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Safety - Milling of Fuels

The document discusses safety aspects of coal mill operation. It provides information on solid fuels used including coal, petroleum coke, lignite, and charcoal. It describes the fuel drying and grinding system and highlights general safety rules regarding combustible dust, oxygen concentration, and ignition sources. The document also discusses factors that can increase the risk of coal self-ignition like volatile content, particle size, moisture content, and contaminants. It provides guidelines for oxygen concentration during coal grinding. Safety control measures like explosion protection, fire protection, and inerting installations are also covered.

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249 views17 pages

Safety - Milling of Fuels

The document discusses safety aspects of coal mill operation. It provides information on solid fuels used including coal, petroleum coke, lignite, and charcoal. It describes the fuel drying and grinding system and highlights general safety rules regarding combustible dust, oxygen concentration, and ignition sources. The document also discusses factors that can increase the risk of coal self-ignition like volatile content, particle size, moisture content, and contaminants. It provides guidelines for oxygen concentration during coal grinding. Safety control measures like explosion protection, fire protection, and inerting installations are also covered.

Uploaded by

Anonymous Cxriyx9HIX
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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You are on page 1/ 17

COAL MILL OPERATION

SAFETY ASPECTS
Coal Shop Safety

SOLID FUELS

 Coal
 Petroleum coke (sulfur % )
 Delayed coke: the most common

 Non grindable fluid coke

 Shot coke (as impurity in delayed coke)

 Lignite
 Charcoal (moinha)

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2
Coal Shop Safety

FUEL DRYING- GRINDING SYSTEM


Raw Coal Dust Collector

Feed Pulverized
Bin Coal Silo

Pulverized
Coal
Grinding - Drying
Hot gases System

Flowsheet of Grinding - Drying System

3
Coal Shop Safety

General Safety Rules


Three Conditions

 Combustible dust (or gas) in exploding


concentration

 Oxygen above the critical concentration

 Ignition source

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COAL IGNITION TEMPERATURE Vs VM Coal Shop Safety

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Safety in Coal Shops – Current TA Coal Shop Safety

High Risk Fuels defined as any fuel >36%VM &


High Risk Operation defined when grinding finer.
Compliance of both TA and specific requirements for
High Risk Fuels & High Risk Operation required PRIOR
to use
For blended fuels
 Weighted average VM of the blend determines the
level of risk.
 If any single component of the blend ≥ 20%, by weight
has a VM higher than the weighted average then, this
fuel’s VM is used to determine the level of risk
TA: Technical Agenda - Safety in Coal grinding Shops Update FEB 2007

6
Coal Shop Safety

General Safety Rules Ignition Process


 Coal absorbs oxygen from atmosphere
Heat Produced Heat Released
 Temperature increases and speeds up oxidation
process
(Inside the pile, the heat cannot be released)
 First three weeks of storage = maximum oxygen
intake.
 Critical Temperature ( 70 - 80 °C) for self-ignition

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Coal Shop Safety

General Safety Rules Ignition Process

For coals stored at a temperature of 20° C, the


risk is worth paying attention to when the storage
time exceeds:

 4 months for anthracite coals

 2 to 3 months for lean, rich and 1/4 rich coals

 1 to 2 months for long-flaming coals

 1 week to 1 month for lignites

8
Coal Shop Safety

General Safety Rules Ignition Process


 Some of the most important factors which
heighten the danger of self-ignition of coal are:
 High volatile content in the fuel (>20 % over dry)
 The more fine-granular the coal, the larger the
reactive surface to absorb oxygen (proportion of
fines greater than 10%)
 Coal containing, besides the fine-granular portion,
also coarse material, since air intake into the coal
heap is facilitated by this heterogeneous structure

9
Coal Shop Safety

General Safety Rules Ignition Process

 Some of the most important factors which


heighten the danger of self-ignition of coal are:
 Freshly mined coal reacts faster with oxygen than
coal stored for a longer period
 Coal with an abnormally high moisture content
 Foreign components such as pyrite (>4%), iron,
phosphorus in the coal ash
 Already hot fuel

10
Coal Shop Safety

General Safety Rules Oxygen Concentration

 Coal grinding should be done in inert atmosphere

 Basic rules for the Oxygen during coal grinding are:

< 14% O2 for Petcoke and Anthracite

< 10% O2 for coal with volatiles below 30%

< 9% O2 for coal with volatile above 30%

The interlocked maxmax is 1 % point higher

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Coal Shop Safety

General Safety Rules Protection Measures

 Explosion protection

 Fire protection/ fighting

 Water spray

 Inerting installation

 CO2

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Coal Shop Safety

CIRCUIT CONTROL

 Mill outlet temperature constant (70-95°C), mill inlet


below safe level.

 Sweep air volume: Fan power ( KW) constant


(damper).

 Fuel fineness: Mill sweep / Separator settings / Roller


pressure /Ball charge.

 Indirect firing : P.F. bin level constant / high bin level.

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Typical Coal Mill Flow Sheet Coal Shop Safety

O2/CO analyser
Temp/Press sensors

O2/CO analyser
Temp/Press sensors

14
Coal Shop Safety

General Safety Rules Safety Control


Sensors Threshold
Grinding mill outlet temp (coke) 115°C
Grinding Mill outlet temp (coal) 95°C
Mill inlet Temperature: HVF 250°C (550F)
Mill inlet temperature: LVFuel 300°C (680F)
Filter outlet O2 (coke) 15%
Filter outlet O2 (coal) 13%
Filter outlet CO 2000 ppm
Fired fuel into the kiln (% H2O) 0.5 - 1.5%
Filter outlet temperature (coke) 105°C
Temperature difference (outlet - inlet) 10°C
Temperature difference variation 10°C
Filter hopper temperature (coke) 85°
“Pulverized” hopper CO 1000 ppm
“Pulverized” hopper temperature 85°
Sources (JP Senechal 1997 memo, S. Fujimoto 1992 training course)

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Coal Shop Safety

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BASIC CONSIDERATIONS Coal Shop Safety

RAW COAL: EXHAUST GASES:


• Feed size : 0-50 mm • Temperature : 75-90°C
• Moisture content : 10-15% H2O • Dust load : 500-600g/m3
• Grindability : 50-70°H

 DRYING
 GRINDING
 CLASSIFYING
HOT GASES: PULVERIZED COAL:
• Temperature : 250-300°C • Fineness : 1-15%
• O2 content : 3-7% R 0.09 mm
• Dew point : 20-70°C • Moisture content : <1.0% H2O

Grinding-Drying of Coal: Basic Considerations


17

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