Coal Preparation
Maintenance, improved recovery and plant capacity are our key coal preparation strategies. Work is focused on maximising yield, reducing production costs, minimising emissions, reducing water consumption and the use of lower quality water without adversely impacting on process efficiency.
Process Control (42 Reports)
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| C3043 | 30/07/1993 |
| Author: Chris J Clarkson, M Gunn, D Wiseman, Chric Wood | JK Tech |
The JKTech study group surveyed personnel from coal preparation plants, equipment suppliers, consultants and coal industry policy makers. The survey found that the industry requirement for process control techniques was varied. and related to the level of sophistication, style of operation and .... read more |
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| C3090 | 01/04/1999 |
| Author: Darren Edward, Chris Clarkson | C Clarkson and Associates |
An ACARP commissioned study into process control in coal preparation plants in 1993 suggested that there exists widespread dissatisfaction within the Australian industry that such .... read more |
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| C4055 | 01/07/1998 |
| Author: Peter Holtham, Richard Kelly | JKMRC, University of Queensland |
It has been recognised for many years that the performance of 'sputnik' type hydraulic raw coal distributors is extremely poor. A number of modifications have been made to the .... read more |
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| C5047 | 19/03/1998 |
| Author: Andrew Swanson, Robert Drummond, Kevin Galvin, Peter Mullins | Quality Coal Consulting, University of Newcastle, CSIRO Energy Technology |
When designing and operating coal preparation plants, it is essential to take into account potential variation in coal quality. Plant operations are also adversely affected by internal distribution biases. This ACARP funded project has studied these factors by making use of Monte Carlo .... read more |
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| C5048 | 01/04/1997 |
| Author: Stuart Nicol, Alan N Buckley | Novatech, CSIRO Energy Technology |
The primary objective of this project was to develop an instrumentally based tracer detection system which would result in a cost effective on-line method for the measurement of separator efficiency in coal cleaning circuits. The method would be based .... read more |
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| C5049 | 25/09/1997 |
| Author: Boulem Boashash, David Hornsby | Queensland University of Technology, ACIRL |
This report establishes the goal of proof of concept of using vibration monitoring and signal analysis techniques to detect feed distribution bias or imbalance between parallel dense medium cyclones in coal preparation plants. In the project, a special purpose DSP data acquisition .... read more |
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| C5051 | 26/03/1998 |
| Author: Brian Sowerby, Cheryl Lim, DA Abernethy, Y Liu, PA Maguire, NG Cutmore, TG Evans, J Ashbury, M Edwards, P Storer | CSIRO Minerals, Mineral Control Instrumentation |
A laboratory feasibility study has been carried out on new and advanced neutron and gamma-ray analysis systems for the direct on-conveyor belt analysis of ash in coal without the need for sample by-lines. Such an analysis system could deliver the combined advantages of a direct .... read more |
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| C5052 | 01/01/1998 |
| Author: Shenggen Hu, Bruce Firth | CSIRO Energy Technology |
Large-scale coal preparation plants require the subdivision of solid/liquid slurries at a number of stages. The unit operations are characterised by preferred feedrates of slurry, solids concentration and particle size distributions for optimal efficiencies. The ideal feed subdivision .... read more |
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| C5065 | 01/09/1996 |
| Author: Chris Wood | JKTech |
The Australian Coal Association Research Program commissioned JKTech to conduct a review of common instruments in Australian coal preparation plants. The objective was to provide information to assist ACARP in directing R&D funds to areas most likely to .... read more |
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| C7044 | 01/10/2001 |
| Author: Peter Holtham | JKMRC, University of Queensland |
The objective of this project was to develop and evaluate new control algorithms more appropriate to the needs of coal preparation plants than existing PI(D) algorithms. Whiten's Form Generating Controller (FGC) which automates the techniques used in manual control was chosen for .... read more |
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| C8047 | 01/05/2001 |
| Author: Nick Cutmore, DG Miljak, TG Rowlands, D Crnokrak, AJ McEwan, RJ Stevens | CSIRO Minerals |
A prototype low frequency microwave analyser has been developed to more accurately monitor thick beds of high moisture coal, using low-cost antennas. The measurement of the moisture content of materials is currently carried out by manual or automatic sampling of product, followed by .... read more |
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| C9042 | 01/09/2007 |
| Author: Cheryl Lim, David Abernethy, S Rainey, LK Noack | CSIRO Minerals |
The present report describes the design and plant-testing of a prototype commercial on-belt ash analyser at the Bengalla CHPP (Muswellbrook, NSW). This analyser uses the Neutron Inelastic Scatter (NIS) and Thermal Neutron Capture (TNC) Analysis (NITA) technique, which has been .... read more |
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| C9043 | 01/11/2000 |
| Author: Allen Hundley | Offshore Scientific |
Offshore Scientific P/L has completed a preliminary study of an acoustic based percent solids / density gauge to be used in coal preparation circuit pipes. This low cost scoping study forms a basis for possible future development of a density gauge that would be low cost, and an alternative to .... read more |
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| C9045 | 01/11/2002 |
| Author: Shenggen Hu, Bruce Firth | CSIRO Energy Technology |
STAGE 1 The objective of this project is to develop an effective and inexpensive Electrical Impedance Spectroscopy (EIS) based technique for on-line monitoring of the operation of DMCs in order to improve timely detection of poor operating conditions and reduce coal .... read more |
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| C9051 | 01/08/2002 |
| Author: Peter Holtham | JKMRC, University of Qld |
This project was designed to build on project C6043, which developed a prototype on-line image analysis instrument to measure coal flotation frothparameters on Microcels at Peak Downs CPP. The project had four objectives: - To determine the most effective means of using the
.... read more |
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| C10046 | 01/02/2005 |
| Author: Michael O'Brien, Shenggen Hu, Ian Hutchinson | CSIRO Energy Technology |
This project has developed and field tested a simple, robust flow rate measuring technique based on signal cross-correlation. It was conducted in two stages. The first, for which a report was published in October 2002, conducted a proof of concept investigation at pilot scale over a wide .... read more |
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| C10051 | 01/07/2001 |
| Author: Terry Bryden, Mike Baldry | Honeywell |
This report covers two main areas, firstly technical advances in process instrumentation used in coal preparation and secondly, equipment health monitoring systems applicable to coal preparation plant equipment. In recent years, automation technology has migrated .... read more |
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| C11009 | 01/08/2004 |
| Author: Elliot Duff, Barry Jenkins | CSIRO ICT Centre |
This scoping study was undertaken to assess various new sensor and network technologies now available for integrated plant systems. It involved a literature review and an investigation of the nature and performance of several combinations of modern sensor and network .... read more |
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| C11010 | 01/04/2006 |
| Author: Barry Jenkins, Elliott Duff, Peter Holtham | Jenkins-Kwan Technology |
The main aim of the project was to develop and test a low-cost system for monitoring of coal preparation plant systems and processes in troubleshooting or investigative applications. The system (or tool) is autonomous, can be interfaced with a wide variety of probes, sensors and .... read more |
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| C11011 | 01/12/2003 |
| Author: Graeme Jameson, NH Willis | University of Newcastle, TUNRA |
This study is concerned with finding a new technique for the determination of a frother's effectiveness in the flotation of coal. A small bench top unit was investigated in an attempt to minimise labour, capital and time costs associated with testing frother effectiveness. A .... read more |
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| C11013 | 01/09/2006 |
| Author: Noel Lambert | TUNRA |
This report describes a new type of online slurry ash analyser. The device calculates the density of particles in a slurry and makes use of the relationship between particle density and ash content. Particle density is measured by using a commercial online slurry density unit (Micro .... read more |
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| C11014 | 21/05/2004 |
| Author: Stephen Sullivan, Andrew Meyers, Bob Leach, Michael O'Brien | A&B Mylec, CSIRO Energy Technology |
The measurement of volume flows, using portable ultrasonic flow meters, has been a major tool used in the data collection phase during plant audits in the coal industry. The accuracy of these ultrasonic flow measurements have been inconsistent due to various influences, generally related .... read more |
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| C11069 | 01/06/2009 |
| Author: Bruce Firth | CSIRO Energy Technology |
The current advances in electronics and smart sensors, coupled with the large amount of information that modern distributed control systems can create, provide opportunities but posses some significant problems. The potential suite of data measurements could provide plant operators, .... read more |
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| C12052 | 01/03/2005 |
| Author: 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 .... read more |
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| C13056 | 01/06/2006 |
| Author: Glenn Hart, M Attalla, P Morgan | CSIRO |
A significant issue within coal washeries is that of over frothing; such problems can occur with pumps, sumps and thickeners when the level of frother in the process water rises too high. The industry has long needed the means to monitor frother levels within the plant water in order to .... read more |
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| C13058 | 01/03/2007 |
| Author: Shenggen Hu, Bruce Firth | CSIRO Enerty Technology |
Separation density (RD50) and efficiency (Ep) are two important performance parameters of dense medium cyclones (DMCs). These two parameters are not directly measured but calculated from particle density partition curves. Currently partition curves for DMCs are .... read more |
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| C14063 | 01/12/2006 |
| Author: Steven Spencer, Y Lui, R Bruniges | CSIRO Minerals |
A proof-of-concept non-intrusive contact Acoustic Emission (AE) monitoring and soft-sensor analysis system has been developed and tested for passive monitoring of adverse operating conditions in coal washery Dense Medium Cyclones (DMCs). AE sensors externally mounted at feed, mid-body, .... read more |
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| C16045 | 20/08/2008 |
| Author: Steven Spencer, R Bruniges, A Williams, V Sharp, S Rainey, G Roberts, R Stevens, M Millen | CSIRO Minerals |
A commercial prototype Acoustic Emission (AE) analyser has been developed for monitoring performance of washery Dense Medium Cyclones (DMCs), in particular the detection of adverse DMC operating conditions. The analyser consists of an electronics module and multiple accelerometer .... read more |
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| C19041 | 01/10/2011 |
| Author: Bruce Atkinson | CPG Resources - QCC Pty Ltd |
Sampling from the discharge of high capacity vibrating screens, especially multi-slope screens, is subject to sampling bias, due to the stratification that occurs on the vibrating screen deck. The stratification in the vibrating bed translates to a stratified falling stream at the discharge .... read more |
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| C19043 | 27/06/2012 |
| Author: Peter Purdon, Laurie Gibson | ALS Coal Technology NSW |
The objective was to directly determine the measuring efficiency of a pilot Ultra-Dynamics density gauge. Direct comparisons were obtained by installing the non-nuclear gauge immediately after a standard nuclear gauge within the ACIRL Pilot Plant. That provides a direct comparison of the .... read more |
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| C19046 | 01/07/2012 |
| Author: Peter Holtham | Julius Kruttschnitt Mineral Research Centre, The University of Queensland |
The objective of ACARP project C19046 was to provide the Australian coal industry with reliable supplier-independent, size-by-size data describing the performance of modern spirals under a range of operating conditions. Data was to be generated for individual spiral starts as well as for the .... read more |
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| C20048 | 07/11/2013 |
| Author: Bob Drummond | QCC Resources |
Currently there are over approximately 30 gravity concentrators comprising both the Advanced Separation Engineering TBS design and the FLSmidth, Reflux Classifier design installed and operating in Australian CPP's treating raw coal plant fines. It is well established that both the .... read more |
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| C20049 | 01/03/2013 |
| Author: Shenggen Hu, Michael O’Brien and Bruce Firth | CSIRO |
Plant feed washability determines the yield achievable for given product ash levels after cleaning. Plant feed washability can vary with time due to variations in feed coal characteristics as coal is sourced from different seams, different locations within a seam, and due to out of seam .... read more |
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| C21052 | 11/11/2013 |
| Author: Michael O’Brien, Andrew Taylor | CSIRO |
Coal contains water which can be defined in various ways, the most common of which are the laboratory determined moisture characteristics of moisture in the analysed sample, air dried/free moisture and equilibrium moisture. None adequately describe the water that can be removed from .... read more |
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| C22033 | 01/06/2018 |
| Author: Shenggen Hu | CSIRO |
The objective of this project was to develop, implement and demonstrate a system that determines the optimal DMC cut‐point at which a target product ash and/or a given incremental ash can be achieved. The operation of dense medium cyclone (DMC) at the optimal cut‐point would reduce .... read more |
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| C25011 | 01/03/2018 |
| Author: Ghislain Bournival, Feng Zhang Noel Lambert, Sushil Gupta, Pramod Koshy and Seher Ata | The University of New South Wales |
In an effort to minimise fresh water use, a number of Australian coal preparation plants use underground water or recycled water. The use of alternative water sources in coal preparation, especially in flotation, has significant effects on flotation and coke characteristics since these water .... read more |
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| C26013 | 01/08/2022 |
| Author: Feng Zhang, Ghislain Bournival, Seher Ata & Noel Lambert | University of New South Wales & Clean Process Technologies |
In an effort to minimise fresh water use, coal preparation plants use recycled water. The water lost during recycling is obtained from various sources such as underground and surface water. The use of alternative water sources in coal preparation has significant effects on flotation and coke .... read more |
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| C28073 | 01/01/2023 |
| Author: Daniel Borrow, Joshua Starrett, Yiyi Liu, Bo Fan, Kaiyuan Qin, San Thang, Kevin Galvin | University of Newcastle |
The overall goal of this project was to apply novel polymers to produce dry stackable tailings in the coal industry. Despite an exhaustive investigation, it was not possible to produce the necessary polymer addition regime needed to achieve the goal of a dry stackable tailing. This report .... read more |
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| C33052 | 16/01/2023 |
| Author: Phil Aitchison | Imagine Intelligent Materials |
Imagine Intelligent Materials (“Imagine”) has developed and tested graphene-based sensing surfaces on conveyor belts to allow real-time monitoring of the structural health of the belt, the strain it is under, damage to the belt and the weight on the belt. Imagine These .... read more |
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| C33057 | 23/10/2024 |
| Author: Fidel Gonzalez | Mincka Engineering |
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 .... read more |
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| C34047 | 30/07/2023 |
| Author: Clint McNally, Ian Hutchinson and Shane Reinhard | CSIRO |
This project focused on developing a real time measurement system for quantitatively assessing the concentration of dilute magnetite (less than 1g/L) in a magnetic separator slurry overflow. The current method of qualitative assessment consists of using a magnetic wand and visual .... read more |
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| C34050 | 01/08/2024 |
| Author: Nigel Spooner & Alexandra Chapsky | The University of Adelaide |
The project's objective was to create a new type of hand-held sensor for real time measurement of fluorine (mineral) contamination in coal. The minerals targeted are the two dominant non-clay fluorine minerals, fluorite and fluorapatite; fluorine hosted in clay minerals was not considered .... read more |