Remove impurities from the coal for a more efficient and cleaner burning fuel with coal processing equipment from Multotec.
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Involves feeding the ore through a size reduction machine which is typically a roll crusher or mineral sizer. Thereafter the material is placed on a sizing screen. Any tramp metal that is present at this stage is removed via an over-belt magnet.
Coarser coal is fed to a dense medium separator (DMS) drum or a large diameter dense medium cyclone.
If a dense media drum is used, the intermediate size fraction reports first to a desliming screen, followed by the dense medium cyclone, which is more suitable to process the smaller size fractions effectively.
The coal product (floats) flows onto the drain and rinse screen, used for media recovery and dewatering. This ensures maximum media recovery from the process, resulting in a clean coal product. The coal waste (sinks) also discharges onto a drain and rinse screen for media recovery purposes.
The product can be screened further into different-sized fractions.
The material reporting to the desliming screen is screened to remove any ultra-fine coal particles.
Ultra-fine coal particles are fed through a classification cyclone followed by spiral separators or other water-based separation equipment, flotation, screens and centrifuges or filter presses.
The use of dewatering screens is generally the first step in the coal dewatering process. Centrifuges then subject the material to high centrifugal forces through high-speed rotation, forcing further separation of the coal from moisture.
View how Multotec coal processing equipment is designed for all stages of coal processing in this industry flowsheet.
Coal beneficiation machinery from Multotec enables you to achieve your processing goals at the lowest cost per ton. We supply coal beneficiation equipment for the entire process, from R.O.M stockpile to dewatering.
Our coal processing solutions:
Multotec can customise your coal beneficiation process according to the calorific value, level of inherent mud and ash, as well as the desired coal quality.
The first segment of the coal beneficiation process involves feeding the ore through a roll crusher and then sizing screen.
Following sizing, the coarser coal is fed to a DMS drum or large diameter DMS cyclone via a conveyor fitted with an overbelt magnet, which eliminates any ferromagnetic contaminants such as old bolts, tool shards, and other metallic scrap. In coal beneficiation, drain and rinse screens are located downstream of the DMS drum or large diameter DMS cyclone.
Finer coal particles are fed from the sizing screen to a desliming screen to remove ultra-fine coal particles. Ultra-fines are fed through a classification cyclone, flotation, spiral separators, screens and centrifuges or filter presses. Less fine particles are fed through a DMS cyclone, screens and centrifuges.
Coal mining can involve extracting coal from surface or underground deposits. Coal surface mining is conducted when coal is less than 90 metres underground. Large machines remove the topsoil and layers of rock known as overburden to expose coal seams. Mountaintop removal is a form of surface mining where the tops of mountains are dynamited and removed to access coal seams.
Underground mining, or deep mining, is necessary when the coal is roughly over 90 metres below the earth’s surface. Some underground coal mines are hundreds of metres deep with tunnels that may extend out from the vertical mine shafts for kilometres.
Modern coal cleaning technologies include DMS cyclones and spiral concentrators.
With DMS, very accurate density separation can be achieved within a short time frame.
Currently, the most efficient coal beneficiation method is the “float-and-sink separation” which increases productivity and separation. By using cyclones with accurate cut-point control, different densities of coal can be separated. DMS makes use of magnetite as a separation medium to improve the accuracy of cut-point separation. The magnetite is later recovered from the coal through drain, rinse screens, and magnetic separation.
Coal fines (particles less than 0.5 mm in size) are beneficiated with spiral concentrators. The refined coal and discards are separated with adjustable blades located at different points in the slurry stream. This allows for separation of products to the required quality.
Lignite is the youngest type of coal deposit. This coal is soft and ranges from black to shades of brown in colour.
Lignite is chiefly used for electricity generation and accounts for 17 % of the world’s coal reserves.
Subbituminous coal is the result of millions of years of continued pressure and high temperatures on lignite.
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Due to its low sulphur content, it burns cleaner than other types of coal, producing less greenhouse gas emissions.
It is used in electricity generation and industrial processes, making up 30% of the world’s coal reserves.
Bituminous coal is harder and blacker than lignite and subbituminous mineralisation and can be divided into two types: thermal and metallurgical.
Used in energy generation for heating and mixed with iron ore to produce steel, this coal makes up 52 % of the world’s coal reserves and accounts for most of the coal industry.
Anthracite is the most mature form of coal deposit and holds the highest carbon content of any coal type.
Also known as hard coal, mines that produce anthracite or hard coal account for roughly 1 % of the world’s total coal reserves.
This is a very small part of the overall coal industry, but is of the highest quality, with the highest calorific value.
We are specialists in coal beneficiation and supply our equipment globally. The effects of Multotec’s equipment in coal beneficiation achieves optimum results in processing. This is the result of 50 years of finding solutions to process more ore at a lower cost.
Our R&D programme responds to real-field challenges as well as cutting-edge coal beneficiation technologies so that we can constantly look for places where process efficiency can be increased.
Multotec’s R&D aims to enhance mineral and coal beneficiation through increasing product speed to market; high levels of product consistency and reliability; for OEMs to assume the role of solution providers; and the recycling of customers’ products at the end of their working life.
A slurry is a mixture of solid particles suspended in a liquid medium (coal ash). In most industrial applications, the suspended solid particles are denser than the liquid. Slurries can, therefore, be categorized as non-settling or settling slurries based on the solid particle size. Settling slurries are unstable mixtures with coarse particles that tend to settle at the bottom. They have high wearing properties that necessitate the careful selection of slurry handling equipment. Non-settling slurries contain very fine particles that can remain suspended in the liquid medium for extended periods. These slurries have a lower wearing effect but still, require careful selection of handling equipment as their behavior varies from that of normal liquids.
Slurries are often used in the industry as a convenient method of handling solids in bulk. They behave somewhat like thick fluids that can flow under gravity and may be pumped using suitable pumping equipment. Slurry pipelines offer economic benefits over land transport and are more environment-friendly, particularly in remote areas. They find applications in steel processing, mining, foundries and power generation.
EDDY Pump has been part of various environmental cleanup projects. Our pumps are uniquely positioned for sensitive projects because of the ultra low turbidity created. The best pumps for contaminated waterway cleanup.
Coal-fired power plants generate more than fifty percent of the world’s electricity. In doing so, they burn hundreds of millions of tons of coal. In the United States alone, more than 470 coal-fired electric utilities burn over 800 million tons of coal every year. Combustion of coal produces several different types of residuals. A very fine powdery material, known as fly ash, is driven out of the boiler with the flue gases. Coarse ash particles that are too large to be carried up with the smoke collect at the bottom of the boiler and are called bottom ash.
Together, fly ash and bottom ash are known as coal ash. Modern coal-fired power plants, in compliance with environmental regulations, use particle filtration or electrostatic precipitators to capture the fly ash before the flue gases are exhausted into the atmosphere. The chemical composition of coal ash can vary considerably based on the type and source of coal being burned. Fly ash is composed of silicon dioxide, calcium oxide and aluminum oxide while bottom ash contains high concentrations of heavy metals including mercury, lead, chromium selenium and arsenic. These substances are hazardous to health and the environment and require careful handling and disposal.
Coal power plants in the US generate about 110 million tons of ash and residuals annually. About 30% of the coal ash is disposed of as dry ash in large on-site or off-site landfills. Another 20% is stored in wet form in large surface impoundments known as ash ponds while 40% is recycled and used in various industrial applications such as manufacturing of cement, wallboards, bricks and pavers.
An ash pond is a structure specially engineered for the wet disposal of bottom ash and fly ash. The size of a coal ash pond depends on the capacity and disposal needs of the power plant with some ponds covering as much as 1,500 acres. Ponds are filled with coal ash slurry and the water is allowed to drain and evaporate over time. Storage of wet coal ash in ponds is subjected to strict Environmental Protection Agency (EPA) regulations as contaminants may leach into the ground water and pose health risks to communities nearby. These regulations are the result of a fly ash slurry spill from a 40-acre coal ash storage pond at the Tennessee Valley Authority’s Kingston plant in December . The spill damaged 40 homes, contaminated the Emory and Clinch Rivers and cost $1 billion to clean up. The new regulations specify structural standards for coal ash surface impoundments including liner requirements to protect the groundwater.
Fly ash and bottom ash collected from the power plant boiler is commonly transported as a slurry through pipelines to specially designed ash ponds. Ash that is generated dry is often mixed with water to facilitate transport. Fly ash is heavy and abrasive with a tendency to harden and compact which makes it difficult to pump. Moving wetted ash to ponds or hoppers using slurry pumps exposes the pumping equipment to extreme operating conditions including a highly abrasive environment, large particles, high pressure, temperature and vibration. This makes the slurry pumps susceptible to failure, causes unplanned downtime and leads to high operating costs. Correct pump selection is therefore of paramount importance in ensuring continuous, trouble-free operation.
EDDY pumps have been used successfully and reliably as sump pumps for pumping coal ash slurries. An EDDY pump is not a centrifugal, vortex or positive displacement pump. It has a patented design that harnesses the power of a tornado. A geometrically designed, spinning rotor creates a synchronized eddy current that lifts and pumps the slurry. This design enables the EDDY Pump to efficiently handle material previously deemed cost prohibitive. The unique design produces higher suction without clogging and without the critical tolerances of other pumps. EDDY pump technology delivers significant maintenance cost reductions and the ability to reliably pump slurries with large solids.
Flexibility of varying rotor options makes these pumps suitable for high solid, highly abrasive, corrosive, high viscosity and high specific gravity slurries. Available in sizes of up to 12”, EDDY Pumps are excellent at moving heavy materials through long pipelines. They create a turbulent flow that prevents settling and helps keep the heavy materials in suspension as the slurry moves down the pipeline. EDDY pumps offer mounting options that allow installation as a vertical pump or a horizontal pump. Submersible pumps and immersible EDDY pump models are also available.
Settled ash is removed from an ash pond at a power plant by coal ash dredging. As discussed earlier, new environmental regulations by the EPA require that all ponds be suitably lined to prevent heavy metal contamination of ground water. Poly liners, clay liners and concrete liners are generally employed for this purpose. Bottom and fly ash dredging of lined ponds presents a challenge as conventional dredging equipment can easily damage the liner causing an environmental catastrophe. EDDY pumps T3 coal ash dredge has been designed for liner safe application in the most sensitive dredging projects. The dredge incorporates a swinging ladder and 5-cable deployment which negates the needs for spuds. The unique design with precision load cell technology and the patented EDDY Pump allows dredging operation on clay, concrete and poly liners with no damage to the liner.
Coal ash slurries require special handling in power plants. They are difficult to transport using conventional pumps and require specialized pumping equipment designed to handle this tough job. EDDY Pump offers a unique solution to this problem with it’s patented pump design that harnesses the power of eddy currents. EDDY pumps deliver high performance over long periods in pond pumping applications to minimize the total cost of ownership. These high-performance pumps have been incorporated in fly ash dredges as dredge pumps suitable for safely removing ash from lined ponds without causing punctures or leaks in the liner. Investment in suitable slurry pumps can minimize expensive maintenance shutdowns and reduce the risk of leakage from lined ash ponds.
Best Applications: If you are pumping slurry, high solids, extremely viscous material, paste, high abrasives (sand & gravel) and material filled with solids, then you've found the ideal pump for your job. Call Us.
Industries Most Served: Mining, Fly Ash, Coal Ash Pumping, Oil and Fracking, Waste Water, Paper/Pulp, Chemical, Energy, Water Districts, Irrigation Districts and Dredging Companies. Our advanced pump technology supports the evolving dredging industry by enabling efficient operations, promoting sustainable practices, and facilitating environmental monitoring.
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