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Successful Application Case Study of Polyurethane High-Frequency Screens at Mongolian Mining Corporation's Coal Washery
Successful Application Case Study of Polyurethane High-Frequency Screens at Mongolian Mining Corporation's Coal Washery
- Background and Requirements of the Coal Washery
Mongolian Mining Corporation: Application of Polyurethane High-Frequency Screens
Mongolian Mining Corporation is a medium-sized coal washing enterprise with an annual raw coal processing capacity of 15 million tons, adopting a combined process of heavy medium cyclones and flotation. During production, the original stainless steel screens had significant issues in the final coal dehydration and coal slime classification processes: high-humidity coal slime easily caused screen hole blockages, requiring 30 hours of shutdown for cleaning each month; incomplete screening led to large fluctuations in clean coal ash content, affecting product quality and market competitiveness, while increasing subsequent processing costs. Therefore, the coal washing plant urgently needed to introduce efficient, anti-blocking, and durable screening equipment.
II. Introduction of Polyurethane High-Frequency Screens
After extensive research and technical comparisons, the coal washing plant finally selected polyurethane high-frequency screens. The screen mesh of this equipment is made of polyurethane material, with strong wear resistance and corrosion resistance, and the opening rate exceeds 98%. Equipped with a 50Hz high-frequency vibration motor, it can effectively prevent hole blocking and significantly improve screening efficiency. According to the actual processing capacity and process requirements, a Derrick screen machine was chosen, with a processing capacity of 76 tons per hour, a screen surface area of 1.85 square meters, and a customized screen hole size of 0.18 mm, perfectly adapting to the needs of coal slime classification and final coal dehydration.
III. Installation and Commissioning Process
1. Installation Preparation
The site was thoroughly cleaned, the foundation structure was checked to be intact, tools and installation materials were available, and the equipment components were.
2. Installation Process
The main body of the screen machine was hoisted and firmly fixed, the tension of the polyurethane screen mesh was adjusted appropriately, and the pipeline and electrical system were connected reliably.
3. Commissioning Stage
No-load trial operation was carried out, materials were gradually fed, and the excitation force and screen surface inclination were adjusted. The operating parameters were continuously optimized through particle size detection, and finally, up-to-standard production was achieved.
IV. Actual Application Effects
1. Significant Improvement in Screening Efficiency
The final coal dehydration efficiency increased from 75% to over 88%, and the coal slime classification efficiency increased from 62% to about 85%. When processing coking coal, the content of fine particles in clean coal dropped to less than 8%, and the ash content was stably controlled within 10.5%.
2. Remarkable Enhancement in Operational Stability
Screen hole blockages were significantly reduced, with monthly shutdown cleaning time shortened to less than 4 hours. The equipment failure rate decreased significantly, and maintenance frequency was reduced, effectively lowering maintenance costs and labor intensity.
3. Prominent Economic Benefits
An additional 1,200 tons of clean coal were produced each month, bringing additional revenue of 380,000 yuan; annual maintenance costs were saved by 150,000 yuan. The improvement in product quality enhanced market competitiveness, and the order volume continued to grow.
4. Improvement in Environmental Benefits
Dust emissions were reduced, and the working environment was improved. The content of fine particles in coal slime water was reduced, alleviating the burden on the subsequent water treatment system and the risk of environmental pollution.
V. Summary and Outlook
The successful application of polyurethane high-frequency screens has completely solved the bottleneck problems in the screening process of Mongolian Mining Corporation's coal washing plant, bringing significant production and economic benefits. With the continuous improvement of the industry's demand for efficient and environmentally friendly equipment, the application prospect of polyurethane high-frequency screens will be broader. The coal washing plant also stated that it will continue to promote process optimization and equipment upgrading to contribute to the green and sustainable development of the coal industry.
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Annie Lu | Huatao Group
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Products: Polyurethane Fine Screens, Tufflex Screens, Shale Shaker Screens, Crusher Machinery