Coal Preparation » Process Control
This project was initiated to tackle the ongoing issue of foreign contaminants in coal processing. While the likelihood of contaminants passing through to coal fired power plants and steel making furnaces is low, the financial risks associated with equipment damage and costly downtime make it essential to ensure contaminant free coal. Despite current controls, contaminants can still reach end users, impacting coal quality and reliability.
The project focused on developing and evaluating an advanced X-ray scanning system to detect ferrous and non-ferrous materials in coal as it moves along conveyor belts. The research involved extensive X-ray detection software simulations and the selection of hardware components, all aimed at creating a practical solution for coal mining operations.
A key outcome of the project was the development of a custom iterative image reconstruction algorithm designed to enhance the accuracy of contaminant detection, even in challenging conditions like high noise levels and the presence of steel cables within conveyor belts. The algorithm proved highly effective in detecting ferrous contaminants, due to the strong contrast between these materials and coal. Non-ferrous contaminants, which have attenuation coefficients closer to coal, were more difficult to detect, but the algorithm showed promise, with further refinement recommended to boost performance.
The project also explored various hardware configurations, optimising X-ray sources and detectors. While standard hardware worked well for ferrous material detection, adjustments to power levels and photon energy are suggested to improve non-ferrous contaminant detection. The development of a prototype for field testing in real-world mining environments is also recommended.
The project's findings highlight the potential of X-ray scanning technology, combined with advanced image processing algorithms, to significantly improve the detection of foreign contaminants, ensuring cleaner, higher quality coal. By identifying contaminants early in the process, this technology helps deliver contaminant-free coal, reducing the risk of equipment damage further down the line.