Adoption of the production and combustion technology of coal-water slurry fuel (CWSF or CWS or

CWF) into the boiler-houses of different capacity

Tomsk - 2011

Project objective: Preparation and execution of CWSF combustion technology in small energy sector

Solving problems:1. Increasing use of coal in heat and power engineering 2. Considerable fuel economy when compared to fuel-bed firing of

coal due to higher efficiency 3. Significant improvement of ecological indicators 4. Possibility of the replacement of mazut (black oil) in the boilers 5. Resolution of problems connected with combustible waste

consists in the possibility of the combustion of slurry coal 6. In perspective CWSF can replace gaze in the boilers and can be

applied in the large-scale energy sector

Project objective

1. Coal is the basis of Siberian heat and power engineering 2. There are 60 000 small boilers (a lot of them with efficiency factor up to

45%) in Siberian Federal District3. A global problem is connected with huge amount of slurry coal4. A possibility exists to use local sources, including anthracite

Fuel consumption structure of thermal power plant in SFD

Project importance for SFD

Coal 86,5%

Gaze 9,0%

Mazut (blackoil) 0,6%Other types offuel 4,40%

Composition: coal (60 – 70%) + water (30 – 40%) + plasticizer (1%)

Preparation: wet milling in ball-tube mill with following cavitation

Size of fractions: 50 – 70 micrometers (smaller than in case of thermal power plant)

Stability: up to 30 days

Efficiency wastes connected with water evaporation: 3%

CWSF properties

Advantages:

• Explosion and fire safety• Possibility of transit by means of pipeline• Possibility of combustion of various solid fuels: low-grade coal,

slate/ shale, peat/ turf, slurry coal with ash content up to 30%• CWSF feed at t >10°С, mazut (black oil) does at t >70°С• Burn-up degree of combustible mass is 95 – 99% Efficiency factor is 90 % (in the case of fuel-bed firing is 50%)• Ash after CWSF combustion is a finished product for

construction materials• High ecological indicators (pulverized coal/ carbon dust, ash,

NOx, CO…)

CWSF advantages

In the purpose of better understanding of given further efficiency indicators occurring in the case of boilers’ transfer to CWSF the following should be taken into account :

Comparative analyze of transfer is carried out by example of the boiler KE 10-13 (in Novosibirsk). It should be mentioned that the technology is worked out for the boilers KE and DKVR with capacity from 5 to 25 tonnes of vapor per hour (or for the same boilers in water-heating mode);

The factor of fuel wastes and costs is used like basic criteria in the process of efficiency calculation. Supplementary effects occur as an immediate result of the transfer. They strengthen economic and ecological effects of CWSF;

CWSF value is formed in agreement with centralized production in the factory which serve the boilers’ network. Technologies of construction, supply and service are completely elaborated.

Initial indicators for evaluation of CWSF efficiency

Effect of application of the technology on the Effect of application of the technology on the objects of heat and power engineeringobjects of heat and power engineering in in housing housing and communal servicesand communal services

reduction in generating cost (of 1 Gcal): when transferring the boilers from mazut (black oil) to coal-water slurry fuel – up to 70%; when transferring the boilers from fuel-bed firing to coal-water slurry fuel – up to 35%;

improvement of the ecological situation: CWSF permits to reduce harmful emissions into the atmosphere up to 1,5-3,5 times (dust, nitrogen oxide, sulfur dioxide and others) It permits to use different types of coal wastes (coal slack, cake) for CWSF production

quick payback of investment: from 1 to 2,5 heating seasons (depending on boiler’s capacity, previously used scheme and so on)

The USA:- the problem of utilization of the large quantity of liquid slurry coal from concentration plants- 1957 – the first in the world coal pipeline (173 km, 1.25 mln tonnes of composition per year), then coal pipeline «Black Mesa» (439 km, 4.6 mln tonnes per year, the only working boiler, but it drives the pulp). - CWSF is used only for transportation, then drying and ordinary combustion- 2007 – under consideration in the Congress in order to be included into the national energy programme

China (from 1995):- 3 research centers, 6 plants- deliveries on tankers to Japan- CWSF production is about 15 million tonnes per year, power generation does 12 GW

Japan:- CWSF deliveries from China- drying and combustion- CWSF combustion with mazut (black oil)

Germany, Italy:- experience of CWSF combustion in small boilers

CWSF: foreign experience

USSR, the Russian Federation:- 1959 – deployment of works on CWSF connected with problem solving relative to usage of huge amount of liquid slurry coal from concentration plants, as well as usage of coal procured by water-jet method- 1960s – gaze pause, interest decline in CWSF- 1970s – oil crisis; new interest in CWSF (project of coal pipeline)

Magnitogorsk (1965 – 1967):- experimental combustion of CWSF in a boiler (170t of vapour per hour)Kuznetsk Bassin:- experimental combustion of 6 000t of CWSF in a boiler (320t of vapour/h) of hydroelectric power station in Belovo - 1989 - 1993 – coal pipeline Belovo - Novosibirsk (262 km, 3 mln t/year)Novosibirsk (1989 – 1993):- experimental combustion of 166 000t of CWSF form Belovo in 4 boilers of thermal power plant (TPP-5)

Moscow, c.c. Amaltea (from 2004):- a project for Ienskoy (Murmansk region), boiler with capacity of 6,5t of vapour/ h (2008)

Novosibirsk:- NoTEP – two-step system of CaCWSF fluid-bed combustion; experimental combustion in boiler of Yenisei PPP (pulp and paper plant); project for Berezovskiy (Kuzbass region)

CWSF: Russian experience

Solutions

New pneumatic spray nozzle of high resource

Low resource of spray nozzle because of abrasive damage

High cost and complexity of machinery for CWSF preparation and transfer

New system of CWSF organization and application: centralized production of CWSF with following transportation by means of motor transport to the boilers

Modernized mode of CWSF preparation considering type of fuel and its mode of transportation

The necessity of raw stuff enrichment/ washing in some technologies

Problems of CWSF usage

During the elaboration of innovative technology of CWSF combustion some crucial problems were solved:

Reagent

Water

Boiler

Spray nozzle

Cavitation generator

Cavitation generator

Storage

Bunker

ClassifierConveyer

BTM

Scheme of CWSF preparation and combustion

The technology of CWSF preparation (60-70% of coal) is elaborated on the basis of ball-tube mill and cavitation generator with plasticizer addition. Average size of coal fractions is about 50-70 micrometers, maximum size is 125 micrometers

Ball-tube mill (BTM)Cavitation generator

Experience of the project’s authors

CWSF combustion in industrial boiler of Building block factory, Matveevka (Novosibirsk)

Wear-resistant pneumatic spray nozzles of high performance were worked out and produced.

Pneumatic spray nozzle

Experience of the project’s authors

Products are protected by patents of the RF for the Pneumatic spray nozzle and the device for CWSF combustion.

There is a preliminary reconstruction permit from the Boiler plant.

Three experimental boiler plants with capacity 1.5;3,7 MW (the last one was made on the basis of boiler KE 10-13, 10t of vapour/ h) were constructed at «Building block plant» in Matveevka.

Nonfailure operating time is 3 years.

Combustion of black coal, anthracite, slurry coal.

Boiler KE 10-13

Experience of theproject’s authors

1. Removal of fire bars and devices for coal feeding from the boiler.

2. Installation of furnace plant with spray nozzles inside the boiler.

3. Pipe fitting for the CWSF furnace supply with diesel fuel (for ignition) and high pressure air.

4. Installation of pressure, temperature, fuel and air consumption sensors, automatic control system.

5. Installation of outcoming gazes treatment structure.

Measures to be adopted for boiler’s transfer to the CWSF combustion

Патентная защита проекта

Russian Federation Patent № 2121424. Device for abrasive treatment of surfaces. L. Maltsev. 1998.RF Patent № 2115176. Cavitation generator. L. Maltsev. 1998.RF Patent № 2106914. Pneumatic spray nozzle. L. Maltsev. 1998.RF Patent Cavitation generator. L. Maltsev, E. Petrova, A. Samakhov, A. Parfenov. 2007. RF Patent № 2346756 Pneumatic spray nozzle. Patent holder: «TeploProm», Ltd., Institute of thermal phisics S. Kutateladze СО RAS. 20.02.2009. RF Patent №87700 Processing line of CWSF production and combustion «TeploProm», Ltd. 20.10.2009.RF Patent № 88100 Device for CWSF combustion «TeploProm», Ltd. 27.10.2009.

Documents for an international patent are in the course of preparation.

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