Beneficiation of fine coal (+500 μm –2000 μm) is a worldwide problem in the mining industry, especially dry beneficiation of fine coal. Coal beneficiation can be divided primarily into two methods, namely wet- and dry beneficiation. Wet beneficiation methods are utilized more in today‘s industry because of the sharp separation efficiency that can be achieved. These processes include wet jigging, dense medium cyclones, spiral beneficiation etc. Due to the lack of a sufficient water supply in some regions around the world including South Africa, dry beneficiation methods are becoming more popular. Recent mechanized mining methods caused the fraction of fines from coal mines to increase over the years. However, due to old inefficient technologies, coal fines contained in slurry ponds could not be beneficiated and had to be discarded. One new dry beneficiation technology that has been used and researched extensively is the fluidized dense medium bed (FDMB) technology. The purpose of this study is to determine whether fine coal can be successfully beneficiated with a FDMB. It also has to be determined whether adding magnetite and introducing a jigging (pulse) motion to the air feed will increase the separation efficiency of the fluidization process. Witbank seam 4 and a Waterberg coal was used in experiments during this study. A coarse (+1180 μm –2000 μm), fine (+500 μm –1180 μm) and a mix of the two samples were prepared and tested. It was found that adding magnetite to the feed of the fluidized bed did not increase the separation efficiency. However, previous studies indicated the opposite results with regards to magnetite addition. The difference in results obtained could be prescribed to the ultrafine nature of the magnetite and the small coal particles size range used. If the presence of fine particles in the bed increases, the stability of fluidization decreases. In turn, the separation efficiency of the process decreases. Subjecting the feed air flow to a pulsating motion did not have a significant effect on separation. Good results were still obtained with jigging experiments, although not better than with normal fluidization. Stratification of coal particles according to quality was evident by the results obtained during experiments. The quality of coal increases from the bottom to the top of the bed. Overall the fluidized bed, in the absence of magnetite, was found to be a sufficient de-ashing process and further research on this technology could be very beneficial to the coal industry. / MIng (Chemical Engineering), North-West University, Potchefstroom Campus, 2014

Dust is a well-known occupational hygiene challenge and has been throughout the years, especially in the coal mining industry. The hazards arising from coal dust will differ between geographical areas due to the unique characteristics of dust from the coal mining environment. It is therefore of upmost importance to identify these qualities or characteristics of coal dust in order to understand the potential hazards it may pose. It is also important to consider the presence of nanoparticles which until recently remained neglected due to the absence of methods to study them. Aim: The aim of this study was to collect significant quantities of airborne dust through static sampling to characterise the physical, morphological as well as elemental properties of inhalable and respirable dust produced at two South African underground and two opencast coal mines. Personal exposure quantification was therefore not the primary concern in this study. Method: Static dust sampling was done at two mining areas of the two opencast and underground coal mines using four Institute of Occupational Medicine (IOM) and four cyclone samplers per area at each mine. A condensation particle counter (CPC) was also used at the opencast areas. The opencast areas included blast hole drilling, drag line and power shovel operations. The underground areas included the continuous miner and roof bolter operations. Gravimetric analyses of the cyclone and IOM samples were done as well as scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) analysis. Results: Mine A (opencast and underground) produces higher grade coal in comparison to mine B (opencast and underground). Gravimetric analysis indicated higher average inhalable (55.35 mg/m3) and respirable (2.13 mg/m3) concentrations of dust in the underground areas when compared to the opencast areas (34.73 mg/m3 and 0.33 mg/m3). Blast hole drilling operations indicated higher average inhalable and respirable dust concentrations (39.02 mg/m3 and 0.41 mg/m3) when compared to the drag line and power shovel operations (30.44 mg/m3 and 0.246 mg/m3). CPC results showed higher average concentrations of sub-micron particles at the blast hole drilling areas per cubic metre (63132 x 106) compared to the drag line and power shovel operations (38877 x 106). EDS analysis from the opencast areas indicated much higher concentrations of impurities (with lower concentrations of carbon – 33.33%) when compared to samples taken from the underground mining activities (65.41%). The EDS results from the opencast areas differed substantially. The highest concentrations of silica were found at the blast hole drilling areas. EDS results from the underground areas indicated that mine A has slightly higher concentrations of carbon (66.2%) with less impurities when compared to mine B (64.62%). The continuous miner operations showed a higher concentration of impurities when compared to the dust from the roof bolter. SEM results from the opencast areas revealed that the majority of particles are irregularly shaped and the presence of quartz and agglomerations are evident. SEM results from the underground areas were similar except that the roof bolter produced smaller sized particles when compared to the continuous miner. It also seemed that the areas with higher levels of impurities produced more sub-micron particles. Conclusions: It is possible to identify the majority of physical and elemental characteristics of coal dust by means of gravimetric analysis, particle counting, SEM and EDS. There were differences found, regarding the morphological; chemical and physical characteristics, between the different opencast and underground areas at mine A and mine B due to the type of mining activity and amount of overburden present. Silicosis, Pneumoconiosis and Chronic obstructive pulmonary disease are some of the possible health concerns. It has been seen that dust from higher grade coal mines contributed to more developed stages of these diseases. / MSc (Occupational Hygiene), North-West University, Potchefstroom Campus, 2015

The swelling and caking propensity of coals may cause operational problems such as channelling and excessive pressure build-up in combustion, gasification and specifically in fluidised-bed and fixed-bed operations. As a result, the swelling and caking characteristics of certain coals make them less suitable for use as feedstock in applications where swelling and/or caking is undesired. Therefore, various studies have focused on the manipulation of the swelling and/or caking propensity of coals, and have proven the viability of using additives to reduce the swelling and caking of powdered coal (<500 μm). However, there is still a lack of research specifically focused on large coal particle devolatilisation behaviour, particularly swelling and caking, and the reduction thereof using additives. A comprehensive study was therefore proposed to investigate the swelling and caking behaviour of large coal particles (5, 10, and 20 mm) of typical South African coals, and the influence of the selected additive (potassium carbonate) thereon. Three different South African coals were selected based on their Free Swelling Index (FSI): coal TSH is a high swelling coal (FSI 9) from the Limpopo province, GG is a medium swelling coal (FSI 5.5-6.5) from the Waterberg region, and TWD is a non-swelling coal (FSI 0) from the Highveld region. Image analysis was used to semi-quantitatively describe the transient swelling and shrinkage behaviour of large coal particles (-20+16 mm) during lowtemperature devolatilisation (700 °C, N2 atmosphere, 7 K/min). X-ray computed tomography and mercury submersion were used to quantify the degree of swelling of large particles, and were compared to conventional swelling characteristics of powdered coals. The average swelling ratios obtained for TWD, GG, and TSH were respectively 1.9, 2.1 and 2.5 from image analysis and 1.8, 2.2 and 2.5 from mercury submersion. The results showed that coal swelling measurements such as FSI, and other conventional techniques used to describe the plastic behaviour of powdered coal, can in general not be used for the prediction of large coal particle swelling. The large coal particles were impregnated for 24 hours, using an excess 5.0 M K2CO3 impregnation solution. The influence of K2CO3-addition on the swelling behaviour of different coal particle sizes was compared, and results showed that the addition of K2CO3 resulted in a reduction in swelling for powdered coal (-212 μm), as well as large coal particles (5, 10, and 20 mm). For powdered coal, the addition of 10 wt.% K2CO3 decreased the free swelling index of GG and TSH coals from 6.5 to 0 and from 9.0 to 4.5, respectively. The volumetric swelling ratios (SRV) of the 20 mm particles were reduced from 3.0 to 1.8 for the GG coal, and from 5.7 to 1.4 for TSH. In contrast to the non-swelling (FSI 0) behaviour of the TWD powders, the large particles exhibited average SRV values of 1.7, and was found not be influenced by K2CO3-impregnation. It was found that the maximum swelling coefficient, kA, was reduced from 0.025 to 0.015 oC-1 for GG, and from 0.045 to 0.027 oC-1 for TSH, as a results of impregnation. From the results it was concluded that K2CO3-impregnation reduces the extent of swelling of coals such as GG (medium-swelling) and TSH (high-swelling), which exhibit significant plastic deformation. Results obtained from the caking experiments indicated that K2CO3-impregnation influenced the physical behaviour of the GG coal particles (5, 10, and 20 mm) the most. The extent of caking of GG was largely reduced due to impregnation, while the wall thickness and porosity also decreased. The coke from the impregnated GG samples had a less fluid-like appearance compared to coke from the raw coal. Bridging neck size measurements were performed, which quantitatively showed a 25-50% decrease in the caking propensity of GG particles. Coal TWD did not exhibit any caking behaviour. The K2CO3-impregnation did not influence the surface texture or porosity of the TWD char, but increased the overall brittleness of the devolatilised samples. Both the extent of caking and porosity of TSH coke were not influenced by impregnation. However, impregnation resulted in significantly less and smaller opened pores on the surface of the devolatilised samples, and also reduced the average wall thickness of the TSH coke. The overall conclusion made from this investigation is that K2CO3 (using solution impregnation) can be used to significantly reduce the caking and swelling tendency of large coal particles which exhibits a moderate degree of fluidity, such as GG (Waterberg region). The results obtained during this investigation show the viability of using additive addition to reduce the caking and swelling tendency of large coal particles. Together with further development, this may be a suitable method for modifying the swelling and caking behaviour of specific coals for use in fixed-bed and fluidised-bed gasification operations. / PhD (Chemical Engineering), North-West University, Potchefstroom Campus, 2015

Beneficiation of fine coal (+500 μm –2000 μm) is a worldwide problem in the mining industry, especially dry beneficiation of fine coal. Coal beneficiation can be divided primarily into two methods, namely wet- and dry beneficiation. Wet beneficiation methods are utilized more in today‘s industry because of the sharp separation efficiency that can be achieved. These processes include wet jigging, dense medium cyclones, spiral beneficiation etc. Due to the lack of a sufficient water supply in some regions around the world including South Africa, dry beneficiation methods are becoming more popular. Recent mechanized mining methods caused the fraction of fines from coal mines to increase over the years. However, due to old inefficient technologies, coal fines contained in slurry ponds could not be beneficiated and had to be discarded. One new dry beneficiation technology that has been used and researched extensively is the fluidized dense medium bed (FDMB) technology. The purpose of this study is to determine whether fine coal can be successfully beneficiated with a FDMB. It also has to be determined whether adding magnetite and introducing a jigging (pulse) motion to the air feed will increase the separation efficiency of the fluidization process. Witbank seam 4 and a Waterberg coal was used in experiments during this study. A coarse (+1180 μm –2000 μm), fine (+500 μm –1180 μm) and a mix of the two samples were prepared and tested. It was found that adding magnetite to the feed of the fluidized bed did not increase the separation efficiency. However, previous studies indicated the opposite results with regards to magnetite addition. The difference in results obtained could be prescribed to the ultrafine nature of the magnetite and the small coal particles size range used. If the presence of fine particles in the bed increases, the stability of fluidization decreases. In turn, the separation efficiency of the process decreases. Subjecting the feed air flow to a pulsating motion did not have a significant effect on separation. Good results were still obtained with jigging experiments, although not better than with normal fluidization. Stratification of coal particles according to quality was evident by the results obtained during experiments. The quality of coal increases from the bottom to the top of the bed. Overall the fluidized bed, in the absence of magnetite, was found to be a sufficient de-ashing process and further research on this technology could be very beneficial to the coal industry. / MIng (Chemical Engineering), North-West University, Potchefstroom Campus, 2014

Dust is a well-known occupational hygiene challenge and has been throughout the years, especially in the coal mining industry. The hazards arising from coal dust will differ between geographical areas due to the unique characteristics of dust from the coal mining environment. It is therefore of upmost importance to identify these qualities or characteristics of coal dust in order to understand the potential hazards it may pose. It is also important to consider the presence of nanoparticles which until recently remained neglected due to the absence of methods to study them. Aim: The aim of this study was to collect significant quantities of airborne dust through static sampling to characterise the physical, morphological as well as elemental properties of inhalable and respirable dust produced at two South African underground and two opencast coal mines. Personal exposure quantification was therefore not the primary concern in this study. Method: Static dust sampling was done at two mining areas of the two opencast and underground coal mines using four Institute of Occupational Medicine (IOM) and four cyclone samplers per area at each mine. A condensation particle counter (CPC) was also used at the opencast areas. The opencast areas included blast hole drilling, drag line and power shovel operations. The underground areas included the continuous miner and roof bolter operations. Gravimetric analyses of the cyclone and IOM samples were done as well as scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) analysis. Results: Mine A (opencast and underground) produces higher grade coal in comparison to mine B (opencast and underground). Gravimetric analysis indicated higher average inhalable (55.35 mg/m3) and respirable (2.13 mg/m3) concentrations of dust in the underground areas when compared to the opencast areas (34.73 mg/m3 and 0.33 mg/m3). Blast hole drilling operations indicated higher average inhalable and respirable dust concentrations (39.02 mg/m3 and 0.41 mg/m3) when compared to the drag line and power shovel operations (30.44 mg/m3 and 0.246 mg/m3). CPC results showed higher average concentrations of sub-micron particles at the blast hole drilling areas per cubic metre (63132 x 106) compared to the drag line and power shovel operations (38877 x 106). EDS analysis from the opencast areas indicated much higher concentrations of impurities (with lower concentrations of carbon – 33.33%) when compared to samples taken from the underground mining activities (65.41%). The EDS results from the opencast areas differed substantially. The highest concentrations of silica were found at the blast hole drilling areas. EDS results from the underground areas indicated that mine A has slightly higher concentrations of carbon (66.2%) with less impurities when compared to mine B (64.62%). The continuous miner operations showed a higher concentration of impurities when compared to the dust from the roof bolter. SEM results from the opencast areas revealed that the majority of particles are irregularly shaped and the presence of quartz and agglomerations are evident. SEM results from the underground areas were similar except that the roof bolter produced smaller sized particles when compared to the continuous miner. It also seemed that the areas with higher levels of impurities produced more sub-micron particles. Conclusions: It is possible to identify the majority of physical and elemental characteristics of coal dust by means of gravimetric analysis, particle counting, SEM and EDS. There were differences found, regarding the morphological; chemical and physical characteristics, between the different opencast and underground areas at mine A and mine B due to the type of mining activity and amount of overburden present. Silicosis, Pneumoconiosis and Chronic obstructive pulmonary disease are some of the possible health concerns. It has been seen that dust from higher grade coal mines contributed to more developed stages of these diseases. / MSc (Occupational Hygiene), North-West University, Potchefstroom Campus, 2015

Thesis (MBA)--Stellenbosch University, 2000. / ENGLISH ABSTRACT: It was found that the hot metal cost of ISCOR Newcastle's single blast furnace can significantly be reduced by the correct use of an integrated model to predict reductant cost based mainly on coal blend. The model uses coal ash chemistry, fluiidity, vitrinite rank and volatile matter to predict coke strength after reaction (CSR), coke ash and coking yield. CSR is used to predict maximum allowable coke nut- and pea consumption in the furnace as well as hot blast temperature. Pitch injection levels are predicted using CSR and blast furnace production rates. Coke ash, pitch injection and hot blast temperature is used to predict the coke rate. The above is used with imported Chinese coke cost to accurately predict reductant cost. It was found that the current optimum blends should include Australian en Nieu Zeeland coals because of price and quality conciderations. Because of its low cost of production and low quality the optimum percentage of Grootegeluk in the blend is determined largely by its transfer price. / AFRIKAANSE OPSOMMING: Die vloeiyster koste van ISCOR Newcastle se enigste hoogoond kan drasties verlaag word deur die korrekte gebruik van 'n geïntegreerde model wat reduktant koste voorspel op grond van steenkoolmengsel. Die model gebruik die chemiese samestelling van steenkool-as, fluiiditeit, vitriniet rang en vlugstof om kooks warmsterkte (SNR), kooks-as en verkooksingsopbrengs te voorspel. SNR is gebruik om die maksimum kooksneute- en -erteverbruik in die hoogoond sowel as blaastemperatuur te voorspel. Pikinspuiting is bereken met SNR en hoogoond produksietempo's. Pikinspuiting en blaastemperatuur word saam met kooks-as gebruik om kookskoers te voorspel. Bogenoemde is saam met die koste van ingevoerde Chinese kooks gebruik om reduktant koste akkuraat te voorspel. Daar was bevind dat die huidige optimum mengsels Australiese en Nieu Zeelandse steenkool moet bevat as gevolg van huidige prys- en kwaliteitsoorwegings. As gevolg van sy lae produksiekoste en lae kwaliteit word die optimum hoeveelheid Grootegeluk bepaal deur sy oordragprys.

Thesis (MScEng (Process Engineering))--University of Stellenbosch, 2009. / Sequestration of carbon dioxide, CO2, has received large interest as a viable option for mitigating the high atmospheric concentrations of this greenhouse gas. Each year 25 gigatons of anthropogenic CO2 (7.3 GtC/yr) are released into the earth’s atmosphere with the combustion of fossil fuels being the major contributing source. Research in the field of sequestration technology involves evaluating various geological structures as possible reservoirs, determining adsorption capacities of natural formations and developing methods for carbon dioxide injection and the monitoring thereof. Identified potential CO2 reservoirs for geological carbon sequestration (GCS) include saline formations, depleted oil and gas fields and deep coal seams. Carbon dioxide sequestration in coal seams provides the economic opportunity of enhanced coalbed methane (CH4) recovery (ECBM). In South Africa, some coal seams are considered a viable option for long term CO2 sequestration projects as they are abundant and closely situated to South Africa’s largest concentrated CO2 point sources. Many studies have been conducted to determine the sorption capacities for methane and carbon dioxide gases on various coals from around the world; however, similar data have not been recorded for South African coals. The objectives of this study are to determine the adsorption capacities for methane and carbon dioxide of three South African coals over a pressure range of 0 – 50 bar. In the study, single-component gas adsorption experiments were conducted and the absolute adsorption capacities are reported. Isothermal adsorption experiments were conducted using both the volumetric and gravimetric methods with the volumetric apparatus pressure range extending up to 50 bar and the gravimetric apparatus up to 20 bar. Carbon dioxide adsorption capacities are much higher than the methane adsorption capacities, which are expected. Gravimetric experiments produce greater adsorption capacities than the volumetric method. However, the relative CO2/CH4 ratios for each coal, as well as the relative CO2/CO2 ratios between coals, remain almost identical. The difference in adsorption capacity is attributed to the strength of the vacuum pump used on each apparatus. The gravimetric apparatus makes use of a much stronger vacuum pump which can thus evacuate the coal pores more adequately than in the volumetric apparatus. The methane and carbon dioxide adsorption capacities of the three moisture-free coals compare well with literature data. The adsorption isotherms fit conventional adsorption models (the Langmuir and Freundlich adsorption equations) extremely well thus indicating that monolayer adsorption takes place. Since no internationally recognised testing standards are in place regarding adsorption procedures on coal, it is very difficult to compare adsorption results presented in the literature. Respective researchers determine their own experimental conditions for the many variables in coal adsorption studies. It is recommended that international testing standards be set in place to make coal research comparable. Such efforts would aid the development of a coal adsorption database, another recommendation, which would advance sequestration technology exchange and eliminate duplication of research efforts. The objectives of the project were achieved by determining the absolute adsorption capacities for carbon dioxide and methane gas of the three South African coals within a pressure range of 0 – 50 bar. Further work is required to investigate adsorption capacities of South African coals under supercritical conditions (above 73 bar abs and 31.1 oC).

The Josef Coal has the largest extent of all the Coals in the Sokolov Basin. The diploma thesis is concerned with studying of two profiles of the Josef Coal located in the opencast mines Medard-Libík and Družba for the purpose of micropetrograhic and chemical analyse. The goal of the diploma thesis is an interpretation of the sedimentary enviroment leading to formation of the Josef Coal based on the comparison of the petrographic and geochemical parametres of both profiles. Both studied profiles were initially macropetrographically described and sampled in a field. Samples were subsequently used for by maceral a chemical- technological analyses. The analysis of all 50 collected samples were performed at the Institute of Rock Structure and Mechanics Academy of Sciences of the Czech Republic. The micropetrographic composition was compared with chemical-technological standards. The macropetrographic description indicates some differences between both studied coal sections. The lower part of The Profile Josef 1 consists of the humic coal which in middle part evolves into the sapropelic one and that type persists the rest of the profile. The Profile Josef 2 is formed by sapropelic coal throughout the entire section except four decimeter thick benches of intercalated humic coal. Diferences in...

A mild gasification method has been developed to provide an innovative clean coal technology. The objectives of this study are to (a) incorporate a fixed rate devolatilization model into the existing 2D multiphase reaction model, (b) expand the 2D model to 3D and (c) utilize the improved model to investigate the mild-gasification process and guide modification of the mild-gasifier design. The Eulerain-Eulerian method is employed to calculate both the primary phase (air) and secondary phase (coal particles). The improved 3D simulation model, incorporated with a devolatilization model, has been successfully developed and employed to determine the appropriate draft tube dimensions, entrained flow residence time, The simulations also help determine the appropriate operating fluidization velocity range to sustain the fluidized bed depth without depleting the chars or blowing the char away. The results are informative, but require future experimental data for verification.

A dissertation submitted to the faculty of Engineering and the Built Environment, University of the Witwatersrand, in fulfillment of the requirements for the degree of Master of Science in Engineering. 21 November 2016 / In this work a comprehensive exergy analysis and heat integration study was carried out on a coal based oxy-combustion power plant simulated using ASPEN plus. This is an extension on the work of Fu and Gundersen (2013). Several of the assumptions made in their work have been relaxed here. Their impact was found to be negligible with the results here matching closely with those in the original work. The thermal efficiency penalty was found to be 9.24% whilst that in the original work was 9.4%. The theoretical minimum efficiency penalty was determined to be 3% whilst that in the original work was 3.4%. Integrating the compression processes and the steam cycle was determined to have the potential to increase net thermal efficiency by 0.679%. This was close to the 0.72% potential reported in the original work for the same action. / MT2017