Coal blending in thermal power plant is a key process used to achieve the desired Gross Calorific Value (GCV), ash percentage, or other quality parameters by mixing coals from two or more sources.
Blending ensures the fuel meets boiler design requirements, reduces cost, and improves combustion efficiency.
🔀 Coal Blending Calculator (2 Streams)
Enter GCVs (kcal/kg) and target output to get Stream A & B TPH and % split.
Show Formula
Coal Blending Formula
Where:
- \(\mathrm{GCV_A}, \mathrm{GCV_B}\) = GCV of Stream A & B (kcal/kg)
- \(\mathrm{TPH_A}, \mathrm{TPH_B}\) = flow rate of Stream A & B (tonnes/hour)
- \(\mathrm{GCV_t}\) = required target GCV of blended coal
Constraint (final total flow):
If \(x\) is the fraction from Stream A, then
Show Example Calculation
Suppose we have:
Stream A GCV = 4800 kcal/kg
Stream B GCV = 3600 kcal/kg
Target (Final) GCV = 4000 kcal/kg
Final Total TPH = 1000 tonnes/hour
Step 1: Calculate fraction of Stream A
Formula: $$ x = \frac{\mathrm{GCV_t} – \mathrm{GCV_B}}{\mathrm{GCV_A} – \mathrm{GCV_B}} $$
Substituting values: $$ x = \frac{4000 – 3600}{4800 – 3600} = \frac{400}{1200} = 0.333 $$
Step 2: Calculate Stream A and Stream B flow rates
Formula: $$ \mathrm{TPH_A} = x \times \mathrm{Final\ Total\ TPH} $$ $$ \mathrm{TPH_B} = (1 – x) \times \mathrm{Final\ Total\ TPH} $$
Substituting values: $$ \mathrm{TPH_A} = 0.333 \times 1000 = 333\ \text{TPH} $$ $$ \mathrm{TPH_B} = (1 – 0.333) \times 1000 = 667\ \text{TPH} $$
Step 3: Check total
Formula: $$ \mathrm{TPH_A} + \mathrm{TPH_B} = \mathrm{Final\ Total\ TPH} $$
Substituting values: $$ 333 + 667 = 1000\ \text{TPH} $$
✅ Result:
Stream A = 333 TPH (33%)
Stream B = 667 TPH (67%)
Blended GCV = 4000 kcal/kg