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Materials Handling

1. Overview of the Coal and Biomass Industry on the Philippines and in the Global Market 2. Nature of Coal and Biomass 3. Sampling Best Practices 4. Sampling Preparation Techniques and Best Practices 5. Coal and Biomass Analytical Tests Analytical Instrumentation

Coal and Biomass Testing Principles

Training Course

Chapter #1 Coal Formation & Rank
o This chapter covers the different Ranks of coal
Peat, lignite, sub bituminous, bituminous and anthracite
o Changes in moisture, volatile, oxygen and CV are covered
o Sulfur in coal, depositional environment
o Sodium and Calcium levels in low rank coals

Chapter #2 Coal Sampling
o Coal Sampling methods accuracy.
Hand sampling issues
Mechanical sampling requirements
Stop belt and Bias Testing
o Errors in sampling high ash or high moisture fuels

Chapter #3 Proximate Analyses
o What it is and how to do it = oven and scale
o Moisture, Volatile, Ash, Fixed Carbon
o Sulfur and CV added for “short prox”
Forms of sulfur – mineral pyrite
o Reporting bases – AR, ADB, Dry, MAF/DAF
How to use and best formats

Chapter 4 Using Prox Analyses
o Coal Price in $/MBtu
o Loading levels lb/MBtu, Kg/M Kcal
o How much sulfur and ash does the boiler see?
o Coal Specifications in percent or loading levels?

Chapter 5 Ultimate Analyses
o Ultimate Analyses – Carbon, Hydrogen, Nitrogen
o Combustion calculations
o Dulong CV
o Air to Fuel Ratios
o Coal Reactivity

Chapter 6 Calc. Net CV
o How to calculate Net CV
o Issues with hydrogen values
o Best use of Net CV
o When not to use Net CV

Chapter 7 HGI
o HGI Hardgrove Grindability Index
o What it measures
o How to measure HGI
o Problems with measuring HGI
o Using HGI to estimate Mill Capacity
o HGI does not estimate wear – Using Quartz estimates

Chapter 8 Ash Fusion Temperatures
o Used for Stoker fired boilers in the 1920’s
o What they are and why they are hard to use
o Reducing and Oxidizing oxen conditions
o Why oxidizing AFT should be higher than reducing AFT

Chapter 9 Ash Chemistry - Major & Minor Elements in Coal Ash
o Ash Chemistry or Major & Minor Elements or "Ash Minerals"
o Which Elements, reported as oxides, and where they come from in the fuel
o How to measure elements, AA, ICP, X-Ray
o Calcium and SO3 levels in coal ash
o Two forms of Iron – FeO & Fe2O3

Chapter 10 Using Ash Chemistry
o Base to Acid Ratio
o Slagging and Fouling potential
o Elemental Loading levels
o Fly ash type,
o Water wall corrosion
o ESP Operation and fly ash resistivity

Coal and Ash Analysis

Training Course

Introduction to Coal Combustion • Intro to Coal Combustion Video
• Good Pulverizers help plants cope
with coal quality issues
• Changing Fuel Specs EPRI 1994
• Coal Specifications Quiz Basic Pulverizer Operation
Mill Wear
"Primary Air • Calculation-of-Pulverizer-Minimum-
Primary-Airflow-and-Proper-Air-to-Fuel-
Relationship ICT
• High Primary flow issues with Low NOx
burners Quiz"
"HGI and Mill Capacity • Mill Capacity Excel spreadsheet
• Calculating PA Inlet Temperature Video
• PA Inlet Temp Excel spreadsheet
•Quiz"
Why Test Fineness
ASTM D 197 Pulverized Coal Sampling
and Testing
Coal Reactivity
ASTM D388 Coal Rank
• Quiz
Air Flow Basics
Combustion Calculations
Air Heater Leakage
Storm AH performance
Heat Rate and Boiler Efficiency
Laboratory methods for Predicting Perfomance
Wall Slag
• Wall Slag with Low Rank coals, Low CV
• Understanding Slag Paper
• Fireside Deposits in Large Boilers
Quiz
Fouling Deposits - Convection Pass
Using High Sodium Coal
High Calcium Coal Fouling
Quiz
Electrostatic Precipitators
Sizing and Costing of Electrostatic Precipitators
Quiz
Coal Blending

Coal Combustion

Training Course

Introductions Systems Thinking Characteristics of coals: Coal sources
Coal ranks and characteristics - basic
Differences and behavior "Dusts: Sources
Equipment reliability impacts
Equipment/area hazards and risks
Controls
Containment
Dust Suppression
Dust Collection
Explosion characteristics
Housekeeping"
"Equipment and process specifics: Receiving (Vessel)
Conveying (conveyor safety, conveyor components, belt cleaners/plows, housekeeping, instrumentation, etc.)
Chutes
Load zones
Dust mitigation (collection, suppression, housekeeping)
Transfer points
Short term storage
Long term storage
Coal pile management, practices
Reclaiming
Crushing and sizing
Bins, bunkers, hoppers, silos
Fire detection and suppression
Pulverizers/Mills
Burner pipes
Ash handling from backend steam generator (boiler) to disposal
Operations, procedures, practices
Maintenance practices"
"Emergency preparedness and response Fire behavior
Fire and explosion
Fire detection and suppression
Hazards to humans and environment
Prevention
Preparedness"Emergency preparedness and response Fire behavior
Fire and explosion
Fire detection and suppression
Hazards to humans and environment
Prevention
Preparedness

Coal and Ash Handling

Training Course

• Health and safety
o Dust, health risks, generation and mitigation
o Fires and explosions, causes, and mitigation
o Guarding to standards and practical aspects on guarding and safety
• Basics of bulk material flow testing
o Why testing?
o Where to test?
o What to test for?
o How to use the results.
• Conveying
o Conveyor design, maintenance and operation considerations
o Types of conveyors and their use
o Conveyor components and what to select and install for best results: belting, pulleys, idlers, motors and gearboxes, couplings, drives, brakes, cleaners and ploughs, holdbacks, magnets, weighers, samplers, trippers and take-ups etc.
o Lubrication
o Belt tracking causes and mitigations
o Instruments for conveyors
• Stockpiling and bins
o Stockpile and bin design considerations
o Stockpile types and selection
o Stockpile stacking and reclaiming machines and methods
o Bin and silo configurations
o Material flow in silos and design methods
o Level measurement methods and instruments
• Chutes
o Chute design considerations
o Trajectories
o Types of chutes
o Wear liner methods and materials
• Chutes and ancillaries design impacts
o Chutes and belt cleaners
o Chutes and tramp magnets
o Chutes and samplers, sampler types
o Chutes and skirts, skirt boxes
o Access to chutes for maintenance
o Chute modelling, DEM, other methods
• Conveyor calculation methods
o Manual methods
o Computer methods
• Air transport
o Pneumatic conveying
o “Vacuum” conveying

Bulk Materials Handling

Training Course

• Basics of bulk materials and the impact on air transport
• Why use air transport?
• Using air flow to transport bulk materials
o Negative pressure – “vacuum” conveying
o Positive pressure – pneumatic conveying
o Other methods – air slides
• Fundamentals of air transport
o Pressure
o Air flow
o Limitations
• “Vacuum” transport systems design
o Generating a negative pressure flow
Machine types – fans, blowers, liquid ring pumps
Venturi
o Recovering bulk from the airstream. = Gas Solid separator design
Damage
Separation
o Design of transport duct/pipe systems = Design for Air flow and velocity requirements to system sizing and pressure requirements. Pipe sizing design.
System size/complexity/length
Bends and junctions
Balancing flows
o Design aspects to consider = maintenance and troubleshooting
Access, where and why
Clean out
Wear
Selection of materials for the system
o Dust management

Problem Identification and Resolution = maintenance and troubleshooting
• Pressure but no flow
• Airflow but no bulk material flow
• Pipe system design errors
• Valves
• High wear, erosion and corrosion
• Attrition of bulk material

Basics of Air Transport for Bulk Materials

Training Course

· Health and safety o Dust, health risks, generation and mitigation
o Fires and explosions, causes, and mitigation
o Guarding to standards and practical aspects on guarding and safety • Initial steps for conveyor design
o Understanding how conveyors function
• Defining the parameters required to design a conveyor: bulk material flow testing, layout, equipment component selection
• Belt conveyor components and selection, conveyor design calculation impact
o Conveyor design, maintenance and operation considerations
o Conveyor components and what to select and install for best results, selection impact on design calculation: belting, pulleys, idlers, motors and gearboxes, couplings, drives, brakes, cleaners and ploughs, holdbacks, magnets, weighers, samplers, trippers and take-ups etc.
o Lubrication
o Belt tracking causes and mitigations
o Instruments for conveyors
• Chutes and conveyor design calculation impact
o Chute design considerations
o Trajectories
o Types of chutes
o Wear liner methods and materials
• Chutes and accessories conveyor design calculation impacts
o Chutes and belt cleaners
o Chutes and tramp magnets
o Chutes and samplers, sampler types
o Chutes and skirts, skirt boxes
o Access to chutes for maintenance
o Chute modelling, DEM, other methods
• Conveyor calculation methods and review
o Detailed review of the design method for belt conveyors
 Standard and other methods
 Conveyor profiles
 Sources of input data
 Explanation of the impact of each input on the design
 Making the calculation result practical
 Future proofing the design
 A quick manual check method.
o Computer methods
 Benefits of computer belt conveyor design methods
 Risks with using computer belt conveyor design methods
o Risks with belt conveyor design methods
 Not checking the design
 Incorrect input data
 Procuring different components to those used
 Operational

Basics of Conveyor Belt Design

Training Course

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