LONG-TERM TESTING AND DEMONSTRATION OF A SMART SPIRAL BANK IN ILLINOIS
Title
LONG-TERM TESTING AND DEMONSTRATION OF A SMART SPIRAL BANK IN ILLINOIS
ICCI Project ID
15/4A-2
Investigator
Mohanty
Institution
Southern Illinois University
ICCI Abstract
In a recently completed study funded by the Illinois Clean Coal Institute, the functionality of a patent-pending automation system for a coal spiral was demonstrated by the PIs in a real-life plant environment. A new triple-start spiral fitted with SIU's automation system was tested in the plant side-by-side the conventional spiral bank. The control system was able to adjust the splitter position automatically as and when changes in feed characteristics occurred and maintain the desired density cut-point at all times. The preliminary economic analysis estimated an added cost of about $500 for the control system for each triple start spiral having the ability to treat nearly 10 tons per hour of raw coal. An expected 2% gain (based on the results obtained at the plant) in clean coal yield from this smart triple-start spiral would result in additional revenues of $40,000 to $75,000 per year. Clearly, the strong financial gain far outweighs the added cost.
The PIs and the equipment manufacturing collaborator believe that the next step for the commercialization of the above automation system is to retrofit the plant's operating spirals with the automation system and operate those over a long period (nearly a full year). In addition to getting an endurance test done on the automation system components, this would also help in generating sufficient amount of performance data from both smart spirals (plant spirals retrofitted with the automation system) and conventional spirals operating side-by-side. Large amount of data would help us do statistical analysis to provide a confidence level to the above-mentioned 2% gain in clean coal yield, which will be coal specific. Therefore, in the proposed study, we plan to retrofit three triple-starts in a bank of six triple-start spirals with SIU's automation system leaving the other three triple-starts to operate in conventional mode. The retrofitted smart spirals will be subjected to an endurance test by running them 24/7 for a period of one full year in the plant environment; performance data will be compared with those of the conventional spirals operating in the same bank. The other hypothesis that will be tested is to automatically adjust splitters in multiple spirals based on the sensor-tube data collected from a single triple-start and a single control panel. A networked feedback system will be developed to indicate to the plant control room operator about the real-time change in the splitter position on a visual display. The proposed study will be undertaken with the active participation of a world-renowned spiral manufacturer (Multotec and PrepTech) and Murray Energy's American Coal Company operating in Illinois. Galatia preparation plant will serve as the host-site for the project. We believe that a successful completion of the proposed long-term demonstration project will lead to the quick commercialization of smart spirals in Illinois and elsewhere.
The PIs and the equipment manufacturing collaborator believe that the next step for the commercialization of the above automation system is to retrofit the plant's operating spirals with the automation system and operate those over a long period (nearly a full year). In addition to getting an endurance test done on the automation system components, this would also help in generating sufficient amount of performance data from both smart spirals (plant spirals retrofitted with the automation system) and conventional spirals operating side-by-side. Large amount of data would help us do statistical analysis to provide a confidence level to the above-mentioned 2% gain in clean coal yield, which will be coal specific. Therefore, in the proposed study, we plan to retrofit three triple-starts in a bank of six triple-start spirals with SIU's automation system leaving the other three triple-starts to operate in conventional mode. The retrofitted smart spirals will be subjected to an endurance test by running them 24/7 for a period of one full year in the plant environment; performance data will be compared with those of the conventional spirals operating in the same bank. The other hypothesis that will be tested is to automatically adjust splitters in multiple spirals based on the sensor-tube data collected from a single triple-start and a single control panel. A networked feedback system will be developed to indicate to the plant control room operator about the real-time change in the splitter position on a visual display. The proposed study will be undertaken with the active participation of a world-renowned spiral manufacturer (Multotec and PrepTech) and Murray Energy's American Coal Company operating in Illinois. Galatia preparation plant will serve as the host-site for the project. We believe that a successful completion of the proposed long-term demonstration project will lead to the quick commercialization of smart spirals in Illinois and elsewhere.
Start Date
1/1/2015
End Date
7/31/2016
Year Funded
2015
Manager
Joe Hirschi
Collection
Citation
“LONG-TERM TESTING AND DEMONSTRATION OF A SMART SPIRAL BANK IN ILLINOIS,” ICCI Reports, accessed May 20, 2024, https://isgswikis.web.illinois.edu/icci_reports/items/show/846.