The Coal Handbook: Towards Cleaner Production, Volume 1: Coal Production

786 Pages·2013·55.57 MB·english

by  Dave Osborne

The coal handbook

© Woodhead Publishing Limited, 2013
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© Woodhead Publishing Limited, 2013
Woodhead Publishing Series in Energy: Number 50
The coal handbook
Towards cleaner production
Volume 1: Coal production
Edited by
Dave Osborne
Oxford Cambridge Philadelphia New Delhi
© Woodhead Publishing Limited, 2013
Published by Woodhead Publishing Limited,
80 High Street, Sawston, Cambridge CB22 3HJ, UK
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ISSN 2044-9372 Woodhead Publishing Series in Energy (online)
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© Woodhead Publishing Limited, 2013
Contents
Contributor contact details xiii
Woodhead Publishing Series in Energy xvii
Foreword xxiii
Preface xxv
Professor Peter Feč ko xxix
Part I Introduction and coal characterization 1
1 Industrial uses of coal 3
D. G. Osborne, Xstrata Technology, Australia, and
S. K. Gupta, University of New South Wales, Australia
1.1 Introduction 3
1.2 Coal use in the power generation industry 9
1.3 Coal use in the steel industry 15
1.4 Coal use in the cement industry 22
1.5 Coal conversion and other industries 24
1.6 In situ gasifi cation 28
1.7 Conclusion 29
1.8 Bibliography 29
2 Coal formation 31
B.J. Arnold, PrepTech, Inc., USA
2.1 Introduction 31
2.2 Coal formation 32
2.3 Coal types 35
2.4 Differences in coalifi cation history 36
2.5 Coal properties and standards for coal classifi cation
systems 44
2.6 Sources of further information and advice 50
2.7 Future trends 50
2.8 References 51
v
© Woodhead Publishing Limited, 2013
vi Contents
3 Coal petrography 53
R. Falcon, University of Witwatersrand, South Africa
3.1 Introduction 53
3.2 Macerals and minerals in coal 55
3.3 Lithotypes, microlithotypes and abnormal conditions found
in coal 67
3.4 The impact of petrographic characteristics on the
technological properties of coal 71
3.5 Development of modern techniques in coal petrographic
analysis 77
3.6 Conclusion 79
3.7 Bibliography 79
4 Coal resources and reserves 80
L. P. Thomas, Dargo Associates Ltd, UK
4.1 Introduction 80
4.2 Classifi cation of coal resources and reserves 81
4.3 Calculation of coal resources and reserves 97
4.4 Reporting of coal resources and reserves 101
4.5 World coal reserves 103
4.6 Future trends 105
4.7 References 105
5 Coal sampling 107
W. Membrey, ALS Ltd, Australia
5.1 Introduction 107
5.2 Accounting for heterogeneity in coal sampling 109
5.3 Other principles of sampling 119
5.4 Types of sampling system 127
5.5 Sample preparation 140
5.6 Future trends 147
5.7 Conclusion 148
5.8 References 149
6 Coal analysis 151
K. Miller, ALS Ltd, Australia
6.1 Introduction 151
6.2 Typical metallurgical (coking) and thermal coal tests 153
6.3 Proximate analysis 155
6.4 Sulfur 161
© Woodhead Publishing Limited, 2013
Contents vii
6.5 Calorifi c value 163
6.6 Ultimate analysis 164
6.7 Carbonate carbon 165
6.8 Common thermal coal tests 165
6.9 Common coking coal tests 171
6.10 Petrographic analysis 176
6.11 Further considerations and future trends 179
6.12 Appendix: standards for coal quality evaluation 180
Part II Coal extraction and preparation 191
7 Advances in coal mining technology 193
L. Lien, United Finance and Management Services, USA
7.1 Introduction 193
7.2 Coal extraction methods 196
7.3 Advances in mining technology 201
7.4 Systems and information 210
7.5 Automation in practice 214
7.6 Future trends and conclusions 220
7.7 References 223
8 Underground coal gasifi cation 226
S. Lavis, R.Courtney and M. Mostade, Clean Coal
Ltd, UK
8.1 Introduction 226
8.2 Lessons learnt from previous trials 227
8.3 Impact of new technologies 233
8.4 Current trends 235
8.5 Conclusion and future trends 236
8.6 References 237
9 Coal comminution and sizing 240
T. C. Eisele, H. J. Walqui, and S. K. Kawatra, Michigan
Technological University, USA
9.1 Introduction 240
9.2 Coal breakers, crushers and sizers 240
9.3 Coal sizing: an introduction 250
9.4 Coal screening and classifi cation 251
9.5 Conclusion 261
9.6 References 261
© Woodhead Publishing Limited, 2013
viii Contents
10 Cleaning of coarse and small coal 2 63
K. P. Galvin and S. M. Iveson, University of Newcastle,
Australia
10.1 Introduction 263
10.2 Theory 267
10.3 Dense medium separation 273
10.4 Wet gravity separation 287
10.5 Dry separation 290
10.6 Conclusion and future trends 295
10.7 Sources of further information and advice 296
10.8 References 297
11 Cleaning of fi ne and ultrafi ne coal 301
R. Q. Honaker, University of Kentucky, USA,
J. Kohmuench, Eriez Manufacturing, USA, and
G. H. Luttrell, Virginia Tech, USA
11.1 Introduction 301
11.2 Fine gravity separators 305
11.3 Froth fl otation technologies and circuit variations 323
11.4 Dry fi ne coal separations 338
11.5 Future trends 342
11.6 References 343
12 Surface chemistry fundamentals in fi ne coal
processing 347
J. S. Laskowski, University of British Columbia, Canada
12.1 Surface properties of coal 347
12.2 Coal fl otation 351
12.3 Solid–liquid separation 360
12.4 Fine coal handleability 382
12.5 Rheology effects in fi ne coal processing 387
12.6 References 413
13 Solid–liquid separation technologies for coal 422
G. Bickert, GBL Process, Australia
13.1 Introduction 422
13.2 Overview of solid–liquid separation (SLS) 423
13.3 Pre-treatment 424
© Woodhead Publishing Limited, 2013
Contents ix
13.4 Centrifugal SLS 425
13.5 Vacuum fi ltration 428
13.6 Pressure fi ltration 429
13.7 Thermal drying 432
13.8 SLS equipment selection 433
13.9 Emerging and future trends 437
13.10 Conclusion 441
13.11 Sources of further information and advice 441
13.12 References 441
14 Economic factors affecting coal preparation: plant
design worldwide and case studies illustrating
economic impact 445
P. J. Bethell, Arch Coal Inc., USA
14.1 Introduction 445
14.2 Current steam coal circuit design 445
14.3 Current metallurgical coal circuit design 450
14.4 Case studies 453
14.5 Poorly liberated coal 458
14.6 Water constrained plants 461
14.7 Future trends 465
14.8 References 466
15 Post-treatment of coal 467
A. Vince, Elsa Consulting Group Pty Ltd, Australia
15.1 Introduction 467
15.2 Estimating required liberation size 470
15.3 Milling coal for liberation 473
15.4 Chemically treating raw coal for liberation 481
15.5 Benefi ciation 484
15.6 Chemical cleaning 498
15.7 Dewatering 500
15.8 Drying 504
15.9 Separation of clays 513
15.10 Other technologies 515
15.11 Acknowledgements 524
15.12 References 524
15.13 Appendix: Nomenclature and abbreviations used 528
© Woodhead Publishing Limited, 2013