Underground Coal Gasification in Poland. Experiences, results and future prospects.

Transcription

1 MINERALS ENGINEERING 2014 UK Energy Symposium Underground Coal Gasification in Poland. Experiences, results and future prospects. Dr. Krzysztof Kapusta, prof. Krzysztof Stańczyk Główny Instytut Górnictwa (Central Mining Institute) POLAND Kegworth15 th May, 2014

2 CENTRAL MINING INSTITUTE (GIG) is a research and development organization related to the Upper Silesian mining industry and region since 1945 The Experimental Mine Barbara in Mikołówwas established 20 years earlier than the Institute and now constitutes its part Poland, Katowice, Plac Gwarków 1

3 MINING AND GEOENGINEERING SUSTAINABLE ENERGY TECHNOLOGIES (CLEAN COAL TECHNOLOGIES) ENVIRONMENTAL ENGINEERING HEALTH AND SAFETY IN INDUSTRY MATERIAL ENGINEERING RADIOACTIVITY AND IONISING RADIATION SCIENCE AND RESEARCH IN GIG

4 The future of coal Why coal is such an important fuel? Coal provides 29% of global primary energy needs and generates 41% of the world's electricity Source: IEA, EURACOAL, 2013

5 Coal-fired power generation in selected countries, 2012 Source: IEA, EURACOAL, 2013 *2011 for non-oecd countries

6 Coal in Europe 2012

7 Main coal basins in Poland Lignite and hard coal

8 Clean Coal Technology Centre (GIG) Locations Katowice testing laboratories Basic research on coal processing processes Coal quality characteristics and geology Numerical modelling Environmental monitoring Laboratory research on CO 2 storage potential Mikołów technological unit Applied research on coal processing technologies Syngas processing and utilisation Coal-derived liquids Large scale experimental installations including UCG tests in real underground conditions

9 Laboratory of Experimental Installations Scope of activities Conducting R&D works in the field of prospective chemical technologies of coal processing, including in particular: process of underground, pressure or non-pressure, coal gasification aimed at production of syngas with a high content of hydrogen and of gases for power use, pressure, fluidized gasification of solid fuels in surface conditions, direct coal liquefaction process aimed at the production of engine fuels and chemical raw materials, processes of hydrogenation and refinement of coal-derived substances, separation and purification of process gases using membrane techniques and methods of absorption and adsorption, including the pressure swing adsorption - PSA, separation of CO 2 from process gases

10 Ex-situ simulation of atmospheric pressure UCG Technical parameters: coal type: lignite, hard coal coal seam length: 7 m gasification pressure: max 0.5 bar temperature: max C coal seam inclination: 0, 15, 30,

11 Atmospheric pressure UCG simulation Preparation of artificial coal seam

12 Ex-situ simulation of high-pressure UCG Technical parameters: coal type: lignite, hard coal coal seam length: 3.5 m gasification pressure: max 50 bar temperature: max C coal seam inclination: 0, 15, 30, 45 0

13 High - pressure UCG simulation Preparation of artificial coal seam

14 Pressurized surface gasifier Technical parameters: feedstock: coal, biomass, wastes gasification pressure: max 50 bar temperature: max C capacity: 10 kg of coal/hour

15 Gas purification and separation module Absorption/adsorption vessels Pressure Swing Adsorption - PSA

16 Direct coal liquefaction (hydrogenation)

17 The UCG Underground Test Ground in EM Barbara Ventilation shaft Prospective locations for the next in-situ UCG tests Gas flow direction Utilisation of gasification products Region of finished UCG tests Experimental hall

18 Underground coal gasification Underground Coal Gasification is the process of in-situ conversion of coal deposits to combustible gaseous products (H 2, CO, CH 4 ) It is not a new technology but one that has evolved In recent years it has undergone a transformation due to technical advances, specific research and sharing of knowledge and information

19 UCG methods LVW Linked vertical well CRIP Controlled retractable injection point Longwall method

20 Linked vertical well (LVW) Source: G.R. Couch, Underground Coal Gasification, IEA 2009

21 Controlled retractable injection point (CRIP) The CRIP process retracts the oxidants injection point to control the location of the combustion front Source: G.R. Couch, Underground Coal Gasification, IEA 2009

22 Longwall UCG method Source: G.R. Couch, Underground Coal Gasification, IEA 2009

23 Possible applications of the UCG product gas

24 Former Polish UCG developments by GIG The first Polish research programme on UCG ( ) Laboratory and industrial scale research Filed-scale UCG experiments in Mine Mars mainly with air as gasification agent

25 Recent UCG projects in Central Mining Institute (GIG) HUGE Elaboration of coal gasification technology for a high efficiency production of fuels and electricity HUGE Funding sources: EU Research Fund for Coal and Steel National Centre for Research and Development (NCBiR) EU 7th Framework Programme COGAR TOPS

26 UCG aspects under study Technical infrastructure for UCG Technological aspects HUGE (RFCS) HUGE2 (RFCS) COGAR (RFCS) Elaboration of coal gasification. (NCBiR) Environment and safety Gas utilization TOPS (7 th FP) Coupled UCG-CCS

27 Projects HUGE & HUGE2 Aims: Hydrogen Oriented Underground Coal Gasification for Europe Theoretical and experimental exploration of the possibilities of in-situ production of hydrogen-rich gas through the underground coal gasification (UCG) technique HUGE 2 Safety and Environmental Aspects

28 Ex-situ experimental installation Złoże węgla Wylot Gas quality control Warstwa nadkładu Odbiór i oczyszczanie gazu System zasilania Powietrze Tlen p I-3 Azot I-4 T Para wodna 1.5 m Pokład węgla Kanał ogniowy Warstwa spągowa 3.0 m Króciec do poboru prób gazu I-5 I-6 p T Chłodnica Wentylator GC Filtr Skład gazu, % obj CO 2 H 2 O 2 N 2 CH 4 CO Separator 1 Zbiornik na kondensat Separator 2 Zbiornik na kondensat Czas, h 1,5 m 0.80m Warstwa stropowa 0.40 m 0.45 m 0.45 m 0.45 m 0.45 m 0.40 m 0.80 m Pokład węgla Kanał ogniowy Wlot 2.2 m Warstwa spągowa 1.4 m 3.0 m 1.5 m Wylot Produkcja gazu, Nm 3 /h Czas, h Installation parameters Coal seam dimensions Gasification agent Gasification temperature Gasification pressure 2,5 x 0,8 x 0,8 m Oxygen, air, steam up to C atmospheric Wysokość pokładu, m Temperature control 1 Strop pokładu Kanał ogniowy Długość pokładu, m

29 Gasification channel Tested configurations Outlet 1.5 m 1.5 m Ignition point Ignition point 3.0 m 3.0 m 3.0 m Ignition point Inlet Outlet Inlet Outlet Inlet

30 Examples of large coal samples 0.5 m

31 Post-gasification studies Cavity shape Roof Seam height, m Gasification channel Seam length, m 0

32 Ex-situ UCG experiments Results Type of coal Gasification agent Average gas composition, % vol CO 2 H 2 N 2 CH 4 CO Heating value, MJ/m 3 Oxygen Hard coal Oxygen + steam Two stage Oxygen cycle Steam cycle Lignite Oxygen

33 Underground Testing Ground EM Barbara Experiments on underground coal gasification process (UCG) in natural conditions

34 In situ UCG experiments Test sites Ventilation shaft Gas flow direction Utilisation of gasification products In-situ HUGE and HUGE2 tests sites Experimental hall

35 Location of HUGE and HUGE2 underground gasifiers and tested configurations of gasification channels HUGE 2 HUGE The average depth of the coal deposit used in the experiments was 30 m with a dip angle of 4 6º and a thickness of m

36 Barbara Mine Coal characteristics No. Coal parameter Value As received 1 Total moisture [%] Ash [%] Total sulphur [%] Calorific value [kj/kg] Analytical 5 Moisture [%] Ash [%] Volatiles [%] Calorific value [kj/kg] Total sulfur [%] Carbon [%] Hydrogen [%] Nitrogen [%] 0.9

37 Coal seam No. 301 before gasification

38 Preparation of gasification channels

39 Scheme of the in-situ installation Supplying system Monitoring Gas collecting system Flare Suction fan Ground Georeactor Pit shaft Air shaft 15 m 1. Oxygen 2. Air 3. Water 4. Nitrogen Dewatering system

40 Coal seam ignition

41 UCG reactor inlet

42 UCG product pipelines

43 UCG product pipelines

44 Gas composition and safety monitoring

45 Oxygen source mobile criogenic tank

46 UCG gas combustion Thermal combustor Flame of UCG-derived gas

47 UCG gas combustion Flare stack (alternative)

48 Contaminants monitoring system Tar compounds in raw UCG gas Raw UCG-gas sampling Raw UCG-gas from underground

49 Contaminants monitoring system Post-processing water (condensate) collection system Condensate flow direction

50 Groups of tar compounds determined in raw gas Compound/group of compounds BTEX: Benzene, Toluene, Ethylbenzene, Xylenes (o-, m- p- isomers) 15 PAHs: Naphthalene (NaP), Acenaphthene (AcP), Fluorene (Flu), Phenanthrene (Phe), Anthracene (AnT), Fluoranthene (Fla), Pyrene (Pyr), Benzo(a)anthracene (BaA), Chrysene (Chr), Benzo(b)fluoranthene (BbF), Benzo(k)fluoranthene (BkF), Benzo(a)pyrene (BaP), Dibenzo(a,h)anthracene (DBA), Benzo(g,h,i)perylene (BghiP), Indeno(1,2,3-cd)pyrene (IND) Sampling method Sampling on sorbent tube with activated carbon (SKC Anasorb CSC, 600 mg) Two samples in parallel Sampling on sorbent tube with polymer rasin (SKC XAD-2, 600 mg) Two samples in parallel Determination method Gas chromatography with FID detector (AGILENT 7890A) Gas chromatography with MS detector (AGILENT 7890A) Phenols: Phenol (hydroxybenzene) o Cresol m Cresol p Cresol Sampling on sorbent tube with silica gel(skc Silica Gel, 600 mg) Two samples in parallel Gas chromatography with FID detector (AGILENT 7890A)

51 Groundwater monitoring Sampling vertical wells

52 Groundwater monitoring Sampling vertical wells

53 General results In-situ experiment HUGE (straight configuration) 90 Concentration [%vol.] Gas production rate, [Nm] 3 /h ,5 0,1 0,01 1E Time [h] Gas production rate CO 2 C 2 H 6 H 2 O 2 N 2 CH 4 CO H 2 S Parameter Gasification agent Value oxygen Oxygen supply rate, Nm 3 /h Experiment duration, hours 355 Average gas production, Nm 3 /h Average gas composition, %: CO H CH CO 13.4 N Average gas heating value, MJ/Nm 3 Total coal consumption, kg Process energy efficiency, % Time, [h]

54 General results In situ experiment HUGE2 (V-shaped configuration) Total gas production rate (m 3 /h) Gasses concentration (% vol) , I Stage II Stage Time (h) Total volume of produced gas Nm 3. Average gas production rate Nm 3 /h. I Stage II Stage Hydrogen Carbon monoxide Methane Ethane Oxygen Nitrogen Hydrogen sulfide Carbon dioxide Parameter Gasification agent Value oxygen Oxygen supply rate, Nm 3 /h Experiment duration, hours 142 Average gas production, Nm 3 /h Average gas composition, %: CO H CH CO 31.7 N Average gas heating value, MJ/Nm 3 Total coal consumption, kg Process energy efficiency, % Time (h)

55 UCG gas (HUGE2) Calorific value Gas calorific value (MJ/Nm 3 ) I Stage Calorific value of obtained gas: Stage I - 10,30 MJ/Nm 3 Stage II - 5,49 MJ/Nm 3 Total (142h) - 8,91 MJ/Nm 3. II Stage Time (h)

56 Numerical modeling of UCG hydrogeology EM Barbara Groundwater flow model (2D) Darcy s law: u = K H H S t + [ K H ] = Q s Contaminant transport model 0 m -0,3 m =0 źródło zanieczyszczeń dno kawerny Char 0, 2 =0, >2 =0 spąg, łupek ilasty Raw coal -10 m =0 Advective dispersive transport: + + =0-50 m 20 m 80 m 100 m =0 250 m

57 Contaminant transport in coal seam and selected rocks 1 year 3 years 10 years 20 years Shale 1 Shale 2 dx 1 Coal dx 2 Char dx 3 Normalized isolines of naphtalene (c/c 0 )

58 Post-gasification studies

59 Post-gasification cavity (HUGE)

60 In-situ gasification experiments UCG pilot plant at Coal Mine Wieczorek

61 UCG pilot plant Wieczorek Site selection

62 UCG pilot plant Wieczorek Geometries of gasification channels w skale płonnej w węglu pokładu otwory badawcze chodnik badawczy dla udostępnienia georeaktora 2,5 m 5,5 m pokład m połączone otwory badawcze o średnicy 200 mm wykonane w kształcie litery V w skale płonnej ok...20m węgiel pokładu 501 chodnik badawczy c hodnik badawczy przekop wentylacyjny poz.400 m

63 UCG pilot plant Wieczorek Underground gallery

64 UCG pilot plant Wieczorek Drilling works

65 UCG pilot plant Wieczorek Surface UCG gas purification module

66 Thank you for your attention

67 Contacts prof. Krzysztof Stańczyk Central Mining Institute( Główny Instytut Górnictwa) Plac Gwarków 1, Katowice, Poland Dr. Krzysztof Kapusta Central Mining Institute( Główny Instytut Górnictwa) Plac Gwarków 1, Katowice, Poland `