Coal is a readily combustible black or brownish-black sedimentary rock. The harder forms, such as anthracite coal, can be regarded as metamorphic rock because of later exposure to elevated temperature and pressure. It is composed primarily of carbon along with variable quantities of other elements, chiefly sulfur, hydrogen, oxygen and nitrogen.
Coal was formed from plant remains that were protected by water and mud against oxidization and biodegradation, thus trapping atmospheric carbon in the ground. Over time, the chemical and physical properties of the remains were changed by geological action to create a solid material.
Coal, a fossil fuel, is the largest source of energy for the generation of electricity worldwide, as well as one of the largest worldwide source of carbon dioxide emissions. Gross carbon dioxide emissions from coal usage are slightly more than those from petroleum and about double the amount from natural gas.[1] Coal is extracted from the ground by mining, either underground or in open pits.
Types of coal
As geological processes apply pressure to dead biotic matter over time, under suitable conditions it is transformed successively into
* Peat, considered to be a precursor of coal, has industrial importance as a fuel in some regions, for example, Ireland and Finland.
* Lignite, also referred to as brown coal, is the lowest rank of coal and used almost exclusively as fuel for electric power generation. Jet is a compact form of lignite that is sometimes polished and has been used as an ornamental stone since the Iron Age.
* Sub-bituminous coal, whose properties range from those of lignite to those of bituminous coal and are used primarily as fuel for steam-electric power generation. Additionally, it is an important source of light aromatic hydrocarbons for the chemical synthesis industry.
* Bituminous coal, dense mineral, black but sometimes dark brown, often with well-defined bands of bright and dull material, used primarily as fuel in steam-electric power generation, with substantial quantities also used for heat and power applications in manufacturing and to make coke.
* Anthracite, the highest rank; a harder, glossy, black coal used primarily for residential and commercial space heating. It may be divided further into metamorphically altered bituminous coal and petrified oil, as from the deposits in Pennsylvania.
* Graphite, technically the highest rank, but difficult to ignite and is not so commonly used as fuel: it is mostly used in pencils and, when powdered, as a lubricant.
The classification of coal is generally based on the content of volatiles. However, the exact classification varies between countries.
Coal as fuel
The emergence of the supercritical turbine concept envisions running a boiler at extremely high temperatures and pressures with projected efficiencies of 46%, with further theorized increases in temperature and pressure perhaps resulting in even higher efficiencies.
Other efficient ways to use coal are combined cycle power plants, combined heat and power cogeneration, and an MHD topping cycle.
Approximately 40% of the world electricity production uses coal. The total known deposits recoverable by current technologies, including highly polluting, low energy content types of coal (i.e., lignite, bituminous), might be sufficient for 300 years' use at current consumption levels, although maximal production could be reached within decades.
A more energy-efficient way of using coal for electricity production would be via solid-oxide fuel cells or molten-carbonate fuel cells (or any oxygen ion transport based fuel cells that do not discriminate between fuels, as long as they consume oxygen), which would be able to get 60%–85% combined efficiency (direct electricity + waste heat steam turbine). Currently these fuel cell technologies can only process gaseous fuels, and they are also sensitive to sulfur poisoning, issues which would first have to be worked out before large scale commercial success is possible with coal. As far as gaseous fuels go, one idea is pulverized coal in a gas carrier, such as nitrogen. Another option is coal gasification with water, which may lower fuel cell voltage by introducing oxygen to the fuel side of the electrolyte, but may also greatly simplify carbon sequestration. However, this technology has been criticised as being inefficient, slow, risky and costly, while doing nothing about total emissions from mining, processing and combustion. Another efficient and clean way of coal combustion in a form of coal-water slurry fuel (CWS) was well developed in Russia (since the Soviet Union time). CWS significantly reduces emissions saving the heating value of coal.
Coal is primarily used as a solid fuel to produce electricity and heat through combustion. World coal consumption is about 6.2 billion tons annually. China produced 2.38 billion tons in 2006 and India produced about 447.3 million tons in 2006. 68.7% of China's electricity comes from coal. The USA consumes about 1.053 billion tons of coal each year, using 90% of it for generation of electricity.The world in total produced 6.19 billion tons of coal in 2006.
When coal is used for electricity generation, it is usually pulverized and then burned in a furnace with a boiler. The furnace heat converts boiler water to steam, which is then used to spin turbines which turn generators and create electricity. The thermodynamic efficiency of this process has been improved over time. "Standard" steam turbines have topped out with some of the most advanced reaching about 35% thermodynamic efficiency for the entire process, which means 65% of the coal energy is waste heat released into the surrounding environment. Old coal power plants, especially "grandfathered" plants, are significantly less efficient and produce higher levels of waste heat. About 40% of the world's electricity comes from coal, and approximately 49% of the United States electricity comes from coal.
Coking and use of coke
Coke is a solid carbonaceous residue derived from low-ash, low-sulfur bituminous coal from which the volatile constituents are driven off by baking in an oven without oxygen at temperatures as high as 1,000 °C (1,832 °F) so that the fixed carbon and residual ash are fused together. Metallurgical coke is used as a fuel and as a reducing agent in smelting iron ore in a blast furnace. The product is too rich in dissolved carbon, and must be treated further to make steel. The coke must be strong enough to resist the weight of overburden in the blast furnace, which is why coking coal is so important in making steel by the conventional route. However, the alternative route to is direct reduced iron, where any carbonaceous fuel can be used to make sponge or pelletised iron. Coke from coal is grey, hard, and porous and has a heating value of 24.8 million Btu/ton (29.6 MJ/kg). Some cokemaking processes produce valuable by-products that include coal tar, ammonia, light oils, and "coal gas".
Petroleum coke is the solid residue obtained in oil refining, which resembles coke but contains too many impurities to be useful in metallurgical applications.
Gasification
Coal gasification can be used to produce syngas, a mixture of carbon monoxide (CO) and hydrogen (H2) gas. This syngas can then be converted into transportation fuels like gasoline and diesel through the Fischer-Tropsch process. Currently, this technology is being used by the Sasol chemical company of South Africa to make gasoline from coal and natural gas. Alternatively, the hydrogen obtained from gasification can be used for various purposes such as powering a hydrogen economy, making ammonia, or upgrading fossil fuels.
During gasification, the coal is mixed with oxygen and steam (water vapor) while also being heated and pressurized. During the reaction, oxygen and water molecules oxidize the coal into carbon monoxide (CO) while also releasing hydrogen (H2) gas. This process has been conducted in both underground coal mines and in coal refineries.
(Coal) + O2 + H2O → H2 + CO
If the refiner wants to produce gasoline, the syngas is collected at this state and routed into a Fischer-Tropsch reaction. If hydrogen is the desired end-product, however, the syngas is fed into the water gas shift reaction where more hydrogen is liberated.
CO + H2O → CO2 + H2
High prices of oil and natural gas are leading to increased interest in "BTU Conversion" technologies such as gasification, methanation and liquefaction. The Synthetic Fuels Corporation was a U.S. government-funded corporation established in 1980 to create a market for alternatives to imported fossil fuels (such as coal gasification). The corporation was discontinued in 1985.
In the past, coal was converted to make coal gas, which was piped to customers to burn for illumination, heating, and cooking. At present, the safer natural gas is used instead.
Liquefaction - Synthetic fuel Production - Coal-To-Liquids (CTL)
Coals can also be converted into liquid fuels like gasoline or diesel by several different processes. In the direct liquefaction processes, the coal is either hydrogenated or carbonized. Alternatively, coal can be converted into a gas first, and then into a liquid, by using the Fischer-Tropsch process.
In the Bergius process, coal is liquefied by mixing it with hydrogen gas and heating the system (hydrogenation). This process was used by Germany during World War I and World War II and has been explored by SASOL in South Africa. Several other direct liquefaction processes have been developed, among these being the SRC-I and SRC-II (Solvent Refined Coal) processes developed by Gulf Oil and implemented as pilot plants in the United States in the 1960s and 1970s.[16] The NUS Corporation developed another hydrogenation process which was patented by Wilburn C. Schroeder in 1976. The process involved dried, pulverized coal mixed with roughly 1wt% molybdenum catalysts. Hydrogenation occurred by use of high temperature and pressure synthesis gas produced in a separate gasifier. The process ultimately yielded a synthetic crude product, Naphtha, a limited amount of C3/C4 gas, light-medium weight liquids (C5-C10) suitable for use as fuels, small amounts of NH3 and significant amounts of CO2.
The process of low temperature carbonization (LTC) can also convert coal into a liquid fuel. Coal is coked at temperatures between 450 and 700°C compared to 800 to 1000°C for metallurgical coke. These temperatures optimize the production of coal tars richer in lighter hydrocarbons than normal coal tar. The coal tar is then further processed into fuels. The Karrick process was developed by Lewis C. Karrick, an oil shale technologist at the U.S. Bureau of Mines in the 1920s.
In the Fischer-Tropsch process, an indirect route, coal is first gasified to make syngas (a balanced purified mixture of CO and H2 gas). Next, Fischer-Tropsch catalysts are used to convert the syngas into light hydrocarbons (like ethane) which are further processed into gasoline and diesel. This method was used on a large technical scale in Germany between 1934 and 1945 and is currently being used by Sasol in South Africa. In addition to creating gasoline, syngas can also be converted into methanol, which can be used as a fuel, or into a fuel additive.
All of these liquid fuel production methods involve significant amounts of carbon dioxide (CO2) in the conversion process. Different liquefaction processes have dramatically different lifecycle carbon footprints depending on which processes and environmental controls are employed. If coal liquefaction using either a direct or indirect process is done without employing either carbon capture and storage technologies or biomass blending, the result is lifecycle greenhouse gas footprints that are generally significantly greater than those released in the extraction and refinement of liquid fuel production from petroleum. However, if CCS technologies are employed, reductions of 5-12% can be achieved in CTL plants and up to a 75% reduction is achievable when co-gasifying coal with commercially demonstrated levels of biomass (30% biomass by weight) in CBTL plants. For most future synthetic fuel projects, Carbon dioxide sequestration is proposed to avoid releasing it into the atmosphere. As CO2 is one of the process streams, sequestration is easier than from flue gases produced in combustion of coal with air, where CO2 is diluted by nitrogen and other gases. Sequestration will, however, add to the cost of production. Currently all US and at least 1 Chinese synthetic fuel projects are including sequestration in their process designs.
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