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Clean Coal TechnologyLiquid Coal as Coal Water Mixture (CWM)
Presented by Sukhdev Singh, Adviser on CWM
For NTPC
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Table of Contents History What is CWM? Making CWM Properties Advantages Making slurry from lignite Disadvantages Facts Vs Facts Comparative Study Live Examples CWM Ball Mill Business potential in India Way Forward
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HistoryIn 1970, world wide oil crisis accelerated the development of CWM as an alternative fuel and many countries researched on CWM. In 1980 CWM technology began to be applied for spectrum of Industries
Today there are more than 100 plants based on CWM as fuel and running successfully across the world and producing around 75,000 MW. These are new as well as retrofitted plants . Single units range from 1 to 600 MW
China Japan Russia Italy Indonesia Philippines Malaysia South Korea
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What is CWM?
A mixture of 66-69% micromesh coal plus 30-33% water and 1% additives
Rheological properties like oil
Stored like oil
Stability of 90-120 days and more
Easy to transport in tankers, pipe line & sea vessels
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Making CWM
Wash the Coal
Crush
Pulverize in Ball Mill, add Water & Surfactants
Put in the agitator
Filter CWM Slurry
Add stabilizer & put in agitator again
Put required additives & agitate again
Transport to Storage Tanks
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Properties of CWM Consistency - solids 66±2 %
Viscosity - (100S) 1200±200 M Pa.s
Average granularity – 4 38 Micron
Ash content < 7 %
Sulphur content <0.5 %
Volatile matter - 28.02——34.53 %
Calorific value 4000-4800 Kcal./Kg
Stationary phase 90-120 days – can be extended
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Advantage of CWM Environment Friendly- Vs -Coal
Nox Levels are reduced by 50% Sox Levels are reduced by 80% SPM Levels are reduced by 40% CO2 Levels are reduced by 15-20% CDM benefits shall be there
Compared to coal Combustion efficiency is >99% against combustion efficiency of 90-91% for coal Boiler efficiency is 94 % as compared to 90-91% for coal fired Boilers Damage to Water walls is less Soot formation is less ESP is much smaller Cost of generation of 1KWh is less than Coal selectively
Other reasons Land required 70-80% less Cost of plant is less as very little coal handling No major ash handling as ash is 6-7% Low O&M cost More fuel inventory possible for emergency Neat and clean plant Completely safe to handle No fear of thefts 90-120 days or more self life Loading and unloading time is less Lignite can be extensively used for Coal slurry (explained in next slide)
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Making slurry from Lignite
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Disadvantage of CWM
Uses high CV and Low ash Coal but lignite can be used to make slurry. Since ash content in Lignite is low, the slurry can be of good quality
CWM cost is higher than pulverized fuel coal
Technology is restricted but available
CWM facility needs additional investment but overseas companies can supply CWM like Coal
Loss of 200 Kcal on account of water Content
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Facts Vs FactsParameter Imp. Coal Furnace Oil F Grade Coal Mix (Imp & F
grade)CWM
Sale Price Rs 8.5/ kg Rs 32/Kg Rs 0.85/Kg Rs 4.65/Kg Rs 7.85/kg
Freight Rs 1.5/ kg Included Rs 1.5/Kg Included Included
Ash Content 10% 0.5% 40% 31% 7%
Heat Value 6300 Kcal 10,000 Kcal 3000 Kcal 3320 kcal 4800 Kcal
Heat Loss(a/c storage etc)
400 Kcal - 400 Kcal 500 200 Kcal
Coal for CWM 0.7 kg - - - 1 kg
Station Heat Rate
2300 Kcal 2300 Kcal 2300 Kcal 2300 Kcal 2300 Kcal
Additional cost to make CWM
- - - - Rs 0.85
Cost of 10,000 Kcal
Rs 16.90 Rs 32.00 Rs 9.00 Rs 13.40 Rs 16.35
Cost Per Unit Rs 3.90 Rs 7.3 Rs 2.07 Rs 3.82 Rs 3.92
Savings w.r.t CWM
Rs 0.02 Rs 3.38 - - -
% Savings 0.5% 46.3% - - -
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Comparative study Parameter Imp. Coal Furnace Oil F Grade Coal Mix (Imp & F
grade)CWM
Cost Per Unit Rs 3.90 Rs 7.3 Rs 2.05 Rs 3.82 Rs 3.92
Cost/Kg Ash Rs 0.15 - Rs 0.60 Rs 0.46 Rs 0.10
Land/MW 1 Acre 0.3 Acre 1 Acre 1 Acre 0.3 Acre
Pollution Less Least Maximum Less Least
O & M Cost Less Least Maximum Less Least
Aux Power Maximum Least Maximum Maximum Least
Safety Least Least Less Less Maximum
CDM Benefits May be Yes No No Yes
Logistics /Convenience
Less Best Less Less Best
Heat Efficiency (approx)
37% 39% 35% 36% 38-39%
What looks better?- Let us think together
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Live examples
CWM plant in China
CWM Storage
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CWM Plants in operation
CWM Power Plant (1.5 Mt/a for 2×670t/h boilers) – New Plant
Power Plant (0.6 Mt/a for 3×230 t/h boilers transformed from burning oil to burning CWM)- the first power plant in China to use single CWM as fuel
Power Plant (1.5 Mt/a for 2×220 t/h +2×410 t/h boilers transformed
from burning oil to burning CWM)- the
demonstration project using the largest CWM
preparation and burning system in
China
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CWM manufacturing Ball Mill
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Business Potential in India-Captive Power Generation
Captive Power plants in India- 20,000 MW
Diesel /FO based Power Plants- 7000 MW
CWM required for 7000 MW- 35 Million tonne/annum-(Valued at $170/tonne)
Business Volume: $8500 million /Annum
Profitability: 10% ( $850 million / Annum)
CDM benefits shall be there to end users
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Proposed Plan – Way forward
To introduce use of CWM in
national planning in
place of OIL and Coal where ever
possible as is the case in
China
To establish R&D on CWM
Center in association
with reputed companies in
the world
To create service
organizations as JV with
technology/ equipment
suppliers and laying of
slurry pipe lines
To make detailed Project
Study/Report on CWM & take action accordingly
