Turnkey Coal Washing & Beneficiation Solutions
Turnkey Stationary Coal Washing Plants (50 – 1000+ TPH)
Maximize Coal Value with Jig & Heavy Medium Cyclone Technology. Customized for Ash & Sulfur Reduction.
Founded in 1999, LUTON GROUP CO., LTD, as a joint-stock enterprise, has over 22 years of exporting experience on manufacturing concrete plants, asphalt plants, self loading mixers, crushers, dry mortar plants,coal washing equipment, and various sorts of construction machinery.
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Raw Coal
Raw coal refers to products produced by coal mines. It only manually sorted out the gangue and debris but has not been washed, screened, and processed. Including natural coke and low-quality coal, excluding low calorific value coals (such as stone coal, peat, oil shale, etc.); According to its origin, raw coal can be divided into three categories: sapropelic coal, humic coal, and humosapropelic coal. According to its carbonization degrees, it can be categorized as peat, lignite, bituminous coal, and anthracite.
Coal Washing
Through the impact of water flow, raw coal with different components and different proportions is separated into different grades with dust and waste rock being removed, and ash and sulfur content being reduced. This is called coal washing.
Why Wash Coal?
Coal washing is an indispensable process in coal deep processing. The coal exploited directly from the mine is called raw coal. The raw coal is mixed with many impurities during the mining process, and the quality of the coal is also different. The coal with low internal ash content and high internal ash content is mixed Together. Coal washing is an industrial process that removes impurities from raw coal, or classifies high-quality coal and low-quality coal.
The products produced after the coal washing process are generally divided into gangue, medium coal, grade B clean coal, and grade A clean coal. The finished coal after the coal washing process is usually called clean coal. Through coal washing, the transportation cost of coal can be reduced, and the utilization rate of coal can be increased. Clean coal is generally an energy source that can be used as fuel, and clean coal from bituminous coal is generally used for coking. It needs to remove sulfur, impurities and other industrial processes to meet the standards for coking.
A Complete 4-Stage Coal Washing Process
Coal washing is not just about rinsing coal with water. It is a precise engineering process based on density separation and surface chemistry. Here is how our stationary plant transforms your raw run-of-mine (ROM) coal into clean, marketable fuel.
1. Crushing & Sizing (Feed Preparation)
Before washing, the raw coal must be prepared to the optimal particle size to release impurities.
Primary Crushing: The ROM coal passes through a Double Roll Crusher or Sizer to reduce large lumps to a manageable size (typically -50mm or -80mm) without generating excessive fines.
Desliming Screen: The crushed coal travels to a wet vibrating screen. Here, high-pressure water sprays remove the fine dust (slime) and wet the material, preparing it for the main separation stage.
Why it matters: Uniform particle size ensures the washing equipment operates at peak efficiency.
2. Density Separation (The Core Process)
Choose between Jigging or Heavy Medium Cyclone based on your coal quality.
Option A: Jig Stratification (For Thermal Coal)
The Principle: The Jig machine creates a vertical pulsating water flow.
The Action: Under the influence of gravity and water pulses, the material stratifies by density. Heavier rocks (Gangue) settle to the bottom and are discharged via the refuse gate. Lighter Clean Coal floats to the top and overflows to the product chute.
Result: Effective removal of visible rock and shale.
Option B: Heavy Medium Cyclone – HMC (For Coking Coal)
The Principle: This process uses a “Medium” (a suspension of water and magnetite powder) to create a precise density liquid (e.g., 1.50 g/cm³).
The Action: The coal and medium are pumped into a cyclone at high pressure. Centrifugal force (up to 200G) forces the heavy High-Sulfur refuse and Pyrite to the outer wall, while the light Clean Coal stays in the center vortex.
Result: The most precise separation possible (Ep < 0.04), crucial for reducing Sulfur and Ash to steel-grade standards.
3. Fines Recovery (Froth Flotation)
Fine coal particles (< 0.5mm) that pass through the screens are sent to the Flotation Cells or Columns.
Surface Chemistry: We add specific reagents (collectors and frothers). The chemical renders the coal surface hydrophobic (water-repelling), while ash and clay remain hydrophilic (water-attracting).
Air Bubbles: Air is injected into the slurry. The fine coal particles attach to the rising air bubbles and float to the surface as a mineralized froth, which is skimmed off as clean concentrate.
Outcome: Maximizes total plant yield by recovering valuable carbon from what would otherwise be waste sludge.
4. Dewatering & Water Recycling (Closed Circuit)
The washed products are wet and need drying before transport.
For Coarse Coal: We use Linear Dewatering Screens and Centrifuges to mechanically remove surface moisture, bringing it down to transportable levels (< 9-12%).
For Tailings & Sludge: The waste water is pumped into a High-Rate Thickener. Flocculants are added to settle the solids rapidly. The clean water overflows and is recycled back to the plant (recovering up to 90% of process water). The thick sludge at the bottom is pressed into dry cakes by a Filter Press.
Advanced Beneficiation Technologies in Coal Washing Process
Choose the right process to maximize your coal recovery rate and profit margin.
Jig Washing Process
The Cost-Effective Solution for Thermal Coal & De-stoning.
Our advanced Jig concentrators utilize air-chamber pulsation technology to separate raw coal from gangue based on density differences. This process is ideal for easy-to-wash coal where removing visible rock and shale is the primary goal.
Key Advantages:
- Low Operating Cost (OPEX): Consumes less water and electricity compared to HMC.
- Wide Size Range: Effectively handles large particles (up to 100mm) without pre-crushing.
- High Capacity: Single unit capacity can exceed 300 TPH.
- Perfect For: Thermal Coal (Steam Coal) upgrading and Gangue rejection.
Heavy Medium Cyclone
The Ultimate Precision for Ash & Sulfur Reduction.
For difficult-to-wash coal or when strict quality standards are required, HMC is the industry standard. utilizing centrifugal force (up to 200x gravity) and a magnetite medium, it achieves sharp separation densities. This is the only effective way to remove Pyritic Sulfur and deeply reduce ash content.
Key Advantages:
- Maximum Recovery: 95-99% organic efficiency. Don’t lose good coal to the waste pile.
- Deep De-Sulfurization: specifically separates high-density Pyritic Sulfur from clean coal.
- Precise Control: Cut-point density can be adjusted automatically (e.g., from 1.3 to 1.8).
- Perfect For: Coking Coal, Anthracite, and High-Sulfur Coal projects.
Which Technology is Right for You?
| Feature | Jig Washing | Heavy Medium Cyclone |
| Main Goal | Remove Rock/Gangue | Precision Ash/Sulfur Control |
| Separation Accuracy | Good (Ep 0.15-0.18) | Excellent (Ep 0.02-0.04) |
| Operating Cost | Low | Medium – Requires Magnetite |
| Ideal Coal Type | Thermal Coal (Power Plants) | Coking Coal (Steel Plants) |
Industrial Modular Design: Built for Mining
Abandon the complexity of civil construction. We deliver a high-performance CHPP (Coal Handling and Preparation Plant) that is easy to install and built to last.
1. Scientific Gravity-Flow Layout (Vertical Structure)
We design our steel structure vertically to maximize gravity flow.
Energy Saving: Cyclones are positioned on the top deck to allow gravity feeding to screens, reducing the need for slurry pumps and electricity consumption.
Compact Footprint: By building “Up” instead of “Out”, we save land space and conveyor belt length.
2. Heavy-Duty Vibration Resistance
Vibrating screens create massive dynamic loads. Ordinary steel frames crack under this stress.
Reinforced Design: Our structural beams are calculated to withstand the high-frequency G-force of dewatering screens.
Shock Absorption: Critical modules are equipped with industrial rubber dampeners to isolate vibration from the main structure.
3. Skid-Mounted Modules (Pre-assembled)
Accelerate your commissioning time with our Skid-Mounted technology.
Plug & Play: Key units (like the Cyclone Cluster and Magnetic Separator) are pre-piped and pre-wired on steel skids in our factory.
Less Site Work: Minimizes on-site piping work, which is the most time-consuming part of coal plant installation.
Complete sets of coal washing equipment
The over ground coal processing system consists of main links such as coal receiving, screening, crushing, coal preparation, storage, and loading. The coal washing process mainly includes the following:
1. After crushing and screening, the raw coal is loaded into the hopper, and the coal below 80mm is sent to the jig through the belt conveyor, after jigging, the clean coal, medium coal and gangue are separated; the gangue and medium coal are discharged through the elevator. The clean coal are sent to the linear dewatering screen through water, it is collected and transported to the site for storage through a belt conveyor.
2. The discharged water beneath the clean coal linear dewatering screen flows into the pulverized coal recovery screen. After dewatering the pulverized coal over 0.3mm, it enters the centrifuge for drying, and then the clean coal which is mixed with other clean coal is transported to the clean coal site for storage through a belt conveyor.
3. The slime water below 0.3mm flows out of the pulverized coal recovery screen. After the slime water is floated, it enters the thickening tank for precipitation, and then it is dehydrated into the tailings slime by the filter press, after which it is transported to the site for storage by a belt conveyor.
Customized Solutions for Your Coal Type
Don’t guess. Match the right beneficiation process to your raw material to maximize profit.
1. Steam / Thermal Coal
The Goal: Increase Calorific Value (CV)
The Challenge:
Your raw coal contains too much visible rock (gangue) and shale, which lowers the Calorific Value (kcal/kg) and increases transport costs. You need a high-volume solution to discharge heavy rocks efficiently.
Our Solution: Intelligent Jigging System
- Process: Uses water pulsation to separate high-density gangue from lighter coal.
- Benefit: Low Cost per Ton. No expensive heavy medium (magnetite) required. Perfect for raising 3000 kcal coal to 5000+ kcal.
- Core Equipment: Batac Jig / Air-Chamber Jig.
2. Coking / Metallurgical Coal
The Goal: Deep Reduction of Ash & Sulfur
The Challenge:
Steel mills have strict standards (e.g., Ash < 9%, Sulfur < 1%). Standard washing isn’t enough to remove Pyritic Sulfur or fine impurities. You need extreme precision to separate “Clean Coal” from “Middlings” (secondary fuel) and “Refuse”.
Our Solution: 3-Product Heavy Medium Cyclone (HMC)
- Process: Uses a magnetite medium and centrifugal force for a sharp density cut (Ep < 0.04).
- Benefit: Maximize Yield. Recover every gram of expensive coking coal while strictly controlling Ash and Sulfur levels.
- Core Equipment: Heavy Medium Cyclone Cluster + Magnetic Separator.
3. Coal Slime & Tailings
The Goal: Turn Waste into Profit
The Challenge:
Fine coal particles (-0.5mm) are often discarded as “slime” in settling ponds. This is wasted money and an environmental liability. Handling this wet, sticky mud is difficult.
Our Solution: Flotation & Mechanical Dewatering
- Process: Froth flotation captures fine coal particles, followed by high-pressure filtration.
- Benefit: Dry & Stackable Product. Turns liquid slurry into dry coal filter cakes (moisture < 20%) that can be sold immediately.
- Core Equipment: Flotation Column + Chamber Filter Press / Arc Screen.
Tips
“What if I have mixed coal?”
Most modern plants use a Combined Process: Jigs for coarse coal (+13mm) to save costs, and Cyclones for fine coal (-13mm) to ensure quality. We can design this hybrid flowsheet for you.
From Raw Coal to Profit
Stop Selling Raw Coal. Defeat Ash Penalties and Wasted Logistics.
Selling unwashed Run-of-Mine (ROM) coal forces you into a “buyer’s market” where you are powerless against strict Ash Penalties. Power plants and traders routinely deduct significant value for every 1% of excess ash and sulfur, often rejecting high-impurity shipments entirely. Furthermore, the logistics math is working against you: for every 30-ton truck of raw coal you ship, you are paying fuel and driver costs to transport 8 to 10 tons of worthless rock (gangue).
A washing plant changes this equation immediately. By removing the gangue on-site, you stop paying to transport waste. More importantly, you physically upgrade the material—transforming a low-grade 3,500 kcal product into a premium 5,500+ kcal fuel. This allows you to dictate pricing and shift your customer base from low-budget local kilns to high-paying international steel mills and power stations.
LUTON
WE ARE THE BEST IN CONSTRUCTION
Founded in 1999, LUTON GROUP CO., LTD, as a joint stock company, has more than 24 years of exporting experience in manufacturing concrete plants, asphalt plants, self-loading mixers, crushers, dry mortar plants and various types of construction machinery.
100+
100+ Countries Exported
30,000+
30,000+ Mixers Sold
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20+ Years of Experience
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