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
+48 32 324 22 67
Dr. Krzysztof Kapusta
Central Mining Institute( Gwny Instytut Grnictwa)
Plac Gwarkw 1, 40-166
Katowice, Poland
+48 32 324 65 35
+48 32 324 65 22`
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