ACARP ACARP ACARP ACARP
Technical Market Support

A Comprehensive Technical Review of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies for Power Generation

Technical Market Support » Thermal Coal

Published: June 20Project Number: C28063

Get ReportAuthor: Soonho Lee, Jongho Kim, Arash Tahmasebi, Jianglong Yu | University of Newcastle

Research and development has been undertaken worldwide to realise coal fired power plants that are capable of operating at higher steam temperatures and pressures to achieve higher plant efficiencies. These efficient units use low-NOx coal burners and are fitted with state-of-the-art technologies for pollutant capture to control environmental emissions. These are commonly referred to as HELE (high-efficiency low-emissions) coal-fired power plants, and the best examples can meet the emission limits for gas-fired power plants.

This project reviewed the HELE technology development   renovation roadmap in three components:

  • Steam cycle side;
  • Fire side featured with low NOx burning; and
  • Flue gas treatments (including PM capture and deSOx/deNOx).

This report aims to provide a comprehensive overview on the HELE pulverised coal power generation side where most Australian thermal coals are and will be used, and covers both the technical R&D and the modelling efforts in the literature for the first two components. The increases in the steam pressure and temperature represents the roadmap to HELE coal boiler technology R&D over the past decades, from subcritical to supercritical through to ultra-supercritical and advanced ultra-supercritical boilers. The increases in the plant efficiency, the drop in coal consumption and the carbon emissions, and lower NOx formation are regarded as the main advantageous features of the HELE coal combustion technologies. The achievements in reaching higher steam pressures and temperatures have been made possible owing to the use of advanced materials that can withstand such conditions.

Extensive numerical modelling efforts have been made in the past several decades, which has improved our understanding of the technical issues associated with HELE boilers, including combustion and boiler performance optimisation, ash deposition, and materials issues at higher operating temperatures. The current modelling research in the open literature has been overviewed in this report, which has improved our understanding of the technical issues in coal fired boilers under HELE conditions, including boiler performance optimisation, ash deposition, and materials issues. The effects of changes in the configuration and operating conditions are discussed with a focus on the optimisation of boiler performance, such as unburnt carbon and NOx emissions. The retrofit and optimisation of burner geometry and operating conditions in low-NOx coal combustion technology, which is necessary to operate HELE power plants, are also overviewed.

In terms of ash deposition, the development of sub-models, including particle sticking and impacting behaviour and its impact on the prediction of ash deposit growth under different temperatures have been discussed. The numerical models for material oxidation and creep of austenitic and nickel-based alloys used under HELE conditions have been developed based on the finite element method to predict the availability of advanced alloys and creep life and the actual service time of the boiler parts. The prediction of oxide scale growth and exfoliation in both steam-side and fire-side as well as creep strength, have also been analysed and reviewed.

The project also identifies further research needs on numerical modelling that are required to further optimise the coal combustion processes and to address the technical issues associated with the advanced HELE power plant operations.

The literature data demonstrate that coal quality seems to be responsible for various issues during coal combustion, especially, slagging and fouling in both subcritical and advanced coal-fired boilers. Coal quality data that influence such issues have been collected from the open literature, based on which we have developed the thermal coal database, currently including 34 Australian and 26 international thermal coals, ranging from subbituminous to bituminous coals. Various slagging/fouling empirical and experimental indices have been included in the database to evaluate the slagging/founding propensity.

Underground

Health and safety, productivity and environment initiatives.

Recently Completed Projects

C28026Measuring The Height Of Fracturing Above Extracted Longwall Panels To Improve Reliability Of Groundwater Impact Predictions

Longwall mining is a mining method widely used in the Australian und...

C25059Development Of An Intrinsically Safe, Integrated Wireless Communications Network With A Distributed Array Of Geotechnical Sensors

For over 20 years, SCT Operations (SCT) have provided a range of ind...

C26051An On-Machine Bolting And Geotechnical Monitoring System

The primary objective of this project was to investigate how laser s...

Underground

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

C29003Wear Debris Removal From Dragline Commutators

The original aim of this project was to establish a method of removi...

C28037Local Scale Dispersion Modelling To Support ACARP Emission Factors

There remains significant concern in the industry regarding the accu...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27032Coal Grain Analysis Applications Handbook

This Handbook sets out recommended practices for using coal grain an...

C26012Improved Flotation Recovery Via Controlling Froth Behaviour

There is no real-time measurement for coal flotation performance, ma...

C27012Towards Better Fine Coal Classification

It is well recognised that the efficient classification of fine coal...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

C27008Selective Absorption Of Methane By Ionic Liquids

The connection of a ventilation air methane (VAM) abatement plant di...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community

NERDDC

National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook

NERDDC