Department of Chemical Engineering: Analysis & Comparison of Cheaper Binder For Coal Fines

SDM COLLEGE OF
ENGINEERING
& TECHNOLOGY
Department of Chemical Engineering
Analysis & Comparison of cheaper

binder for coal fines
Under The Guidance Of:
Kiran Kumar Rathod
Name Of Students U.S.N
Abhishek 2sd10ch001
Rahul Patel 2sd10ch014
Priyanka Jain 2sd10ch015
Saurav Kumar 2sd10ch018
Introduction
•India has vast coal reserves & ranked 5th in coal rich. countries.
•Although we are one of the top 5 leading producer of coal but we also
lag behind by being in top most countries importing coals.
•185 billions tons of coal reserves are present in different regions of

country.
•Coal reserves in India are mainly bituminous & sub-bituminous (not

high grade coal) and thus not safe for environmental point of view.
•Coal in the process of mining, handling & exposure to weather is

subjected to more or less disintegration & its known as slack. If this
slack is wasted the loss ranges 5-50%.
Thus its essential for economical consideration.
 Coal briquetting is a process which converts coking coal &
slack into uniform usually hard and impact resistance
agglomeration, making it useful with high calorific value for
domestic & industrial purpose.
 Coal import can be very expenses in some instances it

accounts upto 70% of delivered cost of coal.
 The first patent for the briquetting of coal fines dates back to
the mid-1800s.
Objective
• Research and evaluate the binding and combustion properties

of various binders for coal fines
• Develop a process to integrate binder and produce robust coal

briquettes.
• Perform combustion testing to determine flame temperature,

emissions profiles, efficiency, and chemical kinetics of the
developed coal/binder product
Physical Properties of coal
Crucible swelling index (free swelling index)
 It is simplest test to evaluate whether a coal is suitable for
production of coke.
 After heating the coal, a small coke button remains in the
crucible.
 The cross sectional profile of this coke button compared to a
set of standardised profiles determines the Free Swelling
Index.
 Heating temperature:- 800 C
Before crushing After crushing into fines

Sulphur Content
 A known quantity of coal is heated with Eschka mixture (2 parts of
MgO and 1 part of anhydrous Na2CO3)
 Temp 800˚C.
 After burning amount of sulphur present in the mix is retained as
oxides and it is precipated as sulphates.The sulphate formed is
precipitated as BaSO4 (by treating with BaCl2).
 % of sulphur in coal = Where, weight of coal sample taken Weight
of BaSO4 precipitate formed xy 1374 .0100 x y
Density
 It depends on the rank of the coal
and mineral impurity present.
Calorific value
 The calorific value determines in part the value of coal as a fuel for
combustion application using bomb calorimeter.
Bomb Calorimeter BOMB
 Heat units in B. t. u. per pound of dry fuels

=14,600 C + 62,000(H - O/8) + 4000 S
Moisture Content
 It is used to find the percentage of water present in coal.

 Typical range is 0.5 to 10% Moisture
 Increases heat loss, due to evaporation and superheating of
vapour
 Helps to a limit in binding fines.
 Temperature:- 105-110 C
 Heating time:- 1 hour
 Sample size:- 60 mesh
 Quantity of sample:- 1 gram air dried coal
% moisture in coal = {loss in wt. of coal X 100}

wt. of coal initially taken
Volatile Matter
 Volatile matters are the methane, hydrocarbons, hydrogen and

carbon monoxide, and incombustible gases like carbon dioxide
found in coal.
 Increases flame length, and helps in easier ignition of coal.
 crucible with lid.
 Quantity of sample:- 1 gram air dried coal
 Sample size:- 60 mesh
 Temperature:- 900-925 C
 Heating time:- 7-10 minutes
 % volatile matter =
{ loss in wt. of moisture free coal X 100}

wt. of moisture free coal taken
Fixed carbon
 Fixed carbon is the solid fuel left in the furnace after volatile
matter is distilled off.
 Fixed carbon gives a rough estimate of heating value of coal.
 % fixed carbon in coal = 100-(% moisture+% ash+% volatile
matter)
Ash content
 It represents the bulk mineral matter
after carbon, oxygen, sulfur and water
has been driven off during combustion.
 Heating temperature:- 750-800 C
 Heating time:- 1 hour
Result of Coal Analysis
Properties Values
FSI 7.2
Density 1306kg/m3
Sulphur 0.59%
Moisture 8.4%
Volatile content 7.62%
Fixed carbon 74.27%
Ash content 9.7%
Calorific Value 6150 kcal/kg
Note-percentage by weight
Characteristics of good binder
1.Highly Coherence- By varying amount of binder & pressure.
2.Hardness and toughness-For better hardness high softening point

binders to be used.
3.Density- Range for density 1.1 to 1.4 & density is increased by

pressure.
4.Size and shape- Large cylindrical, hollow, polygonal, ball shaped
briquette materials are good.
5.Burning qualities-
• Readiness of ignition-Large briquette ignites readily than small
ones.
• Kind of flame-should burn with clean, intense flame without
odour or smoke
 Note-Organic briquette do not produce smoke.
6. Retention of shape-the binders must hold coal particles together

until they are sufficient soften to cohere.
7.Weathering- Dense briquette will stand better for long exposure than
porous.
8. Absorption-Should not absorb more than 3% of moisture.
9.Percentage of ash-It should be less & it depend on sum of contained

in slack & binder used.
 Note-Organic binders have less percentage of ash as

compared to inorganic.
Molasses Lignin Pitch
Dairy Sludge
Test for examination of binders
Determination of percentage of binder
20gms of Its then It should be
coal mixed heated & then
with binder stirred well mechanically
& additive throughly pressed.
The percentage of binder is always calculated on the weight of coal.

Determination of coherence
By adding small amount of water and coal & performing strength
tests on the coal.classified into following grades-
1. Very slight coherence 4. satisfactory
2. Slight coherence 5 .excellent, will stand rough
handling
3. Coherence but not satisfactory 6. Stronger than necessary
Material required in coal briquetting are-
Coal
 The slack taken as raw material should be thoroughly clean and should not
contain impurities. Its not uniform in size so for further process it is jaw
crushed.
 Additive
 In India coal contents high amount of sulphur & on combustion produces
CO2.
 It cause health & environmental problems.
 To overcome calcium carbonate is used to convert sulphur to sulphate.
Reactions Involved-
CaCO3 CaO + CO2
S + O2 SO2
SO2 + 1/2O2 SO3
CaO + SO3 CaSO4
 Binders
 It is used to bind fine particles physically. Various binder available are -
 Pitch • Dairy waste
 Lignosulphonate • Molasses
Methodology
The method of manufacturing of coal briquettes are
1. Briquetting with binding material.
2. Briquetting without binding material.
Briquetting with binder
Make 8-10
Heat untill the Mechanical press
mixtures of slack,
vapour forms & is aplied for 2-3
additive &
pour into moulds min
binders
 Compacted coal briquettes are taken out of moulds.

Processing with
different binders
Applying 2-5
Binder tons of load
Coking Coal/ Briquetted by

Mixed &
slack Mechanical Dried
Milled
0.3 mm Press
particle size
Briquettes
Additive=CaCO
3
4 sample coal
pieces will be
obtained for
analysis
Mould Fabricated for mechanical Press
Advantages to coal briquetting
 Increase in heating value.
 Resistance to weathering
 Resistance to handling
 Efficiency of fuel
 Create less environmental as

compared to mineral coal.
 Spontaneous combustion &

wastage coal can effectively be
controlled.
 Our project give path to utilise

indigenous coal reserves without
polluting environment.
Techniques used to test briquettes
 Strength
The compressive strength is a good indication that sufficient binder is
being used, that the briquetting pressure is adequate and that post
curing treatment is being carried out correctly.
 Drop Shatter test

The Drop Shatter Test is an indication of how the agglomerate will
stand up to Handling , particularly dropping from a height.
 Tumbler Test
The Tumbler Test gives a measure of the Abrasion Resistance and
impact resistance of coke.
 Weathering
There is no standard to test for weathering, many producers simply
immerse the agglomerate in water for four hours and apply hand
pressure to see if disintegration takes place.
 Other Properties :
The normal quality parameters used to measure the quality of coal
and coke can be applied to agglomerates. Analysis for
1. Volatile Matter
2. Calorific Value
3. Sulphur
4. Ash content
Can be carried out using the appropriate standards without
modification
Progress Till Now
 Successfully completed testing and analysis of coal properties.
 Collection of all the binders to be used from various industries

waste-
Lignin-Paper industry
Molasses-Sugar industry
Slurry Waste-Dairy industry
Corn starch-Food industry
Pitch-Petroleum Industry
 Fabrication of the mould for mechanical press with load around 2-

4 tons. For compressing.
 Presently with properties of molasses started the briquetting

techniques.
Plan of Action
Time Part of Work to be Covered
By 15th March Production & processing of coking Coal using

different binders.
Mixing, Heating, Evaporation, Compressing,
cooling.
By 30th March Testing & Analysis of final briquetting coal

obtained.
-Proximate Analysis
-Moisture Test
-Calorific Value Test
By 20th April Analysis, Comparison of the data obtained &

final Result & Conclusion of the project.
Reference
 Komarek K.R Inc.-The briquetting Process.[1]
 New Application of Roller Pressure in Coal related Technologies
18th Int. Conf. Coal Utilization And fuel systems-Dr- Ing Pietsch
W.[2]
 Binders for Fuel Briquetting- A Critical Survey CSIRO, Technical
Communication-Waters PL.[3]
 Greenfields Develops New Techniques For Recovery Coal Fines-By
Steve Ficor
 Kela Energy- Orlando, FL
 Briquetting. (n.d.). Retrieved from
http://www.greenfieldscoal.com/briquetting.php
 Handled like coal, cost effective, increased preparation plant yield.
(n.d.). Retrieved from
http://www.kelaenergy.com/coalProducers.html
 A. Dilo Paul, Senior Scientist, Science Applications International
Corp.6th US-India Energy Dialogue,2009

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SDM COLLEGE OF

Analysis & Comparison of cheaper

•185 billions tons of coal reserves are present in different regions of

•Coal reserves in India are mainly bituminous & sub-bituminous (not

•Coal in the process of mining, handling & exposure to weather is

 Coal import can be very expenses in some instances it

• Research and evaluate the binding and combustion properties

• Develop a process to integrate binder and produce robust coal

• Perform combustion testing to determine flame temperature,

Before crushing After crushing into fines

Bomb Calorimeter BOMB

 Heat units in B. t. u. per pound of dry fuels

 It is used to find the percentage of water present in coal.

% moisture in coal = {loss in wt. of coal X 100}

 Volatile matters are the methane, hydrocarbons, hydrogen and

{ loss in wt. of moisture free coal X 100}

2.Hardness and toughness-For better hardness high softening point

3.Density- Range for density 1.1 to 1.4 & density is increased by

6. Retention of shape-the binders must hold coal particles together

8. Absorption-Should not absorb more than 3% of moisture.

9.Percentage of ash-It should be less & it depend on sum of contained

 Note-Organic binders have less percentage of ash as

The percentage of binder is always calculated on the weight of coal.

Briquetting with binder

 Compacted coal briquettes are taken out of moulds.

Coking Coal/ Briquetted by

 Create less environmental as

 Spontaneous combustion &

 Our project give path to utilise

 Drop Shatter test

 Collection of all the binders to be used from various industries

 Fabrication of the mould for mechanical press with load around 2-

 Presently with properties of molasses started the briquetting

By 15th March Production & processing of coking Coal using

By 30th March Testing & Analysis of final briquetting coal

By 20th April Analysis, Comparison of the data obtained &

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