Correlating laboratory and pilot scale reflux classification of fine coal

MIng (Chemical Engineering), North-West University, Potchefstroom Campus, 2015The search for efficient and economical ways to beneficiate fine coal remains an active research area. Recent developments have shown that the reflux classifier can successfully be used on Australian coals, and based on that, a number of pilot plant investigations have been done in South Africa. While pilot scale units are usually used to test the applicability of a new technology on specific coals, a need exists to gather more fundamental data at a laboratory scale in order to save manpower, costs and time. This study has aimed at introducing a way to pre-test material prior to pilot plant trials in the design chain. The study shows that a laboratory water only reflux classifier can be used as a density fractionator, which accurately produces washability data for coal – this was also investigated by Callen et al. (2008). There is also a linear correlation between density cut-point and fluid velocity within the plates. Only when looking at the model proposed in Walton (2011:68), does it become clear that the relationship is indeed slightly curved. Many investigations from laboratory and pilot tests accept the linear relationship, and describe it as slightly curved due to the settling being in the intermediate settling regime (Iveson et al., 2014; Galvin & Lui, 2011). The separation procedures that produce two products – an overflow and underflow – compare well with fractionation results produced. Thus, fractionation results can generate washability data and predict batch separation operations. The laboratory reflux classifier setup is also dependent on particle size, where individual size ranges achieve e.p.m. values of 0.012 and 0.030, while the combined separation efficiency is 0.039. It was, however, found that the respective laboratory scale reflux classifier that was designed and built was not suitable for continuous operation. The vertical fluidisation section was not high enough to enable a steady fluidised bed. This was necessary for density separation within the bed and to produce a significant pressure differential. It is also recommended to obtain a PID controller.Master