MBE-CMT Presentation PDF

MBE Coal & Minerals Technology GmbH
formerly HUMBOLDT WEDAG Coal & Minerals Technology GmbH
13.04.2011 / German Indonesian Mining Symposium / Jakarta
Helga
Wittmers,
Area
Sales Manager
Rise in Coal
Washing Applications
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
Asia / MBE CMT , Cologne

1

ABSTRACT
Due to difficult deposits and costly mining the German Coal Industry was forced since long to develop
its coal washing technology to very high standards, technically as well as economically.
Most of these advanced dry- and wet- mechanical processes are applicable to beneficiate Indonesian
raw coal very efficiently in order to increase the heating value by reducing ash and sulphur content
and to reduce the water content. Simultaneously high yield of clean coal product at lowest possible
investment and operating cost are secured.
Besides improving the saleable product quality modern washing technology helps to use coal
deposits much more efficient, and the production of high-quality products from inferior deposits or
even from secondary deposits like old dumps of dirty coal created by selective mining becomes
possible, resulting in general in huge environmental advantages.
Two main processes are competing each other all over the world, the Jigging Process and the Dense
Medium Process. These processes are compared in respect to process and cost efficiency, and it is
shown that the decision for or against one of these processes can be based on simple calculations
instead of following trends and fashions.
Finally the report shows the positive impact coal washing has to the environment , such as by far
better use of the coal deposits, reducing transport capacities for clean & dry coal instead of dirty &
wet coal, waste water treatment by closed water circuits, avoiding self ignition of dumps.
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing

Mine
Raw Material
Handling
Crushing
Classifying
Sorting
Classifying
Dewatering
& Drying
Product
Handling
Consumer
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing

Character of the worldwide coal mining industry:

- mining of deposits with increasing depth
- more difficult location with higher waste contents
- increasing mechanisation of the process leading to
higher amount of fines particles
- focus on larger and more efficient mines
- increasing coal price
- rising consumers quality demands
- more strictly environmental regulations
Rise in Coal
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Coal
Industry
Efficient
and Environmental
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byIndonesias
means of Coal
Washing

The coal preparation industry is forced to:

- increase the percentage of processed coal
- line up the processing technology with increasing throughput rates
- provide more automation in the plants and by that
to minimise the operating costs of labour intensive processing
- optimise yield with suitable processes for close size ranges,
especially for treating fines <0,5 mm
- produce high quality clean coal products with
low ash and sulphur contents
- produce coal free tailings
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing

Targets of German Coal Preparation Technology:

- all processes / machines are fully automated
- complete size range of the raw coal 0 - 400 mm is covered
- throughput rate of every plant > 1.000 t/h,
using a single machine line only; availability of > 98%
- with highest yield, the product quality of the should be flexible to suit
the customers requirements
- maintenance friendly machines with highly wear resistant materials
- low capital and operating costs
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing

Coal Processing
equalises fluctuation in production
improves the quality of clean coal by
decreasing ash content
increasing heating value
decreasing sulphur content
sizing according to market requirements
reduction of transport capacities
production of refuse free of coal,
which can be of commercial value even
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing

Ash content %
Raw Coal
Time in hours
Rise in Coal
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Coal
Industry
Efficient
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Ash content %
Raw Coal
Time in hours
Ash content %
Clean Coal
Time in hours
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing

Mine
Raw
Material
Handling Crushing
Classifying
Sorting
Classifying
Dewatering&
Drying
The process step of SORTING

is most significant in respect to
- cost efficiency,
- product quality,
- yield.
Product
Handling
Consumer
The beneficiation plants are always tailor-made

and especially in respect to the process
adapted to the specific raw coal characteristics.
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Industry
Efficient
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Washing
10

Either the HMS-system or the jigging process will be selected

and
several kind of equipment for different ranges of particle size:
Rise in Coal
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Washing
11

worldwide appr. 4 billion t/a

bituminous, subbituminous, anthracite
65% sold to consumers
unwashed
35% washed
washeries (1,2 billion t/a = 100%)

15% < 1mm
85% > 1mm
7%
dewatered
only
Flotation ~ 5%
Spirals
~ 2%
Others
~ 1%
HMS ~ 70 %
Trend
Jigs ~ 25 %
Trend
Others
Rise in Coal
within
Coal
Industry
Efficient
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friendly Mining
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means of Coal
Washing
~ 5%
12

Indonesia
produces appr. 300 mio t/a
~50 % Lignite ~ 30% Subituminous Coal ~ 20 % Bituminous Coal
<
95% sold to consumers

unwashed
5% washed
~ 6 washeries (12 million t/a = 100%)

15% < 1mm
5%
dewatered
only
5%
tailingspond
only
85% > 1mm
Spirals ~ 5%
HMS ~ 55 %
Cyclones and
old and unefficient
HMS-Drums used
Jigs ~ 40 %
old and unefficient

BAUM Type used
Others ~ 5%
Rise in Coal
within
Coal
Industry
Efficient
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byIndonesias
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Washing
13

Jigging Plants in Indonesia:

Except one all Indonesian Jigs are old fashioned BAUM Jigs,
a technology invented by Humboldt Wedag / Germany around 1900
Side pulsated design and by that limited in capacity
Mechanical control valves for the operating air
Mechanical discharge device for refuse
Not flexibel when feed rate and raw coal composition fluctuate
low efficiency and comparable high losses of clean coal to the refuse
The Exception is a chinese Copy of an MBE-CMT BATAC Jig,

but much undersized and incorporated in a faulty process.
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
14

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
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means of Coal
Washing
15

Modern BATAC Jigs eliminated the old BAUM Jig from

efficient processes by significant advantages:
Under bed pulsated, by that unlimited capacity per unit
possible
Electro-pneumatical drive allows flexible & automatic operation

Electro hydaulical discharge device adapts automatically to
fluctuations in feed rate and raw coal caracteristics
Ultrasonic measurement of the jigging bed allows accurate
cutpoint control, leading to
efficiencies very similar to HMS - Processes

Quick adapting to changing requirement in Clean Coal Qualities
Online ash analysers in clean coal conveyor can be used as
function signal for the jigs control
allowing very simple process flow sheets
Rise in Coal
within
Coal
Industry
Efficient
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byIndonesias
means of Coal
Washing
16

BATAC - Jig
for Coking Coal / 400 tph 0 20 mm
Xinji / China
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17

BATAC - Jig
for Coal 6 100 mm
7 m wide / capacity 700 tph
Listwjashnaja / Russia
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18

Washing Process
with BATAC - Jig
200tph 0-50mm
(Indonesian Client)
Rise in Coal
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Efficient
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19

Coal Washery / GA
with BATAC - Jig
200tph 0-50mm
(Indonesian Client)
Rise in Coal
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20

Coal Washing Plant with BATAC -Jig

Raw Coal 0 50 mm
Rise in Coal
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21

Modern HMS Processes

have a slightly better efficiency compared to
BATAC- Jigs, but
need ground magnetite (approx 500 g/t in new plants,
up to 4000 g/t in elder Indonesian plants)
have a much more complicated process flow
need much more electrical power for operation
need more maintenance due to use of abrasive Magnetite
sensitive against fluctuation in feed rate and raw coal caracteristics
very sensitive in case of longer or frequent power cuts
higher operation cost (up to 150% of a comparable Jig plant)
higher investment cost (up to 120% of a comparable Jig plant
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
22

HMS Cyclones for 0 50 mm
Rise in Coal
within
Coal
Industry
Efficient
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friendly Mining
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Washing
23

Depulping screens in HMS process
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
24

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
25

Coal Washery / GA
with HMS-system
180tph 0-50mm
(Indonesian Client)
Rise in Coal
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26

Decision for Jigging - or HMS process

is not a matter of philosophy, but of facts
to be used as a basis for simple calculations,
considering
- cost of operation and investment on one side, and
+ revenues by selling the products on the other side.
Precondition: Propper longterm Mining Model &
related Analysis of the Deposits,
mainly Sink & Float tests
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
27

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
28

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
29

Moisture (a.r.)
Moisture (a.d.b.)
Ash (a.d.b.)
Calorific Value
Total Sulphur
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
20- 24%
15%
10 12%
4200 kcal/kg
0,2%
30

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
31

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
32

Sink & Float Analysis
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
33

Feed
Size
Ash
Sulphur
Moisture
500 tph
0 50 mm
24 % (a.d.b.)
1,24 % (a.d.b.)
4 6 % (a.d.b.)
Clean Coal 395 tph

(=79,2 M%)
Ash
12 % (a.d.b.)
Sulphur
1,30 % (a.d.b.)
Moisture 5 % (a.d.b.)
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
34

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
35

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
36

Summary
- coal processing helps to use coal deposits much more efficient
- production of high quality clean coal products with
low ash and sulphur contents even from inferior deposits
or from secondary deposits like old dumps
- production of coal free tailings i.e to be used in road construction
by that avoiding self-ignition of dumps
- reduction of space requirement for dumps
- waste water treatment by closed circiuts
- positive impact on environment
i.e. Reduction of transportation capacities
Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
37

Rise in Coal
within
Coal
Industry
Efficient
and Environmental
friendly Mining
byIndonesias
means of Coal
Washing
38

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MBE Coal & Minerals Technology GmbH

formerly HUMBOLDT WEDAG Coal & Minerals Technology GmbH

13.04.2011 / German Indonesian Mining Symposium / Jakarta

Asia / MBE CMT , Cologne

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

Character of the worldwide coal mining industry:

MBE Coal & Minerals Technology GmbH

The coal preparation industry is forced to:

MBE Coal & Minerals Technology GmbH

Targets of German Coal Preparation Technology:

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

The process step of SORTING

The beneficiation plants are always tailor-made

MBE Coal & Minerals Technology GmbH

Either the HMS-system or the jigging process will be selected

MBE Coal & Minerals Technology GmbH

worldwide appr. 4 billion t/a

washeries (1,2 billion t/a = 100%)

85% > 1mm

MBE Coal & Minerals Technology GmbH

produces appr. 300 mio t/a

~50 % Lignite ~ 30% Subituminous Coal ~ 20 % Bituminous Coal

95% sold to consumers

~ 6 washeries (12 million t/a = 100%)

85% > 1mm

old and unefficient

MBE Coal & Minerals Technology GmbH

Jigging Plants in Indonesia:

The Exception is a chinese Copy of an MBE-CMT BATAC Jig,

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

Modern BATAC Jigs eliminated the old BAUM Jig from

Electro-pneumatical drive allows flexible & automatic operation

efficiencies very similar to HMS - Processes

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

Coal Washing Plant with BATAC -Jig

MBE Coal & Minerals Technology GmbH

Modern HMS Processes

MBE Coal & Minerals Technology GmbH

HMS Cyclones for 0 50 mm

MBE Coal & Minerals Technology GmbH

Depulping screens in HMS process

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

Decision for Jigging - or HMS process

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

MBE Coal & Minerals Technology GmbH

Sink & Float Analysis