Prediction of Clean Coal Product Using Mathematical Models

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1. INTRODUCTION

1.1 COAL WASH PLANT

The wash plant is feed by a 100T bin fitted with a vibrating feeder to aid and ease the flow of coal onto Conveyor belt 18-31. The bin can be filled up to 80T; above that it overflows through the chute connected to its side. Below 30T the bin is interlocked not to feed the wash plant to avoid coal and the bin lining being subjected to impact causing damage and excess fines generation. The maximum feed rate of the vibrating feeder and the capacity of the belt is 200t/h. Coal from Conveyor belt 18-31 is fed onto a feed preparation screen.

To suppress dust and effect screening, pressurized water from the Magnetic separator effluent chute is used. The screen oversize (-75+6mm) is fed into the DMS drum while the undersize (-6mm) also called fines, goes to the effluent tank. The slurry is pumped to the desliming cyclone to recover water and coal. The cyclone overflow is pumped to the thickener where solids will gravitate to the bottom. The thickener slurry is then pumped to the filters press where a filter cake will be produced. Water recovered from the filter press is recycled back to the thickener. The underflow of the cyclone is dewatered on a screen and combined with the sinks (+32mm ) coal to the thermal stockpile by Conveyor 18-33.

The +6mm particles together with the medium are fed to the 200t/h Wemco drum. The medium density, which ranges from 1.42-1.55 t/m³, can be regulated depending on the quality of coal fed and produced. Coal with a bulk density of 1.0t/m³ is supposed to float while the gangue sinks but because of near density material there is a possibility of the gangue reporting to the float (or middlings being displaced). Inside the drum there is a lifter which collects all the sinks and deposits it into the launder. It is then directed to an extended launder onto a screen. The screen drains the concentrated medium from the sinks coal.

Medium is rinsed off from the coal initially with the Magnetic Separator flood water and finally with clean water sprays. The drained off medium goes to the Correct Medium tank (CM tank) while the rinsed off medium goes to Dilute Medium tank (DM tank). The washed coal is then crushed using a rolling ring crusher to a top size of 32mm and conveyed to the thermal stockpile by Conveyor belt 18-33 onto Conveyor belt18-15.

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