Concentration of coal

CONCENTRATION OF COAL
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INDEX
Sr.
No.
Content Page
No.
01 List of figures 04
02 List of Tables & List of Graphs 05
03 Objective 06
Section Chapter No. & Name Sub Content
04 01.Introduction 07
a) Introduction 08
b) Classification of coal 09
c) Uses and Application of
Coal
12
d) By-product of Coal 13
e) Impurity Present in coal 13
f) Procedureto Preparation
of coal
13
g) Costand Benefits of Coal
Washing
15
h) Froth floatation 16
i) Dense Medium Separator 17
j) Water Density Separator 18
05 02.Litrature Review 20
06 01 03.Experimental
Work(froth floatation)
24

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a) Aim ,Apparatus,
Chemical
25
b) Experimental Setup 25
c) Procedure 26
d) Observation,
observation table,
calculation
26 -33
07 02 04. New technique to
use in coalcleaning:
(Air cyclone used)
34
. a) Experimental work
for air cyclone
35
b) Aim ,Apparatus,
Chemical
35
c) Experimental Setup 36
d) Procedure 37
e) Observation,
observation table,
calculation
37-38
f) Analysis Of top
And bottomCoal
39-42
08 05.MaterialBalance
for air cyclone
43
09 03 06. Designof Coal
Concentration
Plant
45
a) Gyratory Crusher 47
b) Cone Crusher 49

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c) Impact mill 51
d) Cyclone 54
e) Thickener cyclone 55
f) Bag Filter 56
g) Flow chart of Coal
Concentration plant
58
10. 07.Material
Balance forplant
Design
59
08.CostEstimation 61-64
09.Conclusion 66
10.Refrances 67

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List of figures
Chapter No& Name of
chapter
Sr. No. Figure
No
Name of Figure
Page No.
01.Introduction 01 01 Natural Coal Production 07
02 02 Anthracitic coal 09
03 03 Bituminous Coal 09
04 04 Froth Floatation 14
05 05 Dense Medium Separator 15
06 06 Water Density Separator 15
03.Exprimental Work
(forth floatation)
07 07 Experimental Setup for
froth floatation
22
04. New technique to use
in coal cleaning:
(Air cyclone used)
08 08 Experimental Setup for
Cyclone separator
33
06. Design of Coal
Concentration Plant
09 09 Coal Concentration Plant 43
10 10 Raw Coal 44
11 11 Gyratory crusher 45
12 12 Cone Crusher 46
13 13 Impact Mill 48
14 14 Cyclone 50
15 15 Thickener Cyclone 51
16 16 Bag Filter 52
17 17 Flow Chart of Coal
Concentration Plant
54

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List of Tables
Chapter No.&
Name of chapter
Sr No. No. of
table
Name of Table Page No.
01.Introduction 01 01 Coal Content 10
03.Exprimental
Work
(forth floatation)
02 02 Froth Floatation: A 23
03 03 Froth Floatation: B 25
04 04 Froth Floatation: C 27
05 05 Froth Floatation: D 29
04. New technique
to use in coal
cleaning:
(Air cyclone used)
06 06 Cyclone separator: A 34
07 07 Cyclone separator: B 35
08 08 Analysis of coal: A 36
09 09 Analysis of coal: B 38
List of Graphs
Chapter No.&
Name of chapter
Sr.
No.
No.of
Graph
Name of Graph Page No.
03.Exprimental
Work
(forth floatation)
01 01 %efficacy Vs Wt. Of Feed 24
02 02 %efficacy Vs Wt. Of Feed 26
03 03 %efficacy Vs Wt. Of Surfactant 28
04 04 %efficacy Vs Wt. Of Surfactant 30
04. New
technique to use
in coal cleaning:
(Air cyclone used)
05 05 %efficacy Vs Feed 38
06 06 %efficacy Vs Feed 39

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OBJECTIVES
1] To study concentration of coal by air cyclone.
2] To study concentration of coal by froth floatation.
Mineral= valuable mineral and gangue (impurity)

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Chapter No.-01
Introduction

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INTRODUCTION:
Coal is black sedimentary rock. It occurs in layers of rock or coal bed. It
is combustible.
Hence heat is produced by combustion of coal. Coal is a fossil fuel. As geological
processes apply pressure to peat over time, it is transformed successively into
different types of coal. The matter of dead plants/trees was converted into peat
which was converted to lignite afterwards. The lignite was then converted to sub
bituminous coal. After that is was converted to bituminous and lastly to anthracite
coal. The anthracite coal is produced due to explore at high pressure and
temperature to bituminous coal. The anthracite coal is atmospheric rock this
process was carried on for millions of year.
Fig-01: (Natural coal Production)
The coal mostly contain carbon and minor amount of sulphur
,nitrogen ,oxygen iron etc. coal is extract form ground by mining which is open
peat or underground.
China produces nearly 50%of coal production (2000million tones).India

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produces about 7% of world coal production.
Structure of coal:
There are c-rings arbitrarily located/distributed in two dimensions such
layers are there in the third dimension.
COAL:
It is a mineral, a black rock that can be extracted from the earth and
burned for fuel.
Most of the electricity that's produced in the world is powered by the burning of
coal.
The traditional buyers of Indian coal are Nepal, Bangladesh and Bhutan. Export to
Nepal and Bhutan is done in rupee exchange as per the protocol between the two
countries and with Bangladesh it is done in US Dollar. Export of coal to the
neighboring countries was earlier canalized through the Mineral and Metal trading
Corporation, but for the last few years it has been decimalized. Export of coal during
2002-03 to the neighboring countries was12, 650 tones. During 2003-2004 it was
35,831 tones.
Classification of coal:
1. Peat
2. Lignite (Brown coal)
3. Anthracite coal
4. Bituminous coal
Peat:-
This is the first stage of transformation of wood into coal and contains less than
35% carbon. It is seldom sufficiently compact to make a good fuel without
compressing into bricks. Left to itself, it burns like wood, gives less heat, emits
more smoke and leaves a lot of ash after burning.

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Lignite Coal (Brown Coal):-
Also known as brown coal, lignite is a lower grade coal and contains about 35-50
% carbon. It represents the intermediate stage in the alternation of woody matter
into coal. Its color varies from dark to black brown. It is found in Palna of
Rajasthan, Neveli to Tamil Nadu, Lakhimpur of Assam and Karewa of Jammu
and Kashmir.4
Anthracitic Coal:-
Sometimes it is also called “hard coal,” anthracite forms from bituminous coal
when great pressures developed in folded rock strata during the creation of
mountain ranges.
This occurs only in limited geographic areas – primarily the Appalachian region
of Pennsylvania. Anthracite has the highest energy content of all coals & is used
for making coke, a fuel used in steel foundry ovens.
This is the best quality of coal and contains over 85 % carbon. It is very hard,
compact, jet black coal having semi-metallic luster. Anthracite coal ignites
slowly and burns with a nice short blue flame. In India, it is found only in
Jammu and Kashmir and that too in small quantity.
Fig-02: (Anthracitic Coal)
Bituminous coal:-
Great pressure results in the creation of bituminous, or “soft” coal. This is the type
most commonly used for electric power generation in the U.S. It has a higher
heating value than either lignite or sub-bituminous, but less than that of anthracite.
This is the most widely used coal and contains 50 to 85 % carbon. It is dense,

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compact, and brittle and is usually of black color. A good bituminous coal is
composed of alternate dull and bright bands. Its calorific value is very high due to
high proportionof carbon and low moisture content. Most of the bituminous coal is
found in Jharkhand, Orissa, West Bengal, Chattisgarh and Madhya Pradesh.
Fig-03: (Bituminous coal)
Coal contains following element:
1) Carbon
2) hydrogen
3) Sulphur
4) oxygen
5) nitrogen
Carbon forms more than 50% by weight &more than 70% by volume of
coal. This is dependent on coal rank, with higher rank coals containing less
hydrogen, oxygen &nitrogen. Although coal is primarily a mixture of carbon
&hydrogen atoms, sulfur atoms are also trapped in coal.

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Table No-01:(CoalContent)
Uses of Coal:-
1) Thermal Electric Power, Steam Power,
2) Metallurgical Coke, Domestic Fuel, and,
3) Chemical Industry
Application of Coal
1) Power generation is done by bituminous coal.
2) Iron and steel production (Blast furnace)
3) Furnaces for metal and other industries.
4) Reduction of minerals to produce metals e.g. sponge iron.
5) Graphite is used in pencils, lubricated.
6) Anthracite coal is used for domestic cheating.

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By-Product of Coal:
The by-products of coal are many such as Gas, Benzole, Dyes, Pitch,
Creosote oil, Nylon, Sulphuric Acid, Carbolic Acid, Sulphate of Ammonia,
Aspirin, Tanning, Disinfectants, Adhesives, Explosives, Ammonia Liquor,
Naphthalene oil, etc. they provide a number of raw materials for the chemical
industry.
Impurity present in coal:
Nitrogen and sulphur that are chemically reduced during coalification to
the gases ammonia (NH4) and hydrogen sulphide (H2S), which become
trapped within the coal. However, most sulphur is present as the mineral pyrite
(FeS2), which may account for up to a few per cent of the coal and Ash [SiO2,
Al2O3etc.].
Procedure to Preparation of Coal:
Crushing of Coal:
Coal can be crushed by using crushers which converts large size
particles into smaller size particle.
Screening of Coal:
Screens in screening plant are used to group process particles into ranges
by size. These size ranges are also called grades. Dewatering screens are used to
remove water from the product. Screens can be static, or mechanically vibrated.
Screen decks can be made from different materials such as high tensile steel,
stainless steel, or polyethylene.
Wash-ability:
Washing of coal represents the most important step of coal preparation.
The raw run-of-mine coal must require some selective qualitative and
quantitative analysis for finding out the most suitable operating conditions for
cleaning of coal to obtain the desired quality. Among these analyses wash-
ability test is most important. Coal washing removes impurities in the rock,
improving quality and price while reducing eventual emissions. Coal washing is

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known as preparation, processing or beneficiation when it is combined with
crushing the rock. Different processes exist for cleaning coal, most of them based
on the difference in density between coal and other, heavier rock, although finer-
size coal can be cleaned by flotation.
The most common way to wash coal is by (usually magnetite-based)
dense media separation, in which crushed raw coal is introduced into cyclones or
a bath, where the heavier rock falls to the bottom while the lighter coal floats
and then is removed for drying. But whichever form is used, coal washing
consumes energy and water and adds to the producer’s cost. In China, for
instance, washing contributes to the 18% of total national water use that goes to
coal, the second-largest source of water consumption after agriculture.
Coal is a sedimentary rock made from buried vegetation, transformed through
the action of pressure and temperature over tens or hundreds of millions of
years. But not just the organic material becomes coal the vegetation was usually
accompanied by inorganic material, impurities in the form of mineral matter,
also commonly known as ash, which forms as part of the coal. Other impurities
get added during the stripping process while mining. The proportion of ash in
coal is very variable, from less than 10% in high-quality coal to more than 40%.
Ash has several negative effects. It raises transportation costs per energy
unit because the ash (which has no useful heating value) gets transported as part
of the coal; it cuts power plant efficiency by hampering heat transmission; and it
complicates plant operation and maintenance because of corrosion, fly and
bottom ash removal, etc. Higher ash contents also lead to a greater variety of
pollutants, while the lower coal-burning efficiency increases CO2 emissions. So
removing ash through coal washing improves product quality, and hence prices,
and it saves money in transportation and end-use at the consumption point.
Wash-ability test:
The wash-ability test method can be used to investigate the cleaning
characteristics of coarse- and fine-coal fractions. However, especially with the
fine-coal fractions, this test method may not be applicable for low-rank coals.

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The costs and benefits of coal washing:
Metallurgical coal, with its higher quality specifications, generally must
be washed. But while customers want coal of a certain quality and consistent
quality is as important as quality itself most thermal coal is not.
To begin with, coal and ash discrimination is not perfect, so the result is two
fractions with higher and lower calorific value than the original raw coal. Unless
a nearby power plant can burn the rejected fraction, part of the coal’s energy is
lost. While it is difficult to assign a number to that rejection fraction, it tends to
range from 5% to 20%. If unburned, this fraction must be disposed of in an
environmentally friendly manner, which can be problematic. And for
economic and energy-related reasons, especially in places (such as India) with a
coal shortage, the energy in the rejected fraction is an issue.
For example, raw coal of 4 000 kilocalories per kilogram (kcal/kg) and
38% ash can produce two fractions: fourth-fifths of the raw coal that now has 4
500 kcal/kg and 30% ash, and the remaining one-fifth with 2 000 kcal/kg and
70% ash. If the poorer fraction is not burned, 10% of the raw coal’s energy is
lost. Assuming 50 per tone as variable mining costs and 5 per tone as washing
costs, the cost of washed coal is 37% higher on a tonnage basis and 22% higher
on an energy basis. Consequently, washing coal that does not need to travel far is
a complex issue. A policy or regulatory framework that requires internalization
of externalities (such as emissions) would help promote the use of cleaner coal,
with positive impacts on plant efficiencies, emissions and the environment.
There are two methods for cleaning of coal:
1. Froth floatation
2. Dense medium separator
1. Froth floatation:
Fine coal is cleaned using froth flotation methods. Denver cells and
Jameson Cells are two flotation methods used. Spirals perform a simple, low
cost and reasonably efficient separation of finer sized material, based on
particle density and size.
Froth flotation is currently the only viable process for treating very fine

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coal (< 0.20 mm). This process exploits inherent differences in the surface
wettability of coal and rock.
During flotation, air bubbles are passed through a pulp containing coal and rock.
Coal particles selectively attach to air bubbles and are buoyed to the surface for
collection, while common mineral impurities are easily wetted by water and
remain in the waste slurry.
A chemical, called a frother, is added to promote the formation of small
bubbles. The addition rates are very small and typically on the order of 0.1 to 0.5
pound of reagent per ton of coal feed. Another chemical additive, called a
collector, may be added to improve adhesion between air bubbles and coal
particles. Collectors are commonly hydrocarbon liquids such as diesel fuel or fuel
oil. In some cases, clay slimes (< 0.03 mm) may be removed before flotation
using classifying cyclones to improve separation performance. In the United
States, industrial installations use either mechanical stirred-tank flotation
machines or column flotation cell.
Fig-4: (Froth floatation)
2. Dense medium separator:
A popular process for cleaning coarse coal (greater than 12.5
mm) is the dense medium vessel. This density-based separator consists of a
large open tank through which a dense suspension of finely pulverized

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magnetite is circulated. Because of the high density of the Suspension, low-
density coal particles introduced into the suspension float to the surface of the
vessel where they are transported by the overflow into a collection screen.
Waste rock, which is much denser, sinks to the bottom of the vessel where it
is collected by a series of mechanical scrapers called flights. The washed coal
and rock products pass over drain-and- rinse (D&R) screens to wash the
magnetite medium from the surfaces of the products and dewater the
particles. Magnetite is used since it can be readily recovered and reused using
magnetic separators.
DMCs are commonly used to treat particles of coal and rock that
are too small (usually 0.5 to 12.5 mm) to float or sink in a static vessel.
These high-capacity devices make use of the same basic principle as dense
medium vessels (i.e., an artificial magnetite-water medium is used to
separate low-density coal from high-density rock). In this case, however, the
rate of separation is greatly increased by the centrifugal effect created by
passing medium and coal through one or more cyclones.
Fig No-05: (Dense medium separator Cyclone)
Water density separator:

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A variety of density-based separators are available for separating coal and rock in
the particle size range between 0.2 and 1.0 mm. The most common methods
include water-only cyclones and spirals. A water-only cyclone (WOC) is similar to
a classifying cyclone, but typically has a broad wide- angled conical bottom.
Fig No.-06: (Water density separator Cyclone)
Separation of coal and rock occurs becauseof the formation of dense
suspension
Created by the natural fines already in the feed slurry. A spiral (a)
consists of a cork screw-shaped device that sorts coal from rock by selective
segregation that occurs as particles move in the flowing film along the helical
trough. Because of the low unit capacity (two to four tons per hour), spirals are
usually arranged in groups that are fed by an overhead distributor. WOCs and
spirals are often employed in two stages or in combination with other water-
based separators to improve performance.

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Chapter No.-02
Literature review

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Literature review:
1] Experimental work has been undertaken to quantify the influence of angle of
inclination on hydro-cyclone performance in mineral processing applications. Test
work was undertaken at Mount Isa Mine on copper and lead-zinc slurries and in
the JKMRC laboratory on a gold ore and other ores. In both cases the cyclone
performance was monitored at a range of cyclone inclinations from zero to 112°C
to the vertical. Cyclone diameter varied from 102 to 508mm.
The results show that cyclone inclinations greater than 45° can strongly affect the
performance of industrial cyclones.
A new empirical model of classifying hydro cyclone performance has been
developed on the basis of this data, incorporating angle of inclination and slurry
viscosity as variables, and including prediction of cut-size, separation quality,
water recovery and the pressure-flow rate relationship.[1]
2] In this work we develop an equation for the air core diameter in a hydro cyclone
in terms of geometrical and operational parameters, based in a phenomenological
equation which we derived previously. Using this equation the air core diameter in
a 6 inch hydro cyclone was calculated and from this result the discharge type,
spray or roping, could be predicted accurately for the experiments performed by
Plitt et al. and by Bustamante.[2]
3] The impact of Water washing, biodegradation and self-heatingprocesses were
studied on coal waste dumps in the Rybnik industrial region.[3]
A simple and reliable method is described for the determination of selenium in coal
fly ashes. Wall atomization and Smith-Hieftje background correction were used. A
chemical modifier containing CdCl2-PdCl2 was used. Concentrations of selenium
in coal fly ashes were calculated directly by a standard additions method. A
detection limit of 7 μg 1−1, a sensitivity of 1.37 μg 1−1 and an optimum
concentration range up to 100 μg 1−1 were obtained. The characteristic integrated
mass was 13.7 pg of selenium for an absorbance peak of 0.0044 s.[3]
4] Attempts were done to produce blast furnace coke from Victorian brown coal. It
was hydrothermally dewatered and acid washed coal as a blast furnace coke
precursor.[4]

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5] Stable fluidization with consistent flow and a reasonable separating density are
keys to the highly efficient separation in a secondary air-distribution fluidized bed
separator (SADFBS). In this study, a binary dense medium was formed by mixing
fine coal with magnetite powders. The optimum secondary air-distribution layer
(SAL) height of 13 mm was obtained by verifying the density uniformity of the
bed. The suitable static bed height of 60–100 mm was determined by comparing
the fluctuation of bed pressure drops. In addition, the distribution characteristics of
the fine coal particles in various bed layers indicated that the feeding fine coal
content should be not more than 10%, which was verified by the bubbling
performance in the bed. Box–Behnken Response Surface Methodology (BB-RSM)
was employed to evaluate the effects of static bed height (Hs), fluidization number
(N), and feeding fine coal content (P) on the combustible material recovery θ of
feed coal. Based on the experimental data, a mathematical model was established
to describe the relationship between combustible material recovery and the
operational factors. The influential degree of various factors on θ was N > Hs > P.
The separation results of SADFBS suggested that θ value was maximized
when Hs = 100 mm, N = 1.45, andP = 4%, which showed a good separation
performance. The ash content of clean coal reached the lowest value of 2.65%
when Hs = 80 mm, N = 1.70 and P = 7%, with a yield of 64.89% and a combustible
material recovery of 74.86%. The product is generally considered to be ultra-low-
ash clean coal which is the raw materials for activated carbon production.[5]
6) The products obtained by carbonization of a mixture of hydrothermally
dewatered acid washed Victorian brown coal and coking coal tar pitch, which had
been briquetted at 150 or 230 °C and air cured were shown to approach blast
furnace (BF) coke in many of their properties. The samples had higher strength
than BF coke and showed surface areas and reactivity’s much closer to those of a
typical BF coke than products from non-hydrothermally dewatered Victorian
brown coal prepared under similar conditions. The reactivity showed a good
correlation with the relative amount of graphitic structure determined by Raman
spectroscopy.[6]
7] Zhundong coalfield is one super-huge coalfield newly discovered in China.
However, ash-related problems have occurred due to its high content of alkali
metals. Water washing is a possible approach to improve its utilization while little

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research was conducted on Zhundong coals. This study deals with the effect of
water washing on alkali metal removal, thermal behaviors, and NOx emission of
Zhundong coals. Experimental results show that water-soluble sodium is the
predominant chemical form accounting for 70–92% of total sodium, while the case
of potassium is different. The pore structure shows a considerable change after
being washed. Sodium can be effectively removed while the removal ratio is
closely related to water temperature and washing time. The mean apparent
activation energy of coal pyrolysis decreases after being washed at low
temperature, while high temperature of washing water hinders the pyrolysis.
Certain sodium has a catalytic effect on pyrolysis while excessive sodium exhibits
inhibitory influence. The conversions of fuel-N to NO and to N2O of washed coals
are higher than those of raw coals. Water washing has a slight negative effect on
NOx emission and combustion reactivity which is related to the catalytic effect of
sodium within coal structure.[7]
8] Deposition of fly ash particles onto heat-transfer surfaces is often one of the
reasons for unscheduled shut-downs of coal-fired boilers. Fouling deposits
encountered in convective sections of a boiler are characterized by arrival of ash
particles in solidified (solid) state. Fouling is most frequently caused by
condensation and chemical reaction of alkali vapors with the deposited ash
particles creating a wet surface conducive to collect impacting ash particles.
Hence, the amount of alkali elements present in coals, which, in turn, is available
in the flue gas as condensable vapors, determines the formation and growth of
fouling deposits. In this context, removal of alkali elements becomes vital when
inferior coals having high-ash content are utilized for power generation. With the
concept of reducing alkali elements present in a coal entering the combustor,
whereby the fouling deposits can either be minimized or be weakened due to
absence of alkali gluing effect, the ultrasonic leaching of alkali elements from
coals is investigated in this study. Ultrasonic water-washing and chemical-
washing, in comparison with agitation, are studied in order to estimate the
intensification of the alkali removal process by sonication. [8]

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Section: 1
Chapter No.-03
Experimental Work
(1. Froth floatation)

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EXPERIMENTAL METHODS OF PROJECT WORK:
1. Froth floatation:
Aim: To study the coal concentration by using froth floatation method.
Apparatus & equipment to use: Beaker, Conical flask, Funnel etc.
Chemical used: Collector [oil], frother [soap, xanthate], regulator [pH]
EXPERIMENTAL SETUP:
Fig 07-Experimental Setup (Froth floatation)

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Procedure:
1. Take 300ml of water.
2. Add 2 drop oil.
3. Add frother.
4. Keep bubble blowing by using pipette.
5. Separate froth on filter.
6. Weight pure coal on the filter paper.
1) Effect of wt. % of coal.
A) Size of coal: 0-100 micron
Observation:
Water: 300ml
Oil: 2 drops …. (Collector [oil])
Xanthate: 1% of water i.e. 3gm …. (Frother
Observation table:
Table No-02 :( Froth floatation: A)
Feed coal Floated coal % efficiency
1gm 0.81gm 81%
3gm 1.37gm 45.66%
5gm 1.42gm 28.4%

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Calculation:
Formula:-
% efficiency = (collected coal/Taken coal)*100
For 1st reading:
% efficiency= (0.81/1)*100 = 81%
For 2nd reading:
% efficiency= (1.37/3)*100 = 45.66%
For 3rd reading:
% efficiency= (1.42/5)*100 = 28.4%
Graph:
Graph no: 1 (% efficiency vs wt. of feed)
Result: As wt. of coal increases % efficiency of pure coal decreases.

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B) Effect of Size of coal: 100 - 200 micron
Observation:
Water: 300ml
Oil: 2 drops …. (Collector [oil])
Xanthate: 1% of water i.e. 3gm …. (Frother)
Observation table:
Feed Coal Floated Coal % Efficiency
1gm 0.85gm 85%
2gm 1.4gm 70%
3gm 1.95gm 65%
Table No-03 :( Froth floatation: B)
Calculation:
Formula:-
For 1st reading:
% efficiency= (0.81/1)*100 = 81%
For 2nd reading:
% efficiency= (1.4/2)*100 = 70%
For 3rd reading:
% efficiency= (1.95/3)*100 = 65%

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Graph:
Graph no: 2 (% efficiency vs wt. of feed)
Result: As wt. of coal increases % efficiency of pure coal decreases.
2) Effect of varying wt. of surfactant
Observation:
Water : 300ml
Oil : 1-2 drops …. (Collector [oil])
Wt. of coal: 1gm

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Observation table:
Wt. Of Surfactant Floated Coal % Efficiency
1.5 0.67gm 67%
3 0.81gm 81%
4.5 0.87gm 87%
Table No-04 :( Froth floatation: C)
Calculation:
Formula:-
For 1st reading:
% efficiency= (0.67/1)*100 = 67%
For 2nd reading:
% efficiency= (0.81/1)*100 = 81%
For 3rd reading:
% efficiency= (0.87/1)*100 = 87%

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Graph:
Graph no: 3 (% efficiency vs wt. of surfactant)
Result: As wt. of surfactant increases % efficiency of pure coal increases.
B) Size of coal: 100-200 micron
Observation:
Water : 300ml
Oil : 1-2 drops …. (Collector [oil])
Wt. of coal: 1gm

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Observation table:
Wt. Of Surfactant Floated Coal % Efficiency
1.5gm 0.78gm 78%
3gm 0.85gm 85%
4.5gm 0.89gm 89%
Table No-05:(Froth floatation: D)
Calculation:
Formula:-
For 1st reading:
% efficiency= (0.78/1)*100 = 78%
For 2nd reading:
% efficiency= (0.85/1)*100 = 85%
For 3rd reading:
% efficiency= (0.89/1)*100 = 89%

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Graph:
Graph no: 4 (% efficiency vs wt. of surfactant)
Result & discussion: As wt. of surfactant increases % efficiency of pure coal
increases. So optimum Wt. of surfactant may be taken as 4%.

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Section-02
Chapter NO-04
New technique to use in coal cleaning:
(Air cyclone used)

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New technique to use in coal cleaning:
Air cyclone used-
Coal washing is applied widely but drying of coal is necessary
after washing and takes long time and it complicated steps. Hence air is used
for ash removal by classification. [Cyclone]
Generally for separation of coal water & dense media like
magnetite are used in sink & float or high density separation.
After use of water and dense media like magnetite drying is
necessary and it takes long time for drying. Instead of water if we use air
then drying is not necessary and more ash can be removed by using air
and then cleaned coal can be directly used for industrial work.
Initially coal is crushed and screen through 212 micron screen.
Subsequently magnetic separation is carried out to separate iron sulfide for
5 gm coal the % sulfur is then calculated. The coal is dried at 50c in an
oven the temperature is not to rise to avoided combustion.
Proposed work:
A set up is arranged with compressor, Rota meter, pressure gauge, elutriator,
cyclone etc.
The crushed screened coal will be weighed and treated and readings will be
noted for collected concentrate coal at different flow rates, pressures,
particle size etc.

35 | P a g e
2) Air cyclone
Aim: To study the coal cleaning by using air.
Objective: To reduce ash content in coal by using air cyclone.
Apparatus & equipment to use: blower, pressure gauge, valve, air cyclone,
orifice meter.
EXPERIMENTAL SETUP:
Fig 08-Experimental Setup (Cyclone Separator)

36 | P a g e
Procedure:
1) Take 5 gm coal sample in glass column.
2) Start the airflow.
3) Adjust the pressure of air.
4) Collect the sample from top & bottom of cyclone
Observation table:
Sr. no. Feed
(gm)
Wt. of pure
coal at top
(gm)
Wt. of ash
at bottom
(gm)
% of
pure coal
% of ash
1. 1.0 0.54 0.46 54 46
2. 0.90 0.50 0.40 55.55 51.11
Table No-06 :( Cyclone Separator:-A)
Calculation:
Formula:-
For top product
For 1st reading:
% efficiency= (0.54/1)*100 = 54%
For 2nd reading:
% efficiency= (0.50/0.90)*100 = 55.55%
For bottom product

37 | P a g e
For 1st reading:
% efficiency= (0.46/01)*100 = 46%
For 2nd reading:
% efficiency= (0.40/0.90)*100 =51.11 %
Sr. no. Feed (gm) Wt. of
pure coal
at top
(gm)
Wt. of ash
at bottom
(gm)
% of
pure
coal
% of ash
1. 0.25 0.15 0.10 60 40
2. 0.20 0.11 0.09 55 45
Table No-07 :( Cyclone Separator:- B)
Calculation:
Formula:-
For top product
For 1st reading:
% efficiency= (0.15/0.25)*100 = 60%
For 2nd reading:
% efficiency= (0.11/0.20)*100 = 55%
For bottom product
For 1st reading:
% efficiency= (0.10/0.25)*100 = 40%
For 2nd reading:
% efficiency= (0.09/0.20)*100 = 45

38 | P a g e
Analysis of top and bottom coal:
Procedure:
1. Weight top or bottom coal.
2. Take 10ml dil. HNO3 in a beaker.
3. Add top or bottom coal in beaker having dil. HNO3.
4. Keep it for 5 min.
5. Add 30 ml of water into the solution.
6. Filter out the solution.
7. Weigh out the pure coal obtained on filter paper after drying.
Observation table:
Sr.
No
Feed
(gm)
Top
Product
(gm)
Pure Coal
After
Analyzing
(gm)
%
Purity
Bottom
Product
(gm)
Pure Coal
After
Analyzing
(gm)
%
Purity
01 1 0.54 0.52 96.29 0.46 0.35 76.08
02 0.90 0.50 0.47 94 0.40 0.29 72.5
Table No-08:(Analysis of coal:A)
Calculation:
Formula:-

39 | P a g e
1) For top product
For 1st reading:
% efficiency= (0.52/0.54)*100 = 96.29%
For 2nd reading:
% efficiency= (0.47/0.50)*100 = 94%
2) For bottom product
For 1st reading:
% efficiency= (0.35/0.46)*100 = 76.08%
For 2nd reading:
% efficiency= (0.29/0.40)*100 = 72.5%
Graph:
1] % eff. Vs feed for
Graph no: 5 (% efficiency vs feed)

40 | P a g e
OBSERVATION TABLE
B) Size of coal:100-200 micron
Sr.
No
Feed
(gm)
Top
Produ
ct
(gm)
Pure Coal
After
Analyzing
(gm)
%
Purity
Bottom
Product
(gm)
Pure Coal
After
Analyzing
(gm)
%
Purity
01 0.25 0.15 0.12 80 0.10 0.07 70
02 0.20 0.11 0.10 90.90 0.09 0.06 66.66
Table No-09:(Analysis of coal: B)
Calculation:
Formula= % efficiency = (collected coal/Taken coal)*100
1) For top product
For 1st reading:
% efficiency= (0.12/0.15)*100 = 80%
For 2nd reading:
% efficiency= (0.10/0.11)*100 = 90.90%
2) For bottom product
For 1st reading:
% efficiency= (0.07/0.10)*100 = 70%
For 2nd reading:
% efficiency= (0.06/0.09)*100 = 66.66%

41 | P a g e
Graph:
1] % eff. Vs feed for
Graph no: 6 (% efficiency vs feed)
Result: %pure coal obtained in top product is more than wt. of pure coal
obtained in bottom product.

42 | P a g e
Chapter No-05
Material balance for air cyclone:

43 | P a g e
Material balance for air cyclone:
Feed = Top product +Bottom product
1) For 0-100 micron
For 1st reading:
Feed = 1gm
Top product = 0.54gm
Bottom product=0.45gm
For 2nd reading:
Feed = 0.9gm
2) For 100-200 micron
For 1st reading:
Feed = 0.25gm
For 2nd reading:
Feed = 0.20gm

44 | P a g e
Section: 3
Chapter NO-06
Design of Coal Concentration Plant

45 | P a g e
Fig no 9: (coal concentration plant)

46 | P a g e
Coal:
Fig no.10 :( raw coal)
Generally Coal are archive by large rock size then it will reduce to huge amount of
fine particle to separate a ash or other impurity
Procedure to separate ash from mine coal:-
1) Gyratory Crusher (Primary Crusher):-
In design of plant first procedure to crush the coal or reduce size by using a
equipment like a crusher it consists of two vertical cones that are moved by a cam
material is progressively crushed and falls out of the bottom
Designated for greater capacity and continuous operation, suitable for hard
materials having 6 – 60 inches to obtain particles of 0.2 – 4 inches in size. It has
large feed opening and smaller product opening, so that more product can be
generated in one time. If one considers to crush large size material in large
capacity, gyratory crusher is more economical than BTJC with respect to
ENERGY requirement. If large size but less amount of feed is to be reduced, BTJC
is more economical in terms of

47 | P a g e
Fig no. 11 :( Gyratory crusher)
Working principles:
- Crushing action similar to JAW CRUSHER, moving crushing element
approaches to and recedes from a fixed crushing plate
- It has an outer frame carrying an inverted conical surface (concaves) and inner
gyrating crushing head
- Lower end of the spindle is a circular shaft free to rotate in an eccentric sleeve
(driven by a rotating main shaft through a set of bevel gears and rotates within a
fixed cylindrical housing.
- Feed is introduced from the top opening and moving down into a space
between concave and crushing head.
- The crushing spindle is free to rotate, but as soon as feeding of the machine
starts, rotation ceases and gyration is only motion, causing the head to approach
and recede from the concave surfaces, breaking the feed by a CRUSHING
PRESSURE as it passes down through the crusher.
- The crushed materials are getting smaller in size while they move down as the
space between crushing head and cone is getting narrower and the crushing
pressure given by crushing head is more.

48 | P a g e
Technical Data:
Capacity of gyratory crusher: 6 tone/hr.
Rpm: 400
Power: 300Kw.hr
Cost of equipment (Rs):-3, 50,000/-
2) Cone Crusher: -
Cone crusher can be used for coarse feed of finer feed (short head). Reduction ratio
is 2-3 times of Roll crusher. Less maintenance is needed .Feed must be dry and
rather uniform in size Cone crusher is best operated in closed circuit with
screensTelsmith Gyrasphere is a modified cone crusher with spherical contour of
crushing head (facilitates discharge of crushed product) and the crushing plate is
held in position by spring under compression instead of tension.
Fig no. 12 :( Cone crusher)
Vertical shaft imp actors - for all types of materials, waste and recycling
applications.
• Low operating cost

49 | P a g e
• Low power consumption
• High production and crushing ratio
• Hydraulic feed control
• High quality of product with excellent cubical form as per month standards
Automatic lubricated system
Working Principles:
- The inner cone (crushing head) is supported by the tapered eccentric journal
which is rotated by the bevel gears driven by the main shaft.
- The entire weight of crushing head and spindle is supported on a bearing plate
supplied with OIL under pressure
- Differences with gyratory crusher:
The outer stationary crushing plate flares outward to provide an increasing area of
discharge so that the machine can quickly CLEAR itself of the reduced product.
This stationary crushing plate is held in position by a nest of heavy helical tension
springs so that when tramp iron or other uncrushable objects enter the crushing
zone the plate is lifted, preventing fracture of the plate and injury to the machine
Technical Data:
Capacity of cone crusher: 3 tone/hr.
Model; HP1220
Feed opening: 215mm
Output adjust range: 15-30mm
Max feed size: 200mm
Power: 210Kw
Weight: 20t
Cost of equipment (Rs):-17, 00,000/-

50 | P a g e
3) Impact Mill:-
The product to be processed is fed to the mill centrally via an inlet box at the top
and is pre-crushed by primary beater tools when reaching the top of the rotor. The
beaters also accelerate the product, moving it into the milling zone proper, at the
side of the rotor. There the grinding stock fluidized in the air flow is comminuted
by the grinding tools (rotor, stator). The stator is formed by a cover enclosing the
rotor. The inside of this cover is provided with toothed grooves running vertical,
i.e. crosswise to the sense of rotation of the rotor. The outside of the rotor is
covered by numerous U-shaped sections which form a deep cassette-type structure.
This geometry creates extreme air whirls in the rotor's grinding zone which induce
intense secondary commination processes due to the particles crashing into each
other and due to friction and shearing forces. The final particle size can be adjusted
over a wide range by changing the grinding rotor clearance, air flow and rotor
speed.
In addition to (micro) pulverization in the < 100 µm range, the Impact Mill has
proven to be very reliable and efficient in removing fibers from organic substances
(paper, paperboard, cellulose, etc.), grinding-coating, cryogenic grinding,
combined grinding/blending and grinding/drying.
Working Principles:
Material to be ground is fed from the left through a 60 cone and product is
discharged through a 30 cone to the right. As the shell rotates the balls are lifted up
on the rising side of the shell and they cascade down from near the top of the shell

51 | P a g e
Fig no. 13 :( Impact Mill)
The solid particles in between balls are ground and reduced in size by impact. As
the shell rotates the large balls segregate near the feed end and small balls
segregate near the product end
If the rate of feed is increased, coarser product will be obtained and if the speed of
rotation is increased the fineness for a given capacity increases.
During grinding, balls themselves wear and are continuously replaced by new ones
so that mill contain balls of various ages and thus of various ages and thus of
various sizes Ball mill produces 1 to 50 ton/hr. of powder of which 70 to 90 % will
pass through a 200 mesh screen and energy requirement of the ball mill is about 16
kwh/ton

52 | P a g e
In case of a batch operated mill a measured quantity of a solid to be ground is
charged to the mill through the opening in the shell. The opening is closed and the
mill is rotated for several hours. It is then stopped and the product is discharged.
Technical Data:
Capacity of mill:-3tons/hr.
Diameter Rotor: 09 Ft
R.P.M:-10
Cost of equipment (Rs): 6, 80,000/-
5) Cyclone:
Cyclone separators provide a method of removing particulate matter
from air or other gas streams at low cost and low maintenance. Cyclones are
somewhat more complicated in design than simple gravity settling systems, and
their removal efficiency is much better than that of settling chamber. Cyclones are
basically centrifugal separators, consists of an upper cylindrical part referred to as
the barrel and a lower conical part referred to as cone (figure 5.1). They simply
transform the inertia force of gas particle flows to a centrifugal force by means of a
vortex generated in the cyclone body. The particle laden air stream enters
tangentially at the top of the barrel and travels downward into the cone forming an
outer vortex. The increasing air velocity in the outer vortex results in a centrifugal
force on the particles separating them from the air stream. When the air reaches the
bottom of the cone, it begins to flow radially inwards and out the top as clean
air/gas while the particulates fall into the dust collection chamber attached to the
bottom of the cyclone.

53 | P a g e
Fig no. 14 :( Cyclone)
Two standard design for gas-solid cyclones
(1) High efficiency cyclone
(2) High gas rate cyclone

54 | P a g e
Thickener cyclone:
For separate out low density particles and high density particles we use here
thickner cyclone. Thickener cyclone has height of cone is 10 times that of the
cylinder.
Fig no. 15 :( Thickener cyclone)
Equipment Cost (RS)- 3, 00,000/-

55 | P a g e
Bag Filter:
Fig no. 16 :( Bag Filter)
In mechanical-shaker bughouses, tubular filter bags are fastened onto a cell plate at
the bottom of the bughouse and suspended from horizontal beams at the top. Dirty
gas enters the bottom of the bughouse and passes through the filter, and the dust
collects on the inside surface of the bags.
Cleaning a mechanical-shaker bughouse is accomplished by shaking the top
horizontal bar from which the bags are suspended. Vibration produced by a motor-
driven shaft and cam creates waves in the bags to shake off the dust cake.
Shaker bughouses range in size from small, handshake devices to large,
compartmentalized units. They can operate intermittently or continuously.
Intermittent units can be used when processes operate on a batch basis-when a

56 | P a g e
batch is completed, the bughouse can be cleaned. Continuous processes use
compartmentalized bughouses; when one compartment is being cleaned, the
airflow can be diverted to other compartments.
In shaker baghouses, there must be no positive pressure inside the bags during the
shake cycle. Pressures as low as 0.02 in. wig can interfere with cleaning.
The air to cloth ratio for shaker bughouses is relatively low, hence the space
requirements are quite high. However, because of the simplicity of design, they are
popular in the minerals processing industry.
Technical data:
Capacity of bag filter: 2.7ton/hr.
Bags: 100
Coat of equipment: 12, 00,000/-

57 | P a g e
Flow chart of coal concentration plant
Fig no. 17 :( Flow chart of coal concentration plant
GYRATORY
CRUSHER
6 ton/hr.
CONE CRUSHER
3 ton/hr.
HAMMER MILL
3 ton/hr..
CYCLONE SEPERATOR
2.7 ton/hr.
BAG
FILTER
2.7 ton/hr.

58 | P a g e
Chapter NO-07
Material balance for plant design:

59 | P a g e
Material balance for plant design:
1) Material balance for gyratory crusher:
Feed: 6ton/hr.
Production: 6ton/hr.
2) Material balance for cone crusher:
Feed: 3ton/hr.
3) Material balance for hammer mill:
Feed: 3ton/hr.
4) Material balance for cyclone separator:
Feed: 2.7ton/hr.
Production: 2.7ton/hr.
5) Material balance for gyratory crusher:
Feed: 2.7ton/hr.
Production: 2.7ton/hr.

60 | P a g e
Chapter NO-08
COST ESTIMATION

61 | P a g e
COST ESTIMATION
1. Land
Area required = 20acre
Cost for 1 acre = 3lack
Cost of 20 acre = 60 lack
2. Building
Cost for building = Rs. 10000 per square meter
Expected building area = 20*10 m2 = 200 m2 = 2151sq.ft
Expected cost = 200*10000 = Rs. 20, 00, 000/-
3. Shed:
Shed = 30,000Sq Ft at rate of 200 Rs/ft. = 60, 00, 000 /-
4. Raw material: mine coal = 6 ton/hr. = 6000 Kg/hr. = 6000*24 = 144000
Kg/day
Cost of 1ton mine coal = 3, 000/-
Cost of 1Kg mine coal = 3/-
Cost of 144000 Kg coal = 144000*3=4, 32, 000/-
Annual cost of raw material: 4, 32, 000*350= 15, 12, 00, 000/-
Equipment Cost:
Equipment Capacity Cost ( Rs )
Gyratory crusher 6 ton/hr. 3, 50,000/-
2 Cone crusher 3 ton/hr. 17, 00,000/-
Hammer mill 3 ton/hr. 6, 80,000/-
Cyclone 2.7 ton/hr. 3, 00,000/-
Bag filter 2.7ton/hr. 12, 00,000/-
Total cost 42, 30,000/-

62 | P a g e
Fixed Cost/Year
1. Land 60, 00,000/-
2. Building 20, 00, 000/-
3. Shed 60, 00, 000 /-
4. Electricity charge 10, 00,000/-
6. Engineering & supervision 40, 00,000/-
Total cost 1, 90, 00,000/-
Total fixed cost = Equipment cost +Fixed cost
= 42, 30,000 + 1, 90, 00,000 = 2, 32, 30,000/-
Variable Cost/year
1. Utility (5%) = 9, 50, 000/-
3 Maintenance (7%) =13, 30, 000/-
4. Labor (9%) =17, 10, 000/-
5. Depreciation
a. Building (3%) = 5, 70, 000/-
b. Machine (0.5% of equipment) = 95,000/-
6. Insurance (0.5% of equipment) = 95, 000/-
7. Overheads (5%) = 9, 50, 000/-
Total cost = 57, 00, 000/-

63 | P a g e
Pure coal production/ hr. = 2.7ton/hr. = 2700 Kg/hr. = 2700*24 = 64800
Kg/day.
Selling price of pure coal/Kg.. = 10Rs/Kg
Total annual sales = 64800×350×10
= 22, 68, 00,000/-
Net profit per year = Total annual sales – Total variable cost – annual cost of raw
material
= 22, 68, 00,000 - 57, 00, 000 - 15, 12, 00, 000
=6, 99, 00, 000/-

64 | P a g e
Chapter NO-09
Conclusion:

65 | P a g e
Conclusion:
1) % purity of coal is improved from 80% to 90% using air cyclone.
2) Using Cyclone is more effective than Froth floatation
3) Designed plant is of more profitable so we can use this plant design for
production of pure coal.

66 | P a g e
Chapter NO-10
References:

67 | P a g e
References:
1] A.K.Asmoah, Mineral engineering, an empirical model of hydrocyclones
incorporating angle of cyclone inclination, volume 10, issue 3, March 1997, 337-
339
2] F.Concha, A.Barrientos, J. Montero, R. Sampaio; Air core and roping in hydro
cyclones; International journal of mineral processing; volume 44-45, March, 1996,
743-749.
3] Adam Nadudyaniri, Monika J Fabianska, The impact of Water washing ,
biodegradation and self-heating processes on coal waste dumps in the Rybnik
industrial region Fuel, 15 Oct. 2016, 527-529.
4] M.Mamun Mollah, M. Marshall, R. Sakhurov’s; Attempts to produce blast
furnace coke from Victorian brown coal and study on Hydrothermally dewatered
and acid washed coal as a blast furnace coke precursor; Fuel, volume 180, 15
September 2016, Pages 597–605.
5] Jinfeng He, Mingbing Tan, Ran Zhu, Density based separation performance of a
secondary air – distribution fluidized bed separator( SADFBS) for producing ultra-
low ash clean coal,; Fuel, volume 172, 15 May 2016, 178-186.
6] W. Roy Jackson, & etal, Attempts to produce blast furnace coke from Victorian
brown coal. 3. Hydrothermally dewatered and acid washed coal as a blast furnace
coke precursor; Fuel; Volume15 September 2016, Pages 597–605
7] Chang'an Wang, Yinhe Liu, Xi Jin, Defu Che,Effect of water washing on
reactivity’s and NOx emission of Zhundong coals,Journal of the Energy Institute,
19 June 2015.
8] S. Balakrishnan, V. Midhun Reddy, R. Nagarajan , Ultrasonic coal washing to
leach alkali elements from coals, Ultrasonic Sono-chemistry, Volume 27,
November 2015, Pages 235–240.
9] S. Balkrishnan V. Midhun Reddy; Ultrasonic coal washing to leach alkali
elements from coals; ultrasonic chemistry vol.27 Nov. 2015 pages 235-240.

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