Underground Coal Gasification Process Research Articles

Effect of Fixed and Removable Gas-Injection Patterns on the Expansion of Reaction Zones during Underground Coal Gasification

The expansion pattern of the three reaction zones, including oxidation, reduction, and dry distillation zones in the underground coal gasification (UCG) process, is recognized to be different using various gas-injection patterns, on account of which the corresponding stability and syngas components are notably distinguished. The current work carried out UCG model tests in a removable gas-injection point (receded five times). During the stable gasification process, the temperature field map and changes in syngas composition were monitored to determine the area proportions among the three zones and their expansion rates. The differences in the expansion of the three zones between fixed and removable gas-injection points were then explained according to cavity growth. The results showed that the UCG process using a removable gas-injection point exhibited a better performance than that using a fixed point in some aspects, including gasification stability, syngas calorific value, area ratio of the reduction zo...

Sequential mineral transformation during underground coal gasification with the presence of coal partings

Underground coal gasification (UCG) can be adopted to convert unminable coal resources into synthesis gas for use in the production of electricity, fuels, and chemicals. UCG is a promising technology with many health, safety, and environmental advantages over conventional mining techniques. It is of great scientific significance to study the mineral transformation and identify the typical minerals in certain process conditions, because it may help to ensure the stable operation of the gasification processes and improve the utilization efficiency of coal seams. The presence of coal partings has an important impact on mineral transformation. In this paper, the UCG process has been subdivided into pyrolysis, reduction, and oxidation stages, and the progressive coal conversion products were prepared. Ulanqab lignite was used as the test coal. The minerals in the coal transformation products were identified by X-ray diffraction (XRD) and scanning electron microscopy coupled with an energy-dispersive spectrometer (SEM-EDS). The thermodynamic equilibrium simulation software, FactSage 7.2, was used to calculate the relevant phase diagram to assist in understanding the mineral transformations. The experimental results indicate that the different iron-bearing minerals occur in raw coal and non-coal partings which are nontronite (Na0.3Fe2Si4O10(OH)2.4H2O) and glauconite (K (Fe, Al)2(Si, Al)4O10(OH)2) respectively. Pyrrhotite is the main iron-bearing mineral in the pyrolysis products. In the reduction stage, the relative content of Al2O3 is increased due to the presence of non-coal partings, which reacts with FeO to produce hercynite (FeAl2O4) at a temperature above 1100 °C. When the temperature increases to 1300 °C, hercynite is converted to the thermodynamically-stable cordierite (Fe2Al4Si5O18). In the oxidation stage, mullite (Al6Si2O13) is produced when the oxidation temperature reaching 1300 °C, which could be used to reflect the underground reaction conditions in the coal seam. The phase diagram of (SiO2)6.2Al2O3-CaO-Fe2O3 proves that mullite and anorthite (CaAl2Si2O8) are the dominant minerals when the mole fraction of (SiO2)6.2Al2O3 is above 0.7. In addition, the ash melting point rises with an increase of Si and Al content in the presence of non-coal partings.

Mathematical Modeling of the Underground Coal Gasification Process in One Gasification Cycle

Underground coal gasification (UCG) has its own reaction characteristics with the growth of the combustion cavity because the coal seam is fixed while the gasification face moves. The theoretical understanding of UCG requires continuous and deep research. In order to explain the UCG mechanism by means of simulation calculation, based on the analysis of the reaction process of UCG, radial and axial reaction models are established. The comprehensive heat transfer coefficient of the coal seam is determined by comparing the calculation results with the field test results. The differential method is used to calculate variations in the composition of the outlet gas, the temperature field distribution in the channel, the thickness of the radial reaction zone, and the influence of the oxygen fraction on the length of the oxidation zone. The results indicate that in one gasification cycle, the changes of gas composition is close to that of the field test, which initially increases and then decreases with increasin...

Contribution to creating a mathematical model of underground coal gasification process

Underground coal gasification, as an auto thermal process, includes processes of degasification, pyrolysis, and the gasification itself. These processes occur as a result of a high temperature and the management of coal combustion during addition of gasification agent. Air, water vapor mixed with air, air or water vapor enriched with oxygen, or pure oxygen, may be used as gasification agents. Resulting gas that is extracted in this process may vary in chemical composition, so it is necessary to adjust it. That is the reason why it is necessary to develop a mathematical model of the underground gasification process prior to any operations in coal deposit, in order to obtain as much accurate prediction of the process as possible. Numerical calculation provides prediction of gas mixture?s chemical composition, which enables calculation of gas components? energy contents and total energy content of the gas in predicted underground coal gasification process. It is one of the main criteria in the economic assessment of underground coal gasification process. This paper, based on available data on researches in this area, provides a contribution to creation of mathematical model of underground coal gasification.

Valorization of non-balanced coal reserves in Serbia for underground coal gasification

In the name of a better and safer energy future, it is our responsibility to focus our knowledge and activities to save on imported liquid and gas fossil fuels, as well as coal on which energy security of Serbia is based. The rationalization in the use of available energy resources certainly positively affects economy and the environment of a country. This paper indicates motivations for the application of the underground coal gasification process, as well as surface gasification for Serbia. The goal is to burn less coal, while simultaneously utilizing more gas from the onsite underground coal gasification, or by gasification in various types of gas generators mounted on the surface. In both cases, from the obtained gas, CO2, NOx, and other harmful gases are extracted in scrubbers. This means that further gas combustion byproducts do not pollute the atmosphere in comparison with traditional coal combustion. In addition, complete underground coal gasification power requirements could be offset by the onsite solar photovoltaic power plant, which furthermore enhances environmental concerns of the overall coal utilization.

Fire risk prevention in underground coal gasification (UCG) within active mines: Temperature forecast by means of MARS models

This paper focuses on fire prevention in UCG processes within active mines by means of temperature forecasting by a multivariate adaptive regression splines (MARS) approach. The main aim was to develop a model to forecast the temperature of the syngas with one hour of anticipation based on information from different parameters measured every hour (snapshots) during the experiment. As the response time of the syngas temperature to modifications in the composition/amounts of the gasifying agent is very short, this will reduce the temperature if necessary while keeping it as high as possible within the safety parameters, as UCG is a strongly exothermic process. The same model can be used to prevent undesired drops in the temperature of the syngas, as low temperatures could increase the precipitation of contaminants, causing a slowdown in the syngas flow and thus decreasing its calorific value.Temperature forecasting was achieved successfully; thus, the use of artificial intelligence and, specifically, a supervised learning predictive technique such as MARS models will allow active mines for the first time to adequately prevent the risk of fires while obtaining the best syngas quality in UCG processes.

Robust tracking of the heating value in an underground coal gasification process using dynamic integral sliding mode control and a gain-scheduled modified Utkin observer

In this paper, a model-based control and state reconstruction of an underground coal gasification (UCG) process is elaborated. In order to deploy model-based control strategies, a sophisticated model of the UCG process based on partial differential equations is approximated with a nonlinear control-oriented model that adequately preserves the fundamental dynamic characteristics of the process. A robust dynamic integral sliding mode control (DISMC) is designed based on the control-oriented model to track the desired heating value, which is one of the key indicators for evaluating the performance of an UCG process. Unknown states required for the model-based control are reconstructed using a gain-scheduled modified Utkin observer (GSMUO). In order to assess the robustness of the nonlinear control and estimation techniques, the water influx phenomenon is considered as an input disturbance. Moreover, the underlying UCG plant model is subjected to parametric variations as well as measurement noise. In order to guarantee the stability of the overall system, the boundedness of the internal dynamics is also proved. To make a fair comparison, the performance of the proposed controller is compared with an integral sliding mode control (ISMC) and a classical proportional-integral (PI) controller. Simulation results highlight the effectiveness of the proposed control scheme in terms of minimum control energy and improved tracking error. Moreover, the simulation study shows that the combination of DISMC and GSMUO exhibit robustness against an input disturbance, parametric uncertainties and measurement noise.

Experimental Study of Reverse Underground Coal Gasification

Underground coal gasification (UCG) produces less pollution and is safer than traditional coal mining. In order to investigate the effects of different gasifying agents or comprehensive analyses of the characteristics of the gas components in the three zones for the reverse underground coal gasification process, a model test was carried out. The results showed that the oxygen concentration of a gasifying agent is recommended to be higher than 21%, which will lead to more combustible gases and a higher calorific value of gas. Higher flow rates and oxygen content generally afforded more desirable gas compositions and calorific values, with the latter as high as 1430.19 kcal/Nm3. For the enriched oxygen gasifying agent in the reverse gasification process, the flow increase from 10 to 20 Nm3/h affords a rapid increase in the growth rate of the flame front, from 1.80 to 4.88 m/day, which is much faster than that for the air gasifying agent. Increasing the gas injection rate and oxygen concentration will increase the growth rate of the flame front. This affects the distribution of the three zones and further leads to different characteristics of the gas components.

Determination of random pore model parameters for underground coal gasification simulation

Gasification technologies represent the most viable options of thermochemical processing of solid fuels. They are also characterized by lower emissions and higher efficiency when compared to conventional combustion systems. Particular attention has been paid to underground coal gasification offering the possibility of utilization for energy purposes coal resources otherwise inaccessible for economic or safety reasons. The disadvantage of this process is, however, the difficult control both in terms of technological and environmental aspects. The underground coal gasification process requires investigation of numerous heterogeneous reactions and transport processes, influenced by various process parameters, such as the temperature, type and flow rate of a gasification agent and geological conditions of the georeactor. In the paper a new, alternative way of the determination of kinetics of coal gasification by the Random Pore Model application is proposed. The procedure for determination of model parameters is presented. The structural parameter was estimated on the basis of measurements of char porous structure parameters. The reactivity measurements made for selected Polish coals were applied in determination of kinetic constants. The results of gasification process simulations for determined parameters and Random Pore Model are also given.

A coupled thermal-mechanical numerical model of underground coal gasification (UCG) including spontaneous coal combustion and its effects

Underground coal gasification (UCG) is a promising option for extracting energy from coal in unworked or hard to access areas of the subsurface. From a geotechnical perspective, UCG involves various complex phenomena resulting from the elevated temperatures induced within the rock surrounding the UCG burn. This paper presents a coupled thermal-mechanical numerical model developed to represent a UCG trial in Wieczorek, Poland. Temperature dependent mechanical properties were assigned according to results obtained from laboratory experiments and data available in the literature. The coal burning process was simulated by modifying the energy balance equation with an additional term related to the calorific value of coal as a source. This source term was described using a time decay function to reflect the fact that the energy release from coal gradually decreases with time. The mechanical degradation of coal due to burning was simulated by removing the burned zone from the calculation after a specific time, which depended on zone size and type of coal. In this study, it was found that the maximum temperature at the burning zone was always <1000 °C, which agrees with previous research carried out for other UCG trials. The size of the burning zone was predicted to spread about 15 m laterally after 20 days of burning. Ground subsidence was evaluated for single and multiple (parallel) panel simulations; subsidence at the top of the numerical mesh, corresponding to a depth of 395 m below the surface, ranged from 23 mm for a single panel to 85 mm for seven panels. The degradation of mechanical properties of the rock surrounding the burned zone due to heating was found to have a marginal effect on the ground subsidence when parallel burning was carried out. The numerical modelling results obtained from this study may provide guidance for the design and operation of UCG processes.

Robust multi-objective control design for underground coal gasification energy conversion process

ABSTRACTThe efficiency of an underground coal gasification (UCG) energy conversion process can be increased by maintaining a desired heating value of the product gases. In literature this task has been accomplished by adopting nonlinear model-based control strategies. To exploit the flexibility of the linear control design techniques, a linear model of the UCG process has been developed, which retains the dynamics of the nonlinear model around the operating point of interest. To account for external disturbance and modelling inaccuracies, an output-based robust multi-objective H2/H∞ control law integrated with pole placement has been proposed. The problem is solved by formulating linear matrix inequality (LMI) constraints for performance and robustness. The simulation results show that the designed controller gives adequate performance in the presence of modelling inaccuracies and external disturbance. Moreover, it has been shown that performance of the designed controller is better as compared to the standard PI controller.

The effects of thermal treatments on the subcritical crack growth of Pingdingshan sandstone at elevated high temperatures

Increasing the deeper understanding of the thermal damages and failure mechanisms of sandstone undergoing thermal treatments at different temperatures is a key concern for deep-mining and underground coal gasification processes. In this research study, a scanning electron microscope (SEM) apparatus, JSM-5410LV, which was equipped with a built-in digital electro-hydraulic servo loading system, was applied to carry out a series of three-point bending tests on Pingdingshan sandstone following heat treatments at elevated and high temperatures ranging from 25 to 600 °C. The subcritical crack initiation load, peak load, and elastic modulus were found to increase with the increases in the thermal treatment temperatures until a maximum was achieved at 125 °C, after which decreases were observed. However, it should be noted that there were sudden drops observed for the specimens after the thermal treatment temperature reached 150 °C due to the thermal diffusivity of the cement. The subcritical crack growth length was theoretically calculated, and a digital speckle correlation method (DSCM) was applied to verify the initial load and subcritical crack growth length. It was found that the fracture toughness fluctuated significantly when the thermal treatment temperature ranged from 25 to 125 °C, and reached a peak of 47.45 MPa mm0.5. It was also observed that, as the temperature was raised from 175 to 600 °C, the fracture toughness gradually decreased. The subcritical crack growth mode was determined to be intra-granular cracking following the thermal treatments below 125 °C, while a mixture of intra-granular and trans-granular cracking occurred in the specimens which experienced thermal treatments of 175 °C. The relationship between heat treatment temperature and subcritical crack growth was derived, which could be used to develop geothermal energy extraction from the critical temperature resources.

Coal Seam Gasification in Faulting Zones (Heat and Mass Balance Study)

In this article, the mass and heat balance calculations of underground coal gasification process for thin coal seams in faulting zones of Lvivskyi coal basin (Ukraine) are defined. The purpose of the research is to establish regularities of heat and mass balance changes in faulting zones influence due to usage air and oxygen-enriched blast. A comprehensive methodology that included analytical calculations is implemented in the work. The output parameters of coal gasification products for the Lvivvyhillia coal mines are detailed. The heat balance is performed on the basis of the mass balance of underground coal gasification analytical results and is described in detail. Interpretations based on the conducted research and investigation are also presented. Conclusions regarding the implementation of the offered method are made on the basis of undertaken investigations. According to conducted research the technology of underground coal gasification can be carry out in the faulting zone of stable geodynamic and tectonic activity. The obtained results with sufficient accuracy in practical application will allow consume coal reserves in the faulting zones using environmentally friendly conversion technology to obtain power and chemical generator gas, chemicals and heat.

Investigation of the pollution risk of residues from a laboratory-scale underground coal gasification of Malkara (Turkey) lignite

The aim of this study was to examine the risk of heavy metal, ammonia and sulfate transition from underground coal gasification (UCG) chars and process water of Malkara lignite to the groundwater around the UCG cavity. The residues were collected during laboratory-scale underground coal gasification studies of Malkara lignite in ex situ gasification simulator. In order to compare gasification with combustion in terms of water pollution, ash samples were obtained by combustion of Malkara lignite. To determine the leaching behavior of the char and ash samples, two leaching tests (EPA TCLP and EN 12457-2 methods) were applied. The concentration of heavy metals in char, ash and process water samples was determined by ICP-OES. Additionally, ammonia and sulfate analyses were conducted for process water. Based on the results of this study, it has been found that the concentration of some elements, such as B, Sb and Al in char and ash eluates exceeded the maximum level of drinking water standards. However, there is no landfill concern about char samples according to EU Landfill Directive. A significant increase in B concentration was observed in ash samples. Considering B and some other elements combustion residues were identified with much higher water contamination ability, compared to gasification residues. Ammonia concentration was observed extremely high in process water of the gasification tests. UCG technique may be more environmentally applicable technology compared to combustion for Malkara lignite reserves. However, further detailed studies are necessary in the early stage of the UCG field test design and application.

Monitoring and evaluation of simulated underground coal gasification in an ex-situ experimental artificial coal seam system

In this study, to better simulate underground coal gasification (UCG), an artificial coal seam was constructed to use as a simulated underground gasifier, which comprised coal blocks excavated from the coal seam. This study reports the process and results of three independently designed experiments using coaxial-hole and linking-hole UCG models: (a) a coaxial model using a coaxial pipeline as a gasification channel, (b) a coaxial model using the coaxial pipeline combined with a bottom cross-hole, and (c) a linking-hole model using a horizontal V-shaped cross-hole. In the present work, the fracturing activities and cavity growth inside the reactor were monitored with acoustic emission (AE) technologies. During the process, the temperature profiles, gas production rate, and gas content were measured successively. The results show that AE activities monitored during UCG process are significantly affected by operational variables such as feed gas rate, feed gas content, and linking-hole types. Moreover, the amount of coal consumed during UCG process were estimated using both of the stoichiometric approach and balance computation of carbon (C) based on the product gas contents. A maximum error of less than 10% was observed in these methods, in which the gas leakage was also considered. This demonstrates that the estimated results using the proposed stoichiometric approach could be useful for evaluating energy recovery during UCG.

Sliding Mode Control of Underground Coal Gasification Energy Conversion Process

The control of highly complex and nonlinear underground coal gasification (UCG) energy conversion process is a challenging job. As the process occurs under the surface of the earth, so it is either impossible or very expensive to measure all the important parameters, which further complicates the control design. The input of the UCG process is the flow rate of the injected air and the heating value of the product gas is the output. In this paper, a sliding mode control (SMC) algorithm is designed for a simplified model of an actual UCG process in order to maintain a desired constant heating value. The relative degree of the sliding variable is zero, because the input is readily available in it. As the heating value is the only measurement available, the trivial control design is not possible. Therefore, the time derivative of the control is selected as the system input, and then the relative degree becomes one and the conventional SMC may be implemented. This approach let us maintain the output at the desired level and provides insensitivity with respect to different types of uncertainties. The stability of the zero dynamics is proved, which ensures that the overall system is stable. The simulation results demonstrate the robustness of the SMC design against the input disturbance and the modeling inaccuracies.

Sequential Transformation Behavior of Iron-Bearing Minerals during Underground Coal Gasification

Detailed mineralogical information from underground coal gasification (UCG) is essential to better understand the chemical reactions far below the surface. It is of great scientific significance to study the mineral transformation and identify the typical minerals in certain process conditions, because it may help to ensure the stable operation of gasification processes and improve the utilization efficiency of coal seams. The transformation of iron-bearing minerals has the typical characteristics during the UCG process and is expected to indicate the process parameters. In this paper, UCG progress was subdivided into pyrolysis, reduction and oxidation stages, and the progressive coal conversion products were prepared. Two types of lignite with different iron contents, Ulankarma and Ulanqab coals, were used in this study. The minerals in the coal transformation products were identified by X-ray diffraction (XRD) and a scanning electron microscope coupled with an energy-dispersive spectrometer (SEM-EDS). The thermodynamic calculation performed using the phase diagram of FactSage 7.1 was used to help to understand the transformation of minerals. The results indicate that the transformation behavior of iron-bearing minerals in the two lignites are similar during the pyrolysis process, in which pyrite (FeS2) in the raw coal is gradually converted into pyrrhotite (Fe1−xS). In the reduction stage, pyrrhotite is transformed into magnetite (Fe3O4) and then changes to FeO. The reaction of FeO and Al2O3 in the low iron coal produces hercynite above 1000 °C because of the difference in the contents of Si and Al, while in the high iron coal, FeO reacts with SiO2 to generate augite (Fe2Si2O6). When the temperature increases to 1400 °C, both hercynite and augite are converted to the thermodynamically-stable sekaninaite.

A new model for evaluation of cavity shape and volume during Underground Coal Gasification process

Coal seams are converted to syngas by advanced thermo-chemical processes through Underground Coal Gasification (UCG) method. Inability to predict the shape and volume of the underground cavity is an important scientific gap in UCG method which is the main subject of this paper. For this purpose, firstly, a series of equations are introduced to predict the cavity growth dimensions over time. Subsequently, these equations are extended in numerical simulation of the Computational Fluid Dynamics (CFD), incorporating the commercial COMSOL software. According to the simulation, the amount of oxidant necessary to convert a certain amount of coal (in the heterogeneous phase) is calculated. The model results indicated that the shape and volume of cavity could be predicted at the onset of the gasification process. The numerical results agreed well with the field data.

Integrated analysis of geofiltrational parameters in the context of underground coal gasification relying upon calculations and modeling

Objective of the paper is to substantiate and implement the integrated approach aimed at the studies of filtration and mass-transfer processes within roof rocks of coal seams in the context of their underground gasification. Integrity of the studies is substantiated by the use of analytical calculations as well as physical and numerical modeling. Zones with different permeability have been determined and values of specific water inflow have been identified basing upon the performed numerical modeling and involving multicomponent transformations within roof formation. The research data actuality is in the studies of spatial and temporal dynamics of rock technogenic rock permeability above gasification channel depending upon their geological structure which will favour the substantiation of efficient engineering solutions to control a process of underground coal gasification under difficult hydrogeological conditions.

Sensing underground coal gasification by ground penetrating radar

The paper describes the results of research on the applicability of the ground penetrating radar (GPR) method for remote sensing and monitoring of the underground coal gasification (UCG) processes. The gasification of coal in a bed entails various technological problems and poses risks to the environment. Therefore, in parallel with research on coal gasification technologies, it is necessary to develop techniques for remote sensing of the process environment. One such technique may be the radar method, which allows imaging of regions of mass loss (voids, fissures) in coal during and after carrying out a gasification process in the bed. The paper describes two research experiments. The first one was carried out on a large-scale model constructed on the surface. It simulated a coal seam in natural geological conditions. A second experiment was performed in a shallow coal deposit maintained in a disused mine and kept accessible for research purposes. Tests performed in the laboratory and in situ conditions showed that the method provides valuable data for assessing and monitoring gasification surfaces in the UCG processes. The advantage of the GPR method is its high resolution and the possibility of determining the spatial shape of various zones and forms created in the coal by the gasification process.