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Some Design Aspects on the Mini Coal Slurry Flotation Plants Kalyan Sen

This novel flotation plant offers efficient coal fines recovery for enhanced coking coal production, with unique design features and cost-effective processes.

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Some Design Aspects on the Mini Coal Slurry Flotation Plants Kalyan Sen

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  1. Some Design Aspects on the Mini Coal Slurry Flotation Plants Kalyan Sen Central Fuel Research Institute Dhanbad ( India )

  2. Stock of Coal Fines: • About 5.0 Mt of coal fines are locked in the settling ponds. • Addition from central washeries - 1 Mt (ash 25-35 %)/Year • About 0.25 Mt is recovered as coking coal cleans.

  3. A significant amount of Vitrinite enriched coking materials remain unutilized, because of non availability of suitable technology in the existing washeries

  4. Constraints : • The existing Flotation cells in the Washeries were designed with • conventional trough cells with common tailings discharge • and cannot achieve recoverable yield from difficult to wash coking coal slurry

  5. CFRI has developed a novel cost effective close circuit process to treat the slurriesfor producing low ash coalto be utilized in quality coke production .

  6. Salient Features • Individual design of flotation cell with self-suction of input slurry from conditioner • Provision of secondary feeding for re-treatment of concentrate/tailing

  7. Other Merits • Use of synthetic frother for better performance • Indigenously designed low powered emulsifier • Belt discharge type vacuum filter

  8. Merits • Gravity filtration tank for drying of tailing and utilisation in Brick Industries • Completely closed water circuit process • Air, Dust, Sound and Water pollution within permissible limit

  9. The novelty of the tailing discharge system in • cell -to-cell design, • to maintain required Hydrodynamics • to prevent settling of the coarser solids

  10. Cost benefit of the process :(10 tph) Raw Coal Slurry Input :10.0 tph (Ash% = 25-35, Moisture% = 20-25) Output products Cleans :Yield% ( 50-52 ) Ash% (12-15), Moisture% < 20 Tailings :Yield% (48-50) Ash% ( > 45), Moisture% < 20

  11. Net Profit : • On turn over 6.4 % • On investment 16.5 % • Break even point 71.86 % • Rate of return 36.9 % • of fixed capital

  12. Mini Flotation Plant (Capacity : 10 tph)

  13. Thanks

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