COAL TRADING

Compiled by Divyanshu Dayal. dayal1005@gmail.com Created on: 15 Sept13. B.E. Mechanical, MBA, Procurement 2.1 Ultimate Analysis Their binding nature enables them to be PART-1 Determines all component elements solid or used in coke. COAL CLASSIFICATION gaseous like carbon (C), hydrogen (H), oxygen Nitrogen in them is utilized in producing Coal is a hydrocarbon. (O), nitrogen (N) and sulphur (S) ammonia. Coal is classified according to the Bituminous coals are chiefly used to amount of heat it produces. 2.2 Proximate Analysis generate electricity. Heat content of coal depends on Determines percentage by weight of fixed They are also used to produce amount of fixed carbon (carbon in its carbon (FC), volatile matter (VM), moisture aluminum, cement, food, paper and free state and not combined with other (M) and ash (A) content in coal- also sulphur textiles. elements) it contains. (S) and calorific value (CV) can be expressed Rank of coal is degree of progressive on any of the above basis. alteration in the transformation from lignite to anthracite. 3.0 Significance of Various Parameters 1. 2. 3. There are four primary ranks of coal Anthracite (Semi-anthracite, anthracite and meta-anthracite) Bituminous (high-volatile, medium volatile and low-volatile) Lignite (brown coal and lignite) 3.1 Fixed Carbon Fixed carbon acts as main heat generator during burning. 3.2 Volatile Matters Volatile matters are methane, hydrocarbons, hydrogen and carbon monoxide and incombustible gases like carbon dioxide and nitrogen found in coal. Volatile matters proportionately increases flame length and helps in easier ignition of coal. Set minimum limits of furnace height and volume. Influences secondary air requirements and distribution aspects. Influences secondary oil support.

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Bituminous

1.1 Anthracite Hard and very brittle. Dense, shiny black. Homogeneous with no marks or layers. High percentage of fixed carbon. Low percentage of volatile matter chiefly methane (CH4). Used in heating home and production of natural gas.

1.4 Sub-Bituminous Soft coal. Brownish black or black. Most are homogeneous and have smooth surface with no indication of layers. They appear dry, but have high moisture content. When exposed to air they lose part of moisture and make an audible noise. After long exposure to air they disintegrate. They are non-coking coals. Burn readily and can be used for household as well as for industrial plants.

Fig.1 Anthracite

3.3 Ash Content Reduces handling and burning capacity. Increases handling costs. Affects combustion efficiency and boiling efficiency. Cause clinkering and slagging. 3.4 Moisture content Moisture replaces combustible matter and decreases the heat content per kg of coal. Increases heat loss due to evaporation and superheating of vapor. Helps to a limit in binding fines. Aids radiation heat transfer. 3.5 Sulphur content Clinkering and slagging tendency. Corrodes chimney and other equipments such as heaters and economizers. Limits exit flue gas temperature

1.2 Semi-anthracites Dense but softer than anthracite, shiny gray. Somewhat granular in structure. Grains have tendency to break off during handling and produce a coarse, sand-like slack. 1.3 Bituminous Soft coals and are in abundance. Grayish black and either distinctly homogeneous with very faint indication of grains but show distinct layers or granular in structure depending on content of volatile matters from high, middle and low. When granular the coal tends to crumble during handling and reduces to slack. When heated they reduce to cohesive binding sticky mass. Their carbon content is less than anthracite. They have higher volatile matters as compared to anthracite. Volatile matters are higher in calorific value. They burn easily especially in pulverized form. High volatile content makes them good for producing gas.

Fig.2 Sub-bituminous

1.5 Lignite Brown and laminar structure. Comprise of remnants of woody fibers Lignite coals are tough and require heavy impact with hammer to break up the large lumps. When exposed to air they lose moisture rapidly and disintegrate. Due to high moisture and low heating value, they are not economical to transport to long distances. They are also known as brown coals are generally found close to the surface and readily recovered by stripping.

Fig.3 Lignite

2.0 Analysis of Coal 1. Ultimate Analysis 2. Proximate Analysis

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COAL TRADING

Compiled by Divyanshu Dayal. dayal1005@gmail.com Created on: 15 Sept13. B.E. Mechanical, MBA, Procurement 5.0 Coal Conversion Statistics 6.0 Conversions in Proximate Analysis Percentage of parameters like % of Ash, 5.1 As Received Basis (ar): Volatile Matters, Fixed Carbon and Sulphur (Total Moisture (TM) =Free Moisture + can be derived on ad, db, daf basis. Inherent Moisture (IM) ) + Ash + Volatile Matter + Fixed Carbon. 6.1 Air Dried Basis (ad) = ar x (100-IM%)/ (100-TM%) =db x (100-IM%)/ 100 6.2 Dried Basis (db) =ar x 100 / (100-TM%) =ad x 100/ (100-IM%) 6.3 As Received Basis (ar) = ad x (100-TM%) / (100-IM%) = db x (100-TM%) / 100
Fig.5 As Received Basis

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5.2 Air Dried Basis (ad): Inherent Moisture (IM) + Ash + Volatile Matter + Fixed Carbon
Fig.4 Ranks of Coal.

4.0 Typical Parameters of Coal (% by weight unless the unit is specified in the cell) 4.1 Class of Coal Based on Volatile Matters Class VM General Description
(% Weight)

Example: (Pink cell indicates % by weight values derived during proximate analysis and without conversion. Other values are derived by using the formulae mentioned in the conversion section above) ar ad db daf TM 11.0 IM 2.0 2.0 A 12.0 13.2 13.5 VM 30.0 33.0 33.7 39.0 FC 47.0 51.8 52.8 61.0 S 1.0 1.1 1.12 Tbl.3 Example of Conversions.

101 102 201 202 203 204 206 301 305 306 401 402 501 502 601 602 701 702 801 802 901 902

< 6.1 3.1-9.0 9.1-13.5 13.6-15.0 15.1-17.0 17.1-19.5 19.1-19.5 19.6-32.0 19.6-32.0 19.6-32.0 32.1-36.0 > 36.0 32.1-36.0 > 36.0 32.1-36 > 36.0 32.1-36.0 > 36.0 32.1-36.0 > 36.0 32.1-36.0 > 36.0

Anthracites Dry steam coal Cooking steam coals Heated altered low volatile steam coals Prime cooking coals Mainly heat altered coals Very strong coking coals Strongly coking coal Medium coking coal Weakly coking coals Very weakly coking coal Non-coking coal High Volatile Steam Coal Fig.7 Dried Basis Low Volatile Steam Coal Fig.6 Air Dried Basis.

5.3 Dried Basis (db): Excludes all Moistures.

7.0 Mass Metric ton (t) = tonne = 1000 Kilograms = 2204.6 lb Imperial or Long ton (lt) = 1016.05 Kilograms = 2240 lb Short (US) ton (st) = 907.19 Kilograms = 2000 lb 8.0 Calorific Values (CV) kCal/kg: Kilocalories per Kilogram MJ/kg- Megajoules per Kilogram Btu/lb- British Thermal Units per pound 8.1 Gross and Net Calorific Values Gross Calorific Value (GCV), Higher Calorific Value, Higher Heating Value (HHV) The water of the combustion is entirely condensed and that the heat contained in the water vapor is recovered. It is Calorific Value (CV) under laboratory conditions. Net Calorific Values (NCV), Lower Calorific Value, Lower Heating Value (LHV) The products of combustion contain water vapor and that the heat in the water vapor is not recovered. Useful calorific value in the boiler plant. 8.2 Conversions- Gross/ Net (per ISO, for As Received (ar) figures) Kcal/kg Net CV= Gross CV -50.6H-5.85M-0.191O MJ/kg Net CV=Gross CV-0.212H-0.0245M0.0008O Btu/lb Net CV= Gross CV-91.2H-10.5M-0.34O Page 2/4

Medium Volatile Steam Coal

5.4 Dry Ash Free Basis (daf): Excludes all Moistures and Ash.

Tbl.1 Class of coal based on volatile matter.

4.2 Other Parameters Anthracite S 0.6-0.77 M 2.8-16.3 FC 80.5-85.7 Bulk 800-929 Density kg/m3 A 9.7-20.2
Tbl.2 Typical Parameters of Coal.

Bituminous 0.7-4.0 2.2-15.9 44.9-78.2 673-913 kg/m3 3.3-11.7

Lignite 0.4 39 31.4 641-865 kg/m3 4.2

Fig.8 Dry Ash Free Basis

COAL TRADING

Compiled by Divyanshu Dayal. dayal1005@gmail.com Created on: 15 Sept13. B.E. Mechanical, MBA, Procurement M is % Moisture, H is % Hydrogen, O is % 9.2.4 Calorific Value take the form of heavy fuel oil or tar, or Oxygen ( from ultimate analysis, also As Requires high calorific values pulverized coal. Received) PCI allows replacement of coking coal by 9.2.5 Sulphur steaming coal. 9.0 Coal for Power Sector Limit: Max. 1% (ad) PCI with injection rate of 100 kg/tonne 9.1 Stoker Local emission regulations are critical. can replace approximately 119 kg of Stoker is a type of coal firing in boiler. A stoker coking coal or 85 kg of coke. is a device consisting of a feed and a grate and 9.2.6 Nitrogen PCI parameters are similar to that of is used for feeding coal into a furnace, Limit: Max 1.5% to 2% coking coal and requires low sulphur, distributing it over a grate, admitting air to Subjected to regulations on nox emissions. phosphorus and alkalis. Ash should be the coal for combustion and providing a below 8% preferably, however up to means for discharge of ash. 9.2.7 Maximum Size 12% is used. Limits: 40 -50 mm Depends on capacity of grinding equipment. 11.0 Coal For Cement Sector Wet and dry processes are two basic process 9.2.8 Fines Content in cement production and are named in the Limit: Max -3mm manner in which the raw mix is introduced in High fines contents can increase moisture the kiln. contents and create handling problems. Wet process has slurry with 20-40% moisture. In dry process the mix is dry. 9.2.9 Ash fusion temp o Limit: Dry bottom boiler IDT > 1200 C Approximate Coal Consumption in Cement Fig.6 Stoker. o Wet bottom boiler flow temp < 1300 C Plants Parameters 9.1.1 Total Moisture Limits: 8-15% If too low, fines can blow away from the bed without burning. 9.1.2 Ash Limits: 7-30% (ad) Minimum Ash contents are required to protect grate from reflected heat. 9.1.3 Volatile Matter Limits: 25-40% (daf) 9.1.4 Maximum Size: Limit: 30 mm 9.1.5 Size Consist: Limit: Max. 30% -3mm Min. 25% +6mm 9.1.6 Ash fusion temp: Limit: IDT (Initial Deformation Temperature) o min 1200 C If the temp is lower ash melts and forms clinkers 9.1.7 Crucible Swelling Number: Max.3 High swelling coals gives uneven combustion. 9.2 Pulverised Coal (PF- Pulverised Fuel) Firing is combustion of powdered coal suspended as a cloud of small particles in the combustion air. It eliminates supporting grates and thus equipment size restrictions. They are suitable for large boilers. More heat is released per unit volume than stoker firing. Parameters 9.2.1 Total Moisture Limit: 15% (ar) High moisture reduces CV, creates handling problems 9.2.2 Ash Limit: 20% (ad) High Ash reduces calorific value. 9.2.3 Volatile Matter Limits: Min 20-25% (daf)
Type of Plant

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10.0 Coal for Steel Sector 10.1 Coking Coal Steel production requires Coke. Coke is produced by heating coking coal in oven through a process called as Carbonization. Crushed, mostly blended coal (approximately 80% less than 3 mm) is charged into the coke oven and heated until the centre of the charge has o reached a temp of 1100 C. After completion of the carbonization, the incandescent coke is pushed from the oven and quenched with water or inert gas. This process is common due to energy savings resulting from heat recovery. Parameters 10.1.1 Total Moisture Limit: Max. 10% (ar) High moisture creates difficulty in handling and lowers the amount of carbon. 10.1.2 Ash Limit: Max 10% (ad) High ash reduces efficiency of blast furnace. 10.1.3 Volatile Matter Limits: 16-36% (ad) High VM reduces coke yield. 10.1.4 Sulphur Limit: Max. 0.8% (ad) High sulphur reduces quality of steel. 9.1.5 Phosphorus Limit: Max. 0.1% (ad) High phosphorus makes carbon steel brittle. 10.2 Pulverised Coal Injection (PCI) The reduction process in the blast furnace is carried out primarily by carbon monoxide and a maximum o temperature in the furnace of 1650 C is achieved. Additional fuel is injected into the furnace with the blast air and helps to maintain furnace stability. This fuel can

Heat Required Kcal/ kg of Clinker

Tonnes of Clinker produced per tone of coal with CV 6000 kCal/ kg (ar)

Tonnes Coal with CV 6000 kCal/ kg ( ar) per 106 tonnes of Clinker

Most Modern600 10 100,000 Dry process, pre-heating Less Modern1100 5.5 180,000 Dry ProcessSemi Dry Process Least Modern1700 3.5 280,000 Wet Process Tbl.4 Approximate Coal Consumption in Cement Plants

Parameters 11.1 Total Moisture Limit: Max 15% (ar) High moisture creates handling problem. 10.2 Ash Max 25% (ad) Limit: Max. 25%

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COAL TRADING
12 Gradation of Coal 12.1 Indian Coal based on Calorific Values Grade A B C D E F G CV Range (kCal/kg) Exceeding 6200 5600-6200 4940-5600 4200-4940 3360-4200 2400-3360 1300-2400

Compiled by Divyanshu Dayal. dayal1005@gmail.com Created on: 15 Sept13. B.E. Mechanical, MBA, Procurement

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12.2 Indonesian Coal Benchmark (HPB Marker)

Coal Brand Gunung Bayan I Prima Coal 6,700 12.0 0.6 Pinang 6150 6,200 14.5 0.6 Indominco 5,700 17.5 1.6 Melawan 5,400 22.5 0.4 Coal Envirocoal 5,000 26.0 0.1 Jorong J-1 4,400 32.0 0.3 Ecocoal 4,200 35.0 0.2 Tbl.5: Bench Mark for Indonesian Coal GCV (GAR) 7,000 TM (% ar) 10 TS (% ar) 1.0 A 15.0 5.0 5.5 4.8 5.0 1.2 4.2 3.9

12.3 Australian Grades of Coal

Parameter Gross Calorific Value (ADB) Gross Calorific Value (ARB) Net Calorific Value (ARB) Total Moisture (ARB) Inherent Moisture (ADB) Ash Content (ADB) Type 1 Type 2 Type 3 Type 4 Type 5 Type 6 6,500 6,300 6,000 5,800 5,500 5,300 kcal/kg kcal/kg kcal/kg kcal/kg kcal/kg kcal/kg 6,000 5,800 5,500 5,200 4,500 3,600 kal/kg kcal/kg kcal/kg kcal/kg kcal/kg kcal/kg 5,700 5,500 5,200 4,900 4,300 3,400 kcal/kg kcal/kg kcal/kg kcal/kg kcal/kg kcal/kg 9-12% 12-15% 15-20% 22-28% 32-38% 38-44%

7-9%

8-10% 10-12% 12-15% 15-18% 18-21%

8-15% 12-17% 12-17% 10-14% 8-12% 8-12%

Volatile 38-43% 38-43% 37-42% 36-40% 36-40% 36-40% Matter (ADB) Fixed Carbon 43-48% 42-45% 40-43% 38-42% 37-40% 35-39% (ADB) Total Sulfur (ADB) Hydrogen (Hd) (Dry Basis) Handgrove Grindability 38-43 38-43 39-45 45-50 48-52 50-55 1.00% 0.81.0% 0.81.0% 4.90% 0.61.0% 4.90% 0.51.0% 4.90% 0.41.0% 4.90%

4.90% 4.90%

Index (HGI) Ash Fusion Temperature IDT (Initial 1250C 1250C 1250C Deformation Temperature) Size
0-50mm (95%) 0-50mm (95%) 0-50mm (95%)

1250C 1250C 1250C

0-50mm (95%)

0-50mm (95%)

0-50mm (95%)

Tbl.6: Australian Grades of Coal

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