Coal Milling System Gyanendra Sharma NPTI Delhi

Milling System
03/27/2021 Gyanendra Sharma, NPTI Delhi

The design of the Furnace is a major
factor in successful Boiler performance.
Furnace Sizing Parameters:
􀀹 Net Heat Input per Unit Plan Area
􀀹 Furnace Cooling Factor
􀀹 Furnace Exit Gas Temperature
􀀹 Burner Zone Heat Release Rate
􀀹 Volumetric Heat Release Rate
􀀹 Furnace Residence Time
􀀹 Heat Input (role of pulverizers)
Pulverized Fuel Combustion
• In 1884, the more efficient high speed steam turbine was developed by
British engineer Charles A. Parsons which replaced the use of steam
engines to generate electricity.
• In the 1920s, the pulverized coal firing was developed.
• This process brought advantages that included a higher combustion
temperature, improved thermal efficiency and a lower requirement for
excess air for combustion.
• An universal choice for power plants till 1990.
• Fine particles of coal ~ 75 microns.
• Surface area : 150 m2/kg.
• Huge heat release per unit area : 2 – 5 MW/m2.
• Steam generation : ~ 2000 tons/hour.

13 Essentials of Optimum Combustion
Fuel Preparation
1. Fuel feed quality and size shall be consistent.
2. Fuel feed shall be measured and controlled as accurately as possible.
Load cell equipped gravimetric feeders are preferred.
3. Fuel line fineness >75% passing a 200-mesh screen, and 50 mesh
particles <0.1%.
Distribution to Burners
4. Primary airflow shall be accurately measured and controlled to ±3%
accuracy.
5. Primary air to fuel ratio shall be accurately controlled when above
minimum.
6. Fuel line minimum velocities shall be 16.5 m/s.
7. Fuel lines shall be balanced by “Clean Air” test to within 2% of
average.
8. Fuel lines shall be balanced by “Dirty Air” test to within 5% of
average.
.
9. Fuel lines shall be balanced in fuel flow to within 10% of
average
Combustion
10. Over-fire air shall be accurately measured and controlled to
±3% accuracy.
11. Furnace exit shall be oxidizing; 3% oxygen is preferable.
12. Mechanical tolerances of burners and dampers shall be ±
6.5mm.
13. Secondary air distribution to burners shall be within 5-10% of
average.

Pulverizers
• 􀂵Are used for drying of coal and grinding the coal to
required fineness
• 􀂵The number and capacity of mills depends strongly on
the GCV
• 􀂵HGI and Moisture affect the grind ability of the coal and
therefore the capacity of the mill
• 􀂵The required fineness of the coal to boiler and the
maximum allowable mill outlet temperature depends on
the reactivity of the coal.
• 􀂵Low rank coals have higher reactivity and therefore allow
a coarser grind and low mill outlet temperatures
• 􀂵Moisture in coal may also limit the drying capability of a
pulverizer
FACTORS AFFECTING MILLING PLANT
PERFORMANCE
•GRINDIBILTY OF COAL
•MOISTURE CONTENT
•SIZE OF COAL INPUT
•FINENESS DESIRED AS OUTPUT
•MILL WEAR

HGI V/S Mill capacity
H A R D G R O V E G R IN D A B IL IT Y
100
95
90
85
M A X IM U M C A P A C IT Y
80
75
70
65
60
55
50
45
40
35
40 50 60 70 80 90 100 110 120 130 140 150 160
PER CENT CAPACITY
HARDGROVE GRINDABILITY CHART

Effect of HGI on Mill Capacity

Effect of Moisture on Mill Capacity

Effect of fineness on Mill Capacity

Grading of coal
UHV ( Kcal/ kg) Grade

Above 6200 A
5605 – 6200 B
4945 – 5605 C
4205 – 4940 D
3365 - 4200 E
2405 - 3360 F
1300 - 2400 G

Grades of Non-coking Coal
Useful Heat Value (UHV) Corresponding Gross Calorific Value GCV
Grade (Kcal/Kg) Ash% + Moisture % (Kcal/ Kg)
UHV= 8900-138(A+M) at (60% RH & 40O C) (at 5% moisture level)
A Exceeding 6200 Not exceeding 19.5 Exceeding 6454
B Exceeding 5600 but not 19.6 to 23.8 Exceeding 6049 but not
exceeding 6200 exceeding 6454
C Exceeding 4940 but not 23.9 to 28.6 Exceeding 5597 but not
exceeding 5600 exceeding. 6049
D Exceeding 4200 but not 28.7 to 34.0 Exceeding 5089 but not
exceeding 4940 Exceeding 5597
E Exceeding 3360 but not 34.1 to 40.0 Exceeding 4324 but not
F Exceeding 2400 but not 40.1 to 47.0 Exceeding 3865 but not
exceeding 3360 exceeding. 4324
G Exceeding 1300 but not 47.1 to 55.0 Exceeding 3113 but not
Burning of Coal
Let us see what happens when coal is

fired in the furnace and the different
stages of burning

BURNING BEHAVIOR OF COAL
The analysis is carried out using a sophisticated
equipment Differential Scanning calorimeter. This an
advanced analytical technique to assess the burning
characteristics of coal.
Burning behaviour of Coal
( Burning profile temperatures ITvm, ITfc, PT, BT )
ITvm is defined as the volatile ignition temperature, this is the
temperature where combustion of volatile matter just sets in.
ITfc is the ignition temperature – where ignition of char takes
place.
PT,the peak temperature, it is the temperature where the rate
of heat release is maximum due to char combustion.
BT, Burn out temperature, is the temperature where burning
of03/27/2021
coal is complete & exothermic
Gyanendra Sharma,heat release becomes zero.
NPTI Delhi
TYPICAL BURNING PROFILE OF INDIAN NON-COKING COAL

Variation of Coal GCV during the Test Runs -
Station X
4500
GCV - kcal/kg
4000
3500
3000
2500
1 2 3 4 5 6
Test 7
No. 8 9 10 11 12 13

Variation of Coal GCV during the tests
(Station Y)
4600
4400
GCV - kcal/kg
4200
4000
3800
3600
3400
3200
1 2 3 4 5 6 7 8
Test No.

Variation of Auxiliary Power with Coal GCV
5000 7000
Aux. Power - kWh

4500
GCV - kcal/kg
4000 6000
3500
3000 5000
1 2 3 9
Test No.
GCV - kcal/kg Aux. Power - kWh

Furnace of a typical coal fired boiler

Combustion of a fuel particle

Pulverized fuel
• A particle gets maximum 3 seconds residing
time inside the furnace.
• Coal to ground to 80% through 200 mesh
size to ensure rapid combustion.
• Air Fuel temperature leaving the mill to be
approx. 900C.

Volatile matter
• The volatile matter is that portion which is driven
off as gas or vapor when the coal is subjected to
temp. of approx 900C. The amount of volatiles is
an index of the behavior of the coal on
combustion, carbonization and gasification.
Incomplete burning of volatiles will form smoke.
• Volatile matter should be at least 20% to maintain
flame stability.
• For low-volatile and/or high ash coal the flame
speed is low and the air from the secondary nozzle
should be mixed in more slowly to avoid
instability.
Burning of Volatile Matter
• Coal is a complex organic polymer
• Heating causes its structure to decompose
• Weaker chemical bonds break at lower
temperatures
• Stronger ones at higher temperatures
• Thermal decomposition releasing volatile
combustible matter
• Coal is heated at rates of 103 – 105 deg C s-1
• Volatile yield can be upto 50% greater than
indicated by proximate analysis
Char Combustion
• Char consists of porous carbon, mineral
matter, and a small amount of organic
matter.
• Particle temperature is 100-200oC above the
external gas temperature.
• Char burning rate is a key factor in
determining the size of a boiler.

Flame stability
• Fuel-air mixture must have a composition
within the flammability limits
• Stability of the flame is determined by the
concentration of gas phase volatiles and air
• The flame speed depends on the volatile
matter and ash levels of the coal

BOWL MILL – XRP803

COAL MILL

Data of a typical Bowl Mill
• Type XRP 803
• Capacity 49 T /Hr
• Coal size inlet 25 mm
Outlet 70% thru 200 mesh
• Grinding roll Ni Hard Gr II
• Bull ring seg Modified Ni hard / Hi Chrome
• Coupling Gear type flexible coupling (motor)
• Cooling system Immersed in Oil bath, oil cooling by water
• Oil pumps screw pumps, 50 lpm
Data of a typical Bowl Mill
Mill Bearings
• Vertical shaft
• Upper radial bearing C 8159 A Torrington
• Lower radial bearing 220 RU o 03 R3 Torrington
• Thrust bearing T 11000 Timken
• Worm Shaft
• Thrust bearing SKF 29438
• Radial bearing 170 RM 03 Torrington
• Journal Assembly
• Upper radial bearing HH 249949 / 10
• Lower radial bearing EE350750 / 351687
Problems in milling system
1. Mill choking
2. Fineness is poor
3. Mill reject very high
4. Mill outlet temperature low/high
5. Unequal distribution of coal flow
6. No coal flow from bunker/feeder/centre feed pipe
7. Foreign material
8. Lubrication problem
9. Mill / piping erosion high
10. Others

VARIOUS AIR GAPS INSIDE BOWL MILL
Inverted
Cone gap
Liner
bracket
Throat gap ARP
Center Feed
Pipe Gap
03/27/2021 Rotary vanewheel

Gyanendra Sharma, NPTI Delhi
Atul Gupta

figure
SHORT CIRCUITING
• SHORT CIRCUITING
OF COAL-AIR
MIXTURE
THROUGH
ANNULAR GAP
BETWEEN CONE
AND CENTRE FEED
PIPE

Combustion Aspect with
Milling System
Fuel analysis feedback
Milling plant performance
Mill Loading – flow, current, dp, fineness
Total PA air as per air fuel mixture
PA hdr Pressure
SADC tuning and operation
Orifices, coal nozzles and fuel pipe bends condition
Furnace draft, FEGT and O2
APH choking & leakages
Revalidate
03/27/2021 feedbacksGyanendra
and measurement
Sharma, NPTI Delhi
BALL & TUBE MILL

BALL AND TUBE MILL
SPECIFICATION BBD 4760
SHELL LENGTH 6000 mm
SHELL DIAMETER 4700 mm
DESIGN BALL CHARGE 76 MT (1/3 OF
EACH OF
30,40,& 50 mm)
CAPACITY 85 TPH
AIR FLOW THRU’ MILL 121 TPH
PRINCIPLE OF GRINDING
ATTRITION
IMPACT

LINER PROFILE
TRAILING
EDGE
LEADING
EDGE
90
mm

LINER WEAR
TRAILING
EDGE
LEADING
7 mm EDGE
90
mm

BALL LIFTING
BALL RETURN

BALL LIFTING
BALL RETURN

GRINDING

POWER vs COAL LEVEL

HI LEVEL

CENTRE OF GRAVITY HI
LEVEL

CENTRE OF GRAVITY
LOW LEVEL

LINER WEAR
TRAILING
EDGE
LEADING
EDGE
95
mm

FINENESS vs CAPACITY
120 70 %
100
C
A 80 %
P
80
A
C 90 %
I
60
T
Y FINENESS
T (-) 200
40
/
H
20
50 60 70
HARDGROVE GRINDABILITY

FINENESS vs COAL LEVEL
• POOR FINENESS INCEASES UNBURNT
IN BOTTOM ASH
• LIGHTER COAL FLIES AWAY WITH THE
FLUE GAS RESULTING IN HI UNBURNT
IN FLY ASH
• MAINTAINING HI LEVEL WILL
DECREASE THE FINENESS OF THE
COAL WHICH WILL RESULT IN HI
UNBURNT Gyanendra Sharma, NPTI Delhi
03/27/2021
REASONS
• HIGH FINENESS BECAUSE OF LOW
VELOCITY OF AIR
REMEDY

 INCREASE HEADER PRESSURE

COMPARATIVE STUDY
BOWL MILL vs TUBE MILL
• ADVANTAGES OF TUBE MILLS
• PF FINENESS IS HIGH.
• NEEDS NO REJECT HANDLING SYSTEM.
• CAN COPE-UP WITH WIDE VARIETY OF
COAL.
• LESS MAINTENANCE.
• QUICK RESPONSE TO LOAD CHANGE.
• LESS NO. OF MILL CHANGEOVERS
REQUIRED

COMPARATIVE STUDY
Limitations of Tube mills
• TUBE MILLS CANNOT TAKE THE
OVER BURDEN OF STONES (IN BOWL
MILLS IT IS REJECTED)
• THESE MILLS ARE VERY SENSITIVE
TO FREQUENCY CHANGE.
• TAKES MORE TIME IN START UP.
• NO OF DRIVES ARE MORE.
• INTERLOCK AND PROTECTION ARE
TOO HIGH.
COMPARATIVE STUDY
MILL AND AUXILIRIES POWER IN KW
FOR 210 MILL PA FAN SEAL MRC AUXILI TOTAL
MW MOTOR AIR RIES POWER
FAN (LUB
OIL &
OTHER)
BOWL 1280.29 1856.43 16.10 10.06 0.00 3162.88

MILL
TUBE 2480.57 768.18 181.13 0.00 16.10 3445.98
MILL
RC Feeder power consumption is almost same in both the

cases hence not considered
COMPARATIVE STUDY
BOWL MILL vs TUBE MILL contd…
DRAFT SYSTEM POWER IN KW

FOR MILL PA FAN ID FAN FD FAN SEAL MRC AUXILIR TOTAL
210 MOTOR AIR IES POWER
MW FAN (LUB
OIL &
OTHER)
BOWL 1280.29 1856.43 1920.44 464.11 16.10 10.06 0.00 5547.43
MILL
TUBE 2480.57 768.18 1600.37 464.11 181.13 0.00 16.10 5510.45
MILL

COMPARATIVE STUDY
FOR 210 MILL PA FAN ID FAN FD FAN SEAL MRC AUXILIRI TOTAL
MW MOTOR POWER POWER POWER AIR FAN POWER ES (LUB POWER
POWER POWER OIL &
OTHER)
POWER
BOWL 1280.29 768.18 1600.37 464.11 16.10 10.06 0.00 4139.11
MILL
TUBE 2480.57 768.18 1600.37 464.11 181.13 0.00 16.10 5510.45
MILL
RC Feeder power consumption is almost same in both the

cases hence not considered
COMPARATIVE STUDY
FOR 30000 GENERATION TOTAL COST IN COST
HRS IN MU INR (ENERGY + (PAISA PER
MAINT) KWh)
BOWL MILL 12697 177368199 1.40
TUBE MILL 12739 199507928 1.57
TOTAL COST PER TON OF COAL CRUSHED

FOR 30000 COAL CRUSHED TOTAL COST IN COST (Rs.
HRS IN MT INR (ENERGY + PER TON OF
MAINT) COAL
CRUSHED)
BOWL MILL 8146271 177368199 21.77
TUBE MILL
03/27/2021 8146271 199507928
Gyanendra Sharma, NPTI Delhi 24.49
COMPARATIVE STUDY
TOTAL COST PER KWh
FOR 30000 GENERATION IN TOTAL MAINT.COST COST
HRS MU IN INR (PAISA PER
(MATERIAL+WORKS) KWh)
BOWL MILL 12697.33333 64896186.67 0.51

TUBE MILL 12738.66667 39338777.33 0.31
TOTAL COST PER TON OF COAL CRUSHED

FOR 30000 COAL CRUSHED IN TOTAL MAINT.COST COST (Rs.
HRS MT IN INR PER TON OF
(MATERIAL+WORKS) COAL
CRUSHED)
BOWL MILL 7840000 64896187 8.278
TUBE MILL
03/27/2021
7840000 39338777
Gyanendra Sharma, NPTI Delhi
5.018
IMPROVEMENT IN
MAINTENANCE
PRACTICES

• USE OF PNEUMATIC WRENCH TO OPENING &
TIGHTENING OF CHAMBER BOLT, WORM SHAFT
COVER BOLT, CLAMPING RING BOLT.

• USE OF CENTRIFUGE FOR PURIFICATION OF GEAR
BOX OIL TO INCREASE LIFE OF BEARINGS /
GEARBOX.

• USE OF ELECTRICAL HOIST FOR LIFTING & SHIFTING OF
HEAVY COMPONENTS LIKE JOURNAL ASSEMBLY, MDV,
VENTURY ASSEMBLY ETC IN MAINTENANCE WORK.

• USE OF FORK LIFT & HYDRA FOR SHIFTING OF
ABOVE HEAVY COMPONENTS FROM & TO
WORKSHOP / STORE.

– HAND TROLLY FOR SHIFTING JOURNAL
ASSEMBLY.
G. USE OF BEARING INDUCTION HEATER FOR TROUBLE

FREE MOUNTING OF HEAVY BEARING.
H. USE OF MEASURING INSTRUMENT LIKE
MICROMETER, VERNIER CALIPER ETC.

GRINDING ROLL REMOVING FIXTURE
WORM SHAFT DISMANTLING FIXTUR
BOTTOM
03/27/2021BEARING REMOVING JOURNAL
Gyanendra Sharma, NPTI Delhi BEARING REMOVING
FIXTURE FIXTURE
IMPROVEMENT IN
EXISTING SYSTEM

ROTARY VANE WHEEL ASSEMBLY WAS
REPLACED WITH
STATIONARY AIR INLET ASSEMBLY

AIR DIVERSON PLATE HAS IMPROVED
MIXING OF AIR

1. RADIAL GAP OF 120 MM BETWEEN AIR GUIDE
RING AND BOWL OUTER SURFACE.
2. JOURNAL OPENINGS, RADIAL GAP OF AIR
GUIDE RING & BOWL REDUCED TO 5 MM.

Coal Milling System Gyanendra Sharma NPTI Delhi

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Milling System

03/27/2021 Gyanendra Sharma, NPTI Delhi

• Steam generation : ~ 2000 tons/hour.

03/27/2021 Gyanendra Sharma, NPTI Delhi

03/27/2021 Gyanendra Sharma, NPTI Delhi

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PER CENT CAPACITY

HARDGROVE GRINDABILITY CHART

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UHV ( Kcal/ kg) Grade

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A Exceeding 6200 Not exceeding 19.5 Exceeding 6454

Let us see what happens when coal is

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Aux. Power - kWh

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Throat gap ARP

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BOWL 1280.29 1856.43 16.10 10.06 0.00 3162.88

RC Feeder power consumption is almost same in both the

DRAFT SYSTEM POWER IN KW

03/27/2021 Gyanendra Sharma, NPTI Delhi

RC Feeder power consumption is almost same in both the

TOTAL COST PER TON OF COAL CRUSHED

BOWL MILL 12697.33333 64896186.67 0.51

TOTAL COST PER TON OF COAL CRUSHED

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G. USE OF BEARING INDUCTION HEATER FOR TROUBLE

03/27/2021 Gyanendra Sharma, NPTI Delhi