We do not only aim to provide fuel quality measurement equipment. We focus on comprehensive solutions that effectively solve the real problems of our business partners. We offer an innovative approach to optimising fuel quality, ranging from simple solutions to complex homogenization systems. These systems can be implemented in the entire coal handling process from the coal mining control up to the balance control of coal quality in the power plant. The implemetation of coal quality management systems brings not only economic but also environmental benefits.
Optimising your coal production.
Increase the efficiency of coal combustion.
Reduce the cost of coal processing.
Reduction of emissions during combustion.
Application of quality management systems in individual stages of coal processing
In surface mines, mining operations usually rely on geological maps. In practice, the actual quality of the coal in each layer can vary significantly. Based on the mining plan and online information from the bucket wheel excavators, the main operator enters the requirements for the mining performance of each excavator in the mine. The mining management effectively ensures a consistent quality of supply from the bottom, significantly reducing the difficulty of subsequent finishing or homogenisation of the coal. Coal is mixed during transport from individual machines. Online measurement of coal quality at the mine output verifies compliance with the mining plan and customer requirements.
By placing online analysers directly on the mining equipment, it is possible to verify that the quality of the coal meets the expected parameters. This allows the mining requirements of each machine to be adjusted operationally. At the same time, the result of the online measurement is displayed to the machine operator, who may be able to prevent the extraction of overburden.
It is complicated to install the on-line analyzers onto the mining machines in the underground mine. For the excavation controlling, there are used the on-line data on coal quality from different sections of the mine. The final quality is verified at the output of the mine during expedition. The on-line analyzers are mainly used in the technology on the ground but Enelex also offers online analyzer for underground explosive environment.
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Application of quality management systems in individual stages of coal processing
The coal treatment plant is supplied with coal from two sites. Processed and treated coal is supplied to various customers. The material is processed as follows:
Low-quality coal is supplied directly and without modification to the local power plant as an energy heating compound.
Modifiable coal goes through the washing process on one of the four washing lines.
Intermediates are combined with low-quality coal to create the optimal heating mixture tailored to the specific needs of each customer.
Washed coal of varying grades is sold to merchants and small power plants.
Online analysis and the Coal Quality Management System are fully implemented to monitor the quality of input and output products, control treatment technology, and facilitate both mixing and washing coal.
29 GE Online coal quality analyzers (Ash meters)
10 Automatic belt samplers
4 GE operational express coal analyzers
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Application of quality management systems in individual stages of coal processing
Coal stockyards homogenize coal based on predetermined requirements. Sorting coal allows us to achieve a very stable quality of the resulting product. At the stockyard's entrance, coal of different quality is accepted. Based on the result of the online measurement, a defined method of depositing coal in the stockyard is decided.
A system of mapping the quality of coal deposited in layers is used for homogenising coal in the stockyard. The quality of stored coal is measured online by analysers placed on stockyard machines. The exact location of the coal deposit is determined by storing the location of the stockyard machine and the rotation of its arm in the system, along with information on the quality of the material.
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Application of quality management systems in individual stages of coal processing
The power plant operation requires the coal feed of specific calorific value. In case of any deviation an output power loss or even boiler blackout can occur.
The coal ash content and calorific value is monitored before the feeding in to the bunker to ensure the sufficient quality of coal for proper boiler operation. If the on-line balances of coal quality do not conform to the boiler requirements, some of the bunkers can be fed with coal of different quality.
The parameters of all coal being available for the boiler are used by the operator to adjust the working parameters for the boiler as needed. In case of any deviation it is possible to adjust the setup of coal feeders or improve the boiler operation by injection of other fuel (oil or gas).
The comparison of laboratory results and boiler performance with the online measurement of coal quality and quantity helps to verify the effectiveness of the whole system.
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Application of quality management systems in individual stages of coal processing
These systems work on the principle of sorting better and worse quality of coal, which is out of the quality range required by the customer, into steel or concrete bunkers. After filling these bunkers, our system supply the coal back to the conveyor belt where the quality is blended.
The basis is an online analyzer The basis of this system is our online analyzer, which evaluates the quality of coal in real time and automatically controls the separation of coal to the bunkers for lower and higher quality by using of sorting flaps.
If a better quality needs to be blended with the coal that passes through the belt conveyor, it will automatically start to discharge from the appropriate bunker, the same if it is necessary to blend with a lower quality, so that we reach the optimal range required by the customer. If the boilers were supplied with coal of an even better quality than what they are designed for, this would bring problems to customers during combustion.
After the bunkers where the coal is blended, another online analyzer is installed along with an automatic sampler for output quality control as well as for feedback onto proper setup and calibration of the entire system.
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Application of quality management systems in individual stages of coal processing
Revolutionary production line of energy mixtures with automated control for maximum efficiency of mining and coal treatment processes.
The production line of heating (energy) mixtures was designed at first for the needs of the customer (underground mine and coal treatment plant Darkov OKD), which produces washed coal and also coal waste (coal sludge and coal middlings). However, this coal waste can be used very efficiently for blending with washed coal to the optimal heating mixture. This significantly increases the production of the mine and the coal processing plant, even if all qualitative parameters of the sold coal are met (ash content and calorific value). The basis of the production line is a special SW with an automatic control system and system of online coal quality analyzers from ENELEX. The system works completely automatically based on entering the needed parameters of coal, all parameters are fully adjustable.
An unique blending system for optimal fuel quality in the mining and energy industries.
The blending system can be easily applied wherever the optimum fuel mixture is needed, for example, in underground mines and coal treatment plants. The system can also be used to process coal sludge in the plants. Moreover, it is suitable for power plants that buy coal from multiple suppliers with a larger calorific value/ash content range to ensure that an optimally blended fuel mixture is supplied to the power plant system. These blending lines are essential for coal terminals which accept coal of different quality from multiple suppliers and they can blend the different types of coal to the specific optimal coal quality ranges required by individual customers.
Our systems always meet customer's needs.
We design our production lines to blend and sort the desired quality of coal according to the customer's needs. It can blend multiple different quality of input coal types and can be designed for different production capacities as required.
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Application of quality management systems in individual stages of coal processing
Our coal quality management system can also be installed at a coal stockyard in a power plant. Coal is transported to the stockyrad by using of mobile sky-line tripper conveyor. The coal is stored according to real-time information from measuring of calorific value and ash content from online coal quality analyzer and is sorted to different piles based on this measurement and customer requirements.
Each pile must meet an average ash and caloric value within a specified range, which must be verified by the laboratory. Our system utilises special Enelex software to display the capacity and quality of coal for each pile, ensuring the customer has complete information about coal supplies. This enables us to respond to the quality of coal for combustion in the boiler and better plan coal deliveries from suppliers. The picture below shows the filling status for each pile, the quality of coal which is needed to be supplied, whether it is ready for export or waiting for confirmation from the laboratory.
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Application of quality management systems in individual stages of coal processing
A modern system for analysis and sorting of coal quality for customers who transport coal by trucks
The system is perfectly suited to customers who transport coal by truck. It consist of hopper with crusher, belt conveyor with automatic belt sampler, online coal quality analyser, mobile conveyor and special software for process automation.
A complete system for processing coal from trucks: from crushing through sampling, online analysis up to the homogenization for optimal fuel quality
The truck dumps the entire load into the hopper with the crusher, where the coal is crushed to the desired granularity. Coal continues on to the belt conveyor. An automatic sampler designed according required world standard (e.g. ISO, ASTM, GOST) takes a representative sample for the laboratory, which can be used for commercial purposes or calibration and feedback on the settings of the entire system. All fuel is also measured by an online coal quality analyser, which measures the quality and quantity of the fuel in real-time. Based on the results of the online analysis, the coal is sorted at the individual piles at the stockyard by using of mobile conveyor which is controlled by software, or the coal is directly homogenised by the method of storing layers with different quality of coal (chevron method).
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Quality management systems can be applied at different stages of coal processing. They can be used throughout the coal processing process, from mining management up to the balance control of coal quality in the power plant. The implementation of coal quality management systems brings positive economic and environmental benefits. The precisely specified and consistent quality and calorific value of the coal supplied is a crucial parameter for most processes that use coal as a fuel or raw material. The coal quality management system is a complex of technological and organisational measures used to achieve the desired quality of coal for a particular use.
Our coal quality management system is capable of responding to dynamic changes in coal parameters so that it is possible to effectively ensure compliance with quality requirements. In practice, the combination of systems in several stages of coal processing ensures high efficiency of the whole process.
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Optimising the use of mined coal:
Extending the life of the mine by exploiting all the coal reserves and selling it at the highest possible price.
Increasing the efficiency of coal combustion in power plants:
Reducing the number of boiler shutdowns due to the combustion of inappropriate fuel quality.
Reducing the operating costs of coal processing.
Protection of the technology from failure due to inappropriate quality of coal.
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To ensure that the system functions properly, it is important to have the measurement results available immediately, with as little delay as possible. Our system, therefore, includes online coal quality analyzers that measure directly on the conveyor belt:
Coal quantity (flow rate, weight)
Coal ash content
Coal calorific value
Coal moisture
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Automatic coal samplers collect samples for laboratory analyses and monitor deliveries in accordance with legal requirements. To effectively participate in the coal quality management system, the sampler can be supplemented with a rapid analyser. This gives instant results on individual samples. Rapid analyser technology can be integrated directly into the sampler and transmit readings without the influence of human factors.
Coal quality management systems can use the results of rapid laboratory analyses as well as traditional laboratory analyses. Such results are usually delayed and are, therefore, used to validate system operation or to refine balances.
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With an effective operational management system, it is possible to intervene in the operation of the technology to achieve the desired coal quality. Operational control systems vary according to the type of operation and the technological capabilities of each plant. The system includes not only technical capabilities but also organisational and decision-making procedures. Operators of individual technological units have at their disposal data on the state of the technology, including the results of on-line measurements, the current balance for the period and the requirements for the resulting product. The information obtained makes it easier for the operators to make decisions on any operational intervention in the operation of the technology in order to achieve the stated objective.
Achieve higher efficiency in coal mining, processing and utilisation. Take advantage of ENELEX's advanced coal quality management system. Simply contact us by phone or e-mail. We will schedule an appointment to discuss your needs and provide you with a tailor-made solution.
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