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COAL DUST INJECTION

CDI
UNIT TRAINING MANUAL
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CONTENTS

Sl.No. Page No.

1 INTRODUCTION 6
2 PRE-REQUISITE FOR TRAINING 7
3 STANDARD VALUES/PERFORMANCE STANDARDS 8
4 KEY PERFORMACE FACTORS 9
4 TECHNICAL DATA 10-13
5 PERRSONAL SAFETY 14
6 EQUIPMENT SAFETY 15
7 SHIFT HAND OVER 16
8 SHIFT TAKE OVER 17
9 OPERATION PROCEDURE
COAL LIFTING SYSTEM 18-19
COAL GRINDING SYSTEM 20-24
FINE COAL INJECTION SYSTEM 25-29
10 TROUBLE SHOOTING 30-33
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INTRODUCTION
Pulverizesd coal injection (PCI) is a process that involves injecting large volumes of
fine coal particles into the Raceway of a Blast Furnace. This provides not only a
supplemental carbon source but also a speeds up the production of liquid iron
besides reducing the need for Metallurgical coke for reactions in the Blast
Furnace. The desire to move away from the production of the Metallurgical coke
with its inherent environmental problems has motivated the use of Pulverized
coal injection in the Blast Furnace.

The PCI technology is based on simple concept of carrying the finely grounded
(pulverized) dried coal by a conveying gas (normally nitrogen) to the Blast Furnace
where it is distributed to different tuyers and injected through a lance in the blow
pipe. In the blow pipe it is mixed with hot blast and then supplied to the Blast
Furnace in Raceway. The raceway propagates coal and coke combustion and
melts the solid iron ore, releasing molten iron. Durgapur Steel Plant installed its
PCI (CDI) system in the year 2008 and started injection in Blast Furnace # 3 & 4.
After the initial period of stabilization (2008-09) the system has stabilised and
performing as per the expectation. Durgapur Steel Plant also started injecting fine
coal in Blast Furnace # 2 from 15.09.2014.
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PRE-REQUISITE FOR TRAINING

1. Familiarization of Coal Dust Injection (CDI) Unit.

2. Basic knowledge about the operation of CDI.

3. The trainee must be familiar with the performance,

location and operation of all equipments.
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STANDARD VALUES / PERFORMANCE STANDARDS

1. PRODUCT – Fine Coal (Pulverized Coal) of less than

90 microns size & moisture content of less than 1%.
2. The 90 microns size should be equal or more than
80%.

3. PROCESS –
I. Handling of Raw Coal.
II. Grinding of Raw Coal.
III. Injection of Fine Coal.

4. EQUIPMENT – Details available in technical data

page.
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KEY PERFORMANCE FACTORS

1. Coal dust size – 90 microns . Shouid be equal or more than 80%

2. Ratio of Air to B/F gas should be approx. 0.8. in hot gas
generator.
3. Grinding mill inlet temperature T104 should be 250-280
degrees.
4. Grinding mill suction pressure P104 should be -160 mmWC.
5. Grinding mill PD 101 should be 250 – 280.
6. Bag Filter inlet temperature should be 80 -85 degrees.
7. Bag Filter PD 102 should be 90 – 100.
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TECHNICAL DATA

1. GRINDING MILL :
CAPACITY – 35 T/HR

TYPE – ROLLER

MOTOR POWER – 560 KW

R.P.M OF GRINDING TABLE – 24.8

MOTOR R.P.M – 990

DUST SIZE – 75 – 90 MICRON

TOTAL WT. OF MILL BODY – 150 T

MOISTURE CONTENT – 1 % MAX

MILL R.P.M USING LOW SPEED BARRING GEAR – 1.455

HYDRAULIC PRESSURE – 1.6 M Pa. (160 bar)

PUMP DISCHARGE – 30 LPM

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OIL GRADE – YBN – 46 / TH – 46

2. HOT GAS GENERATOR :

FLOW RATE – 20000 Nm3/HR

DIAMETER – 2670 MM

LENGTH – 7561 MM

OUTLET MIXED FLUE GAS TEMPERATURE – 250 – 300 °C

OUTLET PRESSURE – 0.2 – 1.0 Kpa (-VE)

HEARTH NORMAL TEMPERATURE – 800 – 900 °C

HEARTH NORMAL PRESSURE – 200 – 500 Pa

FLUE GAS – BF GAS

IGNITION – WITH CO BURNER

3. BAG FILTER :
NO. OF BAGS – 1176

TOTAL BAG AREA – 2880 M²

BAG SPECIFICATION – 130 x 6000

WORKING PRESSURE - 14000 Pa

TYPE – PULSE JET TYPE

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AIR TO CLOTH RATIO – 125 M³/MIN/M²

BAG MATERIAL – POLYACRYLIC HOMOPOLYMER

CAPACITY – 120000 M³/HR

FILTRATION VELOCITY - < 0.8 M/MIN

INLET GAS TEMPERATURE - < 120 °C

PRESSURE DROP - < 1500 Pa

WORKING PRESSURE – 0.5 – 0.7 Mpa

BIGGEST CONC. AT ENTRANCE – 1000 Mg/Nm³

EMISSION CONC. – 50 Mg/Nm³

4. MILL ID FAN :
FULL PRESSURE – 12220 Pa (0.1222 Kg/cm²)

FLOW RATE – 95000 – 115000 Nm³/Hr

R.P.M – 1460

TYPE – CENTRIFUGAL

MOTOR POWER – 630 KW

MOTOR – 3 PHASE, INDUCTION

MEDIUM TO HANDLE – FLUE GAS

DUST CONTENT IN THE FLU GAS AT THE INLET - < 60 Mg/Nm³

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5. RAW COAL SILO :

VOLUME – 500 M³

CAPACITY – 400 TONS

SHAPE OF CONE PORTION – HYPERBOLIC

NO. OF BLOCKING ELIMINATORS – 7

FLUID USED – NITROGEN

6. FINE COAL SILO :

VOLUME – 900 M³

CAPACITY – 450 TONS

7. INJECTION VESSELS :
NO. OF INJECTION VESSELS – 4

VOLUME OF EACH VESSEL – 30 M³

DESIGN PRESSURE – 1.6 Mpa

NO. OF LOAD CELLS – 3/ VESSEL

FEATURES – BOTTOM FLUIDIZATION, LARGE F/ AREA, GOOD MIXTURE

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PERSONAL SAFETY
1. Always wear safety helmet and safety shoes outside control room.

2. Use handgloves when required.

3. Never touch/clean the moving parts of any machinery.

4.Be careful while climbing staircases, they may be slippery.

5. Ensure that SHUTDOWN has been taken before maintenance or

cleaning job starts in any equipment.

6. Always use gas monitor while moving in gas prone area.

7. Always move in a group of two along with gas monitor and walkie
talkie in furnace area.
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EQUIPMENT SAFETY
1. Never allow any unauthorised person to operate the controls.

2. Manually monitor the CDI area when system is running.

3. stop the machine immediately if any abnormal sound is heard and

inform the mechanical incharge.

4. Always remain alert for taking necessary action for various alarms
given out by instruments.

5. Make sure that the air conditioning system is working to facilitate the
PLC operation.

6. Keep the surrounding area of the equipments clean.

7. All the firefighting equipments should be available at their

designated location and their working condition should be ensured.

8. General housekeeping should be maintained and area should be kept

free of inflammable materials.
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SHIFT HAND OVER

PROCEDURE KEY POINTS
1. Give information in details to shift –
SHIFT HAND OVER incharge and incoming operators regarding
the following :
i) Grinding status.
ii) Injection status.
iii) Maintenance work status.

2. Give information regarding the problems

faced and pending jobs.

3. Convey any specific instruction received in

the shift.

4. Document everything in the Log Book.

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SHIFT TAKE OVER

PROCEDURE KEY POINTS
1. Collect information from outgoing
SHIFT TAKE OVER operators regarding the following :
i) Grinding Status.
ii) Injection Status.
iii) Any Maintenance Job.

2. Collect information from shift in – charge

regarding :
i) Running and pending maintenance jobs.
ii) Any modification and rectifications
executed in the previous shift.
iii) Any specific instructions.

3. Read the Log Book carefully.

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SYSTEM OPERATION PROCEDURE

COAL LIFTING SYSTEM :
1. Ensure that there is sufficient raw coal in the ground hopper.
2. Ensure that the rod gate above the vibro feeder is open.

3. Switch on the MAGNET above the belt conveyor on 4th floor.

4. Start the DUST EXTRACTION fan on the 4th floor.

5. Start the BELT CONVEYOR on the 4th floor.

6. Start the HIGH RISE CONVEYOR.

7. Start the VIBRO FEEDER.

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RAW COAL LIFTING SYSTEM

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COAL GRINDING SYSTEM :

PRE – START CHECK :
1. Ensure that the BAG FILTER and the four VIBRATING SCREENS are
running for not less than 1 hour.

2. Ensure that the two centrifugal compressors and the new booster
compressor are running smoothly.

3. Ensure that the three nitrogen distribution vessels at CDI : D01, D02
& DO3 have reached their set point pressure (6.0, 7.5 & 7.5 Kg/cm2
respectively).

4. Ensure that the cooling water system of equipments and lubrication

station is running smoothly.

5. Ensure that coal feeding from G03 Belt is ok.

6.Ensure the following valve positions :

i) Mill inlet valve HC101 is close.

ii) HGG chimney valve PV103 is open.

iii) ID FAN inlet valve FC104 is close.

iv) ID FAN exit chimney valve PC104 is 100% open.

v) Recirculating line valve TC104 is close.

7. Ignite the HGG and start increasing the temperature by increasing

the BF gas.

8. Start mill LUBRICATION STATION.

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9. When HGG temperature T102 reaches 450°c open VALVE HC101.

10. Start ID FAN. Open the ID FAN inlet valve approx 25%.Close the
chimney valve PV103. Regulate the inlet valve FC104 to make the
system in proper pressure and flow rate. Mill negative pressure P104
should be approximately -160 mmWC.

11. When lubrication station is running normal and oil pressure is

approximately 4 kg/cm² then do the following :

i) Start HYDRAULIC STATION.

ii) Raise the MILL ROLLER.

iii) Start SEAL AIR FAN.

iv) Start the MILL.

v) Start the coal feeder belt G03.

vi) Drop the mill roller down after a delay and set the loading pressure
(approx. 70 bar).

12. Regulate the BF gas flow rate in HGG, Raise the temperature of
HGG. Control the temperature of Mill outlet (Bag Filter inlet) to be 80 –
85 °C and avoid too high temperature to damage the Bag Filter.

13. Control the mill inlet temperature T104 and make the same to be
250 – 280 °C. Regulate the coal feed rate of the coal feeder G03 to be
approx. 30 T/Hr and mill DP PD101 to be approx. 250 – 280 mmWC.
Ensure the mill outlet temperature is 80 – 85 °C. Observe the mill
vibration range and hard impurity discharging (mill rejection) status.
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14. Monitor CDI chimney for any coal emission during Grinding.

15. Collect the fine coal sample. Measure SIZE, MOISTURE , VM and
ASH content of the sample. Control the moisture content of the fine
coal to be less than 1% and size of the fine coal to be less than 90
microns (more than 80%).
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COAL GRINDING SYSTEM

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GRINDING STOP PROCEDURE

1. Decrease HGG temperature. Stop heating by closing BF gas valve
FC101 and PV101.

2. Switch on the Nitrogen cooling regulating valve PV1102 of the Mill.

3. Reduce the coal feeding rate.

4. When Mill outlet ( Bag Filter inlet ) temperature decreases to less

than 70°C STOP Coal feeding ( Stop G03 Belt ).

5. Lift Mill Roller.

6. Stop the Mill.

7. Stop the Seal Air Fan.

8. Open PV103 – HGG chimney valve.

9. Stop the main ID Fan.

10. Close HC101 – Mill inlet valve.

11. As the system temperature falls down, close the Mill Nitrogen
cooling valve PV1102.

12. Examine the Equipments.

13. Stop the Bag Filter and Vibrating Screen after 30 minutes delay.

14. Stop the Lubrication Station.

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INJECTION IN BF # 4
INJECTION VESSELS INVOLVED – VESSEL # 1 (T06A/1) and VESSEL # 2
(T06A/2).

PRE- START CHECKS :

Ensure there is sufficient Fine coal in the Fine coal silo. Depressurizing
valves of injection vessel # 1- PV115 and PV114 are open and pressure
in injection vessel is less than 0.2 kg/cm².

Ensure that the carrying Nitrogen to the Furnace is going through the
line of injection vessel # 1 i.e through PV118 and PV119 and flow of
Nitrogen through FC201 is Approx. 800 Nm³/Hr.

Ensure that there is sufficient number of healthy lances inserted at the

respective Blast Furnace tuyers.

PROCEDURE

1. FILLING INJECTION VESSEL # 1 :

i) Open filling valve PV112.

ii) Open filling valve PV111.

iii) When W201 is 10 T – Close PV111 and PV112 simultaneously.

2. PRESSURIZING OF INJECTION VESSEL # 1 (T06A/1) :

i) Close depressurizing valves – PV114 and PV115.

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ii) Open Pressurizing valve PV113 and ensure that flow control valve
PC201 is 100% open.

iii) Open Fluidizing valve PV116 and control fluidizing flow rate as per
injection rate required.

iv) When Pressure of injection vessel is 2.8 kg/cm² - Open the injection
valve PV117.

v) Now adjust injection vessel pressure, Fluidizing Nitrogen flow,

Carrying Nitrogen Flow according to the injection rate required.

vi) Note that pressure of injection vessel should be at least 1.1 kg/cm²
more than the Furnace Hot Blast Pressure.
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FINE COAL INJECTION SYSTEM

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INJECTION VESSEL CHANGE-OVER

CHANGEOVER FROM INJECTION VESSEL # 1 TO INJECTION VESSEL # 2.

PRE – CHANGEOVER CHECKS :

Ensure that there is 10 T coal in injection vessel # 2 (T06A/2).

PROCEDURE
1. Close the Depressurizing valves PV214 and PV215 of injection vessel
# 2.

2. Ensure that Pressurizing flow control valve PC202 is 100% open. Now
open Pressurizing valve PV213 and Open Fluidizing valve PV216

3. When injection vessel pressure 2.8 kg/cm², Close Pressurizing valve

PV213.

4. Stop injection from injection vessel #1 by closing valve PV117 and

also close fluidizing valve PV116.

5. Change the carrying Nitrogen line. Open PV219 and PV218

simultaneously.

6. Now close PV118 and PV119.

7. Now open PV217 to start injection from injection vessel # 2.

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8. Open the Depressurizing valves PV114 and PV115 of injection vessel

# 1.

9. Now adjust injection vessel pressure, Fluidizing Nitrogen and

Carrying Nitrogen flow to meet the CDI Rate demand of the Furnace.
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TROUBLE SHOOTING
COAL LIFTING SYSTEM :
TROUBLE CAUSES REMEDY

VIBRO FEEDER NOT STARTING OVERLOAD TRIPPED CALL ELECTRICAL

HIGH RISE BELT NOT EMERGENCY STOP PRESSED RELEASE EMERGENCY STOP
STARTING

EMERGENCY PULLCORD RELEASE PULLCORD

PULLED

OVERLOAD TRIPPED CALL ELECTRICAL

BELT SWAY CALL MECHANICAL

BELT CONVEYOR NOT EMERGENCY STOP PRESSED RELEASE EMERGENCY STOP

STARTING
BELT SWAY CALL MECHANICAL

MAGNET NOT STARTING ELECTRICAL FAILURE CALL ELECTRICAL

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TROUBLE SHOOTING
COAL GRINDING SYSTEM :
TROUBLE CAUSE REMEDY
G03 BELT NOT RUNNING BELT SWAY CALL MECHANICAL

OVERLOAD TRIPPED CALL ELECTRICAL

GO3 BOX JAM CALL MECHANICAL

CLEAR BELT DERAILED CHAIN LOOSE CALL MECHANICAL
CLEAR BELT BROKEN
GO3 JAM CALL MECHANICAL

EXCESSIVE COAL SPELIAGE CALL MECHANICAL

FROM MAIN BELT
COAL FEEDING NOT TACHO PROBLEM CALL ETL
SHOWING
INACCURACY OF COAL CALIBRATION PROBLEM CALL ETL
FEEDING
COAL FEEDING PROBLEM CHUT JAM CALL MECHANICAL

MILL VIBRATION BASE BOLT LOOSE CALL MECHANICAL

ABNORMAL SOUND FROM SCRAPER LOOSE CALL MECHANICAL

MILL

COUPLING BOLT BROKEN ALIGNMENT PROBLEM CALL MECHANICAL

MILL DP HIGH EXCESS COAL IN MILL REDUCE COAL FEEDING RATE

LOW ID SUCTION INCREASE THE OPENING OF ID

FAN

LOW PRESSURE OF INCREASE THE HYDRAULIC

HYDRAULIC SYSTEM PRESSURE

HYDRAULIC SYSTEM LEAKAGE IN SYSTEM CALL MECHANICAL

PRESSURE NOT HOLDING

BAG FILTER PD HIGH AL FOIL DAMAGED CALL MECHANICAL

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PULSATING VALVE NOT CALL ELECTRICAL

WORKING

PUPPET VALVE NOT CALL ELECTRICAL

WORKING

NITROGEN PURGING PIPE ARE CALL MECHANICAL

DISPALCED

BAG JAM CALL MECHANICAL

ROTATRY AIR LOCK TRIPPED OVERLOAD TRIPPED CALL ELECTICAL

FOREIGN ELEMENT STUCK CALL MECHANICAL

VIBRO SCREEN TRIPPED BAG FILTER HOPPER JAM REPLACE THE SCREEN (CALL
MECHANICAL)
MOTOR FAULT CALL ELECTICAL
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TROUBLE SHOOTING
COAL INJECTION SYSTEM
TROUBLE CAUSE REMEDY
nitrogen pressure low Booster compressor Start bypass line
down
Pneumatic Valve not Solonoid Valve
operating problem

Low pressure of
nitorgen

Filter cum PRV

problem

Injection rate low Filter jam Call mechanical

Inadequate fludizing Call mechanical

Less no of lances for Increase the no. of

coal injection in lances in furnace
furnace

Individual coal line Check and clean coal

and lance jam in line and lance in
furnace furnace
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