1. OMSTAR ENVIRONMENTAL [Coal Project]

2. Types of Coal Coal in Electricity Generation (2012)
Mongolia 95% ; Australia 69%; Germany 44%; South Africa 93%; India 71%;
USA 38%; Poland 83%; Israel 61%; UK 39%; China 81%; Indonesia 48%; Japan 21%

3. Natural gas is the source of 60 percent of all energy related methane emissions (coal = 28 percent). The natural gas energy sector produces more than twice the methane emissions of the coal mining sector. Methane gas leakage during the production, transport, processing and use of natural gas is an important consideration, particularly with reference to shale gas. Methane emissions from gas and oil systems are grossly under-reported due to lack of infra-red equipment, as the following graphic indicates.
Naked Eye Infrared

4. Coal Combustion
TPP-thermal power plant

7. Oxygen Combustion
Oxygen combustion (oxy-combustion, oxy-firing or oxy-fuel) is an emerging technology applicable to either new or existing EGUs. The advantage offered by this technology is its potential for CO2 emissions control because it produces a concentrated (nearly pure) CO2 exhaust gas stream that requires minimal post-combustion clean-up prior to compression, transportation, and injection for long term storage. The basic concept of oxy-combustion is to use a mixture of oxygen (or oxygen-enriched air) and recycled flue gas (containing mostly CO2) in place of ambient air for coal combustion. The resulting flue gas contains primarily CO2 and water vapor with smaller amounts of oxygen, nitrogen, SO2, and NOX. Consequently, the flue gas can be processed relatively easily to further purify the CO2 (if necessary) for use in enhanced oil or gas recovery or for geological storage.

8. Plasma Ignition and Coal Combustion Stabilization

9. The technology is based on plasma thermo- chemical preparation of coal for burning and allows substituting of gas or fuel oil by coal.
Coal particles of micron in plasma undergo heat shock, as a result they are crushed into fragments, each fragment is of a size of 5-10 micron . It is a result of intensive yield of coal volatiles (CO, CO2, H2, N2, CH4, C6H6 etc.) and accelerates the process of fuel combustion 3-4 times
PFS – plasma –fuel system

10. Plasma Torch is the main element of the plasma-fuel system
Arc burns between a cathode and anode and ionizes plasma gas, blowing through the arc. The plasma torch’s arc power varies from 100 to 250 kW. Dimensions: length 0.5 m, diameter 0.25 m. It’s weight is about 25 kg.
Plasma in operation
Coal consumption through the PFS is 1000 kg/h, heat power is 5 MW

11. Variety of boilers and burners

12. 420 t/h steam boiler
furnace equipping
with PFS
(Almaty TEC-2,
Kazakhstan) :
1 – main pulverized
coal burners,
2 – PFS.

14. 2 2 2 1 3 1 1 3 3 3 3 1 1 2 3
Fig. 3.
Configuration of the plasma ignition system with the RFK-210 boiler furnace at the Yatagan power plant (Turkey):(1) air–fuel mixture, (2) secondary air, and (3) the plasma torch of a direct-flow plasma igniter. 2 1 2

15. Consumption of fuel oil in boilers
Boiler steam capacity, t/h Fuel oil consumption for 1 lighting up, t
50– –6
160– –25
220– –80
640– –100
–140
–250
–350
Conventional technology Plasma technology
1. Fuel Oil Rate for TPP
5.1 mln. t/year (cost is more than $ 2.5 billion) 0
2. Fuel Oil Rate for Kazakhstan TPP
~1 mln. t/year (cost is about $ 500 mln.) 0
3. Investments for TPP
100% %
4. Operating costs
100% %
5. Electric power consumption for TPP auxiliary
3-5% %

17. Omstar Fuel Additives

18. DX1 and Power Generation
MSTAR ENVIRONMENTAL
DX1 and Power Generation
Coal and natural gas power plants are not going away.
Increasing their efficiency and reducing their smokestack emissions is an effective way to bring extra power and cleaner air to the community
Coal, Diesel and Natural Gas Fired Power Plants (Expectations)
DX1 in coal furnaces reduces
SO2 by 20%
NOx by 30%
CO by 15%
Particulate matter by 30% with less ash
DX1 increase output energy by 10%
First pilot plant test in early 2016 in Kazakhstan

19. Installation for coal combustion
1 – combustor (chamber for coal combustion),
2 – plasma torch / air inlet;
3 – chamber for gas and slag separation;
4 – slag catcher;
5 – stand for slag catcher;
6 – chambers of syngas sampling and cooling;
7 - safety valve;
8 - chamber of syngas removal;
9 – pulverized fuel feeders; 10 – solid fuel dust hopper.

20. SIMULATION Thermodynamic computation using TERRA code
10 kg coal + 70 kg air
Coal kinetic code results:
The main products of coal combustion in the combustor exit (0.9 m) are CO2, which has a concentration of 14.8%, H2O - 5.4%, N %, O % and others - 0.2%. Gaseous phase exit temperature was 1273K, and the residence time of the reactants in the combustor s. The degree of fuel burn-up reached 100%.
Using data from thermodynamic and kinetic calculations of Ekibastuzsky coal combustion experimental installation was developed.
Gaseous species concentrations dependence on temperature

21. Installation for coal combustion
Plasma torch and unit for coal and air/oxygen supply

22. Procedure of the experiments

23. Measurements
Analysis for unburned carbon
Exhaust gas direct analysis

24. Temperature in stationary mode, oC
Temperature measurement along combustor versus duration of the experiment 1 2
Temperature in stationary mode, oC 3
Thermocouple No
No additive
With DX1 T 1
>1300 - 2
923
981 58 3
900
955 55 4
877
929 52 4
CHROMEL-ALUMEL THERMOCOUPLES

25. Concentration of unburned carbon in the units of the installation and conversion degree of coal without and with additive
Experiment No
Combustion chamber, %
Slag catcher, %
Chamber of cooling, %
Filter, %
XC, %
1 (0 ml DX1)
7.1
12.3
10.6
22.6
80.3
2 (5 ml DX1)
13.8
12.7
25.3
24.4
82.6
3 (25 ml DX1)
85.0
4 (50 ml DX1)
5.9
10.3
8.4
9.1
87.9
Coal consumption – 10 kg/h
Air flow – 28 kg/h (365 l/min)
O2 flow – 5.6 kg/h (65 l/min)
System – 1 kg of coal kg air

26. ANALYSIS OF EXHAUST GASES
Species
No additive
With DX1
CO2, %
18.9
19.9
CO, mg/m3
989
400
NO, mg/m3
802
724
NO2, mg/m3
SO2, mg/m3
4261
3897

27. Comparison between Open Flame and DX-1

28. ECONOMICS

29. ADVANTAGES OF DX1 APLICATION FOR LOW RANK HIGH ASH COAL COMBUSTION (PRELIMINARY RESULTS)
Increasing of coal conversion degree by 1-7% (earlier ignition and more complete burning)
Increasing of CO2 concentration by 5 % due to more complete C and CO oxidation (by 60%)
Decreasing of NOx by 10% due to deficit of O2 in boundary layer of coal particle during devolatilization (CO, CO2, H2, CH4, H2O, N2)
Decreasing of SO2 by 9% due to fixation of fuel Sulphur into stable compounds (CaS, MgS, CaSO4, MgSO4)

30. Fly Ash Processing

31. System schematic diagram
Fly ash chemical composition (Seoul, Korea)
Process Diagram
№ sample 1 2 3 4 5
SiO2
2,73
4,66
5,81
3,21
4,53
Al2O3
1,17
1,43
4,63
1,33
0,95
K2O
3,47
15,11
2,57
7,28
8,36
CaO
40,23
7,76
39,14
27,49
29,85
MgO
1,13
0,94
2,53
0.97
0,83
Na2O
8,41
20,91
7,93
8,60
10,45
TiO2
0,58
0,80
1,83
0,66
0,39
PbO
0,28
0,91
0,27
0,65
0,85
Fe2O3
0,61
0,90
1,80
0,78
0,67
MnO ND
Untreated Ash
Air/steam
SynGas
Reactor
Electrical Energy
Molten slug
Electrodes
Reactor cross section
System schematic diagram

32. Blowing a jet of ash melt into the fiber
System and process parameters:
- Power kW (current А; voltage VDC);
- ash flow kg/Hr;
- power consumption – 0.9 (kW Hr)/kg;
- Heat loss – kW;
- System efficiency – 53.2%;
- Electrode weight loss – kg/Hr;
- Reactor volume – 0.2 м3
- Molten slug temperature: °С;
- Start up time - 60 mins;
- Air flow: 1080 m3/Hr (air compressor power - 75 kW).
Molten slug
Blowing a jet of ash melt into the fiber
using a three-roll centrifuge.

33. Products
Glasslike slug
Mineral/ceramic wool