Coal preparation plant three-year plan

Foreword xxx Coal Preparation Plant is affiliated to Huozhou Coal and Electricity Group xxxxxx, the coking coal preparation plant with original design capacity of 1.80mt/a, mainly into the raw coal of the mine and some of the coal within the group. The annual cleaning capacity plan is 2.10mt, and the super design ability is 17%. By the end of the first half of the year, 1.07 million tons have been washed, and 51.39% of the annual plan has been completed. It is expected to complete the project at the end of the year, and even break through the plan. Its capacity utilization rate is expected to reach 119.11%. However, with the changes in the mine resources and the overall situation of the internal coal washing system of the Group, the coal preparation plant faces the lack of resources, the adjustment of the washing structure, the low efficiency of coal washing, the incompatibility of the link and the lack of overall development. A series of contradictions. To this end, according to the three-year planned production capacity of the mine and the actual situation of the coal washing plant, the overall development of the coal washing plant in the last three years was planned. The overall planning started from the coal preparation plant's washable resources and process status, focusing on the analysis. Three years into the raw coal source and its optionality, the problems of the process and the necessity of transformation, the supporting transformation of the link, investment, cost, output, etc., clearly proposed the core process transformation plan for the full heavy medium process, further Improve the process and its supporting systems, improve the production capacity, equipment level and competitiveness of the coal preparation plant to ensure the sustainable development of the coal preparation plant. The first chapter xxxxxx coal preparation plant status I. Overview xxxxxx coal preparation plant is xxx mode cooperation development. It is located between xxxx and 4km away from Huozhou City. It is connected to the Dayun trunk road through local highways. There is a 3.828km railway dedicated line connecting St. Buddha Station and Nantongpu Railway. The designed coal preparation plant has an annual washing capacity of 1.8 million tons. It is a coking coal preparation plant. The current technology adopts three products, jigging flotation and tail coal pressure filtration. At present, the selected raw coal is not only from the 1#, 2#, 10#, 11# raw coal of the mine, but also includes the group company xx2# coal, xx10# coal, xxx2# coal, xx2# coal, xx2#, 10# coal, etc. The production products mainly include 8--11 grade 1/3 coking coal and fat coal. 2. The raw coal of the coal preparation plant of the raw coal system is from the inclined well and the peaceful mine of the mine. Most of the raw coal selected is from other mines within the company's internal company. The inclined shaft is transported by belt; the flat raft is transported by 1t mine car, the same two cocking machine rooms are subjected to coal, and each dumping machine room has a buffer bin under each. The internal coal is transported by car to the coal storage yard. The bulldozer is sent to the coal pit. After entering the raw coal preparation system, it is screened and crushed, and then enters the raw coal blending bin. The coal blending system is equipped with an automatic coal blending system. The coal yard of the selected coal plant includes 113 coal yard, 228 coal yard and 101 coal yard. The coal distribution tank is three φ12m, and each warehouse has a capacity of 1300t. The raw coal is prepared as a dual system, with pre-screening, selective crushing, hand selection, and raw coal crushing, which can meet the production requirements. Third, the original design of the process system production process using 0-50mm raw coal to remove the slime after the main washing, medium coal heavy medium cyclone rewash, coal slurry concentrated flotation, tail coal pressure filtration recovery, washing closed circuit cycle Joint process flow. Among them: the jigging is a dual system; the medium coal heavy medium re-election system has not been put into use since the trial production in 1989. After the transformation, the current production process uses a non-grading jigging and flotation combined process. In addition, the design uses the pre-dip desliming operation due to rough running reasons. In actual production, only the operation is changed to pre-wetting and conveying before jigging sorting. At the same time, for the problem that the flotation feed ash is more than doubled after the production, the flotation clean coal can not reach the standard, the flotation process is transformed, and the original one-stage flotation is changed into a rough selection second-stage selection process. IV. Storage and Transportation System The coal preparation plant currently has six cylinders with φ12m and a capacity of 1300t per cylinder. The warehouse is equipped with an automatic coal blending system, three cylinders with φ12m and a capacity of 1300t. There is also one clean coal loading station and one coal loading station. V. Power Supply and Distribution and Automation 1. Electrical System The current coal preparation plant uses bfc type low-voltage power distribution panel. The main components of the screen are dzx10 series circuit breakers and cj10 series AC contactors, which are not suitable for use in unit combination power distribution panels. On-site observation, the installation distance of each electrical component is too small, and there is no reliable isolation between the units and between the screen and the screen. When a loop fails, the fault circuit cannot be reliably broken, causing the entire unit electrical components to burn out, even affecting the entire power distribution panel and adjacent screens, causing more electrical equipment damage and affecting the safe and normal operation of the power distribution system. 2. The automatic coal preparation plant has a centralized control device based on plc. The horizontal block area is damaged, and the centralized control device is in a state of being powered off. Other automation includes: the jig is controlled by numerical control damper, and is equipped with automatic discharging device; automatic coal blending system under the original coal fine coal bin; 501 clean coal belt zz-89 type online measuring instrument for automatic detection. Sixth, the annual production capacity of the coal preparation plant is planned to be 2.1 million tons of raw coal, and the design capacity is 17%; the production of clean coal is 1.03 million tons, an increase of 29%; the total volume of foreign transportation is 1.49 million tons. Year-on-year growth rate; see Table 1 for each indicator. ~ Year-old clean coal and by-product production plan Table 2 Chapter 2 Coal source, coal quality and optional analysis I. Coal source overview 1. Coal source ~--~ The estimated coal source in the year mainly includes the production of the mine. #,2#,10#,11# Raw coal and group companies transfer raw coal internally. Due to the continuous operation of Liyazhuang Coal Preparation Plant and Huipo Bottom Coal Preparation Plant, it is relatively difficult to adjust raw coal internally, and the resources are insufficient. 2#, 10# raw coal. As of the end of June, the remaining recoverable reserves of the mine were 15.502 million tons, and the recoverable reserves were 15.572 million tons. The mine production planning is 800,000 tons per year, 1.2 million tons per year, and 1.5 million tons per year. The three-year production plan of the mines in the wellhead and sub-mining areas is shown in Table 2. Three-year mine production planning Table 2 The adjustable coal transportation volume can ensure 1 million tons per year. According to the recoverable production of resources, the three-year washing capacity of the coal preparation plant is shown in Table 3, among which: 10# raw coal into the washing ratio reaches %; 11# raw coal into the washing ratio reaches %; 1#2# raw coal into the washing ratio reaches; 11# The proportion of raw coal into the washing is expected to be up to 100% of the coal washing plant's three-year washing schedule. 2. The characteristics of the coal seam are mainly 1/3 of coking coal, and sometimes there is partial fat coal. The mine can mine coal seams

Mainly: 1#, 2#, 5#, 6#, 9#, 10#, 10# and 11# coal. At present, the coal seams in the mine are 1#, 2#, 10#, and 11# coals, of which the upper group coals 1# and 2# are medium-ash low-sulfur coals, and the lower group coals have lower sulfur content than the 11# coals. 6#, 9#, 10# coal has a high sulfur content, and sulfur is mainly present in sulfide sulfur and organic sulfur. 2. Analysis of coal quality and optionality (1) Coal quality and optionality of each mine 1. The raw coal of xxx2# is based on the analysis of Bailong 2# raw coal sample data combined with daily production technology. Table 4: Bailong 2# raw coal floating and sinking test Comprehensive results table. The size of the raw coal of the mine 2# is good, the content of the final coal is low, the content of coal slime is 12.46%, and the proportion of theoretical classification of each grade is relatively high. The grade 9 is 1.55, the grade 10 is 1.60, and the grade is 1.65. The selectivity is better. 2, xx10# raw coal according to Bailong 10# raw coal large sample data analysis combined with daily production technology inspection Table 5: Bailong 10# raw coal floating and sinking test comprehensive results table. The size of the 10# raw coal of the mine is better, the content of the final coal is low, the content of coal slime is 12.46%, and the proportion of theoretical sorting is higher, the level is 1.55, the level is 1.60, and the level is 1.65. The selectivity is better. 3, xx11# raw coal according to Bailong 11# raw coal large sample data analysis combined with daily production technology inspection Table 6: Bailong 11# raw coal floating and sinking test comprehensive results table. The size of the raw coal of the mine 11# is good, the content of the final coal is low, the content of coal slime is 12.46%, and the proportion of theoretical classification is high. The grades are 1.55, the grades are 1.60, the grades are 1.60, and the grades are 1.65. The selectivity is better. 4, xxxxxx2 # coal according to xxxxxx2 # raw coal large sample data analysis combined with daily production technology inspection table 7: xxxxxx2 # raw coal floating test comprehensive results table. The size of the raw coal of the mine 2# is good, the content of the final coal is low, the content of coal slime is 12.46%, and the proportion of theoretical classification of each grade is relatively high. The grade 9 is 1.55, the grade 10 is 1.60, and the grade is 1.65. The selectivity is better. 5, xxxxxx10 # coal according to xxxxxx2 # raw coal large sample data analysis combined with daily production technology inspection table 8: xxxxxx2 # raw coal floating test comprehensive results table. The size of the raw coal of the mine 2# is good, the content of the final coal is low, the content of coal slime is 12.46%, and the proportion of theoretical classification of each grade is relatively high. The grade 9 is 1.55, the grade 10 is 1.60, and the grade is 1.65. The selectivity is better. From the analysis of the properties of the above coal seams, the difference in the selectivity of raw coal at each point is large, and the specific gravity and yield of the separation are very different. In actual production, the coal blending should be mainly used to comprehensively utilize resources to achieve the best score. Choose the effect. (II) Comprehensive coal quality and optionality According to the ratio of coal blending into washing in recent years and the situation of coal seam resources, the proportion of coal coming from this plan is estimated: 1#2#% of raw coal,% of raw coal of 10#, and 11% of raw coal . According to the ratio, the composition of the raw coal floating sink is shown in Table 9. The composition of the integrated floating sediments in the washed coal is shown in Table 9. The composition of the floating and sinking is known as: the dominant grade is the density grade, the yield is up, followed by the +1.8 density grade, and the yield is up to %, indicating that there are more defects. Based on the analysis of density analysis of 1.3~1.4, the yield is up to 34.81%, and the ash content of this grade is up to %, which indicates that the ash in the raw coal is higher, and the selectivity of producing low ash clean coal is more difficult. The optional curve is drawn. When the clean coal ash requirement is 9.5%, the theoretical sorting density is kg/l, the ±0.1 content is %, and the selectivity is . When the clean coal ash requirement is 10%, the theoretical sorting density is kg/l, the content of ±0.1 is %, and the selectivity is . When the clean coal ash requirement is 10.5%, the theoretical sorting density is kg/l, the ±0.1 content is %, and the selectivity is . Chapter III Process System Planning and Link Reconstruction I. Main problems existing at the current stage (I) Process 1. From the perspective of coal quality index, production technology index, product index, combined with the principle of maximum yield of clean coal and maximum economic benefit The current production process has the following problems: (1) The current coal quality changes in the raw coal, the coal content is greatly increased, and the jig sorting effect is worse. From the production indicators in recent years, the coal loss in the coal is better. The high 22-25%, vermiculite pollution>8%, large loss of clean coal, affecting the economic benefits of the coal preparation plant. (2), 11# raw coal ash in the range of 29-35%, is a higher ash, the raw coal content of -13mm grade is nearly 60%, the raw coal is brittle. The content of coal slime is about 15%, and the content is moderate. Among them, the floating coal slime accounts for 2-3% of the current grade, the raw coal is not easy to be muddy; the -40.40 density grade 40-45%, the ash content 9.65%-9.90%, the vermiculite content 20- 30%, high vermiculite content. From the perspective of its selectivity, when 11# coal fine coal ash is 10.5%, δp±0.1=48.3%, and the theoretical recovery rate is 58.83%, which is extremely difficult to select coal. It is difficult to produce 9-11 clean coal by using the jigging process. The yield of clean coal cannot be guaranteed. If the 11# raw coal is washed separately, the yield of clean coal is only 28-33%, and the yield is extremely low; #,10# Raw coal mixed into the washing, due to the different nature of coal quality, affecting the maximum yield of clean coal and the stability of product quality. 2. The status quo of the coal washing plant The original design process of the coal washing plant is the jigging main washing-medium coal heavy medium and concentrated flotation process. The design process includes the medium coal heavy medium re-election system, and the total electromechanical equipment station is invested 10,000 yuan. Now the net worth is 10,000 yuan. Since the design time was 1984, the heavy medium cyclone washing process was not very mature at that time, and the reliability and adaptability of the equipment were poor. The reasons for not applying after the production were mainly due to the following two reasons: (1) In the original design process, The production products include 1# clean coal and 2#-based centralized control, and after commissioning, there is no commissioning due to incomplete protection and other reasons. More people, low production efficiency, the efficiency of the whole staff in the first half of the year ton / work, than the standard of the high-efficiency coal preparation plant / ton / work, should be gradually modified automatically. Second, the overall planning (a) core process planning 1, process status production practice shows that the full jigging process can only be adapted to easy to choose coal or medium optional coal, the use of jigging coal washing method for difficult to select, extremely difficult to select coal, efficiency and production The rate is extremely low and the economic benefits are extremely poor. For example, the jigging coal preparation method adopted by the current coal preparation plant produces 9 grade, 10 grade and 11 grade clean coal. The raw coal theory ± 0.1 content is high and difficult to select. The table is the technical indicator of the coal preparation plant in the recent time. Technical index of jigging coal preparation method Table 12 When the level 9 clean coal is produced, the content of ±0.1 is 21.5%, which is difficult to select coal, resulting in extremely low sorting efficiency, reaching 75.34%, and the yield of clean coal is 47.18%. The loss in coal exceeded 28%, the meteorite pollution reached 9%, 25~30% of the coal was mixed into the clean coal, and 15~25% of the meteorite mixed into the coal, which affected the stability of the product quality and seriously lost the coal washing plant. Economic benefits. In the production of grade 10 and 11 clean coal, the ±0.1 content is 17.5% and 14.8%, respectively. It is a medium optional coal. Although it is suitable for jigging sorting, the sorting efficiency is only 80.34% and 85.34%. The coal yield is 51.58% and 56.13%. The loss of clean coal in medium coal is still 18~20%, and the pollution of vermiculite is about 8%. The best economic benefit is not obtained. If the same raw coal adopts the heavy medium coal washing method, the effect will be obviously improved, and the sorting efficiency will be increased by 14.05%, 12.07%, 8.5%, respectively, reaching 89.39%, 92.41%, and 93.84%. The yield of clean coal increased by 8.80%, 7.75% and 5.59%, respectively, reaching 55.96%, 59.33% and 61.72%. The loss of clean coal in coal was reduced to less than 10%, and the pollution of vermiculite was reduced to about 2%. Significantly improved. Table of technical specifications for heavy medium coal preparation Table 13 Comparison of yield and efficiency of full jigging and full heavy medium process Table 14 In the first half of the year, the total coal washing capacity was 725,000 tons, and the production of clean coal was 317,700 tons, which was less than the total weight. Coal is 67,300 tons, and the comprehensive product is 501,900 tons, which is 17,700 tons more than the total heavy medium. According to the calculation of the cumulative product price of the xxxxxx mine in the first half of the year, the total weight of the processing fee is 2.04 yuan/ton of raw coal. In the first half of this year, the loss of profit is 10,000 yuan, which is the loss of raw coal, and the loss of ton of clean coal. Therefore, the transformation of the core process is very necessary. Analysis of the benefits of clean coal loss in the current process Table 15 2. Reconstruction plan According to the actual situation of the coal preparation plant, we believe that the jigging process that affects the yield and efficiency of clean coal should be modified first. (1) Determination of coal preparation method The coal preparation method and process flow are the core issues of the coal preparation plant, which determines the level of economic benefits of the coal preparation plant. According to the raw coal data selected by the coal preparation plant, we have carried out the calculation of the four kinds of process schemes. The yield of clean coal is the lowest, the yield of intermediate products is the largest, and the economic benefit is the worst. The whole heavy medium process has the highest yield of clean coal, the lowest yield of intermediate products and the best economic benefit. Followed by the fine coal heavy medium, once again the medium coal heavy medium process. In summary, the core process transformation selects the full heavy medium process, and its process technology is mature, easy to control centrally and easy to manage. (2) Process flow arrangement 1 principle: retain the full jigging process and implement the full heavy medium process transformation. Make full use of the original production system, and strive to make the production process simple and flexible, and realize flexible switching between the full jigging and the full heavy medium. 2 specific arrangement: see the drawing: process flow chart. Restore the original mud removal operation and add a switching device in the chute before the mud removal screen. That is, it is possible to switch between full weight and full jigging. The sieve material enters the crusher and is broken to below 25mm, and then enters the mixing tank. In order to solve the problem of coarse running of the mud-removing sieve, the water of the desiccant sieve is recovered by the curved sieve of 0.5 mm sieve and then the coarse coal slime is recovered, and then enters the slime water system, and the coarse coal slurry enters the heavy medium sorting system. The mixing tank mixes the raw coal with the circulating medium and is pumped into a three-product cyclone for sorting. The clean coal products are de-intermediated by two demineralized screens of the two fine coals of the original medium coal heavy medium system and the jigging system. The Chinese coal products enter the original medium-weight coal medium-mediated de-screening, and the meteorite products enter the jigging. The system removes the miscible sieve, and the vermiculite product enters the jigging system to remove the miscellaneous sieve. The dilute medium enters the clean coal thin barrel and the medium coal gangue thin barrel respectively, and then enters different magnetic separation systems to recover the magnetic medium. The tailings of the fine coal magnetic separator enters the slime water system after recovering the coarse fine coal slurry through the curved screen and the electromagnetic high-frequency screen vibrating screen. The medium coal gangue thin medium enters the tail coal recovery system after passing through the magnetic separator. 3 Final product balance (3) Selection of main equipment selection equipment In principle, domestic advanced and reliable equipment sorting equipment is selected: 3nzx710/500 pressure-feeding three-product heavy medium cyclone with technical clearance. The upper limit of feeding is controlled at 25mm. Crushing equipment: The use of the mmd system screening crusher with screening function is beneficial to reduce secondary slime. De-intermediation equipment: Zkx vibrating screen with mature technology and reliable operation. Crude coal slurry recovery: It is combined with mvs electromagnetic vibration high frequency vibrating mesh screen to recover and recover. The vibration frequency of the equipment is up to 3000 times/min, which is beneficial to the dewatering and deashing of coarse coal slurry, the ash content is reduced by about 2~3%, and the water content is 21~22%. Media recovery: The original three xctb-1050x2100 magnetic separators were used for medium coal and vermiculite dilute media. The clean coal dilute medium uses a 1030 type magnetic separator with high magnetic field strength. Pump class: The slurry pump of Shijiazhuang Industrial Pump Factory is adopted. Medium preparation: Restoring the original medium preparation system (4) Technology and economy 1 Investment: The estimated total investment is 1 million yuan, including 4.5 million yuan for equipment, 500,000 yuan for civil works, 2.7 million yuan for installation, and 617,000 yuan for reserve. 2 The production cost increased by 3.007 million yuan per year, and the original coal was 20,400 yuan. 3 Benefits: According to the annual plan of 1 million tons of clean coal, the yield of clean coal increased by 9.49%, and the yield of medium coal decreased by 11.45%. The rate was reduced by 1.96%, the foreign transportation volume was reduced by 206,800 tons, and the annual income was increased by 5.77 million yuan. 4 Investment recovery period: Under the conditions of ensuring the original product structure, coal price and raw coal quality, the investment can be recovered in 1.44 years. (II) Supporting Link Planning 1. Renovation of Floatment Dewatering System (1) Process selection After comprehensive comparison and investigation, it is now suitable for the flotation of clean coal and slime dewatering, which is a pressure filter and supporting process, and its process technology is becoming more and more The coal washing plants that have matured, successfully applied and achieved great economic benefits include Xishan Coal and Electricity Xiqu Coal Preparation Plant and Xishan Coal Power Town Chengdi Coal Preparation Plant. The technical features are as follows: Pressure filter is an efficient The new dewatering equipment with energy saving and fully automatic operation has several times the filtration driving force compared with the vacuum filter, so it not only has a large production capacity, but also has a very low filter cake moisture and clean filtrate. Computer automatic control. High production capacity: 0.25~0.35mpa, the output can reach 300~800kg/m2.h, which is 4-8 times higher than vacuum filter. The filter cake has low water content and dewatering of the flotation clean coal. When the working pressure is 0.25~0.35mpa, the moisture content of the filter cake is less than 20%, which is 10~13% lower than that of the vacuum filter cake. Low energy consumption: When the working pressure is 0.25mpa, the power consumption is only about 1/2 of that of the vacuum filter, which saves a lot of power and has high economic and social benefits. Fully automatic operation: The whole machine is controlled by computer, and the operation screens up different screens for intuitive display. The start and stop of the machine and the short-term waiting under special circumstances are all automatic operation, liquid level and material level automatic adjustment and control; It has safety devices such as automatic fault alarm and stop operation. The automatic program can be easily adjusted depending on changes in work status and changes in requirements. The filtrate concentration is low, usually 5~15g/l; low noise: 62.5db. (2) Preliminary design of the transformation plan 1 Remove the original pg116 filter from the original three floors of the main building, install a pressure filter on the original foundation, and add 15m3 of control room, and arrange the corresponding control cabinet and control platform in the control room. 2 Install the discharge device and the discharge hopper on the second floor of the main plant, and arrange the high and low pressure fans. 3 Install a b=1000mm floating fine transport scraper on the first floor of the main building to transfer the float to the 4291 transport belt. 4 Add a floating scum buffering tank ≥50m3 in the basement and install 2 slurry pumps. The schematic diagram of the layout of the transformation and the schematic diagram of the section are shown in the attached figure. (3) The estimated total investment is 4.45 million yuan, including: equipment purchase of 3.94 million yuan, civil installation and other expenses of 510,000 yuan. (4) Expected benefit and investment recovery period 1 This technology is an advanced technology for domestic coal slurry water filtration treatment. It can be determined according to the actual site selection and design. The working parameters of the main engine and the model and specifications of the supporting equipment are determined. The automation operation reduces labor intensity and labor. Employment has greatly improved the working environment. 2 The float water can be reduced from 28--32% to 18--20%, and the total clean coal moisture can be reduced from 11% to 9.5%. After storage and dewatering, it can basically meet the user's requirements for product moisture, and can reduce Loss of freight and loss of excess water deduction, the annual estimated reduction of freight loss of 1,369,200 yuan. 3 The amount of flocculated clean coal blended into the total clean coal can be greatly improved, and the hourly flocculation treatment volume is increased by 4~8 times, which reduces the loss of the flotation machine and the loss of the fine yield due to the untimely treatment of the filtration operation. It can increase the extraction rate of floating fines by 10% and increase the yield of total clean coal by 0.75%. According to the calculation of 2.1 million tons of raw coal in the year, it can be 210 × 0.75% × yuan / ton = 592,900 yuan. 3. It can reduce unnecessary cost input and labor input such as bulldozer operation and coal returning slip operation, and can consume nearly 100,000 yuan per year. 4. The investment recovery period is about 2.16 years. 5. From the perspective of expected benefits and investment recovery period, the investment recovery period is expected to be recoverable for more than 2 years. Although the payback period is longer, the later benefits of the transformation are immeasurable and will inevitably It brings endless power to the virtuous cycle of coal washing production process. 2. The automation system (1) replaces and supplements some control components under the premise of using the existing centralized control design, realizes the centralized control of the process equipment by the control method of the on-site busbar, and improves the protection facilities. (2) Establish a comprehensive information control system based on on-site busbars, namely, dispatching monitoring and automation system. The system completes the main process data such as the amount of coal selected, the amount of coal in each product, the clean coal ash, and the flotation process parameters. As well as the collection and processing of heavy medium suspension density values ​​and forming a historical trend curve, the flotation process parameters, the density of heavy medium suspension and the automatic regulation of the barrels of each medium and the matching of coal blending and clean coal are also completed. Coal regulation. (3) Collecting and processing the working current of high-power equipment and main process equipment and forming an alarm and historical trend curve to provide basis for equipment operation and maintenance. (4) Effectively improve the technical management level of the coal preparation plant, which will form an integrated information control system, reduce processing costs, improve production efficiency, and achieve high-efficiency coal preparation plant level. (III) Other plans 1. The amount of coal is large, the yield is 7%~8%, the ash is 50.30%, and the calorific value is XX kcal. For this reason, a new way of comprehensive utilization of slime is actively sought. 4. The problem of introducing equipment accessories, some of the imported equipment has been used up, and the localization effect is poor. It will be a difficult job to introduce the next step. 5. Improving management tools, realizing regional networks, and developing various management software will also be a focus of our work.