Underground Coal Gasification in Poland. … 2014, Kegworth, 15-05-14, (pdf...Underground Coal...

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Underground Coal Gasification in Poland. Experiences, results and future prospects. MINERALS ENGINEERING 2014 UK Energy Symposium Dr. Krzysztof Kapusta , prof. Krzysztof Stańczyk Główny Instytut Górnictwa (Central Mining Institute) POLAND Kegworth 15 th May, 2014

Transcript of Underground Coal Gasification in Poland. … 2014, Kegworth, 15-05-14, (pdf...Underground Coal...

  • Underground Coal Gasification in Poland.

    Experiences, results and future prospects.

    MINERALS ENGINEERING 2014

    UK Energy Symposium

    Dr. Krzysztof Kapusta, prof. Krzysztof Staczyk

    Gwny Instytut Grnictwa (Central Mining Institute)

    POLAND

    Kegworth 15th May, 2014

  • CENTRAL MINING

    INSTITUTE (GIG)

    The Experimental Mine

    BarbaraINSTITUTE (GIG)

    is a research and

    development organization

    related to the Upper Silesian

    mining industry and region

    since 1945

    Barbara

    in Mikow was established

    20 years earlier than the

    Institute and now

    constitutes its part

    Poland, 40-166 Katowice, Plac Gwarkw 1

    http://www.gig.eu

  • SCIENCE AND RESEARCH IN GIG

    MINING AND GEOENGINEERING

    HEALTH AND SAFETY IN INDUSTRY

    MINING AND GEOENGINEERING

    SUSTAINABLE ENERGY TECHNOLOGIES

    (CLEAN COAL TECHNOLOGIES)

    ENVIRONMENTAL ENGINEERING

    MATERIAL ENGINEERING

    RADIOACTIVITY AND IONISING RADIATION

  • The future of coal

    Why coal is such an important fuel?

    Coal provides 29% of global primary energy needs

    and generates 41% of the world's electricity

    Source: IEA, EURACOAL, 2013

  • Coal-fired power generation in selected countries, 2012

    Source: IEA, EURACOAL, 2013

    *2011 for non-OECD countries

  • Coal in Europe 2012

  • Main coal basins in Poland

    Lignite and hard coal

  • Clean Coal Technology Centre (GIG)

    Locations

    Katowice testing laboratories Basic research on coal processing

    processes Coal quality characteristics and geology Numerical modelling Environmental monitoring Laboratory research on CO2 storage

    potentialpotential

    Mikow technological unit Applied research on coal processing

    technologies Syngas processing and utilisation Coal-derived liquids Large scale experimental installations

    including UCG tests in real undergroundconditions

  • Laboratory of Experimental Installations

    Scope of activities

    Conducting R&D works in the field of prospective chemical technologies of coal processing, including in particular:

    process of underground, pressure or non-pressure, coal gasification aimed at production of syngas with a high content of hydrogen and of gases for power use,

    pressure, fluidized gasification of solid fuels in surface conditions,surface conditions,

    direct coal liquefaction process aimed at the production of engine fuels and chemical raw materials,

    processes of hydrogenation and refinement of coal-derived substances,

    separation and purification of process gases using membrane techniques and methods of absorption and adsorption, including the pressure swing adsorption -PSA,

    separation of CO2 from process gases

  • Ex-situ simulation of atmospheric pressure UCG

    Technical parameters:

    coal type: lignite, hard coal

    coal seam length: 7 m

    gasification pressure: max 0.5 bar

    temperature: max 1600 0C

    coal seam inclination: 0, 15, 30 , 45 0

    0 1 2 3 4 5 6 70

    0.5

    1

  • Atmospheric pressure UCG simulation

    Preparation of artificial coal seam

  • Ex-situ simulation of high-pressure UCG

    Technical parameters:

    coal type: lignite, hard coal

    coal seam length: 3.5 m

    gasification pressure: max 50 bar

    temperature: max 1600 0C

    coal seam inclination: 0, 15, 30 , 45 0

  • High - pressure UCG simulation

    Preparation of artificial coal seam

  • Pressurized surface gasifier

    Technical parameters:

    feedstock: coal, biomass, wastes

    gasification pressure: max 50 bar

    temperature: max 1300 0C

    capacity: 10 kg of coal/hour capacity: 10 kg of coal/hour

  • Gas purification and separation module

    Absorption/adsorption vessels

    Pressure Swing Adsorption - PSA

  • Direct coal liquefaction (hydrogenation)

  • The UCG Underground Test Ground in EM Barbara

    Gas flow direction

    Utilisation of gasification products

    Ventilation shaft

    Prospective locations for the next in-situ UCG tests

    Region of finishedUCG tests Experimental hall

  • Underground coal gasification

    Underground Coal Gasification is the process of in-situ conversion of coal deposits to combustible gaseous products (H2, CO, CH4)

    It is not a new technology but one that has evolved

    In recent years it has undergone a transformation due to technical advances, specific research and sharing of knowledge and advances, specific research and sharing of knowledge and information

  • UCG methods

    LVW Linked vertical well

    CRIP Controlled retractable injection pointpoint

    Longwall method

  • Linked vertical well (LVW)

    Source: G.R. Couch, Underground Coal Gasification, IEA 2009

  • Controlled retractable injection point (CRIP)

    The CRIP process retracts the oxidants injection point to control the location of the combustion front

    Source: G.R. Couch, Underground Coal Gasification, IEA 2009

  • Longwall UCG method

    Source: G.R. Couch, Underground Coal Gasification, IEA 2009

  • Possible applications of the UCG product gas

  • Former Polish UCG developments by GIG

    The first Polish research programme on UCG (1945 1975)

    Laboratory and industrial scale research

    Filed-scale UCG experiments in Mine Mars mainly with air as

    gasification agent

  • Recent UCG projects in Central Mining Institute (GIG)

    HUGE 2007 - 2010

    Elaboration of coal gasification technology for a high efficiency production of fuels and electricity

    2010 - 2015

    HUGE2 2011 - 2014

    TOPS2013 - 2016

    COGAR2013 - 2016

    Funding sources:

    EU Research Fund for Coal and Steel

    National Centre for Research and Development (NCBiR)

    EU 7th Framework Programme

  • UCG aspects under study

    Technologicalaspects

    Technical infrastructure for UCG

    HUGE(RFCS)

    Elaboration of coal

    gasification.(NCBiR)

    HUGE2(RFCS)

    COGAR(RFCS)

    Environment and safety

    Gas utilization

    Coupled UCG-CCS

    TOPS(7th FP)

  • Aims:Theoretical and experimental exploration of thepossibilities of in-situ production of hydrogen-rich gas

    Projects HUGE & HUGE2

    Hydrogen Oriented Underground Coal Gasification for Europe

    possibilities of in-situ production of hydrogen-rich gasthrough the underground coal gasification (UCG)technique

    HUGE 2 Safety and Environmental Aspects

  • Ex-situ experimental installation

    Azot

    TlenPowietrze

    Para wodna

    I-3

    I-4

    p

    T

    I-6

    I-5

    T

    p

    Wylot

    GC

    Separator 1

    Filtr

    Krciec do poboru prb gazu

    Chodnica

    Separator 2

    Warstwa nadkadu

    Warstwa spgowa

    Pokad wgla

    Kana ogniowy

    System zasilania

    Odbir i oczyszczanie gazu

    3.0 m

    1.5

    m

    Wentylator

    Zbiornik na kondensat

    Zbiornik na kondensat

    Zoe wgla

    Warstwa stropowa 0.40 m 0.45 m 0.45 m 0.45 m 0.45 m 0.40 m

    Gas quality control

    0 6 12 18 24 30 36 42 48 54 60 660

    10

    20

    30

    40

    50

    60

    Sk

    ad g

    azu

    , %o

    bj.

    Czas, h

    CO2 H

    2

    O2

    N2

    CH4

    CO

    16

    18

    20

    /hWarstwa stropowa

    Warstwa spgowa

    Pokad wgla

    Kana ogniowy1,5

    m

    1.4 m

    0.80

    m

    0.80 m

    Wlot

    0.40 m 0.45 m 0.45 m 0.45 m 0.45 m 0.40 m

    21 22 23 24 25

    16 2019187

    141312

    1.5

    m

    3.0 m

    2.2 m

    Wylot

    17

    11 15

    6 7 8 9 10

    1 2 3 4 5

    17

    Temperature control

    0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 960

    2

    4

    6

    8

    10

    12

    14

    Pro

    du

    kcja

    gaz

    u, N

    m3 /

    h

    Czas, h

    0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2

    Dugo pokadu, m

    0

    0.2

    0.4

    0.6

    0.8

    1

    Wys

    oko p

    oka

    du, m

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    1000

    1100

    1200

    Strop pokadu

    Kana ogniowy

    Installation parametersCoal seam dimensions 2,5 x 0,8 x 0,8 m

    Gasification agent Oxygen, air, steam

    Gasification temperature up to 16000C

    Gasification pressure atmospheric

  • Gasification channel

    Tested configurations

    Outlet

    1.5 m

    Ignition point

    1.5 m

    Ignition point

    Inlet

    3.0

    m

    Ignition point

    Inlet

    3.0

    m

    Outlet Inlet

    3.0

    m

    Outlet

  • Examples of large coal samples

    0.5 m

  • Post-gasification studies

    Cavity shape

    0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2

    Seam length, m

    0

    0.2

    0.4

    0.6

    0.8

    1

    Sea

    m h

    eig

    ht,

    m

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    Roof

    Gasification channel

  • Ex-situ UCG experiments

    Results

    Type of

    coal

    Gasification

    agent

    Average gas composition, %vol Heating

    value,

    MJ/m3CO2 H2 N2 CH4 CO

    Oxygen 31.7 26.7 3.3 1.5 32.1 8.5

    Hard

    coal

    Oxygen 31.7 26.7 3.3 1.5 32.1 8.5

    Oxygen +

    steam36.1 28.2 4.2 5.5 25.0 8.2

    Two stage

    Oxygen cycle

    Steam cycle

    57.0

    14.0

    15.3

    53.8

    5.1

    4.7

    3.1

    9.8

    17.6

    15.8

    5.0

    11.5

    Lignite Oxygen 70.4 14.3 5.1 1.5 5.6 3.1

  • Experiments on underground coal gasification

    process (UCG) in natural conditions

    Underground Testing Ground EM Barbara

  • In situ UCG experiments

    Test sites

    Gas flow direction

    Utilisation of gasification products

    Ventilation shaft

    In-situ HUGE and HUGE2tests sites

    Experimental hall

  • HUGE 2

    Location of HUGE and HUGE2 underground gasifiers and

    tested configurations of gasification channels

    HUGE

    The average depth of the coal deposit used in the experiments was 30 m with a dip angle of 46 and a thickness of 1.52.0 m

  • Barbara Mine

    Coal characteristics

    No. Coal parameter Value

    As received

    1 Total moisture [%] 11.8

    2 Ash [%] 15.6

    3 Total sulphur [%] 0.5

    4 Calorific value [kJ/kg] 21 708

    AnalyticalAnalytical

    5 Moisture [%] 6.4

    6 Ash [%] 16.5

    7 Volatiles [%] 29.8

    8 Calorific value [kJ/kg] 23 019

    9 Total sulfur [%] 0.5

    10 Carbon [%] 57.95

    11 Hydrogen [%] 3.7

    12 Nitrogen [%] 0.9

  • Coal seam No. 301 before gasification

  • Preparation of gasification channels

  • Scheme of the in-situ installation

    Flare

    Supplying system Gas collecting system

    Suction fan

    Ground

    Monitoring

    Dewatering system

    Georeactor

    Pit shaft Air shaft

    1. Oxygen2. Air3. Water4. Nitrogen

    15 m

  • Coal seam ignition

  • UCG reactor inlet

  • UCG product pipelines

  • UCG product pipelines

  • Gas composition and safety monitoring

  • Oxygen source mobile criogenic tank

  • UCG gas combustion

    Thermal combustor

    Flame of UCG-derived gas

  • UCG gas combustion

    Flare stack (alternative)

  • Contaminants monitoring system

    Tar compounds in raw UCG gas

    Raw UCG-gas sampling

    Raw UCG-gas from

    underground

  • Contaminants monitoring system

    Post-processing water (condensate) collection system

    Condensate flow directionCondensate flow direction

  • Groups of tar compounds determined in raw gas

    Compound/group of compounds Sampling methodDetermination

    method

    BTEX:

    Benzene, Toluene, Ethylbenzene, Xylenes (o-, m- p- isomers)

    Sampling on sorbent tube with activated carbon (SKC Anasorb CSC, 600 mg)

    Two samples in parallel

    Gas chromatographywith FID detector (AGILENT 7890A)

    15 PAHs:

    Naphthalene (NaP), Acenaphthene (AcP), Fluorene (Flu), Sampling on sorbent tube Naphthalene (NaP), Acenaphthene (AcP), Fluorene (Flu), Phenanthrene (Phe), Anthracene (AnT), Fluoranthene (Fla), Pyrene (Pyr), Benzo(a)anthracene (BaA), Chrysene (Chr), Benzo(b)fluoranthene (BbF), Benzo(k)fluoranthene (BkF), Benzo(a)pyrene (BaP), Dibenzo(a,h)anthracene (DBA), Benzo(g,h,i)perylene (BghiP), Indeno(1,2,3-cd)pyrene(IND)

    Sampling on sorbent tube with polymer rasin (SKC XAD-2, 600 mg)

    Two samples in parallel

    Gas chromatographywith MS detector (AGILENT 7890A)

    Phenols:

    Phenol (hydroxybenzene) o Cresolm Cresolp Cresol

    Sampling on sorbent tube with silica gel(SKC SilicaGel, 600 mg)

    Two samples in parallel

    Gas chromatographywith FID detector (AGILENT 7890A)

  • Groundwater monitoring

    Sampling vertical wells

  • Groundwater monitoring

    Sampling vertical wells

  • General results

    In-situ experiment HUGE (straight configuration)

    Parameter Value

    Gasification agent oxygen

    Oxygen supply rate, Nm3/h 10 - 40

    Experiment duration, hours 355

    Average gas production, Nm3/h 202

    Average gas composition, %:

    CO2 16.40,01

    0,1

    0,512

    5

    10

    20304050607080

    90

    Con

    cent

    ratio

    n [%

    vol.]

    CO2

    C2H

    6

    H2

    O2

    N2

    CH4

    CO H

    2S

    CO2H2CH4CO

    N2

    16.414.71.513.452.9

    Average gas heating value,

    MJ/Nm33.75

    Total coal consumption, kg 22 100

    Process energy efficiency, % 56

    0 24 48 72 96 120 144 168 192 216 240 264 288 312 336 3601E-3

    Time [h]

    0 24 48 72 96 120 144 168 192 216 240 264 288 312 336 3600

    50

    100

    150

    200

    250

    300

    350

    400

    450

    Gas production rate

    Gas

    pro

    duct

    ion

    rate

    , [N

    m]3

    /h

    Time, [h]

  • General results

    In situ experiment HUGE2 (V-shaped configuration)

    Parameter Value

    Gasification agent oxygen

    Oxygen supply rate, Nm3/h 10 - 20

    Experiment duration, hours 142

    Average gas production, Nm3/h 78

    Average gas composition, %:

    CO2 15.2

    0,01

    1

    10

    40

    70

    Hydrogen Carbon monoxide Methane Ethane Oxygen Nitrogen Hydrogen sulfide Carbon dioxide

    II StageI Stage

    Gas

    ses

    conc

    entr

    atio

    n (%

    vol

    )

    CO2H2CH4CO

    N2

    15.236.32.4531.712.3

    Average gas heating value,

    MJ/Nm38.9

    Total coal consumption, kg 5 300

    Process energy efficiency, % 70.14

    0 20 40 60 80 100 120 140 160

    Time (h)

    0 20 40 60 80 100 120 140 160

    30

    40

    50

    60

    70

    80

    90

    100

    110

    120Total volume of produced gas - 11 043 Nm3.Average gas production rate - 77.8 Nm3/h.

    II StageI Stage

    Tot

    al g

    as p

    rodu

    ctio

    n ra

    te (

    m3 /h

    )

    Time (h)

  • UCG gas (HUGE2)

    Calorific value

    6

    7

    8

    9

    10

    11

    12

    Calorific value of obtained gas:

    II StageI Stage

    Gas

    cal

    orifi

    c va

    lue

    (MJ/

    Nm

    3 )

    0 20 40 60 80 100 120 140 160

    0

    1

    2

    3

    4

    5

    6

    Stage I - 10,30 MJ/Nm3

    Stage II - 5,49 MJ/Nm3

    Total (142h) - 8,91 MJ/Nm3.

    Gas

    cal

    orifi

    c va

    lue

    (MJ/

    Nm

    Time (h)

  • Numerical modeling of UCG hydrogeology EM Barbara

    Groundwater flow model (2D)

    Darcys law:

    sQHKt

    HS

    HKu

    =+

    =

    ][

    -50 m 250 m

    -10 m

    0 m

    20 m 80 m 100 m

    -0,3 m dno kawerny

    spg, upek ilasty

    = 0

    = 0

    = 0

    = 0

    0, 2

    = 0, > 2

    rdo zanieczyszcze

    Contaminant transport model

    Advective dispersive transport:

    + + = 0 Char Raw coal

  • Contaminant transport in coal seam and selected rocks

    1 year 3 years 10 years 20 years

    Shale 1

    dx1Shale 2

    Normalized isolines of naphtalene (c/c0)

    dx2

    dx3Char

    Coal

  • Post-gasification studies

  • Post-gasification cavity (HUGE)

  • UCG pilot plant at Coal Mine

    Wieczorek

    In-situ gasification experiments

    Wieczorek

  • UCG pilot plant Wieczorek

    Site selection

  • UCG pilot plant Wieczorek

    Geometries of gasification channels

    2,5 m

    otwory badawcze

    w skale ponnejw wglu pokadu

    pokad 501

    chodnik badawczy dla udostpnienia georeaktora

    5,5 m

    30 mc hod

    nik

    bad

    awcz

    y

    c ho

    dnik

    ba

    daw

    czy

    prze

    kop

    we

    nty l

    acy

    jny

    poz.

    400

    m

    poczone otwory badawczeo rednicy 200 mm wykonane w ksztacie litery Vw skale ponnej ok...20m

    wgiel pokadu 501

  • UCG pilot plant Wieczorek

    Underground gallery

  • UCG pilot plant Wieczorek

    Drilling works

  • UCG pilot plant Wieczorek

    Surface UCG gas purification module

  • Thank you for your attention

  • Contacts

    prof. Krzysztof Staczyk

    Central Mining Institute( Gwny Instytut Grnictwa)

    Plac Gwarkw 1, 40-166

    Katowice, Poland

    [email protected]

    +48 32 324 22 67

    Dr. Krzysztof Kapusta

    Central Mining Institute( Gwny Instytut Grnictwa)

    Plac Gwarkw 1, 40-166

    Katowice, Poland

    [email protected]

    +48 32 324 65 35

    +48 32 324 65 22`