Download - 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
separators or water jigs.
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
separators or water jigs.
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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