Safe & Reliable Coal Pulverizing Solutions – High Output, Low Moisture, Explosion-Proof Design Complete turnkey coal pulverizing systems for rotary kilns, blast furnace PCI, and power boilers. Our integrated air-swept ball mill or vertical roller mill systems with dynamic classifiers deliver coal powder with 80-90% passing 200 mesh and residual moisture <1.5%. With a fully inerted grinding atmosphere, explosion suppression technology, and zero-dust operation, we provide safe, energy-efficient EPC services from raw coal receiving to pulverized coal firing — trusted by cement plants, steel mills, and power stations in over 30 countries.
Our coal pulverizing system is a complete, integrated facility engineered to produce stable, high-quality pulverized coal for industrial burners and kilns. We deliver the entire system as a single-source EPC project.
System Scope of Supply
Core Process Equipment:
· Raw coal receiving hopper with grid, belt conveyor and magnetic separator (for tramp iron removal)
· Raw coal storage silo or covered stockpile
· Coal crusher (hammer or impact type, reducing feed to ≤25 mm)
· Weighing belt feeder for precise coal metering
· Air-swept ball mill or vertical roller mill (coal mill)
· Hot gas generator (if no available kiln waste heat) or waste heat recovery system
· Dynamic rotary classifier (integrated in VRM or standalone for ball mill)
· High-efficiency cyclone collector for coarse particle recirculation
· Baghouse dust collector for fine coal powder collection (with explosion isolation)
· Pulverized coal storage silo (bolted steel, with inert gas blanketing and temperature/CO monitoring)
· Dense-phase pneumatic conveying system or screw pump for kiln/burner injection
· Full PLC/DCS safety instrumented system (SIS) with emergency shutdown logic
· Inert gas generation or storage system (N₂ or CO₂)
Coal Types We Process:
· Bituminous coal (volatile matter 20-35%, typical for cement kilns and PCI)
· Anthracite (low volatile matter 6-10%, requires finer grinding)
· Sub-bituminous coal (high moisture 20-30%, requires enhanced drying)
· Lignite / Brown coal (very high moisture 30-60%, special drying and safety measures)
· Petroleum coke (petcoke, low volatile, high hardness, abrasive)
· Blends of coal and petcoke for optimal combustion economics
Product Specifications We Guarantee:
| Application | Fineness (200 mesh passing) | Residual Moisture | Typical Throughput per Mill |
|---|---|---|---|
| Cement rotary kiln | 80-88% | <1.5% | 10-45 t/h |
| Blast furnace PCI | 80-90% (or 0.09mm sieve) | <1.0% | 20-60 t/h |
| Power station boiler | 70-80% | <2.0% | 20-80 t/h |
| Lime kiln | 85-90% | <1.0% | 5-20 t/h |
From Raw Coal to Safe Pulverized Fuel: How Your Coal Grinding System Works
Raw Coal Receiving & Preparation – Raw coal is discharged into a hopper, passes through a magnetic separator to remove tramp iron, and is crushed to ≤25 mm in a hammer crusher. It is stored in a buffer silo to ensure continuous mill operation.
Controlled Dosing & Feeding – A weighing belt feeder precisely measures the coal feed rate into the mill, automatically controlled by the DCS to match the required fuel demand.
Simultaneous Drying & Grinding – The coal enters the air-swept mill (ball mill or VRM), where it is ground and simultaneously dried by a stream of hot gas. The hot gas is generated from an independent hot gas furnace or kiln waste heat, entering the mill at 200-400°C. This reduces coal moisture from 10-15% to <1.5%.
Dynamic Classification – The gas stream carries the ground coal to a dynamic classifier. On-spec fine coal particles (e.g., 200 mesh 85% passing) pass through with the airflow; coarse particles are rejected and fall back into the mill for regrinding.
Product Collection & Inerting – The pulverized coal-laden air is passed through a baghouse where the fine powder is separated. Clean gas is recirculated back to the mill inlet (inert loop) or exhausted. The collected coal powder is discharged via rotary valves into a pneumatic conveying system.
Safe Storage & Firing – The pulverized coal is conveyed to a storage silo blanketed with inert gas (N₂). Temperature and CO sensors continuously monitor for any signs of spontaneous combustion, automatically triggering inerting or emergency discharge if needed. Dense-phase pumps then inject the coal powder into the kiln or boiler burner at a precisely controlled rate.
Standard Coal Pulverizing System Configurations (Air-Swept Ball Mill)
| Mill Capacity (t/h, bituminous) | Ball Mill Model | Mill Motor (kW) | Hot Gas Source | Product Fineness (200 mesh) | Typical Application |
|---|---|---|---|---|---|
| 5-8 | Φ1.7×2.5m | 95 | Hot gas furnace | 80-85% | Small lime kiln or boiler |
| 10-15 | Φ2.2×3.0m | 185 | Kiln waste heat | 85-90% | 1000 t/d cement kiln |
| 18-25 | Φ2.4×4.5m | 315 | Kiln waste heat | 85-90% | 2500 t/d cement kiln |
| 30-40 | Φ2.8×5.0m | 500 | Kiln waste heat | 80-88% | 5000 t/d cement kiln |
| 40-55 | Φ3.2×6.5m | 710 | Kiln waste heat / generator | 80-88% | 8000-10000 t/d cement kiln |
*Vertical roller mills (e.g., GRMC/TRMC series) are recommended for large-capacity PCI systems (>60 t/h) or for grinding hard-to-grind coals (anthracite, petcoke) due to their lower specific power consumption (20-25 kW·h/t vs 25-30 for ball mill).*
Key Safety & Performance Guarantees
| Parameter | Guaranteed Value |
|---|---|
| Product fineness (200 mesh passing) | As per contract ±2% |
| Product residual moisture | <1.5% (bituminous), <1.0% (anthracite) |
| System O₂ concentration (inert operation) | <10-12% (adjustable) |
| Dust emission | <10 mg/Nm³ |
| Temperature at mill outlet | 65-80°C (bituminous) |
| CO in storage silo (alarm/shutdown) | >50 ppm alarm / >100 ppm purge |
| Plant availability | >85% (annual) |
EPC Project Scope Options:
· Full EPC (Turnkey): Complete coal preparation plant from raw coal hopper to burner injection, including crushing, grinding, classification, inert gas system, dust collection, storage, pneumatic conveying, safety instrumentation, civil, and automation.
· EP (Engineering & Equipment Supply): Detailed design plus supply of all core equipment. Civil and erection by client with our technical supervision.
· Core Grinding & Safety System: Supply of the coal mill, dynamic classifier, baghouse, and safety package only.
Tell us your required fuel rate, coal type (proximate analysis & HGI), and installation altitude. We will size the optimal coal pulverizing system and provide a complete safety concept.
Proven Performance: Global Coal Pulverizing System Projects
Case 1: 5000 TPD Cement Kiln Coal Firing System, Southeast Asia
· Scope: Full EPC (Raw coal to kiln burner)
· Configuration: Φ2.8×5.0m air-swept ball mill + dynamic classifier + kiln waste heat utilization
· Coal: Bituminous, HGI 55, moisture 12%
· Performance: Output 35 t/h at 200 mesh 85% passing, residual moisture 1.2%. System O₂ controlled at 8-10%. Zero safety incidents in 5 years of operation.
· Outcome: Replaced an old oil-fired system, reducing fuel cost by 60%. Specific power 26 kW·h/t coal.
Case 2: Blast Furnace PCI System, 2×40 t/h, India
· Scope: Full EPC with vertical roller mill
· Configuration: 2× GRMC20.2 VRMs + independent hot gas generators + dense-phase conveying
· Coal: Anthracite + petcoke blend, HGI 38, moisture 8%
· Performance: Each mill delivers 42 t/h, 200 mesh 88% passing, moisture 0.8%. VRM specific power 22 kW·h/t.
· Outcome: PCI rate achieved 180 kg/t-hot metal, significantly reducing coke consumption. Mill liner life >8,000 hours despite abrasive petcoke.
Case 3: Plant Safety Upgrade: From Open to Inerted Closed Circuit, Africa
· Scope: Retrofit EPC (Added inert gas system, dynamic classifier, upgraded baghouse)
· Original system: Open circuit, 12 t/h, frequent fires and shutdowns
· New system: Closed circuit with inertization, 18 t/h, continuous safe operation
· Result: Capacity increased 50%, safety incidents eliminated. Project payback within 2 years from reduced downtime and increased output.
Safety-Centric EPC Delivery & Guarantees
· Single-Source EPC Responsibility: We are the sole engineering, procurement, and construction partner for your coal pulverizing plant. The safety of the system is not delegated; it is our direct contractual obligation.
· Coal Analysis & Pilot Testing: Before design, we run a full coal analysis (proximate, ultimate, HGI, and explosion indices Kst/Pmax). A pilot grinding test determines optimal mill parameters. We provide a guaranteed safety concept and performance report.
· Safety & Performance Test: A 72-hour continuous performance test is conducted after commissioning. This verifies output, fineness, moisture, system O₂ levels, and all safety interlocks. The plant is only handed over after meeting all contractual guarantees, including the successful demonstration of the emergency inerting procedure.
· After-Sales & Emergency Support: 12-month defect liability period. Wear parts for mills and safety system components are stocked regionally. 24/7 emergency technical support hotline is included. We also offer annual plant safety audits.
Ready to Secure Your Fuel Supply with a Safe, Efficient Coal Grinding System?
Send an inquiry. You will receive:
A complete coal pulverizing system proposal tailored to your fuel rate, coal type, and plant layout.
A detailed P&ID with safety concept, equipment list, and firm EPC price.
A project schedule from design to commissioning.
Optional: Free coal sample analysis (proximate, HGI, explosion indices) and pilot grinding test report.
Your coal data and project requirements are handled under strict NDA.
Kolev Equipment Technology Co., Ltd. is a large-scale private technology enterprise specializing in the research, development, production, and sales of mining and metal ore processing equipment. With over 20 years of experience in ultra-fine grinding, industrial drying, and crushing sand making industries, we provide intelligent solutions and mature supporting products worldwide.
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