dry cleaning of a high sulfur coal case study · 2012-09-12 · dry cleaning of a high sulfur coal...
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![Page 1: Dry Cleaning of A High Sulfur Coal Case Study · 2012-09-12 · Dry Cleaning of A High Sulfur Coal - A Case study B.K.Parekh, Ron Tsantz *,and Joey Pilcher** FGXSepTech,LLC, Lexington,](https://reader034.vdocuments.us/reader034/viewer/2022042400/5f0edd007e708231d4414ead/html5/thumbnails/1.jpg)
Dry Cleaning of A High Sulfur Coal Case Study
B.K.Parekh, Ron Tschantz *,and Joey Pilcher**
FGXSepTech,LLC, Lexington, KY *Imperial Technologies, Inc., Canton, Ohio
**Eagle River Coal, LLC, Harrisburg, IL
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Coal Preparation Equipment used with respect to size of the coal
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Coal Preparation Equipment used with respect to size of the coal
Dry Coal Separators (e.g. FGX)
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Introduction • Wet cleaning plants and
processes are: – More Efficient; – Effectively clean from
coarse to ultrafine; – Not impacted by feed
moisture.
• WHY DRY CLEANING? – Scarcity of water; – Particle degradation in wet
cleaning plants; – Dewatering issues avoided; – Reduced capital and
operating costs; – Reduced environmental
impacts.
1930 1940 1950 1960 1970
20
15
10
5
0
MILLION TONS CAPACITY
(Mcculough et. al., 1968)
Dry cleaning is making a global comeback in the 21st century
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Dry, Fluidized Bed Table Separator • Earliest air tables date back to 1850’s. • Major development during 1910-1930. • Major technology developments in China over the last
two decades.
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What’s FGX?
A completely dry coal preparation method.
A simple, efficient & cost-effective separation process.
A GREEN and energy efficient technology.
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Benefits
Saving transportation costs. Saving water costs. Saving processing costs & increasing plant productivity. (Less maintenance, less chemical, less headache for water treatment…) Permitting is relatively easier.
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Eagle River Coal ,LLC Harrisburg, IL
•High sulfur coal and about 20% ash •Operating for the last 12 months At a rate of ~ 250 tph
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FGX Dry Coal Separator Specifications at Eagle River Coal LLC
• Total capacity of the plant 250 tph – 3” raw feed • Major equipment includes 2 x 125 tph vibrating tables • Plant produces Coarse and small size clean coal, middlings, refuse, and fine dust • Cleaning set-up at a cut point density of 1.8
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Process Flow Diagram of FGX Dry Coal Processing System for Eagle River Coal LLC
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Accelerator
Accelerator Rejects
FGX- 24A
Clean Coal Middlings Rejects
Process Flow Diagram for the Eagle River Coal LLC
ROM Coal
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Raw Coal Screening & Sizing at Eagle River Coal LLC
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Raw Coal Feed & Sizing at Eagle River Coal LLC
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Imperial Technologies Accelerator
Variable Speed Vertical Impact Breaker Fractures Coal without breaking rock, so screening separation is made Processes 10” x 3” ROM Coal to Uniform Sized, Cleaner Coal Product Liberates coal from pyretic material to improve FGX processing efficiency
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Accelerator Benefits
Liberate Coal From Rock/Shale with screening (Lower Ash & Sulfur) Improve Raw Coal Quality Uniform Sized Raw Coal Feed Increases FGX Plant Recovery as compared to crushing everything Maximize Coal Throughput Reduce Plant Wear
Accelerator @ FGX Plant
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Eagle River Coal, LLC
Raw Coal Data: Ash 16 –18% Sulfur ~6.0 % St Total moisture 4.5% Surface moisture 1.5% HGI 52-60
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Eagle River Coal, LLC
Product Data
Product Ash% Sulfur% Heating Value(Btu/lb)
ROM 16-18 5-5.5 12,000-12,200
Clean Coal 8.5-9.5 3.5-3.8 12,800-13,000
Middlings 10.0-12.0 3.8-4.5 11,850-12,250
Refuse 20-28 ~8.00 8,000-8,500
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Yield (two products clean coal and middlings) ~ 80% Combustible Recovery ~92%
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Separation versus Particle Size
0
10
20
30
40
50
60
70
80
90
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8
Relative Particle Density
Pro
bab
ilit
y t
o P
rod
uct
(%)
Overall
2 x 1 in.
1 x 1/2 in.
1/2 x 1/4 in.
-1/4 in.
>85%
Rock
Rejection
0
10
20
30
40
50
60
70
80
90
100
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8
Relative Particle Density
Pro
bab
ilit
y t
o P
rod
uct
(%)
Overall
2 x 1 in.
1 x 1/2 in.
1/2 x 1/4 in.
-1/4 in.
>85%
Rock
Rejection
Particles smaller than 6mm require different operating conditions.
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Dry Coal Cleaning Scheme
Rock
Dry Coal Cleaner
Coal Operation
Loading
Screening
Market
+6mm Product -6mm
Feed Dry Coal Cleaner
Accelerator
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Economic Benefit
• Unit capacity = 500 tph •Yield to reject = 36.4% •Reject Amount = 500 x 0.364 = 182 tph
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• Annual Operating Hours =6000 hrs/yr •Total reject left at mine = 182 tph x 6000 hrs/yr = 1,092,000 tons •Transportation cost = $0.50/t mile •Mine-to-plant distance = 20 miles •Transportation cost/ton = $10.00/ton • Annual transportation savings = 1,092,000 x $10
= $ 10,092,000
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Lost Coal Cost
• Total reject = 182 tph • % 1.60 float in reject = 0.78 % • Total coal loss = 182 x 0.0078 = 1.42 tph • Annual coal loss = 1.42 x 6000 hrs/yr = 8518 tons • Sale price = $ 50/ton • Lost coal cost = 8518 x 50 = $ 425,880/yr
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Summary Economic Benefit
• FGX operating cost = $1.50/ton
• Annual operating cost = $1.50 x 500 x 6000 = $ 4,500,000/yr • Summary Transportation savings = $ 10.09 M Coal loss = $ 0.43 M Operating cost = $ 4.50 M ___________
Net profit gain = $ 5.66 M
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Commercial Dry Table Separators • Over 1000 installations of
dry-air table separators worldwide.
– Brazil
– China
– Mongolia
– South Africa
– South Korea
– India
– USA
• Table capacity = 10 to 250 TPH
• Plus 6 mm material
• Less than 10% surface moisture
Illinois FGX Separator Installation 250 TPH capacity
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Applications
Steam coal deshaling; Pit cleaning/rib coal recovery; Gob pile processing; Deshaling of metallurgical coal; Dry separation of high sulfur coal; High wall mining coal on-site processing; Coal prep in regions with water scarcity; Processing of low-rank coal, e.g. lignite; De-stoning of coal in utilities and cement plants.
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Easy to install; Easy to operate; Low maintenance;
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Commercial installation from 10 to 480 tph on a single unit; Over 1,000 clients in China; Sold in more than a dozen of countries worldwide: China, Indonesia, Kazakhstan, Mongolia, Russia, South Korea, South Africa, The Philippines, Turkey, Ukraine, United States, Vietnam, etc.
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THANK YOU
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ANY QUESTIONS?