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Dr. Sims;　Visit toJapan 2003 1

New BrownNew Brown Coal Coal UtilizationUtilization

Technology Using Technology Using

HeatHeat and and Shear StressShear Stress

KEM Corporation KEM Corporation

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・Dissociation of crystallized water of van der Waals adsorption with coal structure（Dissociation of van der Waals force by heating or by strong shear stress for coal structure.)

・ Exhaust of infiltration water in micro pore and crack(Destruction of micro pore and crack of coal structure by strong shear stress.)

・ CWS is first product. Therefore, it is possible to use it as a gasification raw material.

Brown Coal Processing Method of KEMBrown Coal Processing Method of KEM

ConventionalConventional 　　 Brown Coal Processing Brown Coal Processing MethodMethod・Dehydration by using high pressure hot water. 　　　　　　　　　　　　　　　　　　　　　　　　⇒　 Low

dehydration rate・Dryness that uses high temperature combustion

exhaust gas　・ It returns to the origin coal when water is put in a dry

brown coal.

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Process flow diagram for effective use on brown coal Process flow diagram for effective use on brown coal

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Processing of CWMProcessing of CWM

from Raw Brawn Coal from Raw Brawn Coal

wt.% (as wt.% (as received)received) wt.% (dry basis)wt.% (dry basis)

MoistMoist..

AshAsh CC HH OO NN SS

Indonesian Indonesian (ID) Coal(ID) Coal 35.835.8 4.074.07 66.0366.03 5.195.19 20.5920.59 1.371.37 0.390.39

Loy Yang Loy Yang (LY) Coal(LY) Coal 59.059.0 0.370.37 67.2867.28 4.974.97 25.3425.34 0.600.60 0.280.28

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Processing of CWMProcessing of CWM

from Indonesian Brown from Indonesian Brown Coal Coal

(Raw Material)(Raw Material)

20-150 mm 0.5 mm under

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Appearance of Material Appearance of Material 〔〔 Pulverized Indonesian brown coal Pulverized Indonesian brown coal (Φ0.5mm under) (Φ0.5mm under) 〕〕

State of StartState of Start State of EndState of End

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Appearance after heat and shear stress are givenAppearance after heat and shear stress are given

(Reaction condition : 170℃(Reaction condition : 170℃ ，， 5hr5hr ，， Shear Stress: Shear Stress: ～～ 0.01 MPa0.01 MPa

Pressure 10kg/cm2Pressure 10kg/cm2))

Viscosity: 570 mPa・ s

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Slurry of Indonesian Blown CoalSlurry of Indonesian Blown Coal

(48.6% Moisture)(48.6% Moisture)

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Processing of CWMProcessing of CWM

from Loy Yong Brown from Loy Yong Brown Coal Coal

(Raw Material)(Raw Material)

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AppearanceAppearance of Start Materialof Start Material

〔〔 Pulverized Loy Yong brown coal (Φ0.5mm under) Pulverized Loy Yong brown coal (Φ0.5mm under) 〕〕

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Appearance after heat and shearAppearance after heat and shear 　　 stressstress(Reaction condition : 170℃(Reaction condition : 170℃ ， ， 5hr5hr ，， 　　 Shear Stress: Shear Stress: ～～ 0.01 MP0.01 MP

a,a,

Pressure 10kg/cmPressure 10kg/cm22))

Viscosity: 3８ 0 mPa・s

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Relation between axis torque and shear stress of kneader

1

100

10,000

1,000,000

100,000,000

0 20 40 60 80 100 120 140

Axis torque （ｋｇ･ｃｍ）

Shea

r Str

ess

（Pa)

Axis Torque and Shear Stress of KneaderAxis Torque and Shear Stress of Kneader

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Viscosity of Loy Yong CWM Viscosity of Loy Yong CWM and Processing Time at 170℃and Processing Time at 170℃

Relation between viscosity of product CWMand processing time, at 170℃, 10kg/cm2

100

10000

0 1 2 3 4 5 6Processing time, at 170℃ (hr)

CW

M v

iscosit

y (

cP

)

Pressure 10kg/cmPressure 10kg/cm22

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Relation between viscosity of product CWMand processing temp. (1hr.)

100

10000

150 170 190 210 230 250 270

Processing Temp. (℃)

CW

M v

iscosi

ty (

cP)

Viscosity of Loy Yong CWM and Viscosity of Loy Yong CWM and Processing Temperature( ) ℃Processing Temperature( ) ℃

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Photo. 1(a) High shear stress, high temperature, and high-pressure Kneader

Figure 1 High shear stress, high temperature, and high-pressure Kneader concept chart

New dehydration slurry manufacturing experiment of brown coal

(20 liters: 5.5KW motor)

1. Steam/gas vent 　　　　　　 6. Thermocouple/Presser transmission line gage

2. Presser gage 　　　　　　　　　　 　 7. Pressure transmission line

3. Thermocouple 　　　　　　　　　 　 8. Motor

4. Sample turning on entrance 　 9. Sample outlet

5. Stir axis

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Relation between Shear Stress and Processing TimeLoy Yong Brown Coal : temp. 170℃, 10kg/ cm（ 2）

1

10

100

1000

0 0.2 0.4 0.6 0.8 1Shear Stress (MPa)

Pro

cess

ing

Tim

e(m

in.)

Relation between Shear Stress and Processing Time Relation between Shear Stress and Processing Time

(Loy Yong Brown Coal : Processing Temp. 170℃(Loy Yong Brown Coal : Processing Temp. 170℃））

Pressure 10kg/cmPressure 10kg/cm22

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Slurry production of Loy Yong brown coal with high shear stress, normal temperature, and normal pressure Kneader

― Four hours in the processing time ―

Moisture 56% and viscositiesMoisture 56% and viscosities 　１３５　１３５ mPmPaa ・ｓ・ｓ

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Combustion test of Loy Yong brown coal slurry (at the Tokai Pulp Co. Ltd. Shimada factory. )

During 2.5 hours in the continuous During 2.5 hours in the continuous combustion timecombustion time

Situation of exhaust emissionSituation of exhaust emission

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Schematic diagram of CWM　　　　　　　　　　　　 pre-heating pilot plant.

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Slurry preheating atomization combustion unit　 (3t/day)

Photograph slurry preheating atomization unit (in Maebashi center)

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Atomization of steam and Loy Yong coal particlesAtomization of steam and Loy Yong coal particles

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Relation between CWM Water Content and Oxygen Supply

0.5

0.6

0.7

0.8

0.9

1

1.1

38% 40% 42% 44% 46% 48% 50% 52%CWM Water Content （ｗｔ．％）

Oxy

gen

Supp

ly

O（2/c

oal)

New-CWM（pre-heating case)

New-CWM（Dry Coal base)

Oｌｄ－CWM (Raw Coal＋Water)

Gasification of Indonesian Brown CoalGasification of Indonesian Brown Coal

CWM Water Content and Oxygen SupplyCWM Water Content and Oxygen Supply

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Gasification of Indonesian Brown CoalGasification of Indonesian Brown Coal

CWM Water Content and Cold Gas EfficiencyCWM Water Content and Cold Gas Efficiency

Relation between CWM Water Content and Cold GasEfficiency

55

60

65

70

75

80

85

90

38% 40% 42% 44% 46% 48% 50% 52%CWM Water Content （％）

Col

d G

as E

ffici

ency

（％）

New-CWM pre-heati ng case)（

New-CWM Dry Coal base)（

Ol d-CWM (Raw Coal Water)＋

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CWM withoutpreheating

CWM withpreheating

Effect ofpreheating

Coal supply 100 t/h 84 t/h -16 t/h

Oxygen consumption 110 t/h 71.4 t/h -38.6 t/h

Cold gasification efficiency 71.70% 85.30% 13.60%

Reaction time required 2.0 sec 7.8 sec 5.8 sec

Heat of Syngas (Fix) 500 Gcal/h 500 Gcal/h 0 Gcal/h

Cost of Oxygen （ 5 mil/Nm3） 3,200 US$/h 2,100 US$/h -1,100 US$/h

Cost of Coal （ 12.5 US$/t） 1,300 US$/h 1,100 US$/h -200 US$/h

Total cost of materials per hour 4,500 US$/h 3,100 US$/h -1,400 US$/h

Total cost of materials per year36.0 Million

US$/year24.8 Million

US$/year-11.2 Million

US$/year

Prediction of Economic Prediction of Economic Effect of Preheating Effect of PreheatingPrediction of Economic Prediction of Economic Effect of Preheating Effect of Preheating

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SummarySummary

○○ 　　 CWM of the water content equal with CWM of the bituminous CWM of the water content equal with CWM of the bituminous coal can be made by using the water included in the brown coal when coal can be made by using the water included in the brown coal when Kneader of the KEM Co. is used. Kneader of the KEM Co. is used.

○○ 　　 Thermal efficiency improves greatly if the CWM preheating atThermal efficiency improves greatly if the CWM preheating atomization unit produced based on the KEM patent is used for the coomization unit produced based on the KEM patent is used for the combustion or gasification of the brown coal CWM. mbustion or gasification of the brown coal CWM.

○○ 　　 The brown coal from which use has been limited by combining The brown coal from which use has been limited by combining high shear stress Kneader with the CWM preheating atomization unihigh shear stress Kneader with the CWM preheating atomization unit can be used by the same price as the bituminous coal. t can be used by the same price as the bituminous coal.