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CoalGrindingTechnology(1stPart)

1 Introducon
Noblefuelsarecoal,fueloilandnaturalgas.
Duetotheincreaseoftheoilpricesinthelastdecades,coalusageasprimaryfuelsourceinthecementindustryhasgrown
inlargeproporons.
Forsafetyreasons,coarsecoalisalwayssuppliedonsite.
Then,agrinding/dryingplantisnecessarytoconvertthecoalintovaluablefuel.
Beforechoosingandsizingthecoalgrindingcircuit,wehavetotakeintoconsideraonthefollowingfactors:
*Coalquality
*Hotairsourcesforcoaldrying
*Numberoffuelconsumponpoints
*Typeofkilnandavailablespace,especiallywheninstallinganewplanttoanexisngkiln
*Industrialsafetysystems
Concerningthemachineryandthesystem,achoicemustbemadebetween:
*BallmillandVercalRollermill
*Directandindirectringsystem
*Operaonofthesystemininertornoninertcondion
*Baglterorelectrostacprecipitatorfordustremovalpurposes
Thesepointswillbeanalysedinthefollowingchapters.

2 Typesofcoals
2.1 Introducon:
Coalisareadilycombusblerockcontainingmorethan50percentbyweightofcarbonaceousmaterialformed
fromcompaconandinduraonsofvariouslyalteredplantsandsimilartothoseinpeat.
Seetheclassicaonofcoalaer.
2.2 Classicaonofcoal:
Coalcanbeclassiedinfourcategories:Peat,Lignite,BituminousandAnthracite.

2.3 Peat:
Peatistherststageintheconversionofvegetablemaertocoal.
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Peatistherststageintheconversionofvegetablemaertocoal.
Peatisanorganicfuelconsisngofspongymaterialformedbytheparaldecomposionoforganicmaer,primarily
plantmaterial,
inwetlandssuchasswamps,muskegs,bogs,fens,andmoors(fromEncyclopdiaBritannica).

Overme,theformaonofpeatisoentherststepinthegeologicalformaonofotherfossilfuelssuchascoal,
parcularlylowgradecoalsuchaslignite.
Withcolorrangesfromyellowishbrowntoblack,peathasalowxedcarboncontentofbetween50and55%,
alowercaloric2000kCal/kgandahighhumidity,soitisverybadfuel.
2.4 Lignite:
Thisvarietyofcoalintermediatequalitybetweenpeatandbituminouscoalhasahighercarboncontentthanpeat,
between55and65%.
Itusuallyblackbrowncoloredwithabrousandwoodystructure.
Ithasalowerheatcapacitythanthecommoncoal,4100kCal/kg.
Thehighvolalemaercontent(19%)cancausedisintegraonoftheligniteexposedtoair.

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2.5 Subbituminouscoal:
Subbituminouscoalisbetweenligniteandbituminouscoalandareusedprimarilyasfuelforsteamelectricpowergeneraon.
Thiscoalisfromdarkbrowntoblack.
Itsheatcontentisbetween4600and6400kCal/kg.

2.6 Bituminouscoal(hardcoal):
Bituminouscoalisthemostcommoncoal.
Ithasanevenhighercarboncontentofbetween60and80%,sothattheirheatcapacityisalsohigher.
Bituminouscoaligniteseasilyandburnslongwitharelavelylongsmokyyellowame.
Itdiersfromlignitebyitshighercaloricvaluebetween7200and8600kCal/kg.
Bituminouscoalcanbedivideintwosubgroups:
*Thermalcoalbecauseitisusedtorepowerplantsthatproducesteamforelectricityandindustrialuses.
*Metallurgicalcoalbecauseitisusedintheprocessofcreangcokenecessaryforironandsteelmaking.

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2.7 Anthracite:
Itisthebestofthecoals,withaverylowpolluonandhighcaloricvalueofatleast8600kCal/kg.
Anthraciteisverypureandcontains75to95%carbon.Aerthat,itisgraphitewhichisalmostpurecarbonandwhich
isincombusble.
Anthraciteigniteswithdicultyandburnswithashort,blue,andsmokelessame.

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3 Coalproperes
3.1 Introducon:
Thedegreeofmetamorphismorcarbonizaonofthecoal,fromthestateofpeatuptoanthracite,hasanimportant
relaonshipwithitsproperes,andisknownastheclassorrankofcoal.
Thelowrankcoals,suchasligniteandsubbituminouscoalsaretypicallysoer,friable,opaquewithappearanceofearth,
arecharacterizedbyhighhumidityandlowcarboncontent,andtherefore,lowenergy.
Highrankcoalsaretypicallyharderandstronger.
Theincreaseintherangeisaccompaniedbyanincreaseincarboncontentofthecoalandenergy,aswellasadecrease
inthemoisturelevel.
Themostimportantproperesusedforevaluaonofcoalaretreatedbelow.
3.2 Heatofcombuson:
Istheamountofheatreleasedperunitmassorunitvolumeofasubstancewhenthesubstanceiscompletelyburned.
Caninuencesignicantlyontherequirementsofhandlingandsprayingequipmentsandstorage.
3.3 Specicheat:
ThespecicheatistheamountofheatperunitmassofcoalrequiredtoraisethetemperaturebyonedegreeCelsius.
Thisdependsonthewatercontentandash.

3.4 Moisture:
Themoisturecontentofcoalisdueto2typesofmoistures:inherentandfree.
Inherentmoistureistheoneretainedintheporesofthecoalandisacharacteriscofthecoaltype.
Freemoistureistheoneonthecarbonsurfaceandintheinterscesbetweentheparclesandistheresult
ofthewatersofthemine,thewaterforwashingandtherain.
3.5 Granulometry:
Forsafetyreasons(spontaneouscombusonandexplosion),coalarrivinginthecementplantsarecoarse.
Itisthenveryimportanttoknowthegranulometryofthecoalanditsrankfordimensioningthemachineryrequiredtogrindit.
Theparclesizedistribuonofmilledcoaldependspartlyontherankofthecoalwhichdeterminesitsbrileness.
3.6 Sizestability:
Itistheabilityofcoaltoresisttobreakageduringhandlingortransportaon.
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Itistheabilityofcoaltoresisttobreakageduringhandlingortransportaon.
Thisstabilityisdeterminedbyadropshaertestwhichconsistsinamethodinvolvingadroppingpredeterminedsizecoal
ontoasteelplatefromaspeciedheight.
3.7 VolalesContent:
Thisfactoraectsthecombusbilityofcoalpowderandtherequireddegreeofgrindingbecausethenenessrequired
increasesifthecontentofvolaleisdecreasing.
Thecoalswithlowvolalecontenthavealesseasyignionandneedmoremeforcombuson.
3.8 Grindability:
ThisfactorisdeterminedbytheHardgroveGrindabilityIndex(seelinkherebelow).
hp://www.thecementgrindingoce.com/grindabilitytests.html
3.9 Abrasivity:
Itisnecessarytoknowtheabrasivenessofthecoalinordertopredictthewearofthedierentpartsinthegrinding
installaon.
ThisabrasivenessisobtainedusingalaboratorytestaccordingtoBrishStandardBS1016,part19.
Theindexunitismilligramsofmetalbladesthaterodedperkilogramofcoalsamplesused(mg/kg).
Somegures:

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3.10 Density:
Coaldensityvarieswiththesize,themoisturecontentandthecoalselementabilitywhenitisstacked.
Mostranksofcoalarelowindensity(about700to1800kg/m3)incomparisonwithotherrocks.
3.11 Ashcontent:
Theashcontentofcoalisanimportantmeasureforthecoalquality.
Theashisdenedasthenoncombusblepartofthecoal.
3.12 Summarytableofcoals:
Thistablegivesthefollowingcharacteriscsofthedierentcoals.

4 Petcoke
Petroleumcokeisasolidsubstancecomposedmainlyofcarbonandisabyproductofoilrening.
Petroleumcokeisusedasasourceofenergyaswellascoal.
Oneparcularlyinteresngpropertyofpetcokeisitshighheatofcombuson(about8800kCal/kg).
Itsashcontentisalsoverylowcomparedtocoal

Dierentpetcokesformsavailableare:
*Greencokeusuallyreferstocalcineablecoke,i.e,potenalanodequalitycokethatsllcontainsmoistureandvolale
material,i.e,beforecalcining.
*Calcinatedcokeusuallyreferstopetroleumcokeorgreencokethathasbeenprocessedinacalciner.
*Fluidcokeusuallyreferstoaproductderivedfromtheprocessofauidizedbedconsisngofareactorandaburnervessel.
*Flexicokeusuallyreferstoaproductlikeuidcokewhichisgasiedintoaweakfuelgas.
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*Flexicokeusuallyreferstoaproductlikeuidcokewhichisgasiedintoaweakfuelgas.
*Shotcokeischaracterizedbysmallroundspheresofcokeproducedbydelayingcokingprocess.
HGIofpetcokecanvaryfrom30to90.Somepetcokesareverydiculttogrind.]
Summarytable:

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