Search Results (20)

Coking coal flotation is a typical nonlinear, multi-variable, and multi-objective process in which concentrate quality and combustible matter recovery must be balanced under fluctuating feed and operating conditions. To improve both predictive reliability and decision support, this study proposes an integrated data-driven framework that combines particle swarm optimization-back propagation (PSO-BP) prediction, SHapley Additive exPlanations (SHAP) based interpretation, Non-dominated Sorting Genetic Algorithm II (NSGA-II) optimization, and entropy-weighted Technique for Order Preference by Similarity to Ideal Solution (Entropy-TOPSIS) decision-making. After three-sigma outlier screening, 2000 valid distributed control system (DCS) samples were retained for model development and temporal holdout evaluation, and an additional 200 later-period industrial samples were used for independent validation. The data were partitioned chronologically, with months 1–4, month 5, and month 6 used for training, validation, and temporal holdout testing, respectively, while the months 7–8 dataset was reserved for later-period validation. The results show that PSO-BP consistently outperformed conventional BP under both temporal holdout and later-period validation. SHAP analysis identified raw coal ash and collector dosage as the dominant factors for product-quality prediction, while collector dosage and frother dosage contributed most strongly to tailing heat of combustion. NSGA-II further revealed the trade-off among clean coal ash, clean coal sulfur, and tailing heat of combustion, and Entropy-TOPSIS converted the Pareto-optimal candidate set into a practically balanced operating recommendation. Sensitivity and robustness analyses indicated acceptable stability of both the optimization process and the final decision result. Overall, the proposed framework provides an interpretable prediction–optimization–decision workflow for coking coal flotation and offers a practical basis for future DCS-assisted intelligent regulation. Full article

Coal preparation tailings from the K18 seam of the Abayskaya mine were evaluated as a potential secondary source of critical rare earth elements (REEs). The study showed that REEs are predominantly associated with the mineral fraction of coal; therefore, during beneficiation, approximately 70% of their total content is transferred to flotation tailings. The concentrations of valuable elements in the tailings are as follows (g/t): Li—65; Sc—16; Y—17; Yb—2.5; V—135; and Ti—2293. These values significantly exceed the Clarke values and are comparable to those of some low-grade primary ores, indicating the potential of coal preparation wastes as a technogenic raw material for critical elements. To extract REEs from the resistant aluminosilicate matrix, a fluorine–ammonium sulfate thermochemical activation method was proposed. Using a probabilistic–deterministic experimental design approach, a mathematical model of the process was developed and optimal parameters were determined (400 °C, 120 min, (NH₄)₂SO₄ consumption—140% relative to Al, NH₄HF₂ consumption—110% relative to Si), providing a feed liberation degree (by Al extraction) of up to 94%. Under optimal conditions, high leaching efficiencies of key elements were achieved: Sc (95%), Y (100%), Yb (100%), and Li (100%). The results demonstrate the significant potential of coal preparation tailings as a secondary resource of rare earth elements and confirm the efficiency of fluorine–ammonium sulfate technology for processing this type of technogenic waste. Full article

This study proposes considering the effective re–benefication of coal middlings and other such considered waste materials as a way to ensure that clean coal in coal by–products can be extracted and effectively utilized, saving costs and reducing coal waste. To quantify the clean–coal yield and ash reduction that can be achieved by re–beneficiating four typical by–product streams from the Guobei Coal Preparation Plant (6 Mt a⁻¹) were used for the study. Coking–coal middlings, flotation tailings, and pressure–filter cakes from preparation plants still contain 30–60% combustible matter. Re–beneficiation techniques have been considered to recover this often-wasted coal, reduce waste rock disposal, and cut greenhouse–gas emissions per ton of clean coal produced. Representative samples (n = 4) were collected, sample size–classified as (fine coal particles ≤0.5 mm and coarse particles ≥) and subjected to (i) magnetite removal, (ii) laboratory froth flotation (diesel 507 g t⁻¹, sec–octanol 103 g t⁻¹), and (iii) fine and large particle density separation at 1.3–1.8 g cm⁻³ ZnCO₃ media. Clean–coal yield and ash were measured for each stream and the coal’s particle liberation was examined by SEM. Crushing, grinding and liberation equipment and techniques that aid in the treatment of coal and the re–beneficiation of coal middlings and tailings. The key findings recorded during the experiment are as follows: Flotation of <0.5 mm fractions delivered 46.9–58.3% clean–coal yield at 10.3–17.0% ash. Density separation of 0.5–1.0 mm middlings peaked at 1.4–1.5 g cm⁻³, yielding 34.2% clean coal at 15–18.4% ash. Scanning Electron Microscope analysis confirmed partial liberation as results from re–grinding + second flotation which increased yield by a further 8–12%. A calculated theoretical examination of the preliminary cost–benefit analysis indicates ≈36 CNY t⁻¹≈9 million CNY a⁻¹ in saved disposal costs alone. savings in disposal and 0.25 Mt a⁻¹ additional clean coal for the Guobei plant. The research presented in this paper highlights the current work by Anhui University of Science and technology in collaboration with Guobei coal preparation plant and the results therein achieved. Full article

The characterization of historical tailings bodies is crucial for optimizing environmental management and resource recovery efforts. This study investigated the Bielatal tailings dam (Altenberg, Germany), examining its internal structure, material distribution influenced by historical flushing technology, and the spatial distribution of valuable elements. To evaluate the tailings resource potential, drill core sampling was conducted at multiple points at a depth of 7 m. Subsequent analyses included geochemical characterization using sodium peroxide fusion, lithium borate fusion, X-ray fluorescence (XRF), and a scanning electron microscope with energy dispersive X-ray spectroscopy (SEM-EDX). Particle size distribution analysis via a laser particle size analyzer and wet sieving was conducted alongside milieu parameter (pH, Eh, EC) analysis. A theoretical assessment of the tailings’ potential for geopolymer applications was conducted by comparing them with other tailings used in geopolymer research and relevant European standards. The results indicated average concentrations of lithium (Li) of 0.1 wt%, primarily hosted in Li-mica phases, and concentrations of tin (Sn) of 0.12 wt%, predominantly occurring in cassiterite. Particle size analysis revealed that the tailings material is generally fine-grained, comprising approximately 60% silt, 32% fine sand, and 8% clay. These textural characteristics influenced the spatial distribution of elements, with Li and Sn enriched in fine-grained fractions predominantly concentrated in the dam’s central and western sections, while coarser material accumulated near injection points. Historical advancements in mineral processing, particularly flotation, had significantly influenced Sn distribution, with deeper layers showing higher Sn enrichment, except for the final operational years, which also exhibited elevated Sn concentrations. Due to the limitations of X-ray fluorescence (XRF) in detecting Li, a strong correlation between rubidium (Rb) and Li was established, allowing Li quantification via Rb measurements across varying particle sizes, redox conditions, and geological settings. This demonstrated that Rb can serve as a reliable proxy for Li quantification in diverse contexts. Geochemical and mineralogical analyses revealed a composition dominated by quartz, mica, topaz, and alkali feldspars. The weakly acidic to neutral conditions (pH 5.9–7.7) and reducing redox potential (Eh, 570 to 45 mV) of the tailings material indicated a minimal risk of acid mine drainage. Preliminary investigations into using Altenberg tailings as geopolymer materials suggested that their silicon-rich composition could serve as a substitute for coal fly ash in construction; however, pre-treatment would be needed to enhance reactivity. This study underscores the dual potential of tailings for element recovery and sustainable construction, emphasizing the importance of understanding historical processing techniques for informed resource utilization. Full article

The high consumption of coal in thermal power plants generates a significant amount of bottom ash, most of which is currently disposed of in landfills. However, the presence of unburned carbon in bottom ash limits its potential applications. To enable its use in construction materials, it is essential to reduce the unburned carbon content. Flotation is a promising technique for removing or recovering unburned carbon due to its high throughput and efficiency. This study aimed to optimize key parameters in the flotation process for recovering unburned carbon from bottom ash. The target was to achieve a tailing loss on ignition (LOI) of less than 6%, in accordance with ASTM C618 standards for concrete applications. The parameters evaluated in this study included the frother dosage, collector dosage, air flow rate, and pH. Optimization was conducted using the Taguchi method, which identified frother dosage as the most influential factor in flotation recovery, contributing 80.55%. Additionally, the air flow rate was found to have the greatest impact on combustible recovery (73.34%) and carbon content in the concentrate (41.05%). The optimized process resulted in a tailing LOI of 5.3%, meeting ASTM C618 requirements. These findings demonstrate the effectiveness of the Taguchi method in optimizing the flotation process for bottom ash treatment. Full article

The flotation effect of lean coal is crucial for its clean utilization. Therefore, the flotation characteristics of difficult-to-float lean coal were studied. The analysis results of the feed properties showed that the ash content of the feed was high and the particle size was very fine. The minerals in the gangue mainly included sericite, kaolinite, quartz, white mica, and other substances. After flotation, the functional groups of the coal particles in the tailings decreased, and the absorption peak intensity weakened. Furthermore, the results of multi-factor flotation experiments showed that the dosages of the collector and the frother were significant factors affecting the yield of clean coal. The clean coal yield gradually increased with an increase in the two factors. The ash content of the clean coal increased with an increase in the frother dosage. Within the range of feed concentrations used in this work, the feed concentration was not a significant factor affecting the clean coal’s yield and ash content. Prediction models for the clean coal yield and ash content were proposed. Under optimized experimental conditions, the clean coal yield and the flotation perfection index were 72.15% and 46.63%, respectively, indicating a good flotation effect. Full article

During the Late Permian period, the coal from the Jiashun Mine in Xingren City, Guizhou Province, China, is characterized by a high sulfur (5.84%) and lithium (Li) (94.5 μg/g) content. Lithium is a critical metal in the context of global energy transition. Considering the importance of environmental protection and resource utilization, the mode of occurrence and distribution of trace elements in different coal preparation products were investigated. The obtained results indicated the following: (1) The minerals in Jiashun coal were mainly composed of veined and epigenetic pyrite, quartz, and kaolinite. Most of the minerals could be effectively removed from the cleaned coal through gravity separation. (2) The mode of occurrence of rare earth elements and yttrium (REY) in the coal was relatively complex, and they were mainly found in middlings from gravity separation and in flotation tailings. (3) The mode of occurrence of the trace elements in the coal significantly influenced their removal rate. The removal rate was significantly higher for trace elements removed through gravity separation compared to those removed using flotation. The trace elements mainly found in fine-grained minerals wrapped by organic matter or combined with organic portions had better removal results through flotation. The trace elements that occurred both in the minerals and organic matters had low removal rates (<25%) using two coal preparation methods. (4) Li was more enriched in the middlings from gravity separation (98 μg/g) and in flotation tailings (102 μg/g), reaching the marginal grade (80 μg/g) of Li in coal. (5) Li in Jiashun coal may be derived from intermediate-felsic rocks at the top of the Kangdian Upland and late hydrothermal solutions. Full article

As a byproduct of the coal gasification process, a large amount of coal gasification slag is generated. The failure to fully dispose of it has caused the occupation of land resources and environmental pollution. Before its comprehensive utilization, the carbon and ash constituents must be separated, for which flotation is an effective method. However, the small difference in surface hydrophobicity of them cannot result in a high-efficiency separation. Therefore, a colliding flow pulp conditioning device (CFPCD) was proposed in this work to improve the interaction between the collector droplets and fine particles, and strengthen the modification of collector on the particle surface by generating a properly constructed turbulent flow field. Computational fluid dynamics (CFD) was employed to simulate the internal flow field of CFPCD to obtain the critical flow field parameters, such as the velocity, strain rate, turbulent kinetic energy, turbulent dissipation rate, and turbulent eddy scale. Additionally, particle wrap angle measurements and flotation tests were conducted to verify the performance of pulp conditioning. The results showed that a velocity gradient was obvious in the inner cylinder colliding flow area, thereby inducing the large strain rate and the intense turbulence, which were responsible for the pulp homogenization and the enhanced particle-collector interaction. With the feeding velocity increased, the fluid shear was larger and the improved performance was more obvious. According to the flotation results, the maximum recovery of unburned carbon was obtained with the feeding velocity equal to 2.5 m/s, which was consistent with the tendency of wrap angle. Meanwhile, the loss on ignition of the tailings reached the optimal value, corresponding to 9.94%. Full article

Large-scale application of filled coal mining technology has long been limited by conditions such as the cost of filling. Compared to traditional filling materials, coal flotation tailing filling materials (CFTFM) offers advantages such as low cost and excellent performance. The Box–Behnken response surface method was used to investigate the influence of flotation tailing properties on the mechanical properties and hydration mechanisms of the filling material. Ash content, blending, and calcination temperature of the flotation tailings were used as the investigating factors, and uniaxial compressive strength (7d and 28d), slump, and the slurry water secretion rate of the filling material as the evaluation indicators. The results showed that the influence of the flotation tailings on the uniaxial compressive strength (28d) of CFTFM followed the order ash > calcination temperature > doping, with the interaction of ash and calcination temperature having a greater influence on the uniaxial compressive strength. The optimized pre-treatment conditions for the flotation tailings were 59% ash, 30% doping, a calcination temperature of 765 °C, and optimum uniaxial compressive strength of 7.02 MPa. The effect of flotation tailings on the exotherm of CFTFM hydration was determined using a TAM Air isothermal microcalorimeter, mainly in the induction and acceleration phases. Combined with SEM electron microscopy and IR FT-IR analysis of the hydration products, a descriptive model of the CFTFM hydration mechanism was established. CFTFM hydration can be described in three phases: diffusion, hydration, and hardening. The CFTFM prepared in this study is applicable to the integrated mining and charging synergistic mining technology, which can effectively reduce gangue lifting energy consumption and washing process waste, reduce the cost of filling, and can effectively achieve harmless, resourceful, and large-scale disposal of coal-based solid waste. Full article

In this study, the microencapsulation-hybrid jig separation technique was developed to improve the separation efficiency of pyrite and coal in the particle size range of 1–4 mm where conventional jig separation becomes inefficient. A hybrid jig is a gravity concentrator combining the concepts of jig separation and flotation to stratify particles based on their apparent specific gravity. Meanwhile, microencapsulation—a technique that encapsulates target materials with a protective coating—was applied to render pyrite hydrophilic and improve its separation from hydrophobic coal. The results showed that the required time for separation in the hybrid jig (0.5 min) was shorter than in conventional jig (2 min). Moreover, the effects of particle size on separation efficiency were reduced when a hybrid jig is used. However, the separation efficiency of hybrid jig separation was lower than that of the conventional jig because attachment of bubbles occurred to both pyrite and coal, which are hydrophobic. Using the microencapsulation-hybrid jig separation technique, the separation of coal and pyrite was significantly improved (~100%) because of the formation of hydrophilic iron phosphate coatings on pyrite that limited bubble attachment. This means that microencapsulation-hybrid jig separation is a promising clean coal technology that not only enhances the separation efficiency of the hybrid jig but also passivates pyrite and limits AMD formation in the tailings/rejects. Full article

Black shale ore contains rich strategic metal resources such as vanadium, nickel, and molybdenum, but due to its complex composition, it is currently only used in the vanadium extraction industry. Metals such as nickel and molybdenum have not been effectively recovered, resulting in environmental pollution and resource waste. Using mineralogical features and a combination of beneficiation and metallurgy-based tests, the present work carried out feasibility studies of the combined beneficiation and metallurgy processes. The mineralogical features of the stone coal sample were studied using chemical analysis, an automatic mineral analyzer (BPMA), etc., and we identified the main phase composition, embedded characteristics, and particle size distribution of the associated strategic metals, vanadium, nickel, and molybdenum. The results showed that the grade of V₂O₅ in the stone coal was 1.29%, which was mainly present in carbonaceous clay and mica minerals. The nickel grade was 0.53%, mainly in the form of nickel–magnesium spinel and a small amount of nickel-containing magnesite. The stone coal contained 0.11% molybdenum; the mineral particles were fine, mostly in the form of molybdenite, and some were associated with carbonaceous matter and carbonaceous clay minerals. Based on the mineralogical feature, we proposed using the scrubbing–desliming and flotation process to enrich vanadium, nickel, and molybdenum. Our preliminary experiments obtained two products: vanadium–molybdenum-rich sludge and nickel-containing tailings. The V₂O₅ and molybdenum grades in the sludge were 4.10% and 0.44%, respectively, and the recovery was 41.31% and 51.40%, respectively. The nickel grade in the tailings was 1.49%. These products were roasted and leached. The vanadium, nickel, and molybdenum in the stone coal were effectively recovered through the beneficiation–metallurgy combination process, and the comprehensive utilization rate of the stone coal was improved. Full article

For various sorts of hard coal, enrichment by flotation is used for feed consisting of grains smaller than 0.5 mm. Regarding process automation, coal flotation is a multidimensional, dynamic nonlinear object of control, for which the main control signal is the flow rate of the flotation agent. Typically, in Polish coal-processing facilities the monitoring and control systems of the flotation process can only measure the parameter of the waste quality (content of ash in flotation tailings). This naturally becomes an output signal, enabling an indirect assessment of the ongoing process. Therefore, knowledge of the dynamic properties of the flotation process, analysed as an object with one control input (the flow rate of the flotation agent) and with one output for measuring (content of ash in flotation tailings) may be material in designing automatic control systems for this operation. It is important to use an appropriate identification method when developing a model of the dynamics of the flotation process, especially if the model parameters are to be determined on an ongoing basis. This article discusses the research method and presents the results of applying the method of identifying the dynamic properties of the coal flotation process with the use of the Kalman filter. We carried out a comparative analysis of the results obtained by this method based on the Kalman algorithm and the method of least squares, taken as the reference method. The presented parameters of the dynamic models were calculated based on actual data obtained from industrial tests conducted at the coal-processing plant at one of the Polish mines. It was demonstrated that, for control purposes, the Kalman algorithm can be successfully applied in identification of the coal flotation process. This is due to the fact that it gives satisfactory results in relation to the adopted reference method despite the fact that it is a recursive algorithm. Full article

The high-ash tailings produced by flotation contains a large number of minerals that can be recycled. However, as the separation and purification technology for flotation tailings is not mature and separation efficiencies are low, it is generally treated as separation waste, resulting in the waste of mineral resources. In view of this phenomenon, the particle size composition and density composition of high-ash minerals in flotation tailings of coal slime as well as the type and content of mineral elements were measured. It was determined that the main mineral composition is quartz, and there is also a certain amount of chlorite (silicate mineral). A self-spinning hydrocyclone used for flotation tailings separation and purification was designed, and numerical simulation was carried out by fluent software. The internal flow field-, tangential velocity-, and axial velocity-distribution characteristics of the hydrocyclone at different rotational speeds were investigated. The physical model of the hydrocyclone was set up and the separation efficiency improvement test of fine particles was carried out. The results show that the overflow yield of −0.045 mm particles increased gradually with the increase in cylinder rotation speed. When the rotation speed increased to 900 r/min, the overflow yield of −0.045 mm particles can reach more than 90%, which can effectively realize the material classification according to 0.045 mm. Full article

Pyrite bio-oxidation by chemolithotrophic acidophile bacteria has been applied in the mining industry to bioleach metals or to remove pyritic sulfur from coal. In this process, it is desirable to use autochthonous and already adapted bacteria isolated directly from the mining sites where biomining will be applied. Bacteria present in the remnant solution from a mining company were identified through cloning techniques. For that purpose, we extracted total RNA and performed reverse transcription using a novel pair of primers designed from a small region of the 16S gene (V1–V3) that contains the greatest intraspecies diversity. After cloning, a high proportion of individuals of the strains ATCC-23270 (NR_074193.1 and NR_041888.1) and DQ321746.1 of the well-known species Acidithiobacillus ferrooxidans were found, as well as two new wild strains of A. ferrooxidans. This result showed that the acidic remnant solution comprises a metapopulation. We assayed these strains to produce bioferric flocculant to enhance the subsequent pyrite bio-oxidation, applying two-stage chemical–bacterial oxidation. It was shown that the strains were already adapted to a high concentration of endogenous Fe²⁺ (up to 20 g·L⁻¹), increasing the volumetric productivity of the bioferric flocculant. Thus, no preadaptation of the community was required. We detected Au and Ag particles originally occluded in the old pyritic flotation tailings assayed, but the extraction of Au and Ag by cyanidation resulted in ca. 30.5% Au and 57.9% Ag. Full article

The selective agglomeration of a fine coal tailings stream using a high internal phase emulsion binder was investigated using a continuous steady-state plug flow through a high shear constriction. The emulsion binder effectively switches off the viscous resistance to particle–binder collision and adhesion, revealing the remarkable underlying speed of hydrophobic interactions. The emulsion binder is permeable, meaning the lubrication force between the particle and binder vanishes. The binder comprised a 95% aqueous solution dispersed within a 5% organic liquid (including the emulsifier). The agglomeration occurred within a high shear zone formed using a flow constriction within a 25 mm diameter pipe. The performance of the process was investigated at different flowrates in the range of 20–128 L/min, equating to extraordinarily high superficial flow velocities of up to 4.2 m/s and pressure drops in the range of 20–220 kPa. This rate greatly exceeds the nominal superficial feed velocity in flotation of order 0.01 m/s. Provided there was sufficient shear within the flow constriction, it was possible to process fine coal tailings with a feed ash of 50.1%, and generate a product ash of 8% at a combustible recovery of ~78%. Full article