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Innovations in Coal Usage :Innovations in Coal Usage :Clean Coal Technologies Clean Coal Technologies
for Power Generationfor Power Generation
Mark Van der Riet #
Piet Steenkamp, Johan Dempers *
Greg Tosen$, Chris Gross$
# Enterprises Division, * Generation Division, $ Resources & Strategy Division Eskom Holdings
8th September 2004
“Mining for economic upliftment and skills development”
The South African Mining Week/Electra Mining Africa Conference
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World Fuel Options – Source : IEA WEO 2002
Coal will increase in absolute terms from 2,355 to 3,606 Mtoe (or 55 %) between 2000 and 2030
26%
23%
7%3% 2%
38%
24%
4%
37%
5%2%
28%
CoalOilGasNuclearHydroOther renewables
2000 20309179 Mtoe 15,267 Mtoe+ 66 %
26%
23%
7%3% 2%
38%
24%
4%
37%
5%2%
28%
CoalOilGasNuclearHydroOther renewables
2000 20309179 Mtoe 15,267 Mtoe+ 66 %
“Business-as-Usual” Scenario
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RSA Primary Energy Resources
Coal predominates on a national and regional basis
Source : Deats & Statham, SA Coal ‘97
South Africa
Coal100000
Hydro7500
Nuclear53000
Gas350
Southern Africa
Coal160000
Hydro142000
Nuclear70000
Gas7600
Oil2130
Indicated capacity in MWe
South Africa
Coal100000
Hydro7500
Nuclear53000
Gas350
Southern Africa
Coal160000
Hydro142000
Nuclear70000
Gas7600
Oil2130
Indicated capacity in MWe
Southern Africa
Coal160000
Hydro142000
Nuclear70000
Gas7600
Oil2130
Indicated capacity in MWe
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Eskom Dependence on Coal
2003 ESKOM ELECTRICITY PRODUCTIONTotal GWh = 210 218 (net)
Hydro0.4%
Pumped storage1.3%
Nuclear6.0%
Coal92.3%
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Coal Supplies to ESKOM
• 9 “tied” collieries supply 9 power stations• 1 power station with short term supplies• 6 collieries “cost + ROI”, 3 “fixed price + escalation”
(Duvha, Optimum & Grootegeluk)• tonnages :
Future :• Mothballed : Camden(1600 MW),
Komati (1000 MW), Grootvlei (1200 MW)
1996 85.401 mt
1997 90.169 mt
1998 87.225 mt
1999 88.470 mt
2000 92.289 mt
2001 94 136 mt
2002 96 460 mt
2003 104 370 mt
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Core Capability - Combustion Characterisation
- Impact of Coal Quality
- Optimisation of Pulverised Fuel
Technology
- Clean Coal Technologies
Note: Other R,D&D portfolios cover Environmental and Strategic issues related to coal usage
Eskom Coal Technology R,D&D Focus
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CLEAN COAL TECHNOLOGIES FOR EXISTING ESKOM FLEET
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Eskom Coal R,D&D Program 2005
Fly AshUtilisation
CCSEMDatabase
Net CV, Constant PCalorimeter
Fly AshFormation
Coal, Ash & SlagAssessment
Mass/EnergyBalances
Boiler
RotatingThroat
DynamicClassifier
Mill
Reactive &Non-reactive Ca
ParticulateEmissions Plant
OperationalOptimisation
On-line CoalAnalysis
Coal Processing& Impact on Plant
Coal Variability& Long Term Changes
DTF Pf Pilot Rig Combustion Modelon-line
CombustionOptimisation
RSA Inventoryassessment
Assessment &Recovery
Coal Processing& Impact on Plant
Coarse CoalDiscards
RSA InventoryNon-Commercial Coal
RSA Inventoryassessment
Co-firingDemonstration
Fine CoalDiscards
CoalDiversification
PF Mass FlowMeasurement
On-line AbrasivenessProbe
CorrosionProbe
Non-ContactT Measurement
On-lineReactivity
Flame Monitoring Particle SizeMeasurement
Heat FluxProbes
DiagnosticTools
Air Staging (OverfireAir & Low NOx Burners
SorbentEvaluation (FGD)
SorbentEvaluation (FBC)
ReburnTechnologies
Co-Firing(gas & coal)
Primary EmissionsReduction
SpontaneousCombustion
Safety
International CoalBenchmarking
Strategic
Lab ScaleKinetics
Test Rig
Scale-up/Modelling
Lab ScaleSorbent Testing
Fluidised BedCombustion
Test Rig
Fluidised BedGasification - IGCC
DemonstrationPlant
PilotPlant
Underground CoalGasification
Multi-Technologyand Unit 7
Clean CoalTechnologies
CombustionCourse I : Theory
CombustionCourse II : Practical
Education Boiler/Mill ReliabilityOptimisation
Eskom CoalTechnologies R,D&D
Air Staging (OverfireAir & Low NOx Burners
SorbentEvaluation (FGD)
SorbentEvaluation (FBC)
ReburnTechnologies
Co-Firing(gas & coal)
Primary EmissionsReduction
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New Clean Coal Technologies
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Eskom Coal R,D&D Program 2005
Fly AshUtilisation
CCSEMDatabase
Net CV, Constant PCalorimeter
Fly AshFormation
Coal, Ash & SlagAssessment
Mass/EnergyBalances
Boiler
RotatingThroat
DynamicClassifier
Mill
Reactive &Non-reactive Ca
ParticulateEmissions Plant
OperationalOptimisation
On-line CoalAnalysis
Coal Processing& Impact on Plant
Coal Variability& Long Term Changes
DTF Pf Pilot Rig Combustion Modelon-line
CombustionOptimisation
RSA Inventoryassessment
Assessment &Recovery
Coal Processing& Impact on Plant
Coarse CoalDiscards
RSA InventoryNon-Commercial Coal
RSA Inventoryassessment
Co-firingDemonstration
Fine CoalDiscards
CoalDiversification
PF Mass FlowMeasurement
On-line AbrasivenessProbe
CorrosionProbe
Non-ContactT Measurement
On-lineReactivity
Flame Monitoring Particle SizeMeasurement
Heat FluxProbes
DiagnosticTools
Air Staging (OverfireAir & Low NOx Burners
SorbentEvaluation (FGD)
SorbentEvaluation (FBC)
ReburnTechnologies
Co-Firing(gas & coal)
Primary EmissionsReduction
SpontaneousCombustion
Safety
International CoalBenchmarking
Strategic
Lab ScaleKinetics
Test Rig
Scale-up/Modelling
Lab ScaleSorbent Testing
Fluidised BedCombustion
Test Rig
Fluidised BedGasification - IGCC
DemonstrationPlant
PilotPlant
Underground CoalGasification
Multi-Technologyand Unit 7
Clean CoalTechnologies
CombustionCourse I : Theory
CombustionCourse II : Practical
Education Boiler/Mill ReliabilityOptimisation
Eskom CoalTechnologies R,D&D
Lab ScaleKinetics
Test Rig
Scale-up/Modelling
Lab ScaleSorbent Testing
Fluidised BedCombustion
Test Rig
Fluidised BedGasification - IGCC
DemonstrationPlant
PilotPlant
Underground CoalGasification
Multi-Technologyand Unit 7
Clean CoalTechnologies
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Fluidised Bed Combustion
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Fluidised Bed Combustion (FBC)
• Commercially proven• Low grade coal • RSA low grade in situ
and discard coals• In bed de-SOx
• Lower NOx than with pf technology
• Complies with lowest NOx regulations
9 Feasibily Study–repowering Komati
9 Pilot scale test facility· Concept studies in
progress
water
steam
coal
dust collectors
stack
FLUIDISEDBED COMBUSTION
FLUIDISEDBED
COMBUSTION
combustion air
limestone
8500C
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Underground Coal Gasification
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THE UCG PROCESS - ii
Presented with kind permission of :
Commercial in the FSU since the 1950’s
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Eskom R,D&D - Majuba UCG
9 Concept & Pre-feasibility Studies· Site Characterisation & Pilot plant• Benefits
• Reduced coal mining & washing «transportation « grinding & ash disposal
• Use of Majuba coalfield’s unutilised coal resource
• Rapid “mine” development and start-up• Particulate emissions reduction for Majuba• Potential usage for peaking plant (with a gas
turbine)• Potential application with other unminable
coal resources
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UCG vs. Conventional Mining
UCG-1 ton in situ coal
Mining- 1 ton in situ coal
1.39 MWh95% extraction20 MJ/kg 75% chemical energy recovery35% Majuba unit efficiency with gas
1.20 MWh60% extraction20 MJ/kg 36% Majuba unit efficiency with coal
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THE CHINCHILLA PROJECT - Underground Gasifier
Cleanand
Quiet
•operating Nov 1999 – Apr 2003 (in conservation mode at present)
•GT/Genset (under negotiation)
•Little visible infrastructure, eg. ¹
•No groundwater /surface contamination *
•No surface subsidence
•1 week shutdown possible
•100% availability
•95% coal usage
•75% energy recovery
* By independent audit by Golder Associates, for Australian EPA
Queensland, Australia
Presented with kind permission of :
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Other Emerging Power Gen CCT’s
• Fuel Cells• Integrated Gasification Combined
Cycle (IGCC)• CSLF• ZET’s• HyPyRing• Magnetohydrodynamics (MHD)• Multi-Fuel• Etc.
Part of Eskom’s Longer Term Strategy
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Conclusions
• Coal usage is likely to continue, and even increase internationally
• South Africa relies heavily on coal, and this is unlikely to diminish in the short term
• Sustainable usage of coal requires technical innovation
• Eskom is pursuing a suite of solutions –optimisation of existing plant, FBC and UCG