5blending of Coals Dec 11 Final

Dr V T Sathyanathan
Mankind is in pursuit of truth, let us work towards this

Blending of Imported Coal Blending of Imported Coal
with Indian Coals & with Indian Coals &
Its Associated Effects on Its Associated Effects on
Boiler Boiler Operation Operation
Dr V T Sathyanathan
Technical Advisor Cethar Ltd
(Retired General Manager - B H E L, Trichy)
Trichy - 620014
Dr V T Sathyanathan
Dr V T SATHYANATHAN, Dr V T SATHYANATHAN, M.E., Ph.D. M.E., Ph.D.
Graduated in Mechanical Engineering from Coimbatore
Institute of Technology, Coimbatore in 1971.
Master Degree In Design And Production Of Thermal
Power Equipment From Regional Engineering College,
Tiruchi in 1984.
Ph.D Degree in Mechanical Engineering from Regional
Engineering College, Tiruchi, in 1998 Prediction of
Unburnt Carbon in Tangentially Fired Boilers Using
Indian Coals.
Joined BHEL In 1973, worked in R & D, Field
Engineering Services, Engineering in various capacity
& as General Manager/Quality for two years
Retired as General Manger in 2008 from BHEL Trichy
Presently Working As Technical Advisor in Cethar
Limited Trichy
Dr V T Sathyanathan
Dr V T SATHYANATHAN, Dr V T SATHYANATHAN, M.E., Ph.D. M.E., Ph.D.
Specialised
In Coal, Oil & Gas Combustion, Boiler Pressure Parts Failure Analysis
Trouble Shooting Of Coal , Oil And Gas Fired Boilers, Chemical
Recovery Boilers And Stoker Fired Boilers
Plant Betterment Of Old Boilers
Performance Testing & Performance Optimisation Of Boilers
Has vast experience in the area of Residual Life Assessment of boiler
pressure parts
Petrographic Analysis Of Coal
Member enquiry committee for investigation of a severe explosion in the
Rotary Holding Furnace (RHF) in Copper Smelting Plant of M/s. Sterlite
Industries (I) Ltd., Tuticorin Tamilnadu
Has presented more than 40 papers in both National and International
Seminars & 83 in http://www.brighthub.com/members/drvts.aspx
My PhD work was referred by seven renowned universities abroad
Leeds University, U K etc
Teach Special Subjects In Horticulture - Art Of Bonsai & Cacti
Dr V T Sathyanathan
Introduction
Coal Formation
Coal Blending
Why Blend Coals
Methods of Blending
Establishment of Procedure
Issues of Imported coal firing
Conclusions
Coal blending - What all to look for
Arrangement Arrangement
Dr V T Sathyanathan
Introduction Introduction
Dr V T Sathyanathan
Dr V T Sathyanathan
Coal Formation Theories Coal Formation Theories
Dr V T Sathyanathan
In-situ coal formation
Drift theory of coal formation
Coal formation theories Coal formation theories
Dr V T Sathyanathan
In In--situ Theory situ Theory of of
coal coal Formation Formation
Coal formed froma particular place
Coal generally appear to have been
formed either in brackish or fresh water,
from massive plant life growing in
swamps, or in swamp interspersed with
shallow lakes.
Coal formed in this way have bands of
coal and inorganic sedimentary rocks
arranged in a sequence.
Dr V T Sathyanathan
Huge Tropical Ferns And Giant Tress In Huge Tropical Ferns And Giant Tress In
Vast Swamp Areas Vast Swamp Areas
( ( Wilfrid Wilfrid Francis, 1961 ) Francis, 1961 )
Dr V T Sathyanathan
Drift Theory of Coal formation Drift Theory of Coal formation
Coal formed from plant material on dry land
The original plant debris transported by water
deposited under water in lakes or in the sea
No true soil found below the seam of coal.
Regular settling of inorganic and organic in
succession or togather
Deposition depend on water current
Subsequently by mineral matters, sand etc. and
result in coal seams.
Coal property vary widely due to deposition pattern
Difference in coal properties of Gondwana coals
led to formation of drift theory
Dr V T Sathyanathan
Gondwana land Gondwana land
( Stacks E., et al ) ( Stacks E., et al )
Dr V T Sathyanathan
Indian Coal Formation Indian Coal Formation
The Gondwana coals of peninsular India were
generally believed to be drift origin. The main reason
for favouring such views include:
pronounced regional variation in thickness and
quality of seams.
high ash content of most of the seams.
lateral transition of coal to carbonaceous
shales
absence of seat-earth and upright stems in the
under clays.
scarcity of plant leaf impressions in the roof of
coal seams and
bifurcation and branching of coal seams.
Dr V T Sathyanathan
Blending of coal Blending of coal
Dr V T Sathyanathan
Burns
giving
heat
Organics
Behaviour
friendly
not friendly
Inorganics
Transport
drying
Moisture
Coal
Dr V T Sathyanathan
Sudden or low change in furnace
behavior leading to low boiler
efficiency, load reduction and
serious outage
Time to turn around is normally high
Can also lead to irrecoverable
change in furnace behaviour
Why Fear Blending of coal Why Fear Blending of coal
Dr V T Sathyanathan
Decision about coal blending
must deal with
uncertainty and variability in
coal properties
the effect of off-design coal
characteristics on power plant
performance and cost.
Dr V T Sathyanathan
Can pose peroblem
High Moist High VM Low FC
low rank
Low Moist Low VM High FC
High rank
Organics
Composition Trasformation Deposition Transport Aglomeration Trace Elements
In-organics
Blending
Drift In-situ
Type of Formation
Lignite Bituminus Anthersite
Rank of Coal
Blending of Coals
Time of residence
High swirl Low Swirl
PC FBC
Combustion
Temerature Size
Reducing Oxidising
Oxygen
Effected by
Dr V T Sathyanathan
Blending
of Coal
Type of
Formation
Drift
Insitu
Blending
Organic
In-organic
Rank of
Coal
Lignite
Bituminous
Anthersite
Can pose
problem
Dr V T Sathyanathan
Blending
Organic
Low
Rank
High Moisture
High V M
Low F C
High
Rank
High Moisture
High V M
Low F C
In-organic
Composition
Transformation
Deposition
Transport
Agglomeration
Trace Elements
Dr V T Sathyanathan
Effected by
Time of
Residence
Temperature Combustion
P C
High Swirl
Low Swirl
F B C
Size
Furnace
Particle
Oxygen
Oxidizing
Reducing
Dr V T Sathyanathan
Why Blend Coals Why Blend Coals
Dr V T Sathyanathan
Why Blend Coals Why Blend Coals
Cost saving
Controlling the mineral content of coal
Helping to solve existing problems
Providing fuel that possess better
combustion properties - flame stability
Enhancing fuel flexibility
Improve coal availability
Meeting of SOx particulate & other
emission requirements
Dr V T Sathyanathan
Methods of Blending Methods of Blending
Dr V T Sathyanathan
Methods of Blending Methods of Blending
Blending can be done
At coal mines
At coal preparation plants
At transshipment points
At power stations
In India mostly done at power
stations
Dr V T Sathyanathan
Methods of Blending Methods of Blending (Cont (Cont.) .)
Blending method chosen will depend on
Site conditions
Level of blending required
Quantity to be stored & blended
Accuracy required
End use of blended coal
Manual blending - for small quantity
Stacking method fully mechanised
Bin storage blending
Belt blending
Dr V T Sathyanathan
Establishment of Procedure Establishment of Procedure
For Blended Coal Firing
Dr V T Sathyanathan
Need For Blended Coal Firing Need For Blended Coal Firing
Indian coals contain high ash
Requirement of limiting the ash content of
coals fired at TPS to 34%
Price of low ash imported coal with higher
HHV is equivalent to that of Indian coals
Availability of new fuels like petcoke, refinery
residue, orimulsion, etc at a comparatively
lower price
Dr V T Sathyanathan
Prime Concern Prime Concern
Boiler furnace Slagging
Lead to outages in many cases
Lead to load reduction
Performance parameters change
Arriving at the right proportion
Maintaining the right mix
Dr V T Sathyanathan
Coal Boiler Furnace
Design
Boiler
Operation
Slagging
Dr V T Sathyanathan
Elivation
Heat Loading
Vol Heat
Loading
Size
Slop Angle
Avoid Ash Load
Shape
Furnace
High Swirl Low Swirl
Burner
Water Steam
Type Nos
Soot Blower Mill
Sizing
Air / Coal
Ratio
Primary
Windbox
Control
Secondary
Air
Distribution
ID Fan
Sizing
Slagging
Dr V T Sathyanathan
MAJOR
SILICATES -[ CLAY MINERALS -[ KAOLINITE RALS KAOLINIT E Al
2
Si
2
O
5
(OH)
4
ILLITE - CLAY MINERAL
QUARTZ Si O
2
MINOR
CALCITE Ca CO
3
CARBONATE DOLOMITE (Ca, Mg) ( (CO
3
)
2
ANKERITE CA (FE, Mg) CO
3
SIDERITE FECO
3
DISULFIDES PYRITE Fe S
2
CUBIC
MARCASITE Fe S
2
ORTHORHOMBIC
COFUIMBITE Fe
2
(SO
4
)
3
9H
2
O
SZOMOLONOKILE Fe SO
4
2H
2
O
SULFATES GYPSUM Ca SO
4
2H
2
O
BASSANITE Ca SO
4
1/2 H
2
O
ANHYDRITE Ca SO
4
JAROSITE K Fe
3
(SO
4
)
2
(OH)
6
FELDSPARE PLAGIOCLASE (NaCa) Al (Alsi) Si
2
O
8
ORTHOCLASE KALSi
3
O
8
Common Coal Minerals
Dr V T Sathyanathan
Calcite Pyrites Ouartz
Oxidizing Reducing
700
.
C S
1
H
2
S
FeS.Fe
2
(SO
4
)
3
FeO Fe Temperature
Feo (Partial Melt) invesions
(Partial melt) 950
.
C
970
.
C
S
1
H
2
S
1000
.
TO 1100
.
C
CO
2
Fe
Cao liquid 2570 Fe
2
O
3
SiO
2
2570
.
C liquid liquid
1600
.
C 1723
.
C
Phase Transforamation Of Some Mineral
Matter Commonly Found In Coal
Dr V T Sathyanathan
Kaolinite Illite
Metakaolinite (A1
2
O
3
2sio
2
950
.
C
925
.
C
SI O
2
(Clay lattica destroyed) Spinal amorphous quartz
A1
2
O
3
Mgo glass Si O
2
Silion Spinel 1050
.
C
(2A1
2
O
3.
3 Si O
2
1100
.
C
Si O
2
1100
.
C
Mullite
1:1Mullite type phase
1300
.
C
(3A1
2
O
3
(A1
2
O
3
.Si OO
2
) 2Si O
2
1400 C Sio2
(Coristobailite) 1400
.
C
Mullite
3A1
2
O
3
. 2Si O
2
liquid glass
May not be completely
liquid untill 1800C 1800
.
C
Phase Transforamation Of Some Mineral
Matter Commonly Found In Coal
Dr V T Sathyanathan
Total Iron in Coal Ash Vs IDT Total Iron in Coal Ash Vs IDT
Total Iron in Coal Ash
I
D
T
D
e
g
F
(C)
Oxidizing Basis
Reducing Basis
Dr V T Sathyanathan
Total Iron in Coal Ash Vs HT Total Iron in Coal Ash Vs HT
I
D
T
D
e
g
F
(C)
Total Iron in Coal Ash
Oxidizing Basis
Reducing Basis
Dr V T Sathyanathan
% Basic Components Vs AFT % Basic Components Vs AFT
Dr V T Sathyanathan
% Na % Na
22
O in Coal Ash Vs Deposition Rate O in Coal Ash Vs Deposition Rate
For For Lignitic Lignitic Ash Ash
Dr V T Sathyanathan
1 LB COAL
1.7 SLON
1.7F 1.75
1.7 FLOAT 1.7 SINK
1.5 SOLN 1.9 SLON
1.55 1.9F 1.95
1.55x1.7F 1.75 x 1.9F
PRACTION PRACTION
1.5F
1.5 FLOAT 1.9 SINK
1.3 SLON 2.1 SLON
2.1F
1.35 .95 x 2.7F 2.15
FRACTION
1.35 x 1.5F 2.1 SINK
FRACTION 2.5 SOLN
1.3F
2.5F
2.55
1.3 F 2.15x2.9F
FRACTION FRACTION
2.5 SINK
2.95
2.55x2.9F
FRACTION 2.95
2.95
FRACTION
Gravity Separation Procedure
Dr V T Sathyanathan
EXPERIENCE SEVERE SEVERE MODERATE NONE NONE
CYCLONE INDEX MED - HIGH LOW-MED. LOW LOW LOW
SULFUR SLAGGING INDEX HIGH MEDIUM LOW LOW LOW
FUSION SLAGGING INDEX SEVERE SEVERE MEDIUM LOW LOW
VISCOSITY SLAGGING INDEX MED - HIGH LOW - MED LOW LOW LOW
Slagging Index Matrix
Dr V T Sathyanathan
Dr V T Sathyanathan
Procedure Developed Procedure Developed
Laboratory analyses of fuel samples
Trials at Fuel Evaluation Test Facility at
various blend proportions and optimising the
blend proportion
Implementation of the recommended blend
proportion at TPS for long duration
observation
Furnace inspection during shut down after
long duration operation
Dr V T Sathyanathan
Basis for recommendation Basis for recommendation
Flame stability
Carbon loss
Heat flux reduction due to slagging and
fouling
Heat flux regain ability on wall blowing
SH and RH spray levels
Emission
Acid dew point
Ash resitivity
Dr V T Sathyanathan
Issues of Issues of
Imported coal firing Imported coal firing
Dr V T Sathyanathan
Issues of Imported coal firing Issues of Imported coal firing
The imported coals are mostly from Indonesia,
Australia, south Africa, China and Russia
Indonesian coal is used in many power stations in
India today in varying proportion
Major properties
High volatile matter content >40%
High moisture content >25%
Very low ash content 1 to 10 %
Surface moisture 8 to 10%
Gross calorific value 5000 to 6000 Kcal/Kg
Dr V T Sathyanathan
Issues of Imported coal firing.. Issues of Imported coal firing..
contd contd
Blending of import coal with the Indian coal
is not tried more than 30%
Ash fusion temperature T1, T2 1190 C,
1200C
Gap of T1 and T2 is less resulting in
slagging /Fouling
High volatile content risk for mill fire and
explosion
Mill out let temperature is to be restricted to
< 60C to avoid mill fire
Dr V T Sathyanathan
Contd Contd
To maintain lesser MOT more tempering air
is used
APH performance affected - increased boiler
exit gas temperature
High moisture content reduced milling
capacity and heat loss in the boiler
Slagging and fouling reduces heat
absorption in the furnace and other heat
transfer surfaces
Dr V T Sathyanathan
contd contd
Overall efficiency of the boiler is
reduced, when 100% import coal firing
is resorted to.
Increased fuel air quantity at the burner
to maintain flame front.
Increased wall blowing and soot
blowing frequency
Up set in the secondary air distribution
across the wind box.
Dr V T Sathyanathan
contd contd
Coals from South Africa and Australia found to
have low ash fusion temperatures and high
sulphur content.
Coals from china Russia have very high calorific
value 6000 7000 Kcal/ Kg. for which elevation
heat loading is to be verified and restricted before
usage.
Super heater/ re heater performance and
achieving boiler out let parameters to be studied.
Blending /firing in boiler is to be preceded by
laboratory study/ pilot model study
Dr V T Sathyanathan
Conclusions Conclusions
Dr V T Sathyanathan
Conclusions Conclusions
Blending of coals expected to grow over the
next decade as electric utilities attempt to
Reduce cost
Meet SO
2
emission limits
Improve combustion performance of their
coals
All aspects of a blends behaviour & its effect
on all components of the power stations, from
the stock pile to the stack, should be
considered before the most appropriate blend
composition is chosen
IEA Publication
Dr V T Sathyanathan
Typical Coal Yard Typical Coal Yard
Coal Stockpile
Wetlands
Rail Car
Unloader
Rail Line
Material Handling System
Crusher House
Main Conveyor
Dr V T Sathyanathan
Conclusions Conclusions (cont.) (cont.)
At present, the effect of coal blending
on power station performance are not
completely understood
Even if the blended coal closely
resembles the design coal for the boiler,
the blend does not perform the same
A limitation to blending coals is the
compatibility of the coals themselves;
problems are more likely when blending
petrographically different coals or coals
with different ash chemistry
IEA Publication
Dr V T Sathyanathan
The impact of blending coals of different
hardness on the finalize distribution &
compositional distribution of the
pulersied coal is sill not understood
Non-additivity properties make blend
evaluation for power generation
inherently complex
Traditional indices for ash deposition
are unreliable when applied to blends
IEA Publication
Dr V T Sathyanathan
More work is required on understanding
how the inorganic components of coals
in the blend interact & how it affects
ash behaviour, including its emisivity,
reflectivity & thermal conductivity
SO
2
can be predicted with reasonable
accuracy
No adequate means of predicting Nox
IEA Publication
Dr V T Sathyanathan
Because of the complexity of the combustion
process and the number of variables involved
(which are still not fully understood)
It is difficult to extrapolate small - scale results to
full - scale plant.
Power station operational experience in a wide
range of plant configurations with a variety of coal
feedstock is essential for determining the practical
significance of results from bench - and pilot -
scale tests.
More published data on how the behavior of the
coals / blends utilize in these tests differ from
their actual performance in power station boilers
are required.
IEA Publication
Dr V T Sathyanathan
Tests are widely utilised, providing a
preliminary indication of the behaviour of the
coal / blend.
One of the most successful outcomes of
blending is in providing a fuel of consistent
quality.
Coal is a heterogeneous material and its
properties and composition vary even within a
single seam or single shipment / train load.
There is a need to minimise the variability.
This can be achieved by blending.
Indian power stations use mainly blended
coals only.
IEA Publication
Dr V T Sathyanathan
Coal blending Coal blending --
What all to look for What all to look for
Dr V T Sathyanathan
Coal blending Coal blending -- What all to look for What all to look for
Dr V T Sathyanathan
Dr V T Sathyanathan
Dr V T Sathyanathan
Dr V T Sathyanathan
Coal blending Coal blending -- What all to look for What all to look for (Cont) (Cont)
Dr V T Sathyanathan
Dr V T Sathyanathan
Dr V T Sathyanathan
Dr V T Sathyanathan
How power stations to view
Look at proximate and ash analysis
Look for FC/VM ratio idea on reactivity
Ash composition ratios slagging
Trial with low mixture ratio 95% + 5%
95% of regular usage coal
Watch parameters like SH spray, steam
temp, exit gas temp, unburnt carbon,load
on bottom ash collection after maintaining
load, steam pressure, excess air& mixture
ratio for about a week
My conclusion
Dr V T Sathyanathan
Dr V T Sathyanathan
What to Insist while importing Coal What to Insist while importing Coal
Specify the proximate analysis you
look for
Coal ash composition range which is
compatible with the coal being fired
Restrict moisture level to the minimum
possible may be a max of 20%
If high moisture coal the min size of
coal must be 40 mm or above
Never accept on fines must be zero
This reduces problem in handling
Dr V T Sathyanathan
Preferred Solution for All these Preferred Solution for All these
Decide high moisture coal to be used or not
If yes, then go for 100% high moisture coal firing
rather than blending
Decide to buy only coal with Zero fines and sizes
above 40 mm
Prefer only CFBC boilers for high capacity boilers
Today you can get even super-critical CFBC boilers
CFBC boiler can handle high moisture coals without any
problem
If no, then think of blending in PC fired
boilers
Dr V T Sathyanathan
Dr V T Sathyanathan
ANY QUESTIONS PLEASE ANY QUESTIONS PLEASE
Dr V T Sathyanathan
Thank You All Thank You All

5blending of Coals Dec 11 Final

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Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

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