ABSTRACT A dry coal beneficiation process was developed on a batch scale using a gas-solid fluidized bed separator to upgrade the low-grade coking coal from the Jharia Coalfield. Coal collected from Ena open cast mines of Kusunda area, Dhanbad was crushed to 50 mm and 25 mm sizes for dry processing using the dense medium fluidized bed separator followed by froth flotation for particles below 500 microns. Coal with a + 6 mm size fraction was processed via the dry route, while coal with a −6 mm size fraction and pre-concentrate from the dry route was further crushed to 0.5 mm for the froth flotation process using various reagents. The effect of various process parameters of the dry separator such as bed height, dense medium size, air flow rate were studied using CFD software in a simple 2D plane. The study revealed that the dry process for the −50 + 6 mm fraction achieves higher organic efficiency (90%) compared to −25 + 6 mm (81%) due to better washing characteristics. Dry deshaling of high-ash coking coal (−50 + 6 mm) can reduce the ash content from 35.3% to 29.6% with a yield of 75.4%. The flotation process using NALCO synthetic reagents is highly effective, reducing the feed ash content from 27.3% to 17.5% with a notable yield of 85.0%.
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