Split and collectorless flotation to medium coking coal fines for multi-product zero waste concept

The medium coking coal fines of − 0.5 mm from Jharia coal field were taken for this investigation. The release analysis of the composite coal reveals that yield is very low at 10.0% ash, about 25% at 14% ash and 50% at 17% ash level. The low yield is caused by the presence of high ash finer fraction. The size-wise ash analysis of − 0.5 mm coal indicated that − 0.5 + 0.15 mm fraction contains less ash than − 0.15 mm fraction. Thus, the composite feed was split into − 0.5 + 0.15 mm and − 0.15 mm fractions and subjected to flotation separately. The low ash bearing fraction (− 0.5 + 0.15 mm) was subjected to two stages collectorless flotation to achieve the concentrate with 10% ash. The cleaner concentrate (18.9%) with 10% ash was recovered which has an application in metallurgical industries. The concentrate of 30.2% yield with 12.5% ash could be achieved in one stage collectorless flotation which is suitable for use in coke making as sweetener. As the − 0.15 mm fraction contains relatively high ash, collector aided flotation using sodium silicate was performed to get a concentrate of 23.6% yield with about 17% ash. The blending of this product with cleaner tail obtained from − 0.5 + 0.15 mm produces about 35.0% yield with 17% ash and that can be utilized for coke making. The reject from the two fractions can be used for conventional thermal power plant or cement industries using a 23.5% ash after one stage collector aided flotation and the final tailings produced content ash of 61.6% can be used for fluidization combustion bed (FBC). This eventually leads to complete utilization of coal.