COAL WATER SLURRY FUEL

Alternate Fuel for Thailand

Power-Gen Asia 2014

Royal Daniel
Managing Director
RDaniel@roe.com
Contents

• Introduction of POWER Burns and Roe

• Coal Water Slurry (WS) Fuel in General

• Method of Retrofitting a Steam Boiler

• Operation of CWS Power Plant and its

Performance

• Air Emissions and Thailand Standards

• Conclusion

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Power Engineers/Burns and Roe

TWO FIRMS. ONE POWERHOUSE.

One of the World’s Leading Engineering 80 years of engineering
and Consulting Companies
many of the world’s
 designer of electrical distribution and power largest, innovative and
generating facilities in the U.S. most challenging
 220 Generating Units, totaling 120,000 MW
projects
 Over 20,000 MW of capacity engineered within
the last five years.
 Strong experience in fossil, nuclear and
renewable generation Full Service Regional
Engineering Service in
Ranked as a Top ENR Engineering Firm Thailand – 90 Staff

75 % of Business From Repeat Clients 3

 Who We Are
» POWER Engineers » Burns and Roe
− Began in 1976 as two-person firm − Incorporated in 1932
− Employs ~ 1,800 people − Employs ~ 500 people
− 100% employee-owned − Privately Held and Family Managed
− Strong corporate culture attracts − Leading designer of power
quality long-term employees generation and electrical distribution
− Multidiscipline power delivery and facilities in the U.S.: ~220 Generating
generation experts Units, totaling 120,000 MW
− Largest, dedicated power delivery staff − Strong experience in the fossil,
of any North American consultant nuclear and renewable generation
− Strong experience in renewables: wind, − Broad range of coal, cogeneration,
solar (PV & thermal), hydro, geothermal combined cycle, and recip engine
experience
− Small to mid-sized SC and CC gas
turbine experience − Over 80 years of engineering many of
the world’s largest, innovative and
− Responsive and flexible to clients’ needs most challenging projects 4
Full Range of Services to the Electric
Industry

• Owner’s Engineering
• Independent Engineering Due Diligence
• Project Permitting
• Engineering and Environmental Studies
• Project Siting and ROW Selection
• Detailed Engineering Design
• EPC Engineering Partner for Generation
• EPC Prime for Substation Projects
• Electrical Testing and Commissioning

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Generation Project Markets

• Gas Turbines
• Reciprocating Engines
• Solar
• Wind
• Geothermal
• Hydro
• Nuclear Energy
• Coal-Fired
• Waste-to-Energy

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COAL WATER SLURRY (CWS) FUEL
Alternative Fuel in Thailand
300 MW oil-fired Krabie
Power Plant located in
Krabie, Thailand owned
by Electric Generation
Authority of Thailand
(“EGAT”).

Uneconomical to operate
on HFO. Standby unit.

Plan is to improve
economic to mid-merit
dispatch and add coal to
the fuel mix.

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1. COAL WATER SLURRY (CWS) FUEL IN
General
Rationale of development clean coal technology include:

• Abundance and relative low cost per BTU for coal.

• Reduce dependence on consumption of Natural Gas and the much
higher priced Oil.
• Add coal to the generation fuel mix in an economic and environmental
friendly manner.
• Potential lower life cycle cost by retrofitting uneconomical heavy-fuel
oil boilers than to build new coal plant.
• Diversity of fuel can improve fuel availability and pricing security.
• Fuel options for generation are limited and tendency of the
commercial fuel close to depletion.

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COAL WATER SLURRY (“CWS”) FUEL
An alternative fuel for HFO thermal power plant

Chinese
Technology
developed and/or
refined by Zhejiang
University

Plants range in
size from 2 to 210
MW

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World Wide Experience

EGAT studying
application to
300 MW HFO
Krabie Power
Station,
Thailand

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 The Development of CWS

Fuel Production Process

Feed stock Technology Off taker

To produce CWS fuel, there are three blocks in the process:

1. Feed stock: Acquiring, transporting, storing the subbituminous

coal.
2. Technology: Washing, Crushing, Wet Milling to produce CWS.
3. Off- taker: Storage and transportation of the CWS.

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 Coal Feedstock Specification

Coal Specification for the imported coal to Thailand

1. Total Moisture 20 %
2. Ash Content – Air Dry Basis (“ADB”) 10 %
3. Volatile Matter (ADB) 40 %
4. Fixed Carbon (ADB) 42 %
5. Total Sulfur (ADB) 0.7 %
6. Gross Calorific Value (HHV) 5,500 Kcal/kg
7. Hardgrove Grindability Index >38
8. Grain size < 50 Micron

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 CWS Technology Application

Motor Operated Wet Roller Mill Plant

Chinese technology:

1. Wet roller mill plant:

to grind the coal with
water and additive at
proportion of 70:29:1
2. The average gain size
is around 10 to 20
micron.
3. Tanks farm for CWS
storage and supply to
Customers.

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The physical property of CWS fuel

CWS Fuel Specification

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Clean Coal Technology

1. A Heavy Fuel Oil (HFO) fuel

substitute produced by mixing
coal with water and an additive
which changes the coal state from
a solid to viscous liquid.
2. The properties are:
• Low ash
• Low sulfur
• Low combustion temperature
• Low particulate and dust
• Physical properties are similar
to HFO.
• Transported as liquid

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2. Process of Retrofitting CWS Steam Boiler
1. Survey and Study of the Existing Power Plant

2. Perform Feasibility Study of Retrofitting Power Plant

3. Detailed Design of Retrofitting Power Plant

4. Procurement of the Equipment

5. Implementation of the Retrofitting Power Plant

6. Test and Commissioning of the Retrofitting power plant

7. Performance and Air Emission Test

The typical expected project duration is 18-24 months for

Retrofitting.
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 Retrofitting to a CWS Steam Boiler

Burner modification
Atomize fuel and flame length
Boiler Emission Boiler
modification
Control Control Operation
Boiler heat surface and heat System System and
Reliability
transfer check and calculation Modification
Boiler Modification
Modification Induce Draft (“ID”) fan and
Forced Draft (“FD”) fan
modification
Ash and sediments modification

Five key engineering items which are required to be modified or improved on the
existing heavy oil boiler power plant to allow for using the CWS fuel.

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Steady Ignition and Efficient Combustion

• Special new burners for CWS to ensure efficient economic consumption

of the CWS (more viscous and higher flow rate than HFO).

• CWS will have longer length of the burner flames causing higher
temperatures. Need to control the possible higher exit temperature of the
flue gas, the potential higher upper furnace and super heater
temperatures within the boiler, and to make sure that the flame stability
allows for flexibility for load variations of the boiler.

• Atomizing system to be suitable to the CWS high viscosity and higher

flow rate. Efficient and complete atomization of the CWS is possible with
steam.

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 Ash and Sediments

• Issue is management of boiler fouling from coal ash.

• To prevent the furnace fouling from the accumulation of slag and

sediments, a removal system for the bottom ash is required.

• Another problem of ash during burning the CWS fuel is the speed of flue
gas within the boiler which may cause of abrasive wear of the outer
external walls of the boiler tubes.

• In order to prevent the tube corrosion and abrasive tube wear trouble,
ash content in the CSW needs to minimize. Tube shields can also be
considered at areas of expected high abrasive wear.

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 Heat Transfer and Heating Surface

• Heavy oil fired boiler are designed for higher total heat input while
maintaining lower upper furnace and super heater temperatures than that
achievable with CWS due to the shorter flame length with oil than the
CWS.

• The operating challenge of CWS is to keep the steam output as high as

possible while keeping the required super-heater and re-heater
temperature limits.

• The cooling devices used in CWS fired boiler will need to be adequate
for controlling the operating temperature, and also keeping the surface
temperature of air pre heater.

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 Boiler Control System Modification
(Sufficient Airflow)
• Confirm existing capacity of Forced Draft Fans and Induced Draft Fans
can meet the higher requirements of retrofitting boiler with CWS. The
fans will need some adjustment of to increase the air flow produced.

• The control system of retrofitted CWS boilers needs to be modified for

the stability of operation.

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Boiler Operation Modifications for
Reliability

• The installation of additional equipment for washing the CWS fuel

pipeline to keep them free of CWS blocking.

• Improve new technology of quick ignition and modified switching

system.

• Modification of the internals of pumps, valves, pipelines, heating

surface, and nozzles to protect from abrasion of sediments.

• Modify the control system of CWS boiler for part load operations.

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3. Operation of CWS Retrofitting Power
Plant
Operation side
• Power output of the existing
power plant de-rated by 30%
• Environmental friendly
• Emission can be controlled
• Economic dispatch merit order
improved
• Reliability factor is 85%
Economical side
• Lower Retrofitting cost than
building new plant.
• Expected range of capital cost to
retrofit is 30 to 50% of new build.
• Price of fuel is lower than HFO.
• Life extension to 15 years after
power plant Retrofit.
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The Comparison of Different Type of Fuels

Case study of 300 MW Oil-fired Krabi power plant (EGAT) to CWS

Retrofitting power plant.
Description Unit COAL CWS HFO
Power plant capacity MW 210

Annual electric generation GWH 1490

Gross Heat rate BTU/kwh 9478 8980 8531

Gross calorific value BTU/kg 5213 3981 9952

Daily Fuel consumption Tons/day 2192 2538 1064

Fuel cost in ton USD/ton 65 62.5 481

Fuel cost in MMBTU USD/MMBTU 4.28 4.90 15

Fuel rate Kg/kwh 0.156 0.191 0.084

Annual fuel consumption Millions ton 0.8 0.9 0.4

The comparison of different type of fuel of 210 MW Krabi power plant

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Benefits and Performance of Retrofit
Power Plant
The benefit after retrofit
• Time duration for retrofitting is shorter and lower investment cost
than new build.
• Reliability of operation is the same as oil fired boiler.

Test result of performance and reliability after retrofit

• Fuel efficiency is about same as oil fired.
• Output will be de-rated by 30%.
• Reliability factor of 85%+ for the power plan.

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220 TPH Shantou Oil-Fired Boiler Retrofit
to 100% CWS Thermal Performance

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Operation of CWS Plant and its
Performance

The environmental
friendly power
plant which built to
mitigate the air
emission to lower
level about 50 ppm
of particulate
matter.

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670 tph (200 MW) Nanhia CWS Thermal
Plant Performance

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 4. Air Emission and Thailand Regulation

In Thailand, using normal coal is very sensitive issue with opposition from
NGO and Ecologist. In case of clean coal, we can apply high technology
for controlling the air emission to atmosphere and operate within the
regulation of Thailand as shown in table below:

Particulate matter SO2 NOx

Country Standard
(mg/Nm3) (ppm) (ppm)

Thailand 80 200 450 TISI Standard

30 100 100 GB13223-2011

China
20 17 50 Latest version

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 Forecasted Air Emissions and Standard
Regulation
Low air emission due to lower operating firing temperature than oil and
pulverized coal combustion boilers.

Attributes of a CWS installation:

• CWS is prepared from washed fine coal fuel with low ash and sulfur
content(<7%) and low sulfur(<0.5%).

• The flame temperature in CWS combustion is lower by 100 to 150℃ than

that of pulverized coal combustion. Therefore the pollutants such as fly ash,
SO2 and NOx are relative lower than pulverized coal.

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 Suitable for Tight Plant Sites
• CWS is especially suitable for plant which lacks of the space to install coal
mills and coal storage silos and coal storage yard.

• No requirement to handle solid coal at the plant site with associated noise
and dust issues. CWS can be produced in a remote location and be
transported to the power plant site as a liquid.

• The level of back-end mitigation of emission will be lower for CWS reducing
the requirement for addition back-end emission control by additional
equipment such as Selective Catalytic Reduction (“SCR”) for NOx control,
Flue Gas Desulfurization (“FGD”) for SO2 control, and Electrostatic
Precipitator (“EPS”) for particulate matters emission control. If emission
equipment is still required for CWS, the efficiency of the equipment required
will likely be lower reducing the cost.

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Retrofitted CWS Steam Boiler with
Emission Control System
CWS power plant with the pollution control for NOx,
Sox, and Particulates

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 5. Conclusion

• CWS is a challenging fuel for retrofitting of existing heavy oil fired boilers.
• Proven to be technically and economical viable option.
• CWS may be better than others liquid fuel because of it is lower cost than
heavy fuel oil.
• CWS also brings coal into the generation mix coal fired generation with a
lower air emission profile than pulverize coal fired power plants.
• CWS can be viewed as a bridging clean coal technology for retrofitting
existing heavy oil fired boilers to allow for more coal in the electric power
generation fuel mix at a faster pace.
• Integrated Gasification Combined Cycle (“IGCC”) power plant could be the
next phase of generation of power plant taking advantage of the coal
resources.
• CWS also provides an opportunity for uneconomical heavy fuel oil fired
power plants to produce electricity at more competitive energy price allowing
them to be a larger contributor to the electric generation mix.

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 Thank you

Terima Kasih
Royal Daniel – Managing Director
Kasem Naknual – Consulting Engineer/BD
Rdaniel@roe.com Kasemn@roeasia.com

Burns and Roe Asia Ltd., Thailand

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