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CO2 to Fuel ICI-International Gurgaon-India Mob : +91 9717225088 E mail :[email protected]

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Page 1: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

CO2 to Fuel

ICI-International Gurgaon-India

Mob : +91 9717225088 E mail :[email protected]

Page 2: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

• 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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Page 3: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

• 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

Page 4: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction
Page 5: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

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.

Page 6: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

Gasification Process inside the Kiln

Page 7: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction
Page 8: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction
Page 9: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction
Page 10: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

Waste to Fuel

Page 11: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

Waste to Fuel

Page 12: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

CWS - Coal slurry as a partial / full replacement of oil, gas and coal in Boilers & Cement Kiln.

December 2016 Gurgaon-India

Page 13: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

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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Page 14: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

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Page 15: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

CWS spraying and combustion

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Page 16: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

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Page 17: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

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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Page 18: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

• 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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Page 19: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

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

Page 20: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

• 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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Page 21: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

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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Page 22: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

• 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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Page 23: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

• 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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Page 24: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

• 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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Page 25: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction
Page 26: ICI-Internationalflyash2018.missionenergy.org/presentations/ICI-International.pdf · • In a steam boilers – oil, gas, coalfired –CWS as a main or additional fuel –NOx reduction

Thank You for your time

ICI-International Gurgaon-India E –mail :[email protected]