NATIONAL CLEAN

ENERGY
TECHNOLOGIES


Project: Drying Lignites With
The New-Advanced Technology
And Burning Without Emission


STINGA PROJECT START DATE: 02/02/1999

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 and
technologies 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 polluting
the 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 todays
technology 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 7000
meters below the ground level in Southeastern Anatolia Region. With our system,
National Clean Energy Technology, using oil shales is highly cost-efficient. Stingas
technology 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 only 1 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
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 is
politically 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 todays
energy. Despite their efficiency, they are enviromentally hazardous. Thus, countries
are working hard to replace fossil fuels with alternative energy sources and to
transform 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 disaster
for 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 zyamans High Efficiency New-Advanced
Burning 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.
Faik enol zyaman, on the basis of new-advanced technologies bearing his
signature, succesfully founded a pilot plant, began the production of new drying and
boiler systems, and finally commercialized them. Stingas system had the support of
Supporting 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 lignite
reserves 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)

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)
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.

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%)


Figure 3. Share of primary energy sources in the worlds energy production

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.


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 temperature
of 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-Advanced
Technology Drying System enriches the calorie value of the coal up to 5000 kcal/kg,
thus it both economically and permanently settles the problems.
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 coals
economically 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.
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, Stingas New-Advanced Solid Fuel Burning
Technology 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 a
result 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 costs
of the energy and regional energy dependency will be minimized.
Based on the stats above, its clear that the system developed by Stinga is also
crucial for both Turkey and the world. The widespread usage of Stingas systems in
Turkey 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 combustion
efficiency and their applications to the industry are vital for Turkey.
Stingas new technology will make a huge amount of contribution both to the
national economy and to the fight against pollution. The details about this technology
is given below.


Figure 5. The scheme of New Technology Drying Unit
New-Advanced Drying Technology
Based on Stingas new-advanced technology, the process of drying takes place
in 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 pulverizes
the 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.


Though the temperature of the flue gases released into Drying Unit is 900-
1100C, the flue gases released from the unit is 60-70C. The temperature of the dry
coal is around 90-130C. 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 more
efficient 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 the
moisture 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%.

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.
Stingas Coal Drying System can decrease 50% moisture rate of a coal down to
0%. 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 important
commercial profits.
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 problems
pointed 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 1400-1800C,
- directs radiation beams forming in the high temperature (1400-1800C) 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 them
fully 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
(1400-1800C instead of 1000-1200C). This can prevent the toxic gases (SO2, S03,
NO2 etc.) that are hazardous to the human health and environment.


This case has been proved by the stats based on the Gibs free energy values
obtained through thermodynamic calculations. It also shows that, on 1000-1200C
temperatures, the possibility of transformation of organic sulphuric compounds
(mercaptan, thiophen, etc.) and and inorganic sulphuric compounds (elementary
sulphur, pyrryl, etc.) into SO2 and S03 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 NO2 can be
thermodinamically high.



Figure 7. Beam Reflections of Old and New Boiler Systems

When temperature increased up to 1800C, the possibility of formation of
these gases like SO2 and S03 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.

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 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 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 SO2 and S03
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

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 other
coal 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 SO2 and S03 gases. Since
Stingas new boilers are designed to burn all the volatile gases, it substantially
increases 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.




Figure 9. View of the New-Advanced Boiler System


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 Stingas
New 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 energy
consumption.

The Drying And Burning Of The Coals With
The New-Advanced Technology, Its Implementation
In Our Pilot Plant, Its Industrial Performance

Based on Stingas New Technology designed for drying and burning of the
lignites (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,
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 important
lignite 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. Some
details about the tests mentioned above are demonstrated below.


Figure 10. View of Tavas/Denizli Industrial Pilot System

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 2,1
T3(75) 21,74 41,7 36,55 2685 2,17
T3(110) 16,26 38,45 37,89 3469 3,6
T3(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 Coal
Mine 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
Basis
Original 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 4004
S-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 3930
S-2(128) 4,09 33,72 35,24 39,05 2,02 3678 3856
S-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


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 wet
lignite 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.


As seen on Table 2-4, when the exit temperature of the coal from the drying
unit is around 135-140C, 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 additional
aspects 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 200C and
ends at 525C,
- full combustion of the carbon within the lignite occurs at 620-670C,
- when the moisture rate of original lignites, without depending on their
moisture level and structural specifications, is lowered down to 5% or less by
drying, the system can absorb the atmosphere moisture till it reaches body
moisture (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.
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)












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. The
statistical data given above are excerpted from Minister of Energy Mr. Taner Yldzs
2011 budget speech at The Grand National Assembly of Turkey.



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. To
illustrate, 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 be
transported to the regions 600 km away.
Pulverized coal can not be burnt in the boilers having a capacity less than 5.000.000
cal. However, Stingas new technology boilers can burn domestic pulverized coal with
a 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.
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 coals
and imported pulverized coal, and thus the cost of importing will decrease.
The development of systems for efficient usage of solid energy sources (lignites, oil
shales, 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.
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 on
19.11.2011, 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 they
are 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 and
environmentally.



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 this
plant:
- The amount of water in the lignite (40% moisture) that is used 800 tons per
hour 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, the
required 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 100C up
to 1200C:
[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 100C up to 1200C:
(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)
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%, the
total 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:
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)



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 in
Turkey 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
electric 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%]





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, the
electric 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 NO2 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 oxygen
and as a result, increase the combustion efficiency. However, The Science Magazine
(Issue 18, April 2009) co-published by Dumlupnar University and Gazi University
shows 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.
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 demonstrated
as 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
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)

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 New
Technology 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 researches
till 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.


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 morphological
and 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,
S03, NO2 30-50 mg/m3, 8-15 mg/m3, 15-25 mg/m3) 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 can
save 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.
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 billion
USD 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.









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 thermal
power plants,





















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 important
factor 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.





Comparison Of Otes Heat Generator
With Other Burning Systems

While other burners can burn 5-17% of the CO2 gases, OTES can burn up to
35% (including all the volatiles),
While other burners pipes have high amount of flue dusts and dust catchers
due 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 level
of 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.



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 optimum
efficiency 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 discharge
system.
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 and
7500 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.


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.
















REPORTS






SEYT MER COAL PLANT

ILGIN COAL PLANT

GEBZE INSTITUTE OF TECHNOLOGY

SEHER TEXTILE










SEYT MER RESEARCH TEAMS REPORT
ON 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 the
contributions 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 (900-1200C) obtained through burning dried coals in the
solid 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.

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 through
the 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 and
transported 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 drying
facility,
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.







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 trial
run 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 (900-1200C) obtained by burning coals within the fuel boiler
is 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 (80-100C) is released to the atmosphere.

For trial purposes, 24 ton of -18 mm and +0,5 mm coals from Seyit mer has been
transported 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.



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)





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 Turkish
Lignites, 4th Coal Technology and Use of Coal Seminar







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 (750-900C) released as a result of combustion of air and
the 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 small
particles (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 60C 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 Facility
Laboratories. 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%.








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 8,71
Underflow 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.


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.




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 coals
having 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 value
should 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.





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.












GEBZE INSTITUTE OF
TECHNOLOGY REPORT


Analysis Report on Drying Lignite With The New-Advanced
Technology 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 additional
information. 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.
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
135-140C, 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 135-140C, the moisture
rate 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 another
special 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 from
the combustion flue.
Although the temperature of the flue gases is 750-900C, the exit temperature of the
flue gases after burning is 60-70C, and the exit temperature of the coal is 90-140C.
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
required levels. The thermo-gravimetric features of the original and dried coals were
analyzed with DTA-TGA method with the purpose of determining the optimum
temperature conditions to dry and burn without emission. The analysis results are
demonstrated in Table 2-3.
Table 2 shows TGA curves of the lignite coals in inert gas medium. The full drying of
coal ends at 200C. A maximum temperature of 135-140C is enough to decrease the
moisture rate of the coal to 10%. The desoprtion of the volatiles within the coal begins
at 230-240C, and ends at 600-625C.
Table 3 shows TGA curves of the lignite coals in air medium. The volatiles within the
coal burns between the temperatures 200-450C and 600-825C. Based on the
thermo-gravimetric analysis results, the new drying unit developed and applied in the
pilot plant works in optimal temperature parameters.




Thanks to the interior design of the new boiler system in the pilot plant, dried coals
can be burned in higher temperatures (1400-1800C). This provides the following
benefits:
The transformation of sulphuric organic (mercaptan, thiophen etc.) and
inorganic (pyrite etc.) compounds within the coal into the toxic gases (SO2,
SO3, etc.) that damages the human health and the environment can
thermodinamically be prevented, and sulphuric compunds stands within the
ash without burning.
The amount of unburned carbon within the ash and the flue gases is at
minimum levels (2-4%),
The combustion rate of the coal (dry basis) reaches high levels (96-98%).
However, the temperature of the flue gases discharged in high temperatures can be
decreased to the required levels for drying by being mixed with the air before they are
feeded into the drying unit. The structures and chemical contents of the various coal
and the ash have been analyzed with XRD and EDX methods.
One of the most important advantages of the new drying and burning systems is that
environmental pollution is at minimum levels. The emission contents of the flue
gases discharged from the drying unit in the pilot plant has been analyzed in detail.
Minimum and maximum values of analysis results obtained through various working
parameters are demonstrated below:
SOx 0-25 PPM; NOx 1-118 PPM; NO o-125 ppm; CO 6-138 ppm.
Flue gases consist of nitrogen, oxygen and carbon gas. An amount of 30.000
m3/hour flue gas and 8.000 kg/hour water vapour is released to the atmosphere.
Another advantage of the new drying system is that the lignite coals can be dried till
its moisture decreases even below the structure moisture (8-10%). According to result
of the analyses made in laboratories, the lignites dried till they reach their structure
moisture can humidify only till their structure moisture level even though they are
kept in outdoor for a long time.

New drying technology ensures fixed moisture level, and thus they are not effected by
the weather conditions even when they are stored in outdoor for a long time. No
matter how much tonnage they are, there occurs no inflammation or oxidation where
the coals are stored.
Soakage of the coals stored in outdoor are prevented by the external incrustation in
rainy weather. Soakage thickness of the lignite coal particles on the surface is 5 mm,
and only 5-10% of the layer on the surface leaks. The temperature of dried coals (in
35-40 cm deep) in the stockyard is 80-90C, and it can preserve this temperature for
around 3 months without any inflammation.
The required heat and electric costs to get 1 (one) ton of dry coal (5% moisture) from
the lignite (40% moisture) are demonstrated below:
Amount of coal burned in the new boiler system to get hot flue gases is 30 kg,
Amount of electric energy for a ton of dried coal is 1,25 kWh,
When the labour costs are added to energy costs, the required costs to get 1 (one) ton
of dry coal from the lignite (40% moisture);
Production cost of 30 kg dry coal burned in the boiler:
(0,030 ton * 70 tl/ton = 2,1 tl)
Cost of electric energy: (1,25 kW * 0,16 tl/kW = 0,2 tl)
Employee and other costs (1,2 tl)
o Gross Cost: 3,5 tl/ton



Based on these data, (considering the average sales prices of the original and dry
lignite coals 41 tl/ton and 108 tl/ton- dried with the new drying technology) the
profit rate obtained through selling 1 (one) ton dry coal offered to the market for
residential heating and industrial purposes is:
[108 (41+3,5) = 63,5 tl/ton (gross)]
The most important problem of the modern world is energy. The required energy is
obtained through the fossil fuels. Unfortunately, the enviromental pollution due to
inefficient technologies used in drying and burning of the coals cause serious
problems for the human health and ecological balance.
Therefore, the development and application of new high efficiency and eco-friendly
technologies for drying and burning of the coals (the largest fossil fuel reserve) to
transform them into energy pose a crucial benefit for the world.
The economical and strategical importance of the new national technology that Faik
enol zyaman developed after long years of research and development to burn
without emission and dry the low calorie lignites having huge reserves in our country
is indisputable for Turkey. This new technology is undoubtedly beyond the current
Technologies in the world.
Prof. Dr. Ali ATA
Gebze Institute of Technology / Manager of Nanotechnology Research Center
Prof. Dr. Refik ALBEYL
Project Consultant










SEHER TEXTILE REPORT

RESULTS

1. The system was working in manuel control before fluidized bed automation
control was done, and the coal the system used had 3500kcal/kg calorific value
and 30% moisture. The coal feeding speed was 42% while the system was in
manuel control.
a. As a result of automation control, the same coal was used and the coal
feeding speed was decreased from 42% to 30%, and the saving made
was 28%.
b. The wet coal (1700 kcal, and 55% moisture) from Tavas/Denizli was
dried in the drying facility, and the specifications of the dry coal had
3600 kcal calorific value and 5% moisture. While the coal feeding speed
was 42% in manuel control, it was decreased to 18%. The coal saving
was 58%, and the electric energy saving was 60%.
i. The stabilized pressure obtained through automation control and
dried coal usage was 7,5 bar, and it was stabilized at 7,3 bar. The
system constantly fed 7,3 bar pressure to the facility. It
contributed to the quality of the products.
ii. Fluidized bed combustion efficiency (50-60%) increased to 84-
88% in the efficiency measurement during automation and dried
coal usage.
Note: The emission was measured right after the firebox. If the measurement was
done after economizer, cyclones and hydrous filter, emission values would be close to
perfect.



Authorized Signatures



Seher Textile Inc. Co.
Yasin DEMREL / Factory Manager


The Firm In Charge Of Automation Control
nder ATASOY / Ege Tech Automation


Supplier of Coal From Tavas/Denizli
M. Ozan ALTUN / Altun Group Energy Co. Ltd.


Programming, Emission Measurement and Organization
enol ZYAMAN






PROJECT TEAM

Faik enol ZYAMAN (Patent Holder OTES Energy Partner)
Zbeyde ZYAMAN (Instructor)
Zeynep ZYAMAN (OTES Energy Partner)
Dizem PEK (EU Relations and Foreign Trade Manager)
Melek BER (Labor Economics & Industrial Relations)
Muharrem Ozan ALTUN (CEO ALTUN Group Partner)
Prof. Dr. Ali ATA (Manager of Gebze Institute of Technology
Nanotechnology Research Center)
Prof. Dr. Rafig ALBEYL (Gebze Institute of Technology)
Prof. Dr. Ahmet Dursun ALKAN (Yldz Teknik University)
Fazl MORALI (Istanbul University French Filology)
Osman PAMUK (Mechanical Engineer)
Grkan KSEOLU (Civil Engineer)
Kayhan DURNA (Lawyer)
Cihan CEREN (Economics)
Ahmet UZUNOLU (Teknik Ate Refractor Factory)
Ali DEMR (Demir Metal Co. Ltd.)
Hayri DEMREL (zel Deha Co. Ltd.)
smet DURAK (Duraksan Mining)
Atilla FLZ (AR-GE Specialist)
nder ATASOY (Automation Specialist)
Erdal KSE (Automation Specialist)
Tark KASSIM (Project Representative / Iraq & Jordan)