ARIA

ARIA’s dry coal beneficiation plants use an innovative fluidized bed separation system on a high-frequency vibrating screen to achieve up to 99% ash removal efficiency—without using water.

Low-density clean coal floats upward, while high-density ash settles at the bottom and moves uphill toward discard chutes. Middlings, a mix of coal and fused ash, form a natural barrier between the layers, ensuring high separation accuracy.

Each modular unit handles up to 250 tons per hour, and the screen’s tilt angle is adjustable to suit different ash densities found in raw coal.

To optimize performance, a pre-separation drying system removes up to 95% moisture, enabling the plant to operate at peak efficiency in dry conditions.

Middlings are redirected to a secondary crusher, ensuring full coal recovery by liberating trapped ash.

The entire system is integrated with SCADA-based automation, allowing remote monitoring and real-time adjustment for varying coal properties.

✅ Key Advantages:

Maximised coal recovery from middlings

Zero water requirement

250 TPH capacity per unit

Energy-efficient, low maintenance

SCADA-enabled remote control

A leading mineral processing company in South Africa had installed a 500 TPH air-based coal beneficiation plantimported from South Korea at a site near Johannesburg. However, the plant underperformed due to airflow inefficienciesand unstable fluidized bed formation, leading to breakdowns and production losses.

IASF Technologies India Pvt. Ltd. was brought in to assess and resolve the issue. During the evaluation, Akshay Gaikwad, CEO of IASF, identified that the system’s airflow design was unsuitable for high-moisture South African bituminous coal, which required adjusted parameters for vibration, tilt angle, and air volume.

IASF successfully retrofitted the plant, optimizing its aerodynamics for local coal properties. Post-modification, the plant delivered stable and efficient performance, exceeding expectations.

🔧 Expansion and Localization:

Following this success, IASF moved full-scale production to India to serve both domestic and global markets.

In 2022, IASF built and delivered two new upgraded plants with improved design.

In 2023, two more plants were developed, focusing on cost optimization without performance loss.

Zero Water Requirement: Completely dry operation—no water, no chemicals, no consumables.

Dust-Free Operation: No dust emissions, ensuring an environmentally friendly and clean working environment.

Lower Energy Consumption: Reduced power needs directly translate into lower operational costs.

Up to 95% Ash Removal: High-precision ash separation using adjustable plant parameters.

Fully Automated System: SCADA-based control with minimal manual intervention and low labor cost.

Cleaner Coal Output: Significantly reduces furnace emissions, fly ash, and bottom ash generation.

No Tailings or Slurry Ponds: Discard is 100% ash, eliminating tailings pond maintenance.

Higher Coal Value: Improved GCV (Gross Calorific Value) results in a higher selling price for beneficiated coal.