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Highlights
Coal Beneficiation FBC Combustion of low GCV/high ash rejects generated through beneficiation Utilization of Ash so generated
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.
Better consistency in quality of coal thereby resulting in operational savings at Power station end due to :
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.
Immersed steam raising or water heating tubes which extract heat directly from the bed.
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 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
Cement manufacturing
Brick manufacturing
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
Dry Ash
Pelletise
Sintered
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.
FBC Boilers
Power Classify Fly Ash for Cement Coarse Ash LWA Processing LWA Blocks Ash
LWA