Our coal beneficiation and handling know-how will convert your reserves into marketable products!

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Coal Processing Plants and Handling Equipment

From coal face to coal loading, BATEMAN tackles any coal-processing assignment - from mine evaluation,
sampling and testing, process feasibility and economic-viability studies, through to the design, engineering,
procurement, management, construction and commissioning. BATEMAN optimises the recovery of coal
for the least possible cost.

Coal-beneficiation plants - green- and brown-field plants, retrofits, refits and audits - from 60 to 2 000 t/h.
Modular units are easy to transport, move and re-erect.

Coal-handling systems - stock-yard systems to stack, reclaim, homogenise and blend coal and rapid
trainloading systems.

Coal-conveying systems - overland-, high-tonnage and environmentally-friendly conveying systems.
Dust-control systems - a comprehensive range including bag filters, scrubbers and cartridge filters.

Ash-classification systems for high-quality pulverised fuel ash (PFA).

Cost-effective know-how to produce marketable products - size reduction of run-of-mine coal, screening,
dense-media separation, spiral separation or flotation, multi-slope screens, large-diameter cyclones,
air-pulsed over-the-bed jigs, mass-flow technology, computer simulation of conveying systems, etc.

Flexible contract structuring accommodates projects large and small, e.g. reimbursable, EPCM,
lump-sum, fixed fee or joint ventures.

BATEMAN - minerals-processing and materials-handling engineers and project managers with
in-house technology and design capability to handle the largest turnkey projects. Our track record
numbers over 3 000 successful projects.

Coal beneficiation PDF

From coal face to coal loading, BATEMAN tackles any coalprocessing assignment – including mine
evaluation, sampling and testing, process feasibility and economic viability studies, through
to the engineering, management, construction and commissioning of coal process plants.

We can provide the complete technology needed to design and implement cost effective processes
which produce marketable products. We are leaders in the beneficiation of coal, and in particular in
the application of dense-media technology in difficult coal washing applications.

Coal beneficiation plants

BATEMAN offers the full spectrum of project construction services, from the project inception to
commissioning of the plant. Maintenance services include retrofits, refits, audits and staff training.
Flexible contract structuring accommodates projects large and small, and includes reimbursable, EPCM,
lump-sum, fixed fee or any combination to suit client needs. Joint ventures on projects may be formed
with independent mining consultancies.

Design capability

BATEMAN designs processes for the storage and size reduction of run-of-mine coal, the screening of coal to
size and wet concentration to clean coal through typically dense-media separation (DMS), spirals or flotation,
including de-watering prior to further processing and handling.

New fine-coal separation technologies, such as DMS, column flotation cells and Jameson cells can also be
offered to increase the overall yield or make special low ash products.

Numerous new and upgraded plants have been designed using DMS technology, spiral-separation
technology, multi-slope screens and large diameter cyclones.

These coal plants have ranged in size from 60 to 2 000 t/h and have reflected different styles of
engineering, from computer controlled, multi-modular units to the “minimum but adequate” approach
favoured by some mining houses.

Consulting service

The service identifies the potential processing routes which are likely to optimise the yields of marketable
products which can be obtained from the coal resource. For example, raw washability data can be
processed to estimate product yields needed to derive the capital and operating costs for a specified
capacity plant. The service is supported by:

Coal handling

BATEMAN supplies systems for the bulk handling of both run-of-mine and clean coal. These systems include
stackers and reclaimers, conveying systems, and rapid train loading systems.

Successful solutions for the bulk handling of coal are based on a thorough understanding of the criteria
which affect flow. At the BATEMAN laboratories the behaviour of materials is determined to assist in
designing efficient and effective systems.

Stock yard systems – stackers and reclaimers

Over the past two decades BATEMAN has been responsible for the design, project management and
supply of many stock pile systems for the stacking, reclaiming, homogenising and blending of coal.
BATEMAN / SCHADE equipment is marketed extensively throughout Africa.

Train loading systems

BATEMAN is a world leader in rapid train-loading systems and offers the best and most cost-effective
solution to load-out problems, large or small. Some 20 BATEMAN load-out stations have been installed
worldwide in the past two decades to load coal, iron ore and limestone.

Coal conveying

BATEMAN’s range of conveyors can handle any run-of-mine or clean coal conveying need.
The available systems include:

The JPC (pipe conveyor) conveys materials securely within a longitudinally rolled conveyor belt
forming a pipe, which can negotiate tight horizontal and vertical curves.

It has overcome many of the coal dust and contamination problems commonly encountered with
conventional belt conveyor systems. Pollution is limited by:

With more than 50 units having been installed in South Africa to convey a range of products since 1984,
and in excess of 500 world wide, the JPC is well proven.

Dust Control

The most comprehensive range of systems under one roof enables you to select the best and most cost
effective solution – from system design, manufacture, erection, commissioning, project management and
turnkey installations to after sales service.

The range includes

Our equipment can be found on nearly 2 000 installations – on furnaces, kilns, smelters,
driers, boilers, and mills and on mines, minerals processing, chemical and industrial plants.

Ash classification

The BATEMAN ash-classification plant classifies, selects and
extracts waste ash from coal fired power stations to produce
high quality pulverised fuel ash (PFA) for use in the extension
and improvement of Portland cement.

These plants:

BATEMAN has supplied the two largest ash-classification plants in the world.

Modular coal process plants

BATEMAN’s modular coal processing plants have the capacity to treat between 60 t/h to about
200 t/h of coal. These units can, however, be used in tandem to increase throughput.
BATEMAN’s modular units achieve large savings in capital cost and construction time.

Based on dense-media technology, these plants are typically composed of de-sliming modules to separate
the fine coal, dense-media separation (DMS) modules in which the waste / shale is removed, magnetic
recovery modules for the recovery of the magnetite, and coal washing and de-watering modules.

Heavy-media drum and air pulsed over-the-bed jig modules for the separation of coal from waste are
also available.

All BATEMAN’s modular plants are:

BATEMAN has a track record spanning three decades during which about 210 BATEMAN modular
process plants have been supplied to more than 20 countries worldwide.

Support Services

All BATEMAN projects and plants are supported by an extensive technical back-up and reliable service.
This includes:

With a track record in the coal-processing industry which started in 1968/9 and includes
large and small coal projects, much of which is repeat business for satisfied clients, BATEMAN
optimises the processing and handling of coal with the most up-todate technology.

BATEMAN has successfully served large and small coal clients in Australia, Hong Kong, India, Israel,
South Africa and USA.

For coal handling and conveying, dust control and ash classification, contact coal@batemanengineering.com

The APIC Jig and the JIGSCAN Controller take the Guesswork Out of Jigging (PDF)

Author : Grant Loveday, Co-author : Andrew Jonkers

ABSTRACT

The jigging of coal has progressed from piston jigs to air pulsed Baum jigs to underpulsed jigs. To
minimise energy losses, Apic jigs use balanced butterfly valves for air flow control and feature low
weight jig bodies which are designed to minimise loss of pulse energy. The gate designs used in Apic
jigs ensure maximum efficiency of separation by maintaining the pulse to the end of the bed and by
preventing the jamming of particles. Separation efficiencies (Ep's) below 0.1 have been consistently
obtained on various types of coal from around the globe.

The JigScan air pulsed jig controller maintains the pulse conditions in the face of changes in the feed. It
is also able to measure and control the bed density in a coal jig to an extent not possible using floats.
JigScan does this by measuring the air-water interface in the air chambers and through the use of
various purpose-built sensors and sophisticated analysis techniques. Retrofitted to an existing air
pulsed jig (by another manufacturer), JigScan was able to increase coal yield by 2%.

These two technologies are now offered together as the current state-of-the-art in jigging.

INTRODUCTION

The jigging of coal has more than 150 years of history. Starting in Europe with piston jigs, jigging
expanded dramatically with the remarkably modern Baum Air Jig used for sized or unsized feeds.
Continuous innovation in equipment in the last century has allowed for greater capacities, broader
application, easier operation, and improved control in coal cleaning.

Apic jig technology combines the principle of under-bed pulsation with re-designed mechanical features
for air supply, gate operation and control. The advanced JigScan controller was developed for and has
operated on difficult applications for over 15 years. Strong modelling and simulation capabilities now
facilitate smarter designs and continuous pilot Apic jigs are available to demonstrate applications.
Together, these technologies today supply the user with the widest-ever range of possibilities.

Despite the inroads made into other markets, coal remains a strong focus of Apic technology. The low
operating cost and flexibility of the jigging process make it an attractive alternative to dense medium
processes and even some previously "unjiggable" coals are yielding to the cost-benefits of the modern
Apic jig.

In reviewing the latest developments in this technology, jigging data from Northern as well as Southern
hemisphere coals are discussed.

FUNDAMENTALS

Jigging is a gravity concentration process in which light and dense fractions are separated from each
other by the application of vertical pulses of water. The separation is typically carried out in a
rectangular "wash box", with a screen base upon which the bed of material is supported. The feed
enters along one edge of the box and is transported to the opposite edge by the action of a nett upward
water flow, displacement by the feed and, where necessary, a sloping bed deck. At points along the
length of the bed and at the end of the bed, dense material is withdrawn through gates of some design.
The capacity of a jig is determined by the residence time, which itself is a function of bed area and bed
depth. Typically, an optimum bed depth exists, jig width is used to scale up capacity and jig length used
to scale up residence time from similar applications. Pulses were initially effected by the action of a
crankshaft on a diaphragm. The Baum jig design, still in use by some jig manufacturers today, utilised
the principle of a balanced U-tube in which sinusoidal oscillations were induced by intermittent
application of compressed air. This design was successful in that it utilised a low-density, easily
generated, easily controlled source of pressure. However, the physics of creating an even pulse across
a significant width of bed limits the practical width of Baum jigs.

The French company PIC patented a new jig design in 1947. By placing the air chamber under the
screen instead of next to it, the total footprint of the jig was reduced substantially. Furthermore, since
the pulse generator spanned the width of the jig, the maximum jig width was limited by the physics of air
transport rather than water transport. However this design was not commercialised immediately by PIC
and the first underbed jigs were the Takakuwa (Tacub) jigs – later to become the Batac jig.
By using an "unbalanced" system (the water level in the air chamber is well below the superficial water
level) higher air pressures must be used, but the trade-off benefit is the ability to deviate from a
sinusoidal wave form. Evidence is gathering1 that this is beneficial in improving the sharpness of
separation.

APIC TECHNOLOGY

Since the invention of the air pulsed jig, first PIC, then FCB (who incorporated PIC in 1975 and
commercialised the L-type underbed pulsed jig) and now Bateman-Titaco (who purchased the FCB
design in 1997 and renamed it the Apic jig) have continued to develop the product to its current level of
sophistication. These technological benefits have impacted on the control of the air flow into and out of
the air chambers, the gate mechanisms used for separating the rejects from the coal, the jig structure
and the removal of rejects from the jig body. A further step was taken with the forging of a relationship
with the JKMRC of Brisbane, Australia, for the application of their advanced JigScan jig controller to
Apic jigs. Each of these are dealt with in turn below:

Air flow control

Air from the pressure header must be quickly injected into the air chambers to begin the acceleration
phase. Resistance to air flow delays equilibration of the air chambers with the air chests, resulting in the
production of "soft" pulses. Also, for the same pulse stroke, longer inlet times or higher pressure in the
air header are required to overcome this resistance.

The butterfly valve provides quick-acting flow control and a straight-through flow passage for the
working air. It is also of a balanced design, which means its actuation requires work against inertia only.
However it does require rotary actuation, which is less straightforward than linear actuation. FCB
invested the time and energy in finding the right combination of actuator and valve design to provide the
benefits of the butterfly valve without compromising service life. Additional improvements have been
implemented by Bateman-Titaco to further increase service life.

A further advantage of butterfly valves is that they are easily accessible and their operation can be
checked immediately without any handling or removal.

Gate design

The bed of coal and rejects is stratified over the length of the jig and then must be separated into
product and reject. This separation is crucial as the effort in stratifying the bed can be undone if the
gate area is at all turbulent. However, a degree of turbulence or mixing is inevitable in this zone where
a proportion of the flow changes direction and moves downwards. To prevent light material being
caught and carried to the dense fraction, the pulse must be maintained in the gate area – re-forming the
bed with each pulse.

The obvious conception of a gate – a permanently open aperture through the bed end-wall or through
the screen deck – has limitations in application. For a particular tonnage rate through such a gate, the
aperture will permit passage of only a limited size particle. If the amount of rejects to be removed is
such that the gate aperture is smaller than the largest particle, coarse particles will build up behind this
gate. Consequently, the flowrate will be reduced even further until the rejects bed builds up to the point
where the gate opens wide enough to permit passage of these coarse particles. When this happens,
the flowrate to rejects is so high that the bed quickly drains of rejects and coal begins to report to tailings
before the controller can respond and close the gate. Such cycling is symptomatic of a gate/feed
mismatch. (This was first recognised by PIC, whose gates were made to oscillate open and shut with
each pulse to ensure a constant and infinitely variable rate of rejects discharge.)

The FCB coarse coal gate3 (see Figure 1) overcomes both of the limitations of a simple slot gate.
Firstly, by sitting within its own pulsed compartment and being manufactured of punched plate, the gate
area is continuously pulsed to the end of the bed. This maintains the stratification against any mixing
effect. Secondly, building on the PIC concept, the gate is not a static aperture but is in continuous
motion. The surfaces on which the bed sits are also in continuous motion and the aperture is opened
and shut with each pulse. The result is that the gate cannot become jammed and is easily able to eject
tramp oversize material.

This gate was designed specifically for the Tarong Coal Preparation Plant in Queensland, Australia,
treating a typical Southern Hemisphere coal. This plant was commissioned in 1987, and all subsequent
coarse coal FCB jigs featured this gate design.

The FCB fines gates also oscillate, to prevent jamming. However, being only for the removal of fine
rejects, a narrow slot can be used which does not affect the pulse. This is much like the original highly
effective PIC design.

Jig structure

Ideally, all of the kinetic energy generated in the air chambers would be translated into pulse in the bed
above that air chamber. However, since material passing through the screen deck must be removed
from the hutches, each compartment cannot be totally isolated.

To limit the loss of pulse energy, the base of each compartment in an Apic jig slopes towards a central
discharge pipe, which then leads into the refuse extractor. The relatively small area of the discharge
pipe provides a resistance to flow, forcing the pulse energy through the bed. Where the jig is wide, two
discharge pipes - each fed from one side of the jig - are used. This design also minimises the total
weight of the jig, thereby reducing equipment and structural costs.

The Apic jig is also light due to its “honeycomb” plate and stiffener design, which is bolted to offer
maximum fatigue resistance. It also has a very open design. (It is for instance possible to enter the jig
hutch and to stand inside it.)

A fundamental departure in the form of jigs was made with the transfer of the technology to Bateman-
Titaco. Although purpose-built jigs remain a core product, an urgent need for truly modular jigs was
identified. Jigs built for pilot work were pressed into production roles, and slightly larger transportable
plants were designed to perform short term or low feed rate projects. These jigs have the benefit of offsite
commissioning, are largely self-contained and can be readily re-used elsewhere at the end of the
project cycle. Such modular and mobile plants have become the largest volume seller of the Apic line.
A photograph of one such jig can be seen in Figure 2.

Rejects removal

Bucket elevators are the workhorse rejects removal system of Apic jigs. Apic bucket elevators are
robust and reliable and off-the-shelf designs exist for over 400 t/h of rejects. However, bucket elevators
are by nature large and expensive and, where low capital cost is a priority, other options have been
explored.

For fine feeds, the option exists of simply discharging the sinks product onto a de-watering screen in a
controlled fashion. However, there are limits to the quantity of material that can be discharged in this
manner and it is not a standard option for coarse feeds (>30mm).

A South African company has developed shaftless elevating screw conveyors, which are able to
withdraw even coarse shale. This technology has been trialled on a jig removing -75mm rejects
(sometimes coarser) over a period of 6 months with a good projected life expectancy, high availability
and modest operating cost. Bateman Titaco will continue to explore the limits of this technology before
offering it as a standard equipment option.

Performance

Table 1 and Table 2 show the separation performance of Apic/FCB jigs on coarse and fine coal
respectively. The data covers South African, Australian, German, Indian and American coals.

THE JIGSCAN AIR PULSED JIG CONTROLLER

Starting in 1986, the JKMRC developed an advanced jig controller for Newlands Colliery in Central
Queensland, Australia2. This controller was implemented on one of the two underbed air pulsed jigs (by
another manufacturer) and run continuously to allow comparison of the performance of the two jigs.
Based on the success of the single JigScan over several years, Newlands Coal paid for an upgrade to
the existing JigScan controller and ordered a JigScan for the second jig. Subsequently, JigScan was
installed on the fine iron ore jig at Goldsworthy in Western Australia (same jig type as at Newlands), was
specified as the original equipment controller on the HBI plant iron ore jigs (also WA) and was installed
on the Tarong Coal jigs in Queensland.

JigScan embodies a remarkable departure from conventional jig control. Typically, jig controllers
operate using measurements that are essentially an average of the bed condition over the pulse.
JigScan's fundamental difference is the ability to measure conditions many times within the pulse. The
underbed air pulsed jig had previously been viewed as a highly interactive, poorly understood "black
box". JigScan counters this by presenting ample data on the condition of the jig, providing historical
data for reference and having the ability to interact or even integrate with existing plant control software.
JigScan also takes over many of the more mundane operating functions, performing them continuously
instead of when problems arise and freeing up operators for more important tasks.

Pulse velocity measurement

Using pressure sensing technology purpose developed at the JKMRC, JigScan is able to measure the
pulse velocity and displacement profile. Since the pulse shape (amplitude, abruptness, hold period)
determines the quality and nature of the separation, this information is vital to the plant operator.
Evidence of a change in pulse shape is an indicator of a fundamental problem with the jig, allowing the
operator to take corrective action. Figure 3 shows pulse velocity profiles for three bed depths.
Pulse velocity measurement also provides an opportunity to monitor and control the pulse shape – a
function currently under development.

Water level measurement and control

This same pressure measurement technology can be used to measure the water level in the air
chambers. The water level in the air chambers has a critical effect on the pulse shape3. Mechanically
analogous systems can be used to explain this effect. A high water level results in a small pocket of air,
whose mechanical equivalent is a short, firm spring (see Figure 4). At the end of each pulse, the water
is rapidly slowed as the small pocket of air is rapidly compressed. When blower air is introduced to this
small volume, the change of pressure is rapid and only a small volume of air is required to achieve a
high pressure.

The mechanical equivalent of a low water level is a long, soft spring (see Figure 5). At the end of each
pulse, the water column slowly compresses the large air pocket, and is itself eased to a halt. A large
volume of blower air is required to compress this large volume, and the change in pressure is not as
rapid as with a small volume. On the other hand, energy is conserved and the pulse amplitude
produced by such a system would be larger. However, for a particular volume of compressed air, larger
pulses are produced by the use of a high water level.

From the above, it can be inferred that a high water level should be maintained in the air chambers.
However, if the water level deviates too far upwards from the required level, water can enter the air inlet
pipes. If this occurs, the admission of inlet air will be damped and the jig will enter a failure mode in
which the inlet air can never fully displace the water from the inlet pipes. Avoiding this scenario
therefore becomes critical in maintaining correct operation of the jig and measurement of the water level
allows this to be done automatically. The length of the exhaust stroke is adjusted with each pulse to
maintain the water level at a preset height.

Nucleonic bed density measurement

The conventional method of measuring the depth of shale in the jig bed is by means of a float. The float
is a hollow vessel attached to a vertical rod, which is able to move vertically only. The float is weighted
to give an apparent density close to that of the separation density. The height of the float at some point
in the cycle is then taken as an indication of the amount of reject material in the bed. The float height is
maintained at a preset point by adjusting the rate of reject removal. However, the point at which the
float comes to rest is a function of the pulse shape, the feed size and density distribution as well as the
bed density profile, and the gate controller is unable to distinguish between the various causes of the
float variation. In addition, where there is a large amount of near gravity material, the density gradient
through the bed is low and the equilibrium point of the float is again ill defined.

Nucleonic gauges designed at the JKMRC are installed on the Newlands jigs, allowing the
measurement of the average bed density (solids plus water) at a particular horizon. Again the bed
density is measured many times per pulse, allowing the JigScan software to calculate the moment when
the bed has settled onto the screen plate. This measurement is a true reading of the density at that
height, allowing more accurate control of the reject bed level.

A graph of the bed density at various points above the screen plate is shown in Figure 6. As the bed is
lifted en masse by the jig pulse, higher density material is lifted into the beam and the density seen by
the gauge increases. The density then drops to a minimum as the bed loosens and drops back to the
screen and then compacts to a final packed bed density. It is interesting to note from this graph (and
from Figure 3) that the bed only begins to move once the pulse reaches its maximum velocity.
Model based gate control

In circumstances where the gate has a continuously variable aperture and there is a significant distance
between the density measurement device (float or nucleonic) and the gate, the bed level will vary more
widely than when the float is adjacent to the gate. This is caused by the time lag, which a standard PID
gate controller cannot account for. If the separation is relatively easy (a stone/coal separation) this
variation is not important as long as the stone does not overflow the weir and the coal does not drop into
the gate. Where the separation is more difficult and significant quantities of near gravity material exist,
such as with many Southern Hemisphere coals, this fluctuation will result in a varying cut point and a
concomitant reduction in organic efficiency.

To reduce this effect, a model based gate algorithm was developed which accounts for the lag time, is
self-tuning (it learns which gate setting is appropriate for a particular rate of reject flow) and remembers
its previous settings. This last feature means that when the jig is shut down and restarted, the gate
returns to its previous setting, preventing coal losses.

Performance

Increased yields were found with the use of Jigscan. On coal, a yield increased of 2 per cent was
measured, while on iron ore a client reported a staggering 8 per cent increase.

CONCLUSIONS

The Apic range of jigs offers technically advanced gravity separators in a variety of formats. Their
pedigree is long, beginning with the oscillating gate design and the underbed air pulsed jig patent
contributed by the PIC Company. Development continued with the commercialisation of the L-type jig
by FCB featuring butterfly valves and a new coarse coal gate design. Under Bateman-Titaco they have
continued to evolve, broadened their application and have been implemented in a new mobile format.
Apic jigs currently embody an optimum combination of weight and energy saving with good separation
efficiency. The flexible "pick 'n' mix" format of Apic jig features ensures that the best solution for the
particular application is found, and the "open" philosophy of Apic jig design (operator feedback, ease of
use, easy to maintain) ensures peak performance is maintained.

JigScan is able to stabilise the pulse in the face of feed and other variations, maintaining a uniform
separating environment. It presents ample operator feedback and can communicate with plant control
systems. In certain applications, significant improvements in yield have been recorded. Where the feed
is considered "difficult to treat", JigScan's software and sensors are able to maintain a stable separation.
These two technologies, offered in a joint venture between Bateman-Titaco, JKTech and Mintek,
embody the current state-of-the-art in air pulsed jigging.

References

1. Tanaka M, Jinnouchi Y, Sawata Y and Kawashima S, 1990, "Effect of the wave pattern of pulsation
on the performance of an air-pulsated jig", Proceedings of 11th ICPC, Tokyo, pp.139-144.
2. Jonkers A., “Computer control of jigs - masters thesis”, The University of Queensland, Brisbane
Australia, 1990.
3. Lyman, G.J. "Cleaning coarse and small coal – Water based processes", Australian Coal Preparation
Society, Advanced Coal Preparation Monograph Series, Volume III, Part 7, p. 61.

This extract is from:

The APIC Jig and the JIGSCAN Controller take the Guesswork Out of Jigging (PDF)

Coal handling plant

A coal-handling complex with a rapid-load-out station, robot train mover and stacker and reclaimer.

coal-handling

A coal-handling complex with a rapid-load-out station, robot train mover and stacker and reclaimer.

A drum and cyclone coal-preparation plant.

A drum and cyclone coal-preparation plant.

 

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