MILL PERFORMANCE

FACTORS
• P.F. FINENESS
– CARBON LOSS
– MILL POWER CONSUMPTION
• COAL-AIR RATIO
• MILL REJECTS
EFFECTS OF P.F.FINENESS
• TOO COARSE
– WEAR IN COAL PIPE
– SLOWER IGNITION
– POOR FIREBALL MIXING
– UNSTABLE FLAME FRONT AT LOW LOADS
– HIGH CARBON LOSS
• TOO FINE
– INCREASED WEAR OF PULVERISER
– DECREASED PULVERISER OUTPUT
– INCREASED POWER CONSUMPTION
• 1% CHANGE IN FINENESS EQUALS
APPROXIMATELY 1.5% IN CAPACITY
 PROCEDURE FOR CHECKING COAL
FINENESS
• PERIODICALLY
COLLECT COAL SAMPLE
FROM ALL PIPE LINES
OF A MILL IN TWO
PLANES USING
STANDARD PROBE
• BEFORE COLLECTING
SAMPLE ENSURE
– MILL IS RUNNING AT
MORE THAN 75% LOAD
– MILL IS RUNNING AT A
STEADY LOAD FOR 30
MINUTES
– NO LOAD CHANGE TAKES
PLACE DURING SAMPLE
COLLECTION
 PROCEDURE FOR CHECKING COAL
FINENESS
• MIX ALL THE SAMPLES
COLLECTED FROM A MILL
HOMOGENEOUSLY
• TAKE REQUIRED MASS
OF SAMPLE BY CONING
AND QUARTERING
• CONDUCT SIEVE
ANALYSIS ON THE
SAMPLE
• OPTIMUM FINENESS
– 100% THROUGH 50 MESH
– 90% THROUGH 100 MESH
– 70% THROUGH 200 MESH
 PROCEDURE FOR CHECKING COAL
FINENESS
• DEPENDING ON THE RESULT ADJUST THE
CLASSIFIER VANES
• TO INCREASE FINENESS
– MOVE THE VANES TOWARDS CLOSED POSITION
• TO DECREASE FINENESS
– MOVE THE VANES TOWARDS OPEN POSITION
• AFTER ADJUSTING RECHECK FINENESS
• IF NECESSARY
– ADJUST RING TO ROLL CLEARANCE
– ADJUST PRESSURE SPRING
– REPLACE GRINDING ELMENTS
 EFFECTS OF COAL AIR RATIO
• HIGH AIR FLOW
– AFFECTS COAL CLASSIFICATION
– REDUCES DISCHARGE OF PYRITES
– INCREASES COAL PIPE EROSION
– AFFECTS IGNITION POINT
– MORE P.A. FAN POWER
CONSUMPTION
• LOW AIR FLOW
– INCREASES COAL PIPE SPILLAGE
– CAUSES DRIFTING IN COAL PIPE AND
ULTIMATE COAL PIPE CHOKING
 CLEAN AIR FLOW TEST
• DETERMINES
– WHETHER THERE IS ENOUGH AIR TO
TRANSPORT THE COAL
– AIR FLOW DISTRIBUTION IN COAL PIPES
– COAL PIPE OBSTRUCTION
• METHOD
P IS MEASURED BY PITOT TUBE IN
COAL PIPE AT 0.935R, 0.791R, 0.612R, AND
0.354R WHERE 'R' IS THE RADIUS OF PIPE
IN INCHES
 CLEAN AIR FLOW TEST
PV 0.5
AIR VELOCITY = 18.275 [ ----------------------------- ] Ft/s
1.326 Pb +0.0735 PS
{ ------------------}
460+T
WHERE

PV - PITOT TUBE DIFF.PR.IN INCHES OF WC.

Pb - BAROMETRIC PRESSURE IN INCHES OF Hg.
PS - STATIC PRESSURE IN INCHES OF WC.
T - TEMPERATURE IN 0F
PV 0.5
AIR VELOCITY = 5.5702 [ ---------------------------------------- ] M/s
18.7113 Pb / 25.4 + PS /345.34
( -------------------------- )
273.3 + T
WHERE

PV - PITOT TUBE DIFF.PR.IN mm. OF WC.

Pb - BAROMETRIC PRESSURE IN mm OF Hg.
PS - STATIC PRESSURE IN mm OF WC.
T - TEMPERATURE IN 0C
 CLEAN AIR FLOW TEST
AIR FLOW = 0.32725*D2*V* lbs/min

D - DIA. OF PIPE IN INCHES

V - AIR VELOCITY ft/s
 -AIR DENSITY

DESIRED RESULTS
MEASURED AIR FLOW BETWEEN 135% AND 160% OF
STANDARD AIR FLOW

MEASURED AIR VELOCITIES ARE WITHIN 5% OF

AVERAGE VELOCITIES
CAUSES OF MILL REJECTS
• LOW AIR VELOCITY
– LOW AIR FLOW
– AIR BYPASSING
• HIGH RE CIRCULATION RATIO
– WEAR OF GRINDING ELEMENTS
– IMPROPER SETTING OF GRINDING
ELEMENTS
– IMPROPER SPRING COMPRESSION
– OPERATING MILL WITH HIGHER FINENESS
– HIGH MOISTURE COAL/LOW MILL OUTLET
TEMPERATURE
CAUSES OF MILL REJECTS
• OVER FEEDING EXCEEDING MILL
CAPACITY
– MALFUNCTIONING OF FEEDER OR FEEDER
HINGE GATE
– HIGH RPM OF FEEDER
– REDUCTION IN MILL CAPACITY
• EFFECTS OF REJECTS
– REDUCTION IN BOILER EFFICIENCY
– DETORIARATION OF DUST GUARD SEAL
– OIL CONTAMINATION RESULTING DAMAGE
TO MILL DRIVE COMPONENTS
 MILL PLANT REQUIREMENTS
• MUST BE ABLE TO HANDLE DESIGN QUANTITY
COAL AND PRODUCE AN ACCEPTABLE
PRODUCT EVEN WITH WORN OUT
COMPONENTS
• P.F.MUST BE WITHIN DESIRED GRINDING
RANGE AT ALL STABLE LOADS
• WET COAL UPTO DESIGN WETNESS MUST BE
ADEQUATELY DRIED WHILE FULL OUTPUT IS
MAINTAINED
• AT NO TIME MUST IT BE NECESSARY TO
OPERATE THE MILLING PLANT IN AN UNSAFE
CONDITION
 DRYING CAPACITY
Wf = AO*(TI-TO)*4.043*10-04/MC*(1+)
WHERE
Wf - COAL THROUGHPUT Kg/s
AO - AIR FLOW AT MILL OUTLET
Kg/s
 - LEAKAGE FACTOR =(AO-AI)/AI
AI - AIR FLOW AT MILL INLET Kg/s
TI - AIR TEMPERATURE AT MILL
INLET 0C
TO - COAL-AIR TEMP. AT MILL OUTLET 0C
MC - TOTAL MOISTURE FRACTION OF
COAL
 MILL PLANT CONSTRAINTS
• GRINDING LIMIT
– GRINDABLITY INDEX
– MILL MOTOR CAPACITY
• P.F.FALL OUT LIMIT
– MIN. VEL. OF COAL-AIR 18 TO 20Kg/s
• EROSION LIMIT
– 1.5 TIMES OF FALL OUT LIMIT
• FLAMMABLITY
– SAFE AIR/FUEL RATIO 5:1
• FLAME STABLITY
– MINIMUM THROUGHPUT NOT LESS THAN 50%
• ATTEMPERATION
– MINIMUM AIR TEMP. CONSTANT
 MILL OPERATING WINDOW
BASIC DATA
COAL TYPE - BITUMINOUS
TOTAL MOISTURE - 24% MAXM; 14% NOMINAL
COAL FLOW -12Kg/s(MAX.);10.3Kg/s
NOMINAL
GRADING - 94% < 150 µm
HOT AIR TO MILL TEMP. -2950C(MAX); 2000C(MIN)
AIR FLOW TO MILL - 30.2Kg/s
SEAL AIR FLOW TO MILL - 0.5Kg/s at 150C
RATED P.A. FAN POWER - 406kw at 42.7Kg/s FLOW
MINIMUM AIR FLOW - 21Kg/s
EROSION LIMIT - 33 Kg/s
AIR-FUEL MIXTURE TEMP. -700C
 MILL OPERATING WINDOW
LIMITING VALUES
MAX.COAL THROUGHPUT-12Kg/s at 94%  150 m
STABLITY 0.5*12=6 Kg/s COAL FLOW
EXPLOSION LIMIT AT 5:1 AIR/FUEL RATIO
FAN POWER Wf +Wa =12 + 30.2 + 5 =42.7 Kg/s
FALL OUT - MIN. AIR FLOW -21 Kg/s
EROSION LIMIT - 33 Kg/s
FOR DRYING LIMIT
AT 2900C AIR TEMP. & 24% MOISTURE
 = (30.7-30.2)/30.2 =0.017
Wf = AO*(TI-TO)*4.043*10-04/MC*(1+)
= AO*(290-70)*4.043*10-04/(0.24*1.017)
= 0.36*AO
AO = 2.7 Wf
AIR/FUEL RATIO = 2.7: 1
AT 2000C AIR TEMP. & 14% MOISTURE
AIR/FUEL RATIO = 4.6: 1
 Test Procedure For Collecting
An ASME Fineness Sample
• Sample locations are
positioned correctly with
regard to bends and
restrictions. Ideally, test
taps should be located in
a vertical run of piping,
10 diameters upstream
and downstream from
the nearest disturbance.
A minimum of two taps,
90° apart, is required.
Taps should not be
located at the discharge
of an exhauster.
 Test Procedure For Collecting
An ASME Fineness Sample
• Traverse points collected
from equal area test grid
• Traverse points are sampled
for equal time intervals. This
is necessary for calculation of
total recovered sample (A
fineness test is said to be
representative when the sum
of the samples totals between
90 - 110% of the indicated
feeder flows). Collection of a
timed sample allows for
determination of relative pipe-
to-pipe fuel balance.
 Test Procedure For Collecting
An ASME Fineness Sample
• Traverse points are sampled for equal
time intervals. This is necessary for
calculation of total recovered sample (A
fineness test is said to be representative
when the sum of the samples totals
between 90 - 110% of the indicated
feeder flows). Collection of a timed
sample allows for determination of
relative pipe-to-pipe fuel balance.
Recovered fuel flow per pipe is calculated
using the following equation:)
 Test Procedure For Collecting
An ASME Fineness Sample
Fuel Flow lbs/Hr per burner line
=
gms sampled per pipe 1lb 60min pipe area sft
---------------------------- ---- -------- ---------------
Sample time in min. 453.6 1Hr. Tip area

0.0021 sft
 Procedure to collect coal
samples using the ASME Coal
Sampler :
Insert the sample probe into the dustless connector,
open the ball valve, and slide the probe in to the
first port (probe completely inserted) with the flag
of probe (sample tip) in the direction of flow. Turn
the tip of the probe into the flow, turn on and adjust
the aspirating air to achieve/maintain 10 psi, and
start the stopwatch. Sample each traverse point for
10 seconds (total burner line sample time of 4
minutes, assuming a 24 point traverse grid). Upon
completion of the last traverse point, cut off the air,
and remove the probe. Repeat the process for each
port.
 Procedure to collect coal
samples using the ASME Coal
Sampler : :
• After completing traverses of each test port on a
designated burner line, empty the sampling jug
and the filter canister into a labeled Ziploc bag.
Repeat the process for each burner line on the
pulverizer.
• Once all burner lines on the pulverizer have been
tested, weigh the samples and calculate an
individual burner line fuel flow and sum the results
to determine (%) recovery. If the cumulative
recovery is not between 90% - 110% of the feeder
indication, then repeat traverse again increasing
and/or decreasing the extraction diff. Pr. until
desired recovery is achieved.
 Coal Sieving Procedure
• Air drying of sample is recommended if
high moisture (>10%) coal is being fired
or sieving is not performed immediately
after sample extraction
• Prevents the coagulation of sample on top
of sieve screens which prevents particles to
pass through screens and results in non-
representative coal fineness
• ASTM D-197 specifies drying at 10° – 15°C
above room temperature with (1) to (4) air
charges per minute until weight loss is less
than 0.1% difference.
 Coal Sieving Procedure
• Remove 50 grams of coal from the sample.
This is done by using an ASTM riffler or by
“rolling” the sample (usually between 200 g
and 800 g).
• Shake the sample through a series of 50,
100, 140 and 200 Mesh U.S. Standard sieves
• Record the weight of coal residue on each
screen and coal in the bottom pan (passing
200 Mesh). Great care should be taken in
weighing coal sample residue on each
screen. Residue on 50 Mesh will be very
small and must be weighed accurately to
yield representative data.
 Coal Sieves and
Calculations
• Wt of test sample 50g
• Wt.of residue on 50 mesh R 1g
• Wt.of residue on 100 mesh R 2g
• Wt.of residue on 140 mesh R 3g
• Wt.of residue on 200 mesh R 4g
• Wt.of residue in pan R5g
 Coal Sieves and
Calculations
• % Passing 50 mesh ( 50-R1) *100/50
• % Passing 100 mesh {50-(R1+R2)}
*100/50
• % Passing 140 mesh {50-(R1+R2+R3)}
*100/50
• % Passing 200 mesh {50-(R1+R2+R3+R4)}
*100/50