COAL MILL

OPTIMIZATION
 CONTENTS

• Raw Coal Size

• Mill Throughput
• Coal Fineness
• Coal moisture
• Fuel Hardgrove Gridability (HGI)
• Pulverizes Input Horsepower
• Coal reject
• False Air Infiltration
 RAW COAL SIZE

This is the first and a huge factor on capacity

and throughput, especially with spot market
coal and no control. If yard crusher/dryers are
not in place and we have raw coal greater
than ¾” top size, the capacity will be
significantly impacted. Large raw coal size
can cause a mill to run at maximum amps
due to extra grinding and limit throughput
significantly.
 MILL THROUGHPUT

The amount of fuel in Tons/Hr that the

pulverizes is capable of handling with
maximum power (amps), acceptable
mill outlet temperatures and airflow
limits
 COAL FINENESS

It is necessary to obtain levels of 75% passing

200 mesh and near zero on 50 mesh to
improve fuel balance and distribution. This
distribution will help balance the kiln exit
temperatures, efficient burning, reduced NOX
and CO emissions, minimize slagging/fouling
and de-superheating sprays while improving
overall unit efficiency.
RAW & PULVERIZED COAL MOISTURE

• Raw coal should be stored in shed.

• If shed is not available then pile up in such a
manner that minimum rain water seep through it.
• High raw coal moisture results in high utilization of
Preheater exit gases.
• High pulverized moisture would also effect
combustion in kiln.
• If WHRPP is in operation, high utilization of preheater
hot gases will be the loss of SP boiler steam
generation.
FUEL HARDGROVE GRIDABILITY (HGI)

Harder fuels can significantly

impact throughput and capacity.
Just five (5) points harder (lower
HGI) can impact capacity
significantly.
PULVERIZES INPUT HORSEPOWER

Various types of pulverizes will require

different HP/Ton and the motors must
be capable of switching these fuel
qualities to maintain throughput.
 COAL REJECT

• This can be controlled by primary airflow.

However, to do this right primary air must be
measured and proper velocities must be
maintained to reject pyrites only and not coal.
When you have coal rejects, the possibility exists
to have a pulverizer fire. A pulverizer “puff”
might also occur if the pulverizer is not properly
operated causing reliability issues.
 FALSE AIR INFILTRATION

• Coal mill intensive bag filter gas analyzer oxygen

concentration must be less than 10% in order to
avoid any accident and also for efficient mill
operation.
• If oxygen concentration at Intensive bag filter is high
then do mill audit for the identification &
rectification of false air infiltration points.