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1. allmineral Dry Coal Technology – A suitable alternative for Indian Power Coals Dr. H. Breuer, R.J. Snoby, S.Mishra, D. Biswal

2. allmineral | worldwide 26 |

3. Basic Scenario - The Indian Economy is expected to grow at a minimum rate of 6-7%. One major factor that could hinder the economic growth would be a shortage of available power. - The power generation capacity in India is about 100,000 MW and the country has an ambitious target of adding another 200,000 MW of power generation by the year 2017. - Three quarters of the power generation comes from thermal power stations. This same ratio, 3:1, is projected to continue for the future additional power generation capacities. - Indian coal production for the year 2008 was estimated at 450 million tons; roughly eighty percent is being consumed by power utilities. Recently, the government of India has opened a coal sector and allotted about 190 coal blocks to the private sector power utilities. The coal production in the private sector is expected to go up to 200-300 million ton per annum in the next 5 year period. - The run of mine ash percentage is typically in the range of 45-50%. Beneficiation of this coal is necessary due to the Ministry of Environment & Forests (MoEF) issuing a statute to reduce the ash to a 35% level. 2 |

4. Basic Scenario I Beneficiation Processes I - Heavy Media Systems - Wet Jigging Dry jigging - 3 |

5. Basic Scenario I Beneficiation Processes II - Heavy Media Systems At first glance, people might perceive heavy media as the right solution for cleaning India’s high ash coal with typically a lot of NGM. However, especially for power utilities with a 35% ash requirement, the required separating gravities will usually be in the range of 1.9- 2.0, which would be a very difficult separation to achieve with a heavy media process. Certain heavy media installations recently constructed in India are experiencing problems maintaining such a high gravity separation. The lack of availability of high quality magnetite contributes to the problem for heavy media operations. 4 |

6. Basic Scenario I Beneficiation Processes III - Wet jigging Dry jigging Therefore, coal preparation with jigging technology, both wet and dry, is a superior choice for Indian coals. The separating gravity achieved by jigging processes is only limited by the relative density of the feed material. The fundamentals of jigging technology are stratification and and - separation. The feed solids must be stratified according to density and then separated from one or more of the jigged density layers. 5 |

7. Wet Jigging Plants Allmineral has been active in India since 2005 and has installed both wet & dry jig plants for upgrading coal. Wet plants of 150 resp. 200 tph, feed size 1” x 0, are operating since 2007 in Chhatisgarh. Both are of simple, very compact design as illustrated in the following Pictures. Special features are: •No desliming of feed ahead of the jig , which saves CAPEX and OPEX because of less equipment and smaller wash water circuit •No bucket elevator for jig rejects but frequency controlled dewatering screen, which saves costs as well by reducing the required building space by about 50 % and by avoiding costly bucket elevator maintenance. 6 |

8. ® alljig | for coal benefication Example 01 Lloyds India alljig® 150 t|h start up Feed: Clean Coal: Rejects: Yield: 7 | 1 x F 2200 0 – 25 mm January 2007 35,4 % ash 24,8 % ash 72,8 % ash 77,9 %

9. alljig® I Separation Efficiency I Lloyds India I Imperfection = 0, 14 I 25 – 0 mm 100 90 T% 80 70 60 50 40 30 20 10 0 1000 1200 1400 1600 1800 2000 2200 2400 2600 density, kg/ m³ 8 |

10. ® alljig | for coal benefication Example 02 SKS Ispat India alljig® 200 t|h start up Feed: Clean Coal: Rejects: Yield: 9 | 1 x F 2500 0 – 25 mm June 2007 45,2 % ash 29,8 % ash 71,9 % ash 63,4 %

11. allair® Dry Beneficiation Technology The Indian coal industry has reacted very positively to the allair ® jig, allmineral’s dry coal solution, and as a result more than 25 air jigs are in operation in the coal dominated states of Orissa, Chhatisgarh & Jharkhand. These air jigs are upgrading India coals from CIL mines of Mahanadi Coal Fields (MCL) to the South Eastern Coal Fields (SECL). The great benefit of the dry process is to exploit the given resources while providing a more reliable and consistent quality fuel with low operating cost. The chart in the following figure illustrates the performance of an Allair jig plant over a 40 day period. 10 |

12. allair® I Example for industrial Performance I MCL- Scan I India 80 63,35 ash % 60 46,53 40 20 0 36,56 0 5 10 15 20 25 30 35 40 45 Sam ples Feed coal ash % Clean coal ash% Reject ash % 11 |

13. ® allair 12 | | for dry coal cleaning without water

14. allair® Technology I Advantages Stratification Superimposed pulsating air supply Optimized even air distribution Adjustable screendeck amplitude and frequence Controlled feeding system 13 | Discharge - Automatic discharge control with analog density measurement system - - - -

15. allair® I Dry Beneficiation Technology The allair® jig utilizes the basic principles of jigging; it stratifies the feed material by specific gravity and subsequently measures and discharges the high density (and high ash) strata. To stratify the material, the allair® jig uses pulsating and constant air flow through a perforated jig bed. Vibrating mechanisms assist the transport of material across the bed. The feed star gate provides an even feed distribution over the width of the bed, and the discharge star gate provides an even removal of the heavy particles (rock) from the jig, thereby maintaining a residual layer of refuse below the light particles (coal). To measure the coal-rock interface, a nuclear density measuring device is located towards the discharge end of the jigging bed. This device automatically controls the discharge mechanism (the star gate) of the jig. If more dilution enters the jig, the star gate will speed up and discharge more rock; the opposite is true too, if more coal enters the jig, the star gate will slow down thereby discharging less rock and minimizing the loss of clean coal in the refuse. The entire operation of the separation function is automatic. To complete the allair® jig process, dust particles are removed via a bag house filter. The allair® jig is designed to handle material up to a maximum particle size of 50mm. The maximum feed capacity of the jig depends on the particle size distribution of the feed material. A throughput for coarse material (50mm top size) of 40 TPH per meter of width, and 30 TPH per meter of width for fine feeds (-6mm top size) will ensure optimum performance. A few examples of dry allair® jig plants and operating data achieved in are found in the following figures: 14 |

16. ® allair | for dry coal benefication Example 01 Texas USA allair® 100 t|h start up 15 | 2 x 4´x 8´ 30-6/ 6–0 mm June 2006

17. allair® | for dry coal benefication Example 02 Texas USA allair® 5 x 4´x 8´ 200 t|h 6-0 mm start up July 2008 16 |

18. allair® for dry coal benefication Example 03 Colcarbon Colombia Coking Coal 2 x 50 t|h 2 x allair 0 - 6 mm, 6 – 30 mm G4x8 ® Start up May 2005 17 |

19. allair® for dry coal benefication Example 04 BIK Lugansk/ Ukraine Anthrazite 1 x 50 t|h 1 x allair 0 - 40 mm G4x8 ® Start up March 2008 18 |

20. ® allair | for coal benefication Example 05 SAMCA Teruel | Spain allair® 600 t|h start up 19 | 12 x 4´x 8´ 30 – 0 mm December 2004

21. allair® I Separation Efficiency I SAMCA Spain I Imperfection = 0, 18 I 30 – 1 mm 100 90 80 70 60 50 40 30 20 10 0 T% 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 density kg / m³ 20 |

22. ® allair | for coal benefication Example 06 OCL India allair® 50 t|h start up 21 | 1 x 4´x 8´ 0 – 30 mm 2005

23. allair® I Distribution Curves I MCL- Scan I Yield 71,23 % density kg / m³ 1000 1200 1400 1600 1800 2000 2200 0 10 20 30 40 Feed 50 Clean Coal 60 70 80 Rejects 90 100 22 | Q%

24. allair® I Separation Efficiency I MCL- Scan I Imperfection = 0, 21 100 90 80 70 60 50 40 30 20 10 0 T% 1000 1200 1400 1600 1800 2000 2200 2400 2600 density kg / m³ 23 |

25. Conclusions Dry coal beneficiation will have an edge over other types of non coking coal preparation plants in India, because of: - SCARCE WATER AVAILABILITY IN FUTURE Depleting water levels in various parts of India - - With a population of over one billion, drinking water problems are going to become more and more critical - The government of India is endeavoring to restrict the use of ground water resources for industrial applications - MAXIMUM UTILIZATION OF RESOURCES - To optimize the coal resources, there is a growing trend in India to use circulating fluidized bed combustion (CFBC) boilers in conjunction with pulverized coal boilers. The concept is air jigs to clean the raw coal to 35% ash for use in pulverized coal boilers and to blend the preparation plant rejects with dust collector fines, which will reduce the reject’s ash below 60% for use in fluidized bed boilers. This significates, that the supposed disadvantage of a less efficient dry separation process becomes an advantage. Such a concept will maximize the use of Indian resources and minimize environmental impact. - Currently, there are many CFBC boilers in operation in India. This technology is well proven and gaining importance in India. 24 |

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