WELCOMES YOU Today s Topic QUALITY MANAGEMENT OF COAL

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1 WELCOMES YOU Today s Topic QUALITY MANAGEMENT OF COAL -T.H.MOHAN RAO MANAGER (QC) MOHAN.TH2260@GMAIL.COM MOB:

2 A little thought on successful skills Knowledge is of no value. It s the use of knowledge that makes it valuable..sharing is Caring!! Similarly, life does not pay off for you on what you can do; life pays off for you on what you do. Be a person, who can be: Strength for the Weak Flexibility for the Rigid Mobility for the Static Stability for the Unsteady Precision for the Sharp and Poise for the delicate Your future will be moulded by what you decide you want to be, rather than what you are

3 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 and preparation) 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 dried basis) 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

4 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 rule 18 B of Coal Mines (Conservation and Development) Amendment Rules, 2011 continued 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 s Gazette (Extraordinary) Notification S.O. 2920(E) Dated , the Coal Controller prescribes the procedure and method of sampling/analysis of coal The AGD requirement appears under Item 25 of the Procedure prescribed by the CCO 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)

5 2). HISTORICAL EVENTS ON INFORMATION OF COAL BEING NATURE 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 coking coal mines were nationalized on and BCCL was born 711 non-coking coal mines were nationalized on and CMAL was born CIL was formed on simultaneously, WCL, CCL, CMPDIL, BCCL & ECL were formed. NCL and SECL were formed on (85-86) out of CCL and WCL respectively MCL was formed out of SECL 0n (92-93)

6 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?

7 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 (Reaffirmed 2013) 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 (Reaffirmed 2010) -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) (Reaffirmed 2002) 4 IS:1350 (Part II) (Reaffirmed 2005) Methods of Test For Coal and Coke -do- Proximate Analysis of coal (Ash, Moi, VM and FC) Determination of GCV Methods of test for coal and coke relating to proximate analysis including determination of moisture under different conditions 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 that all parts are equally accessible to the sampling implement and have the same chance of being included in the sample.

8 4). ROLE OF FIXED CARBON, ASH, VOLATILE MATTER AND MOISTURE IN PRICING 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 of coal, moisture has a bearing on the pricing too, since GCV and moisture are inversely proportional to each other During the earlier UHV regime, the pricing mechanism was based on the ash and moisture 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 subtracted from 100. PA is found out by two methods commonly: Airdried sample basis and Equilibrated conditions basis GCV is determined through an equipment called Bomb Calorimeter; first GCV is determined by air-dried basis then Moisture is determined by equilibrated basis and substituted in the following formulae for arriving at Eq. GCV: Eq. GCV = Air dried GCV X (100 Eq. M) (100-Air dried M)

9 6). CALCULATION OF VARIOUS INDICES FOR COKING COAL (Caking Properties of coal) Sl.N o. Index Explanation 1 Caking Index (Agglutinating index) 2 Low Temp Gray-King (LTGK) Assay 3 Crucible swelling index (FSI: Free Swelling Index) 4 Shatter Index 5 Micum Index Max ratio of sand to coal is obtained in a coal sand mixture which, after carbonization under specified conditions, gives a coherent mass capable of supporting a 500 g mass, at the same time the proportion of loose powder being less than 5 percent of the mass of sand and coal. This is the agglutinating index or caking index. (Assay: test carried out to find out the purity) Carbonization of coal in a laboratory under standard conditions at a maximum temperature of 600 o C. The coke residue thus obtained is classified by comparison with a series of described coke types. This is the simplest test to evaluate whether a coal is suitable for production of coke. This involves 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 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. Industry standard FSI figures range from 0 (no increase in size) to 9 (greatest increase in size). The test is designed to simulate the effect of dropping coke on loading, dropping into bunkers and to the charge level of a blast furnace. It measures, therefore, the resistance to shattering, or the impact hardness. The average of three results obtained on 51, 38 & 13 mm shall be reported for each shatter index. 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.

10 7. CONVERSIONS OF UNITS OF COAL

11 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; Fusion temperatures 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. These are defined as follows: Name Is the temperature at which Initial deformation temperature (IT) the point of cone begins to round Softening temperature (ST) also sometimes the base of the cone is equal to its height called the spherical temperature Hemispherical temperature (HT) the base of the cone is twice its height Fluid temperature (FT) the cone has spread to a fused mass no more than 1.6 mm in height

12 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 Cell Office of the CGM/TS to Chairman, CIL Coal Bhavan, Premises - 04 MAR, Plot No.-AF-III, Action Area - 1A, New Town, Rajarhat, Kolkata kskumar@coalindia.in If the applicant wants to check the status of their grievance, then they should indicate the mobile number or mail address. Link for posting the grievances on-line: 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.

13 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

14 Blast the Papers.. THANK YOU ALL

Clause wise changes proposed for the Cost Plus FSA Models pursuant to migration from UHV to GCV regime

Clause wise changes proposed for the Cost Plus FSA Models pursuant to migration from UHV to GCV regime Existing Provision New Provision State Genco /SEB Model FSA 'Base UHV shall mean the UHV of the coal