Slide 1

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 2

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 3

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 4

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 5

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 6

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 7

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 8

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 9

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 10

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 11

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 12

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 13

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 14

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 15

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects


Slide 16

Possible Routes for
Beneficiating High Ash Indian
Coals for Thermal Power
Station
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad, India
Kalyan sen

Characteristics of Indian Coals
Favorable Qualities:


Low sulfur Content
(<0.6%)

Constrains:
Genetic:



High AFT ( >1100 oC)

• High inertinite content
• High moisture content



Low iron content

Operational:



Low Cl2 content (<0.1%)



Low toxic trace elements

Mechanised mining in
large OCP



High reactive inertinites

Organizational:
Multiple sources/Linkages

Beginning of the conscientious effort :
Washery

Coalfield

Year

Cap (Mty)

Linkage

Piparwar, CCL

N.Karanp

1997

6.5

IP

Bina, NCL
Dipika, BSES
Converted
Gidi, CCL
Dugda I, BCCL
Kargali, CCL

Singrauli
Korba

1997
1998

4.5
2.5

Dadri
Dhanu

S.Karanp
Jharia
E.Bokaro

1999
1999
1999

2.5
1.0
2.7

-

Kalinga (8.0 Mty) at Talcher : coming
washeries

Identified Barriers For Beneficiation of
Indian Non-coking Coal

•Economic Barrier
•Policy Barrier

•Technological Barrier
barriers

Optimum Beneficiation Strategy
The beneficiation strategy should focus not on
maintaining a prefixed overall ash limit but on
restricting the non-combustibles to an optimally
minimum level corresponding to the limiting
quality parameter/s
parameters to be considered
 Characteristics

 Heat

ash value < 50 - 55%

value
 Petrographic reactives

Range of cut density (d50 ) for power grade cleans
from Indian noncoking coals
90

Characteristic Ash%

80
70
60

l 50-55%

50
40
30
d 50

20
10
0
1.30

1.40

1.50

1.60
1.70
Relative Density

1.80

1.90

2.00

Possible beneficiation schemes for
power coal
Level Scheme

I

Dry benefin.

Methodology

Ash% Cleans M % over
reducn (%) ROM coal

Separation of stone/shale

3-4

>90

Nil

<10

70-90

2-3%

>10

<60

3-4%

based on differential breakage
potentiality
II

Crushing,
screening &
coarse coal
cleaning

Crushing,
III screening
and total
cleaning
routes

Coarse coal (13/30mm) washed
& mixed with untreated fines;
dewatering screens.
Coarser fraction washed at
optimum efficiency levels:
fine coal by Spiral:
dewatering

pred-yield

Predicted yields of Cleans at different washers for a noncoking coal (100-3mm, Ash 41.0 %)

100

Theoretical

Yield %

80

Rotary
Br.

Woc
Im 0.2 **

60

40
HM washer
Im 0.08

20

Batac Jig
Im 0.12

Baum Jig
Im 0.18

** Raw coal crushed to 25 mm (25-3mm), ash 40.8%

0
20

25

30
Ash %

35

40

CONCLUSION:
Improvement of the overall efficiency and
environmental performance of the coalenergy chain demands
• beneficiation of Indian coal as an integral
component for thermal power generation
• proper identification and removal of the
barriers that act against implementation of
the coal washing strategy
Continued….

CONCLUSION:
• modification/ modernisation of the existing
washeries or installation of new washeries with
improved process design in view of changed
feed characteristics of the ‘difficult-to-wash’
coals.
• beneficiation strategy based on some intrinsic
quality parameters that guarantee the presence
of desired reactive combustibles in the product.

Thank you

Beneficiation of Indian noncoking coal appears to be the best
option, if not a bare necessity for
achieving quality consistency of the
supply to TPS and subsequent
improvement in cleaner energy
production.

Economic Barriers

economic

From producers’ point of view:
•Additional cost of washing
•Shortfall in target supply at the desired
level of quality parameters
•Present system of grading and pricing of coal
•Resource constraints for coal companies
Contd…..

Economic Barriers

economic2

From users’ point of view:
• Reluctance to enter into commercially
enforceable agreement
• Additional cost of washing
• Lack of appreciation of benefits of washing
• Availability of cheaper imported coal at port site
• Lack of ineterest by SEB’s for setting up new
washeries

policy

Policy Barrier
•Present regulatory framework that needs
to be reviewed as investor-friendly
•Lack of proper ambience for inviting
private investors
•Imbalance due to existing duty structure
•Existing system of coal linkages

Technological Barrier

tech-barriers

• Difficult to wash coal: need costlier deep
beneficiation
• Suitable washing scheme for desired
products
• High moisture content, 6-10%
• Loss of coal in Washery rejects
• No suitable techno-economic outlet for
rejects