Coal Handling Research Articles

Complex assessment of ambient particulate matter in a small settlement with coal-handling port

Relevance. Russian coal exports have been steadily increasing in recent years, and Far Eastern ports, originally not adapted to dusty cargoes, have switched to coal operations. Unoptimized coal handling leads to increased content of coal-containing particles in the air and to various environmental problems. Aim. To analyze the concentration of particulate matter in the air and the chemical composition of particles on the surface of conifer needles in the Posyet settlement (Primorsky Krai, Russia), where a large coal terminal operates. Materials and methods. The chemical composition was studied on the surface of conifer needles by X-ray fluorescence and in washout of conifer needle samples using Raman spectroscopy and energy dispersive analysis. Concentrations of particles with the diameter of 2.5 and 10 μm (PM2.5 and PM10, respectively) were measured using automatic monitoring stations. Results and conclusions. Chemical composition was dominated by mineral particles (calcite, silicates, etc.). However, the presence of coal particles (up to 8.3%) and metal particles was also observed. Mean concentrations of PM2.5 and PM10 were within the Russian and international health standards, but close to their upper limits. Concentrations of both measured particle fractions were highest during the winter months (as well as in March, which is traditionally a cold month in the Far East), followed by a gradual decrease. The study obtained new data on the annual variations of concentrations of PM2.5 and PM10, as well as on the basic composition of particles from the surface of woody vegetation (needles) as an indicator of the state of air pollution in this settlement.

Analisis Cara Penanganan Penurunan Kualitas Batubara di Stock ROM Ulak Pandan Sampai Jetty SDJ di PT Bumi Merapi Energy

Coal quality analysis is increasingly important considering the increasing global energy demand. Coal, as the main source of energy, has varying qualities, affecting combustion efficiency and environmental impact. Two commonly used analysis methods are proximate analysis and ultimate analysis, which provide information about the composition of coal. Previous research has shown that chemical analysis affects energy efficiency and environmental impact. This study aims to analyze the quality of coal using both methods and evaluate its characteristics for industrial applications. The benefits of this research include guidance for coal producers and users, as well as contributions to reducing the environmental impact and sustainability of the energy sector. This study uses a descriptive approach with qualitative and quantitative methods, focusing on Seam E coal at PT Bukit Asam Tbk. Primary data includes coal handling, temperature, and quality, while secondary data includes location maps and rainfall data as a reference. This study resulted in the conclusion that 1) Factors that affect the decline in coal quality at mining sites and stockpiles include the mining process, working front conditions, loading, processing in the stockpile, sampling, and handling in the ROM to Jetty SDJ. 2) Efforts made include contamination avoidance, fine coal handling, stacking management, and blending process.

Use of electron microscopy to determine presence of coal dust in a neighborhood bordering an open-air coal terminal in Curtis Bay, Baltimore, Maryland, USA

BackgroundDespite decreasing US consumption, over 90 million metric tons of coal were exported by the US in 2023, requiring significant infrastructure for transport, handling, and storage of coal at export terminals. Residents in Curtis Bay, Baltimore, Maryland, USA live at the fenceline of an open-air coal terminal and have, for decades, reported rapid accumulation of black dust at their homes. Community-level exposure to coal dust originating from coal handling and storage terminals has remained largely unexplored. ObjectivesTo investigate community-identified concerns and use a community-driven approach to determine the presence/absence of coal dust in Curtis Bay surfaces. MethodsPassive settled dust samples were collected from two residential areas, 345 m and 1235 m from the coal terminal, using conductive carbon tape. Scanning electron microscopy and energy dispersive X-ray spectroscopy (SEM-EDX) of standard reference coal material and a positive control material from the coal terminal in Curtis Bay were used to optimize the morphological and elemental classification criteria for coal dust. A manual SEM-EDX protocol was developed to identify coal particles in settled dust collected on conductive carbon tape in community settings. ResultsSEM-EDX analysis confirmed presence of coal dust sampled at both residential locations. Estimated coal dust particle loading at the proximal and distal site were 13.2 and 3.4 coal particles/mm2, respectively. The coal dust particles identified met specific criteria, including size (>5 μm), morphology, and elemental composition (≥75 % carbon, ≤20 % oxygen). DiscussionThese findings are consistent with longstanding community concerns and lived experiences regarding the presence of coal dust in Curtis Bay, which neighbors a major open-air coal terminal. This approach has potential for other communities neighboring coal terminals to assess similar concerns with residential coal dust exposure.

Risk identification and decision-making analysis in lower-ranking coal handling: A FMEA and AHP

Risk identification and decision-making analysis in lower-ranking coal handling: A FMEA and AHP

Optimasi Injeksi Trisodium Phosphate Pada Air Suplai Boiler Di Unit 4 PLTU Nagan Raya Menggunakan Design Expert Metode Pendekatan Response Surface Bok-Behnken

In the steam power plant industry, supporting facilities commonly called BOP (Balance of Plant) include Coal Handling, Ash Handling and WTP (Water Treatment Plant). TSP Trisodium Phosphate is one of the chemicals in water treatment. Besides functioning as a cleaner, TSP also functions to precipitate magnesium, iron, and silica and is able to help maintain the pH value of boiler water. Therefore, this activity was carried out to optimise chemical injection in the water treatment process for boiler water with good quality so as to produce steam with good quality as well. From the analysis results, the optimum injection of chemicals is 0.462 ppm TSP (Trisodium Phosphate) resulting in a pH value of 9.279, SiO2 (Sillicon dioxyde) 64.5 ppb, and Na+ (Sodium) 0.719 ppb.

Contrasting platinum trajectories in three major French rivers using dated sediment cores (1910–2021): From geochemical baseline to emerging source signals

Platinum (Pt) is a Technology Critical Element (TCE) which, since the 1990s, has been mainly used in the industry in catalytic converters for automobile emission control. Previous studies have shown Pt contamination of road-side sediments and surface sediments in urban rivers and lakes but few of them have addressed temporal variations. The present work presents historical Pt concentration trends in 137Cs-dated sediment cores from floodplains or secondary channels at the outlets of three major French watersheds (Loire, Rhone, and Seine Rivers) covering the past ∼110 years, i.e., from the 1910s to 2021. Platinum baseline levels in the sediment were estimated for the Loire River (0.76 ± 0.22 μg kg−1 for the period ∼1910-∼1955) and the Rhone River (1.64 ± 0.41 μg kg−1), and historical Pt variations seem to reflect variations in hydrodynamics and grain size composition. Since the early 2000s, Pt concentrations in the Loire and the Rhone River sediments tend to increase (>2.5 μg kg−1) and were attributed to the use of car catalytic converters, an emerging technology since the 1990s using >50 % of European Pt demand. High and variable historical Pt concentrations (up to 14.6 μg kg−1) in the Seine River sediments may reflect legacy Pt sources due to former anthropogenic activities in this watershed, such as the use of Pt-based catalysts for petroleum refinery since the end of the 1940s, coal handling and precious metals refining, probably concealing the likely presence of an emerging traffic-related Pt signal. This first comparison of historical Pt concentration trends in sediments from contrasting watersheds allows to distinguish signals originating from different natural and anthropogenic sources (background level, historical sources, road traffic).

Perancangan Monitoring Coal Handling System PLTU Kaltim Teluk Berbasis Internet of Things

Abstract— Balikpapan Bay PLTU is a large capacity power plant located in the city of Balikpapan, which is located in East Kalimantan. This PLTU with a capacity of 2X110 MW meets the electricity needs of the Barito Mahakam network, which consists of the East Kalimantan, North Kalimantan, Central Kalimantan and South Kalimantan regions. The main fuel for electricity generation is low grade coal (LRC) or low calorie coal. High Speed Diesel (HSD) oil is used as initial fuel. DCS (Distributed Control System) is used for wood management at PLTU Kaltim Teluk. DCS helps operations by monitoring and controlling the main and supporting components, however, management, supervisors and other staff have difficulty knowing the operating conditions of the generating unit remotely because the monitoring system can only be accessed by the control room operator at the CCR. The aim of this research is to design an Internet of Things-based coal handling system control system for PLTU Kaltim Teluk. This real time based digital monitoring system can collect and display data from every sensor in the field. The research method is a literature study method and a field method to apply the design results and collect monitoring data at the two Balikpapan Bay PLTUs. The results show that testing, which includes integration testing with MySQL, functional testing, and URL and Endpoint testing, was carried out successfully. As expected, all the main features and functions of the PLTU monitoring system are running well. This system has averagepercentage error 0.1%. So this study has an accuracy rate of 99.9%. This system has the ability to make it easier for managers to monitor the system.

Analysis of failure characteristics of screen plates of ring hammer crusher used in coal handling applications

The screen plate, a critical component within a ring hammer crusher (also known as a ring granulator or rolling ring crusher), plays a vital role in the secondary crushing of coal. Functioning both as a platform for coal crushing and as a sieve to achieve the desired coal size, it is essential to understand and examine its failure characteristics to enhance its mechanical and wear resistance properties in coal handling applications. This study thoroughly explored the failure modes, mechanisms, and underlying causes of screen plate failures. Microscopic techniques such as optical microscopy (OM), scanning electron microscopy (SEM), Vickers microhardness test and spectrochemical analysis were utilised to identify the failure mechanism. Failure modes identified from the macroscopic analysis were discharged hole widening, hole wall break-off, plate edge crack, plate fracture, one-sided edge slimming, and general surface wear of the screen plate. The fractographic and wear track analysis identified the principal failure mechanisms of three-body abrasive wear, two-body sliding abrasion wear, shear-induced fatigue fracture and brittle shear fracture. The root causes of the failures are the rotor’s direct impact, defects in the parent material, the presence of hard materials in the coal and the use of unsuitable steel grade in the screen plate manufacturing. The service life of the screen plate can be improved through proper material selection, uniform crusher feeding, surface modification of the surface of the “as purchase” screen plate with appropriate wear-resistant materials, and adherence to good maintenance practices.

Energy Management Assessment through Case Study in Coal Handling System of Coal-Fired Power Plant

Coal Handling System (CHS) is the main system of Coal Fired Power Plant (CFPP), managing coal transportation from Vessel by Ship Unloader to coal yard through belt conveyor (BC) and Stacker/Reclaimer (S/R), then transported to Silo, known as forwarding process. CHS involves various large electric motors. The unwisdom of operating these motors would result in wasteful electrical energy consumption. To assess the energy management, United Nations Industrial Development Organization (UNIDO) provides Energy Management System (EnMS) tools based on ISO 50001 industrial sectors. This tool identifies that operational patterns and maintenance activities have a significant impact on the energy consumption. Technically using Integrated SKF Calculation, applying the scenario of direct replacement conveyor rollers aged more than 2 years by only 30%, saves 103,144.20 kWH per cycle, equal to IDR 102,807,951, rather than replacing rollers when broken only. Meanwhile, Lean Six Sigma concept in increasing cycle performance, could save a monthly 594,984 kWH, equal to IDR 593,044,189.

The Risk Assessment and Human Risk Control in Indonesian Power Plant

Efforts to enhance labor productivity are intrinsically linked to the improvement of Occupational Health and Safety (OHS) standards. The research focused on the optimization of OHS by conducting a COVID-19 risk assessment, with the goal of identifying and implementing Human Resource (HR) risk control measures to augment employee performance. In employing a qualitative methodology, the data were amassed through a combination of interviews, observations, and document analysis involving a diverse group of 23 respondents from various departments. The risk assessment process was meticulously structured into four phases: identification of causes, implementation of preventive measures, development of recovery strategies, and evaluation of consequences. The researchers organized the data into primary and secondary categories for analysis and utilized the Bow Tie method to elucidate the findings. The analysis reveals that the human factor, specifically employees’ non-compliance with safety protocols, poses the greatest risk for virus transmission. The result identifies the warehouse, workshop, administration building, and Coal Handling Control Building (CHCB) as the most critical areas requiring stringent risk controls. The results also provide an overview in preparing the basis for Corrective Action and Preventive Action (CAPA). It provides benefits for implementing OHS in power plant companies through recommendations such as evaluation, preventive action, and risk control through COVID-19 risk assessment. Finally, the research delineates strategies for managing risks through preventive measures and recovery processes to mitigate the impacts and consequences associated with these hazards.

Delphi/AHP를 활용한 화력발전플랜트 고위험시설 선정 연구

Thermal power plants are large-scale plants made up of various types of buildings and equipment to produce electricity and consist of coal handling systems, oil storage facilities, boiler facilities, turbine/generator facilities, substation facilities, water treatment facilities, and auxiliary facilities for operating them. For these special fire-fighting objects, high safety is required in consideration of fire load and fire risk. In principle, the selection of fire fighting facilities applied to each space is primarily in accordance with relevant laws and regulations, and is installed and maintained by the power plant operating institution. However, most power plant operating institutions do not secure safety according to the characteristics of each major dangerous space and maintain fire fighting facilities under the same conditions, which is insufficient to secure actual fire safety. In this study, Delphi and AHP were used to assign weights according to the importance of dangerous spaces, and major dangerous spaces according to priorities were divided into fire/explosion risk facilities and leak/explosion risk facilities.

Application of lean and quality improvement methods for improving operational performance in coal supply chains: a case study

PurposeThe application of lean and quality improvement methods is very common in process improvement projects at organisational levels. The purpose of this research is to assess the adoption of Lean Six Sigma™ approaches for addressing a complex process-related issue in the coal industry.Design/methodology/approachThe sticky coal problem was investigated from the perspective of process-related issues. Issues were addressed using a blended Lean value stream of supply chain interfaces and waste minimisation through the Six Sigma™ DMAIC problem-solving approach, taking into consideration cross-organisational processes.FindingsIt was found that the tendency to “solve the problem” at the receiving location without communication to the upstream was, and is still, a common practice that led to the main problem of downstream issues. The application of DMAIC Six Sigma™ helped to address the broader problem. The overall operations were improved significantly, showing the reduction of sticky coal/wagon hang-up in the downstream coal handling terminal.Research limitations/implicationsThe Lean Six Sigma approaches were adopted using DMAIC across cross-organisational supply chain processes. However, blending Lean and Six Sigma methods needs to be empirically tested across other sectors.Practical implicationsThe proposed methodology, using a framework of Lean Six Sigma approaches, could be used to guide practitioners in addressing similar complex and recurring issues in the manufacturing sector.Originality/valueThis research introduces a novel approach to process analysis, selection and contextualised improvement using a combination of Lean Six Sigma™ tools, techniques and methodologies sustained within a supply chain with certified ISO 9001 quality management systems.

Decision support system for maintenance order priority of multistate coal handling system with hot redundancy

Decision support system for maintenance order priority of multistate coal handling system with hot redundancy

STUDIES OF THE AREA AROUND SINGRAULI COAL FIELD & ENERGY BELT, DISTRICT SIGRAULI, MADHYA PRADESH INDIA

STUDIES OF THE AREA AROUND SINGRAULI COAL FIELD & ENERGY BELT, DISTRICT SIGRAULI, MADHYA PRADESH INDIA

Coal Dust Severity in a Power Plant: In-Situ, Analytical, and Numerical Assessments

One of the most serious occupational hazards in the coal industry is coal dust. Previous research revealed that the vast majority of coal dust assessments were conducted in coal mines, resulting in a lack of understanding of the severity of coal dust during coal handling activities in power plants. Therefore, the severity of combustible coal dust in one of Malaysia's power plants was assessed using a comprehensive analysis that included qualitative observations, in-situ measurements, numerical simulations, laboratory tests, and data analysis. The designated locations include the coal conveyor hall (Zone 1, 2A, and 2B), milling (Zone 3), and bunkering areas (Zone 4). Relevant safety limits, as recommended in National Fire Protection Association (NFPA) 654, were used as guidelines where comparisons with the site data were made. The high coal dust accumulation rate in Zone 1 was revealed to be largely the result of inefficient ventilation performance, as confirmed by in-situ measurement and numerical simulation. Direct referencing to the relevant NFPA 654 guidelines finds the zones encompassing the coal conveyor hall are at “high risk” of fire and explosion. Further laboratory assessments on the dust samples in Zone 1 however reduces the earlier assessment to “medium risk” with the potential of “low risk” with regular housekeeping. Zones 3 and 4 were found to be “low risk” areas due to insignificant accumulation and good air flow management. Overall, the evaluation of the severity of combustible coal dust was successful in establishing the risk mapping for all zones. Cleaning frequencies were also proposed based on the coal dust accumulation rates and the risk mapping.

Internal and cross sectional benchmarking of electrical energy use in opencast coal mine

Electrical energy consumption in the opencast coal mine is very high. Electric shovels, pumps and coal handling plants consume 75% of the total electricity consumption of an opencast coal mine. In this paper, a modelling framework has been developed for electrical energy use benchmarking (internal as well as cross-sectional) of the mine. To develop a mine specific model for benchmarking electrical energy use statistical approach (linear regression method) has been applied. Specific power consumption (SPC) is used as a benchmarking index to assess the operating energy performance of a specific mine and multiple coal mines of India based on the field studies. Seasonal analysis of the electrical energy usage has also been analysed. Our results show the benchmark SPC as 0.50 kWh/t and the energy-saving potential as 10.7% for a single mine and the benchmark SPC of multiple coal mines as 0.52 kWh/t. The result concludes that SPC widely depends on its capacity and mining method and the developed model are useful for benchmarking and targeting for efficient electrical energy use in opencast mine.

Associations between hemoglobin levels and source-specific exposure to ambient fine particles among children aged

ObjectiveWe investigated associations between source-specific fine particulate matter (PM2.5) exposure and hemoglobin levels among children in low- and middle-income countries (LMICs). Method36,675 children aged < 5 years were collected in 11 LMICs during 2017. We associated child hemoglobin with 20 source-specific PM2.5, and calculated changes in hemoglobin that could be attributed to different PM2.5-mixture scenarios, established using real-world data from 88 Asian and African LMICs (AA-LMICs). ResultsMultiple-source analysis revealed PM2.5 produced by solvents (change in hemoglobin for 1-μg/m3 increment in PM2.5: −10.34 g/L, 95% CI –14.88 to –5.91), industrial coal combustion (–0.51 g/L, 95% CI –9.25 to –0.08), road transportation (–0.50 g/L, 95% CI –6.96 to –0.29), or waste handling and disposal (–0.34 g/L, 95% CI –4.38 to –0.23) was significantly associated with a decrease in hemoglobin level. Decreases in hemoglobin attributable to the PM2.5 mixtures were co-determined by the concentrations and their source profiles. The largest PM2.5-related change in hemoglobin was −10.25 g/L (95% CI –15.54 to –5.27) for a mean exposure of 61.01 μg/m3 in India. ConclusionAssociation between PM2.5 and a decrease in hemoglobin was affected by variations in PM2.5 source profiles. Source-oriented interventions are warranted to protect children in LMICs from air pollution.

Enhancing shear strength and handleability of dewatered clay-rich coal tailings for dry-stacking

Mineral tailings dams pose high pollution risks to the environment and catastrophic failures. Dry stacking has been identified as a promising alternative to mitigate these risks and offers various benefits to the mining industry but lacks systematic research outcomes. To facilitate dry stacking, coal tailings slurries were dewatered using either filtration or centrifugation methods, resulting in a semi-solid form (cake) that can be safely disposed of. The handleability and disposability of these cakes are greatly influenced by the selection of chemical aids (such as polymer flocculants) and the mechanical dewatering technique employed. The effects of polyacrylamide (PAM) flocculants with a range of molecular weight, charge, and charge density are presented. Coal tailings samples with differences in clay mineralogy were dewatered using press filtration, solid bowl centrifugation, and natural air drying. Handleability and disposability of the tailings were assessed by their rheological properties, including yield stress, adhesive and cohesive stresses, and stickiness. Residue moisture, type of polymer flocculants, and clay mineralogy were found to be crucial factors affecting the handleability and disposability of the dewatered cakes. The tailing yield stress (shear strength) increased as the solid concentration increased. In the semi-solid regime (above 60 wt% solids), the tailings displayed stiff exponential growth. Similar trends were observed for stickiness and adhesive/cohesive energy of the tailings with a steel (truck) surface. Adding polymer flocculants increased the shear strength of the dewatered tailings by 10–15%, thus favouring disposability. However, the polymer selection for coal tailing handling and processing is a trade-off between its disposability and handleability, which requires a multi-criteria decision-making process. The current results also suggested that cationic PAM could be most suitable for dewatering by press filtration, while anionic PAM should be selected for dewatering by solid bowl centrifugation.

Corrosion and coating defect assessment of coal handling and preparation plants (CHPP) using an ensemble of deep convolutional neural networks and decision-level data fusion

Corrosion and coating defect assessment of coal handling and preparation plants (CHPP) using an ensemble of deep convolutional neural networks and decision-level data fusion

Evaluating the use of rice residue ash in cement-based industries in the Philippines – Greenhouse gas reduction, transportation, and cost assessment

In the Philippines, biomass-fueled cogeneration plants use sugarcane bagasse, rice husk, or a mix of agricultural residues as feedstock. Burning these residues results in the continuous generation of ash, accumulating over time and needing appropriate disposal. As a preliminary, the annual potential amount of rice husk and rice straw generation, the available energy that could be recovered, and potential ash generation in the Philippines were estimated in this study. More specifically, the contribution of generated ashes toward reducing greenhouse gas (GHG) emissions when used to displace part of the required cement in cement-based industries was assessed and evaluated. Residues from paddy rice could provide up to ∼10,444 GWh of electrical energy when used as fuel. Utilization of the generated fly ashes (∼634 kt rice straw fly ash and ∼267 kt rice husk fly ash) alone could, on average, reduce ∼681 kt CO2_eq annually. The transportation of the ashes before their utilization entails significant GHG emissions. However, transporting the ash within the critical distance of 2,995 km would ensure a positive net reduction. In addition, the handling and transportation cost of coal, rice, and sugarcane ashes within the archipelago was also evaluated and compared. The resulting costs (0.94–6.8 USD/40-kg bag) of different ashes are competitive with the current cement retail price (4.00–7.45 USD/40-kg bag). Potential applications, impacts, limitations, and foreseen challenges in using rice residue ashes are also discussed.