Coal Quality Analysis & Impact on Power Plant Performance

Central Power Research Institute

Bangalore

COAL FLOW PROFILE

COMBUSTION SEQUENCE OF COAL

COAL

RELEASE OF MOISTURE

RELEASE OF VOLATILES (Devolatilisation) EMISSIONS

(Flue gas)

COMBUSTION OF CHAR (Char oxidation) FLY ASH ASH BOTTOM ASH

What is coal?
Coal is a readily combustible rock whose composition consists of more than 50 % by weight of carbonaceous material

How is coal formed?

Coal is formed by the physical and chemical alteration of peat by processes involving bacterial decay, compaction heat, and time- (coalification)

Peat is an unconsolidated deposit of plant remains from a watersaturated environment (Marshy land)

Rank of Coals
Rank
Wood
Peat Brown Coal (Lignite) Sub-Bituminous High Volatile Bituminous Coal Medium Volatile Bituminous Coal Low Volatile Bituminous Coal Semi-Anthracite Anthracite * daf -Dry Ash Free Basis

% Carbon (daf)
50
60 71 80 86 90 91 92 95

% Volatile Matter (daf)

>65
>60

Specific Energy (Gross in MJ/kg, daf)

-

14.7

52
40 31 22 14 8 2

23
33.5 35.6 36 36.4 36 35.2

COMPOSTION OF COAL

COAL

CHEMICAL

OPTICAL / PETROLOGICAL

MOISTURE

NON COMBUSTIBLES

COMBUSTIBLES

MACERALS

MINERAL MATTER

1. VOLATILE MATTER 2. CHAR

1.VITRINITE 2.EXINITE 3.INERTINITE

PETROGRAPHIC CLASSIFICATION OF COALS

VITRINITE- Grey in colour ( More reactive )
EXINITE

VITRINITE

INERTINITE- White in colour ( Less reactive )

EXINITE- Grey-black in colour (Reactive in the presence of catalysts)

INERTINITE

PETROGRAPHIC CLASSIFICATION OF COALS

Proximate Analysis parameters and impact on power plant performance

1. MOISTURE CONTENT OF COAL Three forms : I) Surface Moisture : Acquired during spraying water & coal washing

II) Inherent Moisture: Water absorbed in the capillary pores of coal III) Combined Moisure: Water molecules in the form of hydrates

Proximate Analysis parameters and impact on power plant performance

1. MOISTURE CONTENT OF COAL 1% moisture reduces 0.07% of flame stability High moisture content leads to poor coal flow properties & Mill clogging Very Low Moisture content leads to dusty environment Reduction of heat energy derived from coal Preferred moisture content for power plant applications= 4-6%

Proximate Analysis parameters and impact on power plant performance

2. VOLATILE CONTENT OF COAL Contains essentially three compounds i) Gases: Combustible gases like hydrogen, carbon monoxide, methane, ethane and hydrogen sulphide ii) Tar: Complex mixture of hydrocarbons and other organics includes benzene, toluene, phenols, cresols,naphthalene, anthracene and free carbon Contains nitrogen and suphur compounds with cyanides in aqueous condensate

iii) Ammonia liquor:

Proximate Analysis parameters and impact on power plant performance

2. VOLATILE CONTENT OF COAL Responsible for coal ignition Very low volatile content leads to poor ignitability and flame

Very high volatile content leads to spontaneous combustion of coal while storage and smoke formation (leads to forced excess air levels to carry off the smoke) Preferred volatile content for power plant applications= 25% (daf)

Proximate Analysis parameters and impact on power plant performance

3. ASH CONTENT OF COAL Two forms : I) Inherent Ash :

Present in the original vegetable material from which the coal was formed consists of oxides like potassium, sodium, magnesium, calcium, silicon and makes up to 0.7-1.2%. This is inseparable form coal II) Extraneous Ash :

Impurities picked up from adjacent earthy or stony bands in the coal seam. This consists of various materials like shales, clay, pyrites,etc

Proximate Analysis parameters and impact on power plant performance

3. ASH CONTENT OF COAL Higher Ash content leads to poor flame stability and ash disposal problems

Ash with low melting temperatures cause sintered ash depositions (slagging and fouling) over water walls and affects heat transfer.
Higher ash content leads to poor heat input to the boiler Preferred ash content for power plant applications= <40% (d) For Indian boilers

Proximate Analysis parameters and impact on power plant performance

4. CHAR (Fixed Carbon) CONTENT OF COAL
Strong hydrocarbon matrix of coal Contains about 90% elemental carbon Needs thermal energy with oxygen environment for decomposition

Proximate Analysis parameters and impact on power plant performance

4. CHAR (Fixed Carbon) CONTENT OF COAL
Most of the heat energy is contributed by char Char fixes the combustion rate of coal (Char oxidation is the slowest process in the total combustion kinetics) Lesser the combustion rate (coal reactivity) lesser the boiler efficiency

Proximate Analysis

Proximate Analysis

Surface moisture: Percentage loss in weight when exposing coal to the atmosphere in the laboratory condition for 24hrs

Total moisture: Percentage loss in weight when the coal is heated to 110oC and kept in the same temperature till it attains constant weight. Volatile matter: Percentage loss in weight minus Total moisture when the coal is heated to 950oC in inert atmosphere and kept in the same temperature for 7 minutes.
Ash content: Percentage weight remained when the coal is heated to 815oC in oxygen environment and kept in the same temperature till it attains constant weight.

Ultimate Analysis parameters and impact on power plant performance

1. CARBON CONTENT OF COAL
Amount of carbon depends on the maturity of coal and it increases with coal rank Most of the heat energy is contributed by carbon in coal (1kg of carbon gives 8200kcal of heat) Knowledge of carbon content is vital in combustion calculations and theoretical air requirement.

Ultimate Analysis parameters and impact on power plant performance

2. HYDROGEN CONTENT OF COAL
Though hydrogen releases energy, it combines with oxygen to form water which reduces the available heat content of coal.

(The available heat energy is utilized for the latent heat of vaporization of water formed by the combination of hydrogen with oxygen)

Ultimate Analysis parameters and impact on power plant performance

3. NITROGEN CONTENT OF COAL
Nitrogen is responsible for NOx formation NOx is a environmental pollutant which causes acid rain

Ultimate Analysis parameters and impact on power plant performance

4. SULPHUR CONTENT OF COAL Three forms : I) Pyrites : Iron Sulphide (FeS2)

II) Organic Sulphur : Organic compounds in which sulphur combined with carbon in coal

III) Gypsum

: Calcium Sulphate (CaSO4)

Ultimate Analysis parameters and impact on power plant performance

4. SULPHUR CONTENT OF COAL
Sulphur is responsible for SOx formation

SOx is a environmental pollutant which causes acid rain

SOx deposits a film of corrosive sulphuric acid on the cooler parts of the plants

The presence of high quantity of pyrites (Fe2S) causes wear and erosion of mill components and transport pipes.

Ultimate Analysis parameters and impact on power plant performance

4. OXYGEN CONTENT OF COAL

Percentage of oxygen decreases as the rank of coal increases

The greater the percentage of oxygen in coal, the lower is the tendency to form a high-grade coke
Presence of oxygen reduces the available hydrogen by combining with the hydrogen to form water

Other Coal parameters

Coal parameter
Gross Calorific Value Elemental Ash Analysis

About the Parameter

Heat Content of Coal

Applications in Power plant

Energy Calculations Slagging and Fouling tendency of coal Ash Utilization Heavy metal pollution Wear and erosion of crushers, pulverizers, coal flow ducts and bends Slagging and fouling tendency of coal

Elemental constituents in ash (Si,Al,Ti,Ca Fe,,K,Na,Mg,Mn,S,P,etc)

Abrasion Index

Wear Potential of Coal

Ash Fusion Temperature

Melting tendency of ash

Recommended coal quality for pulverized coal power generation

Parameter Total moisture(% )
Volatile Matter (%) air dried basis Ash (%) air dried basis Sulphur (%)- air dried basis Gross calorific value (kcal/kg) air dried basis Hard Grove Grindability Index Ash Fusion Temperature (Initial Deformation Temperature oC) Fouling Index Slagging Index Size distribution

Typical 5-10
18-30 30-45 0.3-0.7 3000-5000 45-80 >1600 Low Low Maximum 38mm Minimum 3mm

Limit 15 max
19 min 40 max 1.5 max 3000 min 45 min 1150 min Med/High Med/High Maximum 50 mm Minimum 0.5mm

Thanks a lot for your patience