ACARP ACARP ACARP ACARP
Coal Preparation

Full Scale Trial of the REFLUX™ Flotation Cell

Coal Preparation » Fine Coal

Published: October 23Project Number: C23045

Get ReportAuthor: Simon Iveson, Joshua Sutherland, Matthew Cole, Daniel Borrow, James Zhou, Kevin Galvin | The University of Newcastle

A 2 m diameter REFLUX Flotation Cell™ (RFC™) was installed at a Hunter Valley mine site and successfully operated during several campaigns in 2021 and 2022. The technology delivered strong performance comparable to or better than the tree flotation curve across a wide range of feed flowrates up to 450 m3/h, which is approximately four times the feed rate of similarly sized conventional flotation technologies.

There are two key findings from the work - functionality and performance:

 

Functionality: A unique feature of the RFC™ when compared with conventional flotation technologies is the decoupling of the underflow rate from the gas flux. This work has been successful in clearly demonstrating the powerful nature of this decoupling in the full‐scale unit, with the ability to limit the excess water reporting to the product (with strong wash water), and hence secure low product ashes while maintaining consistent recovery. In effect, the approach permits the operator to shift the separation from high to lower product ashes by adjusting the product volumetric rate.

 

Performance: When operated correctly, the unit performed better than the industry standard tree flotation curve test (AS 4156.2.1 conducted by an external testing laboratory). The unit demonstrated robust consistent performance across a wide range of feed rates, with only a modest drop in performance as the feed rate increased from 200 m3/h up to over 400 m3/h (the highest feed rate used was 460 m3/h due to capacity limitation of the underflow pump). Across the 2 m diameter of the unit, these rates are equivalent to feed fluxes of 2 to 4 cm/s, significantly higher than the ~ 1 cm/s feed flux limitation of conventional flotation technologies. The unit consistently produced clean products. Combustible recoveries of above 60 % were obtained at < 250 m3/h feed rates. At higher feed rates, recoveries were of the order 50 %, on what were mostly high‐ash feeds.

The full report outlines more broadly the operational performance observed across a wide range of conditions covering different feed rates, gas rates, and frother dosages. There was no discernible effect identified when the frother dosage was varied above 10 ppm. Certain other unexpected issues, unrelated to the technology itself, were also identified and reported. Overall, based on the earlier laboratory work, the RFC™ performed as expected.

Underground

Health and safety, productivity and environment initiatives.

Recently Completed Projects

C34007Evaluating Toxicity Of Different Types Of Respirable Crystalline Silica Particles To Lung Cells And Tissues

Silica dust represents one of the most significant occupational haza...

C29010In-Situ Stress Measurement Using Non-Destructive Techniques (Ndts)

Rock in depth is subjected to stresses due to overlaying burden and ...

C33029Review Longwall Face Ventilation To Mitigate Goaf Gas Emissions Onto Walkways And Tailgate End

As longwall mining increasingly targets deeper coal seams, managing ...

Underground

Open Cut

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

Recently Completed Projects

C35029Renewable Energy As Post-Mining Land Use

In 2020, the Queensland Resources Council (QRC), in partnership with...

C33036Radar Tyre Monitor System

This project focussed on trialling a radar sensing technology design...

C26020Preventing Fatigue Cracking Via Proactive Surface Dressing

Fatigue cracking of plant and equipment presents a significant chall...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C28061Quantitative Based Structural Integrity Evaluations Using Modal Parameters Estimation

This project focused on the development and implementation of a quan...

C34039Development Of A Soft Sensor For Predicting Dense Medium Cyclones Performance

This project details the development of a DMC soft sensor for modell...

C34041A Coal Spiral For The 2020S

The objective of this project is to develop an enhanced coal process...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C35039Impact Of Coal Grain Composition And Macerals Association On Fluidity Development In Australian Coals

The coke quality prediction models use thermoplastic terms as key ex...

C36004Physical And Chemical Structure Characterisation Of Biomass For Biocoke Production

Partial substitution of coking coal with renewable biomass is identi...

C35037Examination Of Contraction Pre And Post Resolidification Using A High Temperature Dilatation Rig

This project examined the contraction of coking coal samples, both p...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C34066Safe Operation Of Catalytic Reactors For The Oxidation Of VAM Operating Under Abnormal Reaction Conditions

The catalyst Pd/TS-1 has shown excellent activity in oxidising venti...

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL)

This third and final stage of this project was the culmination of a ...

C29069Low-Cost Catalyst Materials For Effective VAM Catalytic Oxidation

Application of ventilation air methane (VAM) thermal oxidiser requir...

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