Medium density control for coal washing dense medium cyclone circuits

The dense medium cyclone (DMC) process used in coal beneficiation plants is studied from a control system perspective. Employing the dynamic model of the DMC process derived from mass flow balance, a model-based control strategy is proposed. The controller adjusts the density of medium used to enhance separation in the DMC process according to measurements on percentages of different components in raw coal. The first objective of the control is to maintain the carbon content in the clean coal to a set level. The second purpose is to minimize energy consumption of the DMC process in view of the fast increasing electricity price. The controller solves an optimization problem formulated to determine the density of medium whenever new measurements are available. Both coal quality and DMC operational constraints are accounted for. Simulations, based on measured plant data, are carried out to verify the feasibility and effectiveness of the control strategy designed. The results show that the designed controller is able to fulfill its purpose satisfactorily when the characteristics of the raw coal varies and when measurement uncertainties are in presence

Dense Medium Cyclone

This paper outlines the importance of dense medium cyc-lones in coal cleaning along with process optimisation through modelling. Dense medium cyclone was developed by Dutch State Mines in 1940s and since inception it has gained tremendous importance for coal cleaning application around the globe. Indian coal preparation plants largely rely on washing at intermediate size (i.e. -13+0. 5 mm) because of drift nature of our coals as well as the ease of material handling at this size. Dense medium cyclones are widely used in Indian washeries due to their ability to handle larger tonnage and ease of operation. Dense medium cyclone operation is very sensitive to the variation of process and design variables. The author and his co workers have developed simple empirical models to predict and optimise the performance of dense medium cyclone. The usage of these models developed at the labo-ratory level to improve the plant performance has been discussed. Such optimisation works undertaken by the author resulted in 3-5% increase in yield of clean coal from dense medium cyclone circuits at the same ash level

XVIII International Coal Preparation Congress

Changes in economic and market conditions of mineral raw materials in recent years have greatly increased demands on the ef fi ciency of mining production. This is certainly true of the coal industry. World coal consumption is growing faster than other types of fuel and in the past year it exceeded 7.6 billion tons. Coal extraction and processing technology are continuously evolving, becoming more economical and environmentally friendly. “ Clean coal ” technology is becoming increasingly popular. Coal chemistry, production of new materials and pharmacology are now added to the traditional use areas — power industry and metallurgy. The leading role in the development of new areas of coal use belongs to preparation technology and advanced coal processing. Hi-tech modern technology and the increasing interna- tional demand for its effectiveness and ef fi ciency put completely new goals for the University. Our main task is to develop a new generation of workforce capacity and research in line with global trends in the development of science and technology to address critical industry issues. Today Russia, like the rest of the world faces rapid and profound changes affecting all spheres of life. The de fi ning feature of modern era has been a rapid development of high technology, intellectual capital being its main asset and resource. The dynamics of scienti fi c and technological development requires acti- vation of University research activities. The University must be a generator of ideas to meet the needs of the economy and national development. Due to the high intellectual potential, University expert mission becomes more and more called for and is capable of providing professional assessment and building science-based predictions in various fi elds. Coal industry, as well as the whole fuel and energy sector of the global economy is growing fast. Global multinational energy companies are less likely to be under state in fl uence and will soon become the main mechanism for the rapid spread of technologies based on new knowledge. Mineral resources will have an even greater impact on the stability of the economies of many countries. Current progress in the technology of coal-based gas synthesis is not just a change in the traditional energy markets, but the emergence of new products of direct consumption, obtained from coal, such as synthetic fuels, chemicals and agrochemical products. All this requires a revision of the value of coal in the modern world economy

Evaluation of plantwide control strategies for coal preparation plants

Journal ArticleThe quality of cleaned products from coal preparation plants is often variable due to natural fluctuations in the washability characteristics of the plant feed. To combat this problem, many modern plants have installed on-line analyzers that provide feedback for the real-time control of product quality via the adjustment of circuit cutpoints. Unfortunately, optimization studies show that this approach may actually lead to increased losses of saleable coal. This paper discusses the problems associated with the real-time manipulation of circuit cutpoints and suggests alternative modes of operation that are better suited for plant optimization. A case study involving an eastern U.S. coal plant has been used to compare the economic impacts of these different approaches for plantwide control

ULTRA CLEAN COAL PRODUCTION USING DENSE MEDIUM SEPARATION FOR THE SILICON MARKET

The production of high quality silicon requires the use of ultraclean coal containing less than 1.5% ash. The magnetite used to clean the coal in a dense medium process is a contaminant that seriously impacts the quality of the final silicon product. As such, research has been conducted to evaluate the potential to substitute the magnetite with fine silica–based alternative material generated during the silicon production process. Dense medium cyclone tests were performed based on a statistically designed program to determine the optimum conditions that maximize organic efficiency and minimize probable error and low–density bypass. The results revealed that a clean coal product with less than 1.5% ash can be produced using a medium formed from the silicon production waste with an organic efficiency value of around 99% and a probable error value below 0.02. There was no measurable bypass of high density particles into the product stream or low–density particles into the reject stream

Development of a fine coal beneficiation circuit for the Twistdraai Colliery

Bibliography: p. 167-178.The principal aim of this thesis was to develop a fine coal beneficiation circuit for the Twistdraai Colliery capable of achieving.a saleable 10.0% ash (28 MJ/kg CV) product. Gravity circuit testing involved a comparative study of a conventional double-stage Spiral circuit and a Stokes upward-current washer when treating Twistdraai <850J.1m x 106J.1m fine coal. In addition, froth flotation technologies, in the form of the Microcel column and the Jameson cell were also tested in order to ascertain whether they can be suitably applied · to the Twistdraai naturally fine coal to produce a 10.0% ash steam coal export product. In this investigation, the Twistdraai fine coal surface was characterised by size as well as by density. Functional group determination included the measurement of the coals hydroxyl, carboxylic and total acid groups, since these exert the most important influence on the properties of the coal surface. These are supported by contact angle measurements, petrographic analysis and washability measurements in orde:r to determine the oil wettability of the coal fractions prior to flotation testing. The results described and discussed in this thesis show that it was possible to recover the desired quality of product by employing split-stream processing of the (850J.1m x 0) Twistdraai fine coal circuit feed. This was achieved by application of both gravity concentration and froth flotation technologies treating specific particle size ranges

International perspectives on coal preparation

The report consists of the vugraphs from the presentations which covered the following topics: Summaries of the US Department of Energy`s coal preparation research programs; Preparation trends in Russia; South African coal preparation developments; Trends in hard coal preparation in Germany; Application of coal preparation technology to oil sands extraction; Developments in coal preparation in China; and Coal preparation in Australia