Coal Mining and Use 1.4 Coal Use during the Industrial Revolution 1.5 The Post-Industrial Revolution Use of Coal 1.6 An Overview of Energy in the United States 1.7.. World Primary Energy
Trang 1
CLEAN COAL
ENGINEERING TECHNOLOGY
Cie kemog
Trang 2Butterwonth-Heinemann isan imprint of Elsevier
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1 Clean coal technologies 2 Coal—Environmental aspects 3 Coal-fired
power plats 4 Coafired furnaces I Til
"TP325.MSa8 2011
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Trang 3Contents
Preface
Part I - Background Information
1.1 Organization of this Book
1.2 The History of Coal Use
1.3 Coal Use before the Industrial Revolution
1.3.1 The Early History of U.S Coal Mining and Use
1.4 Coal Use during the Industrial Revolution
1.5 The Post-Industrial Revolution Use of Coal
1.6 An Overview of Energy in the United States
1.7 Coal Production in the United States
18
19
1
US Coal Exports and Imports
}0 World Primary Energy Production and Consumption
1.10.1 World Primary Energy Production
1.10.2 World Primary Energy Consumption
1.11 Projections of Energy Use and Coal’s Contribution
to the Energy Mix
1.11.1 World Consumption of Liquid Fuels
1.11.2 World Consumption of Natural Gas
1.11.3 World Consumption of Coal
1.11.4 World Consumption of Nuclear Energy
1.11.5 World Consumption of Renewable Energy
1.11.6 Energy Outlook for the United States
1.12 Coal’s Role in the U.S.’s 2001 Energy Policy
The Chemical and Physical Characteristics of Coal
2.1 The Definition of Coal
2.2 Origin of Coal
2.3 Coalification
2.4 The Classification of Coal
2.4.1 Basic Coal Analysis
2.4.2 The Ranks of Coal
3 The Types of Coal 2.4.4 The Grades of Coal
Trang 4Worldwide Distribution of Coal
Coal Distribution and Resources
3.1.1 Coal Reserves throughout the World
Major Coal-Producing Regions in the World
3.2.6 Central and South America
Effect of Coal Usage on Human Health
4.2.1 Water Contamination from Preparation Plants
4.2.2 Air Contamination from Preparation Plants
4.2.3 Refuse Contaminants from Preparation Plants
4.2.4 Health and Safety Issues
Coal Transportation
Coal Combustion By-Products
Emissions from Coal Combustion
4.5.7 Greenhouse Gases-Carbon Dioxide
Part II - Coal Utilization Technologies
5 Introduction to Coal Utilization Technologies
S.L.1 Brief History of Boilers and Coal Combustion
Systems 5.1.2 Basic Steam Fundamentals and their Application,
to Boiler Development 5.1.3 The Chemistry of Coal Combustion
5.1.4 Coal Combustion Systems
5.1.5 Influence of Coal Properties on Utility Boiler Design
Trang 55.2.4 Coking Conditions
Gasification
5.3.1 Brief History of Coal Gasification
5.3.2 Principles of Coal Gasification
5.3.3 Gasifier Types
5.3.4 Influence of Coal Properties on Gasification
5.3.5 Regional Distribution of Gasification Systems
5.3.6 Commercial Gasification Systems
Liquefaction
5.4.1 The Beginning of the Synthetic Fuel Industry
5.4.2 Indirect Liquefaction—Fischer-Tropsch Synthesis
Coal Transport to the Power Plant
Coal Handling, Storage, and Processing,
6.2.1 Coal Handling
6.2.2 Coal Storage
6.2.3 Coal Processing/Size Reduction
Steam Generation
6.3.1 Furnace and Convection Pass
6.3.2 Steam Superheaters and Reheaters
Ash and By-Product Handling
6.8.1 Bottom Ash Systems
6.8.2 Convective Pass/Economizer Ash Systems
6.8.3 Fly Ash Systems
6.8.4 Scrubber Sludge Systems
Trang 6Pulverized Coal-Fired Power Plants
7.2.1 Advanced Pulverized Coal-Fired Plants
7.2.2 Advanced Ultra-Supercritical Research
and Development 7.2.3 Oxy-Fuel Firing in Pulverized Coal-Fired Boilers
7.3.5 Pollutant Formation and Control
7.3.6 Supercritical Fluidized-Bed Boilers and Oxy-Coal
Firing in Fluidized-Bed Boilers Integrated Gasification Combined Cycle
7.4.1 Introduction
7.4.2 Gasification Island
7.4.3 Gas Treatment and Sulfur Recovery
7.4.4 Combined Cycle Power Plant
7.4.5 IGCC with Carbon Capture
7.4.6 Benefits and Limits of IGCC
7.4.7 Commercial Status
IGCC Research Needs
Part III - Emissions and Carbon Management
8 Coal-Fired Emissions and Legislative Action
8.2.2 The Clean Air Act Amendments of 1970
8.2.3 Clean Air Act Amendments of 1977 and Prevention
of Significant Deterioration
A Clean Air Act Amendments of 1990 Additional NO, Regulations and Trading Programs
6 Clean Air Interstate Rule
7 Clean Air Mercury Rule
Trang 7Contents
10
8.2.8 New Source Review
8.2.9 Fine Particulate Matter
8.2.10 Impending Legislation and Pollutants under
Consideration for Regulation 8.3 Emissions Legislation in Other Countries
8.4 Air Quality and Coal-Fired Emissions
8.4.1 Six Principal Pollutants
8.4.2 Acid Rain
8.4.3 Hazardous Air Pollutants
8.4.4 Carbon Dioxide
Emissions Control Strategies for Power Plants
9.1 Currently Regulated Emissions
9.3.5 Others
CO, Capture and Storage
10.1 CO, Capture Technologies
10.1.1 Precombustion (IGCC) CO; Capture 10.1.2 Oxy-Fuel Combustion
10.1.3 Postcombustion CO, Capture 10.1.4 Biomass Cofiring
10.2 Transport of CO
10.3 CO; Storage
10.3.1 Geologic Storage 10.3.2 Ocean Storage 10.3.3 Terrestrial Storage 10.3.4 Mineral Carbonation 10.4 Economics of CO Sequestration
Trang 810.4.1 Capture Costs 10.4.2 Costs of Transporting CO;
10.4.3 Storage Costs, 10.5 Permanence and Monitoring, Mitigation, and Verification
Part IV - Clean Coal Technology Programs
11
12
and Energy Security
U.S and International Activities for Near-Zero
Emissions during Electricity Generation
11.1 Introduction to U.S Clean Coal Technology Programs
11.2 Clean Coal Technology Demonstration Program,
11.2.1 CCTDP Evolution 11.2.2 CCTDP Funding and Costs 11.2.3 CCTDP Projects
11.2.4 CCTDP Accomplishments 11.3 Power Plant Improvement Initiative
11.3.1 PPI Projects, 11.3.2 Benefits of the PPIT 11.4 Clean Coal Power Initiative
114.1 Program Importance 11.4.2 Round 1 CCPI Projects
114.5 CCPI Benefits 11.5 Benefits of DOE’s Clean Coal Technology Programs
11.6 Vision 21
11.6.1 Vision 21 Technologies 11.6.2 Vision 21 Benefits
117 FatureGen
118 DOE Carbon Sequestration Program
11.9 International Carbon Sequestration Programs,
11.10 International Clean Coal Technology and Carbon
Sequestration Activities 11/10/1 Canada
11.102 Australia 11.10.3 Germany 11.10.4 Japan 11.10.5 China 11.10.6 Others
Coal and Energy Security
12.1 Overview of US Energy Security Issues
12.2 The Future of Energy in the United States
Trang 9and Sustainable Development 604 12.8.1 International Demand for Electricity 604 12.8.2 Advanced Coal Technology Application Support
for Sustained Coal Utilization 606 12.8.3 Energy Security 607 12.8.4 Sustainable Development 608 12.9 Concluding Statements 609
Part V ~ Supporting Information
Appendix A Regional Definitions 613
A.1_ Organization for Economic Cooperation and Development (OECD) 613 A.2_ Non-Organization for Economic Cooperation
and Development (Non-OECD} 613
3 European Union (EU) 64 A4 Organization of Petroleum Exporting
Countries (OPEC) 64 Appendix B_ Commercial Gasification Facilities
Worldwide 615 Appendix C Coal-Fired Emission Factors 625
Appendix D Original List of Hazardous Air Pollutants 651
Appendix E Initial 263 Units Identified in Phase I
(SO;) of the Acid Rain Program 657
Trang 10xiv Pref
in hand, either near commercialization or under development, that will allow coal
10 be used in an even more environmentally friendly manner The roadblocks (0 implementing these technologies are the financial risks associated with new technologies and the resulting higher costs of energy to the consumers Consumers
in the United States, for example, have become accustomed t0 low energy prices
‘and are reluctant t0 pay more for their energy, whether it is transportation fuels for their vehicles, natural gas or propane for domestic heating, or electricity
‘for their homes, The implementation of these technologies that increase eneray
‘efficiency or reduce pollution will be driven by legislative mandate and, toa lesser extent, the willingness of the consumer to pay more for energy:
‘These words are as true today as they were in 2004
Consequently, the first edition has undergone some major rework, mainly with the addition of updated information and the inclusion of the many activities under- way in the clean use of coal ‘The book has been expanded from 8 to 12 chapters and from 4 to 5 appendices It has been “informally” divided into five sections The first part, which consists of Chapters | through 4, provides detailed background informa- tion on coal It discusses the historical use of coal, how it is currently being used, future trends of coal usage, and a comparison of coal’s contribution and role in the overall energy picture Coal distribution throughout the world, the chemical
‘and physical characteristics of coal, and the effect of coal usage on human health
‘and the environment are presented
“The second part focuses on coal utilization technologies Chapter 5 introduces the four major technologies for utilizing coal: carbonization/pyrolysis, combustion,
‘gasification, and liquefaction Chapter 6 looks at the anatomy of a coal-fired power plant because this isthe technology that developing countries are currently installing
a a rapid pace A discussion of clean coal technologies, such as fluidized-bed combustion, advanced pulverized coal power plants, and integrated gasification combined cycle systems, is provided in Chapter 7
‘The third part ofthe book focuses on emissions and carbon management Coal-fired emissions regulations are presented in Chapter 8 Emissions control strategies are presented in Chapter 9 with carbon capture, and storage is discussed in Chapter 10
In the book's fourth part, a discussion of clean coal technology programs for near-zero emissions when generating electricity is provided in Chapter 11
‘This includes international activities as well as those in the United States Energy security and sustainable development are also discussed in Part IV Coal’s role in providing energy security for the world, with an emphasis on the United States, is presented in Chapter 12 The book concludes with the five appendices in Part V that contain supporting information for the various chapters
1 will conclude by first stating that all errors or omissions are entirely my own
I want to thank my wife, Sharon, and children, Konrad and Anna, for supporting
me these last 15 months Thanks also go to Konrad for helping me with my ltera- ture searches, and Anna for providing some of her “powerplant” photographs A\ very special thank you goes to Ruth Krebs and Elizabeth Wood for their work
‘on the figures
Trang 11Acid gas removal (AGR), 286, 290-291, 292
‘Acid mine drainage (AMD), 85, 91-98, 97,10
Advanced! combustion technology, $
‘Advanced pulverized coal, 1, 133, 255-260
‘Advanced Resources Intemational, 558
‘Aerosol Research and Inlation Epidemiology
Air Pollution Control Act of 1985, 303-304
Air pollution contol deviee (APCD), 118,
8i 182, 301-302, 304-307, 308, 308, 38-30, 315-316, 317, 318-320, 322, 321-338, 380, 332, 331, M7, 340-310,
387, 546, 608 Air Quality Control Act of 1967, 304-205
‘Air quality contol regions (AQCR), 304,305,
306-307 Air quality criteria (AQC)
‘monitoring, 306 standards, 305, 306-307 Air separation unit (ASU), 261, 283
304, 30 Air-to-toth ratio (A/C), 375,410, 449-451,
452-454, 456, 458, 545, Air toxics, 318, 320-321, 328, 328-829, 473,
523-524 AIW group, 558
‘Alabama Power, 456 Alamine (ALA) 491
‘Alaska Industrial Development and Export
Authority, $194,533 Alkali
‘arth metals, 171, 281-282 metals, 93, 171, 281-282 Alkalis, $9, 98, 123, 168-169, 170,171, 208-208,
245%, 246, 267, 278, 281-282, 3694, 382,
383, 384%, 394-395, 396, 397, 399, 481-482, 4551, 493, 500, 501-802 Alkanolamines, 491
Allen, J, 135 Allocttonous, 54 Alloys, 237, 260,399 Alstom power, 138, 475, 523 Alstom Power Ine, 523
‘Aluminum, 106, 119, 127, 133-134, 168, 420,
‘AMD See Acid mine drainage
‘American Clean Energy and Security Aet of 2008,
336-337 American Electric Power Company
Trang 12APCD See Air pollution control device
Appalachian Power Company (APC), 58
AQCR See Air quality conto regions
“Arapahoe Staton, $25
‘Archeological and Historical Preservation Act of
1074, 99
Archeological Salvage Act, 99
[ARIES, See Aerosol Research an! Inhalation
[Atmospheric bubbling fluidized-bed combustion
(BFBC), 264-265, 265, 277 Atmospheric circulating fudized-bed combustion
(CFC), 264-265, 267-268, 277,280, (606-6077
.Atempertor, 236 Autochthonows, 53-54
B Babcock, G 137 Babcock Power, 545-546 Babcock & Wiloox (B&W), 137, 138, 165, 439,
“474, S191, 523, $24, $25,533, 538” Baily Generating Staion, 5
Bakeros, 4 Bald Eagle Protetion Act of 1969, 99 Baldwin energy complex $49-SS0, 580, $SIf Ball mill pulverizers, 234, 235, 2357
Barium (Ba), 106, 117-118, 279 Basin Electric Power Cooperative, 406, 473, $57,
sm Battelle Memorial Institute, 558, $717 Bechtel Corporation, 18, 519% 3381 Bed quality, 272
Bechive ovens, 175 Belt conveyor, 224 Benzlalnthracene, 116 Benzofalpyrene, 16 Benzo[blluoranthene, 116 Benzolghilperslene, 116 Bergivs, F206
Berthelot, 206 Beryllium (Be), 106, 117-118, 121, 279, 315,
3671, 631, 641, 6851, 6461, 648, 6517 Best available contol technology (BACT), 314,
316, 317 Beulah mine, 220-221 Bhopal, Inia, 321 Big Bend Power Staton, $421,543, S436 Bins, 225-226, 247
Biofuels, 38,47, 496,596 Birchwood Power Facility, 544 Bituminous coal, 18-20, 41,48, $4, 36, 60-61, 64,
Trang 13Bromine, 126 Bronze age, 2-3 Brown coal, 2,41, 60-61, 65, 65%, 20-71, 8-79,
80, 81, 267-268, 276, 302-303, 40 Bucket elevator, 224
Buckskin Mine, 181-182, 535, Bulfalo Creek, 103-104
‘Bunker, 224-225, 226, 284 285 Bunsen, R.W.,5
Bums & MeDonnel, Bush, G.W., 49, 317 By-product recovery oven, 175, 176
c Cadmium (Ca), 106, 117-118, 119,121,299, 367,
522, 645, 6464, 6481, 6517 Cage mills, 28, 230-282, 231, 232f CCAIR See Clean Air Interstate Rule aking coal, 63-64, 178, 187, 188, 191 Caleination, 157, 270-272, 273, 274, 398, 411 Caleium (Ca), 98, 106, 19, 157, 158, 168, 171,
173, 248-244, 270, 271-272, 281-28:
3844, 387, 392,394, 399-400, 403, 01,
407, 408, 11, 442-448, 460, 46) 01-502, 526-527, 6510
Calcium hydroxide (Ca(OH,), 383, 388, 398,
403, 406 CCaleium sulfate (Ca80,), 105, 157, 200-201, 289,
270-272, 274, 275, 278, 382, 383,388,
5390, 391, 393, 394-395, 39-400, 403,
4806, 407 CCleium sulfate dibydrate (CaS0,.2H,0), 388,
390, 394, 399, 406, 407 Calium sulfite (CaS0,), 105, 3831, 388, 391,405 Calcium sulfite hemihydrate, 388, 389-390 Callie Oxy-Fuel Project, $76, 77
CAM See Clean Air Mercury Rule dan Clean Power Coalition (CCPC), 573-874
CCanmetENERGY, 873, S74 CCap-and-rade programs, 391,459, 468 Carbon
capture, 1, 282-283, 290-291, 292, 293, 471, S56, 557, $58, 570-STI, S77-S78, 588 capture and storage, 244, 335-336, 485-496, 497-09, 568-571, 572, 574, 376 Carbon dioxide (CO)
capture, 251, 261, 263, 282-283, 283,28, 290-291, 293, 296, 335-386, 473, 883-512, 587,358, 565, $68, 568, 371-574 515 606
Trang 14
66
Carbon dioxide (CO) (Continued)
capture and storage, 497, 498-502, S09, S6,
CCamegie Stoel Company, 174-175,
(Carter, LE Je, President, 49, 594
Caustic soda, 246
CM See Coulbed methane
CCPC See Canadian Clean Power Coalition
CCPL See Clear Coal Power Initiative
CCT See Clean coal technology
CCTDP, See Clean Coal Technology
Demonstration Progeam
Central Electricity Generating Board, 155
Centre for Coal Utilization, Japan (CCU), ST?
40 CER Part 60, Subpart D309
-40 CER Part 60, Subpart Da, 309-310
-40 CER Part 60 SubparDb and De, 310-312
‘Cherokee Staton, 322-523 Chlorine (Ch, 117-118, 126, 171, 279, 328-329,
460, 461, 463, 4664, 6510 CChlocofuoracarbons, 126
‘Chromium (C106, 17-118, 119, 121,279,346,
26, 631, 64, O45, 646, 64, 6517 Chronic lung disease, 109
Chrysene, 116, 176, 64, 647F
‘Chutes, 87, 234
cy ae st City Water, Light and Power, 524
‘Clas technology, 290, Clayton 1 183 (Clean ir Act
of 1963, 304
‘Amensdmenis of 1970, 303, 305-316, 317-319, 438
Amensiments of 1977, 15-317, 318-319,
320, 375
‘Amendments of 1990, 116, 17-118, 279, 308, 33-814, 315, 317-824, 375,385,
421,514 Planning Act, 333, 335, 361
‘Clean Air Intestate Rule (CATR), 32
329, 333, 335, 375, 468, 473 (Clean Air Mercury Rule (CAMB), 328-329, 333,
Clean Coal Power Initiative Projects udvanced coal henefciation processing, 547 clean coal power, 548-549
coproduction, St ful processing, 47 multipolutant contol, S54:
online oplinization systems, 580¢
TOXECON, 550
‘Clean Coal Power R&D Company, 280, 295-296
‘Clean coal technology (CCT), 1 $0, $17 517,
‘5101, $23, 528-526, 527-529, 540, 558-559, 5601, S61, 562, 563, 572-379
‘Clean Coal Technology Demonstration Program
(CCTDP), 513, 514-516, 514-540, 517%, S18, $194, S41, 547, 555-356, 358-560
‘Clean Coal Technology Demonsation Program
Trang 15«lean coal combustion system, $33,
coal-fired diesel engine, 525-526
coal processing, 515-516, 333-537, 540
«val rebuming, $191, 522, 338
(Clean Power Act, 333,335, 3360
Clean Water Act, 99-100)
Clear Skies Act of 2002, 33
rank, 18-20, 53-54, 85-56, 59-61, 73-74, 75-16, 7, 7, T§, 79,80 81,88, 4-148,
150, I1, 162, 168, 169-170, 173,178, 179,189, 267-268, 293, 38-329, 382,
428, 460, 4611, 462, 463,468, 4717 receiving, 23, 219
refuse, 102,108, seam, 13, 53-85, 61, 66,81, 86-87, 88,90, 9,
196, 98,101, 499-300, 508, 366 slurry 101-102, 104, 208,212, 214 storage, 85, 102, 25-226
‘eansporaton, 85, 104-108, 220%,
262, 387 types of, 53, 61-63, 1511, 179, 200, COAL2I, 74 576, 575:
Coal analyses calorie value, 57-58 beating value, 87-58, 60 6l, 6y, 63-64, 7, 79,
SI, 82, 154, 162, 175.1787, 180, 181, 182, 184-185, 212,267, 309-310, 328-329, 385-387, 414, 335
proximate, 57°58, bf, 113 vhữnate, 7-58, 213 Coal analysis bases sir dried, 58-59 dry, 8-89, 13, 178, 4617 Ary, ashe, 58-89, 651
«ry, minera-matter fre, $6 mois, ashtree, 38-89, 65
Dontesk, 78, 79 ibastue, 79 Gippsland, 80, 81 Groat Karoo, 82-83, linois, 48,76, 77,295 Sara, BỊ
Kansk Achinsk, 78, 70 Karaganda, 70
Kuznetsk, 78-79 Lower Silesian, 81-82 Lublin, 81-82
Lusatian, 82