june 3, 2014 beneficiation of lvc coal in india a challenge dr kalyan sen, director central fuel...
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![Page 1: June 3, 2014 Beneficiation of LVC Coal in India A Challenge Dr Kalyan Sen, Director Central Fuel Research Institute Dhanbad 828 108](https://reader035.vdocuments.net/reader035/viewer/2022062619/5517f7ce55034693228b48a1/html5/thumbnails/1.jpg)
April 10, 2023
Beneficiation of LVC CoalBeneficiation of LVC Coalin Indiain India
A ChallengeA ChallengeDr Kalyan Sen, DirectorDr Kalyan Sen, Director
Central Fuel Research InstituteCentral Fuel Research InstituteDhanbad 828 108Dhanbad 828 108
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Coal Scenario in IndiaCoal Scenario in India
83.0% 14.0%
3.0%
Prime coking
LVC
MVCHVCSemi-coking
19%
50%
15%
11%6%
Total Coal Reserves 206239.5 mt
Non-coking
Coking
Others
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COKING COAL FOR COKING COAL FOR METALLURGICAL USESMETALLURGICAL USES
REQUIREMENT : 25mt /yr.
IMPORT (1997-’98) : 10.6mt
SHORTFALL :
Depletion of good upper seam coal high cost of underground mining
(1998-99)
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LVC Coal Scenario in IndiaLVC Coal Scenario in India
LowVolatileCoking
50% ofTotal Coking Coal
15,680 mt
Available Resource
AlternativeProposition
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LVC Coal Scenario in IndiaLVC Coal Scenario in India Annual Production (16 -18 mt)
8 to 10 mt from Jharia 6 to 8 mt from East Bokaro
Present Use Power Stations (major consumption) Beehive ovens (minor consumption)
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Mining ConditionMining Condition
LVC coals outcrop near the fringe areas of coalfields
Easy for Opencast production Low overburden : coal ratio Low slope Possibility of high scale mechanization
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WASHABILITY STUDIESWASHABILITY STUDIESWITH LVC COALWITH LVC COAL
Lab. and Pilot plant study at CFRI
Sample : V/VI/VII/VIII Seam coal
of Jharia Coalfield
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Characteristics of LVCCCharacteristics of LVCC
High raw coal ash 35-45%
High Maturity Ro = 1.3
Low volatile matter content 15-16%
High Inertinite content (60-70%)
Poor washability potential
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LVC CoalsLVC Coals
Presently NLW grade
Unwashable !‘Formidable’ to wash !
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Liberation Potential of GOCP CoalLiberation Potential of GOCP Coal
0102030405060708090
100
Yield %
0 10 20 30
Ash%
Raw coal X 75mm & deshaledDeshaled coal X 13mm
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Liberation of coal/ mineral
particles by progressive size
reduction is insignificant
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‘‘Difficult - to - wash’Difficult - to - wash’
Due to
Typical Geological formation Intergrown Mineral matter High NGM at desired d50
Poor plant performance
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Theo. Yield of products from GOCP coalTheo. Yield of products from GOCP coal
0102030405060708090
1000 10 20 30 40 50 60 70
Ash,%
Yie
ld,%
2- product separation
Cleans ~30% of ash 18%
Rest ash 45% ( sale value ? )
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Theo. Yield of products from GOCP coalTheo. Yield of products from GOCP coal
0102030405060708090
1000 10 20 30 40 50 60 70
Ash,%
Yie
ld,%
Cleans ~30% Ash 18%
3- product separation
Rejects ~20% Ash 60%
Middling 50% Ash ~41%
( fate? )
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CFRI’s ConceptCFRI’s Concept
Sp.Gravity based Washability Model
Limiting Characteristics Ash
Multi-stage washing
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1.25 1.35 1.45 1.55 1.65 1.75 1.85 1.95 2.050
10
20
30
40
50
0
10
20
30
40
50
60
70
80
Char. Ash
Fra
ctio
nal
Yie
ld
Mid Sp. gravity
Ch
ar. Ash
%Density-wise mass distribution of GOCP CoalDensity-wise mass distribution of GOCP Coal
Claens RejectsFoundry
CoalPower Coal
4- product separation
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A Typical FlowsheetA Typical Flowsheet
Cleans Sinks Cleans Sinks Conc.. Tailings
Screened 13/6 mm & 0.5mm
R..O.M Coal X75mm
Cleans A Rejects Effluents
Precleans
75-13/6mm 13/6-0.5 <0.5mmRewash in
HM Bath/Cyclone Flotation
Total Cleans Foundry Fuel
Power Coal20-28%(a 60-65%)
50% (a21-23%)
20-28%(a34-37%)
25-28%(a17-18%) 20-23%(a27-29%)
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Technological SolutionTechnological Solution
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Issuies for AttentionIssuies for Attention
Economics of Clean coal
Washing Circuit
Quality of Product
Effect of Raw coal ash on yield
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PricePrice
ofof
Clean coalClean coal
at 17 - 18 % ash ?at 17 - 18 % ash ?
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Beneficiation in existing washeries
2-product circuit
About 70-75% with 40-45% ash with no
market outlet
Cost of clean coal is approximately 5 times that of raw coal
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Beneficiation in existing washeries
3-product circuit
LVCC requires disposal of 20% as reject
50% middling with 41% ash (outlet ?)
Cost of clean coal is 4 times that of raw coal
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4-Product Circuit4-Product Circuit
Cleans (25-30%), 17-18% ash
Foundry cleans (20-25%), 28% ash
Middlings (20-22%), 34% ash
Rejects (28-30%), 60-65% ash
Cost of clean coal is about 3 times that of Raw coal price
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CircuitCircuitforfor
1 mt washery1 mt washery
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Purpose ofHM Drum
&HM Cyclone
in the Second Stage
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1.3 1.4 1.5 1.6 1.7 1.8 1.9
Relative density
0
10
20
30
40
50
60
70
Ch
ara
cte
ristic
Ash
%
Char. Ash 26-28%
Coarser coal
Smaller coal
Cut Densities for HMB & HMC
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QualityQualityofof
Clean coalClean coal
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Washed Coal AnalysisPetrographic Analysis
Mean Ro % 1.27
Vitrinite % 53.2
Semi Vitrinite % 4.8
Exinite % 0.3
Inertinite % 31.5
Mineral Matter % 10.2
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Washed Coal Analysis
Chemical Analysis
Moisture % 0.9
Ash % 18.3
V. M. (%dmf) 21.0
S.I. 5.0
Max Fl. (ddpm) 150.0
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Washed Coal
Coke Property
Porosity % 48.5
CRI 12.6
CSR 72.9
M40 82.6
M10 9.8
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Effect ofEffect of
Change in Change in
Raw Coal AshRaw Coal Ash
onon
Clean Coal Yield Clean Coal Yield
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Predicted cleans from Raw coals Predicted cleans from Raw coals of varying ash valuesof varying ash values
Raw coal Precleans Foundry Fuel Cleans
ash,% wt ash% wt ash% wt ash%
34.0 47.9 21.8 19.0 28.3 28.9 17.5
35.0 45.0 21.6 17.5 28.4 27.5 17.3
36.0 42.8 21.5 15.4 28.5 27.5 17.6
37.0 42.0 21.6 16.2 28.5 26.8 17.6
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Predicted Cleans Vs. Raw coal ashPredicted Cleans Vs. Raw coal ash
32 34 36 38 40
Raw coal ash,%
20
25
30
35
40
Yie
ld a
t 17.
5% a
sh
ooo o
Y = 60.3 - 0.9 ash
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Thank You