innovations in coal usage - pierre...

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

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

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


Southern Africa

Coal160000

Hydro142000

Nuclear70000

Gas7600

Oil2130


Eskom Dependence on Coal

2003 ESKOM ELECTRICITY PRODUCTIONTotal GWh = 210 218 (net)

Hydro0.4%

Pumped storage1.3%

Nuclear6.0%

Coal92.3%

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

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

CLEAN COAL TECHNOLOGIES FOR EXISTING ESKOM FLEET

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


Coarse CoalDiscards

RSA InventoryNon-Commercial Coal


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




ReburnTechnologies



New Clean Coal Technologies

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 Variability& Long Term Changes

DTF Pf Pilot Rig Combustion Modelon-line

CombustionOptimisation


Assessment &Recovery


Coarse CoalDiscards

RSA InventoryNon-Commercial Coal


Co-firingDemonstration

Fine CoalDiscards

CoalDiversification

PF Mass FlowMeasurement

On-line AbrasivenessProbe

CorrosionProbe

Non-ContactT Measurement

On-lineReactivity

Flame Monitoring Particle SizeMeasurement

Heat FluxProbes

DiagnosticTools




ReburnTechnologies



SpontaneousCombustion

Safety

International CoalBenchmarking

Strategic

Lab ScaleKinetics

Test Rig

Scale-up/Modelling



Test Rig


DemonstrationPlant

PilotPlant




CombustionCourse I : Theory

CombustionCourse II : Practical

Education Boiler/Mill ReliabilityOptimisation

Eskom CoalTechnologies R,D&D

Lab ScaleKinetics

Test Rig

Scale-up/Modelling



Test Rig


DemonstrationPlant

PilotPlant




Fluidised Bed Combustion

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

Underground Coal Gasification

THE UCG PROCESS - ii

Presented with kind permission of :

Commercial in the FSU since the 1950’s

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

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

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 :

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

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

Thank You

innovations in coal usage - pierre...

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