Conversion of Coal Wastes and Coal Plus Other Opportunity Fuel Mixtures, Such as Coal Plus Municipal Solids, to Produce Electricity and/or Liquid Fuels
For the foreseeable future, the Nation’s energy demand will continue to come largely from indigenous fossil energy resources and hydrocarbon fuels. Specifically waste coal plus other opportunity fuels need to be utilized as a feedstock to eliminate a waste stream and optimized to maximize energy yield and cleanly minimize pollutant emissions. Modular equipment is needed for installation in coal preparation locations, military installations, and research park facilities. Thermal decomposition of coal, biomass, and mixed solid waste (MSW) have been shown to reduce a waste stream while providing liquid and gaseous fuel products with low pollutant emissions. However, thermal decomposition processes have several challenges associated with preprocessing biomass and MSW, feeding and conveying material into the reactor, and post processing of syngas to remove undesirable products while upgrading to increase yield of high value products. Increasing total energy output from power plants by utilizing biomass and mixed wastes ultimately lowers energy costs, harmful environmental impacts of emissions, and has significant impacts on the energy security and sustainability of the U.S. economy. Entrained flow gasifiers (EFGs) produce very little CH4 and a wide range of H2/CO ratios (0.5–2.0) but are limited in their ability to effectively feed large biomass or MSW particles into the reactor. A solution to the feeding problems is to use pyrolysis torrefaction (PT) for conversion of waste materials to create a feedstock similar to coal and capable of grinding down and mixing with the coal feed. Mainstream experimentally explored reaction pathways for the conversion of coal waste plus municipal solids (CWPMS) and demonstrated a bench-scale reactor used for torrefaction of the municipal solid waste (MSW) to create a coal-like feed for blending with the coal waste. The material was processed in a pilot-scale EFG to determine product yield and emissions with CWPMS fuels, as well as the ash content and slagging properties of these feedstocks. The PT-EFG system was experimentally validated, where emissions and yield data were used to develop a high-fidelity process model and economic analysis. The following was accomplished in the Phase I: Determined optimal torrefaction process conditions for MSW and biomass through TGA; maximized heating value of fuel while maximizing final mass of torrefied product Demonstrated torrefaction of MSW and biomass feedstocks at 334°C, pulverized to uniform 74 µm particle size, and processed into coal-like feedstocks Demonstrated 8 lb/h pilot-scale EFG using MSW and biomass blends with waste coal; demonstrated 100% biomass in EFG Determined major effects of MSW torrefaction and co-gasifying high-ash coal waste-MSW blends have on pilot-scale EFG Demonstrated blending low-ash, low-sulfur torrefied biomass with high-ash waste bituminous and anthracite refuse coals generates a higher quality syngas compared to syngas from high-ash waste coals Demonstrated a high carbon conversion (> 99.5%) and syngas with 29.47% H2 content, and 0% CH4 content; greater water–gas shift occurs in EFG than predicted by equilibrium ASPEN Plus model Blended lower-ash, high-alkali biomass MSW to lower slag viscosities of the high-ash coal refuse sufficiently for better slag flow compared to feeding the high-ash coal Used low-sulfur biomass to greatly reduce the EFG syngas H2S concentrations and produce non-leachable slag and quench water with very little organic and trace metal contamination Developed a process model and TEA showing the modular PT EFG is cost competitive to existing power plants with the advantage of using low- or negative-value feedstocks such as waste coal stockpiles and non-landfilled MSW; providing a large incentive to implement an economical PT-EFG process
- Research Organization:
- Mainstream Engineering Corporation, Rockledge, FL (United States)
- Sponsoring Organization:
- USDOE Office of Science (SC)
- DOE Contract Number:
- SC0018580
- OSTI ID:
- 1508163
- Type / Phase:
- SBIR (Phase I)
- Report Number(s):
- DOE-MAINSTREAM-0018580
- Country of Publication:
- United States
- Language:
- English
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