coal process

7/27/2019 Coal Process

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COAL

PROCESSPLANTSTHATWORK

COAL

PROCESSPLANTSTHATWORK


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Coal beneficiation

From coal face to coal loading, BATEMAN tackles any coal-

processing assignment including mine evaluation, sampling andtesting, process feasibility and economic viability studies, throughto the engineering, management, construction andcommissioning of coal process plants.

We can provide the complete technology needed to designand implement cost effective processes which producemarketable products. We are leaders in the beneficiation of coal,and in particular in the application of dense-media technology indifficult coal washing applications.

Gordonstone Coals 1 000 t/h fine coal circuit,Queensland, Australia, with cyclones, Jameson cellsand horizontal belt filters.

Coal beneficiation plants

BATEMAN offers the full spectrum of project constructionservices, from the project inception to commissioning of theplant. Maintenance services include retrofits, refits, audits andstaff training. Flexible contract structuring accommodatesprojects large and small, and includes reimbursable, EPCM,lump-sum, fixed fee or any combination to suit client needs.Joint ventures on projects may be formed with independentmining consultancies.

Oakbridge Limiteds 1 500 t/h coal washing module

at Saxonvale, Australia, with two stage cyclones andspirals.

Optimum Collierys 2 000 t/h low ash coalpreparation plant, Middelburg, RSA, with two stagedrums.

Zululand Anthracites 400 t/h multi-product plant, nearUlundi, RSA, with two stage drum and cyclone.

Taaiboschspruits 130 t/h multi-product coalprocessing plant, Piet Retief, RSA, with single stage drum,cyclone and spiral plants.


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Design capability

BATEMAN designs processes for the storage and sizereduction of run-of-mine coal, the screening of coal tosize and wet concentration to clean coal through typicallydense-media separation (DMS), spirals or flotation,including de-watering prior to further processing andhandling.

New fine-coal separation technologies, such as DMS,column flotation cells and Jameson cells can also beoffered to increase the overall yield or make speciallow ash products.

Numerous new and upgraded plants have beendesigned using DMS technology, spiral-separationtechnology, multi-slope screens and large diametercyclones.

These coal plants have ranged in size from60 to 2 000 t/h and have reflected different styles ofengineering, from computer controlled, multi-modularunits to the minimum but adequate approach favouredby some mining houses.

Goedehoops 1 000 t/h drum and cyclone coalpreparation plant, Witbank, RSA.

Consulting service

The service identifies the potential processing routeswhich are likely to optimise the yields of marketableproducts which can be obtained from the coal resource.For example, raw washability data can be processed toestimate product yields needed to derive the capital andoperating costs for a specified capacity plant. The serviceis supported by:

I in-house laboratory facilities and a close associationwith many external R & D organisations, laboratoriesand specialist mining and environment consultants.

I the utilisation of in-house developed coal washabilitysimulation computer programmes. These permit a

quick but comprehensive analysis of large sets ofborehole or bulk sample data. The analyses can beused for:J initial mine feasibility studies to project future plant

yields when combined with a geological data base;J investigating equipment performance limits and

guarantees during the plant design stage; andJ assessing plant acceptance test results to obtain

performance efficiencies.

Coal liberation curves obtained by analysis of abulk coal sample.

Actual versus theoretical cyclone efficiency curvesfor a working DMS plant.

PercentYield

Percent Ash

100

50

00 10 20 30

PartitionNumber

Relative Density

Actualepm = 0.018

Theoreticalepm = 0.029

100

80

60

40

20

0

1.4 1.5 1.6 1.7 1.8 1.9 2


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Coal handling

Stock yard systems stackers andreclaimers

Over the past two decades BATEMAN has beenresponsible for the design, project management andsupply of many stock pile systems for the stacking,reclaiming, homogenising and blending of coal.BATEMAN / SCHADE equipment is marketed extensivelythroughout Africa.

Train loading systems

BATEMAN is a world leader in rapid train-loading systemsand offers the best and most cost-effective solution toload-out problems, large or small. Some 20 BATEMANload-out stations have been installed worldwide in thepast two decades to load coal, iron ore and limestone.

I BATEMAN load-out stations are built on a turnkeybasis and use the flask-loading system to load coal intomoving trains. They are reliable, low maintenanceand safe, and:J load at rates up to 8 000 t/h.J handle a random placement of rail wagons of

varying capacity and type

J load with accuracies which meet most countriesstatutory requirements

J allow for a variation in particle size and bulkdensity of loaded material.

J avoid penalties due to overloading and excess axleloading.

TheBATEMAN rapid load-out station at the National CoalSupply Company in Israel, utilising theBATEMAN flaskloading system with automatic learning system to load60 t hooded coal trucks at a rate of 2 000 t/h.

I The Elbram robot train mover is a BATEMANdevelopment. Elbram advantages include:J constant train speeds from 0 to 14 m/min (clamp

and wheel drive)J train speeds from 0,8 to 15 km/h (wheel drive)J standard diesel or electric prime moverJ handle rail wagon braking systems (vacuum/air)J move trains of up to 12 000 tJ low axle-loadings which comply with the

regulations of railway operating systems.

BATEMAN provided all of the materials-handlingequipment at this Middleburg Mine Services site,including the 4 000 t/h coal rapid load-out station; theELBRAM robot train mover, seen on the far right of thepicture emerging from the load-out bay; and theBATEMAN / SCHADE stacker and reclaimer in the coalyard behind the station and the conveyors.

BATEMAN supplies systems for the bulk handling of

both run-of-mine and clean coal. These systems includestackers and reclaimers, conveying systems, and rapid trainloading systems.

Successful solutions for the bulk handling of coal arebased on a thorough understanding of the criteria whichaffect flow. At theBATEMAN laboratories the behaviour ofmaterials is determined to assist in designing efficient andeffective systems.

TheBATEMAN / SCHADE double harrow bridge reclaimer atGoedehoop Colliery, Witbank, RSA, handles 650 t/h of clean coal.


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Coal conveying

Overland conveyor systems

The overland and long curved overland conveyorsinclude curved, regenerative downhill and high lifttroughed belt conveyor systems. These systems:J convey from 100 t/h up to 4 000 t/h.J are designed using dynamic analysis and computer

simulation to predict and compensate for theperformance under all operating conditions. Thisreduces cost and ensures an effective and efficientconveying system.

This curved overland conveyor, which traverses majorflood and minor marsh areas, farming land and two majorroads, at Majuba Colliery, RSA, was built on a turnkeybasis. It has a capacity of 2 280 t/hr, is 6 km long witha 3 km radius and has a width of 1 200 mm.

Environmentally friendly conveyingsystems

The JPC (pipe conveyor) conveys materials securely withina longitudinally rolled conveyor belt forming a pipe,which can negotiate tight horizontal and vertical curves.It has overcome many of the coal dust and contaminationproblems commonly encountered with conventional beltconveyor systems. Pollution is limited by:

J preventing dust generation and spillage along the

length of the pipeJ minimizing the number of costly potential dust

generating transfer points which can cause coaldegradation.

With more than 50 units having been installed inSouth Africa to convey a range of products since 1984,and in excess of 500 world wide, the JPC is well proven.

BATEMANs range of conveyors can handle any run-of-mine

or clean coal conveying need. The available systems include:

Two horizontally curved pipe conveyors, each of 350 mm diametercarrying crushed run-of-mine (ROM) coal to the washing plant at theArthur Taylor Coal Complex near Witbank, RSA. Each conveyor has

a capacity of 725 t/h.

A horizontally and vertically curved pipe conveyor at AmcoalsNew Vaal Colliery near Vereeniging, RSA.


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Dust Control

The range includes

I Bag filters

I Scrubbers

I Cartridge filters

Our equipment can be found on nearly

2 000 installations on furnaces, kilns, smelters,driers, boilers, and mills and on mines, mineralsprocessing, chemical and industrial plants.

These plants:J handle up to 1 000 000 t/yr of ashJ consistently produce PFA of guaranteed qualityJ improve the profitability of a power facility

J are supplied as a total system using BATEMANlicenced technology

J can be designed in accordance with local labourneeds.

BATEMAN has supplied the two largest ash-classification plants in the world.

The most comprehensive range of systems under oneroof enables you to select the best and most cost

effective solution from system design, manufacture,erection, commissioning, project management andturnkey installations to after sales service.

Ash classificationTheBATEMAN ash-classification plant classifies, selects andextracts waste ash from coal fired power stations to producehigh quality pulverised fuel ash (PFA) for use in the extensionand improvement of Portland cement.

A typical wetscrubber on acoal screeningplant.

The 170 t/hclassification plantfor the Castle PeakPower Station,Hong Kong.

A cut away drawingof a typicalBATEMAN / IBAUash-classificationplant, with the bufferhopper at the top ofthe centrifugalclassifier unit andproduct silo.Product may bedischarged through anumber of loadingspouts into tankers.

A dust hood mounted overa coal conveyor, with

ducting leading to the wetscrubber.


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Modular coal process plants

Based on dense-media technology, these plants aretypically composed of de-sliming modules to separate thefine coal, dense-media separation (DMS) modules inwhich the waste / shale is removed, magnetic recoverymodules for the recovery of the magnetite, and coalwashing and de-watering modules. Heavy-media drumand air pulsed over-the-bed jig modules for the separation

of coal from waste are also available.

All BATEMANs modular plants are:J easy to transport, move, re-erect operate and

maintainJ cost effective and reliableJ pre-designed modules or custom designed unitsJ configured to specific process requirementsJ optional PLC (programmable logic controlled) or

manual systemsJ constructed using wear-resistant equipment and

materials tailored to the requirementsJ re-assembled and shop-tested before delivery to

facilitate commissioningJ erected on site under supervision and

commissionedJ factory calibrated and checked by field service

personnelJ supported by an extensive technical back-up and

reliable spares service.

BATEMAN has a track record spanning threedecades during which about 210 BATEMAN modularprocess plants have been supplied to more than20 countries worldwide.

BATEMANs modular coal processing plants havethe capacity to treat between 60 t/h to about

200 t/h of coal. These units can, however,be used in tandem to increase throughput.BATEMANs modular units achieve large savingsin capital cost and construction time.

BATEMANs modular plants are easy to dismantle, transport and re-assemble it took only two weeks to move this plant from thefabricators premises (above), where it was pre-erected, to the colliery(picture below) for re-assembly. This plant is mounted on fiveseparate modules of which the largest is only 16 m long by3,5 m wide. The steel- and plate-work weigh about 60 t andthe structure is 9 m high.

A BATEMAN pump-fed, modular coal washing plant with a singlecyclone. The plant handles 180 t/h of ROM coal and is one of theworlds largest single cyclone modular engineered plants to be usedfor coal processing. Single-cyclone plants of this size are more costeffective than plants in which several small units are combined, asless duplication of auxiliary equipment like pumps, piping andcontrols is required.


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AllBATEMAN projects and plants are supported by anextensive technical back-up and reliable service. This

includes:J Feasibility studies and preparation of bankable documentsJ Consulting services on exploration, sampling, production

and securityJ Erection supervision, commissioning of plant and

training of personnelJ Factory calibration of modules checked by field service

personnelJ Rapid dispatch service for spares and consumables to

any site world-wide.

With a track record in the coal-processing industry whichstarted in 1968/9 and includes large and small coal projects, much

of which is repeat business for satisfied clients, BATEMANoptimises the processing and handling of coal with the most up-to-date technology.

BATEMAN has successfully served large and small coal clientsin Australia, Hong Kong, India, Israel, South Africa and USA.

A BATEMAN stacker reclaimer at the Richards Bay Coal Terminal,RSA. The machine has a capacity of 6 000 t/h and a reclaimcapacity of 3 500 t/h (average) and handles 50 mm coal.

Support Services

As mineral processing and materials handling engineers andproject managers, BATEMAN has the in-house technologyand design capability to handle the largest turnkey projects.Our track record numbers 2 000 successful projects.

A 150 m diameterBATEMAN / SCHADE circular blending,bridge-scraper reclaimer storing and blending ROM coal atTransvaal Navigation Collieries, Koornfontein, RSA, with astacking capacity of 1 200 t/h and reclaim capacity of 1 700 t/h.

process plants that work

Bateman Engineering BVHaaksbergweg 59, 1101 BR Amsterdam, Netherlands

Offices in Africa, the Americas, Australasia and Eurasia

For coal processing andmodular plants, contact ...

For coal handling andconveying, dust control andash classification, contact ...

coal process

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