Slide 1

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00


Slide 2

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00


Slide 3

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00


Slide 4

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00


Slide 5

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00


Slide 6

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00


Slide 7

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00


Slide 8

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00


Slide 9

Multi-product beneficiation
of Inferior Coals to User
Specific products
By

Kalyan Sen
Central Fuel Research Institute,
Dhanbad (India)

Modified approach:

Concept 1: multi-stage beneficiation
to 4 saleable products

1st Stage - 3-product Jig

2nd Stage - HM & Flotation

Outcome: proposed plant of 1
Mt/y near the Institute

Concept of Multi-stage Beneficiation
(37% Ash)

RAW COAL

100 Wt%

POWER SECTOR

(34 %)
20 %

PIT HEAD WASHERY

1st Stage Washing

PRIMARY
CLEANS
(22.6 %)
50 %

2nd Stage Washing

BEE-HIVE COKE-OVENS

(Coke Ash 31 %)

FOUNDRY
COAL

(27 %)
20 %

MIDDLINGS

REJECTS
(62 %)
30 %

BRICKS

COMPOSITE WASHERY

STEEL
PLANT
CLEANS
(17.5 %)
28 %

(Coke Ash 21%)

Raw Coal
Primary crushing area

alt10

Middling

-100/75 mm

Baum jig

ash< 34%

Rejects

Precleans
Desliming
screen

Screen 13 mm

+ 13 mm

- 0.5 mm
Flotation

+ 0.5 mm
HM Cyclone

HM Bath
Sink

Sink

For FBC
Cleans

Foundry Cleans
ash  28%

Cleans

Conc

Total Cleans ash 17  0.5 %

Multistage washing of lower seam LVC coals for Metallurgical
cleans as well as power coals

Product mix from beneficiation of difficult-to-wash coal
(Raw coal Ash 36-40%)

Cleans (18-19 A%)
24.0%
Fndry. Fuel (25-27 A%)
20.0%

Middlings (33-35%)
18.0%

Flot. conc. (15-16 A%)
6.0%
Tailings (55-60 A%)
4.0%
Rejects (60-65 A%)
28.0%
Raw coal crushed to 75mm

50

W t%

Char.Ash %

100
90

40

a
Ch

ash 28-30

30

ra

e
ct

t
r is

as

ic

h

80
70
60
50

20

40
30
Steel

10
grade

20

FC
PF Coal
ash ~34

ash 17-18
0
1.3

1.4

1.5

1.6

1.7

10

FBC coal
ash 50-60
1.8

1.9

2

2.1

Relative Density

Concept of four-product separation in multi-stage
beneficiation circuit with Inferior coals

0
2.2

Sen1, 2/6

40

Yield,%

Char. Ash, %

100

Step 1 :First cut in Jig (Im 0.14)

90

80

Feed (-75+0.5mm coal)
wt 100%
Ash 34.0%

30

70

60

l = 49
20

50
Clean 1
(73.5%)
Ash 27.0%

40
30

10
20
FBC Coal
Ash 56.5%
0
1.30

10
0

1.40

1.50

1.60

1.70

1.80

Relative Density

1.90

2.00

2.10

Preparation of Inferior Coal in stages

2.20

40

Yield,%

Char. Ash, %

Step 2: Second cut in Jig

100
90
80

30

70

Feed (Clean1)
wt 73.5%
Ash 27.0%

60

20

50
40

l = 30.0

30

10

20
10

0
1.30

0
1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

Relative Density

Preparation of Inferior Coal in stages

2.20

Yield,%

20

Char. Ash, %

100
90
80

15
70
60
10

50
40
30

5
20
10
0
1.30

0
1.40

1.50

1.60

1.70

Relative Density

1.80

1.90

2.00