gekko ipj coal separator applications in coal preparation
DESCRIPTION
Gekko IPJ Coal Separator Applications in Coal Preparation. Andrew Vince (Elsa Consulting Group) Laurie Gibson, Peter Purdon (ACIRL) Tim Hughes (Gekko Systems). Elsa Consulting Group ACIRL Gekko Systems ACARP. Narrative. - PowerPoint PPT PresentationTRANSCRIPT
![Page 1: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/1.jpg)
Gekko IPJ Coal Separator Applications in Coal Preparation
Andrew Vince(Elsa Consulting Group)
Laurie Gibson, Peter Purdon(ACIRL)
Tim Hughes(Gekko Systems)
Elsa Consulting Group ACIRL Gekko Systems ACARP1
![Page 2: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/2.jpg)
Narrative
• Identified Australian circular jigging technology successfully processing
metalliferous ores.
• Confirmed application in coal processing
• For 6 (30) mm x 0.25 mm
• Small modifications necessary for high floats recovery
• Tested out at small lab scale (1 t/h) – good
• Variables – developed DEM/CFD model
• Tested on site at 10 t/h. Not found maximum capacity yet.
• Circular – therefore capacity and efficiency both improve with radius.
• Need to go bigger.
2
![Page 3: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/3.jpg)
Introduction
• Trend to installation of “three circuit” plants.
• This is due to:
• Matching size range to process technology
• Increased plant capacity
• Move to standardised plant design.
• Mid size fraction (eg 1.4 x 0.25mm) is currently
processed less efficiently than others.
• Gekko IPJ Coal Separator is targeting the mid size fraction.
3
![Page 4: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/4.jpg)
Current Processes for Mid-sized Particles
• Spirals
• 1.5 mm top size, low unit capacity, feed rate
sensitive.
• Teetered bed separators
• Cut point varies with particle size.
• Multiple units with split feeds – complicated circuit.
• Reflux classifier
• New technology currently being rolled out in some companies.
• Consumes significant water volumes.
4
![Page 5: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/5.jpg)
Gekko IPJ Coal Separator
• Gekko IPJ Coal Separator represents a competitor technology.
• Unique application possibilities due to high top size capability.
• Successfully deployed in metalliferous industry with more than 100
applications world-wide.
• This project considered application in coal industry.
5
![Page 6: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/6.jpg)
6
![Page 7: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/7.jpg)
Staged Approach
1. Laboratory scale testing.
2. CFD/DEM modelling.
3. Larger scale pilot testing on site.
7
![Page 8: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/8.jpg)
Slurry Feed
Air bleed
Control box
Product barometric leg 1
Product barometric leg 2
Reject barometric leg
Hutch water
Pulse actuator
Hydraulic pump
In LinePressure Jig
IPJ 600 Unit 1 tph
8
![Page 9: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/9.jpg)
Close-up of In Line Pressure Jig With Top Removed
Wedge wirescreen
Feed distributor
Ragging
InLine Pressure Jig Top Removed
Slurry Feed
PressureGauge
In Line Pressure Jig
InLine Pressure Jig Fully Assembled
9
![Page 10: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/10.jpg)
Bowen Basin Pilot Scale
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Bowen Basin 6 x 2 mm
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Bowen Basin 2 x 0.5 mm ww
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Bowen Basin 2 x 0.25 mm ww
10
![Page 11: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/11.jpg)
Hunter Valley Pilot Scale
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Hunter Valley 6 x 2 mm
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Hunter Valley 2 x 0.5 mm ww
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Hunter Valley 2 x 0.25 mm
11
![Page 12: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/12.jpg)
Laboratory Results Summary
Bowen Basin Coal
6 x 2 mm 2 x 0.5 mm 2 x 0.25 mm
t/h D50 Ep ±0.1RD D50 Ep ±0.1RD D50 Ep ±0.1RD
0.76 1.44 0.075 23 1.475 0.200 11 - - -
0.55 1.49 0.100 9 1.55 0.213 5 - - -
0.94 1.50 0.150 6 - - - 2.00 - -
Hunter Valley Coal
6 x 2 mm 2 x 0.5 mm 2 x 0.25 mm
t/h D50 Ep ±0.1RD D50 Ep ±0.1RD D50 Ep ±0.1RD
1.03 1.50 0.098 6 1.58 0.195 2 - - -
1.60 1.54 0.105 20 1.66 0.180 6 - - -
1.13 1.55 0.129 16 - - - 1.94 - -
1.12 1.55 0.129 17 - - - 1.80 0.282 712
![Page 13: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/13.jpg)
CFD/DEM Modelling
• 10 adjustable parameters.
• Too many to investigate experimentally.
• Develop CFD/DEM model to identify initial starting points for site-based pilot testing.
• Volumetric feed rate• Feed pressure• Feed % solids• Stroke length• Stroke frequency
• Stroke shape• Hutch water flow rate• Ragging diameter• Ragging density• Number of ragging layers
13
![Page 14: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/14.jpg)
Hunter Valley Test Work
14
![Page 15: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/15.jpg)
15
![Page 16: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/16.jpg)
16
![Page 17: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/17.jpg)
Issues Overcome
• Upward water flows
• Overcome with automation (commercially).
• Provision of back pressure.
• Migration of ragging.
17
![Page 18: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/18.jpg)
Provision of Back Pressure
18
![Page 19: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/19.jpg)
Blind Cyclones
19
![Page 20: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/20.jpg)
Blind Cyclones
20
![Page 21: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/21.jpg)
Ragging Mobility
21
![Page 22: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/22.jpg)
Site Tests
Feed Hutch Pressure
m3/h Dry t/h % Solids m3/h Bias kPa
Lower 9.32 3.16 20.5 26.0 -13.9 145
Upper 25.8 10.27 26.3 40.2 7.9 185
Stroke Ragging Near Gravity
Blind Cyclone Orifice
Cyc/min Length RD Layers ±0.1 RD mm
Lower 59 10 1.60 2.5 1 42
Upper 100 15 1.80 4.0 22 57
22
![Page 23: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/23.jpg)
Site Test Results
0
25
50
75
100
1.25 1.45 1.65 1.85 2.05 2.25 2.45
Parti
tion
coe
ffici
ent
(%)
Relative density
Partition coefficient curvesCoal A
6 x 2.0 mm
Series2
2.0 x 0.25 mm
Series4
6 x 0.25 mm
Series6 0
20
40
60
80
100
1.25 1.45 1.65 1.85 2.05 2.25 2.45
Parti
tion
coe
ffici
ent
(%)
Relative density
Partition coefficient curvesCoal B
6 x 2.0 mm
Series2
2.0 x 0.25 mm
Series4
6 x 0.25 mm
Series6
0
20
40
60
80
100
1.25 1.45 1.65 1.85 2.05 2.25 2.45
Parti
tion
coe
ffici
ent
(%)
Relative density
Partition coefficient curvesCoal C II
6 x 2.0 mm
Series2
2.0 x 0.25 mm
Series4
6 x 0.25 mm
Series6
23
![Page 24: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/24.jpg)
Site Results Summary
Coal A
Feed 6 x 2 mm 2 x 0.25 mm
Ash (%) m3/h % Solids D50 Ep ±0.1RD D50 Ep ±0.1RD
21.3 24.5 24.4 1.89 0.112 1.0 - - -
Coal B
Feed 6 x 2 mm 2 x 0.25 mm
Ash (%) m3/h % Solids D50 Ep ±0.1RD D50 Ep ±0.1RD
36.8 9.3 22.5 1.70 0.057 1.7 1.91 0.185 5.0
Coal C
Feed 6 x 2 mm 2 x 0.25 mm
Ash (%) m3/h % Solids D50 Ep ±0.1RD D50 Ep ±0.1RD
53.3 10.0 25.6 1.43 0.069 18.0 1.49 0.172 7.1
47.6 18.0 24.1 1.57 0.081 3.7 1.82 0.223 3.2
24
![Page 25: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/25.jpg)
All Site Test Results
40
50
60
70
80
90
100
0 5 10 15
Yiel
d (%
)
Ash (db, %)
Coal A: 6.3 x 2.0 mm
Washability data
Operating Pt
Sizing results
40
50
60
70
80
90
100
0 5 10 15 20
Yiel
d (%
)
Ash (db, %)
Coal A: 2.0 x 0.25 mm
Washability data
Operating Pt
Sizing results
50556065707580859095
100
0 10 20 30
Yiel
d (%
)
Ash (db, %)
Coal B: 6.3 x 2.0 mm
Washability data
Operating Pt
Sizing results
50556065707580859095
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
Coal B: 2.0 x 0.25 mm
Washability data
Operating Pt
Sizing results
25
![Page 26: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/26.jpg)
All Site Test Results
40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
Coal C II: 6.3 x 2.0 mm
Washability data
Operating Pt
Sizing results
40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)Ash (db, %)
Coal C II: 2.0 x 0.25 mm
Washability data
Operating Pt
Sizing results
26
![Page 27: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/27.jpg)
On-site and Lab Test Results
Low Cut Point High Cut Point
Scale Size (mm)
D50 Ep D50 Ep
Lab 6 x 2 1.43-1.55
0.075-0.15
Pilot 6 x 2 1.43 – 1.57
0.069 – 0.081
1.70 – 1.89
0.057-0.112
Lab 2 x 0.25 1.80-2.00
0.282
Pilot 2 x 0.25 1.49 0.172 1.82 – 1.91
0.185-0.223
27
![Page 28: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/28.jpg)
Why you expect performance to improve with scale (diameter)?
• Conventional jig:
• Capacity related to width
• Efficiency related to length.
• Gekko IPJ Coal Separator
• Circular section
• Increasing radius increases
• Capacity
• Efficiency.
• Larger radius leads to increased cleaning.
28
![Page 29: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/29.jpg)
Gekko IPJ Coal Separator(Extrapolated for coal)
<60 % solids
Ø1.50 m 40 tph
Ø2.40 m 80 tph
Ø3.50 m 200 tph
29
![Page 30: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/30.jpg)
Tentative correlations found
Tentative linear correlations 6 x 2 mm: y = mx + C
y D50 Ep
x m C R2 m C R2
Ragging layers 0.03 0 0.67 0.003 -0.002 0.83
Ragging RD 1.46 -0.8 0.76 - - -
Vol feed rate (m3/h)
- - - 0.003 0.03 0.92
Tentative linear correlations 2 x 0.25 mm: y = mx + C
Y D50 Ep
X m C R2 m C R2
Feed % solids -0.1 5 0.89 - - -
Ragging layers 0.003 -0.002 0.67 - - -
Ragging RD 1.3 -0.4 0.46 - - -
Vol feed rate (m3/h)
- - - 0.006 0 0.90
Hutch bias (m3/h) - - - 0.005 0.13 0.84
Stroke length (mm) - - - 0.3 -0.01 0.93
30
![Page 31: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/31.jpg)
Possible Circuitry
50 x 0 mm 50 x 6 mm DMC circuitDMC product
Flotation product
IPJ Product
31
![Page 32: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/32.jpg)
Possible Applications – High NG
40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
PerformanceCoal C I: 6 x 2.0 mm
Washability data
Operating Pt
With scavenger40
50
60
70
80
90
100
0 10 20 30 40 50
Yiel
d (%
)
Ash (db, %)
PerformanceCoal C I: 2.0 x 0.25 mm
Washability data
Operating Pt
With scavenger
40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
PerformanceCoal C II: 6 x 2.0 mm
Washability data
Operating Pt
With scavenger40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
PerformanceCoal C II: 2.0 x 0.25 mm
Washability data
Operating Pt
With scavenger
32
![Page 33: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/33.jpg)
ImplicationsPlant Low cost capacity increases Better matching of incremental ashes
between circuits possible
Screen 6mm rather than 2 mm aperturesLess near sizeEasier screening
Reduced screen areas for desliming AND drain and rinseLess criticality on apertures
DMC Less impact of breakaway sizeHigher efficienciesEstimated 25% less feed tonnesLess medium recirculatingSmaller pumps
Less power consumptionLess maintenanceMuch reduced magnetite losses
IPJ For 1000 t/h ROM plant feed500 t/h in 6 x 0 mm fractionNeed= 3 x 2 units (rough/scav)
Increased longer term recovery through rougher/scavenger configuration.
CC More units handling 6 mm top size
Flotation No change
33
![Page 34: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/34.jpg)
Conclusions
Gekko IPJ Coal Separator• Mature technology for metalliferous processing• Modified successfully for coal applications• Lab scale performance very good (600 mm, 1 t/h)• Site testing better (1000 mm, >10 t/h)• Strong evidence that can get even better (with size and further optimisation)• Possible applications
• Rougher/scavenger configuration• Treating 6 (30) x 0.25 mm particles• Very clean product requirements.
34
![Page 35: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/35.jpg)
Recommendation
35
• Plant testing of rougher scavenger configuration
![Page 36: Gekko IPJ Coal Separator Applications in Coal Preparation](https://reader035.vdocuments.net/reader035/viewer/2022062309/56814092550346895dac233b/html5/thumbnails/36.jpg)
Grateful Acknowledgements
1. Australian Coal Association Research Program and Industrial Monitors.
2. Providers of Hunter Valley and Bowen Basin coals for laboratory testing.
3. Hunter Valley site management, technical and operations personnel.
4. UNSW for CFD/DEM modelling.
5. Organisers and officials of this conference.
6. You.
Elsa Consulting Group ACIRL Gekko Systems ACARP36