Dr V T Sathyanathan

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Dr V T Sathyanathan

Coal Its Origin & Nature

Dr V T Sathyanathan
Retired General Manager, BHEL,Trichy 620014

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Dr V T SATHYANATHAN,

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 Vessels Limited Trichy
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Dr V T Sathyanathan

Dr V T SATHYANATHAN,

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 Was appointed as the enquiry committee member by Government of Tamilnadu, 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 Presented more than 40 papers in National and International Seminars. Write in www.brighthub.com 83 Articles as on June 11 My PhD work was referred by seven renowned universities abroad Teach Special Subjects In Horticulture - Art Of Bonsai & Cacti Mankind is in pursuit of truth, let us work towards this

Dr V T Sathyanathan

Arrangement
Coal - General Coal Formation Theories Indian Coal Formation, Properties & Behaviour

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Dr V T Sathyanathan

Coal General

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Drifting of Continents

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Large Swamps

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Coal formation theories

In-situ coal formation Drift theory of coal formation

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Coal formation theories

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In-situ Theory of coal Formation InCoal formed from a 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.
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Huge Tropical Ferns and Giant Trees in Vast Swamp Areas ( Wilfrid Francis, 1961 )

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Drift Theory of Coal formation

Coal is formed largely from terrestrial plant material growing on dry land and not in swamps or bogs. The original plant debris was transported by water and deposited under water in lakes or in the sea. There will not be a true soil found below the seam of coal. The transported plant debris, by its relative low density even when water logged, was sorted from inorganic sediment and drifted to a greater distance in open water. The sediments, inorganic and organic, settled down in regular succession according to their densities and to the diminishing velocities of the carrying currents. The process of sedimentation of the organic and inorganic materials continue till the currents can deposit the transported vegetation in the locations. These deposits are covered subsequently by mineral matters, sand etc. and result in coal seams.
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Drift Theory of Coal formation (Cont)

The depositions can also stop for a particular period and again begin to happen depending upon the tidal and current conditions. The coal properties vary widely due to the varied type of vegetations deposited. Even animal remains, algae plants and marine plants can be found to be deposited. This is not possible in the case of the insitu coal formation. It was the difference in coal properties of Gondwana coals that led to the formation of the drift theory.

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Gondwana land ( Stacks E., et al )

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Factors that Determine Composition of Coal

( Wilfrid Francis, 1961 )

Mode of accumulation and burial of the plant debris forming the deposits. Age of the deposits and the geographical distribution. Structure of the coal forming plants, particularly details of structure that affect chemical composition or resistance to decay.
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Factors that Determine Composition of Coal (Cont)

(Wilfrid Francis, 1961)

Chemical composition of the coal forming debris and its resistance to decay. Nature and intensity of the peat decaying agencies. Subsequent geological history of the residual products of decay of the plant debris forming the deposits.
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Indian Coal Formation, Properties & Behaviour

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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 shale 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.
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Dr V T Sathyanathan

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

Dr V T Sathyanathan

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

Dr V T Sathyanathan

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

Dr V T Sathyanathan

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

Dr V T Sathyanathan

Macerals in Indian Coal

A : Vitrinte B : Heat Affected Vitrinite C :Oxidised Vitrinite D : Semi-Fusinite E : Composite Maceral Rich in Fusinite
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Oxidised and Weathered Coal Macerals

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Oxidation in Coal Results

( Gray R. J., et al., 1974 ).

Poor coke Poor combustion Poor liquid conversion Reduced volatile matter Increased fines and dust problems Decreased free swelling index

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Dr V T Sathyanathan

Carbonaceous Shale in Indian Coal

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Coal Petrography & Combustion

Petrographic analysis of coal was used to evaluate the pulverized coal combustion right from 1968 The petrographic composition affects the ignition process, combustion and the efficiency of combustion. (Yavorskii I.A 1968) Combustion efficiency of the coal being burnt is inversely related to the inert maceral content of the coal i.e. semi-fusinite, fusinite and oxidised vitrinite Indian coals are found to have oxidised macerals in many cases which effects combustion Composite macerals are also often found in Indian coals which results in higher carbon loss
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Ash Properties & Behaviour

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Inorganic Compounds Four Groups

Inorganic matter from original plants Inorganic - organic complex minerals formed due to inorganic and organic interaction during the first stage of coalification process. Minerals introduced by water or wind into the coal deposits as they were forming. Minerals deposited, during the second phase of coalification process
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Ash Properties & Behaviour

Combustion & ash deposition in a boiler is an complex process Coal devolatilisation Char combustion Mineral matter transformation Fly ash formation, transport & deposition Each of the above is influenced by Heating rate Temperature regime Localised gaseous environment Bulk & local fluid dynamic condition

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Ash Properties & Behaviour (cont.)

Slagging & fouling propensity of coals The viscosity of laboratory ash Ash fusion temperature Various laboratory ash composition ratios Iron : calcium Silica : alumina Base : acid Sodium-in-ash content Total alkali metal content in laboratory ash Segregation of ash during pulversing & its properties
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Ash Properties & Behaviour (cont.)

In a Study Supported by EPRI Unusually complete sampling and analysis of coal, deposits and fly ash along with detailed operating records led to the following conclusions:
Analysis of ash by coal density fractions showed distinct differences between high slagging and low slagging coals Coal preparation to lower ash content also would decrease the slagging potential High specific gravity fraction in slagging coals had calcium content expected to form low viscosity drop-lets downstream of the flame Glassy spheres of melted ash making up furnace deposit came from individual particles of pulverised coal Unidentified mineral fractions which melted between 850 deg C and 1100 deg C Spherical particles in contact with wall tube in furnace deposits high in SiO2 & Al2O3.
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Ash Properties & Behaviour (cont.)

Operational experience on slagging fouling and corrosion in large dry bottom boilers have proven that the tendency towards a conservative design is the right way to minimise problems and damages. But It has to be stated that because of insufficient knowledge of the coal constituents - macerals & minerals - it is not yet possible to propose an optimal design.
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INDIAN COALS Vs OTHER COALS

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Deterioration of Coal Quality Available for Power Generation Over the Period
1970s PROXIMATE ANALYSIS FIXED CARBON VOLATILE MATTER MOISTURE ASH HHV HGI % % % % kcal/kg 36.5 25.5 10.0 28.0 4750 50 32.4 21.6 16.0 30.0 4050 50 25.0 18.0 12.0 45.0 3000 50 2800 50 1980s 1990s 2000s

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Indian Coal Vs USA Coal

PARAMETER HEAT DUTY FUEL FIRED HHV QUANTITY OF FUEL AVERAGE ASH CONTENT QUANITY OF ASH mcal/h. INDIAN UNIT 210 MW 500 MW 454 1070 1215 3800 320 40 128 USA UNIT 210 MW 500MW 454 520 6000 87 8 7 1070 1215 6000 202.5 8 16.2

mkcal/h. 520 kcal/kg. t/h. % t/h. 3800 137 40 55

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Amount of Coal / Ash Handled Over the Period

HHV Unit rating ASH Fuel fired Ash produced kcal/kg mw % t/h t/h 4750 210 28 110 30.8 500 28 272 76.2 4050 210 30 129 38.7 500 30 319 95.7 3000 210 45 174 78.3 500 45 430 193.5

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Dr V T Sathyanathan

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