4th Coal Summit 2012Coal-Bridging the Gap :

Challenges and Strategies

Hotel The Ashok19th&20th November’12

Technological Advancements in Coal Beneficiation

Sunil YadavVice President - Projects & Systems

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INTERNAL

3 Date Author Title

PRESENTATION OUTLINE

1. Introduction

2. Coal Preparation Overview

3. Design Philosophy

4. Technology Advancements ina. Slurry Pumpingb. Classificationc. Gravity Separationd. Flotatione. Thickeningf. Mechanical Dewatering

5. Summary

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INTERNAL

4 Date Author Title

Introduction

•Coal will continue to occupy the centre stage in India’s energy scenario.•Coal accounts for more than 50% of India’s commercial energy.•About 75% of the coal in the country is consumed in Power Industry.•Coal is abundant in India but primarily high in ash and needs to be washed•Coal Washing in India grews at a CAGR of more than 13% over the past 5 years.•It is predicted that it will grow at a CAGR of more than 20% in coming 5 to 7 Years.•20% of coal produced is washed in India against a Global average of 50%•All Coking Coal produced in India gets washed but very little Thermal Coal is washed.•The Trend is shifting to washing of non coking coal due to environmental reasons.•Coal Washing increases the cost of coal, but benefits far outweigh the additional cost.•Benefits accrued in terms of savings in transportation, O&M cost and Efficiency far exceeds the cost incurred.•Technology should be adapted to make Coal washing an integral part of our Energy Chain.

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5 Date Author Title

Coal Preparation OverviewThe process adopted for Coal Washing

Washery Heavy Media Jigs Flotation Others

Dugda 1, BCCL Tromp Bath Baum/Komag Denver-Metso

Dugda 2, BCCL HM Cyclone Denver-Metso

Bhojudih,BCCL Bath Batac Denver-Metso

Patherdih,BCCL Bath Baum

Sudamdih,BCCL HM Cyclone Wemco

Moonidih, BCCL HM Cyclone W/O Cyclones

Mahuda, BCCL HM Cyclone Wemco

Kargali,CCL Wemco Drum Batac

Kedla,CCL HM Cyclone Batac

Piparwar,CCL HM Cyclone Batac

Jamadoba,TISCO HM Cyclone Dorr-Oliver

Bhelatand,TISCO HM Cyclone Dorr-Oliver

West Bokaro #2,#3,TISCO HM Cyclone Outotec

Coal Preparation Overview

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UPGRADATION EFFICIENCIES

100

80

60

40

20

010 100001000100

Flotation Spirals H.M. Cyclone Jigs

Size in Microns

Jigs

HMC

Single Process toMultiple Process

Trends in Coal Washing

DESIGN PHILOSOPHY

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INTERNAL

7 Date Author Title

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

UnitOperations

Building Blocks of a Coal Washery

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Technological Advancements ina. Slurry Pumping

1. Pump Metallurgy has improved over the yearsCast Iron Ni Hard 27% Chrome

2. Plants are now Pump Fed instead of Gravity Fed resulting in lower fixed and operating costs3. Large Capacity Pumps > 5000 m3/h available a. Single large module in place of many smaller ones. b. Smaller foot print of the plant c. Pumping cost reduced. d. Reduced Capex/Opex.4.Local Manufacturing by International Companies has lowered the Capex.

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT24 inch pump can handle>5000 m3/hr flow

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Technological Advancements inb. Classification - Multiflo Banana

1. Multiflo Screens 1. Are becoming Popular for Classification2. Are becoming popular for Drain & Rinse3. Replace Sieve Bend4. Have smaller footprint for same capacity5. Have large capacity and help in

designing high capacity single module.6. Largest width > 4m,length > 8m

( 4.2x8.5)7. 70% more capacity than sievebend-

screen combination8. Are available in Single or double deck.

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

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10 Date Author Title

4.2m wide x 8.4 m long screen

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Technological Advancementsb. Classification- Hydrocyclones

2. Cyclones area.extensively used below 150 Micronsb. Range from 25mm to 1200mmc. Capacities upto 2000 m3/hr Materials of Construction

– Polyurethane– Mild steel with replaceable

rubber liners – Mild steel Polyurethane Lined– Mild steel with SiC Liners– Mild steel with Alumina tiles– Cast Iron

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

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Technological Advancements inc. Gravity Separation - Coarse Coal

Drewboys can handle ROM at capacities > 600 tph per unitRef : Kathara, Durgapur

LoFlo Bath are available from 5’ to 9’and can handle 10”coal at 250 tph per unitRef : Aryan/Global/Gupta Coal

Jigs- Baum/BatacAre the most popular in IndiaAvailable as 2 products/3 productsSimple to operateNo Magnetite RequiredWork at very high cut densitiesVery good deshaler.Ref : Rajrappa/Bhojudih/Dugda/Kedla/Piparwar etc

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

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Technological Advancements inc. Gravity Separation- Medium and Small Coal

HM CyclonesHandles coal of 50mmHas Epm <0.03Largest is 1450mm diaAvailable in Ni Hard/CeramicLife ~ 2 yearsLargest Module > 500 tphNo moving partsRef : TISCO/Jindals/ST-CLI etc

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

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14 Date Author Title

1500 mm Dia HM Cyclone- Worlds Largest-at Multotec South Africa

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Technological Advancements inc. Gravity Separation- Fine Coal

Spirals1. Handles coal 1mm x0.1mm2. Handle Oxidised/Weathered Coal3. Single/Double/Tripple Start4. Cheapest Opex-Gravity is free5. Lasts too long, sometimes > 8 yrs6. With & Without Wash water7. No moving parts, No reagents8. Simple to Operate9. MX7-Double Stage available

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

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Technological Advancement ind. Flotation - Mechanical Tank Cells

Mechanical Cells

•Popular for Rougher

•Installed at West Bokaro/Jamadoba/Bhelatand/•Gidi/Dugda/Rajrappa etc for Coking Coal

•No Reference in Non Coking Coal

•Lab Trials show that it is possible to float Thermal Coal

Tank Cells of 200 m3 volume are available

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

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Technological Advancement ind. Flotation – Microcel Column

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

• Invented during the 70s

• Emerged during the 80s

• One column replaces several cleaning stages

• Allows high grade concentrates

• Simplifies flowsheets

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18

Cleaner Stage

Rougher Stage

Scavenger Stage

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Sparger Retrofit

Product Ash (%)

Yiel

d (%

)

Product Ash / Yield Relationship

Air-water or air-only sparger

Cisa (Microcel™) sparger

Same Product AshIncrease in Yield

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Benefits of Column Flotation

• Improved Recovery

• Optimized Grade

• Increased Throughput

• No Plugging

• On-line Replacement

• Reduced Wear & Maintenance

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Moura Dawson (Anglo Coal)

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Technological Advancements ine.Thickening - Lamellas

Lamella Thickener 12m dia in700 tph coal washery in JPL in Tamnar.

• Compact Design-Space Saving• Small Footprint• Easy Control• ~1/3rd the dia of conventional

thickener• Less or No Flocculant• Quick Stabiliasation

Coal References in India•Gupta Coal, 2 nos in WCL Area•Global Coal inTalcher•Global Coal in Ramagundam•Electrosteel Washery in Parbatpur•Jindal Power at Tamnar•Jindal Steel at Barbil•Bhatia Coal in WCL Area•Eastern Steel and Power ,Jharsugude

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

Lamella Thickener 12m dia in350 tph coal washery in Electrosteel-Bokaro

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Thickening - Conventional & Lamella

23 Date/Title/Author

21 MetresDiameter

50 MetresDiameter

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Technological Advancements inf. Mechanical Dewatering

Mechanical Dewatering is being stretched to lower the moisture in the product

Coarse CoalCentrifugeCan handle upto 50mm

Dewatering HF ScreenLow Power Consumtion~5 Times Gravitational Pull

Drum FiltersDisc are getting phased out

Pressure FiltersFuture of Coal IndustryMassey Coal in US were the first to use.

Pumping

Classification

Gravity Separation

Flotation

Thickening

MechanicalDewatering

INPUT

OUTPUT

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COAL MINE

METSO COAL PREPARATION PLANT

PULVERIZED FUEL POWER STATION

ELECTRICITY TRANSMISSION

METSO CFBC POWER PLANT

ELECTRICITY TRANSMISSION

CEMENT INDUSTRYLWA SINTER PLANT

METSOFLY ASH CLASSIFIER

ASH

COARSE ASH

FINE ASH

PULVERIZED COAL

REJECTS COAL

ZERO WASTE SOLUTION FOR THERMAL COAL

LWA utilization

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COAL MINE

METSO COAL PREPARATION PLANT

PULVERIZED FUEL POWER STATION

ELECTRICITY TRANSMISSION

METSO CFBC POWER PLANT

ELECTRICITY TRANSMISSION

CEMENT INDUSTRYLWA SINTER PLANT

METSOFLY ASH CLASSIFIER

ASH

COARSE ASH

FINE ASH

MIDDLINGS COAL

REJECTS COAL

ZERO WASTE SOLUTION FOR METALLURGICAL COAL

LWA utilization

CLEAN COAL

BLAST FURNACE

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