Milling System Performance

PMI Revision 01

The Purpose of a Pulverizer:

.

y Must be able to pulverize

p

consistently the design

quantity of coal suitable for
combustion.
combustion
y Able to dry wet coal up to the
design wetness even at full
output condition.
y Able to maintain the products
within the desired grading
The Pulverizers are the HEART of a Pulverized Coal
F l d Boiler!
Fueled
B il !
PMI Revision 01

PULVERIZER DESIGN CRITERIA

3

y PULVERIZERS SIZE & TYPE ARE

SELECTED TO PROVIDE A GRINDING

CAPACITY BASED ON COAL
CHARACTERISTICS
y MARGINS IN CAPACITY ARE BASED ON
EXPECTED WEAR LIFE AND RANGE OF
COAL TO BE FIRED
y OPERATING CAPACITY AFFECTED BY
COAL MOISTURE, INLET AIR
TEMPERATURE AND AIR FLOWS
PMI Revision 01

MILL PERFORMANCE INDICATORS

4

y MILL OUTLET TEMPERATURE

y MILL OUT PUT M/T
y MILL FINENESS FRACTIONS
y MILL AIR FLOW
y MILL PRESSURE DROP (D.P)
(
)
y MILL REJECT RATE
y MILL MOTOR AMPERES
y WEAR PART LIFE

PMI Revision 01

CAUSE OF MILL PERFORMANCE

DETORIARATION
5

yQ
QUALITY OF COAL (MOISTUR,
(
, HGI ETC.))
y UN BALANCED FLOW IN COAL PIPES.
y SETTLEMENT OF COAL IN COAL PIPES.
y POOR COAL FINENESS
y LOW PA TEMPERATURE
y FOREIGN MATERIAL INGRESS.
y LOSS THROUGH REJECTION
y WEAR PART LIFE

PMI Revision 01

MILL PERFORMANCE - IDENTIFICATION

METHODS
6

y NO LOAD RUN
y CLEAN AIR FLOW TEST
y DIRTY PITOT TUBE TEST
y MILL FINENESS SAMPLING
y TRENDING OF COAL PIPE METAL

TEMPERATURE

PMI Revision 01

OBJECTIVE OF TESTING
7

y CLEAN AIR BALANCING BETWEEN

y
y
y
y

BURNERS
DIRTY AIR BALANCING BETWEEN
BURNERS
FUEL BALANCING BETWEEN BURNERS
FINENESS TESTING OF PF BETWEEN
BURNERS
SETTLEMENT OF COAL PARTICLE IN
COAL PIPE

PMI Revision 01

CLEAN AIR FLOW TESTS

8

y STEPS INVOLVED ARE DETAILED IN THE

TEST PROCEDURE
y STANDARD L TYPE PITOT IS USED.
y CLEAN AIR FLOW BALANCE IS COMPUTED
BETWEEN COAL PIPES
y DEVIATION OF +\- 2% INDICATES A
SATISFACTORY FLOW BALANCE AND
FURTHER TRENDING IS REQUIRED

PMI Revision 01

PITOT TUBE HOW IT WORKS ?

The Pitot Static tube measures the
total pressure (or impact pressure) at
the nose of the Pitot tube and the
static pressure of the gas stream at
side ports
ports. The difference of these
pressures, i.e. the dynamic or
velocity pressure (Pdynamic) varies
with the square of the gas velocity.
Thus the gas velocity may be
expressed as:

where r is the gas density and C is a

correction constant dependent on the
design of the Pitot Static tube.
NOTE: This equation is typically valid
for incompressible
p
((constant density)
y)
flow

Generic pitot tube configuration

PMI Revision 01

Pitot Static tube duct surveys

10

if average duct velocities, or mass or volumetric flow rates are required,

iit is
i necessary to perform
f
a Pitot
Pi traverse off the
h d
duct.
This involves taking measurements at various positions across the
duct.,
it is necessary to select a suitable location to perform the survey. It is
preferable to survey at least 8 duct diameters downstream and 2 duct
diameters upstream of the equipment.

Aduct is the duct cross sectional area.

n is the number of points (total number of points surveyed).
Vi is the indicated velocity at each measurement point.
PMI Revision 01

An Example of mechanical tuning

Before mechanical tuning

After mechanical tuning

PMI Revision 01

11

Dirty pitot tube measuring the two phase mixture of

Coal & Air

PMI Revision 01

12

PMI Revision 01

13

Acceptance range
14

y Clean air flow distribution to be with in +//

2.5%.
y Dirty air flow distribution to be with in +/5.0%.
y PF distribution to be with in +/-10%.
y Guarantees to be established for end mills
with unequal length in fuel piping

PMI Revision 01

Clean Air Balancing, A Vital First Step to Fuel Line

Balancing
Fuel lines balanced to each burner by Clean Air test 2% or
better.

PMI Revision 01

15

PMI Revision 01

16

ISOKINETIC COAL SAMPLING

The Isokinetic Sampler is used to extract
pulverized coal from (24) points of each
coal pipe (depending on piping size).at
as close to actual velocity entering the
sampler nozzle, as the coal particles
were flowing before collection. This is
called Isokinetic Sampling. The prefix
iso means same, and kinetic means
energy or velocity of the particles.
Because the coal particles are about a
thousand times more dense than air,
air
isokinetic sampling is important to obtain
truly representative coal samples for
sieving Figure No.
sieving.Figure
No 7
PMI Revision 01

17

ISOKINETIC COAL SAMPLING

18

y TESTING METHODOLOGY IS DETAILED IN

TEST PROCEDURE
y ISOKINETIC SAMPLING ENABLES TO
DETERMINE FUEL /AIR RATIO IN EACH OF
THE FUEL PIPE
y WITHIN LIMITS OF DIRTY AIR
DISTRIBUTION, FUEL DISTRIBUTION IS
EXPECTED TO RESULT IN COMPARABLE
TRENDS

PMI Revision 01

Use of the
Isokinetic
C l SSampler
Coal
l

PMI Revision 01

19

PULVERIZING PROPERTIES OF COAL

20

y Grindability
y is defined
f
as the ease with which the

coal can be pulverized. This should not be confused

with hardness. Coal of the same hardness may have a
range off diff
differentt grindability
i d bilit indices
i di
b
because off
other constituents, such as moisture.
y A standard index has been developed based on use of
the Hardgrove Grindability machine and is called the
Hardgrove
g
Grindabilityy Index

PMI Revision 01

Hardgrove Grindability Index

21

y The HGI was developed

p in the 1930s
93 to measure

empirically the relative difficulty of grinding coal to

the particle size necessary for relatively complete
combustion
b ti
y The HGI test tries to mimic the operation of a ball
and track type of industrial coal pulverizer
manufactured by Babcock. It does this using a batch
mode of operation
p
compared
p
with a dynamic
y
situation in an industrial coal pulverizer.

PMI Revision 01

HGI test procedure

22

A 50 gm sample of coal, which has

been p
prepared
p
in a specific
p
manner
and which has a limited particle size
range, 1.18 x 0.6 mm, is placed in a
stationary grinding bowl in which
eight
i h steell b
balls
ll can run iin a circular
i l
path. A loaded ring is placed on top
of the set of balls with a gravity load
of 284 N.
N The machine is run for 50
revolutions. The top is removed and
the ground coal removed. This coal
is sized and the quantity less than
75 microns recorded. This is
converted to a HGI value using a
calibration graph

PMI Revision 01

Standards for measurement of HGI

23

yAS 1038 Part 20:2002, Hardgrove Grindability of coal

yASTM D 409-2006, Grindability of coal by the Hardgrove

machine method
yASTM D5003-06a,
D
6 Hardgrove
H d
G
Grindability
i d bilit ffor petcoke
t k
yBS 1016-1981 Part 20, Hardgrove Grindability
yDIN 51742-2001,
51742-2001 Determination of HGI of hard coal
yISO 5047 1994, Hard coal-Determination of HGI
yGOST 15489-93,
54 9 93, Hard coal-Determination of HGI
yJIS M8861-1993, Determination of HGI

PMI Revision 01

Coal Preparation Method affects Results

24

Testing as per different

standards may result in
commercially significant
differences in the value of
HGI for a specific coal. Such
as ASTM procedure can be
higher
g
than values using
g AS
procedure on the same coal
sample. The differences
generally lie in the allowed
method of preparing the
sample before testing.
PMI Revision 01

Characteristics of HGI
25
y

y
y

Has a relatively low reproducibility

and repeatability leads to ambiguity
in evaluating mill performance and
coal properties.
Exhibits a non linear change in
difficulty to grind.
grind
Coals with low values of HGI are
more difficult to grind and high
values are much easier to grind.
HGI of a blend is not necessarily the
weighted sum of the component
coals
When combined with coal reactivity
or volatile matter, to provide
guidance on likely combustion/
reaction performance

PMI Revision 01

Mill capacity vs HGI

26

y The mill capacity falls when

grinding coal with a lower HGI

y The curve shows variation in
mill capacity with HGI with
100% capacity being nominally
set at HGI of 50.

PMI Revision 01

Fineness and Mill Power

27

Fineness vs mill capacity

at constant HGI

Mill power vs HGI at

constant fineness
fi

HGI is seen as a good measure of the difficulty of grinding coal for coals
with fairly standard properties
PMI Revision 01

HGI limitations
28

y Coals with a moisture content of less than about 10% behave in an

y
y
y
y
y

expected
d manner. H
However as moisture
i
content iincreases the
h HGI
becomes less effective as a predictor
There is an envelope of coal properties within which HGI is reliable.
Thi envelope
This
l
is
i not well
ll d
defined.
fi d
HGI does not provide direct information on the likely wear rates of
critical mill grinding components.
The primary shortcoming of the test is the use of a batch
process
The test uses sample feed with a limited range of particle sizes,
1.18 x 0.6 mm, rather than a complete range of sizes.
Other measures of coal grindability: Used for grindability of
minerals in general is the Bond Work Index uses a pilot scale wet
ball mill. Not precise enough for use with coal

PMI Revision 01

ROLE OF HGI IN PULVERIZER PERFORMANCE

29

y It is normal to define the output

p of a coal p
pulverizer in

terms of the rate of coal produced and the particle

size distribution of this product.
y The accepted standard for defining the output of an
pulverizer is output in tonnes/hour with a particle
size defined by 70% less than 75 microns and 99.5%
99 5%
less than 300 microns when grinding with a HGI of
known value. Mostlyy it is 5
50. This value has no
critical importance other than to provide a value
against which mill capacity is defined.
PMI Revision 01

ROLE OF HGI IN PULVERIZER PERFORMANCE

30

y Coal pulverizer manufacturers provide sets of curves

linking actual performance of the mill with coal with

different properties such as HGI, moisture content % and
feed particle top size. These curves enable results of a test
on a particular coal to be referenced back to the standard
conditions to monitor the performance of the pulverizer.
y Measurement off the
h HGI and
d using
i the
h mill
ill manufacturers
f

curves will provide a first estimate of the performance of a

question when evaluating
g pulveriser
p
mill with the coal in q
performance with new coal.

PMI Revision 01

Coal properties complementary to HGI

31

y Pulverized coal with 70% less than 75 microns and 99.5%

less than 300 microns was recognized as being appropriate

for normal conditions, based upon coal with a medium
volatile matter content or reactivity, which results in
reasonable burnout of coal particles, 9899%, in a well
designed boiler furnace.
y Iff the
h volatile
l il matter content or reactivity
i i iis hi
higher
h than
h
normal, then coal particles somewhat larger will burn out
successfullyy in the normal furnace volume. This coarser
product requirement allows the mill to provide more
output. Alternatively it allows the use of coal with a lower
HGI with effective particle burnout.
burnout
PMI Revision 01

Fineness
32
y Fineness is an indicator of the

q
quality
y of the pulverizer
p
action.
Specifically, fineness is a
measurement of the percentage of
a coal sample that passes through a
set of test sieves usually designated
at 50, 100, and 200 mesh.
y A 70% coal sample passing through
a 200 mesh screen indicates
optimum mill performance. Values
greater than 70% require the mill
to perform more work. The mill
wear and the power onsumption
are increased if the 70% value is
exceeded. Values lower than 70%
mean higher carbon loss and
increased fuel consumption.
PMI Revision 01

Coal Finess
33

y Coal retained on the 50 mesh

screen should be in the 112%

2%
range. Higher values indicate
worn internals or improper
settings.
g Also, the higher
g
percentages can cause boiler
slagging and high unburned
carbon
y The 50 mesh screen is an
indication of relative coarseness.
The 100 mesh screen indicates an
unsuccessful
f l test, and
d the
h 200
mesh screen indicates relative
fineness.

PMI Revision 01

Relationship between grindability and mill capacity

34

PMI Revision 01

Moisture and Grindability Effects on Mill Capacity

35

PMI Revision 01

WHY IS MILL PERFORMANCE TESTING

IMPORTANT?
36

y UNIT CAPABILITY GOVERENED BY MILL

PERFORMANCE
y BOILER AND COMBUSTION SYSTEM
PERFORMACE AFFECTED BY QUALITY OF
PF COAL AND ITS DISTRIBUTIION
y RELIABLE FEEDBACK SHOULD FOCUS ON
TIMELY MILL OVERHAUL
y VERY EFECTIVE CROSS CHECK OF THE
STATION INSTRUMENTS FEEDBACK

PMI Revision 01

USE OF METAL TEMPERATURE IN FUEL PIPE TO

MONITOR CHOCKING
37

y FUEL PIPING METAL TEMPERATURE IS BEING

MONITORED IN FARAKA TO MONITOR FUEL

PIPE CHOCKING.
y RECENT STUDIES SHOWED THAT LOWER THAN
MILL OUT LET TEMPERATURE IS NOT
NECESSARILY AN INDICATION OF PIPE
CHOCKING.
y DIFFERENCE OF 7 TO 8 C WAS OBSERVED
BETWEEN COAL AIR TEMPERATURE METAL
TEMPERATURE FOR A PIPE WHICH WAS
CLEAR.
PMI Revision 01

Pulverizer Troubleshooting-Matrix
38

y LACK OF CAPACITY OR

HIGH POWER
CONSUMPTION

y HIGH MOISTURE
y LOW GCV
y INCREASED RAW

COAL SIZE.
SIZE
y GRINDING TOO FINE
y EXCESSIVE BED
DEPTH
y INSTRUMENT ERROR

PMI Revision 01

Pulverizer Troubleshooting-Matrix
39

y EXCESSIVE MILL

REJECTS

PMI Revision 01

y CHANGE IN COAL

GRINDABILITY, SULFUR
& ASH.
y IMPROPER COAL/AIR
RATIO
y THROAT GAP WEAR.
WEAR

Pulverizer Troubleshooting-Matrix
40

y COARSE GRIND

y CHANGE IN COAL
y
y
y
y

PMI Revision 01

GRINDABILITY
HIGH MOISTURE
INCREASED THROUGH
PUT.
CLASSIFIER SETTING
MILL WEAR.

Pulverizer Troubleshooting-Matrix
41

y LOW COAL \AIR

TEMPERATURE

y HIGH MOISTURE
y LOW PA INLET

TEMPERATURE
y PASSING OF COLD AIR.
y LOW A.H INLET
TEMPERATURE
y NON AVAILABILITY OF
SCAPH

PMI Revision 01

Pulverizer Troubleshooting-Matrix
42

y CHANGE IN MILL

DIFFERENTIAL

y LOW GRINABILITY
y LOW MOSITURE
y MILL INTERNALS

PROBLEMS.

PMI Revision 01

Pulverizer Troubleshooting-Matrix
43

y MILL FIRES

y HIGH VOLATILES
y MOISTURE
y LOW COAL\
\ AIR

TEMPERATURE.
y BURNER LINE BALANCE

PMI Revision 01

PMI Revision 01

44