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Coal Preparation                                  reports

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.


General (43 Reports)

Improving Coal Flotation with Oscillatory Air Supply

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C2700402/09/2020
Author: Hangil Park and Liguang Wang | University of Queensland

This report provides detailed information on coal flotation with oscillatory air supply at pilot scale.

At the start of the project, the effectiveness of three different devices (named A, B and C) for converting steady airflow to oscillatory airflow was evaluated. It was found that ....  read more

 

Lab Froth Flotation Testing Guide with Coal Quality

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C2702807/08/2020
Author: Chris McMahon | McMahon Coal Quality Resources

Correct outcomes from laboratory froth flotation testing in coal borecore exploration are critical to resource predictive potential, market evaluation and economic mining outcomes.

McMahon Coal Quality Resources (MCQR) has observed over many projects that froth flotation outcomes ....  read more

 

Improved Flotation Recovery Via Controlling Froth Behaviour

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C2601227/06/2020
Author: Hangil Park, Liguang Wang | University of Queensland

There is no real-time measurement for coal flotation performance, making it difficult to control the flotation process. Previous laboratory test work in project C23035 has developed a froth diagnostic tool and a frother concentration measuring tool. This project further developed and assessed ....  read more

 

Coal Grain Analysis Applications Handbook

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C2703227/06/2020
Author: Bruce Atkinson, Priyanthi Hapugoda, Silvie Koval, Graham O’Brien, Karryn Warren, Sandra Atkinson | Basacon Services

This Handbook sets out recommended practices for using coal grain analysis (CGA) data to interpret coal quality for a variety of applications, and to understand the use of CGA for quantitative assessment of dust samples. It encompasses typical quantitative and qualitative information in the ....  read more

 

Optimising Coal Fragmentation for Improved Recovery

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C604613/01/2020
Author: Joan Esterle, Darren Thornton, Graham O'Brien, Alan Cocker | CSIRO Exploration & Mining, JKMRC, C Clarkson & Associates, Quality Coal Consulting

Uncontrolled fragmentation, in particular that resulting in the generation of coal fines (

This is the final report for ACARP Project C6046 conducted through the Centre for Mining Technology and Equipment (CMTE) by members of the CSIRO division of Exploration and Mining and University ....  read more

 

Low Cost Online Measurement of Particle Size and Density for Diagnostics Across the Fine Coal Circuit

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C2601411/02/2019
Author: Rohan Stanger, Quang Anh Tran, Peter Stepien, Clint Bruin, Terry Wall | The University of Newcastle and ResTech

This project has developed a novel prototype optical system for profiling fine coal streams in a coal preparation plant. The system determines individual coal particle size, settling velocity and density targeting the size range (100µm - 2.0mm). This information is combined to form ....  read more

 

Implementation of Oxidation Monitoring Tools and New Reagents in Plants to Improve the Flotation of Oxidised Coals

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C2600801/12/2018
Author: Xumeng Chen, Yangyang Huai and Yongjun Peng | The University of Queensland

Flotation of oxidized coals is a challenge confronting the Australian coal industry. The conventional flotation collector, diesel, used for floating non-oxidized coals is not suitable for floating oxidized coals, leading to a significant loss of valuable coals to the tailings. In the previous ....  read more

 

Revised Dustiness and DEM Test Method (Update of AS4156.6) Part 2:Preparation

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C2600728/09/2018
Author: Dusan Ilic, Ken Williams | The University of Newcastle

In 2015 project C23054 investigated and reviewed the Australian Standard for dust extinction moisture (DEM) of coal AS4156.6 and re‐enforced the validity and applicability of the test method described. However, the project outcomes also highlighted a number of possible areas where the ....  read more

 

Derrick Stack Sizer In-plant Evaluation

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C2500701/02/2018
Author: 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 ....  read more

 

Seal, Spray and Wash Water Filtration in Coal Preparation Plants

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C2104722/09/2017
Author: Dr Götz Bickert | GBL Process

The objective of the study was to undertake a review of seal, spray and wash water filtration technologies currently used in Australia and overseas and technologies with the potential to improve process water quality from a solids content perspective. This is relevant for water used for filter ....  read more

 

CGA Workshop Series Driving Implementation

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C2603801/09/2017
Author: Bruce Atkinson & Graham O’Brien | Basacon Services & CSIRO

Over the past ten years, ACARP has funded a number of projects which have been used CGA techniques and associated image processing software to undertake a wide range of projects to address specific industry needs at all stages in the coal chain from green field exploration, optimised coal ....  read more

 

Coal Preparation Equipment Performance Database

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C1506023/03/2016
Author: Bruce Atkinson & Andrew Swanson | QCC Resources

The database is designed to hold raw sizing and float-sink data for coal preparation process equipment.

 

In order to maximise the value of the data, associated information is also stored that includes all available information about the nature of the installation and ....  read more

 

Application of ACARP DMC R&D between CSIRO and JKMRC

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C2405201/08/2015
Author: Mike O'Brien | CSIRO

In 2006 ACARP funded "The Intelligent Plant" project (C11069) to the value of $0.5M over three years for the CSIRO team at QCAT to define the requirements in terms of instrumentation, monitoring, control and overall management of the next generation dense medium cyclone plant). This ....  read more

 

Impact of Sample Preparation Procedure on CGA Result

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C2304217/06/2015
Author: Bruce Atkinson | QCC Resources

A number of ACARP research projects are demonstrating useful outcomes from coal grain analysis (CGA), for example Project C18041.

Samples for CGA are prepared by the same method as for conventional petrographic analyses, namely by grinding to minus 1 mm topsize whilst aiming to keep ....  read more

 

Product Coal Loss Due to Inappropriate Focus on Ep

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C2304321/05/2015
Author: Bruce Atkinson | QCC Resources

The Coal Preparation fraternity is used to focussing on Ep(75/25) values when people consider separation equipment performance. However, Ep only describes a small aspect of performance, and in many cases the Ep value is completely irrelevant or even misleading. For example, when considering ....  read more

 

Coal Preparation Field Promotion 2014

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C2400428/11/2014
Author: Peter Newling | Petan Enterprises

As the sole purpose of this project was to raise awareness of ACARP coal preparation research by plant visits there is no report.  An A4 size pdf of the poster used during the 2014 visit can be downloaded here.

 ....  read more

 

Washability Analysis of Fine Coal using a Water-Based Method

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C2104625/06/2014
Author: Kevin Galvin, Simon Iveson & David Hunter | University of Newcastle

The aim of this project was to develop a water-based method for generating washability data and analysing the partition performance of separation operations. Fractionation experiments were performed in a laboratory Reflux Classifier on coal samples in the -0.250 +0.038 mm, - 2.0 +0.25mm and -16 ....  read more

 

Application Of Nano Particles To Fine Coal Float Sink Tests

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C2004401/11/2013
Author: Gary Cavanough | University of Queensland

The elimination of organic chemicals, used in float/sink testing from laboratories is a priority for the coal industry.  A variety of replacements are under investigation including ferro-fluids, zirconium dioxide and caesium formate.  This project initially investigated the ....  read more

 

Application of X-ray Computed Tomography for Coal Washability Analysis

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C2105001/10/2013
Author: Tuan D Nguyen, Anh V Nguyen, Chen-Luh Lin and Jan D Miller | The University of Queensland, University of Utah

Coal washability is currently obtained by float-sink analysis. The safety and technical concerns associated with the float-sink analysis due to the use of toxic, environmentally hazardous liquids have been recognized by the industry for many years. Moreover, this slow, time-consuming analysis ....  read more

 

Coal Preparation Field Promotion 2012

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C2200120/12/2012
Author: Peter Newling | Petan Enterprises

As the sole purpose of this project was to raise awareness of ACARP coal preparation research by plant visits there is no report. An A4 size pdf of the poster used during the 2012 visit can be downloaded here.

In 2003 ....  read more

 

Improved Automatic Reclaim for Uneven Stockpiles

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C1904429/10/2012
Author: Russ Morrison, Stuart McCarthy | BMT WBM

This investigation has involved the development and testing of an improved control technique for automatically controlled slewing bucketwheel reclaimers. The technique uses laser scanning immediately ahead of the bucketwheel's trajectory, permitting pre-emptive control of slew speed and ....  read more

 

Coal Preparation Field Promotion 2010

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C1904801/09/2010
Author: Peter Newling | ACARP

As the sole purpose of this project was to raise awareness of ACARP coal preparation research by plant visits there is no report. An A4 size pdf of the poster used during the 2010 visit can be downloaded  ....  read more

 

Limits to Plant Capacity

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C1406201/12/2007
Author: Michael O'Brien, Bruce Firth | CSIRO Energy Technology

The current high demand for coal for the export market has raised the issue of the limitations to plant performance and production as the amount of run of mine coal feed to the plant is increased. While there are some obvious limitations such as the amount which the feed conveyor to the plant ....  read more

 

Performance Based Specification for Coal Preparation Plants Maintenance Coatings

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C1406901/10/2007
Author: Henry Bartosiewicz, Paul Curcio | MTI, Monash University

The main objective of this study was to develop a cost effective methodology to ensure that only high quality coating systems are approved for use at the Coal Handling and Preparation Plants (CHPPs) structural components.  This goal is to be achieved through development of methods that ....  read more

 

Extending the Lifetime of Sieve Bends and Centrifuge Baskets

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C1505601/10/2007
Author: Shenggen Hu, Mike O'Brien | CSIRO Energy Technology

Maintenance accounts for 41% of the washing costs in coal preparation. Sieve bends and centrifuge baskets are among the most costly items in the maintenance area (ACARP project C8063), and these costs are associated with their relatively short life due to abrasive wear. In most situations, ....  read more

 

Screen Aperture Wear and Performance and CFD Modeling of Screen Wear

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C1305708/05/2007
Author: Anita Hill, Michael O'Brien, A Taylor, Bruce Firth, JI Mardel, MR Hill, TJ Bastow, RHJ Hannink, L Graham, J Wu, A Bui | CSIRO Energy Technology

In ACARP C11006 (O’Brien et al. 2003), screen aperture dimensions and open area inclusive of pegging were measured using a new image analysis system. In ACARP C11012 (Hill et al. 2004), the material performance and the critical failure mechanisms of screen panels ....  read more

 

Reduced Cyclone Wear and Maintenance

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C1305331/10/2006
Author: Anita Hill, James Mardel, T Markley, T Bastow, R Hannink | CSIRO Manufacturing and Materials Technology

This project gives details of a study of the wear and performance of DMCs from the Hunter Valley and the Bowen Basin.  The project consisted of information gathering, in-situ monitoring of DMCs, and ex-situ failure analysis of DMCs. 

Due to cost factors there is ....  read more

 

Application of the Portable Screen Motion Analyser to Measure Plant Performance

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C1305401/07/2006
Author: Michael O'Brien, Ian Hutchinson, Mark Kockanek | CSIRO Energy Technology

Banana screens have been shown in a previous ACARP project to have a stroke, as measured with a portable screen motion analyser , which is proportional to the mass feed rate to the screen. This report presents the results of pilot plant and coal preparation plant experiments using the  ....  read more

 

Application of Magnetic Fluids for Sink-Float Analysis - Literature Review

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C1305501/06/2004
Author: Kevin Galvin | University of Newcastle

It is now more likely than ever that the Australian Coal industry will need to find an alternative to the heavy liquids used to produce a sink-float analysis of coal. Indeed, the Australian Standard on sink-float analysis is likely to be phased out over the next five years. Thus there is a ....  read more

 

Image Analysis Measurement of Screen Aperture and Open Area

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C1100601/11/2003
Author: Michael O'Brien, Douglas Nemeth, Terry Wex, Stephen Sullivan | CSIRO Energy Technology, A&B Mylec

The project's objective is to develop a portable prototype measurement system using a digital camera and a laptop computer to measure screen aperture and open area. The measurement of the screen aperture will include the number of aperture measurements made, the mean, histogram and the standard ....  read more

 

Portable Screen Motion Analyser

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C1100501/10/2003
Author: Michael O'Brien, Ian Hutchinson, Chris Wesner | CSIRO Energy Technology, CSIRO Exploration & Mining

A previous project developed a method using a portable PC, a triaxial accelerometer and suitable software to determine the stroke and frequency of a vibrating screen and to display the three dimensional motion of the screen on a rotatable and resizable XYZ graph. Screen and panel ....  read more

 

Stockpile Volumes and Tonnages by Remote Means

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C905001/09/2002
Author: John Doyle | Geosensing Solutions

Key results:

  • This research has demonstrated that gravity surveying methods can achieve the resolution necessary to determine the tonnage of coal in a stockpile.
  • Tonnages can be determined without using on pile measurements if microgravity techniques are employed.
  • Low
 ....  read more

 

Improved Performance of Banana Screens in Drain and Rinse

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C804201/07/2002
Author: Michael O'Brien, Bruce Firth, Andrew Meyers, Douglas Nemeth, Adrian Burger | CSIRO Energy Technology

The objective of this project is the identification of the factors controlling the efficiency of the high capacity Banana screens when they are used to recover media via drain and rinse. This includes potential approaches to improve efficiency with respect to fluid recovery, partition curves ....  read more

 

Design of Sampling Systems

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C804631/07/2001
Author: Chris Clarkson, Cameron Dorr, Darren Edward | C Clarkson & Associates, Sedgman

Researchers have developed a specification to enable Australian coal operators to design reliable and accurate sampling systems suited to their individual needs.

Many sampling systems installed in Australian coal mines are unreliable, inaccurate and require a high degree of operator ....  read more

 

Effect of Various Constitutents on Storage and Transportation of Coal

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C605701/07/2001
Author: John Chambers, Yan Liu, Alan Roberts | University of Newcastle

The effect of various constituents of coal on the handleability of both raw and clean coal is generally unknown. There is some information on the influence of moisture content, size distribution and clay content on coal handleability. However the overall influence on handleability of the ....  read more

 

Performance of Banana Screens in Drain and Rinse Applications

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C704822/11/2000
Author: Andrew Meyers | A&B Mylec

This project was primarily concerned with the delineation of issues related to the drain rate of medium through banana screens as the screen deck aperture varied, in particular below 1.0mm. Comparisons with existing sieve bend / low head combination technology were also required to enable ....  read more

 

Impact of Coal Crushing on Washery Feed

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C704901/01/2000
Author: Clement Chao, L Mason, Bruce Firth, Stuart Nicol | CSIRO Energy Techology, Novatech Consulting

In the primary breakage of a run of mine (ROM) coal to its preparation plant top size, there are three aspects of principle interest to the coal producer:

  • Adequate liberation of clean coal from mineral matter to maximise the yield of coal meeting product specifications.
 ....  read more

 

Prediction of Washability as a Function of Breakage

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C505401/09/1999
Author: Tony Kojovic, Graeme O'Brien, F Shi, Joan Esterle | CMTE

The washability and recovery of coal is governed by two processes: breakage and liberation of stone from coal. The efficiency of liberation is coal type and particle size dependent. Particle size distribution is a function of the material properties of the coal and the breakage energy imparted ....  read more

 

Maintenance Requirements in Coal Preparation Plants

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C806301/03/1999
Author: Joe Sanders | Coalproc

ACARP commissioned this study into maintenance issues of coal preparation plants, with the aim to identify areas where research may result in potentially substantial improvements.

The scope of the study included:

  • Review current maintenance practice
 ....  read more

 

Moisture Changes and Stability Problems in Coal Stockpiles

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C405722/01/1999
Author: John Eckersley | James Cook University of North Queensland

This report summarises works conducted at James Cook University on moisture movements and stockpile stability, including the current understanding of factors leading to moisture movement, erosion, shallow surface slipping  ....  read more

 

Improved Washability Prediction Through Establishment of Correct Coal Size Distributions

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C505330/06/1998
Author: Andrew Swanson, I Fletcher, W Membrey, R Davis | Quality Coal Consulting, ACIRL, Mining and Exploration Geology Services

The prediction of coal size distributions during the process of mining, handling and preparation are of great importance in preparation plant design because of the need to adequately cater for appropriate amounts of fine coal, and to be able to provide realistic samples for washability  ....  read more

 

Dry Beneficiation of Coal by Laser Sorting

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C605001/09/1997
Author: Ted Lewis | Callide Coalfields

The project was designed to demonstrate on a pilot scale, the technical viability of the laser based sorting process to coal cleaning. The project was managed by Callide coalfields with Barco Machine Vision Systems (Elbicon Pacific Pty Ltd), supplying and operating the processing unit. ....  read more

 

Improved Prediction of Size Distributions and Their Effects in Materials Handling and Coal Preparation Systems

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C300430/11/1993
Author: Andrew Swanson, IS Fletcher | Quality Coal Consulting

 ....  read more

 

Underground

Health and safety, productivity and environment initiatives.

Underground

Open Cut

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

Recently Completed Projects

C19024Establishing Ecologically Sustainable Mine Water Release Criteria In Seasonally Flowing Streams

Extreme rainfall conditions in the Fitzroy Catchment over an approxi...

C25030Coal Mine Open Pit Final Void Closure And Relinquishment - Addressing Uncertainty In Coal Mine Environmental Planning

This report addresses uncertainties faced by coal mine operators whe...

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27004Improving Coal Flotation With Oscillatory Air Supply

This report provides detailed information on coal flotation with os...

C25018Improving Solids Recovery And Moisture Reduction In Ultrafine Coal Dewatering

This report provides detailed information on fine coal dewatering in...

C27028Lab Froth Flotation Testing Guide With Coal Quality

Correct outcomes from laboratory froth flotation testing in coal bor...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

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...

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

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