Coal-to-Energy Pellet Conversion Project

Key Challenges

RJM was tasked by SIMEC Atlantis Energy, the plant operator, to deliver a new engineering-based solution to convert two units (totalling 220 MWe) of its Uskmouth coal-fired power plant to run on waste-derived energy pellets, comprising a mixture of 50% biogenic material and 50% waste materials (typically plastics) unsuitable for recycling.

This was the first-of-a-kind re-tasking of a front-wall fired boiler, originally designed to fire coal and opened up the possibility of redundant coal plants being given a new lease of life, delivering low carbon power.

RJM Solution

Following an initial study that rejected a conversion to 100% biomass fuel as uneconomic, RJM carried out a number of complex tests and detailed analysis work, including CFD (Computational Fluid Dynamics) modelling, before moving on to a pre-FEED (Front End Engineering Design) study, followed by a detailed FEED study, to arrive at an energy pellet formulation and an appropriately-modified firing system that would deliver a stable flame combined with the desired combustion characteristics.

                                                               Energy pellets

RJM then moved on to medium-scale testing in an R&D combustion facility which confirmed that stable combustion of 100% waste-derived energy pellets would be possible at commercial scale. These physical results also correlated with the CFD (Computational Fluid Dynamics) modelling carried out previously by RJM, confirming the self-sustaining flame with combustion performance within expected parameters.

Results

RJM’s findings demonstrated that a coal-to-energy pellet fuel conversion project was technically feasible and its work formed the backbone of the EPC tender that included the design, supply, installation and commissioning of the full combustion unit.

“RJM made a valuable contribution to the development of the Uskmouth coal-to-energy pellet conversion project. I have been particularly impressed by RJM’s ability to simplify the technically-complex risks associated with the development of a new fuel and combustion system to critical commercial drivers for Board briefings. RJM has some great people who are without doubt world-leading in their sphere of expertise.”
Ernie Rowe, Head of Conversion, SIMEC Atlantic Energy, UK