Coal SYN Gas For Thermal Powerplants

© R.A.D.E INITIATIVE 2013 | [email protected]

COAL SYN-GAS : COAL SYN-GAS :

The most Viable & Economic The most Viable & Economic alternative for retrofitting alternative for retrofitting

Small/MediumSmall/MediumOil-Fired Thermal Power PlantsOil-Fired Thermal Power Plants


• Use Heavy Fuel Oil(HFO) or Residual Fuel Oil (RFO).Use Heavy Fuel Oil(HFO) or Residual Fuel Oil (RFO).• Some small units are powered by a direct fired Some small units are powered by a direct fired

combustion Turbine.combustion Turbine.• Most have a Steam Boiler and Steam Turbine to run the Most have a Steam Boiler and Steam Turbine to run the

Generator.Generator.• Are becoming economically non-viable due to high Fuel Are becoming economically non-viable due to high Fuel

prices.prices.• The price of RFO is not likely to come down to The price of RFO is not likely to come down to

economical levels.economical levels.• Are being either shut down or converted to other Fuels.Are being either shut down or converted to other Fuels.• Shutting down these plants has increased electricity Shutting down these plants has increased electricity

shortage.shortage.


• Many Oil-fired Power plants are being converted to other Many Oil-fired Power plants are being converted to other fuels.fuels.

• Conversions usually involves costly up-gradations of the Conversions usually involves costly up-gradations of the plants.plants.

• Plants are converted to run on Coal, Natural Gas or SYN Plants are converted to run on Coal, Natural Gas or SYN Gas.Gas.

• Most of the changes are made in the Boiler firing Most of the changes are made in the Boiler firing Section.Section.

• Also requires a new Fuel storage & handling section.Also requires a new Fuel storage & handling section.• Apart from the conversion expenses, the new fuels bring Apart from the conversion expenses, the new fuels bring

along their own associated problems.along their own associated problems.• Converted Plants usually run on lower efficiencies than Converted Plants usually run on lower efficiencies than

the originally designed.the originally designed.

Retrofitting of Oil-fired Power-plants


• Oil-fired Power plants are mostly converted to Coal firing.Oil-fired Power plants are mostly converted to Coal firing.• Conversion involves extensive changes to Boilers.Conversion involves extensive changes to Boilers.• Needs the addition of a Coal Pulverizer unit and Blower Needs the addition of a Coal Pulverizer unit and Blower

Section.Section.• Requires the creation of a large Coal Stockyard.Requires the creation of a large Coal Stockyard.• Up-gradation of the Boiler Bottom Ash cleaning section.Up-gradation of the Boiler Bottom Ash cleaning section.• Coal transportation causes extensive Dust pollution. Coal transportation causes extensive Dust pollution. • Coal Stocking has the scope of causing high groundwater Coal Stocking has the scope of causing high groundwater

pollution through leaching in high rainfall areas.pollution through leaching in high rainfall areas.• Needs the erection or up-gradation of an ESP (Electrostatic Needs the erection or up-gradation of an ESP (Electrostatic

Precipitator) for capturing fly ash from the Flue Gasses.Precipitator) for capturing fly ash from the Flue Gasses.• Needs Wet-scrubbers to curtail Sulfur Oxide atmospheric Needs Wet-scrubbers to curtail Sulfur Oxide atmospheric

pollution.pollution.


• Some Oil-fired Power plants are also converted to Some Oil-fired Power plants are also converted to Natural Gas.Natural Gas.

• Subjected to availability and regular supply of Natural Subjected to availability and regular supply of Natural Gas.Gas.

• Plant conversions usually involves only changing of Plant conversions usually involves only changing of Burners & laying Gas pipelines.Burners & laying Gas pipelines.

• Requires the addition of a Buffer tank in case of piped Requires the addition of a Buffer tank in case of piped Gas.Gas.

• Need a large Gas storage tank in case of transported Need a large Gas storage tank in case of transported gas.gas.

• Plant can be easily combined to IGCC (Integrated Plant can be easily combined to IGCC (Integrated Gasifier Combined Cycle) co-generation with the Gasifier Combined Cycle) co-generation with the addition of a Gas Turbine.addition of a Gas Turbine.

• Economics of the plant depend on the fluctuating Economics of the plant depend on the fluctuating International prices of natural gas.International prices of natural gas.

• Being Clean-burning, it doesn’t require any special anti Being Clean-burning, it doesn’t require any special anti pollution equipment.pollution equipment.


• An alternative to natural gas is Coal - SYN Gas ( Synthetic An alternative to natural gas is Coal - SYN Gas ( Synthetic Gas) .Gas) .

• Subjected to availability of any grade of Coal (Anthracite to Subjected to availability of any grade of Coal (Anthracite to Lignite).Lignite).

• Conversions involves changing of Burners & laying Gas Conversions involves changing of Burners & laying Gas pipelines.pipelines.

• Gas can be prepared either on-site or transported from Gas can be prepared either on-site or transported from other locations.other locations.

• Involves erecting a large gasifier or a battery of small Involves erecting a large gasifier or a battery of small gasifier units.gasifier units.

• Construction of a large gas storage tank in case of Construction of a large gas storage tank in case of transported gas.transported gas.

• Plant can be easily combined to IGCC (Integrated Gasifier Plant can be easily combined to IGCC (Integrated Gasifier Combined Cycle) co-generation with the addition of a Gas Combined Cycle) co-generation with the addition of a Gas Turbine.Turbine.

• Economics of the plant depend on the relatively stable Economics of the plant depend on the relatively stable price of coal.price of coal.

• Stack emission levels comparable to Natural Gas.Stack emission levels comparable to Natural Gas.


• Gasification is a process that convert solid feedstock like Gasification is a process that convert solid feedstock like coal or biomass into a combustible gas.coal or biomass into a combustible gas.

• Coal is gasified by being reduced under high pressure Coal is gasified by being reduced under high pressure high temperature with steam in a specialized retort high temperature with steam in a specialized retort known as a Gasifier.known as a Gasifier.

• Coal Gas is also called as Syngas or Synthetic Gas.Coal Gas is also called as Syngas or Synthetic Gas.• Syngas can be burned cleanly with negligible pollution.Syngas can be burned cleanly with negligible pollution.• Basic Syngas consists of Hydrogen, Carbon-monoxide Basic Syngas consists of Hydrogen, Carbon-monoxide

and Nitrogen with trace element of other gases. and Nitrogen with trace element of other gases. • Modern Gasification Systems produce a Syngas at par Modern Gasification Systems produce a Syngas at par

with natural gas called “Synthetic Natural Gas” or SNG. with natural gas called “Synthetic Natural Gas” or SNG. • There are 178 operating gasification plants worldwide.There are 178 operating gasification plants worldwide.



• LOW BTU GAS 150-300 BTU/ft3: Basic Syngas produced LOW BTU GAS 150-300 BTU/ft3: Basic Syngas produced by air fed Gasifier which contains 35-50% nitrogen, but by air fed Gasifier which contains 35-50% nitrogen, but suffices as normal industrial heating or Boiler fuel.suffices as normal industrial heating or Boiler fuel.

• MEDIUM BTU GAS 300-550 BTU/ft3: Higher grade MEDIUM BTU GAS 300-550 BTU/ft3: Higher grade Syngas produced by Oxygen fed Gasifier which requires Syngas produced by Oxygen fed Gasifier which requires a dedicated oxygen Plant. It adds Nitrogen and other a dedicated oxygen Plant. It adds Nitrogen and other gases to the saleable product portfolio.gases to the saleable product portfolio.

• HIGH BTU SNG 1000-1400 BTU/ft3 : Gas at par or higher HIGH BTU SNG 1000-1400 BTU/ft3 : Gas at par or higher than natural gas. Requires gas de-sulphurising unit and than natural gas. Requires gas de-sulphurising unit and a catalytic unit, called a “Shift-reactor” to upgrade the a catalytic unit, called a “Shift-reactor” to upgrade the Gas.Gas.


• LOW BTU GAS : Low Investment - consisting of a battery of LOW BTU GAS : Low Investment - consisting of a battery of small/medium sized Gasifiers with gas scrubbing and small/medium sized Gasifiers with gas scrubbing and compressing systems, Gas storage tank, pipelines and compressing systems, Gas storage tank, pipelines and burners.burners.

• MEDIUM BTU GAS : Medium Investment - comprising of a MEDIUM BTU GAS : Medium Investment - comprising of a battery of small/medium sized Gasifiers with gas scrubbing battery of small/medium sized Gasifiers with gas scrubbing and compressing systems, Main Gas tank, pipelines and and compressing systems, Main Gas tank, pipelines and burners. An Oxygen producing unit. with appropriate gas burners. An Oxygen producing unit. with appropriate gas compressing systems and storage tank.compressing systems and storage tank.

• HIGH BTU SNG : High Investment - Requires special HIGH BTU SNG : High Investment - Requires special expensive imported Gasifiers, gas scrubbers, large Oxygen expensive imported Gasifiers, gas scrubbers, large Oxygen Plant, De-sulphurising unit and a catalytic unit, called a Plant, De-sulphurising unit and a catalytic unit, called a “Shift-reactor” to upgrade the Gas.“Shift-reactor” to upgrade the Gas.


• Virtually any grade of Coal can be converted into Gas.Virtually any grade of Coal can be converted into Gas.• Coal mine waste products like fines, slurry, etc can also be Coal mine waste products like fines, slurry, etc can also be

gasified.gasified.• Economics are predictable as Coal Prices are relatively Economics are predictable as Coal Prices are relatively

stable.stable.• Coal based Syngas is much less polluting than burning Coal based Syngas is much less polluting than burning

Coal.Coal.• Coal Syngas can be manufactured on-site or near the Coal Coal Syngas can be manufactured on-site or near the Coal

mines.mines.• Coal can be blended with Biomass or Municipal Waste to Coal can be blended with Biomass or Municipal Waste to

produce gas.produce gas.• Transporting compressed SYN-Gas is cleaner than Transporting compressed SYN-Gas is cleaner than

transporting Coal.transporting Coal.• Ash left after gasification is a raw material for the cement Ash left after gasification is a raw material for the cement

industry.industry.• No hassle of cleaning and disposing of Fly Ash and Bottom No hassle of cleaning and disposing of Fly Ash and Bottom

Ash.Ash.• The Power plant can be easily upgraded to an IGCC plant.The Power plant can be easily upgraded to an IGCC plant.• Economy of burning Coal and the cleanliness of Natural Economy of burning Coal and the cleanliness of Natural

Gas.Gas.


• Coal Syngas is most widely used worldwide to generate Coal Syngas is most widely used worldwide to generate electricity. electricity.

• Worldwide gasification capacity is projected to grow 70 Worldwide gasification capacity is projected to grow 70 percent by 2015, with 80 percent of the growth occurring percent by 2015, with 80 percent of the growth occurring in Asia.in Asia.

• Low MW Coal Syngas based power Plants are gaining Low MW Coal Syngas based power Plants are gaining popularity in many Asia and African countries.popularity in many Asia and African countries.

• China has 80 Coal-SNG units under planning & China has 80 Coal-SNG units under planning & construction.construction.

• Ukraine in setting up 5 SNG plants at the cost of $35 Ukraine in setting up 5 SNG plants at the cost of $35 billion.billion.

• In India Coal Gasification has only been adopted by several In India Coal Gasification has only been adopted by several Industries like Steel, Ceramics etc., for captive Industries like Steel, Ceramics etc., for captive Consumption.Consumption.

• GE, Siemens, Lurgi, British Gas Ltd, etc., provide Coal GE, Siemens, Lurgi, British Gas Ltd, etc., provide Coal Gasification Technology. Gasification Technology.


• Techno-Commercial Feasibility Study. Techno-Commercial Feasibility Study. • Preparation of Complete Project Report.Preparation of Complete Project Report.• Government Liaison.Government Liaison.• Machinery selection.Machinery selection.• Vendor selection.Vendor selection.• Negotiate with Overseas Technology Providers and Investors.Negotiate with Overseas Technology Providers and Investors.• Complete Technical Assistance for setting up the unit till Complete Technical Assistance for setting up the unit till

commissioning. commissioning. • Assistance in preparing Press rereleases and Publicity Assistance in preparing Press rereleases and Publicity

material.material.


We Specialize in:We Specialize in:•Fuel Handling & Planning. Fuel Handling & Planning. •Fuel Emulsification.Fuel Emulsification.•Diesel Saving.Diesel Saving.•Coal & Biomass Gas.Coal & Biomass Gas.•Other Energy Related Other Energy Related Services.Services.

Documents

Coal SYN Gas For Thermal Powerplants