Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Contents lists available at ScienceDirect

Case Studies in Chemical and Environmental Engineering

journal homepage: www.sciencedirect.com/journal/case-studies-in-chemical-
and-environmental-engineering

Case Report

Computational Fluid Dynamics (CFD) investigation on associated effect of

classifier blades lengths and opening angles on coal classification efficiency
in coal pulverizer
Firas Basim Ismail a, *, Nizar F.O. Al-Muhsen b, Hasril Hasini a, Elaine Why Siew Kuan c
a
Power Generation Unit, Institute of Power Engineering, Universiti Tenaga Nasional (UNITEN), 43000, Kajang, Selangor, Malaysia
b
Technical Instructor Training Institute, Middle Technical University, Baghdad, Iraq
c
College of Graduate Studies (COGS), Universiti Tenaga Nasional (UNITEN), 43000, Kajang, Selangor, Malaysia

A R T I C L E I N F O A B S T R A C T

Keywords: In order to achieve complete combustion of fuel in common thermal power plant, the process of coal fuel
Coal pulverizer classifier classification is crucial, which often governs by classifier in pulverizer. This is because smaller size of coal
Classifier blade length particle has higher surface area, and therefore able to produce higher combustion efficiency. This paper describes
CFD
the Computational Fluid Dynamics (CFD) simulations of coal pulverizer were done for classifier with different
Tromp curve
Energy
blade length and at different opening angle. The objective of the work is to evaluate optimum classifier design
with the highest coal fineness output and separation efficiencies. Preliminary work of validating simulation result
with experimental result of classifier with initial geometry was done, and good agreement was obtained. Grade
efficiencies and sharpness of cut of each different classifier model were determined by plotting of Tromp curves.
Simulation studies showed that classifier blade length of 313.94 mm at 40◦ was found to be optimum, with
71.5% of particles passing fine size sieve (75 μm) and 0.1852 sharpness of cut. Classification of fine coal by the
optimum classifier model is improved by 10%, as compared to original classifier model used in industry.

1. Introduction Classification of coal is crucial in thermal power plant; as finer coal

particle will provide higher rate of combustion maintaining efficient
In common thermal power plant, coal is processed as fuel through operation of the boiler. This is due to the fact that finer particle has
pulverization and classification. After the desired size of coal particle is larger surface area than coarse particle, and thus increase higher reac­
classified, it will then mix with hot air to be combusted, forming fireball tion of volatile matter and air [4–7]. As the combustion rate is increased
for steam generation in boiler [1]. In Malaysia, the coal-fired power with adequate coal fine particle size in the furnace, heat will be trans­
plant is usually known as the base load power plant, as it can consis­ ferred in uniform temperature to water in the boiler pipe. Hence, such
tently generate a huge amount of electrical power. In this research, the phenomenon reduces furnace exit gas temperature, slagging formation,
generating facility of an ultra-supercritical boiler with 1000 MW power water loss in superheating process, and amount of unburned carbon in
generation is focused on [2]. Before the coal is burned, it is pulverized in fly and bottom ash [8]. This also reduces waste emissions of nitrogen
a pulverizer and classified into fine powder. Only those coal particles of oxide (NOx) and carbon dioxide (CO2), which is a need in developing a
the desired size are able to pass through, while the oversized coal par­ low NOx burner for current technology of coal pulverizer [9,10].
ticles will fall back onto the grinding table. The classified coal is then To attain maximum combustion efficiency in boilers, a minimal
mixed with hot air and combusted, in the boiler in order to generate amount of coarse particle distribution at the burner should be achieved.
heat, which is used to vaporize the demineralised water pumped into the Therefore, classification of coal dust is crucial in increasing fuel reac­
boiler. The generated steam is then channelled into the turbine for tivity, by manipulating particle sizes within limits [11–13]. Research
power generation via the kinetic energy produced from the turbine work on classifier efficiency manipulated by vane settings was done by
rotation. The temperature and pressure of the steam can reach up to 538 Shah et al. [14] using CFD modelling. The study concluded that classifier
ᵒC and 24,000 kPa respectively [3]. efficiency decreased linearly with the closing of vane, while pressure

* Corresponding author.
E-mail address: [email protected] (F.B. Ismail).

https://doi.org/10.1016/j.cscee.2022.100266
Received 12 August 2022; Received in revised form 18 October 2022; Accepted 18 October 2022
Available online 28 October 2022
2666-0164/© 2022 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Fig. 1. Schematic diagram of coal pulverizer model: (a) pulverizer components; and (b) coal processing flow in pulverizer.

drop increased. Optimum vane opening of 65% was defined and showed to improve classifier classification efficiency, by increasing classifier
closest uniformity of particle distribution at classifier outlet. In subse­ grade efficiency and sharpness of cut.
quent year, modification of classifier design was also done by Huang According to the presented review for the previous studies, CFD in­
et al. [15], Ren et al. [16] and Wu et al. [17], which they proposed the vestigations for the combined effect of the blade angle and length on the
classifier design with positively bowed guide blades, non-radial arc classification efficiency of an actual coal power plant classifier have
blade and double layer spreading plate respectively. Such blade designs rarely been conducted. In this work, a numerical investigation using the
were simulated and proved to be able to produce smaller particle cut numerical software of Ansys Fluent version 16.0 was conducted based
size, and higher classifier inlet was also made by Atas et al. [18] with on actual input data from a coal-fired power plant. The influences of the
application of numerical simulation and experimental validation. Their coal classifier blades’ opening angles and blades lengths on the coal
findings explained that classification of smaller coal sizes can be classification efficiency were numerically investigated. A new classifier
improved, by placing a plate to reduce classifier inlet which caused model was proposed and experimentally validated, which is aiming to
increment in inlet gas velocity. Besides investigation of classifier design, enhance the coal fineness quality and coal separation efficiency. Tromp
analysis of other parameter such as classifier rotor speed was also done curves were plotted in order to determine the grade efficiency and
by Thomas et al. [19] and Blondeau et al. [20]. According to their sharpness of the cut for the proposed model.
findings, cut size of particle increased when rotor speed increased at
specified inlet air velocity, which eventually improved the particle dis­ 2. Pulverizer overview
tribution. Afolabi et al. [21] and Li et al. [22] had also studied the
relation between air flow rate and particle classification in a classifier. In this section, an overview of the typical design of a vertical roller
Their studies stated that classifier efficiency increased linearly as air coal pulverizer is analysed and discussed. A schematic diagram of the
flow rate in classifier increased. used coal pulverizer is shown in Fig. 1. Typically, in the conventional
Past literature concluded that parameters such as air rates, classifier coal fineness processing, the raw coal is firstly fed into a rotating bowl
rotor speed, and classifier geometry highly affected the coal particle size hub via a centre feed pipe. The rate of coal feed is normally determined
distribution, leading to changes in boiler combustion efficiency. Huang automatically by combustion control system, by considering the end-
Q. et al. [23] numerically investigated the effect of the straight guide user electrical power (kW or MW) demand on the unit, coal quality,
blade structure aiming to enhance the classification precision of a turbo and the number of pulverizes in operation. The rotating bowl hub will
air classifier. Under selected operating conditions comprising rotation generate centrifugal force, and causes the coal in the bowl to move
speeds of 600 and 1200 r/min and air inlet velocity of 20 m/s, an radially outward, building up a bed of coal on the grinding ring. The bed
important improvement was gained in the classification efficiency for of coal is then passed under pivoted grinding assemblies known as rol­
the proposed model. An important improvement in classification effi­ lers. Size reduction of coal is performed, as spring of rollers creates loads
ciency was claimed from a new rotor cage design that was proposed and imparted to the coal. Such crushing phenomenon at localized area
[16]. The investigation was numerically performed under standard between the grinding rings are commonly known as attrition or friction
operating conditions of the rotary speed of 12 m/sec and inlet air flow grinding. The pulverized coal is then carried upward over the edge of the
rate of 12 m/sec. Another technique of double-layer spreading plate was bowl into the path of hot air stream, by the radial and circumferential
theoretically investigated aiming to reduce the possibility of classified movement of the ground coal. Moreover, according to the actual coal
particles aggregation and collision [17]. An improvement of separation classifier that is adopted in the CFD modelling of this study, there were
by about 52% was achieved under stable operating conditions of 12 eight units of pulverizer existing at the referred boiler unit, but only
m/sec inlet flow rate and 1200 rpm rotational speed. On the other side, seven units of pulverizer were operating, as pulverizer namely “A" was
in this work, acquired actual data from a coal-fired power plant station on standby mode. The sampling mass of 50.0 g was used for all coal
in Malaysia, a coal feeding rate of 13.5 kg/sec and an inlet air flow rate fineness tests. Coal fineness above 300 μm was categorized as coarse,
of 16 m/sec, were used in model validation and the CFD analysis. To the while coal fineness below 75 μm was categorized as fine coal powder. All
authors’ knowledge, under the aforementioned operating conditions, no pulverizers were able to classify more than 50% of fine coal. On the
research is performed to investigate the classifier blade length effect on other side, pulverizer namely “B" had the highest coal fineness result of
coal particle distribution in coal pulverizers. Hence, this work attempts 77.78%, and Pulverizer D had the lowest coal fineness result of 51.96%.

2
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Fig. 2. Top view of classifier at different opening angle: (a) 40◦ ; (b) 50◦ ; (c) 75◦ ; (d) 90◦ .

Hot air provided by the primary air fans is supplied to the pulverizer, set at positive pressure. Therefore, air flows upward around the outside
in order to dry the coal, transport recirculating coal within the mill and diameter of the rotating bowl hub from the mill side. At the edge of the
from pulverizer to furnace. The air is admitted from below the pulverizer bowl, smaller or lighter particles of coal are swept from the bowl by hot
bowl, and into an area known as mill side and air inlet, which is typical air, while dense and difficult-to-grind foreign material is rejected

Fig. 3. Top view of classifier with different blade length in millimetre (mm):(a) 110.74; (b) 212.34; (c) 313.94; (d) 415.54.

3
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Fig. 4. (a) Boundary condition for simulation model. (b) Coal pulverizer model with dimensions annotated in millimetre (mm). (c) Air velocity magnitude plot for
grid independence test.

downward through air stream into the mill side. Lastly, the fine coal 2.1.2. Model development
particle in primary air stream is distributed directly to the coal outlet Numerical simulation of coal pulverizer comprises numerous asso­
pipes for subsequent combustion process in boiler furnace. To achieve ciated phenomena that need to be considered in order to overtaking the
optimum plant efficiency, a regular classifier is required to classify 70% difficulties for this CFD modelling [25]. To simulate the classification
of coal particle passing 200 mesh screen (75 μm), and less than 1.0% process of ground coal inside the coal pulverizer, crucial geometric pa­
retained on 50 mesh screen (297 μm) [24]. Therefore, classifier plays an rameters should be included in the developed model such as the blade
important role in controlling coal particle size and its distribution in length and angle. In this study, the coal classifier was developed by using
attaining an optimal combustion performance and efficiency. Creo Parametric 3D modelling software. Moreover, a set of numerical
models for the primary air flow, raw and pulverized coal directions, coal
2.1. Methodology inlet and outlet of the classifier and classified coal direction (collection
zone). The classifier was modelled in four blade lengths of 110.74 mm
2.1.1. Actual data acquisition (original length used in industry), 212.34 mm, 313.94 mm and 415.54
In order to attain reliable and accurate results, an actual data was mm. Moreover, at each modelled blade length, four opening angles of
acquisitioned and adopted for the conducted numerical simulation of 40◦ , 50◦ , 75◦ , and 90◦ were set. Hence, 16 classifiers models for the
this study. The experimental data of pulverized coal fineness were ac­ developed classifier geometry were numerically performed for this
quired from coal fineness test, which was performed at 1000 MW ultra- research. It was expected that extending the blade length, and the
super critical boiler unit of coal-fired power plant in Malaysia. The closing angle of blade to smaller angle, will cause higher output of coal
pulverizer was operating at coal feeding rate of 47,231 kg/hr. Firstly, fineness. This is due to the fact that, the longer blade length and smaller
the sample of pulverized coal was collected at the outlet channel of the opening angle could generate more swirls that reject greater amount of
adopted pulverizer, as shown in Fig. 1. Next, the collected sample of coarse coal particles [26]. Therefore, fuel distribution at the outlet could
pulverized coal was sieved by using sieves with sizes of 300, 212, 150, be potentially improved. Such extension of classifier blade length is also
75 and 45 μm. presumed to improve fuel fineness distribution between 5.0% and 15%
of coal particle passing 75 μm sieve.

4
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Fig. 5. 3D view of pulverizer model CFD grid: (a) full view; (b) cross-sectional view.

In this study, the geometric modelling of the coal pulverizer was

Table 1
simplified, and only critical parts were considered such as the air inlet,
Parameters used in CFD simulation.
coal outlet, classifier and bowl hub. Such simplification was made in
order to minimize computational cost in terms of hardware and pro­ Input Parameter
cessing time. It was also anticipated that the absence of minor parts in Particle injection type Surface
the flow domain would not affect the prediction of coal fineness exiting Material Coal-hv
the classifier. The overview of coal pulverizer dimension is shown in Distribution type Rosin-Rammler
Particle flow rate 13.5 kg/s
Fig. 4b. In general, common industrial pulverizer has height and width Particle minimum diameter 25 μm
of 5700 mm and 3505 mm respectively. The coal inlet chute is located at Particle maximum diameter 300 μm
the centre of classifier with inlet diameter of 456 mm. The average Particle mean diameter 75 μm
height of a classifier is 1054 mm. Several geometries of the adopted Spread parameter 3.5
Primary air flow rate 27.0 kg/s
classifier model with different opening angle and blade length are shown
Gravity - 9.81 m/s2
in Figs. 2 and 3. In this work, the effect of blade angle and blade length
towards particle distribution at outlet as result of coal fineness was
investigated. The overall dimension of all classifiers remained the same, computational effort, certain assumptions were made. Since the static
which they shared the same outer radius of 1474 mm and coal inlet classifier is referred to in this work, the simulation models were assumed
chute with radius of 228 mm. to be solved in steady-state incompressible flow. The Discrete Phase
Model (DPM) was applied for coal injection, with the Rosin-Rammler
2.1.3. Grid refinement and validation distribution function to specify particle size (25–300 μm). Particle-
In order to determine the optimum number of cells to be used in the particle interaction was considered in the simulation. The turbulence
simulation, grid independency investigation was carried out. Boundary closure model of Realizable k-ϵ was used to solve Reynolds-averaged
conditions were applied as described in Fig. 4a, consisting of two inlets Navier-Stokes (RANS) continuity and momentum equations. Gravity
and one outlet. The mesh independency simulation was carried out by force was considered in the simulation due to the high particle to gas
injecting air with velocity of 16 m/s at air inlet boundary, and obtaining density ratio. The simulation procedure was done repetitively for all
the output value of air velocity at coal outlet boundary in average. The geometry models with different classifier blade lengths and opening
test was conducted by utilizing ten different meshes with different angles. Table 1 summarizes the numerical settings used in this work.
number of tetrahedral cells. The grid independence test was conducted
starting from coarse mesh of approximately 2,000,000 cells, and ended 3. Results and discussion
with fine mesh of 10,000,000 cells. As seen in Fig. 4c, increasing the
number of cells beyond 4,000,000 cells do not affect the final compu­ 3.1. Preliminary result and validation
tational results. Hence, it can be concluded that 4,000,000 cells repre­
sent the optimum number of grid to be used in this simulation. Before carrying out the CFD simulation for all geometry models,
validation of the simulated model was performed and compared against
2.1.4. Simulation method
CFD simulation software of ANSYS Fluent 16.0 was used to perform
Table 2
the numerical investigation [27]. An unstructured mesh of approxi­ Experimental data of coal fineness test.
mately 4,000,000 cells as illustrated in Fig. 5 was used for all pulverizer
Sampling mass (g) (%)
models. Coal particles in the model were injected perpendicularly up­
wards from the surface of the bowl hub. Such injection assumes that coal Mass Before Test 50.00 100.0
>300 μm 0.40 0.80
was being ground and blown upwards equally by incoming primary air
>150 μm < 300 μm 0.48 0.96
from the air inlet. >75 μm < 150 μm 18.24 36.48
In order to provide a reasonable balance between accuracy and <75 μm 30.88 61.76

5
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Fig. 6. Particle track by diameter (m) in simulation model.

the attained results of experimental measurements. This was achieved

Table 3
by modelling the actual pulverizer in a power plant and comparing with
Summary of coal fineness results of experimental and simulation.
the simulation results of this study. Such procedure was performed to
ensure the accuracy of simulation assumptions [28]. To analyse the Particle Diameter (μm) Experimental (%) Simulation (%) Deviation (%)
classifier grade efficiencies and sharpness of cut, coal fineness result was >75 38.24 38.50 0.68
firstly obtained at coal outlet for both cases of experimental and simu­ <75 61.76 61.50 0.42
lation. The percentages of pulverized coal sample passing through each
sieve were recorded and tabulated as shown in Table 2. It can be noticed
through and exited at the coal outlet channel. This could be attributed to
that the minor sampling percentage is occurred when the coal particle
the turbulent flow force that play an important role as centrifugal force
size is greater than 300 μm whereas the major sampling percentage is
in returning the coarse coal particles into the grinder [29]. In general,
taken place when the coal particle size is less than 75 μm. In this study,
the simulation is able to classify 61.5% of fine coal passing 75 μm.
when the coal fineness is above 75 μm, it was categorized as coarse coal,
Table 3 summarizes and compares the coal fineness data obtained from
while coal fineness smaller than 75 μm was categorized as fine coal. It
both experimental and simulation.
can be noticed that, the tested pulverizer was able to classify 61.76% of
fine coal, as shown in Table 2.
Coal fineness result for case of simulation is represented in Fig. 6, 3.2. Coal fineness result
which the particle track is shown and coloured by particle diameter (m)
of the used CFD model with classifier blade length of 110.74 mm at 50◦ After the classifier model of original design was validated, further
opening. The simulation was able to track minimum particle size of 25 simulation work with similar operating conditions were performed for
μm and up to maximum size of 203 μm. In the simulation, the particle in the 16 proposed classifier blade designs, as shown in Figs. 4 and 5. In this
all sizes were released from surface of bowl hub. When the flow domain research, the discussions of the simulation results were divided into two
reached the classifier section, it was observed that only high percentage major parts. Firstly, the results discussions focus on the effect of classi­
of fine particle sizes between 25 μm and 150 μm were able to pass fier blade length on coal fineness output; while the second part of the
results discussions emphasizes on the effect of classifier blade opening

6
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Fig. 7. Top view and histogram of particle diameter distribution at coal outlet with classifier blade length (mm) of: (a) 110.74, (b) 212.34, (c) 313.94, (d) 415.54.

angle on coal fineness output. noticed that the high concentration of particles size below 75 μm are
represented in a blue orbit around the classifier area, which are escaping
3.2.1. Effect of blade length at constant opening angle to the coal outlets. When classifiers’ blades are extended to a length of
The effect of the selected four blade lengths namely 110.74 mm, 212.34 mm, the distribution of fine coal particle size below 75 μm is
212.34 mm, 313.94 mm and 415.54 mm on the performance of the increased to a total of 66.75% as shown in Fig. 7 (b). These results could
proposed classifier models was discussed and analysed. In this case, the be mainly attributed to the extension of blade length that reduces the
opening angle was set to be constant at 40◦ . Fig. 10 demonstrates the cross-sectional area of upward airflow, and hence increases the turbu­
coal particle size distribution at the outlet zone of each proposed model. lent flow and consequently creates a pressure drop at the outlet [29].
Besides, these results can be also interpreted by the respective histo­ The pressure decrement could be mainly attributed to the increase of the
grams shown in Figs. 10 and 8. tangential velocity and flow vortices at the coal classifier zone leading a
The histogram of the original classifier design in Fig. 7 (a) shows a greater pressure drop [25]. Therefore, both airflow and particle travel­
classification result with a total of 64.25% of fine coal particles passing ling velocity towards the outlet are decreased when passing the classi­
below 75 μm sieve, and a total of 35.75% of the coarse particles passing fier. In such a phenomenon, the coarse particles with greater mass lose
above 75 μm sieve. By referring to the contours in Fig. 7 (a), it can be their momentum and fall back onto the bowl hub for further pulverizing

7
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Fig. 8. Top view and histogram of particle diameter distribution at coal outlet with classifier blade opening angle of: (a) 40◦ , (b) 50◦ , (c) 75◦ , and (d) 90◦ .

process by gravity [30]. size below 75 μm occur around the classifier area as compared to the
The classifier with blade length of 313.94 mm achieves the highest previous models. As a result, this extension of the blade length is
percentage of the fine coal classification of total 71.50%, as shown in considered excessive because it limits and reduces both coarse and fine
Fig. 7 (c). However, classification of fine coal is reduced to total value of coal particle output.
69.50% by classifier blade length of 415.54 mm. As shown in the con­
tours in Fig. 7 (d), it can be noticed that a lower concentration of particle

8
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

respectively. Both of these classifier blade settings do not produce much

swirl intensity, as the solid-gas flow moves directly upwards to the
outlets with smaller flow resistance. In fact, the larger blade opening
angle provides a larger gap for coarse coal particles to pass through the
classifier instead. Larger coal particle has higher density and higher
momentum when carried by the high velocity of airflow in turbulence
condition [33]. Therefore, they are able to escape from the classifier
with higher kinetic energy than fine coal particles [32]. Overall, both
classifier with blade opening at 75◦ and 90◦ did not contribute that much
to improving fine coal particle output.
Fig. 9 summarizes the results of the coal fineness output of the pro­
posed 16 classifier models in this study. As shown in Fig. 9, the main
outcome of the conducted simulation work shows a proportional
Fig. 9. Summary of coal fineness output in all classifier models. decrease in coal fineness output when the blade opening angle increases
in all cases. On the other hand, it is also observed that the increase in the
classifier blade length could increase the output of coal fineness. How­
ever, the effect of the blade opening angle demonstrates a greater impact
compared to that of the blade length in terms of the coal fineness output
[34]. In general, a classifier with a minimum blade opening angle at 40◦
gives the highest coal fineness output, regardless of the different blade
lengths. In this case, the minimum blade opening angle of 40◦ and blade
length of 313.94 mm shows the highest output of coal fineness with
71.5%. Therefore, four classifiers of the different blade lengths at a
constant opening angle of 40◦ are selected to further analyse their grade
efficiency and sharpness of cut, due to their high output of coal fineness.

3.3. Grade efficiency and sharpness of cut

Besides screening of particle size, defining grade efficiency is also a

classification method to ensure how well particles are separated by
classifier according to size. Therefore, screen sizes obtained from pre­
vious experimental coal fineness test as mentioned in Table 2 is further
analysed for grade efficiency. Equation (1). Was adopted to calculate the
Grade efficiency of the proposed coal classifier [35].
Fig. 10. Tromp curves of classifier blade length (mm): 110.74, 212.34, 313.94 Mcx
G(x) = (1)
and 415.54 at constant opening angle of 40◦ . Total particle in diameter x injected in feed stream

3.2.2. Classifier with different blade opening angle at constant length where Mcx denotes the remaining mass fraction of particles diameters
In this subsection, further simulations with similar operating con­ obtained from coal fineness test in Table 2.
ditions for the adopted four classifier models with constant blade length After determining grade efficiencies of all classifier models, Tromp
of 110.74 mm, and different opening angle of 40◦ , 50◦ , 75◦ , and 90◦ curves were plotted for each selected model shown in Fig. 10, in order to
were performed. Fig. 8 shows the distribution pattern of coal particle in determine the performances of respective classifiers. As shown in
each classifier of different blade opening angles, which are demon­ Fig. 10, G(x) on y-axis represents grade efficiency of a particle at spec­
strated by contours and respective histogram that also shown in Fig. 8. ified diameter, which are classified out of the feed stream and exited the
The histogram of particle distribution at the classifier region in Fig. 8 coal outlet channel. For instance, by referring to Tromp curve of clas­
(a) shows the highest coal fineness output of 64.25%. This could be sifier model with blade length of 110.74 mm, particles with diameter of
attributed to the smallest blade opening angle, which reduces the radial 100 μm achieved grade efficiency, G(x) of 0.6. This means that, classifier
flow area into the classifier, and consequently causes a reduction in the model with this blade length is able to classify 60% of the coal particles
circumferential flow uniformity [31]. Therefore, particles with larger with diameter of 100 μm away from exiting the coal outlet, by returning
sizes and higher momentum are limited to passing through the small them back into pulverizer for regrinding. This allows greater number of
opening gap, leading only coal particles with smaller sizes being able to particles with smaller diameter to exit the coal outlet. On the other
pass through the classifier. When a larger blade opening angle of 50◦ is words, the higher-grade efficiency provided by a classifier model, the
used, the coal fineness output is reduced to 61.5%, as shown in Fig. 8 (b). smaller particle diameter at the outlet of the output, leading to a better
It can be noticed that the concentration the contours of the blue streams chance of complete combustion to attained in the subsequent fuel
is slightly reduced at the centre of the classifier region. A larger blade process.
opening angle of the classifier provides larger space for coal outflow and Based on Fig. 10, classifier model with blade length of 110.74 mm
reduces resistance of airflow to convey more coal particle with higher achieved the best grade efficiency of 36% in separating 40 μm coal
density [28]. Therefore, larger coal particles with higher density and particle meanwhile the classifier model with blade length of 313.94 mm
higher momentum in the conveying airflow has a higher tendency to has the lowest grade efficiency of 28%. All of the classifier models are
occupy the flow spaces [32]. Consequently, the amount of smaller coal able to classify 50% of 75 μm coal particle back to regrinding process.
particles with lower density and lower momentum is reduced in the However, when the particle diameter is increased to 110 μm, the clas­
conveying airflow. sifier model with blade length of 313.94 mm provides the highest-grade
The coal fineness output is further reduced to 59.5% in the case of the efficiency of 72% while the classifier model with blade length of 110.74
blade opening angles at 75◦ and 90◦ , as shown in Fig. 8 (c) and (d) mm gives the lowest grade efficiency of 64%. In this case, utilizing
classifier with low grade efficiency in separating particle with size of 110

9
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

Table 4 Declaration of competing interest

Summary of sharpness of cut for different classifier model.
Sharpness of cut Particle diameter (μm) The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
110.74 mm 212.34 mm 313.94 mm 415.54 mm
the work reported in this paper.
x20 20 20 25 25
x80 150 140 135 140
I20/80 0.1333 0.1429 0.1852 0.1786
Data availability

The data that has been used is confidential.

μm is not recommended. This is due to the fact that the particles with the
size of 110 μm is considered coarse particle, and the number of existing Acknowledgment
particles at the coal outlet should be minimized. After obtaining the
Tromp curves for each classifier model, final analysis of coal cut size and This research was financially supported by Universiti Tenaga
sharpness of cut were proceeded. Sharpness of cut is crucial to be Nasional, Malaysia through BOLD refresh publication fund
determined, in order to compare classifier efficiencies at steady state (J510050002-BOLDRefresh2025-Centre of Excellence).
process operating conditions, which are meant to be the ratio of particle
sizes at 20% and 80% grade efficiency. Sharpness of cut of typical pul­ References
verizer is obtained by Ref. [35], as shown in Table 4.
[1] F.B. Ismail, E.W.S. Kuan, M.S. Nasif, Development and implementation of bottom
x20 ash crushing system in submerged scrapper conveyor (SSC) for coal-fired power
I20/80 = (2)
x80 plant, in: MATEC Web of Conferences, vol. 131, EDP Sciences, 2017, 03002.
[2] A.P. Inc, ALSTOM Steam Auxiliary Components Mills Windsor -Instruction Manual,
ALSTOM Power Inc., Manjung, PK, 2012 2014. Manual.
4. Future research [3] B. J. P. Buhre, L. K. Elliott, C. D. Sheng, R. P. Gupta, and T. F. Wall, "Oxy-fuel
combustion technology for coal-fired power generation," Prog. Energy Combust.
Although vital parameters that could crucially influence the effi­ Sci., vol.31, pp. 283-307, doi:https://doi.org/10.1016/j.pecs.2005.07.001.
[4] R. Jones, C. McCourt, C. Morley, and K. King, "Maceral and rank influences on the
ciency of the coal classification process have been numerically investi­ morphology of coal char," Fuel, vol.64, pp. 1460-1467.
gated in this study, further analyses can be performed on other [5] J. P. Mathews, P. G. Hatcher, and A. W. Scaroni, "Particle size dependence of coal
important factors in order to attain a better combustion process of the volatile matter: is there a non-maceral-related effect?," Fuel, vol.76, pp. 359-362.
[6] D. Yu, M. Xu, J. Sui, X. Liu, Y. Yu, and Q. Cao, "Effect of coal particle size on the
classified coal dust. Therefore, future research is recommended, and proximate composition and combustion properties," Thermochim. Acta, vol.439,
suggested investigations can be suggested as follows: pp. 103-109.
[7] R. Barranco, M. Colechin, M. Cloke, W. Gibb, and E. Lester, "The effects of pf grind
quality on coal burnout in a 1 MW combustion test facility," Fuel, vol.85, pp. 1111-
i The proposed numerical model can be further improved by consid­
1116.
ering the dynamic effect of the classifier. The corresponding grade [8] S.K. Storm, R.F. Storm, D.S. Storm, S. Tuzenew, A. McClellan, A case study of how
efficiency and sharpness of the cut of the classifier with a rotary vertical spindle pulverizer performance is related to overall plant performance, in:
ASME Power Conference, vol. 42053, 2006, pp. 207–213.
motion can then be investigated.
[9] Q. Lin, C. Penterson, Coal pulverizer design upgrades to meet the demands of low
ii The classifier design of various geometrical shapes and blades ar­ NOx burners, in: Electric Power, March 30–April 1, 2004, 2004. Baltimore, MD.
rangements, can be further discussed and analysed. The blades can [10] F. B. I. Alnaimi, M. S. Jasbeer Singh, A. Al-Bazi, N. F. O. Al-Muhsen, T. S.
be differently arranged in a layering manner, in which the edge of the Mohammed, and R. H. Al-Hadeethi, "Parametric investigation of combustion
process optimization for Gas Turbines at SJ Putrajaya," Energy Rep., vol.7, pp.
blades is twisted to face the incoming airflow. 5722-5732, doi:https://doi.org/10.1016/j.egyr.2021.08.202.
iii The rotating throat clearance of the pulverizer can be manipulated, [11] J.G. Singer, Combustion fossil power: a reference book on fuel burning and steam
by considering different angles. The design change will alter the generation, in: fourth ed.Combustion Engineering, 1993, p. 140, 4th edition
(October 1, 1993.
airflow pattern, the velocity and the turbulence intensity of the [12] J. B. Kitto and S. C. Stultz, "Steam/its Generation and Use 41st edition," The
multi-phase flow field in the pulverizer unit. Babcock & Wilcox Company, Barberton, Ohio, USA, pp.
[13] F. B. Ismail, N. F. O. AL-Muhsen, and R. K. Lingam, "Investigation on classification
efficiency for coal-fired power plant classifiers using a numerical approach," J. Eng.
5. Conclusions Sci. Technol., vol.15, pp. 1542-1561.
[14] K. Shah, R. Vuthaluru, and H. Vuthaluru, "CFD based investigations into
The effects of classifier blade length and opening angle on coal optimization of coal pulveriser performance: effect of classifier vane settings," Fuel
Process. Technol., vol.90, pp. 1135-1141.
particle distribution in coal pulverize were numerically investigated.
[15] Q. Huang, J. Liu, and Y. Yu, "Turbo air classifier guide vane improvement and inner
Validation of simulation results with actual plant data was performed. flow field numerical simulation," Powder Technol., vol.226, pp. 10-15.
The original blade length of 110.74 mm can classify 64.25% of fine coal [16] W. Ren, J. Liu, and Y. Yu, "Design of a rotor cage with non-radial arc blades for
turbo air classifiers," Powder Technol., vol.292, pp. 46-53.
particles. The CFD results show that increasing of classifier blade length
[17] S. Wu, J. Liu, and Y. Yu, "Design of a new double layer spreading plate for a turbo
increases the amount of coal fineness whereas decreasing of classifier air classifier," Powder Technol., vol.312, pp. 277-286.
blade opening angle increases the amount of coal fineness output. The [18] S. Ataş, U. Tekir, M. A. Paksoy, A. Çelik, M. Çam, and T. Sevgel, "Numerical and
classifier model with a blade length of 313.94 mm and opening angle of experimental analysis of pulverized coal mill classifier performance in the Soma B
Power Plant," Fuel Process. Technol., vol.126, pp. 441-452.
40◦ can classify the highest amount of 71.50% fine coal particle, with the [19] Y. Yu, M. Saadat, A. Untaroiu, B.R. Thomas, H.G. Wood, Prediction of turbo air
highest value sharpness of cut of 0.1852, which means the greatest classifier cut size based on particle trajectory, in: Turbo Expo: Power for Land, Sea,
classification efficiency. It can be concluded that the adopted classifier and Air, vol. 49828, American Society of Mechanical Engineers, 2016,
V006T21A010.
model with a blade length of 313.94 mm is considered to be the opti­ [20] J. Blondeau, R. Kock, J. Mertens, A. Eley, and L. Holub, "Online monitoring of coal
mum design. This model not only managed to classify the highest particle size and flow distribution in coal-fired power plants: dynamic effects of a
amount of 71.50% fine coal particles among all proposed designs, but it varying mill classifier speed," Appl. Therm. Eng., vol.98, pp. 449-454.
[21] J.L. Afolabi, The Performance of a Static Coal Classifier and its Controlling
also achieves the industry requirements to have 70% of fine coal passing Parameters, University of Leicester, 2012.
a 75 μm sieve. A coal fineness improvement of 7.25% is attained by the [22] H. Li et al., "Performance of the static air classifier in a vertical spindle mill," Fuel,
proposed design. vol.177, pp. 8-14.
[23] Q. Huang;, J. Liu;, and Y. Y. b, "Turbo air classifier guide vane improvement and
inner flow field numerical simulation," Powder Technol., vol.226, pp. 10-15, doi:
https://doi.org/10.1016/j.powtec.2012.03.026.
[24] R. F, Finessing Fuel Fineness, PLANT O&M, 2008.

10
F.B. Ismail et al. Case Studies in Chemical and Environmental Engineering 6 (2022) 100266

[25] H. Li et al., "Operational performance characteristics of an axial double baffles [31] S. M. Iveson, A. Price, and K. P. Galvin, "Separation of coal with a top size of up to 6
three channels classifier for coarse pulverized coal," Powder Technol., vol.400, pp. mm in a full-scale REFLUX™ Classifier," Int. J. Coal prep. Util., vol.42, pp. 694-
117250, doi:https://doi.org/10.1016/j.powtec.2022.117250. 714, doi:10.1080/19392699.2019.1646255.
[26] L. Feng et al., "Classification performance of model coal mill classifiers with [32] Z. Sun, C. Liu, G. Yang, and L. Chen, "Orthogonal vortices characteristic,
swirling and non-swirling inlets," Chin. J. Chem. Eng., vol.28, pp. 777-784, doi:http performance evaluation and classification mechanism of a horizontal classifier
s://doi.org/10.1016/j.cjche.2019.12.002. with three rotor cages," Powder Technol., vol.404, pp. 117438, doi:https://doi.org
[27] A. Fluent, ANSYS Fluent 21R1 User’s Guide, ANSYS, 2021. /10.1016/j.powtec.2022.117438.
[28] L. Huang et al., "Cfd Simulation and Parameter Optimization of the Internal Flow [33] X. Mou, F. Jia, Y. Fang, and C. Chen, "CFD-based structural optimization of rotor
Field of a Disturbed Air Cyclone Centrifugal Classifier," Available at: SSRN cage for high-efficiency rotor classifier," Processes, vol.9, pp. doi:10.3390/
4227862, pp. pr9071148.
[29] Y. Zeng, B. Huang, D. Qin, S. Zhou, and M. Li, "Numerical and experiment [34] L.-L. Zhao, C.-L. Duan, H.-S. Jiang, H.-X. Li, Y.-M. Zhao, and Q.-J. Zheng, "DEM
investigation on novel guide vane structures of turbo air classifier," Processes, vol. simulation of size segregation of binary mixtures of cohesive particles under a
10, no. 5, doi: 10.3390/pr10050844. horizontal swirling vibration," Powder Technol., vol.404, pp. 117456, doi:https
[30] M. Weers et al., "Development of a model for the separation characteristics of a ://doi.org/10.1016/j.powtec.2022.117456.
deflector wheel classifier including particle collision and rebound behavior," [35] G.G. Chase, Grade Efficiency, 11th Eition ed., The University of Akron, 2004.
Minerals, vol. 12, no. 4, doi: 10.3390/min12040480.

11