▲ ▲ Coal mineral sorting solutions

Solution of removing gangue from raw coal

I. Solution background

As coal mining intensifies, the gangue content in raw coal increases. Traditional hand sorting or heavy media sorting methods face challenges such as low efficiency, high energy consumption, and significant environmental pressures. To achieve efficient, accurate, and environmentally friendly intelligent coal sorting, Softfox Technology Co., Ltd. has developed the DRX series X-ray intelligent mineral sorter, which demonstrates significant advantages in the raw coal and gangue removal process.

II. Solution overview

Goals:
• Achieve efficient and automated removal of gangue from coal mines
• Improve clean coal recycle and product quality
• Reduce pressure and costs on subsequent washing systems
• Enable intelligent, unmanned, and continuous operations

III. Process design

📍1. Raw coal preparation
• Material specification requirements: Raw coal particle size must be controlled between 20mm and 350mm (A multi-stage sorting system can be configured as needed. Particles exceeding 350mm require a pre-crusher. A drum screen is recommended to remove small particles. If the material is wet and sticky with pulverized coal, use a roller screen to peel and remove small particles)
• Feeding equipment: A loader and belt conveyor feed the vibrating feeder attached to the sorting machine to ensure uniform material distribution
📍 2. DRX intelligent sorting equipment
• Equipment type: DRX
• Core functions:
(1) High-energy and low-energy X-ray dual-energy imaging technology
(2) AI identifies the physical property differences between coal and gangue
(3) Precisely controls the air jet system to eliminate target objects
📍 3. Sorting process
• Raw coal enters the sorting chamber through the conveying system
• X-ray scanning device obtains the transmission characteristics of mineral particles
• The system identifies coal and gangue and automatically marks the gangue discharge target
• High-speed air valve array achieves precise elimination
• After sorting, the materials enter the "clean coal" and "gangue" collection areas respectively

IV. System advantages

• Accurate sorting: Utilizing high-resolution dual-energy X-rays and a deep learning algorithm, the system achieves an accuracy rate exceeding 95%.
• High efficiency: A single unit can process up to 200 tons/hour, suitable for continuous operation.
• Low energy Consumption: Over 90% more energy efficient than dense medium systems, eliminating the need for water or chemicals.
• Intelligent control: Fully automatic intelligent control using AI, machine vision, and FPGA.
• Environmentally Friendly and Safe: A dry process prevents water pollution and dust spillage.
• Modular design: Flexible configuration of single or multi-unit systems tailored to mine or coal preparation plant scale.

V. Application scenarios

• Pre-processing of raw coal at the mine entrance (direct gangue discharge, reducing the burden on the coal preparation plant)
• Removal of gangue before feeding into the coal washing plant (improving product purity)
• Unmanned intelligent operation scenarios in coal mines

VI. Implementation suggestions

• Research and evaluation: On-site sampling, particle size analysis, and waste rock feature identification.
• System selection: Configure the DRX model based on processing capacity and particle size range.
• Equipment installation: Complete foundation construction, electrical connections, and system commissioning.
• Interconnection testing: Integration and commissioning with conveying, loading, and control systems.
• Training and delivery: Operational training and integration with the remote monitoring platform.
• After-sales service: 24/7 technical response and periodic maintenance services.

VII. Actual cases

VIII. Conclusion

Softfox Technology Co., Ltd.'s DRX series of intelligent mineral sorting equipment has been successfully deployed in numerous coal mines, significantly improving sorting efficiency and resource utilization. This system represents the forefront of intelligent, green, and unmanned coal sorting, and is a powerful complement, upgrade and alternative to traditional coal preparation processes.

Solution of selecting high-quality clean coal

I. Solution background

In the processing of raw coal and washed coal, the clean coal recycle rate and gangue removal rate directly impact economic benefits and resource utilization efficiency. Traditional heavy media and water washing methods suffer from high investment, high water consumption, and unstable efficiency. Softfox Technology Co., Ltd.'s DRX intelligent mineral sorting equipment, based on dual-energy X-ray imaging and artificial intelligence recognition technology, enables efficient, dry, and environmentally friendly clean coal intelligent sorting.

II. Technical features of the equipment

• Identification technology: X-ray Dual Energy + AI Image Recognition
• Sorting method: Dry, high-speed sorting based on density and elemental signature differences
• Processing capacity: Up to 200 tons/hour
• Sorting accuracy: > 95%
• Applicable particle size range: 20 - 350 mm
• Control system: PLC + Industrial computer, supporting remote operation and data monitoring

III. Application 1: Clean coal sorting from raw coal

📍1. Raw coal sorting objectives
• Objective: Remove gangue and low-quality coal from raw coal with a high gangue content, extracting high-calorific-value clean coal.
• Raw coal particle size: 20 - 350 mm (Particles larger than 350mm require a pre-crusher)
📍2. Sorting process flowchart
Raw coal stockpile → Feeder → Belt conveyor → DRX Intelligent Sorting Equipment →
├─ Clean coal output → Clean coal silo
└─ Rejected material (Gangue + Low-quality coal) → Waste conveyor → Transport or backfill
📍3. Key implementation steps
• If necessary, a magnetic separator and drum screen can be installed at the front end to remove impurities and small-sized materials (a roller screen can be used to remove sticky pulverized coal and small particles from wet materials)
• DRX sortor performs X-ray scanning and identification + Separation of clean coal and gangue
• Clean coal calorific value can be increased by 20 - 30%, with a gangue removal rate of >95%.

IV. Application 2: Further quality improvement and sorting of washed coal

📍1. Scenario description
• Washed coal still contains some gangue or low-calorific-value medium coal
• DRX equipment is used to further purify clean coal and improve the quality of commercial coal
📍2. Sorting flowchart
Washed coal storage yard → Conveying system → DRX sorting equipment →
├─ High-quality clean coal → Finished product warehouse
└─ Impurities + inferior coal → Secondary processing or blending
📍3. Performance evaluation
• Further reduction of clean coal ash content by 2 - 5%
• Calorific value-graded products can be produced (e.g., separate sales of coal above 6000 kcal and below 5000 kcal)
• Reduced overall water washing system load and tailwater treatment costs

V. Economic and environmental benefits

• Investment cost: Low (dry sorting)
• Operating energy consumption: Low (dry sorting), no water required
• Clean coal reciclaje: High
• Sorting efficiency: Stable and accurate
• Environmentally friendly emissions: Zero drainage, low dust, no tailwater, and no sludge

VI. Implementation suggestions

1. Site preparation: A dust-proof, enclosed operating area with hardened flooring is required.
2. Production line integration: Seamless integration with existing conveyor systems.
3. Sorting strategy: Flexible adjustment based on calorific value and ash content thresholds.
4. Maintenance and operation: Softfox Technology remote monitoring ensures stable and efficient equipment operation.

VII. Actual cases

VIII. Conclusion

Softfox Technology Co., Ltd.'s DRX series of intelligent mineral sorting equipment has been successfully deployed in numerous coal mines, significantly improving sorting efficiency and resource utilization. This system represents the forefront of intelligent, green, and unmanned coal sorting, offering a powerful supplement, upgrade, and alternative to traditional coal preparation processes.

Solution of coal recycle from gangue

I. Solution background

As coal mining intensifies, the gangue content in raw coal ore increases. Traditional hand sorting or heavy media sorting methods face challenges such as low efficiency, high energy consumption, and significant environmental pressures. To achieve efficient, accurate, and environmentally friendly intelligent coal sorting, Softfox Technology Co., Ltd. has developed the DRX series X-ray intelligent mineral sorter, which demonstrates significant advantages in the raw coal and gangue removal process.

II. Characteristics of sorted materials

Main composition and characteristics of the source
• Gangue heaps contain unselected clean coal lumps and a large amount of gangue with large particle size, high impurity content, and uneven distribution
• Gangue removed from heavy media or jigs in water-washed gangue piles is more uniform, has a concentrated particle size, and low water content

III. Overall goals

• Efficiently identify and recover residual coal (clean coal/medium coal) from gangue
• Improve resource utilization by ≥10%
• Reduce gangue pile volume, environmental footprint, and pollution

IV. Process for coal recycle from guangue pile

📍1. Processing particle size range: 20 - 350 mm (Particles larger than 350mm require a pre-crusher)
📍2. Recommended configuration process

Gangue pile → Loading by loader → Drum screen (Small particle removal) → Conveyor → DRX Intelligent Sorting Equipment
├─ Combustible coal (Clean coal/Medium coal) → Finished product silo → Return to furnace or blending
└─ Real waste rock → Closure compaction/Construction fill/Ecological restoration
📍3. Sorting performance targets
• Coal recycle rate: 10 - 25% (Depending on the coal content of the original waste gangue)
• Accuracy sorting: false picking rate <5%
• Combustible ash reduction: 3 - 6%
• Annual processing capacity: 500,000 Tons/Line

V. Process for coal recovery from washed guangue pile

📍1. Processing particle size range: 20 - 350 mm
📍2. Recommended configuration process
Gangue Pile → Bucket Feeder → Drum screen (Impurity removal) → Conveyor → DRX Intelligent Sorting Equipment →
├─ Combustible coal (Can be used as secondary commercial coal) → Clean coal silo
└─ Real waste rock → Stockpile or secondary recycling
📍3. Advantages and results
• Effectively recovers "missed" coal particles in waste rock
• Can be sorted and reused according to metrics such as calorific value and ash content
• Replaces some newly mined coal, reducing raw coal mining costs

VI. Technical advantages

• Sorting accuracy based on X-ray + AI for precise identification of coal and gangue
• Particle size adaptability supports a wide range of material sizes from 20–350mm
• Dry operation requires no water source and eliminates the pressure of tailwater treatment
• Environmentally friendly, no secondary pollution, and suitable for field operations
• Modular operation and maintenance, remote monitoring, and easy maintenance

VII. Economic and environmental benefit analysis

Estimated annual benefits for a single project line (Indicative)
• Annual processing capacity: 500,000 tons of gangue
• 10% coal recycle, or approximately 50,000 tons of coal
• Average market coal price: 300 yuan/ton (reference)
• Annual incremental benefits: ≥ 15 million yuan/year
• Reduced landfill costs: Gangue compression costs reduced by 10–20 yuan per ton
Additionally, the project can:
• Reduced stockpile footprint
• Reduced green mine remediation costs
• Support for ESG environmental indicators and green financing

VIII. Implementation recommendations

• Equipment layout: It is recommended to set up a mobile or semi-fixed sorting station near the gangue pile.
• Sorting parameter adjustment: Adjust the AI recognition model based on the coal content of the gangue.
• Safety and environmental protection: Configure a dust control system to prevent dust from screening.
• Subsequent utilization: Recovered coal can be used for blending, fuel for medium- and low-calorific value boilers, etc.

IX. Case reference

X. Optional services

Softfox Technology offers:
• Sorting testing services
• Custom project design and installation
• Solutions for managing the operation and maintenance of sorting equipment
• Remote device management

XI. Conclusion

Softfox Technology Co., Ltd.'s DRX series intelligent mineral sorting equipment has been successfully deployed in numerous coal mines, significantly improving sorting efficiency and resource utilization. This system represents the forefront of intelligent, green, and unmanned coal sorting, offering a powerful supplement, upgrade, and alternative to traditional coal sorting processes. It is particularly effective in recovering low-coal content coal from gangue, achieving tasks that traditional processes could not accomplish.