agglomeration process with and without
oil recovery system are evaluated.  The
two base case processes studied are an
oil-agglomeration process using  heptane
with a heptane recovery system and an
oil-agglomeration process using fuel oil
that does not have an oil recovery system.
The design data for the processes are
based on information from vendors and
researchers of oil-agglomeration and oil
recovery systems. The econmics of both
processes are presented and compared,
and several case  variations are  also
examined.

Background
  Much of the coal lost in the waste from
coal-cleaning plants consists of fine  coal
that is difficult to separate from  noncoal
minerals with conventional coal-cleaning
techniques. The use of highly  efficient
coal-cleaning processes and cleaning of
coal with finely dispersed pyrite, both of
which necessitate more extensive use of
fine coal-cleaning techniques, can dra-
matically increase  the quantity of  coal
lost in the  fine waste stream  and the

-------
volume of fine waste produced. The coal
loss represents  a substantial potential
resource,  and the  waste itself, which
consists of a  slurry that is difficult to
dewater and must be confined in a pond,
poses increasingly serious economic and
environmental problems. Consequently,
interest in  methods of  cleaning  and
recovering fine coal has increased. One
of the most effective methods is the oil-
agglomeration process developed by the
National Research Council of Canada.
  The  oil-agglomeration  process  is  a
means both of cleaning fine coal and of
recovering the coal in a more useful form.
Fine coal (in the minus 28-mesh range) is
dispersed  in an  agitated  vessel with a
light oil such as heptane, fuel oil, or
kerosene, and in some  cases a small
quantity of a binder such as asphalt is
used. By carefully controlling the degree
of agitation, the  oil  is dispersed in small
droplets  in which  the coal  and other
oleophilic (oil attracted) minerals collect,
forming small spherical  particles.  Over
90% of the coal in a fine coal slurry can be
recovered in this manner. In  spite  of its
effectiveness, the process has not gained
commercial acceptance because of the
cost of the oil used. The agglomeration
process becomes more economically at-
tractive when designed for low oil-to-coal
ratios; however, there is also a corre-
sponding decrease  in  coal recovery
efficiency and product quality. Recovery
and reuse of the  oil would  allow the
agglomeration  process  to  operate at
higher oil consumption levels with greater
coal  recovery and improved product
quality.
   The recovery process is  ostensibly
simple: the mechanically dewatered ag-
glomerate is heated to vaporize the oil
and the vapor is condensed to recover the
oil. Several companies have investigated
aspects of an  oil-agglomeration process
with an oil recovery system  but many
technical  and  practical details remain to
be defined. The primary  technical chal-
lenge  is the development of a heating
system that provides efficient and con-
trollable heat transfer without thermal
and mechanical  damage to the particles.


Design  and Economic Premises
   The design and  economic premises
used in this study were developed by the
Tennessee Valley  Authority  (TVA) for
economic comparisons of processes re-
lated to coal-cleaning and emission con-
trol in electric  utility applications. The
conceptual process designs are based on
information provided by  vendors of oil-
agglomeration and oil recovery equipment
and systems. The plant  is assumed to
operate at 5,500 hr/yr for 30 years, with
a total operating life of 165,000 hours.
  The quantity and composition of the
feed to  the oil-agglomeration  plant for
this study are assumed to be similar to the
fine coal refuse produced by the Brecken-
ridge  Camp No. 11 coal-cleaning plant
near Breckenridge, Kentucky. The refuse
consists of a 10% solids slurry produced
at a rate of 5.8 million ton/yr. The solids
have  a  maximum size of 28  mesh and
consist  of 47.5% coal, 2.5% pyrite, and
50% other noncoal minerals. The base
case  design  conditions for the oil-
agglomeration process (using heptane)
with a heptane recovery system (recovery
process) and the agglomeration process
(using No.  2 fuel oil) without a recovery
system (nonrecovery process) are shown
Table 1.    Process Design Conditions
in Table 1. Heptane was selected as the
oil in the recovery process because of its
distinct properties which make it easier to
recover than other oils, and No. 2 fuel oil
was used  in the  nonrecovery process
mainly because of its lower cost.
  A 30-day-capacity holding pond and a
30-year-capacity waste disposal pond are
provided for the oil-agglomeration plant
as a replacement  for the large volume
waste  disposal pond that would  have
been required for the coal-cleaning plant
if the waste had not been processed. The
waste disposal ponds are square earthen-
diked  impoundments with a median di-
verter dike and a 12-in. clay lining.
  Raw materials consist  of  a  propane
precipitated asphalt at 189.2 $/ton and
commercial grades of heptane. No. 2 fuel
oil, and kerosene at 1.60, 1.09, and 1.32
$/gal., respectively. All raw materials are
                                                        Process
                                             Heptane
                                           With Recovery
                        Fuel OH
                    Without Recovery
Feedstock
Rate. 10*lb/hr
Slurry concentration. % solids
Solids composition. %by wt(dry)
  Coal
  Noncoal minerals
  Pyrite

Operating Conditions

Time, hr/yr
Coal recovery. % of coal feed
Oil. % of undried product
Asphalt, % of undried product
Oil recovery. % of oil feed

Product"

Production, ton/yr
Solids composition. % by wt (dry)
  Coal
  Noncoal minerals
  Sulfur
  Water
  Heating value. Btu/lb (dry)

Waste
Rate. W'lb/hr
Solids, %
Coal. % of waste
         2.1
        10

        47.5
        50
         2.5
     5.500
        92
        18'
         2
        97.7
   289.000

        89
         8
         3
        <5
     12,900
         1.9
         5
         0.3
      2.1
     10

     47.5
     50
      2.5
  5,500
     90
      6.1"
      0
      0
302.000

     83
     14
      3
     30
 12.000
      1.9
      5
      0.4
* This number corresponds to 14.1% of oil based on the weight of the feed solids and 21.4% oil based
 on the dry weight of the agglomerated product (water-free basis).
"This number corresponds to 5.0% oil based on the weight of the feed solids and 8.7% oil based on
 the dry weight of the agglomerated product (water-free basis/.
CAII product percentages and the heating values are based on the dry weight of the product (coat
 and all noncoal minerals, including pyrite) and do not include the weights or effects on heating
 value ofresidualoH. asphalt, or water (the heating values of the residual oil and asphalt ate taken
 into account in the economics).

-------
delivered  by  rail  in tank cars and are
stored in tanks sized to provide a storage
capacity of 30 days.
  The  economic  estimates  consist of
capital investments and both first-year
and levelized annual revenue require-
ments. Capital investments are based on
mid-1982 costs  and annual revenue
requirements are  projected to 1984 and
are based on 5,500 hr/yr of operation at
full capacity. The capital investments also
include pond credits which  are deter-
mined by subtracting the cost of the 30-
day-capacity holding pond and the 30-
year-capacity waste disposal pond for the
agglomeration plant from the cost of the
coal-cleaning plant 30-year-capacity
waste disposal pond.


Process Description

Oil Agglomeration with
Heptane Recovery
  The process consists of four identical
trains  of  agglomeration and heptane
recovery equipment, supplied by a single
feed tank and raw material storage and
supply system. The flow diagram is shown
in Figure  1. The agglomeration plant is
designed to process a 10% solids slurry at
a rate of 2 x 108  Ib/hr (about 4,000
gal./min of slurry) for 5,500 hr/yr for 30
                                 years. The 10% solids slurry is recovered
                                 from the coal-cleaning plant holding pond
                                 and pumped to  a  scalping screen that
                                 removes particles over 0.5 mm in size.
                                 The slurry that passes through the screen
                                 is stored in an agitated tank from which it
                                 is pumped to the high-shear mix tank.
                                 Along with the slurry, 18% heptane and
                                 2% asphalt (both based on agglomerated
                                 product from the screen) are added to the
                                 mix tank. The high degree of agitation
                                 produces very fine droplets of heptane
                                 and asphalt in which the coal and other
                                 oleophilic  minerals  agglomerate. The
                                 slurry flows to the low-shear mix tank
                                 which has a lesser degree of agitation
                                 and allows the small agglomerates formed
                                 in the high-shear mix  tank to coalesce
                                 into particles 2 to 3 mm in diameter (an
                                 adequate size particle for thermal drying).
                                   The slurry flows by  gravity from the
                                 low-shear mix tank to a vibrating screen
                                 which removes agglomerated particles.
                                 The unagglomerated  particles (mostly
                                 noncoal minerals) and  liquid drain to a
                                 refuse tank. The agglomerated particles
                                 are transferred by belt conveyor to the
                                 heptane recovery system. The agglomer-
                                 ation plant is designed to recover 92% of
                                 the coal in the waste and produce 289,000
                                 ton/yr of product containing 89% coal,
                                 8.0% mineral matter, and 3.0% sulfur
                                 with a heating value of 12,900 Btu/lb
(not including residual heptane and the
asphalt binder).
  The recovery  system consists of a
fluidized-bed dryer; a particle purge ves-
sel; and associated gas circulating, solids
collecting, and  condensing equipment.
The particles are transported from the
feed bin in a screw conveyor and fed to
the dryer through an air lock. The particles
are fluidized with a  heated  mixture of
60%  heptane  and 40%  water  vapors
which vaporizes 95% of the heptane and
water in the particles.
  The gas from the dryer passes through
a cyclone and filter to remove entrained
solids. Two-thirds of the gas  is recycled
through a compressor and  heated to
465°F before entering the dryer and one-
third is passed  through a water-cooled
shell-and-tube heat exchanger that con-
denses and cools the heptane and water
to 100°F. The condensate drains to a
condensate tank in  which the heptane
and water separate. The  heptane  is
returned  to  the agglomeration  system
and the water is pumped to the waste
pond.  Approximately 97.7% of the hep-
tane is recovered.

Oil-Agglomeration Without
Oil Recovery
  The nonrecovery process used No. 2
fuel oil and is based on conditions typical
                         Asphalt
                         Storage
                          Tank
                                    Heptane
                                    Storage
                                      Tank
                                                    Heptane
                                                      Feed
                                                      Tank
      Mud Cat
   Coal Refuse Pond
          n
                                        Low-Shear
                                       Agglomerating
                                           Tank
       Scalping
       Screen
Overflow
   to
Disposal
                                                          Fluid/zed
                                                            Bed
                                                     Feed   Dryer
                                                      Bin
                                                                                                             To Drain
                                                  • To Disposal
                                                    Pond
                                                                                      Steam
                                                                                  Recycle
                                                                                   Gas
                                                                                  Heater  _ -  -
                                                                                          Preparation Plant.
                                                                                        fl   Clean Coal
                                                                                             Stockpile
Figure 1.   Oil-agglomeration process with heptane recovery.

-------
of those conventional oil-agglomeration
processes in which the quantity of oil
used is minimized to reduce cost. The
nonrecovery  process differs from the
recovery process by the use of a  less
expensive oil and a much lower oil content
in the agglomerated product (6.1 % fuel oil
based on the agglomerated product from
the screen—see Table 1) and the absence
of the oil recovery system. As a result of
the lower oil content, the coal recovery is
somewhat lower (90%) and the product
particle size is smaller (+100 mesh). [The
quantity of oil used in the agglomeration
process has the greatest effect on the
product particle  size and coal  recovery
rate. The physical properties of the oil
(e.g., density, viscosity) will have a slight
effect,  but  were  not evaluated in this
study since their effect was considered to
be very minor when compared to the
effect of the oil level.] The flow diagram
for the nonrecovery process is shown in
Figure 2. The equipment and process
descriptions for the nonrecovery process
are similar to the agglomeration circuit in
the recovery process except for the dele-
tion of the asphalt binder for the agglom-
erated coal which is not needed since the
nonrecovery  product  is  not  thermally
dried.

Results
  Capital investments and first-year and
levelized annual revenue requirements
are developed for the base case processes
just described.  Several  case  variations
and sensitivities are examined for the
base cases, and the alternative of using
kerosene or heptane instead of fuel oil is
evaluated for the nonrecovery process.

Capital Investment
  The summary of the capital investment
estimates for the base case processes is
shown  in Table  2.  The  total  capital
investment for the recovery process is $9
million  with  the  pond credit and  $21
million without the pond credit. The total
capital investment for the  nonrecovery
process using fuel oil is almost $13 million
without the pond  credit and a  capital
investment credit of  $0.2  million is re-
ceived with the pond credit. The major
capital investment difference for the base
case processes is in  the total process
capital. The total process capital  for the
nonrecovery  process is  approximately
                           43% less than the recovery process. The
                           smaller process capital cost for the non-
                           recovery  process is due to the exclusion
                           of the  heptane  recovery system, which
                           accounts for  approximately 43% of the
                           total process capital  for  the  recovery
                           process.
                             The pond credit for the nonrecovery
                           process is approximately 6% higher than
                           the recovery process. This is a result of
                           the nonrecovery process  using a  lower
                           oil-to-coal ratio, and thus having  lower
                           coal but  higher  ash recoveries,  which
                           subsequently  decrease the quantity of
                           waste solids and require a smaller refuse
                           pond for the nonrecovery process.
                             The pond credit has a very large effect
                           on the capital  investments and the differ-
                           ence is  illustrative of the  large cost
                           associated with pond  disposal of large
                           volumes  of waste. The pond credit re-
                           duces the total capital investments for the
                           recovery  process by approximately 57%
                           and the  nonrecovery  process  by more
                           than 100%.

                           Annual Revenue Requirements
                             The first-year  annual revenue require-
                           ments for the recovery process are $6.4
   V""	I	f_	r
    \ Coal Refuse Pond/
                          Scalping
                          Screen
                   Overflow
                      to
                   Disposal
                                           °™     ggy°

                                                                   No. 2
                                                                  Fuel Oil
                                                                  Storage
                                                                   Tank
 Low-Shear
Agglomerating ^T^>
                                Screen
                                                          Tank
                                              High-Shear -
I                                                Mixing
                                                 Tank
                                                       Overflow   Collection
                                                    k	I Tank I    I  Tank
                                                      Agglomerated
                                                        Fine Coal
                                                                                                ci—r5>
                                                         Preparation Plant
                                                            Clean Coal__
                                                             Stockpile
                                                                                    To Disposal Pond
Figure 2.   Oil-agglomeration nonrecovery process with fuel oil.

                                   4

-------
Table 2.    Summary of Capital Investments
            Investment Area
                                                  Total Cost, $1000$
                   Nonrecovery Process
 Recovery Process     With No. 2 Fuel Oil
Total process capital
Total indirect investment
Working capital
Other capital charges


    Total capital investment
     10.015
      6.546
        909
      4.029
5.668
3.704
1.109
2.279
excluding pond credit
Pond credit
Total capital investment
21,499
(12.168)
9.331
12.760
(12.926)
1166)
million, as compared with $8.0 million for
the nonrecovery process with fuel  oil,
including the pond credit in both cases.
The  difference in  annual revenue  re-
quirements between the two processes is
due mainly to the larger quantity of oil
consumed by the nonrecovery process,
which replaces that  lost in the coal
agglomerates. Even though a heat credit
is applied for the oil, it is not enough to
offset the difference between the cost of
the two  processes.  The  first-year unit
revenue  requirements are  0.86 $/108
Btu (22 $/ton) for the recovery  process
and 1.10 $/106 Btu (27  $/ton) for the
nonrecovery process, including the pond
credit in both cases. Without the pond
credit, the unit costs are 1.15 $/106Btu
(30 $/ton) for the recovery process and
1.42 $/106 Btu (34  $/ton) for the non-
recovery process. These costs compare
quite  favorably with an eastern  bitum-
inous coal which has a heating value of
11,OOOBtu/lbandcostof1.85$/106Btu
(40.70 $/ton).


Case Variations
  Since the design data for the processes
are based  on laboratory tests,  several
case variations and  sensitivities are ex-
amined, as shown in Table 3, for different
pond credits, raw material costs, asphalt
contents, and  coal  recoveries  for the
recovery process and  the nonrecovery
process with fuel oil.  Different heptane
recoveries  and purge gases are  also
evaluated for the recovery process, along
with the effects of including a pelletizing
system  for the product. The  effects of
using alternate agglomerating  agents
(oils) and of using a centrifuge to separate
the liquid from the coal agglomerates are
also evaluated for the nonrecovery pro-
cess.
  The pond credit has a major effect on
both the capital  investment and annual
revenue requirements of both processes.
With the pond credit, the capital invest-
ments for the recovery and nonrecovery
processes are 57% and over 100% lower,
respectively,  than capital investments
without pond credits. The first-year an-
nual  revenue requirements for the re-
covery and nonrecovery  processes are
increased 34% and 28% without the pond
credit. The smaller percentage increase
for the nonrecovery process results from
the greater importance of the raw material
cost, which is the predominant factor in
its annual revenue requirements. The
recovery and nonrecovery processes are
also sensitive to raw material  price,
asphalt content, and coal  recovery  rates.
The recovery process is also sensitive to
heptane recovery rates and slightly sensi-
tive to the type of purge gas selected. The
addition  of a pelletizing area to  the
recovery process increases the capital
investments and annual revenue require-
ments by 13% and 23%, respectively, and
the use of a centrifuge in the nonrecovery
process increases its capital investment
and  annual revenue  requirements by
150% and 1O%,  respectively.  However,
the cost for adding the pelletizing area to
the recovery process (first-year annual
revenue requirements of 1.06 $/106 Btu
with the pond credit) and  using a centri-
fuge in  the nonrecovery  process  (first-
year annual revenue requirements  of
1.21  $/106 Btu with the  pond  credit) is
still less than the cost of the premise coal
at 1.85$/108Btu.
  The first-year annual revenue require-
ments of  the nonrecovery process are
 projected for two other agglomerating
 agents (heptane and kerosene). The other
 nonrecovery  processes in which  the
 weight of heptane and kerosene in the
 product is the same as for the  fuel oil
 process have substantially higher annual
 revenue requirements—$10.5 million for
 the kerosene process and $15.3 million
 for the  heptane  process, as compared
 with $8.0 million for the fuel oil process.
 The predominant difference is  the oil
 costs—1.09, 1.32, and 1.60 $/gal.  for
 fuel oil,  kerosene, and heptane, respec-
 tively.

 Effect of Oil Consumption on
 Annual Revenue Requirements
  The effect of the quantity of oil used on
 the cost of the nonrecovery processes is
 shown in Figures 3 and 4 in comparison
 with the recovery process at different oil
 recovery efficiencies. The recovery pro-
 cess has the same oil and asphalt content
 in the agglomerated product as the base
 case processes—18% oil and 2% asphalt
 in the agglomerated coal.
  The nonrecovery process annual reve-
 nue requirements increase rapidly with
 increasing  oil consumption. This is  pri-
 marily due to the  higher consumption of
 fuel oil which  is the predominant cost
 factor  in the first-year  annual revenue
 requirements. The cost of the nonrecovery
 product with the pond credit exceeds the
 cost of the premise coal (1.85 $/108 Btu)
 at oil levels of 11 % or higher (9% without
 the pond credit) as shown in Figure 4.
  The recovery process annual revenue
 requirements are not related to oil content
 in the agglomerated  coal but  to  the
 efficiency of the oil recovery system. As
 the recovery efficiency decreases (percent
 oil loss increases), the annual revenue
 requirements increase rapidly as  shown
 in Figures 3 and 4. At an 18% to 20% oil
 loss in the recovery process, the  cost of
 the product with the pond credit exceeds
 that of the premise coal at 1.85  $/108
 Btu. With no pond credit, the cost of the
 recovery product exceeds the premise
 coal at an oil loss of approximately 13.5%.
  At the base case conditions evaluated
 in this study, the recovery process is less
 expensive to operate than the nonrecov-
 ery process. Also, a poorer  quality of
 product is produced in  the nonrecovery
 process,  and there may be greater un-
 certainty concerning the capability of the
 nonrecovery process (at the low oil levels)
 to actually yield a product suitable for use
 in a pulverized-coal-fired boiler. However,
the nonrecovery process could be eco-
 nomically competitive if lower than base

-------
Table 3. Case Variation Cost Sensitivities
Oil Agglomeration With Heptane Recovery
Capital
Investment
Variation
Pond credit
Base case
50% of base case
No pond credit
Raw materials price"
80% of base case
Base case
140% of base case
Asphalt used*
50% of base case
Base case
150% of base case
Coal Recovery*
90% of base case
Base case
105% of base case
Heptane recovery
80%
90%
95%
Base case (97.7%)
99.7%
Purge gas
Base case (air)
Inert gas
Nitrogen
Pallatization
Base case
Base case with
palletization
Centrifuge
Base case
Base case with
centrifuge
Oils
Base case (fuel oil)
Kerosene
Heptane
$10"

9.3
15.4
21.5

9.29
9.3
9.4

9.1
9.3
9.6

9.5
9.3
9.1

10.0
9.6
9.4
9.3
9.2

9.3
9.2
9.8

9.3

10.5








Change. %


+66
+131

-0.1

+1

-2

+3

+2

-2

+8
+3
+1

-1


-1
+5



+13








Annual Revenue
Requirements*
$/1OtBtu

0.86
1.00
1.15

0.79
0.86
1.01

0.78
0.86
0.94

0.95
0.86
0.82

1.96
1.34
1.03
0.86
0.74

0.86
0.74
0.75

0.86

1.06








Change, %


+16
+34

-8

+17

-9

+9

+10

-5

+128
+56
+20

-14


-14
-13



+23








Oil Agglomeration With Fuel Oil
Capital Annual Revenue
Investment Requirements*
$10*

(0.2)
6.3
12.8

(0.3)
(0.2)
0.1


(0.2)
1.0

1.5
(0.2)
(1.2)















(0.2)

0.1

(0.2)
0.1
0.5
Change. % $/10*Btu

1.10
+3,250 1.26
+6.500 1.42

-50 0.86
1.10
+150 1.60


1.10
+600 1.41

+850 1.27
1.10
-500 1.02















1.10

+ 150 1.21

1.10
+ 150 1.45
+350 2. 1 1
Change, %


+15
+29

-22

+45



+28

+15

-7

















+ 10


+32
+92
*1982 dollars.
"first-year annual revenue requirements in 1984 dollars.
cAsphalt and heptane or fuel oil.
a1%. 2%. and 3% of undried product for the recovery process; 0% and 3% for the nonrecovery process.
'83%. 92%. and 97% for the recovery process; 81%. 90%. and 95% for the nonrecovery process.
case oil recoveries are achieved in the
recovery process. As shown in Figure 3,
the first-year  annual revenue  require-
ment with pond credits for the recovery
process with  only 2.3% oil  loss (base
case) is equivalent to the revenue  re-
quirements for the nonrecovey process at
an oil level of 4.5% in the product, but at
oil losses greater than 6.5% (recoveries
less than 93.5%), the first-year annual
revenue requirements for the base case
nonrecovery process (oil level of 6.1 % in
the product) with pond credits are less
than for the recovery process.

Conclusions
  Based on typical costs for coal, the oil-
agglomeration process appears to be an

-------
                              Recovery Process Oil Loss. % of Heptane Feed
                   5.0
                       10.0
                         I
   15.0
    I
20.0
  I

I
a
o

II
10 O
  -
H
      6.0-
5.0-
     4.0-
  £  3.0-

C
     2.0-
     1.0-
Nonrecovery Process with No. 2 Fuel Oil

Recovery Process with Heptane
                       ~~" ~~" Premise Coal Price (1.85 S/10* Btu)

                        •      Base Case
         0         2.0        4.0       6.0        8.0        10.0       12.0       14.0       16.0

                                 Nonrecovery Process Oil in Product, % by wt. in the Agglomerated Coal

Figure 3.    First-year annual revenue requirements (with pond credit) for the recovery and nonrecovery processes.
                                                                                                18.0
                                                                           20.0
effective method for recovering coal fines
from coal-cleaning plant refuse. Both the
recovery and the nonrecovery processes
appear to  be economically  feasible
methods but, depending on the base case
amounts of oil used in the two processes
and the efficiency of the oil recovery in
the recovery system, the recovery process
is more cost effective. As a result of the
more favorable economics for the recov-
ery process at the  higher oil  recovery
efficiencies  (greater than 93%). it  is
recommended  that  this  technology be
tested to determine if the recovery system
can  be operated  with the desired  effi-
ciency. If the  recovery  system cannot
operate at the higher oil recovery  effi-
ciencies (greater than 93%), examination
of the  nonrecovery process may be ad-
visable.
                                   Metric Conversions
                                     Readers more familiar with metric units
                                   may use the following metric conversion
                                   factors:
                                     Nonmetric
                    Times    Yields Metric
                                     Btu
                                     °F
                                     gal.
                                     in.
                                     Ib
                                     ton
                    1.055
                 5/9(°F-32)
                    3.785
                    2.54
                    0.454
                    907.2
                        J
                        °C
                        I
                        cm
                        kg
                        kg

-------
                  5.0
                  Recovery Process Oil Loss, % of Heptane Feed

                 10.0       15.0      20.0
•6
I
     6.0-
     5.0-
 *^
 jo § 4.0-
 § tj
 5 $
 .gl

 II „.
 s>a
 = oa
     1.0-
                         Nonrecovery Process with No. 2 Fuel Oil

                         Recovery Process with Heptane

                         Premise Coal Price (1.85 $/10e Btu)
                         Base Case
Figure 4.
      2.0        4.0         6.0        8.0        10.0       12.0        14.0       16.0

                    Nonrecovery Process Oil in Product, % by wt. in the Agglomerated Coal

First-year annual revenue requirements (without pond credit) for the recovery and nonrecovery processes.
                                                                                                      18.0
                                                                                                                20.0
   L Larkin and J. D. Maxwell are with the Tennessee Valley Authority, Muscle
     Shoals, AL 35661.
   Julian W. Jones is the EPA Project Officer (see below).
   The complete report, entitled "Economic Evaluation of Oil Agglomeration for
     Recovery of Fine Coal Refuse." (Order No. PB 86-161 304 /AS; Cost: $11.95.
     subject to change) will be available only from:
           National Technical Information Service
           5285 Port Royal Road
           Springfield. VA 22161
           Telephone: 703-487-4650
   The EPA Project Officer can be contacted at:
           Air and Energy Engineering Research Laboratory
           U.S. Environmental Protection Agency
           Research Triangle Park. NC 27711
                                                                         U. S. GOVERNMENT PRINTING OFFICE: 1986/646-116/20802

-------
p- a>
   co
oo    <
en    a>

O    S
w    c
IS)    V)
      CD

      
      10
                     q =
                     D  -
                     3  a
                     B)  C
                     s.  c

                     O:
                     I
                     0)
                     00

-------