1. Review of Proven Coal Preparation Technologies Treating Indian Coal th Coal Summit New Delhi th & 7th Sept 2016
GURUDAS MUSTAFI, CEO & Director
GURUDAS MUSTAFI

2. OUTLINE Indian Coal Reserves Importance of Coal for Indian Economy
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
OUTLINE
Indian Coal Reserves
Importance of Coal for Indian Economy
Key Drivers for Coal Washing in India
Proven Coal Preparation Technologies Treating India Coal
Lump Coal Washing
Coarse Coal Washing
Medium Coal Washing
Upcoming Technologies and Challenges
Conclusion
GURUDAS MUSTAFI 2

3. Category Wise Coal Resource in India
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Category Wise Coal Resource in India
Category wise
Total Coal Reserves
(as on )
Prime Coking Coal
5313 Million Tonnes
Medium Coking Coal
27049 Million Tonnes
Semi Coking Coal
1708 Million Tonnes
Non-Coking Coal
Million Tonnes
Tertiary Coal
1493 Million Tonnes
(Source: Coal Reserves, Ministry of Coal, Government of India)
GURUDAS MUSTAFI 3

4. Importance of Coal for Indian Economy
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Importance of Coal for Indian Economy
Prime source of energy for the Indian economy. 61% of the total electricity produced comes from coal & Power sector consumes about 72% of the coal produced.
Coal is the cheapest source of power for electricity generation
Largest domestic resource base in case of fuel sources
Ensures a long term supply
GURUDAS MUSTAFI 4

5. Key Drivers for Coal Preparation in India
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Key Drivers for Coal Preparation in India
Depletion of good quality coal reserves
GURUDAS MUSTAFI 5

6. Key Drivers for Coal Preparation in India
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Key Drivers for Coal Preparation in India
Increased surface mining and mechanization
More than 90% of the total coal being mined is from open cast mines
Heavy mechanization has been undertaken in order to increase production from the mines
Selectivity of coal being mined reduced thus causing an increase in the ash of the ROM
Greater need for maintaining the environment quality
MOEF legislation prohibits generation of power with the use of coal containing >34% ash that have to be transported >500km
Strive to increase the clean electricity production
GURUDAS MUSTAFI 6

7. Key Drivers for Coal Preparation in India
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Key Drivers for Coal Preparation in India
4. Increasing power demand
Coal requirement for power generation has increased many folds with the rising demand for power.
Location of the power plants being far away from the Non-coking coal resources
Non-coking coals, containing high mineral-matter content (35-50 wt%), are presently being utilized for power generation mostly without any washing.
As coal quality further decreases and demand for power further increases, washing initiatives are set to see tremendous growth in the coming future
GURUDAS MUSTAFI 7

8. Key Drivers for Coal Preparation in India
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Key Drivers for Coal Preparation in India
5. Limited Washing Capacity Available
Currently washed thermal coal supply is around 83 Million Tonnes to power plants.
Additional 46 million tonnes washed coal supply with ash<34% is required to cater to the needs of existing power plants.
10 new washeries are underconstruction with a total capacity of 73.5 MTPA.
6 new coal Washeries are in pipeline with a total capacity of 18.6 MTPA.
Economic Strategy to lower Energy sector Trade deficit
With abundant coal resources, increasing coal production for electricity generation will allow export of electricity to neibhouring countries.
GOI saved Rs Crores in form of FOREX by replacing imported coal with increased domestic coal production for power. In next 2-3 years, these savings are expected to touch Rs crores, as per GOI projections
No import of non-coking coal for power generation by NTPC and coal movement rationalization to push domestic coal production.
GURUDAS MUSTAFI 8

9. Coarse/Medium coal washing
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Coal washing in India
Coal Washing
Lump coal washing
(-)400mm
Water Based
Moving Pan Jig
Media Based
Heavy Media Bath
Coarse/Medium coal washing
(-)150mm
Water based
Under Pulsated Jig
Heavy Media Cyclone
Fine coal washing
(-)2mm
Density Difference based
Spiral/WOC
Surface Property based
Flotation
GURUDAS MUSTAFI 9

10. Lump coal washing in India
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Lump coal washing in India
Lower power requirement for size reduction
Reduction in capacity & size of subsequent equipment
Lesser ash content in the coal for further processing
Less wear in the subsequent concentration equipment
Increased efficiency and better capacity utilization of the preparation plant
Washing of -400mm Raw coal lumps
Equipment used are Moving Pan jigs/ Heavy Media Bath.
GURUDAS MUSTAFI 10

11. Fig: ROMJIG® (for separation of 30-400mm)
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Moving Pan Jig
Fig: ROMJIG® (for separation of mm)
GURUDAS MUSTAFI 11

12. At a cut density of 1.9, the average imperfection determined was 0.089
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Result of ROMJIG® Plant
BINA General Results:-
Raw Coal Screen analysis: Products of the plant:
Grain size Wt. % Ash % Product Wt. % Ash %
mm Deshaled coal
mm Unwashed coal
mm Saleable product
Reject
KARGALI PG Test results conducted over a span of 15 days
Raw Coal Screen analysis: Products of the plant:
Grain size Wt. % Ash % Product Wt. % Ash %
mm Deshaled coal
mm Unwashed coal
mm Saleable product
Reject
At a cut density of 1.9, the average imperfection determined was 0.089
GURUDAS MUSTAFI 12

13. Flow Sheet: ROMJIG ® Process for ROM Coal
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Flow Sheet: ROMJIG ® Process for ROM Coal
GURUDAS MUSTAFI 13

14. Fig: TESKA® Heavy Media Bath (for separation of 10-200/250mm)
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Heavy Media Bath
Fig: TESKA® Heavy Media Bath (for separation of /250mm)
GURUDAS MUSTAFI
GURUDAS MUSTAFI 14

15. MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Fig: Drewboy Bath
GURUDAS MUSTAFI 15

16. Result of Heavy Media Bath Plant
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Result of Heavy Media Bath Plant
The ash in raw coal received varies between 34 to 38%.
HEAVY MEDIA BATH The results from a plant installed at Wani supplying washed coal to MSEB are:
Raw Coal Screen analysis: Products of that plant:
Grain size Wt. % Ash % Product Wt. % Ash %
mm Washed coal
mm Unwashed coal
mm saleable product
Operating Cut Density : 1.45
GURUDAS MUSTAFI 16

17. Flow Sheet: Heavy Media Bath for ROM Coal
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Flow Sheet: Heavy Media Bath for ROM Coal
GURUDAS MUSTAFI 17

18. Lump Washing – Advantages & Limitations
low water and power consumption
low expenditure for necessary auxiliary equipment
economical  compared with other proven technologies of large refuse separation
ideal in case of a pit head installation.  
Limitations
when the characteristics of raw coal requires the grain size of beneficiation to be reduced.
reasons can be the grain size distribution
amount of material < 30 mm is more
ash content of the fine material is too high.
Tuesday, April 24, 2018Tuesday, April 24, 2018Tuesday, April 24, 2018

19. Coarse Coal Washing in India
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Coarse Coal Washing in India
For upgradation of coal particles in the range of -150 mm to 25mm
Helps in meeting the quality parameter of the end user, If lump coal washing does not produces desired product quality..
Crushing of lumps to achieve better liberation, subsequently better yield with more recovery
More surface mining produces -100mm coal, upgraded using coarse coal washing technologies
Equipment used are Under Pulsated Jigs, Heavy Media Cyclones
GURUDAS MUSTAFI 19

20. Under Pulsated Jig Heavy Media Cyclone
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Working Principle
Under Pulsated Jig Heavy Media Cyclone
GURUDAS MUSTAFI 20

21. Coarse Coal Jig and its discharge system
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Coarse Coal BATAC® JIG
Treats -150mm coarse coal with high efficiency
Coarse Coal Jig and its discharge system
GURUDAS MUSTAFI 21

22. Salient Features of BATAC® Jig
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Salient Features of BATAC® Jig
Water-only process hence operating cost is relatively low.
High throughput capacity, tph/m jig width for coarse coal and tph/m jig width for Medium sized coal.
Compact design and up to 8 m in width, low foot print.
It can handle feed variations up to 20%, as well as variations in the percentage of water in the feed material.
Can be stopped and restarted instantly. No need to drain the jig after a stop, and restarting takes a few seconds with the same operating parameters as before the stoppage
GURUDAS MUSTAFI 22

23. Results of BATAC® Jig Plant
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Results of BATAC® Jig Plant
BATAC® JIG
The results from a plant installed at Piparwar washery are:
Raw Coal Screen analysis: Products of that plant:
Grain size Wt. % Ash % Product Wt. % Ash %
mm Deshaled
13 – 0 mm Unwashed
Saleable coal
75-0 mm Reject
The results from a plant installed at CESC, Sarasthali are:
mm Saleable coal
6 – 0 mm
75-0 mm Reject
GURUDAS MUSTAFI 23

24. Flow Sheet: BATAC® Jig Washery for Coarse Coal
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Flow Sheet: BATAC® Jig Washery for Coarse Coal
GURUDAS MUSTAFI 24

25. for separation of coal 0 - 100 mm
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Heavy Media Cyclone for Coarse Coal
HMS - Cyclones
for separation of coal mm
GURUDAS MUSTAFI 25

26. Salient Features of Heavy Media Cyclone
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Salient Features of Heavy Media Cyclone
For increasing throughput, the cyclones up to 1400 mm dia have been developed
Efficient separation at specific cut density
Better recovery
Suitable to wash coal with NGM high in the range of 30%.
GURUDAS MUSTAFI 26

27. Result of Heavy Media Cyclone Plant
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Result of Heavy Media Cyclone Plant
Heavy Media Cyclone
The results from a plant installed at Jharsuguda are:
Raw Coal Screen analysis: Products of that plant:
Grain size Wt. % Ash % Product Wt. % Ash %
20- 0 mm Raw coal
Clean coal
mm Reject
GURUDAS MUSTAFI 27

28. Flowsheet for Heavy Media Cyclone for Coarse Coal
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Flowsheet for Heavy Media Cyclone for Coarse Coal
GURUDAS MUSTAFI 28

29. Coarse Coal Washing – Advantages & Limitations
low water and power consumption compared to fine coal washing
less pick up moisture
bottom washing size can be reduced even to 3 mm & fed to same Batac Jig by using right dry screening system.
Equally good operating results achieved with H M process without reducing the lower size
Limitations
material close to border between coal seam and shale band which contains up to 50% of saleable coal
when characteristics of raw coal requires grain size of beneficiation to be reduced
reasons can be grain size distribution
amount of material < 13/6 mm is more
ash content of fine material is too high
Tuesday, April 24, 2018Tuesday, April 24, 2018Tuesday, April 24, 2018

30. Medium Coal Washing in India
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Medium Coal Washing in India
For upgradation of coal particles in the range of -25 mm to +0.5 mm
Helps in meeting the quality parameter of the end user, If coarse coal washing does not produce desired product quality
Crushing of coarse coal to achieve further degree of liberation, subsequently better yield with more recovery
If medium sized coal in feed has high ash content, mixing with clean is not preferred, further upgradation is done with such technologies
Limited coking coal reserves and high prices of coking coal requires most efficient utilization with highest recovery
Equipment used are Under Pulsated Jigs, Heavy Media Cyclones
GURUDAS MUSTAFI 30

31. Fine Coal Jig and its discharge system
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Medium Coal BATAC® JIG
Treats -25mm to +0.5mm Coal
High throughput capacity: TPH/m jig width for Medium sized coal
Upto 8m width per BATAC® Jig unit
Modified discharge system for better discharge of coal product
Fine Coal Jig and its discharge system
GURUDAS MUSTAFI 31

32. Flow Sheet: BATAC® Jig Washery for Medium Coal
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Flow Sheet: BATAC® Jig Washery for Medium Coal
GURUDAS MUSTAFi

33. Heavy Media Cyclone for Medium Coal
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Heavy Media Cyclone for Medium Coal
However a single unit of Heavy media cyclone is capable of handling particles from -100 to +0.5mm, studies have shown that plant/equipment performance goes up if the beneficiation is done in two different HM cyclones i.e mm particles in one unit and mm in another unit.
More classification for upgradation of medium sized coal results in higher recovery and better quality products from the system.
Higher degree of liberation at finer size fraction results in better recovery of quality coal product.
Feed coal characteristics and end product quality requirements are vital parameters in selection & designing of the cyclone.
GURUDAS MUSTAFI 33

34. Flowsheet for Heavy Media Cyclone for Medium Coal
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Flowsheet for Heavy Media Cyclone for Medium Coal
GURUDAS MUSTAFI 34

35. Selection Criteria of Washing Process
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Selection Criteria of Washing Process
Yes
Cut point > 1.9 g/cm³
Yes
Feed is lignite
Yes
Gangue is clay
NGM <10%
Feed is coking coal
NGM upto 25%
NGM upto 30%
NGM <20%
Feed is steam coal
Tendency Criteria for decision between ...
Prefered
Unstable power supply
No effect
Source of magnetite is far
Difficult
Ease of Operation
Yes
Yes
Feed quality & quantity fluctuation
JIG
HMS
GURUDAS MUSTAFI 35

36. Upcoming Technologies & Challenges
MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Upcoming Technologies & Challenges
Dry beneficiation techniques are also being considered for coal beneficiation.
Many R&D and pilot scale test works are being carried out by different major coal testing facilities across the country with dry jigs, Fluidized bed separators, ArdeeSort etc.
Dry separation technologies present benefits of no water requirements and no additional moisture in product.
Yet to prove their acceptability for high near gravity Material (NGM) quality Indian coal.
High moisture content of the raw coal feed during the months of monsoon season would be another challenge for such upcoming technologies. Mining water at pit heads is also a challenge for MDO to provide dry coal feed.
Feasibility of these technologies including three product cyclones, once proved, will make a big impact in Indian Coal washing industry and would be very helpful for the economic growth of the coal sector.
GURUDAS MUSTAFI 36

37. MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Conclusions
The described processes with closed washery circuits for the various applications have proven acceptance in the coal beneficiation industry.
Beneficiating the raw coal before being used to produce power, cement, sponge iron etc. is environment friendly and saves the precious energy resource.
The existing end users of washed coal are experiencing better and consistent coal quality being fed to their plants.
In line with the target of producing 1 billion tonnes coal by CIL and another 500 million coal by private sector by the year 2020, there will be a strong need to bridge the gap of available and required washing capacity for utilizing the produce meeting MoEF guidelines.
GURUDAS MUSTAFI 37

38. MBE Coal & Mineral Technology India Private Limited Formerly McNally HUMBOLDT WEDAG Minerals India Pvt. Ltd.
Thank You
GURUDAS MUSTAFI 38