Australian Coal Preparation Society
The Principles of Coal Preparation
4th Edition 2007
G J (Joe) Sanders
Table of Contents
1 Coal in the Ground
1.1 Introduction
1.2 The Coalification Process
1.2.1 Peat Formation
1.2.2 Coal Seam Formation
1.2.3 Theories of Deposition
1.2.4 Coalfield Formation
1.3 “Gondwanaland”
1.4 The Nature of Coal
1.4.1 Rank and Type of Coal
1.5 Petrographic Constituents of Bituminous Coal
1.5.1 Maceral Analysis
1.5.2 Vitrinite
1.5.3 Liptinite
1.5.4 Inertinite
1.6 Non-carbonaceous Matter in Coal
1.6.1 Moisture in Coal
1.6.2 Mineral Matter
2 Mining and Bulk Handling
2.1 Mining Methods
2.1.1 Introduction
2.1.2 Underground Mining
2.1.3 Surface Mining
2.2 Run-of-Mine (ROM Coal)
2.2.1 General
2.2.2 Middlings
2.2.3 Rocks and Minerals Mined with Coal
2.2.4 Moisture Content
2.3 The Impact of Mining on Coal Preparation
2.3.1 ROM Quality
2.3.2 Preparation Control in Underground Mining
2.3.3 Preparation Control in Open Cut Mining
2.3.4 Selective Mining
2.4 Bulk Handling
2.4.1 Background
2.4.2 Handleability
2.4.3 Tests to Determine Handleability
2.4.4 Stacking/Stockpiling
2.4.5 Reclaiming
2.4.6 Blending
2.5 Transport and Shipping
2.5.1 Transport
2.5.2 Port Handling Facilities
2.5.3 Cargo Assembly for Export
2.5.4 Coal Loading Ports
3 The Safe Storage of Coal
3.1 Issues of Coal Storage
3.1.1 Quality and Properties
3.2 Spontaneous Heating
3.2.1 Factors Affecting Self Heating
3.2.2 Assessment of Propensity to Self Heating
3.3 Preventative Measures
3.3.1 Stockpile Design
3.4 Stockpile Management
3.4.1 Condition Monitoring
3.4.2 Remedial Action
4 Sampling of Coal
4.1 Introduction
4.2 Precision, Accuracy and Bias
4.2.1 Precision and Accuracy
4.2.2 Bias
4.3 The Amount of Coal to be Taken for the Sample
4.3.1 The Sample Increment
4.3.2 Number of Increments
4.4 Sample Location and Collection
4.4.1 Sampling from Conveyors
4.4.2 Sampling from Stockpiles
4.4.3 Sampling from Trucks and Wagons
4.4.4 Sampling from Screens
4.4.5 Sampling from Slurry Streams
4.5 Mechanical Sampling
4.6 Sample Preparation
4.6.1 Air Drying
4.6.2 Particle Size Reduction
4.6.3 Mixing
4.6.4 Division
4.6.5 Preparation
5 Coal Analysis and Testing
5.1 Background
5.2 Chemical Analyses
5.2.1 Moisture
5.2.2 Proximate Analysis
5.2.3 Ultimate Analysis
5.2.4 Other Elements of Significance
5.2.5 Trace Elements
5.3 Reporting of Analytical Results
5.4 Physical - Chemical Properties and Tests
5.4.1 Calorific Value
5.4.2 Caking, Coking and Fluidity Tests
5.4.3 Ash Fusibility (Ash Fusion)
5.4.4 Ash Analysis
5.4.5 Petrography
5.4.6 Coke Strength Tests
5.5 Physical Properties and Characteristics
5.5.1 Introduction
5.5.2 The Mass, Volume and Density Relationship
5.5.3 Relative Density
5.5.4 Relative Density and Ash
5.5.5 Relative Density and Other Properties of Coal
5.5.6 Bulk Density
5.5.7 Hardness and Friability
5.5.8 Miscellaneous Other Tests
5.6 Size Analysis
5.6.1 The Sieving Method
5.6.2 Presentation of Results
5.7 Accuracy of Analytical and Test Results
6 Liberation and Washability
6.1 Coal Washability Issues
6.1.1 Introduction
6.1.2 The Concept of Liberation
6.1.3 Specific Washability Related Sampling Issues
6.1.4 Size Degradation and Sample Preparation Issues
6.2 Float and Sink (F&S) Analysis
6.2.1 Procedures
6.2.2 Float and Sink Testing Apparatus
6.2.3 Float and Sink Liquids – Safety Aspects
6.3 Treatment of Washability Data
6.3.1 The Calculation of Weighted Values
6.3.2 Washability Tables
6.4 Washability Curves
6.4.1 The Cumulative Floats Curve
6.4.2 The Cumulative Sinks Curve
6.4.3 The Relative Density Curve
6.4.4 The Instantaneous Ash Curve
6.4.5 The ±0.1 Relative Density Curve
6.4.6 The Combined Curves Graph
6.4.7 The Mayer Curve
6.5 “Ease of Washing”
7 Partition
7.1 The Partition Concept
7.2 Parameters Derived from the Partition Curve
7.3 The Construction of the Partition Curve
7.4 Data Development with the use of Density Tracers
7.5 Prediction of Process Performance
7.5.1 Calculating Predicted Performance
7.5.2 Example of Performance Prediction
7.6 Partition by Size
8 Crushing and Screening
8.1 Issues of Crushing
8.1.1 The Purpose of Crushing
8.1.2 The Crushing Ratio
8.2 Types of Crushers
8.2.1 Overview
8.2.2 Power Requirements for Crushing
8.2.3 Jaw Crushers
8.2.4 Gyratory Crushers
8.2.5 Rotary Breakers
8.2.6 Hammer Mills
8.2.7 Single Roll Crushers
8.2.8 Sizers
8.2.9 Feeder/Breakers
8.3 Screening – an Overview
8.3.1 The Purpose of Screening
8.3.2 Screens for Various Applications
8.3.3 Basic Principles of Screening
8.4 Types of Screens
8.4.1 Fixed or Static Screens
8.4.2 Shaking Screens
8.4.3 Mechanically Vibrated Screens
8.4.4 High Frequency Screens
8.4.5 Resonance Screens
8.4.6 Roller Screens
8.5 Screen Decks
8.5.1 Types of Screen Deck
8.5.2 Screen Deck Materials
8.6 Efficiency and Capacity of Screens
8.6.1 Measures of Efficiency
8.6.2 Factors Influencing Capacity and Efficiency
8.7 Screening of Fines
8.7.1 Wet Screening
8.7.2 Dry Screening of Small and Fine Sizes
9 Gravity Separation - Jigs
9.1 Introduction
9.2 The Jigging Action
9.2.1 The Basic Design
9.2.2 The Air Cycle
9.2.3 The Work of Pulsation
9.2.4 Adjustments to Expansion and Suction
9.3 Types of Jig
9.3.1 The Baum Jig
9.3.2 The Under-air Jig
9.3.3 The ROMJIG
9.3.4 Small Coal Cleaning in Jigs
9.4 Rejects Removal
9.5 Operational Issues
9.5.1 Factors Affecting the Action
9.5.2 Jig Operation
9.6 Performance and Efficiency
10 Dense Medium Separation – Baths
10.1 Introduction
10.2 Solids for Medium
10.2.1 Material used Commercially
10.2.2 Specifications of Magnetite for use in Dense Medium Processes
10.3 Dense Medium Baths
10.3.1 Chance Cone
10.3.2 Wemco Cone
10.3.3 Barvoys Bath
10.3.4 Drewboy Bath
10.3.5 Tromp Bath
10.3.6 Leebar Bath
10.3.7 Wemco Drum
10.3.8 Teska Bath
10.3.9 Daniels Bath
10.3.10 Parnaby Drum
10.4 Performance of Dense Medium Baths
10.5 Magnetite Cleaning and Recovery
10.5.1 General Considerations
10.5.2 The Magnetite Recovery Circuit
11 Hydrocyclones
11.1 Introduction
11.1.1 Historical Background
11.1.2 Uses of Cyclones
11.2 Design and Construction of Cyclones
11.3 Principles of Operation
11.3.1 The Flow Patterns in a Cyclone
11.3.2 Principal Variables and their Effects
11.4 Classifying and Thickening Cyclones
11.4.1 Applications
11.4.2 Performance of Classifying and Thickening Cyclones
11.4.3 Stacker Cyclones
11.5 Water Washing Cyclones (WWC)
11.5.1 Design and Operation
11.5.2 Parnaby Natural Medium Cyclone
11.5.3 Performance of Water Washing Cyclones
12 Dense Medium Separation – Cyclones
12.1 Background
12.2 The Principles of Dense Medium Cyclone Separation
12.3 Construction and Operation of a Dense Medium Cyclone
12.4 Dense Medium Cyclone Flowsheets
12.4.1 Draft Tube Design Circuit
12.4.2 Circuit with Wing Tank
12.4.3 Pumping or Gravity?
12.4.4 Desliming
12.4.5 Two Stage Operation
12.5 Dense Medium Cyclone Performance
12.5.1 Design Variables
12.5.2 Cyclone Dimensions
12.5.3 Capacity
12.5.4 Operational Variables
12.5.5 Efficiency of Separation
12.5.6 Magnetite and Consumption
12.6 Dense Medium Cyclones for Sizes <0.5mm
12.7 Other Cyclonic Type Separators
12.8 Operating Dense Medium Cyclones – Australian Practice
13 Gravity Based Separation of Fine Coal
13.1 Introduction
13.1.1 What is Fine Coal?
13.1.2 The Issues of Fine Coal Cleaning
13.2 Flowing Film Separators
13.2.1 Shaking Surface Concentrators
13.2.2 Spiral Concentrators
13.3 Processes Based on Hindered Settling
13.3.1 The Principle of Hindered Settling
13.3.2 The Teetered Bed Separator (TBS)
13.3.3 The HydroFloat
13.3.4 The Reflux Classifier
13.3.5 Other Designs Based on Hindered Bed Separation
14 Froth Flotation
14.1 Introduction
14.2 The Principles of Flotation
14.2.1 Surface Properties of Coal and Mineral Matter
14.2.2 The Role of Collectors and Frothers
14.2.3 Flotation Performance
14.3 Assessment of Flotation Characteristics
14.3.1 Issues of Performance Definition
14.3.2 Sampling
14.3.3 Laboratory Tests
14.3.4 Pilot Plant Tests
14.3.5 Modelling
14.4 Froth Flotation Plants Operation
14.4.1 Flotation Circuit with Desliming of Feed
14.4.2 Flotation Circuit with Coal Thickener
14.4.3 Circuit for the Flotation of Ultrafines
14.4.4 Feed Preparation
14.4.5 Addition of Reagents
14.4.6 Froth Washing
14.4.7 Product Handling
14.4.8 Flotation Machines – General
14.5 Mechanically Agitated Flotation Cells
14.5.1 Cell Design
14.5.2 Choice of Cell Configuration
14.6 Column Cells
14.6.1 General
14.6.2 The “SlamJet” Sparging System
14.6.3 The “Microcel” Sparging System
14.7 Jet Flotation Cells
14.7.1 The Jameson Cell
14.7.2 The Pneuflot
14.7.3 The Imhoflot G-cell
14.8 Flotation Performance
14.9 The Estimation of Flotation Capacity
14.10 Oil Agglomeration
15 Dewatering of Product Coal
15.1 Introduction
15.2 Dewatering of Coarse Coal
15.3 Centrifuges
15.3.1 Centrifuging in General
15.3.2 Centrifuge Design and Operation
15.4 Dewatering of Fine Coal
15.4.1 Slurry Screens
15.4.2 Dewatering Cyclones
15.4.3 Filtration
15.5 Vacuum Filters
15.5.1 Drum Filters
15.5.2 Disc Filters
15.5.3 The Horizontal Vacuum Belt Filter (HVBF)
15.5.4 The Hyperbaric Filter
15.6 Screen Bowl Centrifuges
16 Dewatering of Rejects
16.1 Introduction
16.2 Dewatering Coarse and Small Rejects
16.3 Thickening of Tailings
16.3.1 Introduction
16.3.2 Thickening
16.4 Thickeners
16.4.1 Conventional Thickeners
16.4.2 High Capacity/High Rate Thickeners
16.4.3 Paste Thickeners
16.4.4 Other Types of Thickeners
16.4.5 Thickener Troubleshooting
16.4.6 Froth on Thickeners
16.5 Dewatering of Tailings
16.5.1 Introduction
16.5.2 Solid Bowl Centrifuges
16.5.3 Filtration of Tailings
16.6 Closed Water Circuits
16.7 Water Treatment and Discharge from Plant/Mine-site
17 Dry Cleaning
17.1 Introduction
17.1.1 Historical Notes
17.1.2 Characteristics and Performance of Dry Cleaning Processes
17.1.3 Dry Cleaning in the 21st Century
17.2 Air Dense Medium Fluidised Bed
17.3 Air Jigs
17.4 Coal Sorting
18 In-plant Handling and Rejects Disposal
18.1 Introduction
18.2 Feeders
18.3 Chutes
18.4 Conveying
18.5 Pumps and Pumping
18.5.1 Types of Pumps
18.5.2 Pump Sizing
18.6 Valves
18.7 Equipment Protection
18.8 Rejects Disposal
18.8.1 General Considerations
18.8.2 Traditional Separate Coarse and Tailings Disposal
18.8.3 “Dry” Disposal
18.8.4 Co-disposal
18.8.5 Other Methods – Future Trends
18.9 Reclaiming Old Tailings Dams
19 Instrumentation and Controls
19.1 Introduction
19.2 Instrumentation and Measurement
19.2.1 Measurement of Mass Flow
19.2.2 Measurement of Level
19.2.3 Measurement of Volumetric Flow Rate
19.2.4 Measurement of Density
19.2.5 Ash Measurement
19.2.6 Elemental Analysis
19.2.7 Moisture Measurement
19.2.8 Coal Slurry Ash Analysers
19.3 Process Control
19.3.1 Background
19.3.2 Hardware
19.3.3 The Control System
19.3.4 Jig Control
19.3.5 Dense Medium Control using Density Gauges
19.3.6 Thickener Control
19.3.7 Flotation Control
19.3.8 Filtration Control
20 Metallurgical Supervision and Controls
20.1 Introduction
20.2 Samples and Measurements
20.2.1 Flowrate
20.2.2 Mass Flowrate
20.3 Mass Balancing
20.3.1 Process Yield
20.3.2 Process Recovery
20.3.3 The Use of Size Distribution in Mass Balancing
20.3.4 The Use of Dilution Ratios in Mass Balancing
20.3.5 Sources of Error and Misinterpretation in Mass Balancing
20.4 Control Targets
20.4.1 Yield Optimisation or Loss Minimisation?
20.4.2 The Value of Consistency
20.5 Performance Monitoring
20.5.1 The Key Drivers of Performance
20.5.2 Methods of Performance Monitoring
20.5.3 Routine Checks
20.5.4 Periodic Performance Audits
20.5.5 Long Term Trending – Data Historian
21 Data Development for Design
21.1 Introduction
21.2 Type and Detail of Data Required
21.3 Anticipated Use and Markets
21.4 Selection of Data Sources
21.5 Generation of Data from Bore Core Samples
21.6 Data from Bulk Samples
21.6.1 Selection and Collection of Bulk Sample
21.6.2 Analysis and Testing
21.7 Data from the Geological Model and the Mine Plan
21.8 Historic and Regional Data
21.9 Interpretation of Data
21.9.1 Washability
21.9.2 Additivity
21.9.3 The Design ‘Envelopes’
22 Process Selection and Flowsheet Design
22.1 The Road to Good Design
22.1.1 Fit for the Purpose
22.1.2 The Design Team
22.2 Determination of Plant Capacity
22.3 Characteristics of Available Processes
22.4 The Influence of Coal Properties on Process Selection
22.5 Assessment of Alternatives
22.6 Conceptual Flowsheet Design
22.7 Flowsheet Standards
23 Example of Process Selection and Flowsheet
Design
23.1 Limitations and Assumptions
23.2 Information Provided
23.2.1 Laboratory Data
23.2.2 Partition Data
23.3 Design Calculations
Review Answers
Bibliography
Australian Standards
