Summary of process layout and commissioning requirements of coal preparation plant - Henan Hongxing

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Summary of process layout and commissioning requirements of coal preparation plant

The original design process of a coal preparation plant is a combined process of 50 mm raw coal pre screening, > 50 mm particle size crushing, 50 ~ 0 mm particle size coarse separation by classifier, coarse clean coal re separation by dense medium cyclone, coal slime recovery by pressure filter After the transformation, the washing process is a combined process of 50 mm raw coal pre screening, gangue removal by inclined wheel heavy medium separator with particle size larger than 50 mm, coarse separation by classifier for 50 ~ 0 mm particle size, cleaning of jigging clean coal by three product dense medium cyclone with non pressure feeding, and coal slime recovery by Slime Centrifuge, sedimentation filter centrifuge and filter press. In order to better meet the needs of customers and cope with the severe situation of the coal market, coal preparation plants urgently need to be reformed to further improve the production of clean coal, reduce production costs and improve the economic benefits of enterprises. In the following, the process layout and trial operation are taken as the breakthrough to further improve and perfect.

 Coal preparation plant

Process layout

1. General layout of ground process

(1) Layout principle

Combined with the original facilities of the coal preparation plant, the original buildings, structures and other facilities should be reasonably used, and the construction should not affect or less affect the production. The layout of buildings and structures should be compact and reasonable, and the crossing should be reduced as much as possible to facilitate the passage of goods. Properly handle the relationship between the position of buildings and structures and wind direction, so as to make the lighting and ventilation conditions good. Special attention should be paid to the comprehensive utilization of materials and the environmental protection of the plant area, so as to eliminate or reduce the environmental pollution as far as possible, so as to improve the production and living environment of the plant area.

(2) General layout of ground process

Make full use of the square on the west side of the original main plant, and arrange the new main plant and workshop in this area. The general layout of the main plant is carried out on the west side of the main plant according to the general layout of the raw coal plant Belt conveyor It is transported from the original main plant to the new main plant for sorting. The new concentration workshop is located on the northwest side of the new main plant and the west side of the original machine repair workshop, and the flotation reagent warehouse is arranged in the west side of the new main plant.

2. Workshop process layout

According to the actual situation of the site, combined with the coal preparation process flow and the general layout of the ground process, the process layout of the original main plant, the new main plant and the concentration workshop after transformation is carried out.

(1) Process layout of original main workshop

On the first floor of the original main plant building, the tailings pond and transfer pump of clean coal magnetic separation were added. The clean coal magnetic separation tailings of the newly added dense medium separation system and the original dense medium separation system flow into the pool by gravity, and then are pumped to the slurry water concentration cyclone. The bottom flow of hydrocyclone is separated by TBS interference bed separator. TBS concentrate is dehydrated by the original coarse slime arc screen. The material on the arc screen is dehydrated by the original Slime Centrifuge and the new Slime Centrifuge, and then blended with clean coal products. The original tailings bucket of clean coal magnetic separation is used as the tailings bucket of medium coal magnetic separation, and the former tailings bucket of magnetic separation of medium coal and gangue is used as the tailings bucket of magnetic separation of gangue. The medium coal and gangue magnetic separation tailings of the newly added dense medium separation system flow to the corresponding magnetic separation tailings bucket of the original main power house, and then are pumped to the vibrating arc screen respectively. After being dehydrated and recovered by the arc screen and the original sedimentation centrifuge, the medium coal products are mixed. They can also be dehydrated and recovered by the original middlings dewatering screen and the final middlings centrifuge, and then mixed with the middlings.

When the quality of coal is good, the tailings of magnetic separation of medium coal can also be dehydrated by vibrating arc screen and separated by TBS interference bed separator together with the tailings of magnetic separation of clean coal. The TBS concentrate is dehydrated by vibrating arc screen and fine clean coal centrifuge, and then mixed with clean coal products. TBS tailings and gangue magnetic separation tailings are dehydrated by vibrating arc screen and sedimentation centrifuge, and then mixed with medium coal products. When the ash content of gangue magnetic separation tailings is high and cannot be mixed with medium coal products, vibrating arc screen and high frequency screen can be used to dehydrate the tailings of magnetic separation of gangue, and the dehydrated gangue can be used as gangue products. The slime water of the system enters the primary concentration workshop for treatment. When the raw coal quality and product requirements are different, there are certain differences in the washing process. The specific process should be selected according to the actual production demand.

(2) Process layout of new main workshop

The new main plant integrates dense medium separation system, fine slime flotation system and flotation concentrate pressure filtration system. Raw coal enters the new main plant through belt conveyor and is distributed to three product heavy medium cyclone by scraper conveyor. The clean coal and medium coal produced by the dense medium cyclone are decantered twice by arc screen and linear screen, and then sent to the centrifuge. The refined coal products and medium coal products dehydrated by the centrifuge are transported to their respective product warehouses by the reformed 501, 502 and 504 belt conveyors. After the gangue is dehydrated to the gangue bin, the gangue is transported to the gangue bin for three times after being dehydrated and transported to the gangue bin by a fixed medium screen.

The overflow from the concentration cyclone of the original main power house flows into the pulp preprocessor. The mineralized pulp is floated by xjm-s28 mechanical stirring flotation machine. One stage flotation or two-stage flotation can be selected according to actual needs. The flotation concentrate flows into the flotation concentrate tank by gravity, and is sent to the flotation concentrate filter press by pump. The dehydrated flotation clean coal is transferred to the original 501 clean coal belt conveyor through scraper conveyor and disc feeder, and finally mixed with clean coal products. From the first stage of slime pond and Slime Separator, the tailings are separated by magnetic separator.

(3) Process layout of concentration workshop

Build a new building with diameter of 38m High efficiency thickener As a primary concentration equipment. The flotation tailings together with the tail coal and the waste water from the arc screen of the end gangue flow to the primary thickener. The bottom of the thickener flows through the pump to the original main plant, and is dewatered and recovered by the sedimentation filter centrifuge. The overflow of the first stage thickener, the filtrate of the clean coal filter press and the centrifugal liquid of the sedimentation centrifuge flow together to the second stage Thickener (composed of the original two thickeners with diameter of 38m and 24m). The underflow of the second stage thickener is pumped to the original filter press workshop for dehydration and recovery by the filter press; the overflow of the second stage thickener is used as circulating water.

According to the requirements of slime water treatment, two thickeners with diameter of 38m and 24m are used as the secondary thickener, and the raw water tank is used as the standby thickener with a capacity of 3000m3, which fully meets the water storage needs.

 Coal preparation and crushing equipment High efficiency thickener

More coal preparation equipment is available in Hongxing product center: http://econ-world.com/products/products_ 1.html

Commissioning requirements

1. Preparation before commissioning

(1) Before commissioning, all equipment should be carefully cleaned, and the installation instructions and specifications of important equipment should be followed, and relevant records should be made.

(2) Whether there are unsafe factors around the equipment, such as whether the reserved holes are well covered, whether there are railings, and whether there is the possibility of falling objects above. In case of the above situation, it must be handled in time, and the test run can only be carried out after reaching the requirements of safety standards.

(3) Whether the oil level of mechanical equipment is normal, whether there is oil leakage, whether the bearing bush is filled with oil, whether the equipment requiring turning has been turned, and whether the belt tightness is appropriate.

(4) The foreign matters in the container, oil tank and equipment should be clean, whether there are impurities in the motor fan, and check whether the impeller protective cover is loose. If there is any above situation, it must be handled in time.

(5) Check whether the appearance, relevant parts and accessories of the equipment are in good condition, check whether the anchor bolts and nuts of the equipment are missing or tightened, and whether the sealing gasket is in good condition. The missing parts of the equipment should be supplemented, the damaged parts must be replaced in time, and the loose bolts must be tightened.

(6) The personnel participating in the test run must read the instruction manual and relevant documents in detail, understand the equipment performance, master the operation method and safety operation regulations, and make clear the start stop signal.

(7) The safety protection devices on power supply equipment and mechanical equipment shall be strict, and the insufficient parts shall be supplemented. Sufficient lighting facilities shall be provided for trial operation and transition.

(8) Each team shall prepare the record sheet of electromechanical equipment commissioning, and the personnel of each post shall be responsible for recording the temperature, speed, start-up and stop time of the equipment during operation.

(9) Before the start-up of the equipment, the personnel participating in the test run must have the personnel around the equipment and above and below, and can start the machine only when there is no personnel. The start and stop of the equipment must follow the unified command of the person in charge on site.

2. Commissioning requirements

(1) The trial operation of large-scale combined system shall be carried out in accordance with the following sequence.

(2) During the test run, the temperature of the sliding bearing shall not exceed 60 ℃, the temperature rise of the sliding bearing shall not exceed 60 ℃; the temperature rise of the rolling bearing shall not exceed 60 ℃; the temperature rise of the rolling bearing shall not exceed 60 ℃.

(3) All equipment shall be turned before operation to check whether there is any abnormality; for irreversible equipment, the coupling shall be removed first and the correct running direction shall be found out after power on.

The process layout is Important links not to be ignored in coal preparation plant design The effective utilization of the site and the layout of buildings and structures should be considered comprehensively. Combined with the matters needing attention in the process of trial operation, the process design of coal preparation plant can be improved comprehensively, and the goal of increasing production and increasing benefit can be achieved.

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