ACARP ACARP ACARP ACARP
Coal Preparation

Dry Beneficiation Using FGX and X-Ray Sorters

Coal Preparation » Dewatering

Published: November 21Project Number: C27064

Get ReportAuthor: Glenn Sherritt | A&B Mylec

Conventional dry processing methods engage a single beneficiation device (e.g. FGX, Air Jigs) employing air (and vibration) in place of water or medium, as is typical in wet coal preparation. More contemporary dry sorting methods employ advanced electromagnetic sensors coupled with analysers, fast processors and air jets. The air based methods are suited to higher throughputs but display low efficiencies. The electromagnetic sensing and sorting technologies display good and improving efficiencies but are constrained by low throughput. By combining these two technologies in a manner best suited to their respective strengths, higher throughputs and improved metallurgical efficiencies may be achieved. Dry sorting technologies are valued where water is scarce, wet processing impacts thermal coal CV(gar) or when there are cold climate considerations in play. It has the potential to partially beneficiate coal in-pit, thus reducing haulage costs. Dry sorting processes can also offer a low cost processing option for suitable coal types, enabling some junior and mid-tier miners to begin operations by means of a lower capital hurdle. The work undertaken in this project could potentially increase the longevity of existing operations or lead to the opening of additional resources and facilitate new projects which would otherwise remain undeveloped.

Dry separation is utilised for a number of applications. Current applications include use in arid areas where processing of coal reserves are restrained due to low water availability; low value coal product inhibits processing costs, logistic constraints or ex-plant product moisture impacts; removal of high-density material from thin seam mining operations and for coal beneficiation. Dry beneficiation devices are primarily used in China and North America, with installations in South Africa, Indonesia, Vietnam, and Mongolia. Worldwide, it is estimated that there are over 1500 FGX-units in operation (World Coal, 2013). This project looks at two dry beneficiation devices, the FGX and the X-ray Sorter (XRS). The FGX is one of the most prevalent technologies in this space, whilst the X-ray sorter is gaining significant traction across a number of mineral types with a fast-evolving capability. This project looks at both devices both individually and in series as ways to improve conventional dry processing.

The test work has demonstrated both devices provide a beneficiation when dry conditions need to be considered. Whilst the FGX provided the increased throughput capacity, the XRS configured in a second stage application enabled optimisation of product ash and yield. The combined efficiency of the two machines delivered an outcome that ensured minimal misplacement of coal to reject.

Further optimisation suggests these combined technologies provide an option to optimise resource recovery when wet processes are not an option. For operations that currently use or plan to use wet processes, these dry technologies can increase the percentage of ROM that currently qualifies as bypass coal or, to be more precise, coal that is not washed via conventional wet processes. This can be particularly beneficial for thermal operations given that the CV is of paramount importance. Existing bypass coals can be partially dry cleaned for higher sales price or to extend the degree of downstream blending that can be employed.

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