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Coal Water Slurry in Energy Sector

Conference Paper · February 2012

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 COAL WATER SLURRY IN ENERGY SECTOR

Syed Muzammil
BE. Mechanical, KESC
syed.muzammil@kesc.com.pk

Waqas Ahmed
BE. Mechanical, MS Thermal Power, PSO
waqas.ahmed@pso.com.pk

S.M. Fattah Moin Jah

BE. Mechanical, KESC
fattah.moinjah@kesc.com.pk

ABSTRACT
The ravaging energy demand hike has raised stern concern and distress in the world. There is an
exigency for the alternate fuel other than, coal; heavy fuel oil (HFO) and natural gas, since the
conventional fossil fuel reserve are at the threshold point and depleting at very fast rate. Pakistan
being blessed with huge amount of natural resource, coal, has certainly raised a million dollar
question for the stakeholders that how enhanced and swift we can utilize this natural asset.
The coal water slurry is a substitutive fuel with immense potential application in industrial and
steam power plant boilers with significant cost savings and ease of handling. Coal water slurry
(CWS) is a novel coal-based fluid fuel, which is comprised of 65%-70% pulverized coal, 30%-
35% water and 1%-2% additive and physically processed. It can be easily loaded, stored and
pipeline transported just like gas. The paper discusses the proven application of CWS as a clean
fuel for power generation. It also presents it application, energy and cost efficiency prospects in
converting Heavy fuel oil with coal water slurry.
1. INTRODUCTION

All fossil fuels will eventually run out and it is essential that we use them as efficiently as
possible. The use of coal as an alternate fuel is receiving renewed attention due to lessening
supply of oil and its reliance on the political infrastructure.

Coal water slurry (CWS) is a coal based fuel, environment friendly which can be used to
replace petroleum fuel in the energy and process industries. It is a mixture of 65% ~ 70 % coal
with 30% ~35% water and 1% additive. Therefore, CWS is liquid slurry of powdered coal and
water, which maintain a stable state for long period if small amount of additive is added properly.
The product has oil like appearance, good fluidity, which is stable during storage and can be
transported.

The Thar Lignite of Sindh has 50% moisture. The high moisture content helps lower the
concentration of Hazardous Sulphur content which results in more environment friendly
operation. Lignite coal being ideal for onsite slurry formation and transportation via pipeline (i.e.
like Gas, low transportation cost once infrastructure has been laid). Thar coal reservoir only in
section V can generate 10,000MW of energy for the next 30 years. Apart from abundance coal
slurry has the potential to bring cost of production (cheaper raw material) down considerably.
With Electricity abundance we can arrange for rapid industrial growth which should be
accompanied with renewable sources exploration as with prosperity we only can muster up time
to innovate. We are not required to innovate from scratch; all we need to do is improve the
existing working models present in China, Indonesia, Germany, India, USA and Russia e.t.c.

We in Pakistan have a thermal power producing infrastructure already laid. Which

primarily is based on Natural Gas firing, with the depletion we will require either to purchase fuel
from foreign market (Prices / availability due to global dynamics vary) or to use abundant coal
present in Thar, Steam turbines will adjust relatively easily to coal but gas turbine will face
danger of becoming redundant. Gas turbine infrastructure in Pakistan itself is of great importance
especially when the world is moving more and more towards combined cycle for higher
efficiency.
2. Coal water slurry (CWS)

2.1 What is CWS?

CWS is a fuel which consists of fine coal particles suspended in water. Presence of water
in CWS reduces harmful emissions into the atmosphere, makes the coal explosion-proof, makes
use of coal equivalent to use of liquid fuel (e.g. heating oil), and gives other benefits.

Standard Specifications
● Density ：65~70%；
●Viscosity ：~1000CP；
●Size ：d<50μm
●Ash ：A<7%；
●S ：S<0.5%。

2.2 Preparation of CWS

The majority of coal is utilized at run-of-mine state without any treatment for pulverized
coal power stations. However, in conventional coal preparation plants there are two main types of
coal cleaning process; physical and chemical.

2.2.1 Physical cleaning

Physical cleaning is usually used to reduce ash level to around 8% and coal preparation
plant incorporated a wide array of solid-solid and solid-liquid separation equipments. Physical
beneficiation of coal involves the separation of carbonaceous material from the mineral matter
either by varying the density of separation or by froth floatation. There are basically two different
philosophies to which can be used to produce coal with very low ash level 1) isolate particular
coal stream within washery which as result of natural breakage have washability characteristics
which favor the production of low ash coal and 2) crush or grind the coal to achieve liberation
followed by separation.

2.2.2 Chemical cleaning

The process for chemical cleaning coal are of two types 1) dissolve the mineral component
from the coal (e.g. AMAX, UCC and CENfuel; 2) dissolve those coal leaving mineral rich
insoluble coal by-product (eg. Hypercoal)

UCC
The UCC production process involves two steps; a caustic pressure leach to convert
silicate and clays to dissolve sodium silicate and sodalite type minerals. The sodalite is then
dissolved in acid so that it can be removed by simple filtering operation
 figure 1. Schematic process for Ultra Clean Coal

AMAX
AMAX objective is to develop a design base for prototype commercial advanced fine coal
facilities capable of producing ultra clean coal suitable for conversion to stable and highly loaded
CWS. The main specification was an ash content of less than 2 %. The separation technologies
were advanced column froth flotation and selective agglomerations

Hypercoal
Hyper coal is a low ash low alkali product. It is produced by dissolving the coal matter into
an organic solvent, then flashing off the solvent for recycling to the dissolution step of the
process. The insoluble (mineral matter and un dissolved coal) report to high ash bi product coal.
The hyper coal process is therefore very different form UCC process which aims to remove the
ash from coal matter.

figure 2. Schematic Hyper Coal Process []

2.3 Transportation
The economic and environmental advantages and limitations are a matter of considerable
dispute in transportation of CWS. The slurry from the agitated storage tanks is introduced into a
buried steel pipe and propelled by reciprocating positive displacement pumps located at intervals
of approximately 50 to 150 miles, depending upon terrain, pipe size, and other design
considerations. The slurry travels at a velocity just under 6 feet per second, but the precise speed
also depends on the coal particle size distribution , pipe diameter, and economic factors. Ideally,
the flow is maintained at a rate which minimizes power requirements while maintaining the coal
in suspension.
The transportation of CWS has been thoroughly investigated and implemented. One of the
earliest line was 108 miles long, 10 in dia., 50 – 60 % wt, 14 mesh, at velocities 4.5 ~5.25 ft/s,
with positive displacement pump at 30miles interval.
Table1shows the summary of the commercial slurry pipelines worldwide, with dimensions and
mass flow rate annually.
3. APPLICATIONS:

Typical Applications of Coal slurry Include the following

3.1. Power Sector

3.1.1. Steam Generator

With depleting fuel sources Steam turbine continual operation requires recognition of an
alternate fuel source. Steam turbines being equipped with external boilers are the best candidate
to be modified to operate with coal water slurry. If operated with coal instead coal
transportation/storage/handling would be a time taking job. Added provision being that coal
slurry is a way cleaner fuel than coal and gains will be achieved when reducing carbon foot print
also hazardous gas emission.
Current operating plants only in China Include

Maoming Power 125 MW Steam Power Plant

Handling 220 T/h x 2 , 410 T/h x2 of steam[1]

Nanhai Power station

Handling 670 T/h steam [1]

figure 3. Schematic Layout of CWS in thermal power

3.1.2. Gas Turbines

Gas turbine without gas / diesel / fluid fuel would render useless. Coal slurry with
coal particles being reduced to <5 microns also few modifications to nozzles or fuel supply we
can keep our Gas turbine in operation without having to bear the heavy load of expensive fuel
imports.
Another option that can be utilized is performing gasification of CWS fuel forming syn. gas, this
way less modification in gas turbine will be required.
 Test projects of running locomotive turbine with CWS fuel has been performed like Union
Pacific 4,500 Hp coal turbine locomotive [2].

3.1.3. Diesel Engines

Diesel Engine can be defined in a few ways being
i. 4 Stroke
They work well up to power of 20 MW. If operated with CWS fuel will require and additional
filtration system to remove any ash from oil in case.

ii. 2 Stroke
More dominant in engines operating between 20-97 MW (130,000 – 160,000).
Also good for operation with CSW fuels when compared to 4-Stroke. This engine is usually
crosshead type which greatly reduces crankcase oil mixing with combustion by products (ash etc)

Also can be classified as

i. Direct Fired
Slurry is injected directly into the piston in atomized form with single or multiple fire nozzles.
Spray pattern for different stroke engines are as follows.

ii. Indirect Fired

Indirect fired machines are less common but more ideal for CWS fuels. It differs in operation as
fuel is injected in a pre chamber in the cylinder head and which helps in reducing ignition delay
and ensures better atomization of the fuel.

Fuel injection is performed as high speed jets. The velocity being 300-400 m/s. A typical fire
looks as following

Figure 4. Fuel Nozzle Typical Flame

3.1.3.1 LIMITATIONS FOR DIESEL ENGINE OPERATION WITH CWS FUEL.

a. Nozzle
Nozzle adjustment will be required.

b. Ignition.

Diesel engine fuel fire is achieved by obtaining high fuel temperature. With water in fuel heat
transfer to fresh fuel from flue gases needs to increase ( approx 400% ) to achieve a temperature
where fuel will combust just by compression. The boiling point of water reaches 270oC due to
elevated pressure and temperature needs to go another300oC up to achieve combustion.

c. Bore Size
Bore size needs to be big enough as nozzle jet size will increase to 100mm which will require a
bore size of 250 mm to avoid bore cylinder damage.

Diesel Engines are most appropriate to be used with CWS Fuel. Efficiency will utmost go down
by2-5 % (from 52% to 48%) which will still be greater than Pulverized Fuel / IGCC ( 38%-48%)
and natural gas turbines (48%-50%).

4. Cost Analysis

It is difficult to compare the relative costs of using a CWS against traditional coal or oil
firing because the price of the CWS itself varies according to the coal price, the location of the
plant, and/or the plant capacity etc. The economic advantage compared to pulverized coal is
however indicated by significant reduction in handling cost by simplifying facilities required for
loading and unloading activities.
In general,
• 2 tons of coal water slurry (costs ± US$ 200) can replace 1 ton of heavy oil (costs US$ 298), a
significant saving of production cost.
• Users can save ± 70% fuel cost for per ton of fuel oil (heavy oil).
• Coal water slurry can replace heavy oil fuel and brings tremendous economic benefits as an oil
substitute fuel, as shown in table 2 below
 5. CONCLUSION

Coal Water Slurry (CWS) is a new type of liquid fuel, environmentally friendly fuel that
can replace petroleum as fuel in the energy conversion and process industries. CWS consists of
65% - 70% coal, 30% - 35% water and small quantities of chemical additives. CWS has oil like
appearance, can be handled like liquid, burns like oil and coal, the cost is just slightly higher than
coal. It resembles Heavy Fuel Oil with good fluidity; therefore stable during storage and can be
transported conveniently like liquid, through pipes and by pumps. The capital investment costs is
very low relative to coal gasification and liquefaction processes, which can be more than US$6.5
billion for a 100,000 BPSD complex, as compared to US$150 million for CWS of the same size.
It has high combustion efficiency and low in pollution discharge.

The successful introduction of CWS technology into the industries, in Pakistan, to replace
Heavy fuel oil has a very significant impact in the utilization of low rank coal, for new thermal
power plant. The simultaneous and parallel development of advanced coal cleaning technologies
as in the case of CWS could allow Indonesia to make a fast transition, economically, away from
our limited resource of oil and natural gas to our most abundant resource of coal. Coal based
CWS will be the fuel of this century and beyond

6. REFERENCES

[1] Ir. Pontjo H. Soedjanto, CEO - CHIPS Energy Co., Ltd.; and Prof. Zhijun Zhou, Ph.D,
Associate Professor, Institute for Thermal Power Engineering, Zhejiang University, Hangzhou,
“Application Of Coal Water Slurry In Power Generation”, China
[2] L. Wibberly, D. Palfrymen and P. Scaife, Efficient Used of Coal Water fuel Technical
Report 74, April 2008
[3] PPIB, Pakistan Coal Power Generation Potential, Gov-Pak, June 2004

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