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QUALITY MANAGEMENT OF COAL

-T.H.MOHAN RAO

MANAGER (QC)

E-MAIL: MOHAN.TH2260@GMAIL.COM

MOB: 94055 88823

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Flexibility for the Rigid

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Your future will be moulded by what you decide you want to be, rather than what you are

Quality Management of Coal

1. Annual Grade Declaration procedure

2. Historical events on information of coal being nature’s gift to the society

3. Sampling related I.S. and details required for sampling (collection andpreparation) and analysis

4. Role of fixed carbon, ash, volatile matter and moisture in pricing of coal

5. Determination of equilibrated ash, moisture and GCV (also on air driedbasis)

6. Calculation of various indices for coking coal like Caking Index, LTGK, FSI,Micum Index and Shatter Index, etc.

7. Conversion of units of coal

8. Ash fusion temperature and its affects on boiler

9. Grievance redressal system

10. Cost of quality and its impact on coal value & image on company

1). ANNUAL GRDE DECLARATION PROCEDURE

Nominated Owner of the Coal company declares the grades of his colliery

Under sub-rule 1 of rule 4 of the Colliery Control Rules, 2004 and sub-rule 1 of rule18 B of Coal Mines (Conservation and Development) Amendment Rules, 2011continued in force under Sub-sections (1) & (2) of Section 18 of the Mines &Minerals (Development and Regulation) Act 1957 (67 of 1957) and vide MOC’sGazette (Extraordinary) Notification S.O. 2920(E) Dated 30.12.2011, the CoalController prescribes the procedure and method of sampling/analysis of coal

The AGD requirement appears under Item 25 of the Procedure prescribed by theCCO

Documents to be submitted alongwith the AGD proposals:

Duly filled-in and signed Annexure-II, proposing the size-wise grades/quality to be declared

Vertical section of the seam from where samples have been drawn, clearly showing the nature and thickness of the bands

Mine plan showing the two different locations (located at a distance of 13.5 mtrs apart from each other) from where the seam samples have been drawn

Analysis results of seam/check/joint samples (with majority of samples having been analysed at an NABL accredited/Govt laboratory, preferably CIMFR)

2). HISTORICAL EVENTS ON INFORMATION OF COAL BEINGNATURE’S GIFT TO THE SOCIETY

Coal-India’s energy choice

Most predominant fossil fuel, accounting for 55% of India’s energy requirement

Commercial primary energy consumption in India has grown 700% in last 4 decades

Indian coal spreads in 27 major coalfields

Current per capita primary energy consumption in India is about 350 kgoe (kg of oil equivalent)/year

Formation of CIL

NCDC formed with 11 collieries in 1956

226 coking coal mines were nationalized on 1.5.72 and BCCL was born

711 non-coking coal mines were nationalized on 1.5.73 and CMAL was born

CIL was formed on 1.11.75..simultaneously, WCL, CCL, CMPDIL, BCCL & ECL were formed.

NCL and SECL were formed on 1.4.85 (85-86) out of CCL and WCL respectively

MCL was formed out of SECL 0n 1.4.92 (92-93)

2). HISTORICAL EVENTS..Contd..

Factors that lead to nationalization of coal industry in India: Halting wasteful, selective and slaughter mining.

Planned development of available coal resources.

Improvement in safety standards.

Ensuring adequate investment for optimal utilization consistent with growth needs.

Improving the quality of life of the work force.

Geological Perspective: Fossil Fuels (coal) enabled amazing changes , leading to rapid technological

changes

Coal is the precious and priceless gift nature has bestowed on humanity

Without discovery of coal, we would be still living in the pre-historic age, burning firewood for fire, light, heat and energy and relying on livestock for doing tasks strenuous for humans; candle-light after nightfall.

Increasing scarcity of coal and other fossil fuels means, increasing wars for their control

Even nuclear power, non-dependent of fossil fuels, still needs to be enabled with the help of fossil fuels

Can we imagine today’s scientific, technological and automotive progress in the absence of coal and other fossil fuels?

3). SAMPLING RELATED I.S. AND ITS DETAILS REQUIRED FOR SAMPLING IE., COLLECTION AND PREPARATION) AND ANALYSIS:

Sl.No. CODE TITLE PURPOSE SCOPE

1 IS:436 (Part I/Sec1)-1964(Reaffirmed2013)

Methods for sampling of coal and coke

Manual sampling

Methods for sampling from conveyors,

wagons, ships, stock piles and seams by

manual means and lays down a

procedure for reporting the quality of

the material sampled

2 IS:436 (Part I/Sec2)-1976(Reaffirmed2010)

-do- Mechanical sampling

Methods of sampling and sample

preparation of coal using mechanical

systems and lays down a procedure for

the reporting of test results

3 IS:1350 (Part I)-1984 (Reaffirmed 2002)

Methods of Test For Coal and Coke

Proximate Analysis of coal (Ash, Moi, VM and FC)

Methods of test for coal and coke

relating to proximate analysis including

determination of moisture under

different conditions

4 IS:1350 (Part II)-1970 (Reaffir-med 2005)

-do- Determinationof GCV

Methods of test for coal and coke

relating to determination of calorific

value

Essential Condition of Sampling: the whole bulk of coal to be sampled should be exposed, so thatall parts are equally accessible to the sampling implement and have the same chance of being includedin the sample.

4). ROLE OF FIXED CARBON, ASH, VOLATILE MATTER AND MOISTURE INPRICING OF COAL:

The more the FC and VM, the higher will be the price and vice versa

coal prices are also inversely proportional to the content of ash present in them,meaning the higher the ash, the less the price and vice versa

As far as moisture is concerned, since the pricing is based on the heat content or GCV ofcoal, moisture has a bearing on the pricing too, since GCV and moisture are inverselyproportional to each other

During the earlier UHV regime, the pricing mechanism was based on the ash andmoisture contents, which were being deducted from the standard formula.

5). DETERMINATION OF EQUILIBRATED ASH, MOISTURE AND GCV

(ALSO ON AIR DRIED BASIS) By Proximate Analysis (PA) ash (Muffle furnace), moisture (Moisture Oven), VM (VM

Oven) are determined. For arriving at the FC, these three are summed up and subtractedfrom 100. PA is found out by two methods commonly:

Air dried sample basis and

Equilibrated conditions’ basis

GCV is determined through an equipment called Bomb Calorimeter; first GCV is determined byair-dried basis…then Moisture is determined by equilibrated basis and substituted in the followingformulae for arriving at Eq. GCV:

Eq. GCV = Air dried GCV X (100 – Eq. M)

(100-Air dried M)

6). CALCULATION OF VARIOUS INDICES FOR COKING COAL (Caking Properties of coal)

Sl.No.

Index Explanation

1 CakingIndex (Ag-glutinatingindex)

Max ratio of sand to coal is obtained in a coal sand mixture which, after carbonization underspecified conditions, gives a coherent mass capable of supporting a 500 g mass, at the same timethe proportion of loose powder being less than 5 percent of the mass of sand and coal. This isthe agglutinating index or caking index.

2 Low Temp Gray-King (LTGK) Assay

(Assay: test carried out to find out the purity)Carbonization of coal in a laboratory under standard conditions at a maximum temperature of600oC. The coke residue thus obtained is classified by comparison with a series of describedcoke types.

3 Crucible swelling index (FSI: Free Swelling Index)

This is the simplest test to evaluate whether a coal is suitable for production of coke. Thisinvolves heating a small sample of coal in a standardised crucible to around 800 degrees Celsius(1500 °F). After heating for a specified time, or until all volatiles are driven off, a small cokebutton remains in the crucible. The cross sectional profile of this coke button compared to a setof standardised profiles determines the Free Swelling Index. Industry standard FSI figures rangefrom 0 (no increase in size) to 9 (greatest increase in size).

4 ShatterIndex

The test is designed to simulate the effect of dropping coke on loading, dropping into bunkersand to the charge level of a blast furnace. It measures, therefore, the resistance to shattering, orthe impact hardness. The average of three results obtained on 51, 38 & 13 mm shall be reportedfor each shatter index.

5 MicumIndex

The Micum test is a relative measure of the resistance of coke to degradation mostIy by abrasion. Coke, sieved to retain pieces over a specified size, is subjected to treatment under standardized conditions in a rotating drum. The results of size analysis of the treated coke are used as indices of the resistance to breakage by abrasion.

7. CONVERSIONS OF UNITS OF COAL

8). ASH FUSION TEMPERATURE AND EFEECTS ON BOILER:

Gives an indication of the softening and melting behavior of fuel ash

These temperatures are widely cited in fuel specifications for boilers; Fusiontemperatures are based on fuel ash

Valuable guides to the high-temperature behavior of the fuel inorganic material.

Fusion temperatures typically are measured at four defined points under both reducing(reduction or removal of oxygen) and oxidizing (addition of oxygen) conditions. Theseare defined as follows:

Name Is the temperature at which

Initial deformation temperature (IT) the point of cone begins to round

Softening temperature (ST) also sometimescalled the spherical temperature

the base of the cone is equal to its height

Hemispherical temperature (HT) the base of the cone is twice its height

Fluid temperature (FT)the cone has spread to a fused mass no morethan 1.6 mm in height

9). GRIEVANCE REDRESSAL SYSTEM:

Government of India is very keen and laying special emphasis on quick and expeditious redressal of Public Grievances. The grievances by the public can posted to the following address:

Grievance Redressal CellOffice of the CGM/TS to Chairman, CILCoal Bhavan, Premises - 04 MAR, Plot No.-AF-III,Action Area - 1A, New Town, Rajarhat, Kolkata - 700156email - kskumar@coalindia.in

If the applicant wants to check the status of their grievance, then they should indicatethe mobile number or mail address.

Link for posting the grievances on-line: http://pgportal.gov.in/GrievanceNew.aspx

10). COST OF QUALITY AND ITS IMPACT ON COAL VALUE & IMAGE ON

COMPANY: Unless the grade promised is delivered, obviously the realization of the coal value billed

cannot happen

The image of the company is always directly proportional to the discharge of the commitment given to the consumers with reference to delivery of the coal of the right quality and right quantity at the right time

With execution of the FSAs with different consumers, this responsibility is getting discharged in right earnest.

That’s it…Had a Great Time With You All..

Wishing you all the Very Best..

Believe, You All Liked It

A beautiful quote by Dr. APJ

may be very apt here:

“If you salute your duty, you need not salute anybody; If you pollute your duty, you need to salute everybody”

Blast the Papers..

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YOU

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