A coal crushing and screening plant is an industrial facility that processes raw coal extracted from mines into various sizes and removes impurities, making it suitable for use. Coal is primarily used for energy production, but it also plays a crucial role in cement, steel, and chemical industries.

Operation and Stages of a Coal Crushing and Screening Plant

Raw Material Intake: Coal is extracted via open-pit or underground mining. Large blocks of coal are transported to the facility using trucks or conveyor belts.

Pre-Screening: The raw coal is transported through conveyor belts, where large rocks, soil, and other impurities are removed to ensure clean coal enters the crushing system.

Crushing Process: Coal is broken down into the required particle sizes using various crushers, such as:

  • Jaw Crushers: Used for initial coarse crushing of large coal blocks.
  • Cone Crushers: Reduce medium-hard coal into smaller sizes.
  • Impact Crushers: Used for further reduction of coal size.
  • Roll Crushers: Crush coal evenly for uniform particle size distribution.

Screening Process: The crushed coal is separated into different sizes using vibrating screens, typically categorized as:

  • Coal Dust (0-5 mm)
  • Pea Coal (5-20 mm)
  • Nut Coal (20-50 mm)
  • Lump Coal (50 mm and above)

Magnetic Separation: Magnetic separators remove iron and metallic impurities that may be mixed with coal during mining.

Washing and Drying (Optional): Low-quality coal may be washed to reduce ash and sulfur content, improving its energy efficiency. It is then dried to enhance its combustion properties.

Storage and Transportation: The processed coal is stored in stockyards or directly transported via trucks, trains, or ships to industrial facilities.

Applications of Coal Crushing and Screening Plants

Power Plants: Used in thermal power plants for electricity generation.

Cement Industry: Coal is burned to generate high temperatures in cement kilns.

Steel Industry: Coal and coke are used for metal smelting.

Chemical Industry: Coal is used to produce chemicals, tar, and gas derivatives.

Residential Heating: Coal is used as a fuel for heating purposes.