Types of coal

As geological processes apply pressure to peat over time, it is transformed successively into
Lignite, also referred to as brown coal, is the lowest rank of coal and used almost exclusively as fuel for steam-electric power generation. Jet is a compact form of lignite that is sometimes polished and has been used as an ornamental stone since the Iron Age.

Sub-bituminous coal, whose properties range from those of lignite to those of bituminous coal and are used primarily as fuel for steam-electric power generation.
Bituminous coal, a dense coal, usually black, sometimes dark brown, often with well-defined bands of bright and dull material, used primarily as fuel in steam-electric power generation, with substantial quantities also used for heat and power applications in manufacturing and to make coke.
Anthracite, the highest rank; a harder, glossy, black coal used primarily for residential and commercial space heating.
Graphite, technically the highest rank, but difficult to ignite and is not so commonly used as fuel.

Early use

Outcrop coal was used in Britain during the Bronze Age (2-3000 years BC), where it has been detected as forming part of the composition of funeral pyres. It was also commonly used in the early period of the Roman occupation. Evidence of trade in coal (dated to about AD200) has been found at the inland port of Heronbridge, near Chester, and in the Fenlands of East Anglia, where coal from the Midlands was transported via the Car Dyke for use in drying grain. Coal cinders have been found in the hearths of villas and military forts, particularly in Northumberland, dated to around AD400. In the west of England contemporary writers described the wonder of a permanent brazier of coal on the altar of Minerva at Aquae Sulis (modern day Bath) although in fact easily-accessible surface coal from what is now the Somerset coalfield was in common use in quite lowly dwellings locally.

However, there is no evidence that the product was of great importance in Britain before the High Middle Ages, after about AD1000. Mineral coal came to be referred to as "seacoal," probably because it came to many places in eastern England, including London, by sea. This is accepted as the more likely explanation for the name than that it was found on beaches, having fallen from the exposed coal seams above or washed out of underwater coal seam outcrops. These easily accessible sources had largely become exhausted (or could not meet the growing demand) by the 13th century, when underground mining from shafts or adits was developed. In London there is still a Seacoal Lane (off the north side of Ludgate Hill) where the coal merchants used to conduct their business. An alternative name was "pitcoal," because it came from mines. It was, however, the development of the Industrial Revolution that led to the large-scale use of coal, as the steam engine took over from the water wheel.


Uses today

Coal rail cars in Ashtabula, Ohio.


Coal as fuel

See also Clean coal and Fossil fuel power plant

Coal is primarily used as a solid fuel to produce electricity and heat through combustion. World coal consumption is about 5.3 billion tons annually, of which about 75% is used for the production of electricity. The region including the People's Republic of China and India uses about 1.7 billion tonnes annually, forecast to exceed 2.7 billion tonnes in 2025. The USA consumes about 1.0 billion tons of coal each year, using 90% of it for generation of electricity.

When coal is used for electricity generation, it is usually pulverized and then burned in a furnace with a boiler. The furnace heat converts boiler water to steam, which is then used to spin turbines which turn generators and create electricity. The thermodynamic efficiency of this process has been improved over time. "Standard" steam turbines have topped out with some of the most advanced reaching about 35% thermodynamic efficiency for the entire process, which means 65% of the coal energy is rejected as waste heat into the surrounding environment. Old coal power plants, especially "grandfathered" plants, are significantly less efficient and reject higher levels of waste heat. The emergence of the supercritical turbine concept envisions running a boiler at extremely high temperatures and pressures with projected efficiencies of 46%, with further theorized increases in temperature and pressure perhaps resulting in even higher efficiencies[5] Approximately 40% of the world electricity production uses coal. The total known deposits recoverable by current technologies, including highly polluting, low energy content types of coal (i.e., lignite, bituminous), might be sufficient for 300 years' use at current consumption levels, although maximal production could be reached within decades (see World Coal Reserves, below).

A more energy-efficient way of using coal for electricity production would be via solid-oxide fuel cells or molten-carbonate fuel cells (or any oxygen ion transport based fuel cells that do not discriminate between fuels, as long as they consume oxygen), which would be able to get 60%–85% combined efficiency (direct electricity + waste heat steam turbine). Currently these fuel cell technologies can only process gaseous fuels, and they are also sensitive to sulfur poisoning, issues which would first have to be worked out before large scale commercial success is possible with coal. As far as gaseous fuels go, one idea is pulverized coal in a gas carrier, such as nitrogen. Another option is coal gasification with water, which may lower fuel cell voltage by introducing oxygen to the fuel side of the electrolyte, but may also greatly simplify carbon sequestration.


Coking and use of coke

Main article: Coke (fuel)

Coke is a solid carbonaceous residue derived from low-ash, low-sulfur bituminous coal from which the volatile constituents are driven off by baking in an oven without oxygen at temperatures as high as 1,000 °C (1,832 °F) so that the fixed carbon and residual ash are fused together. Metallurgic coke is used as a fuel and as a reducing agent in smelting iron ore in a blast furnace. Coke from coal is grey, hard, and porous and has a heating value of 24.8 million Btu/ton (29.6 MJ/kg). Byproducts of this conversion of coal to coke include coal tar, ammonia, light oils, and "coal gas".

Petroleum coke is the solid residue obtained in oil refining, which resembles coke but contains too many impurities to be useful in metallurgical applications.


Gasification

High prices of oil and natural gas are leading to increased interest in "BTU Conversion" technologies such as gasification, methanation and liquefaction.

Coal gasification breaks down the coal into its components, usually by subjecting it to high temperature and pressure, using steam and measured amounts of oxygen. This leads to the production of syngas, a mixture mainly consisting of carbon monoxide (CO) and hydrogen (H2).

In the past, coal was converted to make coal gas, which was piped to customers to burn for illumination, heating, and cooking. At present, the safer natural gas is used instead. South Africa still uses gasification of coal for much of its petrochemical needs.

The Synthetic Fuels Corporation was a U.S. government-funded corporation established in 1980 to create a market for alternatives to imported fossil fuels (such as coal gasification). The corporation was discontinued in 1985.

Gasification is also a possibility for future energy use, as the produced syngas can be cleaned-up relatively easily leading to cleaner burning than burning coal directly (the conventional way). The cleanliness of the cleaned-up syngas is comparable to natural gas enabling to burn it in a more efficient gas turbine rather than in a boiler used to drive a steam turbine. Syngas produced by gasification can be CO-shifted meaning that the combustible CO in the syngas is transferred into carbon dioxide (CO2) using water as a reactant. The CO-shift reaction also produces an amount of combustible hydrogen (H2) equal to the amount of CO converted into CO2. The CO2 concentrations (or rather CO2 partial pressures) obtained by using coal gasification followed by a CO-shift reaction are much higher than in case of direct combustion of coal in air (which is mostly nitrogen). These higher concentrations of carbon dioxide make carbon capture and storage much more economical than it otherwise would be.

Liquefaction

Coal can also be converted into liquid fuels like gasoline or diesel by several different processes. The Fischer-Tropsch process of indirect synthesis of liquid hydrocarbons was used in Nazi Germany for many years and is today used by Sasol in South Africa. Coal would be gasified to make syngas (a balanced purified mixture of CO and H2 gas) and the syngas condensed using Fischer-Tropsch catalysts to make light hydrocarbons which are further processed into gasoline and diesel. Syngas can also be converted to methanol, which can be used as a fuel, fuel additive, or further processed into gasoline via the Mobil M-gas process.

A direct liquefaction process Bergius process (liquefaction by hydrogenation) is also available but has not been used outside Germany, where such processes were operated both during World War I and World War II. SASOL in South Africa has experimented with direct hydrogenation. Several other direct liquefaction processes have been developed, among these being the SRC-I and SRC-II (Solvent Refined Coal) processes developed by Gulf Oil and implemented as pilot plants in the United States in the 1960s and 1970s.