recommendations of the working groups

Energy Vol. 11, No. 11/12, pp. 1413-1421, 1986 0360-5442/86 $3.00 + 0.00 Printed in Great Britain Pergamon Journals Ltd

RECOMMENDATIONS OF THE WORKING GROUPS

During the final 2 days of the Conference, a number of working groups were established to assess the possibilities for co-operative research in specific areas. Summaries of the reports of the individual groups are presented here.

1. COAL-WATER MIXTURES

Working group members: G. Baker (U.S.A.) Daniel Bienstock (U.S.A.) Murari Chakraborty (India) Tae-Moon Kim (Korea) Sun Zonghai (China) Wang Naixin (China)

Coal-water mixtures (CWM) have been demonstrated as a substitute for oil for use in oil-fired boilers. Industrial units in capacity of 20-25 ton/hr steam generation have been successfully operated. At present, the utilities have not demonstrated use of coal-water slurries as a substitute for oil. With the low price of oil and with the prospect of little if any increase in the next decade, utilities in the United States do not have the incentive to pursue this technology.

In countries such as Korea, where both coal and oil are imported, the objective of using CWM is for use in medium-to-large industrial facilities. Use in smaller facilities is generally uneconomical. Given the need to retrofit and the resultant decrease in capacity, the price differential between oil and CWM is insufficiently attractive. In India, CWM will utilize the effluent from washeries which contain fine coal and to which additional coal is mixed, as well as high-ash coals in water as a feed to fluid-bed combustors and pressurized gasifiers. At present, China uses 30 million tonne/yr of oil in combustion facilities.

The intent, herein, is to displace some of this oil in both industrial and utility boilers, while using this displaced oil for export and processing into oil products and petrochemicals.

The economic and technical problems in commercializing this technology are as follows: 1. The low price of oil. 2. The need to beneficiate coal to reduce operational problems in the boiler. 3. The need to remove sulfur oxides from the gaseous effluent to meet environmental

regulations. 4. The limitations arising from the particular boiler configurations. 5. The present insufficient life of CWM burner nozzles. 6. The need to reduce air-preheat temperatures for industrial boilers. The recommendations for collaboration among international technical organizations

involved in CWS technology are: 1. Encourage scientists from developing countries to spend a year or more in U.S.

research centers performing research in areas such as (a) surface science and rheological problems of CWM containing surfactants/additives upon stability and viscosity, (b) engineering and design of CWM burners, and (c) retrofit of boilers and their maintenance in the use of CWM.

2. Investigate the potential of sending engineers from developed countries to China to gain hands-on experience in operating CWM-fueled boilers such as the 20 ton/hr steam- generating boiler in Beijing.

3. Exchange technical information on the use of CWM in fluidized-bed boilers especially in the use of low-quality and high-ash coals.

4. Promote the greater involvement and participation of developing countries in international meetings and conferences through financial sponsorship of their expenses.

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1414 Recommendations of the working groups

5. Invite engineers from developing countries to make use of the extensive computerized engineering data-bases in coal slurry technology such as that existing at the Pittsburgh Energy Technology Center. Contributions of their technical programs in CWM could be added to the data-base.

2. FLUIDIZED-BED COMBUSTION

Working group members: Fang Bao Chang (China) E. C. Fox (U.S.A.) K. M. V. Malarkkan (India) R. D. La Nauze (Australia) G. Pohl (World Bank) Wang Shumin (China) Liu Xinquan (China)

Status of the technology

All the countries represented have commercialized fluidized-bed combustion (FBC) to some extent. India has two lo-MW(e) units on order and an %MW(e) unit in operation in addition to a number of small units. China has 500 industrial AFBC units in operation, the average size is about 6 MW(e) with the largest 25 MW(e). The United States has 30 or so units operating or on order with the largest being a 160-MW(e) demonstration unit. Australia feels that commercialized units up to 25 MW(e) are feasible. In general it is felt that for bituminous coals of moderate ash content there is commercial technology up to 100-200 MW(e).

Anticipated markets

For most of the participants (China, India, and Australia) the primary interest in AFBC lies in burning very high-ash coals or coal washery rejects for industrial applications. The United States is also interested in high-ash coals but its major market is for high-sulfur coals. China is particularly interested in using high-ash coals and mine wastes near industrial centers to avoid transportation difficulties. India has similar interests. The coal of common interest to the participants is one of low heating value, high-ash, mine waste or coal washery rejects.

Obstacles to commercialization

For the United States, India, and Australia a major obstacle is lack of commercial experience and demonstration of the technology in large sizes [ > 100 MW(e)]. The areas in which improvements in the technology could be made are:

1. Coal preparation/crushing/screening with particular emphasis on reliability and producing feed material of desired size distribution.

2. Developing reliable solids feeding system that has acceptable combustion performance. There is a companion interest in resolving the erosion problems in the solids feed system.

3. In-bed tube design with attention to erosion of in-bed tubes and steam tubes in the convection section. China indicates they have resolved these problems.

4. Freeboard design and combustion performance with interest in the effect of over-fire air on the combustion of high-ash coals.

5. Effect of recycle on combustion performance.

Type of collaboration

It was agreed that at least the exchange of published data should be accomplished. There are several books written in the People’s Republic of China on fluidized-bed combustion design that China would be willing to translate into English. It was also agreed that exchange of personnel for the purpose of training was unnecessary. The best near-

Recommendation of the working groups 1415

term exchange of information should take the form of a workshop. Further exchange of visits and discussions would be determined subsequently.

It was agreed that a workshop that emphasized the common problems of the nations represented would be the best first step to exchange technology. The subject of the workshop should be “Fluidized-Bed Combustion of High-Ash Coals”. The format would be one of prepared papers followed by round-table discussions of areas of common interest. The major areas for discussion should include:

1. Instrumentation and control. 2. Coal preparation/crushing/screening of high-ash coals. 3. Solids feeding. 4. Bed design for long tube life and efficient combustion. 5. Freeboard design to provide maximum combustion of high-ash coals. 6. Effectiveness of recycle to burn high-ash coals.

3. COAL GASIFICATION AND LIQUEFACTION

Working group members: Dai Hewu (China) Klaus Girke (Canada) R. Gray (U.S.A.) Ahmad Mumtaz (Pakistan) Ian Smith (Australia) Abu Talib (U.S.A.) T. Y. Yan (U.S.A.)

The group was unanimous in feeling that with the prevailing oil prices and the anticipation that the oil prices will remain low at least in the short term (5-7 yr), synthetic fuels from coal will not be economical.

It was emphasized that (1) facilities for research and development (R&D), and (2) expertise gained by scientists and engineers over the last decade in pursuing the synfuel programs in various Asia-Pacific countries (United States, Australia, India, etc.), should be utilized in an optimal way. This objective could be achieved by funding exchange of professionals to different R&D facilities and exchange of coal samples for testing in the specialized facilities of a particular laboratory.

The group felt that the processes developed or now being developed have not yet provided a breakthrough in the economics of synfuels production. Thus it was suggested that research for testing new ideas and processes should continue. To stimulate the exchange of ideas on new, cheap methods of coal conversion to gaseous or liquid fuels, and to support existing R&D programs on coal conversion, workshops on “Fundamental Aspects of Coal Conversion” should be held on a regular basis. Such workshops may be held in conjunction with biennial Coal Science Conferences. These workshops would receive small but definite support from the appropriate government agencies.

4. ASH DISPOSAL AND UTILIZATION

Working group members: Mario Berbano (Philippines) George Burnet (U.S.A.) Cheng Benji (China) Feng Minzeng (China) Dean Golden (U.S.A.) Tom Smith (Australia) Chris Webster (U.S.A.) Xu Rong Hua (China) Zhu Yunpei (China)


Ash disposal and utilization are increasingly important concerns in the Pacific and Asian countries, given the expanding use of coal as an energy source. Our group considered the state of development of different uses for coal ash in selected countries and possibilities for increased co-operation among them to expand the range of uses. The present status of coal ash utilization and related technology in the different countries is outlined in Table 1. Possible areas of co-operation among countries are discussed below. Neither the co- operative areas nor the countries listed in the table are meant to be all-inclusive. Several general recommendations about coal ash disposal and utilization are presented at the end of our report.

Table 1. Present status of coal-ash utilization and related technology in selected countries

China USA Australia Philippines

Cement and concrete Structural fills Road base Asphalt filler Grouting Coal mining Cenospheres Activated carbon Magnetite

Ore Heavy media

Minerals recovery Agriculture Structural shapes

(bricks, tiles, panels, refractories, etc.)

C C C R C C C R C C C R u C not known R C C C R

C/R C not known R C C U U R R C u

U R U U U C U U U R R U C R not known U C R C R

C = commercial; R = research; U = undeveloped

Information exchange

The participants from the countries shown in Table 1 agreed to the following direct exchange of information (references to countries in the following imply conference participants from those countries):

Cement, concrete and structural shapes. The use of fly ash as an admixture in cement and concrete enjoys a high state of development in China, the United States, and Australia. Information from these three countries will be sent to the Philippines.

The use of fly ash in the manufacture of structural shapes (brick, panels, tile, refractories, etc.) is advanced in China and Australia and will be shared with the United States and the Philippines.

Road base and asphalt jiller. The practice of using fly ash in road construction in China, the United States, and Australia is well established; information on this practice will be shared with the Philippines. Information from the United States about the use of fly ash as a filler in asphalt will be shared with the Philippines.

Grouting. Information from the United States about the use of fly ash in grouting in construction, closing of walls, etc., will be sent to the Philippines.

Activated carbon. Australia has commercialized the use of the carbon fraction in fly ash as activated carbon. Informtion about this will be shared with China, the United States, and the Philippines.

Cenospheres. Cenospheres are now used as filler material for plastics in China. Information concerning the separation of cenospheres by dry process (for cenospheres heavier than water) and the method of testing and measurement is desired. Additional information will be provided to China by the United States.

Minerals recouery. Research on the recovery of minerals from fly ash is well established in the United States and Australia. Information about leaching, sintering and carbochlorin- ation methods is available and will be shared with China.

Agriculture. The PRC has made advances in the use of coal combustion wastes as soil conditioners, fertilizers, etc. and will share this information with the United States.


Recommendations

1. Encourage safe and effective disposal. 2. Monitor coal waste production, inventory, usage, and characteristics. 3. Promote comprehensive and sustained waste utilization R&D:

(a) new coal conversion technologies require waste disposal/utilization as a primary part of project;

(b) large waste producers should receive priority; (c) other industrial organizations (aluminum and cement) should be made aware of

opportunities; (d) co-disposal or co-utilization of coal conversion wastes should be examined.

4. Foster the exchange of information between the Pacific basin nations interested in coal wastes.

5. OTHER TECHNOLOGIES

Working group members: Zainab Abdullah (Malaysia) Bai Yiyan (China) Ken Bertram (U.S.A.) L. Edouard (France) Paul Farber (U.S.A.) Peter Spurrier (Australia) Terry Surles (U.S.A.) Zhu Yunpei (China)

Introduction

The group which was convened to discuss “other technologies” had eclectic interests: the members chose to discuss the following technological and policy areas:

1. Environmental control technologies. 2. Coal transportation and distribution. 3. Utility systems planning. 4. Process feedstocks. 5. Capital costs investment. 6. Global environment. Owing to time constraints and the group’s interests, these areas were discussed to varying

degrees. The following sections outline the discussions and recommendations in each area.

Environmental control technologies

Status. Environmental control technologies and regulations are, to a great extent, established and available in North America and Western Europe. Unfortunately, in many of the countries just beginning to use coal as an energy source, this is not the situation. Even in a country such as the People’s Republic of China, where coal has been used for many decades, regulations for protection of the environment have only recently been promulgated.

Concurrent with the above problem is the fact that many pollution control techniques and processes (especially for control of sulfur oxides) are expensive, both in capital expenditure and operating costs. Additionally, many processes are either not proven for all coals, or must be carefully matched to the fuel application scenario using a systems analysis approach.

Needs. Before environmental regulations can be set within a country, it is essential that an environmental data-base be established. This is so that a government can determine: (1) Where we are now with respect to our environmental quality? (2) What are our plans for energy and industrial growth? (3) Where do we want our environmental quality to be during, and after, this growth? and (4) What regulatory means will we use to achieve (or


maintain) a desired level of the environment? It is important to realize that different standards may be necessary for different areas of a country due to population, land use, industrial concentration, need for economic development, etc.

Also, it is important that many of the technologies for air and water pollution control (as an example) be effectively and efficiently transferred from countries where they are commercial, to countries just beginning to be interested in their applications. This technology transfer will also require training of personnel from industry and government in the design and operation of facilities as well as the use of monitoring equipment and techniques to ensure compliance with local or national regulations.

A need exists for all environmental control and monitoring technologies to perform R&D aimed at reducing the capital and operating costs of these processes, as well as making them simpler and more reliable to operate than they are at present.

Obstacles. One of the largest obstacles for effective environmental control is the fact that not only are regulations just being developed in many countries, but they are also in a semi-constant state of flux as appropriate levels are decided upon, and different countries are developing differing regulations and control strategies which may, unintentionally, adversely affect their neighbors. Along with the regulatory aspect is the lack of detailed characterization of coals and pollution processes, and there is a need for this so that good “matches” may be found and adequate process performance ensured.

Also standing as an obstacle for environmental control is a lack of adequate training for many government and industry personnel within a country. This directly relates to the determining of compliance with regulations, the proper operation of equipment and systems, and in a more general fashion, the understanding of how environmental quality is being improved, or maintained.

Methods to overcome obstacles. Perhaps the most direct way of showing that collaboration can be of great benefit is to point out that several years ago the countries bordering on the Mediterranean Sea, realizing that the environmental quality of the sea is vital to all their needs, gathered together and jointly agreed upon a course of action. What was important about this conference was that several of the countries in attendance were at war with each other, but still recognized the need for co-operation in this area.

Collaborative efforts. An extensive coal and environmental data-base needs to be established and maintained. This includes the setting up and operating of environmental monitoring (air and water) systems, as well as extensive characterization of coals. Coupled with this should be a technology transfer program which includes an extensive complement of training not only in the processes and techniques themselves, but how they are operated and maintained.

Joint R&D programs should be aimed at reducing the costs, and simplifying the operation of environmental control technologies, as well as adapting control technologies to specific coals and conditions.

There is a need for an international conference to develop, at the very least, a set of guidelines for environmental controls so that not only will one country’s pollution not have an adverse effect on another, but so that a country will not, due to stringent regulations, be placed at an economic disadvantage to another with less stringent laws.

Coal transportation and distribution

The status of coal transport and distribution technologies is that many highly sophisti- cated model systems have been developed and are being used in several Western countries, but that these systems are not always applicable in Asian and other Pacific Region countries. Coal unit trains up to 100 cars in length, for example, are common in the United States, but insufficient trackage and equipment in some Asian countries usually force coal cars to move in conventional trains of considerably shorter lengths (e.g. under 40 cars). Similarly, while coal slurry pipelines have been developed and are in use in Western countries, Asian countries usually expand coal transport capabilities by building railroads, which can transport other commodities and people in addition to coal.

On the other hand, there are some research efforts under way in Western countries for


the development of slurry pipelines for coal-water mixtures (combustible in plants that currently burn oil) as well as coal-fired locomotives and ships to replace oil-fired units. These technologies have markets in Pacific Region countries through developing systems of implementing them cost-effectively and efficiently. Cost reductions can be achieved for Pacific Region countries through identification and selection of standardized versions (e.g. railroad track guages) of applicable technologies and effective co-ordination of domestic R&D and system planning activities with international consulting expertise. Efficient implementation can be achieved through a series of technology transfer efforts designed to provide the necessary training, data-bases, and modeling capabilities to support the technologies.

Such activities are needed to overcome the obstacles posed by exogenous transport issues, intermodal competition, scarce capital, and insufficient supporting infrastructure, data-bases (i.e. on the technology, coal and terrain), and analysis, planning, and modeling experience and capabilities. Lack of operating and maintenance experience with similar systems must also be overcome.

Collaborative efforts between Western and Pacific Region countries which can accomplish the above needs include committees to examine standardization mechanisms and requirements and workshops to relate domestic R&D activities to international consulting expertise and to compare analytical techniques and models. Also needed are technology transfer efforts including training in systems analysis and planning, data-base development, operations and maintenance procedures, and analytical model development. Analytical models developed would include project management models and systems analysis and planning models.

Specific collaborative projects can include a coal trans-shipment facility and a coal- water mixture slurry pipeline. The trans-shipment facility could be similar to the one in Superior, Wisconsin for transferring coal from rail lines to coal ships (e.g. for Chinese coastal movements). The coal-water mixture pipeline would help develop long-distance pipelining technology for these mixtures while reducing pipeline water use in a water- scarce Pacific Region country. In addition, R&D is being conducted in Western countries and in Japan on a new generation of coal-fired locomotives and ships (coal-hauling), and collaboration between these countries and those from the Pacific Region could prove fruitful.

Utility systems planning

The discussion of the issues in this area dealt with the use of various computer models for planning purposes. The group agreed that the present status of the modelling area is robust and that numerous models exist for utility systems supply and demand analysis. However, a number of needs were noted. These are summarized below in no preferential order.

1. There is a need for expanded communications between users of systems planning models. These models use different data sets and assumptions and are structured to address somewhat different circumstances. Exchange of information may result in incorporation of new data sets and ideas into each other’s planning tools.

2. There is a need for standardization for utility system components. The group agreed that while this was useful, regional and local requirements may preclude this from being practical.

3. The group recognized a need for the dissemination of project management techniques to regions and countries that are dealing with major construction activities for the first time. While this was stated in a country context, many private utilities could also have this need.

4. Coupled with number 3, the group felt that it would also be useful to provide information to countries and utilities that would assist them in negotiations with large multinational engineering consulting firms.

5. Finally, although no collaborative effort was mentioned, utilities are constantly


confronted with the issue of controlling and reducing costs. Collaborative and creative programs would be welcome in this area.

There are a number of collaborative efforts that could be developed in dealing with these issues: these are listed below.

1. A committee on Standardization for Utility Systems could be developed. The focus of this committee’s efforts would be to assist developing countries with standardizing their plans in order to reduce internal costs, and allow for electricity export on a regional, multi- country basis.

2. A number of workshops were suggested, including: (a) Project management problems and techniques. (b) Operation and maintenance (O&M) of large-scale facilities. A subset of this

workshop could be defining needs for skilled workers in meeting O&M requirements.

(c) Utility systems models-IAEA already holds a g-week course at Argonne National Laboratory for this. However, the proposed workshop would allow for the exchange of modeling information developed by different countries.

(d) Relating domestic R&D activities with international consulting engineering expertise and experience.

Finally, any mechanisms for technology transfer and training related to data-bases, computer models, and utility operation would be useful. These could be in the form of training programs, workshops, reports, etc.

Process feedstocks

The status in this area is definitely developmental. One corporation in the United States now makes acetic anhydride from coal feedstock. However, the greatest opportunity for development is in the Australian brown coal region. The need is for replacement of other feedstocks with brown coal. The obstacle is that Australia has a relatively small domestic market and would need international interest and investments.

At present, Japan and Australia are embarking upon a co-operative venture. However, given the potential of the resource, other collaborative programs should be of great interest.

Capital cost investments

A problem exists in many countries due to the large investment required for energy facilities. This includes not only the construction of the power plant itself, but the cost involved in transportation networks (built from “the ground up” in many cases) and the mining of the fuels as well. This results in competition for scarce capital especially where energy growth is coupled with an extensive industrialization effort.

Efforts must be made in collaborative programs between countries to develop means to assess and reduce the risks involved in these large capital cost programs. This may be accomplished through unit plant designs where, by having a standardized design, much of the engineering cost and time is reduced. An additional method would be the consideration of an international (as much as possible) grid tying together the electrical systems of several countries (such as is done between the United States and Canada).

Again, technology transfer coupled with a strong training program would help to reduce many uncertainties and aid in a country having more information and in-country expertise from which to make sound engineering and economic decisions. This training program could also prove useful in further economic growth by providing a country with a skilled base of personnel to work with and eventually design, engineer, and construct their own facilities without the need to rely on foreign assistance.

Global environment

This area was touched on rather briefly. The group recognized that there are a number of global environmental issues, with CO2 and transportation of atmospheric aerosols (acid precipitation) being of major concern. These will naturally be coupled with regional issues, such as pollution of regional waterways and water supplies.


The status at present is ambiguous. Different environmental standards and controls are used in different countries, leading to a disparity in emissions. Further lax environmental standards can be used by a country to gain an economic advantage at the expense of other countries. Thus, the problem is not only an environmental one, but an economic one as well. The need is to co-ordinate standards between countries-at least on a regional basis. The present obstacles are the lack of uniform controls and policies between countries, coupled with the reality that a country can gain an advantage economically by having weaker environmental standards.

Collaborative efforts to address and resolve these issues should be performed through existing international organizations. Such organizations can always be supplemented as necessary by appropriate workshops, committees, and technology transfer activities.

CONCLUSION

It is obvious from the foregoing discussions that there are a number of opportunities for information exchange and technology transfer. This is particularly true in the general areas of data-bases, computer models, and management and planning tools and techniques. It is recommended that the East-West Center explore mechanisms for implementing one or more of these collaborative efforts. Further, it appears that this initiative is simply a first step. Other issue areas in energy or only peripherally related to energy should be examined for collaborative interest.

recommendations of the working groups

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