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Dry Cleaning of Coal-Status In the USA
B.K.Parekh, FGX SepTech,LLC,
Lexington, KYwww.fgxseptech.com
Introduction• Wet cleaning plants and
processes are:– More Efficient;– Effectively clean from
coarse to ultrafine;– Not impacted by feed
moisture.
• WHY DRY CLEANING?– Scarcity of water;– Particle degradation in wet
cleaning plants;– Dewatering issues avoided;– Reduced capital and
operating costs;– Reduced environmental
impacts.
1930 1940 1950 1960 1970
20
15
10
5
0
MILLION TONS CAPACITY
(Mcculough et. al., 1968)
Dry cleaning is making a global comeback in the 21st century
Coal Preparation Equipment used with respect to size of the coal
Coal Preparation Equipment used with respect to size of the coal
Dry Coal Separators (e.g. FGX)
Basis of Dry Separation of Coal/Minerals
• Size
•Color/Composition
•Densities
•Electrostatic, or magnetic properties
Size Based Separation
Imperial Technologies Accelerator
Variable Speed Vertical Impact BreakerFractures Coal without breaking rock, so screening separation is
made Processes 10” x 3” ROM Coal to Uniform Sized, Cleaner Coal
Product Liberates coal from pyretic material to improve FGX processing
efficiency
Accelerator Benefits
Liberate Coal From Rock/Shale with screening (Lower Ash & Sulfur)
Improve Raw Coal Quality Uniform Sized Raw Coal Feed Increases Plant Recovery as
compared to crushing whole feed
Maximize Coal Throughput Reduce Plant Wear
Color/Composition based Separation
Dry Jet Process
X-Ray Sorting
Pilot-Scale operation of Dry Jet Process
Electrostatic, or Magnetic Separations
Rotary Triboelectrostatic Separator
Sample Distributor
Feeder
Separation Zone
Rotary Charger
SplitterTo Vacuum
Cyclone
Sample Distributor
Feeder
Separation Zone
Rotary Charger
SplitterTo Vacuum
Cyclone
Hematite
Phosphate Slimes
Density based Separation
Allmineral Air jig
Dry, Fluidized Bed Table Separator• Earliest air tables date back to 1850’s.• Major development during 1910-1930.• Major technology developments in China over the last
two decades.
(a) (b)
Support
Vibrator
SeparatingDeck
SuspensionMechanism
Feed
BafflePlate
AirChamber
Coal Middling Rock
Air
Back Plate
VibratingMotion
AirChamber
AirDuct
DischargeBaffle Plate
CoalRock
SeparatingDeck
Overflow
What’s FGX SepTech Technology?
A completely dry coal preparation method. A simple, efficient & cost-effective separation process.
A GREEN and energy efficient technology.
Coal Properties Requirements for the FGX Separator
• ROM Coal size 3inch X 0 (minus 6 mm or 4 mesh material should be about 20%)
• Surface moisture should be ~ 10%
• Rocks and pyritic sulfur should be in liberated (free) state
Plus 6 mm Powder River Tests
• Mobile 5 tph FGX Separator
• Operating Parameters– Longitudinal Slope (0o –
1.5o)– Cross Table Slope (8.5o)– Blower Frequency (50 – 60
hz)– Table Frequency (40 – 50
hz)
MOBILE FGX PILOT-SCALE UNIT
FGX PILOT-Scale Unit
Dry Air Table Separation
Seeing is believing
We’ll show you BLACK & WHITE (GREY)separation.
Benefits Saving transportation costs. Saving water costs. Saving processing costs & increasing plant productivity.
(Less maintenance, less chemical, less headache for water treatment…)
Permitting is relatively easier.
FGX Pneumatic Coal Cleaning installations in
the USA
Eagle River Coal ,LLCHarrisburg, IL
• Installed in the year 2011
•High sulfur coal and about 20% ash
•Operating for the last 4 yearsAt a rate of ~ 250 tph
Dry Coal Separator at the Eagle River Mining
FGX Dry Coal Separator Specifications at Eagle River Coal LLC
• Total capacity of the plant 250 tph – 3” raw feed
• Major equipment includes 2 x 125 tph vibrating tables
• Plant produces Coarse and small size clean coal, middlings, refuse, and fine dust
• Cleaning set-up at a cut point density of 1.8
Accelerator
Accelerator Rejects
FGX- 24A
Clean CoalMiddlingsRejects
Process Flow Diagram for the Eagle River Coal LLC
ROM Coal
Eagle River Coal, LLC ROM Coal Data:
Ash 16 –18%
Sulfur ~6.0 % St
Total moisture 4.5%
Surface moisture 1.5%
HGI 52-60
Eagle River Coal, LLC Product Data
Product Ash% Sulfur% Heating Value(Btu/lb)
ROM 16-18 5-5.5 12,000-12,200
Clean Coal 8.5-9.5 3.5-3.8 12,800-13,000
Middlings 10.0-12.0 3.8-4.5 11,850-12,250
Refuse 20-28 ~8.00 8,000-8,500
Yield (two products clean coal and middlings) ~ 80%
Combustible Recovery ~92%
Holcim Cement Co., Texas
• FGX-3 Installed in 2012• Process lignite at the a rate of 30 tph• Removes > 80% of the liberated rocks from the ROM feed.
FGX-3 at Holcim Cement Co, Texas
Sun Energy Group, Indiana
FGX-12 installed in July 2015
FGX-12 at Sun Energy Group
Product Yield% Ash% Sulfur% Heat Value(btu/lb)
Clean Coal 82.6 8.2 3.75 11913
Tailings 17.4 75.00 10.00
ROM 100 19.12 7.15 10150
Sun Energy Group Plant Data
Separation versus Particle Size (Ref:Honaker)
0
10
20
30
40
50
60
70
80
90
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8
Relative Particle Density
Pro
babi
lity
to P
rodu
ct (%
)
Overall2 x 1 in.1 x 1/2 in.1/2 x 1/4 in.-1/4 in.
>85%Rock
Rejection
0
10
20
30
40
50
60
70
80
90
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8
Relative Particle Density
Pro
babi
lity
to P
rodu
ct (%
)
Overall2 x 1 in.1 x 1/2 in.1/2 x 1/4 in.-1/4 in.
>85%Rock
Rejection
Particles smaller than 6mm require different operatingconditions.
Cut point density ~ 1.9; Ep = 0.17
Dry Coal Cleaning Scheme
Rock
Dry Coal Cleaner
Coal Operation
Loading
Screening
Market
+6mmProduc
t-6mm Feed
Dry Coal Cleaner
Accelerator
Economic Benefit
• Unit capacity = 500 tph
•Yield to reject = 36.4%
•Reject Amount = 500 x 0.364 = 182 tph
• Annual Operating Hours =5000 hrs/yr
•Total reject left at mine= 182 tph x 5000 hrs/yr = 910,000 tons
•Transportation cost = $0.50/t mile
•Mine-to-plant distance = 20 miles
•Transportation cost/ton = $10.00/ton• Annual transportation savings = 910,000 x $10
= $ 9,100,000
Summary Economic Benefit
• FGX operating cost = $1.50/ton
• Annual operating cost = $1.50 x 500 x 5000 = $ 3,750,000/yr
• Summary Transportation savings = $ 9.10 M Operating cost = $ 3.75 M ___________
Net profit gain = $ 5.35 M
Commercial Dry Table Separators• Over 1000 installations of
dry-air table separators worldwide.– Brazil– China– Mongolia– South Africa– South Korea– India– USA
• Table capacity = 10 to 250 TPH
• Plus 6 mm material• Less than 10% surface
moisture
Illinois FGX Separator Installation250 TPH capacity
Applications
Steam coal deshaling;Pit cleaning/rib coal recovery;Gob pile processing;Deshaling of metallurgical coal;Dry separation of high sulfur coal;High wall mining coal on-site processing;Coal prep in regions with water scarcity;Processing of low-rank coal, e.g. lignite;De-stoning of coal in utilities and cement plants.
Easy to install;Easy to operate;Low maintenance;
Commercial installation from 10 to 480 tph on a single unit; Over 1,000 clients in China; Sold in more than a dozen of countries worldwide: China, Indonesia,
Kazakhstan, Mongolia, Russia, South Korea, South Africa, The Philippines, Turkey, Ukraine, United States, Brazil, Colombia, India,Vietnam, etc.
THANK YOU
ANY QUESTIONS?