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COAL PRODUCERS
Out-of-Seam Dilution
Rock that is extracted with the coal (out-of-seam-dilution) lowers the value of the raw coal and presents an ongoing challenge for preparation plants operators. By monitoring the as-mined coal with an On-Line Analyser, the amount of out-of-seam dilution can be effectively controlled in real time. In this case, you will:
- Improve mine efficiency
- Reduce shipping costs by transporting out-of-seam material
- Increase raw coal value because you can remove ash
- Increase prep plant yield because out-of-seam dilution decreases
For example:
If a coal mine with an average mining height of 2.3 m can reduce the amount of out-of-seam dilution from 0.5 meter to 0.25 meter, the additional revenue generated could be as much as $3.60 per ton. This results due to the increased heating value of the coal less out-of-seam dilution. If a mine ships 5 million tons of raw coal per year, such a reduction in out-of-seam dilution is worth an additional $18 million per year. In such instances, the pay-back period for an on-line analyser system is typically between 3 months and a year.
Coal Sorting and Blending
Traditionally, coal producers use On-Line Coal Analysers to meet tight specifications for sulfur. However, given the power of On-Line Analyser Systems to sort coal consistently and accurately based on multiple quality factors (sulphur, ash, moisture, etc), there are many opportunities for coal producers to realise additional value from these systems.
Sorting based on quality allows raw coal that meets shipping specifications to be bypassed around the preparation plant. The yield of the preparation plant will increases, resulting in a more efficient and profitable operation. The ability to reliably blend various coal qualities to arrive at a specific product allows to:
- Blend poorer quality coals with high quality coals to exactly meet contract specifications
- Market and sell your coal to power generators easily
- Avoid rejected loads and quality penalties
Power Generators
Coal is a global commodity and individual power generators may import fuel from many sources resulting in different coal consistencies. This variability in quality presents real problems for today’s power generators, who depend on a consistent quality coal feed for their boilers. More stringent environmental regulations for S02 and particle emissions present further challenges to the power industry. This results in increased need for Real Time Analysis at power plants. This will to enable you to blend your coal to meet required specifications and help increase plant efficiency through a decrease in forced outages and derates. SGS will work with you to ensure that your On-Line Analyser System optimises your operation and helps you meet the challenges facing power generators today.
Forced Outages and Derates
Forced outages and derates due to poor coal quality or slagging and fouling issues are a major cause of reduced power production at coal-fired power stations. Slagging and fouling problems occur when molten or partly fused ash particles are deposited on surfaces inside the boiler, or when volatile constituents within the coal begin to accumulate on convective surfaces. The results can be devastating to a power plant and may result in:
- Expensive damage to internal equipment.
- Reduction in plant efficiency as convective surfaces exposed to radiant heat is coated with deposits.
- The power output of the plant being reduced (derated) to help minimise or reduce the slagging and fouling problem.
- The plant being shut down (forced outage) to remove the deposits.
If the quality of the coal feed is monitored in Real Time, slagging and fouling problems can be controlled and forced outages and derates can be significantly reduced or eliminated. SGS will work with you to produce a consistent quality coal feed that will reduce or eliminate your slagging and fouling problems, and improve your power plants financial performance.
Performance
Coal generating stations are most efficient when they operate at their output limits. How close a plant can come to its boiler limit is determined by the consistency of the fuel it burns. Fewer deviations in quality will result when the power plant operators are able to operate near their output limit without concerns. Such consistencies in coal quality can only be achieved through On-Line Analyser controlled blending systems. When the feed is blended at a consistent quality, you will be able to operate closer to your power plants design limits and thus increase your overall megawatt production and plant efficiency. Your On-Line Analyser System will be designed specifically to match the needs of your operation, and will be installed and maintained by SGS’ team of world class technical experts with years of experience in On-Line Analyser Systems.
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