Learn common processes of geologic formation of rock and mineral resources.
This section introduces you to the processes leading to the formation of common rock and mineral resources. You will learn how and why these processes work and how they are different.
What You’ll Learn to Do
- Describe the different processes that lead to various ore formation
- Describe the processes that lead to the formation of all fossil fuels: petroleum, natural gas, and coal
The various theories of ore genesis explain how the various types of mineral deposits form within the Earth’s crust. Ore genesis theories are dependent on the mineral or commodity.
Ore genesis theories generally involve three components: source, transport or conduit, and trap. This also applies to the petroleum industry, which was first to use this methodology.
- Source is required because metal must come from somewhere, and be liberated by some process
- Transport is required first to move the metal bearing fluids or solid minerals into the right position, and refers to the act of physically moving the metal, as well as chemical or physical phenomenon which encourage movement
- Trapping is required to concentrate the metal via some physical, chemical or geological mechanism into a concentration which forms mineable ore
The biggest deposits are formed when the source is large, the transport mechanism is efficient, and the trap is active and ready at the right time.
Ore Genesis Processes
- Fractional crystallization: separates ore and non-ore minerals according to their crystallization temperature. As early crystallizing minerals form, they incorporate certain elements, some of which are metals. These crystals may settle onto the bottom of the intrusion, concentrating ore minerals there. Chromite and magnetite are ore minerals that form in this way.
- Liquid immiscibility: sulfide ores containing copper, nickel or platinum may form from this process. As a magma changes, parts of it may separate from the main body of magma. Two liquids that will not mix are called immiscible; oil and water are an example. In magmas, sulfides may separate and sink below the silicate-rich part of the intrusion or be injected into the rock surrounding it. These deposits are found in mafic and ultramafic rocks.
These processes are the physicochemical phenomena and reactions caused by movement of hydrothermal water within the crust, often as a consequence of magmatic intrusion or tectonic upheavals. The foundations of hydrothermal processes are the source-transport-trap mechanism.
Sources of hydrothermal solutions include seawater and meteoric water circulating through fractured rock, formational brines (water trapped within sediments at deposition) and metamorphic fluids created by dehydration of hydrous minerals during metamorphism.
Metal sources may include a plethora of rocks. However most metals of economic importance are carried as trace elements within rock-forming minerals, and so may be liberated by hydrothermal processes. This happens because of:
- incompatibility of the metal with its host mineral, for example zinc in calcite, which favours aqueous fluids in contact with the host mineral during diagenesis.
- solubility of the host mineral within nascent hydrothermal solutions in the source rocks, for example mineral salts (halite), carbonates (cerussite), phosphates (monazite and thorianite) and sulfates (barite)
- elevated temperatures causing decomposition reactions of minerals
Transport by hydrothermal solutions usually requires a salt or other soluble species which can form a metal-bearing complex. These metal-bearing complexes facilitate transport of metals within aqueous solutions, generally as hydroxides, but also by processes similar to chelation.
This process is especially well understood in gold metallogeny where various thiosulfate, chloride and other gold-carrying chemical complexes (notably tellurium-chloride/sulfate or antimony-chloride/sulfate). The majority of metal deposits formed by hydrothermal processes include sulfide minerals, indicating sulfur is an important metal-carrying complex.
Sulfide deposition: Sulfide deposition within the trap zone occurs when metal-carrying sulfate, sulfide or other complexes become chemically unstable due to one or more of the following processes;
- falling temperature, which renders the complex unstable or metal insoluble
- loss of pressure, which has the same effect
- reaction with chemically reactive wall rocks, usually of reduced oxidation state, such as iron bearing rocks, mafic or ultramafic rocks or carbonate rocks
- degassing of the hydrothermal fluid into a gas and water system, or boiling, which alters the metal carrying capacity of the solution and even destroys metal-carrying chemical complexes
Metal can also become precipitated when temperature and pressure or oxidation state favour different ionic complexes in the water, for instance the change from sulfide to sulfate, oxygen fugacity, exchange of metals between sulfide and chloride complexes, et cetera.
Lateral secretion: Ore deposits formed by lateral secretion are formed by metamorphic reactions during shearing, which liberate mineral constituents such as quartz, sulfides, gold, carbonates and oxides from deforming rocks and focus these constituents into zones of reduced pressure or dilation such as faults. This may occur without much hydrothermal fluid flow, and this is typical of podiform chromite deposits.
Metamorphic processes also control many physical processes which form the source of hydrothermal fluids, outlined above.
Surficial Processes (Exogenous)
Surficial processes are the physical and chemical phenomena which cause concentration of ore material within the regolith, generally by the action of the environment. This includes placerdeposits, laterite deposits and residual or eluvial deposits. The physical processes of ore deposit formation in the surficial realm include;
- deposition by sedimentary processes, including winnowing, density separation (e.g.; gold placers)
- weathering via oxidation or chemical attack of a rock, either liberating rock fragments or creating chemically deposited clays, laterites or supergene enrichment
- Deposition in low-energy environments in beach environments
Classification of Ore Deposits
Ore deposits are usually classified by ore formation processes and geological setting. For example, SEDEX deposits, literally meaning “sedimentary exhalative” are a class of ore deposit formed on the sea floor (sedimentary) by exhalation of brines into seawater (exhalative), causing chemical precipitation of ore minerals when the brine cools, mixes with sea water and loses its metal carrying capacity.
Ore deposits rarely fit snugly into the boxes in which geologists wish to place them. Many may be formed by one or more of the basic genesis processes above, creating ambiguous classifications and much argument and conjecture. Often ore deposits are classified after examples of their type, for instance Broken Hill type lead-zinc-silver deposits or Carlin–type gold deposits.
Classification of hydrothermal ore deposits is also achieved by classifying according to the temperature of formation, which roughly also correlates with particular mineralising fluids, mineral associations and structural styles. This scheme, proposed by Waldemar Lindgren (1933) classified hydrothermal deposits as hypothermal, mesothermal, epithermal and telethermal.
Genesis of Common Ores
As they require the conjunction of specific environmental conditions to form, particular mineral deposit types tend to occupy specific geodynamic niches, therefore, this page has been organised by metal commodity. It is also possible to organise theories the other way, namely according to geological criteria of formation. Often ores of the same metal can be formed by multiple processes, and this is described here under each metal or metal complex.
Iron ores are overwhelmingly derived from ancient sediments known as banded iron formations (BIFs). These sediments are composed of iron oxide minerals deposited on the sea floor. Particular environmental conditions are needed to transport enough iron in sea water to form these deposits, such as acidic and oxygen-poor atmospheres within the Proterozoic Era.
Often, more recent weathering is required to convert the usual magnetite minerals into more easily processed hematite. Some iron deposits within the Pilbara of West Australia are placer deposits, formed by accumulation of hematite gravels called pisolites which form channel-iron deposits. These are preferred because they are cheap to mine.
Lead Zinc Silver
Lead-zinc deposits are generally accompanied by silver, hosted within the lead sulfide mineral galena or within the zinc sulfide mineral sphalerite.
Lead and zinc deposits are formed by discharge of deep sedimentary brine onto the sea floor (termed sedimentary exhalative or SEDEX), or by replacement of limestone, in skarn deposits, some associated with submarine volcanoes (called volcanogenic massive sulfide ore deposits or VMS) or in the aureole of subvolcanic intrusions of granite. The vast majority of SEDEX lead and zinc deposits are Proterozoic in age, although there are significant Jurassic examples in Canada and Alaska.
The carbonate replacement type deposit is exemplified by the Mississippi valley type (MVT) ore deposits. MVT and similar styles occur by replacement and degradation of carbonate sequences byhydrocarbons, which are thought important for transporting lead.
Gold deposits are formed via a very wide variety of geological processes. Deposits are classified as primary, alluvial or placerdeposits, or residual or laterite deposits. Often a deposit will contain a mixture of all three types of ore.
Plate tectonics is the underlying mechanism for generating gold deposits. The majority of primary gold deposits fall into two main categories: lode gold deposits or intrusion-related deposits.
Lode gold deposits are generally high-grade, thin, vein and fault hosted. They are primarily made up of quartz veins also known as lodes or reefs, which contain either native gold or gold sulfides and tellurides. Lode gold deposits are usually hosted in basalt or in sediments known as turbidite, although when in faults, they may occupy intrusive igneous rocks such as granite.
Lode-gold deposits are intimately associated with orogeny and other plate collision events within geologic history. Most lode gold deposits sourced from metamorphic rocks because it is thought that the majority are formed by dehydration of basalt during metamorphism. The gold is transported up faults by hydrothermal waters and deposited when the water cools too much to retain gold in solution.
Intrusive related gold is generally hosted in granites, porphyry or rarely dikes. Intrusive related gold usually also contains copper, and is often associated with tin and tungsten, and rarely molybdenum, antimony and uranium. Intrusive-related gold deposits rely on gold existing in the fluids associated with the magma (White, 2001), and the inevitable discharge of thesehydrothermal fluids into the wall-rocks (Lowenstern, 2001). Skarn deposits are another manifestation of intrusive-related deposits.
Placer deposits are sourced from pre-existing gold deposits and are secondary deposits. Placer deposits are formed by alluvialprocesses within rivers, streams and on beaches. Placer gold deposits form via gravity, with the density of gold causing it to sink into trap sites within the river bed, or where water velocity drops, such as bends in rivers and behind boulders. Often placer deposits are found within sedimentary rocks and can be billions of years old, for instance the Witwatersrand deposits in South Africa. Sedimentary placer deposits are known as “leads” or “deep leads.”
Placer deposits are often worked by fossicking, and panning for gold is a popular pastime.
Laterite gold deposits are formed from pre-existing gold deposits (including some placer deposits) during prolonged weathering of the bedrock. Gold is deposited within iron oxides in the weathered rock or regolith, and may be further enriched by reworking by erosion. Some laterite deposits are formed by wind erosion of the bedrock leaving a residuum of native gold metal at surface.
A bacterium, Cupriavidus metallidurans plays a vital role in the formation of gold nuggets, by precipitating metallic gold from a solution of gold (III) tetrachloride, a compound highly toxic to most other microorganisms. Similarly, Delftia acidovorans can form gold nuggets.
Platinum and palladium are precious metals generally found in ultramafic rocks. The source of platinum and palladium deposits is ultramafic rocks which have enough sulfur to form a sulfide mineral while the magma is still liquid. This sulfide mineral (usually pentlandite, pyrite, chalcopyrite or pyrrhotite) gains platinum by mixing with the bulk of the magma because platinum is chalcophile and is concentrated in sulfides. Alternatively, platinum occurs in association with chromite either within the chromite mineral itself or within sulfides associated with it.
Sulfide phases only form in ultramafic magmas when the magma reaches sulfur saturation. This is generally thought to be nearly impossible by pure fractional crystallisation, so other processes are usually required in ore genesis models to explain sulfur saturation. These include contamination of the magma with crustal material, especially sulfur-rich wall-rocks or sediments; magma mixing; volatile gain or loss.
Often platinum is associated with nickel, copper, chromium, and cobalt deposits.
Nickel deposits are generally found in two forms, either as sulfide or laterite.
Sulfide type nickel deposits are formed in essentially the same manner as platinum deposits. Nickel is a chalcophile element which prefers sulfides, so an ultramafic or mafic rock which has a sulfide phase in the magma may form nickel sulfides. The best nickel deposits are formed where sulfide accumulates in the base of lava tubes or volcanic flows—especially komatiite lavas.
Komatiitic nickel-copper sulfide deposits are considered to be formed by a mixture of sulfide segregation, immiscibility, and thermal erosion of sulfidic sediments. The sediments are considered to be necessary to promote sulfur saturation.
Some subvolcanic sills in the Thompson Belt of Canada host nickel sulfide deposits formed by deposition of sulfides near the feeder vent. Sulfide was accumulated near the vent due to the loss of magma velocity at the vent interface. The massive Voisey’s Bay nickel deposit is considered to have formed via a similar process.
The process of forming nickel laterite deposits is essentially similar to the formation of gold laterite deposits, except that ultramafic or mafic rocks are required. Generally nickel laterites require very large olivine-bearing ultramafic intrusions. Minerals formed in laterite nickel deposits include gibbsite.
Copper is found in association with many other metals and deposit styles. Commonly, copper is either formed within sedimentary rocks, or associated with igneous rocks.
The world’s major copper deposits are formed within the granitic porphyry copper style. Copper is enriched by processes during crystallisation of the granite and forms as chalcopyrite—a sulfide mineral, which is carried up with the granite.
Sometimes granites erupt to surface as volcanoes, and copper mineralisation forms during this phase when the granite and volcanic rocks cool via hydrothermal circulation.
Sedimentary copper forms within ocean basins in sedimentary rocks. Generally this forms by brine from deeply buried sediments discharging into the deep sea, and precipitating copper and oftenlead and zinc sulfides directly onto the sea floor. This is then buried by further sediment. This is a process similar to SEDEX zinc and lead, although some carbonate-hosted examples exist.
Often copper is associated with gold, lead, zinc and nickel deposits.
Uranium deposits are usually sourced from radioactive granites, where certain minerals such as monazite are leached during hydrothermal activity or during circulation of groundwater. The uranium is brought into solution by acidic conditions and is deposited when this acidity is neutralised. Generally this occurs in certain carbon-bearing sediments, within an unconformity in sedimentary strata. The majority of the world’s nuclear power is sourced from uranium in such deposits.
Uranium is also found in nearly all coal at several parts per million, and in all granites. Radon is a common problem during mining of uranium as it is a radioactive gas.
Uranium is also found associated with certain igneous rocks, such as granite and porphyry. The Olympic Dam deposit in Australia is an example of this type of uranium deposit. It contains 70% of Australia’s share of 40% of the known global low-cost recoverable uranium inventory.
Titanium and Zirconium
Mineral sands are the predominant type of titanium, zirconium and thorium deposit. They are formed by accumulation of such heavy minerals within beach systems, and are a type of placer deposits. The minerals which contain titanium are ilmenite, rutile and leucoxene, zirconium is contained within zircon, and thorium is generally contained within monazite. These minerals are sourced from primarily granite bedrock by erosion and transported to the sea by rivers where they accumulate within beach sands. Rarely, but importantly, gold, tin and platinum deposits can form in beach placer deposits.
Tin, Tungsten, and Molybdenum
These three metals generally form in a certain type of granite, via a similar mechanism to intrusive-related gold and copper. They are considered together because the process of forming these deposits is essentially the same. Skarn type mineralisation related to these granites is a very important type of tin, tungsten and molybdenum deposit. Skarn deposits form by reaction of mineralised fluids from the granite reacting with wall rocks such as limestone. Skarn mineralisation is also important in lead, zinc, copper, gold and occasionally uranium mineralisation.
Greisen granite is another related tin-molybdenum and topaz mineralisation style.
Rare Earth Elements, Niobium, Tantalum, Lithium
The overwhelming majority of rare earth elements, tantalum and lithium are found within pegmatite. Ore genesis theories for these ores are wide and varied, but most involve metamorphism and igneous activity. Lithium is present as spodumene or lepidolite within pegmatite.
Carbonatite intrusions are an important source of these elements. Ore minerals are essentially part of the unusual mineralogy of carbonatite.
Phosphate is used in fertilisers. Immense quantities of phosphate rock or phosphorite occur in sedimentary shelf deposits, ranging in age from the Proterozoic to currently forming environments. Phosphate deposits are thought to be sourced from the skeletons of dead sea creatures which accumulated on the seafloor. Similar to iron ore deposits and oil, particular conditions in the ocean and environment are thought to have contributed to these deposits within the geological past.
Phosphate deposits are also formed from alkaline igneous rocks such as nepheline syenites, carbonatites and associated rock types. The phosphate is, in this case, contained within magmaticapatite, monazite or other rare-earth phosphates.
Due to the presence of vanabins, concentration of vanadium found in the blood cells of Ascidia gemmata belonging to the suborder Phlebobranchia is 10,000,000 times higher than that in the surrounding seawater. A similar biological process might have played a role in the formation of vanadium ores. Vanadium is also present in fossil fuel deposits such as crude oil, coal, oil shale and oil sands. In crude oil, concentrations up to 1200 ppm have been reported.
Petroleum is a naturally occurring, yellow-to-black liquid found in geological formations beneath the Earth’s surface, which is commonly refined into various types of fuels.
It consists of hydrocarbons of various molecular weights and other organic compounds. The name petroleum covers both naturally occurring unprocessed crude oil and petroleum products that are made up of refined crude oil. A fossil fuel, petroleum is formed when large quantities of dead organisms, usually zooplankton and algae, are buried underneath sedimentary rock and subjected to intense heat and pressure.
Petroleum is recovered mostly through oil drilling (natural petroleum springs are rare). This comes after the studies of structural geology (at the reservoir scale), sedimentary basin analysis, reservoir characterization (mainly in terms of the porosity and permeability of geologic reservoir structures). It is refined and separated, most easily by distillation, into a large number of consumer products, from gasoline (petrol) and kerosene to asphalt and chemical reagents used to make plastics and pharmaceuticals. Petroleum is used in manufacturing a wide variety of materials, and it is estimated that the world consumes about 90 million barrels each day.
Concern over the depletion of the earth’s finite reserves of oil, and the effect this would have on a society dependent on it, is a concept known as peak oil. The use of fossil fuels, such as petroleum, has a negative impact on Earth’s biosphere, damaging ecosystems through events such as oil spills and releasing a range of pollutants into the air including ground-level ozone and sulfur dioxide from sulfur impurities in fossil fuels.
In its strictest sense, petroleum includes only crude oil, but in common usage it includes all liquid, gaseous, and solid hydrocarbons. Under surface pressure and temperature conditions, lighter hydrocarbons methane, ethane, propane and butane occur as gases, while pentane and heavier ones are in the form of liquids or solids. However, in an underground oil reservoir the proportions of gas, liquid, and solid depend on subsurface conditions and on the phase diagram of the petroleum mixture.
An oil well produces predominantly crude oil, with some natural gas dissolved in it. Because the pressure is lower at the surface than underground, some of the gas will come out of solution and be recovered (or burned) as associated gas or solution gas. A gas well produces predominantly natural gas. However, because the underground temperature and pressure are higher than at the surface, the gas may contain heavier hydrocarbons such as pentane, hexane, and heptane in the gaseous state. At surface conditions these will condense out of the gas to form natural gas condensate, often shortened to condensate. Condensate resembles gasoline in appearance and is similar in composition to some volatile light crude oils.
The proportion of light hydrocarbons in the petroleum mixture varies greatly among different oil fields, ranging from as much as 97 percent by weight in the lighter oils to as little as 50 percent in the heavier oils and bitumens.
The hydrocarbons in crude oil are mostly alkanes, cycloalkanes and various aromatic hydrocarbons while the other organic compounds contain nitrogen, oxygen and sulfur, and trace amounts of metals such as iron, nickel, copper and vanadium. Many oil reservoirs contain live bacteria. The exact molecular composition varies widely from formation to formation but the proportion of chemical elements vary over fairly narrow limits as follows:
|Carbon||83 to 85%|
|Hydrogen||10 to 14%|
|Nitrogen||0.1 to 2%|
|Oxygen||0.05 to 1.5%|
|Sulfur||0.05 to 6.0%|
Four different types of hydrocarbon molecules appear in crude oil. The relative percentage of each varies from oil to oil, determining the properties of each oil.
|Alkanes (paraffins)||30%||15 to 60%|
|Naphthenes||49%||30 to 60%|
|Aromatics||15%||3 to 30%|
Crude oil varies greatly in appearance depending on its composition. It is usually black or dark brown (although it may be yellowish, reddish, or even greenish). In the reservoir it is usually found in association with natural gas, which being lighter forms a gas cap over the petroleum, and saline water which, being heavier than most forms of crude oil, generally sinks beneath it. Crude oil may also be found in semi-solid form mixed with sand and water, as in the Athabasca oil sands in Canada, where it is usually referred to as crude bitumen. In Canada, bitumen is considered a sticky, black, tar-like form of crude oil which is so thick and heavy that it must be heated or diluted before it will flow. Venezuela also has large amounts of oil in the Orinoco oil sands, although the hydrocarbons trapped in them are more fluid than in Canada and are usually called extra heavy oil. These oil sands resources are called unconventional oil to distinguish them from oil which can be extracted using traditional oil well methods. Between them, Canada and Venezuela contain an estimated 3.6 trillion barrels (570 × 109 m3) of bitumen and extra-heavy oil, about twice the volume of the world’s reserves of conventional oil.
Petroleum is used mostly, by volume, for producing fuel oil and gasoline, both important “primary energy” sources. 84 percent by volume of the hydrocarbons present in petroleum is converted into energy-rich fuels (petroleum-based fuels), including gasoline, diesel, jet, heating, and other fuel oils, and liquefied petroleum gas. The lighter grades of crude oil produce the best yields of these products, but as the world’s reserves of light and medium oil are depleted, oil refineries are increasingly having to process heavy oil and bitumen, and use more complex and expensive methods to produce the products required. Because heavier crude oils have too much carbon and not enough hydrogen, these processes generally involve removing carbon from or adding hydrogen to the molecules, and using fluid catalytic cracking to convert the longer, more complex molecules in the oil to the shorter, simpler ones in the fuels.
Due to its high energy density, easy transportability and relative abundance, oil has become the world’s most important source of energy since the mid-1950s. Petroleum is also the raw material for many chemical products, including pharmaceuticals, solvents, fertilizers, pesticides, and plastics; the 16 percent not used for energy production is converted into these other materials. Petroleum is found in porous rock formations in the upper strata of some areas of the Earth’s crust. There is also petroleum in oil sands (tar sands). Known oil reserves are typically estimated at around 190 km3(1.2 trillion (short scale) barrels) without oil sands, or 595 km3 (3.74 trillion barrels) with oil sands. Consumption is currently around 84 million barrels (13.4×106 m3) per day, or 4.9 km3 per year. Which in turn yields a remaining oil supply of only about 120 years, if current demand remain static.
Petroleum is a fossil fuel derived from ancient fossilized organic materials, such as zooplankton and algae. Vast quantities of these remains settled to sea or lake bottoms, mixing with sediments and being buried under anoxic conditions. As further layers settled to the sea or lake bed, intense heat and pressure build up in the lower regions. This process caused the organic matter to change, first into a waxy material known as kerogen, which is found in various oil shales around the world, and then with more heat into liquid and gaseous hydrocarbons via a process known as catagenesis. Formation of petroleum occurs from hydrocarbon pyrolysis in a variety of mainly endothermic reactions at high temperature and/or pressure.
There were certain warm nutrient-rich environments such as the Gulf of Mexico and the ancient Tethys Sea where the large amounts of organic material falling to the ocean floor exceeded the rate at which it could decompose. This resulted in large masses of organic material being buried under subsequent deposits such as shale formed from mud. This massive organic deposit later became heated and transformed under pressure into oil.
Geologists often refer to the temperature range in which oil forms as an “oil window”—below the minimum temperature oil remains trapped in the form of kerogen, and above the maximum temperature the oil is converted to natural gas through the process of thermal cracking. Sometimes, oil formed at extreme depths may migrate and become trapped at a much shallower level. The Athabasca Oil Sands are one example of this.
An alternative mechanism was proposed by Russian scientists in the mid-1850s, the Abiogenic petroleum origin, but this is contradicted by the geological and geochemical evidence.
Crude Oil Reservoirs
Three conditions must be present for oil reservoirs to form: a source rock rich in hydrocarbon material buried deep enough for subterranean heat to cook it into oil, a porous and permeable reservoir rock for it to accumulate in, and a cap rock (seal) or other mechanism that prevents it from escaping to the surface. Within these reservoirs, fluids will typically organize themselves like a three-layer cake with a layer of water below the oil layer and a layer of gas above it, although the different layers vary in size between reservoirs. Because most hydrocarbons are less dense than rock or water, they often migrate upward through adjacent rock layers until either reaching the surface or becoming trapped within porous rocks (known as reservoirs) by impermeable rocks above. However, the process is influenced by underground water flows, causing oil to migrate hundreds of kilometres horizontally or even short distances downward before becoming trapped in a reservoir. When hydrocarbons are concentrated in a trap, an oil field forms, from which the liquid can be extracted by drilling and pumping.
The reactions that produce oil and natural gas are often modeled as first order breakdown reactions, where hydrocarbons are broken down to oil and natural gas by a set of parallel reactions, and oil eventually breaks down to natural gas by another set of reactions. The latter set is regularly used in petrochemical plants and oil refineries.
Wells are drilled into oil reservoirs to extract the crude oil. “Natural lift” production methods that rely on the natural reservoir pressure to force the oil to the surface are usually sufficient for a while after reservoirs are first tapped. In some reservoirs, such as in the Middle East, the natural pressure is sufficient over a long time. The natural pressure in most reservoirs, however, eventually dissipates. Then the oil must be extracted using “artificial lift” means. Over time, these “primary” methods become less effective and “secondary” production methods may be used. A common secondary method is “waterflood” or injection of water into the reservoir to increase pressure and force the oil to the drilled shaft or “wellbore.” Eventually “tertiary” or “enhanced” oil recovery methods may be used to increase the oil’s flow characteristics by injecting steam, carbon dioxide and other gases or chemicals into the reservoir. In the United States, primary production methods account for less than 40 percent of the oil produced on a daily basis, secondary methods account for about half, and tertiary recovery the remaining 10 percent. Extracting oil (or “bitumen”) from oil/tar sand and oil shale deposits requires mining the sand or shale and heating it in a vessel or retort, or using “in-situ” methods of injecting heated liquids into the deposit and then pumping out the oil-saturated liquid.
Unconventional oil reservoirs
Oil-eating bacteria biodegrade oil that has escaped to the surface. Oil sands are reservoirs of partially biodegraded oil still in the process of escaping and being biodegraded, but they contain so much migrating oil that, although most of it has escaped, vast amounts are still present—more than can be found in conventional oil reservoirs. The lighter fractions of the crude oil are destroyed first, resulting in reservoirs containing an extremely heavy form of crude oil, called crude bitumen in Canada, or extra-heavy crude oil in Venezuela. These two countries have the world’s largest deposits of oil sands.
On the other hand, oil shales are source rocks that have not been exposed to heat or pressure long enough to convert their trapped hydrocarbons into crude oil. Technically speaking, oil shales are not always shales and do not contain oil, but are fined-grain sedimentary rocks containing an insoluble organic solid called kerogen. The kerogen in the rock can be converted into crude oil using heat and pressure to simulate natural processes. The method has been known for centuries and was patented in 1694 under British Crown Patent No. 330 covering, “A way to extract and make great quantities of pitch, tar, and oil out of a sort of stone.” Although oil shales are found in many countries, the United States has the world’s largest deposits.
Natural gas is a fossil fuel formed when layers of buried plants, gases, and animals are exposed to intense heat and pressure over thousands of years. The energy that the plants originally obtained from the sun is stored in the form of chemical bonds in natural gas. Natural gas is a nonrenewable resource because it cannot be replenished on a human time frame. Natural gas is a hydrocarbon gas mixture consisting primarily of methane, but commonly includes varying amounts of other higher alkanes and sometimes a usually lesser percentage of carbon dioxide, nitrogen, and/or hydrogen sulfide. Natural gas is an energy source often used for heating, cooking, and electricity generation. It is also used as fuel for vehicles and as a chemical feedstock in the manufacture of plastics and other commercially important organic chemicals.
Natural gas is found in deep underground rock formations or associated with other hydrocarbon reservoirs in coal beds and as methane clathrates. Petroleum is another resource and fossil fuel found in close proximity to, and with natural gas. Most natural gas was created over time by two mechanisms: biogenic and thermogenic. Biogenic gas is created by methanogenic organisms in marshes, bogs, landfills, and shallow sediments. Deeper in the earth, at greater temperature and pressure, thermogenic gas is created from buried organic material.
Before natural gas can be used as a fuel, it must be processed to remove impurities, including water, to meet the specifications of marketable natural gas. The by-products of this processing include: ethane, propane, butanes, pentanes, and higher molecular weight hydrocarbons, hydrogen sulfide (which may be converted into pure sulfur), carbon dioxide, water vapor, and sometimes helium and nitrogen.
Natural gas is often informally referred to simply as “gas,” especially when compared to other energy sources such as oil or coal. However, it is not to be confused with gasoline, especially in North America, where the term gasoline is often shortened in colloquial usage to gas.
Natural gas was used by the Chinese in about 500 BC. They discovered a way to transport gas seeping from the ground in crude pipelines of bamboo to where it was used to boil salt water to extract the salt, in the Ziliujing District of Sichuan. The world’s first industrial extraction of natural gas started at Fredonia, New York, USA in 1825. By 2009, 66 trillion cubic meters (or 8%) had been used out of the total 850 trillion cubic meters of estimated remaining recoverable reserves of natural gas. Based on an estimated 2015 world consumption rate of about 3.4 trillion cubic meters of gas per year, the total estimated remaining economically recoverable reserves of natural gas would last 250 years at current consumption rates. An annual increase in usage of 2–3% could result in currently recoverable reserves lasting significantly less, perhaps as few as 80 to 100 years.
In the 19th century, natural gas was usually obtained as a by-product of producing oil, since the small, light gas carbon chains came out of solution as the extracted fluids underwent pressure reduction from the reservoir to the surface, similar to uncapping a soft drink bottle where the carbon dioxide effervesces. Unwanted natural gas was a disposal problem in the active oil fields. If there was not a market for natural gas near the wellhead it was virtually valueless since it had to be piped to the end user.
In the 19th century and early 20th century, such unwanted gas was usually burned off at oil fields. Today, unwanted gas (or stranded gas without a market) associated with oil extraction often is returned to the reservoir with ‘injection’ wells while awaiting a possible future market or to repressurize the formation, which can enhance extraction rates from other wells. In regions with a high natural gas demand (such as the US), pipelines are constructed when it is economically feasible to transport gas from a wellsite to an end consumer.
In addition to transporting gas via pipelines for use in power generation, other end uses for natural gas include export as liquefied natural gas (LNG) or conversion of natural gas into other liquid products via gas-to-liquids (GTL) technologies. GTL technologies can convert natural gas into liquids products such as gasoline, diesel or jet fuel. A variety of GTL technologies have been developed, including Fischer–Tropsch (F–T), methanol to gasoline (MTG) and STG+. F–T produces a synthetic crude that can be further refined into finished products, while MTG can produce synthetic gasoline from natural gas. STG+ can produce drop-in gasoline, diesel, jet fuel and aromatic chemicals directly from natural gas via a single-loop process. In 2011, Royal Dutch Shell’s 140,000 barrel per day F–T plant went into operation in Qatar.
Natural gas can be “associated” (found in oil fields), or “non-associated” (isolated in natural gas fields), and is also found in coal beds (as coalbed methane). It sometimes contains a significant amount of ethane, propane, butane, and pentane—heavier hydrocarbons removed for commercial use prior to the methane being sold as a consumer fuel or chemical plant feedstock. Non-hydrocarbons such as carbon dioxide, nitrogen, helium (rarely), andhydrogen sulfide must also be removed before the natural gas can be transported.
Natural gas extracted from oil wells is called casinghead gas (whether or not truly produced up the annulus and through a casinghead outlet) or associated gas. The natural gas industry is extracting an increasing quantity of gas from challenging resource types: sour gas, tight gas, shale gas, and coalbed methane.
There is some disagreement on which country has the largest proven gas reserves. Sources that consider that Russia has by far the largest proven reserves include the US CIA (47.6 trillion cubic meters), the US Energy Information Administration (47.8 tcm), and OPEC (48.7 tcm). However, BP credits Russia with only 32.9 tcm, which would place it in second place, slightly behind Iran (33.1 to 33.8 tcm, depending on the source). With Gazprom, Russia is frequently the world’s largest natural gas extractor. Major proven resources (in billion cubic meters) are world 187,300 (2013), Iran 33,600 (2013), Russia 32,900 (2013), Qatar 25,100 (2013), Turkmenistan 17,500 (2013) and the United States 8,500 (2013).
It is estimated that there are about 900 trillion cubic meters of “unconventional” gas such as shale gas, of which 180 trillion may be recoverable. In turn, many studies from MIT, Black & Veatchand the DOE predict that natural gas will account for a larger portion of electricity generation and heat in the future.
The world’s largest gas field is the offshore South Pars / North Dome Gas-Condensate field, shared between Iran and Qatar. It is estimated to have 51 trillion cubic meters of natural gas and 50 billion barrels of natural gas condensates.
Because natural gas is not a pure product, as the reservoir pressure drops when non-associated gas is extracted from a field under supercritical (pressure/temperature) conditions, the higher molecular weight components may partially condense upon isothermic depressurizing—an effect called retrograde condensation. The liquid thus formed may get trapped as the pores of the gas reservoir get depleted. One method to deal with this problem is to re-inject dried gas free of condensate to maintain the underground pressure and to allow re-evaporation and extraction of condensates. More frequently, the liquid condenses at the surface, and one of the tasks of the gas plant is to collect this condensate. The resulting liquid is called natural gas liquid (NGL) and has commercial value.
Shale gas is natural gas produced from shale. Because shale has matrix permeability too low to allow gas to flow in economical quantities, shale gas wells depend on fractures to allow the gas to flow. Early shale gas wells depended on natural fractures through which gas flowed; almost all shale gas wells today require fractures artificially created by hydraulic fracturing. Since 2000, shale gas has become a major source of natural gas in the United States and Canada. Following the success in the United States, shale gas exploration is beginning in countries such as Poland, China, and South Africa. With the increase of shale production it has caused the United States to become the number one natural gas producer in the world.
Town gas is a flammable gaseous fuel made by the destructive distillation of coal and contains a variety of calorific gases including hydrogen, carbon monoxide, methane, and other volatile hydrocarbons, together with small quantities of non-calorific gases such as carbon dioxide and nitrogen, and is used in a similar way to natural gas. This is a historical technology, not usually economically competitive with other sources of fuel gas today. But there are still some specific cases where it is the best option and it may be so into the future.
Most town “gashouses” located in the eastern US in the late 19th and early 20th centuries were simple by-product coke ovens that heated bituminous coal in air-tight chambers. The gas driven off from the coal was collected and distributed through networks of pipes to residences and other buildings where it was used for cooking and lighting. (Gas heating did not come into widespread use until the last half of the 20th century.) The coal tar (or asphalt) that collected in the bottoms of the gashouse ovens was often used for roofing and other waterproofing purposes, and when mixed with sand and gravel was used for paving streets.
Methanogenic archaea are responsible for all biological sources of methane. Some live in symbiotic relationships with other life forms, including termites, ruminants, and cultivated crops. Other sources of methane, the principal component of natural gas, include landfill gas, biogas, and methane hydrate. When methane-rich gases are produced by the anaerobic decay of non-fossilorganic matter (biomass), these are referred to as biogas (or natural biogas). Sources of biogas include swamps, marshes, and landfills (see landfill gas), as well as agricultural waste materials such as sewage sludge and manure by way of anaerobic digesters, in addition to enteric fermentation, particularly in cattle. Landfill gas is created by decomposition of waste in landfill sites. Excluding water vapor, about half of landfill gas is methane and most of the rest is carbon dioxide, with small amounts of nitrogen, oxygen, and hydrogen, and variable trace amounts of hydrogen sulfide and siloxanes. If the gas is not removed, the pressure may get so high that it works its way to the surface, causing damage to the landfill structure, unpleasant odor, vegetation die-off, and an explosion hazard. The gas can be vented to the atmosphere, flared or burned to produce electricity or heat. Biogas can also be produced by separating organic materials from waste that otherwise goes to landfills. This method is more efficient than just capturing the landfill gas it produces. Anaerobic lagoons produce biogas from manure, while biogas reactors can be used for manure or plant parts. Like landfill gas, biogas is mostly methane and carbon dioxide, with small amounts of nitrogen, oxygen and hydrogen. However, with the exception of pesticides, there are usually lower levels of contaminants.
Landfill gas cannot be distributed through utility natural gas pipelines unless it is cleaned up to less than 3 per cent CO2, and a few parts per million H2S, because CO2 and H2S corrode the pipelines. The presence of CO2 will lower the energy level of the gas below requirements for the pipeline. Siloxanes in the gas will form deposits in gas burners and need to be removed prior to entry into any gas distribution or transmission system. Consequently it may be more economical to burn the gas on site or within a short distance of the landfill using a dedicated pipeline. Water vapor is often removed, even if the gas is burned on site. If low temperatures condense water out of the gas, siloxanes can be lowered as well because they tend to condense out with the water vapor. Other non-methane components may also be removed to meet emission standards, to prevent fouling of the equipment or for environmental considerations. Co-firing landfill gas with natural gas improves combustion, which lowers emissions.
Biogas, and especially landfill gas, are already used in some areas, but their use could be greatly expanded. Experimental systems were being proposed for use in parts of Hertfordshire, UK, and Lyon in France. Using materials that would otherwise generate no income, or even cost money to get rid of, improves the profitability and energy balance of biogas production. Gas generated in sewage treatment plants is commonly used to generate electricity. For example, the Hyperion sewage plant in Los Angeles burns 8 million cubic feet (230,000 m3) of gas per day to generate power New York City utilizes gas to run equipment in the sewage plants, to generate electricity, and in boilers. Using sewage gas to make electricity is not limited to large cities. The city of Bakersfield, California, uses cogeneration at its sewer plants. California has 242 sewage wastewater treatment plants, 74 of which have installed anaerobic digesters. The total biopower generation from the 74 plants is about 66 MW.
Crystallized Natural Gas—Hydrates
Huge quantities of natural gas (primarily methane) exist in the form of hydrates under sediment on offshore continental shelves and on land in arctic regions that experience permafrost, such as those in Siberia. Hydrates require a combination of high pressure and low temperature to form.
In 2010, the cost of extracting natural gas from crystallized natural gas was estimated to 100–200 per cent the cost of extracting natural gas from conventional sources, and even higher from offshore deposits.
In 2013, Japan Oil, Gas and Metals National Corporation (JOGMEC) announced that they had recovered commercially relevant quantities of natural gas from methane hydrate.
Natural gas production in the U.S. reached a peak in 1973, and went over a second lower peak in 2001, but recently has peaked again and is continuing to rise.
Mid-Stream Natural Gas
Natural gas flowing in the distribution lines and at the natural gas well head are often used to power natural gas powered engines. These engines rotate compressors to facilitate the natural gas transmission. These compressors are required in the mid-stream line to pressurize and to re-pressurize the natural gas in the transmission line as the gas travels. The natural gas transmission lines extend to the natural gas processing plant or unit which removes the higher molecular weighted natural gas hydrocarbons to produce a British thermal unit (BTU) value between 950 and 1050 BTUs. The processed natural gas may then be used for residential, commercial and industrial uses.
Often mid-stream and well head gases require removal of many of the various hydrocarbon species contained within the natural gas. Some of these gases include heptane, pentane, propane and other hydrocarbons with molecular weights above Methane (CH4) to produce a natural gas fuel which is used to operate the natural gas engines for further pressurized transmission. Typically, natural gas compressors require 950 to 1050 BTU per cubic foot to operate at the natural gas engines rotational name plate specifications.
Several methods are used to remove these higher molecular weighted gases for use at the natural gas engine. A few technologies are as follows:
- Joule–Thomson skid
- Cryogenic or chiller system
- Chemical enzymology system
Natural gas is a major source of electricity generation through the use of cogeneration, gas turbines and steam turbines. Natural gas is also well suited for a combined use in association with renewable energy sources such as wind or solar and for alimenting peak-load power stations functioning in tandem with hydroelectric plants. Most grid peaking power plants and some off-grid engine-generators use natural gas. Particularly high efficiencies can be achieved through combining gas turbines with a steam turbine in combined cycle mode. Natural gas burns more cleanly than other hydrocarbon fuels, such as oil and coal, and produces less carbon dioxide per unit of energy released. For transportation, burning natural gas produces about 30 per cent less carbon dioxide than burning petroleum. For an equivalent amount of heat, burning natural gas produces about 45 per cent less than burning coal for power. The US Energy Information Administration reports the following emissions in million metric tons of carbon dioxide in the world for 2012:
- Natural gas: 6,799
- Petroleum: 11,695
- Coal: 13,787
Coal-fired electric power generation emits around 2,000 pounds of carbon dioxide for every megawatt hour generated, which is almost double the carbon dioxide released by a natural gas-fired electric plant per megawatt hour generated. Because of this higher carbon efficiency of natural gas generation, as the fuel mix in the United States has changed to reduce coal and increase natural gas generation, carbon dioxide emissions have unexpectedly fallen. Those measured in the first quarter of 2012 were the lowest of any recorded for the first quarter of any year since 1992.
Combined cycle power generation using natural gas is currently the cleanest available source of power using hydrocarbon fuels, and this technology is widely and increasingly used as natural gas can be obtained at increasingly reasonable costs. Fuel cell technology may eventually provide cleaner options for converting natural gas into electricity, but as yet it is not price-competitive. Locally produced electricity and heat using natural gas powered Combined Heat and Power plant (CHP or Cogeneration plant) is considered energy efficient and a rapid way to cut carbon emissions. Natural gas power plants are increasing in popularity and generate 22% of the worlds total electricity. Approximately half as much as generated with coal.
Natural gas dispensed from a simple stovetop can generate temperatures in excess of 1100 °C (2000 °F) making it a powerful domestic cooking and heating fuel. In much of the developed world it is supplied through pipes to homes, where it is used for many purposes including ranges and ovens, gas-heated clothes dryers, heating/cooling, and central heating. Heaters in homes and other buildings may include boilers, furnaces, and water heaters.
Compressed natural gas (CNG) is used in rural homes without connections to piped-in public utility services, or with portable grills. Natural gas is also supplied by independent natural gas suppliers through Natural Gas Choice programs throughout the United States. However, as CNG costs more than LPG, LPG (propane) is the dominant source of rural gas.
CNG is a cleaner and also cheaper alternative to other automobile fuels such as gasoline (petrol) and diesel. By the end of 2012 there were 17.25 millionnatural gas vehicles worldwide, led by Iran (3.3 million), Pakistan (3.1 million), Argentina (2.18 million), Brazil (1.73 million), India (1.5 million), and China(1.5 million). The energy efficiency is generally equal to that of gasoline engines, but lower compared with modern diesel engines. Gasoline/petrol vehicles converted to run on natural gas suffer because of the low compression ratio of their engines, resulting in a cropping of delivered power while running on natural gas (10%–15%). CNG-specific engines, however, use a higher compression ratio due to this fuel’s higher octane number of 120–130.
Coal (from the Old English term col, which has meant “mineral of fossilized carbon” since the thirteent century)is a combustible black or brownish-black sedimentary rock usually occurring in rock strata in layers or veins called coal beds or coal seams. The harder forms, such as anthracite coal, can be regarded as metamorphic rock because of later exposure to elevated temperature and pressure. Coal is composed primarily of carbon along with variable quantities of other elements, chiefly hydrogen, sulfur, oxygen, and nitrogen.
Throughout history, coal has been used as an energy resource, primarily burned for the production of electricity and/or heat, and is also used for industrial purposes, such as refining metals. A fossil fuel, coal forms when dead plant matter is converted into peat, which in turn is converted into lignite, then sub-bituminous coal, after that bituminous coal, and lastly anthracite. This involves biological and geological processes that take place over a long period. The United States Energy Information Administration estimates coal reserves at 948×109 short tons (860 Gt). One estimate for resources is 18 000 Gt.
Coal is the largest source of energy for the generation of electricity worldwide, as well as one of the largest worldwide anthropogenic sources ofcarbon dioxide releases. In 1999, world gross carbon dioxide emissions from coal usage were 8,666 million tonnes of carbon dioxide. In 2011, world gross emissions from coal usage were 14,416 million tonnes. Coal-fired electric power generation emits around 2,000 pounds of carbon dioxide for every megawatt-hour generated, which is almost double the approximately 1100 pounds of carbon dioxide released by a natural gas-fired electric plant per megawatt-hour generated. Because of this higher carbon efficiency of natural gas generation, as the market in the United States has changed to reduce coal and increase natural gas generation, carbon dioxide emissions have fallen. Those measured in the first quarter of 2012 were the lowest of any recorded for the first quarter of any year since 1992 In 2013, the head of the UN climate agency advised that most of the world’s coal reserves should be left in the ground to avoid catastrophic global warming.
Coal is extracted from the ground by coal mining, either underground by shaft mining, or at ground level by open pit mining extraction. Since 1983 the world top coal producer has been China. In 2011 China produced 3,520 million tonnes of coal – 49.5% of 7,695 million tonnes world coal production. In 2011 other large producers were United States (993 million tonnes), India (589), European Union (576) and Australia (416). In 2010 the largest exporters were Australia with 328 million tonnes (27.1% of world coal export) and Indonesia with 316 million tonnes (26.1%), while the largest importers were Japan with 207 million tonnes (17.5% of world coal import), China with 195 million tonnes (16.6%) and South Korea with 126 million tonnes (10.7%).
At various times in the geologic past, the Earth had dense forests in low-lying wetland areas. Due to natural processes such as flooding, these forests were buried underneath soil. As more and more soil deposited over them, they were compressed. The temperature also rose as they sank deeper and deeper. As the process continued the plant matter was protected from biodegradation and oxidation, usually by mud or acidic water. This trapped the carbon in immense peat bogs that were eventually covered and deeply buried by sediments. Under high pressure and high temperature, dead vegetation was slowly converted to coal. As coal contains mainly carbon, the conversion of dead vegetation into coal is called carbonization.
The wide, shallow seas of the Carboniferous Period provided ideal conditions for coal formation, although coal is known from most geological periods. The exception is the coal gap in the Permian–Triassic extinction event, where coal is rare. Coal is known from Precambrian strata, which predate land plants—this coal is presumed to have originated from residues of algae.
As geological processes apply pressure to dead biotic material over time, under suitable conditions, its metamorphic grade increases successively into:
- Peat, considered to be a precursor of coal, has industrial importance as a fuel in some regions, for example, Ireland and Finland. In its dehydrated form, peat is a highly effective absorbent for fuel and oil spills on land and water. It is also used as a conditioner for soil to make it more able to retain and slowly release water.
- Lignite, or brown coal, is the lowest rank of coal and used almost exclusively as fuel for electric power generation. Jet, a compact form of lignite, is sometimes polished and has been used as an ornamental stone since the Upper Palaeolithic.
- Sub-bituminous coal, whose properties range from those of lignite to those of bituminous coal, is used primarily as fuel for steam-electric power generation and is an important source of light aromatic hydrocarbons for the chemical synthesis industry.
- Bituminous coal is a dense sedimentary rock, usually black, but sometimes dark brown, often with well-defined bands of bright and dull material; it is used primarily as fuel in steam-electric power generation, with substantial quantities used for heat and power applications in manufacturing and to make coke.
- “Steam coal” is a grade between bituminous coal and anthracite, once widely used as a fuel for steam locomotives. In this specialized use, it is sometimes known as “sea-coal” in the United States. Small steam coal (dry small steam nuts or DSSN) was used as a fuel for domestic water heating.
- Anthracite, the highest rank of coal, is a harder, glossy black coal used primarily for residential and commercial space heating. It may be divided further into metamorphically altered bituminous coal and “petrified oil,” as from the deposits in Pennsylvania.
- Graphite, technically the highest rank, is difficult to ignite and is not commonly used as fuel—it is mostly used in pencils and, when powdered, as a lubricant.
The classification of coal is generally based on the content of volatiles. However, the exact classification varies between countries. According to the German classification, coal is classified as follows:
|German Classification||English Designation||Volatiles %||C Carbon %||H Hydrogen %||O Oxygen %||S Sulfur %||Heat content kJ/kg|
|Braunkohle||Lignite (brown coal)||45–65||60–75||6.0–5.8||34-17||0.5-3||<28,470|
|Gasflammkohle||Gas flame coal||35-40||82-85||5.8-5.6||9.8-7.3||~1||<33,910|
|Note, the percentages are percent by mass of the indicated elements|
The middle six grades in the table represent a progressive transition from the English-language sub-bituminous to bituminous coal, while the last class is an approximate equivalent to anthracite, but more inclusive (US anthracite has < 6% volatiles).
Cannel coal (sometimes called “candle coal”) is a variety of fine-grained, high-rank coal with significant hydrogen content. It consists primarily of “exinite” macerals, now termed “liptinite.”
Hilt’s law is a geological term that states that, in a small area, the deeper the coal, the higher its rank (grade). The law holds true if the thermal gradient is entirely vertical, but metamorphism may cause lateral changes of rank, irrespective of depth.
|Mercury (Hg)||0.10±0.01 ppm|
|Arsenic (As)||1.4 – 71 ppm|
|Selenium (Se)||3 ppm|
Coal as Fuel
Coal is primarily used as a solid fuel to produce electricity and heat through combustion. World coal consumption was about 7.25 billion tonnes in 2010 (7.99 billion short tons) and is expected to increase 48% to 9.05 billion tonnes (9.98 billion short tons) by 2030.
China produced 3.47 billion tonnes (3.83 billion short tons) in 2011. India produced about 578 million tonnes (637.1 million short tons) in 2011. 68.7% of China’s electricity comes from coal. The USA consumed about 13% of the world total in 2010, i.e. 951 million tonnes (1.05 billion short tons), using 93% of it for generation of electricity. 46% of total power generated in the USA was done using coal.
When coal is used for electricity generation, it is usually pulverized and then combusted (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; some older coal-fired power stations have thermal efficiencies in the vicinity of 25% whereas the newest supercritical and “ultra-supercritical” steam cycle turbines, operating at temperatures over 600 °C and pressures over 27 MPa (over 3900 psi), can practically achieve thermal efficiencies in excess of 45% (LHV basis) using anthracite fuel, or around 43% (LHV basis) even when using lower-grade lignite fuel. Further thermal efficiency improvements are also achievable by improved pre-drying (especially relevant with high-moisture fuel such as lignite or biomass) and cooling technologies.
An alternative approach of using coal for electricity generation with improved efficiency is the integrated gasification combined cycle (IGCC) power plant. Instead of pulverizing the coal and burning it directly as fuel in the steam-generating boiler, the coal can be first gasified (see coal gasification) to create syngas, which is burned in a gas turbine to produce electricity (just like natural gas is burned in a turbine). Hot exhaust gases from the turbine are used to raise steam in a heat recovery steam generator which powers a supplemental steam turbine. Thermal efficiencies of current IGCC power plants range from 39-42% (HHV basis) or ~42-45% (LHV basis) for bituminous coal and assuming utilization of mainstream gasification technologies (Shell, GE Gasifier, CB&I). IGCC power plants outperform conventional pulverized coal-fueled plants in terms of pollutant emissions, and allow for relatively easy carbon capture.
At least 40% of the world’s electricity comes from coal, and in 2012, about one-third of the United States’ electricity came from coal, down from approximately 49% in 2008. As of 2012 in the United States, use of coal to generate electricity was declining, as plentiful supplies of natural gas obtained by hydraulic fracturing of tight shale formations became available at low prices.
In Denmark, a net electric efficiency of > 47% has been obtained at the coal-fired Nordjyllandsværket CHP Plant and an overall plant efficiency of up to 91% with cogeneration of electricity and district heating. The multifuel-fired Avedøreværket CHP Plant just outside Copenhagen can achieve a net electric efficiency as high as 49%. The overall plant efficiency with cogeneration of electricity and district heating can reach as much as 94%.
An alternative form of coal combustion is as coal-water slurry fuel (CWS), which was developed in the Soviet Union. CWS significantly reduces emissions, improving the heating value of coal. Other ways to use coal are combined heat and power cogeneration and an MHD topping cycle.
The total known deposits recoverable by current technologies, including highly polluting, low-energy content types of coal (i.e., lignite, bituminous), is sufficient for many years. However, consumption is increasing and maximal production could be reached within decades (see world coal reserves, below). On the other hand much may have to be left in the ground to avoid climate change.
Coal gasification can be used to produce syngas, a mixture of carbon monoxide (CO) and hydrogen (H2) gas. Often syngas is used to fire gas turbines to produce electricity, but the versatility of syngas also allows it to be converted into transportation fuels, such as gasoline and diesel, through the Fischer-Tropsch process; alternatively, syngas can be converted into methanol, which can be blended into fuel directly or converted to gasoline via the methanol to gasoline process. Gasification combined with Fischer-Tropsch technology is currently used by the Sasol chemical company of South Africa to make motor vehicle fuels from coal and natural gas. Alternatively, the hydrogen obtained from gasification can be used for various purposes, such as powering ahydrogen economy, making ammonia, or upgrading fossil fuels.
During gasification, the coal is mixed with oxygen and steam while also being heated and pressurized. During the reaction, oxygen and water molecules oxidize the coal into carbon monoxide (CO), while also releasing hydrogen gas (H2). This process has been conducted in both underground coal mines and in the production of town gas.
- C (as Coal) + O2 + H2O → H2 + CO
If the refiner wants to produce gasoline, the syngas is collected at this state and routed into a Fischer-Tropsch reaction. If hydrogen is the desired end-product, however, the syngas is fed into thewater gas shift reaction, where more hydrogen is liberated.
- CO + H2O → CO2 + H2
In the past, coal was converted to make coal gas (town gas), which was piped to customers to burn for illumination, heating, and cooking.
Coal can also be converted into synthetic fuels equivalent to gasoline or diesel by several different direct processes (which do not intrinsically require gasification or indirect conversion). In the direct liquefaction processes, the coal is either hydrogenated or carbonized. Hydrogenation processes are the Bergius process, the SRC-I and SRC-II (Solvent Refined Coal) processes, the NUS Corporation hydrogenation process and several other single-stage and two-stage processes. In the process of low-temperature carbonization, coal is coked at temperatures between 360 and 750 °C (680 and 1,380 °F). These temperatures optimize the production of coal tars richer in lighter hydrocarbons than normal coal tar. The coal tar is then further processed into fuels. An overview of coal liquefaction and its future potential is available.
Coal liquefaction methods involve carbon dioxide (CO2) emissions in the conversion process. If coal liquefaction is done without employing either carbon capture and storage (CCS) technologies or biomass blending, the result is lifecycle greenhouse gas footprints that are generally greater than those released in the extraction and refinement of liquid fuel production from crude oil. If CCS technologies are employed, reductions of 5–12% can be achieved in Coal to Liquid (CTL) plants and up to a 75% reduction is achievable when co-gasifying coal with commercially demonstrated levels of biomass (30% biomass by weight) in coal/biomass-to-liquids plants. For future synthetic fuel projects, carbon dioxide sequestration is proposed to avoid releasing CO2 into the atmosphere. Sequestration adds to the cost of production.
Refined coal is the product of a coal-upgrading technology that removes moisture and certain pollutants from lower-rank coals such as sub-bituminous and lignite (brown) coals. It is one form of several precombustion treatments and processes for coal that alter coal’s characteristics before it is burned. The goals of precombustion coal technologies are to increase efficiency and reduce emissions when the coal is burned. Depending on the situation, precombustion technology can be used in place of or as a supplement to postcombustion technologies to control emissions from coal-fueled boilers.
Finely ground bituminous coal, known in this application as sea coal, is a constituent of foundry sand. While the molten metal is in the mould, the coal burns slowly, releasing reducing gases at pressure, and so preventing the metal from penetrating the pores of the sand. It is also contained in “mould wash,” a paste or liquid with the same function applied to the mould before casting. Sea coal can be mixed with the clay lining (the “bod”) used for the bottom of a cupola furnace. When heated, the coal decomposes and the bod becomes slightly friable, easing the process of breaking open holes for tapping the molten metal.
Production of Chemicals
Coal is an important feedstock in production of a wide range of chemical fertilizers and other chemical products. The main route to these products is coal gasification to produce syngas. Primary chemicals that are produced directly from the syngas include methanol, hydrogen and carbon monoxide, which are the chemical building blocks from which a whole spectrum of derivative chemicals are manufactured, including olefins, acetic acid, formaldehyde, ammonia,urea and others. The versatility of syngas as a precursor to primary chemicals and high-value derivative products provides the option of using relatively inexpensive coal to produce a wide range of valuable commodities.
Historically, production of chemicals from coal has been used since the 1950s and has become established in the market. According to the 2010 Worldwide Gasification Database, a survey of current and planned gasifiers, from 2004 to 2007 chemical production increased its gasification product share from 37% to 45%. From 2008 to 2010, 22% of new gasifier additions were to be for chemical production.
Because the slate of chemical products that can be made via coal gasification can in general also use feedstocks derived from natural gas and petroleum, the chemical industry tends to use whatever feedstocks are most cost-effective. Therefore, interest in using coal tends to increase for higher oil and natural gas prices and during periods of high global economic growth that may strain oil and gas production. Also, production of chemicals from coal is of much higher interest in countries like South Africa, China, India and the United States where there are abundant coal resources. The abundance of coal combined with lack of natural gas resources in China is strong inducement for the coal to chemicals industry pursued there. In the United States, the best example of the industry is Eastman Chemical Company which has been successfully operating a coal-to-chemicals plant at its Kingsport, Tennessee, site since 1983. Similarly, Sasol has built and operated coal-to-chemicals facilities in South Africa.
Coal to chemical processes do require substantial quantities of water. As of 2013 much of the coal to chemical production was in the People’s Republic of China where environmental regulation and water management was weak.
World Coal Reserves
The 948 billion short tons of recoverable coal reserves estimated by the Energy Information Administration are equal to about 4,196 BBOE (billion barrels of oil equivalent). The amount of coal burned during 2007 was estimated at 7.075 billion short tons, or 133.179 quadrillion BTU’s. This is an average of 18.8 million BTU per short ton. In terms of heat content, this is about 57,000,000 barrels (9,100,000 m3) of oil equivalent per day. By comparison in 2007, natural gas provided 51,000,000 barrels (8,100,000 m3) of oil equivalent per day, while oil provided 85,800,000 barrels (13,640,000 m3) per day.
British Petroleum, in its 2007 report, estimated at 2006 end that there were 147 years reserves-to-production ratio based on proven coal reserves worldwide. This figure only includes reserves classified as “proven”; exploration drilling programs by mining companies, particularly in under-explored areas, are continually providing new reserves. In many cases, companies are aware of coal deposits that have not been sufficiently drilled to qualify as “proven.” However, some nations haven’t updated their information and assume reserves remain at the same levels even with withdrawals.
Of the three fossil fuels, coal has the most widely distributed reserves; coal is mined in over 100 countries, and on all continents except Antarctica. The largest reserves are found in the United States, Russia, China, Australia and India.
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