“Green” Coal Project


1. The Russian company CJSC "Compomash-TEK" has developed a new environmentally friendly, energy-efficient, fine-dispersed coal fuel  - ACLF (artificial composite liquid fuel), unrivaled in the world, with the solid particles size under 1 micron, prepared from brown and black coals, which gives the following benefits:

1.1. ACLF can be prepared from different ranks of brown or black coals and their waste with addition of various combustible liquids, solid waste and technical water. Such fuel demonstrates all the technical properties of liquid fuel and retains its qualities in cases of long-term storage and transportation.

1.2. Fine-dispersed grinding, homogenizing, and mechano-chemical activation of the prepared coal-water slurry – ACLF, which is produced on specially designed equipment (Fig. 1), provide for the following:

Fig. 1. Assembled and operational equipment set unit
for preparation and feeding of ACLF

1.2.1. Combustion efficiency of the combustible portion of ACLF reaches 100%, which eliminates the underfiring typical of heating stations and thermal power plants and completely removes CO emissions into the atmosphere.

1.2.2. High reactivity of ACLF at the time of combustion compared with the traditional coal fuel reduces harmful emissions into the atmosphere eight tentfold, to values which are lower than the maximum permissible emission standards set by environmental authorities (dust, soot – to 1 mg/m3; SО2 – to 50 mg/m3; NОх – to 50 mg/m3; СО – 0,  Table 1).

MPE, mg/n.m3

Actual concentration of harmful agents in exhaust gases in the course of combustion, mg/n.m3

Emission type

EES standards adopted in 1995


Russian standards

Coal-powdered combustion

Coal-bed combustion

Fuel oil


Manufactured composite liquid fuel






up to 7000









up to 2500



up to 50






up to 1500







no more than 375

up to 300

up to 2500

up to 400

up to 10

up to 50

 Table 1

* - in the course of gas cleaning;

** - gas separators.

Smoke fumes upon combustion of ACLF have white color, black particles of soot and fly ash typical for coal heating stations and thermal power plants are absent.

1.3. The new generation crushing and grinding equipment used at coal heating stations and thermal power plants to prepare ACLF provides for two- or three-fold reduction of the total electricity consumption as compared to energy consumption of the existing coal preparation equipment, which reduces the cost of the produced “green” fuel by 30-50% with further reduction of the cost price of the produced heat and electric power by 20-30%.

1.4. Burning ACLF enables a 10-15% increase of the efficiency rating of boiler units.

1.5. The possibility to use any ranks of coal (black and brown) to prepare ACLF eliminates the existing dependency of coal heating stations and thermal power plants on specific coal deposits and ranks of coal.

.        Fig 2. Specially designed burners

       (vortex furnace extensions)

with the power capacity

of 6.5, 10, and 35 MW

1.6. ACLF can be efficiently employed in place of fuel oil and gas co-fuels as well as a replacement for fuel oil and natural gas to provide for considerable savings of these resources at oil-gas boiler units of heating stations and thermal power plants upon some modification of the facilities. Special burners have been designed and tested to accommodate this (Fig. 2).

1.7. On the stage of ACLF preparation various solid and liquid combustible wastes may be added besides coal, including technical glycerin, a by-product of bio‑diesel fuel production from vegetable oils (rape) addition of which does not decrease the level of ecological safety of ACLF.

2. ACLF is a fine-dispersed coal-water slurry consisting of up to 60% of fine dispersed coal (with the possibility of adding solid or liquid wastes) and of up to 40% of water. The maximum size of milled coal does not exceed 3 microns. The average size of coal particles is 0.5-0.8 microns. The lowest combustion temperature is up to 4000 kcal/kg and more. Viscosity is up to 800 МPa. Stability of ACLF reaches 1 year.

In the process of ACLF preparation on specially designed new generation unit type equipment decarbonization of coal takes place (see Fig. 1) due to fine-dispersed milling, mechano-chemical treatment, homogenization of the slurry.                   

The dispersion medium of ACLF is an active component which acts as an intermediate oxidant in heterogeneous reactions of the solid and liquid phases of the fuel at the initial stages of the combustion process with partial emission of oxygen and hydrogen.

Besides coal and other hydrocarbons (fuel oil, technical glycerin, peat, etc.) ACLF can include special additives developed by us, which in small quantities (1 to 3%) provide the desired consumer qualities of the produced fuel, as well as increase fluidity, stability, degree of binding of sulfur at the time of fuel combustion. Additives can also be used to reduce the fuel freezing temperature when transporting or storing it. Peat, brown coal, and the pulp-and-paper industry wastes can serve as raw materials for preparation of additives.

The designed equipment sets for preparation of ACLF can be installed directly in heating stations, thermal power plants, as well as in centralized “green” coal fuel preparation unit stations.

3. Efficiency of transferring heating stations and thermal power plants to ACLF (figures taken from the calculations done by CJSC “Compomash-TEK”).

3.1. In cases coal heating stations and thermal power plants are transferred to ACLF.

Replacing 1 ton of regular coal with ACLF will allow to:

·        considerably reduce harmful emissions into the atmosphere and make the coal heating stations and thermal power plants operating on the “green” coal fuel environmentally friendly facilities;

·        save up to USD 20 on small and medium heating stations with fuel-bed firing, and up to USD 15 on big heating stations and thermal power plants.

The cost recovery term for the expenditures on upgrading coal heating stations and thermal power plants can be 2-4 years.

3.2. In cases gas and fuel oil heating stations and thermal power plants are transferred to ACLF.

Replacing 1 ton of fuel oil or 1000 nm3 of natural gas, taking into account the equal heat-production capacity, with ACLF will allow to save up to approximately USD 100. The cost recovery term, starting from the beginning of operation, for the expenditures on setting up ACLF preparation stations and upgrading the boiler units with the fuel feeding system will be up to 1-1.5 years.

To transfer to ACLF some upgrade of the oil-gas boiler units is required, for which we have developed special fuel nozzles and burner devices with nozzle heads in the form of furnace extensions with the function of spinning the combustible product and with an autonomous fly-ash-handling system in place of bottom-ash-handling system (see Fig. 2).

In each particular case of affixment of the ACLF preparation equipment the efficiency is specified.

3.3. In the light of the above, large-scale transfer of coal and oil-gas boiler units to “green” ACLF is appropriate both in economic and environmental terms and will allow to:

·        considerably reduce harmful emissions into the atmosphere, below the set standards, which will help the environment;

·        disengage part of the scarce types of heating station fuels – fuel oil and natural gas;

·        save regular coal due to 100% combustion efficiency;

·        reduce the cost price of the electric and thermal power produced at thermal power plants and heating station by 20-30%.

4. Upon agreement of Clients CJSC “Compomash-TEK” is ready to: conduct inspection of the selected coal or oil-gas power production units and the coals used to assess the efficiency of the transfer and develop business plans; propose a schedule of joint transfer of the facilities with supply of the necessary main equipment and contract supervision; carry out engineering setup and put the equipment into operation.

The technology and the equipment are protected by three Russian patents.

5. Organization of efficient use of “dirty”, ecological hazardous technical glycerin – by-product in rapeseed oil processing in bio-diesel fuel production.

Today many nations of the world switch part of their automobile transport to bio-diesel manufactured of rapeseed oil. Millions tons of “dirty” technical glycerin formed in this process cannot be used in an efficient way and its storage is a serious danger for the environment. Attempts to burn the “dirty” technical glycerin were accompanied by considerable detrimental emissions exceeding the established PDK (maximum permissible concentrations).

At the same time, Kompomash-TEK, CJSC has developed a technology for using the “dirty” glycerin, as a component for producing a new type of ecologically clean fuel oil – a fine-dispersed artificial composite liquid coal fuel (IKZHT), adding manufacturing water and “dirty” glycerin mixture to coal.

The proposed technical solutions include a new developed formulation for IKZHT, and the developed equipment with complex impact on suspension components in fuel production process, including mechanical-chemical, electric-magnetic impacts ensuring the production of fine-dispersed, stable environmentally sound fuel.

As proved by fire tests, the use of technical glycerin increases the fuel capacity of produced fuel oil and due to mechanical-chemical activation, dispersion and homogenization in firing there is no increase in the minimum formed detrimental emissions level. This fuel experimental production and firing have brought positive results.

Taking into consideration the physical and chemical properties of concrete coal type and “dirty” technical glycerin submitted by the Customer, Kompomash-TEK, CJSC is ready to develop IKZHT preparation formulation, to select special equipment for fine-dispersed crushing, mechanical-chemical and electric-magnetic impacts, manufacture and supply, provide supervision and start-up and adjustment works and putting into operation.

Director General,
Doctor of Science in Engineering, Professor
                                                 V.A. Moiseev



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e-mail: info@compomash-tek.ru