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• Effective Energy Technologies GmbH, Austria – Pre-design – CWS production & combustion equipment
• Kögler Technique GmbH, Austria – Control systems for CWS
• Energy Systems, Russia – General Design – Steam power generation – EPC-contractor
• ICI International,India – Consultants /Advisor/Co-ordinator – Cement Kiln & Power generation
Participants of the project
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• As you are aware, the SOx, NOx standards that were notified by the Ministry of Environment, Forests & Climate Change (MOEFCC) in December 2015, according to our estimates, would reduce freshwater withdrawal from coal power sector by 85%, particulate emissions by 65%, and SOx emissions by over 85% and NOx by almost 70%. These are massive cuts and they will be achieved by implementing a set of standards that are no more stringent than what other countries across the world have imposed on their coal power sectors. In fact, China today implements far more stringent standards than those that have been notified by the MOEFCC.
• The MOEFCC has set a deadline of 7 December 2017 for the coal power sector to meet these standards. But the industry has so far dragged its feet. Most companies have not even started initial work. The industry is demanding at least five more years to implement these standards. Demand accepted fresh dead line is being extended by December 2022.
• Thermal power generation process will become more complex owing to the need of addressing climate change issues and mitigating stricter emission norms in future, at the same time tremendous pressure is on the generator to make the electricity affordable to all and to also remain competitive in the market.
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Must Meet - Stringent Regulations
The calorific value of one kg of coal depending on the type, amounts to between
17 MJ/kg - 33 MJ/kg but if we split water vapors present in the flame back to
Hydrogen & Oxygen we get extra energy of 142 MJ/Kg/Water = Kcal
33916.81/Kg/Water. This can save 10-15% fuel in a cement plant with drastic
reduction in CO2 & NOx formation but this is possible only in a Vortex chamber
as in a Vortex at high temperatures the combustion product (water) starts dissociating
back into Hydrogen & Oxygen which invites formation of simpler hydrocarbon products
with the reaction of CO2 +H2O called Sabatier reaction which takes place within the flame
C>CO>CO2>H2O>CH4>C2H4>C2 H6> >>>> and raise the flame temperature.
Gasification Process inside the Kiln
Waste to Fuel
Waste to Fuel
CWS - Coal slurry as a partial / full replacement of oil, gas and coal in Boilers & Cement Kiln.
December 2016 Gurgaon-India
Technology Overview
Carbon Slurry Fuel (CWS)
CWS is a liquid mixture of finely milled coal or other carbonaceous materials with water or an aqueous emulsion:
CWS = Coal (58% ... 70%) + emulsion (29% ... 40%)
Usage of oil-based and organic water emulsions improves CWS calorific value.
CWS has almost the same viscosity as masut (Heavy Fuel Oil) what makes it suitable both for pumping on short and long distances and for spraying into a boiler via specially designed nozzles. Gas, oil/diesel, coal still could be used as a redundant fuel for boilers.
Raw materials for CWS
Coal of most types: brown, gas, long-flaming, skinny, anthracite
Carbonaceous Raw Materials: pyrocarbon (carbon after pyrolysis of tires, rubber), petroleum coke, etc.
Desired raw material ash content - up to 15 ... 16%
CWS could be produced from charcoal which is renewable
Production Process
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CWS spraying and combustion
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Technology: Advantages
Main Advantages of CWS Technology:
• Fuel costs reduction for coal-fired, oil-fired boiler of small and medium power for 30 ... 50%
• Complete combustion of coal (carbon) in the form of CWS compared with layer combustion of coal boilers.
• Significant Reduction of NOx emissions, possibility of compensation of SOx emissions ( with limestone).
• Possibility of using coal fines.
• CWS is explosion proof.
• Reduce slagging on boiler tubes.
• The possibility of recycling sewage sludge, waste
• Possibility of using sewage water/ r eject water / rain water
Costs Reduction
Minimal Emissions
Feedstock Utilization
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• In a steam boilers – oil, gas, coalfired
– CWS as a main or additional fuel
– NOx reduction
– Coal fines utilization
– Improve combustion efficiency – CWS is a pulverized coal in a liquid form
• In cement kilns
– Additional fuel for kilns
– Coal fines utilization
– Improve combustion efficiency
CWS applications
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Initial Data / Potential Savings
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Theory of combustion suggests that 2.67 gm oxygen is required for 1 gm carbon
combustion, 1 gm oxygen is required for 1 gm sulfur combustion, and 8 gm
oxygen is required for 1 gm hydrogen combustion. Hence 1 gm of coal (fuel)
which contains C gm carbon, S gm sulphur and H gm hydrogen, requires (2.67C +
S + 8H) gm of oxygen for efficient combustion
The theoretical oxygen required to burn 1 kg of coal is then
2.67 x C % + 8 x H% + 1 x S % - O% = 1.64 kg of Oxygen for 1 kg of Coal
containing 57.2 % Carbon, 2.2 % Hydrogen , 0.5 % Sulphur and 6.9 %
Oxygen…..Air contains 23.2% by weight of oxygen.
The theoretical air required to burn 1 kg of coal containin 57.2 % carbon
= 1.64 / 23.2% = 7.1 kg of Air for 1 kg of Coal .Petcoke is >90% carbon.
In case of NG this air quantity becomes double
In case of CWS the air quantity is only 3 kg per kg
• For CWS combustion it is suggested to amend a steam boiler with one ore
several CWS nozzles
• Existing burners still will be used as a main and/or stabilization fuel
• It is expected that heat input from CWS shall be between 45..65%. The rest of heat
will be produced by existing coal input
• For 20 tph and smaller boilers pre-chamber might be the best solution for
improving the combustion efficiency. CWS pre-chamber needs an oil only for the
pre-heating phase, later on CWS shall be burned in a pre-chamber without a
support fuel.
Technical specifics
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Wet Milling Machine
Easy Control 1-2-3-4 switches or
One-button Start/Stop
Unique Design Simple, Single Frame
NO foundations
Energy Effective Only 10 kW*h per ton
(ball mills – 55kW*h per t)
WMM includes crushed coal hoper, coal feeder, metal separator, wet milling chamber, CWS pump, control cabinet. Several WMMs could be installed in a raw.
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• CWS shall be stored locally on production facilities. In addition to CWS storage
shall be organized nearby the combustion.
• It is suggested to make one-two days storage both on production and combustion
– Short-term storage allows to exclude any additives & additive mixers which
might be required for producing the CWS with stability higher than 1 week.
– Cycle pumping + high-speed stirrer in a CWS storage tanks will allow to keep
CWS stable at least within a month if it is required.
• CWS storage near the boiler
– Ignition temperature for the CWS is higher than 500…600degrees what
makes CWS explosion-proof and allow to organize the storage in the vicinity
of a boiler
• 2-days storage for one 20tph boiler is equal to approx 60cubic meters. So, it is
suggested to mount 2*30cm tanks both on production and combustion facilities.
CWS storage & transportation
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• Pneumo-nozzle
– CWS is atomized outside of nozzle – no wearing effect
– High rang of CWS flow
– Atomizing agent - air
• Air compressor
– Could be used existing one
• Amount of CWS is varied by cavity pumps with a frequency controllers
CWS spraying nozzle
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• Ash after CWS combustion is a
light-grey powder with density
0.3…0.7t per cm. typical grain
size is 1mm and lower.
• If any ash will be caught it could
be used in any of concrete
production.
Ash utilization
Typical ash of slurry combustion
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Thank You for your time
ICI-International Gurgaon-India E –mail :[email protected]