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NATIONAL CLEANENERGY

TECHNOLOGIES

Project: Drying Lignites With

The New-Advanced Technology And Burning Without Emission

STINGA PROJECT START DATE: 02/02/1999

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PREFACE

Energy is one of the most important requisites of the modern world, and today,

80% of energy needed for our world is obtained from fossil fuels. Thus, the pollution

of our environment on a life-threatening level obliges more effective methods andtechnologies for transforming fossil fuels into energy.

Patent holder Faik enol zyaman, after 14 years of research and development,managed to invent High Efficiency New-Advanced Coal Burning / Heat Generator

and Drying Systems. Main benefits of this advanced system;

- coal combustion without emission,

-

preventing toxic gases released during the combustion process from pollutingthe environment,

- enhancing coal quality and increasing heat calorie considerably,

- a pioneer not only in Turkey also in the world.

Besides, Stingas new advanced technology enables us to use oil shales that todaystechnology avoids to use due to high emission released during the combustion

process. Uneconomical oil shales were already being produced in USA, and finally

SHELL OIL COMPANY invested to extract high quality oil shales by drilling 7000meters below the ground level in Southeastern Anatolia Region. With our system,

National Clean Energy Technology, using oil shales is highly cost- efficient. Stingastechnology pulverizes the rocks beginning from the surface till the end of whole

reserve without drilling and excavation, and transforms them into energy by burning

them. While transforming pulverized coal into energy costs 130 USD (5500 kg/cal),

production of energy with Stingas technology costs only1 USD .

By using new-advanced technologies broadly in Turkish industry, energy

sources of each region will be eligible to process within its own region, thus

transportation costs of energy and regional energy dependence will be minimized.

Stigmas brand new technology will yield a huge profit for Turkish Energy Industry,and make a great deal of contribution in preventing pollution.

This project is a fruit of 14 years of research and development.

Faik enol ZYAMAN

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The Status Of Coal Production And Consumption

In Turkey And The World

In the modern world, for countries aiming to have a high social welfare,providing efficient and clean energy sources for the nations increasing demand ispolitically and economically the most important power indicator. Therefore,

countries are competing with one another in a struggle to use energy sources in

maximum efficiency and to prevent flue gas emissions. International power struggles

are based on reaching more energy sources. Fossil fuels are main sources of todaysenergy. Despite their efficiency, they are enviromentally hazardous. Thus, countries

are working hard to replace fossil fuels with alternative energy sources and totransform these alternative sources into electric power.

Although the enviromental damages caused by fossil fuels have been ignored

since the beginning of The Industrial Revolution, toxic gases released during

combustion have brought about a serious greenhouse effect. This effect had an

adverse effect on human health, climates and food sources. It posed a serious threat

to the health of socities and the sustainability of the life on Earth in near future. Some

scientists and political entities monitoring these course of events foresaw a disasterfor the world and suggested a deterrent mechanism for the countries who polluted

the world. According to this mechanism, the more a country polluted the world, the

more she paid to the countries who polluted less. Besides, it aimed to restrict the use

of fossil fuels and CO2 emissions. Turkey, along with many countries who already

signed, agreed on the suggested mechanism by signing Kyoto Protocol in 2009.

Patent holder Faik enol zyamansHigh Efficiency New-AdvancedBurning Technology that is designed for burning the coals and other solid fuels,

will increase the energy efficiency and minimize the pollution considerably. It is the

advanced version of Clean Coal and Clean Solid Fuels Burning Technology that is

popular in USA and Europe. This technology was patented;

- in Turkey (TPE 2010/05272),

- in USA on 28/12/2010,

- in Russia on 28/02/2011,

- and in 133 countries.

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Faik enol zyaman, on the basis of new -advanced technologies bearing hissignature, succesfully founded a pilot plant, began the production of new drying and

boiler systems, and finally commercialized them. Stingas system had the support ofSupporting Research&Development Projects in Energy Industry Programme (ENAR)

on June 8, 2010.

Statistically, coal has the largest reserve in the world among many other fossil

fuels (oil, natural gas, etc.) Lignites are younger raw coals when compared to hard

coals. Figure 1 demonstrates the lignite quantities in the coal reserves in Turkey and

the world. As it is seen, when compared to coal reserves in the world, Turkeys lignitereserves are 7 (seven) times more than hard coal reserves.

2012 By Region History

Table 1. Coal Reserves To Production (R/P) Ratios

(Source: BP Statistical Review of World Energy 2013)

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Distribution Of Proved Coal Reserves In 1992, 2002 and 2012

(Source: BP Statistical Review of World Energy 2013)

Coal Production Coal Consumption

Coal Production and Consumption By Region

(Source: BP Statistical Review of World Energy 2013)

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Figure 1. Lignite reserves in Turkey and the world

Based on 2010 General Directorate of Turkish Coal report, total coal production in

the world is 6 billion 900 million, and 6 billion out of 6 billion 900 million coal is

high calorie bituminous coal, and the rest of 900 million coal is low calorie lignite.

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Figure 2. Distribution of lignite production percentages by countries

(Other: 38,7% / Poland 6,3% / Australia 7,0%, Greece 7,1%,

USA 7,2%, Russia 7,5%, Turkey 7,7%, Germany 18,6%)

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Figure 3. Share of primary energy sources in the worlds energy produ ction

Based on stats, the share of the primary energy sources within the world energy

production in 2007. Between 1973-2030, the share of oil production will decrease 1,5

times, but the the share of coal will keep increasing. Considering the share of oil and

natural gas reserves will substantially decrease after 2030, the share of renewable

energy sources and coal is predicted to increase, and this will be possible only with

the application of new high efficiency technologies by drying and burning coals

without emission.

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Figure 4. The distribution of coal reserves by specs in Turkey

As it is seen on Figure 3, it is predicted that the share of oil will decrease 1,5

times between 1973-2030, the share of coal will increase a percentage of 17,6% by

2030. When considered that oil and natural gas reserves will reduce due to

consumption, the share of coal in the world energy production is predicted to

increase along with other renewable clean energy sources. This scenario will be

possible only if advanced high efficiency emission-free technologies are used in the

combustion process of the coal.

Figure 4 demonstrates important specs and values of combustion temperatureof the lignite in Turkey. Calorific value of 90% of the lignite reserves in Turkey is

between 1000 kcal/kg and 3000 kcal/kg.

Having low calorie and high moisture values, these coals are not directly used in

heating. They also decrease the efficiency of thermal power plants of Turkey, and

cause serious economic, enviromental and social problems. Stingas New -AdvancedTechnology Drying System enriches the calorie value of the coal up to 5000 kcal/kg,

thus it both economically and permanently settles the problems.

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The differences between the lignitess and other coal types are that the lignitess

have;

- much more volatility,

- high moisture values,- low calorific value,

These differences prevents the lignites from being used in the factories and

domestic heating. Therefore lignites, to be used ecologically and more economically,

need to be dried with new-advanced technologies, and need to be fully combusted

with minimum emission along with volatile hydrocarbons during the combustion.

Today, there have been serious studies about how to dry and burn coalseconomically and efficiently. Despite lots of studies, curent industrial methods used

in drying and burning of the lignites are not not enough in terms of economical and

technological efficiency. Current drying systems used in the world can decrease the

moisture of lignites having 35-55% moisture level to only 25-30% moisture levels. To

decrease the moisture level down to 15-20% levels, 15-25% of dried coals need to be

combusted to be transformed into flue gases. This process is not economical and

causes serious problems to the environment.

In Turkey and the world, the burning systems used in industrial sector do not

fully combust the coals, thus the combustion efficiency of the coals are not higher

than 60-70%. As a result of inefficient combustion, substantial amount of

uncombasted volatiles, coal particles, carbon monoxides, sulphurs and nitrogen

oxides are released to the air with flue gases. Besides, serious amount of

uncombusted carbon ashes and slags disappear during the process. This is both

economically and enviromentally unacceptable.

Consequently, there have been serious studies and investments in the world

about how to dry and combust coals economically and efficiently. Among these

studies, a system by a Turkish businessman Faik enol zyaman stands out. His long years of works have been developed and updated on the basis of practical and

scientific facts, and applied to the innovation of new-advanced efficient drying and

burning technologies.

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Based upon his experience in mining and coal trade, Faik enol zyaman have been working on getting maximum efficiency from lignites that;

- constitute of 80% of coal reserves in Turkey,

- very low calorific values,- high moisture values,

- inefficient in terms of utilization in thermal power plants,

- ineligible to be used in domestic heating.

Over the course of his works, he has figured out the reason of low combustion

efficiency of these coals is not being able to fully combust the considerable amount of

volatile hydrocarbons in the coal. The high moisture level in these kinds of coals is

another reason. He analyzed the technologies used in burning the volatiles released

during the combustion of the coal, and he realized the current systems used in daily

life and industrial area were not enough to maintain the required emission levels

specified by laws. However, StingasNew-Advanced Solid Fuel BurningTechnology was more than enough to maintain the required emission levels, thus it

left its unique mark on Clean Coal Technology Era. This new system uses oxygen in

the atmosphere to enable the full combustion of the coal, and it periodically releases

the ashes and other organic compounds through the combustion chamber. As aresult of this process, we have 97% percentage of combustion efficiency, and the

overall emission levels (except for CO2) is near 0%.

Solid fuels (lignites, oil shales etc.) that have restricted usage due to legal

obligations will be able to be used as an energy source within the reserves they are

thanks to Stingas new coal drying and boiler technologies. The transportation costsof the energy and regional energy dependency will be minimized.

Based on the stats above, its clear that the system developed by Stinga is alsocrucial for both Turkey and the world. The widespread usage of Stingas systems inTurkey will enable the coal reserves to be more long-lasting.

As a country of which energy needs are increasing gradually, that needs to

finance this needs, and that has problems due to high emissions released during the

combustion of energy sources, Turkey must provide cheap, clean and safe local

energy sources. Thus, the developments in technologies that increase combustionefficiency and their applications to the industry are vital for Turkey.

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Stingas new technology will make a huge amount of contribution both to thenational economy and to the fight against pollution. The details about this technology

is given below.

Figure 5. The scheme of New Technology Drying Unit

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New-Advanced Drying Technology

Based on Stingas new -advanced technology, the process of drying takes placein a horizontal sylindirical unit. Working principle of Drying Unit is schematically

demonstrated on Figure 5. First, wet coals are crushed in the grinder, and they are

filtered. Then the fractions having particle sizes are sorted, and forwarded to

revolving drying unit.

When compared to current drying technologies in the industry, one of the

most important features of Stingas new drying unit is that it crushes and pulverizesthe coal particles with specially designed pallets, thus the moisture within the coal

particles will be easily disposed. These pallets can also push the coals to the exit with

a certain speed.

The hot flue gases required to dry the coals are obtained in new boiler systems

developed by Otes Energy, and then forwarded to the Drying Unit. Details about the

new boiler systems developed by Otes Energy are below. Flue gases and water vapour

released during the drying process are released through cyclone.

Another important feature of the Drying Unit is that a certain amount of water

vapour can be released to the atmosphere by directly being absorbed through

different points of the unit. This enables the coal to dry deeply and faster.

Another the working feature of the unit is that moisture value, free from the

moisture value of the coal to be dried, can be decreased to the intended level (even

down to zero) with minimum energy consumption. This feature, depending on the

temperature of dry coal, can be adjusted with special automation system and in

accordance with technological factors below:

- forwarding speed of the wet coal into drying unit,

- moisture value of the wet coal,

- revolving speed of the Drying Unit,

- amount and temperature of flue gases forwarded into the Drying Unit.

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Though the temperature of the flue gases released into Drying Unit is 900-

1100 C, the flue gases released from the unit is 60-70 C. The temperature of the dry

coal is around 90-130 C. This is only possible with Stingas Drying Units special working principle, its design and the transfer of a high level of heat from the flue

gases to the wet coal.

Based on the results we have, for 1 (one) ton of coal, it is enough to obtain the

same amount of energy by burning 2-2,5% of the coal. This system, when compared

to other drying systems in Turkey and the world, is 8-10 times lower. According to

the resources about the world energy industry, only 17% of moisture can be absorbed

at a time. However, with the new system, 50% of moisture can be absorbed at a time.

This proves the fact that Stingas new -advanced drying technology is much moreefficient than many other systems.

When compared to the other drying systems in the industry, new-advanced

drying system can dry coal fractions having different kinds of sizes (0-80 mm)at

certain levels.

Based on the results of tests done in the laboratories of The General

Directorate of Turkish Coal; when a coals 50% moisture is decreased to 5%, its

calorific value increases by 50 for every one percent (1%) of moisture. When themoisture of a coal having 50% moisture is completely absorbed, calorific value of one

(1) kg of coal increases 100%, and the amount of volatile gases increases 90%.

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Figure 6. Interior design of new technology boiler system

New-Advanced Technology Coal Burning System

In the thermal power plants, the coals are burnt in either atomizing boilers or

fluidized-bed boiler. The most serious problem with these kinds of boilers is that

coals and the volatile hydrocarbons in the coals can not be burnt completely, and thus

flue gases, substantial amount of volatiles, slack particles and carbon monoxide are

released directly to the atmosphere. Furthermore, the ash contains a big amount of

slag (70%) and there is a 15% of unburned carbon in it. Flue gases and slack particles

pile up on the exterior surface of serpentines put inside of the boiler to get water

vapour, and this dramatically decreases the thermal efficiency and energy efficiency.

Therefore it causes serpentines to be replaced more often. This whole process pose

problems both economically and environmentally.

Stin gas Coal Drying System can decrease 50% moisture rate of a coal down to0%. For this process, burning of only a 2-2,5% of the whole coal processed is enough.

By this means, calorific values of the lignite reserves that constitute 80% of the whole

countrys coal reserves will be increased and the country will gain importantcommercial profits.

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In Stingas new boiler technology,the process of coal burning takes place in a vertical fixed sylindirical boiler system. This boiler system differs from the current

boiler systems in the industry with its unique special design, working principle and

working conditions. Besides, Stingas boiler technology solves all the problemspointed out above.

Working principle of the boiler system is schematically demonstrated on

Figure 6. Dry coal is filled by air and a spiral system through a hole under the boiler

system. Combustion of the oil takes place on a special layer inside the boiler. The

ashes pour down the edges of the layer, pile up in the storage and they are

periodically expurged out of the boiler. The temperature of the flue gases coming out

of the boiler system is adjusted by the amount of the coal filled into the boiler and the

amount of the air in it.

Another important difference from the current boiler systems in the industry is

that there is a special ceramic reflector above a certain level from the combustion

layer. This reflectors roles are as below: - redirects the heat to the combustion layer by preventing it from being disposed

with the flue gases, and thus increases the thermal efficiency and the internal

temperature up to 1400-1800 C,- directs radiation beams forming in the high temperature (1400-1800 C) to the

combustion layer,

- reflects the flue gases and slack particles back from the reflector surface,

directs them to the combustion layer and makes them fully combust,

- thanks to the flame ring between the combustion layer and the reflector,

prevents the organic volatiles from disposing out of the boiler without

combusting together with the flue gases to the atmosphere, and makes themfully combust.

One of the important features of the New Boiler System is that, distinctly from

the current boiler systems in the industry, it can function in higher temperatures

(1400-1800 C instead of 1000-1200 C). This can prevent the toxic gases (SO 2, S0 3,

NO2 etc.) that are hazardous to the human health and environment.

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This case has been proved by the stats based on the Gibs free energy values

obtained through thermodynamic calculations. It also shows that, on 1000-1200 C

temperatures, the possibility of transformation of organic sulphuric compounds

(mercaptan, thiophen, etc.) and and inorganic sulphuric compounds (elementary

sulphur, pyrryl, etc.) into SO 2 and S0 3 gases by combining with the oxygen of the

water is thermodynamically high. Besides, under these circumstances, it shows that

the possibility of transformation of the nitrogen within the air into the NO 2 can be

thermodinamically high.

Figure 7. Beam Reflections of Old and New Boiler Systems

When temperature increased up to 1800 C, the possibility of formation of

these gases like SO 2 and S0 3 considerably decreases. Consequently, in the New Boiler

System developed in line with the current boiler systems in the industry, the

transformation of sulphuric compounds into toxic gases is much lower (20-30 times

lower).

Stats based on the industry and the results of analyses made in our pilot plant

proves this thermodynamic data. Within this system, when even the coals with high

sulphur (up to 7%) are burnt, the sulphur oxide released during the combustions is

much lower when compared to the other boiler systems in the industry.

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The sulphuric compounds within the morphologic structure of the coal is seen

to pile up in the ash as elementary sulphur. Therefore, this system has a crucial role

in minimizing the environmental pollution that is the one of the biggest problems of

the human kind.

In the thermal power plants running with lignites, the flue gases having big

amounts of SO 2 and S0 3 gases pile up on the exterior surface of serpentines, and this

dramatically decreases the thermal efficiency and energy efficiency. Therefore it

causes serpentine to be replaced more often. This whole process pose problems both

economically and environmentally. The widespread usage of the coals with high

moisture as fuel causes high levels of water vapours to form, and thus SO 2 and S0 3

gases increase the corrosion effect on the serpentines. Based on stats, in Turkey,

250.000 meters of pipelines in the public thermal power plants are replaced with new

ones each year. This causes huge financial loss in thermal power plants.

New Boiler System can also be used as a high efficiency heat generator with several

different purposes (heating, obtaining hot water, production of electrical energy,

etc.).

Figure 8. Schematical View of Special Serpentine System in New Boiler System

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As a result of high heat transfer and the serpentines not corroding, the length

of pipe is minimized considerably. The view of the New Boiler System is

demonstrated on Figure 9.

Stingas Boiler System has the following superior features when compared to othercoal boilers in the industry:

- the efficiency of the coal is very high (95-97%)

- volatile hydrocarbons in the fuel gases do not form, and the slack particles are

around 0 (zero),

- toxic carbon monoxides, sulphur oxides and nitrogen oxides are at minimum

levels (consecutively 30-50 ppm / 8-15 ppm / 15-25 ppm),

- the uncombusted carbon level in the ash is at the minimum levels (0,5-1%),

and there is not any slag,

When serpentines do not work for a long time, the surfaces of them are not

covered with slack particles and do not corrude due to SO 2 and S0 3 gases. Since

Stingas new boilers are designed to burn all the volatile gases, it substantiallyincreases the combustion efficiency and minimizes the emission values.

Sulphur amount in the emission values is crucial. Owing to the design and working

principle of Stingas new boiler system, sulphuric compounds requiring expensive

filters to keep the flue gases transform into elementary sulphurs and they turn out to be below the legal sulphuric emission levels. Details are on the research reports by

Gebze Institute of Technology.

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Figure 9. View of the New-Advanced Boiler System

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In the current boiler systems, the combustion efficiency of the coal varies

between 60% and 70%. Based on the stats, this low combustion efficiency stems from

the fact that only 10% of the volatile gases within the coal can be burnt. In StingasNew Boiler System, the combustion efficiency (carbon+volatile gas) is around 97%.

The amount of carbon in the ash is very low, and since all the volatile gases are burnt,

there is no smoke out of the flue. PLC controls of the design have been made and its

programme consists of 15.000 pages. Its programme enables us to feed the solid fuels

to the combustor proportionally. PLC enables our new boiler system to work at

minimum capacity and to control the liquid oil more proportionally.

Since it keeps the pressure at a constant level and saves up energy, it works

and produces at a certain standard. However, in the old systems, assuming the

required pressure is 10 ATU, when the system reaches 10 ATU, it stops at 10 ATU.

When the pressure decreases down to 8 ATU, it begins to work again. There will be a

20% deviation due to this bar gap, and it not only affects the quality of the product

but requires maximum energy to rise up from 8 ATU to 10 ATU again. However,

Stingas new technology keeps it at a constant 10 ATU, there will be no extra energyconsumption.

The Drying And Burning Of The Coals WithThe New-Advanced Technology, Its Implementation

In Our Pilot Plant, Its Industrial Performance

Based on Stingas New Technology designed for drying and burning of thelignites (high moisture -low calorie), the first pilot plant was established in

Tavas/Denizli, Turkey and the plant has been succesfully running since then.

The capacity of this plant;

- 30 ton/hour for wet coal,

- 20 ton/hour for dry coal,

The dry coal produced in the plant is offered to the market for domestic heating

and industrial usage.

Pilot plant consists of two main sections;

- Boiler System; obtains hot flue gases by burning dry coal,

- Drying System for wet coal,

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The details about technological features and working principles of these two

sections are explained above. The view of the pilot plant is on Figure 10.

In the pilot plant, mostly the wet lignites from Tavas Coal Mine, Denizli are

processed. Besides, different kinds of coals without depending on their morphological

structure, physical and chemical features are used in the plant.

We, as Stinga, forwarded formal applications to the concerned government agencies

for widespread usage of Stingas new technologies in Turkey that has many importantlignite reserves.

As a result of our applications, in 2011, expert teams from The General

Directorate of Turkish Coal (TK) inspected our pilot plant 3 (three) times by drying 3(three) different kinds of lignites, did lots of tests, and in the light of the results from

TKs laboratories, the high efficiency of New Boiler and Drying Technologies has been formally proved. In all of 3 (three) drying tests, expert teams used the lignites

(dried in the pilot plant and with a moisture of 5-10%) from Tavas/Denizli Coal Mine.

As a result of the tests, the reports by the expert teams were sent to the TK. Somedetails about the tests mentioned above are demonstrated below.

Figure 10. View of Tavas/Denizli Industrial Pilot System

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Table 2. Analysis Results Of Lignite From Tavas Dried In Pilot Plant

Sample Moisture Ash Volatile Lower Cal. Value Sulphur

Dry Basis Dry Basis

T1 44,54 42,75 42,57 2192 3,02

T2 39,6 40,27 41,5 2284 3,1

T3(50) 29,24 42,49 36,04 2514 2,1T3(75) 21,74 41,7 36,55 2685 2,17T3(110) 16,26 38,45 37,89 3469 3,6T3(140) 4,79 36,76 38,14 3617 3,07

The first test of the pilot plant was done in September 2011 by the experts from

Seyit mer/Ktahya. In this test, original lignite (42,5% moisture) from Tavas CoalMine was used. The analysis results of the report based on the tests by experts from

Seyit mer are demonstrated on Table 2.

Table 3. Analysis Results Of Lignite From Seyit mer/Ktahya Lignite Enterprises Dried In Pilot Plant

Sample Moisture Ash Ash Volatile Sulphur Lower Cal. Value Lower Cal. Value

Original

Basis

Dry

Basis

Dry

Basis

Dry

BasisOriginal Basis Dry Basis

S-1 39,84 23 38,23 36,41 1,57 2121 3907

S-2(66 ) 15,92 30,44 35,74 38,27 1,76 3250 4004S-2(85 ) 13,71 29,38 33,77 38,8 1,78 3446 4100

S-2(112) 6,59 30,6 32,76 41,18 2,34 3633 3930S-2(128) 4,09 33,72 35,24 39,05 2,02 3678 3856S-2(140) 2,37 34,19 35,1 39,16 2,63 3884 3989

S-3 17,32 28,63 34,63 38,97 1,87 3225 4021

S-4 21,28 29,15 37,08 38,21 2,02 3047 4033

S-5 20,75 35,59 44,91 35,96 2,32 1794 2414

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Table 4. Analysis Results Of Lignite From Ilgn/Konya Dried In Pilot Plant

ORIGINAL

Sample Exit Temperature Moisture Ash Volatile Sulphur Lower Cal. Value Higher Cal. Value

(C) (%) (%) (%) (%)

0,-8mm 45,5 15,94 23,61 3,57 2096 2480

(0,8mm-) 135 2,47 17,81 41,83 4,82 4224 4432

(+8,-20mm) 56 26,6 21,32 31,2 5,24 3070 3384

(0,-8mm) 122 3,2 23,81 42,27 5,52 4535 4771

(+8,-20mm) 52 36 15,1 28,71 4,61 2832 3188(0,-8mm) 80 14,14 25,55 35,39 4,22 3582 3842

(+8,20mm) 45 36,47 16,02 27,33 3,83 2749 3102

DRY

Ash Volatile Sulphur Lower Cal. Value Higher Cal. Value

(%) (%) (%)

29,25 43,32 6,55 4333 4550

18,26 42,89 4,94 4345 4544

29,05 42,5 7,14 4394 4610

24,6 43,67 5,7 4704 4929

23,59 44,86 7,21 4753 4982

29,67 41,22 4,91 4268 4475

25,21 43,02 6,03 4661 4883

The 3rd test of the pilot plant was done in 18 November 2011 (same day with

the 2nd test) by the experts from Ilgn/Konya Coal Mine. In this test, 25 tons of wetlignite from Konya Ilgn Coal Mine was used. The analysis results of the report based

on the tests by experts from Konya Ilgn Coal Mine are demonstrated on Table 4.

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As seen on Table 2-4, when the exit temperature of the coal from the drying

unit is around 135-140 C, the moisture value of the coal from Tavas Coal Mine is

4.79%, Ktahya Seyit mer Coal Mine is 2.37%, and Konya Ilgn Coal Mine is 2.47%. The more the moisture rate of the coal dried in the pilot plant fell, the less the amount

of ash was. By means of the palletsspecially designed in the drying unit, the coal can

be micronized into smaller particles, and the inorganic compounds within the coal

are released, and they are transferred to cyclone through suction fans. The sum of

the slacks from both cyclones contains more ash than the coal dried in the drying

unit. New drying unit not only dries the coal but also purifies the coal from its

inorganic compounds and enriches it. Table 2-4 demonstrates that the new drying

unit increases the calorific values.

Along with the tests done in the pilot plant, some other researches in which

various chemical and physical methods like DTA-TGA, XRD, EDX, etc. used were

done by Gebze Institute of Technology.

Based on the results of these researches, some performances of Denizli Pilot

Plants on drying and burning of the coals have been clarified, and some additionalaspects are demonstrated as below:

- lignites, without depending on their morphological structures, contain volatile

matters and isolating them from the structure of the coal begins at 200 C and

ends at 525 C,

- full combustion of the carbon within the lignite occurs at 620-670 C,

- when the moisture rate of original lignites, without depending on their

moisture level and structural specifications, is lowered down to 5% or less bydrying, the system can absorb the atmosphere moisture till it reaches bodymoisture (around 9-11%), and this moisture rate does not change,

Based on the results of various trials and tests, the required heat and electric costs

to get 1 (one) ton of dry coal in an hour with new technology system from the lignites

(40% moisture) are given below:

- the amount of coal to get hot flue gases in the new Boiler System is 30 kg (3%

according to the coal dried)

- the amount of electric power is 1,25 KW/hour.

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According to initial calculations, when the labour cost is added to the calculations

above, the required cost to get 1 (one) ton of dry coal from the lignite (40% moisture)

is given below:

sales cost of 30 kg coal

dried in boiler

0,30ton*70tl/ton 2,1 tl

the cost of electric energy 1,25kw*0,16tl/kw 0,2 tl

the cost of labour and others 1,2 tl

3,5 tl/ton

As a result, to get 1 (one) ton of dry coal from the wet lignite with the new

drying technology, the required drying cost is only 3% of the sales price of the dried

coal. Considering the average sales price of the original wet coal and dried lignite in

Turkey (consecutively 41 tl/ton and 108 tl/ton), the profit rate of sales of 1 (one) ton

dried coal; [108 (41 + 3,5) = 63,5 tl/ton]Consequently, with the application of new technological methods, the profit of a plant

producing 100.000 tons of dried coal: (100.000 ton * 63,5 = 6.350.000 tl/year)

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Technological and Economical Principals Of

The Application Of The New Drying

And Burning Systems In The Industry

Unfortunately, all of the required oil, natural gas, LPG and LNG to meet the energy

demand of Turkey is imported. In Turkey, for heating, the boilers used in the

residences have 20.000 kcal capacity, and the boilers used in the central heating

systems have 2.000.000 kcal capacity.

The energy sources used in these boilers are mostly fuel oil, diesel fuel, LPG, LNG and

natural gas. 70% of the required fuel for the heating of the residences is met through

import. The energy consumption in Turkey increases 3,7% each year, and the external

energy dependences of Turkey on natural gas and oil are consecutively 98% and 91%.

The energy production mostly based on oil and natural gas is rapidly running short.

Recent stats show that oil reserves will last for 50 years, the natural gas reserves will

last for 40 years.

The energy need in Turkey is mostly met through these two imported energy sources.

It is foreseen that the energy import in 2012 will be 60 billion dollars. It is inevitable

that it will keep increasing. The lifespan of the coal reserves in Turkey is estimated to

last for 220 years. The drying of these coals in the thermal power plants with the

current technologies is not economically efficient. Besides, it causes serious

enviromental problems. Due to the low calorific value and enviromental hazards of

our coal reserves, these coals were prohibited to be used for residential heating. Thestatistical data given above are excerpted from Minister of Energy Mr. Taner Yldzs2011 budget speech at The Grand National Assembly of Turkey.

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Within the scope of measures to prevent pollution, some standards for the coal are

set. The specifications of the imported coals are demonstrated as below:

Calorie : 6000 kcal/kg and higher

Sulphur : below 1%

Ash : maximum 15%

Volatile : between 17% and 27%

Since our local coal reserves do not have those specifications, quality coal demand is

met through imports. The import of lignite increases not only the external energy

dependence but also the cost per calorie when transportation costs are included. Toillustrate, the quality coals imported from Siberia are transported to the railroad by

the trucks, then they are transported to the ports by the railroad, and finally they are

transported to our ports in Turkey by the ships. Then they are transported to the

nearest screening and packing facility, and they are distributed to the whole Turkey.

Besides, even the quality domestic coals in Zonguldak, Soma, Tunbilek might betransported to the regions 600 km away.

Pulverized coal can not be burnt in the boilers having a capacity less than 5.000.000cal. However, Stingas new technology boilers can burn domestic pulverized coal witha capacity up to 5.000.000 cal, and it can burn domestic coal with more efficiency

than imported coal. The volatiles within our domestic lignites (30-45%) are more

than the volatiles within the imported coal (17-27%). Since the current boiler

Technologies can burn only 9% of the volatiles within the coal, The Ministry of

Forestry imposed bans on flue gas emissions. In our new technology boilers, all of the

volatiles can be burnt. Thus, there will be no need for restrictions or bans on flue gas

emissions.

While the whole Europe uses pulverized coal, Turkey uses lump coals (above 20 mm),

but pulverized coal is much cheaper than lump coals. While the price of pulverized

coal is 165 USD, the price of lump coal is around 350 USD. Thus, the import of lump

coals increase the energy costs and trade deficit considerably in Turkey.

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This increased production cost stems from the fact that Turkey uses lump coals. With

Stingas new technology, we will be able to burn both the domestic pulverized coalsand imported pulverized coal, and thus the cost of importing will decrease.

The development of systems for efficient usage of solid energy sources (lignites, oilshales, etc.) and for the protection of environment, and the application of these

systems within the industry are economically, strategically and socially crucial.

Coal reserves in Turkey have low calorie and high moisture. The design of our system

is done accordingly to the coals having low calorie and high volatile level. This system

will prevent the current burning systems and heat generators that can not use

domestic coals, but are designed for the imported coals having high calorie. Since our

system will use domestic coals and even reuse waste coal, it will minimize both the

importation of coal and the importation of all energy and raw energy materials. The

trade deficit arising from the importation of raw energy materials will decrease

considerably.

The purpose of the new technologies designed by Stinga is to enable us to utilize the

coals and other solid energy sources that can not be used efficiently. Based on

Stingas new technology, the potential of producing energy and electric will increase,and the external energy dependence will decrease. Since Turkey will produce high

efficiency and cheap energy, the cost of heating and electric will decrease. It will

prevent toxic gases that are hazardous to the environment, and flue gases related

intoxication.

Our main target groups for new technology are industrial enterprises using heat

generator for heating and producing energy, residences and thermal power plants.

Since enviromental values are protected with low emission levels by our system, the whole nation is our main target group. Considering flue gas emissions and air

pollution, the situation of the industrial regions in Turkey is underwhelming.

In our country, there are coal mines and lignite plants having low calorie coal

reserves, and these coal can not be processed. With the new system, 11 billion tons of

lignite reserves will be burnt efficiently and will be a valuable asset fort he economy.

It will also increase the lifespan of the reserves from 220 years up to 1000 years.

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Besides, with the application of these new technologies developed in our country for

the industries in the world, the lifespan of the fossil sources in the world will

substantially increase. Thus, it will prevent the energy depletion that is the reason of

energy wars, and it will enable people to live in welfare and peace.

With the current Technologies applied in thermal power plants in Turkey using

lignite as fuel, even though the wet coal is extricated from the moisture before being

fed to the combustion unit, the coal is fed to the combustion unit with the extricated

water vapour. In the analysis done in Ktahya Seyit mer Thermal Power Plant on19.11.2011, we reached the conclusions below about the serious economic and

environmental problems caused by the situation above:

- 1-2% of the dry coal is released to the air with the flue gases in the combustion

boiler,

- the ash coming out of the boiler contains 4-5% unburned carbon,

- due to the high moisture level in the boiler, a substantial amount of the dry

coal combines with the inorganic substances and they become slag. The

amount of this slag is 70% of the ash, and there is 15% of unburned coal in the

ash and slag combined.

- since the coal is not fully combusted, there forms carbon monoxide, and theyare released to the atmosphere with a proportion of 60-100 mg/m3,

- the coal that combusts in the boiler has low combustion efficiency, and this

efficiency is around 80-85%,

- the flue gases having big amounts of SO2 and S03 gases pile up on the exterior

surface of serpentines, and this dramatically decreases the thermal efficiency

and energy efficiency. Therefore it causes serpentines to be replaced more

often. This whole process pose problems both economically andenvironmentally.

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Some economic inputs have been conjecturally calculated in the event that the wet

coal in Seyit mer Thermal Power Plant is dried beforehand and then used in thisplant:

- The amount of water in the lignite (40% moisture) that is used 800 tons perhour in ST Plant is:

(800 ton * 0,4 = 320 ton)

- However, when the coal is dried beforehand and its moisture level is lowered

from 40% to 10%, the amount of water would be:

(800 ton * 0,3 = 240 ton)

-

Since the required amount of heat to vaporize 1 kg of water is 550 kcal, therequired amount of heat energy to vaporize 240 ton of water:

(240.000 * 550 = 132.000.000 kcal)

- Since the combustion heat of 1 kg lignite used in thermal power plant is 2120

kcal, the amount of coal to get 132.000.000 kcal heat energy:

(132.000.000 : 2120 = 62.264 kg = 62 ton)

- The required amount of heat to heat 240 tons of water vapour from 100 C up

to 1200 C:

[240.000 * 1 * (1200-100) = 264.000.000 kcal]

- The required amount of coal to get 264.000.000 kcal in the boiler:

(264.000.000 : 2120 = 124.528 kg = 125 ton)

- The amount of coal to vaporize 240 tons of water within the wet coal, and to

heat it from 100 C up to 1200 C:

(62 + 125 = 187 ton/hour)

or

(187 * 24 = 4.488 ton/day)

or

(4.488 * 365 = 1.638.120 ton/year)

- Considering the average sales costs for 1 (one) ton lignite used in the thermal

power plant is 41 TL, the yearly value for 1.638.120 tons of coal: (1.638.120 *

41 = 68.884.920 = 69 Million TL)

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Based on the inputs we have, the amounts of ash, slag and flue gases formng as a

result of coal combustion, and the amount of missing coal are calculated below:

- Since the ash rate within the lignite used in the thermal power plant is 23%,

the total amount of ash in an hour:

(800 * 0,230 = 184 ton)

- Considering the slag rate is 70% when compared to the amount of ash, the

amount of slag in an hour:

(184 * 0,7 = 128 ton)

-

Considering the amount of unburned coal within the ash and slag is 15%, thetotal amount of missing coal in an hour:

[(184 + 128) * 0,15 = 46.8 ton/hour]

or

1123,2 ton/day OR 409.968 ton/year

- Considering the amount of dry coal missing with the flue gases is around 1%,

the amount of missing coal in an hour:

(800 * 0,1 = 8 ton/hour)

or

192 ton/day OR 70.080 ton/year

- The amount of total coal missing with the flue gases, slag and ash in a year:

(409.968 + 70.080 = 480.048 ton)

- Considering the sales price for the original lignite is 41 TL/kg, the value of

480.048 ton coal:

(480.048 * 41 = 19.681.968 = 20 Million TL)

- The savings (in a year) in the event that the lignite (40% moisture) used in

ST Plant is burnt by lowering the moisture rate down to 10% moisture:

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Coal Saving: (1.638.120 + 480.048 = 2.118.168 ton)

Economic Saving: (69 + 20 = 89 Million TL)

The heat energy obtained by using wet coal in thermal power plant for 1 hour:

(800.000 * 2121 = 1.696.800.000 kcal/hour)

The required amount of coal to obtain 1.696.800.000 kcal/hour heat energy:

(1.696.800.000 : 3650 = 464,88 = 465 ton/hour)

The amount of original lignite that can be saved in 1 hour:

(800 465 = 335 ton/hour)

or

8040 ton/day

or

2.934.600 ton/year

Savings made:

(2.934.600 ton * 41 tl = 120.318.600 TL 120 millon TL)

The total savings to be made in 1 (one) year when used dried coal instead of wet

coal with the new drying technology in ST Plant: Coal Saving: (2.118.168 ton + 2.934.600 ton = 5.052.768 ton = 5 million ton)

Monetary Saving: (89 million tl + 120 million tl = 209 million tl)

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Considering the average amount of coal burnt in ST Plant is 7 (seven) million tons, with the new drying technology, 70% of the coal will be saved. The total savings to be

made in 1 (one) year in the thermal power plants (12 public plants that use 80 million

tons) that use the same technology with ST Plant:

Coal Saving: (80.000.000 ton * 70% = 56 million ton)

Monetary Saving: (56.000.000 ton * 41 tl/ton = 2.296.000.000 tl)

According to first calculations, since ST Plant and other thermal power plants inTurkey use high moisture coal, the serpentines within the boilers are corroded due to

high moisture, and thus they need to be replaced more often. This phenomenon

causes serious economical loss.

Another important feature of the thermal power plants is their electric energy

efficiency, that is the conversion rate of the heat (obtained by fuel combustion) into

electric energy. This rate, in thermal power plants using lignite in Turkey, is between

25% and 35%, and it is not more than 40% in the world.

The usage and energy efficiency of the dried coal obtained with the application of our

new drying technology within these thermal power plants substantially increases. The

elect ric energy efficiency of ST Plant according to the coal burnt:

a) Heat energy obtained in 1 (one) hour:

(800.000 kg * 2121 kcal/kg = 1.696.800.000 kcal)

b) Heat energy to obtain 1 (one) kwh:

(1.696.800.000 kcal : 600.000 kwh = 2.828 kcal/kwh)

c) Current energy efficiency of the thermal power plant:

[(860 : 2.828) * 100% = 30.4%]

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The energy efficiency to be reached when the dry coal dried with the new drying

technology in ST Plant is used:

a) Heat energy obtained in 1 (one) hour:

(240.000 kg * 3650 kcal/kg = 876.000.000 kcal) b) Heat energy to obtain 1 (one) kwh energy:

(876.000.000 kcal : 600.000 kwh = 1.460 kcal/kwh)

c) Electric energy efficiency that the thermal power plant can reach:

[(860 : 1.460) * 100% = 58.9%)

By the application of new drying technology in Seyit mer Thermal Power Plant, theelectric energy efficiency will double. This energy efficiency is much higher than the

current electric energy efficiencies of the thermal power plants using lignites in both

Turkey and the world. The biggest problem in the current thermal electric plants is

not to be able to get rid of SO2 and NO 2 emissions. There have been ongoing

researches on developing cyclical fluidized bed technologies to minime these

emissions. However, these researches are not enough, and they cause high operating

and filtration costs. The current situation in the cyclical fluidized bed technologies is

The Ultra Supercritical Boiler that is projected to be more efficient than the current

technology. This technology extricates the nitrogen within the air, runs with oxygenand as a result, increase the combustion efficiency. However, The Science Magazine

(Issue 18, April 2009) co- published by Dumlupnar University and Gazi Universityshows that:

This system obtains oxygen by using 20% of the energy it produced. The 20% energy

is planned to be used to increase plant efficiency. Even though it solves emission

problems, an increase in efficiency of the thermal power plants is not possible today,

and thus it is not economically efficient.

Fluidized Bed, Supercritical, Ultra Supercritical Boilers have low efficiency and

unsolved emission problems. We analyzed the process from the end to the beginning,

and detected that the problem is not during the combustion, but just before the time

the coals are feeded to the boiler. This is the main basis of New-Advanced High

Efficiency Drying Technology. This is the main answer as to why the moisture rate

can not be lowered from 50% to 0-5% with low costs.

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Our technology resolved this problem. As a result of the decrease in the moisture, the

required amount of air decreased 70%, and this provided some benefits:

- Decreasing the moisture within the coal (45-50%)

- Increasing the calorific value (100%)- Decreasing the amount of coal (70%)

- Decreasing the combustion air (75%)

- Decreasing Water Vapour (94%)

Our study based on the data from Seyit mer Thermal Power Plant is demonstratedas below. We would like to emphasize the fact that the moisture decrease (down to

10%) is taken into consideration while the efficiency is calculated. However, the table

below shows that the moisture of the coal is reduced to 5%. The usage of only 5%

moisture coal will itself contribute 54 million TL to the economy.

Unit Current State New Technology

Fuel Type kcal/kg 2.120 3.850 Amount of Moisture % 40 5

Burned Coal ton/day 24.000 6.000

Burning Air m3/day 120.000.000 30.000.000

Water Vapour ton/day 8.000 325

Vapour Related Emission Reduction 94%

Yearly Amount of Fuel Consumption ton 8.640.000 2.160.000

Yearly Cost of Fuel Consumption tl 359.160.000 96.120.000

The sum of decreasing operating costs and profit earned due to only drying coal is

263.040.000 tl.

New Boiler System can also be used as a high efficiency heat generator with several

different purposes (heating, obtaining hot water, production of electrical energy, etc).

The thermal power plants in Turkey use 30.000.000 ton/year coal for industrial and

heating purposes. These coals are mainly imported coals and lignites that are

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transported to the different regions of Turkey. The yearly transportation costs of

these coals economically damage the country. The extent of the damage is

approximately demonstrated below:

a) When the original lignites (40% moisture) are dried in new technology high

efficiency heat generator;

i. A unit of 4535 kcal/kg coal is obtained from a unit of 2096

kcal/kg. (Source: Analysis Report by Ilgn Coal Operating)

b) 18.000.000 ton coal can be obtained from 30.000.000 ton original wet lignite.

The average price per ton of original wet lignite is 35 tl.

Considering the drying costs with new technology is 3,5 tl:

(30.000.000 ton * 35 tl/ton = 1.050.000.000 tl)

Considering the average sales price for dried 0-80 mm coal is 200 tl/ton:

(18.000.000 ton * 200 tl/ton = 3.600.000.000 tl)

Industrial sales value increase:

(3.600.000.000 tl 1.050.000.000 tl = 2.550.000.000 tl)

The diesel fuel per kilometer saved due to decreasing tonnage (12 million ton coal

from 30 million ton) is 0.50 lt. Considering there will be 600.000 runs with trucks(20 ton capacity):

(600.000 run * 0.50 lt/run = 300.000 lt)

Considering the average transportation distance is 600 km:

(300.000 lt * 600 km = 180.000.000 lt)

(180.000.000 lt * 3,5 tl/lt = 630.000.000 tl)

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Thus, the overall cost saving from the fuel will be 630.000.000 tl. Considering the

loading costs and amortization costs, the saving will be 3.180.000.000 tl.

Considering 12 public thermal power plants and the economic saving demonstrated

above, the overall saving for the whole country could be:

(2.296.000.000 + 3.180.000.000 = 5.476.000.000 tl = 5,5 billion tl)

Oil shales of which our country has big reserves can be burned in Stingas NewTechnology Boiler System besides coals. Recently our company has bought an oil 700

hectare oil shale field. Its height is 200 meter, and there is a 20 meter of top soil. We

picked samples from both the heighest and lowest layer of the field, and applied some

tests by burning them. Our tests demonstrated that the whole reserve is ideal to use.

In the samples from various parts of the field, the volatile gas rate is 35-75%, and the

calorific value is 1400-1800 kcal. In a study made by the French in 1939, the fuel

content is around 2.7%. Since our technology burns the whole oil shale and when it is

added to the calorific value, there seems no energy loss. The ashes released during the burning of oil shales can be used as an additive in the quality cement and in soil

amendment in agriculture.

Oil shales have been researched only for the purpose of producing oil, and only the oil

shales reserves having high oil content have been included in these studies. However,

the oil shale reserves having 35-75% volatile gases and low oil content have been

shown to be 20 times more than the oil shale reserves havinh high oil content. While

our oil shale reserves having oil content were 850 million ton according to researchestill 2009, the researches in 2011 showed that our oil shale reserves had 26 million ton

capacity. Since the fields having oil shale reserves do not have ground cover, they can

be extracted from the ground without explosions. Since they have low moisture (1-

3,5%), there is no need to dry them, and they can easily be burned in our new

technology boilers, and transformed into energy. The costs till the process in which

they are transformed energy are at minimum level.

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RESULTS

1- Based on our practical and scientific studies for years, as a pioneer in Turkey

and the world, New High Efficiency Drying and Burning Technology Without

Emission has been developed by Stinga, secured by patents and applied in the

pilot plant. The widespread application of this national clean technology in

Turkish industry will provide economical, ecological, social and strategical

benefits to our country.

2- Thanks to the interior design and the working principle of it, New Coal Drying

System can decrease the moisture rate to the required levels an deven down to

zero by using a portion of 2-2,5% coal independently from its morphologicaland other physical-chemical specifications.

3- Thanks to its interior design and technologic features, it can burn the volatiles

within the coal along with the carbon, and increase the combustion efficiency

up to 97%.

4- Since it can work in high temperatures (1400-1800%), the amount of unburned

coal is around 0,5-1%, and there is no slag. Besides, there is almost no

unburned coal in the flue gases, and the emission levels of the toxic gases (SO2,

S0 3, NO2 30-50 mg/m 3, 8-15 mg/m 3, 15-25 mg/m 3) are at minimum.

5- Our new technology has been applied in Tavas/Denizli Thermal Power Plant,

and it runs smoothly. The dry coal produced in the plant can be used for

industrial and heating purposes.

6- With the participation of experts and the terms of reference issued by Ministry

of Energy to General Directorate of Turkish Coal, 3 different coals

(Tavas/Denizli, Seyit mer/Ktahya, Ilgn/Konya) were used in the pilot plant,and some relevant tests were made. The results of the tests approve the high

performance of the new-advanced Technologies.

7- Applying New Drying Technology only in Seyit mer Thermal Power Plant cansave 5 million ton coal and 209 million tl per year. Besides, applying our new

technology in 12 public thermal power plants can save 56 million ton coal and 2

billion 300 million tl per year.

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8- The monetary saving by using our new technology for industrial and heating

purposes is 2 billion 550 million tl. If the coal is is dehumidified and then

transported, it will save 630 million tl.

9- The application of new drying technology across Turkey will save 5,5 billion tl,

and it will contribute a lot to Turkeys trade deficit (energy import: 50 billionUSD per year / trade deficit: 100 billion USD).

10- When our new technology is applied in private thermal power plants, our

domestic lignites will be used.

11- The application of new drying technology across Turkey will double the electric

energy efficiency (from 30% to 59%) of thermal power plants using lignite. This

means the energy efficiency will be higher than the current electric energy

efficiency of the thermal power plants in Turkey and the world.

12- New Boiler System can also be used as a high efficiency heat generator with

several different purposes (heating, obtaining hot water, production of

electrical energy, etc.). This technology also enables us to use oil shales, forest,

agricultural and animal biomass sources, and other solid wastes as fuel.

13- New ecologist Technologies have minimum emission levels, and thus

contribute to human health protection, and prevents the ecological balance

from corrupting.

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FUTURE GOALS

1- Increasing combustion efficiency of coals to 99%,

2- Decreasing all the emissions down to zero except for CO2 (that is the end

product of materials with hydrocarbon structure,

3- Using flue gas CO2 in dry ice production,

4- Developing high efficiency usage of oil shales along with coals within new

boiler system,

5- Utilizing the ashes and other inorganic wastes as a result of combustion in

different industrial areas,

6- Producing energy from oil shales by burning without emission in thermalpower plants,

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OTES ENERGY SYSTEMS

(STINGA TECH INC)

Technical Information

Factors Effecting Combustion Efficiency In Coal-Fired Mines:

The control of coal-fired burning system is more difficult than fluid-fired

burning systems. The most striking difference is the substantial amount of carbon

monoxide within the flue gases, and unburned carbon in the burner. Other importantfactor is the moisture rate of the coal. To accurately calculate the efficiency of coal-

fired systems, analysis of coal and ash must be regularly done wlong with the flue gas

temperature and the composition. The data about coal composition, carbon rate in

the coal and calorific value of the coal is necessary. Regular analysis of flue gases is a

plus with regard to the control of the working conditions of the boiler and enhancing

its efficiency.

The losses in the coal-fired boilers do not only stem from flue gases. The loss from the

unburned fuels is also a vital loss. The moisture rate in the coal can change, and this

effects the real calorific value obtained from the coal. The amount of oxygen in the

flue gas and gas temperature can substantially change depending on the design of the

burner and the boiler, coal composition and the phsycial quality of the coal. Calorific

values of coal can considerably vary. Besides, when the coal is stored in outdoor, its

calorific value can substantially decrease due to oxidation and moistening. Thus, the

storage of the coal in appropriate places will save money. Since, in practice, feeding

controls are adjusted wrongly, and the amount of excess air is too much, flue gas

losses are relatively high. Putting devices controlling air and fuel on the boilers with

big capacity can enhance the efficiency.

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Comparison Of Otes Heat Generator

With Other Burning Systems

While other burners can burn 5-17% of the CO2 gases, OTES can burn up to35% (including all the volatiles),

While other burners pipes have high amount of flue dusts and dust catchersdue to flue gases, OTES pipes are clear since its technology can burn the gases,

While other burners working efficiency in fireboxes with stoker, fluidized bed,travelling grate is around 40-70%, OTES has the highest efficiency (97%),

Other burners have big losses due to excessive feeding and CO2, and they have

substantial amount of flue gas losses as a result of burning coal with high levelof air. OTES can overcome these problems with its programme, operating

system and special design.

Some burning systems have different levels of coal bed thickness. While some

parts have high level of thickness (due to low amount of air), some parts have

low level of thickness (due to high amount of air). If the coal is not distributed

coequally, the flue gas analysis will show high rates of oxygen and CO2. OTES

distributes the coal homogeneously, The amount of air should not be adjusted according to the view of the coal, but

to the flue gas analysis and burning efficiency. OTES perfectly adjusts the

amount of air,

Most of the burners are selective about the fuels. They can only burn fuels with

certain sizes. The high level of dust effects the combustion efficiency. Besides,

most of the systems can not burn the dust. OTES can burn any size of coal, and

easily adjust the optimum conditions and provide high efficiency,7

In the general practices, feed controls are adjusted wrongly, and there are big

flue gas losses due to excessive air. The devices controlling the air and fuel on

the boilers with big capacity can be a solution. However, the burning tecnique

and the way it operates is not sufficiently efficient, and their costs are high.

OTES is a whole package that overcomes all these flaws.

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General Presentation

While this project is being developed, the main goal was to provide the highest

energy that is needed by the industry and big plants in a most economical way

possible. As a result of long-lasting research and development process, we developed

OTES Burning System.

The system is a unique design with its burning technique, firebox and refractory

when compared to the current burners running with solid fuels. OTES optimumefficiency in the furnace depends on its ability to burn dust coal (2000-7500 kcal),

special firebox design, burner type exclusive to OTES, working method with PLC

control, homogenous distribution of fuel and oxygen and automatic ash dischargesystem.

OTES burning system is produced in various capacities. Since every business has

different needs and systems, our application process is as follows:

Analysis of the current situation, Creating application project, Approval and Consensus,

Production of heat generator, Transportation, Installation, Start-up

Advantages Of OTES Heat Generators:

Shifting To Cheap Fuel: It can burn the coals with a size 0-30 mm, with a

moisture rate below 15%, and with a calorific value between 2000 kcal and7500 kcal,

Efficient: System is complete, and it has 97% efficiency, Burning The Gases: It can obtain 1500-3200 kcal additional energy by burning

the gases released by the coal. Depending on the quality of the fuel, it can burn

all the volatiles with various levels including CO2.

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Wide Working Range: The system can work within the capacity from 10% to

100%. It can easily satisfy the capacity increase and capacity decrease. No Additional Units and Extra Cost: Since gases are burned within the system,

there will be no need for additional dust holding cyclon and recycling systems.

Easy Operation: Operating is simplified and done with PLC. Since there is no

operator involvement, it provides constant and optimum efficiency.

Minimum Flue Gases: Since it controls the fuel and oxygen, it regulates the

flue gases and flue temperature, and provides optimum combustion efficiency.

Eco-Friendly: Since the burning efficiency and the amount of ash in the flue is

minimized, it is eco-friendly.

Slag and Ash Discharge System: Another advantage of the system is the

automatic slag crusher and discharge system.

Technical Support and Maintenance: The system is a product of 10 years long

research and development process. Malfunction and maintenance points are

inspected, and malfunctions are minimized.

Warranty: The system has 2 years warranty with the exceptions of ordinary

wear, misuses and natural disasters.

Warranty of Efficient Combustion: 97% burning efficiency is guaranteed by

OTES Heat and Energy Systems.

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REPORTS

SEYT MER COAL PLANT

ILGIN COAL PLANT

GEBZE INSTITUTE OF TECHNOLOGY

SEHER TEXTILE

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SEYT MER RESEARCH TEAMS REPORTON TAVAS COAL DRYING PLANT

Research team visited OTES Tech Inc. Coal Drying Plant in Tavas to inspect the coal

drying systems. The coal drying plant founded by Faik enol zyaman with thecontributions of OTES Tech Inc. is 3 km away from Avdan Village, Tavas and 78 km

away from Denizli. There are 2 drying facilities (-30 mm coals/rotary furnace & +30

mm coals/vertical furnace) in the plant. Since vertical furnace had some

malfunctions, the team of experts could inspect only the rotary furnace.

Lignites produced in the open mine are transported to the coal stockyard with trucks.

Coals obtained from the stock are feeded into the screen (30 mm screen aperture) by

being crushed by roll crusher. While +30 mm coals are dried in coarse coal drying

facility (vertical furnace), -30 mm coals are dried in dust coal drying facility (rotary

furnace). Then they are discharged on the stockyards.

Rotary Furnace

-30 mm coals are feeded into the bunker, and then feeded into the rotary furnace

with the wind measurer (30 t/h capacity) under the bunker. The rotational speed of

the rotary furnace (1,5 m calibre/20 m length) can vary 60-100 cycle/min depending

on the required exit temperature of the material. The slope of the rotary furnace is

2%. In the furnace, there are 1700 pallets easing the flow of the materials. The

materials feeded into the furnace are carried to the upper level of the furnace with the

pallets, and they drop to the ground, and this action continues till the materials are

discharged. The flue gases (900-1200 C) obtained through burning dried coals in thesolid fuel boiler are feeded into the rotary furnace. The flue gases within the furnace

contact -30 mm coals, and then absorbed by the flue fans and discharged. The -0,5

coal particles forming as a result of moisture loss during the contact of -30 mm coals

feeded into the rotary furnace are discharged by the cyclones. Coals classified as -30

mm and +14 mm on the screen (14 mm screen aperture) are discharged on different

stockyards. The amount of waste is around 5% of the feeded material.

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Fuel Boiler

The hot air required to dry the coal is obtained by burning the coals in the fuel boiler.

The coal taken from the bunker is feeded into the boiler from the boiler base throughthe spirals, and distributed homogeneously across the boiler base. The coal is burned

by the air taken from atmosphere, and the flue gases are feeded into the rotary

furnace.

To inspect the amount of dry coal to be burned per a ton of dried coal, team of experts

made a test. As a result of the test, 5.100 kg dried coal is obtained by burning 250 kg.

dry coal. Considering the moisture loss and the escape dust coal in the cyclone is

around 5%, the amount of feeding is around 8.250 kg.

Burned dry coal per a ton of dried coal: (250 kg : 5.100 kg = 4,90%

Burned dry coal per a ton of coal feeded into the system: (250 kg : 8.050 kg = 3,11%)

Experimental Data

T1 Sample from the raw coals produced in the opencast coal stockyard andtransported to the drying facility,

T2 Sample from the colas feeded into the drying facility,T3 Sample from the coals having different exit temperatures dried in the dryingfacility,

T4 Sample from the coals burned in the fuel boiler,T5 Sample from the cyclone underflow,

The results of the moisture analysis of the samples are as follows.

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The moisture rate of -30 mm coals feeded into the drying facility or coals with

39,60% moisture rate could be decreased down to 4,79%. Since the furnace in which

+30 mm coals are dried is broken, team of experts could not inspect it. However, it is

difficult to decrease the moisture rate of the +30 mm coals as low as -30 mm coals.

The percentage of the volatiles within the coal was around 41,50%. Due to the high

temperature in the rotary furnace, some of the volatiles were discharged with the flue

gases, and the percentage of the volatiles within the exit product was around 36,04%.

The amount of dust coal taken from the cyclone underflow (as a result of

fragmentation due to drying the coals and lowering their moisture) is around 5%.

Coal Drying In Rotary Furnace

The drying facility owend by OTES Tech Inc. has been inspected in line with Head of

Research and Development Departments demand. A team of experts has made a trialrun with - 18 mm and +0,5 mm coals from Seyit mer.-30 mm lignites to be dried were feeded into the rotary drying furnace (2% calibre/20 m length). The rotational

speed of the rotary furnace can vary 60-100 cycle/min depending on the required exit

temperature of the material. In the furnace, there are pallets easing the flow of

materials. The flue gas (900-1200 C) obtained by burning coals within the fuel boileris feeded into the system from the reverse direction. -0,5 mm particules forming in

the rotary furnace due to moisture discharge are taken as underflow with a cyclone,

and the flue gas (80-100 C) is released to the atmosphere.

For trial purposes, 24 ton of - 18 mm and +0,5 mm coals from Seyit mer has beentransported to the drying facility and has been dried. The samples have been analysed

in SLI Laboratories for the comparison of moisture changes before and after drying. Within the framework of this trial run, 24 ton sample has been feeded into the drying

facility, and dried through the flue gases obtained within the fuel boiler. Then

samples have been taken from the dried coals in different temperatures, and analyzed

in SLI Laboratories. The -0,5 coal particles forming as a result of fragmentation due

to moisture loss during their contact with the flue gases are discharged through the

cyclones. Experts also analyzed these coals from the cyclone underflow.

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Table 4. Analysis Results of Coals Dried In Rotary Furnace

Sample / Moisture / Ash (Dry Basis) / Volatile (Dry Basis) /Lower Calorific Value (Original) / Sulphur (Dry Basis)

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After drying process, the coals from different temperatures were piled up, and a

sample was taken from this pile, and analyzed. Besides, this sample was kept in

outdoor for 3 days, and moisture analyses were remade.

As seen on the previous table, 39,4% moisture rate of the coal feeded into the drying

facility decreased down to 2,37%. Depending on the lower moisture, the calorific

value increased. Considering that the sample was taken homogeneously from the

feeded coal, a unit of moisture decrease caused 40-50 kcal/kg lower calorific value

increase. The moisture rate of the coals (-18 mm and +0,5 mm / 39,84% moisture

rate) feeded into the drying facility decreased down to 2,37%. Since vertical furnace in

which +30 mm coals are dried was broken, the team of experts could not inspect it.

However, it is difficult to decrease the moisture rate of the +30 mm coals since +30

mm coals have less surface area.

Before Drying After Drying Amount % Amount %

(+) 18 33,2 8,2

(+10) (-)18 39,7 31,1

(-)10 27,1 60,7

Table 5. Screen Analysis Results of Coals Dried In Rotary Furnace

References:

[1] General Directorate of Turkish Coal, Lignite Industry Report, 2012

[2] 9th Development Report (2007-2013), Specialized Commission Mining Report

[3] Gney, A. Ateok, nal, G and Atak, S (1997) Improving Methods For TurkishLignites, 4th Coal Technology and Use of Coal Seminar

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KONYA ILGIN COAL PLANT REPORT

On 11 July 2011, 24 ton of raw coal, as sample, was transported to

Tavas/Denizli Drying Facility by 2 trucks. The raw coal sample in one of the trucks

was crushed in the crusher, and classified as +20 mm and -80 mm. The raw coal

sample in the other truck was crushed and classified as 0 mm and -20 mm.

Drying system: the flue gas (750-900 C) released as a result of combustion of air andthe coal feeded into the 2 boilers automatically meets the wet coal in the drying

column. It has a capacity of 20 ton/hour.

The humid air forming as a result of dehumidifying the coal in the drying column is

absorbed from the other side of the column with fans to the cyclones. The smallparticles (around 0,20 mm) in the cyclones coming with the humid air are extricated

as underflow, and the humid air is extricated as topflow and discharged to the

atmosphere with 60 C temperature.The coals discharged from drying are classified by the screens (0,8mm and +8 mm).

The exit temperature of the coal, flue, column and burning boiler can be read on PLC

system.

Samples from the coals (+8 mm & -20 mm, 0 mm & -8 mm, in different

temperatures) are taken from the drying facility, and brought to the Ilgn FacilityLaboratories. 12 ton dried coal are transported to our facility by trucks, and

discharged on stockyards. Experts took samples from this stock in different times,

and applied moisture tests on them.

As a result: the moisture rate of the samples kept in outdoor was 1,98% 56 hours after

the drying. The same samples were kept in room conditions 76 hours after the drying,

and their moisture rate was 10,33%.

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TAVAS/DENZL RESEARCH AND DEVELOPMENT

Sample Exit Temperature Original Moisture (%) Ash (%) Volatiles (%) Sulphur

0,-20 mm 45,5 29,25 43,32 6,55

(0,-8mm) / (+8,-20 mm) 135C / 56C 2,47 / 26,60 18,26 / 29,05 42,89 / 42,50 4,94 / 7,14(0,-8mm) / (+8,-20 mm) 122C / 52C 3,20 / 36 24,60 / 23,59 43,67 / 44,86 5,7 / 7,21(0,-8mm) / (+8,-20 mm) 80C / 45C 14,17 / 36,47 29,76 / 25,21 41,22 / 43,02 4,91 / 6,03

2 times dried (+8,-20 mm) 56C 26,4 32,7 39,21 8,71Underflow 34,89 35,94 42,02 6,37

*Since calorie measuring device is broken, the result of calorific values of the sample

will be clear after they are analyzed in Seyit mer Plant.

Factors Determining Coal Quality

Degree of carbonization (hard, bituminous, half-bituminous, lignite, peat) Coal specifications (moisture, ash, calorific value, volatile, fixed carbon) Specifications by forming process (carbon, hydrogen, sulphur, nitrogen,

oxygen)

Ash compound (SiO2, AI2O3, Fe2O3, CaO, MgO, Na2O, K2O, P2O5, TiO2) Ash fusion temperature,

Percentage value of Moisture, Volatile Matter, Ash, Fixed Carbon,

within the coal is determined by proximate analysis.

Some standardized methods (ASTM, ISO, DIN and BS) have been developed for

proximate analysis.

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Why is coal drying important?

The most important parameter influencing the calorific value of the coal is the

amount of moisture, The moisture content determines the boiler efficiency, fuel combustion rate,

flame temperature, heat transfer within the steam generator, primary air

temperature requirement and ash resistance in electrostatic filters,

The moisture content also influences volatile matter discharge, combustion

processes, mass diffusion resistance,

Drying coals has detractive effect on emissions. Every 1% increase in the

moisture content increases the heat requirement by 20 Btu/kWh,

Lignites that will be used for electric production or different purposes must be

dried due to the reasons above.

The Purpose of Drying Seyit mer and Ilgn Lignites

One of the strategic targets (2010-2014) by General Directorate of Turkish Coal is

supporting research and development projects. Within the framework, the projects

about the drying and briquetting of coals are aimed to accomplish. The targets are as

follows:

Drying coals (38-40% moisture / 18-100 mm) offered for sale, Decreasing the moisture percentage of the coals offered for sale, and providing

a widespread usage,

Offering more quality coals to the customers, and increasing market share of

the coal in the industry, Drying coals (0- 18 mm) given to Electricity Generation Company (EA), and

decrasing their moisture percentage from 40% to 30%,

Producing products that are in line with the thermal power plant design

parameters of EA, and achieving savings in energy production.

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FEASIBILITY

There is enough coal in Turkey and the world in terms of energy and reserve,

but 80% of these reserves have low calorie (1200-2500 kcal/kg). 20% of the reserves

have 2500-7500 kcal/kg. Coals having high calorific value can be burned with 40-

60% combustion efficiency, and they are used for heating and industrial purposes.

The rest of the coals having low calorific value can be used only in thermal power

plants, and they have 18% combustion efficiency. They also cause maximum air

pollution.

The current new technology coal drying systems can increase the calorific value of the

low calorie coals from 1500 kcal/kg up to 3500 kcal/kg. Thus the low calorie coalshaving increased calorific value can be offered to the market. While coals having 1500

kcal/kg can be offered to the market with a price 15 tl/ton, coals having 3500 kcal/kg

can be offered to the market with a price 80 tl/ton. The boilers used in residences use

coals in sizes varying between 10 mm and 80 mm. The market price for nut coals (10-

30 mm) is 130 tl/ton, and the price for coals in size 30-80 mm is 170 tl/ton.

The moisture rate of orum origined coals having 2500 kcal/kg lower calorific valueshould be decreased from 40% to 10%. Considering the moisture rate in the air is 5%,

there will be a 35% decrease in moisture rate of the coal. Each unit of moisture has 50

kcal/kg, and (35% * 50 kcal/kg = 1.750 kcal/kg), thus it will increase the calorific

value of orum origined coal to 4250 kcal/kg. The market price for these coals; - 0-10 mm : 110 tl/ton

- 10-30 mm : 170 tl/ton

- 30-80 mm : 230 tl/ton

There is a big amount of low calorie coals in the nature, and when it is extracted via

open operation, the cost is very low. For instance, the cost of extracting 1 ton dry coal

is 8 tl/ton. Since its moisture rate (40%) will be decreased, its weight will decrease as

well. The cost of decreased weight is 3,2 tl/ton. The cost of drying coals is 4 tl/ton.

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SUMMARY

The cost of extracting is 8 tl/ton,

The costdecreased weight due to moisture loss is 3,2 tl/ton, The cost of drying is 4 tl/ton, Total cost is 15,2 tl/ton, Market price for dust coal is 80 tl/ton, The profit on sale is 64,8 tl/ton, Market price for nut coal varies between 130 tl/ton and 170 tl/ton (average:

150 tl/ton),

The profit on sale is 134,8 tl/ton.

Thanks to new technology drying systems, 40% moisture of the coal can be

dehumidifed, and the coal can be dried with low cost by consuming 55 kWh electric

energy and by burning 1% of the coal to be dried. However, in the old drying

technology, only 10% of the moisture rate of the coal can be dehumidifed, and the

coal can be dried by consuming 250 kWh electric energy and by burning 25% of the

coal to be dried. These systems are not economically efficient, and since they can not

completely dehumify the coal, they have not been developed.

Besides, there is no lump coal drying facility in the world, and investing on lump coal

drying systems can be highly profitable.

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GEBZE INSTITUTE OF

TECHNOLOGY REPORT

Analysis Report on Drying Lignite With The New-AdvancedTechnology And Burning Without Emission

The new technology developed for drying and burning lignite coals without

emission was applied in Tavas/Denizli Pilot Plant (with a capacity 20 ton/hour

original wet coal, and a capacity 12 ton/hour dry 40% miosture coal), and the plant

has been running since then.

Various tests was applied in the pilot plant to determine the economical and

technological benefits of this process by General Directorate of Turkish Coal and

Gebze Institute of Technology. The results of these tests were indicated in the report

National Clean Energy Technologies: Drying The Lignites With The New-Advanced

Technology And Burning Without Emission prepared in 2012. The analysis report by GIOT (Gebze Institute of Technology) is based on the data

from the report National Clean Energy Technologies, and it also includes additionalinformation. These data is based on the direct results obtained through the tests

applied in the pilot plant by GIOT, and the results obtained through the various

analyses (DTA-TGA, XRD, EDX, Gas Chromatography, etc.) made in the GIOT

laboratories.

Original lignites of Tavas/Denizli Coal Mine has been used in the pilot plant. Many

samples were taken from various parts of the coal mine in various time periods, and

their physical and chemical specifications were analyzed, and minimum and

maximum values obtained through the samples were demonstrated in the Table 1.

Coals having different physical-chemical specifications and morphological structures

from Tavas/Denizli, Seyit mer/Ktahya and Ilgn/Konya were dried in the pilot

plant with the participation of experts from General Directorate of Turkish Coal.

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Note:

In Table 2-4;

- T-1 Tavas/Denizli original wet lignite to be dried in the drying facility

- T-2 Original wet lignite feeded into the drying unit

- T-3 Dried coals having different exit temperatures in the drying unit

In Tables 2-4, when the exit temperature of the coal discharged from drying unit is

135-140 C, the moisture rate of;

- Tavas/Denizli coal is 4,79%,

- Seyit mer/Ktahya is 2,37%, - Ilgn/Konya is 2,47%.

When the exit temperature of the rotary furnace is around 135-140 C, the moisturerate of the coal decreases almost 10-15 times, and the combustion heat value

increases 1.8 times. The special interior and overall design and working principle of

the drying unit enables the obtained high efficiency.

Another difference of the new drying unit is that a substantial amount of water

vapour within the unit can be absorbed and released to the atmosphere with anotherspecial system through various points of the rotary furnace. This enables the system

to dry the coal faster and deeper, and the ash rate of the dried coal decreases by 10-

15%.

With the new drying unit, the moisture rate can be decreased to the required level

and even to zero independently from the moisture rate of the coal to be dried. The

moisture, with a special automation system, rate can be adjusted accordingly with the

exit temperature of the coal depending on the following technological factors:

- Feeding speed of the original coal to the drying unit,

- Exit temperature of the coal,

- Moisture rate of the original coal,

- Rotational speed of the drying unit,

- The amount and temperature of the flue gases feeded into the drying unit fromthe combustion flue.

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Although the temperature of the flue gases is 750-900 C, the exit temperature of theflue gases after burning is 60-70 C, and the exit temperature of the coal is 90-140 C. As seen on Table 2-4, since the exit temperature of the dried coal is low, the loss of

volatiles (hydrocarbon gases etc.) within the coal is at minimum levels.

According to the practical results, the required heat energy to dry 1 (one) ton of wet

coal feeded into the drying unit can be met by burning 2-2,5% of dry coal. This

amount is 8-10 times less than the current coal drying systems in Turkey and the

world.

According to the resources about the technologies used in the world, the demification

rate of coals, at a time, is only 17% in the current systems. However, in the new

drying technology, the demification rate is 50%. Besides, the new drying technology

makes it possible to burn the various coal fractions having 0-30 mm particle sizes at