4 th Coal Summit 2012

1. 4th Coal Summit 2012 Coal-Bridging the Gap : Challenges and Strategies Hotel The Ashok 19th&20th November’12

2. Technological Advancements in Coal Beneficiation Sunil Yadav Vice President - Projects & Systems

3. INTERNAL PRESENTATION OUTLINE Introduction 2. Coal Preparation Overview Design Philosophy 4. Technology Advancements in Slurry Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering 5. Summary

4. INTERNAL Introduction • Coal will continue to occupy the centre stage in India’s energy scenario. • Coal accounts for more than 50% of India’s commercial energy. • About 75% of the coal in the country is consumed in Power Industry. • Coal is abundant in India but primarily high in ash and needs to be washed • Coal Washing in India grews at a CAGR of more than 13% over the past 5 years. • It is predicted that it will grow at a CAGR of more than 20% in coming 5 to 7 Years. • 20% of coal produced is washed in India against a Global average of 50% • All Coking Coal produced in India gets washed but very little Thermal Coal is washed. • The Trend is shifting to washing of non coking coal due to environmental reasons. • Coal Washing increases the cost of coal, but benefits far outweigh the additional cost. • Benefits accrued in terms of savings in transportation, O&M cost and Efficiency far exceeds the cost incurred. • Technology should be adapted to make Coal washing an integral part of our Energy Chain.

5. INTERNAL Coal Preparation Overview Coal Preparation Overview The process adopted for Coal Washing

6. DESIGN PHILOSOPHY UPGRADATION EFFICIENCIES Size in Microns Flotation Spirals H.M. Cyclone Jigs Trends in Coal Washing

7. INTERNAL Building Blocks of a Coal Washery INPUT Pumping Classification Gravity Separation Unit Operations Flotation Thickening Mechanical Dewatering OUTPUT

8. Technological Advancements in a. Slurry Pumping INPUT Pump Metallurgy has improved over the years Pumping 2. Plants are now Pump Fed instead of Gravity Fed resulting in lower fixed and operating costs Classification 3. Large Capacity Pumps > 5000 m3/h available a. Single large module in place of many smaller ones. b. Smaller foot print of the plant c. Pumping cost reduced. d. Reduced Capex/Opex. Gravity Separation Flotation 4.Local Manufacturing by International Companies has lowered the Capex. Thickening Mechanical Dewatering OUTPUT 24 inch pump can handle >5000 m3/hr flow

9. Technological Advancements in b. Classification - Multiflo Banana INPUT 1. Multiflo Screens Are becoming Popular for Classification Are becoming popular for Drain & Rinse Replace Sieve Bend Have smaller footprint for same capacity Have large capacity and help in designing high capacity single module. Largest width > 4m,length > 8m ( 4.2x8.5) 70% more capacity than sievebend-screen combination Are available in Single or double deck. Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering OUTPUT

10. INTERNAL 4.2m wide x 8.4 m long screen

11. Technological Advancements b. Classification- Hydrocyclones INPUT 2. Cyclones are a.extensively used below 150 Microns b. Range from 25mm to 1200mm c. Capacities upto 2000 m3/hr Pumping • Materials of Construction • Polyurethane • Mild steel with replaceable rubber liners • Mild steel Polyurethane Lined • Mild steel with SiC Liners • Mild steel with Alumina tiles • Cast Iron Classification Gravity Separation Flotation Thickening Mechanical Dewatering OUTPUT

12. Technological Advancements in c. Gravity Separation - Coarse Coal INPUT Jigs- Baum/Batac Are the most popular in India Available as 2 products/3 products Simple to operate No Magnetite Required Work at very high cut densities Very good deshaler. Ref : Rajrappa/Bhojudih/Dugda/Kedla/Piparwar etc Pumping Classification Gravity Separation Drewboyscan handle ROM at capacities > 600 tph per unit Ref : Kathara, Durgapur Flotation LoFlo Bath are available from 5’ to 9’ and can handle 10”coal at 250 tph per unit Ref : Aryan/Global/Gupta Coal Thickening Mechanical Dewatering OUTPUT

13. Technological Advancements in c. Gravity Separation- Medium and Small Coal INPUT HM Cyclones Handles coal of 50mm Has Epm <0.03 Largest is 1450mm dia Available in Ni Hard/Ceramic Life ~ 2 years Largest Module > 500 tph No moving parts Ref : TISCO/Jindals/ST-CLI etc Pumping Classification Gravity Separation Flotation Thickening Mechanical Dewatering OUTPUT

14. INTERNAL 1500 mm Dia HM Cyclone- Worlds Largest-at Multotec South Africa

15. Technological Advancements in c. Gravity Separation- Fine Coal INPUT Pumping Spirals Handles coal 1mm x0.1mm Handle Oxidised/Weathered Coal Single/Double/Tripple Start Cheapest Opex-Gravity is free Lasts too long, sometimes > 8 yrs With & Without Wash water No moving parts, No reagents Simple to Operate MX7-Double Stage available Classification Gravity Separation Flotation Thickening Mechanical Dewatering OUTPUT

16. Technological Advancement in d. Flotation - Mechanical Tank Cells INPUT • Mechanical Cells • Popular for Rougher • Installed at West Bokaro/Jamadoba/Bhelatand/ • Gidi/Dugda/Rajrappa etc for Coking Coal • No Reference in Non Coking Coal • Lab Trials show that it is possible to float Thermal Coal Pumping Classification Gravity Separation Tank Cells of 200 m3 volume are available Flotation Thickening Mechanical Dewatering OUTPUT

17. Technological Advancement in d. Flotation – Microcel Column INPUT Pumping • Invented during the 70s • Emerged during the 80s • One column replaces several cleaning stages • Allows high grade concentrates • Simplifies flowsheets Classification Gravity Separation Flotation Thickening Mechanical Dewatering OUTPUT

18. Cleaner Stage Rougher Stage Scavenger Stage

19. Product Ash / Yield Relationship Yield (%) Cisa (Microcel™) sparger Air-water or air-only sparger Product Ash (%) Sparger Retrofit Same Product Ash Increase in Yield

20. Benefits of Column Flotation • Improved Recovery • Optimized Grade • Increased Throughput • No Plugging • On-line Replacement • Reduced Wear & Maintenance

21. Moura Dawson (Anglo Coal)

22. Technological Advancements in e.Thickening - Lamellas INPUT • Compact Design-Space Saving • Small Footprint • Easy Control • ~1/3rd the dia of conventional thickener • Less or No Flocculant • Quick Stabiliasation Pumping Classification • Coal References in India • Gupta Coal, 2 nos in WCL Area • Global Coal inTalcher • Global Coal in Ramagundam • ElectrosteelWashery in Parbatpur • Jindal Power at Tamnar • Jindal Steel at Barbil • Bhatia Coal in WCL Area • Eastern Steel and Power ,Jharsugude Gravity Separation Flotation Lamella Thickener 12m dia in 700 tph coal washery in JPL in Tamnar. Thickening Lamella Thickener 12m dia in 350 tph coal washery in Electrosteel-Bokaro Mechanical Dewatering OUTPUT

23. Thickening - Conventional & Lamella 50 Metres Diameter 21 Metres Diameter

24. Technological Advancements in f. Mechanical Dewatering INPUT Coarse Coal Centrifuge Can handle upto 50mm Pumping Mechanical Dewatering is being stretched to lower the moisture in the product Classification Dewatering HF Screen Low Power Consumtion ~5 Times Gravitational Pull Gravity Separation Flotation Drum Filters Disc are getting phased out Thickening Mechanical Dewatering OUTPUT Pressure Filters Future of Coal Industry Massey Coal in US were the first to use.

25. ZERO WASTE SOLUTION FOR THERMAL COAL PULVERIZED FUEL POWER STATION METSO COAL PREPARATION PLANT ELECTRICITY TRANSMISSION PULVERIZED COAL METSO FLY ASH CLASSIFIER COAL MINE REJECTS COAL FINE ASH COARSE ASH CEMENT INDUSTRY LWA SINTER PLANT ASH ELECTRICITY TRANSMISSION LWA utilization 25 METSO CFBC POWER PLANT

26. ZERO WASTE SOLUTION FOR METALLURGICAL COAL PULVERIZED FUEL POWER STATION BLAST FURNACE CLEAN COAL ELECTRICITY TRANSMISSION MIDDLINGS COAL METSO FLY ASH CLASSIFIER COAL MINE METSO COAL PREPARATION PLANT FINE ASH REJECTS COAL COARSE ASH CEMENT INDUSTRY LWA SINTER PLANT ASH ELECTRICITY TRANSMISSION LWA utilization METSO CFBC POWER PLANT

28. Be Comfortable with Metso!

29. Any Questions ? Thank You for your time