EFFECT OF SURFACE MOISTURE IN COAL ON UNIT

HEAT RATE AND OPERATING COSTS FOR INDIAN

04-02-2015
THERMAL POWER PLANTS

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 INTRODUCTION

The installed capacity of the country is ~250 GW out

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of which ~140 GW is the share of coal based power
generation (~ 57 %).

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Coal is contributing to ~ 1.5 % of the GDP as it is the
main energy source for power generation.

Nearly 60 % of the coal is transferred from the mine

to the power plant through Indian railways, 25 %
through trucks and the balance through dedicated 2
transfer systems such as merry-go-round-systems,
etc.
 INTRODUCTION

Indian coal

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being of drift origin are of high ash (25-50 %)
Gross Calorific Values (GCV) in the range of 2300-4500
kcal/kg.

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Sulphur (< 0.6 %) is not a problem except in very few
specific mines.
Coal utilization efficiency (before it is used in the
boilers ,i.e., from mills till bunkers) is in the range of
80-98 %.
The main non chemically reactive ingredients in coal
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which result in the drop in GCV are ash and moisture.
 COAL QUALITY

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Due to the open cast mining process, besides the inherent ash
the extraneous mineral matter (clay, sand, and stones
generally referred as mud) also gets mixed up with the coal is
called as extraneous ash.

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It is not ash, techno commercially it is called as extraneous
ash because it is an incombustible component.
Extraneous mineral matter can be removed through washing
processes typically the run of mine jig wet washing process.
Inherent ash cannot be removed except by complex and cost
chemical methods in small sample sizes at the laboratory
scale
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 COAL QUALITY

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Moisture in coal consists of inherent moisture (IM) and
surface moisture (SM). Then total moisture (TM) is a sum
of IM and SM.
Equilibrated Moisture means the moisture content, as

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determined after equilibrating at 60% relative humidity
(RH) and 40 C as per the relevant provisions (relating to
determination of equilibrated moisture at 60% RH and 40
degree Celsius) of BIS 1350 of 1959).
Surface moisture is the difference between total moisture
and inherent moisture and is also called as excess moisture
(EM).
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 COAL QUALITY

IM or equilibrated moisture is a non controllable

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parameter.
SM is an added quantity and can vary in any range.
Hence TM is affected by the criticality of SM. This

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brings down the GCV of coal (thermal content of
coal) which reduces the output it delivers, reduced
boiler efficiency and unit overall efficiency.
Wet coal is difficult to handle
movement in conveyors, chutes, hoppers, bunkers
and pipes 6
Grinding, milling and flowability
COST OF COAL (Rs./GCal) AS PER COAL INDIA
PRICES

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GROSS CALORIFIC VALUE, RUN OF COST OF
kCal/kg MINE COAL HEAT (FOB),
GRADE OF PRICE, Rs./GCal
COAL MIN MAX MEAN Rs./t

G1 7000 7000 3542 506

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G2 6700 7000 6850 3393 495.33
G3 6400 6700 6550 3244 495.27
G4 6100 6400 6250 3032 485.12
G5 5800 6100 5950 2886 485.04
G6 5500 5800 5650 2360 417.70
G7 5200 5500 5350 1840 343.93 7

G8 4900 5200 5050 1700 336.63

 RUN OF COST OF
MINE HEAT
GROSS CALORIFIC VALUE, kCal/kg COAL (FOB),
GRADE OF PRICE, Rs./GCal

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COAL MIN MAX MEAN Rs./t

G9 4600 4900 4750 1500 315.79

G10 4300 4600 4450 1400 314.61
G11 4000 4300 4150 1130 272.29

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G12 3700 4000 3850 910 236.36
G13 3400 3700 3550 690 194.37
G14 3100 3400 3250 610 187.69
G15 2800 3100 2950 510 172.88
G16 2500 2800 2650 474 178.87
G17 2200 2500 2350 420 178.72 8
 GRADUAL RISE IN COST [FOB (FREIGHT ON
BOARD)] OF IMPORTED COAL OVER THE YEAR

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120
FOB cost of imported thermal coal, $/t

100

80

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60

40

20

0
1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 9
Year
 DROP IN GCV OF COAL FOR 1 % MOISTURE
INCREASE

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60
Drop in GCV (kcal/kg) for 1 % moisture

y = 0.01x + 6.1
55

50

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45

40

35

30
3000 3500 4000 4500 5000 10
Calorific value (kcal/kg)
 EFFECT ON COAL MOVEMENT AND
HANDLING IN THE COAL YARD

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IM - affects the coal combustion process,
SM - gives rise to difficulties in handling (transfer and
flow ability) of coal with severe capacity reduction of all
equipment in the coal plant ranging from crushers to

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conveyors.
Units tripping on mill choke up, load hunting due to
insufficient flow from bunkers, raw coal feeder jam, etc.,
are quite common during this period.
Even though the bunker level may be full, only 30 % of
the bunker capacity can be utilized due to bonding of
coal at the bunker periphery and flow is only through rat 11
hole in the bunker centre.
 EFFECT ON COAL MOVEMENT AND
HANDLING IN THE COAL YARD

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Rainy season restricts the plant load ability due to the
movement of sticky coal which contains clayey mineral
matter.
When the surface moisture of coal exceeds 6 %, it

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becomes sticky in addition to the stickiness created by
the clay content of the mineral matter leading to severe
capacity restriction in the tipplers, conveyors, crushers,
bunkers and mills.

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 DEMANDS OF THE RAINY SEASON
THROUGH SEVERAL MEASURES

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Stocking of sufficient coals of sandy background
which do not have serious sticky properties as
compared to coals of clayey background.
Use of washed coals of sandy background.

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Blending of raw coal (GCV=14.5 GJ/kg) with
washed coals (GCV=17.5 GJ/kg) or imported
coals (GCV=21 GJ/kg).
Optimal (partial) filling of bunker levels.
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SOME OF THE SOLUTIONS FOR WET COAL HANDLING
MANAGEMENT OF COAL YARD MANAGEMENT OF MANAGEMENT OF CHUTES
CONVEYORS AND BUNKERS

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Rain guards for conveyors Increased Deflector plates of Stainless
conveyor angles steel (SS 304) to chutes
Tarpaulins to cover wagons Multi bladed Vibratory
cleaners feeders/thumpers/rappers
in place of static feeders
Providing slopes for drainage Reduction in belt Air blasters

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of water speeds
Concreting of storage yards Skirt board seals,
and providing retaining walls baffle plates and
centering plates
at loading points
Rain water channeling, Self cleaning Chute modification to
dredging and cleaning of screening system increase angle
flow passages
Compacting by special Well designed 15
compactors instead of bull wash down
dozers. drainage system
SOME OF THE SOLUTIONS FOR WET COAL HANDLING

MANAGEMENT OF COAL YARD MANAGEMENT OF MANAGEMENT OF

CONVEYORS CHUTES AND

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BUNKERS
Storage pile design improvement Management of Widening of
through compacting. Pyramidal carry over return passages
shapes with drains on either side
lead to low water absorption.
Further the piles must not have

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surface depressions or pits.
Used oil may be sprayed on coal Conveyor belt
yard instead of reselling. sealing between
Alternatively it can be blended chute and pan of
with fuel oil. vibratory feeder to
prevent spillage
Dome for storage of coal Water jet cleaning

Provision for ground level

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tippling (non-pit type) of wagons
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 CORRELATION BETWEEN SURFACE MOISTURE
AND EQUILIBRATED MOISTURE IN MINED COAL

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14
y = -0.827x + 11.927
12
Surface Moisture (%)

10

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8
6
4
2
0
5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
18
Equilibriated Moisture (%)
 CORRELATION BETWEEN TOTAL MOISTURE AND
EQUILIBRATED MOISTURE IN MINED COAL

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20

18
Total Moisture (%)

16

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14

12

10
y = 0.173x + 11.927
8
5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
Equilibriated Moisture (%) 19
 BASIS FOR SALE OF COAL

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In the case of indigenous coals - the heating value
for commercial purposes is based on equilibrated
moisture
Total moisture does not get reflected in the

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commercial heating value.
Surface moisture does not get accounted in the
costing.
TPS must insist for coal costing considering TM at
mining point.
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SM addition enroute to TPS and in coal yard must
be borne by user.
 IMPORTED COAL

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8,000
y = -85.406x + 7223.4
GCV of imported raw coal (kcal/kg)

7,000 R = 0.9057
6,000

5,000

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4,000

3,000

2,000

1,000

0
0 10 20 30 40 50 60 21
Total moisture in raw coal (%)
 EFFECTS OF MOISTURE IN COAL ON POWER
STATION PERFORMANCE

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There are three cost effects of moisture in coal:
Increase in operation costs due to decreased boiler
efficiency and decreased overall unit efficiency
(increase in heat rate)

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Increase in operation and maintenance costs
attributed to handling of wet coal.
Decrease purchase cost of coal due to higher moisture
and hence lower GCV.

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 EFFECTS OF MOISTURE IN COAL ON
POWER STATION PERFORMANCE

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83.5

83.0
Boiler efficiency, %

82.5

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82.0

81.5

81.0 y = -0.0202x2 + 0.3588x + 81.879

R = 0.9812
80.5
10 12 14 16 18 20 22 23
Moisture content, %
 INCREASE IN UNIT HEAT RATE DUE TO
INCREASED MOISTURE

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2660
y = 0.6319x2 - 11.562x + 2628.6
2650 R = 0.9277
Unit Heat Rate. kcal/kWh

2640
2630

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2620
2610
2600
2590
2580
2570
10 12 14 16 18 20 22 24
Moisture content, %
 COST SENSITIVITY OF MOISTURE IN COAL

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Indian coal
The fuel supply agreements for Indian coals do not have
any provision for accounting the effect of total moisture.
Only equilibrated moisture (IM) gets factored in the pricing.

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SM > 7% during the months from October to May and > 9%
during the months from June to September, the coal
quantities shall be calculated in percentage by which the
surface moisture exceeds the foregoing limits.
This corresponds to a TM of approximately 12 % in summer
and 14 % in rainy season which rarely happens.
On this account Indian coal costs do not show sensitivity to 25
total moisture as indicated in the following figures.
 COST SENSITIVITY OF MOISTURE IN
INDIGENOUS COAL

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1600

1400 y = 4.7112x + 844.65

Indigenous coal price, Rs./Gcal

R = 0.031
1200

1000

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800

600

400

200

0
0 5 10 15 20 26
Total Moisture, %
 SENSITIVITY OF INDIAN COAL PRICE (Rs./t)
TO TOTAL MOISTURE

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4900

4700 y = -16.121x + 4442

R = 0.0929
Indian coal price, Rs./t

4500

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4300

4100

3900

3700

3500
0 5 10 15 20 27
Total Moisture, %
 SENSITIVITY OF INDIAN COAL PRICE (Rs./t) TO TOTAL
MOISTURE IF THE MOISTURE EFFECT IS CONSIDERED

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4400
4350
4300
4250
Coal cost, Rs./t

4200

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4150
4100 y = -43.38x + 4556.2
4050
4000
3950
3900
0 2 4 6 8 10 12 14 16 28
Total Moisture, %
 SENSITIVITY OF INDIAN COAL PRICE (RS./GCal) TO
TOTAL MOISTURE IF MOISTURE EFFECT IS CONSIDERED

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880
870
860
850
Coal cost, Rs./Gcal

840

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830
820 y = -9.7836x + 921.21
810
800
790
780
770
0 2 4 6 8 10 12 14 16 29
Total Moisture, %
 COST SENSITIVITY OF IMPORTED COALS TO
MOISTURE

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5500
5000
Imported coal price, Rs./MT

4500
4000 y = -90.488x + 5702.7

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3500 R = 0.8939

3000
2500
2000
1500
1000
0 10 20 30 40 50 60 30
Total moisture, %
 COST SENSITIVITY OF IMPORTED COALS TO
MOISTURE

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900
y = -0.2174x2 + 3.5573x + 730.98
Imported coal price, Rs./GCal

800 R = 0.6839

700

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600

500

400

300
0 10 20 30 40 50 60 31
Total moisture, %
 COST SENSITIVITY OF COALS TO
GENERATION COST AND FUEL COST
Sl. Particular Design/ Units Value

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No. operating
01 Boiler efficiency Design % per 1 % -0.123
increase in
02 Boiler efficiency Operating -0.270
moisture
03 Unit heat rate Design kcal/kWh per 1 % 3.1
increase in
04 Unit heat rate Operating 8.2
moisture

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05 Impact on cost of energy Design Rs./kWh 0.010
generated due to decreased
performance of boiler
06 Impact on cost of energy Operating Rs./kWh 0.015
generated due to decreased
performance of boiler
07 Impact on cost of energy Design Rs./kWh 0.36
generation due to lower
purchase price of high
moisture coal
08 Impact on cost of energy Operating Rs./kWh 0.38 32
generation due to lower
purchase price of high
moisture coal
COST SENSITIVITY OF MOISTURE IN COAL

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Imported coal
It is clearly seen that the cost impact due to actual
decrease in energy efficiency is very small (Rs. 0.01 to
0.015/kWh) as compared to reduced fuel purchase

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cost component of generation cost (Rs. 0.36/kWh)
because as the TM increases the price of coals
decrease.

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 CONCLUSIONS

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Moisture in coal has a negative impact on the energy
performance and all efforts are required from the mine
till the coal is fired into the boilers, to ensure that
moisture does not get added to the coal and its heating
value is preserved.

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If the boilers are designed for operating on high moisture
coals, the high moisture imported coals can be
successfully fired in an economical fashion as the open
market price of coals with higher moisture will be lower
than coals with lower moisture.

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 CONCLUSIONS

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The overall cost of generation will be lower for coals with
higher moisture contents.
The increased generation cost due to lower boiler efficiency
and unit overall efficiency (Rs. 0.015/kWh) will be completely

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offset by the component due to decreased purchase price of
higher moisture coals (Rs. 0.38/kWh).
Therefore, for imported coals the economics is in favour of
operating on higher moisture coals based on the coal pricing.
In the case of indigenous coals, the heating value for
commercial purposes is based on equilibrated moisture
which is equivalent to inherent moisture and the total 35
moisture does not get reflected in the commercial heating
value.
 CONCLUSIONS

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In other words, surface moisture does not get accounted in the
costing.
However, in the case of both imported coals and indigenous
coals, addition of surface moisture or moisture
addition/deterioration in heating value in the coal yard of the

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power plant is to the account of the user and must be
minimized.
Besides just the heating value the difficulties in flow ability,
crushing, pulverizing and injection of coal into the furnace of
the boiler present operational problems which affect
loadability.
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The impact of 1% moisture on unite heat rate is 8-9 kcal/kWh.
 THANK YOU

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