Integrated Solution for Coal Gangue Sorting, Treatment, and Resource Utilization

Coal gangue sorting treatment and resource utilization overall solution

Coal gangue sorting process, coal gangue treatment program, coal gangue comprehensive utilization solutions

1. Program Overview
This program for the coal gangue produced by the coal washing plant characteristics, to provide specialized sorting treatment and resource utilization of the overall solution. Coal gangue is solid waste produced in the process of coal washing, containing valuable components such as sulfurous iron ore and other gangue resources can be utilized. Through the scientific design of coal gangue treatment process, it can efficiently recover the sulfurous iron ore and realize the resource utilization of coal gangue, creating both economic and environmental benefits.

2. Characterization of raw materials
The composition of coal gangue is complex, mainly containing:

• Sulfurous iron ore: large specific gravity (4.9-5.2g/cm³), with high economic value.

• Coal composition: has a certain calorific value, can be utilized as fuel

• Gangue component: mainly silica-aluminates, can be used for building materials production

• Other impurities: a small amount of other mineral components

3. gangue sorting process design
Raw material pretreatment
Coal gangue raw materials → uniform feed → crushing and screening → particle size classification

Coal gangue sorting process selection

• High content of sulfurous iron ore: gravity separation process (jig separation)

• Higher coal content: gravity separation - flotation joint process

• Complex composition: joint process can be customized according to specific conditions

Core sorting system

• Crushing and screening: to realize full dissociation of materials and particle size control.

• Jigging separation: Utilizing the density difference to recover sulfurous iron ore efficiently.

• Dewatering and drying: product moisture control to meet the subsequent utilization requirements

Gangue tailing treatment system

• Gangue classification: according to the composition and particle size classification processing

• Resource utilization: raw materials for building materials or fuel utilization

4. Coal gangue treatment technology characteristics
Technological Advantages

• Strong adaptability: can deal with different mining areas, different nature of the coal gangue

• High recovery rate: the recovery rate of sulfurous iron ore can reach more than 90%.

• Stable product quality: the sulfur content of sulfur concentrate>35%.

• Low operation cost: gravity separation process has low energy consumption and obvious cost advantage.

Equipment Characteristics

• Specialized equipment: Specialized sorting equipment designed for gangue characteristics.

• Wear-resistant design: the key components are made of wear-resistant materials with long service life.

Environmental performance

• Wastewater recycling: realize the recycling of production wastewater.

• No chemical additives: physical sorting, environmentally friendly.

5. Sorting effect indicators
Product quality index

• Sulfur concentrate grade: Sulfur content>35%.

• Sulfur recovery rate: 90-95

• Processing capacity: 10-300 tons/hour (can be customized)

6. Resourceful utilization of waste residue after gangue sorting
Application in the field of building materials

• Cement raw materials: replace clay raw materials, reduce production costs

• Concrete aggregate: used as construction aggregate after treatment.

• Brick-making raw materials: production of gangue bricks, hollow bricks and other building materials.

• Road base material: used in road construction with stable performance.

Fuel utilization

• Low calorific value fuel: used in circulating fluidized bed boiler for power generation.

• Fuel blending: blending with coal to improve the utilization rate of resources.

Other utilization directions

• Soil conditioner: used to improve soil structure

• Filling material: used for mine backfill and land reclamation.

• Industrial raw materials: used in the production of ceramics, refractory materials, etc.

7. Economic Benefit Analysis
Investment Benefits

• Equipment investment: customized according to treatment scale

• Payback period: short

Sources of income

• Benefits from sorting: sales of sulfur concentrate

• Resource reuse: gangue slag preparation of new building materials and other products sales revenue

• Disposal cost saving: reduce solid waste disposal cost

• Policy subsidies: tax incentives for comprehensive utilization of resources

8. Environmental benefits
Resource saving

• Reducing the mining of sulfur iron ore resources, saving land resources and reducing energy consumption.

Environmental protection

• Reduce the pollution of coal gangue stockpiling, prevent spontaneous combustion accidents, and reduce carbon emissions

Circular Economy

• Realize the resourceization of waste, promote the development of circular economy, and meet the requirements of sustainable development.

9. Service support
Technical support for coal gangue treatment

• Raw material testing and analysis

• Coal gangue treatment program design, site planning, design drawings

• Selection and configuration of gangue equipment

Engineering service

• Engineers to guide the installation and commissioning

• Operator training

• Production process optimization

After-sales service

• Equipment Warranty Service

• Spare parts supply guarantee

• Technical consulting service

10. Configuration of gangue treatment program
Program A (resource recovery type)
Focus on maximizing the recovery of sulfurous iron ore, relatively concentrated investment, short return cycle. Adopting mature gravity separation process for efficient recovery of sulfurous iron ore characteristics in the coal gangue.

Recommended reason:

• Fast investment recovery, significant economic benefits

• Simple process, reliable operation

• Adapt to different nature of gangue raw materials

• Flexible adjustment of process parameters according to the characteristics of raw materials

Program B (comprehensive utilization type)
On the basis of Scheme A, the gangue deep processing system is added to realize the dual goal of "recovery of sulfurous iron ore + gangue resourceization". It not only produces sulfur concentrate, but also processes gangue into building materials, realizing the full quantitative utilization of gangue.

Advantages of the program:

• Resource utilization rate reaches 100%

• Creating multiple income channels

• Completely realize zero emission of solid waste

• Meet the requirements of circular economy development

• Enjoy the policy support of comprehensive utilization of resources

Selection Recommendation:

• For customers with limited investment budget or mainly focusing on the recovery of sulfurous iron ore, Option A is recommended.

• For enterprises pursuing comprehensive benefits and focusing on environmental protection requirements, Program B is recommended.

• Can take step-by-step implementation strategy, first build Program A, later upgraded to Program B

Coal gangue sorting treatment and resource utilization program through the scientific sorting process and efficient resource utilization, to achieve the solid waste "waste to treasure". The coal gangue treatment program not only solves the problem of solid waste disposal, but also creates significant economic and environmental benefits, is an effective way to realize the green development of the coal industry. The comprehensive utilization of coal gangue program can provide personalized configuration according to customer demand, to meet different investment budgets and processing requirements. Welcome to consult us to get the program and quotation!