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Rosemary Falcon , Roland Zepeck, Mike Andrews
Powergen, Johannesburg November 2012
IMPACT of COAL QUALITY on COMBUSTION and POWER GENERATION
Southern African Scenarios and challenges in Clean Coal Technologies
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Outline
1. Introduction -low carbon economy, dependence, prod users, qualities
2. Current experiences in combustion performance
3. Advanced Methods of Investigation
Coal Quality Assessments
Temperature Assessments using Thermography
Observations
4. Conclusions
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1. Introduction
Relevance of coal in SA - Highest dependence on coal in the world
92% of energy /electricity is coal-based,
- 14 major coal-fired power stations
- 6 000 industrial boiler users
40% of liquid fuels derived from CTL
Major foreign exchange earnings
Commitment to a Low Carbon Economy -
South Africa is committed to GHG and CO2 reduction
Methods to reduce GHG emissions CCS; Increased combustion and boiler efficiency
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Flue gas
Turbine
Mill Boiler
De-NOx ESP De-SOx
Generator Condenser
Steam Water
Coal
CO2 Storage Pollutants to be reduced
•SO2, NOx, Mercury •Particulate matter
CO2
CO2 Capture
(2) Reducing of non-GHG emissions
(3) Carbon Capture and Storage
(1) Reducing coal consumption
(increase boiler efficiency)
Technologies for cleaner coal generation
Future Technologies for a Low Carbon Economy
4
i.e. Reduction in both GHG and non-GHG (NOx, SO2, PM) emissions.
N2, H2O
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Outline
1. Introduction -low carbon economy, dependence, prod users, qualities
2. Current experiences in combustion performance
3. Advanced Methods of Investigations
Coal Quality Assessments
Temperature Assessments using Thermography
Observations
4. Conclusions
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Challenges in the Coal Industry - 1
• Run-of-mine coal qualities are generally poor (high ash)
• Beneficiation of coal is a “must” (difficult)
• Bulk of the best quality coals have been mined out in conventional areas
• Remaining coal resources lie in relatively remote coalfields
• Infrastructure in those areas is as yet lacking (also many are difficult to mine conventionally)
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Challenges in the Coal Industry - 2
• Increasing export tonnages to the India and the Far East leaves poorer grades for local markets
• Increased costs to obtain higher grades and qualities of coal
• Variable combustion efficiencies occur due to poor and variable feedstocks
• Environmental constraints increasingly stringent post 2012 (SOx, NOx, CO2, particulates); C tax pending
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LARGE SCALE POWER GENERATING PULVERISED FUEL BOILER
Power Station L – • Extreme difficulty in ignition • Required 7 burner designs (Mark 7) • 10m added to height of boiler • 1m extra between rows of burners • Tube mills selected to ensure extra fine pf sizes • Burner mouths melted • Pop-corn fly ash blocked air heaters • Unusually high % of fly ash
Power Station M – • Ignition and combustion difficulties when using coal from different zones in the coal sequence (non-design coals)
Unscheduled outages sometimes occur at a rate of one a week per boiler in some power stations
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Eskom 2012
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WATERTUBE BOILERS CHAIN GRATE SPREADER STOKERS
Spreader stoker Boilers:- • Poor ignition when air-born • Delayed combustion • High level freeboard fire-ball • Extreme slagging and fouling • High percentage fines carryover • Excessively high back end temperatures • Excessively high temperatures on the grate, melting and fusing of chains and refractory linings
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FLUIDISED BED BOILERS
• Corrosion of the sparge pipes below the rims • Agglomeration of particles within the moving bed • Ash deposits dropping down to the base • Difficulties in ash removal • Difficult temperature control
During the commissioning of one
bubbling bed boiler, the entire bed slagged
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CEMENT KILNS
Flame configuration, heat transfer and burnout change with coal type - Grade, CV and proximate analyses are the same
Desired effect – short hot flame
Problem effect – long flame
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SPECIFICATIONS OF TWO COALS NB: THE SAME PROXIMATE ANALYSES
BUT DIFFERENT COMBUSTION PROPERTIES
Coal A Coal B
Gross Calorific Value MJ/kg ad : 28,70 28,93 Proximate Analyses %ad :
Inherent Moisture 3,7 2,4 Volatile Matter %ad 30,5 28,9 Ash Content %ad 11,1 12,2 Fixed carbon 54,7 56,5
Combustion efficiency 83,0 66,0 C in ash% 4,4 15,5
Unburnt C in ash can be as high as 73% in some industrial boilers ; often 25-35%+
Slagging can occur even when ash fusion temperatures are high
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It has therefore become vital to find ways to:-
increase combustion efficiency
Increase power generating capacity
Reduce outages (due to slagging, fouling, water tube/wall damage etc)
Minimise GHG and especially CO2 emissions
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Outline
1. Introduction -low carbon economy, dependence, prod users, qualities
2. Current experiences in combustion performance
3. Advanced Methods of Investigation
Coal Quality Assessments
Temperature Assessments using Thermography
Observations
4. Conclusions
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a
QUALITY OF FEEDSTOCK
Additional analyses
FUNDAMENTAL CONSTITUTION
Petrographic and CCSEM Analyses
Vitrinite
Exinite
Inertinite
Quartz
Clay
Pyrite
Refl. of Vitrinite
Std Deviation
Reflectogram
ORGANIC INORGANIC RANK
MACERALS MINERALS MATURITY
Conventional analyses
EMPIRICAL PROPERTIES
Chemical and Physical Analyses
PROXIM.OTHER ASH ULTM
CV
AFT
Sl
HGl
SiO2
Al2O3
Fe2O3
CaO
MgO
C
H
O
N
P
S
H2O
VM
ASH
FC
KEY
MACERALS – Microscopic residues ofdecomposed plants materials
RANK – Levels of maturity
COAL QUALITY ASSESSMENTS FOR COMBUSTION
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a
QUALITY OF FEEDSTOCK
Additional analyses
FUNDAMENTAL CONSTITUTION
Petrographic and CCSEM Analyses
Vitrinite
Exinite
Inertinite
Quartz
Clay
Pyrite
Refl. of Vitrinite
Std Deviation
Reflectogram
ORGANIC INORGANIC RANK
MACERALS MINERALS MATURITY
Conventional analyses
EMPIRICAL PROPERTIES
Chemical and Physical Analyses
PROXIM.OTHER ASH ULTM
CV
AFT
Sl
HGl
SiO2
Al2O3
Fe2O3
CaO
MgO
C
H
O
N
P
S
H2O
VM
ASH
FC
KEY
MACERALS – Microscopic residues ofdecomposed plants materials
RANK – Levels of maturity
COAL QUALITY ASSESSMENTS FOR COMBUSTION
TO ORGANIC COMPOSITION IN COAL
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INERTINITE
VITRINITE
15 m
10 m
5 m difference
MACERAL BURNOUT TIMES AT 1 000oC AND
A VELOCITY OF 11m/sec
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BEHAVIOUR OF COAL LUMPS ON HEATING - BITUMINOUS COAL -
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DOMINANT FORMS OF CHAR DERIVED FROM BITUMINOUS
COAL
HIGHLY POROUS AND
REACTIVE
MIXED SEMI-POROUS
AND DENSE INERT
DENSE INERT
NON- REACTIVE
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Power station L
INERT ORGANIC PARTICLE
Coal feedstock Fly ash char
Coal particle (feed) and Unburnt char particle (in fly ash) NB: inert carbon form in char is unchanged
[ToC in Boiler estimated to be 1800oC]
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SPECIFICATIONS OF TWO COALS NB: THE SAME PROXIMATE ANALYSES
BUT DIFFERENT COMBUSTION PROPERTIES
Coal A Coal B
Gross Calorific Value MJ/kg ad : 28,70 28,93 Proximate Analyses %ad :
Inherent Moisture 3,7 2,4 Volatile Matter %ad 30,5 28,9 Ash Content %ad 11,1 12,2 Fixed carbon 54,7 56,5
Combustion efficiency 83,0 66,0 C in ash% 4,4 15,5
Petrographic Composition % :
Maceral comp (vitrinite%) 62,0 30,0 Rank (RoV random%) 0,73 0,75
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ORGANIC MATTER VARIES ACCORDING TO Age, Continents and Regions (Gondwana to Laurasia) Nature of the coal seam
Mine plan and extraction procedures Levels of Beneficiation
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Qualitative Organic Matter differences between Carboniferous Laurasian and Permian Gondwana Coals
Key Technological Property on heating
GERMAN COAL
RUN-OF-MINE
SOUTHERN AFRICAN
RUN-OF-MINE
Organic
% Petrograph
ic component
s
Reactive vitrinite 80 25
Highly reactive Liptinite/exinite
10 5
Inert to semi-inert Inertinite
10
70
Ash % Low High
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* Petrographic observations indicate that reactive macerals ignite and burn out fast whereas inert maceral forms undergo delayed ignition and combustion. *
Age, Continents and Regions
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COAL QUALITY CHANGES SUBJECT TO MINE PLAN - WHOLE SEAM OR SELECTED PARTS OF THE SEAM -
Hanging wall
Upper dull coal
Mid-seam parting
Lower bright t coal
Foot wall
Selective mining
Whole seam mining
Dull coal is inertinite rich and poorly reactive
Bright coal is vitrinite rich and highly reactive
Nature of the coal seam Mine plan and extraction procedures
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ASH, VOLATILE MATTER AND MACERAL CONTENT CHANGES WITH BENEFICIATION
HMS BENEFICIATION PROCESS PRODUCTS ASH % VOLATILE%
Low ash - 8 30 Middlings 1 - 14 24 Middlings 2 - 25 18 Discard - 75 10
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Levels of Beneficiation
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Facts and Fantasies
FANTASY FACT
CV, proximate, ultimate and ash analyses are sufficient to market and select a coal
NO – coals from different geographic regions, collieries, seams, washed products will require in-depth analysis and technical
assessment to ensure efficient combustion performance
All volatiles are combustible
NO – some are incombustible and inert; this is evident especially in coals with ash
contents >20%; e.g. CO2 from carbonate minerals and H2O from clays
Low volatile coal is not likely to ignite and combust
NO – there are certain coals with low volatiles which will ignite and combust if the combustion conditions are suitable –
BUT IT IS NECESSARY TO COMPENSATE FOR THE MORE EXTREME CONDITIONS
NECESSARY TO BURN THEM
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Outline
1. Introduction -low carbon economy, dependence, prod users, qualities
2. Current experiences in combustion performance
3. Advanced Methods of Investigation
Coal Quality Assessments
Temperature Assessments using Thermography
Observations
4. Conclusions
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Video – Grate-fired furnace
Lateral view of thermal camera into grate-fired boiler – computer determines temperature based upon colour
THERMOGRAPHY
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Grate fired – delayed combustion 1
1544
1517
1453
1409
1382
1544
COAL X - Sequence 1
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Grate fired – delayed combustion 2
1762
1758
1750
1747
1727
1699
COAL X- Sequence 2
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Grate fired – delayed combustion 3
1699
1736
1732
1729
1741
1722
COAL X- Sequence 3
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Grate fired – delayed combustion 4
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1793
1792
1782
1771
1788
1787
COAL Z
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PF-Boiler - Power station A
Thermographic angle of viewing
1734
1726
1697
NB: Top of an off-centre fireball – temperatures 1700oC ++
1717
1707
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Outline
1. Introduction -low carbon economy, dependence, prod users, qualities
2. Current experiences in combustion performance
3. Advanced Methods of Investigation
Coal Quality Assessments
Temperature Assessments using Thermography
Observations
4. Conclusions
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Observations
Proximate (volatiles and ash analyses) and calorific value alone do not indicate how coals will burn, at what temperatures and for how long.
There is clear evidence that certain coals burn at higher temperatures than was previously thought
There is also clear evidence of delayed combustion – longer than previously believed
These facts are likely to have significant impact on boiler operation and
combustion efficiencies e.g. Thermal damage to water tubes and superheaters, clinkering and excessive NOx formation
These facts are likely to have significant impact on future boiler design, e.g. Requiring high temperature steels in boiler manufacture
Further work needs to be done to study combustion performance linked to more specific properties of coal and using thermography to control and achieve higher combustion efficiencies
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Outline
1. Introduction -low carbon economy, dependence, prod users, qualities
2. Current experiences in combustion performance
3. Advanced Methods of Investigation
Coal Quality Assessments
Temperature Assessments using Thermography
Observations
4. Conclusions
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Conclusions
Anomalous combustion behaviour can be explained By in-depth analysis of coals (petrographic composition)
By observation and monitoring in situ using on-line thermography
Combustion and thermal efficiency can be improved and controlled By monitoring combustion behaviour via thermography
By adjusting operating conditions in real time
Significant reductions in CO2 and NOx emissions can be achieved by ensuring optimum combustion and burn-out
by maintaining maximum steam output
By reducing slagging, fouling and water tube failures and minimum outages
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Energy – source of Industrialisation! Africa needs this….
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Coal provides over 45% of the world’s energy requirements
THANK YOU