AUSTRALIAN COAL PREPARATION SOCIETY ADVANCED COAL PREPARATION MONOGRAPH SERIES
Volume II
MATERIALS OPERATIONS
PART 3
MATERIALS HANDLING
CONTENTS 1 2 INTRODUCTION OBJECTIVES
2.1 2.2 2.3 Integrated Coal Preparation Concepts Interactive Effects System Selection
MATERIAL CHARACTERISTICS
3.1 3.2 3.3 3.4 Angle of Repose Bulk Density Stratification and Segregation Coal Characteristics Which Affect Gravity Flow 3.4.1 Rank 3.4.2 Size Distribution and Mean Particle Size 3.4.3 Particle Shape 3.4.4 Moisture Content 3.4.5 Chemical Additives 3.4.6 Oxidation 3.4.7 Hardness and Friability 3.4.8 Bulk Density 3.4.9 Constituents 3.4.10 Period Stored Material Flow Properties Design for Flow
3.5 3.6
CONVEYING
4.1 4.2 General Conveyor Design
4.3
Belt Power and Tension Formulae 4.3.1 Equipment Friction Factors 4.3.2 Terminal Friction Constant, tf, Expressed in Metres of Centre-tocentre Distance 4.3.3 Additional Friction Considerations 4.3.4 Component Frictions and Tensions 4.3.5 Power
STOCKPILING
5.1 5.2 5.3 5.4 General Considerations Stockpiling Systems Stockpiling Equipment Blending
EQUIPMENT UNITS IN COAL HANDLING SYSTEMS
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 Unit Operations Equipment Types Bins Chutes and Hoppers Feeders Dump Stations Rail Loaders Rail Receival
7 8 9
PLANT LAYOUT AND DESIGN SERVICES CONCLUSION
REFERENCES FURTHER READING 16 Figures 7 Tables
PART 4
PRINCIPLES OF SAMPLING
CONTENTS 1 2 3 INTRODUCTION SAMPLING TERMINOLOGY APPLICATION OF ELEMENTARY STATISTICS TO SAMPLING
3.1 3.2 Basic Probability Theory Statistical Analysis of a Typical Sampling System 3.2.1 General Consideration of Overall System 3.2.2 Analysis of the Primary Sampling Stage 3.2.3 Analysis of the Secondary Stage 3.2.4 Analysis of the Tertiary Stage 3.2.5 Analysis of the Preparation Stage Manual Sampling Determination of Precision and Bias Remarks
3.3 3.4 3.5
4 5
SAMPLING STANDARDS ADVANCED SAMPLING THEORY
REFERENCES 14 Figures 7 Tables
PART 5
SAMPLING EQUIPMENT AND PRACTICE
CONTENTS 1 2 INTRODUCTION MECHANICAL SAMPLING
2.1 2.2 General Sample Cutters 2.2.1 General 2.2.2 Cutter Aperture and Geometry 2.2.3 Cutter Velocity for Falling Stream Cutters 2.2.4 Cutter Velocity for Cross Belt Cutters 2.2.5 Cutter Selection Crushers 2.3.1 General 2.3.2 Crusher Selection Feeders 2.4.1 General 2.4.2 Feeder Selection Mechanical Sampling Systems 2.5.1 General 2.5.2 Single-stage Sampling Systems 2.5.3 Two-stage Sampling Systems 2.5.4 Three-stage Sampling Systems 2.5.5 Centralised Sample Processing
2.3
2.4
2.5
MANUAL SAMPLING
3.1 3.2 3.3 3.4 General Sampling from a Falling Stream Stopped Belt Sampling Stockpile Sampling
SAMPLING OF SLURRIES
4.1 4.2 4.3 4.4 4.5 General Sampling from a Falling Stream Sampling from Pipes Sampling from Tanks Sampling from Launders
SAMPLE PREPARATION
5.1 5.2 5.3 5.4 Introduction Fundamentals of Sample Preparation Air Drying Particle Size Reduction
5.5 5.6 5.7
Sample Mixing Sample Division General Analysis Sample
SAMPLE IDENTIFICATION, STORAGE AND RETRIEVAL
REFERENCES 11 Figures
PART 6
COMMINUTION AND SCREENING
CONTENTS
COMMINUTION
1 INTRODUCTION TO COMMINUTION
1.1. 1.2. Objectives Coal Structure
BREAKAGE THEORY
2.1 2.2 2.3 2.4 Fundamentals Coal Strength Stress and Strain Fracture 2.4.1 Crushing 2.4.2 Impact 2.4.3 Attrition 2.4.4 Wedge Action
COMMINUTION PROCESSES
3.1 3.2 3.3 3.4 3.5 Simulation of Breakage Power Requirements 3.2.1 Bonds Law Product Size Size Control Comminution Circuits 3.5.1 Open Circuits 3.5.2 Bypass (Scalping) Circuits 3.5.3 Stage Crushing 3.5.4 Closed Circuit Crushing Factors in Comminution Equipment Selection 3.6.1 Feed Composition 3.6.2 Feed Size Distribution 3.6.3 Feed Moisture 3.6.4 Product Characteristics 3.6.5 Feed Rate 3.6.6 Reduction Ratio 3.6.7 Machine Size 3.6.8 Cost
3.6
COMMINUTION MACHINES
4.1 4.2 Stages of Comminution Primary Crushers 4.2.1 Jaw Crushers
4.3
4.4
4.2.2 Gyratory Crushers 4.2.3 Roll Breakers 4.2.4 Rotary (Bradford) Breakers 4.2.5 Pick Breakers (Feeder Breakers) 4.2.6 Impact Breakers Secondary Crushers 4.3.1 Single and Multi-roll Crushers 4.3.2 Hammer Mills 4.3.3 Impactors Tertiary Machines 4.4.1 Tumbling Mills 4.4.2 Roll-race Mills (Vertical Spindle Mills) 4.4.3 Hammer Mills
COMMINUTION SUMMARY
SCREENING
6 INTRODUCTION TO SCREENING
6.1 6.2 6.3 Sizing Dewatering Beneficiation
PRINCIPLES OF SCREENING
7.1 7.2 7.3 7.4 Behaviour of Particles on a Vibrating Screen Probability Theory Open Area Blinding and Plugging 7.4.1 Feed Moisture 7.4.2 Near-size Particles 7.4.3 Screen Motion 7.4.4 Screen Deck Materials 7.4.5 Aperture Configuration Effective Aperture Screening Rate Variation Bed Depth
7.5 7.6 7.7
SCREEN SURFACES
8.1 8.2 8.3 8.4 8.5 8.6 Perforated Plate Woven Wire Weldmesh Wedge Wire Polyurethanes Rubber
STATIC SCREENS
9.1 Grizzly Screens
9.2 9.3 9.4
Divergators Sieve Bends Rapped Sieves
10
VIBRATING SCREENS
10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 Operating Modes of Vibrating Machines Overcritically Operated Machines Machines Operating Close to Resonance Two Bearing Screens Four Bearing Screens Elliptical Motion Screens Linear Motion Screens Resonance Screens Speed, Slope and Stroke
11
SPECIAL DESIGNS OF SCREENS
11.1 11.2 11.3 11.4 11.5 11.6 Banana Screens The Mogensen Sizer High Frequency Dewatering Screens The VorSiv Screen The Derrick Screen Rotating Probability Screens
12
WET SCREENING
12.1 12.2 12.3 Wet Screening Applications Preparation of Slurries for Screening Water Requirements for Wet Screening 12.3.1 Sprays 12.3.2 Shower Boxes Cross Dams Vibration
12.4 12.5
13 14 15
DESLIMING MEDIUM RECOVERY SCREEN PERFORMANCE
15.1 Screen Capacities 15.1.1 Raw Coal Sizing Screen Capacities 15.1.2 Desliming Screen Capacities 15.1.3 Dewatering Screen Capacities 15.1.4 Medium Recovery Screen Capacities Simulation of Screening Processes Screen Efficiency 15.3.1 Factors Affecting Performance
15.2 15.3
16
SCREEN SELECTION AN EXAMPLE
16.1 16.2 16.3 Raw Coal Sizing Screens Desliming Screens Medium Recovery Screens
17
DESIGN AND LAYOUT
17.1 17.2 17.3 17.4 Head Box Arrangement Sieve Bend Arrangement Vibrating Screen Arrangement Screen Support Systems 17.4.1 Suspended Supports 17.4.2 Floor Mounted Supports 17.4.3 Screen Deck Attachment
18
OPERATION OF VIBRATING SCREEN SYSTEMS
18.1 18.2 18.3 Operation Trouble Shooting Maintenance
19
SCREENING SUMMARY
ACKNOWLEDGMENTS REFERENCES 53 Figures 14 Tables
