Coal Additive

Less coal. More heat. Cleaner stack.

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1. The Energy Reality

Global Scale 

Thermal power plants are the most prevalent industrial power facilities worldwide, producing 60–70% of global electricity. In 2024, global coal mining hit a record 8.8 billion tonnes per annum, with Asia accounting for the majority of demand.

Coal is also the fuel of choice for many industrial processes, particularly in steel and cement production, where high temperatures are essential and no easily scalable alternatives exist yet. While renewables are growing, coal remains indispensable for baseload power.

India’s Scale

India is the third-largest coal consumer globally, burning over 1.3 billion tonnes annually. This translates to approx.. 13 Crore metric tons per annum which means about 3.5 lakh metric tons of coal is burned in India everyday.

Breakdown of coal use in India (2024):

  • Non-coking coal: ~84% (electricity generation)
  • Coking coal: ~14% (steelmaking)
  • Lignite: ~2% (regional power/heating)

Coal powers ~73% of India’s electricity, with more than 150 thermal plants and approx.. 300–400 cement, steel and other large plants, each burning hundreds to thousands of tonnes per day. 

2. The True Cost of Coal

Global

Fossil fuels account for ~73% of global Green House Gas (GHG) emissions, with coal alone responsible for ~40% of that share.

India

  • CO₂: ~1.18B tonnes annually from power sector, 80%+ from coal
  • SO₂: 45–60% of national emissions from coal
  • NOₓ: ~30% of national emissions from coal
  • PM2.5: >15% of anthropogenic emissions from coal
  • Mercury: ~80% of industrial mercury emissions from coal

These pollutants cause climate change, acid rain, health crises, and ecosystem damage.

3. The Nexerg Breakthrough

What it does: A drop-in combustion improver that raises flame quality and lowers heat rate so you burn less coal for the same load—low capex, no downtime, reduced maintenance.

We have developed a next-generation nano-tech coal additive that aims to:

Primary Benefits

Coal Use Reduction

  • Typical baseload service: 3–8% reduction
  • Optimized units (good O₂ control, steady PLF, stable coal quality): 10–15% reduction
  • Performance gain is inversely related to coal ash content.

Mechanisms of Action

  • Increases combustion efficiency
  • Lowers unburnt carbons (LOI)
  • Raises flame temperatures → improved thermal efficiency

CO₂ Reduction

  • Falls proportionally with coal saved
  • 3–8% typical; 10–15% in best-tuned units

Stack Pollutants (boiler-out / engine-out)

  • PM/soot & CO: ↓ 20–35% (cleaner burn, lower LOI)
  • NOₓ: ↓ 5–10% (via smoother flame, lower fuel throughput; unit-specific)
  • SO₂: proportional to fuel → expect 3–8%↓ with coal savings (FGD-equipped units already control SO₂)
  • Mercury: proportional to fuel — reductions follow coal savings

Safety

  • No harmful metallic residues
  • No formaldehyde or untested toxins

Secondary Benefits (often excluded from direct coal/CO₂ calculations)

  • Lower fuel procurement costs: Reduced coal requirement
  • Lower handling & logistics costs: Less coal volume moved daily
  • Lower disposal costs: Reduced ash & unburnt carbon residues
  • Reduced wear & tear: Smoother combustion → improved boiler/turbine efficiency

System-Level Enhancements

  • Methane Impact: Every % coal reduction cuts upstream mine CH₄ emissions → multiplying climate benefit
  • Lower Auxiliary Power: Reduced fan load & boiler stress → up to 1–1.5% heat-rate improvement
  • Reduced Downtime: Cleaner burn minimizes fouling/slagging → higher availability, less maintenance downtime → translates to ~1–2% effective coal-equivalent savings
  • Ash Quality Upgrade: Lower LOI in fly ash makes it marketable for cement use instead of being a disposal liability

4. How the Technology Works

Nexerg’s additive combines advanced nano & chemical science with organic chemistry to improve combustion at the molecular level:

  1. Micro-Crack Formation – Releases trapped volatiles
  2. Moisture Displacement – Breaks hydrogen bonds to displaces bound moisture
  3. Hydrocarbon Chain Breakdown – Makes fuel more combustible
  4. Molecular Surface Modification – improves oxygen availability & coal reactivity
  5. Higher flame temperatures –  more complete fuel burn.

The result: cleaner, hotter, and more efficient burning- no harmful metallic residues, formaldehyde, or untested toxins.

5. From Lab to Industry

The additive is in an advanced R&D stage which is ready for field trials. Early results show:

  • Increased flame intensity & stability
  • Reduced visible smoke & emissions
  • Lower ash & unburnt char
  • Faster ignition (also shows signs of lower ignition temperature)
  • Better moisture displacement

6. Dose & use

  • Dose window: 50–150 ppm (liquid), tuned to coal rank, fineness, and O₂ profile.
  • Integration: Dosing at conveyor head or bunker; best to spray after crushing before feeding to bunker
  • Compatible with all common air-pollution-control devices. 
    • ESP / Baghouse: Particulate control through ESP (electric fields to capture fly ash) or baghouse (fabric-filter system doing the same via filtration).
    • FGD: Flue-Gas Desulfurization—scrubbing SO₂ using wet limestone/ gypsum or dry sorbents.
    • SNCR / SCR: Selective Non-Catalytic Reduction through injecting urea/ammonia into hot gas to reduce NOₓ without a catalyst OR Selective Catalytic Reduction doing the same with a catalyst, giving deeper NOₓ cuts.

A Transition Technology for a Critical Decade

Coal cannot be phased out overnight. Nexerg provides a bridge technology — immediate, scalable, and measurable — reducing fuel use and emissions while green energy capacity scales.