A project report submitted to the Faculty of Engineering, University of the Witwatersrand, Johannesburg in partial fulfilment of the requirements for the degree of Master of Science in Engineering Johannesburg, 1993 / Superfines of less than 200 micron are generated when mining coal. They have not been successfully beneficiated in the past and are not acceptable to the consumer. A processh as been developed whereby the superfines are beneficiated, briquetted without the use of binders and devolatilised to produce a premium smokeless briquette which will attract a premium price in the export market. [Abbreviated abstract. Open document to view full version] / MT2017

M.Sc. (Geography) / Coal mined in South Africa for the competitive international market, has to be selected to meet the many quality specifications of customers. This upgrading is done by washing the coal in a heavy medium separation plant. Marketable coal, discard and slurry are produced from this washing. Discard consists mainly of poor quality coal, carbonaceous shale and waste rock. Iron pyrite (FeS2) occurs in all of the above in higher concentrations than in the marketable coal. Both the carbonaceous materials and pyrites generate heat when oxidizing. If this oxidation is not arrested at an early stage on a discard dump and the temperature of the dump increases above BOoC, spontaneous combustion is quite likely. The South African Council for Scientific and Industrial Research (CSIR) has estimated that smouldering discard dumps in the Eastern Transvaal highveld region contribute approximately 400 000 tons of S02 per annum to the atmospheric pollution in that area. As a result, significant localized acid rain occurs, Louw (1990). The oxidation of iron pyrites to sulphuric acid, and the oxidation of other trace elements, is accelerated under the high temperature conditions generated by spontaneous combustion. Leaching of these oxidation products results in local groundwater and surface water contamination. This study describes different disposal technique and pilot study aimed at minimising the oxidation within the dumps. Slurry, which consists of discard and/or coal of less than 1 mm in diameter is co-deposited with discard in sequential layers of approximately 200 mm thick. This has resulted in reducing the permeability, porosity and air and water exchange within the dump. This in turn has led to a reduction in spontaneous combustion, pollution and costs. A visual increase in stability of the discard dumps, moisture content and operational ease of placement were experienced. The saleable value of the dump as a low value heat source is also preserved.

Coarse coal refuse is difficult to reclaim due to high potential acidity and coarse fragment content, low water holding capacity, low fertility, and other problems. Little is known about coal refuse properties, particularly as they relate to revegetation potential. This study was undertaken to determine the physical and chemical properties of composite samples from 27 coal waste piles of varying age. Selected physical and chemical properties varied widely across this sample set. The mean coarse fragment (>2mm) content of these materials was 60%. The average texture of the fine (<2mm) fraction was a sandy loam with 15% clay. The mean water retention difference, between 0.03 MPa and 1.5 MPa of soil moisture tension, on a whole sample basis was 0.08 g water/g refuse. The pH values varied from 8.3 to 3.0, and the older piles generally had lower pH values than the more recent piles. The saturated paste electrical conductivity (EC) was higher in the younger coal waste materials. Total elemental analysis revealed that Si, Al, Fe, and K were the most abundant elements in these materials. The mineralogy of three selected samples was found to be dominated by quartz in the sand and silt fraction and mica in the clay fraction. The physical factor most limiting to plant growth was found to be low water holding capacity. Low pH was found to be the chemical factor most limiting to plant survival. These findings indicate that some refuse piles may be suitable for direct seeding, but many will require heavy lime and/or organic treatments. / Master of Science

As a consequence of new coal mining practices, coal preparation plants have been inundated with increased loads of coal and clay particles in their wastewaters. Traditionally, the industry has employed primary sedimentation as the fundamental treatment scheme for these sediment-laden blackwaters. This study was undertaken to determine the effects of a combination of coagulant addition and rapid mixing on the settleability of these particles. After initial testing, aluminum sulfate and two low molecular weight cationic polymers, Cyanamid Magnifloc 513C and Cyanamid 515C, were chosen as primary coagulants for use in this work. An artificial wastewater was prepared from finely powdered (62 to <38 microns) raw coal samples and tap water, after initial tests indicated that typical frothing and/or collector agents had no demonstrable effect on coagulant function. Initially determined optimum coagulant dosages, as well as flocculation and sedimentation times, were kept constant while rapid mix intensities were varied at G values of 330 sec⁻¹, 700 sec⁻¹, 2000 sec⁻¹ and 7000 sec⁻¹ for each sample. Using a combination of residual turbidity and particle size analyses to determine the effectiveness of each rapid mix intensity, it was discovered that only the highest mixing intensities and durations (G(t) values) caused floe disintegration due to overmixing. At the lower G(t) matrices floe formation and settleability was consistently good. When aluminum sulfate was used as a coagulant, the wastewater was tested at a high pH of 8.1 to 8.3 and a low pH of 5.5 to observe floe behavior under different conditions of coagulant mechanism. The test results were similar for both pH values except at the lowest mixing intensities where the high pH samples settled well, resulting in low residual turbidities, but the low pH samples had relatively high turbidities. / Master of Science

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