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Example:-

Coal India Limited

A Govt. Undertaking Company

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CPP (Coal preparation process facility )

It is a process of washing coal of soil and rock,

preparing it for transport to market .ROM ( Run of Mine )

The coal delivered from the mine that reports the

to coal preparation plant is called Run-Of-Mine.

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Coal needs to be stored at variousstages of the preparation process,

and conveyed around the CPP

facilities.

Stockpiles

1. Provide surge capacity.

2. Stacker.

3. Reclaimers.

4. Reduced rate of heat lost,

leading to a higher risk of

spontaneous combustion

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Travelling, lugging boom stackers that straddle a feed

conveyor are commonly used to create coal stockpiles.

STACKERis a large machine used in bulk material

handling applications.

Movement of Stacker

Luffing

Travelling

Slewing

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A Reclaimers function is torecover bulk material such asores and cereals from astockpile

Reclaimers Types

Bucket wheels Reclaimers.

Scraper Reclaimers.

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Stackers and Reclaimers were originally manually-

controlled manned machines with no remote control.

Modern machines are typically fully automated with

their parameters.

Some older Reclaimers may still be manually

controlled, as reclaiming is more difficult to automate

than stacking .

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A Routine sample is taken at a set frequency,either over a period of time or per shipment

Types of Sampling

Cross cut sampler.

Falling stream sampler.

Continuous measurement of ash, moisture, KCal , sulfurFe, Ca, Na, and other element constituents of the coal arereported by cross belt elemental analyzers. Thisinformation can be calibrated periodically to the lab dataper ASTMmethods.

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Liberation data on the raw coal sample

Low density material is clean coal whereas high

density material is reject (rock). The intermediatedensity material is called middlings

Liberation data is commonly obtained by float and

sink analysis.

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Crushing reduces the overall top-size of the

ROM coal so that it can be more easily

handled and processed within the CPP

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Screens are used to group process particles into

ranges by size. These size ranges are also

called grades.

Dewatering screens

Screens can be static, or mechanically vibrated.

Screen decks can be made from differentmaterials such as high tensile steel, stainless

steel, or polyethylene.

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Gravity separation methods make use of

the different relative densities of different

grades of coal, and the reject material. Jigs

Jigs are a gravity separation method for rough

coal.

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Fine coal is cleaned using froth flotation

methods

Spirals perform a simple, low cost andreasonably efficient separation of finer

sized material, based on particle

density and size.

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Dewatering

Water is removed from the product to reduce the mass, and

runoff on the stockpile

Dewatering tailings (reject)

Water is removed from tailings to recycle water. Filters,

centrifuges and thickeners are used in this part of the process

Thickeners

Thickeners are used for dewatering slurries of either tailings or

product.

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Measurement of flow, density, levels, ash

and moisture are inputs to the controlsystem. PLCs are used extensively in plant

Instruments:Density gauges and online

elemental coal analyzers.

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