Managemen Sys ems
in
P oduc ion Enginee ing
2020, Volume 28, Issue 4, pp. 259-267
Da e o submission o he a icle o he Edi o : 03/2020
Da e o accep ance o he a icle by he Edi o : 07/2020
DOI 10.2478/mspe-2020-0037
NEW IMPLEMENTATIONS OF KOMAG JIGS FOR COKING AND STEAM COAL
IN COLLABORATION WITH CARBO-ECO AND FUGOR COMPANIES
Pio MATUSIAK
KOMAG Ins i u e o Mining Technology
Ho s GONDEK
VSB – Technical Uni e si y o Os a a
Abs ac :
The basic p ocess o mine als’ mechanical p epa a ion, including coal, is a bene icia ion p ocess which has a deci-
si e impac on quan i a i e-and-quali a i e pa ame e s o comme cial p oduc s. A p esen he p oduc s o he
MBE-CMT, Allmine al and Teno a companies ha e big ma ke sha es as ega ds o eign wa e pulsa o y jigs, as
well as ITG KOMAG on he local Polish ma ke . New implemen a ions o jigs, de eloped a he KOMAG Ins i u e
o Mining Technology, o bene icia ion o coking coal and s eam coal in collabo a ion wi h Ca bo-Eco L d. and
Fugo L d. companies, we e ealized in 2019. Technical and echnological pa ame e s o new de ices a e de-
sc ibed in he a icle. Supply sys ems o eed a e p esen ed as well as he me hod o collec ing ailings and mid-
dlings. New design solu ions, applied in mode nized p epa a ion plan s, aimed a an imp o emen o jigs p oduc-
ion capaci y and e iciency a e p esen ed. In he case o each jig, a e i s ac i a ion and conduc ed adjus ing
p ocesses, exac es s o a bene icia ion e iciency we e pe o med and hei esul s a e p esen ed in he abula
o m. Basic bene icia ion accu acy indica o s and pa ame e s o p oduc s’ sepa a ion as well as balances o p od-
uc s a e gi en. The es esul s, ob ained om newly ac i a ed jigs, a e discussed.
Key wo ds: bene icia ion p ocess, ha d coal, jig
INTRODUCTION
A bene icia ion o ha d coal is an in eg al and ex emely
impo an pa o a p oduc ion p ocess o comme cial as-
so men s aimed a a quali y inc ease o ex ac ed mine-
al and a eaching quali a i e-and-quan i a i e pa ame-
e s o p oduc s equi ed by pu chase s.
An imp o emen o coal quali y is achie ed due o con-
duc ing a se ies o echnological p ocesses, among o he s,
a bene icia ion in pulsa o y jigs [1, 15].
The solu ion o selec ed jigs, designed a he KOMAG In-
s i u e o Mining Technology, implemen ed in 2019 o a
bene icia ion o ha d coal, a e p esen ed in he a icle.
Special a en ion is paid o he pa ame e s and s a e-o -
he-a solu ions o he OM ines pulsa o y jigs o s eam
and coking coal.
LITERATURE REVIEW
Pulsa o y jigs a e basic de ices o a bene icia ion o ha d
coal in Polish mechanical p epa a ion plan s. A elabo a-
ion o he i s designs o jigs was s a ed a KOMAG in
1955.
I was he equipmen , ha ing wo ai chambe s si ua ed
beside he wo king ough, along he jig axis [20, 24, 26,
29]. The ollowing jigs we e designed:
− OBM ( ines pis onless jig),
− ODM ( ines double – ough pis onless jig),
− OBZ (g ain pis onless jig).
The jigs we e cha ac e ized by conside able dimensions
and a big weigh . In he se en ies o he las cen u y he
jigs, ha ing ai chambe s unde he sie e deck, ins alled in
bo om boxes ans e sely o he jig longi udinal axis [2,
26], s a ed o be designed a KOMAG.
A p esen jigs o a bene icia ion o di e en g ain clas-
ses, including ines jigs – OM (Fig. 1 and 2) o he g ains
20-0(0.5) mm, medium-size g ain jigs – OS designed o
he g ains 80(50)-0(0.5) mm, and he g ain jigs – OZ o
g ains 120-20 mm a e cons uc ed a he KOMAG Ins i-
u e.
260 Managemen Sys ems in P oduc ion Enginee ing 2020, Volume 28, Issue 4
Fig. 1 Two pulsa o y jigs OM15, ZG ”Sobieski”
Sou ce: [33].
Fig. 2 OM24 jig, ”Bo ynia-Zo iówka” Mine, Zo iówka B anch
Sou ce: [33].
Thei design is mode nized con inuously, acco ding o
use s’ expec a ions bo h in he aspec o he shape geo-
me y o bo om boxes, ixing o sie e decks, an imp o e-
men o au oma ic adjus men o hea y p oduc s’ collec-
ion, pulsa o y al es and o wo king ai collec o s [21, 22,
23].
A p esen he p oduc s o he MBE-CMT (Ba ac-Jig), All-
mine al (ALLJIG) and Teno a (APIC-Jig) companies ha e
big ma ke sha es as ega ds o eign wa e pulsa o y jigs.
The abo e men ioned jigs a e used in bene icia ion p o-
cesses o coal and me al as eeds. In ela ion o he kind
and pa ame e s o he aw ma e ial o be bene icia ed
(mainly he scope o g ain sizes), each o he p oduce s
o e s app op ia e ypes o jigs which o en di e in ai
low con ol sys em o pulsa o y chambe s, using di e-
en ypes o al es.
The sys ems o pulsa o y ai dis ibu ion in wa e jigs, due
o hei impac on shaping he equi ed wa e pulsa ion
cu e, a e subjec o a con inuous imp o emen p ocess
in pa allel wi h a de elopmen o he d i es’ echnology
and an elabo a ion o new ma e ials, o a bigge ex en
han he o he jig assemblies. As each o he h ee jig p o-
duce s uses di e en design and cons uc ion solu ions o
pulsa o y al es, so each o hem is discussed sepa a ely
[3].
The BATAC jigs ha e unde - he-sie es wo king chambe s
posi ioned longi udinally, an elec onic pulsa ion con ol
and an elec ohyd aulic adjus men o he p oduc s’ col-
lec ion. In ela ion o g ain sizes in he eed, he dis ibu-
ion sys ems o pulsa o y ai use pneuma icly supplied
disk al es o oscilla o y (bu e ly ype) ones [31].
In he ALLJIG jigs o a y al es a e used o supplying com-
p essed ai o he equipmen wi h side chambe s in he
p ocess o bene icia ing and cleaning agg ega es.
Howe e , in he case o he jigs wi h unde - he-sie es
wo king chambe s disk al es a e used [30] o a bene i-
cia ion o coal eeds and o me al o es.
In he APIC jigs he elec onic JigScan sys em, elabo a ed
in 1986 by he JKMRC Company is used. I con ols he
low by an adjus men o he oscilla o y al es ope a ion
[19, 32, 34] on he base o measu emen s o ai p essu e
in he wo king chambe , as well as in he e a ding and
ou le ese oi .
A e iew o pulsa o y jigs’ designs was conduc ed on he
basis o in o ma ion p esen ed in ad e ising ma e ials
and on he p oduce s’ web-si es.
OPERATIONAL PRINCIPLE OF PULSATORY JIGS
A bene icia ion in jigs consis s in using he in-wa e alling
speed o g ains, ha ing di e en densi ies. The ma e ial,
unde bene icia ion, is subjec o cyclic loosening in he
pulsa o y wa e en i onmen which causes i s s a i ica-
ion and anspo on he su ace o sie e deck in he di-
ec ion o he zone o bene icia ed p oduc s’ sepa a ion.
Ini ially p epa ed mix u e o ha d coal g ains, conduc ed
o he wo king box, is subjec o a pulsa ion in he wa e
en i onmen on sie e decks in he ollowing wo king com-
pa men s o he jig. A s a i ica ion o ma e ial is ealized
due o a mo emen o wa e in he wo king chambe [11],
using e.g. comp essed ai . When he wa e mo es o-
wa ds he op, he ma e ial on he sie e is aised and i
alls down on o he sie e deck.
Subjec ing he ma e ial o nume ous pulsa ions enables
o di ide i in o laye s, om he g ains wi h he bigges
speed o alling down, si ua ed on he sie e deck o he
g ains wi h he smalles speed o alling down, aised o
he su ace o he ma e ial unde bene icia ion. Sepa a ed
ma e ial mo es con inuously in he di ec ion o he sepa-
a ion zone, a he end o he jig wo king compa men
[11].
Basing on measu emen and con ol signals o bene icia-
ion p oduc s collec ing sys ems, a sepa a ion o he ma-
e ial o he op p oduc (concen a e), which mo es o e
he o e low h eshold, ending a single jig compa men
and he bo om p oduc ( ailings) conduc ed h ough he
collec ing channel, si ua ed below he sie e deck, in he
sys em o collec ing p oduc s [2], is ealized.
IMPLEMENTATION OF STATE-OF-THE-ART JIGS OF KO-
MAG TYPE
An implemen a ion o jigs o s eam and coking coal, de-
signed a he KOMAG Ins i u e and commissioned in 2019,
is p esen ed in he examples gi en below.
P. MATUSIAK, H. GONDEK – New Implemen a ions o KOMAG Jigs o Coking and S eam Coal…
261
ZG ”Sobieski” Coal Mechanical P epa a ion Plan – s eam
coal
A design o jigs o he ZG ”Sobieski” Coal Mechanical P e-
pa a ion Plan was elabo a ed a he KOMAG Ins i u e o
Mining Technology in 2018. New h ee-p oduc jigs
OM15L and OM15P we e p oduced by Fugo L d. They e-
placed wo wo ked ou Allmine al jigs.
The commissioning, a a pa icipa ion o KOMAG esea -
che s, was pe o med by he Ca bo-Eco L d. in wo s ages
o ensu e he Plan p oduc ion con inui y.
A wo-s age app oach consis ed in a disassembly o one
Allmine al jig and in i s exchange o a new one o KOMAG
ype and hen o he o he one, which was ope a ed du-
ing he exchange pe iod. In he i s hal o 2019 he
OM15L jig (so called “g ey sys em”) was s a ed and in he
o he hal o 2019 he OM15P jig (so called “g een sys-
em”) was s a ed (Fig. 3).
Fig. 3 ZG ”Sobieski” OM15L and OM15P jigs
Sou ce: [25].
A mode niza ion o he ZG “Sobieski” Mechanical P epa-
a ion Plan consis ed in an adap a ion o he Plan o a
h ee-p oduc bene icia ion o asso men s: Pea Coal, Ja-
e and Fines and a possibili y o inc easing he ines be-
ne icia ion node loading o 16000 /d o g oss weigh .
Supply o eed o OM15 jigs
Raw ma e ial om he su ge ank is collec ed wi h bel e-
ede s equipped wi h new echnological scales and di ec-
ed o new ib a o y sc eens WZL1 2.8 x 6.0 (Fig. 4) o
sie e decks ha ing he slo s = 2 mm, equipped wi h wa e
sp ays.
Fig. 4 An ins alla ion o desludging sc eens WZL1 2.8 x 6.0 be o e
ZG ”Sobieski” OM15 jigs
Sou ce: [25].
A sepa a ion o he eed on o wo g ain classes: op p o-
duc 30-2 mm, which is di ec ed o a bene icia ion o new
h ee-p oduc jigs OM15L and OM15P and he bo om
p oduc , which oge he wi h wa e is di ec ed o he ank
o echnological-and suspension wa e sys em, is ca ied
ou on ib a o y desludging sc eens (WZL1).
Th ee-p oduc bene icia ion o g ain class 30-2 mm in
OM15 ines jig
A new bene icia ion node (Fig. 3) consis s o wo ines jigs
OM15L and OM15P (30-2 mm), o maximal capaci y up o
320 /h each. The decks o slo ed sie es s = 5 mm a e in-
s alled in hem. The wo king componen s we e sho ened
o 2200 mm in he jigs due o oo small space a he ins al-
la ion si e, a he cos o a sho e collec ing sys em o
p oduc s.
A pulsa o y mo ion is gene a ed in he jig by an ac ion o
comp essed ai on o he wa e le el, deli e ed by new Ae-
zen blowe s o absolu e p essu e abou 0.4 ba . The jigs
consis o h ee compa men s, in wo i s ones ailings is
sepa a ed and in he las one – middlings is sepa a ed. In
he bene icia ion p ocess, in he OM15L and OM15P ines
jigs, h ee p oduc s a e ob ained:
− concen a e – collec ed om he jig oge he wi h wa-
e h ough he o e low h eshold o he las com-
pa men and i is di ec ed o dewa e ing o he sys-
em o s a iona y dewa e ing slo ed sie es o he slo
s = 2 mm, on he exis ing PWE2 sc eens. I is a wo-
deck sc een, in which he bo om deck is made o
slo ed sie es o he slo s = 2 mm, bu he op one has
he sie es slo 25 mm,
− middlings – aised and dewa e ed by he exis ing buc-
ke con eyo B-800 (Fig. 5) and nex by he bel
con eyo and he sc een di ec ed o he UP
1000x1000 c ushe . The c ushe ma e ial and he
sc een be ween- he-sie es p oduc (6-2 mm) can be
subjec o a seconda y bene icia ion in he OM15L and
OM15P jigs o egain coal g ains om he middlings,
so called conc e ions,
− ailings – aised and dewa e ed wi h use o a new buc-
ke con eyo B-1000 (Fig. 5) o he capaci y up o 250
/h.
Fig. 5 ZG ”Sobieski” bucke con eyo s
Sou ce: [33].
262 Managemen Sys ems in P oduc ion Enginee ing 2020, Volume 28, Issue 4
Coal Mechanical P epa a ion Plan ”Bo ynia-Zo iówka”
Mine, Zo iówka B anch – coking coal
A design o a jig o he Coal Mechanical P epa a ion Plan
o he “Zo iówka” Mine was de eloped a he KOMAG In-
s i u e o Mining Technology in 2018. A e ha ing p odu-
ced he equipmen by he Fugo L d., in he second hal o
2019, he Ca bo-Eco L d. commissioned he mode nized
bene icia ion sys em. A new bene icia ion node (Fig. 6)
consis s o he single ough ines jig OM24 (20-2 mm), o
capaci y up o 640 /h, which eplaced a double ough
h ee-compa men jig OM 24D3E.
Fig. 6 OM24 ines jig, Zo iówka Mine
Sou ce: [25].
A deck, made o pe o a ed sie es L 25 x 5, was used in
i . I was he i s applica ion o he Polish design jig ha ing
he wo king ough wid h o 3500 mm.
Raw ines (20-2 mm), ob ained in he esul o he ini ial
classi ica ion on he PZ2275 sc eens (4 de ices), is he
eed o all he jig sys ems. To al eed load o wo ked ou
jigs eached 5000 /d, a abou 20 h/d o hei ope a ion.
A new jig enables o inc ease he load up o 12000 /d.
Tailings om he jig is dewa e ed in he B-1000 bucke
con eyo and middlings, a e i s dewa e ing in he B-800
bucke con eyo (Fig. 5), is connec ed on he bel
con eyo and subjec o addi ional dewa e ing on he WP
1.5 x 2.5 sc een. The dewa e ed, abo e men ioned p o-
duc is used o gene a ing ene gy mixes.
The concen a e p oduc is di ec ed o a common ough,
om which i is di ec ed o wo dewa e ing sys ems, con-
sis ing o i e OSO 2400 sie es and o one OSO 3200 sie e
as well as o six sie e cen i uges (2 de ices o WOW 1.3,
2 de ices o HSG 1200, 2 de ices o HES 1300).
An inno a i e solu ion o he jig eeding boxes, wi h an
o e low ough and he sp ay imp o ing a uni o m dis i-
bu ion o he ma e ial be o e he jig and a be e use o
he wo king bed (Fig. 7) was applied in he mode nized
bene icia ion sys em.
Fig. 7 Sys em o eed supply o OM24 jig
Sou ce: [23].
METHODS
To ob ain he ma e ial o labo a o y analyses some aw
coal samples ( eed) and bene icia ion p oduc s samples,
sepa a ely o bo h ypes o coal, we e aken.
ZG ”Sobieski” – s eam coal
The eed samples we e aken om he ou le s o he
WZL1 sc eens di ec ing he ma e ial o he wo king
oughs o jigs. Due o lack o access o o e low h esh-
olds o he jigs, he concen a e p oduc was sampled on
he collec ing chu es o he classi ica ion p oduc s o he
PWP2 2.5 x 5.25 sc eens, howe e middlings and ailings
we e aken om he discha ge o bucke con eyo s. Due
o he ac ha bo h middlings as well as ailings a e col-
lec ed (dewa e ed) om bo h jigs by common bucke con-
eyo s, combined middlings and ailings we e aken o
es s.
The ma e ial om coal dumps was he eed o jigs du ing
a p ocess o aking samples. Du ing a collec ion o samples
pe iodic, sho -las ing s ops o he eed occu ed.
Bo ynia-Zo iówka Mine, Zo iówka B anch – coking coal
The eed was aken om he bel con eyo supplying he
eed o he chu e ins alled on he jig inle . To concen a e
p oduc was collec ed along he whole leng h o he hi d
compa men o e low h eshold .
Middlings was sampled di ec ly om he bucke
con eyo , howe e ailings was aken om he bel
con eyo collec ing he ma e ial dewa e ed in he bucke
con eyo . Du ing he sampling p ocess, he eed was sup-
plied in a s able way and he e we e no signi ican luc ua-
ions in loading he jig wi h he ma e ial [14].
Labo a o y analyses
The aken samples we e qua e ed and hey we e ans-
po ed o he labo a o y back-up acili ies o he Di ision
o P epa a ion Sys ems in which hey we e subjec o he
ollowing analyses [16, 17].
Labo a o y es s we e ealized acco ding o he equi e-
men s o he PN-EN ISO/IEC 17025:2005 S anda d using
he measu ing appa a us ensu ing he cohe ence o mea-
su emen s. The supe ised measu ing equipmen such as
scales HR 120, WPT15H, B200, chambe s o e PM-
6/1100A and calo ime e LECO AC 350 we e used in he
es s.
Calcula ions and a de e mina ion o basic sepa a ion p o-
cess pa ame e s (sepa a ion densi y, p obable dissipa ion
and impe ec ion) we e made in acco dance o he S an-
da d PN-G-07020:1997.
The ash con en , acco ding o PN-ISO 1171:2002 S anda d
was de e mined in he ob ained densi y ac ions o he
eed and o he bene icia ion p oduc s.
Hea o combus ion was de e mined o eeds and bene-
icia ion p oduc s and also calo i ic alues we e calcula ed
acco ding o he S anda d PN-ISO 1928:2002.
A eed g ain size analysis was conduc ed on he sie e
mesh 20; 16; 10; 6; 3 and 0.5 mm, ob aining g ain classes
> 20; impe 20-16; 16-10; 10-6; 6-3; 3-0.5 and 0.5-0 mm.
P. MATUSIAK, H. GONDEK – New Implemen a ions o KOMAG Jigs o Coking and S eam Coal…
263
The abo e men ioned analysis was conduc ed acco ding
o he PN-ISO 1953:1999 S anda d.
The eed and p oduc s o sepa a ion in hea y media o
densi y 1.3; 1.4; 1.5; 1.6; 1.7; 1.8 and 2.0 g/cm
3
, gi ing
densi y ac ions < 1.3; 1.3-1.4; 1.4-1.5; 1.5-1.6; 1.6-1.7;
1.7-1.8; 1.8-2.0 and > 2.0 g/cm
3
, we e subjec o densi y
analyses in he g ain class 0.5 mm.
Densi y analyses we e made in acco dance wi h he PN-
G-04559:1997 S anda d. The ash con en and he calo i ic
alue we e gi en in an analy ical s a e. An analy ical moi-
s u e on he le el o 3% was accep ed o calcula ing he
calo i ic alues in he case o all he samples unde analy-
sis.
RESULTS AND DISCUSSION
OM15L and OM15P ines jigs, ZG “Sobieski” – s eam coal
In Tables om 1 o 4 he esul s o he eed bene icia ion
p ocess in he jigs OM15L and OM15P [18] a e lis ed. The
esul s o eed g ain analyses a e gi en in Table 1. In Table
2 and 3 he esul s o densi y-ash analyses o he eed and
o he bene icia ion p oduc s a e p esen ed. The balance
o bene icia ion p oduc s in a o m o hei pe cen age
and mass sha es is gi en in Table 4. The ou pu s o basic
ac ions o he eed and bene icia ion p oduc s o he
OM15L and OM15P jigs a e p esen ed in Fig. 8 and 9.
Table 1
G ain size composi ion o eed – OM15L and OM15P jigs
G ain
class OM15L Feed OM15P Feed
mm Ou pu , % Ou pu , % Ou pu , % Ou pu , %
> 20 17.78
74.41
18.77
89.11
20-16 9.37 9.96
16-10 22.47 24.64
10-6 20.98 21.99
6-3 13.81 13.75
3-0.5 13.63 15.59 10.03 10.89
0.5-0 1.96 0.86
To al 100.00 100.00 100.00 100.00
Sou ce: [18].
Table 2
Densi y-ash composi ion o eed and p oduc s – OM15L jig
F ac-
ion
densi y
Feed Concen a e
Middlings Tailings
g/cm
3
Ou pu , %
Ash, %
Ou pu , %
Ash, %
Ou pu , %
Ash, %
Ou pu , %
Ash, %
< 1.5
52.53
10.14
96.54
9.87
17.42
25.02
0.92
22.51
1.5
-
1.8
5.03
40.78
3.18
36.06
47.61
41.19
3.96
45.05
> 1.8
42.44
86.03
0.28
61.67
34.97
67.92
95.12
86.64
To al
100.00
100.00
100.00
100.00
A e age
43.89
10.85
47.72
84.40
Calo i ic
alue,
MJ/kg
15.14 25.69 13.29 2.24
Sou ce: [18].
Table 3
Densi y-ash composi ion o eed and p oduc s – OM15P jig
F ac-
ion
densi y
Feed Concen a e
Middlings Tailings
g/cm
3
Ou pu , %
Ash, %
Ou pu , %
Ash, %
Ou pu , %
Ash, %
Ou pu , %
Ash, %
< 1.5
53.87
9.10
96.39
8.81
17.42
25.02
0.92
22.51
1.5
-
1.8
5.28
40.30
3.37
35.21
47.61
41.19
3.96
45.05
> 1.8
40.85
85.94
0.24
63.17
34.97
67.31
95.12
86.64
To al
100.00
100.00
100.00
100.00
A e age
42.14
9.83
47.72
84.40
Calo i ic
alue,
MJ/kg
15.30 25.09 13.29 2.24
Sou ce: [18].
Table 4
Balance o bene icia ion p oduc s – OM15L and OM15P jigs
P oduc
Feed Concen a e
Middlings Tailings
OM15L
OM15P
OM15L
OM15P
OM15L
OM15P
OM15L
OM15P
Sha e,
% 100.00
100.00
53.38
54.81
3.42 3.77 43.20
41.42
Sha e,
/h 300.0 300.0
160.1
164.4
10.2 11.3 129.6
124.3
Ash,
% 43.89 42.14
10.85
9.83 47.72
47.72
84.40
84.40
Sou ce: [18].
Fig. 8 Ou pu o basic ac ions o eed and bene icia ion p o-
duc s – OM15L jig
Sou ce: [18].
Fig. 9 Ou pu o basic ac ions o eed and bene icia ion p o-
duc s – OM15P jig
Sou ce: [18].

264 Managemen Sys ems in P oduc ion Enginee ing 2020, Volume 28, Issue 4
The a e age alues o he impe ec ion coe icien , de e -
mined on he basis o sepa a ion cu es o jigs, we e o
he OM15L jig I = 0.174 and o he OM15P jig I = 0.169.
Feed
A g ain analysis in he OM15L (and OM15P) jigs showed a
signi ican sha e o he class > 20 mm, being espec i ely:
17.78% (18.77%). The bigges g ains eached he size o
abou 40 mm. A sha e o class 3-0 mm was on he le el
15.59% (18.77%) a only 1.96% (0.86%) sha e o class < 0.5
mm. A densi y analysis, in accep ed basic ac ions, sho-
wed ha he sha e o he ailings ac ion (> 1.8 g/cm
3
), in
he g ain class > 0.5 mm was 42.44% (40.85%), o pa ing
ac ion (1.5-1.8 g/cm
3
) – 5.03% (5.28%) and o concen-
a e ac ion (< 1.5 g/cm
3
) – 52.53% (53.87%). The ash
con en in he g ain class > 0.5 was signi ican and i was
43.89% (42.14%). The densi y ac ion < 1.5 g/cm
3
con a-
ined 10.14% (9.10%) o ash, howe e he ac ion > 1.8
g/cm
3
( ailings ac ion) – 86.03% (85.94%). The eed calo-
i ic alue was 15.14 MJ/kg (15.30 MJ/kg).
Concen a e
The conduc ed densi y ash analyses showed ha he con-
cen a e p oduc con ained 96.54% (96.39%) o he ac-
ion < 1.5 g/cm
3
o he ash con en equal o 9.87%
(8.81%). A sha e o ailings ac ions (> 1.8 g/cm
3
) in he
p oduc unde analysis was 0.28% (0.24%) a he ash con-
en equal o 61.67% (63.17%). The ou pu o he concen-
a e p oduc was 53.38% (54.81%), a he a e age ash
con en in he p oduc unde analysis, was 10.85%
(9.83%). The calo i ic alue o he concen a e p oduc
was 25.69 MJ/kg (25.09 MJ/kg).
Middlings
The esul s o analyses showed ha middlings con ained
47.61% o he ac ion 1.5-1.8 g/cm
3
o he ash con en
equal o 41.19%. Sha es o concen a e ac ions (< 1.5
g/cm
3
)
and o ailings ac ions (> 1.8 g/cm
3
), in he p oduc unde
analysis, we e espec i ely 17.42% and 34.97%. The
ou pu o middlings was 3.42% a he a e age ash con-
en , in he p oduc unde analysis, was 47.72%. The calo-
i ic alue o middlings was 13.29 MJ/kg.
Tailings
The esul s o conduc ed analyses showed ha o al los-
ses o concen a e ac ion (< 1.5 g/cm
3
) in ailings we e
0.92%, whe eas he o al sha e o combus ible ma e ials
(< 1.8 g/cm
3
) in he abo e p oduc was equal o 86.64%.
The ou pu o ailings was on he le el 43.20% a he ash
con en o 84.40%. The ailings calo i ic alue was 2.24
MJ/kg.
OM24 ines jig, Bo ynia-Zo iówka Mine, Zo iówka B anch
– coking coal
In Tables om 5 o 7 he esul s o he eed bene icia ion
p ocess in he OM24 jig [14, 16] a e lis ed. Resul s o g ain
size analyses o he eed a e p esen ed in Table 5.
Table 5
G ain size composi ion o eed – OM24 jig
G ain class Feed
mm Ou pu , % Ou pu , %
> 20 3.62
44.31
20-16 6.32
16-10 12.24
10-6 11.98
6-3 10.15
3-0.5 35.19 55.69
0.5-0 20.50
Suma 100.00 100.00
Sou ce: [17].
In Table 6 he esul s o densi y-ash analyses o he eed
and bene icia ion p oduc s a e gi en. The balance o be-
ne icia ion p oduc s, in a o m o hei pe cen age and
mass sha es, is shown in Table 7. The ou pu s o basic
unc ions o he eed and o bene icia ion p oduc s o he
OM24 jig a e p esen ed in Fig. 10.
Table 6
Densi y-ash composi ion o eed and p oduc s – OM24 jig
F ac-
ion
densi y
Feed Concen-
a e Middlings
Tailings
g/cm
3
Ou pu , %
Ash, %
Ou pu , %
Ash, %
Ou pu , %
Ash, %
Ou pu , %
Ash, %
< 1.4
56.54
4.37
88.57
4.20
20.52
6.62
1.23
5.57
1.4
-
1.8
10.61
27.77
10.84
24.02
17.61
32.61
4.04
36.84
> 1.8
32.85
82.89
0.59
59.29
61.87
77.59
94.73
86.22
To al
100.00
100.00
100.00
100.00
A e age
32.65
6.67
55.10
83.24
Calo i ic
alue,
MJ/kg
22.21 32.14 13.17 3.80
Sou ce: [17].
Table 7
Balance o bene icia ion p oduc s – OM24 jig
P oduc
Feed Concen a e
Middlings
Tailings
Sha e, %
100.00 59.19 18.73 22.08
Sha e,
/h 580.0 343.3 108.6 128.1
Ash, % 32.65 6.67 55.10 83.24
Sou ce: [17].
The impe ec ion coe icien , de e mined on he basis o
he jig a e age echnological e iciency (on he basis o he
concen a e sepa a ion cu es and he sum o “hea y”
p oduc s), was equal o I = 0.150, a he sepa a ion densi y
Δ = 1.579 g/cm
3
and p obable dissipa ion equal
o Ep = 0.087 g/cm
3
.
P. MATUSIAK, H. GONDEK – New Implemen a ions o KOMAG Jigs o Coking and S eam Coal…
265
Fig. 10 Ou pu o basic ac ions o eed and bene icia ion p o-
duc s – OM24 jig
Sou ce: [17].
Feed
The g ain analysis showed an insigni ican sha e o class
> 20 mm which was 3.62%. The sha e o class 3-0 mm was
high and i was on he le el o abou 55% (including class
< 0.5 mm – 20.50%). The densi y analysis, in accep ed ba-
sic ac ions, demons a ed ha he sha e o he ailings
ac ion (> 1.8 g/cm
3
) in he g ain class > 0.5 mm was
32.85%, o he pa ing ac ion (1.4-1.8 g/cm
3
) – 10.61%
and o he concen a e ac ion (< 1.4 g/cm
3
) – 56.54%.
The ash con en in he g ain class > 0.5 mm was on he
le el o 32.65%. The densi y ac ion < 1.4 g/cm
3
con a-
ined 4.37% o ash, whe eas he ac ion > 1.8 g/cm
3
( ailings) – 82.89%. The eed calo i ic alue was
22.21 MJ/kg.
Concen a e
The conduc ed densi y ash analyses showed ha he con-
cen a e p oduc con ained 88.57% o he ac ion
< 1.4 g/cm
3
o he ash con en equal o 4.20%. A sha e o
ailings ac ions (> 1.8 g/cm
3
) in he p oduc unde analy-
sis was 0.59% a he ash con en equal o 59.29%. The
ou pu o he concen a e p oduc was 59.19%, a he
a e age ash con en in he p oduc unde analysis, was
6.67. The calo i ic alue o he concen a e p oduc was
32.14%.
Middlings
The conduc ed analyses demons a ed ha middlings
con ained only 17.61% o he ac ion 1.4-1.8 g/cm
3
o he
ash con en equal o 32.61%. The sha es o concen a e
ac ions (< 1.4 g/cm
3
) and o ailings ac ions
(> 1.8 g/cm
3
) in he p oduc unde analysis we e espec-
i ely 20.52% and 61.87%. The ou pu o middlings was
18.73% a a e age and signi ican ash con en was on he
le el o 55.10%. The calo i ic alue o middlings was
13.17 MJ/kg.
Tailings
The esul s o conduc ed analyses showed ha o al los-
ses o concen a e ac ion (< 1.4 g/cm
3
) in ailings we e
1.23%, whe eas he o al sha e o combus ible ma e ials
(< 1.8 g/cm
3
) in he abo e p oduc was equal o 5.27%.
The ash con en in he ailings ac ion (> 1.8 g/cm
3
) was
86.22%. The ou pu o ailings was on he le el o 22.08%,
a he ash con en o 83.24%. The ailings p oduc calo i ic
alue was 3.80 MJ/kg.
CONCLUSIONS
The esea ch wo k, conduc ed a he KOMAG Ins i u e in
collabo a ion wi h o he esea ch and de elopmen o ga-
niza ions [5, 27], p oduce s bu mainly wi h end use s o
he esea ch esul s [4], enabled a gene a ion o in-
no a i e echnological and cons uc ional jigs [11]. A de-
sign de elopmen o KOMAG ype pulsa o y jigs conce -
ned all he subassemblies which esul ed in a p oduc i i y
inc ease, an imp o emen o bene icia ion accu acy indi-
ca o s and a educ ion o echnological wa e consump-
ion [12, 13]. I was also possible o ob ain a educ ion o
jigs ins alla ion su ace which enabled o educe hei we-
igh .
An imp o emen o he coal concen a e quali y, a equi-
ed echnological pa ame e s, was achie ed among
o he s due o: a mode niza ion o he eed supply sys em
o he jigs, and also a mode niza ion o he wo king ai
supply sys em, an au oma ic media con ol and a modi i-
ca ion o he hea y p oduc collec ion sys em assembly.
Addi ionally an in oduc ion o he au ho s’ jig con ol sys-
em KOGA [6, 7, 8, 9, 10, 18, 28] enabled an inc eased su-
pe ision o he bene icia ion p ocess.
Conclusions om es s o he OM15L and OM15P ines
jigs
Conduc ed echnological es s demons a ed a co ec
ope a ion o he OM15L and P jigs in condi ions o con i-
nuous ope a ion a he ZG “Sobieski” P epa a ion Plan .
An assessmen o a h ee-p oduc bene icia ion o coal i-
nes in he g ain class 20(40)-0 mm in he OM15L and
OM15P jigs, consis ing in aking samples and analysing he
quali y o ob ained p oduc s, showed ad an ageous sepa-
a ion accu acy indica o s.
The esul s o conduc ed analyses poin ed ou ha he o-
al losses o he concen a e ac ion (< 1.5 g/cm
3
) in ai-
lings did no exceed 1%.
Du ing he sampling p ocess, an amoun o he ma e ial
di ec ed o a bene icia ion was maximum 320 /h in he
case o a single jig.
The OM15L and OM15P ines jigs, al hough he supplied
eed was e y non-homogeneous and sepa a ed in an un-
s able way (sho b eaks in eed supply o jigs occu ed),
ob ained simila esul s, impe ec ion o OM15L on he
le el o I = 0.174 and o OM15P – I = 0.169.
Conclusions om es s o OM24 ines jig – coking coal
The conduc ed echnological es s con i med a co ec
ope a ion o he OM24 jig in he condi ions o a con i-
nuous ope a ion o he P epa a ion Plan o he “Bo ynia-
Zo iówka” Mine, Zo iówka B anch. The eed, subjec o
bene icia ion in he jig unde es ing, was cha ac e ized by
a big sha e o small g ains (< 3 mm) on he le el o 55.69%.
The assessmen o he h ee-p oduc bene icia ion o i-
nes in he g ain class 20(30)-0 mm in he OM24 jig, consi-
s ing in sampling and analysing he quali y o ob ained
266 Managemen Sys ems in P oduc ion Enginee ing 2020, Volume 28, Issue 4
p oduc s, showed ad an ageous sepa a ion accu acy indi-
ca o s. The impe ec ion coe icien was equal
o I = 0.150.
Du ing a ealiza ion o he es s an amoun o he ma e ial
di ec ed o a bene icia ion, being on a e age 580 /h, was
supplied in a s able way and he e we e no signi ican luc-
ua ions in loading he jig wi h he abo e men ioned ma-
e ial.
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Pio Ma usiak
ORCID ID: 0000-0002-9393-4309
KOMAG Ins i u e o Mining Technology
Di ision o P epa a ion Sys ems
Pszczyńska 37, 44-101 Gliwice, Poland
e-mail; pma [email protected],
Ho s Gondek
ORCID ID: 0000-0002-0243-2603
VSB Technical Uni e si y o Os a a
17. lis opadu 2172/15,
Os a a-Po uba, 708 00, Czech Republic
e-mail: ho s .gondek@ sb.cz