University of Engineering and Technology, Lahore.

May, 2015

Department of Mining Engineering

Report on the Coal Analysis of Batala Steel Industry

Group:
Fahad Akbar 2012-min-06
Umer Ishtiaq 2012-min-11
Abdul Basit 2012-min-26
Muhammad Hammad 2012-min-38

Instructor:
Engn’r. Muhammad Shahzad
May 8, 2015

This report is prepared by the mining students of University of Engineering and technology,
Lahore, Pakistan under the department of mining engineering. The views presented in this report
are not compulsory to be match 100% with the company data, due to security reasons. But we as
presenters tried well to describe detail information. It is just our effort to know about our
particular field in the application of Practical area.

Contacts:

This report is prepared by Mining students (12 Session). General information about the data in
this report can be obtained from:

 Muhammad Fahad Akbar (fahadakbar43@gmail.com)

 Umer Ishtiaq (umerishtiaq11@gmail.com)
 Muhammad Hammad
 Abdul Basit
Preface:

The data presented in this report is acquired from Batala group of Industries. The data presented
is just related to study and collected by the proper approval of the Company’s board of directors.
The main goal to do such an effort is just to have information about usage of coal in industry and
submitted to our Professor as an assignment. We are not intimating the company’s data and just
providing as to meet our subject’s requirement.

The data worked only for current 2015. We are not responsible if the data vary in the further
years.

As Company may tend to vary their data as per required.

Contents:

Company profile…………………………………………………………………….2

Supervisions………………………………………………………………………….2

Coal type……………………………………………………………………………..2

Afghani Coal………………………………………………………………………....3

South African Coal…………………………………………………………………..3

Indonesian Coal……………………………………………………………………...3

Present situation……………………………………………………………………...4

Blended Form of Coal……………………………………………………………….4

Import of Coal……………………………………………………………………….5

Production and operation in Industry……………………………………………….6

Problem they faced…………………………………………………………………..7

Solution provided by us……………………………………………………………...7

Conclusion…………………………………………………………………………....8

Comments…………………………………………………………………………....8
Company Profile:

Batala Steel is the oldest name in steel making. They are in the steel business for over a century.
Their first beginning was with the manufacturing of T-irons and Girders at Badami Bagh Lahore
Pakistan. Then afterward they shifted their work at the Bund road, Shadipura Lahore Pakistan.
Then, they started manufacturing Steel billets with the exception of T-irons and Girders. But due
to new variety of products and changing behavior of market demand them to produce new
products. Hence with the passage of time they starts to expand their work and now are in
business of making many products of steel like Carbon steel (high, medium, low) and Alloy steel
as well.

Supervisions:

Engn’r Muhammad Arsalan: He is an Electrical engineer from University of Lahore and

worked for Batala Industries in the Coal Department.

Engn’r Rizwan: He is an Metallurgical engineer from University of Engineering and

Technology, Lahore from 2008 batch. He manages metallurgical department.

Coal Type:

In the Batala group of industries combination of different types of coal used. They actually using
coal of three types obtained from different locations.

 Afghanistan Coal.
 South African Coal.
 Indonesian Coal.

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Afghanistan Coal:

The type of coal present in Afghanistan is of sub-bituminous. The quality of coal they required
for their production is not to as standard. Hence Afghani Coal is used with the combination of
other coal. The following data gave the properties of Afghan Coal:

Coal Afghani
Coal Type: Sub-Bituminous
Gross Calorific Value (GCV): 6200 kcal/kg
Moisture Content (MC): 15%
Ash: 16%
Ash Fusion Temperature (AFT): 1350o C
Volatile Matter (VM): 40%
Sulfur: < 1%
Afghani coal Part (Combination with other): 1 unit. (9.10%)

South African Coal:

This coal imported from the South Africa directly to Karachi through the Port. Different dealers
buy this coal which is then provided to different industries. Awan traders are most famous
dealers of coal which provides coal to the industry. South African Coal used by Batala Industry
has the following features:

Coal South African

Coal Type: Bituminous
Gross Calorific Value (GCV): 6000 kcal/kg
Moisture Content (MC): 14%
Ash: 13%
Volatile Matter (VM): 25%
Sulfur: Maximum 1%
South African coal Part (Combination with other): 5 units. (45.45%)

Indonesian Coal:

The most favorable coal is imported from Indonesia and is of good quality than the others two.
Following are properties which reveal the quality of this coal:

Coal Indonesian
Coal Type: Bituminous
Gross Calorific Value (GCV): 6900 kcal/kg
Moisture Content (MC): 12%
Ash: 12%
Sulfur: Maximum 1%
Indonesian coal Part (Combination with other): 5 units. (45.45%)

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Present Situation:

Currently, there is no operation perform in the Batala group of industries to improve the coal
quality which they were imported from the different locations. But what they are doing is that
mix coal of three different types to form such a mixture to meet with their coking requirement.

Afghani Coal Indonesian coal South African coal

9%

45%

46%

Blended Coal Mixture properties (Currently in operation):

Coal Afghani+ S.A + Indonesian

Coal Type: Good quality (blended)
Gross Calorific Value (GCV): 6500 Kcal/kg
Moisture Content (MC): 3-4.5%
Ash: 11%
Ash Fusion Temperature (AFT): 1450oC
Volatile Matter (VM): 23-24%
Sulfur: < 1%
Size of coal: 25-50 mm

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Import of coal:

This has been already described that they used coal of Indonesia, South Africa and little amount
blended with the Afghanistan coal. But they got this coal not directly from these locations, but
from suppliers through Karachi. AWAN traders are big buyer of coal from those and other
countries through shipping of Karachi Port. While it is further sell to different industries. Batala
group industries bought coal at the following rate:

Afghani Coal: 14,000/ ton

Indonesian coal: 25,000/ton

South African Coal: 21,000/ton

Note: Price is in Pak Rs.

Production:

The company has big storage of coal. Numerically they have 500-600 tons of coal every time
stored. This coal is further used in the production of steel. The coal storage plant is away from
the gasifier plant where it is burnt. The coal is taken to the plant in the form of hand car. Batala
steel industry woks for 24 hours and their production is 225 ton/day. And the total coal used per
day to prepare 225 ton of steel is only about 26 tons. But this value is average. Not every day the
same amount of coal is used, this figure may vary due to changing conditions. As sometimes loss
may occur or choking occurs in the gasifier plant and it may not be able to perform efficiently,
hence labor and time both required for the proper functioning. The production of steel also may
vary.

Operation at industry:

There is a gasifier plant in the industry used to burn the coal. Batala has very large plant. It is
3.2 m long.

The coal is taken into the gasifier plant using hand cars and then transferred to the plant. The
figure shows the plant setup:

For burning of coal to produce heat a cage is installed to transfer the coal on the top of the
gasifier which is transferred into a bunker. Two bunkers are there from which one of the bunkers
is used to store the feed of coal while the next one is attached to the furnace used for burning.

A feed of 250-300kg is dropped into the furnace for burning. When the coal is dropped into the
furnace, a blower is used to provide steam, through the holes present in the machine, to control
the fire produced by the fire grade. This blower is also used to manage the smoke produced by
the fire.

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 The temperature of steam provided by the blower is 4440 C and saturation temperature of the
steam is 1150 C. The plant seems to produce high heating value as the temperature of the furnace
in shut down condition was analyzed to be 2500C.

During burning of the coal mineral matter is left known as ash. Ash is collected through ratchet
which is rotated by the hydraulic jacks. Plates are attached to the ratchet and ash is collected in
those plates during the rotation of ratchet. A trolley of ash is produced on daily basis when the
plant is operated continuously whole day.

The whole procedure of burning coal in an gasifier is controlled by a panel that is located in a
room and a technical person is there to operate all the functions. Following figure shows the
panel:

Operating Panel Gasifier

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Working hours:

Factory is running for 24 hours.

Plant works for 10 hours.

Problems they faced:

1. Moisture:

The amount of moisture in the blended coal they used there is relatively high. Moisture content
increases up to specific values due to many reasons, and it is necessary to lessen the moisture
value to have good heating value.

2. Size:

The size of coal they are using in the gasifier is of 25-50 mm. This is size as they received coal
directly from the supplier; they are not doing any such operation to reduce the size.

Solution we provided:

As an undergraduate students and learner under the supervision of Engn’r Muhammad Shahzad
we provide them the following solutions:

Solution to problem 1:

As there in the site we noticed that the storage area of coal is directly exposed to air and there is
not as such shelter as the coal requires. Hence the rain water may affect the coal due to which
quality may also reduce. Hence we tell them to arrange a proper shelter for the area where coal is
stored and avoid coal to expose with water as much as possible.

Solution to problem 2:

The size on which they burning their coal is usually high, and as We all are aware from the fact
that the burning of coal can be made effective if its size is very small. Their size range is
25-50 mm and if it is converted to pulverized form, surface area increases and burning worked
more effectively.

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Conclusion:

The work principle on which they are currently operated their mill is also very good. But they
can save more cost usage of coal. The proper removal of moisture and small size range can be
better operated the whole mill. Furthermore this will also enhance the life of smelter plant.

Comments:

The whole tour to survey the industry gives us many new things, a lot of knowledge, practical
application of relative field, awareness to operational work and many more. The tour for us
proves to be very beneficial and we learned so many things.

At the end we thanked to our Instructor MUHAMMAD SHAHZAD, who gave us this chance to
do something practically and convert this knowledge to description. This also learns the way to
present and write an idea.

References:

BATALA Group of Industries