Maintenance, improved recovery and plant capacity are our key coal preparation strategies. Work is focused on maximising yield, reducing production costs, minimising emissions, reducing water consumption and the use of lower quality water without adversely impacting on process efficiency.
Fine Coal (58 Reports)
|Author: Andrew Vince | Elsa Consulting Group Pty Ltd |
The pilot scale performances of a 0.150mm aperture conventional and a 0.150mm aperture pressure sieve bend were assessed. The slimes contamination level of the pressure sieve bend product was around ½ of that of the conventional unit. This, however, was achieved at reduced .... read more
|Author: Richard Rong | JKMRC, University of Qld |
A 480mm-diameter novel classifying cyclone, known as the JKCC, was tested at Dartbrook Coal Handling and Preparation Plant (CHPP) to assess its performance in an industrial environment. The JKCC was installed in a primary CC bank and operated together with other 480mm commercial CCs. The .... read more
|Author: Kevin Galvin, Kathika Liyanaarachchi, Simon Iveson, Grant Webber, Catherine Whitby, John Ralston, Daniel Weissmann, Diana N. H. Tran | University of Newcastle, University of South Australia |
The objective of this study was to establish a major step change in the technology used by the coal preparation industry to beneficiate fine particles, especially particles smaller than 0.200 mm. We use the term “Inverse Flotation” to describe the new method of fine coal beneficiation. .... read more
|Author: Philip Ofori, Bruce Firth, Andrew Taylor | CSIRO Energy Technology |
A frother is traditionally added to the flotation feed slurry prior to the introduction of air. There is the possibility of the frother being added to the gas-phase as an aerosol rather than via direct addition to the slurry. This is an approach which has received very little attention in .... read more
|Author: Peter Koh | CSIRO Mathematics, Informatics and Statistics |
The work is an extension of a previous ACARP project C17038 in using the latest advances in computational fluid dynamics (CFD) to improve understanding of the hydrodynamics in coal flotation, and to improve the design and operation of the Microcel columns and Jameson Cells in existing .... read more
|Author: Neill Turner-Dauncey | Tekpro Metallurgical |
Every year millions of tons of good quality ultrafine coal are discarded along with the high ash slimes material onto tailings dams throughout Australia's coal mining regions. With Baleen Filter's new micro-screening technology, originally developed for the water treatment industry, .... read more
|Author: Xumeng Chen and Yongjun Peng | University of Queensland |
Coal oxidation has deleterious effects on coal flotation. Using the conventional reagents suitable for floating non-oxidised coals, mild coal oxidation reduces the combustible recovery from flotation while severe oxidation makes the flotation impossible. To help the coal preparation plants to .... read more
|Author: Steve Blanshard, Bruce Atkinson | Tunra Limited (University of Newcastle) |
The aims of the project were:
.... read more
- to develop a new type of flotation machine for the beneficiation of fine coal particles
- to test and demonstrate the machine by applying it to the flotation of coal in selected operating preparation plants
|Author: Joe Sanders, Mike Williamson | Coalproc, M & J Coal Consulting |
In a simplistic view, the conerstone of the emerging new flotation technology is the fineness of air bubbles. In contrast with the mechanically agitated cells new technology may be termed collectively as 'microbubble flotation'.
Amongst the .... read more
|Author: Bruce Firth | BA Firth |
Fine coal beneficiation is virtually essential for coking coals unless the raw coal is of extremely low ash value, i.e. 10%. Most steel mills seek to have no more than 12% ash in coke and therefore selectivity in beneficiation is more important for lower ash coking coals than for .... read more
|Author: Philip Ofori, Bruce Firth | CSIRO Energy Technology |
This project has established the potential of an advanced flotation process unit for cleaning fine and ultrafine coal, based on the superimposition of the centrifugal flow characteristics of the hydrocyclone on the flotation process. The sub-processes .... read more
|Author: Bruce Atkinson, Andrew Swanson | QCC Resources |
This project has generated a large quantity of detailed process efficiency information, on a size-by-size basis, for modern fine coal processing equipment.
This project is complemented by data from a parallel ACARP project (C12050) relating to detailed performance information .... read more
|Author: Graeme Jameson, Trent Moorman, Tim Hunter, Seher Ata | University of Newcastle, TUNRA |
The objective of this project was to develop a new test to determine the ultimate flotation response curve. The current method for doing so is known as a Tree Analysis Test and is covered by Australian Standard 4156.2.2 - 1998(1).
The effect of collector concentration, frother .... read more
|Author: Anne Lahey, Chris Clarkson | C Clarkson and Associates |
The primary objective of this project was to develop practical process control procedures to automate and optimise the new flotation technologies using currently available equipment.
This was achieved by fulfilling a series of secondary objectives, which included a study of .... read more
|Author: Glenn Hart, S Morgan, N Bramall, Stuart Nicol | CSIRO Energy Technology, Novatech Consulting |
The objective of this project was to provide a simple retrofittable device to enhance the flotation behaviour of poorly floating coals. A device capable of inducing cavitation in flotation feed generates very small "picobubbles" on the surface of coal particles, which have a greater affinity .... read more
|Author: James Dickinson and Kevin Galvin | The University of Newcastle |
The objective of this project was to investigate the potential to improve the desliming performance of fine coal flotation by using a Reflux Flotation Cell (RFC), and to establish increased certainty in the scalability from a laboratory scale unit to a pilot scale unit for future construction .... read more
|Author: Paul Botman & Peter Holtham | Julius Kruttschnitt Mineral Research Centre |
ACARP Project C16044 investigated the use of eucalyptus oils as both frother and collector in coal flotation. The application of eucalyptus oils as reagents in froth flotation dates back to the beginning of the process itself. It was realised early on that natural oils are complex mixtures of .... read more
|Author: Anne Lahey, Chris Clarkson | C Clarkson and Associates |
The major objectives of this project were to develop a technique for measurement of residual frother in plant streams and to determine the mechanisms by which residual frother is adsorbed and transported through the plant circuits.
The current trend in coal flotation is towards .... read more
|Author: Kevin Galvin, A.M. Callen, S. Spear | University of Newcastle |
A comprehensive study examining the potential of the Reflux Classifier to be applied to the beneficiation of coarser coal up to 8 mm in size was undertaken. It was established in this study that the Reflux Classifier can be operated successfully using a feed with an upper size of 4 mm and also .... read more
|Author: Kim van Netten & Kevin Galvin | University of Newcastle |
In this project a novel economic binding agent was investigated for use in the agglomeration of fine coal. The novel binding agent was a high internal phase (HIP) water-in-oil emulsion and it was to substitute the pure oil traditionally used in coal agglomeration processes. The substitution was .... read more
|Author: Bruce Firth, Michael O'Brien, Darren Edward, Chris Clarkson | CSIRO Energy Technology, C Clarkson & Associates |
This project formed part of a major program under the CMTE, with the overall objective of enhancing coal recovery by developing new or improved technology for fine coal .... read more
|Author: Graeme Jameson | University of Newcastle, TUNRA |
This project is aimed at the development of methods and equipment for the recovery of coal particles by flotation, focussing on sizes up to 1 mm, with possible extension to a top size of 2 mm.
The project is based on the idea that the best way to process a flotation feed containing a .... read more
|Author: Graham O'Brien, Philip Ofori, Barry Jenkins, Bruce Firth | CSIRO Exploration & Mining, CSIRO Energy Technology, Jenkins-Kwan Technology |
In coal flotation, particles of different components of the coal such as maceral groups and mineral matter and their associations have differing hydrophobic characteristics and therefore different flotation responses. By using a new coal grain analysis method for characterising .... read more
|Author: Steven Spencer, Ryan Bruniges, Gif Roberts, Vic Sharp, Alvaro Catanzano, Warren Bruckard, Kevin Davey | CSIRO |
This project has provided proof-of-concept for monitoring of washery Jameson cell and Microcel column process state by passive acoustic emission (AE) methodology. Successful trials of an AE monitoring system developed at CSIRO were undertaken on a Jameson cell at Mt Thorley-Warkworth washery .... read more
|Author: Bruce Atkinson, Noel Lambert, Graeme Jameson | University of Newcastle, OJK Technology, TUNRA |
The objectives of this project were:
- To demonstrate the effectiveness of froth washing on full-scale conventional flotation cells.
- To develop design parameters for installation to any mechanical flotation bank.
Froth washing is used in mineral flotation .... read more
|Author: Simon Iveson, Anthony Price and Kevin Galvin | The University of Newcastle |
Previous laboratory and pilot‐scale test work in ACARP Project C16040 (Galvin et al., 2009) had established the potential of REFLUX™ Classifiers (RC™) to beneficiate coal particles up to 4 mm in size, and even up to 8 mm in size, at separation efficiencies comparable to that .... read more
|Author: R. Moreno-Atanasio, N.H. Syed and K.P. Galvin | University of Newcastle |
The aim of this project was to develop a generalised model of the Reflux Classifier (RC) utilizing a combination of a continuum approach based on the mechanisms of segregation and dispersion within the system, and a tracer particle approach based on the Discrete Element Method (DEM). The .... read more
|Author: Bruce Firth | BA Firth |
The objective of this project was the 'Quantification the effects of sub-optimal operation' in a coal preparation plant. This was achieved by the analysis of particular operational issues and how they can affect the recovery of saleable coal.
Previous work in this area was .... read more
|Author: Andrew Vince | Elsa Consulting Group |
The pilot scale performance of the following different screen types has been assessed:
.... read more
- A Derrick Stack Sizer™ ; Tested by Derrick Corporation in Buffalo, New York State
- A Kroosh high frequency screen; Tested by ACIRL Maitland, New South
|Author: Bruce Atkinson, Andrew Swanson | Downer Edi Engineering - QCC Pty Ltd |
A proprietary water injector (WI) was installed and tested on a 1000 mm diameter hydrocyclone (classifying cyclone) at Rix's Creek Coal Preparation Plant in the Hunter Valley, NSW.
Water injection rates of up to 60% of the cyclone underflow water flow rate were evaluated.
.... read more
|Author: Liguang Wang, Hangil Park and Junyu Wang | The University of Queensland |
This report provides detailed information on a cyclic frother with high flash point and its coal flotation performance, two frother concentration measuring techniques, and a froth diagnostic tool.
Coal flotation tests at laboratory scale using mechanically agitated cell and Jameson .... read more
|Author: Philip Ofori, Graham O'Brien, Bruce Firth, Clint McNally, Anh Nguyen | CSIRO, University of Queensland |
The main goal of this project was to examine a new approach to maximising the recovery of product specification coal during coal flotation using new generation reagents complemented by the use of the Coal Grain Analysis tool. The Coal Grain Analysis tool, developed by CSIRO, was used to .... read more
|Author: Philip Ofori, Graham O’Brien, Clint McNally, Bruce Firth | CSIRO |
The main goal of this project was to examine the effectiveness of using new generation reagents for maximising the recovery of product specification coal during coal flotation. Previous work had indicated that coarse-sized inertite, inertinite-rich and vitrinite-rich composite particles are .... read more
|Author: Bruce Atkinson, Steve Blanshard | Jetflote |
This project was concerned with the development and validation of an improved laboratory flotation test designed to "fingerprint" the ultimate flotation performance that can be achieved for a particular coal feed. It is important to note that the aim was to measure a .... read more
|Author: Shenggen Hu and Philip Ofori | CSIRO |
The performance of flotation cells can be impaired by the occurrence of unfavourable hydrodynamic behaviours, such as channel flows, pulp circulation flows, dead volumes and excessive shear stress. In ACARP project C21051, hydrodynamic behaviours in both Microcel columns and Jameson cells were .... read more
|Author: Peter Koh | CSIRO Minerals |
This work involves using the latest advances in computational fluid dynamics (CFD) to increase understanding of the hydrodynamics in coal flotation and to identify any opportunities to improve design and operation of both the Microcel column and Jameson cell. The CSIRO CFD model incorporates .... read more
|Author: Shenggen Hu, Philip Ofori, Bruce Firth, Adrian Burger, Mike O'Brien | CSIRO Energy Technology |
The overall objective of this project was to develop an effective and inexpensive on-line monitoring system for the improved monitoring and control of fine coal flotation processes.
STAGE ONE REPORT
The specific aims of stage 1 are to investigate how the electrical .... read more
|Author: Tony Wei, Yongjun Peng, Sue Vink | University of Queensland |
Froth stability is known to play an important role in determining mineral flotation recovery and selectivity. Overly stable froth causes high entrainment of gangue minerals in flotation and is difficult to handle in downstream processes. On the other hand, unstable froth is associated with the .... read more
|Author: Joan Cowburn, G Harbort, Emmy Manlapig, Z Pokrajcic | Xstrata Technology, JKMRC |
The ACARP funding allowed the design of a production sized Jameson Cell test rig with internal sampling arrangements and for investigations into combustibles recovery under different Jameson Cell operating conditions.
Reduction in downcomer turbulence through operation with .... read more
|Author: Xumeng Chen and Yongjun Peng | The University of Queensland |
Clay minerals commonly occur in Australian coal deposits and have deleterious effects on coal flotation. Firstly, clay minerals can adsorb on coal particles as slime coatings and reduce coal surface hydrophobicity, resulting in a lower combustible recovery. In addition, clay minerals can be .... read more
|Author: Bo Wang, Di Liu, Yongjun Peng, and Sue Vink | The University of Queensland |
Clay minerals present a widespread problem in the flotation of all kinds of minerals in that they can coat mineral surfaces resulting in low mineral flotation recovery, contaminate the flotation product through mechanical entrainment due to the small particle size and cause high pulp viscosity .... read more
|Author: Graeme Jameson, Bruce Atkinson, JeffEuston | University of Newcastle |
The construction and operation of an 80m3/hr flotation demonstration plant is described. The hypothesis that coal particles as coarse as 2mm can be effectively treated by froth flotation has been demonstrated on a plant scale. Excellent yields and combustible recoveries were achieved by .... read more
|Author: Mike O'Brien, Andrew Taylor, D Nemeth, Bruce Firth, Chris Clarkson | CMTE |
Thisproject conducted an evaluation of the improvement in the sizeseparation step between 0.1 and 0.4mm, using a 1m diameter classifyingcyclone. This has potential advantages over traditional designs,in reduced capital and maintenance costs, simpler plant layout,and elimination of .... read more
|Author: Kevin Galvin, J Zhou, BD Belcher, SJ Pratten, AM Callen, Noel Lambert, and G Nguyentranlam | TUNRA, University of Newcastle |
The Reflux Classifier is a new device for separating particles on the basis of either density or size. Water flows up through a distributor plate at the base, suspending particles within the vessel. A set of parallel inclined plates amplifies the segregation rates of the particles, .... read more
|Author: James Dickinson, Kaiqi Jiang, Kevin Galvin | University of Newcastle |
Low pulp density and low grade streams in the coal and minerals industries are generally discarded to waste due to the low or negative financial return and large capital investment required. Yet, such losses to tailings dams are likely in the billions of dollars each year. The challenge facing .... read more
|Author: Kevin Galvin, James Zhou, Kim van Netten | University of Newcastle |
The purpose of this investigation was to establish the optimum control regime of the Reflux Classifier for coal sourced from various seams. Experiments were carried out at a CHPP in the lower Hunter Valley using an RC300 with six pressure probes installed along the vertical section and fitted .... read more
|Author: Brad Garraway | QCC Resources |
The principle of using laser diffraction as a means of measuring a volume size distribution in slurry is well established. Laboratory devices have been in use since the 1960's for monitoring ultrafine solids in cosmetics, pharmaceuticals, paper manufacture and minerals processing.
.... read more
|Author: Khoi Nguyen, Peter Holtham | JKMRC |
Researchers have developed an on-line, vision-based prototype instrument to measure coal flotation froth properties.
Traditionally, optimal metallurgical performance in coal flotation circuits has been difficult to achieve due to the wide variety of .... read more
|Author: Peter Holtham, Aaron Power | JKMRC, University of Queensland |
This project's objective was to assess the applicability of the flotation rate constant-bubble surface area flux (k-Sb) relationship to describe coal flotation, and its use as a means of characterising and optimising fine coal flotation (irrespective of cell technology).
Site work was .... read more
|Author: Shenggen Hu and Philip Ofori | CSIRO |
The performance of flotation cells can be impaired by the occurrence of biased feed distribution and unfavourable hydrodynamic behaviours, such as short-circuiting, pulp circulation flows, dead volumes or excessively high shear stress.
The hydrodynamics of a .... read more
|Author: Moetaz Attalla, Clement Chao, Stuart Nicol | CSIRO Energy Technology, Novatech Consulting |
Evidence is presented which illustrates that subjecting coal flotation feed to ultrasonic radiation can result in yield improvements of the order of 15%. The effect is most marked with coals containing large amounts of material in the - 0.05 mm size range. This type of size .... read more
|Author: Glenn Hart, P Townsend, S Morgan, P Morgan, Brucde Firth | CSIRO Energy Technology |
The use of cavitation to enhance the flotation of minerals and coal has been studied over a number of years. Nicol et al. (1986) reported that the use of a superimposed acoustic field nucleated precipitation of extremely small air bubbles (picobubbles) on the surface .... read more
|Author: Glenn Hart, Bruce Firth, Jeff Graham, Peter Purdon | CSIRO Energy Technology, ACIRL |
Since the early 1990s, there has been considerable development of the technology and equipment available for coal preparation which potentially can overcome the serious limitations identified in fine coal Dense Medium Cyclone (DMC) circuits. These limitations were poor size classification and .... read more
|Author: Kevin Glavin | TUNRA, University of Newcastle |
Galvin and Pratten (1999) have previously reported the technique of utilizing
the density segregation effect of a narrow size range of particles in a fluidised bed to determine
.... read more
|Author: Bernd Länger & Götz Bickert | GBL Process |
In the Hunter Valley (HV), coal preparation plants often discard ultrafines < 125 micron because of the high clay and high ash content. Recovery of the coal that is currently lost in this fraction can potentially increase plant yield by 1 to 2 %. The use of small diameter hydrocyclones (100 .... read more
|Author: P Ofori, Bruce Firth | CSIRO Energy Technology |
Froth flotation is currently the most widely used method for fine particle processing but the capital and operating costs are high. This is mainly due to the use of the force of .... read more
|Author: Philip Ofoir, Bruce Firth, A Taylor, Mike O'Brien, M Munro | CSIRO Energy Technology |
The overall objective of the TurboFlotation project was the development of an inexpensive compact process based on centrifugally enhanced flotation, capable of reducing the material residence time by an order of magnitude. The project was conducted jointly by the CSIRO Energy Technology Coal .... read more
|Author: Michael Campbell, Noel Lambert | ACIRL, TUNRA Clean Coal |
This report describes the development of a new reliable method for determining the ultimate flotation response for 0 to 500 µm higher rank coals. The method evolved from continuous development of laboratory flotation tests that were then compared to the “Standard” methods. By .... read more