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Session 2 Module 1 Coal Blending

Coal blending involves mixing different grades of coal to improve combustion properties and reduce costs. It requires understanding the properties of each coal, such as calorific value, ash content, and grindability, as the properties of the blended coal may not be a simple average. Compatibility testing using techniques like DTG and DSC analysis is important before blending to avoid issues from differences in burning profiles. The right blending ratio and method must be selected and maintained based on factors like ash fusion temperatures and slagging and fouling tendencies. Trial runs at power plants are needed to monitor the effects of blending on operations. Proper infrastructure and testing is necessary to ensure blended coal performs as expected.

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Arjun Mac
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129 views13 pages

Session 2 Module 1 Coal Blending

Coal blending involves mixing different grades of coal to improve combustion properties and reduce costs. It requires understanding the properties of each coal, such as calorific value, ash content, and grindability, as the properties of the blended coal may not be a simple average. Compatibility testing using techniques like DTG and DSC analysis is important before blending to avoid issues from differences in burning profiles. The right blending ratio and method must be selected and maintained based on factors like ash fusion temperatures and slagging and fouling tendencies. Trial runs at power plants are needed to monitor the effects of blending on operations. Proper infrastructure and testing is necessary to ensure blended coal performs as expected.

Uploaded by

Arjun Mac
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Coal Blending

Pankaj Ekbote
NTPC Ltd
Why Blending
•
Adequate coal supply from Indian sources not available
•
Reduce the Power generation cost
•
The low-grade coals can be mixed with better grade coal
•
improve the calorific value of coal being fired
•
mixing high grade imported coal with the low grade high ash coals
•
attempt to reduce cost, meet SO2 emission limits
Effect of blending and properties of
Agglomerate
•
Mixing any two coals without analysis may lead to more problems
•
The properties may not be the ‘average’ properties of the mix.
•
The individual constituent may retain:
• Fusion Temperature (Ash Characteristics)
• Grindabilty Properties (HGI)
• Combustion reactivity
• Swelling characteristics
•
Some properties may be additive
• Calorific Value
• Total Moisture
• Total ash
Before blending understand ……..
•
the origin of coal
•
chemistry of inorganic, organic part and the combustion properties &
behavior
•
The grindability of coal
•
The variation in ash content
•
Differential Thermo gravimetric (DTG)& Differential Scanning
Colorimetric (DSC) are used for Burning profile analysis before
deciding to blend.
•
The combustion efficiency and carbon loss will have to be also
addressed during blending of coals. It is also necessary to look into
the aspects of slagging, fouling and emission characteristics like NOx,
SOx and particulate.
Behavior and Compatibility

•
Coal with similar burning profile is expected to behave similarly in a
full scale boiler.
•
By comparing burning profile of an unknown coal with that of a coal
with known full scale performance, compatibility can be judged.
•
Comparison of burning profile temperature provides qualitative
assessment of coal reactivity
Ash fusion temperature
• Ash composition of two coal from different origin may be different.
• May have different ash fusion characteristics
• It is necessary to see that blended coal ash IDT should be higher than
FEGT temperature.
• Ash fusion temp is a measure to assess slagging and fouling
propensity of coal
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 resistivity
Prime Concerns
•
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
Aspects of Imported Coal
Imported coal has high VM (25-45%)
–Care to be taken to avoid spontaneous combustion in stack yard
–Control Mill inlet air temperature to maintain low mill outlet temperatures
•Imported coal has low Ash Fusion Temp
–Reducing atmosphere in Furnace
–Clinkering & Slagging tendency
Imported coal has Compatibility issues
•
–Secondary Combustion
•
–High Sulphur, SOx emissions
•
–Increase in Unburnt Loss
•
–Operation at High Excess Air
Blending Methods
Method How it is Done Done Where Benefits Difficulties

Bed Stacking of two coal in -Blending during reclaiming Only one system to run -Entire coal to be stacked first
yard in layers -Homogenization at transfer for bunkering coal -More running Hours for CHP &
blending point more APC
-Not possible to change ratio
Silo Bending Imported coal from Silo is -On conveyer below Silo V. accurate Blending High Capital cost
mixed with domestic coal - Homogenization at transfer ratio can be achieved
carried by conveyer below point -Ratio can be varied
Silo

Blending by Imported is Dozed to -At common transfer point Ground hopper is an


Ground ground Hopper - Homogenization at transfer additional Feeding rate is not accurate
Hopper Domestic coal is fed point Source of reclaiming
directly from track hopper
wagon tippler
Blending on Two types of coal are -At common transfer point Blending ratio can be -Entire coal to be stacked first
Moving Belt stacked in two yard of - Homogenization at transfer changed any time -More running Hours for CHP & more
(Both coal different stacker & point APC
reclaimed) reclaimers
Blending on
Moving Blelt
Imported coal is reclaimed -At common transfer Blending ratio can be Accuracy wise inferior to
from yard and Domestic changed any time
Imported
coal is directly fed from
point Only imported coal need
Silo blending
reclaimed & - Homogenization at transfer
Domestic - track track hopper/ wagon to stacked
Hopper) tripler point
Practical approach
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 for about a week like
SH spray
Steam temp
Exit gas temp
Unburnt carbon
Load on bottom ash collection after maintaining load
Steam pressure
Excess air
Mixture ratio
Conclusion
•Compatibility
of characteristics of two coals must be assessed before blending to
avoid combustion related problems.
•Optimum blend ratio needs to be determined and maintained during blending
(Based on AFT, Burning Profile &HGI)

•Proper Methodology for blending must be followed based on available infra


structure

•Blending in transfer point before bunkering ensures good mixing in different stages
& is the recommended practice

•For new projects provisions need be made for firing blended coals at design stage

•There’s a need to develop models for Indian coals, that could predict impact of coal
blends & coal quality variations on boiler performance
Thanks

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