Waste to EnergyOur industry wastes >50% fuel through stacks

ICI-InternationalGurgaon-India

• 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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Waste Heat to Power

Waste Heat run Power Plant

Hot Water run Power Plant

Hot Air run Generator

Waste to Fuel

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

Technology Overview

Carbon Slurry Fuel (CWS)CWS is a liquid mixture of finely milled coal or other carbonaceousmaterials with water or an aqueous emulsion:

CWS = Coal (58% ... 70%) + emulsion (29% ... 40%)Usage of oil-based and organic water emulsions improves CWS calorificvalue.CWS has almost the same viscosity as masut (Heavy Fuel Oil) whatmakes it suitable both for pumping on short and long distances and forspraying 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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Waste Coal to Oil - 60% Coal + 40% Water

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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.• 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 carboncombustion, 1 gm oxygen is required for 1 gm sulfur combustion, and 8 gmoxygen 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 then2.67 x C % + 8 x H% + 1 x S % - O% = 1.64 kg of Oxygen for 1 kg of Coalcontaining 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 is= 1.64 / 23.2% = 7.1 kg of Air for 1 kg of Coal.

In case of NG this air quantity becomes doubleIn 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 thepre-heating phase, later on CWS shall be burned in a pre-chamber without asupport fuel.

Technical specifics

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Wet Milling MachineEasy Control

1-2-3-4 switches orOne-button Start/Stop

Unique DesignSimple, Single Frame

NO foundations

Energy EffectiveOnly 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 Youfor your time

ICI-InternationalGurgaon-India