02 Grinding of Coals & Pet Cokes - Vers 2006

2.
Grinding of coals & pet cokes

Content
Coal, pet-cokes Æ varieties & proprieties
Coal grinding systems
Grinding process
Fine coal storage
Statistics
2
Holcim Group Support Cement Manufacturing Course 2006/Geo
Coal and Petcoke types
Coal classification after RANK
4
Petcoke types
Bulk
R 31.5mm R 16.0mm R 8.0mm R 4.0mm Humidity
Type % % % %
Density
%
HGI Picture
3
T/m
Sponge 9 23 42 60 0.7 8.8 <70
Shot 14 79 92 95 0.8 2.5 <45
Fluid 6 17 57 96 0.69 8.1
5
Coal grinding systems
Tube mill system

Roller mill system
Special features
Air Swept Mill
Features
Separator
Drying compartment
Shoe-bearing at the
inlet side
Retention time of the
coal is longer
Drying Chamber Can deal with coal of
variable proprieties
Not so sensitive to
WEAR
NOT suitable for
direct firing system
FLS - Tirax
7
Typical Arrangement for a Coal ASM
Filter
Raw Coal
Bin
Coal dust
Bin
Hot Gas
Mill To Kiln
Dosing
8
Vertical Mill System (ex: Loesche Mill)
Feed
Product
High efficiency Not suited for
classifier FLEXI COKE!!
Hot gas
9
Typical Arrangement – Coal Grinding in VRM
Safety Explosion
Vent Bag Filter
CO2
Feed Inertization
Bin
Coal Mill Fine Coal

(VRM) Silo
Safety Shut-Off
Gates
10
Coal Grinding Process
Proportioning (feed)
Drying
Grinding
Separating
Special features
Quality requirements
Instrumentation
Proportioning (feeding)
Provide homogeneous raw coal mix
Front end-loader mix Æ not suitable!
Raw coal and Petcoke show a

typical cohesive property
The feed bin must be designed

for mass flow
Ideal capacity of a feed bin is

3 Hours of continuous operation!
Same precautions as per raw

material
12
Drying
Heat sources System
…or hygroscopic equilibrium reached

For higher moistures Æ pre-drying
Coal / pet-coke with 0 – 20 % H20
Kiln gases In Roller Mills
Product with < 1% H20

~… m3/h
Æ higher
drying capacity
is NECESSARY!!
Hot Gas
Generator
Cooler hot
gases* (only
non-inert) ~…m3/h
13
Grinding - Material Circulation
NO recirculation
Mill Exit /
bucket elevator!! Fine Coal
Raw Coal
Feed
Table rejects Hot gas
e.g. FLS ATOX Coal Mill

14
Grinding Æ Inert/Non-inert grinding system
Æ Oxygen content >14%
Non - inert Æ Hot gas from cooler or hot
gas generator
Æ Temperature and CO
monitoring required
Æ Simple system / layout
Æ Higher safety risk
Æ Not for fuel with > 26 %
volatiles content
Æ Oxygen content < 12%

Æ Hot gas from preheater
Æ Low explosion and fire risk
Inert
-> safety
Æ Solution for various solid
fuel types (petcoke, coal,
lignite)
Æ Temperature, O2, CO
monitoring required
For new installations Æ Inert system is MANDATORY! 15

Separation – fineness
Dynamic separator
Efficient separation
Constant fineness
Flexible
Reduced oversized particles
High Efficiency separator is recommended!

16
Filter for coal grinding systems - General
Explosion doors and vents with explosion-proof limit switches
All external surfaces of the bag filter shall be insulated.
All internal surfaces exposed to the process gases shall be

protected against corrosion
Explosion protection measurement shall include:
CO and O2 at bag filter inlet, outlet, and hopper
Alarm on CO rate increase
Temperature sensors in bag filter
Inerting and fire suppression injection ports
The housing and plenum shall be equipped with explosion vents.
The minimum valley angles for hoppers and duct slopes shall be
70° in order to avoid coal dust accumulations.
Hoppers shall have rounded corners.
17
Filter for coal grinding systems - standard
HGRS Recommendation
For a filter load (air to cloth ratio) of max. 1.0 m3/m2 x
min. Æ dust concentration in the cleaned (de-dusted
gas) < 30 mg/m3
Utilization of teflon membranes is NOT recommended
BAGS
Must be treated with silicone
PEAC-Needle felt (50% Polyester und 50% Polyacryl-Fazes)
with surface spec. weight of 600 g/m2
Shall not exceed 3.6 m in length.
Grounding system to prevent static electricity accumulation
Wire cage supports Æ corrosion resistant
18
Recommended Fineness Coal – Petcoke
HGRS Standard Recommendation:
Coal:
Æ % R90μm <= ½ * (% volatiles)
Æ % R200μm <= 1%
Petcoke:
Æ % R90μm <= 5%
Æ % R200μm < 0.5%
19
Specific Energy Consumption vs Coal Grindabilty
Espec in function of
grindability and coal
meal fineness
Grindability according to
Hardgrove Index (HGI)
Example based on Espec
of ATOX coal mill
Å hard soft Æ 20
Special features Æ Ducts (Gas-ducts)
Pressure resistant up to 8 bar (check local standard)
Before vessels inlets Æ quick shut-off gates must be installed
Dust-deposit possibilities must be avoided:
No horizontal ducts
Sufficient gas speed (20-25 m/s)
For de-dusting – 70° must be respected
21
Transport of fine coal (product)
Velocity in the ducts: 28-35 m/s
Duct-bends Æ foreseen wear protection
Curve radius ~2m
Example: Wear Example: Wear protection
protection by proper on duct elbow (e.g. Basalt)
design (Diverter pot)
22
Ideal coal bin design
Designed for mass-flow.
A cone-in-cone design Æ bin discharge
hopper with wall slopes of 65 degree for
the external and 77 degree for the
internal hopper.
Material of construction for both
hoppers would be stainless steel plates.
The minimum diameter of the circular
hopper discharge openings would be at
least 1400 mm.
Material discharge would be activated
by a live bottom feeder.
The flow rate would be controlled by a
proportioning rotor scale (or a flow
meter).
23
Coal dust dosing
Rotor weigh feeder
Proportions & weighs the coal dust
feeds the coal dust by gravimetric or

pneumatic transport to the process
PFISTER
Rate 0.2t/h - 500t/h
Accuracy +/- 0.5%
Material properties < 5mm
free/moderate flowing, non-caking
24
Statistics
Maintenance
Specific energy consumption
Process parameters
Specific Energy Consumption vs. Hardgrove (Loesche)
Typical values
26
Mill Capacity vs. Hardgrove
Mill capacity vs. Hardgrove
180
160 5 % R 90 um
10 % R 90 um
140
15 % R 90 um
20 % R 90 um
120
Hardgrove
100
80
60
40
20
0
50 75 100 125 150
% Mill capacity
27
Mill Inlet Temperature vs volatiles content
Ignition temp. vs. volatiles
ignition temp. 0.5 x ignition temp. Recommended temperature
700
600
500
Mill inlet temp. [deg C]
400
300
200
100
non-inert operation possible inert operation
0
0 10 20 30 40 50 60
volatiles [%]
28
Conclusion
System Design
Grinding systems for coal and pet-coke require special
design features
Process
Safety is the major concern
Target: constant product fineness
Future
HGRS standard: ONLY inert operation installations
29

02 Grinding of Coals & Pet Cokes - Vers 2006

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2.

Grinding of coals & pet cokes

Sponge 9 23 42 60 0.7 8.8 <70

Shot 14 79 92 95 0.8 2.5 <45

Fluid 6 17 57 96 0.69 8.1

 Tube mill system

Coal Mill Fine Coal

 Raw coal and Petcoke show a

 The feed bin must be designed

 Ideal capacity of a feed bin is

 Same precautions as per raw

…or hygroscopic equilibrium reached

Product with < 1% H20

Table rejects Hot gas

e.g. FLS ATOX Coal Mill

Æ Oxygen content < 12%

For new installations Æ Inert system is MANDATORY! 15

High Efficiency separator is recommended!

 All external surfaces of the bag filter shall be insulated.

 All internal surfaces exposed to the process gases shall be

HGRS Standard Recommendation:

 feeds the coal dust by gravimetric or

 Specific energy consumption

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Tube mill system

Raw coal and Petcoke show a

The feed bin must be designed

Ideal capacity of a feed bin is

Same precautions as per raw

All external surfaces of the bag filter shall be insulated.

All internal surfaces exposed to the process gases shall be

feeds the coal dust by gravimetric or

Specific energy consumption