Environmental Clean Technologies (ECT) is an Australian company developing a unique, low-cost method to dewater brown coal and transform this abundant but widely unusable resource into a Black Coal Equivalent (BCE). The main thrust of the project is the establishment of a large scale Coldry production plant at the Loy Yang Power Station in Victoria’s Latrobe Valley. International engineering firm Arup is completing the design of the facility.

In a recent update, ECT states: “Our key objective is to demonstrate Coldry at a commercial scale to enable the broader global commercial uptake and roll out of the technology, and the Coldry Demonstration Plant (CDP) project is how we intend to do this. With this key objective in mind, we’re on track to begin the final stages of preparation ahead of construction commencement targeted for H1 2014.” Ongoing activities include final site confirmation within the Loy Yang precinct; transition from MoU to formal detailed agreements with AGL Loy Yang for the site, coal supply, electrical supply and waste energy interconnections; a construction package tender issue and final selection of vendors; and project approvals, including planning permits and required EPA approvals. ECT states: “Our work with Arup has delivered a great design, which we’re now finalising along with targeted “value-engineering” driven cost-reduction efforts.”

Since February 2013, when ECT advised the market that Arup had largely completed the earlier scoped Design for Tender (DFT) process, engineering work has continued with an emphasis on preparation to deliver the demonstration project. Specifically, in collaboration with McConnell Dowell (MacDow), Arup has prepared initial project cost estimations for the Coldry Demonstration Plant (CDP) based on a ‘generic site’ within the Loy Yang precinct. With the detail available from the estimate, a prioritised list of opportunities to reduce capital cost has been developed. Progress continues in this area, with a few examples resulting in reduced capital estimates being reduced structural requirements through enhanced equipment layout; a modified conditioning belt conveyor structure, reducing the need for complicated pipe and duct systems for air distribution and; simplification of pipe and duct systems stemming from design improvements to the conditioning belt conveyor structure. In addition, a creative solution for distribution conveyors on top of the Packed Bed Dryer structure is to be used, eliminating an entire “tripper” conveyor.

Detailed planning is well advanced for the balance of the pre-construction engineering works, as well as initial construction programs, while permit and approval requirements have been identified, and preparatory works have begun, including initial site-specific inspections and reports. Regarding product transportability, further detailed studies have been completed, confirming the low tendency for spontaneous combustion of Coldry versus other regularly transported coals providing confirmation of suitability for bulk handling. Arup has commenced the second round of project estimation works, which will include significantly more detail related to site works, and incorporate the outcomes of the value engineering activities performed to date.

Based on research initially conducted by CRA and University of Melbourne in the early 1980′s, the technology – Coldry – is a patented process that changes the naturally porous form of brown coal to produce a dry, dense pellet, via a process referred to as ‘brown coal densification’. The Coldry process offers benefits that according to ECT include:

• A process that has been tested and proven successful on a wide range of brown coal types;
• A more energy efficient process for removing water from brown coal than firing the coal in a boiler;
• Enhanced efficiency in the process of generating electricity through use of Coldry pellets;
• Evaporative water loss reductions, and optional recovery of high purity water streams as by-products