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coal beneficiation technology

coal beneficiation technology

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Published by Chandan Das

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Published by: Chandan Das on Dec 05, 2009
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08/17/2013

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2ND ASIAN MINING CONGRESS
16-19 January 2008, Kolkata, IndiaThe Mining, Geological and Metallurgical Institute of India (MGMI)
OPTIMIZING BENEFICIATION OF INDIAN NON COKINGCOAL WITH PROVEN TECHNOLOGIES
Gurudas Mustafi*
*Vice President, Humboldt Wedag India Pvt. Ltd., Kolkata, India
BENEFICIATION / DE-SHALING OFLUMP SIZED COAL
The development of the ROMJIG (Fig 1) openedthe possibility, to use a very simple process for thebeneficiation or de-shaling of the lump size coal - the topsize is 400 mm and the bottom feed size is 30 mm - byusing only one technologically improved machine andsome standard auxiliary equipment.In fact the idea was to solve the problem of preparingnon coking coal, as far as possible dry in R.O.W. Size/ state.Such plants are in operation at Bina and Kargali toseparate refuse and clean coal. (Ref : Flow Sheet 1)
BENEFITS
The removal of a certain portion of the refuse fromthe uncrushed raw coal offers great advantages forexample to name a few-Decrease of power requirements for sizereduction.-Increased yield of graded coal in the case ofdomestic coal production,-decreased yield of slurry,-more favourable homogenising properties ofthe raw coal,-decreased wear in the concentration machines,-more favourable utilisation of the preparationcapacity, i.e. increased efficiency of thepreparation plant.-low water and power consumption, lowexpenditure for other auxiliary equipmentThis process stands any time economical comparedwith other proven technologies of large refuse separation
Bina / India : Deshaling in front of a Powerplant ROMJIG
 
82 
Optimizing Beneficiation Of Indian Non Coking Coal with Proven Technologies 
RESULTSBINA 
Presently from this plant of NCL washed coal is produced with ash < 34% and is linked to Delhi Vidyut Board. Ingeneral the results are:
Raw Coal Screen analysis:Products of that plant:Grain sizeWt. %Ash %ProductWt. %Ash %
250 - 30 mm68.7842.13deshaled coal49.7631.3430 - 0 mm31.2238.08unwashed coal31.2238.08250 - 0 mm100.040.87saleable product80.9833.94Refuse19.0270.37
KARGALI
During the performance tests conducted over a span of 15 days a series of tests were conducted and followingresults were computed on an average basis:
Raw Coal Screen analysis:Products of that plant:Grain sizeWt. %Ash %ProductWt. %Ash %
350 - 50 mm45.340.75deshaled coal34.2630.750 - 0 mm54.732.56unwashed coal54.732.56350 - 0 mm100.036.27saleable product88.9631.84Refuse11.0471.96At a cut density of 1.9, the average imperfection determined was 0.089
PROBLEMS
Whenever the characteristics of the raw coal doesnot allow, to achieve the required product quality with theROMJIG by only washing the lump size coal, the grainsize of beneficiation has to be reduced.Reasons can be the grain size distribution, whenthe amount of material< 30 mm is too small and the ash content ofthe fine material is too high> 30 mm size fraction is quite high in bothquantity & ash content
REMEDIES
This leads immediately to the beneficiation of coarsecoal by means of Batacâ jig or Heavy Media TeskaâSeparator.
BENEFICIATION OF COARSE GRAINCOAL
For beneficiation of coarse coal there are two provenprocesses - Heavy Media Bath / Drum or Jigs.Both Batacâ Jig (Fig 2) or Heavy Media TeskaâSeparator / Heavy Media Bath (Fig 3) are in operation invarious washeries.
 
Gurudas Mustafi 
83 
A typical process for such a jig plant requires onlyvery few equipment while some additional equipment andthe magnetite circuit essentially comprising of magnetizer,magnetic separators and de-magnetizer are involved insuch a HM Separator / Bath plant. The coarse product 75(150)  13 / 6 mm is fed either to the Batac jig or HeavyMedia Teska Separator / H.M.Bath, where it is separatedinto refuse and clean coal and un-washed fraction (-) 13 / 6 mm mixed with Clean Coal. (Ref : Flow Sheets 2 & 3).The top size can be reduced to 50 mm depending on thegrain size distribution.In Batac jig the bottom washing size can be reducedeven to 3 mm, without a modification of the flow sheet.The only problem is the dry screening at the lower sizes,which can be solved by using the right screening system.Equally good operating results are achieved withthe Heavy Media Teska Separator / H.M.Bath withoutreducing the lower size and for which it needs to beensured that the media recovery circuit is properlydesigned and media of the correct quality & quantity ismade available.
RESULTSPIPARWAR
Piparwar washery under Central Coalfields Limitedhaving a capacity of 6.5 mtpa is equipped with two suchBatac Jigs, which forms the heart of the plant supplyingwashed coal of around 82 to 83% yield having ash < 34%to NTPC for their Delhi based power plants. Raw coalpresently fed has an ash in the range of 39 to 40%
PRIVATE WASHERIES
Plants with Jig and HM Bath for similar applicationhave been set up for private entreprenuers to wash powergrade coal in different locations adjacent to MCL, SECL& WCL mines. Some of these are already in operation .Results given in Table -1
RESULTS
The ash in raw coal received varies between 34 to38%. Results shown in both cases are with 38% ash inraw coal but from different mines of WCL.
HEAVY MEDIA BATH
The results from a plant installed at Wani supplyingwashed coal to MSEB are:
Table - 1 : Results from Private Washeries
Raw Coal Screen analysis:Products of that plant:Grain sizeWt. %Ash %ProductWt. %Ash %
50 - 13 mm68.0037.80washed coal41.0024.1013 - 0 mm32.0040.00unwashed coal32.0040.0050 - 0 mm100.0038.50saleable product73.0031.07Refuse27.0058.60Operating Cut Density: 1.45

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