Gravity-Based Dry Beneficiation of Low-Calorific Coals Using an Air Table Separator

Increasing constraints related to water consumption and operational complexity have intensified interest in dry coal beneficiation as an alternative to conventional wet cleaning, particularly for low-calorific coals used in thermal power plants. In this study, the performance of a gravity-based dry beneficiation process using an air table was experimentally investigated for run-of-mine coals from the Soma Coal Basin, utilized in the Soma A Thermal Power Plant. The coal was crushed to −10 mm and classified into three size fractions, 5–10 mm, 3–5 mm, and 1–3 mm, before beneficiation. A pilot-scale air table with a capacity of 10 t/h was employed, and operating parameters including table inclination, airflow rate, and vibration frequency were optimized for each size fraction. Clean coal yields of 86.8–88.7% were achieved, while the ash content was reduced from 32 to 35% in the feed to 27.8%–29.7% in the clean coal (dry basis), remaining within the acceptable ash limits of the boiler design. The reject fractions exhibited high ash contents of approximately 71%–72%, indicating effective de-stoning and removal of high-density gangue minerals. Low and consistent Ep values (0.05–0.06) together with nearly constant cut-point densities (D50 ≈ 1.82%–1.83 g/cm3) demonstrated sharp and stable density-based separation. The dust fraction remained limited (1.4%–2.1%), confirming mechanically stable operation. The removal of approximately 10% of the feed as high-density reject was found to reduce coal milling energy demand and lower the energy consumption of ash handling and disposal systems. Overall, the results show that air table-based dry beneficiation enables water-free and energy-efficient pre-concentration of low-calorific coals, offering strong potential for application in water-scarce regions.