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Coal Beneficiation for Optimal Utilization of Coal

Highlights
Coal Beneficiation FBC Combustion of low GCV/high ash rejects generated through beneficiation Utilization of Ash so generated

THUS OFFERING ZERO WASTE SOLUTION

What is Beneficiation

Segregation of good quality coal from not so good quality coal or rejects.

Why Beneficiate/Wash
Ever increasing concern about environment.

Greater emphasis on increasing production has resulted in deterioration of raw coal quality.

To reduce strain on already over stretched Railway system. In November 1997 MoEF, Govt. of India decided that all thermal plants located at a distance of 1000 km recently revised to 500 km in July, 2012 or more from the pithead or located in urban areas or critically polluted areas irrespective of distance (except Pit head stations) must use coal not exceeding 34% Ash from June 2001.

It is however, felt that washing all coals to 34% ash is not justifiable in all cases due to unfavorable techno economic of washing some very difficult coals with low yields. However, it could be taken as a broad guide line.

Advantages of Coal Beneficiation


Lower Ash content

Better consistency in quality of coal thereby resulting in operational savings at Power station end due to :

Lower generating costs from improved thermal efficiency and availability

Lower Ash disposal

Lower Operation and maintenance cost

Reduction in support fuels.

and savings in transport

However immediate perceived benefits from lower ash coal is that there will be reduction in freight costs. Besides transport costs very low monetary value is given to other benefits viz savings in ash disposal costs, reduced land requirements, reduced transport and handling costs, social benefits like reduced settlement costs and reduced effects on cultivation in the impact zone and improved health and living conditions.

FBC Combustion

On washing if it is not possible to reduce the ash content in rejects to less than 65-70% which allows safe disposal without danger of self combustion it will be worth utilizing washery rejects in Fluidised Bed Combustion FBC at the washing site for power generation.

An FBC system releases heat more efficiently at lower temperatures. Since lime stone is used as particle bed control of So2 and Nox emissions in the combustion is achieved without any additional control equipment.

Types of fluidised bed combustion boilers


Atmospheric Bubbling type (AFBC)
Tubes above the bed which extract heat from hot combustion gases before they enter the flue duct. Distribution plate through which air is blown for fluidizing.

Pressurised Fluidised Bed (PFBC)

Circulating Fluidised Bed (CFBC)

Features of Bubbling type Boilers :

Immersed steam raising or water heating tubes which extract heat directly from the bed.

Circulating Fluidised Bed Combustion (cfbc)


CFBC technology has evolved from Conventional Bubbling Bed Combustion as a means to overcome some of the draw back associated with conventional Bubbling bed combustion/
CFBC boilers are generally claimed to be more economical than AFBC boilers for industrial application requiring more than 70-100 T/hr steam.

CFBC requires huge mechanical cyclones to capture and recycle large amount of bed material which requires tall boilers.

CFBC could be good choice in following conditions Capacity of Boiler is large or medium. Sulphur emission and Nox control is important Low grade fuel or fuel with highly fluctuating fuel quality. METSO has developed CFBC boilers which can use coal with GCV as low as 1100 Kcal

Pressurised Fluidised Bed Combustion (pfbc)

Pressurised Fluidised Bed Combustion is a variation of Fluid Bed technology that is meant for large scale coal burning applications. In PFBC the bed vessel is operated at pressure of upto 16 ata. (16kg/cm2 ). The PFBC system can be used for cogeneration or combined cycle generation, by combining the gas and steam turbines. In this way, electricity is generated more efficiently than in conventional system. The overall conversion efficiency is higher by 5-8%

In FBC boilers, the bottom ash constitutes roughly 30-40% of the total Ash, the rest being fly Ash which generally has lower percentage of unburnt carbon

Potential areas of Ash Utilisation

Cement manufacturing

Roads & Embankment construction

Stowing material in mines/ back filling in open cast mines.

and many more medium and high value added products.

Brick manufacturing

Light Weight Aggregate (LWA). Stone chips or Precast Concrete units.

Agriculture & Forestry

Important Factors in use of Fly Ash


Chemical content (Alumina, Silica, Iron Oxide and Calcium Oxide).

Classification
Various types of classifiers are used to remove coarse and less/ non reactive fly Ash. Centrifugal classifiers are efficient with no moving parts and are designed for effective separation between 20-100 m. By removing the required over size coarse material, the centrifugal classifier produces an in spec fly ash suitable for blending with Cement and Ready Mix Concrete

Fineness (finer is the ash, higher is the Pozzolonic reactivity)

Loss in ignition i.e.% of Unburnt Carbon Content

Light Weight Aggregate (lwa)


Properties Fineness Carbon in Ash Fusion Temperature Consistency Criteria Maximum 22% retention on 45 m seive 0-9% maximum by weight Maximum softening temperature 1300 C

Manufacturing Process (lwa)


Wetted & Mixed

Dry Ash

Pelletise

Sintered

Why use LWA

Reduction in weight reducing Loading

Improve Thermal properties

Improve fire resistance

Improve durability

Environmental benefits

With increasing concern of environmental degradation and ever increasing pressure on land required for dumping ash more and more emphasis is being laid on effective use of Ash which is becoming one of the imperatives for sustainable environment ensuring near ZERO WASTE solution.

Coal Beneficiation Flow Chart


Raw Coal Beneficiation Clean Coal Rejects

FBC Boilers
Power Classify Fly Ash for Cement Coarse Ash LWA Processing LWA Blocks Ash

LWA

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