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    Eskom Develops UCG Technology Project

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    Eskom is developing underground coal gasification (UCG) technology to address South Africa's growing energy needs. A 3,000 Nm3/h pilot plant was commissioned in 2007 at Majuba coalfield. The first electricity from UCG gas was generated in May 2007. Challenges include geological complexities, equipment issues, and optimization of operations. Eskom's roadmap includes expanding the pilot plant, co-firing UCG gas with coal at an existing power station, and eventually developing commercial-scale UCG-IGCC plants up to 350MWe. UCG could help extend coal reserves, deploy new capacity faster, and utilize coal resources more efficiently.

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    Eskom Develops UCG Technology Project

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    Eskom is developing underground coal gasification (UCG) technology to address South Africa's growing energy needs. A 3,000 Nm3/h pilot plant was commissioned in 2007 at Majuba coalfield. The first electricity from UCG gas was generated in May 2007. Challenges include geological complexities, equipment issues, and optimization of operations. Eskom's roadmap includes expanding the pilot plant, co-firing UCG gas with coal at an existing power station, and eventually developing commercial-scale UCG-IGCC plants up to 350MWe. UCG could help extend coal reserves, deploy new capacity faster, and utilize coal resources more efficiently.

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    Chris Gross

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    Eskom is developing underground coal gasification (UCG) technology to address South Africa's growing energy needs. A 3,000 Nm3/h pilot plant was commissioned in 2007 at Majuba coalfield. The first electricity from UCG gas was generated in May 2007. Challenges include geological complexities, equipment issues, and optimization of operations. Eskom's roadmap includes expanding the pilot plant, co-firing UCG gas with coal at an existing power station, and eventually developing commercial-scale UCG-IGCC plants up to 350MWe. UCG could help extend coal reserves, deploy new capacity faster, and utilize coal resources more efficiently.

    Copyright:

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    Download as PDF, TXT or read online from Scribd
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    68 views25 pages

    Eskom Develops UCG Technology Project

    Uploaded by

    pngoc8
    Eskom is developing underground coal gasification (UCG) technology to address South Africa's growing energy needs. A 3,000 Nm3/h pilot plant was commissioned in 2007 at Majuba coalfield. The first electricity from UCG gas was generated in May 2007. Challenges include geological complexities, equipment issues, and optimization of operations. Eskom's roadmap includes expanding the pilot plant, co-firing UCG gas with coal at an existing power station, and eventually developing commercial-scale UCG-IGCC plants up to 350MWe. UCG could help extend coal reserves, deploy new capacity faster, and utilize coal resources more efficiently.

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    Eskom Develops UCG Technology Project

    Chris Gross Mark Van der Riet


    21st June 2007 Houston, USA

    SOUTH AFRICAN COAL

    Eskom Generated Electricity


    2006 : 221216 GWh Net
    Coal 93.05%

    Gas turbine 0.04% Nuclear 5.10%

    Hydro 0.52%

    Pumped storage 1.30%

    om sk E

    G UC

    ESKOM UNDERGROUND COAL GASIFICATION PILOT PROJECT

    Rationale for Eskoms stakeholding


    Opens an opportunity for more rapid deployment of new capacity Showcases a cleaner coal technology plant Introduces potential CDM credits Allows more efficienct utilisation of coal resources Creates a potential for a new petrochemical entity Extends RSA coal reserves, by opening up presently unminable resources, which have a broader geographic availability that at present.

    Existing plant age


    Eskom's Installed profile
    Dashed line = Approved peak demand + 20% Reserve Margin

    55 45000

    60

    65

    70

    75

    80

    85

    90

    95

    00

    Now 05

    10

    15

    20

    25

    30

    35

    40

    40000

    Grootvlei
    Komati

    Majuba 4-6

    35000

    Camden Cahora Bassa Zesco

    Majuba 1-3 30000 Megawatt Installed Kendal


    Palmiet

    25000

    Matimba Lethabo

    20000

    Tutuka Koeberg

    15000
    Vanderkloof Port Rex Acacia

    Drakensberg

    Duvha Matla Arnot Kriel


    HF Verwoerd

    10000

    5000

    Grootvlei Camden
    Ingagane Highveld Salt River Taaibos Wilge

    Komati

    0 55 60 65

    Hendrina 80 85 90 95 Year 00 05 10 15 20 25 30 35 40

    70

    75

    Most stations at mid life refurbishment point.

    Long-term energy forecast


    Capacity outlook 2005 to 2024

    Build base-load plants Build open cycle gas turbine plants (peaking) Build pumped storage plants (peaking) Return to service (mothballed plants) Existing system (Eskom and non-Eskom) Total imports (firm capacity from Cahora Bassa)

    Maximum demand Based on a 6% GDP growth, a high 4,4% growth scenario in demand for electricity before demand-side management Total capacity required to maintain 15% net reserve margin on moderate forecast Forecast moderate national peak demand before demand side management Moderate peak demand after demand-side management

    Rationale for Eskoms stakeholding


    Opens an opportunity for more rapid deployment of new capacity Showcases a cleaner coal technology plant Introduces potential CDM credits Allows more efficienct utilisation of coal resources Creates a potential for a new petrochemical entity Extends RSA coal reserves, by opening up presently unminable resources, which have a broader geographic availability that at present.

    UCG-IGCC Comparative Emissions


    1000 900 800 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 Conv PF CO2 Super PF NOx Conv IGCC UCG-IGCC Nat Gas CC SOx Particulates

    700 600 500 400 300 200 100 0

    Ref : Australian ACARP LCA study, Case Study B20, June 2002

    The only cleaner coal-based technology is the proposed ultra-supercritical PF

    NOx/SOx/Particulates kg/MWh net

    CO2 kg/MWh net

    Rationale for Eskoms stakeholding


    Opens an opportunity for more rapid deployment of new capacity Showcases a cleaner coal technology plant Introduces potential CDM credits Allows more efficienct utilisation of coal resources Creates a potential for a new petrochemical entity Extends RSA coal reserves, by opening up presently unminable resources, which have a broader geographic availability that at present.

    Resource Utilisation Efficiency


    33% of coal resource utilised Thermal Efficiency
    33

    Mining Efficiency
    66

    0%

    New Ultra-supercritical or Conventional IGCC with Longwall U/G Mine 36% of coal resource utilised

    100%

    Thermal Efficiency
    36

    Chemical Efficiency
    71

    Mining Efficiency
    95

    0%
    Thermal Efficiency

    UCG-IGCC 0.5% of resource utilised


    Extraction Efficiency

    100%

    13

    25

    50

    0%

    CCGT with CBM

    100%

    Rationale for Eskoms stakeholding


    Opens an opportunity for more rapid deployment of new capacity Showcases a cleaner coal technology plant Introduces potential CDM credits Allows more efficienct utilisation of coal resources Creates a potential for a new petrochemical entity Extends RSA coal reserves, by opening up presently unminable resources, which have a broader geographic availability that at present.

    Rationale for Eskoms stakeholding


    Opens an opportunity for more rapid deployment of new capacity Showcases a cleaner coal technology plant Introduces potential CDM credits Allows more efficienct utilisation of coal resources Creates a potential for a new petrochemical entity Extends RSA coal reserves, by opening up presently unminable resources, which have a broader geographic availability than at present.

    Eskoms UCG Routemap


    UCG technology potential noted - April 2001 Ergo Exergy Technologies Inc. (Canada) contracted in Scoping study - Nov 2002, highlighted potential at Majuba colliery Pre-feasibility study - Dec 2003, confirmed Majuba potential Detailed site characterisation study - July 2005, confirmed the potential 20th January 2007 Eskom commissioned a 3000 Nm3/h pilot plant on Majuba coalfield 31st May 2007 first electricity generated from UCG gas at Majuba
    Events since Zeus UCG Workshop 2006

    Eskom UCG Research Site


    Outer Water Sampling Zone Research Zone

    Inner Water Sampling Zone

    Production Area

    Directional Hole

    Majuba UCG flare 20 Jan 2007

    Majuba UCG electricity 31 May 2007


    The first electricity from Majuba UCG gas was generated at 15:00 on 31st May 2007. This marks the first new electricity generation from UCG gas since 1958, in Angren, Uzbekistan. The 100 kWe diesel engine generator has been converted to run on a maximum of 80% UCG gas, with 20% diesel. The diesel is required to lubricate the engine internals.

    100 kWe generator starting up on UCG gas

    UCG Pilot Plant Challenges


    Geological setting dolorites & schedule impact Insufficient geological & hydrogeological exploration data Unique products, due to unique coal and geological setting Equipment leadtimes Cost escalation & time creep Lengthly analytical service setup Surface plant technical difficulties and maintenance Energy efficiency (specifically diesel)

    NOTE : The UCG process has remained robust throughout

    Present UCG Activities


    Accelerating process development Optimising the pilot plant operations Developing co-firing with coal into Majuba Power Station boilers Skills development & technology transfer Optimising, planning, detailed engineering & costing of the next phases Research into challenges : Dolorites & drilling problems Coal seam drying Well linkage Environmental impacts Heat & mass balances Materials

    Dolorite Intrusions

    ESKOM UNDERGROUND COAL GASIFICATION COMMERCIALISATION

    Eskom UCG Development Path

    Timescale

    01/2007

    05/2008

    12/2008

    12/2010

    08/2011

    Phase 1A-1 3,000 Nm3/h 6 MWth flare

    Phase 1B 70,000 Nm3/h 28 MWe cofire

    Phase 2 125,000 Nm3/h 25 MWe cofire

    Phase 3 625,000 Nm3/h 250 MWe cofire

    Phase 4 630,000 Nm3/h 350 MWe IGCC

    RD&D
    Comm

    EIA

    Engineering & Investment

    Procurement Commercial 3,700,000 Nm3/h 2100 MWe IGCC

    Construction

    Co-firing & 350 MW UCG-CCGT


    Compressor Plant
    450 000 Nm3/h Air

    Fuel Solution
    Gas Treatment Plant & Flare
    630,000 Nm3/h Gas

    UCG Module
    125,000 Nm3/h Gas

    Majuba P/S

    UCG Module
    125,000 Nm3/h Gas

    UCG Module
    125,000 Nm3/h Gas

    UCG Module
    125,000 Nm3/h Gas

    Final Gas Treatment - GT


    630,000 Nm3/h Gas

    Gas Compressors
    2 x 315 000 Nm3/h Gas

    UCG Module
    125,000 Nm3/h Gas

    Capacity Solution

    350 MWe IGCC

    Thank You & Acknowledgements


    Eskom Resources & Strategy - ERID Eskom Generation - Primary Energy & Technology Majuba Power Station UCG Team EON Consulting Servies Ergo Exergy Inc. Specialist consultants

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