coal preparation i poland

8/19/2019 Coal Preparation i Poland

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Authors: Wieslaw S. Blaschke, Lidia Gawlik

Current situation andCurrent situation andCurrent situation andCurrent situation andCurrent situation andCurrent situation andCurrent situation andCurrent situation anddevelopment prospectsdevelopment prospectsdevelopment prospectsdevelopment prospectsdevelopment prospectsdevelopment prospectsdevelopment prospectsdevelopment prospects

of coal preparationof coal preparationof coal preparationof coal preparationof coal preparationof coal preparationof coal preparationof coal preparation

in Polandin Polandin Polandin Polandin Polandin Polandin Polandin Poland

POLISH ACADEMY OF SCIENCES – Cracow

Mineral and Energy Economy Research Institute

SILESIAN TECHNICAL UNIVERSITY – Gliwice

Department of Mining and Geology


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!Coal preparation is one of the main

technological and economic issues connected

with the mining industry

!Coal preparation technologies are adjusted to

demand of domestic and foreign consumers

! Coal preparation technologies depend on

characteristicof raw coal


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Structure of coal production in Poland

84,2% - steam coal

15,8% - coking coal

All coking coal is washed

About 48% of steam coal is washed


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431231Total

4—4< 500

215161000 – 500

11561500 – 1000

7252000 – 1500

TotalCoking coalSteam coal

Number of coal preparation plantsRange of gross

capacity, t/day

Capacities of coal preparation plants in Poland


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Heat content Ash content

above 25 MJ/kg 80.4% below 10% 47.7%

22 - 25 MJ/kg 14.9% 10 - 15% 37.2%20 - 22 MJ/kg 3.6% 15 - 25% 9.1%

below 20MJ/kg 1.1% above 25% 6.0%

Sulphur content

below 0.6% 33.4%

0.6 - 1.0% 36.8%

1.0 - 2.0% 22.9%above 2.0% 6.9%

Coal quality in seams


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ROM coal quality

Heat content: 14.9 MJ/kg - 24.2 MJ/kg

Ash Content 17% - 42%


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Quality of saleable coal:

Steam coal (as received)

Sulphur content: 0.45% - 1.22% (average: 0.83%)

Ash content: 8.0% - 24.1% (average: 19.1%)

Heat content: 29.7 MJ/kg - 19.8 MJ/kg (average: 22.4 MJ/kg)

Coarse coal

Sulphur content: 0.67%

Ash content: 6.8%

Heat content: 29.5 MJ/kg

Coking coal (dry basis)

Sulphur content: 0.51% - 0.87% (average: 0.67%)Ash content: 5.8% - 8.3% (average: 6.8%)

Heat content: 28.2 MJ/kg – 31.6 MJ/kg (average: 29.5 MJ/kg)


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Demanded quali ty in the internat ional markets:

Heat con tent: Q = ~ 25 MJ/kg

Ash content : A = maximum 15%

Sulphu r con tent: S = 0.8 –1.0%

Quality of coal fines for the domestic purposes are

much lower than international standards:

Qual i ty o f so ld f ines in Poland:

Q=20.6 MJ /kg

38% - unwashed coal f ines : A = 22.6%S = 0.86%

Q= 22.1 MJ /kg

40% m ixtures of washed A=21.1%

and unwashed coal: S = 0.87%

Q= 24.8 MJ /kg

22% washed coal f ines: A = 12%

S = 0.72%


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50 – coal preparation plants exist

(40 in coal mines and 10 independent)In all coal preparation plants there exist section for preparation middle and

coarse grains (above 20 (10) mm).

Production capacity of those sections is 90.8 mln tonnes of raw coal.

In 38 coal preparation plants there exist sections for preparation fines of

grain sizes from 20 (10) mm to 0.5 mm.

Sections for slimes flotation work in 16 coal preparation plants. They treat

coals of grain sizes from 1.0 (0.5) mm to 0 and can wash 10.1 ml tonnes of

raw coal.

Capacities of coal preparation plants and their sections are not fully used, as

they work only to meet market demand.

Production capacities of coal preparation plants are used in 68%,sections for coarse grains preparation - in 44%,

fines sections - in 79%

flotation sections - in 66%


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0.7716.123 865100.0102.1Total - hard coal

0.7518.920 4473.83.92.3.4. Semi-products

0.8423.322 31926.727.22.3.3. Fines mixtures

0.8829.820 39427.427.92.3.2. Unwashed fines

0.7211.325 39216.016.32.3.1. Washed fines

0.8420.822 26970.171.52.3. Grain class 20(10)(8)–0 mm

0.596.128 1162.72.82.2. Grain class 20–8 mm

0.656.227 4247.88.02.1. Grain class + 20 mm

0.8017.922 85284.486.22. Steam coal

0.656.929 36615.615.91. Coking coal

S, %A, %Q, kJ/kg%Ml t

Quality parametersProductionItem

The structure of production and quality of saleable

coal (2002 averages)


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8.433 6802 10514Flotation class 1.0 (0.5)–0 mm

63.1252 64015 79030Gravitational washing class

20(10)–0 mm

1Gravitational washing class

65–0 mm

79.0316 16019 76042Gravitational washing class +

20(10) mm

Out of which:

Sections of grain class washing

174.1696 48043 53043Coal preparation plants (total)

Mlt/year

t/day

(16 hoursof work )

Production capacityGross

capacity,

t/h.

Number

of

sections/

plants

Item

Number of coal preparation plants and units in

Poland and their capacities


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10035 550Total

0.9300Parnaby – Barells

1.9660Spirals

1.3450Dense media

cyclones

2.1765Hydrocyclones

46.216 440Jigs

47.616 935Dense media

separators

%t/h

Capacity of the sectionTechnology of

washing

Capacities of the sections according to applied

washing equipment


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Ov al throw sc reen

Jaw crus her

(1)

S traight-line vibrating sc ree n

Raw co al

Refuse

(2)

Ov al throw sc reen

Dens e-medium se parator

(3)

(4)

S traight-line v ibrating s cre e n

(7)

(18)

S tationary sc reen 1,0 mm

S traight-line vibrating sc ree n

to dens e medium tank

Recuperator

Recuperator

Clas s ifying tank

Nuts Cube s

Ov al throw sc reen

Jaw crus her

Peas to se l l

or to c rush

Dorr thicke ner

Vacuum dis c filter

Circular water

Vor siv conical siev e

S traight-line v ibrating s cre en

(5)

(6)

(10)

(11)

(14)

(15)

(16)

(17)

(13)

(12)Ov al throw s cree n

(9)

(8)

Fines IIA

The technological scheme of steam coal preparation plant


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Concentrate

Lamella tickeners

Livella’s screen

Straight-line vibrating screen

Jiq

Flocculant

Concentrate

Spirals

Vibrating centrifuge

Spirals

HC D=500

Bend sieve

Screen

Spirals

Screen

Spirals

HC D=100

30-0 mm

HC D=100

Concentrate

Filter presses

Hyperbaric filter

Dorr tickener

Circural water

Wastes

Tailings

Slimes from washing+ 30 mm

Wastes

Flocculant

(1)

(2)

(3)

(4)

(5)

(11)

(12)

(13)

(14)

(15)

(17)

(18)

(16)

(10)

(9)

(8)

(7)

(6)

The technological

scheme of the coal fines

preparation and

desulphurisation plant


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To a classification sump

Screen

Crusher

φφφφ 120 mm

Screenφφφφ 20 mm

Dense-medium sep.

Sieve

Screen

Crusher

Concentrate

20-0 mm

Raw co al

Screen

Sieve

γ γγ γ = 1.47

γγγγ = 1.74

Screen

γ γγ γ = 1.1

Recu perator

Sus pend ed matter

Middlings 200-20 mm

Wastes

200-20 mm

Jig

Wastes

20-0 mm

Middlin g s

20-0 mm

Vor-siv conical sieve

Centrifug e

Concentrate

20-0 mm

Classification sump

From recu peration

Flotation

Vacuum filter

Dryer

Thickener

Flotation

concentrate Filter press es Circural

water

Tailings

The technological scheme of the coking

coal preparation plant


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Groups of steam coal preparation plants:

I. Two - product washing of grain sizes 200 - 20 (10) mm in dense media

separators or water jigs.

Grains below 20 (10) mm are sold as raw coal.

II. Two - product washing of grains 200 - 20 (10) mm in dense mediaseparators or water jigs.

Two - product washing of grain sizes 20 (10) - 2 mm in water jigs or

water cyclones.

Grains below 0.5 mm are added to coal fines to prepare saleablemixture of steam coal.

III. Two - product washing of grain sizes 200 - 20 (10) mm in dense media


Two - product washing of grains 20 (10) - 2 mm in water jigs.Washing of grain sizes 2 - 0.5 mm in spirals.

Two - product washing of grains 0.5 - 0.2 mm in hydrocyclones.


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Groups of steam coal preparation plants:

IV. Two - product washing of grains 200 - 20 (10) mm in dense media


Washing of grain sizes 20 - 0.5 mm or 12 - 0.9 mm in dense media

cyclones.

Washing classes 3 (0.9) - 0 (0.2) mm in water cyclones

or spirals.

V. Classes above 0.5 mm are washed in one of above-mentionedschemes.

For the class below 0.5 mm flotation is used.

VI. Three - product washing is used in some coal preparation plants.

Separated middlings are re-washed or sold as coal of lower quality.


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Groups of coking coal preparation plants:

I. Three - product washing of grain sizes 200 - 20 mm in dense

media separators.

Two - product washing of classes 20 - 0.5 mm in water jigsor in dense media cyclones.

Two - product washing of crushed middlings (class 6 - 0.5)

in water jigs or in dense media cyclones.

Grains below 0.5 mm are floated.

II. Selective crushing of raw coal to get grains 60 (50) mm.

Three - product washing of class 60(50) - 0.5 mm in jigs.

Crushing of middlings to below 6 mm and washing

of class 6 - 0.5 mm in water jigs or dense media cyclones.

Flotation of grains below 0.5 mm.


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Polish typical coal preparation plant


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Polish preliminary

classification screens


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Equipment - washing of coal sizes

above 20 (10) mm

Polish dense media separators type Disa

(Disa 1, Disa 2S, Disa KU, Disa KR)

or Polish water jigs (OBZ, OZ, OZL, OS).

One separator Drew-Boy from the firm Denver -

washes coal sizes 600 - 6 mm - very effective.


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Polish dense

media separator

type DISA


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Equipment - fine grains washing

Classes 20 (10) - 0.5 (0.2) mm are usually washed in Polish jigs

(OBM, OM, OS)

and domestic hydrocyclones (HWO, HKZ).

Foreign machines are also installed:

— Allmineral and Batac jigs,

— Parnaby and AKW hydrocyclones,

— Krebs dense media cyclones,— Reichert spirals.

— Barrel concentrators.

427 concentrators work in Poland,out of which 351 - of Polish production

76 - from import.


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Polish jigs type OS


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Equipment - flotation

Flotation is used to wash coking coal.

In two of steam coal preparation plants flotation is

experimentally used. (Polish steam coals are difficult to float).

The basic flotation machines are mechanic flotation machines

produced in Poland (IZ5, IZ12)

and column flotation machines (FLOKOB 12, FLOKOB 24,

FLOKOB 40).

Imported flotation machines are also used - type Allminerall

(Allflot) and Denver.


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Section of flotation


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Equipment - dewatering

Coarse grains:

In vibrating screens produced in Poland (WP-2, PWP-1, PWE,

PWL-Z).

Concentrates of grain sizes below 20 mm:

screen - dewatering sieve (OSO) - vibration centrifuge (WOW) -dewatering machine (Nael).

In some plants Humbold centrifuges (HSG) work, as well as

Wemco (H-900) or Humbold dewatering machines (Konturbex).


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Equipment - dewatering

Slimes (grains below 0.5 mm):

dewatering sieve - hydraulic classifier - radial thickener

Dorra - vacuum filter.

• vacuum and disc filters (FTB, FTC, FTBO),

• domestic filter presses (PF-570, PF 1.2, PF 1.5),

• hydrocyclones HKZ.

• pressure filters Andritz (HBF-96)

• belt filter presses (CPF-2200, PL-2200)

• Sieve-sedimentary centrifuges and sedimentary centrifuges

from BIRD, Decanter, Humbold-Wedag and Wemco.

Flotation tailings:

domestically produced filter presses ROW (type PF-570),

imported presses from Andritz (type CPF-2200).

Filter presses EIMCO and CENDED 2000 are also used.


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Polish filter press type PF


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Polish dewatering machines


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Equipment - drying

Drying of coal concentrates is applied only in coking

coal preparation plants.

13 dryers work in Poland, and they are equipped in:

♦domestically produced dryer machines

(type ROW I and ROW II)

♦foreign dryers type Denver and Hoelter.

E i t t l


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Equipment - control

The work of coal preparation plants is centrally

monitored and controlled from control room.

In a part of plants the equipment for on-line monitoring

of sulphur and moisture content are installed.

Some of parts the plants are automated (heavy media,

jigs, flotation).


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coal preparation i poland

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