WHAT IS COAL SOLID FUEL

COAL
- ( C3H4)n -
MIXTURE INORGANIC
OF MINERAL &
HYDROC- MOISTURE
ARBON
WHAT IS UHV ?

UHV: Useful Heat Value

Study group constituted by

Govt. Of India in1962
suggested to derive UHV by
subtracting Ash Penalty from
GCV

UHV = 8900 138 ( A + M )

 What is GCV ?
THE CALORIFIC VALUE OF
COAL IS DEFINED AS THE
AMOUNT OF HEAT EVOLVED
WHEN A UNIT
WEIGHT OF THE COAL
IS COMPLETELY BURNT

Mazumdars formula : GCV=85.56(100-

1.1A-M)-60M
GCV= 2062+0.6842UHV
TRANSITION FROM
UHV TO GCV
UHV: BEFORE 1ST JANUARY,2012

GCV: ON/AFTER 1ST JANUARY,2012

USEFULL
GROSS
HEAT VALUE
CALORIFIC VALUE
Why Transition from UHV to GCV ?
In earlier days around 85% of marketable coal
are from UG mines & rest are from OC mines &
now the situation is just reversed
The constant 8900 in the formula for UHV is
highest dmmf CV of coking coal of Jharia
coalfield. This value corresponds to coal
having 90.5% carbon & hydrogen 4.8% in
demmf basis. This figure is not acceptable in
present days when, a large quantity of coal is
mined from other coalfields like MCL, IB coal
field, North Karanpura etc.
Why Transition From UHV to GCV ?
The equal weightage factor 138 for both ash &
moisture is not valid for high ash coal
( generally coal from OCPs)
UHV at Ash+Moisture value of 64.5% is ZERO
But GCV value in this range is around 2300
KCal/Kg
Low ash indigenous/imported coal can give
the high GCV then the UHV
Internationally coal is traded as per its GCV
GRADING OF COAL
Old Concept NON
COKING
COAL

A B C D E F G

UHV UHV UHV UHV UHV UHV UHV

>6200 >5600-6200 >4940-5600 >4200-4940 >3360-4200 >2400-3360 >1300-2400
(K Cal/Kg) (K Cal/Kg) (K Cal/Kg) (K Cal/Kg) (K Cal/Kg) (K Cal/Kg) (K Cal/Kg)
GRADATION OF COAL
New Concept
GROUP GCV Bands GROUP GCV Bands
NO (Kcal/Kg) NO (Kcal/Kg)
G1 >7000 G10 >4300 - 4600
G2 >6700 - 7000 G11 >4000 - 4300
G3 >6400 - 6700 G12 >3700 - 4000
G4 >6100 - 6400 G13 >3400 - 3700
G5 >5800 - 6100 G14 >3100 - 3400
G6 >5500 - 5800 G15 >2800 - 3100

G7 >5200 - 5500 G16 >2500 2800

G8 >4900 - 5200 G17 >2200 2500

G9 >4600 - 4900
TRANSITION FROM UHV TO GCV
Sl. No. GRADE UHV(KCal/Kg GRADE GCV(KCal/Kg GCV(KCal/Kg
AS PER
CALCULATION
1 A >6200 G1 >7000 >6380
2 B 5601-6200 G2 6701-7000 5972 - 6380
G3 6401-6700
3 C 4941- 5600 G4 6101-6400 5522 - 5971
G5 5801-6100
4 D 4201- 4940 G6 5501-5800 5107 - 5521
G7 5201-5500
G8 4901-5200
5 E 3361- 4200 G9 4601-4900 4444 - 5016
G10 4301-4600
6 F 2401- 3360 G11 4001-4300 3790- 44430
G12 3701-4000
G13 3401- 3700
7 G 1301- 2400 G14 3101-3400 3039 - 3789
G15 2801-3100
G16 2501-2800
G17 2201-2500
SAMPLING

WHAT IS SAMPLING ?
WHY IS SAMPLING ?
HOW TO DO ?
WHEN TO DO
WHERE TO DO ?
DISPUTE ?
SAMPLING
To check the quality of coal consignments, it is
desirable to sample it & to know the quality
parameter from which the relevant price of the
coal can be ascertained
The basic purpose of collecting and preparing
a sample of coal is to provide a test sample which
when analyzed will provide the test results
representative of the lot sampled from which it is
taken
COLLECTION OF SAMPLES FROM WAGONS
(AS PER EXISTING FSA )

Sample to be collected in No. of wagons No.of

loading end in the rake Sub lots
In case of dispatch by Rail
each rake of Coal supplied Up to 30 4
from one Delivery Point wagons
shall be considered as a Lot (2000 Tes)
for the purpose of sampling.
Each rake shall be divided >30 wagons 5
into sub-lots in a manner up to 50
that the quantity of wagons
Coal/number of wagons in (3000 tes)
such sub-lots is more or less
equal. >50 wagons 6
and above
(>3000 Tes)
Samples collected from all the Contd
selected wagons in a rake shall
be mixed to form Gross
Sample accordingly.
 Contd.
Wagons to be selected as per Random Number .
25% of the total wagon to be selected from each
sub-lot.
In each wagon selected for sampling, the sample
will be drawn from the spot in a manner so that
if in one wagon the sample is collected at one end,
in the next wagon the spot will be in the middle of
the wagon and in the third wagon at the other end
and this sampling procedure will be repeated for
subsequent wagons.
 Contd

The spot will be leveled first

and at least 25 cm of Coal
surface shall be removed/
scrapped from the top and
the place will be leveled for
an area of 50 cm by 50 cm.
About 50 kg of sample shall be
collected from each selected
wagon of the sub-lot in the rake
by drawing 10 increments of
approx. 5 kg each
 PREPARATION OF FINAL SAMPLE
The gross sample collected shall be crushed to 5 cm by
mechanical means, mixed thoroughly and quartered.
This process to be done for at least two times
Material so obtained shall be crushed to 12.5 mm by a
Jaw Crusher and then to 3.3 mm by a Palmac type of
reduction mill or Jaw Crusher.
Primary Jaw Crusher
Input : Above 100 mm
Output : -12.5 mm
 Contd
The crushed material shall be reduced either by
coning and quartering or by ruffling
Secondary Jaw Crusher
Input : -12.5 mm
Output : -3.35mm
 Contd
The crushed material shall again be reduced
either by coning and quartering or by ruffling
Pulverisor
Input : -3.35mm
Output : 212micron
 Contd
The crushed material shall again be reduced
either by coning and quartering or by ruffling
 Contd

The sample so reduced shall be

finally ground to pass through
212 micron IS sieve using a
Raymond mini mill.
From the final sample passing
through 212 micron IS sieve, 1.5
Kg shall be taken, which shall
constitute the laboratory
sample.
 Contd
Such laboratory sample shall be divided into two
equal i.e. Set-I and Set-II & sealed

Set I shall be used for joint analysis

Set II shall be kept under joint seal as stand-by

sample in the safe custody for a period of fourteen
days or until the analysis results of Set I are
accepted without dispute, whichever is earlier.
Mechanical Sampling
The method of preparation of coal samples
collected by any mechanical installation

Mechanical
Installation

Size reduction Sample mixing Sample dividing

apparatus apparatus apparatus
 AugerSampling
Auger Samplers
Systems are utilized to sample
stationary bulk materials from trucks, railcars, barges,
and stockpiles. These samples are utilized to establish
the commercial value of the coal or to allow the operator
to blend coals efficiently.
Benefit of Auger Samping
Can collect each increment in less than 1 minute.
Samplers are crushed on line with in the Auger
sampler
Sample collection process is free from biasness
Rejects fall directly back in to the wagon
Can complete sampling of rake load of coal with
in 2 hours
The unit is self cleaning
Sampling is weather protected
Rail Mounted Auger
Truck Mounted Auger
Portable Trailer Mounted
Portable Trailer Mounted
Auger
Auger is a mobile auger
sampling system with the
capability of sampling
approximately 240 trucks
per 8-hour shift
Stationary Auger Sampling System
Stationary Auger
Sampling System is a
permanently
installed auger
sampling
system. The
sampling system is
typically utilized in
high volume
locations when
multiple sample
collectors are
required.
Belt Mounted Mechanical Sampler
Seam Sampling In Russia
Platform Mounted Auger
ANALYSIS
 PROXIMATE
ANALYSIS

GCV ASH (%) MOISTURE (%)

TGA-601 &AC-500 (LECO)
AUTOMATIC
ANALYZER FOR ABC FOR
PROXIMATE DETERMINATION
ANALYSIS OF GCV
 POST SAMPLING MANAGEMENT
ANALYSIS
RESULT

GCV DEVIATES
FROM THE PRE
GCV MATCHES
DECLAIRED RANGE.
WITH THE PRE
DECLAIRED RANGE DISPUTES

RESULT IS FINAL
FOR DOWN UP
ALL COMMERCIAL GRADATION GRADATION
PURPOSES
 DISPUTE MANAGEMENT
IF ANALYSIS RESULT DEVIATES,
REFEREE IS CHALLANGED (AS
DESIRED BY PARTIES) & SAMPLE
SET-II IS SENT TO INDEPENDENT
LABORATORY FOR THE PURPOSE
OF ANALYSIS

THE ANALYSIS RESULT OF THE

INDEPENDENT LABORATORY IS
BINDING FOR ALL COMMERCIAL
PURPOSE.
 DISPUTE MANAGEMENT

DESIRED ANALYSIS RESULT

BUT COMPLAINT AGAINST QUALITY

PROPERLY MAINTAINED REGISTERS

& RECORDS PLAYS THE VITAL
ROLE IN SUCH DISPUTE MANAGEMENT