CO2 enhanced coal gasification and BlueCoal new Clean Coal Technologies proposals from Poland

European Union Side Event Paris, Le Bourget, 9th December 2015 CO2 enhanced coal gasification and BlueCoal new Clean Coal Technologies proposals from Poland Aleksander Sobolewski INSTITUTE FOR CHEMICAL PROCESSING OF COAL, ZABRZE, POLAND

Contents 1. Introduction 2.IChPW competencies on Clean Coal Technologies 3.Background of CO 2 -enhanced coal gasification 4. Development of IChPW CFB coal gasification process 5. Residential heating vs. air quality in Poland 6.BlueCoal new coal-base smokeless fuel 7. Conclusions 2/54

Introduction: coal in Poland (2015) huge geological reserves of coal large coal production (hard coal and lignite both) coal the base of energy mix (85% of electric power comes from coal) coal main fuel for residential heating (>70%) Energy security political priority 4/54

Motto: Sustainable Development - YES! Air quality protection - YES! Decarbonisation of EC - WHY? Key for success : Clean Coal Technologies 5/54

60 years of technological experience 180 employees / researchers Institute activities : thermochemical conversion of solid fuels for power and chemical industries, efficient and safe cokemaking, environmental friendly municipal heating (coal and biomass) SOLID FUELS waste to energy processes All the areas of technological and process research are related to issues of environmental protection, and reduction of greenhouse gases emission. 7/54

Clean Coal Technology Center (CCTW), Zabrze, Poland Zabrze, Poland The CCTW in numbers: -9 pilot-scale plants, -12 bench-scale R&D stands, -fuel preparation plant, -sampling preparation rooms, -on-line process monitoring, -4 accredited laboratories, -own air monitoring station. 8/54

IChPW competencies on solid fuel gasification 9/54

Background of CO 2 -enhanced coal gasification Process background + + COAL O 2 CO 2 C + O 2 = CO 2 + r H 1 (1) C +CO 2 = 2CO - r H 2 (2) Energy balance: Conversion od 1 kmol C according reaction (1) allows to achieve the necessary amount of energy for the conversion of 2.3 kmol C according to the reaction (2) CO Syngas component 11/54

Background of CO 2 -enhanced coal gasification Technological concept (2009) Chemical sequestration of CO 2 an alternative to the geological storage. CO 2 should be both carbon and oxygen carrier for gasification processes. Increase of process efficiency and simultaneous decrease of process emission level. 12/54

Development of CO2-enhanced gasification - why CFB? Available gasifiers: Parameter Fluidized gasifier Entrained flow gasifier Grain size Max. ash content Temperature Residence time Vol. concentration of fuel Applicability bellow 6 mm No limit 750 1100 o C 180 600s 0.15 0.30 m 3 /m 3 YES bellow 0.2 mm bellow 20% 1250 1500 o C 3 5 s 0.01 0.03 m 3 /m 3 No 13/54

Step by step - lab-scale tests TG analysers: Coupling systems: TG-MS-FTIR; TG-GC-MS HPTG with MS Laboratory test facility: Fluidized Bubbling reactor, Pressure conditions: up to 15 bars Continuous coal feeding: 4 kg/h Gases: O 2, CO 2, H 2, H 2 O 14/54

Step by step - pilot-scale tests Technological studies Pilot scale Pilot scale: Atmospheric CFBR: 1000 C, 200 kg/h Air, O 2, CO 2, H 2 O Pilot scale: Pressurized CFBR: 1,0 MPa, 1000 C, 100 kg/h Air, O 2, CO 2, H 2 O 15/54

Step by step 1 MW pilot-scale plant flow sheet 17/54

Step by step 1 MW pilot-scale plant flow sheet 18/54

Results: 1 MW Pilot-Scale, ambient pressure Lignite coal Low-rank coal Bełchatów Janina Wieczorek Gasification temperatures [ o C] 855-950 890-980 820-1000 Coal feed [kg/h] 85-130 125-140 95-140 Air flow [m 3 /h] 40-120 45-145 70-130 CO 2 flow [m 3 /h] 0-65 0-60 0-45 O 2 flow [m 3 /h] 0-20 0-25 0-10 Content of combustibles* [% vol.] up to 65 up to 60 up to 45 * Calculated on CO 2 -free base 19/54

Results: Pilot-Scale, elevated pressure Lignite coal Bełchatów Low-rank coal Janina Gasification temperatures [ o C] 810-950 890-935 Coal feed [kg/h] 15-85 30-40 Air flow [kg/h] 0-85 5-10 CO 2 flow [kg/h] 0-105 45-70 O 2 flow [kg/h] 0-35 10-30 Pressure [bar] 1,3-6,2 1,8-2,7 Content of combustibles* [% vol.] up to 75 up to 60 * Calculated on CO 2 -free base 20/54

Results: Pilot-Scale, effect of CO 2 feed 21/54

Results: Pilot-Scale, carbon substitution 22/54

Methanol production (1): Technological block diagram 23/54

Methanol production (2): Operating parameters Methanol efficiency: 41,8% (referring to total amount of AR coal, HHV) 52,2% (referring to coal converted, HHV) Methanol and Power efficiency 53,7 % 24/54

Scenarios for gasification technology development in Poland (1) Short term activities beyond 2020 Development of industrial scale plant based on selected commercial available technology Medium and long term activities beyond 2030 Development of industrial scale plant based on developed gasification technology in CFB reactor (Demo stage needed) 25/54

Scenarios for gasification technology development in Poland (2) Configuration and production directions 1. Medium scale CHP plants integrated with coal gasification 2. Substitution of NG for hydrogen production and ammonia synthesis 3. Methanol synthesis and olefins production 26/54

Introduction: Poland - climatic conditions Average ambient air temperature 20 15 10 5 heating season The average annual air temperature 0-5 August September October N ovem ber D ecem ber January F ebruary M arch April M ay June July The average summer temperatures are between 16.5 C and 20 C, in the winter - between -6 C and 0 C. The average annual air temperature in Poland is 7-9 C (outside mountain areas). Residential heating is necessary! 28/54

Introduction: Air quality - Poland vs. Europe PM 10 B(a)P Poland the most hot area in EU? 29/54

District heating influence for air quality in Krakow (Poland) Air quality recorded by air monitoring station "Krakow - Krasinski Avenue" during the summer months: July and August 2013 and the heating season months: January and February 2013 Contamination NO X SO 2 Particulate Matter PM10 Particulate Matter PM2.5 [µg/m 3 ] [µg/m 3 ] [µg/m 3 ] [µg/m 3 ] limit value - - 50 - winter season 234 17 94 70 summer season 190 5 41 29 30/54

Air quality protection NGOs activities in Poland 31/54

Residential heating air emission reduction System philosophy Options (technological concepts) - district heating, natural gas - automatic boilers - low-emission coal-based fuel - biomass pellet system implementation and operating cost air quality improvement community acceptance 32/54

Factors determining residential heating emission reduction Synergetic effect of factors determining lowstack emission reduction Fuel quality Better fuel - qualified coal / elimination of coal slurries - smokeless fuels / low-emission -biomass/ wood pellets Control & education Better boiler - chimney and ash sensor - new automatic boilers - installation modernisation Boiler quality Logistics - e-monitoring -community and worker education -thermal modernisation of buildings - society education 33/54

Residential heating installations in Poland (up to 500kW) Automatically operated boiler with continuous fuel feeding system electronic control engine Automatically operated boilers (retort, grate boilers and others) Shaft boilers (firing from the top of the bed) Manual operated chamber boilers Manual operated chamber boilers engine without electronics 34/54

Solid fuels for residential heating in Poland 11 12 mln t of hard coal (data from Mining Companies) 6 8 mln t of biomass (Central Statistical Office of Poland data) 0,5 1 mln t of lignite (own estimation) 0,5 1 mln t of wastes (own estimation) 35/54

elektricity Solid fuels for residential heating in Poland Unit cost of heat production in small scale boilers 100 90 80 70 60 50 40 30 20 10 0 coal sludge fine coal nut coal qualified fine coal (bags) eco pea coal (bags) lump wood wood pellets natural gas heating oil 36/54 PLN/GJ/produced heat

Key question: Who and why is using coal-fired residential heating? 37/54

Key question: Poor part of Polish society! We use coal because is the cheapest We cannot afford heating type change 38/54

Recently implemented actions are of low performance because they do not take into account the core problem: Main issues of residential emission are old and improper operated boilers fired with low-quality coals In Poland we are not able to replace all old boilers in following 10 years Smokeless fuels must be adapted into present infrastructure (stoves, boilers) and society mind 39/54

Hard coal BlueCoal characteristic: - easy ignition - stable combustion BlueCoal -easy ash removal -low air emission Parameter Symb. Unit hard coal BłueCoal proximate analysis ash A r % 5 15 <10% volatiles V daf % 31 34 4 8 total sulphur S r t % 0,6 1,2 <0,4 calorific value Q r i MJ/kg 19 25 28 max. undersize < 0,1mm - % 25 5 smell - - odorless odorless 41/54

Fuel upgrade idea coal fuel preparation combustion of LOW-EMISSION FUEL compaction additives emission to air thermal processing in temp. higher than 450 o C ash usable energy 42/54

Bluecoal work programme under GEKON project 2013-2014 2014-2015 2015-2016 SEMI-TECHNICAL TRIALS IN IChPW INITIAL PILOT PROGRAMME PILOT PROGRAMME ~1 ton 15 tons 2000 tons 43/54

Semi-technical trials in IChPW Emission of coal and smokeless fuel combustion in chamber boiler 1500 particulatesł, mg/m 3 n (ref. 10% O 2 ) 1000 500 0 hard coal smokeless fuel Dust 8x 1400 TOC 6x total organic comp., mg/m 3 n(ref. 10% O 2 ) 1200 1000 800 600 400 200 0 hard coal smokeless fuel 44/54

Initial pilot programme Zabrze 2014/2015 Target: efficiency control of new fuel in real conditions, operators opinion gathering. Tested heating devices Implementation: location: Zabrze, I/II 2015, 2 boilers > 50 kw, 10 boilers < 50 kw, comparative emission measurements in chimneys, operators opinions gathering. 45/54

Initial pilot programme Zabrze 2014/2015 particulates, mg/m 3 n 1600 1400 1200 1000 800 600 400 200 TOC., % 100 80 60 40 20 0 boiler stove stove-kitchen 0 boiler stove-kitchen hard coal smokeless fuel hard coal smokeless fuel Particulates emission of hard coal and smokeless fuel combustion in Zabrze Total Organic Compounds emission of hard coal and smokeless fuel combustion in Zabrze Hard coal vs smokeless fuel TOC - reduction more than 3 times Σ16 WWA acc. EPA - reduction more than 4 times B(a)P - reduction more than 10 times SO 2 - reduction more than 2 times 46/54

Big pilot programme 2015/2016 Locations pilot trials 2000 tons of fuel! Present state: material under delivery to selected locations JEDLINA-ZDRÓJ ROSZKÓW ZABRZE KRAKÓW 47/54

Conclusions (1) coal gasification: 1. At present there are no coal gasification plants in Europe. Several studies completed last years show, that Coal To Chemicals (via gasification) looks a profitable business. The most interesting directions for coal gasification should be ammonia and methanol production. 2. Pilot-scale tests (1 MWth) confirmed possibility of CO 2 -enhanced coal gasification (lignite and hard coal) in CFB, 3. CO 2 -enhanced coal gasification is attractive alternative for CCS technology by chemical storage. At present European Commission replace CCS to CCU. 49/54

Conclusions (2) smokeless fuels: 1. The problem of air emission reduction from municipal heating is difficult and multi-threaded. Any solutions should take into account both environmental regulations and the costs of implementing just to be accepted by society. 2. For the current condition of municipal heating infrastructure in Poland, effective and quick" solution could be introduction a refined, coal-based smokeless fuels. Applied technologies are ready for industrial implementation. 3. Pilot scale tests of BlueCoal (season 2015/16, 2000t, 5 locations)) should confirm the readiness of new fuel and get the necessary recommendation for start of commercial scale production in the near future. 50/54

Motto for present times: 51/54

Conclusions (3): For both cases : CFB CO 2 -enhanced coal gasification, BlueCoal - smokeless fuel production, the key for success will be commercially ready, proof and cheap technology. In XXI century in EC we should be more open for new Clean Coal Technologies. Clean Coal Technologies are really clean. 52/54

ACKNOWLEDGMENTS The research results presented herein were obtained during the course of the project Development of coal gasification technology for high-efficiency production of fuels and energy, Task No. 3 of the Strategic Program for Research and Development: "Advanced energy generation technologies" funded by the Polish National Center for Research and Development 53/54

Thank you for your kind attention 54/54