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89
ABSTRACT
Four physical properties have been identified as being of greatest value when developing or
evaluating fuel briquette formulations or processes. They are resistances to crushing, impact, abrasion and water penetration. Arbitrary tests for these properties have evolved in this laboratory
during a decade of investigations of binders and formulations for briquetting coal fines and the
like. The simple test methods are described and some typical results are given.
Tests of several types of commercial and pilot process fuel briquettes have been used to set
realistic target values for these four physical properties. In the process development stages, it is
suggested that the tests should relate to the briquette material, rather than the briquette as an
entity, and that this can be achieved by transforming the raw data into various indices. These
would allow intra-laboratory or inter-laboratory comparisons of briquette formulations. This approach is illustrated by presenting results for compressive strength, impact resistance and abrasion resistance. The same could apply to water resistance and some suggestions are discussed.
The needs of research and development and of production in respect of briquette testing are
seen as different, but complementary. It is hoped that the paper will stimulate researchers and
producers alike to work towards the adoption of codes of standard practice in briquette testing.
INTRODUCTION
Rhys Jones and Schinzel have written comprehensive reviews of the science
and technology of coal briquetting [1,2 ] which cover the background of this
topic. The production of fuel briquettes began before the turn of the 20th century and the recognition of the need for quality control stems from around that
time [3,4]. However, despite prolonged efforts by the International Briquetting Association to establish standard test methods in North America, only
one standard (tentative) procedure was adopted by ASTM, Designation D267767T, but this was discontinued from 1986 [5]. Some of the history of the development of this and other standard procedures fofftesting fuel briquettes has
been recorded by Eckerd [6 ].
It is significant to note that ASTM D2677-67T is related to barbeque (charcoal) briquettes, because by the time the standard was adopted (1967), oil had
0378-3820/90/$03.50
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become the general heating fuel and the coal briquetting industry had ceased
to be significant in the USA energy market. Also, the failure of the fuel briquette industry to adopt standards probably reflects the severe competitiveness and the difficulties of trying to market a low value, high tonnage product
made by using widely varying raw materials and manufacturing methods. Suitability for purpose, customer satisfaction and economics would have ruled the
marketplace.
This paper identifies the physical tests which should be carried out in the
quality control laboratory to determine the handling performance of fuel briquettes and describes the simple practices adopted in this laboratory. The paper suggests ways of treating the test results so that intra- and inter-laboratory
comparisons can be made more meaningful, with the objective of encouraging
the adoption of international standards of performance. Combustion tests are
not considered in this paper, although environmental concerns make it just as
important to establish standards for permissable smoke emission during the
combustion of briquetted fuels.
IMPORTANT PHYSICALPROPERTIES
Over the past several decades, researchers and developers of coal and other
fuel briquettes have identified the important physical properties of their products to be compressive strength or crushing resistance, impact resistance, abrasion resistance, water resistance, weathering and density.
All of these properties relate to the effectiveness of the agglomeration process, i.e. strength and durability of the bonds holding the fuel particles together. Fuel briquettes need to be able to withstand the crushing loads they
receive in handling, transport, storage and firing. They should be able to resist
drops in conveyor belt transfers, from chutes into bins and off trucks onto the
ground. They should also be able to withstand the abrasion that occurs during
short distance conveying or long distance haulage. Fuel briquettes may be
transported in uncovered trucks and stored outdoors. Therefore they should
resist penetration by water, which in some cases may directly attack the binding agent or in other cases may lead to degradation by weathering processes,
such as freeze-thaw cycles. Other climatic conditions, such as high temperatures, can lead to briquette fusion in stockpiles if the binder softens. There are
two types of density to be considered in briquetting - - the density of a single
briquette and the bulk density of a large volume of briquettes. The former is
important in briquette formulation and quality and the latter in the packaging,
transport and marketing of fuel briquettes.
Not all of these properties are independent. Direct relationships would be
expected between compressive strength, impact resistance and abrasion resistance. Density usually follows compressive strength, but the reverse does not
necessarily hold true, since density cannot take account of the effectiveness of
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bonding. Weathering becomes important for long term outdoor storage, but
the briquettes must first survive the sometimes severe handling treatments
they are likely to receive in industrial use before they get to storage. Therefore,
the first four properties have been identified as being the most important, although density has been fairly routinely measured as well.
COMPRESSIVE STRENGTH
Whereas the crushing resistance of coal and coke is inferred from the results
of standard drop shatter tests [ 7 ] and abrasion tests [8 ], many fuel briquette
investigators have employed some form of direct crushing test to evaluate
bonding in their manufactured fuel [6,9-12]. Tests on limited samples of briquettes maximise progress in the development of new formulations or processes, especially in the evaluation of binders [ 11 ].
The compressive load on a briquette in a storage bin during filling is likely
to be relatively small. Taggart [ 13 ], states that the "equivalent liquid density"
of - 3 8 mm bituminous coal (bulk density 800 k g / m 3) in a bin is only 210 kg/
m 3. This means that the pressure on a coal briquette at a depth of 3 m would
only be about 6 kPa. Watmough's theory [14] predicts that for a briquette
stream free-falling into a bin at 5 tonne per hour through a height of 2 metres,
the average extra pressure exerted on a briquette already within the bin burden
will only be in the vicinity of one-hundredth of the pressure due to the burden
itself, and therefore can be neglected.
The crushing loads experienced by industrial fuel briquettes could be far
more severe than those experienced by domestic fuel briquettes. The highest
crushing loads would most likely occur during bucket-filling of a front-end
loader or during conveying in a screw-conveyor. Tests carried out in 100 and
150 m m diameter screw conveyors with roll-pressed 20 g starch-bonded coal
briquettes of compressive strength around 350 kPa showed that they could not
withstand the crushing forces in the conveyors [15]. In other situations even
greater compressive strengths may not overcome the problem. In some coalfired boiler feeding systems, e.g. in under-fed stokers, even the coal gets crushed,
so it would be unreasonable to expect coal briquettes to survive where the parent coal cannot. Tests on commercial fuel briquettes and on lump sub-bituminous coal have been used to establish a minimum target value of 375 kPa
for compressive strength. Whilst this value obviously far exceeds the crushing
loads that would occur in unenclosed belt conveyors and normal bin storage
operations, experience suggests that it would be wise to maintain compressive
strength above the 350 kPa level.
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93
2OO
z 150
q
IO0
50
0"5
1.5
215
Movement mm
Fig. 2. Compressive load versus crosshead movement curve to obtain load at fracture.
TABLE1
Typical compressive strength test results; roll-pressed sub-bituminous coal briquettes/starch-based
binder
Run No.
65A
67A
67B
69A
70A
73A
76
76A
76B
76C
#2
#3
#4
#5
#6
12.6
18.5
17.4
15.0
22.9
16.4
15.6
37.0
20.2
41.0
14.2
16.3
19.1
16.4
20.7
22.7
16.5
30.0
18.3
27.3
13.0
16.5
21.7
16.0
26.8
15.6
12.7
28.5
21.3
42.0
15.2
13.9
24.2
15.0
26.7
20.0
20.4
29.5
17.9
38.5
15.9
15.2
16.4
17.8
23.9
18.9
12.4
35.0
24.6
35.0
12.1
18.9
24.8
16.9
22.9
17.3
20.0
16.5
38.0
Mean
stress (kPa)
Target = 375kPa
Pass/Fail
237
285
354
278
413
318
290
588
340
688
F
F
F
F
P
F
F
P
F
P
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of compressive strength on briquette size and shape and makes it possible to
compare the strengths of the briquette materials rather than the briquettes per
se. Thus a briquette size or shape can be "designed" to meet industrial handling
requirements.
IMPACT RESISTANCE
Once a briquetting project reaches pilot production, an industrial-type standard drop shatter test, could be adapted from those existing for coal and coke
[7] or that due to Wright [4].
However, each test would require 250-1000 briquettes. For bench-scale laboratory research and development work, such productions would not only be
onerous, but also unwarranted. A more suitable standard test was needed for
laboratory use.
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TABLE 2
N o . of drops/No, of pieces
IRI a
Target I R I = 50
Pass/Fail
Test#l
#2
#3
#4
#5
#6
67
;3
;2
t2
_,
3
;2
43
68
62
42
!2
_,
3
!3
37
69
!2
12
_2
3
;3
48
70
_4
_2
_3
94
71
;
2
~4
_2
3
22
,2_2
71
72
_2
5
;2
;2
;2
,4
52
73
2
3
~
2
!
2
~3
~
4
72
73A
!
3
!
2
_1
4
z2
_2
3
54
76
53
~3
5,
~I
~,
72
76A
54
45
33
52
42
161
76B
~2
63
63
35
52
2~
203
76C
_~
2
a2
24
~3
150
RESISTANCE
Again, standard tumble abrasion tests exist for coal and coke [8], for which
25-50 kg of sample are required. For laboratory testing, a scaled-down tumble
test requiring about 1 kg of sample was developed to suit 5-30 g fuel briquettes
made in bench- and small pilot-scale equipment. Even this test requires 35200 briquettes, so fewer abrasion tests have been carried out during the early
stages of fuel briquette developments.
Obviously, briquette shape will affect abrasion in a drum tumble test. Everything else being equal, briquettes with sharp edges will report a lower abrasion
resistance than those with rounded shapes. This was evident when testing 10
g, 25 mm diameter cylindrical peat briquettes. The top and bottom rims were
abraded until they became rounded, whilst the central parts of the cylinders
were largely unaffected.
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TABLE 3
Typical abrasion test results: roll-pressedsub-bituminouscoal briquettes/starch-based binder
Run No.
Abrasionresistance
(60 briquettes in tumbler)
% retained on 1/8" BS mesh
67
67A
67B
68
69
69A
70
73A
76
76A
76B
76C
89.2
91.5
94.4
82.3
91.6
94.1
96.6
73.8
87.3
97.4
98.4
96.7
F
F
F
F
F
F
P
F
F
P
P
P
of the drum over its full length. For a given fuel briquette size and shape, e.g.
as produced in a double roll-press, a fixed number of briquettes approximating
to 1 kg is charged to the drum. The charge is fixed by number rather t h a n by
mass, because coming from a constant volume mould, it is believed t h a t the
variation in briquette masses between different production runs (using the
same press and the same coal) will have less of an effect on abrasion t h a n the
change in surface area due to the variation in the number of briquettes. The
drum is sealed and rotated on a tumbler drive for 100 revolutions at 50 rpm.
The charge is screened on a 1/8" or 3 mm BS mesh wire screen and the percentage oversize is reported as the abrasion resistance.
Our abrasion resistance target involving ~ 20 g, 44 33 22 mm, ovoid, flourbonded coal briquettes (60 in each test) was 95% + 1/8" mesh. Some results
of single tumble tests are listed in Table 3. Briquette formulations which met
the targets for compressive strength (375 kPa ) and impact resistance (IRI = 50 )
usually also met the 95% abrasion resistance requirement (compare Tables 1,
2 and 3). No a t t e m p t has been made to correlate our tumbler test with the
standard methods for coal and coke.
WATER RESISTANCE
W h e n agglomeration is achieved through binderless, hot briquetting or the
use of an insoluble binder, coal briquettes are usually resistant to water. On
the other hand, m a n y fuel briquettes are bonded using water-sensitive binders
and include porous filler materials, e.g. charcoal or coke. In such cases it may
be necessary to water-proof and routinely test the products.
97
The need for a briquetted fuel to be water resistant depends to a large extent
upon its end use. Most, if not all, manufacturers of barbecue briquettes, using
starch or other water-soluble binders, market their products in a packaged
form to avoid despoilage by short exposures to rain or accidental wetting. On
the other hand, manufacturers of industrial fuel briquettes usually have to face
up to weather-proofing their products to accommodate transport in open wagons or trucks and outdoor stockpiling. Thus the majority of industrial fuel
briquettes have incorporated water insoluble binders or some water-proofing
method to protect any soluble binder.
Some investigators have used a weathering test [4 ] instead of a water resistance test. The weathering test goes beyond testing the binder or bonding
achieved during manufacture to include a test of the stability of the filler material, coal, lignite, char, etc., under climatic conditions of outdoor storage. The
water resistance test used in our work is not intended as a measure of long term
weathering resistance.
Laboratory testing
The four tests outlined in this paper have provided sound and useful criteria
for the evaluation of~briquette binders and formulations [ 15,16 ]. We have found
it convenient to use our drop shatter test as a preliminary guide to estimate
satisfactory strength before carrying out the more difficult and time-consuming tests for compressive strength and abrasion. Compression testing is intro-
98
duced after the briquettes have achieved the IRI target value. If crushing resistance proves satisfactory, greater quantities of briquettes are produced and
abrasion testing then becomes possible. Because water resistance, the fourth
test, only requires a single briquette at a time, it is usually operated, along with
the drop test, from the start, especially when the binder is water-sensitive.
One of the frustrations of briquetting research has been the lack of yardsticks to set the goals for briquette performance. In our work we have worked
backwards, so to speak, by evaluating the properties of parent coals and commercially briquetted products [15] (few as they are in New Zealand). The
interest in briquetting fluctuates, but what happens in respect of quality control and quality assurance in the industry in the future, will develop out of
laboratory research and development work. Therefore, it would seem reasonable that the researchers in this field should provide the lead towards standardisation in testing.
99
Commercial opportunities could arise out of the needs for non-polluting solid
fuels and combustible waste utilisation especially in markets which have traditionally used wood for domestic heating and cooking. The timely development of standardised testing procedures for both physical and combustion
properties would enhance confidence in any rejuvenated fuel briquetting
industry.
Four laboratory tests are recommended to monitor the physical strength
properties of briquetted fuels either during process development or commercial
production. They are a drop shatter test, a crushing resistance test, a tumbler
abrasion test and an immersion water resistance test.
The results of these tests can be converted into separate indices which will
allow briquette properties to be more easily compared between various testing
laboratories.
Expressing compressive strength as a stress rather than as a force permits
comparisons of binder or material performance, per se, independently of briquette size.
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1 Rhys Jones, D.C., 1963. In: Lowry, H.H. (Ed.), Briquetting, Chemistry of Coal Utilization,
(suppl. Vol.). Wiley, New York, NY, Ch. 16, pp. 675-753.
2 Schinzel, W. 1981. In: Elliott, M.A. (Ed.), Briquetting, Chemistry of Coal Utilization, (2nd
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7 See for example: ASTM D440-49, D3038-72 and BS1016: Part 13.
8 See for example: ASTM D441-45, D3402-81 and BS1016: Part 13.
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