1. SDM COLLEGE OF
ENGINEERING
& TECHNOLOGY
Department of Chemical Engineering
Analysis & Comparison of cheaper
binder for coal fines
Under The Guidance Of:
Kiran Kumar Rathod
Name Of Students U.S.N
Abhishek 2sd10ch001
Rahul Patel 2sd10ch014
Priyanka Jain 2sd10ch015
Saurav Kumar 2sd10ch018

2. Introduction
•India has vast coal reserves & ranked 5th in coal rich. countries.
•Although we are one of the top 5 leading producer of coal but we also
lag behind by being in top most countries importing coals.
•185 billions tons of coal reserves are present in different regions of
country.
•Coal reserves in India are mainly bituminous & sub-bituminous (not
high grade coal) and thus not safe for environmental point of view.
•Coal in the process of mining, handling & exposure to weather is
subjected to more or less disintegration & its known as slack. If this
slack is wasted the loss ranges 5-50%.
Thus its essential for economical consideration.

3.  Coal briquetting is a process which converts coking coal &
slack into uniform usually hard and impact resistance
agglomeration, making it useful with high calorific value for
domestic & industrial purpose.
 Coal import can be very expenses in some instances it
accounts upto 70% of delivered cost of coal.
 The first patent for the briquetting of coal fines dates back to
the mid-1800s.

4. • Research and evaluate the binding and combustion properties
of various binders for coal fines
• Develop a process to integrate binder and produce robust coal
briquettes.
• Perform combustion testing to determine flame temperature,
emissions profiles, efficiency, and chemical kinetics of the
developed coal/binder product
Objective

5. Crucible swelling index (free swelling index)
 It is simplest test to evaluate whether a coal is suitable for
production of coke.
 After heating the coal, 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.
 Heating temperature:- 800 C
Before crushing After crushing into fines
Physical Properties of coal

6. Sulphur Content
 A known quantity of coal is heated with Eschka mixture (2 parts of
MgO and 1 part of anhydrous Na2CO3)
 Temp 800˚C.
 After burning amount of sulphur present in the mix is retained as
oxides and it is precipated as sulphates.The sulphate formed is
precipitated as BaSO4 (by treating with BaCl2).
 % of sulphur in coal = Where, weight of coal sample taken Weight
of BaSO4 precipitate formed xy 1374 .0100 x y
Density
 It depends on the rank of the coal
and mineral impurity present.

7. Calorific value
 The calorific value determines in part the value of coal as a fuel for
combustion application using bomb calorimeter.
Bomb Calorimeter BOMB
 Heat units in B. t. u. per pound of dry fuels
=14,600 C + 62,000(H - O/8) + 4000 S

8. Moisture Content
 It is used to find the percentage of water present in coal.
 Typical range is 0.5 to 10% Moisture
 Increases heat loss, due to evaporation and superheating of
vapour
 Helps to a limit in binding fines.
 Temperature:- 105-110 C
 Heating time:- 1 hour
 Sample size:- 60 mesh
 Quantity of sample:- 1 gram air dried coal
% moisture in coal = {loss in wt. of coal X 100}
wt. of coal initially taken

9. Volatile Matter
 Volatile matters are the methane, hydrocarbons, hydrogen and
carbon monoxide, and incombustible gases like carbon dioxide
found in coal.
 Increases flame length, and helps in easier ignition of coal.
 crucible with lid.
 Quantity of sample:- 1 gram air dried coal
 Sample size:- 60 mesh
 Temperature:- 900-925 C
 Heating time:- 7-10 minutes
 % volatile matter =
{ loss in wt. of moisture free coal X 100}
wt. of moisture free coal taken

10. Fixed carbon
 Fixed carbon is the solid fuel left in the furnace after volatile
matter is distilled off.
 Fixed carbon gives a rough estimate of heating value of coal.
 % fixed carbon in coal = 100-(% moisture+% ash+% volatile
matter)
Ash content
 It represents the bulk mineral matter
after carbon, oxygen, sulfur and water
has been driven off during combustion.
 Heating temperature:- 750-800 C
 Heating time:- 1 hour

11. Result of Coal Analysis
Properties Values
FSI 7.2
Density 1306kg/m3
Sulphur 0.59%
Moisture 8.4%
Volatile content 7.62%
Fixed carbon 74.27%
Ash content 9.7%
Calorific Value 6150 kcal/kg
Note-percentage by weight

12. Characteristics of good binder
1.Highly Coherence- By varying amount of binder & pressure.
2.Hardness and toughness-For better hardness high softening point
binders to be used.
3.Density- Range for density 1.1 to 1.4 & density is increased by
pressure.
4.Size and shape- Large cylindrical, hollow, polygonal, ball shaped
briquette materials are good.
5.Burning qualities-
• Readiness of ignition-Large briquette ignites readily than small
ones.
• Kind of flame-should burn with clean, intense flame without
odour or smoke

13.  Note-Organic briquette do not produce smoke.
6. Retention of shape-the binders must hold coal particles together
until they are sufficient soften to cohere.
7.Weathering- Dense briquette will stand better for long exposure than
porous.
8. Absorption-Should not absorb more than 3% of moisture.
9.Percentage of ash-It should be less & it depend on sum of contained
in slack & binder used.
 Note-Organic binders have less percentage of ash as
compared to inorganic.

14. Molasses Lignin Pitch
Dairy Sludge

15. Test for examination of binders
Determination of percentage of binder
The percentage of binder is always calculated on the weight of coal.
Determination of coherence
By adding small amount of water and coal & performing strength
tests on the coal.classified into following grades-
1. Very slight coherence 4. satisfactory
2. Slight coherence 5 .excellent, will stand rough
handling
3. Coherence but not satisfactory 6. Stronger than necessary
20gms of
coal mixed
with binder
& additive
Its then
heated &
stirred well
throughly
It should be
then
mechanically
pressed.

16. Material required in coal briquetting are-
Coal
 The slack taken as raw material should be thoroughly clean and should not
contain impurities. Its not uniform in size so for further process it is jaw
crushed.
 Additive
 In India coal contents high amount of sulphur & on combustion produces
CO2.
 It cause health & environmental problems.
 To overcome calcium carbonate is used to convert sulphur to sulphate.
Reactions Involved-
CaCO3 CaO + CO2
S + O2 SO2
SO2 + 1/2O2 SO3
CaO + SO3 CaSO4
 Binders
 It is used to bind fine particles physically. Various binder available are -
 Pitch • Dairy waste
 Lignosulphonate • Molasses

17. Methodology
The method of manufacturing of coal briquettes are
1. Briquetting with binding material.
2. Briquetting without binding material.
Briquetting with binder
 Compacted coal briquettes are taken out of moulds.
Make 8-10
mixtures of slack,
additive &
binders
Heat untill the
vapour forms &
pour into moulds
Mechanical press
is aplied for 2-3
min

18. Binder
Briquetted by
Mechanical
Press
Additive=CaCO
3
Coking Coal/
slack
0.3 mm
particle size
Mixed &
Milled
Dried
Briquettes
Processing with
different binders
4 sample coal
pieces will be
obtained for
analysis
Applying 2-5
tons of load

19. Mould Fabricated for mechanical Press

20. Advantages to coal briquetting
 Increase in heating value.
 Resistance to weathering
 Resistance to handling
 Efficiency of fuel
 Create less environmental as
compared to mineral coal.
 Spontaneous combustion &
wastage coal can effectively be
controlled.
 Our project give path to utilise
indigenous coal reserves without
polluting environment.

21. Techniques used to test briquettes
 Strength
The compressive strength is a good indication that sufficient binder is
being used, that the briquetting pressure is adequate and that post
curing treatment is being carried out correctly.
 Drop Shatter test
The Drop Shatter Test is an indication of how the agglomerate will
stand up to Handling , particularly dropping from a height.
 Tumbler Test
The Tumbler Test gives a measure of the Abrasion Resistance and
impact resistance of coke.

22.  Weathering
There is no standard to test for weathering, many producers simply
immerse the agglomerate in water for four hours and apply hand
pressure to see if disintegration takes place.
 Other Properties :
The normal quality parameters used to measure the quality of coal
and coke can be applied to agglomerates. Analysis for
1. Volatile Matter
2. Calorific Value
3. Sulphur
4. Ash content
Can be carried out using the appropriate standards without
modification

23. Progress Till Now
 Successfully completed testing and analysis of coal properties.
 Collection of all the binders to be used from various industries
waste-
Lignin-Paper industry
Molasses-Sugar industry
Slurry Waste-Dairy industry
Corn starch-Food industry
Pitch-Petroleum Industry
 Fabrication of the mould for mechanical press with load around 2-
4 tons. For compressing.
 Presently with properties of molasses started the briquetting
techniques.

24. Plan of Action
Time Part of Work to be Covered
By 15th March Production & processing of coking Coal using
different binders.
Mixing, Heating, Evaporation, Compressing,
cooling.
By 30th March Testing & Analysis of final briquetting coal
obtained.
-Proximate Analysis
-Moisture Test
-Calorific Value Test
By 20th April Analysis, Comparison of the data obtained &
final Result & Conclusion of the project.

25. Reference
 Komarek K.R Inc.-The briquetting Process.[1]
 New Application of Roller Pressure in Coal related Technologies
18th Int. Conf. Coal Utilization And fuel systems-Dr- Ing Pietsch
W.[2]
 Binders for Fuel Briquetting- A Critical Survey CSIRO, Technical
Communication-Waters PL.[3]
 Greenfields Develops New Techniques For Recovery Coal Fines-By
Steve Ficor
 Kela Energy- Orlando, FL
 Briquetting. (n.d.). Retrieved from
http://www.greenfieldscoal.com/briquetting.php
 Handled like coal, cost effective, increased preparation plant yield.
(n.d.). Retrieved from
http://www.kelaenergy.com/coalProducers.html
 A. Dilo Paul, Senior Scientist, Science Applications International
Corp.6th US-India Energy Dialogue,2009