Modular Coal Pyrolysis Plants

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Our modular pyrolysis plants are configured in such a way as to provide optimum flexibility and scalability and is especially suitable for deployment in remote areas.

These modules are packaged in standard ISO container format which aids world-wide transport, whether by ship, train or truck. In the basic configuration, the main final products are pyrolysis fuel oil, char and heat. However, it is possible to add downstream units such as power generation, refining to road fuels, steam plant and other higher value products.

High volatile coal is conveyed from the mine to a covered stockpile from which the coal is fed into the pyrolysis plant. Each plant unit is designed for a nominal throughput of 100 tonnes per day. Any number of these units can be operated side-by-side to provide full scalability.

Depending on the quality of high volatile coal received, each coal pyrolysis unit produces between 1 and 2 barrels of oil per tonne of the coal fed into it.

The pyrolysis oil is of such a high quality that it can be used in a power generation module without further processing. A Fuel Module can be configured to refine the pyrolysis oil to a road fuel which can be blended with commercial road fuels for industrial use; or else a full micro refinery can be added on. Each fuel cut is stored in separate tanks which are sized to suit the specific conditions.

In some cases it may be practical to store fuel directly into transportable ISO tankers which can be arrayed to increase on-site storage capacity or to facilitate offsite transportation. One of these tankers will typically be filled up within a day by a single coal pyrolysis plant module.

PCE has collaborated with Auto Evolve Concept (AEC) to develop a hybrid power generation solution using our CHR process together with heavy oil fuel generators to form an integrated CHR Power Generation facility (CPG). This solution is ideal for remote and off-grid power supply as a substitute for diesel fuel power generation. This system can also be used as support to Solar PV for continued power generation outside day light hours. The basic assumptions for such a system are:

  • Lower costs than diesel fuel.
  • Availability of thermal source, e.g., coal, either sourced locally or already being brought in from elsewhere
  • Signficantly low kWh tarriff, $0.10 as opposed to $0.30 or more for diesel generation depending on distance from where the diesel fuel is sourced.
  • Economical for generation capacity of between 2 – 50MW

The basis for this system is the ability to produce onsite heavy fuel oil (HFO) using the pyrolysis process. The HFO is then used to fuel generators as shown in the opposite diagram. The availiability and yield of high volatile material is a key determinant for this system. Material yielding approximately 200BPD has the capacity to generate 8MW. The capital cost for an 8MW generation capacity is estimated at $13.2m. The feed-in tarrif estimated at $0.10 per kWh.

A potential application of integrated CHR and power generation (CPG) is in cement manufacturing. In such instances, coal or any suitable material used to generate heat for kiln is pyrolysed to extract the hydrocarbons (HFO) which is then used to generate electricity for the cement plant. The CPG facility utilizes existing on-site coal handling facility, with only slight modifications. The char product is feed back to the coal blending/grinding system as an alternative heat energy source for the kiln.

Power Generation Using Coal Pyrolysis Plants

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