tabas project mine & cpp - coal research forum · minerals industry joint seminar. tabas coal...
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![Page 1: TABAS PROJECT MINE & CPP - Coal Research Forum · Minerals Industry Joint Seminar. TABAS COAL PREPARATION PLANT. TABAS PROJECT. MINE & CPP. PRESENTED BY: MEHRDAD GHAFFARI - IRITEC](https://reader031.vdocuments.net/reader031/viewer/2022012917/5ae346f77f8b9a7b218cdd95/html5/thumbnails/1.jpg)
Minerals Industry Joint Seminar
TABAS COAL PREPARATION PLANT
TABAS PROJECTMINE & CPP
PRESENTED BY:
MEHRDAD GHAFFARI - IRITEC(CPP engineering coordinator)
November 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
November 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
TUNNEL STARTING
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
FIRST ARCS
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
ROADHEADER STARTING
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
FIRST MECHANIZED COAL
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
FIRST JUNCTION
November 26th,2008 University of Nottingham
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Minerals Industry Joint SeminarNovember 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
TABAS COAL PREPARATION PLANT
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
CPP GENERAL LAYOUT 1
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
CPP GENERAL LAYOUT 2
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
CPP BLOCK DIAGRAM
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
SCREEN HOUSE UNDER CONSTRUCTIONNovember 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
HEAVY MEDIA UNDER CONSTRUCTIONNovember 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
TABAS COAL PREPARATION PLANT
DESIGN
PRESENTED BY:
PAOLO BOZZATO - ECOMIN(process engineer)
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
INTRODUCTION
CLEAN COAL REQUIREMENTSCOAL WASHABILITYLABORATORY AND PILOT TESTSPROBLEMS DURING BASIC DESIGNFINAL EQUIPMENT LIST
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
CLEAN COAL CHARACTERISTICS
CLEAN COAL ASH 10.5-11.0 %
CLEAN COAL MOISTURE 9.0 %
Max –3 mm IN CLEN COAL 78 %
CLEAN COAL PRODUCTION 750,000 t/yr
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
COAL WASHABILITY 1
HARDGROVE INDEX OF COAL: 96 – very friable
University of NottinghamNovember 26th,2008
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Minerals Industry Joint Seminar
COAL WASHABILITY 2
Index Coal Washability
0102030405060708090
100
0 5 10 15 20 25Clean Coal Ash %
Cle
an C
oal Y
ield
%
Coarse Coal Small Coal Fine Coal
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
LABORATORY TESTS
SIZE & ASH DISTRIBUTIONHEAVY LIQUIDS RELEASE ANALYSISMIDDLINGS CRUSHING AND HLDROP TEST (FOR ROTARY BREAKER DESIGN)
WET ATTRITION TESTSEDIMENTATION TEST
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
PILOT TESTS
TRI-FLO TESTFLOTATION TEST (6-in ID column) SPIRAL TESTSCREEN BOWL CENTRIFUGE TESTFILTER PRESS TESTHORIZONTAL FILTER TESTDISK FILTER & DRUM FILTER TEST
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
CONCEPTUAL DESIGN 1FEASIBILITY ALTERNATIVE
Plant Feed< 50 mm
Middlings Crushing
Basket Centrifuge
Disc Fliter
Thickener
Filter Presses
REJECTS CLEAN COAL
0.5-0 mm
50 - 0.5 mm
TriFlo Middling
Two Stage Mechanical
Flotation
Mixer
Preparation Screens
25-0.5 mm50-25 mm
13-0.5 mm
50-13 mm
TriFlo 700(1 Unit)
50-0.5mmScreen
Plant Feed< 50 mm
Middlings Crushing(Cage Mill)
Preparation Screens
TriFlo 500(2 units)
TriFlo 700(1 Unit)
Column Flotation
Thickener
Filter Presses
REJECTS CLEAN COAL
25-4 mm
50-25 mm
0.5 - 0 mm
50 - 4 mm
4 - 0.5 mm
Screen Bowl Centrifuge
(Instead of Disc Filters)
BasketCentrifuge
NEW
Basket Centrifuge
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
CONCEPTUAL DESIGN 2(ALMOST) FINAL ACCEPTED
Plant Feed< 50 mm
Middlings Crushing
Preparation Screens
TriFlo 500(2 units)
TriFlo 700(1 Unit)
Basket Centrifuge
Screen Bowl Centrifuge
Column Flotation
Thickener
Filter Presses
REJECTS CLEAN COAL
25-4 mm
50-25 mm
0.5 - 0 mm
50 - 4 mm
4 - 0.5 mm
TriFlo Middling 45 t/h
300 t/h
345 t/h
130 t/h
65 t/h
50 t/h
195 t/h
80 t/h
247 t/h
140 t/h
110 t/h 8 t/h
180 t/h
120 t/h
Plant Feed< 50 mm
Middlings Crushing
Preparation Screens
TriFlo 500(2 units)
TriFlo 700(1 Unit)
Filter Press
Screen Bowl Centrifuge
Column Flotation
Thickener
Filter Presses
REJECTS CLEAN COAL
50-4 mm
0.5 - 0 mm
50 - 4 mm
4 - 0.5 mm
TriFlo Middling 45 t/h
300 t/h
345 t/h
130 t/h
65 t/h
50 t/h
195 t/h
80 t/h
247 t/h
140 t/h
180 t/h
120 t/h
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
FINAL DESIGN 1
CHP – Feed Handling
-50mm
Reject
StockpileOverspill Bunker
50 mm screen
Surge Bin
To Screen House
Rotary Breaker
From Mine
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
FINAL DESIGN 2Screen House
To Coarse Coal Section
To Small Section
To Flotation Section
50X6mm
6X0.5mm
- 0.5mm
ROM Screen
DeslimingScreen
DeslimingScreen
ROM Screen
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
EQUIP 1 - PREP SCREENS
Banana screens 4 off 9 x 3 m – Manuf. LINATEX (SA) Supplier SCAMAC (I)
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
FINAL DESIGN 3
Coarse Coal Preparation To Rejects Screen
To Middling Screen
To Clean Coal Screen
High Gravity Sump
Low Gravity Sump
1
3
2
From Screen House
50X6 mm
Split Deck Screen
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
FINAL DESIGN 4Coarse Coal Preparation
To Screen house
High G
ravity Sump
Dirty water Sump
Diluted Medium Sump
Middling Sump
Cage crusher
1
3
2
To Screen House
Middling
To Rejects
To Clean Coal
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
EQUIP 2 - HM TRI-FLO
1 off 700 ID – 2 off 500 ID - Ecomin (I)
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Tri-Flo Problems?
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
EQUIP 2 - HM TRI-FLO
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
EQUIP 3 - MIDDLINGS CRUSHERCAGE MILL TYPE - MAGCO (UK)
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
FINAL DESIGN 5
November 26th,2008 University of Nottingham
Flotation
To Thickener
To Centrifuge
From Screen House
From Centrifuge
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Minerals Industry Joint Seminar
EQUIP 4 - COLUMN FLOTATION
6 OFF 14 FT ID X 8 m - Manuf. CPT (Canada) and Ecomin (I)
November 26th,2008 University of Nottingham
SlamJet®
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Minerals Industry Joint Seminar
FINAL DESIGN 6
November 26th,2008 University of Nottingham
Clean Coal Dewatering (Centrifuge)
To Clean Coal
To Flotation
To Thickener
Small clean coal Flotation concentrate
To Filter Press
To Flotation
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Minerals Industry Joint Seminar
EQUIP 5 - CC DEWATERINGScreen Bowl Centrifuges – Manuf. Andritz (D)
Filter Press – Manuf Tecnicas Hidraulicas (E)
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
EQUIP 6 - TAILS THICKENER40 m thickener – Manuf Dorr Oliver Eimco
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Thickener Problem?!
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Filter Press – Manuf Tecnicas Hidraulicas (E)
EQUIP 7 - TAILS FILTER
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
EQUIP 8 – CONT’SLURRY PUMPS – Krebs & Ecomin (I)
WATER PUMPS – KSB (D)
MAGNETIC SEPARATOR HM – Magnapower (SA)
AIR COMPRESSORS – BOGE (D)
FIXED SIEVES – Ecomin (I)
AUTOMATION – SAET (I)
ASH MONITOR & DENSITY METERS – RGI (D)
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Handling Problems?!
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
TABAS COAL PREPARATION PLANT
OPERATION
BY:HASSAN NOORI - IMPASCO
(process engineer)
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
TABAS COAL PREPARATION PLANT
INTRODUCTION
RESULTS
PROBLEMS
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Monthly TonnageFeed & Clean Coal
0
10000
20000
30000
40000
50000
60000
(ton)
Oct2007Nov2007Dec2007Jan2008Feb2008Mar2008Apr2008May2008June2008July2008Aug2008Sep2008Oct2008
Feed
clean coal
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Monthly Feed Ash & Clean Coal Yield
0
10
20
30
40
50
60
70
%
Oct2007Nov2007Dec2007Jan2008Feb2008Mar2008Apr2008May2008June2008July2008Aug2008Sep2008Oct2008
Feed ashYield
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Total CPP Feed & Production
• Total Feed: 400,000 t• Average Clean Coal Yield: 36.5 %• Total Clean Coal: 145,000 t• Average Feed Ash: 51.9 %• Average Clean Coal Ash 11.5 %• Average Moisture (total): 10.3 %
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Ash of Each Circuit (OCT 2008)
0
10
20
30
40
50
60
70
0 1 2 3 4 5 6 7 8 9 10 11 12
%ash TF700ash TF500ash Flot.
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Material Split of Feed
15
20
25
30
35
40
45
50
0 1 2 3 4 5 6 7 8 9 10 11 12
%
coarsesmallflotation
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Performance Test FeedWt Ash% %
3,32 81,909,29 79,2014,06 75,8014,98 71,1012,45 63,9014,29 51,7012,15 47,1019,47 46,00
100,00 61,40Total
+ 50- 50 + 25- 25 + 12-12 + 6- 6 + 3- 3 + 1
- 1 + 0.5- 0.5
Sizemm
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
WashabilityMarch 2008 – Performance Test
Plant Result 8.35% Ash & 13.8% Yield
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
PLANT FEED – CURRENT
SIZE Weight % Ash % Total 100 45,4
+ 6 mm 39,4 54,6- 6+0,5 mm 40,3 39,2 - 0,5 mm 20,3 40,0
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Current Washability
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Partition curve & Ep TF 700
Ep overall = 0.041
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Partition curve & Ep TF 500
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Problems
Commissioning?!
Design
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Design problems 1
1. Direct feeding from the mine (no blending)
2. Stock pile ROM3. Coarse coal flow sheet4. Crusher protection5. Small clean coal dewatering6. Centrifuge or crusher!?
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
SBC Feed & Cake
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Ultrafine Coal Washing
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Design problems 27. Size of columns8. Clean coal Filter press inside the main
building9. Handling?!
November 26th,2008 University of Nottingham
How do you design for this?
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Minerals Industry Joint Seminar
GENERAL PROBLEMS?!
THREE EXAMPLES
1. Piping
2. Vibration
3. Staff Experience
November 26th,2008 University of Nottingham
Easy ones: don’t do it like this
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Minerals Industry Joint Seminar
Questions?
November 26th,2008 University of Nottingham
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Minerals Industry Joint Seminar
Did you get enough for today?
November 26th,2008 University of Nottingham