Clean Coal Engineering Technology

Concern over the effects of airborne pollution, green house gases, and the impact of global warming has become a worldwide issue that transcends international boundaries, politics, and social responsibility. The 2nd Edition of Coal Energy Systems: Clean Coal Technology describes a new generation of energy processes that sharply reduce air emissions and other pollutants from coal-burning power plants. Coal is the dirtiest of all fossil fuels. When burned, it produces emissions that contribute to global warming, create acid rain, and pollute water. With all of the interest and research surrounding nuclear energy, hydropower, and biofuels, many think that coal is finally on its way out. However, coal generates half of the electricity in the United States and throughout the world today. It will likely continue to do so as long as it's cheap and plentiful [Source: Energy Information Administration]. Coal provides stability in price and availability, will continue to be a major source of electricity generation, will be the major source of hydrogen for the coming hydrogen economy, and has the potential to become an important source of liquid fuels. Conservation and renewable/sustainable energy are important in the overall energy picture, but will play a lesser role in helping us satisfy our energy demands today. Dramatically updated to meet the needs of an ever changing energy market, Coal Energy Systems, 2nd Edition is a single source covering policy and the engineering involved in implementing that policy. The book addresses many coal-related subjects of interest ranging from the chemistry of coal and the future engineering anatomy of a coal fired plant to the cutting edge clean coal technologies being researched and utilized today. A 50% update over the first edition, this new book contains new chapters on processes such as CO2 capture and sequestration, Integrated Gasification Combined Cycle (IGCC) systems, Pulverized-Coal Power Plants and Carbon Emission Trading. Existing materials on worldwide coal distribution and quantities, technical and policy issues regarding the use of coal, technologies used and under development for utilizing coal to produce heat, electricity, and chemicals with low environmental impact, vision for utilizing coal well into the 21st century, and the security coal presents. Clean Liquids and Gaseous Fuels from Coal for Electric Power Integrated Gasification Combined Cycle (IGCC) systems Pulverized-Coal Power Plants Advanced Coal-Based Power Plants Fluidized-Bed Combustion Technology CO2 capture and sequestration Copyright......Page 2 Dedication......Page 3 Preface......Page 4 Organization of this Book......Page 6 Coal Use before the Industrial Revolution......Page 7 The Early History of U.S. Coal Mining and Use......Page 8 Coal Use during the Industrial Revolution......Page 9 The Post-Industrial Revolution Use of Coal......Page 10 An Overview of Energy in the United States......Page 11 Coal Production in the United States......Page 17 Coal Consumption in the United States......Page 25 U.S. Coal Exports and Imports......Page 27 World Primary Energy Production......Page 29 World Primary Energy Consumption......Page 36 Projections of Energy Use and Coal's Contribution to the Energy Mix......Page 40 World Consumption of Liquid Fuels......Page 43 World Consumption of Coal......Page 44 Projected Coal Consumption in North America......Page 45 Projected Coal Consumption in OECD Europe......Page 46 Projected Coal Consumption in Non-OECD Asia......Page 47 World Consumption of Nuclear Energy......Page 49 World Consumption of Renewable Energy......Page 50 Energy Outlook for the United States......Page 51 Projected Energy Consumption in the United States......Page 52 Projected Energy Production in the United States......Page 53 Coal's Role in the U.S.'s 2001 Energy Policy......Page 54 References......Page 56 Origin of Coal......Page 57 Coalification......Page 58 Basic Coal Analysis......Page 61 The Ranks of Coal......Page 63 The Types of Coal......Page 65 Classification Systems......Page 67 The ASTM Classification System......Page 68 International Classification/Codification Systems......Page 69 References......Page 72 Coal Distribution and Resources......Page 73 Coal Reserves throughout the World......Page 74 United States......Page 78 Russia......Page 82 Kazakhstan......Page 83 Australia......Page 84 Poland......Page 85 South Africa......Page 86 Central and South America......Page 87 The Effect of Coal Usage on Human Health and the Environment......Page 88 Underground Mining......Page 89 Subsidence......Page 90 Generation of Gases......Page 91 Liquid Effluents/Acid Mine Drainage......Page 94 Hydrologic Impact......Page 96 Health Effects and Miner Safety......Page 97 Surface Mining......Page 99 Liquid Effluents and Acid Mine Drainage......Page 100 Health Effects and Miner Safety......Page 101 Legislation and Reclamation......Page 102 Coal Preparation......Page 103 Refuse Contaminants from Preparation Plants......Page 105 Health and Safety Issues......Page 106 Coal Transportation......Page 107 Coal Combustion By-Products......Page 108 Environmental Effects......Page 110 Health Effects......Page 112 Nitrogen Oxides......Page 113 Environmental Effects......Page 114 Particulate Matter......Page 115 Environmental Effects......Page 116 Health Effects......Page 117 Carbon Monoxide......Page 119 Trace Elements......Page 120 Environmental Effects......Page 121 Lead......Page 122 Arsenic......Page 123 Fluorine......Page 124 Molybdenum......Page 125 Radionuclides......Page 126 Greenhouse Gases-Carbon Dioxide......Page 127 Environmental Effects......Page 130 References......Page 132 Coal Combustion......Page 136 Brief History of Boilers and Coal Combustion Systems......Page 137 Size and Number of Units......Page 142 Boiler Design......Page 143 Fuel Diversity and Global Product Competition......Page 144 Basic Steam Fundamentals and their Application to Boiler Development......Page 145 Devolatilization of Pulverized Coal and Volatiles Combustion......Page 147 Char Combustion......Page 148 Coal Combustion Systems......Page 152 Fixed-Bed Combustion......Page 153 Underfeed Stokers......Page 154 Overfeed Stokers......Page 155 Spreader Stokers......Page 157 Fluidized-Bed Combustion......Page 158 Role of Sorbents in an FBC Process......Page 160 Comparison of Bubbling and Circulating Fluidized-Bed Combustion Boilers......Page 161 Suspension Firing......Page 164 Dry-Bottom Firing......Page 165 Wet-Bottom Firing......Page 167 Cyclone Furnaces......Page 168 Furnace Design......Page 169 Slagging and Fouling Potential......Page 171 Carbonization......Page 175 Brief History of Carbonization High-Temperature......Page 177 Coking Processes......Page 178 Coal Properties for Coke Production......Page 181 Low-Temperature Carbonization......Page 182 Smokeless Fuel Commercial Processes......Page 183 Low-Rank Coal Upgrading......Page 184 Brief History of Coal Gasification......Page 186 Principles of Coal Gasification......Page 187 Gasifier Types......Page 188 Fixed-Bed Gasifiers......Page 189 Influence of Coal Properties on Gasification......Page 192 Fixed Carbon......Page 193 Regional Distribution of Gasification Systems......Page 194 Fixed-Bed Gasifiers......Page 197 Fluidized-Bed Gasifiers......Page 200 HTW Gasifier......Page 201 KRW Gasifiers......Page 203 GE Energy Gasifiers......Page 204 Shell Gasifiers......Page 205 Prenflo Gasifiers......Page 206 References......Page 218 Coal Transport to the Power Plant......Page 221 Coal Handling, Storage, and Processing......Page 225 Coal Handling......Page 226 Coal Storage......Page 227 Coal Processing/Size Reduction......Page 228 Furnace and Convection Pass......Page 238 Steam Drums......Page 239 Steam Turbines......Page 241 Steam Condensers......Page 244 Water Treatment......Page 245 Environmental Protection......Page 248 Convective Pass/Economizer Ash Systems......Page 249 Fly Ash Systems......Page 250 Scrubber Sludge Systems......Page 251 Rankine Cycle......Page 253 Combined Cycle......Page 255 Pulverized Coal-Fired Power Plants......Page 256 Advanced Pulverized Coal-Fired Plants......Page 257 Improved Fabrication Technology......Page 262 Oxy-Fuel Firing in Pulverized Coal-Fired Boilers......Page 263 Steam Generator Design Issues......Page 264 Overall Process Issues......Page 265 Introduction......Page 266 Heat Transfer......Page 268 Fuel Flexibility......Page 269 Pollutant Formation and Control......Page 271 Transformation of Sorbents in the FBC Process......Page 272 Bed Quality......Page 274 Porosity......Page 275 Surface Area......Page 276 NOx Formation......Page 277 Combustion Temperature......Page 278 NOx Reduction Techniques......Page 279 Trace Elements......Page 280 Ash Chemistry and Agglomeration Issues......Page 283 Integrated Gasification Combined Cycle......Page 284 Introduction......Page 285 Gasification Island......Page 286 Gas Treatment and Sulfur Recovery......Page 287 Amine Processes......Page 288 Selexol......Page 289 Rectisol......Page 290 IGCC with Carbon Capture......Page 292 Efficiency......Page 293 NOx Emissions......Page 294 References......Page 298 Pre-Industrial Revolution......Page 303 Post-Industrial Revolution......Page 304 Pre-1970 Legislation......Page 305 The National Air Quality Control Act of 1967......Page 306 The Clean Air Act Amendments of 1970......Page 307 Air Quality Criteria and National Ambient Air Quality Standards......Page 308 National Emission Standards......Page 309 40 CFR Part 60 Subpart Da......Page 311 40 CFR Part 60 Subparts Db and Dc......Page 312 Emission Factors......Page 315 Prevention of Significant Deterioration......Page 317 Clean Air Act Amendments of 1990......Page 319 Title I: Provisions for Attainment and Maintenance of National Ambient Air Quality Standards......Page 320 Title III: Air Toxics......Page 322 The SO2 Program......Page 323 Title V: Permitting......Page 325 Ozone Transport Commission NOx Budget Program 1992-2002......Page 326 NOx Budget Trading Program/NOx SIP Call 2003-2008......Page 327 Clean Air Interstate Rule......Page 329 Clean Air Mercury Rule......Page 330 New Source Review......Page 332 Fine Particulate Matter......Page 334 Multipollutant Legislation......Page 335 Climate Change/Greenhouse Gas Emissions......Page 337 Sulfur Dioxide......Page 339 Nitrogen Oxides......Page 343 Particulate Matter......Page 347 Trace Elements/Mercury......Page 348 Carbon Dioxide......Page 350 Air Quality and Coal-Fired Emissions......Page 351 Six Principal Pollutants......Page 353 Ozone......Page 354 Particulate Matter......Page 356 Carbon Monoxide......Page 360 Lead......Page 363 Acid Rain......Page 364 Hazardous Air Pollutants......Page 368 Mercury......Page 370 Carbon Dioxide......Page 371 References......Page 373 Emissions Control Strategies for Power Plants......Page 377 Currently Regulated Emissions......Page 378 Chemistry of Sulfur Oxide Formation......Page 379 Sulfur Dioxide Control......Page 380 Worldwide Deployment of FGD Systems......Page 381 Techniques to Reduce Sulfur Dioxide Emissions......Page 384 Using Low-Sulfur Fuels......Page 385 Coal Cleaning......Page 387 Wet Flue Gas Desulfurization Wet FGD......Page 389 Limestone- and Lime-Based Scrubbers......Page 390 Limestone with Forced Oxidation......Page 392 Limestone with Forced Oxidation Producing a Wallboard Gypsum By-Product......Page 393 Magnesium Enhanced Lime......Page 394 Limestone with Dibasic Acid......Page 395 Lime Dual Alkali......Page 396 Regenerative Processes......Page 397 The Wellman-Lord Process......Page 398 Regenerative Magnesia Scrubbing......Page 399 Spray Dry Scrubbers......Page 400 Sorbent Injection Processes......Page 402 Furnace Sorbent Injection......Page 404 Economizer Injection......Page 407 Duct Sorbent Injection-Duct Spray Drying......Page 408 Duct Sorbent Injection-Dry Sorbent Injection......Page 409 Circulating Fluidized-Bed Scrubbers......Page 412 Economics of Flue Gas Desulfurization......Page 413 Spray Dry Processes......Page 414 NOx Formation Mechanisms......Page 415 Thermal NO......Page 416 Fuel NO......Page 417 NOx Control in Pulverized Coal Combustion......Page 418 Combustion Modifications......Page 422 Low-NOx Burners......Page 423 Furnace Air Staging......Page 426 Fuel Staging Reburn......Page 427 Cofiring......Page 429 Selective Catalytic Reduction......Page 431 Selective Non-Catalytic Reduction......Page 434 Hybrid SNCR/SCR......Page 435 NOx Control in Stoker-Fired Boilers......Page 436 Flue Gas Recirculation......Page 437 Process Optimization......Page 438 References......Page 477 CO2 Capture and Storage......Page 484 CO2 Capture Technologies......Page 486 Precombustion IGCC CO2 Capture......Page 487 Postcombustion CO2 Capture......Page 488 Amine-Based Liquid Solvent Systems......Page 491 Aqueous Ammonia Process......Page 493 Solid Sorbents......Page 494 Membranes......Page 495 Ionic Liquid Systems......Page 496 Biomass Cofiring......Page 497 Transport of CO2......Page 498 Geologic Storage......Page 499 Ocean Storage......Page 501 Mineral Carbonation......Page 502 Capture Costs......Page 503 Postcombustion CO2 Capture Economics......Page 504 Oxy-Fuel Combustion Economics......Page 506 Economics of Biomass Cofiring......Page 507 Costs of Transporting CO2......Page 508 Geologic Storage Costs......Page 509 Permanence and Monitoring, Mitigation, and Verification......Page 510 References......Page 511 Introduction to U.S. Clean Coal Technology Programs......Page 513 Clean Coal Technology Demonstration Program......Page 514 CCTDP Evolution......Page 515 CCTDP Projects......Page 516 SO2 Control Technologies......Page 517 NOx Control Technologies......Page 522 Combined SO2/NOx Control Technologies......Page 523 Advanced Electric Power Generation Technology......Page 525 Fluidized-Bed Combustion......Page 526 Integrated Gasification Combined Cycle......Page 527 Coal Processing for Clean Fuels Technology......Page 533 CCTDP Accomplishments......Page 537 Power Plant Improvement Initiative......Page 541 PPII Projects......Page 542 Benefits of the PPII......Page 546 Program Importance......Page 547 Round 1 CCPI Projects......Page 548 Round 2 CCPI Projects......Page 553 Round 3 CCPI CCPI-3A and CCPI-3B Projects......Page 556 CCPI Benefits......Page 558 Benefits of DOE's Clean Coal Technology Programs......Page 559 Vision 21 Technologies......Page 563 FutureGen......Page 565 DOE Carbon Sequestration Programs......Page 568 International Clean Coal Technology and Carbon Sequestration Activities......Page 572 Canada......Page 573 Australia......Page 574 Japan......Page 576 China......Page 577 Others......Page 578 Coal and Energy Security......Page 584 Overview of U.S. Energy Security Issues......Page 585 The Future of Energy in the United States......Page 587 Energy and the Economy......Page 588 Natural Gas Use in Power Generation......Page 591 Coal's Potential to Reduce U.S. Dependence on Imported Crude Oil......Page 593 Coal's Role in Future U.S. Electric Power Generation......Page 595 Production of Hydrogen from Coal......Page 602 International Demand for Electricity......Page 603 Advanced Coal Technology Application Support for Sustained Coal Utilization......Page 605 Energy Security......Page 606 Sustainable Development......Page 607 Concluding Statements......Page 608 Non-Organization for Economic Cooperation and Development Non-OECD......Page 612 Organization of Petroleum Exporting Countries OPEC......Page 613 Commercial Gasification Facilities Worldwide......Page 614 Coal-Fired Emission Factors......Page 624 Original List of Hazardous Air Pollutants......Page 650 Initial 263 Units Identified in Phase I SO2 of the Acid Rain Program......Page 655 A......Page 658 B......Page 659 C......Page 660 D......Page 664 E......Page 665 F......Page 667 G......Page 668 I......Page 669 M......Page 670 N......Page 672 P......Page 673 S......Page 675 U......Page 677 Z......Page 678 Concern over the effects of airborne pollution, green house gases, and the impact of global warming has become a worldwide issue that transcends international boundaries, politics, and social responsibility. The 2nd Edition of Coal Energy Systems: Clean Coal Technology describes a new generation of energy processes that sharply reduce air emissions and other pollutants from coal-burning power plants.

Coal is the dirtiest of all fossil fuels. When burned, it produces emissions that contribute to global warming, create acid rain, and pollute water. With all of the interest and research surrounding nuclear energy, hydropower, and biofuels, many think that coal is finally on its way out. However, coal generates half of the electricity in the United States and throughout the world today. It will likely continue to do so as long as it's cheap and plentiful [Source: Energy Information Administration]. Coal provides stability in price and availability, will continue to be a major source of electricity generation, will be the major source of hydrogen for the coming hydrogen economy, and has the potential to become an important source of liquid fuels. Conservation and renewable/sustainable energy are important in the overall energy picture, but will play a lesser role in helping us satisfy our energy demands today. Dramatically updated to meet the needs of an ever changing energy market, Coal Energy Systems, 2nd Edition is a single source covering policy and the engineering involved in implementing that policy. The book addresses many coal-related subjects of interest ranging from the chemistry of coal and the future engineering anatomy of a coal fired plant to the cutting edge clean coal technologies being researched and utilized today. A 50% update over the first edition, this new book contains new chapters on processes such as CO2 capture and sequestration, Integrated Gasification Combined Cycle (IGCC) systems, Pulverized-Coal Power Plants and Carbon Emission Trading.
Existing materials on worldwide coal distribution and quantities, technical and policy issues regarding the use of coal, technologies used and under development for utilizing coal to produce heat, electricity, and chemicals with low environmental impact, vision for utilizing coal well into the 21st century, and the security coal presents.

Clean Liquids and Gaseous Fuels from Coal for Electric Power
Integrated Gasification Combined Cycle (IGCC) systems
Pulverized-Coal Power Plants
Advanced Coal-Based Power Plants
Fluidized-Bed Combustion Technology
CO2 capture and sequestration