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<p>A batch-scale dry coal beneficiation process was employed for its efficiency in minimizing water usage and enhancing liberation, utilizing a gas-solid fluidized bed separator to beneficiate high-ash Indian coking coal. The present work aims to design and optimization of a batch-scale gas-solid fluidized bed separator, employing Computational Fluid Dynamics (CFD) for a parametric study, and subsequent processing with a froth flotation method. The coal was collected from Bastacolla open cast mines in the Dhanbad, Jharkhand and processed as received after crushing to -50 + 6&#xa0;mm and − 25 + 6&#xa0;mm size fractions for dry operations in a Dense Medium Fluidized Bed separator. The − 6&#xa0;mm size fraction, along with pre-concentrate from the dry process, was crushed to 0.5&#xa0;mm for froth flotation using various reagents such as kerosene and synthetic reagents as collectors, and Methyl Isobutyl Carbinol (MIBC) and synthetic reagents as frothers. The effects of different process parameters (bed height, dense medium size, air flow rate) of the dry separator and reagent dosage for froth flotation were evaluated. The dry process with the − 25 + 6&#xa0;mm fraction showed superior performance, achieving a higher yield and better ash rejection at a cut density of 1.78 compared to the − 50 + 6&#xa0;mm size due to enhanced washability upon liberation. Dry deshaling of high ash coking coal (-25 + 6&#xa0;mm) reduced ash levels from 49% to 40% with a yield of 62.40%. The flotation process using synthetic reagents proved more effective than kerosene plus MIBC, reducing feed ash from 38.17% to 32.94% with an appreciable yield of 65.70%.</p> Graphical abstract <p></p>

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A combined approach study of dry and froth flotation techniques for optimization of resources by using CFD for quality enhancement of high ash coking coal

  • 期刊论文

  • 发表日期：

    2026年2月24日

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  • Durga Prasad G,
  • B. C. Meikap,
  • Sushanta K. Behera

摘要

A batch-scale dry coal beneficiation process was employed for its efficiency in minimizing water usage and enhancing liberation, utilizing a gas-solid fluidized bed separator to beneficiate high-ash Indian coking coal. The present work aims to design and optimization of a batch-scale gas-solid fluidized bed separator, employing Computational Fluid Dynamics (CFD) for a parametric study, and subsequent processing with a froth flotation method. The coal was collected from Bastacolla open cast mines in the Dhanbad, Jharkhand and processed as received after crushing to -50 + 6 mm and − 25 + 6 mm size fractions for dry operations in a Dense Medium Fluidized Bed separator. The − 6 mm size fraction, along with pre-concentrate from the dry process, was crushed to 0.5 mm for froth flotation using various reagents such as kerosene and synthetic reagents as collectors, and Methyl Isobutyl Carbinol (MIBC) and synthetic reagents as frothers. The effects of different process parameters (bed height, dense medium size, air flow rate) of the dry separator and reagent dosage for froth flotation were evaluated. The dry process with the − 25 + 6 mm fraction showed superior performance, achieving a higher yield and better ash rejection at a cut density of 1.78 compared to the − 50 + 6 mm size due to enhanced washability upon liberation. Dry deshaling of high ash coking coal (-25 + 6 mm) reduced ash levels from 49% to 40% with a yield of 62.40%. The flotation process using synthetic reagents proved more effective than kerosene plus MIBC, reducing feed ash from 38.17% to 32.94% with an appreciable yield of 65.70%.

Graphical abstract