GLOBAL
COAL BENEFICIATION SCENARIO
GLOBAL OVERVIEW OF
COAL PREPARATION
™ Annual worldwide
production of Hard
Coal: 5000 Mt (approx)
™ Currently more than 2500 CPPs in operation in the world
™ More than one-third of
world’s coal production is beneficiated
GLOBAL OVERVIEW OF COAL PREPARATION
PRESENT
STATUS & FUTURE TRENDS IN COAL
PREPARATION IN FOLLOWING COUNTRIES:
™AUSTRALIA
™CHINA
™UNITED STATES
OF AMERICA
™RUSSIA
™CANADA
™SOUTH AFRICA
™INDIA
AUSTRALIA
„ COAL RESERVES
™ 74.2 Bt
™ 62 Bt (Lignite)
„ RAW COAL PRODUCTION
™ 4th in the world
™ 397 Mt (2005)
„ EXPORTS
™ 234 Mt (124 Mt Metallurgical coal & 110 Mt
Thermal coal)
™ 60% of total production
exported, accounts for
28% of global
coal export market
„ COAL WASHING
CAPACITY
™ Most of ROM
coal produced is routed through
CPP. Fraction
exported is fully washed
AUSTRALIA
„ PRESENT STATUS
CP industry enjoying
greatest boom in last 25 years. As a result:
™ New processing facilities being
established.
™ Existing facilities
being upgraded.
™ Rail & port facilities
being expanded.
™ Since 2004,
additional 20,000 tph
washing capacity has
been
added or
under construction to
cope up with the
buoyant international demand.
AUSTRALIA
TECHNOLOGY IN VOGUE
„ Raw coal crushed to 50/60 mm.
„ Coarse coal washing
™ Mainly by DMC (Dia:1000 mm or more)
™ Drums or Baths in some plants.
™ Jigs at few plants.
„ Fine coal washing
™ Spiral + Jameson or Microcel technology.
™ Limited use of froth flotation for metallurgical
coal.
„ Dewatering
™ Coarse & medium size- Vibrating or scroll
type basket
centrifuges
™ Flotation products- Vacuum filters &
screen bowl
centrifuges.
™ Tailings- High rate gravity thickener & Belt
Press Filter.
CHINA
„ COAL RESERVES
™ 2nd in the world in terms of coal reserves.
™ 2040 Bt (Mineable coal reserves)
„ RAW COAL PRODUCTION
™ Largest coal producer.
™ 1960 Mt (2004)
™ Main energy source (60%).
„ COAL WASHING CAPACITY
™ 2000 CPPs
(2004)
™ 800 Mty (Projected
for 2005)
CHINA
TECHNOLOGY IN VOGUE
„ Raw coal crushed to 100/50 mm.
„ Coarse coal
washing (100/50 – 25/13
mm)
™ Mainly jigs (60%)
™ Dense medium separator (Drewboy,
Vertical lifting
wheel separator)
„ Small coal
washing (50/25/13 – 0.5 mm)
™ 2-Product Dense medium
cyclones (Dia. 660-1300
mm)
™ 3-Product Dense medium
cyclones (Dia. 1000-1400
mm)
„ Fine coal washing (-0.5 mm)
™ Mainly flotation.
™ Column flotation (for very fine
coal).
CHINA
TECHNOLOGY IN VOGUE (contd.)
„ Dry separation
(limited application)
™ Mainly Compound dry separators.
™ Limited use of Air dense medium dry separator
„ Dewatering
™ Mainly High frequency screen
™ Centrifuge (vertical & horizontal)
™ Pressure filter
™ Fast diaphragm filters
™ Plate-and-frame filters (for slime recovery)
UNITED STATES OF AMERICA
„ COAL RESERVES
™ 1st in the world
in terms of proven coal reserves.
™ 111 Bt (Anthracite & Bituminous)
™ 135 Bt (Sub-bituminous & Lignite)
„ RAW COAL PRODUCTION
™ 2nd in the world.
™ 1100 Mt (2006)
™ About 90% consumed in domestic market.
„ COAL WASHING CAPACITY (2006)
™ 265 operating CPPs.
™ 986 Mty raw coal
throughput capacity (about 90%
of total production).
™ 562 Mty Clean
coal production.
UNITED STATES OF AMERICA
„ PRESENT STATUS
™ Majority of the bituminous coal and
anthracite produced
beneficiated through
specific gravity and
froth based coal
preparation.
™ Sub-bituminous coal not beneficiated.
™ No commercial scale specific gravity
beneficiation of low
rank coals except of
Bituminous “C” coals
™ Significant amount of mercury removed
through specific gravity beneficiation
process as mercury present
in most coals is
associated with
pyrite.
UNITED STATES OF AMERICA
TECHNOLOGY IN VOGUE
„ Each CPP employs
3 or more independent
processing
circuits for different size fractions.
„ Coarse coal washing (100 - 10 mm)
™ Dense Medium
Vessel
„ Medium coal washing (10 - 1 mm)
™ Dense Medium
Cyclones (Dia. < 1000 mm)
„ Small coal washing (1 - 0.15 mm)
™ Water Only
cyclone
™ Spirals
™ Combination of both
UNITED STATES OF AMERICA
TECHNOLOGY IN VOGUE (Contd.)
„ Fine coal washing (<0.15 mm)
™Froth flotation (after desliming -35/40
micron)
„ Dewatering
™Coarse size fraction
™Basket Type Dryers
™Fine size fraction
™Screen bowl centrifuges
™Combination of
vacuum filter &
thermal dryers.
RUSSIA
„ COAL RESERVES
™2nd in the world
after USA in terms of
proven coal reserves.
™170 Bt (Proven)
„ RAW COAL PRODUCTION
™Ranks 6th in the world.
™300 Mt (2005)
„ COAL WASHING CAPACITY (2006)
™42 CPPs, 28
concentrators, 17
mechanized sizing units.
RUSSIA
„ PRESENT STATUS
™ Mainly bituminous & brown coal.
™ Majority of coking coal beneficiated
(92% in 2005).
™ Only part of thermal coal beneficiated
(13% in 2005).
™ Generally low sulphur content (< 1%).
RUSSIA
TECHNOLOGY IN VOGUE
Sl. No.
|
Equipment
|
%
|
1
|
Heavy media Baths & Cyclones
|
53.1
|
2
|
Jigging
|
30.1
|
3
|
Flotation
|
9
|
4
|
High-angle separators (Water
only cyclones)
|
4.2
|
5
|
Spiral separators
|
2.4
|
6
|
Pneumatics (for thermal brown coals)
|
1.2
|
DEWATERING OF FINE COAL
™High frequency
screens
™Centrifuges (Settling
& filtering)
™Belt press
filters 16
™Continuous disc
filter (operating under pressure)
CANADA
„ COAL RESERVES
™ 7.3 Bt (Recoverable)
„ RAW COAL PRODUCTION
™ 62 Mt (2003)
ƒ 30 Mt (Bituminous coal)
ƒ 22 Mt (Sub-bituminous coal)
ƒ 10 Mt (Lignite)
„ CONSUMPTION/ EXPORTS/ IMPORTS
™ 62 Mty Domestic consumption
™ 28 Mty export & import each
„ COAL WASHING CAPACITY
™ 35 Mty beneficiated.
CANADA
„ PRESENT STATUS
™Production dropped by about
20% and stabilized since
2003.
™Coal industry is small compared
to oil sands industry.
CANADA
TECHNOLOGY IN VOGUE
„ CPPs usually
employ 4 independent processing
circuits for different size
fractions.
„ Coarse coal washing (100 - 10 mm)
™ Heavy Medium Drums
& Baths
„ Medium coal washing (10 – 0.5 mm)
™ Heavy Medium
Cyclones
„ Small coal washing (0.5 - 0.15 mm)
™ Water Only
cyclone
„ Fine coal washing (<0.15 mm)
™ Froth flotation
™ Column flotation
™ Spirals
SOUTH AFRICA
„ COAL RESERVES
™55.5 Bt
„ RAW COAL PRODUCTION
™5th in the world
™307 Mt (2004)
™241 Mt (2004)- Saleable production
„ EXPORTS
™65 Mt (27% of saleable
production
exported).
SOUTH AFRICA
„ PRESENT STATUS
™ New generation CPPs
utilize the benefits of
economies of scale
employing single large
volume units.
™ About 92% of electricity
generated from coal
which is highest in the world.
™ Leader (Sasol) in
consumption of coal for
conversion to liquid fuels which was
necessitated due to 2
major oil shocks in 1973 &
1979.
™ Primary product of CPPs is
export steam coal.
™ Secondary product is fed to
domestic power
stations.
SOUTH AFRICA
TECHNOLOGY IN VOGUE
„ Raw coal crushed to 80 mm.
„ Employs split
size wash.
„ Coarse coal
washing (80 – 8 mm)
™ Mainly large diameter pump fed dense media
cyclones
™ Dense medium separator (Wemco Drum,
Drewboy)
™ Jigs at few plants.
„ Small coal
washing (8 – 0.8 mm)
™ Smaller diameter
cyclones.
„ Fine coal washing
™ Mainly spirals
™ Limited use of froth
flotation.
COMPARATIVE STATUS OF
COAL PREPARATION IN VARIOUS COUNTRIES WORLDWIDE
Sl. No.
|
Country
|
Coal Production, Mty
|
No. of
Washeries
|
Washing capacity (Mty)
|
1
|
China
|
2226
(2005)
|
2000
|
800
|
2
|
USA
|
1100
(2006)
|
265
|
986
|
3
|
India
|
432 (2006)
|
53
|
134
|
4
|
Australia
|
397
(2005)
|
70
|
NA
|
5
|
South
Africa
|
307
(2004)
|
NA
|
NA
|
6
|
Russia
|
300
(2005)
|
87
|
95
|
INDIA
„ COAL RESERVES (AS ON
1.1.2006)
™ 253 Bt (Geological)
™ 96 Bt (Proved)
„ RAW COAL PRODUCTION (2006-07)
™ 405 Mt (Non-coking coal)
™ 27 Mt (Coking coal)
„ COAL WASHING CAPACITY
™ Pre-third party investment
¾ 19 in CIL
ƒ 12 coking-20.1 Mty
ƒ 7 non-coking- 20.2 Mty
¾ 7 Outside CIL (coking- 11.27 Mty)
™ Post-third party investment
¾ 27 Non-Coking CPPs (83
Mty)
™ Washeries under construction
¾ 3 CPPs (24
Mty)
INDIA
„ PRESENT STATUS
™Washing capacity of CPP got
more
than doubled since post- third party investment.
™Non-coking coal washing
capacity: 103 Mty
™Coking coal washing capacity: 32
Mty
INDIA
TECHNOLOGY IN VOGUE
:
„ Raw coal crushed to 100/75/50
mm.
„ Coarse coal washing (100/75/50 – 25/13 mm)
™ ROM jigs (Moving screen jig)
™ Coarse coal jigs
™ Dense medium separator
™ Barrel washer
„ Small coal washing (50/25/13 – 0.5 mm)
™ Small coal jig
™ Dense medium cyclones (Dia. 600-1000 mm)
INDIA
TECHNOLOGY IN VOGUE (contd.) :
„ Fine coal washing (-0.5 mm)
™ Flotation
™ Spirals
™ Water only cyclones
„ Dewatering
™ Vacuum filters
™ High frequency screen
™ Centrifuge
™ Belt press filter
INDIA
NON-COKING COAL -
ADDITIONAL WASHING CAPACITY REQUIREMENT
„Proj.
Non-coking coal production (XI Plan) :
639.35 Mty
„Superior grades with ash
content < 34% : 143 Mty
„Inferior grades with ash content > 34%
™ Linked to pithead TPS : 160 Mty
™ Captive mining production : 104 Mty
™ Remaining :
243 Mty
(including non-metallurgical
coking coal)
„Non-coking coal washing
capacity : 103 Mty
„Additional capacity requirement : 140 Mty
„Non-coking coal washeries
under pipeline : 32 Mty
INDIA
„ RECENT CIL INITIATIVES
™ Till recently, Third Party investment was the
preferred mode for setting
up of new washeries whereas in a major shift in Corporate policy,
CIL has now decided to set up a number of washeries in CCL &
SECL on Build and Operate basis with CIL’s own investment.
™ In an FDs and HODs
meeting in CIL, Kolkata in January
2007, it has been decided
that all inferior quality coal (>34% ash) produced from future
mines or expansion projects having
capacity 2.5
Mty or above and not linked to pithead power
plant needs to be washed.
ECONOMICS OF USING
WASHED COAL
Previous studies :
ƒ National Productivity Council
at
Satpura TPS of MPEB, 1988-89
ƒ CMPDI at Dadri TPS of NTPC in
1998
ƒ BSES Ltd.
ECONOMICS OF USING
WASHED COAL
Conclusions of previous Studies
:
Washing leads to -
ƒ Improvement of PUF
ƒ Improvement in Generation
ƒ Reduction in Specific coal
consumption
ƒ Increase in Boiler efficiency
ƒ Reduction in smoke (Greenhouse gases) &
dust
ƒ Improvement in overall economics
ECONOMICS OF USING
WASHED COAL
In July, 2005, a Committee was formed
under the chairmanship of Member (Energy), Planning Commission and consisting of representatives from NTPC,
BHEL, CEA, CIL, CMPDIL & GSECL. The
Committee submitted “Report of Working
Group on Suitability of Using Washed Coal in Thermal Power Plants” in May
2006. Major findings are as
follows :
ECONOMICS OF USING
WASHED COAL
Integrated Plant Techno-Economic Analysis :
MINE
ROM COAL
PIT HEAD
500 MW POWER PLANT
MINE
ROM COAL
PIT HEAD
500 MW POWER PLANT COAL WASHERY
CFBC POWER PLANT
MINE
ROM COAL
PIT
HEAD COAL WASHERY CFBC POWER PLANT
WASHE DCOAL
LOAD CENTRE
500 MW POWER PLANT
33
ECONOMICS OF USING
WASHED COAL
Integrated Plant Techno-Economic Analysis :
|
ECONOMICS OF USING
WASHED COAL
Washed
Coal Break-even Cost Analysis :
(No reject utilization through
FBC)
WASHED COAL
PIT HEAD
500 MW POWER PLANT
ECONOMICS OF USING WASHED COAL
Washed Coal Break-even Cost Analysis :
Location of
2X500 MW
power plant
|
COE paise/kwh
(Base value*)
|
Cost of
40% ash RoM coal (Rs./Ton)
|
Breakeven cost of washed coal with
30% ash (Rs./Ton)
|
Pithead
|
154.99
|
515.00
|
692
|
500 km from mine
|
194.63
|
1055.00
|
1347
|
1000 km from mine
|
231.63
|
1599.00
|
1962
|
*Base value
is with 40% ash RoM coal
ECONOMICS OF USING
WASHED COAL
Break-Even
Cost of Washed Coal w.r.t. PLF :
SN
|
PLF (%)
|
Break-Even Cost of
Washed Coal with 30% Ash
(Rs / Ton)
|
Remarks
|
1
|
80
|
692
|
Base Case
|
2
|
81
|
714
|
Valid only for power plants where poor
quality of coal is sole reason for low performance of the plant.
|
3
|
82
|
736
|
|
4
|
83
|
757
|
|
5
|
84
|
778
|
|
6
|
85
|
799
|
*30% Ash Washed coal
based 2x500 MW pithead Plant
ECONOMICS
OF USING WASHED COAL
Major Findings are :
„ Integrated Plant Sensitivity Analysis shows that
washing is viable in case of load centre
power plants if washed coal is
transported beyond break-even distance of 300-400 Kms
„ Washing may be viable for pithead power stations also when use of washed coal leads to substantial
improvement of PLF and for power plants running at part load due to deterioration in coal quality
„ Washing may be viable for pithead power stations also when yield of washed coal is
substantially higher
|
when Rejects are not
being utilized
39
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