coal mining derivation equipments india

1. PAIN-POINT DRIVEN OPENING

Managing coal extraction in India’s diverse and demanding geology presents distinct operational hurdles. Plant managers and engineering contractors face persistent challenges that directly impact profitability and project timelines. Are you contending with:

• Excessive Downtime from Blockages: Sticky, high-ash coal and sudden rock intrusions can jam conventional systems, halting operations for hours. Each hour of unplanned downtime can cost upwards of ₹5-8 lakhs in lost production and labor.
• Inefficient Separation Leading to Low Yield: Inconsistent derivation and separation result in product contamination or valuable coal loss to reject streams, diminishing the overall yield from each tonne of raw material.
• High Maintenance Costs & Component Wear: Abrasive materials rapidly degrade standard equipment liners, screens, and moving parts, leading to frequent replacements, high spare part inventories, and escalating maintenance budgets.
• Inflexibility Across Seam Variability: Equipment that cannot adapt to fluctuations in feed size, moisture content, or ash variability forces operators to run at sub-optimal rates, sacrificing efficiency for stability.

The central question is: how can your operation achieve consistent throughput, higher purity yield, and lower cost-per-tonne in the face of these challenges? The answer lies in specifying purpose-engineered coal mining derivation equipment for India.

2. PRODUCT OVERVIEW

This content addresses Heavy-Duty Coal Screening and Separation Plants, core coal mining derivation equipment for Indian mines. These systems are engineered to receive, size, clean, and separate raw mined coal into defined product fractions.

Operational Workflow:

1. Primary Receiving & Scalping: Run-of-mine (ROM) coal is fed via dump hopper onto a rugged grizzly or scalper screen to remove oversize rock and debris.
2. Primary Sizing & Deshaling: Material is conveyed to primary vibrating screens for separation into coarse, mid-size, and fine fractions. Critical deshaling occurs here, removing large shale and rock.
3. Secondary Cleaning & Derivation: Mid-size fractions (typically -50mm +12mm) are routed to dense medium separators (DMS) or jigs for precise gravity-based separation of coal from impurities.
4. Dewatering & Stockpiling: Cleaned coal fractions are dewatered using vibratory dewatering screens or centrifuges before conveyance to product stockpiles.

Application Scope: Suitable for both open-cast and underground mine headworks; processing ROM coal; producing sized thermal coal for power plants or washed coal for steel/cement industries.

Limitations: Not designed for fine coal slurry beneficiation below 0.5mm (requires froth flotation circuits). Site requires adequate space for feed hopper, plant footprint, and product stockpile management.

3. CORE FEATURES

Our engineered range of coal mining derivation equipment for India incorporates these critical features:

• Modular Bolt-Together Construction | Technical Basis: Pre-engineered structural steel modules with high-strength bolted connections | Operational Benefit: Enables faster on-site erection with reduced foundation work; allows for future plant reconfiguration or expansion | ROI Impact: Reduces installation time by up to 40%, lowering project capital deployment period

• Dual-Mass Vibrating Screen Drive | Technical Basis: Two counter-rotating eccentric masses generating a linear vibration force | Operational Benefit: Transfers energy directly to the bed of material with minimal stress on the screen body; handles heavy loads during surge feeding | ROI Impact: Increases screen availability by ~15% through reduced structural fatigue failures

• Abrasion-Resistant Liner System | Technical Basis: Interchangeable liners made of AR400 steel or ceramic-composite materials at high-wear points | Operational Benefit: Extends service life in chutes, hoppers, and screen decks exposed to abrasive shale | ROI Impact: Cuts liner replacement costs by up to 60% annually and reduces change-out downtime

• PLC-Based Process Control Logic | Technical Basis: Programmable Logic Controller with HMI touchscreen monitoring feed rates, motor loads, and bin levels | Operational Benefit: Provides operators with real-time process visibility and enables automatic feed regulation to prevent overloads | ROI Impact: Optimizes throughput stability, improving overall yield consistency by an average of 8%

• Centralized Greasing & Lube Points | Technical Basis: Manifolded lubrication lines routing from central stations to all major bearing points on vibrating units | Operational Benefit: Ensures critical bearings are serviced without extended shutdowns; enhances operator safety | ROI Impact: Prolongs bearing life by 30%, preventing costly unscheduled stoppages

4. COMPETITIVE ADVANTAGES

Performance Metric	Industry Standard	Our Coal Mining Derivation Equipment Solution	Advantage (% improvement)
Screening Efficiency (-50mm fraction)	85-88% efficiency rate under variable moisture conditions	Patented deck design maintains >92% efficiency up to 10% surface moisture	+5-7% more material correctly sized per cycle
Mean Time Between Failure (Vibrating Units)	~2,000 operating hours before major bearing service required	Heavy-duty bearing housing & forced lubrication extends service interval	+50% increase to ~3,000 hours
Power Consumption per Tonne Processed	~1.8 - 2.2 kWh/tonne for screening & conveying circuit	High-efficiency IE3 motors & optimized drive geometry reduce draw	12-15% lower consumption (~1.6 kWh/tonne)
On-Site Commissioning Time (200 TPH Plant)	6-8 weeks from component arrival to hot commissioning	Modular design & pre-wired control panels streamline erection	Reduction of 2-3 weeks

5. TECHNICAL SPECIFICATIONS

• Capacity/Rating: Models from 100 TPH to 1,200 TPH ROM feed capacity.
• Power Requirements: Main plant drives require 415V/50Hz/3-phase supply; total connected load ranges from 150 kW (100 TPH model) to 850 kW (1,200 TPH model).
• Material Specifications: Primary structure: IS 2062 E250 Grade steel; High-wear components: IS / ASTM AR400 Steel; Screen decks: PU / Rubber modular panels.
• Physical Dimensions (Typical 300 TPH Plant): Feed Hopper Capacity: 30m³; Plant Length (incl. conveyors): ~45m; Width: ~12m; Max Height: ~9m.
• Environmental Operating Range: Designed for ambient temperatures from 0°C to 50°C; dust-protected electrical enclosures (IP65); suitable for operation up to 95% relative humidity.

6. APPLICATION SCENARIOS

#### Central Indian Open-Cast Mine | Challenge: Frequent screen blinding due with high clay-content overburden mixed with coal seams causing hourly stoppages during monsoon season.| Solution: Installation of a primary derivation circuit featuring our ball-deck anti-blinding screen technology within their existing setup.| Results: Screen blinding incidents reduced by over 80%. Sustained monsoon season throughput achieved at 92% of dry-season capacity versus the previous 60%.

#### Eastern India Coal Washery Contractor Challenge Needed mobile derivation equipment capable of being relocated between multiple small-to-mid size mine sites on short notice.| Solution Deployment of skid-mounted semi-mobile screening plant units requiring minimal site civil work.| Results Plant relocation time between sites cut from three weeks five days enabling contractor serve four different mine leases within single financial year maximizing asset utilization

7 COMMERCIAL CONSIDERATIONS

Our approach provides flexibility tailored capital expenditure profiles common Indian mining sector

Pricing Tiers:
Base Plant Package Includes primary secondary screening modules basic conveyors manual lube system control panel
Premium Plant Package Adds DMS cyclone module automated lubrication PLC-based process control premium wear liners
Customized Solutions For large-scale integrated projects including turnkey civil design installation commissioning

Optional Features:
Online particle size analysis system remote monitoring telematics package dust suppression fog cannons fire suppression systems

Service Packages:
Standard Warranty months comprehensive parts labor critical components
Extended Service Contracts Annual maintenance contracts inclusive scheduled inspections spare parts discounts
Operator Training Programs Onsite classroom hands-on training proper operation routine maintenance procedures

Financing Options Collaborations with leading NBFCs offer lease financing structures operating expense models easing upfront capital burden

FAQs

What if my existing feeder crusher setup different specifications your plant designed Field data shows our plants are designed interface variety common feeder crusher configurations We conduct pre-order site audit recommend design modifications necessary ensure compatibility your specific layout

How quickly see operational efficiency improvements after installing your derivation equipment Most clients report measurable improvements within first month operation as throughput stabilizes blockages reduce Yield improvements become clearly evident after one full production cycle typically weeks as consistent product quality is achieved

What typical lead time supply commissioning a TPH unit For standard model configurations lead time typically weeks ex-works Commissioning requires additional weeks site depending civil readiness Our project team provides detailed timeline upfront

Do you provide spares support remote locations Yes We maintain regional spare parts hubs key mining states Jharkhand Chhattisgarh Odisha West Bengal ensuring critical spares availability within hours Additionally provide detailed lifecycle planning recommended spares inventory minimize risk extended downtime

Are there any hidden costs installation we should budget Primary costs are clearly defined proposal includes ex-works price freight site foundation drawings Site-specific costs client responsibility typically include civil foundations local electrical cabling final connection water supply dust suppression piping operator labor during commissioning We provide detailed checklist assist your budgeting