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Impact of Material Chemistryon the Performance Characteristics of aCoal Handling Plant

Kumar Harshit, Syed Ali Hussain Jafri, and Pallav Gupta

ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Centrifugal Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Different Types of Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Comminution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Beneficiation (Coarse Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Beneficiation (Fines Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Site Details of Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Life Cycle of Warman Pump (Primary Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Graph of Head Versus Flow Rate for Two Distinct Pumps (171 and 172) . . . . . . . . . . . . . . . . . . 19Life Cycle of a Warman Pump (Secondary Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Graph of Head Versus Flow Rate for Secondary Pumps 167 and 168 . . . . . . . . . . . . . . . . . . . . . . 22Life Cycle of Warman Pump (Over-Dense Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Graph of Head Versus Flow Rate for Over-Dense Pump 165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Curves of Other Horizontal Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Other Horizontal Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

K. Harshit · P. Gupta (*)Department of Mechanical Engineering, A.S.E.T., Amity University, Noida, Uttar Pradesh, Indiae-mail: [email protected]

S. A. H. JafriDepartment of Mechanical Engineering, Integral University, Lucknow, UP, India

© Springer Nature Switzerland AG 2019C. M. Hussain (ed.), Handbook of Environmental Materials Management,https://doi.org/10.1007/978-3-319-58538-3_173-1

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AbstractThe handling tasks at a coal beneficiation plant enhance the preparation of coal byimproving the techniques involved in each process and the various associatedparameters. The various kinds of equipment available at the plant increase theefficiency of the respective machines and improve the quality of the productderived from the plant operations. Economical storage, loading and unloading ofcoal cars, maintenance of machines, and the improving technical knowledgeassociated with each job depend completely on the handling equipment and themanagement of the plant. In the present chapter, a complete assessment of thecoal beneficiation plant is presented in detail, with the four major parameters:pumps installed, processes involved, material chemistry, and performance indi-cators. These four parameters have major roles in the production of coal at therespective plants, so it is crucial that the production and manufacturing firmsfocus their major interests on these points. The text emphasizes the types ofprocesses and operations involved at the beneficiation plant as well as thehandling characteristics. The separation of coal into different segments is signif-icant for production as this increases the economic aspects for the respectivefirms. Handling of the coal is an essential function in the industry because itensures the proper channelling of the coal to operations in different branches ofthe plant, such as the thermal power plant and power house. These results and theother parameters discussed in the chapter concern the impact of material chem-istry on the performance of the plant’s machinery along with the various featuresof machines such as pumps, allowing us to analyze the role of all the elementsinvolved during the separation of coal. The approach of this chapter is focused ondetailed study of the pumps, that is, the centrifugal pumps installed at the washeryplant, as they are the most basic elements for proper and efficient operation. Thechapter also provides various mathematical relationships, tabular representations,and graphical approaches to aid the reader in understanding the major parameters.

KeywordsBeneficiation · Material chemistry · Efficiency · Industries · Performance

Introduction

The combustible black sediment found in the layers of rock strata is termed coal.This natural nonrenewable resource has an essential role in the production industryas it is the premium source for the generation of electricity, and for this reason it isexported throughout the globe for various purposes. Coal is composed primarily ofcarbon, with other elements including hydrogen, nitrogen, and oxygen. In the classof material application, coal is one of the most important natural resources alongwith petroleum, as these run parallel when considering the economic condition ofany of the countries (Krevelen 1961).

2 K. Harshit et al.

Progress in technology allows using the techniques in any aspect of production ina very sophisticated manner, so that the associated complex problems can be solvedreadily and easily. The presence of coal is a gift of nature to a particular locale, but itsutilization techniques are the most important consideration (Krevelen 1961). Auto-mation of coal production nowadays is crucial for the steel industry as well as miningareas (Ji-ping 2010a). Covered here is the complete automation of coal productionfrom its extraction from the mines to the processing zone, where it is separated intodifferent segments – clean coal, middling coal, and rejection coal – and finally ismade ready for transportation. On the basis of this presentation, it can be assumedthat efficient handling of this resource by automation should be taken on seriousgrounds by any of the industries. Research efforts across the globe on improvingautomation techniques are determining optimal solutions for many aspects of pro-duction. In the coal industry, advanced techniques are being implemented withvarious upgraded machine tools for proper technological application. Because tech-nological advances are contributing to many firms, we can say that organizationsshould give more attention and investment of resources to these technical aspects(Ji-ping 2010b).

The major segment of this chapter is focused towards the application of thepumps established at the TISCO plant, as a case study, for the production of coalin three categories: clean coal, middling, and rejection. The pumps installed at theplant are of various types, but the present chapter is concerned with centrifugalpumps. Pumps have an essential role in industry, with various associated applica-tions during many operations (Stepanoff 1948). Pumps are located at almost all theregions of the coal plant, depending upon the type of operation at the respective zone(Moser and Schnitzer 1985). Pumps have a significant role in all aspects of theindustry depending upon the operation involved in separation of the coal intosegments (Lazzarin 1995). A washery plant has different units overseeing thepumps on the basis of their type and operation, which aid in identifying problemsand rectifying these efficiently (da Costa Bortoni et al. 2008). The performancecurves presented in this chapter help in analyzing the relationship between variouspump parameters during operations in a beneficiation plant. Detailed study of thepumping system is discussed along with all possible parameters to be considered inthe respective segments (Srinivasan 2008).

The context of the chapter is also aimed at describing the types of processinvolved at the plant in handling and separating the coal. The process is dividedon the basis of the operations used during separation (Wheelock and Markuszewski1984). Separation corresponds to the middling and rejection processes, which areanalogous; these have certain features differentiating the coal on the basis of size anddensity of the material produced (Gan et al. 1972). Distinctive processes take placeduring particular operations, such as comminution and beneficiation (Nadkarni andWilliams 1983). The beneficiation plant is completely focused on the preparation ofcoal from the raw material through a simple crushing operation (Krevelen 1961).This process involves complex circuit methods for cleaning purposes, covering eachand every size of coal, that reject all the impurities linked with the run of the mine(ROM) materials (Akbarnezhad et al. 2011). These different methods are the key in

Impact of Material Chemistry on the Performance Characteristics of a Coal. . . 3

coal preparation, in which gravity separation is significant in the segmentation of rawcoal having different sizes, densities, etc., by the use of equipment such as cyclones.The froth floatation method is a dominant coal cleaning method for fine-sizedparticles (Gan et al. 1972). The beneficiation plant is used for the preparation ofcoal in which impure coal is made into clean coal, plus middling and rejection,depending on the market demand. The main agenda of this industry, which is takenas a case study, is to produce the maximum amount of clean coal having a minimumash content. The other content obtained from the raw coal apart from clean coal alsohas certain functions: rejection coal is used in the production of electricity whereasmiddling is used by the company itself for various purposes (Yoshiie et al. 2012).

The chapter is also an attempt to understand the three main factors of the coalbeneficiation plant: the performance characteristics of the machines installed, therole of the machines (pumps), and processing technologies. Performance character-istics have been plotted on the basis of data collected by the pumps during operation,and these data help in establishing a framework regarding the different parametersassociated with pumps (Stepanoff 1948). Along with the production and handling ofcoal, the coal plant is also focused on the safety of the environment (Carley 2009).

Centrifugal Pump

A turbo-machinery device is used for transportation of fluid by converting the flowof fluid from rotational energy into hydrodynamic energy. Fluid strikes the motor,which allows the impeller to rotate, thus resulting in the rise of water, leading to thedevelopment of mechanical energy. The rotating axis allows the entry of fluid, whichis finally carried away through an exit (Croba and Kueny 1996). The context here isfocused on the study of centrifugal pumps and their applications in the separationand handling of coal (Lobanoff and Ross 2013).

Basic formulae to be incorporated for calculation:

Solving for water horsepower

WHP ¼ Q�H=3960

Water Horsepower

WHP = Q*H/3960 Solve for water horsepower

Q = 3960*WHP/H Solve for flow rate or discharge

H = 3960*WHP/Q Solve for total head

N = WHP/BHP Solve for pump efficiency

BHP = 100*Q*H/3960n Solve for brake horsepower

where WHP = water horsepower; Q = flow rate or discharge; H = total head;n = pump efficiency; and BHP = brake horsepower.

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Different Types of Pumps

Primary PumpThe role of the primary pump is to deliver the overflow of clean coal, consisting offine particles (Gan et al. 1972). This flow is supplied to the primary distribution box,from which it is finally carried over to the cyclones, where it is again distributed onthe basis of density (Gan et al. 1972). Density of the substance is modified by mixingor adding media used for gravity separation, and then finally, by means of a conveyorbelt, the coal is carried to the desired tank location. These pumps work in pairs, andthe pairs work alternately depending upon the requirement (Fig. 1).

The unit numbers are 170, 171, 172, and 173.

Secondary PumpThe secondary pump has a function similar to that of the primary pump. It is used forcarrying particles to the secondary distribution box located at the 25-m height block.The coal is then carried forward towards the secondary cyclones that are used toseparate the middling and rejection quantities (Gan et al. 1972). Finally, with theconveyor belt of these particles, coal is carried to the rejection and middling tanks(Yoshiie et al. 2012).

The unit numbers are 166, 167, 168, and 169.

Over-Dense PumpA high-density solid constitutes the mixtures of solids and liquids having variouscharacteristics including both physical and chemical parameters. The over-densepump has a significant function in the transportation of high-density solids during theseparation process. Substances having a high proportion of solids, such as sewagesludge, waste sludge, and bituminous coal sludge, are carried to distant locations inthe beneficiation plant (Nadkarni and Williams 1983). These conveying distancesare made possible by bridging with a high-density pump or mechanical conveyingequipment (Fig. 2).

The unit numbers are 164 and 165.

Fig. 1 Primary pump setup atplant


Dilute PumpThe dilute pump is also important in delivering the working constituents to desiredlocations along the conveyor belts (Ji-ping 2010a). Figure 3 presents a pictorialrepresentation of the dilute pump at the coal beneficiation plant, with specific unitnumbers associated with each pump. Unit numbers help in recognizing the locationof the pump as well as other machines as it is a little difficult task to locate the pumpswithout numbers.


Thickening PumpUnderflow slurries of particles sized from 5 mm to 13 mm are carried out during theoperations at the beneficiation plant (Nadkarni and Williams 1983). Various concen-trated slurry mixtures containing abrasive particles have a high-grade nickel con-centrate, a mixture of copper and nickel, or a copper slurry with low nickel content,with flows up to 359 l/min (95 US GPM), and up to 72% solids density of 4.29–4.97(Krevelen 1961). Depending upon demand and operating conditions, the soft rubberlined (SRL) centrifugal pump has been replaced by the VF80s pump (Ji-ping 2010a).Various parameters are changed in these pumps: air domes of approximately 80 lhave been set up at the discharge line to control the pulsating rate caused by theslurries, and expansion bellows are installed at the suction side to improve thesuction condition (Lazzarin 1995) (Fig. 4).


Fig. 2 Over-dense pumpsetup at plant

Fig. 3 Dilute pump setup atplant

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Froth Floatation PumpThe froth pump is essential in the separation of rich minerals from gangue duringmineral processing (Yoshiie et al. 2012). In this process air is added, and richminerals are trapped in the air bubbles and finally rise to the top of the floatationcell tank, allowing the waste particles such as clay, etc., that have no further use, tosettle at the bottom of the cell (Gan et al. 1972). Different processes such asscavenging and cleaning are carried out inside the floatation tank (Ji-ping 2010a).

The floatation pump also has a significant role in extraction plants for oils andother resources where froth is used for the removal of bitumen and other undesirablesubstances (Lazzarin 1995). As it is difficult to move oils at low speed and temper-atures, a change is made in the pump speed depending on the operational demands(Moser and Schnitzer 1985). Changes in pump speed also lead to the development offriction from self-lubrication of fluid where water separates and forms differentlubricating layers (Stepanoff 1948). When water or any working fluid enters thepump, different operations take place, low pressure is developed at the impeller, andpre-rotation produces the centrifugal force that allows the slurries to settle and air torest at the center (Moser and Schnitzer 1985). According to Abulnaga (2004), thepump may use (a) a large eye diameter, (b) an inducer or extension of the impellervanes into the suction pipe, (c) a recirculating pipe from the discharge side of thepump with pressurized froth to break up the bubbles at the eye, (d) tandem vanes atthe impeller shroud, (e) split or secondary vanes at the shroud, or (f) a verticalarrangement; hence, the split vane should be thick enough to resist the wear (Fig. 5).

Unit numbers are 175 and 176.

Vertical Sump PumpVertical sump pumps are intended for use in industrial pumping applications to pumpclean or lightly contaminated liquids, fibrous slurries, and liquids containing largesolids from the deep sumps (Croba and Kueny 1996; Lobanoff and Ross 2013). Thepumping head is suspended into the pumped liquids and the drive motor is dryinstalled on the top. The pump has a separate discharge pipe and support pipecolumn (Lazzarin 1995). The vertical sump pump has a vertical line shaft withslide bearings or a cantilever design without slide bearings (Ji-ping 2010a). Avertical sump pump at the coal plant is shown in this figure (Fig. 6).

Unit numbers are 304A and 304B.

Fig. 4 Thickening pump


Effluent PumpThe effluent pump is used to handle semi-solids and to pump filtered effluent to leachfields from the septic tank in the beneficiation plant (Nadkarni and Williams 1983).These pumps are crucial in segmentation of coal when are used as sump pumps andsometimes become clogged by some thick liquid, or grass or debris, etc. (Stepanoff1948). Separation of semi-solids from raw coal is efficiently handled by the effluentpump, and thus the plant can produce a high quality of clean coal with completepurity (Srinivasan 2008) (Fig. 7).

Unit numbers are 111 and 112.

Processes

The present chapter discusses the various operations associated with the handling ofcoal at a beneficiation plant (Sanders 2007). The coal beneficiation plant has acapacity of 600 tonnes per hour; it has a control room handling all the plantoperations. As not much reduction in size of the feed is required for a coalbeneficiation plant, a de-shelling plant is needed (Gan et al. 1972; Carley 2009).As there is no grinding plant, the dewatering section is present at a lower height than

Fig. 5 Froth floatation Pump

Fig. 6 Vertical sump pumpsetup at plant

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the main beneficiation plant so as to optimize the cost associated with the pump. Afiltration section is present at the beneficiation plant for the dewatering of fine coal.The various processes involved in the coal beneficiation plant depend upon the typesof equipment used there and are categorized in various forms.

Comminution

Comminution is the reduction of solid materials of one average particle size to asmaller average particle size by crushing, grinding, cutting, vibrating, or other pro-cesses (Gan et al. 1972). In geology, it occurs naturally during faulting in the upper partof the Earth’s crust. In industry, it is an important unit operation in mineral processing,ceramics, electronics, and other fields, accomplished with many types of mill (Moserand Schnitzer 1985). In dentistry, it is the result of mastication of food. In generalmedicine, it is one of the most traumatic forms of bone fracture (Lazzarin 1995)

Equipment used:

• Banana screenIts distinctive shape gave the multi-sloped screen the name “banana.” In industry,the “banana” term is used interchangeably with the term “multi-sloped.” Used inwet and dry applications, banana screens are vibratory equipment that uses thedistinctive shape for inclined horizontal screens, which as the name implies arehorizontal and do not have the banana shape (Ji-ping 2010a). Improper screeningmeans that a large amount of fines will remain with the oversized material (Ganet al. 1972; Carley 2009). The result is high recirculation volumes and greaterwear of downstream process equipment. Being multi-slope, the screens offerhigher screening capacity, as mentioned earlier (Ji-ping 2010b). They also aregood for recovery in feeds with a very high percentage of near-sized material(Gan et al. 1972).

The banana screens used at CHP were from Metso, their aperture size was113 mm, and dry screening was done; these screens were used to perform closedcircuit crushing.

Specifications of banana screen:

Fig. 7 Effluent pumpinstalled at washery #2


• Single deck• Width, 1800 mm• Length, 4800 mm• Tonne per hour (tph), 120–125• Motor, 15 kv• Speed, 1500 rpm• Equipment numbers: 178, 179, 180, 181, 182, 183, 184, 185

Specifications of clean coal screen:

• Single deck• Capacity, 80 tph• Feed size, 13 mm–0.5 mm• Equipment numbers: 156, 157, 162, 163

Specifications of middling screen:

• Capacity, 60 tph• Size, 13 mm–0.5 mm• Model number, T11

Specification of middling and rejection screen:

• Capacity, 80 tph (Fig. 8)

• Roll CrushersA simple standard roll crusher consists of two horizontal cylinders that revolvetoward each other. The set of roll crushers is determined by shims, which causethe spring-loaded roll to be held back from the solidly mounted roll (Ji-ping2010a). The main advantage with roll crushing is that lesser fines are produced;for this reason crushing is used for coal crushing as the processing cost of fines ishigher than that of coarse particles (Stepanoff 1948). Roll crushers are very useful

Fig. 8 Banana screeninstallation at Washery #2

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in handling friable, sticky, frozen, and less abrasive feeds, such as limestone,chalk, coal, gypsum, phosphate, and soft iron ores (Srinivasan 2008). The rollsmay be gear driven but this limits the distance adjustment between the rolls, andmodern rolls are driven by a V-belt from different motors (Ji-ping 2010b;Lobanoff and Ross 2013). The great disadvantage of the roller crusher is thatlarge rolls are required in relationship to the size of the feed particles so as toachieve a reasonable ratio and also require a large amount of capital (Gan et al.1972; Yoshiie et al. 2012).

• Impact CrushersThe impact crusher is used for coarser crushing. In this crusher, material fallstangentially on to a rotor running at a speed of 250–300 rpm, receiving a glancingimpulse (Ji-ping 2010b; Moser and Schnitzer 1985; Lazzarin 1995; Croba andKueny 1996; Lobanoff and Ross 2013). The material is spun and goes to theimpact plates. This crusher gives a much better control of product size becausethere is less attrition. The impact crusher used at West Bokaro is completelycovered with plates, thus producing less dust (Srinivasan 2008). The fracturedpieces that pass through the clearances of the rotor and breaker plate enter asecond chamber created by another breaker plate (Croba and Kueny 1996;Lobanoff and Ross 2013). Finally, material is transported to the third chamberbased on clearance. This grinding path is designed to reduce flakiness and givesvery good cubic particles.

• Process OverviewAfter the coal is mined it goes into pre-treatment (crushing), which is performedin three stages: primary, secondary, and tertiary (Srinivasan 2008). Primarycrushing is done through roller crushers with a capacity of 750 tph and areduction ratio of 4; the feed size of 1000 mm is reduced to 250 mm after primarycrushing (Croba and Kueny 1996; Lobanoff and Ross 2013). The secondarycrushing is also done through the roller crusher with the same capacity of750 tph and a reduction ratio of 3.3; here the size of the coal is reduced from250 mm to 75 mm. Tertiary crushing is accomplished with an impact crusherwhere coal size is reduced from 75 mm to 13 mm; this is a type of closed circuitcrushing. Finally, the optimal size of 13 mm is obtained, which coal is sent forbeneficiation (Gan et al. 1972; Yoshiie et al. 2012).

Beneficiation (Coarse Circuit)

In the mining industry, coal beneficiation or beneficiation in extractive metallurgy isany process that improves (benefits) the economic value of the ore by removing thegangue minerals, which results in a higher-grade product (concentrate) and a wastestream (tailings) (Stepanoff 1948; Srinivasan 2008). Exemplary beneficiation pro-cesses are froth floatation and gravity separation (Nadkarni and Williams 1983;Yoshiie et al. 2012).


Equipment Used:

• Dense Media Cyclone (DMC)The dense media cyclone provides a high centrifugal force and a low viscosity inthe medium, enabling much finer separations to be achieved (Feng 2006). Feed tothese devices is typically de-slimed at about 0.5 mm, to avoid contamination ofthe medium with slimes and to minimize medium consumption (Fourie et al.1980; Chen et al. 2012). The commonest form of DM cyclone is that made by theDutch State Mines in the 1940s. The DMC has an included cone angle of 20�. Thecoal is suspended in the medium and introduced tangentially to the cyclone eithervia a pump or by gravity feeding (Chen et al. 2012; Wood 1990) (Fig. 9).

• High-Frequency ScreenWith high efficiency, small amplitude, and high frequency of screening, regardingthe working principle, the high-frequency screen differs from the conventionalscreens. It creates good conditions for separating materials, especially small-sizedmaterials (Gan et al. 1972). When the machine operates, the low-frequencyelectromagnetic vibrator vibrates the feeder. Then, the output part of the meshdirectly moves the whole screen (Ji-ping 2010a). At the same time, the high-frequency electromagnetic vibrator shakes the middle of the mesh screen via arubber cushion (Ji-ping 2010a). The mesh screen is composed of three stainlesssteel layers. The lowest layer, which is of high strength, is connected with theshake motor; the other two layers are workable screens in mine processing (Crobaand Kueny 1996; Lobanoff and Ross 2013).

• Dewatering MaterialIn this machine from the term only signifies the removal of water and surfacemoisture to enhance the quality of the product (clean coal) (Dzinomwa et al.1997) (Fig. 10).

This section considers these two processes only, and other operations areexplained in the next sections. The entire apparatus is covered with a casingcalled a “bowl” during the segmentation of coal.

• Process ReviewCoarse circuit beneficiation provides the segmentation of coal by the gravityseparation method, which is then followed with other processes. Gravity

Fig. 9 Cyclone installed atcoal plant


separation uses a cyclone for segmenting coal in various forms: clean coal,middling, and rejection (Srinivasan 2008; Gan et al. 1972). Screening is alsodone for segmentation of coal by various methods followed by dewatering of coalusing the bird (Tao et al. 2000; Sabah et al. 2004).

Beneficiation (Fines Circuit)

The process of beneficiation has been discussed in the previous section with thevarious characteristics.

Equipment used:

• Froth floatationFroth floatation is a process for separating minerals from gangue by takingadvantage of differences in their hydrophobicity (Gan et al. 1972). Hydropho-bicity differences between valuable minerals and waste gangue are increasedthrough the use of surfactants and wetting agents (Stepanoff 1948). Selectiveseparation of the minerals allows processing complex (that is, mixed) ores to beeconomically feasible (Srinivasan 2008). The floatation process is used for theseparation of a large range of sulfides, carbonates, and oxides before furtherrefinement (Beamish and Blazak 2005). Phosphates and coal are also upgraded(purified) by floatation technology. For froth floatation, the ground ore is mixedwith water to form a slurry with the desired mineral (Lazzarin 1995). It is thenrendered hydrophobic by the addition of a surfactant or collector chemical(although some mineral surfaces are naturally hydrophobic, requiring little orno addition of collector) (Stepanoff 1948). The particular chemical obtained fromthe froth floatation cell depends on the nature of the mineral that is recovered fromthe various processes (Moser and Schnitzer 1985; Lazzarin 1995).

This slurry (more properly called the pulp), a combination of hydrophobic andhydrophilic particles, is then introduced to tanks known as floatation tanks orfloatation cells. These particles are then aerated to form air bubbles. The hydro-phobic particles attach to the air bubbles, which rise to the surface, forming froth.The froth is removed from the cell, producing a concentrate (“con”) of the target

Fig. 10 Bird in standbyinstalled at Washery #2


mineral (Yoshiie et al. 2012). The minerals that do not float in the froth arereferred as “floatation tailings” or “floatation tails.” These tailings may be sub-jected to further floatation stages to recover any valuable particles that did notfloat the first time: this process is known as scavenging (De Korte 2010; Dwariand Hanumantha Rao 2009). The final tailings after scavenging are usuallypumped for disposal as mine fill; they may also be pumped to tailings disposalfacilities for long-term storage.

• ThickenerA thickener is used to increase the concentration of a suspension by sedimenta-tion, accompanied by the formation of a clear liquid (Osborne 1986). In mostcases, concentration of the suspension is high and hindered settling takes place .Thickeners carry batches or continuous units, consisting of relatively shallowtanks. The clear liquid is then taken off from the top and the thickened suspensionflows at the bottom (Yoshiie et al. 2012). The tank consists of one or more rotatingradial arms, from each of which are suspended a series of blades (Ji-ping 2010b),shaped so as to move the settled solids toward the central outlet. In some caseschemicals are also added in the thickener tank to make the solids settle faster, andthe rest flows from the bottom of the tank (Gan et al. 1972). Awater sprayer maybe added at the top of the thickener tank to sink the froth on the top layer(Nadkarni and Williams 1983). The direction of water spraying is similar to thedirection of the rakes so that the water spray does not counter the flow of water inthe tank. A high-rate thickener operates alternatively along with the thickener andthe other is kept on standby, or vice versa (Fig. 11).

• High-Rate ThickenerHigh-rate thickeners built as dedicated machines are available in sizes up to 40 min diameter, but retrofits of conventional thickeners are often larger in size (Ganet al. 1972). When viewed from outside, high-rate thickeners look very much likeconventional machines except that their tanks have a greater height-to-diameterratio. Their height is derived from operation by calculating retention time andreduced area. As to the internals, there are several approaches to the mechanismof high-rate thickening. Design options include deep feed wells with progressiveflocculation along the incoming stream route (Ji-ping 2010b); another is directinjection into the feed well or recirculation of liquid from the clear zone toenhance settling rate by diluting the feed internally (Srinivasan 2008). There

Fig. 11 Thickener installedat beneficiation plant


are also concepts that resemble a sludge-blanket that clarifies with feed wells thatare submerged in the sludge bed (Stepanoff 1948): these also provide an addi-tional benefit of trapping the fines to produce a clear effluent.

Unit number HRT is 101 (Fig. 12).Parts associated with the high-rate thickener are as follows (Fig. 13):

1. Hydraulic power pack2. Hydraulic cylinder3. Hydraulic motor4. Planetary gear box

• Vacuum Belt FilterThe belt filter (sometimes called a belt filter press) is an industrial machine usedfor the solid–liquid separation process, particularly the dewatering of sludge inthe chemical industry, in mining, and in water treatment (Asmatulu et al. 2005).The process of filtration is primarily obtained by passing a pair of filtering clothsand belts through a system of rollers. The feed sludge to be dewatered isintroduced from a hopper between two filter cloths (supported by perforatedbelts) that pass through a convoluted arrangement of rollers; water is squeezedout of the sludge (Lazzarin 1995). When the belts pass through the final pair of

Fig. 12 High-rate thickenerinstalled at Washery #2

Fig. 13 Parts of thickenerinstalled at Washery #2


rollers in the process, the filter cloths are separated and the filter cake is thenscraped off into a suitable container (Lobanoff and Ross 2013). Belt filters use avacuum system to minimize off-gas and effluent during operations (Moser andSchnitzer 1985).

• Reflux ClassifierThis industrial machine separates fine particles on the basis of either density orsize, improving the efficiency of the process with its unique tilted design(Honaker et al. 2000). A reflux classifier was developed by combining a conven-tional fluidized bed with a system of inclined channels to achieve enhanced ratesof segregation of high-density particles and enhanced conveying of low-densityparticles (Gan et al. 1972). The technique relies on the fact that the value of amaterial is usually related directly to its density (Yoshiie et al. 2012). The deviceconsists of a system of inclined channels attached to a conventional fluidized bed.The inclined channels permit significantly higher feed rates (Srinivasan 2008).The reflux classifier can be applied to a relatively broad range of particle sizes andcan achieve higher recovery of valuable material than other water-based technol-ogies (Wheelock and Markuszewski 1984). The technology has succeeded insolving an existing processing problem by achieving the separation of coal(Honaker 2010). It essentially helps in the recovery of premium, high-grademetallurgical coal.

• Process ReviewThe fine flows from all the de-sliming screens are combined and sent to a frothfloatation (FF) tank, and then to a FF cell of capacity 100 tph via an FF pump: inthe FF cell the lighter coal particles leave as froth, are sent for dewatering to thescreen bowl centrifuge and vacuum belt filter (VBF), and then the final driedclean coal is mixed with the coarse clean coal and stored in a clean coal(CC) bunker (Ji-ping 2010b; Gan et al. 1972; Nadkarni and Williams 1983;Yoshiie et al. 2012; Dzinomwa et al. 1997). Heavier gauge particles from FFcells leave as tailings and are sent to the thickener; after thickening the underflowis forwarded to a reflux classifier, and overflow from the reflux classifier goes tothe CC bunker while underflow is sent to a tailing dewatering plant (Duong et al.2000).

Performance

The present chapter discusses the performance characteristics associated with pumpsand also helps in understanding relationships between the machine parameters andoperations. The data in this chapter are taken from the operation of various equip-ment during a particular process (Laskowski 2001). The graphs and charts help inanalyzing the characteristics of the equipment installed at the beneficiation plant(Chen and Yang 2003; Dwari and Hanumantha Rao 2007). Such data are crucial inanalyzing the performance parameters of machines and also help in enhancing thequality of the product as well as production efficiency (Lockhart 1984).


Site Details of Pumps

For a case study we used the TISCO plant. Coal handling is the major operation apartfrom mining and other operations. Site details help in understanding the character-istics of the pump installed at the washery plant.

Various parameters illustrated include model number, quantity, flow rate, slurryhead, particle size, specific gravity, pH value, temperature, application, sealingarrangement, impeller mock, average working life, particle size, working hours,pulleys, and motor. Table 1 also presents the specifications of all different pumpsinstalled at the plant, covering all the associated details.

Life Cycle of Warman Pump (Primary Pump)

Coal preparation is widely dependent on the operations associated with pumps, andthe pumps installed at the beneficiation plant are crucial. Key factors affecting thelife of a pump are given next.

Primary pump 172 also possesses various features related to the specifications.The tables suggest improvements to be considered for enhancing pump working life.

Tables 2 and 3 present the detailed parameters of primary pumps 171 and172, covering essential specifications including impeller, design capacity of eachpump, design head of the pump, motor rpm, pump rpm, media to be handled, specificgravity of liquid, and motor efficiency (Mehta and Borio 1983). Details (in table)highlighted by the yellow watermark in both sections of the pump show the requiredrpm at which the pump should run, that is, 1040. A minor difference is observed

Table 1 Site details of pump

SITE DETAILS DESIGNED ACTUAL DESIGNED ACTUAL DESIGNED ACTUAL DESIGNED ACTUAL DESIGNED ACTUAL DESIGNED ACTUAL DESIGNED ACTUALMAKE WARMAN WARMAN WARMAN WARMAN WARMAN WARMAN WARMAN WARMAN WARMAN WARMAN WARMAN WARMAN WARMAN WARMANMODEL 10/8 RM 10/8 RM 10/8 RM 10/8 RM 8/6 RAH 8/6 RAH 8/6 RAH 8/6 RAH 10/8 RM 10/8 RM 6/4 DAH 6/4 DAH 8/6 EAH 8/6 EAHQUANTITY 2 2 2 2 2 2 2 2 2 2 2 2 3 3FLOW(m3/hr) 765 650 380 380 910 136 650SLURRY HEAD(m) 58.1 44.9 65.3 65.3 28.5 52 41.8PUMP RPM 898 923 923 555 1075 972SP. GRAVITY 1.45 1.05 1.8 1.8 1.1 2 1.2PARTICLE SIZE(mm) (-)275 MICR ( - )0.5 MM ( - ) 13 MM ( - ) 13 MM (-)0.5 MM (-250) MIRC (- )0.5 MMPH VALUE 7 8.5 7 8.1 7 8.5 7 8.5 7 8.1 7 8 7 8TEMPERATURE AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT AMBIENT

APPLICATION

PRIMARY CYCLONE

FEED

PRIMARY CYCLONE

FEEDEFFLUENT

PUMPEFFLUENT

PUMP

SEC. CYCLONE

FEED

SEC. CYCLONE

FEED

SEC. CYCLONE

FEED

SEC. CYCLONE

FEEDDILUTE PUMP

DILUTE PUMP

OVER DENSE PUMP

OVER DENSE PUMP

CLARIFIED PUMP

CLARIFIED PUMP

SEALING ARRANGEMENT EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLER EXPELLERIMPELLER MOC A05 A05 A05 A05 A05 A05 A05 A05 A05 A05 A05 A05 A05 A05MOTOR KW/HP 320 HP 220 HP 220/275 HP 220 HP 110 KW 100 HP 1480MOTOR RPM 994 991 990 990 986 1465 1480PUMP PULLEY SIZE 615X6 560X7 465X5 465X5 785X5 490X4 345X5MOTOR PULLEY SIZE 560X6 515X7 440X5 440X5 500X5 340X4 510X5TOTAL WORKING HOURS/DAY 22 22 22 22 22 22 22

AVERAGE WORKING LIFE/PUMP 4200

RUNNING WITH

PROPER LIFE 1400 1400

RUNNING WITH

PROPER LIFE

RUNNING WITH

PROPER LIFE

RUNNING WITH

PROPER LIFE

SL NO.-5 SL NO.-6 SL NO.-7TAG NO:172/173 TAG NO:111/112 TAG NO:168/169 TAG NO:166/167 TAG NO:137/138 TAG NO:164/165 TAG NO:106/107/108

SL NO.-1 SL NO.-2 SL NO.-3 SL NO.-4


Table 2 Primary pump 171

Washery II Primary pump

Description Unit Value

existing Ideal

Pump tag no. WS2/PMP/171/CLR

Make of pump Warman Warman

Model 10/8 RM 10/8 RM

Impeller F8147A05 F8147A05

Design capacity of each pump m3/h 765 765

Design head of the pump Mtr 58.1 58.1

Media to be handled Magnetite slurry Magnetite slurry

Specific gravity of liquid 1.4 1.4

Pump rpm rpm 992 1040

Efficiency at rated duty % – 63

Motor efficiency 90% 90%

Absorbed power consumption by the pump (BKW) KW 230 269

Amps drawn by motor at site amps 320

Motor KW/rpm/voltage 200/992/415

Note: This pump is running at lower than rated duty parameterTo obtain the flow of 765,000 m3/h @ 58.1 m, the head pump should run at rpm of 1040

Table 3 Primary Pump 172

Life cycle study of Warman pump at TISCO-West Bokaro

Washery II Primary pump


existing Ideal



Model 10/8 RM 10/8 RM










Amps drawn by motor at site Amps 255

Motor KW/rpm/voltage 200/992/415

Note: This pump it is running at lower than rated duty parameterTo obtain the flow of 765 m3/h @ 58.1 m, the head pump should run at the rpm of 1040


from both pumps in absorbed power consumption (BKW): in 171 it is slightly moreas compared to that of 172 in the existing case. Thus, current drawn from the motorat site for 171 pumps is greater with respect to pump 172.

Graph of Head Versus Flow Rate for Two Distinct Pumps(171 and 172)

The detailed study of both pumps has been mentioned in the section “Life Cycle ofWarman Pump (Primary Pump)” of this chapter covering all the associated factorsaffecting pump working life. Figure 14 represents the relationship between head (m)on the ordinate with respect to the flow rate (m3/h) on the abscissa for the primarypump 171: this is the performance curve for horizontal Warman pump 10/8 m. Thearrow shown in Fig. 14 indicates the parameters at which the pump should operateduring segmentation.

The following information is shown below:

1. Flow: 765 m3/h2. Head: 58.1 m3. Speed: 1040 rpm4. Efficiency: 63%5. NPSHr: 6.1 m

Fig. 14 Head versus flow rate of 171


Details of pump 171 follow:

1. Pump1.1. Discharge: 203 mm1.2. Suction: 254 mm

2. Impeller2.1. Vanes: 52.2. Vane phi: 549 mm2.3. Type: closed2.4. Metal: F8147

3. Frame rating (kw)3.1. E: 1203.2. EE: 2253.3. F: 2603.4. R: 3003.5. FF: 4253.6. FFX: 425

4. Minimum passage size: 65 mm5. Seal: gland seal pump6. Liner (normal maximum rpm)

6.1. Polymer: 9206.2. Metal: 1100

The other graph gives details regarding primary pump. The graphs of primarypumps 171 and 172 are similar because they have the same function during seg-mentation. Figure 15 represents the relationship between head (m) on the ordinate

Fig. 15 Head versus flow rate of pump 172


with respect to the flow rate (m3/h) on the abscissa for the primary pump 172. Thered arrow shown in Fig. 15 indicates the parameters at which the pump shouldoperate during segmentation. The following information is shown below:

1. Flow: 740 m3/h1. Head: 32 m2. Speed: 635 rpm3. Efficiency: 69.44. NPSHr: 4.4 m

Details of pump 172:


2. Impeller2.1. Vanes: 52.2. Vane phi: 686 mm.2.3. Type: closed2.4. Metal: G81472.5. Metal: FAM8147

3. Frame rating (kw)3.1. F: 2603.2. FF: 4253.3. FFX: 4253.4. STX: 5603.5. ST: 5603.6. G: 6003.7. GG: 9003.8. T: 1200


6.1. Polymer: 7156.2. Metal: 1100

The data represented here give us detailed information about the pumps installedat the plant, and these data help us in understanding the difference between the twopumps.

Life Cycle of a Warman Pump (Secondary Pump)

Coal preparation is widely dependent on the pump operation, and the pumpsinstalled at the beneficiation plant are crucial. Factors affecting the life of thepump follow:


Table 4 represents the detailed parameters of secondary pump of unit number167 and 168, covering essential specifications such as impeller, design capacity ofeach pump, design head of the pump, motor rpm, pump rpm, media to be handled,specific gravity of liquid, and motor efficiency.

Graph of Head Versus Flow Rate for Secondary Pumps 167 and 168

The detailed study of both pumps has been mentioned in the section “Life Cycle ofWarman Pump (Secondary Pump)” of the given chapter, covering all the associatedfactors affecting their working life. Figure 16 represents the relationship betweenhead (m) on the ordinate with respect to the flow rate (m3/h) on the abscissa for thesecondary pumps 167 and 168: this is the performance curve for horizontal Warmanpump 8/6AH. The red arrow shown in Fig. 16 indicates the parameters at which thepump should operate during segmentation. The following information is representedbelow:

1. Flow: 3 m3 80/h2. Head: 65.3 m3. Speed: 1176 rpm4. Efficiency: 58%

Table 4 Secondary pumps (167 and 168)

Life cycle study of Warman pump at TISCO – West Bokaro

Washery II Secondary pump


existing Ideal

Pump tag no. WS2/PMP/167/CLR andWS2/PMP/168/CLR


Model 8/6 RAH 8/6 RAH









Absorbed power Consumption by the pump (BKW) KW 158 210

Amps drawn by motor at site amps 220 –

Motor KW/rpm/voltage 162/991/415 –

Note: This pump is running at lower than rated duty parameterTo obtain the flow of 380 m3/h @ 65.3 m the head pump should run at the rpm of 1176


Details of pumps 167 and 168:



3. Frame rating (kw)3.1. E: 1203.2. EE: 2253.3. F: 2603.4. R: 3003.5. FFX: 4253.6. FF: 4253.7. SX: 5603.8. S: 560


6.1. Polymer: 7156.2. Metal: 1500

Fig. 16 Head versus flow rate of secondary pump 167 and 168


The data represented here give us detailed information about the pumps installedat the plant. These data help in understanding the differences between the two pumps(Funk 1981).

Life Cycle of Warman Pump (Over-Dense Pump)

Coal preparation is widely dependent on the operations associated with this pump.Parameters affecting the life of the over-dense pump follow:

Table 5 represents the detailed parameters of the secondary pump of unit number165, covering essential specifications such as impeller, design capacity of eachpump, design head of the pump, motor rpm, pump rpm, media to be handled,specific gravity of liquid, and motor efficiency.

Graph of Head Versus Flow Rate for Over-Dense Pump 165

The detailed study of both pumps has been mentioned in the section “Life Cycle ofWarman Pump (Over-Dense Pump)” of the given chapter covering all the factorsassociated with them and affecting their working life. Figure 17 represents therelationship between head (m) on the ordinate with respect to the flow rate (m3/h)on the abscissa for the over-dense pump 165: this is the performance curve for the

Table 5 Over-dense pump 165

Life cycle study of Warman pump at TISCO – West Bokaro

Washery II Over-dense media pump


existing Ideal



Model 6/4 DAH 6/4 DAH

Impeller E4147A05 E4147A05


Design head of the pump Mtr 52 52

Media to be handled Coal+water Coal+water

Specific gravity of liquid 2 1.8





Amps drawn by motor at site Amps 84 –

Motor kw/rpm/voltage 75/1480/415 –

Note: This pump is running at lower than rated duty parameterTo obtain the flow of 136 m3/h @ 52 m, the head pump should run at rpm of 1463


horizontal Warman pump 6/4AH. Arrow shown in Fig. 17 indicates the parametersat which the pump should operate during segmentation. The following information isrepresented here:

1. Flow: 136 m3/h2. Head: 52 m3. Speed: 1463 rpm4. Efficiency: 53%

Other details of pump 165 are these:


2. Impeller2.1. Vanes: 52.2. Vane phi: 365 mm2.3. Type: closed2.4. Metal: E4147

3. Frame rating (kw)3.1 D: 603.2 DD: 1103.3 E: 1203.4 Q: 1503.5 EE: 2253.6 R: 300

Fig. 17 Head versus flow rate of over-dense pump 165



6.1. Polymer: 13256.2. Metal: 1800

Curves of Other Horizontal Pumps

Detailed study of various pumps has been mentioned in the sections “Life Cycle ofWarman Pump (Primary Pump),” “Life Cycle of Warman Pump (Secondary Pump),”and “Life Cycle of Warman Pump (Over Dense Pump)” of this chapter, covering allthe associated factors affecting their working life (Kubo et al. 1982). Figure 18represents the relationship between head (m) on the ordinate with respect to the flowrate (m3/h) on the abscissa for the pump 10/8AH. This curve represents the perfor-mance curve for the horizontal Warman pump 10/8AH; it also provides informationregarding factors such as impeller and minimum passage size. The red arrow shownin Fig. 18 indicates the parameters at which the pump should operate duringsegmentation. The following information is represented below:

1. Flow: 740 m3/h2. Head: 32 m3. Speed: 635 rpm4. Efficiency: 69.4%5. NPSHr: 4.4 m

Details of 10/8AH are these:

1. Pump1.1 Discharge: 203 mm1.2 Suction: 254 mm

2. Impeller2.1. Vanes: 52.2. Vane phi: 686 mm2.3. Type: closed2.4. Metal: G81472.5. Metal: FAM8147

3. Frame rating (kw)3.1 F: 2603.2 FF: 4253.3 FFX: 4253.4 STX: 5603.5 ST: 5603.6 G: 6003.7 GG: 9003.8 T: 1200



6.1 Polymer: 7156.2 Metal: 1100

Figure 19 represents the relationship between head (m) on the ordinate withrespect to the flow rate (m3/h) on the abscissa for the pump 10/8 M: this is theperformance curve for the horizontal Warman pump 10/8 M. The red line shown inFig. 19 indicates the parameters at which the pump should operate during segmen-tation. Other details associated with pump 10/8 AM follow:


2. Impeller2.1. Vanes: 42.2. Vane phi: 549 mm2.3. Type: closed2.4. MetA: F8145

3. Frame rating (kw)3.1. E: 1203.2. EE: 2253.3. F: 260

Fig. 18 Head versus flow rate for 10/8AH pump


3.4. R:3003.5. FF: 4253.6. FFX: 425


6.1. Polymer: 9206.2. Metal: 1100

Figure 20 represents the relationship between head (m) on the ordinate withrespect to the flow rate (m3/h) on the abscissa for the pump 8/6AH: this is theperformance curve for the horizontal Warman pump 8/6AH. The red arrow shown inFig. 20 indicates the parameters at which the pump should operate during segmen-tation. Other details for pump 10/8AH are as follows:



Fig. 19 Head versus flow rate for 10/8 M


3. Frame rating (kw)3.1. E: 1203.2. EE: 2253.3. F: 2603.4. R: 3003.5. FFX: 4253.6. FF: 4253.7. SX: 5603.8. S: 560


6.1. Polymer: 9406.2. Metal: 1500

Figure 21 represents the relationship between head (m) on the ordinate withrespect to the flow rate (m3/h) on the abscissa for the pump 100SP: this is theperformance curve for the horizontal Warman pump 100SP. The red arrow shown inFig. 21 indicates the parameters at which the pump should operate duringsegmentation.

Fig. 20 Head versus flow rate for 8/6AH


Details of pump 100SP are as follows:


2. Impeller2.1 Vanes: 52.2 Vane phi: 370 mm2.3 Type: closed2.4 Metal: SP10206A2.5 Metal: SP10206B

3. Frame rating (kw)3.1 RV: 75

4. Minimum passage size: 32 mm5. Liner (normal maximum rpm)

5.1 Unlined: 1400

Other Horizontal Pumps

Apart from primary pumps, various other pumps installed at the plant are essential inthe handling and preparation of coal (Burt 1999). In this section detailed informationis presented regarding other Warman horizontal pumps, including impeller,

Fig. 21 Head versus flow rate for 100SP pump


minimum passage size, etc. Other details cover the factors affecting its working life.Details for the 4-4 CXU pump are as follows:


2. Impeller2.1 Vanes: 52.2 Vane phi: 306.07 mm2.3 Type: closed2.4 Metal: DXU41417

3. Frame rating (kw)3.1 C: 303.2 CC: 553.3 D: 603.4 DD: 110

4. Minimum passage size: 39.37 mm5. Seal: centrifugal sealed pump6. Liner (normal maximum rpm): 22007. Curve revision: 1

The other details represented below are for a 3-3 cxu horizontal pump. The givenpump handles the various parameters associated with coal segmentation such asimpeller and minimum passage size. The details of the 3-3 CXU including allparameters covering its working life are these:


2. Impeller2.1 Vanes: 52.2 Vane phi: 220.22 mm2.3 Type: closed2.4 Metal: CXU3147

3. Frame rating (kw)3.1 C: 30

4. Minimum passage size: 26.67 mm5. Seal: centrifugal sealed pump6. Liner (normal maximum rpm): 31707. Curve revision: 1

Issued May 5The details represented next are for an 1.5-1AH horizontal pump. The given

pump also covers the various parameters associated with coal segmentation such asimpeller, minimum passage size, etc. Details covering factors affecting pump work-ing life are provided in Table 6.



2. Impeller2.1. Vanes: 52.2. Vane phi: 152 mm2.3. Type: closed2.4. Metal: B1127

3. Frame rating (kw)3.1. B: 15

4. Minimum passage size: 14 mm5. Seal: gland sealed pump6. Liner (normal maximum rpm): 32007. Curve revision: 1

Performance Curve

The primary selection tool is called a pump curve. Pump curves are essential dataabout a given pump’s ability to produce flow against a certain head. When you arereading a curve, the pump’s flow rate is on the top and bottom and its height forpushing is on the sides.

According to the operation of the different pumps set up in the washery, theseperformance curves show the relationship between head (m) on the ordinate withrespect to the flow rate (m3/h) on the abscissa for the pumps given here. These pumpsare represented below:

a. Pump HM250b. Pump HH200

Figures 22 and 23 represent the performance curves of pump HM250 and pumpHH200, respectively. The curve is obtained on the basis of the operation performedduring the segmentation of coal.

Table 6 Details of 1.5-1AH pump

Efficiency Updated

Revision Notes

Tests: 45 87B2 87B3 87B4

Reference

Issued Feb 1


Conclusion

This chapter gives us an ample amount of information about the working of pumps,the characteristics of pumps installed at the plant, the performance characteristics ofthese pumps, and the working operations associated with the segmentation of coal.The present chapter is broadly classified on the basis of these three parameters:pump, process, and performance. The final segment of the chapter presents summa-rized information regarding all three parameters associated in the preparation of coal,represented as follows:

Fig. 22 Performance curve of pump HM250


1. All pumps installed at the beneficiation plant are manufactured by Warman.2. Pumps installed at the plant are indicated by a specific unique unit number.3. The process runs under optimum conditions; thus, the firm is able to produce

1000 tons of coal per day from all three washery plants at TISCO, West Bokaro,Jharkhand, India.

4. A flow rate of 765 m3/h @ 58.1 m is obtained when the head pump runs at rpmof 1040 for primary pumps 171 and 172.

5. A flow rate of 380 m3/h @ 65.3 m is obtained when the head pump runs at rpmof 1176 for pumps 167 and 168.

Fig. 23 Performance curve of pump HH200


6. Maximum efficiency obtained during the process is 69.4% for primary pump172.

7. Minimum efficiency obtained during the process is 53% for secondary pump165.

8. The average working time of a pump is 22 h/day.9. Equipment associated with the process apart from pumps is manufactured by

Metso and other companies.10. Performance parameters help in understanding the relationship between various

features associated with operations; that is, flow rate versus head graph forseveral pumps in Section 4.0, etc.

11. All the data are taken during the operations performed by each of the machines.12. The firm also takes care for the safety of the environment: thus, the organization

continues to plant trees at regular time intervals (70% of the area is under greenvegetation).

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