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Practical Application of TBS Separator in Yuxi Coal Preparation Plant
With the rapid development of China's coal preparation technology, the traditional extensive development of coal preparation technology has gradually changed into personalized development. For example, slime flotation technology, dense medium cyclone separation technology and other coal preparation technology. In the selection of different equipment to achieve the above coal preparation process, different types of equipment, different performance, resulting in the final coal preparation results and efficiency are quite different. The coarse slime separation technology is relatively mature at present, and the process based on the teeter bed separator shows good results.This paper is to share a pratical application of Teeter Bed Separator which is designed by Beijing HOT Mining Tech Co Ltd.
1. General situation of Yuxi coal preparation plant
The annual output of the Yuxi coal preparation plant was designed at 3 million tons. The designed production capacity of a coal preparation plant is 3 MT per year, and the teeter bed separator is not used in the design and operation stage of the coal preparation plant. The material with particle size of 0.5 ~ 1 mm is separated by non pressure three product dense medium, and the material with particle size of less than 0.5 mm is separated by floating coal preparation process. However, in recent years, the content of fine coal in raw materials of coal mine is gradually increasing, which makes the proportion of coal mine materials with particle size less than 1 mm reach the maximum About 30%, which seriously affects the quality and effect of non pressure three product dense medium separation. Coarse slime is not fully utilized, and the medium used in separation increases, which increases the production cost of coal preparation plant, and has a very adverse impact on the economic benefits of coal preparation plant. In order to change the above unfavorable situation, in recent years, the process and equipment in the coal preparation plant have been upgraded. The advanced teeter bed separator has been introduced from abroad and put into use. The labor intensity of the staff has been significantly reduced, the failure rate of the equipment is low, and the separation effect and quality have been greatly improved.
2. Analysis of the basic structure and working process of the TBS separator
2.1 Basic structure of teeter bed separator
????Fig1_Basic structure of TBS
The device can automatically adjust the separation density according to the actual situation of the coal preparation plant to realize low density separation. The production cost of the teeter bed separator is low, and the space occupied in the workshop is small.
When the teeter bed separator is working, water flows into the water pipe rising from the bottom, and materials are put into the feeding well. The basic working principle of the equipment is to use the density difference of different substances in the feed to make it have different precipitation characteristics and laws under the interference of rising water flow, and finally realize the separation.
2.2 Work flow of teeter bed separator
Under the action of continuous pressure, the water flows into the equipment from the rising water pipe, and is distributed through the washing water distribution chamber, so that the water flow can uniformly act on the disturbance plate. Coal mine materials are put into the feeding well, and sink under the action of gravity. The materials contained in the materials have different densities. The higher the density of the materials, the faster the sinking speed. On the contrary, the smaller the material density is, the smaller the sinking speed is. Under the action of upwelling water, the materials with different densities can be stratified. The material with lower density flows out from the overflow tank on the upper layer of the equipment, while the material with higher density sinks into the bottom of the equipment and flows out from the underflow discharge outlet. A density sensor is set inside the equipment to detect the material density in the equipment. The sensor is directly connected with the PID controller, and the test results are directly input into the controller for analysis and processing. If it is found that the material density in the equipment exceeds the threshold set by the system, the controller will issue a command to open the underflow discharge valve to discharge the high-density material. After that, the material density in the equipment will decrease and the valve will close.
Based on the above analysis, the separation effect of the teeter bed separator is mainly affected by three factors. First, the density of coal mine materials. Second, the concentration of coal mine materials. Third, the speed and flow of upward flow.
3. Research on practical application effect of teeter bed separator
3.1 The coarse slime separation system after the after upgrading
????Fig2_Diagram of coarse slime separation process of TBS
As shown in Figure 2, the process flow diagram of coarse slime separation after upgrading is shown. In the original separation process, the raw materials from Coarse Slime Separator directly enter into the teeter bed separator, but there are many fine slimes with particle size less than 0.35 mm inside, which will reduce the efficiency of the teeter bed separator
In order to solve this problem, before the material enters the teeter bed separator, the classification cyclone is used to treat it. In this way, the content of fine slime with particle size less than 0.35 mm in the material is reduced, so that the concentration and particle size of the material entering the teeter bed separator are relatively more stable. After being treated by the teeter bed separator, the tail stream is discharged as tailings, and the overflow is further treated by the arc vibrating screen to obtain the concentrate.
Compared with the traditional process, the above coarse slime separation system has obvious advantages, mainly in two aspects. Firstly, the feed volume of flotation has been effectively reduced; secondly, the production cost has been effectively reduced, the production efficiency has been improved, and the effect of energy conservation and emission reduction has been achieved.
????Fig3_ The influence of feed concentration on ash content and separation efficiency
3.2 Practical application effect of teeter bed separator
3.2.1 Clean coal yield has been significantly improved
After the installation and commissioning of the teeter bed separator in the coal preparation plant, the practical application effect of the separator was studied, and the relevant indexes of concentrate and tailings were detected. The results show that the tailings yield and ash content are 20.68% and 58.33% respectively, and the concentrate yield and ash content are 79.32% and 12.13% respectively when the feed particle size is 0 ~ 1.5 mm and the ash content is 20.47%. The use of the teeter bed separator makes the comprehensive efficiency of coal preparation reach 93.98%, and the imperfection I value is 0.14. The above data show that the use of the teeter bed separator process makes the process of the coal preparation plant reach a very high level.
The further statistical analysis of the particle size in the concentrate shows that the proportion of the material with the particle size of 0.125 ~ 0.5 mm is about 44.5%, which indicates that the teeter bed separator has a very high recovery effect for the material with the particle size of 0.125 ~ 0.5 mm, which effectively alleviates the recovery pressure of the flotation system. The ash content of concentrate product is about 12% ~ 13%, which has no effect on the quality index of concentrate product. The ash content of tailings is more than 60% and remains stable, which indicates that the teeter bed separator has relatively good separation effect.
3.2.2 Good economic benefits have been achieved
The coarse slime separation system was upgraded in the coal preparation plant, and the material was pretreated by the classification cyclone before entering the teeter bed separator The slime amount in the dense medium system is reduced, the separation effect is better, the loss of medium coal is reduced, and the medium used in the coal preparation process is reduced a lot. The use of teeter bed separators can significantly improve the separation accuracy and reduce the waste of coarse and fine slime.
According to the preliminary statistics, after upgrading, the annual production of clean coal in the coal preparation plant is about 30000 tons. If the price of clean coal is calculated as $150 / T, it can increase the income of about $4.4 million for the coal preparation plant. For the use of the medium, the calculation is based on the reduction of 1kg medium per 1t raw coal. Assuming that the raw coal selected by the coal preparation plant is 3 million tons per year, and the medium price is calculated as $100/T, the annual medium cost saved by the coal preparation plant can be calculated as $300000.
In addition, the use of the teeter bed separator also effectively reduces the labor intensity of the staff. Based on the above analysis, the practical application of teeter bed separators in coal preparation plants has created very good economic and social benefits for coal enterprises.
4. Conclusion
The coarse slime treatment process in a coal preparation plant will have an important impact on the efficiency and quality of coal preparation. At present, both coal preparation plants and scientific research institutions attach great importance to the analysis and research of the coarse slime treatment process. teeter bed separator is a relatively advanced coal preparation equipment at present. The selection of this equipment can significantly improve the coarse slime separation process, and effectively improve the efficiency and quality of coal preparation. Based on the analysis of this paper, the practical application of the teeter bed separator in the coal preparation plant shows that the output and quality of clean coal have been significantly improved, and the quality has reached an advanced level, creating good economic benefits for the coal preparation plant.
H-CSS Series Teetered Bed Separator was installing on customer site in Mongolia.
Beijing HOT Mining Tech Co Ltd has delivered so many design and transformation projects of coal preparation plant in China, Russia, Mongolia, and so on. We aim to provide effective solution and equipment for the customers to help them improve the performance of the minerals processing progress.
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