Coal preparation plant design for Seyitomer lignite establishment (SLI) in Turkey

2nd International Conference on: Advances in Mineral Resources 1 Coal preparation plant design for Seyitomer lignite establishment (SLI) in Turkey M. Kaya Osmangazi University, Mining Eng. Dept., Eskisehir, Turkey A. Gitmez Western Lignite Establishment, Kütahya, Turkey ABSTRACT The main purpose of this study was to design a modular/mobile coal preparation plant with a capacity of 300 t/h for Seyitömer B3 vein (almost 70% of the whole SLI deposit). Firstly, coal washing properties and washability curves were determined by sink and float tests. Then, equipment sizing, selection, flow sheet development, economic evaluation, investment and operating costs were determined for coarse (- 150+18mm), fine (-18+0.5mm) and slime (- 0.5+0.1mm) coals. Economic evaluation of the proposed flow sheet showed the feasibility and profitability of the investment. 1. INTRODUCTION Seyitömer Lignite Establishment carries out low rank/grade lignite production work at open cast with dragline-excavator system. Total reserve and annual saleable production capacity of the establishment are 343 and 7.5 million tonnes, respectively. Produced coal is consumed by industry, domestic heating and power stations which are nearby and have a capacity of 600 MW. Turkish Coal Enterprise (TKI), which is a state owned enterprise, was founded in 1957 in Turkey and operates SLI for lignite production in Kütahya region. The average calorific value of the SLI lignite s changes from 1500-1842 kcal/kg. 10% of the whole reserve is suitable to domestic heating and 90% is suitable for power generation. 92% of the coal production is used for electricity production at the power station and 8% is sold for domestic heating. There are four units at the power station and demands a coal with a lower calorific value (LCV) of 1750 kcal/kg, 35% ash, 40% moisture and 0-200 mm in size. For domestic heating lignite must have a LCV of 2600-3000 kcal/kg and a size of +100 mm. Price of the lignite for domestic heating is 3.5 times more expensive than for power generation. Most coals are not utilized as mined but usually undergo some level of preparation ranging from simple crushing to extensive cleaning in coal washeries. Recent studies indicate that the coal preparation prior to the combustion is a viable alternative for meeting the stringent air quality requirements in big cities (Leonard and Mitchell, 1968). The main objectives of coal preparation/cleaning are to increase the calorific value of coal through the removal of ash, moisture and to desulfurize coal to combat air pollution. Coal preparation/cleaning reduces the transportation coasts, lower operating, maintenance and equipment costs, and improves furnace/boiler performance (Önal, 1994). 2. EXPERIMENTAL There are 6 different coal production areas/veins (A1, B1, B2, B3, dragline and Arslanlı) at Seyitömer. Coals produced from different production areas are mixed. Average mixed coal particle size distribution of SLI lignite coal shows that 32% of the coal is coarser than 50 mm and approximately 61% is coarser than 18 mm. 33% of the coal is between 18 and 0.5 mm in size and 6.5% of the coal is finer than 0.5 mm. Table 1 shows SLI reserve share for. B3 vein. It contains about 69% of the whole SLI reserve. The average calorific value of B3 vein changes from 1066 to 1560 kcal/kg. The lowest value of

2 2nd International Conference on: Advances in Mineral Resources Table 1: Importance of B3 vein for SLI Reserve % in Total (t) Reserve Thermic B3 Vein (ROM) Power Station Total TOTAL SLI RESERVE LCV (kcal/kg) 236714165 68.97 1066-1560 308098708 89.77 1579 343224445 100 1683 LCV was considered in our calculations. All of the B3 vein coal will be sold to the power station after concentration. For SLI lignite coal, lower calorific value changes from 400 to 2600 kcal/kg according to particle size. In general as the particle size decreases, the LCV of the coal decreases (Gitmez, 2005). The ash content of the SLI lignite coal changes between 35% and 85% according to particle size. In general as the particle size becomes coarser, the ash content decreases. The moisture content of SLI lignite changes between 25% and 48%. As the particles become coarser, the moisture content increases. Equations 1 and 2 show the regression equations between LCV and ash content for -18+0.5mm and -100+18 mm size fractions for SLI B3 vein coals. LCV = -41.626*Ash%+3441.6 R 2 =0.9792 for - 100+18 mm (1) LCV = -54.972*Ash%+3482.9 R 2 =0.9982 for - 18 +0.5 mm (2) As the ash content of the lignite increasing, the lower calorific value decreases. There is a straight line (y=ax+b type) relation between LCV and ash content of SLI lignite coals. R 2 is very high and changes between 0.9792 and 0.9982. Heavy/dense medium separation (HMS)/ (DMS) is used in coal preparation to produce a commercially graded end-product, clean coal (CC) being separated from the heavier shale or high ash coal. Heavy liquid tests can be used to evaluate any gravity separation process for coals. Weight % within ±0.1 specific gravity (SP) of separation can be used to determine the type of separation (Wills, 1988). Sink-and-float tests were performed at SP from 1.3 to 2.0 g/cm 3. As the medium SP increases the floating coal amount and ash in the floated coal increases. Weight % within ±0.1 gravity of separation was also determined for 150 +18 and -18+0.5 mm size fractions to select the HMS type and operation conditions (Table 2). According to results given above, if weight % within ±0.1 specific gravity is between 15 and 25, HMS with very efficient process and sensitive/expert operation is necessary. Previously it was found that B3 SLI coal had a very high slaking ratio 70.2%, thus; SLI coal can not be easily wet separated (Koca and Kaya, 1996). After sink-float test, the floating product size distributing changes as follows: -100+18 mm size fraction has a weight of 50-64%, -18+0.5 mm has a weight of 19-33%, -0.5+0.1 mm has a weight of 5-8% and -0.1 mm has a weight of 9-14%. Average % amounts for -100+18 mm is 57.84, -18+0.5 mm is 22.76, -0.5+0.1 mm is 7.04 and -0.1 mm is 12.36. 3. SELECTION AND SIZING OF CONCENT- RATION EQUIPMENTS The coal preparation plant was designed in three size classes with the following equipments for SLI B3 coal vein. For coarse coal (-150+18 mm), Heavy Medium Drum Separation. For fine coal (-18+0.5 mm), Heavy Medium Cyclone. For slime coal (-0.5+0.1 mm), Spiral were selected. The plant will work actively 300 days a year and 20 hours a day. The yearly capacity will be 6.8 million tonnes. Actual hourly capacity is 1133 tonnes, this will be rounded to 1200 t/h. Two parallel groups modular/mobile 2*300t/h coal preparation plant were selected. 4 mobile concentrators will process 1.7 million tonnes of ore a year (Gitmez, 2005). 3.1 For Coarse Coal (-150+18 mm) Heavy medium drum separators are build in several sizes up to 3.6 m drum diameter. The maximum capacity is 250 t/h. Separation is car- Table 2: % Float amount at ±0.1 sp.gr. range for -150+18 and -18+0.5 mm size fractions. Size -150+18mm -18+0.5 mm Sp.Gr. B3 B3 B3 B3 1.35 17.33 22.91 11.82 15.39 1.45 25.95 13.94 11.57 14.59 1.55 31.58 10.00 13.08 21.48 1.65 31.07 10.66 17.66 22.81 1.75 28.17 13.46 22.37 22.78 1.85 22.68 8.38 25.47 28.58 1.95 14.14 5.65 49.50 30.91

2nd International Conference on: Advances in Mineral Resources 3 Run-of-Mine Screen 18 mm +18 172 t/h 49% ash Heavy Medium Drum Density 1750 gr/l -18 128 t/h 55% ash +18 Clean Coal Washing Screen +18 Float 137 t/h 1768 kcal/kg 40,6% ash Slime Sep. Screen 0,5 mm +18 Tailing Washing Screen +18 Sink 35 t/h 79,1% ash -0,5 50 t/h 54% ash Hydrocyclone +0,5-18 78 t/h 55,8% ash Heavy Medium Cyclone Density 1750 gr/l +0,5-18 Clean Coal Washing Screen +0,5-18 Float 38,9 t/h 1967 kcal/kg 36,7% ash -0,1 32 t/h 65% ash -0,5+0,1 18 t/h 38,8% ash +0,5-18 Tailing Washing Screen +0,5-18 Batan 39,1 ton/h % 74,7 küllü Thickner Spiral +0,5-18 Tailing Wash Screen -0,5+0,1 C.Coal 12,7 t/h 2213 kcal/kg 23,1% ash Figure 1: Coal concentration plant flowsheet. ried out by continuous removal of the sink product through the action of lifters fixed to the inside of the rotating drum. The float product overflows a weir at the opposite-end of the drum from the feed chute. One heavy medium drum separator with 3.6*3.6 m in size and 140-250 t/h capacity is enough for our purposes. 3.2 For Fine Coal (-18+0.5 mm) DSM cyclone can be used for the size range 40-0.5 mm. The operation principle is similar to the conventional hydrocyclone. The ore is suspended in a very fine medium of ferrosilicon or magnetite and introduced tangentially to the cyclone under pressure (150-250 kpas). The sink product leaves the cyclone in the apex, while the floats product is discharged via the central vortex finder. Two heavy medium cyclones with a diameter of 51 cm and capacity of 165 m 3 /h can be used in the proposed coal preparation plant. 3.3 For Slime Coal (-0.5+0.1mm) Hydrocyclones and spirals can be used for slime +0,5-18 Tailing Wash Screen -0,5+0,1Tailing 5,3 t/h 76,4% ash particles. In spirals feed solid % is around 40 and capacity 1.8-2.2 t/h. Vibrating screens can handle material up to 250 mm in size down to 250μm. Vibrating screen may have two or three decks. Sieve bends and dewatering screens for coarse and fine coals can be used. Capacity of sieve bend can change between 70 and 120 m 3 /h/m 2. Three 35.6 cm diameter slime cyclones, sixteen 3.25 turn spirals were chosen. 4. PLANT FLOWSHEET DEVELOPMENT Plant is designed in two parts: run-of-mine (ROM) coal preparation and concentration divisions. Ready ROM coal silos/bins have sufficient capacity to feed the concentrator for one hour. Run-of-mine coal will be carried by trucks to the coal preparation plant silos. +500 mm coal amount is very low and +150-500 mm coal amount is between 4 and 15% in ROM coal. Figure 1 shows coal concentration plant block diagram along with the mass balance. Figure 2 shows coal concentration plant flowsheet and

4 2nd International Conference on: Advances in Mineral Resources 1 Run-of-Mine 9 Heavy 11 13 +18 Clean Coal 12 14 Bunker Medium Drum Screens +18 Clean Coal Belt 15 13 Silo 2 16 17 Vibrating 16 +18 Tail Screen Grizzly Feeder 3 Tail Belt Silo Double Roll Crusher 17 18 4 Run-of-Mine 18 HMS Magnetic To HMS Tank Stock Belt Separator (Thick Liquid) 19 20 Screen Wash Water 5 21 27 25 Ready Run-of- HMS Tank -- +0,5-18 CC 28 Mine Stocks 22 Pumps Wash Screen 21 +05,-18 mm Clean Coal 31 6 23 Heavy 26 Vibrating Plant Medium Feeder Cyclone 37 30 Centrifugal Drier 33 32 Screen Wash Water 7 Plant Feeding 29 +0.5-18 Tails 38 17 Tails 27 Belt Wash Screen Belt To Dust Belt 1 39 To Tails Silos To Dust Silos 8 Run-of-Mine 2 40 Classification Screen 30 HMS Magnetic To HMS Tank Separator (Thick Liquid) 3 41 20 Slime Removal 8 42 Screen Screen Wash Water 9 31 59 Slime Tank 39 60 41 Cleaned Water Thickner 32 Slime Pump Tank 43 61 33 Slime 44 40 To Tailing Pond Classification Tails Pump Cyclones 45 54 27 To Dust Belt 34 Protective 47 To Dust Silos Sieve Bend To ROM Screen 37 Spiral CC 53 55 Dewatering 48 Screen To Slime Tank 35 56 38 Spiral Tails 57 ROM: Run-of-Mine Spiral Dewatering Screen 17 CC: Clean Coal Tails Belt 58 Tail Silos HMS: Heavy Medium Separation To Thickner Figure 2: Coal concentration plant flowsheet and equipments used. equipments used. Table 3 shows the mass balance for the proposed coal concentration plant for Seyitömer B3 lignite coals. The equipment list, capacities, sizes and motor powers of the selected equipment for the concentrator are also given in the Table 4. 5. MOBILE COAL CONCENTRATION PLANT CAPITAL INVESTMENT AND OP- ERATING COSTS Modular/mobile concentrators are cheaper than on-board/stationary concentrators. In order to

2nd International Conference on: Advances in Mineral Resources 5 Table 3: Seyitomer region B-3 vein coal processing plant mass balance (Capacity 300 t/h). Flow Flow Name t/h m3/h m3/h Total Pulp No Coal Water Magnetite % Solid 1 Run-of-Mine Screen 350 0 --- 350 100,00 2 Run-of-Mine Screen Overflow 172 0 --- 172 100,00 3 Run-of-Mine Screen, Underflow 128 0 --- 128 100,00 4 Slime Separation Sieve Beld (2) 128 0 --- 128 100,00 5 Slime Separation Screen Sieve Bend (2) Overflow 115 32 --- 147 78,26 6 Slime Separation Screen Sieve Bend (2) Underflow 13-32 --- -19-66,67 7 Slime Separation Screen (2) 115 32 --- 147 78,26 8 Slime Separation Screen (2) Overflow 78 --- --- 78 100,00 9 Slime Separation Screen (2) Underflow 37 32 --- 69 53,76 10 +18 Rima Screen ahead of Coal Washing Screen 137 --- 206 343 40,00 11 +18 Coal Washing Screen 137 0 206 343 40,00 12 +18 Coal Washing Screen Overflow 137 0 --- 137 --- 13 +18 Coal Washing Screen Underflow --- 0 206 206 --- 14 '+18 Rima Screen ahead of Tailing Washing Screen 35 --- 53 88 40,00 15 +18 Tailing Washing Screen 35 0 53 88 40,00 16 +18 Tailing Washing Screen Overflow 35 0 --- 35 --- 17 +18 Tailing Washing Screen Underflow --- 0 53 53 --- 18 Heavy Medium Drum Magnetic Separator --- 0 39 39 --- 19 Heavy Medium Drum Magnetic Separator Thick Liquid --- --- 32 32 --- 20 Heavy Medium Drum Magnetic Separator Thin Liquid --- 146 --- 146 --- 21 Heavy Medium Cyclone Feed 78 --- 244 322 --- 22 Heavy Medium Cyclone Overflow 39 --- 177 216 --- 23 Heavy Medium Cyclone Underflow 39 --- 67 106 --- 24 +0,5-18 Coal Washing Screen Sieve Bend 39 --- 195 234 16,67 25 +0,5-18 Coal Washing Screen Sieve Bend Overflow 39 --- 39 78 50,00 26 +0,5-18 Coal Washing Screen Sieve Bend Underlow --- --- 156 156 --- 27 +0,5-18 Coal Washing Screen 39 0 39 78 50,00 28 '+0,5-18 Coal Washing Screen Upper Deck Flow (10-18) 20 0 ---- 20 100,00 29 +0,5-18 Coal Washing Screen Bottom Deck Flow (0,5-10) 19 6 ---- 25 76,92 30 +0,5-18 Coal Wasing Screen Underflow --- -6 39 33 --- 31 Centrifugal Drier Feed 19 6 ---- 25 76,92 32 Centrifugal Drier Exit 19 1 ---- 20 95,24 33 Cenrtifugal Drier Water Exit --- 5 ---- 5 --- 34 '+0,5-18 Tailing Washing Screen Sieve Bend 40 --- 200 240 16,67 35 '+0,5-18 Tailing Washing Screen Sieve Bend Overflow 40 --- 40 80 50,00 36 '+0,5-18 Tailing Washing Screen Sieve Bend Underflow --- --- 160 160 --- 37 +0,5-18 Tailing Washing Screen 40 0 40 80 50,00 38 +0,5-18 Tailing Washing Screen Overflow 40 0 --- 40 100,00 39 +0,5-18 Tailing Washing Screen Underflow --- 0 40 40 --- 40 Heavy Medium Cyclone Magnetic Separator --- 0 12 12 --- 41 Heavy Medium Cyclone Magnetic Separator Thick Liquid --- --- 9 9 --- 42 Heavy Medium Cyclone Magnetic Separator Thin Liquid --- 68 --- 68 --- 43 Slime Classification Cyclone 50 0 --- 50 100,00 44 Slime Classification Cyclone Overflow 32 0 --- 32 100,00 45 Slime Classification Cyclone Underflow 18 0 --- 18 100,00 46 Protective Sieve Bend 18 0 --- 18 100,00 47 Protective Sieve Bend Overflow 0 0 --- 0 --- 48 Protective Sieve Bend Underflow 18 0 --- 18 --- 49 Spiral 18 0 --- 18 100,00 50 '+0,1-0,5 Coal Dewatering Sieve Bend 13 21 --- 34 37,91 51 '+0,1-0,5 Coal Dewatering Sieve Bend Overflow 13 11 --- 24 53,59 52 '+0,1-0,5 Coal Dewatering Sieve Bend Underflow --- 10 --- 10 --- 53 '+0,1-0,5 Coal Dewatering Screen 13 11 --- 24 53,59 54 '+0,1-0,5 Coal Dewatering Screen Overflow 13 1 --- 14 90,71 55 '+0,1-0,5 Coal Dewatering Screen Underflow --- 10 --- 10 --- 56 +0,1-0,5 Tailing Dewatering Screen 5,3-20,8 --- -16,0-33,13 57 +0,1-0,5 Tailing Dewatering Screen Overflow 5,3-1,0 --- 4,3 124,41 58 +0,1-0,5 Tailing Dewatering Screen Underflow --- -19,8 --- -19,8 --- 59 Thickner Feed 32 0 --- 32 100,00 60 Thickner Overflow --- -96 --- -96 --- 61 Thickner Underflow 32 96 --- 128 25,00

6 2nd International Conference on: Advances in Mineral Resources Table 4: Equipment list for Seyitomer coal concentration plant at a capacity of 300 t/h. No Equipment Name Amo. Capacity Size Motor Power 1 Run-of.Mine Bunker 1 100 ton 5x3x7,5 m -- 2 Vibrating Grizzly Feeder 1 375 t/h 0,91 x 2,44 m 20 kw 3 Double Roll Crusher 1 77 t/h 51 cm x 46 cm 7,5 HP 4 Run-of-Mine Stock Belt 1 375 t/h 36 18 kw 5 Ready Run-of-Mine Silo 3 100 ton 5x3x7,5 m -- 6 Vibrating Plant Feeder 3 350 t/h 0,91 x 1,83 m 7,5 HP 7 Plant Feeding Belt 1 375 t/h 36 18 kw 8 Run-of-Mine Classification Screen 1 350 t/h 2,44 x 4,88 30 HP 9 Heavy Medium Drum 1 140-250 t/h 3,6 x 3,6 10 Heavy Medium Drum Tank 1 24 m 3 (φ 4,25 x 3,7, h) m -- 11 Heavy Medium Drum Pump 1 403 m 3 /h 200/150 F 45 kw 12 +18 Clean Coal Dewatering Horizontal Screen 1 206 m 3 /h 0,5 x 1,25 --- 13 +18 Clean Coal Double Deck Washing Screen 1 170 t/h 1,82 x 4,88 20 HP 14 +18 Clean Coal Belt 1 170 t/h 30" 12 kw 15 +18 Tailing Dewatering Horizontal Screen 1 53 m 3 /h 0,2 x 1,25 --- 16 +18 Tailing Washing Screen 1 40 t/h 1,82 x 4,88 15 HP 17 Plant Tailing Belt 1 86-476 t/h 30" 17 kw 18 HMS Magnetic Separator 1 225 m 3 /h (φ 610 x 1771) mm 1,5 kw 19 Slime Removal Sieve Screen Belt 2 180 m 3 /h 1,55 x 1,06 (R1550) --- 20 Slime Removal Screen 2 180 t/h 1,82 x 4,88 15 HP 21 Heavy Medium Cyclone Tank 1 24 m 3 (φ 4,25 x 3,7, h) m --- 22 Heavy Medium Cyclone Pump 1 188 m 3 /h 150/100E 20 kw 23 Heavy Medium Cyclones 2 165 m 3 /h (φ 510) mm --- 24 +0.5-18 Clean Coal Screen Sieve Beld 1 115 m 3 /h 1,55 x 1,06 (R1550) --- 25 +0.5-18 Clean Coal Double Deck Washing Screen 1 45 t/h 1,82 x 4,88 20 HP 26 Centrifugal Drier 1 80-200 t/h (W,H,L) 1.50x1.83x2.43 Drive - Eccentric 30 HP -5 HP 27 Dust Belt 1 134 t/h 24" 5,6 kw 28 +0.5-18 Tailing Screen Sieve Belt 1 115 m 3 /h 1,55 x 1,06 (R1550) --- 29 +0.5-18 Tailing Washing Screen 1 45 t/h 1,82 x 4,88 15 HP 30 HMS Magnetic Separator 1 225 m 3 /h (φ 610 x 1771) mm 1,5 kw 31 Slime Cyclone Tank 1 24 m 3 (φ 4,25 x 3,7, h) m --- 32 Slime Cyclone Pump 1 378 m 3 /h 200/150 F 45 kw 33 Slime Cyclone 3 139 m 3 /h (φ 356) mm --- 34 Spiral Protective Sieve Beld 1 t/h 1,25 x 1,0 (R1550) --- 35 Spiral 16 50 m 3 /h 3,25 turn 0.96-meter Ø helix 160-mm Ø center column --- 36 +0.1-0.5 Coal Dewatering Sieve Beld 1 65 m 3 /h 1,55 x 1,06 (R1550) --- 37 +0.1-0.5 Coal Dewatering Screen 1 15 t/h 1,82 x 3,66 10 HP 38 +0.1-0.5 Tailing Dewatering Screen 1 10 t/h 1,82 x 3,66 10 HP 39 Thickner 1 359 t/h (DxH) m 12x3.5 --- 40 Tailing Pump 1 110 m 3 /h 150/100E 160 kw 41 Cleaned Water Tank 1 44 m 3 (W,H,L) m 3x3.7x4 --- 42 Clean Water Pump 1 350 m 3 /h 150/100E 132 kw 43 Fresh Water Supply Pump 1 110 m 3 /h 75/50C 55 kw 44 Fresh Water Tank 1 22 m 3 (W,H,L) m 3x2.5x3 ---

2nd International Conference on: Advances in Mineral Resources 7 Table 5: Yearly revenue obtained from coal sales with and without concentration. Products obtained from the proposed coal plant Size (mm) Product t/h Product t/y kcal/kg Run-of- Mine Coal - 150+18 137 776338 1768-18+0.5 38.9 220435 1967-0.5+0.1 12.7 71967 2213 Sale Price ($/t) Revenue ($/y) 1700000 1066 2.202 3743982 TOTAL 188.6 1068740 1840 12.663 13533950 establish a plant, capital investment and operating costs estimates are required for calculating the profitability. Capital investment costs include major equipment costs, installation, building construction, etc. Operating costs include raw materials, salaries, electricity, water etc. Equipment prices are obtained from Turkish domestic machine producers. Plant component cost ratio method was used for capital cost estimation (Mular and Bhappu, 1978). It has flexibility and involves a breakdown of fixed capital costs into components whose costs are a ratio of major equipment costs. 5.1 Revenue It is the gross increase of assets that represents the total sales value of coals delivered to the power plant for electricity production. Yearly mobile plant capacity is 1.7 million tonnes. Table 5 shows the yearly revenue obtained from coal sales with and without concentration. Runof-mine coal without concentration can be sold to the power plant and generates yearly 3.74 million $ revenue. If the coal is processed in the proposed coal plant the revenue increases up to 13.53 million $. Proposed coal plant works at a capacity of 300 t/h and 3 shifts a day. 38 workers will work at the mobile plant and the labor cost will be around 349254 $/y based on Turkish working conditions. The total plant costs about 4.714 million $ (Table 6). 5.2 Expenses: capital and operating cost estimates Table 6 shows capital and operating costs for the proposed plant. The total capital and operat- Table 6: Capital investment and operating costs without credit and loan use and calculations for the proposed mobile coal concentration plant (300 t/h). (US $) Calculation Fixed Capital Investment 2059515 Total Plant 4713876 Total Direct s 2171365 Scrap Value 205951 Purchased Equipment 932835 (1) 932835 Installed Equipment 233209 (2) (1)*0.25 Process Piping 93283 (3) (1)*0.10 Instrumentation 55970 (4) (1)*0.06 Buildings and Site Development 186567 (5) (1)*0.20 Auxiliaries 23320 (6) (1)*0.025 Outside Lines (Clean water, effluent water electricity etc.) 23320 (7) (1)*0.025 Total Physical Plant 1548507 (8) (1)+ +(7) Engineering and Construction 309701 (9) (8)*0.20 Contingencies 46455 (10) (8)*0.15 Size Factor 154851 (11) (8)*0.10 Total Plant Fixed Capital Investment 2059515 (12) (8)+ +(11) ing costs based on domestic equipment producers prices is 4713878 $ (1$=1.34 New TL) and based on foreign equipment producers prices (Mular and Bhappu, 1978) is 9024764 $. Therefore the coal plant was designed by using domestic equipment producers prices that are cheaper. Table 7 shows the yearly direct and indirect operating costs for the proposed mobile coal plant. Total plant cost is 4.71 million $. 6. CONCLUSIONS The proposed four 300 t/h mobile coal concentration plants are suitable and economical for SLI B3 lignite coal. The economic evaluation

8 2nd International Conference on: Advances in Mineral Resources Table 7: Direct/indirect operating costs. Direct Operating s Yearly, $ Unit, $/t Consumption per ton runof-mine coal Electric Power 479270 0.2819 (13) 2.67kwh/t, 0.106 $/kwh Fuel/Oil 152239 0.0896 (14) 0.06 l/t, 1.49$/l Magnetite 126866 0.0746 (15) 1 kg/t, 0.075$/kg Anionic Flocculants 76119 0.0448 (16) 0.02 kg/t, 2.24$/kg Labor Salary 349254 0.2054 (17) In Turkish Conditions Supervising 52388 0.0308 (18) (17)*0.15 Maintenance Supplies 333798 0.0072 (19) (13+14+15+16)*0.4 Charges 10298 0.0061 (20) Yearly depreciation*0.05 Indirect General s 367719 0.2163 (21) (17+18+19)*0.50 Laboratory 17463 0.0103 (22) (17)*0.05 Miscellaneous 205951 0.1211 (23) (12)*0.10 Total Direct s 2171365 1.2773 (24) (13)+.+(23) Indirect s Yearly, $ Unit, $/t Calculation Method Depreciation/Consumption 29904 (25) (26+27)*0.066 Tax and Insurance 41190 (26) (12)*0.02 Amortization 411903 (27) (12)*0.20 TOTAL INDIRECT COST 482997 (28) (25+26+27) TOTAL COSTS 2654363 1.5614 (29) (24+28) TOTAL PLANT COST 4713878 for 10 years showed that the proposed plant payback itself in 0.92 years. The profitability of investment is 99.79%. The proposed plant will generate 57.85 million US $ useable profit in 10 years. REFERENCES Gitmez, A., 2005. Coal concentrators design for Seyitömer and Soma lignite s in Turkish, MSci. Thesis, Osmangazi University, Eskisehir. Koca, H. and M. Kaya, 1996. Cleaning of Seyitömer Lignites by Otisca Process, Proceedings, 6 th Inter. Mineral Proc. Sym., Kuşadası, Sept., pp. 441-449. Leonard, J.W. and D.R. Mitchell (ed.) 1968. Coal Preparation, N.Y.; AIME-SME. Mular, A.L. and R.B. Bhappu, 1978. Mineral Processing Plant Design, N.Y., SME. Onal, G., 1994. Coal Preparation in Coal, Kural, O. ed., Istanbul, ITU, pp: 223-238. Wills, B.A., 1988. Mineral Processing Technology, Oxford; Pergamon Press.