Safety Using Coal

GENERAL

Using coal and coal meal may under certain conditions involve
spontaneous ignition during transport, storage and handling.
Spontaneous ignition resulting in open fire or explosion can be
avoided by taking suitable precautions. Safety precautions depond,on
the properties of the coal type concerned, storage conditions and the
processes in which the coal is involved.

Spontaneous ignition

Coal liberates volatile matter which reacts chemically with

atmospheric air, creating flammable gases. The chemical reaction
taking place close to the coal surface generates heat. Heat not
conducted away is absorbed in the coal. Rising temperature in the
coal causes liberation of volatile matter. As long as this access to
atmospheric air, further heat is evolved as a consequence of the
chemical reaction through the generation of flammable gasses. In
coal bunkers or coal dust accumulations, the surface heat can be
given off to the surroundings, but inside the bunker or coal dust-
accumulation, the temperature will rise and gradually' reach the point
of ignition of the coal type concerned.

Spontaneous ignition starts as smouldering fire, but if there is

sufficient supply of oxygenous atmospheric rich air, the smouldering
fire will develop into open fire.

Coal dust explosion

A mixture of coal dust and air may be explosive, because it may

ignite suddenly accompanied by excessive pressure increase. Such
explosion takes place when the following conditions are present at
the same time:

1. The dust content of the coal/air mixture must be- within a certain
explosion-dangerous range, specified by a lower and upper explosion
limit. This range is 30-2000 g of coal/M3 air, with the highest
pressure increase rate being 800-1000 g of coal/m3 air.
2. The oxygen concentration in the air must be min. 15-17%.

3. There must be a reason for the mixture being subjected to

sufficiently high temperature, called ignition temperature. For
instance, smouldering coal dust or a spark which may originate from
friction or static electricity.

There must be a possibility for a certain turbulence so that the flame

can spread quickly. The explosiveness of the c6al dust/air mixture
depends on several conditions. Ignition temperature and lower and
upper explosion limit depend on the chemical composition of the coal
type concerned. The electrostatic self charge, of the coal dust
particles which is due to processing, may cause formation of
sparks.

The risk of explosion is highest if the coal dust is dry and fine-grained
and when gaseous types of coal containing little ash are concerned.,
Explosions in coal dust/air Mixtures may be more or less violent,
depending on the kind.-of mixture and ignition. Explosions may be
slight "puffs" which usually are harmless.

General precautions against fires and explosions.

Spontaneous ignition takes place after a temperature rise which takes

a certain time. The time available for temperature rises must there-
fore be restricted as much as possible. The storage time of coal and
coal meal and any other period during which the materials are at rest
must therefore be reduced as much as possible, be- cause heat is
given off easier to the surroundings when the materials are in
movement. Heat supply from the surroundings must be avoided to
extent possible so that same does not contribute to temperature
rises. Since the temperature rise is a consequence of the chemical
reaction between volatile matter and atmospheric air, access of air
must be limited as much as possible.

In closed. spaces this can be achieved by replacing atmospheric air

by CO2 or other extinguishing gas also called inert gas.
Coal dust explosions are prevented by excluding the possibility that
the aforementioned four conditions can occur at the same time. The
surest way to do this is to eliminate one or several of the-conditions
which are dealt with in the following section.

Plant conditions.

All spaces containing coal meal handling machinery must be kept

thoroughly clean on account of the fire and explosion hazards in
connection with coal dust. If the building is shaken due to an
explosion in the machinery, coal dust ..may drizzle down or be
whirled up. This involves the risk of a serious explosion in the entire
coal mill plant. Spaces must be designed to facilitate cleaning as
much as possible. Provide vacuum cleaning, if possible.

When cleaning, avoid whirling up dust with, e.g., compressed air. The
building structure must not have any inaccessible, horizontal faces,
aces at sectional irons, beams, braces, brick projections, cornices,
etc. must have an angle of 60' from horizontal level so that no coal
dust is accumulated here. Live cables must preferably be run in
cable ways in the walls or be run outside the building. Cable boxes
inside the building thus be enclosed and horizontal-faces must have
an angle of min. 60'* from horizontal level.

All equipment must be earthed so as to avoid static electricity. Static

electricity involves the risk of spark formations which can cause fires
or explosion. Smoking is prohibited and such prohibitions to be
indicated clearly. Dust escape, All coal meal conveying parts of the
installation, must operate at a negative pressure so as to avoid coal
dust escape.

Coal dust escape may occur as a consequence of wrong gate

settings or maladjustments. On account of the fire hazard, coal dust
must be removed as quickly as possible. Pressure relief. Machine is
incorporated in the coal grinding installation must be designed so that
deflagrations and explosions do not burst into closed spaces, but are
directed into the open through pressure relief. Pressure relief must be
marked and persons be prohibited from staying in areas in which
explosions can take place. Pipes, air separators, cyclones and filters
must be dimensioned and pressure-relieved in compliance with VDI
3673 for the protection of personnel' and installations.

Precautions during repair

Repair work must be carried out go that unnecessary fire hazards,

are avoided. Electric tools must 'comply with class 8X,, meaning
special spark-proof design. Welding must not take place if there is
coal dust in the vicinity. The repair area must be cleaned thoroughly
of coal dust before work is commenced so that spark formations
originating from mechanical activities do not present any risk. Any
personnel must definitely not stay in front of explosion relief flaps,
because this is highly dangerous.

SPONTANEOUS IGNITION IN RAW COAL

The following conditions influence the risk of spontaneous ignition in

coal:

1. Content of volatile matter in coal.

2. Lump size of coal.
3. Coal heap temperature and water content.
4. Coal heap height.
5. Coal heap compression.
i
Content of volatile matter in coal.

Coal liberates volatile substances which form combustible gasses in

connection with atmospheric air. The content of volatile constituents
depends on the type of coal. Coals with a high gas content ignite
easier spontaneously than coal with a low ash content. Anthracitic
types of coal have a low gas content and do not ignit6 spontaneously
every after prolonged storage. Lignite types of coal have a gas
content of 50% or more and ignite spontaneously relatively easy.
Intermediate types of coal with a gas content of 25-40% can ignite
spontaneously when stored for a ,lengthy period under adverse
conditions.

Lump size of coal

The lump size of coal varies and there is a certain amount of coal
dust in all coal stocks. Coal dust is created during transport through
mechanical friction between the coal lumps. When the coal is stored,
a certain classification takes place which may result in coal dust
accumulations. Such dust accumulations increase the risk of
spontaneous ignition.

Temperature and water content in coal heap.

Rising temperature in the coal heap increases the risk of

spontaneous ignition. For spontaneous ignition temperatures.
Decreasing moisture content in the heap will like- wise increase the
risk of spontaneous ignition.

Coal heap height

Coal having high content of volatile matter for instance lignite must be
stored in height of 6mt Max.

Compression

Coal heap compression reduces the hazard of spontaneous ignition,

because compression limits the possibility of air circulation in the
heap and consequently of oxidation. Also, compression reduces air
pockets in the heap and consequently limits the possibility of
oxidation.

Measurement of spontaneous ignition in Raw Coal

The risk of spontaneous ignition can be reduced considerably by

observing the following rules.

Transport damages

Dust formation must be avoided as much as possible. Therefore, do

not transport the coal more than necessary. Required drop heights
during transport to be made as small as possible so as to avoid coal
dust formations. Keep the coal free from oil-soaked cotton waste,
rags, etc. which may ignite spontaneously.
Storage schedule

Long-term oxidation and high temperatures must be avoided to extent

possible. The storage time must therefore be as short as possible.
Coal types with a very low ignition temperature may advantageously
be stored below water. When storing smalls containing larger coal
pieces, the large pieces must not accumulate at walls or around
columns. This may result in a stack-effect promoting increased
oxidation and consequently risk of spontaneous ignition. High coal
heaps should be built up in layers which are washed together by
intensive watering. This will compress the coal and reduce the air
gaps. For the same reason the bunkers should be compressed with,
f. inst., a bulldozer.

Avoid unnecessary heating of the coal, for instance by furnaces

nearby or solar heat in dry and sunny climates, open coal stores must
be covered with a thin layer of limestone, raw meal, filter dust or
similar material which can reflect the sun rays and prevent solar
heating of the coal heap.

Storage in silos

Storage of coal in closed silos calls for special attention due to the
content of volatile matter in the coal. Coal gives off constituents
which, when mixed with air, are gasses involving the risk of fire and
explosion. Therefore, avoid long-term storage in silos.

Coal heaps

When storing in coal heaps, they will always contain a certain amount
of air (oxygen) which together with the volatile matter result in easily,
inflammable gasses. The internal heap pressure may result in
temperature which may ignite the gasses. The temperature
development, in coal heaps must there- fore be observed closely. On
account of the internal pressure, the heights must not be exceeded. if
it is possible to arrange several smaller heaps, this must have
preference over one single large heap. The heaps must be arranged
with certain spaces in between so that any fire cannot spread
between the heaps.
Temperature measurement is easiest done by inserting a number of
iron pipes into the heap, one end of which is closed. Using a suitably
long thermometer the temperatures can then be measured
systematically.

Temperatures above 50*C are critical. At 700C spontaneous ignition

is likely.

Spontaneous ignition resulting in fire is expected at the following

temperatures.

150"C in-brown coal (lignite) 2500C in coke and petroleum coke

3000C in anthracite coal types The temperatures apply to mixtures of
small and large coal pieces. If temperature rises above 70 deg C are
ascertained, the coal stock must either be used' as quickly as
possible or, if possible, be spread out for Cooling showering with
water may increase the risk of spontaneous ignition, particularly when
sulphurous coal is concerned. The Content of pyrites is oxidized more
easily, liberating sulphur, which lower ignition temperature than coal.

Blowing compressed' air over the coal heap surface can prevent
spontaneous ignition if no air can reach the inside of the heap.

PRECAUTIONS AGAINST FIRES IN COAL HEAPS

It is very difficult to extinguish fire in coal heaps. The nor sure

extinction method is to spread out the coal heap and put out the fire
by spraying ample quantities of water on the coal. Extinction attempts
with water without spreading the heap have normally only a poor
effect. The supplied water volume must be ample, because if too little
water is supplied this may cause a gas explosion. When water vapor
comes into contact with glowing coal, the water vapor may be
changed into water gas which is an explosive gas consisting of
carbon, oxygen and hydrogen.

Damming-up of water around a burning coal heap in an open storage

site in an attempt to "drown" the fire wall usually only make the water
penetrate 3-4 meters into the heap sides, which is rarely enough to
put out the fire in the core of the heap. Covering with sand, earth or
foam may delay the development, but does not extinguish a coal fire.
Carbon dioxide has no extinguishing effect in coal heaps.
Compression of coal heaps during or after fires is risky, because the
core may have burnt away so that there is a risk of collapse.

COAL MILL PLANTS AND COAL DRYING PLANTS

Coal grinding plants must be designed so that danger of explosion is

avoided to extent Possible. Since it is not possible to entirely avoid
danger of explosion. Grinding of coal into coal meal involves danger
of explosion in several places of the installation. Partly where
unintentional dust accumulation occurs and partly where the coal
meal is dry and the temperature is high.

Neither is it always possible to maintain inert conditions, e.g. during

involuntary stoppages. Moreover to limit the consequences in case of
an explosion. E.g. by preventing that thin flames cause fires which
may be more harmful than the explosion.

Increasing dryness and grain fineness involve increasing risk of

spontaneous ignition and explosion. When grinding coal into coal
meal, the water content must therefore not be reduced more than
necessary. The water content is controlled with the temperature on
the discharge side of the mill. The temperature depends on the coal
type and is determined through laboratory examinations.

Determination of dehydration curves for coal.

Precautions

The-precautions apply especially to coal mill plants. Although the coal

meal conveying machinery operates at negative pressure to avoid
dust escape, this cannot be avoided completely. E.g. electric panels
must be mounted in separate overpressure rooms. This reduces the
risk of fire as a consequence of spark ignition or spontaneous
ignition.

Mills and fans are not pressure relieved, but dimensioned to VDI
3673 for the protection of personnel and machines. Moreover, the
plant is constructed so that deflagrations and explosions escape into
the open. Nobody must of course, stay in front of pressure relief
openings and where thin flames may burst out. The design of
explosion relief flaps must not be changed.

The coal mill plant must be run in with limestone or another

noncombustible material so that any defects can be corrected without
the risk of fire or explosion. This will fill hollow spaces, inclined faces,
and other places in which coal meal may accumulate, with such
materials instead of coal dust. The coal mill must be controlled so that
the temperature after the mill is adapted to the coal type. The max.
discharge temperature must be adhered to strictly, because the coal
meal is otherwise dried too much.

This involves the risk of deflagations and explosions in among others

the coal meal silo and other, plant installations-after the mill. Coal
grades must not be mixed prior to grinding, un- less they have
approximately the same properties. This, because the correct
discharge temperature of a mixture may be impossible to determine.
Different coal grades must therefore be ground separately and be
proportioned separately to the kiln burner.

Temperature conditions

The operating temperature of a coal mill depends on the coal type.

The discharge temperature must be watched closely, because too
high temperatures will dry the coal meal too much involving the risk of
deflagrations and explosions as well as spontaneous ignition in the
coal meal silo. At the mill inlet the coal is moist and the permissible
maximum temperature depends only on the plant machinery.

A ball mill with over-hanging drying chamber can withstand a high

inlet temperature. Ball mills without over-hanging-drying chamber and
vertical mills can only withstand substantially lower inlet
temperatures. With ball mills it is crucial that the dry and hot tailings
from the air separator are mixed thoroughly with the moist and cold
fresh feed before the feed is subjected' to the hot air/'gas in inlet.

At the mill outlet the discharge air temperature is controlled by

thermometer probes.The thermometer probes have two alarms, max.
I and max. 11. Max. I must be set to give alarm 'at a temperature
which is 5 deg C higher than the normal operating temperature. Max.
11 must be set to give alarm at a temperature which is 10'C above
the normal operating temperature. Alarm at max. I indicate that a
disadvantageous development may be on the way.
At max. 11 the mill plant is automatically cut out. Hot air supply When
coal mills or coal drying plants are commissioned, stopped or at
standstill., no hot air must be drawn through, because this may whirl
up dust. With a critical mixture of dust & air and heat in the vicinity of
the ignition temperature there is a risk of explosions. During inert
operation however, inert exit gas must carefully be drawn through
the mill before starting same and adding the feed. During such
inertization there must be no overheating anywhere.

Inert operation of coal mill Giants

Coal mills for inert operation are designed so that all air involved in
coal grinding and conveyance is inert gas. Since an explosion among
others requires an oxygen concentration of 15-17% or more, the risk
of explosion is substantially reduced during inert operation. Inert
operation is controlled and monitored by means of O2 measuring
equipment.

When starting up, sufficient inert gas must be drawn through the coal
conveying machinery of the mill plant to ensure an inert atmosphere
before starting the feed. Inert operation with dry raw coal may
develop so much 'heat that it may be difficult to maintain the
temperature after the mill down at the correct level. The temperature
is regulated by adding cold air to the required gas volume, however,
to much cold air added to the inert gas eliminates the fire-
extinguishing effect. The inert condition may however be maintained
and the temperature be regulated at the same time by means of
water inject ion.

Water injection may involve condensation problems in. parts of the

downstream installation. Suitable insulation pay solve most problems
of moisture condensation.

Inspection and service

When inspection or maintenance work inside a coal mill or in some
other machine of the coal mill plant is required, a watchman Must be
stationed directly: at the open cover. The watchman must be
provided with suitable fire extinguishing equipment. At least one
carbon dioxide fire extinguisher.
There is a risk of gas formations which may be ex- .plosive and there
is also a risk of poisoning the personnel staying inside the machinery.
Personnel who are to work inside the machinery must carry portable
gas analyzing equipment which gives alarm for Co max. and 02 min.

When internal inspection or work inside the coal mill plant machinery
is to take place, the system must be emptied of coal meal and be
ventilated with cold air before entering. Before stopping the mill, it
must run for some time without feed and heat supply. During this
process it must be blown through intensively with cold air until as
much coal dust as considered necessary has been removed.

Coal mill linings and grinding media may suffer damage when
operating for too long without coal charge. The duration must be
judged on the basis of the grinding sound. However, operation
without heat supply must at least last so long that the temperature
after the mill drops substantially. Vertical mills must be run empty and
blown through as long as deemed necessary on account of the
vibrations.

When shutting down the mill plant, fire can be prevented by

introducing raw meal or filter dust into the- mill system. Such non-
combustible material covers the coal meal to form protective layer.

When the mill has stopped it must be slightly ventilated- When a

page from a newspaper, or similar placed over an opened manhole is
sucked, into the mill, ventilation must be considered sufficient to
remove carbon monoxides and gas formations from the remaining
coal charge.. Without sufficient ventilation there is a risk of carbon
monoxide poisoning when entering the mill. Even very low
concentrations of CO are lethally poisoning.

Inhalation of air containing insufficient oxygen is suffocating within

very short time. After inertization with CO2 or N2 it is very important to
blow through and ventilate thoroughly before any personnel enters
the machinery. If a cover is removed before blowing through has
taken place there is risk of explosion if air comes into contact with
coal dust still entering somewhere in the system. If this happens there
is a risk of a secondary explosion, because the pressure wave from
one explosion may whirl up coal dust in other places of the system
and a thin flame, if any, may also involve a risk. if personnel is to stay
inside some part of the mill plant. This is the only way to ensure
correct ventilation.

Ventilation air from an operating mill must never-be blown into a cold kiln because of the
risk of explosion in the' kiln installation when subsequently lighting up the kiln. The
ventilation air must be routed to the open through a pipe connected to the pressure side
of the fan.

Sources of error.

Should an explosion occur despite observance of the specified

precautions? The reason maybe following.

1. Too high discharge temperature at mill outlet. That is, excessive

drying of the coal meal.

2. Collective grinding of too different grades of coal.

3. Repeated unsuccessful attempts to start the mill plant at too short

intervals between attempts.

4. Coal meal deposits which ignite spontaneously during standstill

and are whirled up during re- start of mill.

5. Hot air passage through 'mill during standstill,; starting or during

stoppage.

6.. Open of a cover during operation or before the system has cooled
after stoppage.

7. Electric spark which may occur in an electrostatic precipitator or

through electrostatic charging due to insufficient earthing.

When an explosion occurs, the reason must be found and remedied.

COAL DUST FILTERS

The finest coal meal. fraction is in the dedusting filters. Therefore the
risk of explosion is highest here. The bag filter cleaning intervals must
be adhered to so that coal meal does not obstruct the bags and
ignites spontaneously. Coal meal accumulation in filter bottom
hoppers is a fault which must be corrected without delay.
Condensation may occur in a filter, if the difference between the exit
gas temperature and the dew point temperature is too small. This
results in dust accumulations which may be the starting point for
spontaneous ignition. The difference between exit gas temperature
and dew point temperature should be min. 150C. In certain situations
the problem may be solved by subsequent insulation. The dampers in
filter inlet and outlet pipes must close tight. Test the performance at
regular intervals. The dampers must-be closed when the coal mill
plant is stopped. The rapping gears of electrostatic precipitators may
fail. Their alarm systems must be checked at regular intervals.

Filter fire

Filters are-equipped with thermo sensors and usually also with CO

meter. In case of too high CO indication or too high temperature,
which is indicative of fire has started, the coal mill plant must be
stopped so that the coal meal supply to the filter is interrupted, and
the dampers in the filter inlet and outlet pipes must be closed. The
filter cleaning mechanisms and dust conveyance after the filter must
remain in operation for 20-30 minutes after the coal meal supply has
stopped.

The filter must subsequently be ineriized by replacing the oxyygenous

air by fire-extinguishing gasses. The inert gasses normally used are
either CO2 or N2 Inert gas must not be blown in so fast that the
pressure relief are tripped.' Check that there is always sufficient inert
gas in spare for at least two intertizations. The operating personnel
must have been thoroughly trained in the function and application of
the inertization equipment. Fire develops over a certain period of
time and the alarm equipment ensures early recording. Therefore
there is sufficient time to inertize manually.
If a smouldering fire is permitted to develop beyond a certain point, it
cannot be extinguished by inertization. For that reason coal dust
filter must be equipped with hatches for manual removal of dust and
embers or transport to a reservoir which is not part of the normal
transport system.

COAL MEAL SILOS

General

Coal meal silos must be tight so as to avoid-unnecessary oxidation of

the coal meal by entering air. The extraction must be closed tight with
a. slide gate in case of lengthy stoppage of extraction. Storage of coal
meal in a silo always requires supervision. The risk of fire and embers
is high. The coal meal is dry and has a relatively large surface so that
oxidation can take place easily.

The ignition risk depends on the coal type, since lignite with a high
gas content easily ignites spontaneously if the temperature exceeds
60-700C. Gaseous pit coal with- 25-40% volatile matter does not
ignite spontaneously very easily, but may ignite after lengthy storage.
Coal meal silos must be used in such a way that they are kept as 'full
as possible during operation. in case of planned kiln shutdowns of
long duration the coal meal silo must be run empty before the kiln is
stopped.

Fire surveillance in coal meal silos

Coal meal silos must be checked for temperature rises and, CO

development indicating that spontaneous ignition is developing. As
long as coal meal is supplied and extracted during operation, there is
practically not risk that the coal meal ignites spontaneously. This risk
will only arise after standstill for some time. Spontaneous ignition of
certain types of lignite takes place after standstill for only 8 hours.
Certain types of pit coal ignite spontaneously only after standstill for
week s. The time elapsing before a smouldering fire is developing
can therefore not be stated in advance.
Temperature monitoring

Coal meal silos are equipped with thermo sensors at the top of the
silo and in the outlet cone.
Thermo sensors usually have two alarm levels. designated as high
temp. & very high temp. Alarm indicates a serious risk of silo, fire and
requires immediate stoppage of the coal meal supply and
preparations for extinction.

CO monitoring

The CO concentration in the air inside a silo depends on the coal

meal type and the exchange of air in the silo. The CO concentration
can therefore only be determined during normal operation. For
instance, 800-1400 ppm (MI/M3) may be expected for lignite (brown
coal) during normal conditions. Correspondingly, 150-400 ppm may
be expected for gaseous pit coal under the same conditions. CO
meter have several measuring ranges. For a given plant a normal CO
concentration level must be found during normal operation. CO
measurements give a sure warning about the development of a
smouldering fire, and when adjusted correctly, the CO alarm will trip
before the thermo sensor give alarm.

When alarm for silo fire is given, the free silo space must be
inertized. The volume of inert gas blown in must be adapted to the
charge in the silo.CO2 inertization requires 1.5 kg CO2 per m3 of free
volume in the silo. (Silo volume minus contents). Coal meal silos
should be kept maximum filled with coal meal during operation so as
to limit the free volume.

Extinguishing with water

Extinction of silo fires with water is advised against. Water vapor may
react with the smouldering coal and create explosive water gas, If it
is necessary to used water it must be atomized. Partly because this
will prevent embers and coal dust from being stirred up and partly
because water fog has a certain airdisplacihg effect.

RULES APPLYING ESPECIALLY TO COAL MEAL FIRING IN

KILNS

When firing with coal meal, same is injected at high pressure. It is

important that the coal meal ignites and combusts as intended so that
no coal meal is carried further into the plant to places where it can
accumulate and cause fires and explosions. Coal meal feeding must
not be started before the air injection to the burner is in operation.
This is ensured through electrical interlocking. The inter locking also
stops'the coal meal feed, if downstream conveyors sbould stop.

The coal meal must be blown into the firing space at a velocity which
is substantially above the speed at which the coal meal jet combusts.
(12-15 m/s). This will prevent backfiring in the burner. Before coal
meal is injected, sufficient heat must have been created ahead of the
nozzle for instantaneous ignition of the coal meal so that no unburnt
coal meal is carried along by the kiln draught. Unburnt coal meal may
settle at subsequent obstacles and cause an explosion there.

Start coal meal firing at strongly reduced kiln draught. Possibly with
stopped exit gas fan-and the exit gas damper only slightly open.
Injection of coal meal takes place at a considerable positive pressure
so that burner pipe, etc. must be checked for leaks at regular
intervals to ensure that no coal dust escapes to the surroundings.

OTHER PRECAUTIONS

There are separate instruction manuals for operation for all machines
included in coal-processing installations. For the entire plant there is
a process instruction manual. Moreover there is documentation in
the form of flow sheets and electrical interlocking diagrams. Study
this documentation before commissioning the plant. Note that there
may be Local Regulations which must be adhered too