SOP Coal Loss Accounting Qualitative (Part II)

MSD VISION & MISSION
VISION
TO BE THE PREFERRED SOLUTION

PROVIDER FOR ACHIEVING COMMERCIAL
EXCELLENCE ACROSS THE
ADITYA BIRLA GROUP
MISSION
CREATE VALUE BY INSTITUTIONALISING

SYSTEMS, INTRODUCING BEST PRACTICES
AND REALISING GROUP SYNERGY
CTC VISION & MISSION

CTC ACTS AS A CATALYST, BY PROVIDING GROUP WIDE
TECHNOLOGICAL SERVICES IN SUPPORT OF UNIT’S
EFFORTS FOR :
• TECHNICAL PROBLEM SOLVING

• COST REDUCTION
• SHARING KNOWLEDGE AND EXPERIENCE
GROUP VALUES
SOP Coal Loss Accounting : Qualitative (Part-II) has been developed on the foundation of following group values –
INTEGRITY
We define Integrity as honesty in every action. Each one of the Coal Management team should act and take decisions
in a manner that are fair, honest and following the highest standards of professionalism. ‘Integrity’ should be the
cornerstone for all the dealings, be it with customers, employees, suppliers, partners, shareholders, the communities or
the government.
COMMITMENT
On the foundation of Integrity, Commitment should be seen as “Doing whatever it takes to deliver as promised”. Each
one of the Coal Management team should take ownership for their work, teams and the part of the organization they
are responsible for. Through this value they shall build an even sharper results oriented culture that is high on reliability
and accountability. Their commitment is likely to make them a formidable leader and competitor in every market that
they are in.
PASSION
Passion is defined as a missionary zeal arising out of an emotional engagement with work, which inspires each one to
give his or her best. Each one of the Coal Management team are expected to be energetic and enthusiastic in the pursuit
of their goals and objectives. They should recruit and actively encourage employees with a ‘Fire in the belly’. With this
Value, they would build a culture of innovation and break-through thinking leading to superior customer satisfaction
and Value creation.
SEAMLESSNESS
Seamlessness is understood as thinking and working together across functional silos, hierarchy levels, across business
lines and geographies. Each one of the Coal Management team shall demonstrate high level of teamwork through
sharing and collaborative efforts and garner the synergy benefits from working together. Before they can truly benefit
from a borderless world, they need to build a borderless organization. They should visualize free flow of knowledge
and information across the Group.
SPEED
Speed is looked upon as responding to internal and external customers with a sense of urgency. They should continuously
seek to crash timelines and ensure expeditious completion of their tasks. Each one of the Coal Management team
should aim on time service to the present and future needs of their customers.
l Integrity l Commitment l Passion l Seamlessness l Speed

ACKNOWLEDGEMENTS
We would like to put on record our deep appreciation for the valuable
inputs received during visit to the following units:
l Hindalco – Renusagar Power Division
l Awarpur Cement Works
l Rajashree Cement
l SFD Nagda
We would like to give special thanks to our group members, who have given their continued
support and proactive suggestions/ discussions which has gone a long way in making and
finalizing this SOP.
l Shri NK Sharma – Renusagar Power Division
l Shri R K Gupta – Renusagar Power Division
l Shri V N Srivastava – Awarpur Cement Works
l Shri Dinesh Randad – Awarpur Cement Works
l Shri R S Lawrence – Awarpur Cement Works
l Shri Sunil Kothari – Rajashree Cement
l N K Dwivedi – Rajashree Cement
l Shri B N Agarwal – Harihar Polyfirbres
l Shri Rajendra Jain – SFD Nagda
l Shri SK Dhanuka - SFD Nagda

STANDARD OPERATING PROCEDURE
ON
COAL LOSS ACCOUNTING
QUALITATIVE
(Part II)
MANAGEMENT SERVICES DIVISION

&
CENTRAL TECHNICAL CENTRE
March 2007
SOP-Coal Loss Accounting : Qualitative, (Part-II)
SOP-COAL LOSS ACCOUNTING : QUALITATIVE, (PART-II)
TABLE OF CONTENTS
1. Coal Quality Overview ....................................................................................................................... 3

1.1 Grades of Coal ................................................................................................................ 5
1.2 Coal Contents ................................................................................................................. 6
1.3 Coal Quality Control Parameters ................................................................................... 7
1.4 Proximate Analysis ........................................................................................................ 8
1.5 Ultimate Analysis ........................................................................................................... 10
1.6 Grindabilty ..................................................................................................................... 12
1.7 Use of Coal in Power Generation .................................................................................. 12
1.8 Use of Coal in Cement Industries ................................................................................. 13
1.9 Effect of Coal Quality on Power Plant Performance .................................................... 13
1.9.1 Common problems due to poor and inconsistent quality of coal ................................... 13
1.9.2 Benefits of washed coals ................................................................................................ 14
1.0 A Coal quality analysis flow diagram .......................................................................................... 15
1.0 B Testing standards for coal and coke ......................................................................................... 15
1.0 C Coal sampling flow diagram – Hindalco, Renusagar ............................................................... 16
1.0 D Coal sampling flow diagram – Grasim, Rajashree Cement ...................................................... 17
1.0 E Coal sampling flow diagram – Awarpur Cement Works ........................................................... 18
2. Coal Sampling .................................................................................................................................... 19
2.1 General Principles of Sampling .................................................................................................... 19
2.2 General Procedures for Establishing a Sampling Scheme ............................................................ 20
2.3 Design of Sampling Scheme .......................................................................................................... 21
2.4 Joint Sampling ............................................................................................................................... 21
2.5 Auto Sampling .............................................................................................................................. 22
2.6 Dust Suppression System ............................................................................................................. 23
3. Procedure for Determination of Moisture ............................................................................................ 24
4. Procedure for Determination of Fixed Carbon Percentage in Coal ..................................................... 25
5. Procedure for Determination of Volatile Matter in Coal ..................................................................... 26
6. Procedure for Determination of Ash Content in Coal .......................................................................... 28
7. Procedure for Determination of Calorific Value .................................................................................. 30
Management Services Division & Central Technical Centre 1

8. Procedure for Determination Hardgrove Grindabilty Index of Coal ................................................... 36

9. Procedure for Sampling and Fineness Test of Pulverized Coal .......................................................... 38
10. Procedure of Sampling Coal from Trucks During Unloading ............................................................. 45
11. Procedure for Collection, Preparation and Analysis of Samples from Railway Wagons Outside
Plant ..................................................................................................................................................... 47
12. Coal Quality Testing Equipments ....................................................................................................... 52
13. Procedure for Determination of Boiler Efficiency .............................................................................. 60
14. Glossary -Coal ..................................................................................................................................... 68
Annexure -1 Technological Development in Coal Testing equipments ............................................... 73
Annexure – 2: Daily Coal Quality Reporting Format ......................................................................... 87
Annexure – 3 : Monthly Coal Analysis Report ................................................................................... 88
SOP-COAL LOSS ACCOUNTING : QUANTITATIVE

MINE TO FACTORY
TABLE OF CONTENTS
1. Overview of Coal Mining ................................................................................................................ 89

2. Handling of Coal at Mines .............................................................................................................. 91
3. Loading of Coal on Truck or Rake At Mines .............................................................................. 96
4. Loading or Discharge of Coal from Vessel ................................................................................... 102
5. Transit of Coal .................................................................................................................................. 108
6. Stock Verification .............................................................................................................................. 110
Annexure – 1: Risk Assessment Procedure .................................................................................. 113
2 Management Services Division & Central Technical Centre

1. COAL QUALITY - OVERVIEW
Coal becomes greater in value and rank as it ages and therefore loses its undesirable components as
time passes. The amount of carbon increases from about 65 percent to 96 percent with time, between
the stages of Peat to Lignite as shown in fig.1 Hydrogen decreases from five percent to two percent.
Oxygen can decrease from amounts of up to 30 percent to traces as low as one percent. Sulphur’s
component changes from a low trace to as much as four percent in the sub-bituminous and bituminous
stages back to small traces again. Moisture decreases as well through the stages of formation from 70
percent to five percent.
Fig.1 VARIOUS STAGES OF COAL FORMATION

Coal quality is evaluated by composition of carbon, moisture, volatile matter and ash etc. This
composition ultimately determine the value of coal.
• Moisture is a component that costs money to transport as well as it consumes energy. It is

therefore seen as a negative quality. Moisture should be as minimum as possible.
• Ash is viewed negatively as it is the product of inflammable materials. It not only lowers
the quality of coal but also increase the transportation and handling cost.
• Carbon is main component of coal .It acts as a main heat generator during burning. It
should be as maximum as possible.

• Volatile matter is the component that will generate the heat when coal is burnt and therefore is
the positive component. High volatile matter content indicates easy ignition of fuel.
Based on fixed carbon and moisture contents, coal can be broadly classified into two catagories as
shown in Fig. 2
Fig. 2
A Typical Proximate analysis of various coals is shown in graph.
T y p i c a l proximate a n a l y s i s o f v a r i o u s c o a l s ( I n p e r c e n t a g e )
6 0
51.3
50 46.8
P e r c e n t a g e
38.6
40
34.7
29.8 Indian Coal

30
23.3 Indonesian Coal
20.7
20 17
14 South African Coal
9.4 8.5
10
6
0
M o i s t u r e A s h Vo l a t i l e matter F i x e d c a r b o n
contents

Elements which are found in coal include carbon, hydrogen, sulphur, nitrogen, and oxygen.
1.1 Grades of Coal
The common coal used in Indian industry is bituminous and sub-bituminous coal. The gradation
of Indian coal is based on its calorific value.
The quality of coal is specified by notified agencies by useful heat value (UHV) is as follows:
Grade Calorific Value range- (KCal / Kg)

A Exceeding 6200
B Exceeding 5600 but not exceeding 6200
C Exceeding 4940 but not exceeding 5600
D Exceeding 4200 but not exceeding 4940
E Exceeding 3360 but not exceeding 4200
F Exceeding 2400 but not exceeding 3360
G Exceeding 1300 but not exceeding 2400
Normally D, E and F coal grades are available to Power Sector.
The formula for calculation of UHV is as follows
UHV = 8900 - 138(A + M) kcal/kg

Where
UHV = Useful heat value
A = % Ash
M = % Moisture in coal determined under standard conditions of 60% RH & 40°C basis

1.2 Coal Contents :
The typical raw coal components, presently being used by the power stations is given below:
Sulphur
0.2
1.0
Moisture
21
4
Ash
30
Volatile 55
25
18
Matter
Fixed carbon
20
38
0 20 40 60 80 100
Minimum Maximum
1. Ash Content: 30% to 55%, generally around 45%.
2. Moisture content: 4% to 21% except in rainy season when it goes higher in some cases.
3. Sulphur content: 0.2% to 1.0%
4. Gross Calorific Value: 3000 K Cal/kg. to 5000 K Cal/kg. (3500 K Cal/kg.)
5. Volatile matter: 18% to 25 %
6. Fixed Carbon 20% to 38%
Elemental analysis, moisture content, and grades of typical Indian coals
Coal C% H% S% N2% O2% Ash% Moisture GCV UHV

Grade % (Kcal/Kg) (cal/gm)
D 30-33 2.1-2.4 0.4-.6 0.7-.8 NA 25-27 7-8 4999-5555 4332-4760

E 37.9 2.4 0.53 0.8 6% 30.4 7.5 4529.0 3670.0
F1 41.87 3.33 0.56 0.94 6% 34.07 7.8 4137.0 3122.0
F2 44.47 3.37 0.35 0.99 6% 36.3 8.4 3833.0 2731.0

1.3 Coal quality control parameters :
The quality of coal is primarily measured by how well it burns, how much heat it gives out in
the process, and how much ash it leaves behind afterwards. These characteristics depend on
how much of the coal is fuel (i.e. carbon and hydrogen) and how much of it is non-combustible
components like water and mineral impurities. As a first step following components are analyzed
by measuring the change in weight of a sample heated and ultimately burnt to yield.
Moisture : The water given off by heating to 105ºC in nitrogen (to prevent any
burning).
Volatile Matter : Gases and vapours formed by decomposition of the coal by heating in
nitrogen to 900ºC. These gases contain virtually all of the coal’s hydrogen
and the carbon which combines with it (e.g. as methane, CH4).
Fixed carbon : Fixed carbon is the carbon left over after the volatiles have been driven
off, determined from the change in weight when the devolatised sample
is burnt in air.
Ash : Ash is the incombustible residue; mostly from mineral impurities in the
coal. The ash content is the most important measure of coal quality.
Calorific Value : The Calorific Value (energy content) of the coal is measured by burning
a small sample in a calorimeter. The energy released is usually measured
in mega joules per kilogram (MJ/kg), or giga joules per tone (GJ/t), which
are the same. The fuel energy of any coal is about 32 MJ/kg; this is reduced
according to the content of water and mineral impurities. The Calorific
Value is the most important measure of coal value.
Calorific Value is a complex function of the elemental composition of the coal. Calorific
value is mostly determined by experimental measurements.
A close estimate can be made with the Dulong formula
GCV = (144.4 * %[C]) + (610.2 * % [H])-(65.9 * % [O]) +(0.39 * %[O]2)

Where C = Carbon, H = Hydrogen O = Oxygen
Calorific value (CV) is given in Kcal/kg or Btu/lb. Values of the elements C, H, and O, are
calculated on a dry ash-free coal

1.4 Proximate analysis
Proximate analysis is the simpler of the tests and is used to determine the moisture, ash,
volatile matter and fixed carbon content.
Fixed
Determines (on an as-received basis) Moisture carbon
Ash
z Fixed carbon (solid fuel left after the
volatile matter is driven off).
Volatile
Matter
z Moisture content
Fixed carbon Volatile Matter Ash Moisture
z Volatile matter (gases released when

coal is heated).
z Ash (impurities consisting of silica, iron,

alumina and other incombustible matter)
Significance of various parameters in proximate analysis
a. Fixed carbon
Fixed carbon is the solid fuel left in the furnace after volatile matter is distilled off. It consists
mostly of carbon but also contains some hydrogen, oxygen, sulphur and nitrogen not driven
off with the gases. Fixed carbon gives a rough estimate of heat value of coal.
b. Volatile Matter
Volatile matters are the methane, hydrocarbons, hydrogen and carbon monoxide, and
incombustible gases like carbon dioxide and nitrogen found in coal. Thus the volatile matter
is an index of the gaseous fuel present. Typical range of volatile matter is 20 to 35%
Volatile matter
z Proportionately increases flame length and helps in easier ignition of coal
z Sets minimum limit on the furnace height and volume.
z Influences secondary air requirement and distribution aspects.
z Influences secondary oil support

c. Ash content
Ash is an impurity that will not burn. Typical range is 15 to 40%
Ash
z Reduces handling and burning capacity
z Increases handling cost
z Affects combustion efficiency and boiler efficiency
z Causes clinkering and slagging
d. Moisture content
Moisture in coal decreases the heat content per kg of coal. Typical range is 6 to 14%.
Moisture
z Increases heat loss, due to evaporation and superheating of vapour
z Helps, to a limit, in binding process
z Aids radiation heat transfer
e. Sulphur content
Typical range is 0.5 to 0.7 %
Sulphur
z Affects clinkering and slagging tendencies
z Corrodes chimney and other equipment such as air heaters and economizers
z Limits exit flue gas temperature

Fixed Carbon
Proximate Volatile
Moisture
Analysis matter
Ash
1.5 Ultimate analysis
Ultimate analysis is used to determine the elemental composition in terms of Carbon,

Hydrogen, Sulphur, Nitrogen and Oxygen by difference.
Determines the amount of :
z Carbon
Carbon
Ash
z Hydrogen Sulphur
Nitrogen
z Oxygen Oxygen
Hydrogen
z Nitrogen
Carbon Hydrogen Oxygen
Nitrogen Sulphur Ash
z Sulphur
The ultimate analysis includes the various elemental chemical constituents such as Carbon,
Hydrogen, Oxygen, Nitrogen and Sulphur.
It is useful in determining the quantity of air required for combustion and the volume and
composition of combustion gases. This information is required for the calculation of flame
temperature and the flue gas duct design.

Typical comparison of various coals is shown in graph.
60
58.9
50
41.1
40
30 Indian coal%
Indonesian coal%
20
11.9
9.4 9.9
10 6 4.2
2.8 1.2 1 0.4 0.56
0
Moisture Carbon Hydrogen Nitrogen Sulphur Oxygen
Relation between Ultimate analysis and proximate analysis

%C = 0.97C+ 0.7( VM-0.1A)-M (0.6-0.01M)
%H = 0.036C + 0.086 ( VM-0.1 x A)-0.035M2 (1-0.02M)
%N = 2.10-0.020VM
C = % of fixed carbon
Where A = % of ash
VM = % of Volatile matter
M = % of Moisture
Note: The above equation is valid for coal containing greater than 15% moisture content
The percentages can be reported by weight in a variety of different ways:
As sampled (as received) - exactly as the sample came to the lab
Dry - based on the air dried sample (not completely dried)
Dry, Ash free - based on the air dried sample with ash removed
Dry, Mineral Matter Free (DMMF) - based on the air dried sample with all mineral (inorganic)
matter removed
Mineral matter is not directly measured but may be obtained by one of a number of empirical
formulae based on the ultimate and proximate analysis. Further empirical relationships are
also possible between carbon, hydrogen, oxygen and CV.

1.6 Grindability
This is particularly important if a coal is to be burnt in the pulverized state. In this case,
significant work must be done in order to reduce the coal down to particles of sufficient size
for combustion. The Hard grove grindability index is calculated by applying a standard amount
of work on a sample of coal and determining the increase in surface area. The value, G is
based on the fraction of coal of initially sieved with a size 16 mesh, passing through mesh size
30 after a standard mill. The value ranges between 20 and 100 for most coals. The easiest to
grind being the bright, bituminous coals.
Hard grove grindability Index measurement (HGI)
With this technique the hardness of coal can be determined. The sample is first ground and
sieved to a specific size, and ground in the HGI equipment under special conditions.
The grindability value obtained is compared with a calibration curve based on international
standard tests. The hardness gives information about the energy consumption when grinding
coal. A low HGI value indicates a hard coal, which will require more energy for grinding, than
a coal of high HGI value.
1.7 Use of coal in Power Generation
In our group units like Hindalco, Renusagar power division, Grasim Nagda, coal is mainly
used for power generation.

1.8 Use of coal in Cement Industries

In Rajashree Cement, Awarpur Cement, Aditya Cement and Vikram Cement coal is used for
cement making along with power generation.
Typical Flow Diagram of Clinker Production
1.9 Effect of coal quality on power plant performance
Coal quality is a vital factor in determining plant efficiency. It not only affects the overall
profit margin but also contributes to other significant problems, if quality of coal is poor.
1.9.1 Common problems of power plants due to poor and inconsistent raw coal
quality are listed below:
z Damage to conveyor belts and crusher elements
z Frequent choking of chutes and feeders
z Reduced pulverizing capacity of the mills
z Higher erosion of grinding elements
z Reduced availability of mills due to higher outages
z Reduced flame stability requiring additional oil support

z Slagging and fouling of the water walls
z Faster erosion at the coal burners and flue gas path
z Increased requirement of land for dumping of ash and ash handling equipment
z Reduced Plant Load Factor (PLF) as well as reduced station thermal efficiency
z Higher emissions and related environmental impacts.
z Several other operational problems may also arise due to poor and inconsistent
quality of coal.
1.9.2 Benefits of washed coals:
Some of the well recognized benefits arising from combustion of washed coal in thermal
power stations are :
Reduction in:
z Emissions into the atmosphere
z Ash handling and disposal costs
z Requirement of oil support
z Load on transportation system
z Operating and maintenance costs in existing plants
z Capital cost of new plants
Increase in:
z Thermal efficiency
z Plant availability
z Plant output

1.0 A COAL QUALITY ANALYSIS FLOW DIAGRAM
Coal Quality Analysis
Proximate Analysis Ultimate Analysis
Moisture Volatile Matter Carbon Hydrogen
Fixed carbon Ash Oxygen Nitrogen
Sulphur
Hard grove Particle size

Calorific Value Abrasion index
grindability index Analysis
1.0 B TESTING STANDARDS FOR COAL AND COKE
Testing standards :
Sl. No Description Testing Standards Contents
1.0 Proximate analysis Moisture
Volatile Matter
IS : 1350 Part I 1984
Fixed Carbon
Ash
2.0 Ultimate analysis Carbon
IS : 1350 Part IV
Hydrogen
Nitrogen
IS : 1350 Part IV
Oxygen
IS : 1350 Part III Sulphur
3.0 Calorific Value IS : 1350 Part II Calorific Value
4.0 Hardgrove Grindabilty Index IS : 4433 1979 Hard grove Grindability Index
5.0 Sieve analysis ASTM D 197 Determination of fineness of coal
6.0 Abrasion Index IS : 9949 1986 Determination of abrasiveness of coal

HINDALCO - RENUSAGAR POWER DIVISION :

1.0 C FLOW DIAGRAM OF COAL SAMPLING, QUALITY CHECK POINTS
NCL, JHINGURDA
Loading
Station
Road CCL,
ARW-1 ARW-2
Transport OTHERS
Unloading Unloading
Wagon
railway
siding Morwa
C. H. P-1 C. H. P-2 & 3 Coal Yard
As Received As Received As Received As Received

Coal Sample Coal Sample Coal Sample Coal Sampling
Crusher Composite Sample

Coal Sample
Crushed
CoalYard
Jaw Crusher
Indirect feeding Direct feeding
Coal scale / Fired Testing for Moisture, Ash,

Coal bunker Volatile Matter,
coal feeder Coal Sample
Fixed Carbon and CV
Boiler Coal Mill Fineness Sample

1.0 D RAJASHREE CEMENT - COAL SAMPLING AND ANALYSIS FLOW

DIAGRAM
Coal Rake
Pyro Stream Kiln Stream
Residue Residue
Ash Ash
IM Check IM Check
Point Point
Coal Mill Residue

Ash
IM Check Pyro Kiln
Point Silo Silo
Bunker
Coal Coal
Hopper-2 Hopper-1 Reclaimer
Computer Crusher
For
Blending
2BC 32
Ash Moisture Analyser Coal Stock Pile
Check
Total Moisture Ash Point Stacker

1.0E AWARPUR CEMENT WORKS: FLOW DIAGRAM OF COAL SAMPLING,

QUALITY CHECK POINTS
Trucks Weighment at Coal trucks receive

weigh bridge at Main gate
Unloading in open yard Heap formation Transportation with

with dozer tipper for crushing
Water spray
Sampling for Moisture,

Ash and SO3
Water spray Crushing
Sieve analysis
Reclamation Stacking
Yard
Evaporation
Raw Coal hoppers Coal Mills Fine coal bins Measuring devices
Sieve analysis Sampling for

Moisture, Ash, CV, SO3
Kiln
Firing Equipments
Coal Mills Calciner

2. COAL SAMPLING
Coal is a highly heterogeneous substance in terms of the inorganic and organic constituents and
exhibits wide variability with respect to size and chemical composition of the particles. An estimation
of the true value of the desired parameters of a bulk material, to a certain degree of confidence,
through analysis on a few grams of test sample is definitely a daunting problem. The basic purpose
of collecting and preparing a sample of coal is to obtain a test sample which when analyzed will give
the test results representative of the lot sampled.
In order that the sample represents the lot from which it is taken, it is collected by taking a definite
number of increments distributed throughout the whole volume of coal.
The procedure for sampling will, however, differ with the purpose and method of sampling. Samples
may be required for technical evaluation, process control, and quality control or for commercial
transactions. For quality assessment of coals from new sources, samples are to be drawn from
in-situ coal seams, either as rectangular blocks or pillars cut from full seam height, or from seam
channels or from borehole cores.
To check the quality of coal consignments, it is desirable to get the sample from conveyor belts. The
reference method of ‘stopped belt’ sampling is often implemented to standardize the mechanical
automatic sampling system.
Quality monitoring of coal is an important activity for any commercial transactions between the
consumers and the producers.
The sampling procedure will depend mainly on the nature of sample collection i.e. by mechanical
or manual means, from moving belt or from stationary lots like wagons, stockpiles, etc. Normally
any sampling scheme is supposed to confirm to relevant national or international standards. However,
due to cost and time constraints, very often some changes are made in the method of sampling
jointly by the seller and the purchaser. It is a known fact that about 80% of the total variances
involved at the different stages of sample collection, preparation and analysis comes from errors
during its collection only.
2.1 General principles of Sampling
The main requirements for coal sampling are,
z All particles of coal in the lot to be sampled are accessible to the sampling equipment and
each individual particle shall have an equal probability of being selected and included in
the sample.

z The dimension of the sampling device used should be sufficient to allow the largest particle
to pass freely into it.
z The first stage of sampling known as primary increments is the collection of an adequate
number of coal portions from positions distributed over the entire lot to take care of the
variability of the coal. The primary increments are then combined into a sample, as taken
or after reducing the mass of the sample to a manageable size. From this gross sample, the
required number and types of test samples are prepared by a series of processes jointly
known as sample preparation.
z The minimum mass of the gross sample should be sufficient to enable particles to be
present in the same proportions as in the lot of coal from which it is taken.
z To ensure that the result obtained has the required precision, the following issues are to
be considered.
z Variability of coal
z Number of samples from a lot
z Number of increments comprising each sample
z Mass of sample relative to the nominal top size
The ideal method of sampling is the stopped belt method, which is considered free of bias. As
implementation of such method will affect the continuity of plant operations, it is not always
practicable for routine sampling. However, any mechanical sampling device needs to be checked
for bias by comparing with the results from stopped belt reference method
2.2 General procedure for establishing a sampling scheme
1 Decide the purpose for which the samples are taken e.g. plant performance evaluation,
process control, commercial transactions etc.
2 Identify the quality parameters to be determined, i.e. general analysis, total moisture, size
analysis, washability, etc.
3 Catagorize the size of coal in three parts i) small [0-2”] ii) large coal [2 - 6”] iii) Run of
mine coal [0-9”]
4 Define the lot .

4 Define the precision required
5 Decide whether continuous or intermittent sampling is required
6 Determine the number of sub-lots and the number of increments per sub lot to achieve the
required precision.
7 Determine or estimate the nominal top size of the coal
8 Determine the minimum mass per increment and the minimum mass of the total sample
9 Decide on the method of combining the different increments to produce the gross sample
10 Decide on drawing common or separate samples, for general analysis and moisture
2.3 Design of sampling scheme
Sampling scheme has to be designed based on the purpose of sampling and after ascertaining
at what stage of coal handling operation the sample is required.
z Division of lots: A lot may be sampled as a whole or a series of sub lots. Each sub lot will
constitute one sample.
z Basis of sampling: It can be either time basis or mass basis. In time basis the sampling
interval is defined in minutes/seconds and mass is proportional to the flow rate, whereas
in mass basis the interval is defined in tonne and the mass of increments is uniform.
z Accuracy: In all methods of sampling, sample preparation and analysis, errors may be
introduced at every stage and the measured value may differ from the true value of the
parameter. As the true value is not exactly known it is difficult to assess the accuracy of
the results, but an estimation of accuracy of the results can always be made.
Decide required accuracy precision for each parameter of a lot and then the number of
sub-lots, number and mass of increment are to be estimated.
2.4 Joint sampling
Normally, joint sampling is carried out at the loading end by the representatives of the producer
and the customer, following a methodology mutually agreed upon by both parties. Depending
on the agreement, the loading point results can be taken exclusively for commercial transactions.
In some cases the mean value of the results of joint sampling at both the loading and unloading

ends is considered. The variance values in the quality parameters are often defined, beyond
which several bonus/penalty clauses are imposed. What needs to be stressed is whether the
variance value identified is compatible with the sampling scheme. More clearly, whether the
variation in the value lies within the precision limit that can be achieved through the
implementation of a particular sampling scheme. This requires periodic testing, which
unfortunately is rarely practiced in India.
It is a common experience that in spite of joint sampling, there often exist wide discrepancies
in the results at the two different ends. There may be multiple reasons for this:-
z Procedures agreed for sampling and sample preparation are not followed at the two ends.
z In case of manual sampling human discretion becomes a significant factor
z Deviation from the procedures identified in the agreement
z The level of accuracy required / agreed upon remained undefined, while designing the
sampling scheme.
2.5 Auto Sampling:
To get a correct assessment of the quality parameters, it is recommended that

sampling should be done through auto mechanical sampling systems. Immediate
steps need to be taken to bring the existing Auto mechanical sampling system in
working conditions, followed by testing of bias. The system should be studied for a
prolonged period to identify its limitations and constraints.
PRIMARY SAMPLER
SAMPLING SYSTEMS FOR CRUSHED COAL (-) 20mm

2.6 Dust Suppression system:
The Dust Suppression System is meant to suppress the

coal dust generated during transfer of coal at feed/
discharge points of conveyors in various transfer points.
There are several existing methods of controlling dust
but many are ineffective, costly and have detrimental
effects on plant and machinery. An effective system for
the control of fugitive dust in industry should meet the
following objectives.
1. Must be efficient to meet Health and

Safety requirements.
2. It should be practical and simple in operation.
3. Have low initial cost.
4. Have low operating costs.
5. No adverse effects on product quality or plant and machinery should be created.
At Rajashree Cement Works, dust suppression system is installed at Wagon tippler area.
This system is designed in-house by plant team and effectively working as a means to
suppress the coal dust at the time of unloading as well as feeding to the respective units.
Water spray is being done on the reclaimer belt having material sensors to prevent escaping
the fine dust of coal.
System consists of high pressure water pump, water storage tanks to store sufficient amount
of water for a day operation and high pressure jet nozzles to spray water in mist form.
Salient features of the system installed at Rajashree Cement :
1. System prevents to escape the fine coal particles in the atmosphere, mixes coal particles
with water mist and collect in coal bunker. Thus substantial amount of fine coal is
recovered.
2. System uses recycled water of treatment plant. There is no additional requirement of

fresh water.
3. Clean and Environment friendly atmosphere.

3. PROCEDURE FOR DETERMINATION OF MOISTURE
3.1 Purpose
To know the moisture content of coal, crushed to pass through 212 micron IS sieve.
3.2 Scope
This method is applicable to all types of coals.
3.3 Reference
IS -1350 (Part -1) 1984
3.4 Definition
It is the moisture in coal which has been air dried under the laboratory atmosphere
condition prior to analysis and determined as a part of proximate analysis of coal.
3.5 Procedure
For detailed Procedure please refer to SOP- Coal Loss Accounting

4. PROCEDURE FOR DETERMINATION OF FIXED CARBON PERCENTAGE IN COAL
4.1 Purpose
To know the carbon content of coal chemically bounded in coal besides the carbon which is
associated with volatile matter.
4.2 Scope
4.3 Reference
IS -1350 (Part -1) 1984
4.4 Definition
Fixed carbon (percent) is the figure obtained by subtracting from 100 the sum of the percentage
moisture, volatile matter and ash of the coal.
4.5 Procedure
4.5.1 The coal sample shall be ground to pass through 212 micron sieve for laboratory analysis.
4.5.2 The percentage of moisture in coal sample shall be determined.
4.5.3 The percentage of ash in coal sample shall be determined.
4.5.4 The percentage of volatile matter in coal sample shall be determined.
4.5.5 The percentage of fixed carbon shall be calculated as follows:

% Fixed Carbon = 100 - (Moisture %+Ash %+Volatile matter %)

5. PROCEDURE OF DETERMINATION OF VOLATILE MATTER IN COAL
5.1 Purpose
For assessment the use for which coal is suitable and for classification also.
5.2 Scope
5.3 Reference
IS -1350 (Part -1) 1984
5.4 Definition
The Volatile matter is the loss in mass less than due to moisture, when heated under standard
conditions.
5.0 Procedure
5.5.1 The volatile matter determination crucible shall be put (with lid and plunger) in stand
5.5.2 The crucible with stand shall be placed in furnace at a temperature of 900 ± 10º C for
7 minutes.
5.5.3 The crucible with stand shall be removed from the furnace and cooled first on a metal
and then in desicator for 20 minutes.
5.5.4 The crucible (with lid and plunger ) shall be weighed and 1 gm of coal sample (ground
to pass 212 micron IS sieve) shall be weighed in crucible.
5.5.5 The coal sample shall be pressed with plunger and the crucible shall be covered with
lid.
5.5.6 The crucible shall be put in stand.

5.5.7 The crucible with stand shall be placed in furnace at a temperature of 900 ± 10º C for
7 minutes.
5.5.8 The crucible shall be removed, cooled and weighed as mentioned in clause 5.5.4
5.5.9 The volatile matter of the coal sample shall be calculated as given below :
Calculation
100 ( M 2 -M 3 )
% Volatile matter V= -M 0
( M 2 -M1 )
Where M0= % moisture content in the sample
M1 = Mass in gm of empty crucible with lid and plunger
M2 = Mass in gm of crucible with lid and plunger plus mass of coal sample before heating
M3 = Mass in gm of crucible with lid and plunger plus mass of coal sample after heating

6. PROCEDURE OF DETERMINATION OF ASH CONTENT IN COAL
6.1 Purpose
To check the quality of coal and to calculate useful heat value (UHV) of coal for grade
specification
6.2 Scope
This method is applicable to all types of coal.
6.3 Reference
IS -1350 (Part -1) 1984
6.4 Definition
Ash is the organic residue left when the powdered sample of coal has been incinerated in air in
open dish until it no longer change in weight at 815 ± 10º C.
6.5 Procedure
6.5.1 The air dried laboratory coal sample shall be thoroughly mixed and ground to pass
212 micron IS sieve
6.5.2 A clean dry empty ash determination silica crucible shall be weighed.
6.5.3 Approximately 1 gm of coal shall be weighed.
6.5.4 The coal shall be spread on the crucible so that it does not exceed 0.15 gm/cm2
6.5.5 The uncovered dish shall be inserted into the muffle furnace at room temperature.
6.5.6 The temperature shall be raised to 500º C in 30 minutes and to 815 ± 10º C in 30 to
60 minutes and shall be maintained at this temperature for 60 minutes.
6.5.7 The crucible shall be removed from furnace and shall be allowed to cool first on a cold
metal plate for 10 minutes and finally in a desicator.

6.5.8 It shall be weighed after 20 minutes.
6.5.9 It shall be reignited at the same temperature until the change in mass of ash shall be
less than 0.001 gm.
6.5.10 The ash shall be brushed and the empty crucible shall be reweighed.
6.5.11 The mass of ash shall be obtained by difference.
6.5.12 The percentage of ash content shall be calculated as given herein under :
Calculation
Ash % by mass = 100X (M3 – M4)/ (M2 – M1)
Where,
M1 is the mass in gm of crucible
M2 is the mass in gm of crucible +mass in gm of coal sample
M3 is the mass in gm of crucible and ash
M4 is the mass in gm of crucible after brushing out the ash and on reweighing

7. PROCEDURE OF DETERMINATION OF CALORIFIC VALUE
7.1 Purpose
To check the quality of coal and to calculate calorific value of coal.
7.2 Scope
This standard prescribes the methods of test for coal and coke relating to the determination of
calorific value
7.3 Terminology
a. Gross calorific value –
Number of heat units liberated when a unit mass of fuel is burnt at constant volume in oxygen
saturated with water vapour, the original material and final products being at approximately
25 0C. The residual products are taken as carbon dioxide, sulphur dioxide, nitrogen and water;
the residual water other than that originally present at vapour, being in the liquid state
To convert gross calorific value to net calorific value.
NCV = GCV -53 * H
Where
NCV = Net calorific value in Kcal/kg
GCV = Gross calorific value in Kcal/kg
H = Percentage of hydrogen present in the coal sample, including hydrogen of moisture and
of water constitution
b. Net Calorific value
Number of heat units liberated when a unit mass of the fuel is burnt at constant volume in
oxygen saturated with water vapour, the original and final materials being at approximately
250 C. The residual products are taken as carbon dioxide, sulphur dioxide, nitrogen and water
vapour.

7.4 Sampling –
7.4.1 Methods of sampling -As per IS: 436(Part 1)-1964 for coal and IS: 436(Part II)-1965
for Coke
7.4.2 Preparation of samples for test
7.4.2.0 General: It is expected that methods of sampling prescribed in IS:

436(Part 1)-1964 for coal and IS: 436(Part II)-1965 shall have been followed
in the preparation of samples sent to laboratory.
7.4.2.1 The samples prepared in accordance with IS: 436(Part 1)-1964 for coal and
IS: 436(Part II)-1965 shall be in sealed containers and shall consist of the
following:
A) Analysis sample of about 300 g of air dried coal or coke, ground to pass
212 micron IS sieve (see IS -460-1962)
B) Special moisture sample of 1 kg of coal or 2.5 kg of coke, crushed to pass

12.5 mm square- mesh screen (see IS: 460- 1992) to be sent in duplicate.
7.4.2.2 Where air –drying has been adopted in the preparation of the samples, the
percentage loss of moisture in this operation shall be required to be recorded
on the label together with the method of sampling used.
7.4.2.3 Samples received in the laboratory, if already ground to pass 212 micron IS
sieve, shall be re- sieved to verify that all the material passes the sieve, and
then air – dried for 24 hours and mixed and bottled as above.
7.5 Calorific value of coal and coke
7.5.0 General – Two methods have been described to determine the calorific value of coal
and coke. They are: (a) making use of calorimetric bomb immersed in a static or
isothermal water jacket. (b) Making use of calorimeter bomb immersed in an adiabatic
jacket.
7.5.0.1 The calorific value as determined in these methods is the gross calorific value
of coal and coke at constant volume expressed in calories per gram.

7.5.0.2 Temperature dependence of calorific value –the calorific value of coal and
coke decreases with increase of temperature. The magnitude of dependence
varies between 0.1 and 0.3 cal/g0C, the lower value being for anthracites;
correction for variation in temperature of determination is, therefore, usually
negligible.
7.5.1 Principle – The coal or coke is burned in a bomb calorimeter of known heat capacity.
The principal observation is that of a temperature rise which, when corrected for the
errors of the thermometer and multiplied by the effective heat capacity at the mean
temperature of the chief period, gives the heat release. Further, allowance is necessary
for
a) Cooling loss
b) Heat gain due to heat released by the ignition system
c) Heat of formation of sulphuric and nitric acids from sulphur dioxide and
nitrogen.
7.5.2 Apparatus: Details are as per IS 1350(Part II) -1970
7.5.2.1 Combustion bomb
7.5.2.2 Calorimeter vessel
7.5.2.3 Water jacket
7.5.2.4 Stirring arrangement
7.5.2.5 Thermometer
7.5.2.6 Thermometer viewer
7.5.2.7 Crucible
7.5.2.8 Ignition circuit5.2.9 Timer
7.5.2.9 Pressure regulator and pressure gauge
7.5.3 Reagents : Details are as per IS 1350(Part II) -1970

7.5.4 Isothermal calorimeter Method
7.5.4.1.0 Coal used for the determination of calorific value is the analysis sample
ground to pass through 212 micron IS sieve. The sample is exposed in a
thin layer for the minimum time necessary for the moisture content to
reach equilibrium with the laboratory atmosphere.
7.5.4.1.1 Weigh the crucible to the nearest 0.1 mg and introduce into it in sufficient
quantity of the samples to cause a temperature rise of 2 0 to 3 0 C. Weigh
the crucible and contents to determine the weight of sample taken. Also
determine the moisture of the sample at the same time.
7.5.4.1.2 Connect a piece of firing wire rigidly across the terminals of the bomb.
Tie a known weight of cotton to the firing wire and arrange the ends of the
cotton so that they touch the sample.
7.5.4.1.3 Put 1 ml of distilled water in the bomb. Assemble the bomb and charge it
slowly with oxygen to a pressure of (30 atm) without displacing the original
air. Put sufficient water in the calorimeter vessel to cover the flat upper
surface of the bomb cap. This quantity of water should be the same, within
1 g, as that used in determining the mean effective heat capacity. The
temperature of the water shall be about 2.50C lower than that of water
jacket.
7.5.4.1.4 Transfer the calorimeter vessel to the water jacket; lower the bomb into
the calorimeter vessel and check that the bomb is gas tight. If gas escapes
from the bomb, discard the test.
7.5.4.1.5 Assemble, start up the apparatus and keep the stirrer and the circulation
arrangements in continuous operation throughout the determination. Use
a constant rate of stirring. After an interval of not less than ten minutes,
read the temperature to .0010C and continue the readings for five minutes,
that is, the preliminary period, at equal intervals of not more than one
minute, tapping the thermometer lightly during 10 seconds prior to each
reading. If, over a period of five minutes, the average deviation is less
than 0.000 72 0C per minute, close the battery circuit momentarily to fire
the charge and continue to those of the preliminary period. If the rate of

change of temperature is not constant within this limit, extend the

preliminary period until it is constant.
7.5.4.1.6 In the chief period, which extends from the instant of firing until the time
after which the rate of change of temperature again becomes constant,
take the earlier readings to the nearest 0.010C. Resume the readings to this
precision as soon as possible. Determine the rate of change in the after
period (which follows the chief period) by taking readings at 1 minute
intervals for at least five, preferably ten minutes.
7.5.4.1.7 Remove the bomb from the calorimeter vessel, release the pressure and
dismantle the bomb. Examine the bomb interior and discard the test if
unburnt sample or sooty deposits are found.
7.5.4.1.8 Wash the contents of the bomb into a beaker with distilled water. Wash
the underside of the bomb cap and the outside of the crucible with the
distilled water; add the washings to the beaker. Dilute to approximately
100 ml and boil to expel carbon dioxide. While still hot, titrate with standard
barium oxide solution using phenopthalein solution as indicator. Add 20
ml of sodium carbonate, warm, filter and wash the precipitate with distilled
water. When cold, titrate the filtrate with the hydrochloric acid solution,
using the methyl orange solution as indicator, ignoring the phenopthalein
color change.
7.5.4.2 Corrections –The followings corrections are made to the experimental observations.
7.5.4.2.1 Thermometer corrections
7.5.4.2.2 Cooling correction
a) The Regnault- Pfaundler( R-P) correction
b) Whitaker correction
7.5.4.2.3 Heat of ignition – the heat release from the cotton and firing wire is restricted
from the total heat release. The heat release from the cotton is calculated
from the weight, after drying at 1050C, of a known length of cotton thread,
and using the calorific value of a cellulose (4180 cal/g). Determine the weight
of a piece of wire equal in length to the distance between the poles of the

bomb, and calculate the heat release by allowing 335cal/g for nickel-
chromium wire, or 100 cal/g for platinum wire.
7.5.4.2.4 Heat of formation of acids – The heat gain due to the formation of sulphuric
acid and nitric acid is subtracted from the total heat released. These
corrections amount to 3.6cal/ml of 0.1 N sulphuric acid and 1.43 cal/ml of
0.1 N nitric acid present in the bomb washing and calculated as follows:
Sulphuric acid correction = 3.6 (a + b – 20) cal; and

Nitric acid correction =1.43 (20-a) cal;
Where
a = vol in ml of 0.1 N hydrochloric acid used
b = vol in ml of 0.1 N barium hydroxide used
7.5.4.2.5 Correction for unburnt carbon
If unburnt carbon is suspected, its heat equivalent, on the basis of 1 mg of

carbon equals 8 calories shall be added to the determined heat release.
Unburned carbon is determined as the loss in weight on ignition of the residue
from the crucible.
7.5.4.3 Calculation – as per IS 1350(Part II) -1970

8. PROCEDURE FOR DETERMINATION OF HARDGROVE GRINDABILITY INDEX OF COAL
8.1 Purpose
To know the properties like hardness, strength and to estimate the coal behavior with respect
to coalmill/pulverizer.
8.2 Scope
This method is applicable to all types of coals except brown coal and lignite..
8.3 Reference
IS – 4433 -1979
8.4 Definition
A prepared sample of coal is ground in a standard laboratory mill under defined conditions.
Hardgrove grindability index is calculated by the standard formula as per IS standards.
8.5 Sampling
Sample collection and preparation shall be in accordance with IS 436 (Part 1/ Sec 1) 1964
Except initial crushing shall be to 4.75 mm instead of 10 mm. Final coal sample of about 1kg
may be obtained by sample divider of suitable size and capacity.
8.6 Procedure
8.6.1 Before test grindability machine should be thoroughly cleaned and space the balls as
evenly as possible around the grinding bowl.
8.6.2 Sample of about 50± 0.01 gm prepared as per IS 436 (Part 1/ Sec 1) 1964 shall be
distributed evenly in grinding bowl surface is smoothened. Fasten the bowl and
assemble the top grinding ring and preset the counter and automatic stopping device
so that machine can operate for 60±0.25 revolutions.

8.6.3 Now switch on the apparatus
8.6.4 When rotation is stopped switch off machine and dismantle the bowl.
8.6.5 Empty the grinding balls and ground coal on protective sieve. Also brush any coal
from the bowl and the balls into the protective sieve setting them aside.
8.6.6 Brush any coal and dust from the inside and underside of the protective sieve into 75
micron sieve and set it aside.
8.6.7 Replace the cover on the 75 micron sieve. Shake the assembled pan, 75 micron sieve
and cover for 10 minutes. Carefully brush any coal dust from the underside of 75
micron sieve into the pan. Repeat this application for two more times for a period of 5
minutes each. Clean the underside of 75 micron sieve after each repetition.
8.6.8 Weigh separately to the nearest 0.01 gm of the coal retained on the 75 micron sieve and
the coal passing the 75 micron sieve. If the sum of these masses differs by more than
0.3 gm from the initial mass of 50± 0.01 gm, the test shall be rejected.
8.6.9 Calculations
8.6.9.1 Hard Grove grindability index can be calculated using the formula
HGI = 13 + 6.93 M
Where
M = mass of the test sample passing through 75 micron sieve after grinding.
In practice M is obtained by deducting from 50 gm of mass of ground sample
retained on 75 micron sieve.
In IS 4433 -1979 a standard table to ascertain the value of HGI from the
experimental values of mass of the coal particles over 75 microns is also
provided

9. PROCEDURE OF SAMPLING AND FINENESS TEST OF PULVERIZED COAL
9.1 Purpose
This Test method covers the determination of the fineness by sieve analysis of coal sampled
from a dry pulverizing operation.
9.2 Scope
This method is applicable to dry pulverized coal and not applicable to products of wet milling
or to fines that have clustered into an agglomerated mass.
9.3 Reference
ASTM D 197 -87
9.4 Definition
This test provides a means for assisting in the evaluation of pulverizers and Pulverizers system
in terms of fineness specifications.
9.5 Sampling, storage system
9.5.1 In the pulverized coal storage system, the coal after pulverized is conveyed into bins.
9.5.1.1 Collection of gross sample – Collect not less than ten increments of
representative pulverized coal preferably as it is being discharged from the
collector. This is best accomplished by collecting increments of not less than
50 g at regular intervals by means of scoop, dipper or a device capable of
removing increment from a specific location within the stream of pulverized
coal.
9.5.1.2 Preparation of the laboratory sample – A small riffle (sample divider) can be
used for mixing and dividing the sample by splitting. Mix the gross sample
by splitting and recombining the halves a minimum of two times. Divide the
sample amount by successive riffle splitting operations on one half of the
sample until the sample is divided to approximately 500 g for the laboratory
sample.

9.5.1.3 As an alternative to riffle mixing and splitting, the sample can be prepared as
follows: Place the gross sample on a sheet of rubber, plastic, or paper and
mix it by raising first one corner of the cloth and then the other so as to roll
the coal over and over at least 20 times. After mixing, divide the sample;
continue the operations of mixing and dividing until the sample is divided
sufficiently so that all of one of the divisions weighs approximately 500 g.
This shall constitute the laboratory sample.
9.6 Sampling, Direct feed system
9.6.1 In the direct feed system, the coal is pulverized and delivered to the furnace in
an air stream. It is difficult to obtain representative samples, as it is necessary
to sample the coal from a moving stream of coal –air mixture inside the pipe
between the pulverizer and furnace. It is preferable to collect such samples
from vertical pipes, as horizontal pipes a greater amount of segregation may
take place.
9.6.2 Apparatus for sample collection : It is very difficult to collect a representative

sample of solids from a moving coal air system, it is essential that an equipment
and sampling procedures are uniformly consistent to assure valid and
reproducible results. Recommended equipment and sampling arrangement are
shown in fig 1, 2 and 3


9.6.2.1 In figure recommended arrangement for sampling pulverized coal in a direct

fired system using a dustless sampling connection with an aspirator and a
cyclone collector. In collecting the sample, turn on the compressed air to the
dustless connection and adjust to give a balanced pressure at the connection.
Insert the sampling tip into the dustless connection with the tip facing directly
into the coal – air stream. Readjust the compressed air to give a balanced
pressure with the nozzle inserted. Traverse the fuel transport line across the
entire diameter of the pipe by moving at a uniform rate with the tip facing
directly into the coal – air stream. The aspirating air on the cyclone collector
may or may not be used, depending on the static pressure in the fuel transport
line.
9.6.2.2 Fig. 3 shows detailed dimension of a recommended sampling tip. The area
of the tip shown in is 12.7 mm by 24.1 mm or 306 mm2). which is the
projected area of the tip facing the coal –air stream.
9.6.3 Collection of gross sample as per ASTM D 197
9.7 Fineness Test
9. 7.1 Drying sample - Air dry the entire laboratory sample in a drying oven at 10 to 15º
above the room temperature. Continue the drying until the loss in weight is not more
than 0.1% /hour

9. 7.2 Dividing the sample – After air drying, divide the sample amount to 50 to 100 gm.
9.7.3 Sieve Test
9.7.3.1 Select the proper sieve sizes for the test and thoroughly clean each by carefully
brushing and tapping to assure that no solid particles from previous tests are trapped
in the meshes. Nest the sieves together with the coarsest mesh at the top and in
descending order with the finest mesh in the bottom of the nest to receive the undersize.
Place 45 to 55 g of coal weighed to 0.05 g on the top sieve and cover with a fitted
cover to prevent loss.
9.7.3.2 Place the assembled set into the sieving machine and make the necessary
adjustments for the sieving operation. Adjust the timer for a 10 minute period and start
the machine
9.7.3.3 At the end of sieving period, remove the stack, slip off the receiver pan, and
carefully brush into the pan receiver any particles that have adhered to the bottom
surface of the bottom sieve. Carefully transfer all of the pan contents into another
receptacle and return the clean pan receiver to the bottom of stacker sieves. Retain the
transferred fines for weighing
9.7.3.4 Return the stacked sieves to the sieving machine, set the timer for a 5 minute
period and start the machine. At the end of this interval, remove the stack and repeat
the procedure. However, this time collect the fines from the pan receiver and those
brushed from the under- surface of the sieve and weigh. When the collected fines from
the 5 minute sieving weigh less than 0.5 g, consider the sieving operation complete. If
the fine weigh in excess of 0.5g, reassemble the stack and repeat the sieving operation
at 2 minute intervals until less than 0.2 g of fines are collected for a 2 minute interval.
9.7.3.5 Combine the fines collected in all of the operations and weigh on a balance
sensitive to 0.01 g. Disassemble the sieves beginning with the largest. Material that
can be brushed from the bottom of a sieve shall be considered to be part of the sample
that has passed through that sieve. This material can be brushed directly onto the next
finer sieve. Material that is lodged in the sieve shall be considered a portion of the
sample that was retained on the sieve.

9.7.3.6 Weigh and record the amount of material collected from each sieve surface,
including the undersize material.
9.8 Calculations:
9.8.1 Calculate the fineness from the weights of the residues on the sieves, including the
undersize from the finest sieve, and express as percentage of weight of the original
sample. A difference between the original sample portion and cumulative sieve weight
is considered to be due to loss (or gain) of the undersize material and is so calculated.
If the loss is greater than 1% for coals having 75% or less undersize or is greater than
2% for coals having more than 75% undersize, discard the results and repeat the
determination.
9.9 Report:
The fineness test shall be reported as follows:
Retained on USA Passing Percentage %

Standard USA Standard
No 8 (2.36 mm) ———-

No 16 (2.36 mm) No 8 (2.36 mm)
No 30 (2.36 mm) No 16 (2.36 mm)
No 50 (2.36 mm) No 30 (2.36 mm)
No 100 (2.36 mm) No 50 (2.36 mm)
No 200 (2.36 mm) No 100 (2.36 mm)
No 325 (2.36 mm) No 200 (2.36 mm)
——- No 325 (2.36 mm)
9.10 Fineness test by hand sieving
9.10.1 For field testing or similar operations where a sieving machine is not available. The
test can be performed by a hand –sieving operation. The object of hand sieving
operation is to duplicate as nearly as possible the details of test as performed by
mechanical sieving.

This can be accomplished as below.
9.10.2 Prepare the sieves and the sample amount with the exception of placing the nest of
sieves into a sieving machine.
9.10.3 Instead, hold the nest of sieves with both hands and move back and forth in a slightly
circular orbit while resting on a ¼ inch (6.4 mm) plate (suggested dimensions 4 by
12 inch (100 X 300 mm)). With each movement, the stack is permitted to move over
the plate edge and tap the table surface. The above described manual movement is
designed to stimulate the rotation and tapping of machine sieving.

10. PROCEDURE OF SAMPLING OF COAL FROM TRUCKS DURING UNLOADING
10.1 Purpose
To know the quality parameters of coal transported by trucks.
10.2 Scope
This method is applicable for sampling of coal from trucks during unloading. Head of the
department shall ensure that the specified jobs are being carried out and corrective actions
are taken wherever required.
10.3 Reference
IS -436 (Part -1/ Sec 1) 1964
10.4 Definition
It is a sampling of coal to check the quality of coal during unloading in yard by trucks.
10.5 Environment and safety measures
10.5.1 Ensure use of nose mask and goggles during collection and preparation of coal
samples. Ensure proper ventilation by switching on exhaust fan.
10.5.2 Clean the work area, sampling plate, pastel and Mortar.
10.5.3 Mix the coal sample after several coning and quartering to make it homogenous.
10.5.4 After crushing the coal sample, make powder and pass through 212 micron sieve.
10.6 Procedure
10.6.1 For the purpose of sampling a lot shall be divided into sub-lots in conformity with
IS -436 (Part -1/ Sec 1) 1964
10.6.2 The gross sample from sub-lots shall be collected by suitable hand shovel in
conformity with IS – 436 (Part -1/ Sec 1) 1964

10.6.3 The total gross sample for a day shall be mixed together and shall be broken
manually to less than 5 cm and then reduced to 1/4th of original gross sample by
coning and quartering.
10.6.4 The reduced sample obtained shall be crushed to pass through 12.5 mm by jaw
crusher. About 1 kg of coal sample shall be collected for determination of moisture
and shall be kept in sealed container.
10.6.5 The crushed gross sample shall be again crushed to 3.35 mm by mill and reduced
to 2 kg by coning and quartering.
10.6.6 About 300 gm of so reduced coal shall be ground to pass through 212 microns IS
sieve for laboratory analysis.
10.6.7 The analysis shall be carried out for the determination of the following:
Moisture %
Ash %
Volatile Matter %
Fixed Carbon %
Gross Calorific value K Cal /kg

11. PROCEDURE FOR COLLECTION, PREPARATION AND ANALYSIS OF

SAMPLES FROM RAILWAY WAGONS OUTSIDE PLANT
11.1 Purpose
To know the quality (Moisture, ash, GCV) for fixation of prices.
11.2 Scope
This method is applicable for sampling of coal from railway wagon. It is also applicable to
imported coal transported through wagons.
11.3 Reference
IS – 436 Part -1/ Sec -1 of 1964 and as upgraded in Nov 1996
11.4 Definition
Since it is not possible to check every piece of coal in a consignment, laboratory tests are
carried out on a sample which represents the bulk of coal from which it was drawn.
11.5 Responsibility : Concerned Quality Department person
11.6 Procedure
A Collection of sample
(IS – 436 Part -1/ Sec -1 of 1964 and as upgraded in Nov 1996)
11.6.1 Making Sub- Lots
11.6.1.1 Average number of wagons in one rack ( lot) : 58
11.6.1.2 Average weight (MT) per rake (lot) : > 3000
11.6.1.3 No. of sub- lot shall be made as per IS standard : 6

(Clause 0.3.4.1 and 3.1)

11.6.1.4 No. of wagon in each lot
Sub-lot one (01) : 10 wagons (1 to 10 from power)

Sub-lot two (02) : 10 wagons (11 to 20 from power)
Sub-lot three (03) : 9 wagons (21 to 29 from power)
Sub-lot four (04) : 10 wagons (30 to 39 from power)
Sub-lot five (05) : 10 wagons (40 to 49 from power)
Sub-lot six (06) : 9 wagons (50 to 58 from power)
Note: If the wagons are more than 58 in nos. those will be added in sub – lot no.6
11.6.1.5 From each sub –lot 25% of wagon shall be selected i.e. 3 wagons from
each sub-lot.(As per clause 4.2.1 A)
11.6.2 Methods of Random Selection of Wagons
11.6.2.1 Random selection of wagons as per Appendix –A (clause 4.2.1 and 7.2)
shall be done.
11.6.2.2 Table no. 5 “Random Sample table” (as per clause A.2.1) shall be used.
11.6.2.3 Since no. of wagons are less than 100, 1st set of random nos. shall be
used.
(Random sample nos. for this purpose are reproduced and enclosed for
reference)
11.6.2.4 Random selection of wagons shall be done as follows :
i) For Sub-lot 1
¾ Any no. between 1 and 10 shall be selected
¾ Selected no. shall be located in the table.
¾ Another two nos. shall be selected by moving left or right or

moving upwards /downwards and selecting nos. less than 10
¾ All these selected nos. shall be arranged in a sequence.
¾ This nos. shall become the wagon nos. from which the samples
shall be collected.
ii) For Sub- lot 2

moving upwards/downwards and selecting nos.between
11 and 20.
shall be collected.
iii) For Sub- lot 3

moving upwards /downwards and selecting nos. between
21 and 29.
shall be collected.
iv) For Sub- lot 4

30 and 39.

shall be collected.
v) For Sub- lot 5

40 and 49.
All these selected nos. shall be arranged in a sequence.
shall be collected.
vi) For Sub- lot 6

50 and 58.
All these selected nos. shall be arranged in a sequence.
shall be collected.
11.6.3 Methods of Sample collection
11.6.3.1 Samples shall be collected all through the process of unloading of coal.
11.6.3.2 Weight of each increment (kg) Approx. : 07 kg.
11.6.3.3 No. of increments (about 7 kg each) from each wagon : 16

11.6.3.4 Quantity of coal samples shall be collected from each wagon :

(16 x 7) kg = 112 (approx.)
11.6.3.5 These collections shall be filled in two bags of about 50 kg each (approx.)
11.6.3.6 Each bag shall be selected with proper sealing arrangement.
11.6.3.7 Sealing shall be done in presence of authorized person from chemical

Lab., Coal quality, Technical services department (whenever deputed)
and representative of Supplier /Clearing agent (If available on site)
11.6.3.8 Each bag shall be tagged for identification indicating the sub-lot no. and
wagon number from which the sample has been collected.
11.6.3.9 Quantity of coal sample shall be collected from each sub-lot (16x 7x3):
336 kg (approx.)
11.6.3.10 Quantity of coal sample shall be collected from each lot and rake
(16x 7x3x6) kg comprising between (35 to 40 bags) : < 2000(approx)
11.6.3.11 All collected sample bags (35 to 40 nos.) shall be shifted to Coal Testing
Laboratory at plant.
B Sample preparation (IS 436 part I Sec -1 1964)
1.0 All the bags (35 to 40 nos.) shall be unsealed and opened at Coal Testing
Laboratory under the supervision of authorized persons (Whenever deputed)
and the representative of supplier / clearing agent (If available)
2.0 All the collected samples shall be poured in one heap.
3.0 Sample preparation shall be done as per (IS 436 part I Sec -1 1964)

12. COAL QUALITY TESTING EQUIPMENTS
BOMB CALORIMETER
With Digital Beckman thermometer for finding out the Calorific value of
Coal, coke, etc. Complete with 25 essential accessories with factory
test certificate for Bomb. Also available With Printer Models. Also
available additional accessories like Oxygen empty Gas cylinder with
factory and Ministry of Explosive certificates, Two stage pressure regulator
for inlet and out going pressure.
JUNKER’S GAS CALORIMETER
The Calorimeter, pressure governor, non-recording Gas Flow meter in which calorific value is ascertained
from the rise of temperature imparted to a measured quantity of gas. Range 1000-26000 Kcal/m2, 120 –
300 BThu/C.ft. Consists of calorimeter, pressure governor, and non-recording 1-litre flow meter and is
supplied with 2 litres and 50 ml measuring jars, 3 Thermometers and flexible tubing.
JAW CRUSHER – LAB MODEL
For speeding up crushing of aggregates, ores, minerals, coal, coke, ceramic and other similar materials.
Jaw size: 100 * 150 mm, max. size of feed : 50 mm (approx.), Product discharge size : 5 mm to 15 mm,
capacity 100 to 200 kg (Based upon material). Complete with 3 HP motor, starter, V-belt, pulley drive and
mounting for 440V, 50 Hz AC mains.
HARDGROOVE GRINDABILITY TESTER
As per IS: 4433/1967. It is a miniature pulveriser employing the ball bearing principles of grinding. Supplied
with automatic revolution counter, weights and built-in reduction gear. Wired for 240V, single phase, 50
Hz. AC mains.
ROLL CRUSHER – LABORATORY MODEL
For crushing different ore samples and minerals. Roll size: dia 200 mm and length of rolls 100 mm. Feed
size 8 mm, product size 1 to 2 mm. For 440 V, 50 Hz, 3 phase AC.
MINERAL JIG – LABORATORY MODEL
Stroke length is variable between 0” to ¾” at 400 rpm approx. size of screen compartment 4” * 6”,

complete with a mild steel stand structure driven by ½” HP 200 V AC motor and one 8 mesh screen and
one trash screen for the screen box along with starter.
BALL MILL – LABORATORY MODEL
Internal dia. 18 * 18 long, opening of 150 mm width and 350 mm long (approx.) speed of rotation is 56 ±
2 RPM. 12 Nos. of 1 ¼” dia. Steel balls are supplied with the unit. For 440 V, 50 Hz AC, 3 phase operation.
PULVERISER – LABORATORY MODEL (6” MINI MILL)
Designed for powdering lab model Rotor with beaters mounted on shaft direct coupled with 1 HP 3 phase,
440V, 50 Hz AC. With screen and cotton bag. Designed for powdering lab coal samples to 72/100 mesh.
PROXIMATE ANALYSER
For coal and coke as per IS: 1350. Consists of carbon & Hydrogen Analyzer, Volatile matter determining
furnace, Ash determination furnace, Moisture determination Oven.
MUFFLE FURNACE – HIGH TEMPERATURE – ELECTRIC
With Digital temperature indicating-cum-controller, thermocouple, air break magnetic contactor, fuses.
Maximum temperature up to 1400°C and regular recommended temp. not to exceed 1300°C. Available in
various sizes.
Vibrating Screen
Shaker Screens
Rota Screen
Electromagnetic Screens
Vibratory Feeder (Electromagnetic type)
Magnetic separators (Electromagnetic type)
Magnetic separators (Permanent magnet type)
Magnetic Drum
Magnetic pulley

6200 Automatic Isoperibol Calorimeter
To determine the calorific value of coal
Model 6200 is a microprocessor controlled isoperibol oxygen bomb calorimeter which is widely used for
both routine and occasional calorific tests. It uses the time-tested Parr 1108 oxygen bomb and oval bucket
in a compact calorimeter, producing reliable results with good repeatability, but differing from the 1271
and 6300 Models in that the bomb and bucket both must be removed from the calorimeter and refilled
manually for each test, thereby requiring more of the operator’s time than the automatic and semi-automatic
models.
All sensors, controls and jacketing in the 6200 Calorimeter are built into a single, compact cabinet to
provide a self-contained operating unit consisting of:
z A temperature-controlled water jacket with a built-in circulating system and an electric heater.
z An 1108 oxygen bomb with an oval bucket which fits into the insulating water jacket.
z A built-in semi-automatic system for charging the bomb with oxygen.
z A high precision electronic thermometer.

z A bright, color, touch screen display for data entry and operation control.
z Special communication ports for printer, computer and network (LAN) connections.
z Removable compact flash memory card slot for simple program updates and test report archiving.
Touch Screen
Precise Electronic Thermometry
Temperatures are measured with a high precision electronic thermometer using a specially designed
thermistor sensor sealed in a stainless steel probe which is fixed in the calorimeter cover. Measurements
are taken with 0.0001° resolution over a 20° to 40°C working range, with all readings shown in Celsius.
Effective Thermal Jacketing
Outstanding thermal jacketing is provided by a circulating water system driven by a built-in, high capacity
pump which maintains a continuous forced flow around the sides and bottom of the bucket chamber and
through the cover as well. The jacket temperature is held constant for isoperibol operation and no water
additions or waiting periods are required at the end of a run. A sealed immersion heater and a built-in heat
exchanger, both operated by the calorimeter controller, provide precise jacket temperature control.
A Reliable Oxygen Bomb
The Parr 1108 Oxygen Bomb furnished with the calorimeter will safely burn samples liberating up to
8000 calories per charge, using oxygen charging pressures up to 40 atm. An alternate 1108CL bomb with
superior resistance to chlorine and halogen acids is recommended for tests involving waste material and
chlorinated samples.

A Built-In Oxygen Filling System
To speed and simplify the bomb filling operation, the 6200 Calorimeter has a semi-automatic system for
charging the bomb with oxygen. Oxygen from a 1A commercial cylinder is connected to a microprocessor
controlled solenoid installed in the calorimeter. To fill the bomb, the operator simply slips the filling hose
connector onto the bomb inlet valve and pushes the touch screen to start the filling sequence. Filling then
proceeds automatically at a controlled rate to a pre-set pressure. Built- in safety provisions will prevent an
accidental overcharge.
Automatic Standardization
The 6200 Calorimeter will automatically generate its energy equivalent (EE) value from a series of
standardization tests, calculating a mean value from either (a) all standardization tests, or (b) from the last
10 operator designated tests for each bomb/bucket combination. The user can enter the maximum standard
deviation he will accept and the calorimeter will advise him if his tests fail to meet this criteria. Energy
equivalent values for up to four bomb/bucket combinations can be stored in the computer.
Many User Options
Although specific procedures are recommended, various options are available to the user:
z Program parameters can be adjusted to accommodate unusual sample sizes and precision
requirements.
z The calorimeter can be programmed to accommodate any titrant concentrations selected by the user.
z Calorific values can be reported in any of several measurement units.
z The calorimeter program can be adjusted to compensate for the subtle differences in the way acid
correction values are handled in ASTM, BS, DIN and ISO methods.
z Program controls can be protected from inadvertent changes.
z A bomb usage tally can be maintained to notify the user when each bomb should be serviced.
Multiple Language Options
Parr Model 6200 can be set to provide the programming options, operating menus, reports and error
messages in the following choice of languages: English, French, and German.

Automatic Data Transfer
The calorimeter is equipped with RS232C communication ports for reporting to a printer and receiving
sample weights from an analytical balance. Transferring results to a laboratory computer is accomplished
using an Ethernet connection using standard network protocols.
Compatible Modular Design
The 6200 Calorimeter is fully compatible with existing 1108 Parr Bombs and closed-circuit water handling
systems making it easy to fit the instrument into an existing laboratory set-up. A modular design, with the
controller electronics assembled in a removable chassis, simplifies maintenance.
Accessories for the 6200 Calorimeter
1757 Printer
1757 Printer
Operating results and operator messages are displayed clearly on the touch screen for review and action.
Many users who connect their calorimeter to a computer will choose to print their results from their
computer and will not need a dedicated printer for their calorimeter. For users who prefer to have a
dedicated printer at the calorimeter, Parr offers the compact model 1757 Printer. The printer port can be
configured to work with many other printers with serial communications that the user may choose. The
1757 printer is a compact, dot matrix printer setup for 40- character/line reports. It is the default printer for
the 6200 calorimeter. It is housed in a separate 5.5 inches wide, 9 inches deep and 7 inches high. It
operates from its own power supply.
6510 Water Handling System
For users who wish to operate their 6200 Calorimeter on a closed loop system, the 6510 Water Handling
System incorporates a precision pipette for measuring and delivering the water for the calorimeter bucket
at the same fixed temperature for each test. This water handling system incorporates a built-in, compact,

solid-state water chiller. As a result, no external water chiller is required. It also provides cooling water to
the jacket of the 6200 calorimeter, if required.
1563 Water Handling System
The 1563 Water Handling System is designed to work with a separate water cooler. The Parr 1552 Cooler
is recommended for this purpose. The 1563 Water Handling System incorporates a precision pipette for
measuring and delivering the water for the calorimeter bucket at the same fixed temperature for each test.
This unit is capable of supporting and supplying temperature controlled water for up to two calorimeters.
Extra Bomb and Bucket
An extra A391DD Calorimetric Bucket and 1108 Oxygen Bomb will greatly improve the throughput of
the 6200 Calorimeter as they permit the next test to be prepared in advance.
Coal Abrasion Index tester
Coal handling material suffers abrasive wear losses due to abrasion

characteristic of coal. Resistance to coal abrasive wear at ambient and
elevated temperature can be found with the help of this equipment
Application
This tester can be used to assess the relative abrasive wear resistance
characteristic of material to help selection of right type of material of
construction for mixing, crushing, grinding and burning equipment.
Standard
BIS 9949-1986
Features
z Auto shut off after preset revolutions.
z Easy to clean chamber.
z Dust confinement.
z Optional heating of chamber for high temperature tests.

Specifications
Parameter Unit Min Max Remarks
Test Speed RPM 0 1500 Variable
Revolution Counter 1 9999 Presetable in steps of one
Temperature o
C Ambient 400oC Optional
Power V/HZ/PH/KVA 415/50/3/3 Other voltages on request
Contact Details:
Ducom Instruments Pvt. Ltd.
477/A, 4th Phase,

Peenya Industrial Area,
Bangalore-560058., India.
Phone: +91 80 4152 5162
Fax: +91 80 4152 5162
Email: ducom@vsnl.com or ducom@vsnl.net

13. PROCEDURE FOR DETERMINATION OF BOILER EFFICIENCY
13.1 Overview
The performance of boiler, like efficiency and evaporation ratio reduces with time due to poor
combustion, heat transfer, surface fouling and poor operation and maintenance practices. Even
for a new boiler, reasons such as deteriorating fuel (like coal) quality, water quality etc. can
result in poor boiler performance.
A boiler efficiency test helps us to find out the deviation of boiler efficiency from the design
efficiency.
Any observed abnormal deviations could therefore be investigated to pinpoint the problem
area for necessary corrective action.
13.2 Purpose:
The main purpose of evaluation of boiler efficiency

is to determine the current efficiency level and to
compare it with design efficiency. It is an indicator
of day to day variation in boiler efficiency with
respect to design value.
13.3 Reference standards: IS 8753, Indian standards

for boiler efficiency testing.
13.4 Boiler Efficiency
Thermal efficiency of boiler is defined as the percentage of heat input that is effectively utilized
to generate steam. There are two methods of assessing the boiler efficiency by using coal as
fuel.
13.4.1 Direct Method
In this method energy gain of the working fluid (water and steam) is compared with the energy
content of the boiler fuel (coal, oil etc)
13.4.2 Indirect Method
In this method efficiency calculation is based on the difference between the losses and the
energy input of boiler fuel.

13.5 Direct Method
This is also known as “Input-output method”. This is due to the fact that it requires only the
useful output (steam) and the heat input (i.e. coal) for evaluating the efficiency.
STREAM
OUTPUT
Input Fuel
(coal) + air
BOILER Flue Gas
WATER
Fig.1 Heat balance diagram by direct method
The efficiency can be evaluated by using the formula

Boiler efficiency = (Heat output / Heat input) ×100
Following are the parameters to be monitored to evaluate the boiler efficiency by Direct method.
Sl.No. Parameters to be monitored Unit
1 Quantity of steam generated per hour Kg/hr
2 Quantity of fuel used per hour ( for coal) Kg/hr
3 Working pressure kg/cm2(g)
4 superheat temperature ,if any O

C
5 Temperature of feed water O

C
6 Type of fuel and gross calorific value of the fuel (coal) kCal/kg of fuel

η) = Qx (hg -hf) /q x GCV

Boiler efficiency (η
Where,
Q= Quantity of steam generated per hour in Kg/hr
hg =Enthalpy of saturated steam in kCal/kg of steam
hf= Enthalpy of feed water in kCal/kg of water
q = Quantity of fuel used per hour (for coal) in Kg/hr
GCV = Gross calorific value of coal (kCal/kg of coal)
Note: Boiler may not generate 100% saturated dry steam and there may be some amount of
wetness in the steam.
It is very important to measure accurate flow of coal or any solid fuel. The measurement
must be based on mass, which means that bulky apparatus must be set up on the boiler
house floor. Samples must be taken and bagged throughout the test, the bags sealed and
sent to laboratory for analysis and calorific value determination. In latest practices
problem of weighment is alleviated by direct mounting the hoppers over the boilers on
calibrated load cells.
Advantages and disadvantages of direct method
Advantages:
z It is very simple and quick method for boiler efficiency evaluation and plant person can
easily evaluate the efficiency on daily basis.
z It requires very few parameters to find out boiler efficiency and calculation is also very
simple.
z It requires only few instruments for monitoring.
z It gives a fair idea of boiler efficiency
Disadvantages:
z It does not shows the reason for low efficiency
z It does not calculate various losses which are accountable for various efficiency levels.

13.6 Indirect method
Indirect method is also called as “heat loss” method. The efficiency of boiler can be arrived
at by subtracting various heat loss fractions from 100.
The standard do not include blow down loss in the efficiency determination process.
1. Dry flue gas

2. H2 loss
STREAM
3. Moisture in fuel
OUTPUT
4. Moisture in air
7. Surface losses 5. Fly ash loss
Input fuel
BOILER Flue Gas Sample
Air
Water
6. Bottom ash loss
Blow down
Fig. 2 Heat balance diagram by indirect method
Main losses which occurs in the boiler are tabulated below
Sl. No Types of losses

1 Loss of heat due to dry flue gas
2 Loss of heat due to moisture in fuel
3 Loss of heat due to moisture in combustion air
4 Loss of heat due to combustion of hydrogen
5 Loss of heat due to radiation
6 Loss of heat due to unburnt
Table No 1

In the above, loss due to moisture (Sl.no 2) in fuel and loss due to combustion of hydrogen
(Sl.no 4) are dependent on the fuel
Losses (Sl.no 2 and 4) can not be controlled by the boiler design.
Data required for evaluation of boiler efficiency using direct method as tabulated below
Sl. No Description
1 Ultimate analysis of coal
2 Percentage of oxygen or CO2 in the flue gas
3 Flue gas temperature in OC ( Tf)
4 Ambient temperature in OC (Ta)
5 Humidity of air in kg/kg of dry air
6 Gross calorific value of fuel( coal) in kCal/kg
7 Percentage combustible in ash ( in case of solid fuel like coal)
8 Gross calorific value of ash in kCal/kg (in case of solid fuel like coal)
Procedure for boiler efficiency evaluation:
First of all we have to calculate the amount of theoretical air requirement for the combustion
of fuel
This may be calculated by following equation:
Theoretical air requirement
= [(11.6 x C) + {34.8 X ( H2 - O2/8)} + ( 4.35 x S )] /100 kg/kg of fuel
Where,
C = carbon %
H = Hydrogen %
0 = Oxygen %
S = Sulphur %
Excess Air supplied (EA) can be calculated as:

EA = 02 %/( 21-O2 %) x 100
Actual mass of air supplied/ kg of fuel (AAS) = {1+ EA/100} x Theoretical air Calculation of
various losses as shown in table no 2
1. Percentage heat loss due to dry flue gas
= {m x Cp x ( Tf-Ta) x 100 } / GCV of fuel
Where,
m = mass of dry flue gas in kg/kg of fuel
m = combustion products from fuel: CO2 + SO2 + nitrogen in fuel + Nitrogen in the
actual mass of air supplied + O2 in flue gas. ( H2O / water vapour in the flue gas
should not be considered.
Cp = Specific heat of flue gas ( 0.23 kCal/kg OC)
Tf = Flue gas temperature in OC
Ta = Ambient temperature in OC
GCV = Gross calorific value of fuel
2. Percentage heat loss due to evaporation of water formed due to H2 in Fuel
= [9 x H2 x {584 + Cp ( Tf-Ta)} / GCV of fuel] x 100
Where,
H2 = kg of hydrogen in 1 kg of fuel
Cp = Specific heat of superheated steam ( 0.45 kCal/kg OC)
3. Percentage heat loss due to evaporation of moisture present in fuel
= [ M x {584 + Cp ( Tf-Ta)} / GCV of fuel] x 100
Where,
M = kg of moisture in 1 kg of fuel
584 is the latent heat corresponding to the partial pressure of water vapour
4. Percentage heat loss due to moisture present in air
= {AAS x humidity factor x Cp ( Tf-Ta) / GCV of fuel} x 100

Where,
5. Percentage heat loss due to unburnt in fly ash
= {(Total ash collected per kg of fuel burnt x GCV of fly ash) / GCV of fuel} x 100
6. Percentage heat loss due to unburnt in bottom ash

= {(Total ash collected per kg of fuel burnt x GCV of bottom ash)/ GCV of fuel} x 100
7. Percentage heat loss due to radiation and unaccounted loss
The other heat losses from a boiler consist of the loss of heat by radiation and convection
from the boiler into the surrounding boiler house.
Normally surface loss and other unaccounted losses are assumed based on the type and
size of the boiler as given below:
For Industrial fire tube boiler/ packaged boiler = 1.5 to 2 %
For Industrial water tube boiler = 2 to 3 %
For power plant boilers = 0.4 to 1%

Heat Balance :
After calculation of various losses mentioned above, a simple heat balance would give
the efficiency of boiler.
The efficiency is the difference between the energy input to the boiler and the heat losses
calculated.
Boiler heat balance:
Input/output parameter kCal/ kg of fuel %
Heat input in fuel = 100
Various heat losses in boiler
1. Loss of heat in dry flue gas =
2. Loss due to hydrogen in fuel =
3. Loss due to moisture in fuel =
4. Loss due to moisture in air =
5. Loss due to unburnt in fly ash =
6. Loss due to unburnt in bottom ash =
7. heat loss due to radiation and unaccounted loss =
Total losses =
Efficiency of Boiler (ç) = 100-(1+2+3+4+5+6+7)

14. GLOSSARY- COAL
Anthracite
A hard, compact coal characterized by high luster and low sulphur content. Anthracite is comprised
of less volatile matter than bituminous coal, which provides for its nearly non-luminous flame, with
highest carbon content (86% to 98%) and thus highest heat value (nearly 15,000 BTUs-per-pound);
Bituminous
Type of coal with carbon content from 45% to 86% and heat value of 10,500 to 15,500 BTUs-per-
pound; used primarily to generate electricity and make coke for steel.
Bitumen
A hard, black, combustible substance formed from decomposed vegetable matter subjected to
pressure, temperature, and moisture for millions of years. Varying conditions of formation result in
diverse coal chemistries and heat contents. Bituminous coal is one of several phases in an evolutionary
development process which includes (from least developed to most developed): peat, lignite
(sometimes called brown coal), sub bituminous, bituminous, anthracite (sometimes called hard coal)
and graphite. A mixture containing hydrocarbons — often produced by the processing of coal or oil
— used in asphalt or tar for road surfacing or waterproofing.
Coke
A hard, dry substance containing carbon that’s produced by heating bituminous coal to a very high
temperature in the absence of air
Lignite
Type of coal with lowest carbon content (25% to 35%) and a heat value of only 4,000 to 8,300
BTUs-per-pound; called “brown coal;” used mainly for electric power generation.
Peat
partially carbonized vegetable material.

Sub bituminous
Type of coal with 35% to 45% carbon content and heat value of 8,300 to 13,000 BTUs-per-pound;
generally has lower sulfur content than other types, and so is cleaner-burning.
Ash
The non-combustible and inorganic component of coal remaining after complete burning. Ash yields
no heating value.
Ash Fusion Temperatures
a. Initial Deformation Temperature
Temperature at which the top of the ash cone begins to round.
b. Softening Temperature
Temperature at which the ash cone fuses into a spherical lump.
c. Fluid Temperature
Temperature at which the ash cone spreads out over the base as a flat layer.
z 2,600 degrees F – A high ash fusion temperature.
z 2,100 degrees F – The lowest approximate ash fusion temperature of coals.
z 1,950 degrees F – The ash fusion temperature of several coals.
z 1,850 degrees F – The approximate ash fusion temperature of coals.
ASTM
American Society for Testing and Materials. The ASTM provides a system for classifying coal as
well as other testing parameters..
BTU
British thermal unit the amount of heat required to raise the temperature of one pound of water one
degree Fahrenheit under normal conditions.

BTU (as received)
indicates the heating value of coal at the location of consumption.
BTU (dry basis)
The method of fuel analysis where the moisture is eliminated and the other constituents are
recalculated to total 100 percent.
Clean Coal Technology
Because of environmental pollution concerns from the burning of coal, increased efforts are being
made to develop better emission control or reduction technologies. These technologies apply to
cleaning impurities from the coal itself, improving the effectiveness of the burning process, and/or
improving the pollutant recovery systems for the escaping products of combustion.
Coke (coal)
In general, coke is made from bituminous coal (or blends of bituminous coal) from which the volatile
constituents are driven off by baking in an oven at temperatures as high as 2,000 degrees Fahrenheit,
so that the fixed carbon and ash are fused together. Coke is hard and porous and has a gray, sub-
metallic luster. It is used both as a fuel and for chemical reactions in smelting iron ore in a blast
furnace in making pig iron and steel. Coke has a heating value of 13,000 to 14,000 BTU/pound.
Dried Coal
Moisture, an inherent component of coal, requires heat for its evaporation and release in the products
of combustion. Surface moisture in cold climates increases handling problems. Normal atmospheric
drying of coal is accelerated by passing hot combustion gases over or through beds of coal to be
dried (usually metallurgical coal).
Grindability Index
Indicates the ease of pulverizing a coal in comparison to a reference coal. This index is helpful in
estimating mill capacity. The two most common methods for determining this index are the Hard
grove Grindability Method and Ball Mill Grindability Method. Coals with a low index are more
difficult to pulverize. On a one to 100 scale, the lower the value the harder the coal.

Megawatt (MW)
A watt is a unit of electric power; the output capability of electric generating plants, companies and
systems is usually expressed in terms of megawatts (millions of watts). One watt = 3.4 BTU/hr. One
kilowatt = 1.3 horsepower..
Proximate Analysis
A percentage measurement of the physical properties of coal including moisture, volatile matter,
fixed carbon and ash. Proximate analysis is usually accompanied by a statement of sulphur content,
BTUs per pound, ash fusion temperature and grindability, expressed in percentages by weight.
Sulphur
A non-metallic chemical element comprising varying degrees of coal’s composition. Sulphur burns
off when coal is heated but promotes clinkering, slagging and corrosion. Coals with high sulphur
contents are susceptible to spontaneous combustion in storage piles. Sulphur present in stack emissions
is regulated by clean air standards.
Sulphur Classifications
z Pyritic
The only inherent form of sulphur in coal which can be removed by washing.
z Organic
Inherent and generally cannot be removed from coal.
z Sulphates
Oxidation products, present on the surface of fresh coal in small amounts. Sulphates can be
removed conveniently through standard cleaning processes.
Ultimate Analysis
Chemical properties of coal represented in percentage of weight. Included are carbon, hydrogen,
sulphur, oxygen and nitrogen.

Volatile Matter
Portion of coal which is driven off in a gaseous form when the coal is heated. Volatility is classified
as follows:
Composition by Weight
high volatile over 31%

medium volatile 22% to 31%
low volatile under 22%
Fixed carbon — The solid combustible residue left after the moisture and volatile matter have been
driven off by heating. In the proximate analysis, it is calculated by subtracting the sum of moisture,
ash and volatile matter from 100 percent.
Fly ash — The fine particles of ash that are carried through the various passes in the furnace by the
products of combustion and are usually collected in the last pass of boiler by a precipitator or dust
collector.
Moisture —
z Free moisture (or surface moisture) — The portion of total moisture that comes from external
sources such as rain or snow.
z Inherent moisture (or bed moisture) — Moisture that exists as an integral part of the coal
seam prior to mining.
z Total moisture — Moisture that is determined as the loss in weight of a coal sample in an air
atmosphere under rigidly controlled conditions of time, temperature and air flow. . . .
Rank — A classification of coal that indicates the degree of coalification or alteration from lignite
to anthracite.
Spontaneous combustion — An ignition caused by the accumulation of heat generated by the slow
oxidation of coal in an air supply sufficient to support oxidation but insufficient to dissipate the
heat. An example of where this can occur is a storage pile. The tendency of a coal to spontaneously
combust or self-heat increases with increasing amounts of sulfur and moisture.

ANNEXURE -1
TECHNOLOGICAL DEVELOPMENT IN
COAL TESTING EQUIPMENTS














ANNEXURE - 2 DAILY COAL QUALITY REPORTING FORMAT
Coal Receipt
Indian Coal Imported Coal / Pet Coke Total Coal Receipt
Month Qty Moist Ash Volatile Fixed GCV Qty Moist Ash Volatile Fixed GCV Qty Moist Ash GCV
MT % % Matter Carbon MT % % Matter Carbon MT % %
April
May
June
Management Services Division & Central Technical Centre

July
August
September
October
November
December
January
February
March
87
88
ANNEXURE- 3 MONTHLY COAL ANALYSIS REPORT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Moisture %
Volatile
Matter %
Fixed
Carbon %
Ash %
Calorific
Value %
Management Services Division & Central Technical Centre

STANDARD OPERATING PROCEDURE
ON
COAL LOSS ACCOUNTING
QUANTITATIVE
(Mine To Factory)
MANAGEMENT SERVICES DIVISION

March 2007
SOP-COAL LOSS ACCOUNTING : QUANTITATIVE
MINE TO FACTORY
TABLE OF CONTENTS
1. Overview of Coal Mining ......................................................................................................... 89
2. Handling of Coal at Mines ........................................................................................................ 91
3. Loading of Coal on Truck or Rake At Mines ........................................................................ 96
4. Loading or Discharge of Coal from Vessel ............................................................................. 102
5. Transit of Coal ............................................................................................................................ 108
6. Stock Verification ........................................................................................................................ 110
Annexure – 1: Risk Assessment Procedure ............................................................................ 113

SOP-Coal Loss Accounting: Quantitative, (Mine to Factory)
1. OVERVIEW OF COAL MINING
The choice of mining method is largely determined by the geology of the coal deposit. Underground mining
currently accounts for about 60% of world coal production, although in several important coal producing
countries surface mining is more common.
1.1 UNDERGROUND MINING
There are two main methods of underground mining: ‘room & pillar’ and longwall mining.
In room-&-pillar mining, coal deposits are mined by cutting a network of ‘rooms’ into the coal seam
and leaving behind ‘pillars’ of coal to support the roof of the mine. These pillars can be up to 40% of
the total coal in the seam – although this coal can sometimes be recovered at a later stage. This can
be achieved in what is known as ‘retreat mining’, where coal is mined from the pillars as workers
retreat. The roof is then allowed to collapse and the mine is abandoned.
Longwall mining involves the full extraction of coal from a section of the seam or face’ using mechanical
shearers. A longwall face requires careful planning to ensure favourable geology exists throughout the
section before development work begins. The coal ‘face’ can vary in length from 100-350m. Self
advancing, hydraulically-powered supports temporarily hold up the roof while coal is extracted.
When coal has been extracted from the area, the roof is allowed to collapse. Over 75% of the coal
in the deposit can be extracted from panels of coal that can extend 3km through the coal seam.
The main advantage of room–&-pillar mining over longwall mining is that it allows coal production to
start much more quickly, using mobile machinery that costs under $5 million (longwall mining machinery
can cost $50 million).
The choice of mining technique is site specific but always-based on economic considerations;
differences even within a single mine can lead to both methods being used.
1.2 SURFACE MINING
Surface mining – also known as opencast or open-cut mining – is only economic when the coal seam
is near the surface. This method recovers a higher proportion of the coal deposit than underground
mining as all coal seams are exploited – 90% or more of the coal can be recovered.
Management Services Division 89

The productivity per man-shift in open cast mining is more than 5 times that in underground mining.
Large opencast mines can cover an area of many square kilometers and use very large pieces of
equipment, including:
z draglines, which remove the overburden;
z power shovels; large trucks, which transport overburden and coal;
z bucket wheel excavators, and
z conveyors.
Explosives first break up the overburden of soil and rock; it is then removed by draglines or by
shovel and truck. Once the coal seam is exposed, it is drilled, fractured and systematically mined in
strips. The coal is then loaded on to large trucks or conveyors for transport to either the coal prepa-
ration plant or direct to where it will be used.
90 Management Services Division

2. HANDLING OF COAL AT MINES
2.1 COAL PREPARATION
The raw coal produced from the mine (run-of-mine or ROM) hardly suits the need of the consumers.
It is necessary to exercise control over one or more of its properties like size (mainly) depending
upon the nature of its use.
Coal straight from the ground, known as run-of-mine (ROM) coal, often contains unwanted impuri-
ties such as rock and dirt and comes in a mixture of different-sized fragments.
However, coal users need coal of a consistent quality. Coal preparation – also known as coal
beneficiation or coal washing – refers to the treatment of ROM coal to ensure a consistent quality
and to enhance its suitability for particular end-uses.
The treatment depends on the properties of the coal and its intended use. It may require only simple
crushing or it may need to go through a complex treatment process to reduce impurities.
To remove impurities, the raw run-of-mine coal is crushed and then separated into various size
fractions. ROM coal usually has a size of 0-500mm. The sized coals may be available in various
ranges, such as steam sized coal : 250-25mm, rubble: 50-25mm, smithy: 25-13mm, and slacks: 50-
0mm, 25-0mm, and 13-0 mm. The screening of coal is done on various types of screens, revolving,
vibrating and shaking. Larger material is usually treated using ‘dense medium separation’. In this
process, the coal is separated from other impurities by being floated in a tank containing a liquid of
specific gravity, usually a suspension of finely ground magnetite. As the coal is lighter, it floats and can
be separated off, while heavier rock and other impurities sink and are removed as waste.
The smaller size fractions are treated in a number of ways, usually based on differences in mass, such
as in centrifuges. A centrifuge is a machine, which turns a container around very quickly, causing
solids and liquids inside it to separate. Alternative methods use the different surface properties of
coal and waste. In ‘froth flotation’, coal particles are removed in a froth produced by blowing air into
a water bath containing chemical reagents. The bubbles attract the coal but not the waste and are
skimmed off to recover the coal fines. Recent technological developments have helped increase the
recovery of ultra fine coal material.
2.2 COAL HANDLING
The loading and unloading of trucks and railroad cars can generate large amounts of dust. Basically
dust percentage depends on the size of coal also. This is major coal loss point at mines sector also.
During transportation, fine dust is lost to relative (head) wind.

2.3 COAL TRANSPORTATION
The way that coal is transported to where it will be used depends on the distance to be covered.
Coal is generally transported by conveyor, ropeway or truck over short distances. Trains and barges
are used for longer distances usually within domestic markets.
Ships are commonly used for international transportation, in sizes ranging from Handymax (40-
60,000 DWT), Panamax (about 60-80,000 DWT) to large Capesize vessels (about 80,000+ DWT).
(DWT – Deadweight Tonnes which refers to the deadweight capacity of a ship, including its cargo,
bunker fuel, fresh water, stores etc).
Around 725 million tonnes (Mt) of coal was traded internationally in 2005 and around 90% of this
was sea-borne trade. Coal transportation can be very expensive – in some instances it accounts for
up to 70% of the delivered cost of coal. So measures are taken at every stage of coal transportation
and storage.
Technological Characteristic of Rolling stock and Railway Transport
The cars used in pits have an open body to permit excavator loading and mechanical or manual
emptying. They must withstand large impact loads, ensure rapid emptying and possess a higher
stability. Self-emptying dumpers have found the widest application in this loading process and most
of the dumpers with hinged sides of a capacity 180 MT approximately.
The body capacity of a wagon “q” is the maximum amount of load (in MT) admissible by the design
strength of the wagon. Wagon volume ‘Vc’ corresponds to the geometrical volume of the body. The
summary body capacity of the wagon of a rake is referred to as the useful mass of the rake. Strength
and loading conditions require that the volume of a dumper should be 4-6 times greater than the
volume of excavator bucket. The mass of individual lumps must not exceed 3-3.5 MT at a dumping
height (emptying) height, measured from the car bottom, hdm = 2-2.5 m and 5-6MT at hdm£0.5 m.
When the material is loaded with rail-mounted bucket-chain excavators, the specific volume of wagon
(per meter length) must be in line with the output and moving speed of the excavators.
In this regards railway track layout and design of division points is also very important
The track layout of a quarry depends on its production and surface dimensions of the pit, the intensity
of freight traffic, the kind of wagon/ rake, opening diagram, mining methods etc. The track layout of
a quarry includes:

a) Temporary tracks laid at faces and waste disposal areas; these tracks are shifted periodically
as the mining, stripping and waste dump benches advance;
b) Connecting tracks linking the face and waste-dump ways with the tracks laid in the main
trenches and on the surface, with the stations and other departments of the enterprise;
c) Track laid the main trenches and access track (ramps) connecting the operating levels of a pit
with surface tracks;
d) Division points ensuring safe and efficient train movement in a pit and on the surface.
Technological Characteristic of Rolling stock and Haulage Vehicle
Quarries and pits mostly favour rear-dump trucks over other existing kinds of motor vehicles.
The type of engine, transmission, running gear, steering and the truck body tipping gear are chosen
based on the capacity of the motor vehicles. Normally dump trucks powered by carburetor engines
of up to 5 –t capacity are used for hauling soft rocks (when they are loaded by excavators with a
bucket capacity up to 1 m3), dimension stone, and also for hauling supplies, materials, equipment,
etc. Similar excavators are also served by diesel-powered dump trucks of 5-7 MT capacities. Me-
dium (10-20 MT) and heavy-duty (over 20 MT) diesel-powered dump trucks find wide application
in quarry haulge.
Truck Positioning in Faces and at Waste Dumps
The various types of face and cut, the different width of the cuts, the nature of truck movement on
benches (one-way or opposing movement), the relationship between the directions of motion of the
trucks and excavator, and the high mobility of trucks make it possible to position them for loading in
a great number of ways.
Trucks may move on the bench in the direction of the excavator, which carries a cut, or in the
opposite direction. The manner in which the trucks approach the excavator subdivides the way in
which trucks are positioned for loading into 3 groups: straight past, with a loop turn, with a dead-end
turn. The mine rock must be loaded into the truck body from the side or rear; the bucket must not be
carried on top of the cab. Empty (idle) trucks must be positioned outside the radius of action of the
bucket.

With an end face in through cut and one-way truck movement (two transport exist on a bench),
trucks are positioned as shown in Figure below. For positioning movement straight past (1,3,9)
pattern is utilized, for one-way traffic loop turn (2,10) or dead-end (12,14) patterns are applied
(with face grading or large yield of oversize lumps). With opposing truck movement they are posi-
tioned for loading as illustrated in Fig. (loop turn patterns 19,20 (wide operating beams) and dead-
end patterns 23,24 (narrow beam)). With one-way movement turning around of empty dump trucks
is preferable (20, 24). With wide through cuts similar loop turn patterns 27, 28 and also the dead-
end pattern 30 are followed.
In dead-end production cuts, trucks are usually positioned for loading according to pattern 24, and
sometimes 26; in wide dead-end trench cuts, trucks are positioned according to patterns 33 and 34.
With frontal faces, selective mining usually requires that trucks be positioned for loading according to
dead-end patterns 17, 18, 38, and loop turn 36.
Truck movement on bench and schematics of truck positioning for loading

Type of Face
One-way Opposing
Type of cut
Special
Cut with Through and loop dead-end loop dead-end
mining
Direction of excavator and empty truck movement
conditions
Opposing One-way Opposing One-way Opposing One-way Opposing One-way
Normal A n Wide
Through
≈ (1.5 – working
1.7) Rdn bems
Minimum
dead-end
Through
Normal and Width of

narrow An ≈ working
0.5R dn
bems
End Face
Without
Ch, 16. Truck Haulage
face
Wide grading
Through
A w> 2R dn
With face
grading
Sufficient
Dead-end trench
for loop
turning A ≥
2 (Rmn+ m)
Insufficient
for loop
turning A <
2 (Rmn+ m)
Through
Longitu-
dinal
Narrow
Figure: Spotting dump trucks for loading
Rmin — minimum truck turning radius; m — clearance between truck and trench slope

FLOW CHART
Flow Activity Responsibility Unit Control Remarks
Mining of coal Coal India Nil
Coal Handling plant Coal India Liaison with

respective person
Storage at Bunker Coal India Liaison with respective

person to know the
stock quantity
Loading through Auto Loader Coal India Liaison with respective

person for good loading
Loading Supervision Co –ordinate with

Coal India’s Staff Mainly Mine manager,
Field In-charges are
important
Triming, Marking and Leveling Maintain the good level

with more than 1 ft height
from wagon in
Trapezoid profile.
Weighment Supervision Coal India Check the process and

liaison with respective
person Check point:
Calibration

3. LOADING OF COAL ON TRUCK OR RAKE AT MINES
3.1 Administration
3.1.1 Check job instructions like
a) Loading commenced
b) Exact Location
c) Number of Dumpers present
d) Quantity
e) Customer
f) Total Time of Loading
3.1.2 In case of Coal India, submit the requisition in head office of Coal India on 1st date of every
month and care should be taken to forward the same into the respective regional office of
Coal India.
3.1.3 Confirm receipt of instructions with Authorised person. Authorised person should take care
and liaison with Coal India and Railways regarding the placement of rake so that the material
can be loaded within 20th of every month.
3.1.4 Always check the stock at the bunker and try to load the material when production rate is
high.
3.1.5 What is the nature of the material and what facilities are available - size of coal, sampling lot
size, handling conditions, and preparation facilities?
3.1.6 Is a ‘Permit to Work’ required and/or local induction? For local permit contact with the
colliery manager.
3.1.7 Are sufficient inspectors available to cover all eventualities of the operation?
z No – immediately contact with Authorised Person. It is the responsibility of the inspec-

tor to ensure that the office is fully aware of the situation so that adequate infrastructure
can be provided.

3.2 Health & Safety
3.2.1 Is there a risk assessment for the nominated location and material?
z Yes – Ensure required personal protective equipment (PPE) and risk management prac-
tices in place before starting work.
z No - carry out risk assessment with Field Services Technical Coordinator and docu-
ment risk management procedures.
3.3 Pre-Loading Planning
3..3.1 Establish the loading plan with material handling agent or transporter.
z Material in one or more stockpile?
z Multi stockpile discharge?
z Online discharge?
z Anticipated hours of working.
z Availability of the enough space for truck movement.
3..3.2 Is volumetric assessment required?
z Yes – Ensure that the two volumetric assessments furnished. One completed from stockpile
prior to loading and another completed after loading.
3.4 Rake or Truck Inspection
3.4.1 Collect and record the relevant dates/times of rake placement or truck position.
3.4.2 Depute the adequate inspectors.
3.4.3 The following parameters of all the trucks/ wagons shall be checked properly.
z Fitness.
z Condition.

z Rust free.
z Dust free.
z Visual identification.
z Crack free and good condition.
3.4.4 Foreign Matter: The wagon/ truck should be free from any types of foreign material. The
following shall be considered as the foreign materials:
z Any chemicals other than loading materials.
z Rust.
z Lumpy dust (stone etc.).
z Grease.
z Oil.
z Welding residuals.
3.5 Coal Inspection
3.5.1 Confirm stockpile/ running of material and loading with the authorized person of mines.
3.6 Loading
3.6.1 Inspect the wagon from a safe location regularly during loading. The number of visits re-
quired will depend on the nature of the coal and the loading conditions. As a minimum the
wagon should be checked 2 or 3 times per shift and at any time when the coal visibly
changes.
3.6.2 Describe weather conditions during discharge and possible effects on moisture content of
coal.
3.6.3 Note the times and any changes in material appearance, water ingress, especially when
loading start.

3.6.4 Report on loading procedure,
3.6.5 Crane, grab type and approximately lifting capacity.
3.6.6 Were wagon or truck loading simultaneously or individually?
3.6.7 Was coal placed into integrated or independent hoppers?
z Did hopper feed for road transport or a conveyer belt system
3.6.8 Or was coal placed directly on to the quay?
z How was it picked up and delivered to storage?
3.6.9 Was the equipment and quay clean prior to loading?
3.6.10 Was “Grabbing” within the wagon or rake aided by pay-loader at any time?
3.6.11 Describe the condition of the quay at completion of loading.
3.6.12 Were quay and plot sweepings recovered?
z Yes - into a separate lot or during loading?
z If sweepings were not recovered estimate the amount of material lost and immediately
inform to the authorized person and request recovery of sweepings.
3.7 Weighing
3.7.1 Was coal weighed by weighbridge, belt weigher or hopper load cell?
3.7.2 Describe scales, weighing capacity and weighing divisions
3.7.3 Prior to loading was the weighing equipment calibrated and tested by an independent certi-
fication authority and valid certificates sighted?
3.7.4 No – Request alternative, certified weighing equipment be made available immediately.

3.7.5 Test equipment with calibrated, stamped or known weights?
3.7.6 If weighing equipment fails calibration check request adjustment and re-test until scales OK.
3.7.7 Was the coal transported prior to weighing?
3.7.8 By road?
z Was coal covered, tailgates securely closed, and any spillages?
z When and how often were the vehicles tare weighed?
3.7.9 By conveyor belt - any spillages or losses at belt cross-over points or elsewhere?
3.7.10 By hopper - can the pit and the hopper tops be sighted for signs of leakage or seepage of
coal?
3.7.11 Was the loading quantity assessed by only weighment or volumetric assessment?
3.7.12 By volumetric assessment?
z Was the bulk density of coal determined at for 10 readings?
z Was the surface of the coal loaded plain or symmetric?
z Was the dimensional measurement done by instrument or manual?
z Has the quantity surveyor adequate training and experience of handling the instruments
or manual measurement.
coal?
3.7.15 If significant spillage or losses are observed bring them to the attention of responsible person
on site to recover lost material. If no satisfactory response, estimate amount of material lost,
inform authorised person and follow instructions.

3.8 Transport & Storage
3.8.1 Was coal transported to storage or silos by conveyor belt?
z Covered?
z Open?
3.8.2 Coal transported by covered/open by rake or by road?
z Distance.
z Condition of storage facility covered or open, floor area.
z Other material stored nearby [contamination]
z Security

4. LOADING OR DISCHARGE OF COAL FROM VESSEL
4.1 Administration
4.1.1 Check job instructions
4.1.2 Confirm receipt of instructions with Authorised person.
4.1.3 What is the nature of coal and what facilities are available:- size of coal, sampling lot size,
handling conditions, preparation facilities?
4.1.4 Is a ‘Permit to Work’ required and/or local induction?
4.1.5 Are sufficient inspectors available to cover all eventualities of the operation?
z No – immediately contact Field Services Coordination Team Leader. It is the respon-

sibility of the inspector to ensure that the office is fully aware of the situation so that
adequate cover is provided.
4.2 Health & Safety
4.2.1 Is there a risk assessment for the nominated location and material?
z Yes – Ensure required personal protective equipment (PPE) and risk management prac-
tices in place before starting work.
z No - carry out risk assessment with Field Services Technical Coordinator and docu-
ment risk management procedures.
4.3 Pre-Discharge/ Loading Planning
4.3.1 Establish the discharge/loading plan with stevedore and/or ship’s agent.
z Material in one or more holds?
z Multi hold discharge?
z Sequence of discharge from holds

z Anticipated hours of working
z Availability of unloading labour / Gang
z Discharge using ship’s crane or shore crane?
z Grab type and lifting capacity?
4.3.2 Is draft survey required?
z Yes – Ensure survey completed prior to discharge.
4.4 Vessel Inspection
4.4.1 Present yourself to Chief Officer and/or Captain.
4.4.2 Record relevant ships dates/times.
4.4.3 Record “comments made by vessel” – e.g. load port dates, loading and weather conditions,
weather on voyage, bilges pumped (ensure reports states “comments made by vessel”)
4.5 Coal Inspection
4.5.1 Confirm stowage of material and discharge plan with Chief Officer.
4.5.2 Report type of hatch covers and apparent condition, particularly on underside (i.e. obvious
rust?)
4.5.3 Report condition of hatch/hold:- any damage or significant rust?
4.5.4 Report coal condition when hatches opened.
z Was the coal steaming?
z Any condensation on underside of hatch covers?
z Any visible water inside hatches?
4.5.5 Observe coal in the hold (from the deck) and record relevant observations.

z Are lighting conditions adequate to view cargo?
z Was the cargo in a peaked or a trimmed condition?
z Any indications of travel cracks, oxidation, water staining, free water, visible contami-
nation?
4.5.6 Was the material uniform in colour, fines or fines with agglomerates? (If so to what approxi-
mate percent and size?).
4.6 Discharge
4.6.1 Inspect the hold from a safe location regularly during discharge. The number of visits re-
quired will depend on the nature of the coal condition and the discharge conditions. As a
minimum the hold should be checked 2 or 3 times per shift and at any time when the coal
visibly changes.
4.6.2 Describe weather conditions during discharge and possible effects on moisture content of
coal.
4.6.3 Note times and any changes in material appearance, water ingress, especially when dis-
charge is reaching bottom of the hold.
4.6.4 Report on discharge procedure,
z Crane, grab type and approximately lifting capacity.
z Were holds discharging simultaneously or individually?
4.6.5 Discharge rate per hour, measure cycle time – does it meet assured levels?
4.6.6 Was coal placed into integrated or independent hoppers?
z Did hopper feed road transport or a conveyer belt system
4.6.7 Or was coal placed directly on to the quay?
z How was it picked up and delivered to storage?

4.6.8 Were “Save-alls” fitted between vessel and quay or deflector plates fitted to cranes?
4.6.9 Was the equipment and quay clean prior to discharge?
4.6.10 Was “Grabbing” within the hold aided by pay-loader at any time?
4.6.11 Was the hold cleaned at completion of discharge?
4.6.12 Describe the condition of the quay at completion of discharge.
4.6.13 Were quay and hold sweepings recovered?
z Yes - into a separate lot or during discharge?
z If sweepings were not recovered estimate the amount of material lost and immediately
inform stevedore, ship’s agent and request recovery of sweepings. If no action immedi-
ately inform authorised person.
4.7 Weighing
4.7.1 Was shipment weighed by draft survey?
z Yes – obtain surveyor’s initial, interim and final reports.
4.7.2 Assess the conditions of the port for draft surveys, i.e. calm water, good visibility?
4.7.3 Was coal weighed by weighbridge, belt weigher or hopper load cell?
z Describe scales, weighing capacity and weighing divisions
4.7.4 Prior to discharge was the weighing equipment calibrated and tested by an independent
certification authority and valid certificates sighted?
z No – Request alternative, certified weighing equipment be made available immediately.

If request refused immediately advise Client Account Coordinator and follow
instructions.
4.7.5 Test equipment with calibrated, stamped or known weights?

z If weighing equipment fails calibration check request adjustment and re-test until scales
ok.
4.7.6 Was coal transported prior to weighing?
z By road?
¾ Was coal covered, tailgates securely closed, any spillages?
¾ When and how often were the vehicles tare weighed?
material?
4.7.9 If significant spillage or losses are observed bring them to the attention of responsible person
on site to recover lost material. If no satisfactory response, estimate amount of material lost,
inform Client Account Coordinator and follow instructions.
z Weights given to Client Account Coordinator as instructed
4.8 Transport & Storage
4.8.1 Was coal transported to storage or silos by conveyor belt?
z Covered?
z Open?
z Was any water sprayed during transportation?
4.8.2 Coal transported to storage by covered/open conveyor belt or by road?
z Distance from vessel to storage area.
z Condition of storage facility covered or open, floor area.
z Other material stored nearby [contamination]
z Security

4.9 Other
4.9.1 Record weather conditions during discharge and sampling.
4.9.2 Record any stoppages and reasons for stoppage.
4.9.3 Record any other relevant information.
4.9.4 Complete report and forward to authorised person.

5. TRANSIT OF COAL
5.1 Security Procedure in Transit
5.1.1 Was coal transported by rake with security guard?
z Number of security?
- Generally minimum 6 numbers securities are required in which 3 will be armed (gun).
z Gunman or simple person?
- At least 3 gunman are required.
5.1.2 Was critical theft zone during transportation identified?
z Place with probability of theft.
z Appointment of local security guard.
z Surface marking of the cargo on wagon or truck.
5.1.3 Was coal transported by rake or truck sealed ?
z Integrity of the sealing agency.
z Checking arrangement of seal at different location.
5.2 Other
5.2.1 Record weather conditions during discharge and sampling.
5.2.2 Record any stoppages and reasons for stoppage.
5.2.3 Record any other relevant information.
5.2.4 Complete report and forward to authorised person/agency.

5.3 Assessment
The assessment shall include:
5.3.1 Identification and evaluation of critical infrastructures.
5.3.2 Identification of threats to those infrastructures including material
5.3.3 Identification of security weakness in coal movement, transportation infrastructure,

protection systems, communication system.
5.3.4 Identification of proper trapezoid loading profile, trimming and marking
5.3.5 Identification of suitable cover by using tarpolins or similar material.
5.4 Recommendation to reduce transit losses
5.4.1 Deploy the security guard with gun man
5.4.2 Improve the security in theft prone zone and implement the local security.
5.4.3 Conduct public campaigns at theft prone zone
5.4.4 Load the material in a systematic manner and trim the upper part to identify the theft mark
5.4.5 Cover the wagon and seal it, if possible
5.4.6 Check the online weighment system to avoid loss.
5.4.7 Deploy private agency for security purpose, if losses are significantly high.

6. STOCK VERIFICATION
6.1 Introduction
6.1.1 Coal stock can be determined by measuring the volume of the coal yard and height of the
stack pile. The following procedure specifies a method for the quantitative assessment of
coal stock in a stack pile.
6.1.2 Team Building is required for stock assessment. The team consists atleast one from pur-
chase or commercial side, one from user side i.e. from plant side and another from adminis-
trative side. Depending on situation independent third party can also be deputed. Stock
verification should be carried out atleast once in every quarter.
6.2 Procedure
6.2.1 Normally stack of coal are in irregular shapes, i.e. they are not in proper geometrical shapes.
In order to get better assessment of the stacks, the stacks are subdivided longitudinally into
several subdivisions.
z Divide the whole plot into 20 or more imaginary subdivisions. Measure the length and
breadth of the each subdivision.
z Measure the common height of the stack. Then take the adequate measurements of
uneven height of each subdivision. Calculate the average height of each subdivision by
using steel tape or theodolite.
z Calculate the volume of each subdivision by multiplying area with average height.
z Collect the coal from each subdivision and measure the bulk density and moisture as
per procedure given below.
6.2.2 Procedure of Measuring the Bulk Density
z Principle
A weighed container of known volume is filled with coal and the increase in mass is
determined.

z Apparatus
a) Cubical Container of capacity 0.200m3 and internal dimension 585mm, with a smooth
inner surface, rigidly constructed and fitted with handle.
b) Weighing machine, Spring Balance or Platform balance with accuracy 50 gms.
z Procedure
Place the container on the weighing machine and record its mass. Charge the coal
slowly into the container until pieces of coal project above the top of the container
across the whole surface. The height of drop of the coal shall not exceed 250 mm.
Slide a straight edge across the top of the container and remove any pieces of coal,
which obstruct its passage. Weigh the charged container.
z Calculation
The bulk density in a small container (rs) of the coal, in Kg per m3, on dry basis is given
by the equation:
ρs = ( m 2 -m1 ) × (100-M ) / (100V )
Where,
m1 is the mass in kg, of the empty container;
m2 is the mass in kg, of the container plus coal;
V is the inner volume in m3, of the container;
M is the total moisture content of the coal determined in accordance with ISO 589.
6.2.3 Calculation for Quantity Assessment
Measure the Height of the subdivision by using steel tape or theodolite and take the
average of these height of each subdivision.

Average Height of Each Subdivision,
h1 is the depth in m, of the 1st hole;
n is the number of holes.
The Volume of each Subdivision,
where,
L1 is the length in m, of the 1st subdivision;
B1 is the breadth in m, of the 1st subdivision;
H1 is the depth in m, of the 1st subdivision;
The Quantity of Coal of 1st Subdivision, W1 = V1 X B.D1
where,
B.D is the Bulk Density in MT/m, of the coal
Total Quantity of the stock

ANNEXURE – 1
Procedure for Risk Assessment
The aim of risk assessment is to reduce the risks caused by work and to eliminate, or minimize, injuries and
damage to people and property.
The principals of risk assessment are fourfold and really only embody common sense principles.
They are:
a) Identify the hazards What could happen?
b) Evaluate the risks posed by that hazard Could it happen?

What is the impact?
c) Control those risks Eliminate the hazard or create a

safe system of work?
d) Monitor the controls and measures taken Review and record
A management decision must be made on how to control the risks which have been assessed and evalu-
ated. The priority of the work done to control them and the level of this control will reflect the level of effect
and likelihood of it happening as determined in the evaluation.
It is important to remember that a review of the assessments will be as required if there is a change in the
risk or process.

Two components will be considered once a hazard has been identified. These will be the severity of the
hazards i.e. how bad could it be and the likelihood of occurrence i.e. how likely is it to happen. The grades
of severity and likelihood of occurrence are as follows:
Severity Descriptions
Health Safety Environment
1 Insignificant Normal work can Negligible damage Negligible environmental impact

resume after basic
first aid
2 Minor Lost time injury not Minor damage Minor environmental e.g.
reportable to not reportable to localised spillage
Regulatory body Regulatory body
3 Moderate Injury/Disease Dangerous/significant Moderate pollution incident (e.g.

reportable to damage reportable Contamination of water course)
Regulatory body to regulatory body with some restitution costs
4 Serious Fatality/Terminal Substantial property Severe pollution incident with short

Disease/major injury damage term implications with significant
costs
5 Very Serious Multiple/Fatality Catastrophic damage Catastrophic pollution

i.e. process or property incident with long
shutdown term implications and
very high costs
Likelihood Description
1. Very Unlikely The Risk may occur in exceptional circumstances
2. Unlikely The Risk is unlikely to occur
3. Possible The Risk will possibly occur
4. Likely The Risk has a significant chance of occurring
5. Very Likely The Risk is almost certain to occur than not

Multiplying the two components together to give a risk factor can then assess the magnitude of the risk.
LIKELIHOOD
1 2 3 4 5
Very Unlikely Unlikely Possible Likely Very Likely
5
S Very Serious
E
4
V Serious
E 3
Moderate
R
I 2
Minor
T
Y 1
Insignificant
Low = 1 - 6, Medium = 7 - 14, High = 15 – 25

NOTES

SOP Coal Loss Accounting Qualitative (Part II)

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MSD VISION & MISSION

TO BE THE PREFERRED SOLUTION

CREATE VALUE BY INSTITUTIONALISING

CTC VISION & MISSION

• TECHNICAL PROBLEM SOLVING

l Integrity l Commitment l Passion l Seamlessness l Speed

l Hindalco – Renusagar Power Division

l Awarpur Cement Works

finalizing this SOP.

l Shri NK Sharma – Renusagar Power Division

l Shri R K Gupta – Renusagar Power Division

l Shri V N Srivastava – Awarpur Cement Works

l Shri Dinesh Randad – Awarpur Cement Works

l Shri R S Lawrence – Awarpur Cement Works

l Shri Sunil Kothari – Rajashree Cement

l N K Dwivedi – Rajashree Cement

l Shri B N Agarwal – Harihar Polyfirbres

l Shri Rajendra Jain – SFD Nagda

l Shri SK Dhanuka - SFD Nagda

MANAGEMENT SERVICES DIVISION

SOP-COAL LOSS ACCOUNTING : QUALITATIVE, (PART-II)

1. Coal Quality Overview ....................................................................................................................... 3

Management Services Division & Central Technical Centre 1

8. Procedure for Determination Hardgrove Grindabilty Index of Coal ................................................... 36

SOP-COAL LOSS ACCOUNTING : QUANTITATIVE

1. Overview of Coal Mining ................................................................................................................ 89

2 Management Services Division & Central Technical Centre

1. COAL QUALITY - OVERVIEW

Fig.1 VARIOUS STAGES OF COAL FORMATION

• Moisture is a component that costs money to transport as well as it consumes energy. It is

Management Services Division & Central Technical Centre 3

A Typical Proximate analysis of various coals is shown in graph.

29.8 Indian Coal

4 Management Services Division & Central Technical Centre

1.1 Grades of Coal

Grade Calorific Value range- (KCal / Kg)

Normally D, E and F coal grades are available to Power Sector.

The formula for calculation of UHV is as follows

UHV = 8900 - 138(A + M) kcal/kg

Management Services Division & Central Technical Centre 5

1.2 Coal Contents :

1. Ash Content: 30% to 55%, generally around 45%.

3. Sulphur content: 0.2% to 1.0%

4. Gross Calorific Value: 3000 K Cal/kg. to 5000 K Cal/kg. (3500 K Cal/kg.)

5. Volatile matter: 18% to 25 %

6. Fixed Carbon 20% to 38%

Elemental analysis, moisture content, and grades of typical Indian coals

Coal C% H% S% N2% O2% Ash% Moisture GCV UHV

D 30-33 2.1-2.4 0.4-.6 0.7-.8 NA 25-27 7-8 4999-5555 4332-4760

6 Management Services Division & Central Technical Centre

1.3 Coal quality control parameters :

A close estimate can be made with the Dulong formula

GCV = (144.4 * %[C]) + (610.2 * % [H])-(65.9 * % [O]) +(0.39 * %[O]2)

Management Services Division & Central Technical Centre 7

1.4 Proximate analysis

z Volatile matter (gases released when

z Ash (impurities consisting of silica, iron,

Significance of various parameters in proximate analysis

z Proportionately increases flame length and helps in easier ignition of coal

z Sets minimum limit on the furnace height and volume.

z Influences secondary air requirement and distribution aspects.

z Influences secondary oil support

8 Management Services Division & Central Technical Centre