Coal SYN Gas For Thermal Powerplants

COAL SYN-GAS :

The most Viable & Economic alternative
for retrofitting Small/Medium
Oil-Fired Thermal Power Plants

© R.A.D.E INITIATIVE 2013 | rade.initiative@gmail.com

• Use Heavy Fuel Oil(HFO) or Residual Fuel Oil (RFO).
• Some small units are powered by a direct fired combustion Turbine.
• Most have a Steam Boiler and Steam Turbine to run the Generator.
• Are becoming economically non-viable due to high Fuel prices.
• The price of RFO is not likely to come down to economical levels.
• Are being either shut down or converted to other Fuels.
• Shutting down these plants has increased electricity shortage.


Retrofitting of Oil-fired Power-plants

• Many Oil-fired Power plants are being converted to other fuels.
• Conversions usually involves costly up-gradations of the plants.
• Plants are converted to run on Coal, Natural Gas or SYN Gas.
• Most of the changes are made in the Boiler firing Section.
• Also requires a new Fuel storage & handling section.
• Apart from the conversion expenses, the new fuels bring along their
own associated problems.
• Converted Plants usually run on lower efficiencies than the
originally designed.


• Oil-fired Power plants are mostly converted to Coal firing.
• Conversion involves extensive changes to Boilers.
• Needs the addition of a Coal Pulverizer unit and Blower Section.
• Requires the creation of a large Coal Stockyard.
• Up-gradation of the Boiler Bottom Ash cleaning section.
• Coal transportation causes extensive Dust pollution.
• Coal Stocking has the scope of causing high groundwater pollution
through leaching in high rainfall areas.
• Needs the erection or up-gradation of an ESP (Electrostatic
Precipitator) for capturing fly ash from the Flue Gasses.
• Needs Wet-scrubbers to curtail Sulfur Oxide atmospheric pollution.


• Some Oil-fired Power plants are also converted to Natural Gas.
• Subjected to availability and regular supply of Natural Gas.
• Plant conversions usually involves only changing of Burners &
laying Gas pipelines.
• Requires the addition of a Buffer tank in case of piped Gas.
• Need a large Gas storage tank in case of transported gas.
• Plant can be easily combined to IGCC (Integrated Gasifier
Combined Cycle) co-generation with the addition of a Gas Turbine.
• Economics of the plant depend on the fluctuating International
prices of natural gas.
• Being Clean-burning, it doesn’t require any special anti pollution
equipment.


• An alternative to natural gas is Coal - SYN Gas ( Synthetic Gas) .
• Subjected to availability of any grade of Coal (Anthracite to Lignite).
• Conversions involves changing of Burners & laying Gas pipelines.
• Gas can be prepared either on-site or transported from other locations.
• Involves erecting a large gasifier or a battery of small gasifier units.
• Construction of a large gas storage tank in case of transported gas.
• Plant can be easily combined to IGCC (Integrated Gasifier Combined
Cycle) co-generation with the addition of a Gas Turbine.
• Economics of the plant depend on the relatively stable price of coal.
• Stack emission levels comparable to Natural Gas.


• Gasification is a process that convert solid feedstock like coal or
biomass into a combustible gas.
• Coal is gasified by being reduced under high pressure high
temperature with steam in a specialized retort known as a Gasifier.
• Coal Gas is also called as Syngas or Synthetic Gas.
• Syngas can be burned cleanly with negligible pollution.
• Basic Syngas consists of Hydrogen, Carbon-monoxide and
Nitrogen with trace element of other gases.
• Modern Gasification Systems produce a Syngas at par with
natural gas called “Synthetic Natural Gas” or SNG.
• There are 178 operating gasification plants worldwide.


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

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

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


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

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

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


• Virtually any grade of Coal can be converted into Gas.
• Coal mine waste products like fines, slurry, etc can also be gasified.
• Economics are predictable as Coal Prices are relatively stable.
• Coal based Syngas is much less polluting than burning Coal.
• Coal Syngas can be manufactured on-site or near the Coal mines.
• Coal can be blended with Biomass or Municipal Waste to produce gas.
• Transporting compressed SYN-Gas is cleaner than transporting Coal.
• Ash left after gasification is a raw material for the cement industry.
• No hassle of cleaning and disposing of Fly Ash and Bottom Ash.
• The Power plant can be easily upgraded to an IGCC plant.
• Economy of burning Coal and the cleanliness of Natural Gas.

• Coal Syngas is most widely used worldwide to generate electricity.
• Worldwide gasification capacity is projected to grow 70 percent by
2015, with 80 percent of the growth occurring in Asia.
• Low MW Coal Syngas based power Plants are gaining popularity in
many Asia and African countries.
• China has 80 Coal-SNG units under planning & construction.
• Ukraine in setting up 5 SNG plants at the cost of $35 billion.
• In India Coal Gasification has only been adopted by several Industries
like Steel, Ceramics etc., for captive Consumption.
• GE, Siemens, Lurgi, British Gas Ltd, etc., provide Coal Gasification
Technology.


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


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


Coal SYN Gas For Thermal Powerplants

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