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A technology evaluation of five coal gasifier systems (Koppers-Totzek, Texaco, Babcock and Wilcox, Lurgi and BGC/Lurgi) and procedures and criteria for evaluating competitive commercial coal gasification designs is presented. The technology evaluation is based upon the plant designs and cost estimates developed by the BDM-Mittelhauser team.
A contemporary underground coal mine in eastern Kentucky was assessed in order to determine potential off-site and on-site environmental impacts associated with the mining system in the given environmental setting. A 4 section, continuous room and pillor mine plan was developed for an appropriate site in eastern Kentucky. Potential environmental impacts were identified, and mitigation costs determined. The major potential environmental impacts were determined to be: acid water drainage from the mine and refuse site, uneven subsidence of the surface as a result of mining activity, and alteration of ground water aquifers in the subsidence zone. In the specific case examined, the costs of environmental impact mitigation to levels prescribed by regulations would not exceed $1/ton of coal mined, and post mining land values would not be affected.
The technology status of phosphoric acid and molten carbon fuel cells, combined gas and steam turbine cycles, and magnetohydrodynamic energy conversion systems was assessed and the power performance of these systems when operating with medium-Btu fuel gas whether delivered by pipeline to the power plant or in an integrated mode in which the coal gasification process and power system are closely coupled as an overall power plant was evaluated. Commercially available combined-cycle gas turbine systems can reach projected required performance levels for advanced systems using currently available technology. The phosphoric acid fuel cell appears to be the next most likely candidate for commercialization. On pipeline delivery, the systems efficiency ranges from 40.9% for the phosphoric acid fuel cell to 63% for the molten carbonate fuel cell system. The efficiencies of the integrated power plants vary from approximately 39-40% for the combined cycle to 46-47% for the molden carbonate fuel cell systems. Conventional coal-fired steam stations with flue-gas desulfurization have only 33-35% efficiency.
Technology readiness and development trends are discussed for three advanced power generation systems: combined cycle gas turbine, fuel cells, and magnetohydrodynamics. Power plants using these technologies are described and their performance either utilizing a medium-Btu coal derived fuel supplied by pipeline from a large central coal gasification facility or integrated with a gasification facility for supplying medium-Btu fuel gas is assessed.
Results from the initial effort to establish baseline economic performance comparators for a program whose intent is to define, develop, and demonstrate advanced systems suitable for coal resource extraction beyond the year 2000 are reported. Systems used were selected from contemporary coal mining technology and from conservation conjectures of year 2000 technology. The analysis was also based on a seam thickness of 6 ft. Therefore, the results are specific to the study systems and the selected seam extended to other seam thicknesses.
Sixteen coal conversion processes are described and their projected goals listed. Tables show the reactants used, products derived, typical operating data, and properties of the feed coal. A history of the development of each process is included along with a drawing of the chemical reactor used.
A conceptual design study was conducted to assess technical feasibility, environmental characteristics, and economics of coal gasification. The feasibility of a coal gasification combined cycle cogeneration powerplant was examined in response to energy needs and to national policy aimed at decreasing dependence on oil and natural gas. The powerplant provides the steam heating and baseload electrical requirements while serving as a prototype for industrial cogeneration and a modular building block for utility applications. The following topics are discussed: (1) screening of candidate gasification, sulfur removal and power conversion components; (2) definition of a reference system; (3) quantification of plant emissions and waste streams; (4) estimates of capital and operating costs; and (5) a procurement and construction schedule. It is concluded that the proposed powerplant is technically feasible and environmentally superior.
In an effort to establish baseline information whereby specific projects can be evaluated, a current set of parameters which are typical of coal gasification applications was developed. Using these parameters a computer model allows researchers to interrelate cost components in a sensitivity analysis. The results make possible an approximate estimation of hydrogen energy economics from coal, under a variety of circumstances.
Organic sulfur is removed from coal by treatment with an organic solution of iron pentacarbonyl. Organic sulfur compounds can be removed by reaction of the iron pentacarbonyl with coal to generate CO and COS off-gases. The CO gas separated from COS can be passed over hot iron fillings to generate iron pentacarbonyl.
Raw coal upgraded by supercritical-solvent extraction system that uses two materials instead of one. System achieved extraction yields of 20 to 49 weight percent. Single-solvent yields are about 25 weight percent. Experimental results show extraction yields may be timedependent. Observed decreases in weight of coal agreed well with increases in ash content of residue.
Water-based process for desulfurizing coal not only eliminates need for costly organic solvent but removes sulfur more effectively than an earlier solvent-based process. New process could provide low-cost commercial method for converting high-sulfur coal into environmentally acceptable fuel.
Advanced power-generation systems using coal-derived fuels are evaluated in two-volume report. Report considers fuel cells, combined gas- and steam-turbine cycles, and magnetohydrodynamic (MHD) energy conversion. Presents technological status of each type of system and analyzes performance of each operating on medium-Btu fuel gas, either delivered via pipeline to powerplant or generated by coal-gasification process at plantsite.
Proposed process modification incorporates viscosity depressants to prevent coal from solidifying during liquefaction. Depressants reduce amount of heat needed to liquefy coal. Possible depressants are metallic soaps, such as stearate, and amides, such as stearamide and dimer acid amides.
A fluidized bed coal reactor includes a combination nozzle-injector ash-removal unit formed by a grid of closely spaced open channels, each containing a worm screw conveyor, which function as continuous ash removal troughs. A pressurized air-coal mixture is introduced below the unit and is injected through the elongated nozzles formed by the spaces between the channels. The ash build-up in the troughs protects the worm screw conveyors as does the cooling action of the injected mixture. The ash layer and the pressure from the injectors support a fluidized flame combustion zone above the grid which heats water in boiler tubes disposed within and/or above the combustion zone and/or within the walls of the reactor.
Geologic characteristics of coal resources which may impact new extraction technologies are identified and described to aid system designers and planners in their task of designing advanced coal extraction systems for the central Appalachian region. These geologic conditions are then organized into a matrix identified as the baseline mine concept. A sample region, eastern Kentucy is analyzed using both the developed baseline mine concept and the traditional geologic investigative approach.
One approach for detection of the coal interface is measurement of pick cutting loads and shock through the use of pick strain gage load cells and accelerometers. The cutting drum of a long wall mining machine contains a number of cutting picks. In order to measure pick loads and shocks, one pick was instrumented and telemetry used to transmit the signals from the drum to an instrument-type tape recorder. A data system using FM telemetry was designed to transfer cutting bit load and shock information from the drum of a longwall shearer coal mining machine to a chassis mounted data recorder. The design of components in the test data system were finalized, the required instruments were assembled, the instrument system was evaluated in an above-ground simulation test, and an underground test series to obtain tape recorded sensor data was conducted.
Summed signals and dielectric-filled antenna improve measurement. Improved FM radar for measuring thickness of coal seam eliminates spectrum splitting and reduces magnitude of echo from front coal surface.
Coal mining machine cuts swath wider than itself and cuts entry passages into coal seam in one pass.