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Glimpses of all Past International Coal Preparation Congress

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Preamble: This paper discusses the Theme and Technical Highlights of all the past International Coal Preparation Congress commencing 1950 till 2023. Indeed, it covers the historic development in the field of coal preparation technology. ICPC’s objective is to provide a forum where coal preparation technologists from around the world can meet on a four-year frequency and exchange ideas and technologies. ICPC Events in Chronological Order: Year of      ICPC Hosting Country Theme of ICPC Highlights of Outcome of ICPC I- ICPC 1950 Paris, France.   Definition of Process Efficiency on Scientific Basis. •     Tromp Curve by Tromp.•     Ecart     Probable     Error and Imperfection Factor by Terra. II- ICPC 1954 Essen, Germany.  Jigging and Cleaning of Fines. •     Tacub Jig.•     Batac Jig.•     Sieve Bend by DSM.•     Pressure Filter.•     Froth Flotation. III-ICPC 1958 Liege, Belgium.   Various Process employed for cleaning small coal. •     Dry Cleaning of small coal.•     Standard Method of Filtration for tailing disposal.•     Automation of Coal Preparation Plants. IV-ICPC 1962 Harrogate UK. Defining Washability Characteristic through Indices.Treatment of coal fines and improved method of dewatering of froth concentrate and tailing. •     CFRI Dhanbad (India) presented first-time. Washability Indices as a means of classifying coals as to their ease of cleaning.•     Vacuum Filtration.•     Filter Presses of larger size.•     Deep Cone Thickener.•     Application of radioactive isotopes for Baum Jig bed control and Ash Monitor. V- ICPC 1966 Pittsburgh, USA. A significant strength of coalin the United States by increased productivity. Legislation relating to Environment. •     Electronic Coal Separator Utilising X-rays.•     Froth Flotation and Automation.•     Multidune Separator.•     Automation of Jigs and Heavy Media Systems.•     Centralized Control System of washery.•     OSO Sieve.•     Rapped Sieve Bends. VI- ICPC 1973 Paris, France. Coal preparation and utilization of waste. •     Utilization of collierydiscard.•     Flotation cell design.•     Oil agglomeration.•     Flip-flop screens.•     Centrifuges. VII- ICPC 1976 Sydney, Australia. Problem of Beneficiation ofsmall coal and reducing the moisture content of small coals. •     Beneficiation of fines byoil agglomeration.•     Flotation column.•     Triboelectric Cyclone Separator.•     Shell Pelletizing System.•     Jet-CycIo Cell.•     Biological Leaching Techniques for reduction of sulfur in coal. VIII- ICPC 1979 Donetsk, USSR New Techniques andTechnology for Coal Preparation. •     Flotation Cell Impellerand Diffuser Design.•     Mini-micro-Computer for complete plant.•     Solid Bowl Centrifuges.•     Continuous Belt Press.•     Two Stage Flotation.•     High-capacity Thickeners with Lamella Plates. IX- ICPC 1982 New Delhi, India.  The Preparation of DifficultCoal. •     Influence of CycloneDiameter on Separating Performance.•     Application of HGMS in Coal Preparation.•     Optimization and Control in coal Preparation.•     Beneficiation of Non-Coking Coal for power generation in India. X- ICPC 1986 Edmonton, Canada. Cleaning of Small & FinesCoal. •     Process Control andOptimization.•     New Developments for Improved Operation.•     Optimum Cleaning of Thermal Coal.•     Dewatering, Disposal and Utilization of Plant Discard. XI -I CPC 1990 Tokyo, Japan Advanced Coal Preparationfor the 1090s and beyond. •     Recent Trends in Coal Preparation Technology.•     Process Monitoring, Control and Optimization.•     Innovation in Coal Cleaning Technology•     Innovation in Flotation Technology.•     Production of Ultra-Clean Coal. XII- ICPC 1994 Krakow, Poland New Trend in Coal Preparation Technology &Equipment. •     Vibrational grinding ofbrown coal and anthracite.•     Removal of Ash and Sulphur by Advanced Physical, Chemical, and Biological Methods.•     Three Product Dense Medium Cyclone.• On-line determination of Moisture, Ash, and Ballast Content and the thermal value of coal.•     Beneficiation of Difficult- -To- Wash Coals. XIII- ICPC 1996 Brisbane, Australia Best practices inInternational Coal Preparation. •     Rational coal preparation Flow Sheet.•     Beneficiation of thermal coal in India — Issues and Options.•     Development of large capacity dense medium cyclone circuits.•     Dynamics of a teetered bed separator.•     Use of spiral separators in coal preparation.•     Pneumatic flotation machines. XIV- ICPC 2002 Sandston, South Africa. Current Development inCoal Preparation Technology. •     ROM Jigs to de-shalethe plant feed.•     Application ROM Jig first time in South Africa.•     Tri-FIo Separator.•     Hydrosizers and Teeter Bed Separators.•     Ring Granulators for crushing coal. XV -ICPC 2006 Beijing, China. Designing for the Environment. •     Coal Preparation and Environment.•     Coal Plant Design and Construction.•     Dense Medium and other Gravity Separation.•     Dry Separation.•     Monitoring and Automatic Control. XVI- ICPC 2010 Lexington, USA.  Opportunity to be exposedto how coal preparation and coal quality are addressed around the world. •     Analysis of ProcessingBeing Widely Used for Cleaning of Thermal Coal•     Delineation of Large Diameter Dense Medium Cyclone Performance.•     Super-Large Gravity-Fed Three- Product Heavy Medium Cyclone.•     A Novel Approach for Improved Column Flotation of Fines and Coarse Coal.•     New Development of Modular Coal Preparation Plant Design. XVII-ICPC 2013 Istanbul, Turkey. Advance coal cleaningtechnology. Carbon trade and Management. •     Large Diameter DenseMedium Cyclone Performance in low Density/ High Near Gravity Environment.•     New Generation of Coal Cleaning Equipment•     Application of Belt Press for tailing dewatering•     Cutting the cost of Coal line Preparation in spiral Separators. XVIII-ICPC 2016 Saint-Petersburg, Russia. To assist scientific and technological cooperation for the benefits of achieving progress in coal preparation and to find solutions to environmental issues, directly correlating with the strategic program of development of coal industries. •     Developments in washability predictions using CGA.•     Technologies in use for the processing of fine coal.•     Dense Medium Bath and Drum Separators- a revaluation of their role in modern coal preparation plants.•     Optimal utilization of Dense Medium Cyclones.•     Design of coal Preparation Plants- Problems and Solutions.•     Dry coal separation. XIX-ICPC 2019 New Delhi, India. All aspects of Coal Processing and Coal Gasification •     Developments in coal to chemicals.•     Emerging uses of coal through its conversion into high value.•     Low polluting energy and Petro-substitute XX-ICPC 2023 Australia To produce power at a significantly lower level of greenhouse emission. •     Developments in coarse coal processing.•     Fine coal beneficiation•     Dewatering of fine products. Dry Beneficiation The above Congresses have been rewarding technically and culturally. The International Organizing Committee (IOC) determined that the Congress will be held on a four-year frequency. The members of the IOC are either representatives of their country’s coal preparation society or government entities related to the coal industry. References: 1. Coal Preparation and Use- A World Review- S. Ranga Raja Rao. 2. Technical Papers 9th International Coal Preparation Congress, New Delhi 3. Coal and Coal Preparation in South Africa- A 2002 review. 4. XVI International

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How to OPTIMIZE CLEAN COAL YIELD AT LOWER ASH% FOR COKING COAL

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By Om Prakash & Aadil Keshwani: Indian coking coal reserves are depleting rapidly. Coking coal is invaluable, with washed coal vital for coke preparation, a key component in steelmaking. This paper explores optimizing clean coal yield with lower ash percentages through advanced beneficiation equipment and newly developed requisites such as reagents and flocculants. 1. Today coking coal washeries are to follow the most modern coal beneficiation technology to optimize the clean coal yield % at lower ash%. The state-of-the-art technology flow sheet for coking coal is depicted below Mostly prepared feed size range (-) 50 mm (+) 0.5 mm is beneficiated through two stages of Heavy Media Cyclone. This ensures the least percentage of misplacement of materials which adds to clean coal yield. If the laboratory test supports, then the following stages of washing can be adopted. Size Fraction                        Process Route  (-) 50 mm (+) 1.5 mm                      by Heavy Media Cyclones (-) 1.5 mm (+) 0.5 mm                     by Spiral Concentrators (-) 0.5 mm                                          by Flotation.  The de-slimed feed (-) 0.5 mm is subjected to fine beneficiation circuit. By introducing a pulp density adjusting tank between conditioner and flotation will be a good measure to maintain optimum pulp flotation density. To optimize the flotation reagents consumption normally the pulp conditioning is done at 30% solid by weight then after that conditioned pulp is diluted to required flotation density around 10% solid by weight. This adjustment is taken care of by Pulp Density Adjusting Tank. By adopting this route clean coal yield can be optimized 2. Use of most efficient JFE design Heavy Media Cyclones which can guarantee the lowest imperfection values. 3. DSM Design JFE HM Cyclones are a much better option to ensure higher efficiencies 4. Use of most efficient DSM design hydro cyclones which can guarantee the lowest imperfection values. JFE Hydro cyclones are most efficient. For classification and thickening process, the JFE design hydro cyclone battery is very helpful prior to the thickener. This helps in optimizing thickener size and good process water in recirculation in the circuit. 5. Use of efficient Magnetic Separators with required gauss strength for HMC circuit will guarantee the lowest magnetite consumption i.e. 800 grams per tonne of ROM coal. This low-intensity wet Magnetic Separator is a very long magnetic pick-up zone. This is very efficient for dense media recovery. 6. Use of Spiral Concentrator for size fraction (-) 1.5 mm (+) 0.5 mm helps in optimizing the yield of clean coal at low ash%. Spirals are: 7. Use of a Flotation System can add on yield of clean owing to the following features: 8. Use of Inclined Plate Settlers- IPS by which clarification is achieved when upstream velocity is low enough to allow solids to report to the inclined plates by using latest developed flocculent Inclined Plate Settlers have many practical advantages. 9. Use of the latest design fines clean coal dewatering devices like Pressure Filter/ Horizontal Vacuum Belt Filter which adds GCV on the product. The driving force of this filtration method is the pressure differential across the cake. A higher-pressure drop will give a faster dewatering rate and a lower residual moisture, as smaller voids are emptied from liquid.  Service and maintenance requirements are low for Pressure Filter. Hence the least downtime which helps in betterment of yield of clean coal.   10. The use of Belt Filter Press for fine-tiling dewatering investment is justified. Belt Filter Press remains a preferred technology for dewatering of fine tailing from coal washery. 11. By using instruments to measure the yield and the underflow and overflow medium densities and how the data can be used to optimize the operation of the heavy media cyclones. This can also be one of the appreciable efforts to optimize the yield of clean coal at lower ash%. 12. Use of the right quality and granulometry of magnetite in case of heavy media separators. Specification of ground magnetite for Heavy Media Cyclone Circuit: Specification of Magnetite Content                                              Specification             Fe3O4 (Magnetite Content)             98.5%             Specific Gravity                                  4.90-5.15             Particle Size                                        90% passing 45 Microns.             Fe Content                                          68-70% By use of right quality and ground size of magnetite in the heavy media circuit the maintenance of consistent cut point can be ensured which is mostly helpful for the coal feed having high +/- 0.10 NGM %. This is also a step towards optimization clean coal yield. Specification of reagents and flocculent Use of proper flotation reagents in place of conventional frother and collector can add value in the yield of clean coal. Nalco Water flotation reagents for frother and collector has established an excellent result in coal flotation industries. Conventional Reagents & Flocculent        Latest Developed Reagents &Flocculent                                                                                     By NALCO WATER Frother- Pine Oil                                                      Frother- N 9840 Collector- Diesel Oil                                                 Collector- N 88001 Thickener Flocculent-Alum                                    Thickener Flocculent-Anionic- A83384 Cationic- A102 Plus    Conclusion: By using most modern design of equipment items installed in the coal beneficiation plants can play a vital role for optimizing yield of clean coal at lower ash %. Similarly, by using the required grade of magnetite for Heavy Media Circuit, latest developed flotation reagents and flocculants for settling aids yield of clean coal can be very well optimized in the coal beneficiation plants. Coking coal deposits for our country are very limited and washed coking coal should be used judiciously. A good number of fine coal beneficiation circuits are installed in BCCL and CCL but most of fine coking coal beneficiation circuits are not in operation. By making these fine circuits operational we gain heavily on clean coal yield and steel sectors can reduce the import of coking coal. References: About Authors: Om Prakash obtained his Master of Technology from IIT Kharagpur (India) in Mineral Engineering with a specialization in Coal Preparation in the year 1979 followed by a Postgraduate in Business Administration from Pondicherry Central University. He has been closely associated with the Denver USA technology for Coal Flotation, Separator Poland, and Fives Cail Babcock France technologies

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IME Exhibition 2023

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At John Finlay, we are thrilled to have been invited as a guest speaker at the prestigious IME 2023 Exhibition Mining Expo_IME , where We had the opportunity to present an insightful use case of AI and ML in the realm of mineral beneficiation technology. During our presentation, we shed light on the transformative potential of these cutting-edge technologies in optimizing the processing of vital resources such as iron ore, coal, lead zinc, and manganese ore. This is a step towards a green future. With the use of AI and ML at John Finlay we are able to introduce dry separation which not only saves water but reduces use of harmful chemicals and saves capex and opex costs at the same time saving the environment. We are excited to share the glims of my presentation with you all. Please stay tuned for the video, which will delve deeper into the innovative applications and benefits of AI and ML in this critical sector. #IME2023#MineralBeneficiation#AIinMining#MLInnovation#IronOre#Coal#LeadZinc#ManganeseOre#coalmining#mineralprocessing ##mineralbeneficiation#coalwashry#coalindia#coalbeneficiation#coal#ironoreAadil Keshwani

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