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Coal PreparationCoal Preparation

Coal Preparation

The coal preparation plant (CPP), also referred to as a coal handling plant, coal processing plant, or coal wash plant, is a facility that performs various processes to prepare coal for transport and market utilization.

The complete plant consists of several key stages, including washing the coal to remove impurities such as soil and rock, crushing the coal into graded-sized chunks, and screening it to ensure proper sizing. Additionally, dewatering processes are employed to remove excess moisture from the coal. The final step involves stockpiling the different grades of coal, preparing them for transportation to the market for further use.

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Coal Beneficiation Process

  1. Crushing & Screening: The raw materials undergo crushing and screening processes to separate them into different particle sizes. Dry or wet sieving is used to sieve coal lumps and pulverize them to the desired particle size.
  2. Washing: Coal washing is a crucial step in coal processing. It involves eliminating impurities in raw coal and classifying the coal based on quality. Raw coal, which is directly mined from the mine and contains impurities, is processed to improve its overall quality.
  3. Separation: The coal preparation plant employs mechanical processes to separate impurities from the raw coal. Based on the different physical and chemical properties of coal and other substances, the treated clean coal is categorized into various quality and specification products. Separation methods commonly used include jig gravity separation, heavy medium, and flotation separation.
  4. Dewatering Process: When dealing with thermal coal, the sorting process ensures that it meets requirements. The washed clean coal is dehydrated and stored in coal storage bunkers. The wastewater produced during the process is concentrated and precipitated using a thickener. Coal slime can be directed to the tail coal bunker or stacked in the open air. Clean water is typically recycled for use as circulating water.

Coal Processing Plant

1. Coal Washing Plant

Raw material conditions:
1. Coal, contain with clay
2. Feeding size 0-150mm

  • Raw materials are fed to the hopper of the trommel scrubber by an excavator or loader. The trommel scrubber is equipped with a 2-layer screen at the end. After washing off the clay, the materials are screened and separated into three outputs: above 50mm, 20-50mm, and below 20mm. The outputs above 50mm and 20-50mm are then transported to another location using belt conveyors.
  • The materials below 20mm flow to the dewatering screen through gravity flow. To facilitate this, the dewatering screen is positioned at a lower level than the trommel scrubber. This height difference allows the 0-20mm slurry to flow to the dewatering screen.
  • The oversized materials from the dewatering screen are sent to the rotary dryer system for drying coal. This is achieved by using a feeding conveyor.
  • The finished dried product is then transported using a discharging conveyor.

Highlights of this coal wash plant include the Trommel Scrubber for screening and separating coal ores into three different sizes and the use of a Rotary Dryer to obtain dry coal products.

2. Coal Crushing Plant

  • Jaw crusher
  • Impact crusher
  • Vibrating screen
  • Jig separator

  1. Crushing: Coal is initially crushed in a jaw crusher, followed by further crushing in an impact crusher.
  2. Screening: The vibrating screen separates the coal into three different particle sizes.
  3. Separation: Each particle size range (less than 12mm, 12-35mm, 35-45mm) enters a separate jig for separation.


  • Simple process flow
  • Easy equipment operation and maintenance
  • Large screening capacity
  • No limitation on coal type for accurate preparation

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