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Gekko IPJ Coal Separator Applications in Coal Preparation

Gekko IPJ Coal Separator Applications in Coal Preparation. Andrew Vince (Elsa Consulting Group) Laurie Gibson, Peter Purdon (ACIRL) Tim Hughes (Gekko Systems). Elsa Consulting Group ACIRL Gekko Systems ACARP. Narrative.

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Gekko IPJ Coal Separator Applications in Coal Preparation

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  1. Gekko IPJ Coal Separator Applications in Coal Preparation Andrew Vince (Elsa Consulting Group) Laurie Gibson, Peter Purdon (ACIRL) Tim Hughes (Gekko Systems) Elsa Consulting Group ACIRL Gekko Systems ACARP

  2. Narrative • Identified Australian circular jigging technology successfully processing • metalliferous ores. • Confirmed application in coal processing • For 6 (30) mm x 0.25 mm • Small modifications necessary for high floats recovery • Tested out at small lab scale (1 t/h) – good • Variables – developed DEM/CFD model • Tested on site at 10 t/h. Not found maximum capacity yet. • Circular – therefore capacity and efficiency both improve with radius. • Need to go bigger.

  3. Introduction • Trend to installation of “three circuit” plants. • This is due to: • Matching size range to process technology • Increased plant capacity • Move to standardised plant design. • Mid size fraction (eg 1.4 x 0.25mm) is currently • processed less efficiently than others. • Gekko IPJ Coal Separator is targeting the mid size fraction.

  4. Current Processes for Mid-sized Particles • Spirals • 1.5 mm top size, low unit capacity, feed rate • sensitive. • Teetered bed separators • Cut point varies with particle size. • Multiple units with split feeds – complicated circuit. • Reflux classifier • New technology currently being rolled out in some companies. • Consumes significant water volumes.

  5. Gekko IPJ Coal Separator • Gekko IPJ Coal Separator represents a competitor technology. • Unique application possibilities due to high top size capability. • Successfully deployed in metalliferous industry with more than 100 • applications world-wide. • This project considered application in coal industry.

  6. Staged Approach Laboratory scale testing. CFD/DEM modelling. Larger scale pilot testing on site.

  7. IPJ 600 Unit 1 tph Slurry Feed Air bleed Control box In Line Pressure Jig Product barometric leg 1 Hutch water Product barometric leg 2 Pulse actuator Reject barometric leg Hydraulic pump

  8. InLine Pressure Jig Fully Assembled InLine Pressure Jig Top Removed Slurry Feed Pressure Gauge In Line Pressure Jig Close-up of In Line Pressure Jig With Top Removed Wedge wire screen Feed distributor Ragging

  9. Bowen Basin Pilot Scale

  10. Hunter Valley Pilot Scale

  11. Laboratory Results Summary

  12. CFD/DEM Modelling • 10 adjustable parameters. • Too many to investigate experimentally. • Develop CFD/DEM model to identify initial starting points for site-based • pilot testing. • Volumetric feed rate • Feed pressure • Feed % solids • Stroke length • Stroke frequency • Stroke shape • Hutch water flow rate • Ragging diameter • Ragging density • Number of ragging layers

  13. Hunter Valley Test Work

  14. Issues Overcome • Upward water flows • Overcome with automation (commercially). • Provision of back pressure. • Migration of ragging.

  15. Provision of Back Pressure

  16. Blind Cyclones

  17. Blind Cyclones

  18. Ragging Mobility

  19. Site Tests

  20. Site Test Results

  21. Site Results Summary

  22. All Site Test Results

  23. All Site Test Results

  24. On-site and Lab Test Results

  25. Why you expect performance to improve with scale (diameter)? • Conventional jig: • Capacity related to width • Efficiency related to length. • Gekko IPJ Coal Separator • Circular section • Increasing radius increases • Capacity • Efficiency. • Larger radius leads to increased cleaning.

  26. Tentative correlations found

  27. Possible Circuitry DMC product 50 x 0 mm 50 x 6 mm DMC circuit Flotation product IPJ Product

  28. Possible Applications – High NG

  29. Conclusions • Gekko IPJ Coal Separator • Mature technology for metalliferous processing • Modified successfully for coal applications • Lab scale performance very good (600 mm, 1 t/h) • Site testing better (1000 mm, >10 t/h) • Strong evidence that can get even better (with size and further • optimisation) • Possible applications • Rougher/scavenger configuration • Treating 6 (30) x 0.25 mm particles • Very clean product requirements.

  30. Recommendation • Plant testing of rougher scavenger configuration

  31. Grateful Acknowledgements Australian Coal Association Research Program and Industrial Monitors. Providers of Hunter Valley and Bowen Basin coals for laboratory testing. Hunter Valley site management, technical and operations personnel. UNSW for CFD/DEM modelling. Organisers and officials of this conference. You. Elsa Consulting Group ACIRL Gekko Systems ACARP

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