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E-raamat: Coal Processing and Utilization

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(S.D.S. Autonomous College, Andhra Pradesh, India), (CSIR, Coal Preparation Division, Dhanbad, India)
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  • Ilmumisaeg: 05-May-2016
  • Kirjastus: CRC Press
  • Keel: eng
  • ISBN-13: 9781498778596
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Coal Processing and UtilizationSuurem pilt
  • Formaat: PDF+DRM
  • Ilmumisaeg: 05-May-2016
  • Kirjastus: CRC Press
  • Keel: eng
  • ISBN-13: 9781498778596
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This book is a direct outgrowth of classes that the authors gave over a period of three decades to a university audience taking a Mineral Beneficiation course as a major that included coal processing and utilization. It is designed to be used as a students (or laymans) first introduction to coal processing and utilization, motivating the concepts before illustrating them by means of concrete situations. As such, this book gives an integrated overview of coal processing and utilization along with clean coal technology, presenting all the basic principles, theory and practice in a systematic way. Every topic covered is dealt with in a self-explanatory manner so that any new reader may find this book interesting and easy to understand.

The book makes available the hard core of fundamentals of coal processing and utilization in a form which is general enough to meet the needs of many and yet is unburdened by excess baggage best discussed in research journals. The salient feature is that all the technical terminology used in this book has been sufficiently explained in order to allow the reader to understand the concepts effectively without needing to consult additional literature.

Problems are introduced not so much to be solved as to be tackled. Some of them are included to lay the ground work for the subsequent theory and will help the readers in teaching, research and operating plants. Overall, this book will be of interest to professionals and engineers in the fields of energy, mining, mineral, metallurgical and geological engineering, as well as to engineering geologists and earth sciences professionals.

Arvustused

"I am delighted that the book "Coal Processing and Utilization" has been published, and I express my sincere thanks to both authors for their untiring endeavor in writing such a vital and timely book. The topic is presented in a clear manner, and the unfolding concept of coal preparation and its utility is explained well through calculations and a problem-solving approach.

I firmly believe that this book will be highly useful for both graduate and postgraduate engineering students as well as practicing coal preparation engineers in the industry. I look forward to more publications of this kind in the near future."

Om Prakash, General Manager - Engineering, Metso India Pvt Ltd.

"The beauty of the book that it is not bound by any boundaries of syllabus which is normally a part of text book. The use of simple English, small sentences, simple lucid style for proper understanding of concepts attracts any reader. This freelance style keeps the reader engrossed with the book, be it be a diploma - degree graduate student, fresher and professional executive. The integrated picture of coal characterization, processing and utilization has been portrayed beautifully meeting the objectives set in. The problems at end of the chapters with Indian context is noteworthy. The chapters on coal washing efficiency, carbonization, gasification, liquification and carbon capture - storage are exemplary. The book will be an asset to diploma, graduate and post graduate students, professionals of fuel, mineral, mining, chemical engineering, coal washeries and thermal - metallurgical plants."

Dr. B.P. Ravi, Professor at the Department of Mineral Processing, VSKU - PG Centre, India. "I am delighted that the book "Coal Processing and Utilization" has been published, and I express my sincere thanks to both authors for their untiring endeavor in writing such a vital and timely book. The topic is presented in a clear manner, and the unfolding concept of coal preparation and its utility is explained well through calculations and a problem-solving approach.

I firmly believe that this book will be highly useful for both graduate and postgraduate engineering students as well as practicing coal preparation engineers in the industry. I look forward to more publications of this kind in the near future."

Om Prakash, General Manager - Engineering, Metso India Pvt Ltd.

"The beauty of the book that it is not bound by any boundaries of syllabus which is normally a part of text book. The use of simple English, small sentences, simple lucid style for proper understanding of concepts attracts any reader. This freelance style keeps the reader engrossed with the book, be it be a diploma - degree graduate student, fresher and professional executive. The integrated picture of coal characterization, processing and utilization has been portrayed beautifully meeting the objectives set in. The problems at end of the chapters with Indian context is noteworthy. The chapters on coal washing efficiency, carbonization, gasification, liquification and carbon capture - storage are exemplary. The book will be an asset to diploma, graduate and post graduate students, professionals of fuel, mineral, mining, chemical engineering, coal washeries and thermal - metallurgical plants."

Dr. B.P. Ravi, Professor at the Department of Mineral Processing, VSKU - PG Centre, India.

Preface xix
Foreword xxi
Acknowledgements xxiii
List of tables xxv
List of figures xxix
Part A Coal 1(120)
1 Introduction
3(2)
2 Clean coal technology
5(2)
3 Coal - its origin and formation
7(6)
3.1 Origin of coal
8(1)
3.2 Formation of coal
9(4)
3.2.1 Peat stage or biochemical stage
9(1)
3.2.2 Metamorphic or geochemical or dynamochemical stage
10(3)
4 Constituents of coal
13(10)
4.1 Coal substance
13(1)
4.2 Moisture
14(1)
4.3 Mineral matter
15(2)
4.4 Petrographic constituents of coal
17(6)
4.4.1 Lithotypes in banded coals
17(1)
4.4.2 Lithotypes in sapropelic coals
18(1)
4.4.3 Coal maceral groups
18(2)
4.4.4 Vitrinite reflectance as a measure of rank
20(1)
4.4.5 Micropetrographic characteristics of gondwana coals
21(2)
5 Sampling of coal
23(6)
5.1 Important terminology in sampling practice
24(1)
5.2 Sampling
24(1)
5.3 General principles of sampling
25(1)
5.4 Sampling methods to collect primary sample
26(1)
5.5 Sample preparation
27(2)
6 Size analysis of coal
29(16)
6.1 Sieve analysis
32(1)
6.2 Testing method
33(2)
6.3 Particle size analyzer
35(1)
6.4 Presentation of particle size distribution data
35(4)
6.5 Sub-sieve sizing
39(1)
6.6 Illustrative examples
40(3)
6.7 Problems for practice
43(2)
7 Proximate analysis of coal
45(12)
7.1 Moisture
46(1)
7.1.1 Determination of moisture
46(1)
7.2 Volatile matter
46(1)
7.2.1 Determination of volatile matter
47(1)
7.3 Ash
47(2)
7.3.1 Determination of ash
48(1)
7.4 Fixed carbon
49(1)
7.4.1 Determination of fixed carbon
49(1)
7.5 Pre-wetting of coal sample
49(1)
7.6 Reporting proximate analysis
50(1)
7.6.1 As received or as sampled
50(1)
7.6.2 Air-dried
50(1)
7.6.3 Dry or moisture free
50(1)
7.6.4 Dry, ash free (d.a.f.)
50(1)
7.6.5 Dry, mineral matter free (d.m.m.f.)
51(1)
7.7 Calculations
51(2)
7.7.1 As received or as sampled basis
51(1)
7.7.2 Air-dried basis
51(1)
7.7.3 Dry or moisture free basis
52(1)
7.7.4 Dry, ash free (d.a.f.) basis
52(1)
7.7.5 Dry, mineral matter free (d.m.m.f.) basis
52(1)
7.8 Instrumental methods for proximate analysis
53(1)
7.9 Illustrative examples
54(2)
7.10 Problems for practice
56(1)
8 Ultimate analysis of coal
57(4)
8.1 Determination of carbon and hydrogen
57(1)
8.2 Determination of nitrogen
58(1)
8.3 Determination of sulphur
58(1)
8.4 Determination of oxygen
59(1)
8.5 CHNS-O elemental analyser
59(1)
8.6 Usefulness of proximate and ultimate analyses
59(1)
8.7 Standard methods of analysis
60(1)
9 Calorific value of coal
61(8)
9.1 Illustrative examples
64(2)
9.2 Problems for practice
66(3)
10 Rank of a coal
69(2)
11 Important properties of coal
71(10)
11.1 Density
71(1)
11.2 Specific gravity
72(1)
11.3 Bulk density
72(1)
11.4 Porosity
73(1)
11.5 Reflectance
74(1)
11.6 Refractive index
75(1)
11.7 Hardness
76(1)
11.8 Abrasiveness
76(1)
11.9 Grindability
77(1)
11.10 Friability
78(1)
11.11 Weathering
79(1)
11.12 Oxidation of coal
79(2)
12 Classification of coal
81(6)
12.1 Peat
82(1)
12.2 Lignite (or) brown coal
83(1)
12.3 Sub-bituminous coal (or) black lignite
83(1)
12.4 Bituminous coal
84(1)
12.5 Semi-anthracite
85(1)
12.6 Anthracite
85(2)
13 Coking and non-coking coals
87(10)
13.1 Caking and coking coal
87(1)
13.2 Coking coal
88(7)
13.2.1 Crucible swelling number (CSN) or free swelling index (FSI) (IS 1353:2010)
89(1)
13.2.2 Agglutinating value or caking index (IS 1353:2010)
90(1)
13.2.3 Gray-king low temperature carbonization assay (IS 1353:2010)
90(2)
13.2.4 Roga index
92(1)
13.2.5 Plastic properties of coal
93(2)
13.3 Non-coking coal
95(2)
14 Classification of Indian coals
97(4)
15 Indian coals
101(20)
15.1 Gondwana coals
101(6)
15.1.1 Coal fields of Jharkhand and Bihar
101(2)
15.1.1.1 Jharia coal field
102(1)
15.1.1.2 Bokaro coal field
102(1)
15.1.1.3 Giridih coal field
102(1)
15.1.1.4 Ramgarh coal field
103(1)
15.1.1.5 Karanpura coal field
103(1)
15.1.1.6 North Koel valley coal fields
103(1)
15.1.1.7 Deogarh coal fields
103(1)
15.1.1.8 Rajmahal coal fields
103(1)
15.1.2 Coal fields of West Bengal
103(1)
15.1.3 Coal fields of Chhattisgarh and Madhya Pradesh
104(2)
15.1.3.1 Central Indian coal fields
104(1)
15.1.3.2 Satpura coal fields
105(1)
15.1.3.3 North Chhattisgarh coal fields
105(1)
15.1.3.4 South Chhattisgarh coal fields
106(1)
15.1.4 Coal fields of Maharashtra
106(1)
15.1.4.1 Kamptee coal field
106(1)
15.1.4.2 Bokhara coal field
106(1)
15.1.4.3 Umrer coal field
107(1)
15.1.4.4 Wardha valley coal field
107(1)
15.1.5 Coal fields of Andhra Pradesh
107(1)
15.1.6 Coal fields of Odisha
107(1)
15.1.7 Upper Gondwana coals
107(1)
15.2 Tertiary coals
107(1)
15.3 Lignite deposits
108(1)
15.4 Indian coal resources
109(9)
15.5 Coal producing organizations in India
118(1)
15.6 R & D institutes working in the area of coal preparation
119(2)
Part B Coal processing 121(270)
16 Coal processing
123(6)
16.1 Need for coal processing
124(2)
16.2 Objectives of coal processing
126(1)
16.3 Coal beneficiation methods
126(1)
16.4 Essential operations in coal processing plants
127(2)
17 Screening of coal
129(16)
17.1 Preliminary sizing
129(1)
17.2 Grading
130(1)
17.2.1 Size specifications in coal preparation practice
130(1)
17.3 Screening of coal
131(4)
17.3.1 Fixed Bar Grizzly
132(1)
17.3.2 Revolving Trommel
132(1)
17.3.3 Shaking or Jigging screens
132(1)
17.3.4 Vibrating screens
133(1)
17.3.5 DSM Sieve Bend
133(2)
17.4 Screen surfaces
135(2)
17.5 Factors affecting the rate of screening
137(1)
17.6 The choice of a screen
137(1)
17.7 Screen efficiency
137(3)
17.8 Illustrative examples
140(2)
17.9 Problems for practice
142(3)
18 Size reduction of coal
145(10)
18.1 Crushing of coal
146(1)
18.2 Various forces in crushing
146(1)
18.2.1 Impact force
146(1)
18.2.2 Attrition force
147(1)
18.2.3 Shear force
147(1)
18.2.4 Compression force
147(1)
18.3 Crushing machines
147(7)
18.3.1 Rotary breaker
148(1)
18.3.2 Toothed roll crusher
149(2)
18.3.3 Hammer mill
151(1)
18.3.4 Feeder breaker
152(1)
18.3.5 Sizer
153(1)
18.4 Grinding
154(1)
19 Pulp/Slurry density
155(6)
19.1 Illustrative examples
157(3)
19.2 Problems for practice
160(1)
20 Washability of coal
161(30)
20.1 Float and sink test
162(5)
20.1.1 Procedure for float and sink test
162(5)
20.2 Near gravity materials
167(2)
20.3 Yield reduction factor
169(1)
20.4 Washability index
170(1)
20.5 Optimum degree of washability (O.D.W.)
171(2)
20.6 Washability number
173(1)
20.7 Effect of sizing on washability characteristics of a coal
173(1)
20.8 Mayer curve
174(5)
20.8.1 Construction of M-curve
175(1)
20.8.2 M-curve for a three product system
175(1)
20.8.3 M-curve for blended cleaned and un-cleaned coal
176(1)
20.8.4 M-curve for blending clean coal from two plants
177(2)
20.9 Illustrative examples
179(9)
20.10 Problems for practice
188(3)
21 Coal beneficiation processes
191(2)
22 Principles of gravity concentration processes
193(18)
22.1 Motion of particles in a fluid
193(6)
22.1.1 Equal settling particles
195(1)
22.1.2 Settling ratio
196(3)
22.2 Heavy medium separation
199(2)
22.3 Jigging
201(3)
22.4 Flowing film concentration
204(2)
22.5 Concentration criterion
206(1)
22.6 Illustrative examples
207(2)
22.7 Problems for practice
209(2)
23 Heavy medium separation
211(18)
23.1 Principle
211(1)
23.2 Heavy medium
212(2)
23.3 Separating vessels
214(1)
23.4 Medium recovery system
215(1)
23.5 Chance cone process
216(3)
23.5.1 Separation of middlings
218(1)
23.6 Barvoys process
219(1)
23.7 Dutch state mines process
220(2)
23.8 Tromp process
222(1)
23.9 Drewboy process
223(2)
23.10 Wemco drum separation process
225(1)
23.11 Barrel washer
226(3)
24 Jigging
229(12)
24.1 Harz jig
232(1)
24.2 Jigs for coal beneficiation
233(12)
24.2.1 Baum jig
233(2)
24.2.2 Batac jig
235(1)
24.2.3 Feldspar jig
236(1)
24.2.4 ROM jig
237(4)
25 Flowing film concentration
241(4)
26 Cyclone separation
245(18)
26.1 Cyclone
245(6)
26.2 Heavy medium cyclone
251(6)
26.2.1 Medium recovery
255(2)
26.3 Water—only cyclone
257(6)
26.3.1 Design variables
259(4)
27 Froth flotation
263(24)
27.1 Contact angle
265(1)
27.2 Flotation reagents
266(3)
27.2.1 Frothers
267(1)
27.2.2 Collectors
268(1)
27.2.3 Depressants
269(1)
27.2.4 pH regulators
269(1)
27.3 Theories of flotation of coal
269(1)
27.4 Flotation machines
270(2)
27.5 Flotation operation
272(1)
27.6 Number of flotation cells required
273(1)
27.7 Factors affecting the flotation of coal
274(4)
27.7.1 Preparation of the pulp
274(1)
27.7.2 Particle size
274(1)
27.7.3 Oxidation and rank of coal
275(1)
27.7.4 Pulp density
275(1)
27.7.5 pH and water characteristics
275(1)
27.7.6 Flotation reagents
276(1)
27.7.7 Conditioning time
276(1)
27.7.8 Retention time and flow rate
277(1)
27.7.9 Pulp aeration
277(1)
27.7.10 Flotation Machine Operation
278(1)
27.8 Evaluation of flotation performance
278(1)
27.9 Flotation column
279(1)
27.10 Jameson cell
280(3)
27.11 Oleo flotation
283(1)
27.12 Oil agglomeration
284(1)
27.13 Illustrative examples
285(2)
28 Centrifugal separators
287(12)
28.1 Coarse coal separators
287(5)
28.1.1 Vorsyl separator
287(1)
28.1.2 LARCODEMS
288(2)
28.1.3 Dyna Whirlpool
290(1)
28.1.4 Tri-Flow separator
291(1)
28.2 Fine coal separators
292(7)
28.2.1 Falcon concentrator
293(1)
28.2.2 Kelsey jig
294(1)
28.2.3 Knelson concentrator
295(1)
28.2.4 Multi Gravity Separator
296(3)
29 Dry beneficiation of coal
299(12)
29.1 Air dense medium fluidized bed separator
301(1)
29.2 All-air jig
302(2)
29.3 FGX dry cleaning system
304(2)
29.4 Radiometric techniques
306(5)
30 Dewatering
311(14)
30.1 Dewatering of coarse coal
312(1)
30.2 Dewatering of small coal
312(2)
30.3 Dewatering of fine coal
314(11)
30.3.1 High frequency vibrating screen
314(1)
30.3.2 Classifying and thickening cyclones
315(1)
30.3.3 Thickener
316(1)
30.3.4 Vacuum filters
317(3)
30.3.5 Pressure filters
320(2)
30.3.6 Centrifuges
322(3)
31 Coal washing efficiency
325(24)
31.1 Dependent criteria
325(2)
31.1.1 Organic efficiency
326(1)
31.1.2 Anderson efficiency
326(1)
31.1.3 Ash error
326(1)
31.1.4 Yield error (or) yield loss
327(1)
31.2 Independent criteria
327(7)
31.2.1 Probable error (or) Ecart Probable Moyen (Er)
331(1)
31.2.2 Error area or tromp area
332(1)
31.2.3 Imperfection
332(2)
31.3 Plant efficiency measurement
334(2)
31.3.1 Control of medium density
335(1)
31.3.2 Control of product quality
335(1)
31.3.3 Quality of different size fractions
335(1)
31.3.4 Moisture content
336(1)
31.4 Methods to measure plant efficiency
336(5)
31.4.1 Mass meters
336(1)
31.4.2 Measurement of misplaced materials
337(1)
31.4.3 Efficiency testing
337(1)
31.4.4 Tracers
337(2)
31.4.5 Strain gauge measurement in chutes
339(1)
31.4.6 On-line ash and moisture monitors
339(1)
31.4.7 Automatic density control
340(1)
31.4.8 Control of d50
340(1)
31.4.9 Control of medium viscosity and contamination
341(1)
31.5 Illustrative examples
341(6)
31.6 Problems for practice
347(2)
32 Coal washing practice in India
349(24)
32.1 Coking coal washing
349(11)
32.1.1 Low volatile coking coals
358(2)
32.1.2 New private coking coal washeries
360(1)
32.2 Non-coking coal washing
360(13)
32.2.1 Technology used for washing Indian non-coking coals
363(2)
32.2.1.1 Wet beneficiation
363(1)
32.2.1.2 Dry beneficiation
364(1)
32.2.2 Non-coking coal washeries in India
365(3)
32.2.3 Present status of washing
368(3)
32.2.4 New non-coking coal washeries
371(2)
33 Global coal washing
373(8)
33.1 Wet washing processes
374(2)
33.1.1 Ascending current washers
374(1)
33.1.2 Launder washers
375(1)
33.1.3 Concentrating tables
376(1)
33.2 Dry cleaning processes
376(2)
33.2.1 Hand picking
376(1)
33.2.2 Mechanical pickers
376(1)
33.2.3 Pneumatic tables
377(1)
33.2.4 Pneumatic jigs
377(1)
33.2.5 X-Ray based sorting
377(1)
33.3 Coal washing in important countries
378(3)
34 Recent developments in coal processing
381(10)
34.1 Chemical comminution for coal cleaning
381(1)
34.2 Ultrasonic grinding
382(1)
34.3 Gravity separation
382(3)
34.4 Three product cyclone
385(1)
34.5 Flotation
385(2)
34.6 High gradient magnetic separation (HGMS)
387(1)
34.7 Electostatic separation
388(1)
34.8 Chemical beneficiation
389(2)
Part C Coal utilization 391(68)
35 Coal utilization
393(4)
35.1 Coking coal
393(1)
35.2 Semi coking coal
393(1)
35.3 Non linked washery (NLW) coal
394(1)
35.4 Non coking coal
394(1)
35.5 Beneficiated coal
394(1)
35.6 Middlings
394(1)
35.7 Rejects
394(1)
35.8 Coal fines
395(2)
36 Carbonization
397(22)
36.1 Coking mechanism
398(2)
36.2 Coke ovens
400(6)
36.2.1 Beehive coke oven
400(1)
36.2.2 By-product coke oven
401(3)
36.2.3 Non-recovery coke oven
404(1)
36.2.4 Coke production
405(1)
36.3 Role of coke in blast furnace
406(3)
36.3.1 Blast furnace process
406(3)
36.4 Selection of coal for metallurgical coke
409(4)
36.4.1 Reactivity to CO2
410(1)
36.4.2 Coke reactivity index (CRI) & coke strength after reaction (CSR) (IS 4023:2013)
411(1)
36.4.3 Shatter test (IS 1354:2010)
411(1)
36.4.4 Micum test (IS 1354:2010)
412(1)
36.4.5 Heaven test
412(1)
36.4.6 Porosity of coke
412(1)
36.5 Classification of coking coals
413(3)
36.5.1 Prime coking coals
413(1)
36.5.2 Medium coking coals
413(1)
36.5.3 Semi-coking coals
414(1)
36.5.4 Weakly coking coals
414(2)
36.6 Pulverized coal injection
416(3)
37 Combustion
419(22)
37.1 Use of coal for power generation
420(7)
37.1.1 Pulverized coal firing thermal power plant
422(3)
37.1.2 Power generation
425(1)
37.1.3 Selection of coal for boiler firing
426(1)
37.2 Use of coal for sponge iron production
427(5)
37.2.1 Sponge Iron production
431(1)
37.3 Use of coal for corex process
432(2)
37.4 Use of coal for cement production
434(7)
37.4.1 Cement production
439(1)
37.4.2 Selection of coal for cement manufacture
439(2)
38 Gasification
441(10)
38.1 Gasification of coal
441(3)
38.2 Types of gasifiers
444(2)
38.2.1 Fixed or moving bed gasifiers
444(1)
38.2.2 Fluidized bed gasifiers
445(1)
38.2.3 Entrained flow gasifiers
446(1)
38.3 Other fuel gases
446(1)
38.4 Selection of coal for gasification
447(1)
38.5 Integrated Gasification Combined Cycle (IGCC)
448(1)
38.6 Underground coal gasification
449(1)
38.7 Gasification industry
450(1)
39 Liquefaction
451(4)
39.1 Production of liquid fuels
452(1)
39.1.1 Bergius process
452(1)
39.1.2 Solvent extraction
452(1)
39.1.3 Refining carbonization products
453(1)
39.1.4 Coal gasification and fischer-tropsch process
453(1)
39.2 Practice of liquefaction of coal
453(2)
40 Carbon capture and storage
455(4)
40.1 Carbon dioxide capture
455(1)
40.2 Carbon dioxide transport
456(1)
40.3 Carbondioxide storage
457(2)
Annexure I Applications of computers 459(6)
Annexure II List of international and national standards used in coal and coke analysis and evaluation 465(8)
References 473(4)
Further readings 477(4)
Solutions to problems for practice 481(22)
Subject index 503
Dr. D.V. Subba Rao is retired associate professor and head of the department of Mineral Beneficiation at S. D. S. Autonomous College, (India). He has 32 years of experience at S. D. S. Autonomous College and presently serves as a guest faculty in the department of Mining Engineering at GIET, India. He has published multiple books on mineral beneficiation and has been member and chairman of academic bodies such as BOS in Mineral Beneficiation, BOS in Materials Handling and BOS in Applied Chemistry as well as the academic council and governing body of S. D. S. Autonomous College.



Dr. T. Gouricharan is senior principal scientist and head coal preparation division ath the CSIR (Central Institutde of Mining & Fuel Research), India. He has a Ph.D in Mineral Processing from VSK University, Bellary (India), and has 26 years of experience in the department of Coal Preparation at CSIR, and 4 years of experience as a professor and faculty member at the Academy council of Scientific Industrial Research. Dr. Gouricharan has published more than 80 papers in Indian and international journals and national and international conferences.
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