REVIEW OF PROVEN COAL PREPARATION TECHNOLOGIES TREATING INDIAN

REVIEW OF PROVEN COAL PREPARATION TECHNOLOGIES TREATING INDIAN COAL 6 TH COAL SUMMIT 2016 NEW DELHI 6 TH & 7 TH SEPT 2016 GURUDAS MUSTAFI, CEO & DIRECTOR MBE Coal & Mineral Technology India Pvt. Ltd Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 1

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. OUTLINE Ø Indian Coal Reserves Ø Importance of Coal for Indian Economy Ø Key Drivers for Coal Washing in India Ø Proven Coal Preparation Technologies Treating India Coal üLump Coal Washing üCoarse Coal Washing ü Medium Coal Washing Ø Upcoming Technologies and Challenges Ø Conclusion Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 2

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Category Wise Coal Resource in India Tertiary Coal 0% Category wise Total Coal Reserves Coking Coal 11% Non-coking Coal 88% (as on 01. 04. 2014) § Prime Coking Coal 5313 Million Tonnes § Medium Coking Coal 27049 Million Tonnes § Semi Coking Coal 1708 Million Tonnes § Non-Coking Coal 266002 Million Tonnes § Tertiary Coal 1493 Million Tonnes (Source: Coal Reserves, Ministry of Coal, Government of India) Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 3

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Importance of Coal for Indian Economy Prime source of energy for the Indian economy. 61% of the total electricity produced comes from coal & Power sector consumes about 72% of the coal produced. Coal is the cheapest source of power for electricity generation Largest domestic resource base in case of fuel sources Ensures a long term supply Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 4

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Key Drivers for Coal Preparation in India 1. Depletion of good quality coal reserves Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 5

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Key Drivers for Coal Preparation in India 2. Increased surface mining and mechanization • More than 90% of the total coal being mined is from open cast mines • Heavy mechanization has been undertaken in order to increase production from the mines • Selectivity of coal being mined reduced thus causing an increase in the ash of the ROM 3. Greater need for maintaining the environment quality • MOEF legislation prohibits generation of power with the use of coal containing >34% ash that have to be transported >500 km • Strive to increase the clean electricity production Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 6

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Key Drivers for Coal Preparation in India 4. Increasing power demand • Coal requirement for power generation has increased many folds with the rising demand for power. • Location of the power plants being far away from the Non-coking coal resources • Non-coking coals, containing high mineral-matter content (35 -50 wt%), are presently being utilized for power generation mostly without any washing. • As coal quality further decreases and demand for power further increases, washing initiatives are set to see tremendous growth in the coming future Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 7

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Key Drivers for Coal Preparation in India 5. Limited Washing Capacity Available • • Currently washed thermal coal supply is around 83 Million Tonnes to power plants. Additional 46 million tonnes washed coal supply with ash<34% is required to cater to the needs of existing power plants. 10 new washeries are underconstruction with a total capacity of 73. 5 MTPA. 6 new coal Washeries are in pipeline with a total capacity of 18. 6 MTPA. 6. Economic Strategy to lower Energy sector Trade deficit • • • With abundant coal resources, increasing coal production for electricity generation will allow export of electricity to neibhouring countries. GOI saved Rs. 22000 Crores in form of FOREX by replacing imported coal with increased domestic coal production for power. In next 2 -3 years, these savings are expected to touch Rs. 40000 crores, as per GOI projections No import of non-coking coal for power generation by NTPC and coal movement rationalization to push domestic coal production. Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 8

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Coal washing in India Coal Washing Lump coal washing (-)400 mm Coarse/Mediu m coal washing (-)150 mm Fine coal washing (-)2 mm Water Based Media Based Water based Media Based Density Difference based Surface Property based Moving Pan Jig Heavy Media Bath Under Pulsated Jig Heavy Media Cyclone Spiral/WOC Flotation Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 9

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Lump coal washing in India Lower power requirement for size reduction Reduction in capacity & size of subsequent equipment Lesser ash content in the coal for further processing Less wear in the subsequent concentration equipment Increased efficiency and better capacity utilization of the preparation plant Washing of -400 mm Raw coal lumps Equipment used are Moving Pan jigs/ Heavy Media Bath. Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 10

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Moving Pan Jig Fig: ROMJIG® (for separation of 30 -400 mm) Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 11

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Result of ROMJIG® Plant BINA General Results: Raw Coal Screen analysis: Products of the plant: Grain size Wt. % Ash % Product Wt. % Ash % 250 - 30 mm 68. 78 42. 13 Deshaled coal 49. 76 31. 34 30 - 0 mm 31. 22 38. 08 Unwashed coal 31. 22 38. 08 250 - 0 mm 100. 0 40. 87 Saleable product 80. 98 33. 94 Reject 19. 02 70. 37 KARGALI PG Test results conducted over a span of 15 days Raw Coal Screen analysis: Grain size Wt. % 350 - 50 mm 45. 3 50 - 0 mm 54. 7 350 - 0 mm 100. 0 Reject Products of the plant: Ash % Product Wt. % Ash % 40. 75 Deshaled coal 34. 26 30. 7 32. 56 Unwashed coal 54. 7 32. 56 36. 27 Saleable product 88. 96 31. 84 11. 04 71. 96 At a cut density of 1. 9, the average imperfection determined was 0. 089 Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 12

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Flow Sheet: ROMJIG ® Process for ROM Coal Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 13

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Heavy Media Bath Fig: TESKA® Heavy Media Bath (for separation of 10 -200/250 mm) GURUDAS MUSTAFI Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 14

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Fig: Drewboy Bath Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 15

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Result of Heavy Media Bath Plant The ash in raw coal received varies between 34 to 38%. HEAVY MEDIA BATH The results from a plant installed at Wani supplying washed coal to MSEB are: Raw Coal Screen analysis: Products of that plant: Grain size Wt. % Ash % Product Wt. % Ash % 50 - 13 mm 68. 00 37. 80 Washed coal 41. 00 24. 10 13 - 0 mm 32. 00 40. 00 Unwashed coal 32. 00 40. 00 50 - 0 mm 100. 00 38. 50 saleable product 73. 00 31. 07 Operating Cut Density : 1. 45 Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 16

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Flow Sheet: Heavy Media Bath for ROM Coal Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 17

Lump Washing – Advantages & Limitations ü Advantages § Limitations Ø low water and power consumption Ø low expenditure for necessary auxiliary equipment Ø economical compared with other proven technologies of large refuse separation Ø ideal in case of a pit head installation. § when the characteristics of raw coal requires the grain size of beneficiation to be reduced. § reasons can be the grain size distribution § amount of material < 30 mm is more § ash content of the fine material is too high. Copyright © 2010. MBE Coal & Mineral Technology India Pvt. Ltd. Saturday, September 18

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Coarse Coal Washing in India For upgradation of coal particles in the range of -150 mm to 25 mm Helps in meeting the quality parameter of the end user, If lump coal washing does not produces desired product quality. . Crushing of lumps to achieve better liberation, subsequently better yield with more recovery More surface mining produces -100 mm coal, upgraded using coarse coal washing technologies Equipment used are Under Pulsated Jigs, Heavy Media Cyclones Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 19

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Working Principle Under Pulsated Jig Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. Heavy Media Cyclone GURUDAS MUSTAFI 9/26/2020 20

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Coarse Coal BATAC® JIG • Treats -150 mm coarse coal with high efficiency Coarse Coal Jig and its discharge system Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 21

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Salient Features of BATAC® Jig • Water-only process hence operating cost is relatively low. • High throughput capacity, 100 -120 tph/m jig width for coarse coal and 70 -85 tph/m jig width for Medium sized coal. • Compact design and up to 8 m in width, low foot print. • It can handle feed variations up to 20%, as well as variations in the percentage of water in the feed material. • Can be stopped and restarted instantly. No need to drain the jig after a stop, and restarting takes a few seconds with the same operating parameters as before the stoppage Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 22

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Results of BATAC® Jig Plant BATAC® JIG The results from a plant installed at Piparwar washery are: Raw Coal Screen analysis: Products of that plant: Grain size Wt. % Ash % Product Wt. % Ash % 75 - 13 mm 73. 55 39. 3 Deshaled 61. 35 32. 7 13 – 0 mm 26. 45 35. 2 Unwashed 26. 45 35. 2 Saleable coal 87. 80 33. 45 75 -0 mm 100. 0 37. 97 Reject 12. 2 70. 5 The results from a plant installed at CESC, Sarasthali are: Raw Coal Screen analysis: Products of that plant: Grain size 75 - 6 mm 6 – 0 mm 75 -0 mm Wt. % Ash % 84. 22 45. 86 15. 78 39. 1 100. 0 44. 79 Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. Product Saleable coal Wt. % Ash % 60. 83 32. 15 Reject GURUDAS MUSTAFI 39. 17 64. 42 9/26/2020 23

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Flow Sheet: BATAC® Jig Washery for Coarse Coal Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 24

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Heavy Media Cyclone for Coarse Coal HMS - Cyclones for separation of coal 0 - 100 mm Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 25

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Salient Features of Heavy Media Cyclone • For increasing throughput, the cyclones up to 1400 mm dia have been developed • Efficient separation at specific cut density • Better recovery • Suitable to wash coal with NGM high in the range of 30%. Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 26

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Result of Heavy Media Cyclone Plant Heavy Media Cyclone The results from a plant installed at Jharsuguda are: Raw Coal Screen analysis: Products of that plant: Grain size Wt. % Ash % Product Wt. % Ash % 20 - 0 mm 100. 0 52. 32 Raw coal 100. 0 52. 32 Clean coal 46. 83 34. 4 20 - 0 mm 100. 0 52. 32 Reject 53. 17 68. 10 Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 27

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Flowsheet for Heavy Media Cyclone for Coarse Coal Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 28

Coarse Coal Washing – Advantages & Limitations ü Advantages § Limitations Ø low water and power consumption compared to fine coal washing Ø less pick up moisture Ø bottom washing size can be reduced even to 3 mm & fed to same Batac Jig by using right dry screening system. Ø Equally good operating results achieved with H M process without reducing the lower size q material close to border between coal seam and shale band which contains up to 50% of saleable coal § when characteristics of raw coal requires grain size of beneficiation to be reduced § reasons can be grain size distribution § amount of material < 13/6 mm is more § ash content of fine material is too high Copyright © 2010. MBE Coal & Mineral Technology India Pvt. Ltd. Saturday, September 29

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Medium Coal Washing in India For upgradation of coal particles in the range of -25 mm to +0. 5 mm Helps in meeting the quality parameter of the end user, If coarse coal washing does not produce desired product quality Crushing of coarse coal to achieve further degree of liberation, subsequently better yield with more recovery If medium sized coal in feed has high ash content, mixing with clean is not preferred, further upgradation is done with such technologies Limited coking coal reserves and high prices of coking coal requires most efficient utilization with highest recovery Equipment used are Under Pulsated Jigs, Heavy Media Cyclones Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 30

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Medium Coal BATAC® JIG • Treats -25 mm to +0. 5 mm Coal • High throughput capacity: 70 -85 TPH/m jig width for Medium sized coal • Upto 8 m width per BATAC® Jig unit • Modified discharge system for better discharge of coal product Fine Coal Jig and its discharge system Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 31

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Flow Sheet: BATAC® Jig Washery for Medium Coal Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFi 9/26/2020 32

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Heavy Media Cyclone for Medium Coal • However a single unit of Heavy media cyclone is capable of handling particles from -100 to +0. 5 mm, studies have shown that plant/equipment performance goes up if the beneficiation is done in two different HM cyclones i. e. -100+25 mm particles in one unit and -25+0. 5 mm in another unit. • More classification for upgradation of medium sized coal results in higher recovery and better quality products from the system. • Higher degree of liberation at finer size fraction results in better recovery of quality coal product. • Feed coal characteristics and end product quality requirements are vital parameters in selection & designing of the cyclone. Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 33

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Flowsheet for Heavy Media Cyclone for Medium Coal Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 34

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Selection Criteria of Washing Process Yes Cut point > 1. 9 g/cm³ Yes Feed is lignite Yes Gangue is clay NGM <10% Feed is coking coal NGM upto 25% NGM <20% Feed is steam coal NGM upto 30% Tendency Criteria for decision between. . . Prefered Unstable power supply No effect Source of magnetite is far Yes Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. Difficult Ease of Operation Feed quality & quantity fluctuation GURUDAS MUSTAFI 9/26/2020 35

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Upcoming Technologies & Challenges • Dry beneficiation techniques are also being considered for coal beneficiation. • Many R&D and pilot scale test works are being carried out by different major coal testing facilities across the country with dry jigs, Fluidized bed separators, Ardee. Sort etc. • Dry separation technologies present benefits of no water requirements and no additional moisture in product. • Yet to prove their acceptability for high near gravity Material (NGM) quality Indian coal. • High moisture content of the raw coal feed during the months of monsoon season would be another challenge for such upcoming technologies. Mining water at pit heads is also a challenge for MDO to provide dry coal feed. • Feasibility of these technologies including three product cyclones, once proved, will make a big impact in Indian Coal washing industry and would be very helpful for the economic growth of the coal sector. Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 36

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. Conclusions • The described processes with closed washery circuits for the various applications have proven acceptance in the coal beneficiation industry. • Beneficiating the raw coal before being used to produce power, cement, sponge iron etc. is environment friendly and saves the precious energy resource. • The existing end users of washed coal are experiencing better and consistent coal quality being fed to their plants. • In line with the target of producing 1 billion tonnes coal by CIL and another 500 million coal by private sector by the year 2020, there will be a strong need to bridge the gap of available and required washing capacity for utilizing the produce meeting Mo. EF guidelines. Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 37

MBE Coal & Mineral Technology India Private Limited Formerly Mc. Nally HUMBOLDT WEDAG Minerals India Pvt. Ltd. k n a Th You Copyright © 2016. MBE Coal & Mineral Technology India Pvt. Ltd. GURUDAS MUSTAFI 9/26/2020 38