Coal Preparation

COAL PREPARATION
Engr. Muhammad Shahzad

Assistant Professor
Department of Mining Engineering
University of Engineering and Technology,
Lahore.
Presentation Scheme
 Introduction to Coal Preparation
 Coal Characteristics related to Coal Preparation
 Coal Comminution and Sizing
 Cleaning of Coarse and Small Coal
Introduction to Coal Preparation
 What is coal preparation?
 Coal preparation is the stage in coal
production at which the run-of-mine
(ROM) coal, consisting of particles,
different in size and mineralogical
composition, is made into a clean,
graded, and consistent product
suitable for the market.
 Why is it needed?
 To increase heat value
 To lower transport cost
 To reduce emissions
 To improve marketability
Current Status
 World Preparation Industry
 2,300 plants worldwide
 1.5 billion clean tpy
 40% of consumed production
 U.S. Preparation Industry

 highest installed feed capacity
(>663 million tpy)
 267 plants in 16 states
 Pakistan Preparation Industry

 186 billion tons coal reserves
 No state-of-art coal processing plant*
Coal Characteristics related to Coal Preparation
 Inorganic matter in coal
 Objective of coal preparation
 Another definition of ash
 Relation between mineral matter and ash
MM % = 1.08 [% ash] + 0.55 [% sulfur] (for US coals)
MM = 1.1 [% ash] (in Australia)
 Heterogeneity of coal and sources of mineral matter in coal
 At the seam level
 At the ply and lithotype level
 At the macerals level
 At the submicroscopic level
 Extraneous and inherent mineral matter
 Recent findings
 Sulfur in Coal
 Importance of sulfur
 Types of sulfur in coal and their methods of determination
 Methods for determination of total sulfur in coal
 Typical sulfur analyses of world coals by Meyers
 Total sulfur (from 0.38% to a high 5.32%)
 Pyritic sulfur (0.09% to a high of 3.97%)
 Organic sulfur (0.29% to a high of 2.04%)
 Removability of sulfur (pyritic sulfur)
 Application of gravity separation
 Limitation of gravity separation
 Application and limitation of froth flotation
 Factors affecting coal desulfurization
• Pyrite particle size
• Dissemination of pyrite
 Liberation
 What does coal liberation mean?
 Coal liberation and float sink
analysis
 Effect of particle size
 M-Curve/Primary washability curve
and coal liberation
 Float-sink tests
Feed = Product 1 + Product 2 + . . . Product n
F = P 1 + P2 + . . . P n
On percent basis:
100 = γ1 + γ2 + . . . γn
where γ is the product yield (wt.%);
γ = (Pi/F)100
Ash balance can be expressed as follows:
Fα = P1 λ1 + P2 λ2 + . . . Pn λn
100α = γ1λ1 + γ2λ2 + . . . γ3λ3
Coal Comminution and Sizing
 What is comminution?
 Why is it needed?
 Coal Breaker and Crushers
 Rotary Breakers
 Introduction
 RPM (12-14)
 Feed size
• 8 ft. dia – 15 inch
• 12 ft. dia – 30 inch
 Product size
• Normal (3-8 inch)
• Min (1.0-1.5 inch)
 Advantages
• Highly reliable (Not damaged by hard rock or tramp iron)
• Long-lived screen plates (life > 10 years)
 Disadvantages
• Effect of moist, clayey materials
 Rotary Breakers
 Factors affecting designed (manufacturer) capacity
• Breaker diameter, length, diameter of holes, open area fraction
 Factors affecting basic capacity needed

• Hardness, size, distribution, and quantity of rejectable rock in coal
 Rotary Breakers
 Correction factor for hardness
Hardgrove factor = 0.01(HGI) + 0.4
 Correction factors for size distributions
 Breaker capacity needed
where BC = necessary basic capacity,

tons/h; DC = desired actual capacity, tons/h;
R = expected quantity of unbroken reject rock, tons/h.
 Rotary Breakers
 Selection of Coal Breaker based on capacity needed (An Example)
 A breaker is needed to process 750 tons/h (680 metric tons/h) of raw coal.
The target topsize is 3 inches (7.6 cm). There is expected to be 150 tons/h
(136 metric tons/h) of reject material. The coal has an HGI of 77. The coal
feed is 30% coarser than the desired topsize, and 40% of the coal is less
than 1.5 inches (3.8 cm) (half of the 3 inch topsize).
 Solution
The basic crusher capacity needed is then:
Note: Referring back to the 3-inch opening column of Table 9.1, a 9-foot (2.7 m)
diameter breaker would need to be 20.5 feet (6.25 m) long to give the desired
capacity, and an 11-feet (3.4 m) diameter breaker would need to be 16.5 feet (5 m)
long.
 Roll Crusher
 Introduction
 Factors affecting design
and operation of roll
crusher
• Speed and diameter
of the rolls,
• Desired capacity,
• Feed and product
size distributions
 Types of Roll Crushers
 Roll Crusher
 Types of roll crushers
• Single roll

Mainly used for oversize control

Reduce coal lumps to less than 6-14 inch

Product size (2-3 inch)

Capacity of single roll

30 tons/h for a 24 inch long roll with product size of ¾ inch

1500 tons/h for an 84 inch long roll with product size of 10 inch
• Double roll

Mainly used for size reduction

Product size (min ¼ inch, normal 2 inch)

Capacity

75 tons/h for a 24 inch long roll giving product size of ¾ inch
 Tramp oversize protection and use of grizzly
 Hammer Crushers
 Hammer Mill
• Introduction
• Factors affecting the performance

Rotor speed and diameter;

Type, configuration, and condition of the hammers;

Hammer clearance;

Feed characteristics and feed rate; and

Grid opening size
• Capacity (2500 tons/h to produce few mm product size from 5cm feed)
 Impactors
 Coal Sizing
 Introduction
 Stages of coal sizing
 Coarse coal sizing
 Intermediate coal sizing
 Fine coal sizing
 Coal Screening
 Introduction
 Screen media
 Sieve bends
• Construction & Working
• Applications
 Coal Sizing
 Coal Screening
 Vibrating screens
• Applications
 Circular motion screens
• Construction and working
 Coal Sizing
 Coal Screening
 Horizontal screens
• Construction and working
• Applications
 Banana screen
• Applications
 Coal Sizing
 Coal Screening
 Screen Selection
 Factors affecting screen capacity (type of screen surface, excitation
mechanism, screen geometry, type of coal)
Where
U = Quantity, in short tons/hour, of coal particles that will need to pass through the screen deck.
A = Basic screen capacity as determined using a standard material. Some representative values
are shown in Table 9.2.
B = Oversize factor, B = 1.23 – 0.876 (Fraction oversize)
C = Half-size factor, C = 0.434 + 2.259 (Fraction halfsize) 1.575
 Coal Sizing
 Coal Screening
Where
E = Wet screening factor, (typical water addition rates are 5–7 gallons/min for each ton/h of
solids). The wet screening factor is a function of the screen opening size, with a maximum value
of 2.5 for 3/16-inch (0.48 cm) screens, falling to 2.0 for ¼ -inch (0.635 cm) and 1/8-inch (0.318
cm) screens. The factor declines to 1.25 for 1-inch (2.54 cm) screens, and to 1.0 for 1/32-inch
(0.079 cm) and finer screens.
F = Material weight factor, accounting for the change in feed density. The standard is 100 pounds
per cubic foot (1600 kg/m 3 ), but the bulk density of coal is typically closer to 50 pounds per
cubic foot (800 kg/m 3 ). The factor F for a typical coal would therefore be 50/100 = 0.5.
G = Open area correction factor. If the screen to be used has a different open area than the
‘standard’ screens shown in Table 9.2, then
 Coal Sizing
 Coal Screening
Where
H = Screen opening shape factor, which applies when the screen openings are not square. For
‘short slot’ openings (rectangles 3–4 times longer than their width), the factor is 1.15. For ‘long
slot’ openings (more than four times longer than their width), the factor is 1.20.
J = Efficiency factor. This applies when the screen will remove less than 95% of the coal that is
finer than the opening size of the screen. It can be estimated from the equation J = 4.4 – 3.6
(fraction of fines to be removed)
 Coal Sizing
 Coal Screening
Where
H = Screen opening shape factor, which applies when the screen openings are not square. For
‘short slot’ openings (rectangles 3–4 times longer than their width), the factor is 1.15. For ‘long
slot’ openings (more than four times longer than their width), the factor is 1.20.
J = Efficiency factor. This applies when the screen will remove less than 95% of the coal that is
finer than the opening size of the screen. It can be estimated from the equation J = 4.4 – 3.6
(fraction of fines to be removed)
 Coal Sizing
 Coal Screening
 Screen Selection (An Example)
A coal is to be screened at 0.5 inches (1.27 cm). The desired feed is 500 tons/h, with
50% of the material coarser than 0.5 inches, and 35% finer than 0.25 inches. The
screen will operate dry, and screens are available with ‘short slot’ openings and an
open area of 65%. Assuming than a screening efficiency of 90% is acceptable,
calculate the necessary screen area.
Solution:
 U = 500 (0.5) = 250 tons/h of material that should pass through the screen
 A = 2.47 (from Table 9.2)
 B = 1.23 – 0.876 (0.50) 0.792 (50% of the material is coarser than thee screen size)
 C = 0.434 + 2.259 (0.35)1.575 = 0.866 (35% of the material is less than half of the screen size)
 D = 1 (only one screen is used)
 E = 1 (no washwater is added)
 F = 50/100 = 0.50 (Coal bulk density is estimated at 50 pounds per cubic foot)
 G = 65/54 = 1.2 (Screen has more open area than ‘standard’ 0.5-inch screen)
 H = 1.15 (for ‘short slot’ screen openings)
 J = 4.4 – 3.6(0.90) = 1.16 (removing 90 % of finer rather than 95 %)
 Coal Sizing
 Coal Screening
 Screen Selection (An Example)
A coal is to be screened at 0.5 inches (1.27 cm). The desired feed is 500 tons/h, with
50% of the material coarser than 0.5 inches, and 35% finer than 0.25 inches. The
screen will operate dry, and screens are available with ‘short slot’ openings and an
open area of 65%. Assuming than a screening efficiency of 90% is acceptable,
calculate the necessary screen area.
Solution:
 Coal Sizing
 Coal Classification
 Advantages of classifiers over screens
 Hydrocyclone
Cleaning of Coarse and Small Coal
 Introduction
 General Coal Preparation Plant
 Objective of coal handling and preparation plant
• to remove sufficient mineral matter to meet designated
product requirements, with minimal loss of combustible
material to the tailings.
• to minimise the production of fines, given that fine particle
processing is much more expensive, and the fine clean coal
product and the fine tailings are more difficult to dewater and
handle.
 Introduction
 General Coal
Preparation Plant
 Philosophy of
coal handling
and preparation
plant
 Introduction
 Classification targets
 Coarse coal class (> 50 mm)
 Small (intermediate) coal class (1.0 to 50 mm)
 Fine coal class (0.2 to 1.0 mm)
 Ultrafine coal class (<0.2 mm)
 Introduction
 Technology options for density separations
 Dry separation technologies
• Advantages
• Available technologies

optical or X-ray sorters and pneumatic jigs and tables
(for coarse class)

air tables and air-fluidised beds (for small/intermediate
class)
• Disadvantages
 Introduction
 Technology options for density separations
 Wet separation technologies
• Water-only systems

Jigs (for coarse and intermediate class)

Water-only cyclones, shaking tables, fluidised (teeter)
beds: < 3 mm, spirals: <1.4 mm (for fine class)

flotation: 0.040 - 0.2 mm (for fine class)
• Water-based dense mediums

Dense medium baths or vessels: upto 300 mm (for
coarse class)

Dense medium cyclones: 4.0 to 50 mm (for
intermediate/small class)
• Effect of near density material requirements of customer
 Theory
 Principles of gravity separation
 Based on the differences in settling velocity of high density and
low density particles.
 For spherical particles, in Stokes’ law regime where viscous
forces dominate (Ret = utρf d/μ < 1), free-settling velocity ut is:
 For the intermediate regime (1 < Ret < 500),
 In the Newton’s law regime (500 < Ret < 105):

 Theory
 For the full range up to Ret < 105:
here for Stokes’ regime, k = 2, m = 1 and for Newton’s regime,

k = 0.5 and m = 0.5.
 Hindered settling velocity uths:
Where n is the Richardson–Zaki coefficient, which varies from

2.4 for coarse particles to 4.6 or more for fine particles.
 where all the particles in the suspension have the same density
uths = ut εn
Where ε is suspension porosity.
 Theory
 Free settling ratio:
 For dilute systems where ρsusp = ρf
where m/k = 0.5 for small particles (in Stokes’ regime), m/k = 1 for
large particles (Newton’s regime) and 0.5 < m/k < 1 for particles of
intermediate size (approximately 0.05 to 5.0 mm for coal in water)
Where is called concentration criterion.
 Theory
 Principles of
gravity separation
 Free settling
ratio:
 Theory
 For medium having (ρA < ρf < ρB), then there is an infinite free-settling
ratio
 Effect of high density and viscosity
• Reduced settling rate
• Longer residence time required
 Free settling ratio – a measure of size range suitable for given
density-based separation
 Systems constructed to suppress the particle size effect
• Spirals: circulating transverse current – high shear rate
• Shaking table: fluid velocity – high shear rate
• Jigs: over short distance settling – differential settling
 Theory
 Dense medium separation
 Choice of medium
• Historical evolution
• Magnetite suspensions

1.2–1.8 R.D

magnetite particle size range 10–60 μ m

Unstable medium: in which the density difference between
the underflow and overflow medium is greater than about 0.4
R.D.
 Theory
 Dense medium baths
 Theory
 Dense medium baths
• Basic principle
• Variations in design
• Application & limitations
• Advantages
 Theory
 Dense medium cyclones (DMCs)
 Development and applications
 Standard DMC design
• Cyclone diameter Dc controls both throughput and upper size
limit.
 Theory
• Cyclone diameter Dc controls both throughput and upper size
limit.
 Feed inlet diameter Di = 0.15–0.25 Dc
 Vortex finder (outlet) diameter Do = 0.43–0.5 Dc
 The apex (spigot) underflow diameter Du = 0.3–0.4 Dc
 Optimum operating pressure = slurry head of around 9 Dc

Optimum medium to solids feed ratio = 3:1 and 5:1 (for coal)
• Medium separation by DMC operation and its effect
• Density offset
 Theory
 Dense medium
cyclones (DMCs)
• Ep as a function of
density cut size
and particle size.
 Theory
• capacity of the standard design DMC as a function of cyclone
diameter
 Theory
 Large cyclones and separation efficiency
 Theory
 Particle size and large cyclones separation performance
 Advantages of DMCs
 Theory
 Medium separation and recovery circuits
 Theory
 Wet Gravity Separation
 Jigs
 Theory
 Wet Gravity Separation
 Jigs
 Theory
 Dry Separation
 Introduction
 Disadvantages
 Advantages
 Problem of high density cut point
 Theory
 Dry Separation
 Pneumatic jigs
 Theory
 Dry Separation
 Air tables
 Theory
 Dry Separation
 Air tables
 Conclusion and Future Trends
 Effect of water shortage problem and forecast of hybrid
plants
 Increase in cut-size in water-based plants
Cleaning of Fine and Ultrafine Coal
 Introduction
 Advantages and disadvantages of fine coal cleaning
 % of fine coal in feed and factors affecting it
 Size range of fine and ultrafine coal
 Techniques for up-gradation of fine and ultrafine coal
 Available techniques for treating fine and ultrafine coal and
their applicability
 Flowsheet of typical fine coal cleaning circuit
 Introduction
 Variations in Fine coal cleaning processes and overall
circuitry arrangements
 Fine Gravity
Separators
 Spiral concentrators
 Popularity of spirals
in coal industry and
its reasons
 The concept of
“start” and need of
feed distributor
 Fine Gravity Separators
 Operating Principles
 Fine coal spiral operating conditions and performances
• Major advantage of spiral
• SG-cut point and its dependence
• Major Advantage of spiral

Recommendations

Volumetric feed slurry rate = 7 – 8 m3/h

Solids concentration = 25 – 30%

Mass flow rate = 2.0 – 2.7 t/h
 Ultrafine coal spiral operating conditions and performances
• Recommendations

Mass flow rate = 0.5 t/h
(affected by: (1) impacts of increased particle population
with a reduction in particle size, (2) the need for greater
particle retention time)

Optimum volumetric flow rate = 3 m3/h

Solids concentration = 15%
 Ultrafine coal spiral operating conditions and performances
• Particular advantage of spiral for ultrafine cleaning

Reducing sulfur content appreciably for 0.149 – 0.044 mm
fraction

Examples

Pittsburgh No. 8 seam coal

Sulfur reduction from 3.44% to 0.98%

Ash contents reduction by 67%

Illinois Basin coal

Sulfur reduction from 3.62 5 to 2.53 %

Ash reduction from 21% to 7%
• Benefits over froth flotation

Lower operating costs No horsepower usage

No chemical requirement Minimal component wear

No additional man power needed
 Water-only cyclone
 Advantages
 Disadvantages
 Dependence of Ep and
SG on particle size
 Operating principle
 Operating parameters
 WOCs banks for achieving high throughput capacity
 WOC-spiral concentrator circuit
 Fluidized-bed density separator
 Advantages
 Disadvantages
 Operating Principles
Where Ut = hindered-settling velocity of a particle (m/s),

g = acceleration due to gravity (m/s2),
d = particle size (m),
ρs = density of the solid particles (kg/m3),
ρf = density of the fluidizing medium (kg/m3),
η = apparent viscosity of the fluid (kg.m−1.s−1),
ϕ = volumetric concentration of solids,
φmax =maximum concentration of solids obtainable for a given material,
β = a function of Reynolds number (Re).
 Fluidized-bed density separator
 Operating parameters
• volumetric flow rate
• mass feed flow rate
• fluidization water rate
• teeter-bed height
• Recommendations

Mass flow rate 15 – 20 t/h/m2

Solid concentration = 30% or above

Fluidization water rate = 15 m3/h/m2
 Fluidized-bed applications
 Froth Flotation
 Introduction
 Flotation Technologies
 Conventional flotation cells
• Introduction and operation
 Froth Flotation
 Conventional flotation cells
• Introduction and operation
• Variation in design and function in commercial units
 Froth Flotation
 Flotation column cells
• Introduction and
difference with
conventional cell
• Mode of operation
• Methods of sparging
• Advantages of
column cells

Deep froth &
effect of wash
water
 Froth Flotation
 Flotation column cells
• Primary advantage of using wash water
 Froth Flotation
 Circuit Variation
 Traditional by-zero circuit
 Froth Flotation
 De-slime circuit
 Froth Flotation
 Advantages and disadvantages of by-zero circuit
 Advantages and disadvantages of de-slime circuit
 Alternate circuit configurations
 Froth Flotation
 Alternate circuit variations
• Split-feed circuit
 Froth Flotation
 Alternate circuit variations
• Another circuit modification
 Froth Flotation
 Equipment Design specifications
 Slurry residence time
 Froth Flotation
 Froth loading and stability
 Froth Flotation
 Froth loading and stability
 Dry Cleaning
 Future trends
Thank You

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Engr. Muhammad Shahzad

 U.S. Preparation Industry

 Pakistan Preparation Industry

 Factors affecting basic capacity needed

 Breaker capacity needed

where BC = necessary basic capacity,

The basic crusher capacity needed is then:

 For the intermediate regime (1 < Ret < 500),

 In the Newton’s law regime (500 < Ret < 105):

here for Stokes’ regime, k = 2, m = 1 and for Newton’s regime,

Where n is the Richardson–Zaki coefficient, which varies from

 For dilute systems where ρsusp = ρf

Where Ut = hindered-settling velocity of a particle (m/s),

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