ACARP ACARP ACARP ACARP
Coal Preparation

Derrick Stack Sizer In-plant Evaluation

Coal Preparation » General

Published: February 18Project Number: C25007

Get ReportAuthor: Darren Mathewson | Quality Process Solutions

Across the industry, millions of tonnes of saleable quality ultrafine coal are ultimately discarded into tailings dams along with the high ash slimes material. While a classifying cyclone is widely considered to be a size separating unit there is also a substantial density separation occurring simultaneously. Consequently, regardless how efficient the hydrocyclones are operated, the separation of particles will vary according to both density and particle size. As a result, there will always be a significant amount of coarse low-density particles reporting to the overflow stream.  

Based purely on the principle of size classification, the Derrick Stack Sizer is a small footprint high capacity technology capable of recovering coal from fine waste streams and reducing the ash value of existing fine product streams. The Stack Sizer can be used as a replacement for classifying cyclones, to recover coal from thickener underflow, to scavenge flotation tailings or even to replace flotation. Effective ultrafine size separation may be a viable alternative to flotation for a thermal coal mine. Even if the hydrocyclone overflow is beneficiated by flotation, a significant proportion of the coal may be lost due to inherent process inefficiency. A Derrick Stack Sizer could be used to recover coal lost in the flotation tailings. It therefore has the potential to be a 'gamechanger' and revolutionise the industry for both thermal and coking coal mines.

There are >100 Derrick Stack Sizers installed in the coal industry world wide. However, there are currently no Derrick Stack Sizers installed in the Australian coal industry. The objective of this project was to provide the Australian coal industry with useful performance of Derrick Stack Sizers across a range of operating conditions. Plant trials will allow sites to properly assess the benefits of Derrick Stack Sizers across a range of site specific circumstances, without requiring each site to individually assess the technology.

A single-deck Stack Sizer was tested at two sites in NSW and one in Qld. The trial unit installation was managed by WPE Process Equipment, while its performance at each site was independently audited. The data collected during the site trials included: feedrate, % solids and ash by size for each stream and float-14 sink and laser sizing of the feed. The Stack Sizer operating variables included screen aperture, feedrate, repulp water flowrate and feed % solids.

Underground

Health and safety, productivity and environment initiatives.

Recently Completed Projects

C27039True Triaxial Strength Of Coal Measure Rocks And Its Impact On Roadway Stability And Coal Burst Assessment

Rocks in the ground are subject to a range of stresses. The stresses...

C3063Underground Vehicle Design Standards And Statutory Implications

The Australian underground diesel vehicle fleet has evolved since di...

C3064Conveyor Belting And Lagging Shear Characteristics - Drive Drum Slip

The primary aim of this project was to investigate the relationsh...

Underground

Open Cut

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

Recently Completed Projects

C26029Geological Controls On Fluorine And Phosphorus In Bowen Basin Coals

Increasing global restrictions on fluorine in product coal prompted ...

C28033Raw Ash To Yield Relationships

Correct outcomes in yield predictions for product ash from coal bore...

C27038Establishing Self-Sustaining And Recognisable Ecological Mine Rehabilitation

In recent years an increasing interest has been placed on mining ope...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27064Dry Beneficiation Using FGX And X-Ray Sorters

Conventional dry processing methods engage a single beneficiation de...

C26010Multi-Sloped Screening Efficiency With Changing Strokes, Frequencies, Feed Solids And Feed Rates-Pilot Plant Study

Optimising multi-sloped screens is often described as an art and the...

C28059Impact Of Water Quality In Coal Handling And Preparations Plants

The objective of this project was to deliver a concise reference do...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C23052Novel Stone Dust Looping Process For Ventilation Air Methane Abatement

This multi‐phase project is concerned with the mitigation of m...

C27054Optimisation Of A Thermal Flow Reversal Reactor For Ventilation Air Methane Mitigation

Ventilation air methane (VAM) generally accounts for 50-85% of the t...

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...

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