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Abstract:

This document is a report for the project titled 'Particle Impact Erosion and Abrasion Wear - Predictive Methods and Remedial Measures'.

The overall objectives of the project can be listed as follows;

To select a suite of test coals that is representative of the range of ash contents and ash qualities normally encountered in steam coals worldwide, and to subject these coals to a programme of basic characterisation work using both conventional laboratory techniques and Computer Controlled Scanning Electron Microscopic (CCSEM) techniques.

To measure the rate of abrasive wear of coal mill grinding elements associated with the milling of these coals, using the Mini-mill Test Facility operated by Mitsui Babcock in Renfrew.

To measure the rate of erosive wear associated with the impact of pulverised coal particles made from these coals on a carbon steel target, under controlled conditions, using the Erosion Test Rig operated by Mitsui Babcock in Renfrew.

To measure the relative erosion resistance of a range of target materials, including a number of specialist coatings.

To develop correlations between the abrasion and erosion characteristics of the test coals and the ash characteristics of the coals, measured using CCSEM techniques.

This project involved a detailed investigation of the abrasion and erosion characteristics of a suite of pulverised coals, selected to represent the full range of coal quality encountered by boiler plant designers and operators worldwide, and of the relative erosion resistance of a range of materials. The principal objective of the abrasion and erosion work was to develop improved correlations between the abrasion and erosion behaviour of the coals and their basic characteristics, as measured using CCSEM techniques. The CCSEM techniques are relatively novel, and generate quantitative information about the chemical and microstructural characteristics of the pulverised coals, which is not available by any other technique.

The abrasion and erosion testwork and the CCSEM characterisation of the test coals have been very successful, and very good correlations have been developed between the measured abrasion and erosion rates and the volume percent of hard mineral particles above a certain size in the pulverised coals. These correlations are suitable for predictive purposes, and the work has resulted in the development of laboratory procedures suitable for the assessment of the abrasion and erosion behaviour of unfamiliar coals. This represents a very significant step forward in our understanding of the abrasion and erosion behaviour of coal particles.

The project also involved the measurement of the relative erosion resistance of a range of materials and coatings, relevant to the materials of construction of the components of coal milling and combustion equipment and of boiler plant.

This report is divided into the following sections:

Introduction
The Selection and Characterisation of the Test Coals
The Abrasive Wear of the Grinding Elements of Vertical Spindle, Ball and Race, Coal Mills
The Erosion Behaviour of Coal and Ash Particles and the Erosion Resistance of Materials
The SEM and CCSEM Analysis of the Raw and Pulverised Coal Samples
Correlating the CCSEM Pulverised Coal Data with the Abrasion and Erosion Properties of the Coals
Conclusions
Suggestions for Further Work
References

Publication Year:

2004

Publisher:

Department of Trade and Industry

DOI:

No DOI minted

Author(s):

Foster, DJ, Livingston, WR, Wells,J, Williamson, J, Gibb, WH & Bailey, D

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