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Coal Drying and Grinding

Drying
And

Grinding
Of

Coal

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Coal Drying and Grinding

Table of contents

1. Introduction
2. Different coal types, composition and analyses
2.1. Analyses of solid fuel
2.2. Hard-grove Grindability Index
2.3. Abrasion Index
2.4. Coal Dewatering
3. Necessary Fineness of Coal
4. Drying of Coal
5. Mills for Grinding Coal
5.1. The Tirax Mill
5.2. Vertical Roller Mills
5.3. Ball Mills Compared with Vertical Roller Mills
6. Arrangement of Coal Grinding Plants
6.1. Direct Firing
6.2. Semi-Direct Firing
6.3. Indirect Firing
6.4. Central Coal Grinding Plants
6.5. Inert Coal Grinding Plants
7. Instrumentation and Automation of the Coal Grinding Plant
8. Raw Coal stocking
9. Filters and Coal-dust Hoppers
10. Safety Precautions
10.1. Temperature monitoring
10.2. Gas Analyzing Equipment
10.3. Inertisation System
10.4. Explosion Relief venting

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DRYING AND GRINDING OF COAL FOR FIRING IN


CEMENT KILNS
1. INTRODUCTION
During the last two decades a large number of existing cement plants
have been converted from oil to coal firing, and new cement plants
have often been arrange for coal firing. The growing interest in coal
firing was caused by the increase in oil prices during the seventies.

The coal grinding plants constructed since then have normally been
designed with due consideration to the latest regulations regarding
construction, lay-out and operation of coal handling facilities. The
current safety regulations, as well as the introduction of modern fuel
efficient kiln types, have had a great influence on the up to date design
of coal grinding plants, which will be dealt with in the following.

2. DIFFERENT COAL TYPES, COMPOSITION AND


ANALYSES
The volatile content of a coal normally depends on the age of the coal,
where the oldest coal type “Anthracite” has a very low volatile content,
and the youngest type “Lignite” a high volatile content.

In fig.1 is shown an example of coal types with typical contents of


volatile, ash and hygroscopic moisture.

In the later years “Petcoke” is taking over an increasing part of the


market due to an attractive price.

In fig.2 can be seen a description of petcoke. The petcoke used in the


cement industry is normally of the type called “Green Delayed
Petroleum Coke”.

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2.1 Analyses of solid fuel


When buying coal on the world market, the cement plant normally
receives a “Certificate of Analyses” based on which the plant is paying
for the coal. An example of such certificate is shown in fig.3.

The cement plant laboratory further makes analyses as shown in fig.4.


for determination of the net heat value and the ash composition, and
at times also the abrasion index and the grindability index.

The ash amount and composition is used to calculate the necessary


correction of the rawmix.

2.2 Hardgrove Grindability Index


All cost can be analyzed for grindability in the laboratory according to
Hardgrove. The grindability index is often named HG index or Just HGI.

The method is performed after either ISO 5074 or ASTM 409-93A. An


increasing HGI indicates an easier grindable coal.

In fig.5 is shown the relation between HGI and mill specific power
consumption for grinding to different sieves on 90μ in a ball mill.

In fig.6 is shown the same relation for grinding in vertical mill.

2.3 Abrasion Index


To be able to calculate the wear of the different parts in the grinding
installation, it is necessary to know the abrasiveness of the coal. The
abrasion index is investigated in the laboratory according to BS 1016,
part 19 (British Standard) and is measured in mg/kg. In FLS we define
normal abrasive coal to have a AI index not higher than 20 mg/kg.

The abrasion can also be expressed as a YGP index (Yancey Geer and
Price). The relation between YGP and AI index is as follows:

YGP=4xAI

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2.4 Coal Dewatering


Before the first start-up with a new type of coal, it is advisable to make
a dewatering curve. The determination of the dewatering curve is
shown in fig. 7.

In fig. 8 can be seen dewatering curves for different coal types. Based
on the dewatering curve can be selected the most appropriate and
safe mill outlet temperature for the first start-up.

3. NECESSARY FINENESS OF COAL


To ensure a complete combustion of the coal dust, this must be
ground to a fineness which is dependent of the content of volatiles and
where to be burned.

In fig. 9 is shown the recommended fineness of coal dust for calciner


and kiln as a function of the volatiles (daf) content.

Of importance is also the relation between the 90μ residue and the
200μ residue. The coarse particles will ignite later and may course CO
and temperature increase later in the kiln system.

In fig.10 can be seen the max: recommended value of 200μ residue in


relation to the 90μ residue. In general the 200μ residue must be as
small as possible.

4. DRYING OF COAL
The moisture content of raw coal of various types may well vary
within wide limits. It is necessary to dry the coal in order to facilitate
procedures during the grinding, transport and possible storing
processes.

Beside the free moisture which evaporates at ambient temperature,


the coal contains “hygroscopic” or inherent water, which could be
defined as water evaporating by heating from 30° to 105°C.

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The risk of fire and explosions can be limited considerably, if the coal
meal is produced with a certain content of residual water.
The recommended residual water content depends on the content of
hygroscopic moisture in the raw coal. As a guideline can be
recommended to dry 1-2 % away of the hygroscopic water.

The residual moisture for different coal types typically lies in the
following range:

Anthracite coal and petcoke: 0.5 – 1.00 %

Bituminous coals: 1.5 – 2.50 %

Lignite coals: 8.0 –12.0 %

Before the initial start of a coal grinding plant and when shifting from
one type of raw coal to another, a dewatering curve should be made.
This dewatering curve should indicate residual water vs. temperature.
A typical dewatering curve appears in fig.11. Based on the curve can be
selected mill outlet temperature which gives the correct residual
moisture. In this example is found that the set point of the mill outlet
temperature shall be 65°C to obtain a residual moisture of 1.5 %.

In practical mill operation is normally seen, that a somewhat higher


mill outlet temperature is needed to obtain the wanted residual
moisture. The reason for this is, that the retention time for coal dust is
much shorter in normal mill operation then in the laboratory oven.

In fig. 12 is shown a practical example for illustration of the selection of


set-point and maximum temperature levels based on the actually
obtained residual moisture.

It is usually found that the coal mill should be operated with an outlet
temperature of 65° - 75°C and in certain cases, up to approximately
80°C. To avoid condensation in ducts and filters, the temperature after
a coal mill should be 15° - 25°C higher than the dew point.

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Relation between dew point after the mill, quantity and temperature
of the drying air, and the moisture content of the raw coal appear from
fig. 13. It should be noted that the dew point is solely dependent on
the temperature of the drying air and is an increasing function of this
temperature. Regarding the dew point, a temperature of the drying air
of 300° - 350°C or lower appears to be appropriate. As an example, the
following figures can be read from the diagram. If the moisture content
in the raw coal is 10% and drying air from a cooler of 300°C is available,
1.2 kg dry air per kg of dry coal will be needed for drying, and the dew
point after the mill will be approximately 52°C. The residual moisture
in the coal meal has not been included in the calculation.

In case of new mill installation, a dew point calculation is always done


as a part of the process design calculations. In existing installations the
best way is to go and measure the dew point in the air after the
dedusting filter.

5. MILLS FOR GRINDING COAL


For coal grinding can be used grinding machinery such as the vertical
mill, the ball mill, the Alrilor coal pulverizer, the horizontal impact
crusher, the roller press etc.

In this lecture is only described the ball mill and the vertical mill, as
these two grinding systems are the most common used.

5.1 The Tirex Mill


The Tirex mill shown in fig. 14 is a ball mill design for drying and
grinding. The material first passes through a drying compartment with
lifters. In coal mill of older designs, the grinding was carried out in two
grinding compartments.

However, grinding in larger mills with high capacity and drying by


means of inert gas of low temperature implies that the velocity of the
air through the mill will usually be high. In order to reduce the

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differential pressure over the mill, the mills of today are arranged with
only one grinding compartment and classifying lining.

The Tirax mill is a fully air swept mill, so all the mill discharge material
is transported to the separator by air. In previously designed mills, the
coarse reject material from the separator was transported back to the
mill through the outlet trunnion to the fine grinding compartment. At
high air velocities, this arrangement is considered to be inconvenient.

Instead, the coarse return material is transported to the inlet end of


the mill by a screw conveyor. In the feed chute, the dry material reject
is mixed with the wet raw coal thus eliminating the risk that the
material ignites at the inlet to the mill.

The separator is often of the static type. Control of the separation is


performed by vertical displacement of an internal central tube for the
smaller sizes and by vane settings for the larger sizes. Changing the air
velocity through the separator will also have some influence on the
separation.

In fig. 15 can be seen the recommended ball charge for Tirax coal mill.

5.2 Vertical Roller Mills


Vertical mills for grinding coal are produced by a number of
manufacturers. Some could be mentioned: Raymond, Loesche, Pfeiffer,
Polysius, B & W and FLS.

Fig. 16 illustrates an FLS ATOX mill.

Coal grinding takes place between a rotating table and three grinding
rollers. The raw coal is fed to the center of the table and from there it
passes between the rollers and the table. After being ground, it flows
over the edge of the table and enter the racing current of the hot air
coming through the air nozzle ring encircling the grinding table.

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The ground coal is carried by the air to the built in static or dynamic
separator. The course particles are, via reject cone, return to the mill
for further grinding while the fine particles exit the mill with the air
through the mill outlet.

For the latest precalciner kiln systems, both ball mills and roller mills
equipped with dynamic separators to improve the combustion process
in the precalciners.

5.3 Ball Mills Compared With Vertical Roller Mills


For grinding an average coal (HGI 55 and 10% > 90μ), the vertical mill
consumes about 9 kWh/t for the mill motor and 8 kWh/t for the fan,
i.e. in total 17 kWh/t. Under the same conditions the Tirex mill will
consume about 19kWh/t for the mill motor and 4kWh/t for the fan, in
total 23kWh/t. Thus, the vertical mill consumes approx: 25 % less
energy than the ball mill. This corresponds to about 0.7kWh/t of
clinker.

The Atox mill requires larger amounts of air for material transport than
the Tirax mill. Consequently, when the coal is ground in a vertical mill,
larger quantities of air needed to be dedusted than when grinding
takes place in a ball mill.

On the other hand, since the vertical mill requires and allows a higher
air flow than the ball mill, the vertical mill has a higher drying capacity.
For comparison of Tirax mills and vertical mills, the advantages of the
latter could be summarized as follows:

Advantages:
1. Lower energy consumption
2. Higher drying capacity
3. Output capacity can easily be varied within a wide range
corresponding to the fuel consumption of the kilns
4. Fast feed-output response
5. Accept larger feed sizes; up to 80mm

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6. Lower noise level


7. Requires less building volume

Disadvantages:
1. Larger quantity of air to be dedusted
2. Lass suitable for abrasive coal. Wear parts are expensive and
replacement causes downtime
3. Sensitive to variations in feed rate and feed quality
4. Higher maintenance costs

The vertical mill is to day dominating for new mill installations.

6. ARRANGEMENT OF COAL GRINDING PLANTS


Various factors have to be taken into consideration when arranging a
coal grinding plant:

• Quality of coal
• Supply of hot air for drying
• Type and number of kilns
• Investment cost
• Maintenance cost
• Reliability

Based on an evaluation of these matters, decision can be made


regarding the following:

• Direct, semi-direct or indirect firing


• Inert or non-inert operation
• Ball mill or vertical roller mill
• Bag filter or ESP for possible dedusting

6.1Direct firing
Direct firing implies a simple and cheap installation (fig. 17).
Adjustment of fuel to the kiln are adjusting the coal feed rate to the
mill. This arrangement includes neither a filter nor coal meal bin and

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has therefore been considered safer than other arrangements, as far


as fires and explosions are concerned.

Today however, very few coal grinding plants in the cement industry
are arranged for direct firing since this simple system has serious
drawbacks compared to other arrangements:

• Any mill stop will cause a kiln stop.


• Varying and inaccurate dosing of fuel to the kiln causes higher
fuel consumption than for arrangements with a more accurate
coal feeding system.
• All the mill vent air goes to the kiln as primary air. This will also
cause an increase in fuel consumption. The amount of mill vent
air is larger than the amount of primary air necessary for
combustion of the coal in a modern fuel efficient cement kiln
system. By operating with an excess amount of primary air,
less hot air from the clinker cooler is used as secondary air.

An example of the calculation for the primary air and the gas amounts
from vertical and ball mills is shown on fig. 18 for direct firing. A
relation between the amount of primary air and the increase in heat
consumption of the kiln is indicated in fig. 19.

Further, the water vapor coming from the mill and entering the kiln,
together with the primary air, has to be heated up to the kiln exhaust
gas temperature. This contribution to the heat consumption of the kiln
appears in fig. 20.

6.2Semi-Direct Firing
Semi-direct firing system only differs from the direct firing installation
by a silo for ground coal install between the precipitating cyclone and
kiln (fig. 21). This silo for coal meal implies that the kiln will be less
dependent on the operation of the mill. The coal meal is extracted
from the silo by one or more feeding apparatuses. The mill vent air

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goes to the kiln burner, as was the case for the arrangement for direct
firing.

6.3Indirect Firing
Indirect firing arrangements are today the most common in new
cement plants (fig. 22). A coal silo and a filter for dedusting the mill
vent air are included in the arrangement.

Consequently, by using this arrangement, the primary air for the kiln
burner can be reduced to an amount which is necessary for proper
burning of the coal. The kiln can also be operated with minimum fuel
consumption.

6.4Central Coal Grinding Plants


Indirect firing can be arranged as a central coal grinding plant. It can
have its own separate supply of hot air from an auxiliary heat
generator, and it will have a number of coal meal silos, each one with
equipment for feeding coal meal to a kiln. Central coal grinding plants
are often applied for cement kilns with precalciners and are obviously
suitable to supply coal to a number of kilns. Examples of central coal
grinding plants are shown in fig.23 and 24.

The coal mill systems described so far have been supplied with hot air
for drying from a clinker cooler, a kiln hood or an auxiliary heat
generator.

For temperature control, the hot air is usually mixed with a certain
amount of cold ambient air. The mix of air to mill will, in all cases, have
oxygen content close to 21% as for atmospheric air and the operating
conditions are called non-inert.

6.5Inert Coal grinding Plants


It is well known that explosions occur in the coal grinding plants. The
following conditions are required before an explosion can take place:

1. Dry coal meal of suitable fineness.

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2. Coal dust concentration in the air between 100 and 2000g/m³.


3. Ignition source.
4. Oxygen content higher than 12-14%.

A condition for a coal dust explosion to take place is that the O ₂


content of the air should exceed the following limits:

14% O₂ for ordinary bituminous coal

12% O₂ for lignite coal

If a coal grinding plant can be operated with an O₂ content in the


process air below these limits, coal dust explosion will not take place.
When these conditions are fulfilled, the coal grinding plant is, per
definition, operated under inert conditions.

Kiln exhaust gas with an oxygen content of typically 3-5% is obviously


suited as drying gas for an inert coal grinding plant (fig.25).

The inert conditions of the plant are monitored by a reliable oxygen


analyzer at the coal mill filter outlet. If the oxygen content exceeds
10%, the analyzer will first cause an acoustic alarm allowing time for
the operator to remedy possible irregularities. However, at 12% O ₂ the
plant will stop operation automatically.

Before the mill start, it is necessary to lower the oxygen content after
the filter to less than 10%, which is a start condition for the mill. This is
achieved by drawing a modest flow of inert kiln gas through the coal
grinding system. During this pre-start process, the mill exit
temperature must be kept below the maximum temperature alarm
limit.

7. INSTRUMENTATION AND AUTOMATION OF THE


COAL GRINDING PLANT
Fig. 26 show an example of instrumentation, including automatic
controllers recommended for a coal grinding plant.

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It is very important to maintain a constant temperature after the mill.


In this case, it is achieved by automatic control of a cold air valve
letting cold air into the hot air from the clinker cooler.

At the entrance of the mill there must be a small negative pressure to


avoid dust leaking out. This pressure must be regulated since an overly
high negative pressure may cause an excessive amount of false air to
leak in to the system. The pressure is maintained by controlling the
damper before the hot air booster fan.

The feed rate to the mill is controlled by constant monitoring of the


noise level from the mill. The operator will decide when to start the
grinding plant and often also when to stop it again.

Start and stop of the individual machinery takes place in certain


sequences controlled by the electrical interlocking system. The
electrical interlocking system may, however for safety reasons, also
cause an automatic stop of the operation. This may, for instance, be
the case if a coal meal silo is filled to capacity or if mill exit
temperature exceeds the upper of the two maximum alarm limits.

8. RAW COAL STOCKING


Today, coal of varying quality is used, and blending is therefore
necessary. Fig. 27 shows an example of short term storage for coal
with a high blending effect.

The main problem with coal stock pile is “spontaneous combustion.”


Coals vary a great deal in the tendency to take up oxygen. In general,
the tendency is relatively low for high rank (low volatile) coals. It is
higher for coals of high bed moisture content, high oxygen content,
and high volatile content, all of which characterize a low rank coal.

An important factor in the heating process is the total surface area of


the coal exposed to the air: the larger the surface, the greater the risk
for the coal to absorb and react with oxygen.

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For long-term storage in open stockpiles, the following rules and


guidelines are important:

• The storage site should be dry, even and clean and with good
drainage.
• Straw, wood, oily rags and other combustible material must be
avoided in the storage area.
• The coal delivered to storage should be spread over the entire
to a thickness of 0.5m and then compacted before new layer
are put on the pile. A practical and effective approach to
sealing a coal pile is a continuous layer of fine coal followed by
a covering of lump coal to prevent loss of the seal through the
action of wind and rain.
• If possible, sized coal should be stored with the fines removed.
In such piles, the relatively small coal surface area develops
only a small amount of heat which can readily dissipate.
• The temperature of the coal pile should be tested periodically.
• If possible, the storage should be covered, for instance with
plastic and/or a thin layer of raw meal.

Raw coal silos


It is important that the raw coal silo is design for “mass flow” (opposite
of core or funnel flow), to ensure that the silo contains no passive
zones where the coal can accumulate.

This is obtained in following way:

• A steep bottom cone inclination ≥ 70°


• Inside lining of the cone with ceramic or stainless steel
• The bottom opening as big as possible

9. FILTERS AND COAL DUST HOPPERS


There are particularly two places in the coal grinding plant where a fire
could develop:

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• The filter
• The coal dust hopper

The filter could be a bag filter or an electrostatic precipitator. The


advantage of bag filter is its low price. Disadvantages are the higher
pressure drop and higher maintenance costs. When using a bag filter,
the air and coal meal from mill separator can be taken directly to the
filter. This is not the case for an electrostatic precipitator.

Air from the mill separator, with coal meal in suspension, must be in a
cyclone before going to an electrostatic precipitator, in order to reduce
the dust concentration to a safe level before the air and residual dust
enters the electrostatic field of the filter.

If fire occur in a bag filter, normally all bags must be replaced. To


ensure a safe operation, both types of filters should be equipped with
the following:

1. Knocking devices at the bottom hopper


2. CO analyzer
3. Thermometers
4. Equipment for inertisation with CO₂ or N₂
5. Explosion venting devices
6. Heating of bottom hopper with low temperature heat tracing

Coal meal silos should be equally well equipped with safety devices
shown in fig. 28.

10. SAFETY PRECAUTIONS


A modern coal grinding plant is equipped with several arrangements,
first for avoiding fires and explosions, secondly for fire fighting and last
for reduction of damage in case of explosion.

• Electrical safety interlocking of machine and process


• CO monitoring
• Inertisation system

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• Explosion relief venting.

In fig. 29 is shown a flow sheet with dedusting in a bag filter and a coal
dust hopper with extraction to kiln burner and calciner. It can be
noticed that the filter is equipped with sealing off valves, and that the
coal dust from the filter can be transported out of the system instead
of to the coal dust hopper. This possibility can be used in combination
with fire fighting in the filter.

10.1Temperature monitoring
As well mill filter as coal dust hoppers are equipped with processes
temperature monitoring, which is a part of the electrical safety
interlocking. It is very important that this equipment and the electrical
interlocking always is functional.

10.2 Gas analyzing equipment


A gas analyzer measure continuously the CO level in filters and coal
dust hopper. In case of inert grinding, also the O₂ level is measured
after the main filter outlet. The measured value goes into the electrical
safety interlocking.

It is not possible beforehand to inform of the alarm limits for the CO


level, as this is different from one coal to another. The best way is to
observe where the CO level during mill standstill is stabilizing and then
set the alarm limit 100ppm higher than this.

If a fire is developing, it is normal to observe a very sharp increase of


the CO level. If the mill receives heat from kiln preheater, the CO level
during mill operation shall not go into the electrical interlocking, as it
most certain comes from the kiln. In this situation the CO level is used
as a startup interlocking.

10.3Inertisation system
In case of fire in filter or coal dust hopper is used CO₂ or N₂ injection
for fire fighting.

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Injection with CO₂


CO₂ is the most common used media for fire fighting.

The CO₂ can be supplied from either a central CO₂ tank or a battery of
CO₂ bottles.

The CO₂ amount for inertisation of a given volume is 2kg of CO₂ per m³
free volume.

Injection with N₂
N₂ can be used in the same way as CO₂ for fire fighting.

N₂ is normally supplied in a battery of bottles due to the high pressure


(200 bar).

The N₂ amount for inertisation of a given volume is 1kg of N₂ per m³


free volume.

10.4Explosion relief venting


If, in spite of all precautions, an explosion should occur, it is necessary
to relieve the explosion pressure to the outside (of building) to avoid
damage on personal and machinery.

In fig. 30 is shown the two most common types of explosion relieves,


the busting disk and the self closing relief valve.

The self closing valve is the more expensive solution, but also the best,
as it do not need to be replaced after the explosion, and because it
very fast again closes to the surroundings.

The necessary opening area for explosion venting, and thereby the
amount and size of the relief valves, depend on the type of coal to be
ground in the installation.

In fig. 31 is shown a table of coal classification based on which the


necessary explosion venting area can be calculated.

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General Comments:
Aside from the already mentioned safety precautions, the following
tips should be added to the list regarding safety of coal grinding plants:

• The arrangement for feeding raw coal should be designed to


ensure a steady feed of raw coal to the mill. Feed failure and
subsequent increase of temperature in the mill have caused
explosion in the plant.
• Horizontal surfaces, where coal dust may settle, should be
avoided to the greatest possible extent. This applies inside as
well as outside the machinery. Duct should have proper
inclinations (minimum 60° upward and 45° downward).
• Gas velocity in ducts: minimum 20m/s.
• Mill separator, duct between separator and filter, filter and
coal meal silos should be fitted with pressure relief valves,
which must open to the outside air, not inside buildings.
• The installation should be well maintained. This includes
mechanical maintenance, electrical maintenance, and in
particular, safety equipment.
• Building and machinery should be kept clean.
• Finally, but not less important: Common sense must prevail
when operating a coal grinding plant. Common sense,
combined with a properly designed plant and machinery which
is in accordance with current industrial standards, reduces the
risk of operation of a coal grinding plant to a minimum.

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Fig.1

Typical values of volatiles,


ash and hygroscopic moisture for
different coal types

Coal type Volitiles Ash Hygroscopic


moisture
% % %
Anthracite <8 3--5 <2
Semi-anthracite 5--15 3--5 2--6
Quarter rich coal 15--20 5--8 2--6
Bituminous coal 20--30 8--15 2--6
Rich coal 30--40 10--20 2--6
Lignite 40--50 15--30 10--15

Petcoke < 15 <2 <1

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Fig.2

Petroleum coke
Petroleum coke is black solid, obtained mainly by cracking and carbonizing residue
feed stocks and from the distillation of heavier petroleum oils. The main commercial
applications of petroleum cokes depend on their properties and they are typically used
as energy sources for solid fuel application such as lime and cement kilns and
sometimes as fuel for boilers and power generation. Some calcined cokes are used in
the manufacturing of electrodes for aluminium and steel electro-melting.

Petroleum coke exists in the following basic forms:

1. Green coke is the immediate product of a semi-continuous batch coking


process known as delayed coking, which contains significant residual
hydrocarbon content.
2. Calcined coke, a product derived from green coke, in which the
hydrocarbons have been removed by heating under reducing conditions in
kiln to temperatures in excess of 1200°C.
3. Fluid coke, the product of a continuous fluidized-bed coking process.
4. Flexi coke, a product from the continuous fluidized-bed coking process, in
which the major part of the coke is gasified to a low calorific value gas for
refinery use.

Green coke (delayed coke) has a distinctive hydrocarbon smell. It can contain up to 15%
volatile material, mostly hydrocarbons, including polycyclic aromatic hydrocarbons
(PAHs). Calcined coke purity is largely feedstock dependent. Needle coke and regular
coke are calcined cokes of different purities, the needle coke being the purer from
which is used for electrodes production.

Calcined coke, as a consequence of the calcining process, has a virtually zero volatile
content. It is inherently a much dustier material than green coke and depending on its
use it is usual to add a small amount (0.3% wt or less) of high viscosity oil or a very
small amount of surfactant usually in a water solution to act as a dust suppressant.

Fluid coke has spherical grains and contains less volatile material than green coke. The
normal grain size of fluid coke is less than 6 mm. Flexi coke is similar to fluid coke but
contains even less volatile material and has much finer grains and thus is more dusty.

Green coke
Bulk Density 0.70-0.90 kg/dm³
Real Density 1.35-1.45 kg/dm³

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Fig.3

CERTIFICATE OF ANALYSIS
! June 1, 1995

VESSEL NAME: CASTILO DE ALMANSA


CARGO DESCRIPTION: Green Delayed Petroleum coke
LOAD PORT: Houston, Texas
DATE OF LOADING: May 26-30, 1995

PROXIMATE ANALYSIS As Received Dry


% Moisture 6.35 -
% Ash 0.45 0.59
% Volitile Matter 9.49 10.41
% Fixed Carbon 83.71 89.00-

ADDITIONAL ANALYSIS

% Sulpha 4.04 4.31


Gross BTU/lb 14,432 15,411

Hard grove Grindability Index 42

NOTES
Representative sample of Green Delayed Petroleum Coke were obtain in
accordance with ASTM standards during actual loading of M/V CASTILLO
DE ALMANSA on May 26-30,1995.

Composit samples prepared and analysis conducted in accordance with


applicable ASTM standards.

Cargo loaded reported to be 53,699,590 metric Tons

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Fig.7

Determination of Dewatering for Coal


The determination is made as follows:

1. To begin with, crush a representative raw coal sample to 5mm.


Weigh out 500grams of the sample and spread it in an open
tray to a thickness of approx: 1cm.
2. Dry the sample for 24hrs at 30°C. Coal weight after drying: is
W₃₀g.
3. Now dry the sample for 5hrs at 50°C. Weight after drying: is
W₅₀g.
4. Dry the sample further for 5hrs at 65°C. Weight after drying: is
W₆₅g.
5. Dry the sample further for 5hrs at 85°C. Weight after drying: is
W₈₅g.
6. Finally, dry the sample for 2.5 hrs at 105°C. This will expel all
water. Weight of dry coal: W₁₀₅g.

On this basis, the water content of the coal after drying at t° C can be
calculated for each of the five operations, since the water content is
calculated in percent of the weight after drying at the temperature
concerned:

(Wt-W₁₀₅) x Wt / 100 %
The dewatering curve is drawn by plotting in a co-ordinate system: the
water content, thus found as a function of the rising temperature.

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Fig.15

Recommented Ball charge


for
Tirax Coal Mills

Raw coal feed, precrushed to - 15mm

Older 2 compartment mills.

ф in mm 1st.Comp: Wear Comp: 2nd. Comp: Wear Comp:


50 25% 50% * *
40 40% 50% * *
30 35% * * *
25 * * 40% 100%
20 * * 40% *
15 * * 20% *
(All amounts by weight)

Single compartment mill with classifying lining.

ф in mm 1st.Comp: Wear Comp:


50 11% 25%
40 18% 25%
30 16% 50%
25 22% *
20 22% *
15 11% *
(All amounts by weight)

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Fig.18

Direct Firing
L min: Antracite coal = 0.00139 kg air/kcal
Fuel = 0.00141 kg air/kcal
Lignite = 0.00143 kg air/kcal

Kiln fired with antracite coal: Bn = 6000 kcal/kg

L min = 0.00139 x6000 = 8.34 kg air/kg coal

Kiln System

% Primary air kg air/kg coal


10% 0.834
15% 1.25
20% 1.67
30% 2.5

Vertical Mill Ball Mill

Min kg air/kg coal Min kg air/kg coal

Nozzle ring = 1.7-1.8 Mill air = 1.2


False air = 0.2 False air = 0.3-0.4
Water vapour = 0.2 Water vapour = 0.2
Total = 2 kg air Total =1.6 kg air

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Fig. 31

Classification of coal

Coal type Kst -value Pmax - value Volatiles


bar x m/s bar %

Lignite 150 9.3 >36


High volitile
120 9.3 26--36
bituminous
Low volitile
90 86
8.6 11 26
11--26
bituminous
Pet coke 60 6.9 8--11

Anthracite 1 0.6 <8

Kst reflacts the speed and strength of the pressure


wave from the explosion.

Pmax gives the max: pressure to be reached


in a closed container.

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