1
25-013
Arch Resources’ Industry First Application of Eriez Stackcell®
Technology for Recovery of Low-Ash Metallurgical Coal from an
Ultrafine Refuse Stream
John Nielson
Arch Resources, Philippi, WV
Erich Dohm
Eriez USA, Erie, PA
Drew Hobert
Eriez USA, Erie, PA
ABSTRACT
Metallurgical coal is an essential component for the blast
furnace-basic oxygen furnace (BF-BOF) steelmaking pro-
cess, which accounts for roughly 70% of total global steel
production. To meet the growing demand for metallurgical
coal, Arch Resources identified the potential to recover low-
ash coal from ultra-fines discarded prior to the deslime flota-
tion circuit across their portfolio of operations. Historically,
many flotation circuits were designed to discard this ultra-
fine coal due to high clay content and technological barriers
to cost-effectively upgrade and dewater the coal to a saleable
product. Recent advancements in high-intensity flotation
technology, including the Eriez StackCell, have enabled
coal producers to recover ultra-fine coal while minimizing
capital and operating costs. In July 2023, Arch Resources
commissioned the first full-scale ultra-fines recovery circuit
utilizing StackCell high-intensity flotation technology at
the Leer Mining Complex. This paper reviews the approach
utilized to develop the flotation process design, learnings
from the commissioning and ramp-up period, and perfor-
mance data through the first year of operation.
INTRODUCTION
Metallurgical Coal Demand
Steel production is critical for modern infrastructure and
economic development, providing essential materials for
construction, transportation, and manufacturing indus-
tries. Global steel production levels are projected to increase
by 20% from 1.9 billion metric tons in 2023 to 2.3 billion
metric tons in 2050 to fuel global economic expansion,
urbanization and renewable energy infrastructure, particu-
larly in emerging markets including India and China [1].
Approximately 70% of global steel production is derived
from the blast furnace-basic oxygen furnace (BF-BOF)
steelmaking process, which relies heavily on metallurgi-
cal coal as both a fuel and a reducing agent. Specifically,
it is estimated that 780 t of metallurgical coal is required
to produce 1,000 t of steel via the BF-BOF process [1].
Accordingly, global metallurgical coal production reached
1.1 billion metric tons in 2022 [2].
Efforts to decarbonize steel production include the
development of alternative technologies such as hydro-
gen- based direct reduction and electric arc furnaces (EAF)
using scrap steel. However, these methods face limitations,
including the availability of high-grade iron ore and the
current cost of hydrogen production [3]. Consequently, the
BF-BOF process will remain a cornerstone of steel produc-
tion for the foreseeable future, and thus metallurgical coal
demand will remain robust to support global economic
expansion.
Arch Resources Refuse Recovery Opportunity
Arch Resources operates the Leer preparation plant in
North Central West Virgina. The plant utilizes Heavy
Media Cyclones to process the 2"×1 mm fraction, reflux
classifiers treat the 1 mm×100M and deslimed flotation is
used to treat the 100×325M size fraction (see Figure 1).
Deslimed flotation has been successfully employed at
many of Arch Resources’ operations with the product being
25-013
Arch Resources’ Industry First Application of Eriez Stackcell®
Technology for Recovery of Low-Ash Metallurgical Coal from an
Ultrafine Refuse Stream
John Nielson
Arch Resources, Philippi, WV
Erich Dohm
Eriez USA, Erie, PA
Drew Hobert
Eriez USA, Erie, PA
ABSTRACT
Metallurgical coal is an essential component for the blast
furnace-basic oxygen furnace (BF-BOF) steelmaking pro-
cess, which accounts for roughly 70% of total global steel
production. To meet the growing demand for metallurgical
coal, Arch Resources identified the potential to recover low-
ash coal from ultra-fines discarded prior to the deslime flota-
tion circuit across their portfolio of operations. Historically,
many flotation circuits were designed to discard this ultra-
fine coal due to high clay content and technological barriers
to cost-effectively upgrade and dewater the coal to a saleable
product. Recent advancements in high-intensity flotation
technology, including the Eriez StackCell, have enabled
coal producers to recover ultra-fine coal while minimizing
capital and operating costs. In July 2023, Arch Resources
commissioned the first full-scale ultra-fines recovery circuit
utilizing StackCell high-intensity flotation technology at
the Leer Mining Complex. This paper reviews the approach
utilized to develop the flotation process design, learnings
from the commissioning and ramp-up period, and perfor-
mance data through the first year of operation.
INTRODUCTION
Metallurgical Coal Demand
Steel production is critical for modern infrastructure and
economic development, providing essential materials for
construction, transportation, and manufacturing indus-
tries. Global steel production levels are projected to increase
by 20% from 1.9 billion metric tons in 2023 to 2.3 billion
metric tons in 2050 to fuel global economic expansion,
urbanization and renewable energy infrastructure, particu-
larly in emerging markets including India and China [1].
Approximately 70% of global steel production is derived
from the blast furnace-basic oxygen furnace (BF-BOF)
steelmaking process, which relies heavily on metallurgi-
cal coal as both a fuel and a reducing agent. Specifically,
it is estimated that 780 t of metallurgical coal is required
to produce 1,000 t of steel via the BF-BOF process [1].
Accordingly, global metallurgical coal production reached
1.1 billion metric tons in 2022 [2].
Efforts to decarbonize steel production include the
development of alternative technologies such as hydro-
gen- based direct reduction and electric arc furnaces (EAF)
using scrap steel. However, these methods face limitations,
including the availability of high-grade iron ore and the
current cost of hydrogen production [3]. Consequently, the
BF-BOF process will remain a cornerstone of steel produc-
tion for the foreseeable future, and thus metallurgical coal
demand will remain robust to support global economic
expansion.
Arch Resources Refuse Recovery Opportunity
Arch Resources operates the Leer preparation plant in
North Central West Virgina. The plant utilizes Heavy
Media Cyclones to process the 2"×1 mm fraction, reflux
classifiers treat the 1 mm×100M and deslimed flotation is
used to treat the 100×325M size fraction (see Figure 1).
Deslimed flotation has been successfully employed at
many of Arch Resources’ operations with the product being