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2
A Maharatna Company
Issues & Concerns - Utility Perspective
• Compatibility of coals
• Blend Proportions
– Optimum blending ratio
– Maintaining desired blend proportions
• Methodology of Coal Blending
• Safe operation
-Slagging/clinkering
-Fire in stack yard or Mill
• Impact of blending
– Cost of Generation
– Auxiliary Power consumption
– Environmental Emissions
– Operating & performance parameters
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A Maharatna Company
Present Practices
Commonly Used Coal Characteristics
• Moisture
• ASH
• FC
• VM
• GCV
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A Maharatna Company
Compatibility - Coal characteristics
Typical DSC Burning Profile used for analysis of compatibility of two coals
A Maharatna Company
Burning Profile Analysis
CL-2 & CL-3 have lower softening CL-2 1100 1370 1400 1430
temps 1370˚C & 1400˚C and CL-3 1160 1400 1430 1450
relatively slagging prone coal CH-1 1320 1630 >1650 >1650
CH-2 1240 1570 1590 1615
CH-3 1320 1620 1640 >1650
HGI 77 61 44 66 59 77
Indigenous low ash coal, CL-1 with lowest peak temperature (PT-439 C) is
most reactive,
Imported low ash coal with highest PT (514 C) and burnout temperature
(598 C) is least reactive
Blending CH-3 with CL-3 may result flame fluctuation, thermal instability or
increase in combustible losses.
A Maharatna Company Safe operation
BLENDING METHODOLOGY
Comparisons of different coal blending Methodologies
A Maharatna Company
Blending in Stacking of two -Blending during Only one -Entire coal to Not tried
Beds coal in yard in reclaiming system to run be stacked first
layers -Homogenization for bunkering -More running
at transfer point coal Hours for CHP
& more APC
-Not possible
to change ratio
Blending by Imported coal -On conveyer - V. accurate High Capital Facility not
Silo from Silo is below Silo Blending ratio cost available in
mixed with - Homogenization can be NTPC
domestic coal at transfer point achieved
carried by -Ratio can be
conveyer below varied
Silo
Stations gets coals from different mines MCL Talcher, MCL Ib, SCCL, Indonesia
Tests were carried out in labs to get an qualitative idea about compatibility of coals
with respect to their burning behavior.
Differential Thermo gravimetric Analysis/Burning Profile & Ash Fusion Tests were
carried out for Domestic, Imported and blends of 10, 20, 30 and 40% of MCL Talcher
& Indonesian coals
Typical Proximate Analysis of Domestic Coal of different sources & Imported Coal
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A Maharatna Company
Thermo gravimetric Analysis
The four figures are the burning profiles of the four types of coals. Solid line is the weight loss on
account of burning of coal and dotted line is the 1st derivative of the weight loss. The bottom peak
denotes maximum weight loss, peak at lower temperature indicates more reactive coals. 17
A Maharatna Company
Thermo-gravimetric Analysis
The four figures are the burning profiles of the four different blends of coals. 10% Imported
with MCL Talcher, 20% imported with MCL Talcher, 30 % & 40% blends
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A Maharatna Company
Analysis of DTG burning profile
DTG of Imported ( Presently used) coal was compared with DTG of
proven domestic coal
DTG Peak 418 399.3 481.6 366.7,480.4 DTG Peak 429.5 417,427.5 418.5 389.6
• Peak temp & Burnout temperatures of imported & domestic coals are
comparable & compatible
• DTG Profiles of blended coals of different ratio are well within the range
of proven coal
• This results indicates that these blends when fired in boiler shall not
cause any combustible loss problem
A Maharatna Company
Ash Fusion Temperatures
• Burning profile (DTG) temperatures of blends are in the same range as those of
domestic coals being fired.
• Combustion reactivity of the blends is similar to domestic coal & should not cause
any combustion related problems.
• Initial deformation temperature of both the imported coal and of 40 % blend is
lower than 1300ºC.
• Therefore, coal blends over 30% may cause melting of ash in furnace and initiate
slag formation or clinkering in reducing atmosphere.
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A Maharatna Company
Ash Constituents
MCL Talcher MCL IB CAF Fly Ash Imported
SiO2 % 64.84 62.6 61.42 63.68 42
Al2O3 % 26.75 28.73 28.71 19.75 23.94
Fe2O3 % 3.19 3.59 4.39 3.43 7.98
CaO % 1.49 1.38 1.55 2.57 8.89
MgO % 0.48 0.39 0.59 1.93 3.45
• Imported coal ash have Higher concentrations of iron, calcium, magnesium &
sulphur which may initiate slagging
• Since ash content of coal is small and further when blended 10,20 or 30% its
contribution to blended coal ash becomes negligible
• Blending higher proportion of imported coal shall increase the content to
appreciable extent.
• Concentrations of sodium & potassium, cause for fouling deposits in boiler are also
higher.
• Hence during optimization of blend ratio compatibility w.r.t coal ash chemistry must
be followed.
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A Maharatna Company Conclusion
• Compatibility of characteristics of two coals must be assessed before
blending to avoid combustion related problems.
• 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
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A Maharatna Company
Thank You