Comparative economics of advanced fine-coal cleaning in refuse pond recovery and active mine applications

The economics of “conventional” and “advanced fine-coal cleaning” (AFCC) circuits for refuse pond reclamation as well as active mine applications were evaluated. The benefit of an innovative tailings-management scheme on the profitability of mining enterprises was also evaluated in this study. Analyses were conducted for two scenarios involving the generation of 5.81 % product ash, a quality obtained during AFCC circuit operation at SIU, and a more typical 8% product ash. The inability of the conventional circuits to achieve profitability while producing the lower-ash product is revealed from this approach. On the other hand, the AFCC circuits achieve a return on investment in excess of 50% in the water-only mode as well as the dense-medium mode, both with and without tailings management. The comparison of water-only and dense-medium applications of the AFCC circuit indicates a better suitability for the dense-medium circuit for producing premium-quality products. As a result of reduced overhead costs and the use of existing material-handling facilities, the application of AFCC circuits in active mines provides for better economics when compared to applications in refuse-pond recovery operations. Sensitivity analysis reveals the significance of capacity utilization on project economics.