Dr Kalyan Sen

Emerging Dimension

forUtilization of Global Coal

Import of Coal

0

5

10

15

20

25

1990-91

1991-92

1992-93

1993-94

1994-95

1995-96

1996-97

1997-98

1998-99

1999-00

2000-01

2001-02

2002-03

2003-04

Coking Coal

Non-Coking Coal

Total Import

‘why difficult - to - wash’

due to

typical geological formation intergrown mineral matter high NGM at desired d50

Lower seam coal

Upper seam coal Upper Seam Coal

Lower Seam Coal

Upper Seam Coal

Mass Ditribution of Upper and Lower seams Coals

Raw coals crushed to 75mm

1.2 1.4 1.6 1.8 2

Relative Density

0

10

20

30

40

50

60

Fractional Mass %

A X

Upper Seam Coal

Lower Seam Coal

1.3 1.45 1.55 1.65 1.75 1.85 1.95 2.150

5

10

15

20

25

30

0

20

40

60

80Y

ield

,%

Mid Rel. Den

Characteristic ash, %

Fractional Yield/Ash vs. Rel. Density

Relationship between fract. Ash% & mid. sp. gr. is one of the inherent properties of coal

universal in nature

linear, in sp. gr. range of coaly matter

co-eff. of linearity indicates the maturity

hence, the name

Characteristic Ash ()

Characteristic ashas

optimum quality parameter

for coking coal =26-28%

limiting value for

non-coking coal =50-55%

This is why, for metallurgical use,

Western coals(av. ash% 12-16) are washed

down to 8-12%,in comparison to Indian coals that need to be washed down

to 17-19% ash

Similarly, for thermal power plant use,

Western coalsare washed down to 12-16%,

in comparison to Indian coals that need to be washed down

to 30-34% ashor below

Range of cut density (d50) for Steel and Power Sectors

0

20

40

60

1.25 1.45 1.65 1.85

Relative Density

Frac

. Ash

% 26+ 2% Steel

52.5+ 2.5% Power

Less Matured Coal

More Matured Coal

START

mc = mo ?

Obs. mass - mo

Obs. density - do

Density dist. RelationMaterial balance

Density at cut-points

S/A, F/S, , p ….

Cal. mass - mc

Cal. density - dc

STOP

Control Roominformation

Change density

YesNo

OperationFlow Chart

Maximum compositeYield at desired

quality

optimizationstrategy

State-of-the-ArtIntegrated Coal Washing

Pilot Plant

Raw Coal Section

Dry Deshaler

Raw Coal Section

Single Roll Crusher

Raw Coal Section

Double Roll Crusher

Coarse Coal Plant

Jig

Coarse Coal Plant

HM Drum

Fine Coal Section

Targetted

Fine Coal Treatment Pilot Plant

PLC based Control Room

STN - 1 STN - 2

PRINTER

HUB

P L C ( GE-Fanuc)

STATION (OPERATORS TESRMINAL)

HONEYWELL SERVER

(OPRT + PROGRAMMING TERMINAL)

CONVERTOR

SE

RIA

L I

NT

ER

FA

CE

SINGLE &

MULTILOOP

CONTROLLER

TO EXISTING PLANT LOCAL I / O SUB - SYSTEM

CENTRAL CONTROL ROOM

GE

NIU

S

LA

N

CONTROL

SYSTEM

Total support I/O nos. - 4096

SINGLE &

MULTILOOP

CONTROLLER

J B

J B

BinWeigher

WeightFeeder

I/P Converter

Trans-mitters

ControlValves

Spiral

Thanks