Plant Efficiency Assessment Technique
Below is a summary of the Coal Preparation Plant Efficiency Assessment Technique adopted by Elsa Consulting Group.
To provide reliable estimates of existing plant performance that can be used in a variety of business and technical ways, including:
- Quantify and determine value of any loss of saleable material in plant rejects
- Determine whether or not plant, circuit or individual equipment items meet vendor performance guarantee(s)
- Audit the performance of custom toll processing operations
- Audit the performance of contractor-operated plant operations
- Identify and quantify potential plant circuit improvements
The technique is applicable to all coal (metallurgical and thermal) and mineral processing plants with and without by-pass options.
Basis of technique:
Determine a pseudo steady-state mass balance for all process flow streams relating to a process equipment item, circuit or entire plant. Typically this will involve:
- Maximised use of on-line and routine measurements.
- Determination of critical parameters, for example:
- rejects ash
- proportion of product material in rejects
- Cut points and Eps for multiple circuits
- Flotation response curves.
The pseudo steady-state mass balance would then be used to, for example:
- Reconcile actual performance against expected performance or design performance from bore core or other data sources
- Identify significant gaps and design gap closure strategies
- Investigate other potential improvement options including:
- Consideration of alternative feed and/or product blending options
- Substitution of particular equipment items with newer and/or alternative technologies.
Typical inclusions in a comprehensive coal preparation plant performance assessment are:
- Feed blending system
- Bore core data
- Coarse coal circuit
- Small coal circuit
- Fine coal circuit
- Magnetite circuit
- Reagent systems
- Control systems
- Routine measurements
- Moisture control systems.