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4 th Coal Summit 2012 Coal-Bridging the Gap : Challenges and Strategies Hotel The Ashok 19 th &20 th November’12
Technological Advancements in Coal Beneficiation Sunil Yadav Vice President - Projects & Systems
© Metso Date Author Title INTERNAL 3 PRESENTATION OUTLINE 1.Introduction 2.Coal Preparation Overview 3.Design Philosophy 4.Technology Advancements in a.Slurry Pumping b.Classification c.Gravity Separation d.Flotation e.Thickening f.Mechanical Dewatering 5.Summary
© Metso Date Author Title INTERNAL 4 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.
© Metso Date Author Title INTERNAL 5 Coal Preparation Overview The process adopted for Coal Washing Washery Heavy MediaJigsFlotationOthers Dugda 1, BCCLTromp BathBaum/KomagDenver-Metso Dugda 2, BCCLHM CycloneDenver-Metso Bhojudih,BCCLBathBatacDenver-Metso Patherdih,BCCLBathBaum Sudamdih,BCCLHM CycloneWemco Moonidih, BCCLHM CycloneW/O Cyclones Mahuda, BCCLHM CycloneWemco Kargali,CCLWemco DrumBatac Kedla,CCLHM CycloneBatac Piparwar,CCLHM CycloneBatac Jamadoba,TISCOHM CycloneDorr-Oliver Bhelatand,TISCOHM CycloneDorr-Oliver West Bokaro #2,#3,TISCOHM CycloneOutotec Coal Preparation Overview
© Metso UPGRADATION EFFICIENCIES Flotation Spirals H.M. Cyclone Jigs Size in Microns Jigs HMC Single Process to Multiple Process Trends in Coal Washing DESIGN PHILOSOPHY
© Metso Date Author Title INTERNAL 7 Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering INPUT OUTPUT Unit Operations Building Blocks of a Coal Washery
© Metso 8 Technological Advancements in a. Slurry Pumping 1.Pump Metallurgy has improved over the years Cast IronNi Hard27% Chrome 2. Plants are now Pump Fed instead of Gravity Fed resulting in lower fixed and operating costs 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. 4.Local Manufacturing by International Companies has lowered the Capex. Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering INPUT OUTPUT 24 inch pump can handle >5000 m3/hr flow
© Metso 9 Technological Advancements in b. Classification - Multiflo Banana 1. Multiflo Screens 1.Are becoming Popular for Classification 2.Are becoming popular for Drain & Rinse 3.Replace Sieve Bend 4.Have smaller footprint for same capacity 5.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 combination 8.Are available in Single or double deck. Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering INPUT OUTPUT
© Metso Date Author Title INTERNAL m wide x 8.4 m long screen
© Metso 11 Technological Advancements b. Classification- Hydrocyclones 2. Cyclones are a.extensively used below 150 Microns b. Range from 25mm to 1200mm c. 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 Mechanical Dewatering INPUT OUTPUT
© Metso 12 Technological Advancements in c. Gravity Separation - Coarse Coal Drewboys can handle ROM at capacities > 600 tph per unit Ref : Kathara, Durgapur LoFlo Bath are available from 5’ to 9’ and can handle 10”coal at 250 tph per unit Ref : Aryan/Global/Gupta Coal 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 Flotation Thickening Mechanical Dewatering INPUT OUTPUT
© Metso 13 Technological Advancements in c. Gravity Separation- Medium and Small Coal 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 Flotation Thickening Mechanical Dewatering INPUT OUTPUT
© Metso Date Author Title INTERNAL mm Dia HM Cyclone- Worlds Largest-at Multotec South Africa
© Metso 15 Technological Advancements in c. Gravity Separation- Fine Coal Spirals 1.Handles coal 1mm x0.1mm 2.Handle Oxidised/Weathered Coal 3.Single/Double/Tripple Start 4.Cheapest Opex-Gravity is free 5.Lasts too long, sometimes > 8 yrs 6.With & Without Wash water 7.No moving parts, No reagents 8.Simple to Operate 9.MX7-Double Stage available Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering INPUT OUTPUT
© Metso 16 Technological Advancement in d. 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 Mechanical Dewatering INPUT OUTPUT
© Metso 17 Technological Advancement in d. Flotation – Microcel Column Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering INPUT OUTPUT Invented during the 70s Emerged during the 80s One column replaces several cleaning stages Allows high grade concentrates Simplifies flowsheets
© Metso 18 Cleaner StageRougher StageScavenger Stage
© Metso Sparger Retrofit Product Ash (%) Yield (%) Product Ash / Yield Relationship Air-water or air-only sparger Cisa (Microcel™) sparger Same Product Ash Increase in Yield
© Metso Benefits of Column Flotation Improved Recovery Optimized Grade Increased Throughput No Plugging On-line Replacement Reduced Wear & Maintenance
© Metso Moura Dawson (Anglo Coal)
© Metso 22 Technological Advancements in e.Thickening - Lamellas Lamella Thickener 12m dia in 700 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 Mechanical Dewatering INPUT OUTPUT Lamella Thickener 12m dia in 350 tph coal washery in Electrosteel-Bokaro
© Metso Thickening - Conventional & Lamella 23 Date/Title/Author 21 Metres Diameter 50 Metres Diameter
© Metso 24 Technological Advancements in f. Mechanical Dewatering Mechanical Dewatering is being stretched to lower the moisture in the product Coarse Coal Centrifuge Can handle upto 50mm Dewatering HF Screen Low Power Consumtion ~5 Times Gravitational Pull Drum Filters Disc are getting phased out Pressure Filters Future of Coal Industry Massey Coal in US were the first to use. Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering INPUT OUTPUT
© Metso 25 COAL MINE METSO COAL PREPARATION PLANT PULVERIZED FUEL POWER STATION ELECTRICITY TRANSMISSION METSO CFBC POWER PLANT ELECTRICITY TRANSMISSION CEMENT INDUSTRY LWA SINTER PLANT METSO FLY ASH CLASSIFIER ASH COARSE ASH FINE ASH PULVERIZED COAL REJECTS COAL ZERO WASTE SOLUTION FOR THERMAL COAL LWA utilization
© Metso COAL MINE METSO COAL PREPARATION PLANT PULVERIZED FUEL POWER STATION ELECTRICITY TRANSMISSION METSO CFBC POWER PLANT ELECTRICITY TRANSMISSION CEMENT INDUSTRY LWA SINTER PLANT METSO FLY ASH CLASSIFIER ASH COARSE ASH FINE ASH MIDDLINGS COAL REJECTS COAL ZERO WASTE SOLUTION FOR METALLURGICAL COAL LWA utilization CLEAN COAL BLAST FURNACE
© Metso 27
© Metso Be Comfortable with Metso!
Any Questions ? Thank You for your time
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