Coal Sampling Slide Show Without Photos

COAL SAMPLING
Importance of Correct Sampling

Procedures
PT Sucofindo Coal Quality Training

Course, Surabaya, October 8 to 11 20
01
Outline
• Why take samples??

01
Outline
• Why take samples??
• To determine the quality of the bulk

material

01
Outline
• Aims of this topic to give and
understanding of
• Importance of sampling
• How to determine correct procedures
• Sampling problems and solutions

01
Fundamentals
• Correct sampling essential to produce
accurate results

01
Fundamentals
• Correct sampling essential to produce
accurate results
• Errors
– 80 % sampling
– 15% sample preparation
– 5% testing

01
Fundamentals
• Consider sampling a 5000 ton barge
• Say 500 kg is collected as the gross sample
• This means the gross sample is 0.01 %

relative by mass to bulk material

01
Fundamentals
• The gross sample is prepared and divided to
obtain 100 g of laboratory sample
• This means the laboratory sample is 0.02 %

relative by mass to gross sample

01
Fundamentals
• 2 x 1 g test samples are tested for ash
content
• This is 2 % relative by mass of the

laboratory sample

01
Fundamentals
• The 2 g test samples are said to represent
5000 tons of coal
• The test sample is 0.00000004 % relative

by mass to the material sampled

01
Fundamentals
• Coal is one of the most difficult bulk
materials to sample correctly
• Coal is heterogeneous and composed of

particles ranging from 50mm to 0.0001mm
• Each particle has different properties

01
Fundamentals
• Factors influencing sampling
– Quality Variability of Material

01
Fundamentals
– Top Size of Material

01
Fundamentals
– Sampling Precision

01
Fundamentals
– Quantity of Material

01
Fundamentals
– Sampling Method

01
Fundamentals
– Sampling Method
– Sampling Location

01
Fundamentals
– Sampling Method
– Sampling Location
– Desired Testing Parameters
01
Terms
• Lot
– Consignment of coal to be sampled
– Examples are vessel, barge, truck and shift

production

01
Terms
• Increment
– Material collected by single sampling action

01
Terms
• Gross sample
– Sample resulting from combination of the

increments

01
Terms
• Sampling unit
– Smaller portion of lot

– Also known as sub-lot
– E.g Vessel is lot and barge is sub-lot

01
Precision and Accuracy
• Precision - Closeness of agreement between results
• Precise and Accurate Precise and Inaccurate
• Imprecise and Accurate Imprecise and Inaccurate
• Precision measures the agreement between results.
• Accuracy is the closeness of a result to the true value.

01
Precision and Accuracy
• Precision - Closeness of agreement between results
• Accuracy - Closeness of agreement between result and true value
• Precise and Accurate Precise and Inaccurate
• Imprecise and Accurate Imprecise and Inaccurate
• Precision measures the agreement between results.
• Accuracy is the closeness of a result to the true value.

01
Quality Variance
• Coal is a
Heterogeneous
Substance

01
Quality Variance
• Coal is a
Heterogeneous
Substance
• Quality differs
between all particles

01
Quality Variance
• Coal is a • Sample properties
Heterogeneous must reflect bulk
Substance material properties
• Quality differs
between all particles

01
Size Ash Index
• Measure of ash
variation between size
fractions

01
Size Ash Index
• Measure of ash • Can be determined for
variation between size other parameters e.g
fractions sulphur

01
Size Ash Index
fractions sulphur
• Is a measure of
difficulty of sampling

01
Size Ash Index
fractions sulphur
• Is a measure of • Must be used in

difficulty of sampling conjunction with
quality variance

01
Quality Variance
• Depends on coal characteristics

01
Quality Variance
– Type

01
Quality Variance
– Type
– Processing

01
Quality Variance
– Type
– Processing
– Handling

01
Quality Variance
• High Variance - More Increments

01
Quality Variance
• High Variance - More Increments
• Low Variance - Less Increments

01
Top Size
• Larger Top Size - Larger Sample Mass

01
Minimum Mass of Sample
• Depends on top size
• Refer to standard methods

01
Minimum Mass of Increment
• Depends on top size
• Refer to standard methods

01
Sampling Precision
• Precision depends on:

01
Sampling Precision
– Primary increment variance

01
Sampling Precision
– Preparation and testing variance

01
Sampling Precision
– Number of primary increments

01
Sampling Precision
– Number of primary increments
– Number of sampling units (sub-lots)

01
Sampling Precision
• Desired precision is usually set as:
– 0.2% up to 10% ash
– 2% relative above 10% ash

01
Sampling Precision
• Can be increased by:
– Increasing number of primary increments

01
Sampling Precision
• Can be increased by:
– Increasing number of primary increments
– Increasing number of sampling units (sub-lots)

01
Number of Increments
• Standard methods now require calculation
of number of increments

01
• Standard methods now require calculation
of number of increments
• Calculated from desired precision, sampling

variance, preparation and testing variance
and number of units

01
• This method ensures the correct number of
increments are taken for each particular
coal

01
Sampling Lot
• Lot is the consignment of coal
• Examples
– Vessel, barge, truck, shift production, exposed
seam

01
Sampling Unit
• The lot can be divided into smaller portions
called sampling units
• Also called sub-lots
• Example
• 60 000 ton vessel is the lot
• Each barge is sampled as a unit

01
Stopped Belt Sampling
• Manual
• Sample collected from laden stopped belt
• Reference method for bias testing
• Impracticable for routine use

01
Stockpile Sampling
• Manual
• Performed when building or breaking down

a stockpile
• If sample taken from formed stockpile

cannot be considered representative
01
Truck or Wagon
• Manual or Mechanical (auger)
• Sample must be taken from entire cross

section
• If taken from top only cannot be considered

representative
01
Barge or Vessel
• Sampling from barge or vessel hold is not
recommended
• Unsafe and unrepresentative

01
Channel Sampling
• Manual
• Collection of sample from exposed seam
• In pit quality control

01
Falling Stream
• Manual
• Collect from cross section of coal stream

using ladle
• Manual sampling recommended up to 200

tph only
01
Moving Belt
• Manual
• Not recommended
• High chance of bias

01
Limitations of Manual Sampling
• Operator dependant
• If done incorrectly prone to bias
• Valid up to 200 tph
• Safety of operator is prime concern

01
Mechanical Sampling
• Only option at high flow rates
• > 200 tph

01
Mechanical Samplers Design
• Must be free of significant bias
• Designed for highest expected flow rate
• Capacity to retain entire increment
• Self clearing
• Minimise size degradation
• Minimise moisture loss
• No contamination
01
Falling Stream Sampler
• Constant velocity through coal stream
• Diverter chute type

• Bucket type
• Swing arm type

01
Cross Belt Sampler
• Constant velocity through coal stream
• Collects entire cross section from belt
• Perpendicular to belt
• Angled to belt

01
Cross Belt Sampler
• Schematic diagram of
cross belt sampler

01
Primary Sample
• Treatment is important to retain sample
integrity
• Mechanically collected samples are higher

mass
• Need to consider on line preparation

01
On Line Preparation
• Secondary Sampling System
• Belt feeder
• Crusher
• Secondary Sampler
• Sample Collector
• Rejects returned to main belt
01
On Line Preparation
• Can have tertiary sampler
• Depends on primary sample mass
• And secondary sample division ratio

01
Bias Testing
• All mechanical sampling equipment must
be bias tested
• Compare actual bias to tolerable limit

01
Bias Testing
• Stopped belt sample is reference sample
• Mechanical sample is comparison sample
• Minimum 30 pairs of samples

01
Maintenance of Sampling
Equipment
• Essential to perform routine preventative
maintenance
• Sampling equipment is part of plant capital

01
Sampling Scheme
• Safety

01
Sampling Scheme
• Safety
• Representative

01
Sampling Scheme
• Safety
• Representative
• Sampling Method

01
Sampling Scheme
• Safety
• Representative
• Sampling Method
• Access to Sampling Location

01
Sampling Scheme
• Safety
• Representative
• Sampling Method
• Instructions to Operators

01
Sampling Scheme
• Safety
• Representative
• Sampling Method
• Supervision

01
Sampling Scheme
• Safety
• Representative
• Sampling Method
• Supervision
• Sample Security and delivery to Laboratory
01
Common Problems
• Size Bias

01
Common Problems
• Size Bias
• Moisture Loss or Contamination

01
Common Problems
• Size Bias
• Moisture Loss or Contamination
• Contamination

01
Implications of Incorrect
Sampling
• Incorrect results means incorrect quality
control

01
Sampling
control
• This means potential losses

01
Sampling
control
• This means potential losses
• Financial and Resource

01
Why invest in proper sampling
equipment
• A complete sampling system will cost around
250 000 US Dollars. A cross belt sampler
would cost around 30000 US dollars.
• Management may consider this a high

investment compared to using an operator
with a scoop collecting samples

01
equipment
• However you must consider potential
financial losses arising from out of
specification product coal

01
equipment
• Consider quality specification
• Ash maximum 5.0 % air dried
• Penalties apply over 5.0 % at the rate of

0.50 US$ per ton per 1.0% pro rata

01
equipment
• If the shipment result is ash 6.0 % air dried
• The penalty for a 60 000 ton vessel is

30000 US Dollars

01
equipment
• If the out of specification product arises from
incorrect sampling thus quality control
• The penalty of 30000 US Dollars pays for a

cross belt sampler
• You must also consider the cost of loss of

customer confidence in your product
01
equipment
• The coal end user faces the same situation
controlling coal feed quality
• What is the impact on incorrect quality on

the process

01
Conclusion
• Sampling must be done correctly to achieve
meaningful results
• Correct sampling is not difficult if you

follow the standard procedures and have
knowledge of the coal quality variance and
sampling preparation and testing variance

01
Conclusion
• Correct sampling means more accurate
quality control
• Thus coal quality more likely to be in

specification

01
Conclusion
• Correct sampling means less disputes over
quality differences between load and
discharge port
• And seller, buyer/user satisfied with product

01

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COAL SAMPLING

Importance of Correct Sampling

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

• To determine the quality of the bulk

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

• Say 500 kg is collected as the gross sample

• This means the gross sample is 0.01 %

PT Sucofindo Coal Quality Training

• This means the laboratory sample is 0.02 %

PT Sucofindo Coal Quality Training

• This is 2 % relative by mass of the

PT Sucofindo Coal Quality Training

• The test sample is 0.00000004 % relative

PT Sucofindo Coal Quality Training

• Coal is heterogeneous and composed of

• Each particle has different properties

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

– Consignment of coal to be sampled

– Examples are vessel, barge, truck and shift

PT Sucofindo Coal Quality Training

– Material collected by single sampling action

PT Sucofindo Coal Quality Training

– Sample resulting from combination of the

PT Sucofindo Coal Quality Training

– Smaller portion of lot

– E.g Vessel is lot and barge is sub-lot

PT Sucofindo Coal Quality Training

• Precise and Accurate Precise and Inaccurate

• Imprecise and Accurate Imprecise and Inaccurate

• Precision measures the agreement between results.

• Accuracy is the closeness of a result to the true value.

PT Sucofindo Coal Quality Training

• Accuracy - Closeness of agreement between result and true value

• Precise and Accurate Precise and Inaccurate

• Imprecise and Accurate Imprecise and Inaccurate

• Precision measures the agreement between results.

• Accuracy is the closeness of a result to the true value.

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

• Is a measure of • Must be used in

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training

PT Sucofindo Coal Quality Training