Clean Coal Technology

&COCO2

SequestrationSequestration

Prof. D. K. SharmaProf. D. K. SharmaCentre for Energy Studies

Indian institute of Technology

Agenda for DiscussionAgenda for Discussiongg►►Coal reserves in IndiaCoal reserves in India►►Need for cleaning Indian coalsNeed for cleaning Indian coals►►Benefits of beneficiation of coalsBenefits of beneficiation of coals►►Benefits of beneficiation of coalsBenefits of beneficiation of coals►►Types of clean coal technologiesTypes of clean coal technologies►►PrePre--combustion clean coal technologiescombustion clean coal technologies►►During combustion clean coal technologiesDuring combustion clean coal technologies►►During combustion clean coal technologiesDuring combustion clean coal technologies►►Post combustion clean coal technologiesPost combustion clean coal technologies

N d f h i l l i f lN d f h i l l i f l►►Need for chemical cleaning of coalNeed for chemical cleaning of coal►►ConclusionsConclusions

Clean Coal TechnologiesClean Coal TechnologiesClean Coal TechnologiesClean Coal Technologies

C lC l ii i t ti t t ff Ab tAb t 2525%%►► CoalCoal isis anan importantimportant sourcesource ofof energyenergy.. AboutAbout 2525%%ofof world'sworld's primaryprimary energyenergy isis suppliedsupplied byby coalcoal..

►► AboutAbout 5555%% ofof coalcoal producedproduced inin thethe worldworld isis usedused forfor►► AboutAbout 5555%% ofof coalcoal producedproduced inin thethe worldworld isis usedused forforpowerpower generation,generation, remainingremaining forfor steel,steel, cement,cement,domesticdomestic heating,heating, otherother industriesindustries andand forfor

d tid ti ff t it i h i lh i lproductionproduction ofof certaincertain chemicalschemicals..►► WorldWorld coalcoal productionproduction increasedincreased forfor moremore thanthan 5050%%

betweenbetween 19731973--19921992 andand thisthis increasedincreased fromfrom 34613461betweenbetween 19731973 19921992 andand thisthis increasedincreased fromfrom 34613461MtMt toto 55225522 MtMt betweenbetween 19901990 andand 20072007(( almostalmost3333%%))..

World Coal Institute Coal Facts

Countries where coal is the main Countries where coal is the main fuel for power generation(%)fuel for power generation(%)

PolandPoland 9393Poland Poland –– 93 93 S. AfricaS. Africa-- 93 93 ChinaChina –– 7878China China 78 78 Australia Australia –– 80 80 India India -- 70 70 Czech Republic Czech Republic –– 59 59 Greece Greece –– 58 58 GermanyGermany 4040Germany Germany –– 40 40 USA USA –– 50 50 IndonesiaIndonesia –– 4747Indonesia Indonesia 4747Morocco Morocco –– 6969Israel Israel –– 7171Kazakhstan Kazakhstan -- 70 70

Current Installed Power Generation in Current Installed Power Generation in IndiaIndia

Total Generation Capacity = 1,50,000 MWTotal Generation Capacity = 1,50,000 MW►► Thermal = 93 392Thermal = 93 392►► Thermal = 93,392Thermal = 93,392(77458 MW Coal Based)(77458 MW Coal Based)(14734 MW Gas Based)(14734 MW Gas Based)( 1200 MW Di l B d)( 1200 MW Di l B d)( 1200 MW Diesel Based)( 1200 MW Diesel Based)

►► Hydel = 36,647 MWHydel = 36,647 MW►► Nuclear = 4,120 MWNuclear = 4,120 MW►► Wind & Renewable Sources of Energy = 13,242 MWWind & Renewable Sources of Energy = 13,242 MW(Wind = 9,344 MW)(Wind = 9,344 MW)►► Total coal reserves in India = 258 bTTotal coal reserves in India = 258 bT►► Current Coal Production = 450 mT/annumCurrent Coal Production = 450 mT/annum►► Coal Requirement 2012 = 550 mTCoal Requirement 2012 = 550 mT►► Target : Power for all by 2012Target : Power for all by 2012►► Target : Power for all by 2012Target : Power for all by 2012

To add 1,00,000 MW by the end of 11To add 1,00,000 MW by the end of 11thth plan plan Ultra Mega ProjectsUltra Mega Projects Sasan Mundra Ratnagiri KrishnapatanSasan Mundra Ratnagiri KrishnapatanUltra Mega Projects Ultra Mega Projects –– Sasan, Mundra, Ratnagiri, Krishnapatan, Sasan, Mundra, Ratnagiri, Krishnapatan,

Orissa, Jharkhand and Tamilnadu > 4,000MWOrissa, Jharkhand and Tamilnadu > 4,000MW-- Supercritical Supercritical boilersboilers

►► According to IEO ( International Energy Outlook) According to IEO ( International Energy Outlook) 2008 estimates World Coal Consumption would2008 estimates World Coal Consumption would2008 estimates World Coal Consumption would 2008 estimates World Coal Consumption would increase by 65% and world trade by 53% between increase by 65% and world trade by 53% between 2005 and 2030.2005 and 2030.

►► Coal's share in world energy consumption would Coal's share in world energy consumption would increase.increase.

I di i i i l i b dI di i i i l i b d►► Indian companies are acquiring coal mines abroad.Indian companies are acquiring coal mines abroad.

►► Tata Steel has acquired a 35% stake in coking coalTata Steel has acquired a 35% stake in coking coal►► Tata Steel has acquired a 35% stake in coking coal Tata Steel has acquired a 35% stake in coking coal mines in Mozambique.mines in Mozambique.

• Coal is available in a few places whereas Coa s a a ab e a e p aces e easthermal power stations are scattered all over the country.o e e cou y

• Problems – Pollution, Transportation B ttl k C t f t t ti f lBottlenecks, Cost of transportation of coal, Fly Ash Management, limited stacks of coal

il ble t The l Po e St tio Co t ofavailable at Thermal Power Stations, Cost of Imported Coals etc.

Coal Resources & Coal Reserves in Coal Resources & Coal Reserves in IndiaIndia

C i l E 58C i l E 58 60% li d b l60% li d b l►► Commercial Energy = 58 Commercial Energy = 58 –– 60% supplied by coal60% supplied by coal►► Estimated resources down to a depth of 1200 Estimated resources down to a depth of 1200

metersmeters –– 258 billion tonnes258 billion tonnesmeters meters 258 billion tonnes258 billion tonnes►► About 62% of reserves are of inferior grade with About 62% of reserves are of inferior grade with

gross C.V. = 4000 Kcal/kg (G= 10 gross C.V. = 4000 Kcal/kg (G= 10 9 9 or 16.7 or 16.7 g g (g g (GJ/tonne)GJ/tonne)

►► Coal reserves within 600m depth (i.e. 90%) are of Coal reserves within 600m depth (i.e. 90%) are of commercial interest as deeper reserves may not becommercial interest as deeper reserves may not becommercial interest as deeper reserves may not be commercial interest as deeper reserves may not be exploited in near future.exploited in near future.

►► 85% of the reserves are of non85% of the reserves are of non--coking coalcoking coal►► 85% of the reserves are of non85% of the reserves are of non coking coalcoking coal►► ~ 15% ~ 15% -- coking coals coking coals –– steel plantssteel plants►► Import of coking coalsImport of coking coalsp gp g

71% f ki l f i f i71% f ki l f i f i►►71% of noncoking coals are of inferior 71% of noncoking coals are of inferior quality i.e. ash 34quality i.e. ash 34--55%, GCV = 310055%, GCV = 3100--5000 5000 K l/kK l/kKcal/kgKcal/kg

►►Open Cast MiningOpen Cast Mining►►Quality of Coal Quality of Coal –– High Ash contentsHigh Ash contents►►More than half (70%) the coal in IndiaMore than half (70%) the coal in India►►More than half (70%) the coal in IndiaMore than half (70%) the coal in India►►Mined by open cast miningMined by open cast mining

O t P d ti it th 5 tiO t P d ti it th 5 ti►►Open cast : Productivity more than 5 times Open cast : Productivity more than 5 times that by underground mining/unit manshift that by underground mining/unit manshift

d ti itd ti itproductivityproductivity

►► SinceSince indigenousindigenous coalcoal reservesreserves areare limited,limited,therefore,therefore,O lO l tt ll th ith i lili ii bb ffi i tffi i t►► OnlyOnly wayway toto prolongprolong theirtheir liveslives isis byby efficientefficientutilizationutilization ii..ee.. byby adaptingadapting CCTsCCTs andand advancedadvancedpowerpower generationgeneration engineeringengineering cyclescycles.. TheseThesepp gg g gg g yysystemssystems maymay havehave toto bebe operatedoperated inin IndianIndian coalscoals

Declining gross calorific value of coalDeclining gross calorific value of coalAverage GCVAverage GCV

19601960 61 5900 K l/k61 5900 K l/k19601960--61 5900 Kcal/kg61 5900 Kcal/kg19701970--71 5250 Kcal/kg71 5250 Kcal/kg

19801980 1981 4200 Kcal/kg1981 4200 Kcal/kg19801980--1981 4200 Kcal/kg1981 4200 Kcal/kg19921992--1993 4100 Kcal/kg1993 4100 Kcal/kg19951995--1996 3500 Kcal/kg1996 3500 Kcal/kg19951995 1996 3500 Kcal/kg1996 3500 Kcal/kg

Homogenisation of coal and blending of coal Homogenisation of coal and blending of coal studies on quality of coals are importantstudies on quality of coals are importantq y pq y p

UHV = 8900 UHV = 8900 –– 138(A + M)138(A + M)

Projections of Power RequirementProjections of Power RequirementProjections of Power RequirementProjections of Power Requirement

I d E li f Pl iI d E li f Pl iIntegerated Energy policy of Planning Integerated Energy policy of Planning CommissionCommission

220 GW by 2011220 GW by 2011--20122012425 GW by 2021425 GW by 2021--20222022425 GW by 2021425 GW by 2021 20222022778 GW by 2031778 GW by 2031--20322032C l d d b ll hC l d d b ll hCoal demand by all the sectors i.e. Power, Coal demand by all the sectors i.e. Power,

iron and Steel, Cement etc. may increase iron and Steel, Cement etc. may increase from 426 MT in 2005from 426 MT in 2005--06 to 730 MT by 06 to 730 MT by 20112011--12 and 2021 MT by 203112 and 2021 MT by 2031--3232

Problems due to high ash coalsProblems due to high ash coalsProblems due to high ash coalsProblems due to high ash coals

►► Erosion of equipments and boiler partsErosion of equipments and boiler parts►► Erosion of equipments and boiler partsErosion of equipments and boiler parts..►► Difficulty in pulverization.Difficulty in pulverization.►► Poor emissivityPoor emissivity►► Poor emissivityPoor emissivity►► Poor flame temperature.Poor flame temperature.►► Low radiative transferLow radiative transfer►► More unburnt carbons.More unburnt carbons.►► Excessive amount of flyash and bottom ashExcessive amount of flyash and bottom ash►► Lower combustion efficiencyLower combustion efficiency►► Lower combustion efficiencyLower combustion efficiency►► Increase ash resistivity due to higher amounts of Increase ash resistivity due to higher amounts of

silica and alumina.silica and alumina.►► Reduction in ESP efficiency Reduction in ESP efficiency ►► Increased emissionsIncreased emissions

Benefits of coal beneficiationBenefits of coal beneficiationBenefits of coal beneficiationBenefits of coal beneficiationAlthoughAlthough coalcoal washingwashing maymay increaseincrease thethe costcost ofofAlthoughAlthough coalcoal washingwashing maymay increaseincrease thethe costcost ofofcoal,coal, inin generalgeneral thethe costcost ofof powerpower generatedgenerated fromfromcoalcoal firedfired powerpower plantplant usingusing cleanclean coalcoal maymay reducereduceifif llll thth l tl t tt dd blbl i t di t d ithithifif allall thethe plantplant costscosts andand problemsproblems associatedassociated withwiththethe useuse ofof ROMROM coalcoal areare consideredconsidered..

►► Reduction of transport costReduction of transport cost-- depending upon depending upon distance and ash contents in coal.distance and ash contents in coal.

►► Load on transportation network will be reducedLoad on transportation network will be reduced►► Load on transportation network will be reduced.Load on transportation network will be reduced.►► Air pollution by diesel engines will be reduced on Air pollution by diesel engines will be reduced on

way.way.yy►► Fugitive emissions will be reducedFugitive emissions will be reduced-- Coal Handling.Coal Handling.►► Energy consumption in loading& unloading will be Energy consumption in loading& unloading will be

lessless-- less shales ash to be handledless shales ash to be handledlessless-- less shales, ash to be handled.less shales, ash to be handled.►► Transportation of shales etc. with mine output for Transportation of shales etc. with mine output for

additional increase in ash.additional increase in ash.

►►Coal yard capacity requirement is reduced.Coal yard capacity requirement is reduced.►►Conveyors availability/life will be Conveyors availability/life will be

increased.increased.increased.increased.►►Electrical consumption for coal processing Electrical consumption for coal processing

will be reducedwill be reducedwill be reduced.will be reduced.►►Maintenance cost of crusher and other coal Maintenance cost of crusher and other coal

banding plant equipment will be reducedbanding plant equipment will be reducedbanding plant equipment will be reduced.banding plant equipment will be reduced.►►Pollution due to coal handling will be Pollution due to coal handling will be

d dd dreduced.reduced.►►Dust production and water requirement Dust production and water requirement

will be reduced.will be reduced.►►CHP equipments may be better utilized.CHP equipments may be better utilized.q p yq p y

►►Power consumption in induced and forced Power consumption in induced and forced draft fans will be reduced.draft fans will be reduced.Q lit f fl h d b tt h ill bQ lit f fl h d b tt h ill b►►Quality of fly ash and bottom ash will be Quality of fly ash and bottom ash will be reduced.reduced.

►► Less load in ESPsLess load in ESPs►► Less load in ESPs Less load in ESPs ►►Better performance of super heater, Better performance of super heater,

economizer etc.economizer etc.economizer etc. economizer etc. ►►Milling plant Milling plant –– less load & power less load & power

consumption and less wear and tear.consumption and less wear and tear.pp►►Maintenance cost of milling units will be Maintenance cost of milling units will be

reduced.reduced.►►Availability of milling plant will increase.Availability of milling plant will increase.►►Power consumption in primary air fan will Power consumption in primary air fan will

b d db d dbe reduced.be reduced.►►Air required for turbulence will be less.Air required for turbulence will be less.

L il tL il t►► Less oil support.Less oil support.

►►Less specific coal consumption.Less specific coal consumption.►►Less specific coal consumption.Less specific coal consumption.►►Improved boiler efficiency.Improved boiler efficiency.

PLF b i dPLF b i d►►PLF may be increased.PLF may be increased.►►Boiler tube may be reduced.Boiler tube may be reduced.yy►►Erosion may be reduced. Corrosion Erosion may be reduced. Corrosion

may also be reducedmay also be reducedmay also be reduced.may also be reduced.►►Pollution of air, water & land may be Pollution of air, water & land may be

reducedreducedreduced.reduced.►►Pollution due SPollution due S--may be reduced by may be reduced by

desulphurisation. SOx. Acid desulphurisation. SOx. Acid rains/corrosion.rains/corrosion.

►► COCO22 emission/unit power generation may be emission/unit power generation may be reduced ( Green House Effect).reduced ( Green House Effect).

►► Less handling of mill reject/less mill rejects.Less handling of mill reject/less mill rejects.►► Beneficiation may help in maintaining uniform Beneficiation may help in maintaining uniform

quality (MM) of coal.quality (MM) of coal.►► Unburned carbon may be reduced in ashes.Unburned carbon may be reduced in ashes.►► MM MM –– Micro constituents may also reduce.Micro constituents may also reduce.►► Handling costs of ash slurry may be reduced.Handling costs of ash slurry may be reduced.►► CV of coal will increase proportionately.CV of coal will increase proportionately.►► Less outages.Less outages.►► Reduction in over all maintenance costs.Reduction in over all maintenance costs.►► Deleterious effects of MM may be Deleterious effects of MM may be

minimized/reduced.minimized/reduced.

Effects of beneficiation of CoalEffects of beneficiation of CoalEffects of beneficiation of CoalEffects of beneficiation of Coal

►► Concentration of certain minerals may increaseConcentration of certain minerals may increase►► Concentration of certain minerals may increase Concentration of certain minerals may increase proportionately proportionately –– effect on combustion, corrosion, effect on combustion, corrosion, erosion, fusion temp. etc. may be studied.erosion, fusion temp. etc. may be studied.

►► Increase of moisture contents may reduce the CV of Increase of moisture contents may reduce the CV of coal.coal.

►► Loss of coal as rejects.Loss of coal as rejects.►► Loss of coal as rejects.Loss of coal as rejects.►► Disposal or utilization of rejects.Disposal or utilization of rejects.►► Increase in the cost of coal. Who will bear the cost?Increase in the cost of coal. Who will bear the cost?►► MM is finely dissemenated in Indian coalMM is finely dissemenated in Indian coal--

washability characteristics are poor.washability characteristics are poor.►► Environmental effects of coal washingEnvironmental effects of coal washing –– land air &land air &►► Environmental effects of coal washing Environmental effects of coal washing –– land, air & land, air &

waterwater-- may be studied.may be studied.

The United Nations Environment The United Nations Environment Programme (UNEP)Programme (UNEP)

G o ing conce n abo t Me c Poll tionG o ing conce n abo t Me c Poll tion►► Growing concern about Mercury PollutionGrowing concern about Mercury Pollution

►► GlobalGlobal MercuryMercury AssessmentAssessment highlightshighlights thethe►► GlobalGlobal MercuryMercury AssessmentAssessment highlightshighlights thetheCoalCoal--FiredFired PowerPower PlantPlant && HeatHeat ProductionProduction isisthethe largestlargest singlesingle sourcesource ofof anthropogenicanthropogenicgg gg p gp gMercuryMercury EmissionEmission::

Hg, NOHg, NO22 and SOx NOx 22% and SOx NOx 22% 2000 year2000 year2000 year2000 year

Emission from SOx 63% Energy Emission from SOx 63% Energy EnvironmentEnvironment

P G ti H (37%)P G ti H (37%)Power Generation Hg (37%) Power Generation Hg (37%) Research CentreResearch Centre

North North

Clean Coal TechnologiesClean Coal TechnologiesClean Coal TechnologiesClean Coal TechnologiesExisting technologies:Existing technologies:Existing technologies:Existing technologies:--►► Pulverized coal combustion Pulverized coal combustion –– ESPs ESPs –– Fly Ash DisposalFly Ash Disposal►► 500 MW Thermal Power Station500 MW Thermal Power Station

Fl idi d B d C bFl idi d B d C b 250MW C i250MW C i►► Fluidized Bed Combustors Fluidized Bed Combustors -- <250MW Capacity<250MW Capacity►► Advantages : Low SOx and NOx emissionsAdvantages : Low SOx and NOx emissionsFor control of pollution For control of pollution ::-- Clean coal technologies can be usedClean coal technologies can be used►► Pre combustion control Pre combustion control –– Coal cleaningCoal cleaning►► During combustion control During combustion control –– Fluidized Bed Combustion, Fluidized Bed Combustion,

Bubbling bed fluidized bed( Small Scale) Recirculatory FB Bubbling bed fluidized bed( Small Scale) Recirculatory FB (l S l )(l S l )(large Scale)(large Scale)

►► PostPost--combustion controlcombustion control-- FGD, NOx, reduction, ESPsFGD, NOx, reduction, ESPs►► Emerging Technologies:Emerging Technologies:Pressurised fliudized Bed combuster, IGCC, CoalPressurised fliudized Bed combuster, IGCC, Coal--water Mixture water Mixture

combustion, Cocombustion, Co--processing of coalprocessing of coal--waste biomass.waste biomass.

Green House EffectGreen House EffectGreen House EffectGreen House Effect

F d i th ti f COF d i th ti f CO / U it l/ U it l►► For reducing the generation of COFor reducing the generation of CO22/ Unit coal / Unit coal fired, the efficiency may have to be improved from fired, the efficiency may have to be improved from the existing 33the existing 33 38% to>45%38% to>45%the existing 33the existing 33--38% to>45%38% to>45%

►►Use of supercritical boilers (development of Use of supercritical boilers (development of Ferrosteels)Ferrosteels)Ferrosteels)Ferrosteels)

►►Use of Ultra supercritical boilers, blending or Use of Ultra supercritical boilers, blending or homogenization of coals cleaning of coal to obtainhomogenization of coals cleaning of coal to obtainhomogenization of coals, cleaning of coal to obtain homogenization of coals, cleaning of coal to obtain cleaner coals for usecleaner coals for use

►►Ultra mega power plants in IndiaUltra mega power plants in India SupercriticalSupercritical►►Ultra mega power plants in IndiaUltra mega power plants in India--Supercritical Supercritical boilersboilers

►► To reduce COTo reduce CO2 2 emissions:emissions:-- the efficiency of power the efficiency of power generation may be improved by using supercritical generation may be improved by using supercritical boilers(<212bar 600boilers(<212bar 600ooC)C)boilers(<212bar, 600boilers(<212bar, 600ooC)C)

►► Ultra supercritical boilers in future.Ultra supercritical boilers in future.►► Net efficiency Net efficiency –– 50% (325bar/62550% (325bar/625ooC)C)

F 33%F 33% 38% t t i PFC B il38% t t i PFC B il►► From 33%From 33%--38% at present in PFC Boiler.38% at present in PFC Boiler.►► No. of projects are in progress in Japan, Denmark No. of projects are in progress in Japan, Denmark

&Germany.&Germany.P t ti l f l b d th b t di dP t ti l f l b d th b t di d►► Potential of coal bed methane may be studied.Potential of coal bed methane may be studied.

►► InIn--situ gasification of difficult to be mined coals may be situ gasification of difficult to be mined coals may be studied.studied.R h & D l t k b t d d t d lR h & D l t k b t d d t d l►► Research & Development work may be extended to develop Research & Development work may be extended to develop technologies for combustion, gasification & beneficiation & technologies for combustion, gasification & beneficiation & liquefaction of coals.liquefaction of coals.

►► Which gasification technology may suit Indian coals havingWhich gasification technology may suit Indian coals having►► Which gasification technology may suit Indian coals having Which gasification technology may suit Indian coals having high ash contents(5high ash contents(5--50%).50%).

►► Indian coals are unique in having higher ash contents. Most Indian coals are unique in having higher ash contents. Most of the technologies were developed to handle lower ashof the technologies were developed to handle lower ashof the technologies were developed to handle lower ash of the technologies were developed to handle lower ash coals.coals.

Clean Coal TechnologiesClean Coal TechnologiesClean Coal TechnologiesClean Coal TechnologiesTwelve Categories:Twelve Categories:Twelve Categories:Twelve Categories:--

1.1. Precombustion control of pollutionPrecombustion control of pollution--beneficiation,beneficiation,1.1. Precombustion control of pollutionPrecombustion control of pollution beneficiation, beneficiation, cleaning, homogenization, blending etc.cleaning, homogenization, blending etc.

2.2. During combustion controlDuring combustion control-- Fluidized bed Fluidized bed combustion staging of combustion optimizationcombustion staging of combustion optimizationcombustion, staging of combustion, optimization. combustion, staging of combustion, optimization. Boiler tuning, low NOx burners, oxyfuel Boiler tuning, low NOx burners, oxyfuel combustion etc.combustion etc.

b i lb i l G O SC SG O SC S3.3. PostPost--combustion controlcombustion control-- FGD, DeNOx, SCR, ESPs, FGD, DeNOx, SCR, ESPs, bag houses etc.bag houses etc.

4.4. Conversion of coal to clean fuel formsConversion of coal to clean fuel forms--gasificationgasification4.4. Conversion of coal to clean fuel formsConversion of coal to clean fuel forms gasification gasification of coal, liquefaction and carbonization of coal, of coal, liquefaction and carbonization of coal, hydrogasificaion of coal etc.hydrogasificaion of coal etc.

55. Refining of coal. Refining of coal--OrganoOrgano--refining of coal, chemical refining of coal, chemical leaching of coal, desulfurisation of coal etc.leaching of coal, desulfurisation of coal etc.

66. Stepwise coal conversion . Stepwise coal conversion -- Integrated ProcessIntegrated Process--OrganoOrgano--refining (Nonrefining (Non--fuel uses &premiumfuel uses &premiumOrganoOrgano--refining (Nonrefining (Non--fuel uses &premium fuel uses &premium combustion uses) and use of RC for power combustion uses) and use of RC for power generation.generation.

77. Co. Co--processing of coal processing of coal -- CoalCoal--oil mixture oil mixture combustion, coalcombustion, coal--waste gasification. Coalwaste gasification. Coal--biomass combustion & gasification Coalbiomass combustion & gasification Coal waterwaterbiomass combustion & gasification. Coalbiomass combustion & gasification. Coal-- water water Mixture combustion etcMixture combustion etc..

88 Underground coal gasificationUnderground coal gasification88. . Underground coal gasificationUnderground coal gasification99. use of coal bed methane. use of coal bed methane10 supercritical PC boilers etc10 supercritical PC boilers etc10. supercritical PC boilers etc.10. supercritical PC boilers etc.11. Ultra supercritical boilers, pressurised 11. Ultra supercritical boilers, pressurised

pulverised coal combustion.pulverised coal combustion.12. IGCC, fuel cells, H12. IGCC, fuel cells, H22 etc.etc.

Precombustion ControlsPrecombustion ControlsPrecombustion ControlsPrecombustion Controls

B fi i ti f C lB fi i ti f C l Ji i d diJi i d di►► Beneficiation of CoalBeneficiation of Coal-- Jigging, dense media, Jigging, dense media, Cyclones, Froth Flotation, Oil Agglomeration, Cyclones, Froth Flotation, Oil Agglomeration, Oleoflotation etc.Oleoflotation etc.O eo otat o etcO eo otat o etc

►► Homogenisation of coal by mixing better quality Homogenisation of coal by mixing better quality coal with the low quality coal. Skill or techniques of coal with the low quality coal. Skill or techniques of

l i i Bl di f diff t ll i i Bl di f diff t l I t dI t dcoal mixing. Blending of different coalscoal mixing. Blending of different coals-- Imported Imported coal or good coal with inferior coal for upgradation.coal or good coal with inferior coal for upgradation.

►► Supplementary or matching characteristics may beSupplementary or matching characteristics may be►► Supplementary or matching characteristics may be Supplementary or matching characteristics may be used.used.

►► Ash Fusion TemperatureAsh Fusion Temperaturepp►► HGIHGI►► Slagging factor depends on Basic / Acidic ratio.Slagging factor depends on Basic / Acidic ratio.

►►Chemical Cleaning of CoalChemical Cleaning of Coal-- Super Clean Super Clean coalcoalcoalcoal

►►Bioleaching of CoalBioleaching of Coal-- Use of MicrobesUse of Microbes►► Integrated ApproachIntegrated Approach►► Integrated ApproachIntegrated Approach►►Consumption of Coal 1997Consumption of Coal 1997--20002000

Industry 1996Industry 1996--97 199797 1997--98 199898 1998--9999All Industries 283.12 292.59 282.64All Industries 283.12 292.59 282.64Cement 12.71 13.57 13.31Cement 12.71 13.57 13.31Fertilizer 5.26 5.66 6.4Fertilizer 5.26 5.66 6.4Iron and Steel 23 39 21 43 20 93Iron and Steel 23 39 21 43 20 93Iron and Steel 23.39 21.43 20.93Iron and Steel 23.39 21.43 20.93Thermal Power 199.24 210.77 215.38Thermal Power 199.24 210.77 215.38Other Industries 42.52 41.16 26.62Other Industries 42.52 41.16 26.62(Paper, textile, bricks(Paper, textile, bricksand kiln and others)and kiln and others)

Low

DeepCoal Cleaning

HighLow

Cleaning

Total CleaningCombustibleRecovery

Dense–Medium Coarse/ Small/ Fine Coal

Dense Medium Coarse/Small/Fine CoalYield

Cost SettlingPriceDense–Medium Coarse/Small/Fine Coal

Coarse/Small Coal Cleaning

Price

Coarse coal Cleaning

LowHigh

Breaking/ Crushing/ Screening only

No coal Preparation sold Raw

Low

p

Fluidized Bed Combustion [FBC]Fluidized Bed Combustion [FBC]During Combustion During Combustion --CCTCCT

Fluidized Bed Combustion (FBC) has been Fluidized Bed Combustion (FBC) has been developed to fire low grade fuels with developed to fire low grade fuels with hi h h hi h l h iddli thi h h hi h l h iddli thigh ash, high sulphur, middlings etc.high ash, high sulphur, middlings etc.

FBCFBC –– CombustionCombustion << 900900ooCC –– lessless NOxNOx formationformationUseUse ofof LimestoneLimestone -- TrappingTrapping SS asas gypsumgypsumFF llll ll (( 1010MW)MW) B bbliB bbli FBCFBC LLForFor smallsmall scalescale (<(<1010MW)MW) –– BubblingBubbling FBCFBC –––– LargerLarger

ScalesScales 100100--125125 MWMW ––usedused CirculatingCirculating FBCFBC..EfficiencyEfficiency –– SameSame asas ofof PFPF CombustionCombustion 3333--3838%%EfficiencyEfficiency SameSame asas ofof PFPF CombustionCombustion 3333 3838%%FBCFBC –– HighHigh AshAsh CoalsCoals.. WasheryWashery RejectsRejects.. MiddlingsMiddlings

etcetc..

Advantages of FBCAdvantages of FBCAdvantages of FBCAdvantages of FBC

1 Less SOx and NOx production1 Less SOx and NOx production1. Less SOx and NOx production1. Less SOx and NOx production2. Combustion without Oil support2. Combustion without Oil support3. Boiler is compact3. Boiler is compact4 Heat and mass t ansfe is good4 Heat and mass t ansfe is good4. Heat and mass transfer is good4. Heat and mass transfer is good5. Less effect of inconsistency in coal 5. Less effect of inconsistency in coal yy

quality quality 6 Ash produced is less erosive and may6 Ash produced is less erosive and may6. Ash produced is less erosive and may 6. Ash produced is less erosive and may

be utilized properly. be utilized properly.

►►Work to develop large scale AFBC is inWork to develop large scale AFBC is in►►Work to develop large scale AFBC is in Work to develop large scale AFBC is in progress.progress.

►►AFBC at Provence /Gardene, France AFBC at Provence /Gardene, France ––250MW capacity under operation since 250MW capacity under operation since 1995 Ai i t l t 600MW i1995 Ai i t l t 600MW i1995. Aim is to scale up to 600MW in 1995. Aim is to scale up to 600MW in the future.the future.

►► In US FBC of 300 MW capacity has been In US FBC of 300 MW capacity has been developed.developed.developed. developed.

►►A few operational problemsA few operational problems--►►A few operational problemsA few operational problemsexperienced.experienced.

Pressurised Fluidized Bed Pressurised Fluidized Bed Combustion (PFBC) plantsCombustion (PFBC) plants

►►Pressurised Fluidized Bed Combustion Pressurised Fluidized Bed Combustion (PFBC) plants (PFBC) plants –– generate gas generate gas –– expanded expanded through a gas turbine to generate additional through a gas turbine to generate additional power. Efficiency of PFBC combined cycle power. Efficiency of PFBC combined cycle plantsplants-- 4242--45%.45%.

►►Commercial scale plants are presently in Commercial scale plants are presently in p p yp p yoperation and some are under development operation and some are under development in Spain (Esccaron), USA (Todd), Sweden in Spain (Esccaron), USA (Todd), Sweden (Vartan), Japan (Wakamarsu)(Vartan), Japan (Wakamarsu)

Supercritical Boilers:Supercritical Boilers:--More than 100 under operationMore than 100 under operation ––abroadabroadMore than 100 under operation More than 100 under operation abroadabroad►►Efficiency of PF fired boilersEfficiency of PF fired boilers

I I di 33%I I di 33% 35%35%►► In India ~ 33% In India ~ 33% -- 35%35%►►Abroad ~ 38%Abroad ~ 38%►►Efficiency of PF fired plants may be Efficiency of PF fired plants may be

improved by moving to higher improved by moving to higher p y g gp y g gTemperatures and Pressures.Temperatures and Pressures.

►►Development of New Ferritic steelsDevelopment of New Ferritic steels►►Development of New Ferritic steels Development of New Ferritic steels coupled with improved steam turbines coupled with improved steam turbines design has allowed this to happen.design has allowed this to happen.design has allowed this to happen.design has allowed this to happen.

►►Supercritical PF boiler Supercritical PF boiler –– Being Being commissioned in Denmarkcommissioned in Denmarkcommissioned in Denmarkcommissioned in Denmark

►►Efficiency ~ 45%Efficiency ~ 45%

Supercritical PFBCSupercritical PFBCFirst supercritical PFBC is under construction in Japan.First supercritical PFBC is under construction in Japan.

System requires hot gas clean up or a gas turbine to System requires hot gas clean up or a gas turbine to withstand particulates in the gaswithstand particulates in the gaswithstand particulates in the gas.withstand particulates in the gas.

Ceramic candle filters, cyclones are used.Ceramic candle filters, cyclones are used.

Research & Development WorkResearch & Development Work –– PFBC technology is required inPFBC technology is required inResearch & Development Work Research & Development Work PFBC technology is required in PFBC technology is required in following areas :following areas :

1.1. Coal and Sorbent preparation and feeding systems Coal and Sorbent preparation and feeding systems 2.2. Hot gas CleaningHot gas Cleaning3.3. Effects of gas contaminants or gas turbine performance Effects of gas contaminants or gas turbine performance

efficiency and life etc.efficiency and life etc.BHEL BHEL has developed > 100 MW AFBC Boilers in India has developed > 100 MW AFBC Boilers in India ––

Temperature 540Temperature 540ooCCTemperature 540Temperature 540ooCCWork has also been carried out on PFBC facility of 6TPD at Work has also been carried out on PFBC facility of 6TPD at

Hyderabad Hyderabad –– BHELBHELPower Generation Efficiency is more in IGCC.Power Generation Efficiency is more in IGCC.yyIt is easier to clean Gas than Solid fuels. Hot gas Cleaning & It is easier to clean Gas than Solid fuels. Hot gas Cleaning &

cyclone scrubbers may be used.cyclone scrubbers may be used.

►►UltraUltra--Superritical (USC) Superritical (USC) –– PF boilers have PF boilers have also been developedalso been developedalso been developedalso been developed

►► Steam Temperatures < 566Steam Temperatures < 566ooCC-- in future 700in future 700ooCC►► Pressure < 248 BarPressure < 248 Bar-- in future >330 barsin future >330 bars►► Pressure < 248 BarPressure < 248 Bar-- in future >330 bars.in future >330 bars.►►Higher efficiencies < 50% over the Next Higher efficiencies < 50% over the Next

Decade or soDecade or soDecade or soDecade or so►► Improvement in efficiency means less fuel fired/ Improvement in efficiency means less fuel fired/

unit power generationunit power generationunit power generation.unit power generation.►► Less pollution due to fuel burning.Less pollution due to fuel burning.►► Such projects are in progress at GermanySuch projects are in progress at Germany►► Such projects are in progress at Germany, Such projects are in progress at Germany,

Denmark, Japan.Denmark, Japan.►► Japanese aim to go up to 650Japanese aim to go up to 650ooC and 350 bar byC and 350 bar by►► Japanese aim to go up to 650Japanese aim to go up to 650ooC and 350 bar by C and 350 bar by

adding 12% Cr W Steel.USAadding 12% Cr W Steel.USA-- 700700ooC and 350 C and 350 barsbarsbars.bars.

IGCC POWER GENERATIONIGCC POWER GENERATION

►► IGCC technology is in the final stage of IGCC technology is in the final stage of demonstration and is moving towards demonstration and is moving towards commercialization stages.commercialization stages.

►► IGCC plants 100 MW operated at Cool water IGCC plants 100 MW operated at Cool water p pp pfor 5 years(1984for 5 years(1984--89) US has taken up 3 89) US has taken up 3 IGCC projects under Clean Coal Technology IGCC projects under Clean Coal Technology p j gyp j gydemonstration projects.demonstration projects.

►► In India BHEL In India BHEL ––IGCC plantsIGCC plants

►►Moving Bed GasifiersMoving Bed Gasifiers--10001000ooC & 10kg/cmC & 10kg/cm22

to generate 6 2 MW(4MWto generate 6 2 MW(4MW--Gas TurbineGas Turbine--2 22 2to generate 6.2 MW(4MWto generate 6.2 MW(4MW--Gas TurbineGas Turbine--2.2 2.2 MW from Steam Turbine)MW from Steam Turbine)

►►BHEL BHEL ––Pressurized fluidized bed gasifier to Pressurized fluidized bed gasifier to handle 150TPD coal (1000handle 150TPD coal (1000ooC & 10 atm.)C & 10 atm.)

►►CFBC boilersCFBC boilers--costlier than PF boilerscostlier than PF boilers

►►High SHigh S--lignitelignite--CFBCCFBC

►► IICT, HyderabadIICT, Hyderabad-- Moving bed gasifierMoving bed gasifier►►BHELBHEL-- APGen APGen –– 100 MW IGCC100 MW IGCC

Advantages of IGCCAdvantages of IGCC1.1. Higher efficiency >45%Higher efficiency >45%2.2. Low emissions of NOx, CO etc.Low emissions of NOx, CO etc.3.3. Up to 99% S recovered.Up to 99% S recovered.4.4. Low water consumptionLow water consumption5.5. Generation of small quantity residueGeneration of small quantity residue6.6. May handle high ash coal and other materials May handle high ash coal and other materials

such as biomass petroleum coke plastics etcsuch as biomass petroleum coke plastics etcsuch as biomass, petroleum coke, plastics etc. such as biomass, petroleum coke, plastics etc. also.also.

IGCCIGCC plants(plants(8080 100100MW)areMW)are beingbeing•• IGCCIGCC plants(plants(8080--100100MW)areMW)are beingbeingcurrentlycurrently operatedoperated--BuggenumBuggenum (the(theNetherlands)Netherlands) && WabashWabash RiverRiver (USA)(USA)Netherlands)Netherlands) && WabashWabash RiverRiver (USA)(USA)

•• IGCCIGCC plantsplants underunder constructionconstruction inin USAUSA(T(T TT C kC k Pi iPi i Pi )Pi ) dd(Tampa,(Tampa, TomsToms CreekCreek.. PinionPinion Pine)Pine) andandSpainSpain (Puertollano)(Puertollano)..

•• ExistingExisting systemsystem atat thethe demonstrationdemonstrationstagestage areare alreadyalready achievingachieving efficiencyefficiency ofof4545%% andand areare expectedexpected toto reachreach 5050%%withwith technologytechnology andand materialmaterialdevelopmentdevelopment..

Clean Coal Technology Program Started in USA in 1986

Millions and Billions of dollars are being spent on Clean Coal Technology Programmes World over.gy g

USDOE Clean Coal Technology Update - Participation of commercial organizations on cost sharing basis.commercial organizations on cost sharing basis.

Several applications have been received by them.

USDOE Programmes:Clean Coal Technology Development Program Power Plant I t I iti ti (CCTDPPPII)Improvement Initiative (CCTDPPPII)Clean Coal Power Initiative (CCPI)

DOE Strategic Goals:President’s Coal Research Initiative

COCO SEQUESTRATION AND UTILIZATIONSEQUESTRATION AND UTILIZATIONCOCO22 SEQUESTRATION AND UTILIZATIONSEQUESTRATION AND UTILIZATION1.1. Photosynthesis Photosynthesis AfforestationAfforestation--Fuelwood Fuelwood

farmingfarming-- Faster growing Faster growing a ga g as e g o gas e g o gtreestrees--Algal PondsAlgal Ponds

2.2. Coalbed Methane ExtractionCoalbed Methane Extraction Two COTwo CO22 molecules lead to molecules lead to the evolution of one the evolution of one molecule of methanemolecule of methane

3.3. Oil Drilling Oil Drilling Winning oil from Residual Winning oil from Residual Oil in WellsOil in Wells

h i l h ih i l h i ( h l)( h l)4.4. Chemical synthesis Chemical synthesis COCO22+C+CCHCH33OH(Methonal) OH(Methonal) CHCH33(Methane)(Methane)

5.5. COCO22-- Gasification of CoalGasification of Coal COCO22+C +C 2CO 2CO i i C l ii i C l i b d d C l ib d d C l i6.6. Dumping in Coal Mines Dumping in Coal Mines Abandoned Coal MinesAbandoned Coal Mines

7.7. Dumping in Salt MinesDumping in Salt Mines Salt formation, Slow Salt formation, Slow Reactions, Deposition under Reactions, Deposition under pressurepressurepressurepressure

8.8. Dumping in oceans Dumping in oceans Dissolution in Ocean WaterDissolution in Ocean Water9.9. Scrubbing with Monoethanol Scrubbing with Monoethanol Adsorption and DesorptionAdsorption and Desorption

A i th A iA i th A iAmine, other AminesAmine, other Amines

10.10. Dumping of AquiferDumping of Aquifer Dissolution in waterDissolution in water11.11. UtilizationUtilization Dry ice, Cold Drinks, Fire Dry ice, Cold Drinks, Fire

Extinguishers, As Chemical Extinguishers, As Chemical Reagents, Urea Manufacture, Reagents, Urea Manufacture, S C i i l i fS C i i l i fSuper Critical Extraction of Super Critical Extraction of Essential Oils and Pharma Essential Oils and Pharma ceuticals, Reagents, Polymers, ceuticals, Reagents, Polymers, P t h i l tP t h i l tPetrochemical, etc.Petrochemical, etc.

12.12. Artificial PhotosynthesisArtificial Photosynthesis COCO22+H+H22O O GlucoseGlucose13.13. Alkali Leaching Alkali Leaching CarbonatesCarbonates14.14. BiosequestrationBiosequestration Use by T. Use by T. ferroxidansferroxidans, ,

chemoautotrophs, chemoautotrophs, Photosynthesis bacteria, Photosynthesis bacteria, yycynobacteria, etc. cynobacteria, etc.

15.15. Efficiency improvement Efficiency improvement Superficial Boilers, IGCC, PFBC, Superficial Boilers, IGCC, PFBC, Zero Emission, Power Zero Emission, Power ,,Generation Generation

16.16. Solar Cracking Solar Cracking COCO22 C + C + OO22 ΔΔhvhvgg 22 2 2

17.17. Plasma CrackingPlasma Cracking COCO22 C + C + OO2 2 ΔΔ18.18. Anaerobic FermentationAnaerobic Fermentation COCO22+C+CCHCH33OH OH CHCH3 3

ConclusionsConclusions►►Clean coal Technologies may help in the efficient Clean coal Technologies may help in the efficient

utilization of coalutilization of coalutilization of coal.utilization of coal.►►These may lead to the reduction of COThese may lead to the reduction of CO22 emissions emissions

with the possibility of earning credits of CDMwith the possibility of earning credits of CDMpo b y o a g d opo b y o a g d o►► Efforts in cleaning coal, Fluidized bed combustion, Efforts in cleaning coal, Fluidized bed combustion,

supercritical boilers have already started in India.supercritical boilers have already started in India.►►There may be a need to go in for even chemical There may be a need to go in for even chemical

cleaning of coal to conserve coal reserves by their cleaning of coal to conserve coal reserves by their efficient utilizationefficient utilizationefficient utilization.efficient utilization.

►►However, chemical cleaning processes may have However, chemical cleaning processes may have to be made economical Some efforts in thisto be made economical Some efforts in thisto be made economical. Some efforts in this to be made economical. Some efforts in this direction are underway in Japan and in our direction are underway in Japan and in our laboratory at IIT Delhi.laboratory at IIT Delhi.

THANK YOTHANK YO