Mill Optimisation

Importance of Milling

Influence on Mill Performance on Combustion and Boiler Performance

  • Milling performance is critical in controlling the combustion process in the boiler;
  • Coal pf fineness influences:
    -ignition delay;  
    -combustion efficiency;
    -particle erosion;
    -loss on ignition (and hence coal costs);
    -value of ash and ability to dispose / sell;
    -emission levels;
    -boiler slagging and fouling;
    -potential damage to superheater tubes from combustion delay;

Need for Testing

  • Mill maintenance costs are one of the highest maintenance costs in a coal fired power station;
  • Testing allows a change to 'condition based' maintenance (from set mill operating hours) which in HRL's experience can increase time between minor / major mill overhauls by up to 10%;
  • Optimising milling performance can reduce coal consumption and therefore costs;
  • Testing can help detect mill performance issues early and can help direct / target maintenance activity.

Broader hrl: Mill Performance Capability

The EUcoalsizer fits into  broader mill performance service offer to assist in optimising- mill performance.

  • Measurement of pf flow per burner duct microwave technology;
  • Coal flow balancing (e.g. by adjustment of values on PF pipes);
  • Check / calibration of coal flow obtained from volumetric or gravimetric coal feeder to mill and check on mill capacity limits (and assessment of reason for limits);
  • Mill power consumption (per unit of coal throughput) including as a check on classifier recirculation rates;
  • CFD modelling of milling system to solve flow related issues;
  • Adjustment of classier vane setting or redesign to adjust pf fineness;
  • Mill condition and inspection;
  • Measurement of pressure drop across mill / classifier;
  • Mill performance as a function of load / coal throughput;
  • Measurement of PA flow / auxiliary air / mill seal air flowrate;
  • Comparison of measurements against station instruments;
  • 'Clean' (no coal flow) testing to measure air flow distribution to burners;
  • Assessment of individual mill performance and recommendations for maintenance, physical modifications, or operational changes;
  • Measurement of mill inlet / outlet temperature, and check on temperature stability;
  • Testing of mill performance following major overhaul to demonstrate performance gain and to help optimise future overhaul scope of work;
  • Assessment of materials, failure analysis, requirement for repair or replacement.

Introducing the EUcoalsizer

EUcoalsizer Features

  • Measures (in real time) pf particle size distribution (PSD), coal and air flow;
  • Provides spatially resolved (2D) readings;
  • Allows real time coal : air flow tuning and adjustment of coal feeders / mill control settings;
  • Requires larger 3" ports to be installed.

Benefits of EUcoalsizer

  • Cost of testing is dramatically reduced.  Testing is conducted by a single operator;
  • The cost competitiveness allows regular e.g. quarterly or bi-annual testing of all mills;
  • This in turn facilitates moving to a 'condition based' maintenance program and hence a reduction in mill maintenance cost, as well as prioritising mill maintenance to optimise combustion performance;
  • Allows milling performance to be characterised following a change in coal supply (or evaluation of suitability of a particular coal supply);
  • Allows real-time assessment of changes to mill operation and settings on pf size and hence adoption
  •  of a mill operation optimisation program;
  • Optimising mill performance can result in reduction in coal consumption, carbon in ash and allows full benefit to be obtained from combustion tuning.


"We have utilised hrl: for many years and have found hrl: to retain and utilise the same personnel on our tasks providing a high degree of familiarity of the hrl: personnel to the work and our personnel.  Additionally, hrl: have some highly ex...

Paul Farington

What our clients say:

Are you ready to transform your business performance?

Phone 1800 475 832

Latest News

hrl: is able to undertake a wide range of tests for building materials

Posted by Steven Kulibaba on 23 June 2017
Building Product Testing hrl: is able ...
Posted in: building testing Media Release Compliance expertise  
< Previous | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | Next >

Sign up: newsletter & updates


Our certifications

NATA accredited AtS/NZS ISO 17025, AS/NZS ISO 17020NATA Accredited Laboratories number 561.

ISO 9001 Quality Management certied by BSI under certicate number FS605116.

Ready to transform your business performance?

Contact our technical consultants on -
1800 475 832 or to get started today.

See expertise in action:



Language selector