DRY COAL BENEFICIATION PLANTS
Executive Summary
Coal mining operations involve the steps below after the rock is extracted from the mine:
- Crushing.
- Screening to desired sizes
- Beneficiation of Rock and Coal
- Material handling.
IASF Technologies India Pvt. Ltd. has revolutionized the coal beneficiation process with the ARIA Coal Beneficiation Plants. This innovative dry technology utilizes airflow to separate coal from rock and impurities, achieving an impressive 99% accuracy and production levels of 250 tons per hour per modular unit.
Unlike conventional Dense Media Beneficiation (DMS) plants that rely on water, the ARIA Coal Beneficiation Plant eliminates the need for water consumption and sludge production, resulting in a significantly reduced environmental footprint. This translates to lower operational costs and a more sustainable approach to coal processing.
The efficacy of ARIA Coal Beneficiation Plants has been demonstrated through successful installations in South Africa at prominent mining groups such as Palesa Coal and Africoal SA. These case studies showcase the plant’s ability to deliver exceptional beneficiation efficiency while minimizing environmental impact and operational expenses by 35%.
By adopting ARIA Coal Beneficiation Technology, you can optimize its coal processing operations, reduce reliance on water resources, and contribute to India’s more sustainable and environmentally responsible energy sector.
Working Principle of Dry Coal Beneficiation Plants
ARIA Waterless coal beneficiation plants work on a simple principle of the formation of a fluidized bed on a vibrating screen. this fluidized bed allows lower-density product to rise higher and the higher-density ash to sink to the bottom.
The screen continuously vibrates with the predefined frequency to allow for the flow of higher-density ash uphill toward the discard chutes.
The medium-density particles in which the coal and ash are fused together form the middlings and they form a barrier between ash and coal. this barrier ensures efficient separation of ash.
The vibrating screen is designed in such a way that 250 tons of coal can be handled at any given time and the angle of tilt can be adjusted depending on the various densities of ash found in raw coal.
To mitigate the moisture content in the raw coal equipment is introduced before the separation plant which successfully extracts 95% of moisture content to enable the plant to operate at maximum efficiency.
The process flow of the complete operation is set in such a way that the middlings from the separator screen are redirected to a secondary crusher to enable liberating the fused ash and ensuring no coal is wasted in the middlings.
Automation and control with an integrated SCADA system ensures that remote parameter settings are possible to enable IASF engineers to tweak the settings in case of any change in raw coal properties.
History of ARIA Dry Coal Washeries
One of the renowned mineral processing companies in South Africa had purchased an Air Beneficiation plant from South Korea and installed at a mine near Johannesburg. This 500TPH plant did not work well and had airflow-related problems which did not allow accurate fluidized bed formation and beneficiation of coal resulting in numerous breakdowns and production interruptions.
IASF Technologies was requested to assess this plant and recommend solutions to allow for this plant to operate in the desired fashion. Upon first assessment by Akshay, it was found that the airflow was not adequate and the aerodynamics for the flow routing was faulty.
The main reason for this malfunction was the coal found in South Africa is bituminous coal which has high moisture content increasing the mass of the raw coal and requiring different parameters of airflow, vibration, angle of tilt, etc. as compared to the coal found in South Korean subcontinent.
The modifications and retrofitting made by IASF technologies worked successfully and the plant started operating beyond expectations.
Further, IASF technologies manufactured 2 more plants in 2022 with new and improved design which is still operational with exceptional results.
thereafter two more plants were built in 2023 which concentrated on minimizing plant costs without affecting the operations of the plant. thereafter IASF Technologies decided to move the complete operations to India to manufacture these plants in India and supply to the local Indian clientele.
Key Features of ARIA Dry Coal Washery
No water is required for operations, hence no chemicals and no consumables.
No Dust emissions, hence environmentally friendly operations.
Lower energy requirements lead to lower operations costs.
Ash separation up to 95% can be achieved with user-defined parameter settings.
Completely automated plant with minimal on-site labour.
Cleaner coal leads to reduced emissions at the furnaces and reduced fly ash and bottom ash.
No loss of good coal in tailings, and no requirement for maintenance of tailing ponds as all the discard is 100% ash.
Cleaner coal means an increased selling price of coal due to an increase in GCV (Gross Calorific Value)
Process Flow of ARIA Dry Coal Washery Plant
CONTACT US FOR MORE INFORMATION ON ARIA DRY COAL BENEFICIATION PLANTS
IASF Technologies India Pvt. Ltd.
ADDRESS: Gat 87/5, Malwadi, Talegaon Chakan Road, Talegaon Dhabade, Maval, Pune, Maharashtra, India 410506
PHONE: +91 8484 92 93 63
ALTERNATE: +91 82630 94819
EMAIL: INFO at ARIAIASF.COM