Project overview

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Project overview

“Multi-fuel energy generation for Sustainable and Efficient use of Coal (SECoal)”

Speaker: Sylwester Kalisz

KIC InnoEnergy | CC Poland+ project review | Krakow, 11-12 April 2011

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SECoal project - goal and impacts

Objective:

SECoal project is dedicated to deliver innovative approaches to the co-utilization of multi-fuel inputs of various origin and quality in conjunction with coal-based power generation. It aims at quick delivery of industrially demanded, yet innovative, technological solutions and products ready for direct deployment in power utilities

For existing business processes:

•SECoal will enhance security of energy supply through diversification of fuels; contribute to reduction of greenhouse gas emissions through enhanced usage of bio-derived fuels

•SECoal will deliver incremental innovation technologies directly applicable in related industries

•SECoal will contribute to reduction of operating costs of power generation utilities

For new business processes:

•SECoal will deliver innovative co-firing technologies thanks to services provided by dedicated, newly established spin-off company

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SECoal project summary Topical Area: Project type: R&D / pilot / demonstrationProject Duration: Project manager: Total Budget (K€)Total KIC request (K€)

Partners name Ger Pol Swe Ben Fra Ibe Res Uni Ind Oth1 X X 13172 X X 15003 X X 4204 X X 1355 X X 12306 X X 4057 X X 5128 X X 3009 X X 1953,2

10 X X 45011 X X 890

Prod

uctio

n

Tran

spor

t

Dist

ributi

on

Reta

il

Stor

age

Big

(i.e.

ABB)

Med

ium

(i.

e….)

Smal

l (i.

e.)

1 Ventilation Air Methane Thermal Combustion Plant: a) Pilot plant b) Industrial plant for average ventilation shaft

X X X X X a) 1 b) 60

2 CFB Simulator X X X 1

3 A novel technology to treat biomass for producing alkali deficent pellets

X X X X X X 10

4 Catalyst for methane oxidation (lean streams) X X X X analysis in progress

5 High capacity (1.5 t/h) liquid bio-fuel burner X X X X X X X X 10

6 Biomass micronisation system concept X X X X X X X X 1 (per unit)

7 Monitoring system of low-NOx corrosion hazard X X X X 4

8 Diagnosis and monitoring system for fouling and slagging

X X X X 4

9 Additive-enriched fuel – market guidelines/services

X X X X X X 5

10 LCV biogas burner concept X X X X X X 5

11 Expert services in co-firing technologies (LCA, fuel database and on-line monitoring)

X X X X X X 2

3 years

MASTER DATAImproving effi ciency of energy production and reduction of emissions R&D (30%) / pilot (30%) / demonstration (40%)

Sylwester Kalisz9112,22730,7

PARTNERS DATACC Typology (Rough) %

TOTAL budget

KTH (Royal Institute of Technology)

SUT (Silesian University of Technology)WUT (Wroclaw University of Technology)

UJ (Jagiellonian University)CzUT (Czestochowa University of Technology)

CUT (Cracow University of Technology)ICE-PAS (Institute of Chemical Engineering-Polish Academy of Sciences)

BZF - Bay Zoltán Foundation for Applied Research (Hungary)EDF Polska CUW Sp. z o.o.

IFK (Institute of Combustion and Power Plant Technology, University of Stuttgart)KIT (Karlsruhe Institute of Technology

MARKET DATA

Innovative Product/Service created as output of project

Innovation ImpactBuyer of the product/service in the energy value

chain

Potential market (M€)

Incr

emen

tal

Disr

uptiv

e

Decr

ease

En

ergy

cost

Ope

ratio

nal

secu

rity

Low

er G

as

Emis

sion

s Utility

Feed

Stoc

k Eq.Manufacturer

Oth

er

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SECoal project WP organisation

WP1Components for

advanced co-utilization concepts

WP2Efficient and economic utilization of lean gases

from in situ processing of coals

WP3Modeling tools,

monitoring and control of multi-fuel power

generation

WP4Advanced concepts of integrated multi-

fuel, low-emission power generation

WP5Social impacts,

public perception and educational

programmes

WP0MANAGEMENT AND MARKET ANALYSES

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SECoal project WPs WORK PACKAGE DESCRIPTION WP No 0 Work package Title

Project management, techno-economic, market and patent analyses

Institution(s): Task leader

ALL partners SUT

Objectives:-secure best practices in project management and thematic coordination-deliver business oriented techno-economic analyses of SECoal products-deliver market search analyses for implementation of SECoal products-deliver patent search analyses for better management of SECoal IP rights Work plan and distribution of tasks: Task 0.1 Project coordination-thematic coordination-tasks coordination-budget and timeline coordination- Task 0.2 Techno-economic analysis of WtE (Waste-to-Energy) opportunities-waste fuel availability-ranking of technologies -regulatory constraints and opportunities-competing waste fuel handling technologies-market depth Task 0.3 Techno-economic analyses of direct and in-direct co-firing scenarios-energy density and transportation issues - pelletizing vs. torrefaction-technology barriers in direct co-firing-technology barriers in in-direct co-firing-regulatory constraints and opportunities-business opportunities Task 0.4 Patenting and IP rights management-support to product patenting – patent search services, patent filing Milestones: M 0.2.1 Data on WtE opportunities gathered (Q3 2011)M 0.3.1 Data on best co-firing practices gathered (Q3 2011) Deliverables/Outcome KPI: D 0.2.1 Report on WtE opportunities (Q1 2012)D 0.3.1 Report on best co-firing practices (Q1 2012)

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SECoal project WPs

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SECoal project WPs WORK PACKAGE DESCRIPTION WP No 2

Work package Title

Efficient and economic utilization of lean gases from in situ processing of coals

Institution(s): Contact person (s)

UJ (A. Adamski) – WP LeaderICE-PAS (K.Gosiewski)SUT-IPET (M.Pronobis/S.Kalisz)IFK (M.Zięba)WUT-DCTF (J.Trawczyński)

Objectives:WP2 is focused on :- inventory of coal mine methane emissions- catalytic combustion of lean methane-air mixtures- non-catalytic combustion of lean methane-air mixtures- power generation with use of waste, low calorific value gases Work plan and distribution of tasks (including timing of tasks): see time schedule Task 2.1 Inventory and characterization of coal mine methane emissions with particular emphasis on Ventilation Air Methane - VAMTask 2.2 Catalytic combustion of lean methane-air mixtures including evaluation of catalytic systems and determination of minimal content of CH4 allowing its autothermic combustion (UJ, WUT-DCTF)

• Development of the oxide binary/ternary catalyst• Development of methane enrichment system• Catalytic tests and catalyst shaping - laboratory and real VAM feed

Task 2.3 Direct, non-catalytic combustion methods of CH4-lean gases (SUT-IPET, IFK, ICE-PAS)

• Adaptation and testing of flameless burner for utilization or flaring of CH4-lean gases (IFK)• Reverse flow non-catalytic combustion of coal mine VAM (ICE-PAS). Total cost – 400 k€

Links to KIC InnoEnergy Strategy: Exploitation: Links to innovation system- WP2 will contribute to utilization of a massive streams of a greenhouse gas (methane) in an energy recovery processes Education: Links to education programsWP2 will contribute to the Summer School foreseen in WP5. Findings from WP2 will be presented at the related EIT MSc and PhD labeled courses. Deliverables/Outcome KPI: D2.2.1 Report on formulation and performance of catalyst for lean methane total combustion (Q2 2013) UJD2.2.2 Technical report on catalytic VAM mitigation (Q2 2013) WUT-DCTFD2.2.3 Patent applications on catalyst for methane total combustion (Q4 2011/Q4 2012)D2.3.1 Report on testing of the flameless burner for the utilization of CH4-lean gases (Q4 2012)IFKD2.3.2 Selection of the appropriate honeycomb monolith geometry together with the combustion kinetic description for this monolith. (Q4 2012) ICE-PASD2.3.3 Basic design parameters for the TFRR pilot research unit (Q4 2013) ICE-PAS

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Work package Title

Modeling tools, monitoring and control of multi-fuel power generation


WUT-IPEFM (H.Kruczek) – WP LeaderCzUT (W.Nowak/R.Rajczyk)SUT-IPET (M.Pronobis/S.Kalisz)CUT (J.Taler/P.Wais)BZF (G.B.Lenkey)

Objectives:WP3 is focused on :- 1D and 3D calculation models for biomass combustion in utility PC and CFB units- additives in CFB and PC combustion technologies - monitoring of fouling and corrosion under multi-fuel combustion conditions Work plan and distribution of tasks (including timing of tasks): see time schedule Task 3.1 Development of comprehensive 0D, 1D and 3D calculation models for biomass combustion and modelling of utility PC and CFB units (CzUT – task leader, SUT-IPET, WUT-IPEFM, BZF)Task 3.2 Analysis of synergy effects of co-processing of agro biomass and bio-wastes with coal for heat and power generation

(WUT-IPEFM)Task 3.3 Development of co-utilization and combustion systems in CFB and PC technologies with additives to avoid fouling, slagging and corrosion problems (SUT-IPET – task leader, CzUT)Task 3.4 Development and design of monitoring system for fouling and corrosion under multi-fuel combustion conditions (CUT, WUT-IPEFM, BZF)Links to KIC InnoEnergy Strategy: Exploitation: Links to innovation system- WP3 will contribute to enhancement of multi-fuel power plant reliability - WP3 will deliver new monitoring and control systems for multi-fuel combustorsEducation: Links to education programsWP3 will contribute to the Summer School foreseen in WP5. Findings from WP3 will be presented at the related EIT labeled courses. Deliverables/Outcome KPI: 3.1.1 Report of biomass combustion phenomena (Q1 2012)3.1.2 Report of 0D and 1D model validations (Q4 2012)3.1.3 Report of updated 3-D model (Q4 2013)3.1.4 Report of 3-D model validations and industrial test runs. (Q4 2012)3.1.5 Model of 3D biomass combustion in the CFB boiler (CzUT) (Q4 2012)3.1.6 Model of 3D biomass combustion in the PC boiler (SUT) (Q4 2012)3.2.1 Report on effects of co-processing of agro biomass and bio-wastes with coal WUT (Q1 2012)3.3.1 Optimized additive product for commercial deployment (SUT) (Q4 2012)3.4.2 Applying and testing of an sample probe to evaluate the deposit, slagging and corrosion behavior under multi-fuel combustion conditions (WUT) (Q4 2011)3.4.3 Installation of computer-based system for monitoring in on-line mode of slagging and fouling (CUT, IST) (Q4 2011)3.4.4 Tests that allows for optimization of sootblower sequencing based on actual cleaning requirements (CUT) (Q4 2011)3.4.5 Risk based inspection methodology and system for on-line monitoring of combustion system (BZF) (Q4 2012)

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Work package Title

Advanced concepts of integrated multi-fuel, low-emission power generation


SUT-IPET (M.Pronobis/S.Kalisz) – WP LeaderWUT-IPEFM (H.Kruczek)CUT (J.Taler/P.Wais)KTH-EFT (W.Yang)BZF (G.B.Lenkey)EDF (H.Kubiczek)

Objectives:WP4 is focused on :- novel, integrated co-utilization concepts- maximization of co-firing share- development of jet enhanced combustion system- mitigation of negative co-firing effects Work plan and distribution of tasks (including timing of tasks): see time schedule Task 4.1 Hybrid in-direct co-firing system with use of depleted oxidizer (SUT-IPET)Task 4.2 Mitigation of negative impacts of co-utilization with use of innovative fuel additives (slagging, fouling, alkali metals capture) (SUT-IPET, EDF, BZF) Task 4.3 Hybrid in-direct co-firing system using biogas and biochars (WUT-IPEFM)Task 4.4 Multi bio-fuel fired CFB unit – coupled with coal fired boiler (WUT-IPEFM, CzUT)Task 4.5 Development and design of jet enhanced combustion system (SUT-IPET) and novel boiler combustion system with pretreated biomass (KTH-EFT)Task 4.6 Development and implementation of installation for co-firing pulverized coal and biomass up to 20% total fuel energy (CUT) Links to KIC InnoEnergy Strategy: Exploitation: Links to innovation system - WP4 will contribute to enhancement of multi-fuel capacity with significant reduction of negative side-effects- WP4 will deliver new combustion system for solid fuelsEducation: Links to education programs WP4 will contribute to the Summer School foreseen in WP5. Findings from WP4 will be presented at the related EIT labeled courses. Deliverables/Outcome KPI:4.1.1 Report from in-direct co-firing with depleted oxidizer (Q3 2013) SUT-IPET4.2.1 Report on the Hungarian experiences of biomass co-firing, alkali related problems, potential solutions. (BZF) (Q2 2012)4.2.2 Optimized fuel mix of lignite/coal and biomass/waste co-firing (SUT-IPET, WUT, BZF) (Q4 2012)4.2.3 Database for biomass fuels (BZF) (Q1 2012)4.2.4 Optimizing software for optimizing co-firing systems (BZF) (Q1 2012) 4.5.1 Report on an integrated CHP plant with biomass pretreatment aiming for CO2 reduction (Q4 2011) KTH-EFT4.5.2 Report on a novel boiler combustion system with pretreated biomass (Q1 2013) KTH-EFT4.6.1 Implementation of installation for co-firing pulverized coal and biomass up to 20% total fuel energy (CUT) (Q4 2012)

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Work package Title

Social impacts, public perception and educational programmes


BZF(G.B.Lenkey) – WP Leader ALL

Objectives:WP5 is focused on :- dissemination of SECoal results- public acceptance to co-utilization practices- increase of professional knowledge in the field of co-utilization- LCA analyses on environmental loads Work plan and distribution of tasks (including timing of tasks): see time schedule 5.1 Comparative LCA (Life Cycle Assessment) analyses of multi-fuel co-utilization technologies (BZF)

• Input- output data collection for different technologies,• Set up the model for different technologies• Evaluation of the results of the LCA

5.2 Optimizing the multi-fuel co-utilization and clean coal technologies from environmental loading point of view (BZF)

• Data mining from the LCA analysis,• Determining of criterion system for optimizing• Set up the model for optimizing• Optimization with applying simulation software• Evaluation of the optimization• Evaluation of the results of the LCA

Task. 5.3 Summer school for biomass utilization technology Links to KIC InnoEnergy Strategy: Exploitation: Links to innovation system- WP5 will contribute to public understanding of innovative co-utilization concepts Education: Links to education programsWP5 will prepare the Summer School and will interact with related EIT labeled courses. Deliverables/Outcome KPI: 5.1.1 LCA case study for each technology, input-output database, GaBi 4.3 LCA Software (Q1 2012)5.2.1 Case study for optimisation, using Simul8 Software (Q1 2013)5.3.1 Summer school (Q3 2013)

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SECoal project plan 2011 2012 2013

Task/Milestones Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

T0.1

T0.2

M0.2.1 X

T0.3

M0.3.1 X

T0.4

T1.1

M1.1.1 X

M1.1.2 X

T1.2

M1.2.1 X

T1.3

T1.4

M1.4.1 X

T1.5

M1.5.1 X

M1.5.2 X

T2.1

T2.2

M2.2.1 X

M2.2.2 X

M2.2.3 X

T2.3

M2.3.1 X

M2.3.2 X

M2.3.3 X

M2.3.4 X

T3.1

M3.1.1 X

M3.1.2 X

M3.1.3 X

M3.1.4 X

M3.1.5 X

T3.2

T3.3

M3.3.1 X

T3.4

T4.1

M4.1.1 X

T4.2

M4.2.1 X

M4.2.2 X

M4.2.3 X

M4.2.4 X

M4.2.5 X

T4.3

T4.4

T4.5

M4.5.1 X

T4.6

T5.1

M5.1.1 X

M5.1.2 X

T5.2

T5.3

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SECoal project products: Reverse flow non-catalytic combustion of coal mine Ventilation Air Methane

Heat recovery effectfor 1.0 %vol.CH4 ~37 MWtfor 0.4 %vol.CH4 ~4.3 MWt

Effects were calculated per average coal mine shaft in Poland: (flowrate: 720 000 Nm3/h)

Methane has Global Warming Potential at least 25 times higher

than CO2!!!

Demonstration plant in ICE-PASEcological effect (Methane combusted):

With the SECoal Project Ms Anna Pawlaczyk’s PhD thesis will be connected

for 0.2%vol.CH4 8581 tCH4/ year

for 0.5%vol.CH4 21452 tCH4/ year

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SECoal project products: CFB simulator

CFB simulator will be a powerful software that will help to design, operate and optimize performance of large and medium scale circulating fluidized bed boilers

Picture – not existing yet

Market value – CFB simulator will be able to help with design and with operational problems thus cutting costs by some percent. Industrial CFB boilers owners already expressed their will to use such a product.

At least 1 PhD thesis and 2-3 MSc or BSc thesis

Introduction: late 2013

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SECoal project products: Catalyst for methane oxidation (lean sources - VAM)

Working temperature: 250 – 350 °C

Main challenges: finding the formula of an efficient and economically reasonable catalytic system; determination of minimal content of CH4 allowing its autothermic combustion; evaluation of the versatile method of methane enrichment;

Educational achievements:

Ph.D. Thesis 3

M.Sci. 10

B.Sci. 11

Market value - analysis in progress

Possible date of commercialization (idea + laboratory/semi-pilot scale): 2013-2015

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SECoal project products: Monitoring system for corrosion hazard in pulverized coal boilers

Visualization of the measurements of oxygen concentration and „on-line” layout of corrosion hazard ofpulverized boiler obtained with the use of neural networks

poz. 19 500poz. 19 500

poz. 21 8004

poz. 30 900

poz. 26 800

poz. 34 500

left wall

poz. 30 900

poz. 19 500

poz. 26 800

poz. 21 800

OFA OFA

rear wall

poz. 31 800

poz. 19 500

poz. 26 800

poz. 23 000

right wall

poz. 30 900

poz. 26 800

poz. 29 700

OFA OFA

front wall

2

3

1

2 3

4

Boiler operator’s control station

4

3

2

4

3

21

1

5 55

1

5

MarketAll power stations equipped with PC boilers

80 units x 200 000 zł in Poland.

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SECoal project products: Burners for liquid biofuel

Burner for bio-liquid fuel output : 1.5 t/hr applicable for start up and co-firing biofuel in PC boiler

Market: PC and stoker boilers installed in PP and CHP40 PC units x 1 000 000 PLN

Multistream Burner for bio-liquid fuel output: 300-700 kg/hr applicable for co-firing biofuel in PC boiler( additional effect- reduction NOX emission by reburning mechanism in high temperature)

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SECoal project products: Micronisation of agro-biomass

New installation for biomass fuel producers to apply in PP and CHP plant using co-firing of biomassCost of industrial installation at output 3 t/hr- 5 mln PLN - market is under analysis

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SECoal project products: Expert services in co-firing technologies (LCA, fuel database and on-line monitoring)

Risk based inspection methodology and system for on-line monitoring of combustion system• Special equipment and system will be developed for monitoring the damage of critical locations of high

temperature components in the combustion system (software and hardware)• Reduction of maintenance cost • Reduction of production loss due to not planned shutdowns• MSc and PhD theses involved: 1 MSc• Estimate of time to market: 3 years

Software for optimising co-firing systems and database for biomass fuels• Development of a Biomass Database• Development of optimizing methods/software for co-firing of agro-biomass and bio-waste with coal • Increase of efficiency of co-firing system• Reduction of costs of maintenance • Increased production• Estimate of MSc and PhD theses involved: 1 PhD • Estimate of time to market: 2 years

LCA (Life Cycle Assessment) analyses of multi-fuel co-utilization technologies • Development of LCA models for different technologies• Optimisation method of multi-fuel technologies from environmental poitn of view• Decrease the load on environment, i.e. CO2 emission• Estimate of MSc and PhD theses involved: 1 PhD• Estimate of time to market: 2 years

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SECoal project products: spin-off in co-firing technology services

Fields of activity:• technologies for emission reduction from power generation and industrial

processes• technologies increasing the renewable energy share in overall energy

supply• services in energy management with special focus on the use of waste

energy sources.

The offer will consist of: technical advice, consulting services, R & D work, sales of licenses and upgrades of existing installations.

Status•Market analysis initiated: supply and demand identified;•Business model in verification;•Commercialization strategy conditioned by new Regulation in exploitation of IP rights at the Silesian University of Technology; •Spin-off business plan in progress

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SECoal project budget

CC Sweden

Sources of Budget, in k€ SUT

WU

T

UJ

CzU

T

CUT

ICE-

PAS

BZF

EDF

IFK

KIT

KTH TOTAL

2011Partner in-kind 288 288Partner in-cash 0EIT requested contribution 139 140 30 15 110 35 30 100 111,8 36 85 831,8National funding 300 360 60 30 300 100 70 1220Regional funding 0European funding 104 104Other sources 20 255 275

Total 439 500 90 45 410 135 120 100 399,8 140 340 2718,8

Period T0 -> 31/12/2011CC Poland + CC Germany

CC Sweden

Project Budget, in k€ (all costs included) SU

T

WU

T

UJ

CzU

T

CUT

ICE-

PAS

BZF

EDF

IFK

KIT

KTH TOTAL

2011

Project Management (WP0)** 24 10 5 5 5 5 5 5 7,2 5 10 86,2Market Analysis (WP0)** 10 10 5 5 8,6 5 30 73,6User Requirements (WP0)** 10 10WP1 Co-utilization components 55 80 250 130 70 585WP2 Utilization of lean-gases 10 80 80 120 134 424WP3 Modeling, monitoring and control 65 120 40 350 115 690WP4 Advanced multi-fuel power generation 225 120 80 180 605WP5 Social impacts and education 0Demonstrator, prototype or equivalent ** 50 80 50 10 40 230Exploitation plan ** 5 10 15

Total 439 500 90 45 410 135 120 100 399,8 140 340 2718,8

Period T0 -> 31/12/2011CC Poland + CC Germany

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SECoal project budget distribution

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SECoal project: Summary

Criterion

1 Partners: Involvement of Education, Research and Industry. Industry involvement in terms of participation in market assessment, prototyping and exploitation is paramount.

2 Partners: InnoEnergy partners (formal KIC level partners or/and Associate partners) from at least 2 cc

3 Expected or foreseen economical market impact of the project outcomes. Economic impact being quantitative and/or qualitative (i.e. by increasing efficiency, reduction of green house emissions, or increase security)

4 Clear identification of what is new vs state of the art (i.e. in technology, business models, …)

5 Duration 1 to 3 years.

6 Results within 18 months. Easy to assess/with clear contribution to KPI: At least one new product / serviceor At least one new patentor At least on spin-off / patent transferred to SMEAnd At least one scientific publication

7 A deliverable should be a demonstrator, prototype or equivalent, in the premises of the industry within the project team

8 Aligned with KIC strategy (e.g. SET plan, sustainability etc.)

9 Impact on Society and Public Acceptance considered

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SECoal project: Recent developments and Open issues

• Migration of GIG from SECoal to ACoPP• Partnership cancellation: IST and KTH – Energy Dept.• PA prepared and circulated within partners for signing• Most of partners report they are just about to sign• IP most difficult• Formal industrial partner – EDF (co-manager: H.Kubiczek)• Budget availability (?)

Project overview

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