Dry Coal Preparation of Fine Particles by KAT Process

Jambal Davaasuren a, Byoung-Gon Kim b, Ju-Hyoung Lee c, Gendeekhuu Davaatseren d, Magsar

Bazarragchaa d,
a
b

c
d

Korea University of Science and Technology (UST), 217 Gajungro, Yuseong-gu, Daejeon 305-350, Korea
Korea Institute of Geoscience & Mineral Resources (KIGAM), 92 Gwahang-no, Yuseong-gu, Daejeon 305-350,Korea
Hanbit Korea Standard Engineering Co.,Ltd, 39, Jungsansaneop-ro, Buk-gu,Ulsan,Korea
Mongolyn Alt Corporation (MAK),44 Chinggis Avenue, Khan Uul district, 1 khoroo, Ulaanbaatar, Mongolia

Abstract
In this study, effectiveness of KAT Process, dry coal preparation process developed by KIGAM
(Korea Institute of Geoscience and Mineral Resources), was assessed for bituminous coal from MAKNaryn Sukhait (NS) coal mine, Mongolia. 1-25 mm raw coal delivered from Mongolia was screened and
classified with 1-5 mm, 5-10 mm, 10-20 mm, and over 20 mm particle size range. Separation tests were
conducted for 1-5 mm and 5-10 mm size fractions using two types of pilot scale KAT Process units,
suitable for each size range. Prepared test samples were concluded as well liberated samples having less
than 3 % of weight material between specific gravity range of 1.6 to 2.0 g/cm. Test results conducted
under optimum conditions observed at previous investigations. Overall, the average ash rejection and
combustible recovery for 1-5 mm fraction was 81% and 77% respectively and the feed ash content was
decreased from 35% to 12% in product and the average product yield was 56.3%. The 5-10 mm size
fraction average ash content was 48.4%. After the dry separation, about 41% of the feed was recovered as
product with average 9.4% ash content. Ash rejection and combustible recovery was 91.7% and 76.8%
respectively. Conducted tests showed that KAT process can effectively remove large amount of dense
impurities from low grade coal thus producing an acceptable ash content clean coal product.
Keywords : Low grade coal, Dry coal beneficiation, Air table, Autogenous medium

1. Introduction
Coal is the one of the main fossil fuel for energy and most of worldwide energy consumptions
still depend on coal. Coal needs to be cleaned from its gangue minerals in order to increase its quality and
to meet the industrial standards through many kinds of coal beneficiation techniques. Today the dominant
coal beneficiation technologies mostly rely on wet methods which requires huge amount of process water
and inescapable high operation cost during processing procedures. Waterless coal beneficiation
technologies have some notable advantages compared to wet technologies. The dry beneficiation methods
are based on the differences in physical properties between coal and mineral matters such as density, size,
shape, lustrousness, magnetic susceptibilities, electrical conductivity, frictional coefficients. [4]. The dry
coal-cleaning separators can be broadly classified into three groups: air tables, air jigs, and dry dense
medium separators [5]. Optical sorting, magnetic and electrostatic separators also considered as part of
the dry processes. Dry preparation of coal can be economical by reducing capital and operational costs. It
will not utilize water and no dewatering of the product will be required. Although having above economic
and environmental advantages, dry separation processes still quite inefficient in separation accuracy for

finer size material comparing to modern wet processing technologies with more sharper separation
performances. This study investigates the air table separation performance of fine particle (1-10mm), low
grade coal with large amount of dense impurity. KAT (Korean Advanced Technology) table is a type of
pneumatic table separator. It separates the components in the ROM coal according their specific density
differences. The denser material settle down to form a lower layer and moves to the oscillating direction
of the table deck by the action of eccentric motion. The upper layer of light particles roll down by the
means of airflow and table shaking to the lower part of the deck and accumulates along the blocking wall,
and when the level of accumulated light particles exceed the height of blocking wall it will start overflow.
This specific design of KAT table generates an autogenetic medium of light particles along the lower end
of the deck thus increases a product quality. KAT table is separating ROM coal into 3 different fractions.
The light fraction-coal, the heavy fraction-reject and the middling.

a)
b)
Fig.1 a) Illustration of dry separator unit. b) Material separation trajectory on the table deck.

2. Material preparation
A low grade 1-25 mm ROM coal sample was collected from Naryn Sukhait coal mine of
Mongolyn Alt Corporation, Mongolia. Delivered sample was screened to obtain +20mm, 10-20 mm, 5-10
mm and 1-5 mm size fractions. 5-10 mm and 1-5 mm size fractions were used for dry beneficiation tests.
Float and Sink tests were carried out on every size fractions using prepared dense solutions of
Tetrabromoethane and Tetrachlorethylene with density ranges between 1.3g/cm3 o 2.0g/cm3 at 0.1g/cm3
intervals. Each relative density float and sink materials were measured for proximate analysis and
calorific values using Leco TGA701 Thermogravimetric analyzer and Leco AC600 Calorimeter.
Table.1. Analysis of the 1-5 mm size fraction test samples.
1-5 mm size fraction
Weight (%) of
Cumulative
Cumulative
Test2.0 g/cm dense Calorific Value
Ash content
1
material
(Kcal/kg)
(%)
1
2
3

35.4
32.8
33.3

4746
4996
4989

37.5
34.7
34.7

Table.2. Analysis of the 5-10 mm size fraction test samples.

5-10 mm size fraction

Test

Weight (%) of 2.0

g/cm dense material.

Cumulative
Calorific Value
(Kcal/kg)

Cumulative
Ash content
(%)

51.8
3485
51.1
1
50.3
3705
49.3
2
48.5
3792
48.2
3
4
47.4
3961
46.4
5
47.5
3928
46.9
The KAT air table experiments were aiming to remove over 2.0 g/cm specific density fractions from
feed coal thus decreasing ash content of product. From Table.1 and 2, it can be seen that both size fraction
feed has large amount of dense noncombustible particles, over 33% in 1-5 mm and 47-51% in 5-10 mm
size fractions.

3. Experimental
All tests were conducted in a dry coal preparation pilot plant installed at Hanbit KSE, Ulsan,
Korea. Tests were purposed to investigate KAT tables effective feeding rate with optimum ash rejection
value. For each test about 1 ton of prepared and weighted raw coal fed onto the table deck through belt
conveyor from feed hopper. After feed coal poured on the deck, coal dust and ultra fine particles were
blown upward by airflow and enters to the dust hood placed above the deck. These dust and fine material
further delivered to cyclone separator. KAT-1 table operating parameters, other than feeding rate, were
fixed based on previous test observations. Feeding rate was increased from 3.7 t/h to 5t/h for 1-5 mm and
from 5t/h to 31 t/h for 5-10 mm.
Table.3. KAT-1 and KAT-2 table operating parameters
KAT-1, Naryn Sukhait, 1-5 mm
Test
Test-1 Test-2 Test-3
Unit
Feeding rate
3.7
4
5
Ton/hour
Airflow frequency
60
60
60
Hz (0-60)
Table frequency
40
40
40
Hz (0-60)
Cross table slop
5.5
5.5
5.5
Degree
Longitudinal slope
5
5
5
Degree
KAT-2, Naryn Sukhait 5-10 mm

Test
Feeding rate
Air frequency
Table frequency
Cross angle
Longitudinal angle

Test-1
5
Full
53
7
5.5

Test-2
6.5
Full
53
7
5.5

Test-3
10
Full
53
7
5.5

Test-4
20
Full
53
7
5.5

Test-5
31
Full
53
7
5.5

Unit
Ton/hour
Full open
Hz (0-60)
Degree
Degree

Product, middling and reject were collected in a ton bag and sampled for analysis. Reference samples
were analyzed for density distributions and ash contents. The actual yield and ash rejections were
calculated by using an ash balance equations 1 and 2. After every test the feed ash content was
recalculated using weight and ash (%) of product, middling and reject material.
[1]
[2]

4. Results
Dry coal cleaning tests with Naryn Sukhait 1-5 mm size fractions showed that KAT air table is
effectively removing high density reject materials from feed coal. Test results for 1-5 mm size coal test
shown in Table.4 and 5.The run No.2 gives most favorable results with product ash content of 9.4% and
85.5% ash rejection rate. The heat content of feed coal was increased from 4996 Cal/g to 7214 Cal/g with
74.1% combustible recovery.
Table.4. KAT-1 table products
Naryn Sukhait,1-5 mm
Product

Middling

Reject

2.0
g/cm
Sink
fraction

Calorific
value
(Kcal/kg)

Ash
(%)

Yield
(%)

2.0
g/cm
Sink
fraction

Calorific
value
(Kcal/kg)

Ash
(%)

Yield
(%)

2.0
g/cm
Sink
fraction

Calorific
value
(Kcal/kg)

Ash
(%)

Yield
(%)

10.3

6627

16.0

57.2

41.8

4170

44.5

20.4

93.7

475

86.1

22.4

4.3

7214

9.4

53.4

32.7

4748

37.9

22.9

97.2

231

88.7

23.7

5.6

7107

10.7

58.3

33.8

4751

37.3

14.0

91.5

647

84

27.6

Test

Table.5. KAT-1 test results, Naryn Sukhait,1-5mm

Test
Feed Ash (%)
Product Ash (%)
Reject Ash (%)
Feed Cal/g
Product Cal/g
Actual Yield (%)
Recovery of ash in Product (%)
Ash Rejection (%)
Ash Reduction (%)
Combustible Recovery (%)

1
37.48
15.96
66.25
4746
6627
57.21
24.36
75.64
57.42
76.90

2
34.73
9.42
63.74
4996
7214
53.41
14.49
85.51
72.88
74.12

3
34.72
10.7
68.3
4990
7107
58.3
17.97
82.03
69.18
79.75

AVG
35.6
12.0
66.1
4911
6983
56.3
18.9
81.1
66.5
76.9

2.0 g/cm sink material fraction decreased to 4.3% in product and increased to 97.2% in reject.
Table.6 and 7 shows test results for Naryn Sulhait 5-10 mm size fractions. From conducted tests run No.4
gives most favorable results. Feeding rate was 20 ton hour and feed ash 46.4% decreased to 9.4% in
product and ash rejection rate was 92%. Run No.5, test with feeding rate of 31 ton hour, also gives good

results. About 47.8% of feed was recovered to product with 10.6 % ash and ash rejection was 89.2%.
Table.6. KAT-2 table products
Naryn Sukhait,5-10 mm
Product

Middling

Reject

2.0
g/cm
Sink
fraction

Calorific
value
(Kcal/kg)

Ash
(%)

Yield
(%)

2.0
g/cm
Sink
fraction

Calorific
value
(Kcal/kg)

Ash
(%)

Yield
(%)

2.0
g/cm
Sink
fraction

Calorific
value
(Kcal/kg)

Ash
(%)

Yield
(%)

6.3

6721

13.3

41.1

52.8

3385

52.9

18.2

97.3

258

88.6

40.7

1.3

7432

6.9

34.5

52.4

3357

53.4

32.8

99.6

130

89.8

32.7

7336

7.7

36.7

42.9

4001

46.1

26.1

99.1

151

89.6

37.2

3.3

7290

8.4

44.4

57.1

3069

56.8

18.9

95.9

350

87

36.6

5.1

7116

10.6

47.8

67.8

2195

66.9

13.5

92.8

585

84.7

38.6

Test

Table.7. KAT-2 test results, Naryn Sukhait,5-10 mm

Test
Feed Ash (%)
Product Ash (%)
Middling mixed to Reject Ash (%)
Feed Cal/g
Product Cal/g
Actual Yield (%)
Recovery of ash in Product (%)
Ash Rejection (%)
Ash Reduction (%)
Combustible Recovery (%)

1
51.1
13.3
77.7
3485
6974
41.1
11.7
88.3
71.5
72.7

2
49.3
6.9
71.6
3705
7432
34.5
4.8
95.2
86.0
89.8

3
48.1
7.7
71.6
3794
7338
36.8
5.9
94.1
84.0
65.4

Fig.1. KAT process during operation

4
46.4
8.4
76.7
3961
7290
44.4
8.0
92.0
81.8
75.8

5
46.9
10.6
80.1
3928
7116
47.8
10.8
89.2
77.4
80.4

AVG
48.4
9.4
75.5
3775
7230
40.9
8.3
91.7
80.1
76.8

6. Conclusions
The low grade high ash coal cleaning and de-ashing study was conducted using a dry air gravity
table. It is found that KAT table is able to reduce significant amount of high ash dense particles from 1-5
mm and 5-10 mm size fractions of Naryn Sukhait mine multi seam and high impurity coal.
Overall, the average ash rejection and combustible recovery for 1-5 mm fraction was 81% and 77%
respectively and the feed ash content was decreased from 35% to 12% in product and the average product
yield was 56.3%. The 5-10 mm size fraction average ash content was 48.4%. After the dry separation,
about 41% of the feed was recovered as product with average 9.4% ash content. Ash rejection and
combustible recovery was 91.7% and 76.8% respectively. Closely sized feed material gives better
separation results. It is found that KAT table effective feeding rate is 4.5-5 ton/h for 1-5 mm size fraction
and 20-30 ton/h for 5-10 mm coal. Conducted tests showed that KAT process can effectively remove
large amount of dense impurities from low grade bituminous coal thus producing an acceptable ash
content clean coal product.

References:
1. R.H.Yoon, G.H.Luttrell, R.Asmatulu (2002) : Extending the upper particle size limit for coal flotation,
The Journal o f The South African Institute of Mining and Metallurgy, October 2002, 411-415
2 US Department of energy (2007) : Development of an advanced deshaling technology to improve
the energy efficiency of coal handling, processing, and utilization operations. Final Technical
Report./ http://sciencepolicy.colorado.edu/students/envs_5720/honaker_2010.pdf/
3 R.K.Dwari & K.Hanumantha Rao (2007):Dry beneficiation of coal A Review, Mineral
Processing and Extractive Metallurgy Review: An International Journal,28:3,177-234
4 D.P.Patil & B.K.Parekh. (2011) : Beneficiation of Fine Coal Using the Air Table, International
Journal of Coal Preparation and Utilization, 31:3-4,203-222
5 Zhenfu Lou, Maoming Fan et al., (2008) : Density dependent separation of dry fine coal in a
vibrated fluidized bed, Powder Technology 187, 119-123,
6 M.Kademli, O.Y Gusloy. (2013): Investigation of Using Table Type Air Separators for Coal
Cleaning, International Journal of Coal Preparation and Utilization, 33:1,1-11
7 J.W.Leonard & B.C.Hardinge (1991) Coal Preparation. Fifth edition.
8 Bo Zhang et al,(2014) Utilization an Air-dense Medium Fluidized Bed Dry Separating System
for Preparing low ash coal, International Journal of Coal Preparation and Utilization,34:6,285295,DOI
9 Jinxiang Chen, Rick Honaker,(2015) Dry separation on coal-silica mixture using rotary
triboelectrostatic separator, Fuel Processing Technology131(2015) 317-324.
10 M.K.Mohanty, R,Q,Honaker, A.Patwardhan, (2002), Altair jig: an in-plant evaluation for fine coal
cleaning, Minerals Engineering, 15 (2002) 157-166.