ACARP ACARP ACARP ACARP
Coal Preparation

Process and Condition Monitoring of Dense Medium Cyclones by Acoustic Emissions

Coal Preparation » Process Control

Published: March 05Project Number: C12052

Get ReportAuthor: Steven Spencer, Y Lui, V Sharp | CSIRO Minerals

A proof-of-concept robust, low-cost, non-intrusive contact Acoustic Emission (AE) monitoring and soft-sensor analysis system has been developed for monitoring of coal washery Dense Medium Cyclone (DMC) process state and machine condition. AE sensors are mounted on the external shell of an operating DMC, typically at feed, mid-body, underflow and overflow locations, with data logged at intervals to a computer in the plant control room for later analysis and prediction of key DMC operating and performance variables, and unit wear state.

Contact AE process and condition monitoring systems suitable for DMCs are relatively low-cost and can be readily installed in an operating washery. The current system has been successfully trialled on industrial DMCs at two NSW coal washeries and on a hydrocyclone in the laboratory.

The most significant outcome of the project is the demonstrated ability of a robust, low-cost, non-intrusive multiple sensor contact AE monitoring and analysis system to quantitatively predict changes in DMC operating conditions and qualitatively predict changes in DMC wear state.

Specific findings of the project of significance to plant operators include:
  • ?Back-up' soft-sensors can be formulated for robust quantitative prediction of washery DMC operating variables including module dry feed rate, Specific Gravity (SG) of feed dense medium and DMC inlet pressure, based on suitably processed contact AE signals.
  • DMC general wear state can be qualitatively predicted from suitably processed contact AE signals.
  • There are strong indications that feed imbalance to parallel DMCs can be predicted from suitably processed contact AE signals associated with the DMC feed monitoring locations.
  • There are indications that spigot overload can be predicted from suitably processed contact AE signals associated with the DMC feed and underflow monitoring locations.

The next step in the development of a contact AE monitoring system for DMCs (already commenced in ACARP project C14063) is to construct a proof-of-concept software alarm module for detection of adverse operating conditions, such as incipient surging, clay ball build-up and spigot overload. An additional project could involve developing a prototype low-cost AE monitoring and analysis system that includes operating and performance variable, general wear state and adverse operating condition alarm modules, suitable for long-term, on-line process and condition monitoring of DMCs at washeries. A conceptual design for an industrial prototype on-line contact AE monitoring system suitable for long-term use in coal preparation plants has already been developed as part of the current project.

Underground

Health and safety, productivity and environment initiatives.

Underground

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C19024Establishing Ecologically Sustainable Mine Water Release Criteria In Seasonally Flowing Streams

Extreme rainfall conditions in the Fitzroy Catchment over an approxi...

C25030Coal Mine Open Pit Final Void Closure And Relinquishment - Addressing Uncertainty In Coal Mine Environmental Planning

This report addresses uncertainties faced by coal mine operators whe...

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27004Improving Coal Flotation With Oscillatory Air Supply

This report provides detailed information on coal flotation with os...

C25018Improving Solids Recovery And Moisture Reduction In Ultrafine Coal Dewatering

This report provides detailed information on fine coal dewatering in...

C27028Lab Froth Flotation Testing Guide With Coal Quality

Correct outcomes from laboratory froth flotation testing in coal bor...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL) - Phase 2 Demonstration In A Packed Bed Reactor

An alternative approach to high temperature oxidation of ventilation...

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community

NERDDC

National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook

NERDDC