Refined coal

United States

The best known producer of refined coal is a company based in Denver, Colorado called Evergreen Energy Inc. The company is publicly traded and is listed on the NYSE Arca exchange. According to the company's web site and its Form 10-K on file with the U.S. Securities and Exchange Commission, it was founded in 1984 with the goal of commercializing a coal upgrading technology first developed in a Stanford University laboratory by Edward Koppelman. Taking the K from Koppelman's name, Evergreen, known formerly as KFx Inc., branded its refined coal product as "K-Fuel."

Much of the coal in the western United States is known as "lower-rank" coal that falls under the categories of "sub-bituminous" and "lignite" coals. These coals have high moisture levels and can be 20 to 30 percent water. This relatively high moisture content when compared to "higher rank" coals like bituminous and anthracite coals make lower-rank coals less efficient. The average heat content of sub-bituminous coal consumed in the United States is approximately 8,500 British thermal units (Btu) per pound. The K-Fuel(R) process uses heat and pressure to remove approximately 30 percent of the moisture from raw, low-rank coal and raises its thermal content to approximately 11,000 Btu per pound.^[1] In addition to raising the coal's heat value, a significant amount, up to 70 percent, of the elemental mercury in the coal is removed and, because of its higher efficiency, lower chloride and nitrogen oxides emissions are achieved on a per kilowatt hour generated basis.^[3]

The advantages of the refined coal process are more efficient transportation and the ability of utilities to switch to a fuel made of 100 percent refined coal or a blend of raw and refined coals in order to achieve lower emissions and greater efficiency.^[4] A disadvantage is that the industry requires significant subsidies. An examination of government figures show that in 2007, for every megawatt-hour generated, refined coal received $29.81 in federal support, solar power received $24.34, wind power received $23.37, and nuclear power received $1.59.^[5]

Australia

The producer of densified coal in Australia is a company based in Melbourne, Victoria called Environmental Clean Technologies Limited (ECT Limited)^[6] The company is publicly traded and listed on the Australian Stock Exchange (ASX). The company was listed in 2005 with the primary purpose of commercialising the Coldry Process coal upgrading methodology first developed in the Chemical Laboratory of Melbourne University by Dr B. A. John in the 1980s. The name of the process derived from the Calleja Group, which acquired the technology in 1994 and developed the technology to pilot demonstration at Maddingley Mine, Bacchus Marsh, Victoria in 2004 before licensing the technology to ECT Limited for further commercialisation in 2005.

The State of Victoria contains approximately 25% of the world's known reserves of brown coal (lignite). This coal is also amongst the world's 'wettest' coal, with a typical moisture content of 60 per cent water by weight. High moisture content makes Victorian brown coal an inefficient fuel source and is the primary reason why the Hazelwood power station in the Latrobe Valley is regarded as the world's dirtiest coal-fired power station. The Coldry Process uses low-pressure mechanical shear to create a natural exothermic reaction within the coal that then naturally expels 80 per cent of the moisture content. Expelled moisture is then captured and recovered as distilled water. Victorian brown coal transformed by the Coldry Process has a raised thermal content of 5874 kcal/kg, which is comparable to most export-grade Australian black coal.

The advantage of the Coldry Process is its ability to allow power generators to switch to a blend of raw as mined brown coal and Coldry pellets to achieve lower emissions in existing inefficient boilers, or achieve substantially less emissions by introducing black coal boilers and using 100 per cent Coldry refined coal pellets as a black coal equivalent. The Coldry Process provides the added advantage of creating new revenue streams for power generators through the production of a product that can be exported to other countries as a replacement for black coal. Unlike other refined coal processes, the Coldry Process is a commercial methodology that does not require subsidy.

United States

Evergreen Energy constructed a full-scale coal refinery near Gillette, Wyoming that began operation in late 2005. Designed originally to be a commercial plant, the facility encountered design and operational problems. Evergreen idled the facility in March 2008^[7] and instead used the plant as a process development platform with its engineering, construction and procurement contractor Bechtel Power Corporation.

Evergreen is now seeking to construct a coal refinery using the improved Bechtel design at locations in the Midwestern United States and in Asia.^[8]

Australia

Calleja Group constructed a full-scale 16,000 tonne per annum pilot demonstration plant at JBD Business Park at Maddingley Mine near Bacchus Marsh, Victoria that began operation in early 2004. From 2005 ECT Limited upgraded the facility, added a water recovery process with Victorian Government funding in 2007 and operated the plant as a process development platform with its engineering partner ARUP. In 2009 ECT Limited secured and agreement with Thang Long Investment Company (Tincom) of Vietnam to finalise commercial feasibility ahead of construction of a 2 million tonne pa export plant by 2014 and 20 million tonne pa export by 2020. ECT Limited is using the ARUP improved design to secure technology licensing agreements with brown coal suppliers in China, India, Indonesia, Poland, Greece and Russia.

China

GBCE has built and is now operating the world’s first industrial scale coal upgrading facility. It has capacity to process 1 MTPA of coal feedstock and is located in Holingol, Inner Mongolia, the largest lignite producing region in China.^[9] The coal is typically high moisture (35 – 40% TM) and 3200 – 3400 kcal gar. Depending on market requirements, it produces 5000 – 5500 kcal coal (gar) with greatly reduced moisture content (< 10% gar). The plant uses LCP coal upgrading technology which is a pyrolytic process that employs heat and pressure in an oxygen free environment to continue the coalification process that occurs naturally in the earth. The processed coal by this technology is hydrophobic and transportable which means it will not reabsorb moisture or break up into powder during transportation.