Innovative Design of Fine Coal Cleaning Circuits for Improved Sulfur Rejection

Modern processing plants incorporate a complex array of solid-solid and solid-liquid separation processes that remove unwanted impurities from run-of-mine coals. The most popular processes used for coal cleaning include dense medium separation, gravity concentration and froth flotation. Unfortunately, the processes traditionally used to upgrade the finest fractions of coal are generally inferior in terms of separation performance. In particular, these circuits often perform very poorly in reducing sulfur levels in the fine coal products.

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Using Dust Management to Improve Safety and Reduce Maintenance on Conveyors

Orlando Utilities Commission-Stanton Energy Center (SEC) is one of Central Florida’s leading environmental stewards, meeting or exceeding all air permit limits with advanced pollution control equipment while generating electricity to serve more than 342,000 residents.

The company follows a similar philosophy with respect to its working environment, cleaning the entire coal yard and all handling equipment every day. “Typically each day after we finish filling or bunkering the silos, the whole system is cleaned,” said Stuart Cason, material handling supervisor, SEC. “That includes the yard, all the conveyors, chutes, floors, impact zones and rollers.  In some places, it’s a wet wash-down, while in others we sweep. It’s seven days a week, every week of the year.”

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Addressing Safety with Automation

The average American uses approximately 3.4 tons of coal and nearly 40,000 lb of newly mined materials each year, according to the National Mining Association. Industry leaders generally agree that the demand for raw materials, such as coal, will continue to increase worldwide as developing countries industrialize and populations grow. To satisfy current and future demand for coal and other minerals, mining companies have to search for new, innovative ways to attain this valuable source of energy. This often means exploring and operating in difficult terrain in more remote locations. Inevitably, this shift means new challenges for safety and efficiency.

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Conveyor Component Upgrades Boost Uptime & Safety

Whether it’s coal mining or power plant applications, material handling systems are integral to overall efficiency. Rather than merely moving material from point A to point B, today’s optimum conveyor performance must meet a myriad of standards—from ensuring specified flow rates, to achieving operational goals of minimizing vibration, noise, and belt wear and tear—while maximizing plant capacities and uptime.

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Genset Powers Rope Shovels During Pit-to-pit Moves

Teck Coal operates some of the largest coal mines in North America and uses a mining or shovel motivator for mobile power. The existing 30-year-old motivator was underpowered and frequently in need of maintenance. Downtime costs were significant. To solve the problem, a local power products supplier designed an innovative replacement specific to the mine’s needs that relies on a state-of-the-art generator set from MTU Onsite Energy.

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