THE DANIELS COMPANY USA USA A Member of
THE DANIELS COMPANY (USA) USA A Member of GT Global ADVANCED DESIGN & PROCESS TECHNOLOGY FOR INDIA COAL Robert Hollis Vice President The Daniels Company
OUTLINE USA Introduction – The Daniels Company & GT Global Capability of The Daniels Company Advantages of The Daniels over Its Competitors Benefit from Merging with Beijing Guohua Tech. Group Examples of previous CHPP projects Project Management for India CHPP
INTRODUCTION USA l Beijing GT Group (China) +550 Plants (2015) l The Daniels Company (USA) 180 Plants & Coal handling Facilities (2015) GT GLOBAL
DANIELS’ LONG HISTORY USA COMPETITIVE CHPP DESIGN l THE DANIELS COMPANY (Daniels) is a EPC (Engineering, Procure and Construction) Company with extensive turnkey experience in the design and construction of coal preparation plants, coal storage, reclaim and coal (train/truck) loading facilities. Its special expertise lies in the development of customized, cost effective and efficient processing flow sheets, followed by the translation of this flow sheet into a well designed coal preparation facility.
DANIELS’ LONG HISTORY USA COMPETITIVE EQUIPMENT MANUFACTURING l The Daniels Company’s manufacturing arm Daniels Fabrication, manufactures variety of coal processing equipment including Daniels dense media vessels, sieve bends, rotary breakers and automatic level control boxes. Daniels Fabrication also undertakes the fabrication of plate work including chutes, hoppers, sumps, and conveyor components including trusses (up to 60 m span), conveyor tubes, channel pans, bents (up to 75 m height), head, tail and take up frames. Many other major processing equipment can be manufactured by our sister company BGTG.
DANIELS’ LONG HISTORY USA THE DANIELS COMPANY’S LONG HISTORY l Engaged in coal preparation project since 1950 s l. The only company engaged in coal processing & material handling systems to still be in business over 60 years in USA.
DANIELS’ CAPABILITY USA CAPABILITY: l Engineering, Procurement and Construction of coal preparation plants and coal handling facilities l Upgrading existing CHPP to improve clean coal recovery efficiency, eliminate bottlenecks and/or coal processing capacity l Consulting services – Performance evaluation of coal preparation facility to optimize clean coal recovery efficiency l Supply full line of CHPP equipment
DANIELS’ ADVANTAGES USA DANIELS’ ADVANTAGES OVER ITS COMPETITORS l The Daniels Company’s long history has accumulated significant experience of CHPP design and construction l Over 180 coal preparation plants and coal handling facilities have been built by The Daniels Company in USA and overseas since it was founded. l Coal preparation plants were built with capacity up to 10 MTPA and coal handling facilities were built with capacity up to 30 MTPA. Long distance conveyor system were built with trusses up to 60 meter and bents up to 75 meter height
DANIELS’ ADVANTAGES USA DANIELS’ ADVANTAGES OVER ITS COMPETITORS l The Daniels Company always provides its clients with plant performance guarantees to design & supply the most efficient process circuit for each size fraction of raw coal to its clients. This generates maximum benefits to our clients at relative low cost. This has allowed The Daniels Company to survive from 1950 s until present time while its competitors have disappeared. l Historically, preparation plants designed and built by Daniels have met and exceeded on time, on budget and on performance required by the customers.
DANIELS’ ADVANTAGES USA DANIELS’ ADVANTAGES OVER ITS COMPETITORS l The Daniels Company is experienced in the following various process circuits, which have been incorporated in its plants over a period of several years, in United States, Canada, Colombia and India. -Coarse circuit (H. M. Vessel, H. M. cyclones, and Jig -Small coal circuit (H. M. cyclones, W. O. C & combination) -Fine coal circuit (2 -stage W. O. C, W. O. C/Spiral combo, spiral, H. M. C) -Ultrafine coal circuit (Conventional cells, column cells, Jameson cells, stack cells, floatair cells, jet-type flotation cells and etc. ) -3 -product HM cyclone technology from BGTG is most likely a good fit for processing India coals.
DANIELS’ ADVANTAGES USA DANIELS’ ADVANTAGES OVER ITS COMPETITORS l. The first Daniels H. M. Vessel was produced from The Daniels Company. Currently there are hundreds of Daniels H. M. Vessels operating in the whole world (China, Russia, Poland, India, Canada, USA, Indonesia, Mexico). The world largest H. M. Vessel, built by The Daniels, is currently operating in a Murray Energy plant in the USA. It has a feed capacity of 900 tph of coarse coal and 400 tph of reject material.
DANIELS’ ADVANTAGES USA DANIELS’ ADVANTAGES OVER ITS COMPETITORS l The Daniels Company is the only company in USA who is designing and constructing CHPP and also manufacturing part or most of CHPP equipment, such as HM vessels, HM cyclones, vibrating screens, sieves, centrifugal dryers, flotation cells and etc. l The Daniels Company’s staff always keeps up with the latest developments in coal processing and coal handling technologies.
Merging with BGTG USA l Beijing GT Group (China) +550 Plants l The Daniels Company (USA) +180 Plants & Coal handling facilities GT GLOBAL
DANIELS’ ADVANTAGES USA DANIELS’ ADVANTAGES OVER ITS COMPETITORS l After merging with Beijing Guohua Technology Group, The Daniels Company can now access manpower & equipment from combined resources. This enables The Daniels Company to offer competitive cost CHPP to its clients with high quality and efficient operations that can be managed by The Daniels Company. l Utilizing the well recognized 3 -product H. M. cyclone technology enables The Daniels Company to offer its clients with optional technology to further improve clean coal recovery. Currently about 1/3 of China washed coal is going through +550 coal plants built by BGTG. l The 3 -product HM cyclone is particularly suited to process Indian coals, which usually require high separation density (>1. 8 kg/L). The 3 -product cyclone can provide in one circuit and one-step the ability to produce both coking coal and thermal coal.
• • Coarse circuit: 100% H. M. process, no spiral & no RC High-efficiency to maximize valuable clean coal yield 3 -product HM cyclone will produce 3 product at once High efficient flotation at many-years maintenance free Raw coal 3 -product H. M. cyclone Rejects Clean coal Middlings Clean coal sieve bend Middlings sieve bend Circulating water Flow spilter Reject H. M. draining screen Middlings H. M. draining & classifying screen Fine coal H. M. cyclone Centrifuge Reject magnetic separator Clean coal H. M. drain, rinse & classifying screen Middling magnetic separator Clean coal magnetic separator Centrifuge Reject Flow spilter Raw coal H. M. tank/pump Clean coal Middlings Fine coal H. M. tank/pump Clean fine sieve bend Sieve bend Flotation cells (1 st stage) Screen-bowl centrifuge Flotation feed tank Flocculant Ca 2+/Mg 2+ionic agglomerate 2 nd stage thickener Flotation concentrate 1 st stage thickener To middlings H. M. Draining & classifying screen Screen-bowl centrifuge Filtrate Filter press Flotation cells 2 nd stage flotation feed tank Filter press feed tank Clean coal Wash water Filter cake Mixed into middlings
DANIELS’ ADVANTAGES USA • • • Enable client to set up high density cut points up to 2. 3 s. g. Accurately separate coal particles down to 0. 25 mm Very simple design without using any other separators Raw coal 3 -product H. M. cyclone Rejects Clean coal sieve bend Flow spilte r Reject D&R screen Clean coal H. M. D & R & classifying screen Clean coal magnetic separator Reject magnetic separator Circulating water Centrifuge clean fine sieve bend Raw coal H. M. tank 1 st stage thickene r Clean coal Fine coal H. M. tank Clean coal
ADVANTAGES OF NEW HM PROCESS OVER TRADITIONAL PROCESS USA FOR INDIAN COKING COAL 1. The new HM process with non-desliming significantly simplifies HM process using less equipment (without desliming screens, hydrocyclone, spirals, TBS and etc. ) and smaller plant space required, which results in lower capital investment 2. Gravity-fed reduces secondary coal fines generation considerably 3. Lower operating cost due to simple process, less equipment & much higher separation efficiency than traditional processes 4. Using low single density HM suspension to achieve stable high separation density 5. Higher clean coal yield due to higher separation efficiency compared to traditional HM process especially for high ash and difficultywashing coal requiring high separation density
ADVANTAGES OF NEW HM PROCESS OVER TRADITIONAL PROCESS USA FOR INDIAN THERMAL COAL 1. The new HM process with non-desliming also significantly simplifies HM process using less equipment 2. Gravity-fed reduces secondary coal fines generation considerably 3. Lower capital & operating cost due to simple process, less equipment & higher separation efficiency 4. Using low single density HM suspension to achieve stable high separation density easily as high as 2. 3 to produce high ash reject (pure rock).
ADVANTAGES OF NEW HM PROCESS OVER TRADITIONAL PROCESS USA 2. Gravity-fed reduces secondary coal fines generation considerably Industrial plant tests indicate: The secondary slime generated during washing process with gravity-fed H. M. cyclone is 5~7 percentage points (in total feed) less than that produced during process with pressurized feeding cyclone. This is very important and beneficial to the design of thermal coal plant. Test at Linhuan Plant: Difference of Amount of -0. 5 mm Fines between Gravity-fed & Pump-fed Pump feed ※ Gravity feed Slurry Volume (m 3/h) 700 Solid Content (g/L) 135 102 Amt of -0. 5 mm (t/h) 94. 5 71. 4 Each cyclone feed rate: 302 t/h Difference 32. 4%
ADVANTAGES OF NEW HM PROCESS OVER TRADITIONAL PROCESS USA 3. Lower operating cost due to simpler process, less equipment, & much higher separation efficiency (higher centrifugal force and lower separation size limit) than traditional processes • Higher centrifugal force: HM suspension feed pressure is double the traditional HM process (17 times of cyclone diameter instead of 8 times) • Lower separation size limit: effectively separate coal particle size down to 0. 25 mm in the 3 -product cyclone and down to 0. 1 mm in fine coal HM cyclone Coal Size Fraction Epm Value Throughput Capacity > 0. 5 mm (I) 0. 02 -0. 025 (II) 0. 025 -0. 045 Up to 1300 t/h, 0. 5~0. 25 mm 0. 099 kg/L Up to 1300 t/h, 0. 1~0. 074 mm 0. 08 kg/L No ultrafine magnetite needed
ADVANTAGES OF NEW HM PROCESS OVER TRADITIONAL PROCESS USA 3. Lower operating cost due to simpler process, less equipment, & much higher separation efficiency (higher centrifugal force and lower separation size limit) than traditional processes r o F king Co al Co The Performance (Ep Values) of Spiral, TBS & HM Cyclone VS. Coal Size Reference: “Performance of the Teetered Bed Separator at the Murray Energy Century Preparation Plant”- Paper published in Coalprep 2009 Kentucky
ADVANTAGES OF NEW HM PROCESS OVER TRADITIONAL PROCESS USA 4. Using low single density HM suspension to achieve stable high separation density Vortex finder Apex
Characteristics of Indian Coal USA THERMAL COALS: Such as Mahanadi, Kusmunda, Adani, Piparwar & ETC
Characteristics of Indian Coal USA THERMAL COALS: Such as Mahanadi, Kusmunda, Adani, Piparwar & ETC
Characteristics of Indian Coal USA COKING COALS: DOHRI, DUGDA, DAHIBARI & ETC
EXAMPLES USA EXAMPLES OF PREVIOUS PROJECTS
PLANTS BUILT BY DANIELS USA Caretta Mineral Coal Preparation Plant (2015)
PLANTS BUILT BY DANIELS USA Caretta Mineral Coal Preparation Plant (2015)
PLANTS BUILT BY DANIELS USA
PLANTS BUILT BY DANIELS USA
PLANTS BUILT BY DANIELS USA
COAL HANDLING BUILT BY DANIELS USA
PLANTS BUILT BY BGTG USA 12 MTPA Huainan Coal Preparation Plant by BGTG
PLANTS BUILT BY BGTG Shenhua Bayanner CHPP Project in Inner Mongolia China by BGTG
PROJECT DESIGN FOR INDIA CHPP USA 1. Properly selected & state of the art process technology will be used in the India projects to ensure maximizing clean coal recovery. Completely closed-circuit operation will be selected to recover all fines and tailings, which will result in: l No tailings ponds l Without any effluent discharged from plant to protect the environment
USA PROJECT MANAGEMENT FOR INDIA CHPP 2. Performance guarantee for the India CHPP designed and built by The Daniels Company.
USA PROJECT MANAGEMENT FOR INDIA CHPP 3. Provide world-class reliable coal preparation equipment for the ETT CHPP project: • HM Washers from the world famous largest HM vessel supplier The Daniels Company USA • H. M. Cyclones from the famous largest 3 -product HM cyclone provider BGTG or acceptable outside suppliers • Vibrating screens & vibrating centrifuges from the famous UK-based DVE or acceptable outside manufacturers • Screen bowl centrifuges from the Decanter, Andritz or acceptable outside suppliers
USA PROJECT MANAGEMENT FOR INDIA CHPP 4. Provide the best & most reliable after-sales service On-site warehouse of spare parts Periodical performance evaluation On-site technical service & consulting
USA PROJECT MANAGEMENT FOR INDIA CHPP 5. Can provide CHPP plant operation and/or CHPP plant management. On-site training will be provided when required.
USA PROJECT MANAGEMENT FOR INDIA CHPP 6. The Daniels Company will provide General EPC contract services. CHPP plant construction and on-site construction management & installation will be subcontracted to our recognized reliable local Indian partner.
WHAT GT GLOBAL CAN OFFER USA
THE DANIELS COMPANY (USA) A Member of GT Global USA
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