Coal Fire and Explosion Pre-ignition Detection Systems in Coal Transport, Storage & Process Installations

The CO extractive continuous monitoring system by FORNEY Corp. is used for detection of hazards caused by smoldering in coal processing, transport and storage devices.

Typical application - coal mill fires:
Fire and explosions may occur during the grinding, pulverizing and handling of pulverized coal in the mill section of power generation plants. Conditions within the mills, particularly during start-up, shut-down and significant load changes result in the scenario where the coal has the possibility to self-heat faster than the rate of heat-dissipation to its environment, spontaneous combustion (smoldering) may occur. During the smoldering or pyrolize the high amount of CO is emitted as a result of incomplete combustion. If the pulverizer passes through an explosive condition at the same time there is an ignition source present (as a result of spontaneous combustion of coal), the result will be an explosion.
This means that if CO concentration is monitored, it can be used as an early warning of a potential fire before the real fire starts.

CPDS-CEMplicity® (Coal Pre-ignition Detection System) detects smoldering which is accompanied by build-ups of CO. Usually it is early enough to protect the installation against an explosion or fire.
The analyzer which is the heart of the system continiously monitors dry CO concentrations from up to 8 measuring points. Each point is equipped with the probe with sintered filter and sample conditioning box which dryes the sample and has valves for blowback control.
System outputs: continuous CO concentration 4-20mA reading per every measuring point, relay outputs: alarm and fault for every point, RS MODBUS output.

System components:

  • air conditioned main cabinet containing: up to two analyzers (up to 16 measuring points served), system controller with HMI interface (touch display), main vacuum pump, air control panel, power supply panel and terminals, air and umbilical bulkheads, input and output terminals; cabinet is designed for installation on the plant floor near protected devices to reduce sample line length and response time
  • sample lines connecting probes with the main cabinet. Line contains tubes for sample and calibration gas and wires for blowback valves control
  • extractive Tungsten or Hastelloy probes flange mounted on measuring point by 2" threaded coupling with manual shutt off valve; sample conditioning boxes are mounted within 2 m of the probe
  • cal gas cylinder with equipment

This system represents the new concept in mill fire detection and has a lot of features: it is centralized and operates fully automatic, making continuous measurements, controlling the blowback, providing automatic calibration and the system moisture protection function while steaming the protected installation.