RI 6274 Cleaning Unsized Fine Coal In A Dense-Medium Cyclone Pilot Plant

A dense-medium cyclone pilot plant was built to clean 112-inch to 0 size coal. This pilot plant does not require the removal of the extremely fine material (usually minus 1/2-mm) from the feed, which is necessary in conventional dense-medium cyclone plants. The essential difference between conventional cyclone plants and the pilot plant is in the medium-recovery system. The latter uses a combination of sieve bend screens, classifying cones, and magnetic separators for medium recovery. Eight tests were run in the pilot plant at a feed rate of 5 tons per hour with four different raw coals and one crushed jig middling product. Sharp separations were obtained as indicated by an average error area of 27 and probable error of 0.047 for the 112-inch to 200-mesh size range. Magnetite loss averaged about 2.5 pounds per ton of feed. The influence of several factors on cleaning performance of the cyclone was investigated. The diameters of both the overflow and underflow orifices were found to be important for optimum cleaning performance, but these diameters could vary over a wide range without serious effect; however, if this range was exceeded, cleaning performance deteriorated. Better cleaning performance was obtained when the cyclone inlet pressure was increased from 9 psig to 13 psig. The size of the magnetite particles in the medium was found to have a substantial effect, and the best cleaning results were obtained with grade B magnetite. Demagnetizing the magnetite in an effort to decrease the effective particle size did not improve cyclone performance.