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NUENERGYTM – Cokemaking
Technology for Current Challenges
Mariano de Cordova (NUENERGY Argentina); Dicky Walia (NUENERGY USA); Jorge Madias (Metallon); Alfredo Fernandez (NUENERGY
Mexico)
NUENERGYTM Technology
• Content – Introduction
– Process and Equipment
– Environmental Impact
– Products and Applications
– NUCARBONTM Project Evaluation
– NUCOKETM Cost Evaluation
– Conclusions
Introduction
• NUENERGYTM fundamentals:
- Use of thermal and sub bituminous coals to produce a solid fuel (NUCARBONTM ) and liquid (NULITETM) and gaseous by-products with significant cost reduction
– Use of NUCARBONTM to produce formed coke (NUCOKETM) in a continuous process, that can be easily adapted to variations in coke demand
– Reduction of CAPEX and OPEX, as needed by the steel industry
– Comply current environmental standards
Introduction
• NUENERGYTM Milestones – 1988-1990: First equipment and batch process testing – 1991-2000 10 t per day pilot plant in Bristol, Virginia, USA – 2000-2005 Progress in research and development in pilot plant – 52 coals tested – 2006-2009 Pilot plant in Conway, Arkansas, USA; briquetting and char
calcining for formed coke at General Shale Brick Plant, Virginia, USA
– 2010 test-license to ArcelorMittal to test NUENERGYTM technology – 2012 Pyrolyzer Furnace Apparatus and Method for Operations
patented – 2013 Method of Making Char patented; exploring options to build a
50,000 tpa plant
Process and Equipment
• NUENERGYTM - two step process
– First Process involves the production of:
• NUCARBONTM [Char]
• NULITETM[Coal Liquids]
• Uncondensed Methane Gas
– Second Process involves the production of
• NUCOKETM[Formed Coke]
Process and Equipment
• Process 1
– Stocking and milling of coal – Coal drying, by means of an endless screw
• heat being produced by a combustor burning part of the clean gas produced in the process
– Coal pyrolysis in twin screws, heating coal to 427 ºC – 650 ºC, in absence of air, with low heating rate, to preserve the quality of condensed liquids • heat obtained by burning part of the clean gas produced
– Char cooling to below 260º C, in an endless screw, with water – Char grinding – Treatment of raw gas by means of a primary condenser to
recover tar and a tower to recover BTX-containing light oil
Process and Equipment
• Process 1 – Coal Stocking and Preparation
Process and Equipment
• Process 1 - Coal Drying, Pyrolysis, Off Gas Condensation & NUCARBONTM Cooling
Process and Equipment
• Process 1 – Treatment of Raw Gas
Process and Equipment
• Data and Results of Tested Coals Coal Name Pocahontas 3 Teco Myra PRB
Coal type Bituminous, low
volatile Thermal coal
Sub-Bituminous
Properties Coal Char Coal Char Coal Char
Moisture (%) 6.40 0.27 3.0 1.3 27.1 0.1
Volatile matter, dry base (%) 17.39 5.36 35.2 8.4 45.8 7.7
Fixed carbon, dry base (%) 74.92 86.11 56.1 82.0 44.7 77.4
Ash, dry base (%) 7.69 8.53 8.7 9.6 9.5 14.9
Sulfur (%) 0.69 0.66 0.88 0.79 0.35 0.57
Heat Value, dry base (Btu/lb.)
14,452 13,967 14,35
4 11,449
12,508
ηchar (%) 100 81.6 100 70.2 100 34.8
ηliquids (%) N/D 100 14.7 N/D
ηclean gas (%) N/D 100 12.1 N/D
Water vapor (%) N/D 100 3.0 N/D
Total (%) 100 100
Process & Equipment
• Flow chart - Energy and Material Balance for Teco Myra Coal
COAL
GRINDING
COAL
DRYING
COAL
PYROLYSIS NUCARBONTM
MOISTURE
CLEAN
PROCESS
GAS
RAW GAS TREATMENT NULITETM
CLEAN AVAILABLE GAS
2000 lb
1 TON COAL
100%
60 lb 3%
97% 70.20%
1404 lb / 0 .700 t1940 lb
536 lb 26 .80%
2 mmBTU
5 mmBTU
241.20 lb 12 .06%
294.80 lb / 1 BARREL
14.70%
3 mmBTU
Process & Equipment
• Process 2
– Silos for NUCARBONTM, fines, coking coal and binder – Dosing and mixing. For good quality coke, a typical mix is 60%
NUCARBONTM, 30% coking coal and 10% tar pitch – Briquetting of the mix – Coking in a continuous tunnel oven, with several heating zones,
where the green briquettes, charged in ceramic wagons, are calcined to around 1100 ºC
– The formed coke exits the tunnel furnace and enters the quenching tower
– The gas produced in the process can be reused as a source of process heat
Process & Equipment • Process 2
Process & Equipment
• Process 2 – Block Diagram
Environmental Impact
• Emissions of particulate matter and raw gas to the environment,
associated with charging and discharging operations in conventional ovens, are minimized, as the process is continuous and closed
• To keep gaseous emissions and particulate matter below admissible limits, an incinerator, a demister and a scrubber are used
• CO2 generation is small, because moisture and volatile matter are removed from coal
• 100% of mercury in coal (70 ppb) is removed to the raw gas • EPA qualifies this process as “a conversion of the coking type coal
into three distinct new fuels forms of enhanced value and such should be classified as fuel conversion plant under 40CFR, Section 52.21 (b)(l)(iii)(q)” in relation to air quality
Products & Applications
• NUCARBONTM vs. Anthracite
Property NUCARBONTM Teco Myra coal
Anthracite
Moisture (%) 1.3 5.3
Volatile matter, dry base (%) 8.4 6.9
Ashes, dry base (%) 9.6 14.9
Fixed carbon, dry base (%) 82.0 78.2
Sulfur (%) 0.79 0.65
Grindability Index (GI) 45-50 45
Bulk density (kg/m3) 450-600 839
Mercury (ppb) 0 70
Thermal properties Lower Calorific Value, dry base (Btu/lb.)
14,354 12,308
Ignition temperature (ºC) 570 630
Reactivity, Critical Air Blast (l/min) 0,017 0.039
Loss on Ignition (LOI) Smaller Larger Price (USD/t) 0–15* 225-250
* Price after sales of byproducts (NULITETM + clean gas)
Products & Applications
• Applications, replacing anthracite, thermal coal or petroleum coke
– Fuel in power stations – As a carburizer in steel ladles and foaming slag agent in EAFs – For pulverized coal injection in blast furnaces (PCI) – As fuel and reducing agent in DRI rotary kilns – Raw material for NUCOKETM
– Absorbing agent for removal of heavy metals in wastewater – For economical substitution of activated carbon
• Commercial organizations that could be interested are – Mining companies, to add value to their products – Iron & steel corporations, to ensure a reliable supply of NUCOKETM
and NUCARBONTM
Products & Applications
• NUCOKETM vs. Conventional Coke
Properties NUCOKETM Conventional coke
Moisture (%) 2 max. 5-7
Volatile matter (%) 0.5-1.0 1.0 max.
Ash (%) 7 8
Fixed carbon (%) 92 91
Sulfur (%) 0.6 0.7
Bulk density (lb./cubic feet)
38 29
Stability (%) 61-66 58
Hardness (%) 69 67
CSR, NSC (%) 65-74 55 min.
CRI, NSC (%) 24-31 32 max.
Cost Evaluation
• Basis:
Raw materials USD/t U/0.8 t NUCOKETM USD/0.8 t NUCOKETM
NUCARBONTM 0 0.6 0
Coking coal 200 0.3 60
Binder 450 0.1 45
Operating cost 16
Total cost USD/0.8 t NUCOKETM 121
Total cost USD/t NUCOKETM 151.25
Raw materials USD/t U/t NUCARBONTM USD/t NUCARBONTM Thermal coal 60 1.43 86 Operating cost 25
Total cost USD/t NUCARBONTM 111
Credits: (NULITETM )100 USD/barrel x 1 barrel/t -100 Credits: (Methane) 4 USD /mmBTU x 3 mmBTU/t -12 Final Cost / t NUCARBONTM 0
Conclusions
• NUENERGYTM technology produces NUCARBONTM [char] and NULITETM
[light crude oil] with a proven process and equipment commercially available, with several tests to guarantee the yield
• NUCARBONTM is a carbon-rich product, which can be applied as a fuel in power stations, for slag foaming in EAFs and as a recarburizer in steel ladles, replacing anthracite or petroleum coke
• The cost of NUCARBONTM , after sales of byproducts (NULITETM and gas) is practically zero, what makes the project very attractive
• NUCOKETM is a product that can be used as fuel and reducing agent in blast furnaces, and as fuel in cupolas, replacing conventionally produced coke at lower cost
• NULITETM is a BTX-rich process byproduct (light oil) that can be used in refineries, mixed with oil, to produce gasoline and diesel oil
• The process generates enough gas to satisfy process needs and sales the balance as a byproduct, improving the economical equation of the process
Thank you for your attention! Mariano de Cordova, Dicky Walia, Jorge Madias, Alfredo Fernandez
