Download presentation
Presentation is loading. Please wait.
1
6th Coal Summit Theme : Indian Coal-Sustaining the Momentum
Hotel Le Meridien, New Delhi 6th & 7th September 2016
2
Technical Session VIII: Coal Beneficiation
Recent Advances in Coal Beneficiation Technologies Sunil Yadav Vice President ( Technical Support )
3
Indian Coal Problem Solution 2 mm
Mineral matter is finely disseminated in coal matrix ( not a black white separation ) Difficult to obtain low-ash product Causes low thermal efficiency in power plants Requires sweetener for metallurgical application >$3 billion import Solution 1. Use of Heavy Media Separation 2. Use of Flotation for Fines Recovery 3. Fine grinding for liberation of mineral matter Fine coal cleaning Fine coal dewatering 2 mm In the lower picture, black areas represents mineral matter. As shown they are finely disseminated in coal matrix.
4
BIRD'S CLASSIFICATION OF '+/- 0.10 NGM AND DIFFICULTY OF SEPARATION
Degree of Difficulty Process Recommended Type of Process Equipment 0 - 7 % Simple Any Process High Tonnage Jigs, Tables, Spirals % Moderately Difficult Efficient Process High Tonnage Heavy Media Separation % Difficult Efficient Process Medium Tonnage % Very Difficult Efficient Process Low Tonnage % Exceedingly Difficult Very Efficient Process Low Tonnage Above 25 % Formidable Exceptionally Efficient Process Expert Operation Heavy Media Separation with Close Control Date Author Title
5
UPGRADATION EFFICIENCIES
DESIGN PHILOSOPHY Feed Pumping UPGRADATION EFFICIENCIES Classification Gravity Separation Coarse Coal Gravity Separation Small & Fine Coal Size in Microns Clarification Thickening Flotation Spirals H.M. Cyclone Jigs Mechanical Dewatering Jigs HMC Single Process to Multiple Process Trends in Coal Washing Products
6
Heavy Media Separation Perfect Water Based Separation Separation-Jigs
INTERNAL Heavy Media Separation Perfect Separation Water Based Separation-Jigs MISPLACEMENT Floats in Sinks Sinks in Floats Date Author Title
7
Progression of Technology
Hand Picking Water Based Process Jigs Heavy Media Baths/Cyclones Black/White Separation NGM <7% NGM <10% NGM >10% Easy Moderately EASY Difficult Water Based Process Barrels/ Baum Jigs
8
Building Blocks of a Coal Washery
INTERNAL Building Blocks of a Coal Washery INPUT OUTPUT Pumping Classification Screen & Cyclone Gravity Separation Coarse Coal Unit Operations Gravity Separation Small Coal Thickening Mechanical Dewatering Date Author Title
9
Technological Advancements in a. Slurry Pumping
INPUT Pump Metallurgy has improved over the years Pumping Cast Iron Ni Hard 27% Chrome 2. Plants are now Pump Fed instead of Gravity Fed resulting in lower fixed and operating costs Classification Screen & Cyclone 3. 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. Gravity Separation Coarse Coal Gravity Separation Small Coal 4.Local Manufacturing by International Companies has lowered the Capex. Thickening Mechanical Dewatering OUTPUT 24 inch pump can handle >5000 m3/hr flow
10
Technological Advancements in b. Classification - Multiflo Banana
INPUT 1. Multiflo Screens Are becoming Popular for Classification Are becoming popular for Drain & Rinse Replace Sieve Bend Have smaller footprint for same capacity Have large capacity and help in designing high capacity single module. Largest width > 4m,length > 8m ( 4.2x8.5) 70% more capacity than sievebend-screen combination Are available in Single or double deck. Pumping Classification Screens Gravity Separation Coarse Coal Gravity Separation Small Coal Thickening Mechanical Dewatering OUTPUT
11
INTERNAL 4.2m wide x 8.4 m long screen Date Author Title
12
D62 – 10 Technological Advancements b. Classification- Hydrocyclones
INPUT 2. Cyclones are a. Extensively used below 150 Microns b. Range from 25mm to 1200mm c. Capacities upto 2000 m3/hr Pumping 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 Classification Hydrcyclones Gravity Separation Coarse Coal Gravity Separation Small Coal D62 – 10 Thickening Mechanical Dewatering OUTPUT
13
Technological Advancements in c. Gravity Separation - Coarse Coal
INPUT Jigs- Baum/Batac Are the most popular in India Available as 2 products/3 products Simple to operate No Magnetite Required Work at very high cut densities Very good deshaler. Ref : Rajrappa/Bhojudih/Dugda/Kedla/Piparwar etc Pumping Classification Gravity Separation Coarse Coal Drewboys can handle ROM at capacities > 600 tph per unit Ref : Kathara, Durgapur Gravity Separation Small Coal LoFlo Bath are available from 5’ to 9’ and can handle 10”coal at 250 tph per unit Ref : Aryan / Global / Gupta Coal / Bhatia Thickening Mechanical Dewatering OUTPUT
14
Technological Advancements in c. Gravity Separation- Small & Fine Coal
INPUT HM Cyclones Handles coal of 50mm Has Epm <0.03 Largest is 1450mm dia Available in Ni Hard/Ceramic Life ~ 2 years Largest Module > 500 tph No moving parts Ref : TISCO/Jindals/ST-CLI etc Pumping Classification Gravity Separation Coarse Coal Gravity Separation Small Coal Spirals Handles coal 1mm x0.1mm Single/Double/Tripple Start Cheapest Opex-Gravity is free Lasts too long, sometimes > 8 years With & Without Wash water No moving parts, No reagents MX7-Double Stage available Thickening Mechanical Dewatering OUTPUT
15
Efficiency of Washing Lower Ep at Tata Steel gave 2% additional Yield at West Bokaro. Payback for Multotec Cyclones was less than 3 months
16
HM Cyclone Diameter in MM
Advancement of HM Cyclone Diameters in India Thermal Coal ???? HM Cyclone Diameter in MM 500/ 610 660/ 710 800 1000 1100 1300 1500 Tata Steel ESPL ST-CLI JPL JSPL Coking Coal Break Away Size----? Fines Washing------?
17
Breakaway Size
18
1500 mm Dia HM Cyclone- Worlds Largest-at Multotec South Africa
INTERNAL 1500 mm Dia HM Cyclone- Worlds Largest-at Multotec South Africa Date Author Title
19
Developing Technologies f. Clarification & Thickening
Compact Design-Space Saving Small Footprint Easy Control ~1/3rd the dia of conventional thickener Less or No Flocculant Quick Stabiliasation Feed Pumping Classification Gravity Separation Flotation Clarification Thickening Mechanical Dewatering Products
20
”Compact” Sedimentation
By using sliding instead of free sedimentation the settling speed is increasing dramatically. This effect is mainly used in clarification. The thickening effect is not too impressive. Applications: Effluent treatment when space is a shortage. Comparing compact and classical clarifiers Compact means ”doing the same job in a smaller space!” Comparison compact and classical clarifiers Date/Title/Author
21
Date/Title/Author
22
Lamella Thickener - Compact Size
23
Old Process Plant with Large and Ground Conventional Thickener
Building Less Green Cover Pump House @ 3-4 M below ground New Process Plant with Compact and Above Ground Lamella Thickener Process Building More Green Cover Pump House above ground Date Author Title
24
Some References in India
LTE in ESPL Coal Washery At Jaduguda LTC in NMDC Bailadila for Iron Ore- 2 nos. LTE in JPL Coal Washery At Tamnar, Raigarh Date Author Title
25
Typical Flow Chart for Thermal Coal Washery
INTERNAL Typical Flow Chart for Thermal Coal Washery Washery (Modular) Coal Handing Section-Pre & Post Closed Water Circuit Product Handling Reject Handling Date Author Title
26
INTERNAL Date Author Title
27
INTERNAL Date Author Title
28
Power Generation using rejects
Metso’s Coal Chain Feeders Gyratory Crushers Screens Conveyor Solutions Coal Handling Ash Classifiers Ash Handling Systems Power Generation using rejects Wet Screens & Feeders Hydrocyclones Slurry Pumps Coal Jigs Magnetic Separators D M Cyclones Spiral Concentrators Thickener Filter Coal Washery Stackers Reclaimers Wagon Tipplers Feeders Conveyor Solutions Ash Handling System FGD Ash Classifiers Power Generation Ship loaders & un-loaders Stackers Reclaimers Wagon tipplers Conveyor solutions Ports
29
www.metso.com company/metso metsoworld metsogroup metsoworld
Similar presentations
