Modeling and optimization of fine coal beneficiation by hydrocyclone and multi-gravity separation to produce fine lignite clean coal

We evaluated the suitability, contribution to the national economy, and environmental impact of hydrocyclone and Multi-Gravity Separation (MGS) processes using fine-sized coal taken from the Soma coal sludge pond. The lignite coal tailings were treated by a two-stage concentration scheme for the recovery of fine clean coal. Pre-enrichment experiment parameters were determined by the Taguchi experimental design method, and the results were interpreted by the Statistical Packages for the Social Sciences (SPSS) 15.0 program to evaluate the optimum parameter values. The tailings initially contained 54.82% ash and had a LCV of 2,279 kcal/kg; after hydrocyclone pre-enrichment, the concentrate was 42.60% ash and had a calorific value of 2,573 kcal/kg (55.75% coal yield). After the final enrichment process, the ash of the pre-concentrated coal was decreased to 24.21% and left a clean coal with a base calorific value of 3,226 kcal/kg (36.16% coal yield). The total sulfur of the obtained clean coal was 0.52% and the combustible sulfur rate was 0.10%. To reduce the ash content of the obtained clean coal, a decantation process was performed that decreased the ash content to 21.84% and the base calorific value was increased to 4,109 kcal/kg.