Coal Flaring

September 2007
Harworth Power Ltd
CMM Flaring
Harworth Power
Part of UK Coal PLC -Ex Nationalised “British Coal”

• UK Coal 4000 employees, 14Mt capacity, surface and deep mines
• VAM oxidation technology trialled on an operating coal mine
• CMM utilised in boilers since the 1960s
• CMM utilised in gas turbines and gas engines since 1991
• CMM utilised in high efficiency gas engines since 2000 (30MWe installed)
• CMM destructed in enclosed flares since 2004 (7 flares installed)
• Part of the UK ETS since 2001, 2.3Mt CO2e verified (3.9Mt total)
Separate unit specialising in assisting mines maximise capture, quality
and utilisation – engineers deployable to assist in design and
implementation
• Typical capture rates 40% - 60% of coal face district gas
• Typical gas quality 30% to 50% methane
• All gas is utilised in generators, boilers or flared
Key Issues in Flaring of CMM
• Gas is NOT utilised – but destroyed

• Safety
• Capital Cost
• Operating Cost
• Equipment Delivery
• Will the Government allow gas to be flared rather than
utilised?
• Ideal scenario in the US – distributed remote gas sources
without realistic or economic means us using heat,
electricity or low quality gas near the well head.
Coal to CMM Flaring
Coal Mining General Data
Kellingley Thoresby Welbeck Harworth Stillingfleet

Colliery Colliery Colliery Colliery Mine
Depth (m) 900 750 700 850 700
Tonnage (Mt) 1.455 Mt 0.829 Mt 0.868 Mt Mothballed Mine Closed Mine
Seam Thickness 2.1 1.85 1.85 2 3
Gas M3/tonne 5.3 5.2 5.0 6.2
Gas Typical Flow 400 – 600 250 - 350 350 - 450 650 – 850 950
Rate (l/s)
Gas Typical 40 – 50% 30 – 40% 35 – 45% 45 – 55% 80%
Concentration
Utilization / 2x 20,000 lb/hr 2x 1.4MWe gas 2x 20,000 lb/hr 2x 20,000 lb/hr 4x 3MWe gas
destruction dry sat steam engine generators dry sat steam dry sat steam engine generators
boilers 1x 2,000 Nm3/hr boilers boilers
3x 1.4MWe gas enclosed flare 2x 1.4MWe gas 5x 1.4MWe gas
engine generators engine generators engine generators
1x 2,000 Nm3/hr 2 x 2,000 Nm3/hr 1x 2,000 Nm3/hr
enclosed flare enclosed flare enclosed flare
18MWe CCGT
Overview
Gas Flaring.
Technology:
Destruction of drained methane gas through combustion in
a gas flare. 2000 Nm3/hr destruction capacity per flare.
Benefits:
A low capex cost technology with a short manufacture and
installation lead time.
Simple, low cost and reliable to operate, gas flaring offers a
very high potential for significant GHG reduction.
Low maintenance requirements.
Installation Requirements:
80 litres/s pure methane flow at 20% purity or above,
Methane drainage infrastructure already in place,

Suitable flame arrestor technology installed to prevent flame
propagation into the mine.
Mine Suitability:
A disciplined drainage approach ensuring that methane is
only drained above 20% purity.
Flare P&I Diagram
• 2000 Nm3/hr methane destruction capacity

• >27% CH4 for reliable flare start
• Flare will operate down to 20% CH4
• Automatic control
• Internet Remote Monitoring and Control
• Skid mounted for ease of installation
Importance of Gas Purity
• Gas will not burn or explode outside of the flammable

range
• Gas will not allow an existing flame to propagate into the
mine outside of the flammable range
• Multiple failsafe concentration transducers automatically
stop supply of gas to extraction pumps and flare
• Careful consideration of system T90 reaction period
• Only effective means of protection against lightning as an
ignition source
Flammability of Methane / Air at Atmospheric Pressure

and Temperature
The flammability of mixtures of Methane and Air
‘Coward Diagram’
B
20
C
Flammable
Region
15
D
Capable of forming
E flammable
Oxygen
mixtures with air
Concentration per se.
10
Not capable of
forming
flammable
5 mixtures with air
0 F
5 10 Methane 15 20
25
Concentration
Hierarchy of Explosion Prevention and Mitigation
1. Prevent formation of flammable atmosphere – measure

concentration and stop flow
2. Prevent exposure of ignition source to flammable
atmosphere – necessary for destruction / combustion
3. Prevent propagation through flammable mixture – use of
equipment/burner design, flame arresters and valves
4. Dissipate energy – bursting discs / relief valves / vents

5. Prevent of release of explosion energy – vessel and
pipework design
10
Flame Propagation in Pipework
Flame Speed
Overdriven Detonation
Choked flame speed (Mach 1)
M=1
Detonation
Deflagration
Point of
Ignition Direction of flame propagation
50 x Pipe Diameters
11
Specific Flare Safety Features
• Safety risk assessments carried out for

design and operation to prevent flashback
• HAZOP
• Hazardous Area Classification
• Flame Arrester suitability assessment
• Multiple redundancy and safety features
• Gas quality monitoring and oxygen inter-
trip
• PLC controlled with certain high integrity
functions duplicate hard wired
• Burner velocity design to prevent
flashback
• Temperature sensing to prevent flame
arrester burn through
• Purge for start-up
12
September 2007
Thank you
Neil Butler
Technical Director
44-7798-571612
nbutler@harworthpower.com
USA Coal Mine Methane Conference
The modern high temperature flare
St Louis, 26th September 2007
www.clarke-energy.com
Clarke Energy supplies, installs and maintains

HAASE flares
15
Cheap and dirty versus state-of-the-art
60% CH4 99.9% CH4

destruction destruction
16
HAASE flare types – high temperature continuous duty
and low temperature emergency
0.3s retention
•99.9% CH4 destruction
•CH4 down to 25% or lower

with propane assist at
ignition
•Turn down 5:1 or greater
HT type LT type 2 LT type 1

17
HAASE lining – 10 year guarantee
18
Cold side lining fixing
19
German and UK regulations
TA-Luft UK
NOX 200 mg/m3 150 mg/m3
CO 100 mg/m3 50 mg/m3
Temperature 1,200oC (1830oF) 1,000oC (2200oF)
(Reference 3% O2 by vol. in exhaust gas)
20
Naturally ventilated and fan ventilated
20MW
27MW
10:1 turndown
fan assisted
21
4 x 4500m3/h + 2 x 1500m3/h (1 @ 10:1 turndown)
Total –
105MW
10:1
turndown
22
HAASE lean gas flare (pilot) – down to 10%
methane
23
Telecontrol system – can record values for
carbon credits
On-site-control Remote control
24
Hatfield Colliery
4 x Roots blower delivering

880Nm3/h (each) at -500mbarg to
-100mbarg delivery
2 x Roots blower delivering

1660Nm3/h (each) at -100mbarg to
+200mbarg delivery
25
The HAASE state of the art high temperature flare
in summary;
99.9% CH4 destruction
Down to 25% CH4 , or lower with propane
assistance at ignition
Turn down ratio 5:1 standard, 10:1 or greater
optional
10 year lining guarantee
Exceeds German TA Luft requirements
26
Thank you!
Clarke Energy distributes GE Energy Jenbacher and HAASE
best in class products – supplying, installing and maintaining

Coal Flaring

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September 2007

Harworth Power Ltd

Part of UK Coal PLC -Ex Nationalised “British Coal”

Key Issues in Flaring of CMM

• Gas is NOT utilised – but destroyed

Coal to CMM Flaring

Coal Mining General Data

Kellingley Thoresby Welbeck Harworth Stillingfleet

Tonnage (Mt) 1.455 Mt 0.829 Mt 0.868 Mt Mothballed Mine Closed Mine

Seam Thickness 2.1 1.85 1.85 2 3

Gas M3/tonne 5.3 5.2 5.0 6.2

installation lead time.

Simple, low cost and reliable to operate, gas flaring offers a

very high potential for significant GHG reduction.

Low maintenance requirements.

Methane drainage infrastructure already in place,

Suitable flame arrestor technology installed to prevent flame

propagation into the mine.

Flare P&I Diagram

• 2000 Nm3/hr methane destruction capacity

Importance of Gas Purity

• Gas will not burn or explode outside of the flammable

Flammability of Methane / Air at Atmospheric Pressure

Hierarchy of Explosion Prevention and Mitigation

1. Prevent formation of flammable atmosphere – measure

equipment/burner design, flame arresters and valves

4. Dissipate energy – bursting discs / relief valves / vents

Flame Propagation in Pipework

Specific Flare Safety Features

• Safety risk assessments carried out for

The modern high temperature flare

St Louis, 26th September 2007

Clarke Energy supplies, installs and maintains

60% CH4 99.9% CH4

•99.9% CH4 destruction

•CH4 down to 25% or lower

•Turn down 5:1 or greater

HT type LT type 2 LT type 1

(Reference 3% O2 by vol. in exhaust gas)

On-site-control Remote control

 4 x Roots blower delivering

 2 x Roots blower delivering

 99.9% CH4 destruction

 Down to 25% CH4 , or lower with propane

 Turn down ratio 5:1 standard, 10:1 or greater

 10 year lining guarantee

 Exceeds German TA Luft requirements

Clarke Energy distributes GE Energy Jenbacher and HAASE

best in class products – supplying, installing and maintaining

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4 x Roots blower delivering

2 x Roots blower delivering

99.9% CH4 destruction

Down to 25% CH4 , or lower with propane

Turn down ratio 5:1 standard, 10:1 or greater

10 year lining guarantee

Exceeds German TA Luft requirements