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CDftL LOG AND METHOD This invention relates to novel coal products, particularly lumps of coal which are bound by a plastic matrix in a predetermined shape.

While from l e— o- ime, reference will be made to coal "log", it will be understood that it is intended that that term "log" includes predetermined shape of a mass of coal lumps in a matrix binder and includes elongated square of cylindrical shapes, with ?r without shaped holes therein, brick or book shapes, pie shaped, pill or pancake shaped or ball shaped, etc.

In a prior art commerci a l product sold under the trademark "TIBERi-OG" by The Sphinx Corp. of Akron, Ohio, the coal log had fine particles but had a size range of coal up to about 1 1 /2: inches bound in a therirtosetting isocyanate resin matrix and molded in a polyurethane plastic bag. It utilized a vsfy good grade of house coal (see test data set forth later herein). Such product was difficult to light, smoky and did not burn clean and was generally unsuccessful commercially.

In the prior art of coal logs, coal particles in a resin matrix, a wide variety of coals have been used, see Schaffer U.S. Patent ,586,936. However, 1 have found that a hard, non-porous, non-absorbent, low sulphur, low ash, high BTU coal having a grindability index undB^ about 1 is most desirable and, although somewhat more expensive, cannel coal has these properties has been found to be most preferred. Cannel coal is * form of bituminous or "soft" coal which ignites easily and

burns with a hct "candle-1 ike" flame and is especially desirable for open fires and metallurgical processes. (See Van Nost and' s Scientific Encyclooedia 193S at page 197.) Moreover, much larger coal sizes, which are herein characterized as "lumos" are used. While no coal log product can be made with a zer amount of fines or dust—like particles, a feature of the present invention is that the coal is in much larger pieces, such as lumps preferably in a size range of

« about 1 1/4 to 3 l/£ inches in a diameter resulting in an average size of ¹ about 2 1/3 inches, as opposed to small granulated pieces of coal or coal dust. Since the present invention uses much larger pieces of coal than prior art coal logs, it is better able to produce various sizes of coal logs giving longer burn times and considerably higher BTU' s per pound and si nificantly less smoke and with larger air interstices between the varieties of coal lump sizes. In contrast, small coal pieces tend to comoact in conjunction with the resin binder and form a more dense solid mass with few, if any, air interstices for supporting easy ignition and , combustion.

It is known i n the art of making charcoal briquettes to use a low odor base solvent as an igniter for the briquettes and reference is made to such an igniter called L.O.B.S. ^(TM> produced by Ashland Oil, Inc. and used the Kingsfσrd Products

Company as an ignition enhancement in that company* s charcoal ^b ri ^q uette oroducts. Most prior art coal logs (as well as other

artificial fuel logs) have had the problem of being difficult to ignite. A further feature of this invention is in the use of a low odor base solvent (such as the .0. B. S ^TM ⁾ product) as art igni ion enhancement comoonent in conjunction with the burnable molding bag described later herein.and larger air interstices described above. The low odor base solvent is spray mixed with the coal l mps and resin matrix components so that it is present in small but effective amounts and t impregnated throughout the coal lumps and resin in each coal log and facilitates burning of the log. Since the ignition enhancing component is interspersed and admixed in the resin matrix forming the above interstices, the ignition enhancing effect is applicable to all lumps of coal in the log.

Manganese is known as an anti-creosote forming element for wood burning fireplaces and water based catalytic manganese complex sorayed on wood burning fires allows the wood to burn more effectively, reduces smoke emission (that creates creosote) and produces more heat and converts existing creosote to a ash. According to this invention, a catalytic manganese complex may be admixed with the resin to produce similar results in coal log products of this invention.

In the pr i or art commercial Tige log product, the binding resin matrix (which required water to facilitate the chemical reaction) was understood to be thermosetting in nature, used heat which resulted in slower manufac ring process and required more employees to produce a given quantity of coal

/ logs. According to this invention, a self— uring ployol isocyanate binder consisting of equal oarts poly ethylene — polyphenyl isocyanate and polyethyer ployol and a catalyst IC^-* H5. _C , O S _N ) is used resulting in a significantly lower employee work force. By the practice of this invention a work force of 5—6 employees can produce four or more coal logs per second (approximately 14,4øcι per our) . Moreover, no water is required to induce the chemical reaction.

The coal is introduced to one end of a rotating mixing vessel in metered amounts (which can be controlled by a microprocessor) and is immediately sprayed with metered amounts of polyethyer ployol and the catalyst (which have the consistency of mineral oil) and thoroughly admixed to thoroughly coat the surfaces of the coal with the polyethyer ployol and catalyst. Then the polymethylene — polyphenylisocyanate component of the resin is sprayed on the coal lumps coated with the oolyethyer ployol and catalyst mixture (these resin components being on the surface of and only minimally absorbed, at the surfaces of the coal lumps because of the non—porous, non— bsorbent quality of cannel coal) and the chemical reaction begins. As the coal and resin mixture exit from the rotating mi x i ng vessel, it is loaded into plastic bags, which mold the product during the self—curing phase ⁽ 2-24 hours) to form coal logs which preferably weigh about four pounds each. Larger or smaller "logs" can easily be made according to the invention. By virtue of this process and

use of larger size lumps of coal a greater yield of coal logs per ton of coal, in ratio to the polymer isocyanates, is achieved.

A further important feature of the coal log according to this invention relates to the bag in which it is molded. Prior coal logs (as well as other coal logs) have used paper, pσlyurethane and polyethylene bags. It has been discovered that polyurethane and polyethylene plastic bags- tend to melt

« and adhere to and/or are absorbed into the coal as it burned thus inhibiting the free-flow of air to the coal per se with the result that prior art coal logs were difficult to ignite and smoldered rather than burned easily and with particular coals used (e.g., generally non—cannel- types) were smokey and generally unsatisfactory. According to a feature of this invention, burnable polypropylene plastic bags are used. In this particular envi ronment , the polypropylene bag 1) burns easily, 2) does not melt to a form that is absorbed by the coal and resin to smother or impede burning, 3) assists in the ignition of the coal log and 4> serves as the molding form for the coal. It should be noted that coated paper, bags hήve these

_* desirable features and also can assist ignition. Mesh bags can be used provided the mesh openings are of proper si ze to prevent coal lumps from falling out. (Since the coal lumps are coated with the cured resin, there is little chipping or dust formation) which would spill or leak through the open meshes o mesh bags. Moreover, the bag need not be circular and

elongated to form the conventional "log" shape. It can be pillow, or pancake or brick shaped so that one "log" can essentially lay flat on a fire place grate and one or aiore leaned on the "log" laying on the grate.

The objects of the invention are to provide an improved coal product comprised of lumps of coal which are bound by a resin matrix in predetermined shapes which are easily combustible, cl eaner burning to produce more heat, less smoke, and hence less pollution and is cleaner handling and prevents or eliminates creosote build—uo on chimney walls. ^'

DESCRIPTION OF THE DRAWINGS:

The above and other objects, advantages and features of the invention will become more apparent when considered with the following specification and accompanyi g drawings wherein:

Fig. 1 is a schematic representation of a manufacturing facility for producing coal logs according to this invention,

Fig. 2 and its enlargement balloon is a drawing showing the coal lumps and their adherence i n σredetermined shapes by surface—to—surface contact of the lumps leaving in many c ses air flow spaces or interstices for enhancing the combustion process,

Fig. 3 is an isometric view of a cylindrical coal log incorporating the invention,

Fig. 4 is an isometric view of a dual log i corporating the invention,

Fig. 5 is an isometric view of " pancake" shaped coal logs

incorporating the invention on a fireplace grill or grate,

Fig. 6 is a further isometric view of a pair of brick or book shaped coal logs incorporating the invention resting on a fireplace grate,

Fig. 7 is an isometric view of a coal log having a pie segment shape,

Fig. β is a side elevation view of a coal log as fot^ ed in an open mesh bag,

Figs. 9A and 9B are isometric views of coal ball logs in containers, and

Fig. lø is a side elevational view of pancake or brick shaped logs in a bag.

DETAILED DESCRIPTION OF THE INVENTION Referring now to Fig. 1, the coal log production facility illustrated is essentially the same as utilized in the prior art in production of Tigerlog ™ by the Sphinx Corporation, noted earlier herein. Coal, and in this preferred example, cannel coal, is dumped from a dump into hopper 18 which is located outside building wall 11. A conveyor 12 having a portion 12a beneath the hopper and an inclined portion 12b leading through facility wall 11 to an internal weighing and metering hopper 13 has its motor 12M controlled by a central control unit 14. Central control unit 14 is coupled to load cell sensing elements 16 which are utilized to determine the amount of coal metered from hopper 13 onto feed conveyor 17 which is a horizontal portion 17a and an inclined portion 17b,

with a control of drive motor 1 M being effected by central control 14. Thus, a predetermi ed amount of cannel coal is therefor delivered to the input hopper of a continuous zig-zag liquid—solid blender 2ι3 (manufactured by Patterson—Kelly, Inc. of East Strandsburg, Pa. ) . Liquid—solids blender 20 works with a tumbling action whereby particles move by gravity and produces an intimate blend of one part in about five thousand. Multiple recycling of a product is achieved because at each half turn, part of the liquid—solid blend moves forward and part of it moves backward in the zig-zag mixing drum with random splitting, merging, tumbling and rolling to bring the coal lumps and liquid particles into intimate contact. Short- term feed variations are leveled off by the time the blended material reaches the discharge chute and the recycling serves as an averag i ng device so that the blend is more precise than with short term inαut proportions. In addition to the coal lumps which are i ntroduced into hopper 19, other dry solids such as the colorant crystals can be introduced in the hopper in metered amounts from colorant crystal hopper 19CC and controlled from controller 14 via line 19CCL fov admixing with the various resins and other components to be described later herein. Blending time is in the order of about two minutes and can be adjusted by adjusting the slope of the axis of the rig—zag chamber.

Hopper 19 delivers input dry coal lumps and colorant if desired to initial feed and blending cylinder 21 which is

rotatable about a fixed axis and contains a liquid spray dispersion system diagramma ical ly shown as spray heads £2—1, 22-2... 2-n so that selected metered liquids are discharged as a mist or spray of controlled droplet size to impinge on the coal lumos (and, if desired, colorant) introduced through hopper 19. In the liquids-solids zig-zag machine, the in i-iate dispersion of liquids into the solids is accomplished by a high degree of airatiσn and a suspension of the solid coal lumps in the immediate area of the liquid spray.

As illustrated, controller 14, which may include modern microprocessor and memory storage chips and the like for performing the different metering and control functions, controls the introduction of the various components in closely metered amounts so as to achieve a high degree of consistency and for uniformity in the resulting coal product. A polyethyer ployol (Vora ol 21£iZ>™> is introduced from supply 23 via pump metering unit 23P to spray head 22-1 and, at the same time, a predetermined quantity of a catalyst Cata—Chek 821? ^ 2 ^5 -+ S _n ) from supply 26 is metered by a pump 26P to spray nozz le 22-2. Likewise, a metered amount of a liquid ignition enhancing component, preferably a low odor base solvent (L. O. B. S. (™) by Ashland Oil Company, Inc. from supply 27 and metering pump 27P is sprayed onto the coal lumps introduced from hopper 19 and exiting through the continuously rotating zig-zag mixer 25. This assures a thorough mixing and adequate coating of the coal lumps with the resin, ignition enhancing

low odor base solvent and the chemical colorant crystals.

Instead of a liquid ignition enhancing component, a solid ignition enhancer can be added via a further hopper (not shown) similar to hopper 19CC. However, the low odor base solvent ignition enhancer has produced highly satisfactory results in the practice of the invention and is preferred.

In addition, at this point, an anti—creosote compound such as catalytic manganese complex from source 28 may be pumped by a pump 28P to one of the spray nozzles 22. Anti—creosote water based catalytic manganese complex is - marketed under the trademark ACS by the Rolfite Company of Stanford, Connecticut, and allows the coal lumps to burn with less smoke emission and produces more heat and converts existing creosote on chimney walls to ash.

The microprocessor i n control station 14 controls the mixer according to the formula ordered by a particular customer. For example, if it is not desired to have the colorant added, the computer merely- prevents or does not order the introduction of the colorant crystals. In a similar manner, if it i.r> desired that no ,anti-creosote compound be added, this is achieved simply by the computer not admitting that particular chemical comoonent into the system.

After being thoroughly admixed with the coal lumps, the isocyanate is added to initiate the chemical reaction. The isocyanate (Lupranate ~* ^"M — polymethylene - polyphenylisocyanate) is supplied from source 3ø via metering

// pu p 3®P is sprayed from spray head 32 onto the thoroughly coated coal lumps in rotating mixer chamber 33 at the end of the PK zig-zag mach i ne £8.

It will be appreciated that one of the features of the invention is that the resin matrix binding the coal lumps into a solid mass does not require the admixture of water for the reaction to take pl ace. Moreover, in some cases, it may be desirable to pre— dry the coal so as to reduce the moisture content and thereby enhance its ignition properties. Thus, on conveyor 18B, a coal dryer, which simply is a heated air source, may be utilized to pre—dry the coal before admission into the hopper 19. As has been noted earlier herein, cannel coal is a coal that is rich in volatile constituents and burns with a bright flame and breaks with a conchoidal fracture.

That is, a fracture having many convexities and concavities which tend to facilitate the ignition and burning of the product in this particular environment. Moreover, it is a hard, non-porous, non-absorbent, high BTU coal low in sulphur, low in ash and has a grindability factor of less than 14 which are further attributes highly advantageous for use in- this particular application. Since there are larger pieces of coal

(1 1/2 inch to 3 i ches in diameter (within the 1 1/2 inch to 3

1/2 inch range) as opposed to smaller granulated pieces of coal or dust ⁾ , there are larger air spaces in each coal log notwithstanding the fact that precisely the same quantity of coal may be used as in prior art coal logs (e. g. , about four

pounds of coal) which facilitates the enhanced ignition properties and likewise facilitates the continuous ease of burning, reduces smoke and hence is less polluting.

The PK zig-zag machine drum 25 and the input drum 21 and output rotating drum 33 are all rotatable as a unit and are supported on bearings (not shown) and driven by a drive chain (not shown). As the drum rotates, a metered amount of the coal lumps coated with the ployol isocyanate binder matrix and Various additive chemicals and in particular with the low odor' base solvent serving as an ignition enhancer thoroughly impregnating the coal and/or the resin matrix, is delivered from a discharge chute 36 to a four—way, four logs per section log assembly unit 4<2> which carri es open ended pol ypropylene bags to receive approximately four pounds of the constituent which then is cured in the bag to form a solid mass of coal. The plastic bag may be tied off or heat sealed with a twist- tie or heat sealed or the like.

Coal logs CL, shown in rectangular section i n Fi g. 1, each in their individual plastic bags are conveyed on a conveyor 4^1 (controlled by control controller 14) to a box loading station 42 where a predetermined number of coal logs are loaded into cardboard boxes 42 at cardboard boxing station 43. A short ramp conveyor 44 delivers the boxed coal logs to a. pallet loading station 45 where the boxes are load and strapped onto the pallets 46. As noted earlier herein," this manufacturing facility is essentially the same as the one

/J utilized by the manufacturer of Tigerlogs except for the addition of various pumps and spray heads for spraying additional chemical low odor base solvent and/or the catalytic manganese complex. In addition, a hopper for the addition of solid crystals colorant component has likewise been added.

Referring now to Fig. 2, coal lumps 5ø-l, 50-2...50-n are shown bound at their contacting edges to each other by a resin matrix 52 leaving interstitical air soaces 53 scattered throughout the log. At the same time, the low odor base solvent ignition enhancer, colorant or the catalytic manganese complex anti-creosote compound (if used) are likewise scattered throughout the matrix and the coal log to thereby assure an easy ignition of the coal uniform flame color and/or the emission of the anti-creoso ing compound during use of the coal log in a conventional fireplace.

Fig. 3 shows a tubular plastic bag 6<3 in which the coal log, typically four pounds, has been molded in a polypropylene bag 61 with the end 62 of the bag 61 gathered in and sealed by a tie 63 which may be a conventional twist tie or the bag tπay . be heat sealed to close the log to prevent the admission of any contaminates or moisture.

I n F i g. 4, the polypropylene plastic bag 61' is shown as being formed as two logs or a dual log 60' in which the central portion of the polypropylene bag 6ø' is necked in as at 61 βo that two coal logs can be simultaneously loaded into a fireplace, for example, and burnt with equal facility. Such a

log would then weight about eight pounds which is suitable for- convenience of use in fireplaces and the li e by the average householder.

In Fig. 5, pill shaped coal logs 65—1, 55-2 arm shown on a fireplace grate 63 with the coal log 62—1 lying flat or substantially flat on the unoer surface of the grate 65 and coal log 62—2 having one end on the tip end on the fireplace grate 66 and one side leanmq or resting upon coal log 62—1. Similarly, brick or book shaped coal log 64—1 and 64—2 (Fig. 6) having holes 64H and in plastic bags which have been heat sealed at end 65HS are resting on a fireplace grating 63* with coal log 64-1 lying flat on the upper surface of grate 63' and the second brick or booked shaped coal log 64—2 having one end on the grate and leaning on the end of the coal log 64—1. For convenience of use in a home fireplace, such logs may be 1—2 pounds in weight and packed i n stacked fashion in either a clear or colored plastic bag 6ΞB (color coded according to colorant, for example) and heat sealed 65HS or twist tied as at 63T.

In Fig. 7, the log 7ø is shown as pie or wedge shaped for boxing and to resemble split wood logs. In Fig. 8, the coal has been molded in a fine mesh net bag 75 and due to the stretch character of such fine mesh net poly bag 73 (since the mesh is open, the melt character of this bag is not critical) lumps 75L-1, 73L-2 protrude out from the sides, but this does not adversely affect the product. Since each coal lump is

coated with a cured resin, the coal w ll be clean handling and comparatively dust f ree. A twist tie 75T closes off the mouth of the bag. In Figs. 9A and 9B, the coal logs S0, 80-1, 8ø-2...00-N have been molded into a ball shape and l oaded into an ignition assisting paperboard (wax coated) box container θ£ or color coded paper or plastic bags Q3 according to whether colorant is added, or the anti—creosoting component added, etc. In Fig. 10, the pill shaped logs 65 of Fig. 5 (or brick c shaped logs 64 of Fig. 6) are stacked in the bag 65B and the mouth of the mesh bag closed by a twist tie 75T.

Example No. 1 j

One hundred pounds of cannel coal in a size range of 1

1/2 inches to 3 inches ^; 'in diameter was thoroughly mixed with twenty—eight ounces (735 grams) of polyester ployol (Varβnσl 212ø (™>) and one gram of a cataylst (Cata-Chek 820 <™>| C32 H5 O S _n > and thoroughly mixed and then twenty—eight ounces (795 grams) of polymethylene—polyphenyl isocyanate

(lupranate <™)> was thoroughly mixed with the coated coal lumps which then initiated the reaction. This mixture was then loaded into cylindrical polypropylene bags (heat sealed at the sides and bottom with flat dimensions of about 6 1/2 inch by 17 inches) so that the resulting coal log weighed about four pounds and allowed to sel f-cure. Total production time was about four minutes and yielded twenty-five four pound logs.

Example No. 2

As a second example, the coal log formed i n Example No. 1 was modified by the addition of about thirty—six ounces of liquid low odor based solvent (L.0. B. S. (™) as sold by Ashland Oil Co.) as an ignition enh&ncer. Coal logs made according to this example were easily ignited and burned extremely well leaving very little ash and producing very little smoke.

Example No. 3.

Same as Example No. 2 with the addition of about thirty ounces of catalytic manganese complex in a. liquid state (which has a slight odor (apple in a decomposed state) . The burn results were the same as in Example No. 2 with additional known anti-creosoting effect of catalytic manganese complex.

Example No. 4.

The same as Example No. 2 with .the addition- f about 5.60 ounces of dry colorant. The dry colorant mix comprised about - equal parts copper sulfate. and ammonium chloride (0.8 pounds of copper sulfate to about 1 pound of ammonium chloride and in this examole 5.6 ounces of this mixture used) and gave the same pleasing result in flame coloration as an equivalent weight of copper chloride which has been conventionally used, and may also be used in this invention.

For coal logs, while 2% by weight of a polymer to 6> by

17 weight of poly ?r , -ivides satisfactory r- Its, the ' o-fcf satisfactory results were obtained with coal logs having about

3% polymer, the less polymer, the better since there is less clogging of the desired air interstices in the larger coal lumps of this invention.

Laboratory analysis of coal in a Tigerlog (™> coal product is as follows.

TIGERLOG SAMPLE NO. 1

^' rølSIURE/ASH

A ASS RREECCEEIIVVEEDD D DRRYY BBAASSIISS Jr'Kfc-fc; ((

Moisture 2.43 XXXXX XXX

Ash 13.34 • 14.67 XXX

Volatile 41.78 42.82

Fixed Carbon 42.46 43.51 XXX

Sulfur 0.86 0.88 XXX

BTU 12641 12956 '15007

Grindability Index 15.5

The log had i h ash level and smoke was low in BTU and soft in grinding and hence was not suitable in the practice of this invention.

Laboratory analysis of second coal sample ⁽ not TIGERLOG l™> revealed the following

EAGLE COAL SAMPLE - LOGAN CO. NO. 2 l^ISTOKVASH

AS RECEIVED DRY BASIS FREE

Moiftture 3.34 xxxx XXX

Aah 4.99 5.16 XXX

Volatile 35.70 36.93

Sulfur 0.68 0.70 XXX

BTU 14167 14656 15455

w _h i _l e t _h e c -1 has a low asn aπα 'u'πnut- concent and, It was very low on volatiles and had a very high grindability in _d ex and hence was not suitable for the practice of this nven ion.

Laboratory analysis of a third coal samole ⁽ not TIGERLOG (TM) revealed the following:

CHANNEL COAL, BERGOO SAMPLE NO. 1

AS ^• RECEIVED T" BASIS FREE

Hoiatura 2.85 XXXU XXX

Aah 6.99 7.19 XXX

Volatile 27.12 27.91 ^'

Sulfur 0.75 0.77 ^• XXX

BTD 197 14613 15746

Griadability Index 63.3

Again, while ash and sulphur contents was low, it waε also low in volatiles and had a very high grindability index and hence was not suitable for the practice of this invention.

Laboratory analysis of a fourth coaϊ sample (not TIGERLOG (™) revealed the following:

CANNEL COAL SAMPLE - LOGAN CO. NO. 1

MOlSπJFEfcSH FREE

AS RECEIVED DRY BASIS

Moisture 2.43 XXΛΛΛ XXX

Ash 9.06 9.29 XXX

Volatile 45.84 46.98

Sulfur 0.88 0.90 • XXX

BTU U&IA 14773 16285

Grindability Index 13.0

Although the ash and sulphur content are higher than the above second and third samples, the αrindadTlity ind»x is f*vor*bl low with v * s »' h T level and

when manu actured ito coal lo rtgs accordm to this invention, the logs were easily ignited, burned with good and lively flames and proved to be very satisfactory in the practice of this invention.

Laboratory analysis of a fifth coal sample (not TIGERLOG (TM ^% revealed the followi g:

CANNEL COAL

MOISTURE/ASH

AS RECEIVED DRY BASIS FREE

Moisture 2.44 XXXX XXX

' Ash 7.33 7.51 XXX

Volatile 53.21 54.55

Sulfur 1.17 1.20 XXX

BTU 14291 14649. 15839

Grindability Index 11.1

This sample had the highest level of volatiles and the lowest grindability index and proved to be the most satisfactory in the practice of the invention.

In this invention, canne l coa l is highly preferred because it has been found to perform most satisfactory as a coal log since it is more easily ignited and this easy ignition is enhanced significantly by the addition of the low odor based solvent ignition enhanci ng liquid compound (sold commercially under the trademark L.0. B. S. by the Ashland Oil Company) and because it burns with a hot candle-like f l ame due to its high percentage of volatile matter. As noted above, canne l coal breaks with a. conchoidal fracture and it is rich i volatile constituents and burns with a bright flame. The bright flame in conjunction with the colorants provides most pleasing visual effects in a

aid fireplace and thus is the most highly preferred form of coal for this invention.

While there has been shown and described a preferred embodiment of the invention, it will be appreciated that other embodiments will be readily apparent to those skilled in the art and it is intended that such readily obvious embodiments be encompassed within the claims appended hereto.

WHAT IS CLAIMED IS: