NEW EFFICIENT AND SIMPLIFIED COAL PREPARATION PROCESS

Shuyan Zhao Tangshan Guohua Technology Co., Ltd. Tangshan, Hebei, China
ABSTRACT: New efficient and simplified heavy medium coal preparation and slurry treatment processes, developed by Tangshan Guohua Technology Co., Ltd., are introduced and discussed in the paper. These new processes have become mainstream technologies in Chinese coal preparation plants and significantly influenced Chinese coal preparation industry.

INTRODUCTION

In 21 century, heavy medium coal preparation technologies have been developed rapidly in China. The coal preparation capacity using heavy medium processes surpassed that using jigging process first time in China in 2007. This resulted from a series of heavy medium process technologies developed by Chinese coal preparation researchers since 1980s, especially from many new efficient and simplified coal process technologies developed by Tangshan Guohua Technology Co., Ltd. in last 10 years, which played a significant important role in the such development.

The new coal preparation processes, developed by Tangshan Guohua Technology Co., Ltd., have been recognized rapidly by Chinese coal preparation industry due to their high efficiency, simplification, energy saving, and discharge reduction. Since 2000, Tangshan Guohua Technology has designed and contracted more than 330 heavy medium coal preparation plants, in which the production capacity of the largest plant was 2362 st/h. The coal preparation plant engineering projects, designed by Tangshan Guohua Technology Co., Ltd. during 2008 - 2009, covered close to 70% of the coking coal market in China.

HEAVY MEDIUM COAL PREPARATION PROCESS WITHOUT DESLIMING & SIZING OF RAW COAL FEED

Sizing and desliming of raw coal feed is the conventional heavy medium coal preparation process, in which the raw coal is classified first. Large size lump coal is processed with heavy medium vessel or the other heavy medium separators. Small size coal after deslimed is processed using a single or two stages of H.M. cyclones with a single or double (high and low) densities of heavy media. Coarse fine coal is processed with spiral, TBS, or the other separators. This traditional heavy medium process is not only complicated but also produces low separation efficiency for the coarse fine coal. Even no qualified clean coal can be produced when difficult washing coal is processed. In addition, larger size of low separation limit results in a large

amount of fine coal entering the relative high cost and low efficient flotation operation.

Using the developed new heavy medium process without desliming & sizing, three qualified products including clean coal, middling and reject or two products (clean coal and reject) can produced at one time using a single low density heavy medium suspension instead of using high density or double densities of heavy media. The new heavy medium process not only considerably simplifies process flow circuits but also significantly improves separation efficiency. In addition, the new process solves the problem with which pure reject cannot be produced at high density (1.9 kg/L) for Chinese coal using heavy medium vessels or the other H.M. separators or 2-product cyclones.

Process Features of the Heavy Medium Cyclone

Since the velocity gradient in the H.M. cyclone destroys the structure viscosity of heavy medium suspension, the separation efficiency of non-deslimed coal is still very high if the structure dimensions of the cyclone and operating parameters are set up properly. Table 1 shows the separation results using 3-product cyclones without desliming & sizing of different washability raw coals from four Chinese coal preparation plants. Table 1. Separation results using 3-product H.M. cyclones
Feed Plant Size inch Shanxi Wenfeng 3 1/8-0 Anhui Linhuan 3 3/4-0 0.1 Amt % 6.55 14.30 38.26 47.58 Raw 15.77 36.03 34.22 31.78 Clean 6.37 9.79 9.54 11.51 Middling 35.23 37.79 24.47 27.89 Reject 80.27 85.17 76.99 67.66 % 82.04 61.79 56.65 49.95 Separation Density Ash, % Clean yield kg/L 1st stage 1.529 1.540 1.430 1.476 2nd stage 1.963 1.860 1.688 1.749 Probable Error Epm kg/L 1st stage 0.022 0.020 0.025 0.021 2nd stage 0.048 0.040 0.045 0.042 Recovery % 98.9 99.5 99.8 97.4

Guizhou Laowuji 3 1/8-0 Shanxi Jinyan 3 1/8-0

The data in Table 1 indicate the high separation efficiencies were obtained in all the four coal plants for the different washability coals; Probable error Epm1=0.020-0.025kg/L (1st stage), Epm2=0.040-0.050kg/L (2nd stage), and recovery>97% are achieved and reach or surpass the separation efficiencies of the other plants using the other H.M. processes.

Low Separation Limit and Fine Coal H.M. Cyclone

The low separation limit, using 3-product H.M. cyclone without desliming & sizing, is what every process technician and engineer would like to know. The plant tests of 60 gravity-fed 3-product cyclone, developed by Tangshan Guohua Technology Co., Ltd., were carried out in Shenhua Mengxi Qipanjing Coal

Preparation Plant in April 2009. The separation probable error Epm=0.099kg/L for the fraction of 0.5-0.25 mm (32-60 mesh) was obtained at the raw coal throughput of 648-668 st/h. The test results and partition curve for 0.5-0.25 mm (32-60 mesh) fraction are shown in Table 2 and Figure 1.

Table 2. Test results of 0.5-0.25 mm size fraction in Qipanjing Coal Preparation Plant
Raw coal Density In fraction Ash In fractn In total Ash In fractn In total Ash In fractn In total Ash In fraction Ash partition kg/L % <1.30 1.30-1.40 1.40-1.50 1.50-1.60 1.60-1.70 1.70-1.80 >1.80 Total 37.28 26.73 13.60 5.30 2.72 2.05 12.32 100.00 % 4.05 10.89 21.60 33.22 41.35 49.98 71.62 % 48.87 28.74 13.49 4.92 2.55 0.66 0.77 % 36.87 % 4.19 % 11.75 9.73 8.00 7.53 10.54 8.14 44.31 % 2.60 2.16 1.77 1.67 2.34 1.80 9.82 % 5.95 13.30 21.37 29.84 36.56 42.81 63.00 % 3.30 2.79 1.85 1.91 1.61 2.42 86.12 % 0.08 0.07 0.04 0.05 0.04 0.06 2.07 2.40 % 17.88 34.28 36.64 42.10 42.42 46.88 74.81 69.27 % 39.55 23.90 11.99 5.43 4.30 2.36 12.47 100.00 % 4.33 11.20 20.69 30.18 37.45 43.63 65.15 19.27 % 6.78 9.30 15.15 31.60 55.24 78.90 95.34 Clean coal Middling Reject Calculated Raw Clean

21.68 10.92 10.18 20.50 3.71 1.92 0.50 0.58 30.19 38.44 46.20 67.10

20.09 100.00

75.44 11.24 100.00

22.16 41.20 100.00

Figure 1. 0.5-0.25 mm fraction partition curve

Based on the Chinese coal industrial test standard MT/T811, the size at which its separation probable error Epm0.1 kg/L is considered as the low separation limit of the equipment at coal size 0.5 mm (32 mesh). Therefore, the low separation limit of the 60 gravity-fed 3-product H.M cyclone developed by

Guohua has reached 0.25 mm (60 mesh). The low separation limits of H.M. cyclone processes in many coal preparation plants, designed by Tangshan Guohua, have reached 0.25 mm (60 mesh) in China. For extreme difficult washing coal or required lower separation limit than 0.25 mm (60 mesh), the fine coal H.M. cyclones, developed and patented by Tangshan Guohua, can be utilized to further reduce the low separation limit. The working principle for the fine coal H.M. cyclone is that the magnetite carried with clean coal is always finer due to the effect of centrifugal force on the magnetite particles in the cyclone. The finer fraction of H.M. suspension drained from the clean coal can be used as the separation H.M. suspension for the fine coal H.M. cyclone. Therefore, no special ultrafine magnetite suspension is required to make, transport, and recover, which significantly simplifies the H.M. process flow circuit. The low separation limit of the fine coal H.M. cyclone can reach 0.1 mm (150 mesh). The detailed process flow circuit is shown in Figure 2. The separation results are given in Table 3.

Figure 2. The process flow circuit using the fine coal H.M. cyclone

Table 3. Separation results using the fine coal H.M. cyclone in Xinzhuangzi Coal Preparation Plant in Anhui China Separation density, kg/L 1.52 Probable error Epm, kg/L 0.08 Yield 100.00 Feed, % Ash 20.33 Celan coal, % Yield 67.56 Ash 9.69 Middling, % Yield 32.44 Ash 42.50

Heavy Medium Consumption

The heavy medium consumption, using the H.M. cyclone without desliming & sizing, is also what the every coal process technician and engineer would like to take care of. Low heavy medium consumption is able to be realized based on our industrial practice if we make sure to do the follows: - Proper selection of magnetic separator and good operation adjustment - Proper selection of drain and rinse screen. Screen width, screen deck structure, and spray position are all important - There should be enough circulated H.M. suspension slit out to avoid too high viscosity - Make sure to have clear thickener overflow to realize using clear water to rinse the materials on the H.M. drain screen deck

Tangshan Guohua designed many heavy medium process plants without desliming & sizing of raw coals in China. The average H.M. consumption, using 3-product cyclone without desliming & sizing, is 1 kg/t. The heavy medium consumptions in some of plants are very low. For example, H.M. consumption in Wenfeng Coal Preparation Plant of Shanxi China was as low as 0.55 kg/t in 2006 and has been kept consistently. Industrial practice indicates the H.M. consumption using non-desliming and non-sizing of raw coal is close to that using pre-desliming and sizing of raw coal.

CLEAN FINE COAL SLURRY FLOW CIRCUIT

The fine coal slurry circuit in a coking coal preparation plant can be divided into two parts, i.e., clean fine coal flow circuit and fine tailing flow circuit.

Purposes of the clean fine coal treatment circuit are: - Economically and efficiently separate the fine coal fraction - Reduce the moisture content of clean fine coal as much as possible.

The clean fine coal process circuit with two stage flotation and two stage dewatering & recovery, promoted by Tangshan Guohua, is shown in Figure 3. The tailing of clean coal magnetic separator is pumped to clean fine coal sieve bend to classify. The underflow of the sieve bend enters the 1 st stage flotation while

the overflow of the sieve bend, combined with the froth of the flotation, is dewatered and recovered with a screen-bowl centrifuge to primarily recover >0.045 mm (325 mesh) fraction of coarse fine coal. The fine fraction of <0.045 mm (325 mesh) from the filtrate & overflow of the screen-bowl centrifuge enters the 2nd stage flotation. The froth of the 2nd flotation is dewatered and recovered with the filter press. The filtrate of the filter press is clear and used as wash water circulated in the plant. The dewatered product from the screen-bowl centrifuge and the filter cake from the filter press (the both as clean fine coal products) are combined into the final clean coal product in the plant.

Figure 3. Two stage flotation and two stage dewatering and recovery of clean fine coal process circuit

Features of the process flow circuit are:

Unique classified flotation process technology Floatability and selectivity of most Chinese fine coals are difficult since a large amount of high ash clay is usually contained in the flotation feed of <0.03 mm size fraction. The ash is always misplaced in the froth product and results in high ash content of the clean product of the flotation. In the fine process flow circuit, the screen-bowl centrifuge has two functions. One of them is dewater the froth of the 1st stage flotation while another function is to remove ultrafine fraction (containing high ash material) from the froth to reduce ash content of the froth product. The removed ultrafine fraction (actual filtrate & overflow from the screen-bowl) is further cleaned with the 2nd stage flotation to reduce the ash content of clean fine coal by about 1%. Since the production throughput of flotation is about 1/4-1/3 of the plant capacity, the reduction of ash content of the flotation clean product plays an important role in stabilizing and guarantee the ash content of the plant final clean coal product.

Addition of coarse fine to the feed of the screen-bowl centrifuge Mixing the coarse fine from the overflow of the clean sieve bend into the flotation froth as the screen-bowl feed to make sure <0.045 mm (325 mesh) fraction in the feed less than 40%, could meet the requirement of consequent dewatering and recovery equipment. At the same time, it simplifies the process procedure of the overflow of the sieve bend.

Two stage dewatering The froth product combined with the coarse fine is first dewatered effectively with the screen-bowl centrifuge to recover the product with about 80% of coarse fine material >0.045 mm and about 30% of fine material <0.045 mm (325 mesh). The rest of the fine coal is recovered completely using the filter press (a complete solid-liquid separation device).

Table 4 gives the yields and moisture contents of clean products in Aiweiergou Coal Preparation Plant of Xinjiang China in 2006 using the fine process circuit. The 15% of moisture content of the coarse fine clean coal ensured the moisture content of the final clean product reached at 9.78%. Currently, the moisture content of the clean filter cake from the filter press is <20%.

Table 4. The yields and moisture contents of clean coal products in Aiweiergou Coal Preparation Plant
Product Lump clean Small clean Coarse fine Fine clean Total Fine clean Dewatering equipment & models DMM3036 drain and rinse screen LLL1030 550 Vertical centrifuge LWZ1200 1800 screen-bowl centrifuge XMZ500/1600-U filter press Yield, % 12.75 57.40 23.88 5.97 29.85 100.00 Moisture, % 4.83 6.33 15.18 32.00 18.54 9.78

Final clean product

Pressurized filters and clean coal filter presses are employed in many cases to dewater and recover the fine clean coal in one stage in some of coal plants in China. However, construction capital cost could be reduced by 14.3% and manpower saved by 37.5% using our promoted 2+2 fine circuit compared to using the one stage of filter press. Electrical power consumption could be reduced by 70.45% and construction capital cost saved by 54.05% using our promoted 2+2 fine circuit compared to using the one stage of pressurized filter.

TAILING SLURRY TREATMENT FLOW CIRCUIT

The purpose of fine tailing treatment flow circuit promoted by Tangshan Guohua is described as below: Recover coarse fine reject as much as possible to reduce its moisture content and to mix it into the middling product to increase its value Realize complete separation of solid and liquid for the small amount fine tailings Addition of Ca++ and Mg++ ionic type agglomerates as a primary agent and polypropylene type flocculant as a secondary agent to ensure the overflow of thickener clear to realize using clear water to wash coal.

Figure 4. Tailing treatment process flow circuit with 2-stage thickening and 2-stage recovery

The tailing treatment process circuit flow diagram with 2-stage thickening and 2-stage recovery is shown in Figure 4. Tailings (flotation tailing and tailings from the reject and middling magnetic separators after coarse fines removed) first enter the 1st stage incline tube thickener to classify. The underflow of the thickener

is dewatered with a screen-bowl centrifuge to primarily recover >0.045 mm (325 mesh) coarse fine fraction. The overflow of the thickener enters the 2nd stage incline tube thickener. The underflow of the 2 nd stage thickener is dewatered using a filter press to completely recover all ultrafine tailings. The clear overflow of the 2nd stage thickener and clear filtrate of the filter press are used as wash water circulated in the plant to realize using clear water to wash coal.

Currently one stage of filter press is widely used to recover the fine tailings in the world. Sometimes, the tailings are also discharged to tailing ponds or tailing dams in some of plants. The low heating value tailing coal is abandoned. The disadvantages using one-stage filter press are 1) sticky filter cake brings troubles to material sales on the market, 2) multiple units of filter presses have to be used due to low production capacity of the filter press, which results in high construction capital cost, and 3) ultrafine tailings are accumulated and a vicious circle takes place if the coal contains a large amount primary slime and ultrafine clay materials. The tailing ponds or tailing dams are prohibited in China due to the strict environment regulations Table 5Process parameters of LWZ series screen-bowl centrifuge
Coal plant Applications Date of tests Solid Feed content Ash, % Surface moisture, % Ash, % Dewatered Yield, % products Solid recovery, % Liquid mixing rate, % Solid Screen-bowl filtrate content Ash, % Yield, % Solid Screen-bowl overflow content Ash, % Yield, % Dewatering efficient, % g/L % g/L % 86.91 5.39 54.20 5.33 12.28 11.87 132.40 12.72 15.88 9.31 81.52 62.01 77.61 70.54 8.53 187.00 10.61 48.68 29.46 81.06 3.45 56.50 5.52 53.01 18.94 78.81 70.54 81.06 g/L % Aiweiergou Plant, China
Clean coarse fine dewatering

Huoshaopu Plant, China

Tailing coarse fine dewatering

Wangfenggang Plant, China

Tailing coarse fine dewatering

2006.7 278.5 25.64 11.42 15.24 11.10

2003.11 470 39.38 40.12 15.70 36.54

2008.3 253.6 22.96 48.63 12.50 45.72

The LWZ series of screen-bowl centrifuges with centrifugal force 200-280 and length/diameter ratio 1.43-2.00 is recommended to use in the 2+2 model tailings treatment circuit promoted by Tangshan Guohua to primarily recover >0.045 mm (325 mesh) coarse fine tailings. The recovery rate of >0.045 mm (325 mesh) fraction is more than 97%. Removing rate of <0.045 mm (325 mesh) fraction with the centrifuge is about 50%. The moisture content of the dewatered product is about 16.5%. The process parameters of LWZ series of screen-bowl centrifuges are given in Table 5. It should be pointed out that the moisture content of the product and solid recovery are related to properties of the feed of the screen-bowl.

CONCLUSIONS

The new efficient and simplified heavy medium process technology, developed by Tangshan Guohua Technology Co., Ltd., has been widely used in Chinese coal preparation industry. Its application reduces 20-40% of capital and operating costs and 40-60% of power consumption. The use of the new process technology brought significant economic benefit to the Chinese coal preparation plants and changed the Chinese coal preparation industry considerably, which becomes an important milestone for China to enter from a large coal preparation country to a powerful country in coal preparation industry.

It is well known that Chinese coal belongs to very difficult to wash coal. Furthermore, the properties of raw coal feeds to the plants fluctuate often and considerably during ordinary operation compared to the Western country plants. Therefore, the new coal preparation process technologies, suitable to the Chinese coal plants, may find their applications in the coal preparation industries of many other countries.

10