Erick Mitchell Henrique Braga et al.
Metallurgy andMetalurgia
materials e materiais
Influence of moisture
and particle size on
http://dx.doi.org/10.1590/0370-44672018720006 coal blend bulk density
Erick Mitchell Henrique Braga1,5 Abstract
Guilherme Liziero Ruggio da Silva1,6
Rian Carlo Vieira Amaral1,7 Coal blend bulk density is an important property in the coking process. Some
Marina do Carmo Carias2,8 variables, such as moisture and particle size, which are controlled or measured in
http://orcid.org/0000-0003-1855-1284 the coal beneficiation process in steel mills, exert a strong influence on this feature.
Paulo Santos Assis3,9 This study aims to understand the density variation of coal blends by the influence of
Leandro Rocha Lemos4,10 moisture and particle size when using dry and wet bases. The investigations showed
that higher density can be reached when drying the coal blend or even with excess of
Gerdau Ouro Branco
1
moisture by an agglomeration process. However, for a coal blend of lower moisture
Ouro Branco - Minas Gerais - Brasil content, such as 4%, the better effects on the coking process are evident. Changes on
the density from particle size require care, since they can fall in a region of high density
2
Universidade Federal de Ouro Preto - UFOP, Rede achieved by larger particles or in a region with excess coal fines, where either or both
Temática em Engenharia de Materiais (REDEMAT), can compromise the coke quality.
Ouro Preto - Minas Gerais - Brasil.
Keywords: coal, bulk density, moisture, particle size.
3
Universidade Federal de Ouro Preto – UFOP,
Escola de Minas, Departamento de Engenharia
Metalúrgica, Ouro Preto - Minas Gerais - Brasil.
4
Universidade Federal de Minas Gerais – UFMG,
Escola de Engenharia, Departamento de
Engenharia Metalúrgica e Materiais,
Belo Horizonte - Minas Gerais – Brasil.
E-mails: [email protected],
6
[email protected],
7
[email protected],
8
[email protected], [email protected],
10
[email protected]
1. Introduction
Coke is the main fuel used in the mainly in terms of its strength (Drum density. However, variables such as mois-
blast furnace for hot metal production. Index and Coke Strength after Reaction) ture and coal particle size can also have a
An efficient operation of the blast furnace that will allow a steady operation of the strong influence on these operations.
is mainly linked to the coke quality that blast furnace and coke rate reduction. Sabadini et al. (2013) and Leeder et
depends on the coal blending used and the However, it is significant to consider the al. (2014) reported that the gain of oil ad-
coking process. impact of high density on the coking pres- dition on coal charge bulk density depends
Among the coal characterization sure of coal on the coke chamber walls and on the moisture content of the coal blend.
parameters, the coal charge bulk density the ability of the coke oven to support it. When the moisture content becomes ex-
is one of the most important properties, Coal pre-treatment processes, such cessively high (> 11%), the effect of oil has
which in the case of coke ovens, helps as preheating (Standish et al., 2011), no influence on the bulk density increase.
to determine the coal charge to be put stamping (Standish et al., 2011), dry It is important to note that when
into the oven with a specific volume. The charging (Masahiko et al., 2016), briquet- a coal blend of high moisture content is
increase in its value leads to a greater ting (Masahiko et al., 2016), and even, charged into the coke oven which has a
amount of charging, increasing coke pro- oil addition (Sabadini et al., 2013) and certain volume, this implies that for the
duction and contributing to an improve- mechanical vibration (Nascimento, 2016) same density, there will be less coal than
ment in its quality (Sabadini et al., 2013), are commonly employed to increase the expected, reducing productivity. In addi-
REM, Int. Eng. J., Ouro Preto, 72(2), 237-242, apr. jun. | 2019 237
Influence of moisture and particle size on coal blend bulk density
tion, variations in the moisture content the coking process and the final mechani- points (Silva et al, 2011).
of coal cause adverse effects on the stable cal strength of the coke (Ulhôa, 1988). On the other hand, reactive particles
operation of coke ovens, leading to an Silva et al. (2011) justifies the impor- of inferior size (< 0.15mm) lose their
increase in heat consumption and varia- tance of particle size distribution linked swelling and fluidity, and their excessive
tions on coke quality. Whereas, when the to the petrographic characterization. As generation leads to a decrease in coal
moisture overly declines, the amount of inert materials present in coals have higher charge bulk density. Consequently, the
dust during the transportation increases hardness and resistance to crushing, they contact effectiveness between the coal
and also the pulverized coal into the ascen- are concentrated within a higher size particles decreases, by effect, the mechani-
sion pipes (Wakuri et al., 1985). range, while the reactive macerals, the cal resistance of coke also decreases (Silva
When combining the influence of softer portion, present an antagonistic et al, 2011).
moisture and particle size on bulk density, behavior. Due to its infusibility and char- In view of this situation, the present
Elliott (1981) demonstrated in their work, acteristics mentioned previously, the exces- article intends to present and understand
which for the same moisture, bigger parti- sive presence of inerts become responsible the effect of moisture content and the
cles also have higher density. However, the for fracture and cracking areas in coke particle size variation of coal charge on
coal particle size and the greater constancy and, therefore, coal crushing becomes a bulk density, showing the results for wet
in its distribution become quite critical for fundamental operation to eliminate these and dry bases.
2. Materials and methods
2.1 Density determination by varying the moisture and grain size of the coal blend
A characteristic coal blend as two grain size fractions by ASTM below 2.83 mm and another with par-
shown in Table 1 was prepared, dried 7Mesh sieve. Thus, two base blends ticle size above this range (Figure 1).
at 105 °C for 2 hours and divided into were made: one with particle size
Coal type and pet coke in the Proximate Analysis (weight%) Petrographic (%)
blend (weight %)
High Volatile 22 Moisture 6.98
Reactives 69.29
Medium Volatile 54 Volatile Matter 25.72
Low Volatile 18 Ash 8.07
Reflectance 1.13
Pet coke 6 Other – Sulfur 0.84
Rheology
Maximum Fluidity Softening Maximum Solidification Contraction
(Log MF/ddpm) Temperature Temperature of Temperature (vol %)
(°C) Fluidity (°C) (°C)
2.71 403 455 487 -11.54
Ash Mineral Analysis (weight %)
Na2O K2O Al2O3 CaO MgO Fe2O3
0.58 1.69 26.90 1.95 0.84 7.29
MnO SiO2 TiO2 P2O5 ZnO
Table 1
0.04 54.81 1.42 0.62 0.02
Analysis of the coal blend used.
Coal blends were used to compose ranges for use in top-filling coking plants. entire container, the density of each blend
new blends with particle sizes 77, 79, From a known fixed volume container was determined (see Figure 1).
81, 83 and 85% below 2.83mm, typical and the weight of the blend which fills the
Figure 1
Determination method
of coal charge bulk density.
The samples were then homog- Thus, new densities were measured. following moisture levels: 5, 6, 7, 8,
enized in a rifle splitter adding water The procedure was repeated, homog- 9, 10, 12, 14 and 16%.
to achieve a moisture content of 4%. enizing and adding water, for the
238 REM, Int. Eng. J., Ouro Preto, 72(2), 237-242, apr. jun. | 2019
Erick Mitchell Henrique Braga et al.
3. Results
The density results for measure- size variation on a wet basis are pre- by discounting of moisture content in
ments at all moisture levels and grain sented in Table 2 and on a dry basis Table 3.
Bulk density (kg/m3)
Moisture
Particle size
< 2.83mm
4% 5% 6% 7% 8% 9% 10% 12% 14% 16%
85% 791 734 695 682 657 641 635 652 707 726
83% 828 765 725 698 669 662 665 684 739 771
81% 784 748 705 672 662 661 673 697 756 799
Table 2 79% 812 760 691 678 670 680 672 709 775 848
Coal blend bulk density for different mois- 77% 820 769 714 693 677 677 680 713 774 840
ture levels and particle size on wet basis.
Bulk density (kg/m3)
Moisture
Particle size
< 2.83mm
4% 5% 6% 7% 8% 9% 10% 12% 14% 16%
85% 759 698 653 634 605 583 571 574 608 610
83% 795 727 681 649 616 602 599 602 636 648
81% 753 711 663 625 609 602 605 613 650 671
79% 780 722 649 631 617 619 605 624 667 712
Table 3
Coal blend bulk density for different mois- 77% 788 730 672 644 623 616 612 627 666 705
ture levels and particle size on dry basis.
From these data, graphs were plotted grain size and moisture on a wet basis and
that elucidate the bulk density behavior by on a dry basis (Figure 2).
(a) (b)
Figure 2
Coal blend bulk density
for different moisture levels and particle size
on (a) wet basis and (b) dry basis.
4. Discussion
4.1 Behavior of results
The coal charge bulk density (BD) linear regression of blend bulk density tion coefficient (R²) equal to 92.1%
under study can be expressed by Equa- (Aiken, 1991; Tabachnick et al., 2011; (C ohen e t a l . , 2 013), where
tion 1, obtained from a multivariable Cohen et al., 2013) with a determina- M = moisture and PS = particle size.
BD =731+39146*M2+380*PS-9472*PS*M (1)
Using interacting plots, we come 4, where they can separately realize the blend bulk density for wet basis and even
to the results of the Figure 3 and Figure moisture and particle size impact on coal with an overlapping dry basis.
REM, Int. Eng. J., Ouro Preto, 72(2), 237-242, apr. jun. | 2019 239
Influence of moisture and particle size on coal blend bulk density
Figure 3
Interaction plot
(bulk density/particle size).
Figure 4
Interaction plot
(bulk density/moisture content).
Figure 4 shows the influence of coal charged in a coke oven. Although the wet and dry bases is higher, thus influenc-
charge moisture on bulk density, which density increases beyond 10%, the differ- ing the expected productivity that would
has a direct impact on the weight of the ence in the charge bulk density between be reduced.
4.2 Theories for obtained results
4.2.1 Effect of particle size on charge bulk density
When particles are divided, the total volume increases, justifying the results for distance of 25 cm is 0.2 mm, which means
surface area and the number of voids be- an excessive crushing at 85% < 2.83mm. that we do not realize that the empty space
tween the particles are increased (Figure The reason for misunderstanding: the increases when the particle size of the coal
5), reducing the density because the coal resolution limit of the human eye at a decreases.
Figure 5
Division effect of a particle
on its surface area and void formation.
Thus, the modification of density be a loss of fluidity, compromising the not be fully enveloped by reactive par-
due to particle size changes must be coke quality. While for a coarser grain ticles and depending on their size, they
careful since the reducing of particle size size, such as 77% < 2,83mm, it falls into will serve as cracking points reducing
for finer fractions up to 83%, there may a region where the inert particles will the coke quality too.
240 REM, Int. Eng. J., Ouro Preto, 72(2), 237-242, apr. jun. | 2019
Erick Mitchell Henrique Braga et al.
4.2.2 Effect of moisture on coal charge bulk density
The effect of the moisture on two effects, substitution and compac- both for high and low moisture levels
coal charge bulk density following a tion, that has a valley where the lowest (Figure 6).
U-shaped curve suffers the action of bulk density occurs, which goes up
Figure 6
Effect of moisture on
coal charge bulk density.
The bulk density initially decreases, In the second part of the graph, up to 4% is more interesting because the
since coal density is 1.4 g/cm3 and the the excess moisture causes coal particle density difference between its wet and dry
water density is 1g/cm3. Thereby, the sub- agglomeration forming pseudo-particles bases is lower; thus, the productivity of the
stitution of coal by water justifies the result (Kato et al., 2006). Therefore, there is coke oven is greatly increased, and the en-
found. This can also be explained by the a compaction effect that leads the space ergy consumption is reduced, since there is
fact that the water enables hydrophobic between the particles to decrease and the lower excess moisture to be removed. How-
coal particles to repulse each other, in- density to increase. ever, it is necessary to consider the effect of
creasing the free space and, consequently, In respect to the bulk density earning lower moisture on the increasing of carbon
decreasing the density. due to changes in moisture, drying of coals deposition into the coke oven chamber.
5. Conclusions
The coal blend bulk density for cok- region with excess of coal fines, where Due to coal blend burdening grain
ing processes can be adjusted by changes both can compromise the coke quality. size and moisture control, under the
on particle size, i.e., the coal crushing The drying of coal or even the excess economic and environmental point of
level, or even drying or humidifying the of moisture by an agglomeration process view, there is a rise of the bulk density
coal, that are easily manipulated in the can increase the bulk density. Neverthe- in cokemaking that is extremely impor-
coal beneficiation. less, coal blend with a moisture content tant, since it permits increase the coke
The modification of density in re- as low as 4% can present better benefits yield, reduces the heat consumption and
lation to the particle size requires care, on the productivity and during the coking produces a high-strength coke, thereby
since it can fall in a region of high density process; however, it needs attention with enabling an increase in the soft coal ratio
achieved by larger particles or even in a carbon deposition into the coke oven. of the blend.
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