gekko ipj coal separator applications in coal preparation
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Gekko IPJ Coal Separator Applications in Coal Preparation
Andrew Vince(Elsa Consulting Group)
Laurie Gibson, Peter Purdon(ACIRL)
Tim Hughes(Gekko Systems)
Elsa Consulting Group ACIRL Gekko Systems ACARP1
Narrative
• Identified Australian circular jigging technology successfully processing
metalliferous ores.
• Confirmed application in coal processing
• For 6 (30) mm x 0.25 mm
• Small modifications necessary for high floats recovery
• Tested out at small lab scale (1 t/h) – good
• Variables – developed DEM/CFD model
• Tested on site at 10 t/h. Not found maximum capacity yet.
• Circular – therefore capacity and efficiency both improve with radius.
• Need to go bigger.
2
Introduction
• Trend to installation of “three circuit” plants.
• This is due to:
• Matching size range to process technology
• Increased plant capacity
• Move to standardised plant design.
• Mid size fraction (eg 1.4 x 0.25mm) is currently
processed less efficiently than others.
• Gekko IPJ Coal Separator is targeting the mid size fraction.
3
Current Processes for Mid-sized Particles
• Spirals
• 1.5 mm top size, low unit capacity, feed rate
sensitive.
• Teetered bed separators
• Cut point varies with particle size.
• Multiple units with split feeds – complicated circuit.
• Reflux classifier
• New technology currently being rolled out in some companies.
• Consumes significant water volumes.
4
Gekko IPJ Coal Separator
• Gekko IPJ Coal Separator represents a competitor technology.
• Unique application possibilities due to high top size capability.
• Successfully deployed in metalliferous industry with more than 100
applications world-wide.
• This project considered application in coal industry.
5
6
Staged Approach
1. Laboratory scale testing.
2. CFD/DEM modelling.
3. Larger scale pilot testing on site.
7
Slurry Feed
Air bleed
Control box
Product barometric leg 1
Product barometric leg 2
Reject barometric leg
Hutch water
Pulse actuator
Hydraulic pump
In LinePressure Jig
IPJ 600 Unit 1 tph
8
Close-up of In Line Pressure Jig With Top Removed
Wedge wirescreen
Feed distributor
Ragging
InLine Pressure Jig Top Removed
Slurry Feed
PressureGauge
In Line Pressure Jig
InLine Pressure Jig Fully Assembled
9
Bowen Basin Pilot Scale
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Bowen Basin 6 x 2 mm
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Bowen Basin 2 x 0.5 mm ww
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Bowen Basin 2 x 0.25 mm ww
10
Hunter Valley Pilot Scale
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Hunter Valley 6 x 2 mm
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Hunter Valley 2 x 0.5 mm ww
0
25
50
75
100
1.200 1.450 1.700 1.950 2.200 2.450
Parti
tion
coeffi
cien
t to
prod
uct
Relative Density
Hunter Valley 2 x 0.25 mm
11
Laboratory Results Summary
Bowen Basin Coal
6 x 2 mm 2 x 0.5 mm 2 x 0.25 mm
t/h D50 Ep ±0.1RD D50 Ep ±0.1RD D50 Ep ±0.1RD
0.76 1.44 0.075 23 1.475 0.200 11 - - -
0.55 1.49 0.100 9 1.55 0.213 5 - - -
0.94 1.50 0.150 6 - - - 2.00 - -
Hunter Valley Coal
6 x 2 mm 2 x 0.5 mm 2 x 0.25 mm
t/h D50 Ep ±0.1RD D50 Ep ±0.1RD D50 Ep ±0.1RD
1.03 1.50 0.098 6 1.58 0.195 2 - - -
1.60 1.54 0.105 20 1.66 0.180 6 - - -
1.13 1.55 0.129 16 - - - 1.94 - -
1.12 1.55 0.129 17 - - - 1.80 0.282 712
CFD/DEM Modelling
• 10 adjustable parameters.
• Too many to investigate experimentally.
• Develop CFD/DEM model to identify initial starting points for site-based pilot testing.
• Volumetric feed rate• Feed pressure• Feed % solids• Stroke length• Stroke frequency
• Stroke shape• Hutch water flow rate• Ragging diameter• Ragging density• Number of ragging layers
13
Hunter Valley Test Work
14
15
16
Issues Overcome
• Upward water flows
• Overcome with automation (commercially).
• Provision of back pressure.
• Migration of ragging.
17
Provision of Back Pressure
18
Blind Cyclones
19
Blind Cyclones
20
Ragging Mobility
21
Site Tests
Feed Hutch Pressure
m3/h Dry t/h % Solids m3/h Bias kPa
Lower 9.32 3.16 20.5 26.0 -13.9 145
Upper 25.8 10.27 26.3 40.2 7.9 185
Stroke Ragging Near Gravity
Blind Cyclone Orifice
Cyc/min Length RD Layers ±0.1 RD mm
Lower 59 10 1.60 2.5 1 42
Upper 100 15 1.80 4.0 22 57
22
Site Test Results
0
25
50
75
100
1.25 1.45 1.65 1.85 2.05 2.25 2.45
Parti
tion
coe
ffici
ent
(%)
Relative density
Partition coefficient curvesCoal A
6 x 2.0 mm
Series2
2.0 x 0.25 mm
Series4
6 x 0.25 mm
Series6 0
20
40
60
80
100
1.25 1.45 1.65 1.85 2.05 2.25 2.45
Parti
tion
coe
ffici
ent
(%)
Relative density
Partition coefficient curvesCoal B
6 x 2.0 mm
Series2
2.0 x 0.25 mm
Series4
6 x 0.25 mm
Series6
0
20
40
60
80
100
1.25 1.45 1.65 1.85 2.05 2.25 2.45
Parti
tion
coe
ffici
ent
(%)
Relative density
Partition coefficient curvesCoal C II
6 x 2.0 mm
Series2
2.0 x 0.25 mm
Series4
6 x 0.25 mm
Series6
23
Site Results Summary
Coal A
Feed 6 x 2 mm 2 x 0.25 mm
Ash (%) m3/h % Solids D50 Ep ±0.1RD D50 Ep ±0.1RD
21.3 24.5 24.4 1.89 0.112 1.0 - - -
Coal B
Feed 6 x 2 mm 2 x 0.25 mm
Ash (%) m3/h % Solids D50 Ep ±0.1RD D50 Ep ±0.1RD
36.8 9.3 22.5 1.70 0.057 1.7 1.91 0.185 5.0
Coal C
Feed 6 x 2 mm 2 x 0.25 mm
Ash (%) m3/h % Solids D50 Ep ±0.1RD D50 Ep ±0.1RD
53.3 10.0 25.6 1.43 0.069 18.0 1.49 0.172 7.1
47.6 18.0 24.1 1.57 0.081 3.7 1.82 0.223 3.2
24
All Site Test Results
40
50
60
70
80
90
100
0 5 10 15
Yiel
d (%
)
Ash (db, %)
Coal A: 6.3 x 2.0 mm
Washability data
Operating Pt
Sizing results
40
50
60
70
80
90
100
0 5 10 15 20
Yiel
d (%
)
Ash (db, %)
Coal A: 2.0 x 0.25 mm
Washability data
Operating Pt
Sizing results
50556065707580859095
100
0 10 20 30
Yiel
d (%
)
Ash (db, %)
Coal B: 6.3 x 2.0 mm
Washability data
Operating Pt
Sizing results
50556065707580859095
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
Coal B: 2.0 x 0.25 mm
Washability data
Operating Pt
Sizing results
25
All Site Test Results
40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
Coal C II: 6.3 x 2.0 mm
Washability data
Operating Pt
Sizing results
40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)Ash (db, %)
Coal C II: 2.0 x 0.25 mm
Washability data
Operating Pt
Sizing results
26
On-site and Lab Test Results
Low Cut Point High Cut Point
Scale Size (mm)
D50 Ep D50 Ep
Lab 6 x 2 1.43-1.55
0.075-0.15
Pilot 6 x 2 1.43 – 1.57
0.069 – 0.081
1.70 – 1.89
0.057-0.112
Lab 2 x 0.25 1.80-2.00
0.282
Pilot 2 x 0.25 1.49 0.172 1.82 – 1.91
0.185-0.223
27
Why you expect performance to improve with scale (diameter)?
• Conventional jig:
• Capacity related to width
• Efficiency related to length.
• Gekko IPJ Coal Separator
• Circular section
• Increasing radius increases
• Capacity
• Efficiency.
• Larger radius leads to increased cleaning.
28
Gekko IPJ Coal Separator(Extrapolated for coal)
<60 % solids
Ø1.50 m 40 tph
Ø2.40 m 80 tph
Ø3.50 m 200 tph
29
Tentative correlations found
Tentative linear correlations 6 x 2 mm: y = mx + C
y D50 Ep
x m C R2 m C R2
Ragging layers 0.03 0 0.67 0.003 -0.002 0.83
Ragging RD 1.46 -0.8 0.76 - - -
Vol feed rate (m3/h)
- - - 0.003 0.03 0.92
Tentative linear correlations 2 x 0.25 mm: y = mx + C
Y D50 Ep
X m C R2 m C R2
Feed % solids -0.1 5 0.89 - - -
Ragging layers 0.003 -0.002 0.67 - - -
Ragging RD 1.3 -0.4 0.46 - - -
Vol feed rate (m3/h)
- - - 0.006 0 0.90
Hutch bias (m3/h) - - - 0.005 0.13 0.84
Stroke length (mm) - - - 0.3 -0.01 0.93
30
Possible Circuitry
50 x 0 mm 50 x 6 mm DMC circuitDMC product
Flotation product
IPJ Product
31
Possible Applications – High NG
40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
PerformanceCoal C I: 6 x 2.0 mm
Washability data
Operating Pt
With scavenger40
50
60
70
80
90
100
0 10 20 30 40 50
Yiel
d (%
)
Ash (db, %)
PerformanceCoal C I: 2.0 x 0.25 mm
Washability data
Operating Pt
With scavenger
40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
PerformanceCoal C II: 6 x 2.0 mm
Washability data
Operating Pt
With scavenger40
50
60
70
80
90
100
0 10 20 30 40
Yiel
d (%
)
Ash (db, %)
PerformanceCoal C II: 2.0 x 0.25 mm
Washability data
Operating Pt
With scavenger
32
ImplicationsPlant Low cost capacity increases Better matching of incremental ashes
between circuits possible
Screen 6mm rather than 2 mm aperturesLess near sizeEasier screening
Reduced screen areas for desliming AND drain and rinseLess criticality on apertures
DMC Less impact of breakaway sizeHigher efficienciesEstimated 25% less feed tonnesLess medium recirculatingSmaller pumps
Less power consumptionLess maintenanceMuch reduced magnetite losses
IPJ For 1000 t/h ROM plant feed500 t/h in 6 x 0 mm fractionNeed= 3 x 2 units (rough/scav)
Increased longer term recovery through rougher/scavenger configuration.
CC More units handling 6 mm top size
Flotation No change
33
Conclusions
Gekko IPJ Coal Separator• Mature technology for metalliferous processing• Modified successfully for coal applications• Lab scale performance very good (600 mm, 1 t/h)• Site testing better (1000 mm, >10 t/h)• Strong evidence that can get even better (with size and further optimisation)• Possible applications
• Rougher/scavenger configuration• Treating 6 (30) x 0.25 mm particles• Very clean product requirements.
34
Recommendation
35
• Plant testing of rougher scavenger configuration
Grateful Acknowledgements
1. Australian Coal Association Research Program and Industrial Monitors.
2. Providers of Hunter Valley and Bowen Basin coals for laboratory testing.
3. Hunter Valley site management, technical and operations personnel.
4. UNSW for CFD/DEM modelling.
5. Organisers and officials of this conference.
6. You.
Elsa Consulting Group ACIRL Gekko Systems ACARP36
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