Ash deposition behavior of upgraded brown coal in pulverized coal combustion boiler

Ash with a low melting point causes slagging and fouling problems in pulverized coal combustion boilers. Ash deposition on heat exchanger tubes reduces the overall heat transfer coefficient due to its low thermal conductivity. The purpose of this study is to evaluate the ash deposition for Upgraded Brown Coal (UBC) and bituminous coal in a 145 MW practical coal combustion boiler. The UBC stands for Upgraded Brown Coal. The melting temperature of UBC ash is relatively lower than that of bituminous coal ashes. Combustion tests were conducted on blended coal consisting 20 wt.% of UBC and 80 wt.% of bituminous coal. Before actual ash deposition tests, the molten slag fractions in those coal ashes were estimated by means of chemical equilibrium calculations. The calculation results showed the molten slag fraction for UBC ash reached approximately 90% at 1523 K. However, that for blended coal ash decreased to 50%. These calculation results mean that blending UBC with bituminous coal played a role in decreasing the molten slag fraction. This phenomenon occurred because the coal blending led to the formation of alumino-silicates compounds as a solid phase. Next, ash deposition tests were conducted using a practical pulverized coal combustion boiler. A water-cooled stainless-steel tube was inserted in locations at both 1523 K and 1273 K in the boiler to measure the amount of ash deposits. The results showed that the mass of ash deposition for blended coal did not greatly increase, compared with that for bituminous coal alone. Therefore, appropriately blending UBC with bituminous coal enabled the use of UBC without any ash deposition problems in practical boilers.     

The fate of trace elements and bulk minerals in pulverized coal combustion in a power station

The behaviour of 15 trace elements (As, Ba, Cr, Cu, Mn, Mo, Nb, Ni, Pb, Rb, Sr, V, Y, Zn and Zr) and 10 major and minor elements (Al, Ca, Fe, K, Mg, Na, P, S, Si and Ti) in coal during combustion in a power station has been studied. Synchronized sampling of pulverized coal, bottom ash and fly ash was undertaken over a limited time period. Fly ash morphology was studied by SEM and the mineral composition was studied by EDX and XRD. Major, minor and trace elements were determined by XRF and AAS. Differences between the composition of the ashes of pulverized coal, bottom ashes and fly ashes have been observed. As, Cu, Mo, Pb and Zn were concentrated in the fly ash. The relationship between the composition of the fly ashes and their particle size was studied. Enrichment factors were calculated for each element in different size fractions. As the particle sizes of fly ash decrease, the concentrations of As, Cu, Mo, Pb and Zn increase. From the different composition of bottom ashes and fly ashes (and relying on the results of the characterization of the feed coal carried out in previous work), it can be assumed that pyrite and carbonates make a greater contribution to the furnace bottom ashes. Quartz carries through into the fly ash. This mineral is almost absent in the finest fractions, reflecting the absence of small quartz particles in the feed coal.     

Ash deposition of a Spanish anthracite: effects of included and excluded mineral matter

This study has been undertaken to provide an insight into the effects of mineral matter distributions in coal on the nature of boiler slags formed during the combustion of a high ash Spanish anthracite. Three density fractions were prepared, and the light and heavy fractions were combined to give a sample containing mainly excluded mineral matter. The mineral matter in the medium density fraction was predominantly included. Slag deposits were prepared in the laboratory from the whole coal, the light+heavy and medium density fractions. The coal with excluded mineral matter was found to produce a slag similar in nature and chemistry to the whole coal ash deposit. The coal with included mineral matter produced a vitreous, iron-rich deposit. The deposits were compared with slags, obtained from a Spanish power station boiler, burning a blend containing the same anthracite.     

煤粉炉掺烧生活垃圾对灰渣特性的影响研究

利用小试规模煤粉炉,研究掺烧不同比例生活垃圾对燃煤灰渣特性的影响,主要包括飞灰元素组成、飞灰粒径分布、飞灰形貌、灰熔点和结渣特性等影响变化研究。结果表明,随着生活垃圾掺烧比例的增加,灰分中Ca、Fe、Cl和S元素含量增加,Al、Mg、K、Na、Ti和Si含量降低,飞灰球形颗粒分布减少,层状堆积结构增多;灰渣熔融特征温度呈平缓下降趋势,但变化范围小于2%,影响较小;掺烧量为25%时,飞灰表面发现少量褐色大颗粒。总之,生活垃圾掺烧对燃煤灰渣特性影响很小,该结果为实际煤粉炉开展掺烧生活垃圾试验提供了一定理论基础。     

The roles of lime and iron oxide on the formation of ash and deposits in PF combustion

This paper presents the results of a study to assess the slagging propensities of a suite of UK, Spanish and South African coals, ranging from lignites to anthracites. Laboratory deposits were collected on ceramic deposition probes at gas temperatures of ∼1250°C, using an entrained flow reactor that simulates the time-temperature conditions experienced by pulverised coal particles in a large utility boiler. The degree of sintering and consolidation of the deposits would not have been predicted from bulk ash chemistry, indicating the importance of mineral matter distributions in the pulverised coal. Deposits with similar base to acid ratios and Fe₂O₃ contents displayed a range of slagging propensities on CCSEM analysis, consistent with the visual ranking. CCSEM analysis of the fly ashes collected from the combustion gases revealed a similar chemical composition to the coal ash and ash collected at the base of the EFR. CaO was observed to have readily assimilated into the aluminosilicate fly ash particles. On deposition, the CaO distribution largely remained unchanged. Fe₂O₃ was redistributed on forming a deposit possibly aided by CaO already dissolved in the aluminosilicates. The study provides an insight into the observations made by boiler operators burning coals with high CaO and Fe₂O₃ ashes.     

Experimental study of ash formation during pulverized coal combustion in O2/CO2 mixtures

The present paper was addressed to mineral transformations and ash formation during O₂/CO₂ combustion of pulverized coal. Four Chinese thermal coals were burned in a drop tube furnace to generate ashes under various combustion conditions. The ash samples were characterized with XRD analysis and ⁵⁷Fe Mössbauer spectroscopy. The impacts of O₂/CO₂ combustion on mineral transformation and ash formation were explored through comparisons between O₂/CO₂ combustion and O₂/N₂ combustion. It was found that, O₂/CO₂ combustion did not significantly change the mineral phases formed in the residue ashes, but did affect the relative amounts of the mineral phases. The differences observed in the ashes formed in two atmospheres were attributed to the impact of the gas atmosphere on the combustion temperatures of coal char particles, which consequently influenced the ash formation behaviors of included minerals.     

Ash transformation during co-firing coal and straw

Co-firing straw with coal in pulverized fuel boilers can cause problems related to fly ash utilization, deposit formation, corrosion and SCR catalyst deactivation due to the high contents of Cl and K in the ash. To investigate the interaction between coal and straw ash and the effect of coal quality on fly ash and deposit properties, straw was co-fired with three kinds of coal in an entrained flow reactor. The compositions of the produced ashes were compared to the available literature data to find suitable scaling parameters that can be used to predict the composition of ash from straw and coal co-firing. Reasonable agreement in fly ash compositions regarding total K and fraction of water soluble K was obtained between co-firing in an entrained flow reactor and full-scale plants. Capture of potassium and subsequent release of HCl can be achieved by sulphation with SO₂ and more importantly, by reaction with Al and Si in the fly ash. About 70–80% K in the fly ash appears as alumina silicates while the remainder K is mainly present as sulphate. Lignite/straw co-firing produces fly ash with relatively high Cl content. This is probably because of the high content of calcium and magnesium in lignite reacts with silica so it is not available for reaction with potassium chloride. Reduction of Cl and increase of S in the deposits compared to the fly ashes could be attributed to sulphation of the deposits.     

Studies of sintering of coal ash relevant to pulverized coal utility boilers: 1. Examination of the Raask shrinkage—electrical resistance method

The Raask shrinkage and electrical resistance method for determining the onset of sintering of fly ash has been tested on a soda lime glass, coal ASTM ashes, fly ashes and pulverized synthetic mineral mixtures. Results with the glass confirmed those of Raask and showed that particle size distribution and bulk density affected the resistance values: the sinter point was indicated by a change in the characteristic temperature coefficient of resistance. The shrinkage and electrical sinter points were usually the same, but a high Na content lignite gave 850°C for shrinkage but 600°C for characteristic resistance change. Sinter points were 200°C less for fly ash than for ASTM ash. The fly ashes had a slight enrichment of alkalies and a decrease in Fe content compared to the total ash. Holding a compact at a temperature above the sinter point gave increased strength and shrinkage, but no decrease in electrical resistance, indicating that the decrease in resistance as temperature increased was due to the establishment of contact points between particles, with little effect of the continued growth of a contact neck. Addition of pulverized sodium silicate or iron silicate glasses to a synthetic ash also reduced the sinter points, as did alkali additions, whereas addition of pyrite did not. It was concluded that the method was a valuable tool, but sources of variability had to be determined and controlled.     

Characteristics and composition of fly ash from Canadian coal-fired power plants

Fly ashes were collected from the electrostatic precipitator (ESPs) and/or the baghouse of seven coal-fired power plants. The fly ashes were sampled from power plants that use pulverized subbituminous and bituminous feed coals. Fly ash from bituminous coals and limestone feed coals from fluidized-bed power plant were also sampled. The fly ashes were examined for their mineralogies and elemental compositions. The fly ashes from pulverized low sulfur coals are ferrocalsialic, those from high sulfur coals are ferrosialic and the fly ashes from the fluidized bed coals are ferrocalcic. The concentrations of As, Cd, Hg, Mo, Ni, and Pb in fly ash are related to the S content of the coal. Generally, those feed coals with a high S content contain higher concentrations of these elements. The concentrations of these elements are also greater for baghouse fly ash compared to ESP fly ash for the same station. The S content of fly ash from high S coal is 0.1% for pulverized ESP fly ash and 7% for baghouse fly ash from the fluidized bed, indicating that most of the S is captured by fly ash in the fluidized bed. The baghouse fly ash from the fluidized bed has the highest content of Cd, Hg, Mo, Pb, and Se, indicating that CaO, for the most part, captures them. Arsenic is captured by calcium-bearing minerals and hematite, and forms a stable complex of calcium or a transition metal of iron hydroxy arsenate hydrate [(M²⁺)₂Fe₃(AsO₄)₃(OH)₄·10H₂O] in the fly ash. Most elements in fly ash have enrichment indices of greater than 0.7 indicating that they are more enriched in the fly ash than in the feed coal, except for Hg in all ESP ashes. Mercury is an exception; it is more enriched in baghouse fly ash compared to ESP. Fly ash collected from a station equipped with hot side ESP has a lower concentration of Hg compared to stations equipped with cold side ESP using feed coals of similar rank and mercury content. Fly ash particles from fluidized bed coal are angular and subangular with cores of quartz and calcite. The quartz core is encased in layer(s) of calcium-rich aluminosilicates, and/or calcium/iron oxides. The calcite core is usually encased in an anhydrite shell.     

Comparison of calculated mercury emissions from three Alberta power plants over a 33 week period - Influence of geological environment

Feed coals and fly ashes from two coal-fired power plants burning Alberta subbituminous coal were analyzed for C, Cl, Hg, and S and calorific values (for feed coal only), every week for a period of 33 weeks. The feed coals used in this study were deposited in brackish water and are compared to the coals deposited in a freshwater environment. The Hg and char (unburnt carbon) content of the fly ash was monitored to determine the variation of Hg and its possible relationship to the char types in the fly ash. The feed coals have Hg content of 0.026-0.089 mg/kg and their fly ash contains 0.02-0.243 mg/kg of Hg. The C content of the fly ashes ranges from 0.15% to 0.51%. The carbon/char was separated from the fly ash using HF and HCl. Reactive vitrinitic (formed from woody part of plants) and less reactive inertinitic (natural char) chars were separated by density separations of various specific gravities using ZnBr₂.The char is mostly reactive vitrinitic (67-80 vol.%). Both stations have similar range of C content for their respective fly ashes. However, station 2 shows a much wider range of Hg in fly ash compared to station 1. In general, the fly ash from coal deposited under brackish water environment (stations 1 and 2) appears to have same or higher Hg content for lower C content compared to the fly ash from coal deposited under fresh water environment.The calculated emitted Hg for the period of 33 weeks for station 1 is estimated to be 64-90% of the total input of Hg with an average of 74%. The calculated emitted Hg shows a more complex pattern for station 2 and falls into two groups; with group (a) showing higher enrichment index for both Hg and S. The calculated emitted Hg for this group is 43-74% with an average of 57%, indicative of more Hg being captured by fly ash, possibly due to interaction between Hg and S. In the second group (b) the emitted Hg is calculated to be 74-95% with an average of 85%. The relative enrichment of both Hg and S in group (b) is low compared to group (a), indicative of possible slight paleo-weathering of the feed coal.The present study indicates that geological parameters such as paleo weathering and also depositional environment of the feed coal may influence the Hg content of fly ash.     

Two-dimensional modelling of deposits formation on platen superheaters in pulverized coal boilers

The 1D modeling of deposits formation is not able to describe properly the gas and particles flow in the vicinity of heat transfer tubes in boilers. Especially, the recirculation zones in the down-stream side of tubes are not possible to reproduce by the 1D models. Known applications of the CFD codes to deposition modelling were able to reproduce only the rate of particles deposition on surfaces, while for practical reasons the most important information is the shape and size of deposits, because it enables prediction of heat transfer abatement with boiler operation time. Paper presents 2D modelling of deposits on platen superheaters in pulverized coal boilers. Particularly, the observed in industrial boilers bridging of the tubes spacing was reproduced by the model in which the particle size dependence of the ash sticking probability was proposed. It has been demonstrated that the ash particles size play important role in the deposits growth mechanism.     

煤气化细灰及其原煤的热解特性与官能团特征

对气流床水煤浆气化细灰和粉煤气化细灰及其原煤的热解特性与官能团特征进行研究,结合工业分析、元素分析、红外光谱(FTIR)方法以及热重-质谱联用(TG-MS)技术,分析了两种气化工艺所得细灰的特性,以及细灰与原煤官能团结构特征的差异。结果表明,气化细灰在经历煤气化过程后仍有部分挥发分未完全分解,细灰中的挥发分含量与其气化工艺有关;煤气化过程中,部分官能团未分解,并可能有部分官能团重排生成了较稳定的含氧化合物等新官能团。     

Characterisation of meat and bone mill for coal co-firing

A most interesting solution for the disposal of meat and bone meal (MBM) is co-feeding with coal in combustion plants. MBM, is however, quite different from any other traditional or alternative solid fuel in terms of chemical composition, ash content and microstructural properties. Its effects on the performance of a boiler are largely unexplored. The present paper addresses the characteristics of MBM as alternative solid fuel and the effects of co-feeding MBM (6%) and coal (94%) in a utility boiler.A first activity consisted in the characterisation of the physico-chemical properties and the reactivity of MBM. The experimental campaign included ultimate and proximate analysis, granulometric analysis, ICP, SEM, XRD. An extensive campaign of isothermal and non isothermal thermogravimetric experiments was carried out to assess the reactivity of MBM upon pyrolysis, combustion and gasification and to obtain appropriate kinetic expressions.A second activity focused on co-firing of MBM and coal. Bottom and fly ashes were collected from an industrial boiler operated with MBM and coal. Ash samples were characterised by SEM, XRD, ICP, TGA and granulometric analysis. Results of this activity showed that MBM contributes mostly to bottom ash, however also the fly ashes are different from those typically encountered when the boiler is operated with coal alone. Differences concern the chemical composition and particle size distribution of ashes, in particular a large population of very fine particles characterised by perfectly spherical shape and non negligible carbon content is observed.     

粉磨工艺对水泥厂煤粉中矿物分布规律的影响

采集了山东泰安中联水泥厂立式辊磨和管式球磨两种不同粉磨方式的出磨煤粉,通过浮沉、工业分析、粒度分析,研究了不同粉磨工艺对于煤粉粒度-灰分规律的影响。研究发现,两种不同粉磨工艺的出磨煤粉都呈现出灰分随密度级别的增大而递增,随着粒度的增加而递减的规律,各密度级别浮沉产率和粒度-灰分曲线相似,说明粉磨方式对煤粉中矿物规律没有影响。     

煤粉炉和循环流化床锅炉飞灰吸附汞动力学及其吸附机制

在固定床吸附反应器内对两台300MW等级燃煤发电机组循环流化床锅炉和煤粉锅炉飞灰样品进行气相零价汞吸附实验,通过改变实验工况研究温度、入口汞浓度和入口气体流量对飞灰汞吸附能力的影响。采用颗粒内扩散模型、准一阶和准二阶动力学模型、耶洛维奇（Elovich）模型对实验数据分别进行拟合,从动力学的角度探讨两种锅炉飞灰对气相零价汞吸附的影响机制以及两种锅炉飞灰与气相零价汞之间吸附动力学行为差异。结果表明：相同工况下循环流化床锅炉飞灰汞吸附过程的穿透时间和平衡吸附量远大于煤粉锅炉飞灰。吸附温度为150℃时,两种锅炉飞灰对气相零价汞的平衡吸附量最大。由于外扩散阻力随气体入口流量的增加而减小,入口汞浓度的增加可提高传质推动力,飞灰对汞的吸附得以增强。动力学分析表明飞灰的零价汞吸附由外扩散、内扩散和表面化学吸附共同控制,其中表面化学吸附是该吸附过程中的控制步骤;准二阶动力学模型和Elovich动力学模型更适合于描述该吸附过程。相同实验条件下,循环流化床锅炉飞灰吸附过程拟合所得的颗粒内扩散系数、准一阶动力学常数和初始吸附速率均大于煤粉锅炉飞灰。     

煤种性质对煤粉工业锅炉结焦的影响

燃煤锅炉内结焦会对锅炉运行的安全性和经济性造成极大损害,因而分析影响燃煤锅炉结焦的因素,进而有效预防燃煤锅炉结焦至关重要。在实际应用中,针对影响燃煤锅炉结焦的不同因素,可采取不同的预防措施。研究发现煤的灰熔融性温度、煤粉颗粒大小、锅炉燃烧气氛、一二次风动力场、锅炉截面热负荷和锅炉热负荷等都会影响燃煤锅炉结焦。为了解决某地区煤粉工业锅炉预燃室、炉膛、对流受热面大面积燃烧结焦问题,笔者结合燃煤锅炉燃烧结焦的机理,先后采取调整燃烧气氛、增大二次风刚性、减小煤粉颗粒粒径、更换孙家岔煤粉等措施对不同条件下的结焦现象进行对比分析,发现煤种、煤粉粒径大小是影响某地区煤粉工业锅炉燃烧结焦的因素。通过SEM-EDS(扫描电镜和能谱分析)对锅炉焦块进行微观形貌与元素组成分析,现场取样锅炉现用煤粉和孙家岔煤粉进行煤质及灰成分对比分析,并根据灰成分进行结渣性判别指标计算,结果表明锅炉燃烧现用煤种灰熔融性温度较低,煤灰软化温度Ts为1 170℃,小于1 200℃,为易熔煤,容易结渣,属于典型的易结焦煤种;结渣性判别指标计算结果显示,4项指标评价为"严重",1项指标评价为"中等",结渣性严重。综合分析认为:锅炉燃烧煤种发生改变,煤的灰熔融温度较低是影响某地区煤粉工业锅炉燃烧结焦的最本质因素。为进一步解决现场实际问题,采取破坏煤灰中酸碱平衡,提升煤的灰熔融温度,配合调节煤粉粒径等措施,如对锅炉现用煤种掺混5%的石英,提高煤灰中Si O2含量,掺混后煤粉的灰熔融温度达到1 280℃,提高了110℃;调大煤粉磨机频率,从19 Hz增大到22 Hz,煤粉粒度(200目,0.075 mm)过筛率从70%增大到85%。经过上述调整后,锅炉运行平稳,结焦状况显著改善,燃烧调整措施取得了较好的效果。     

燃煤过程中颗粒物的形成机理研究进展

介绍了煤粉燃烧过程中颗粒物的形成机理，包括亚微米飞灰和残灰颗粒的主要形成途径．亚微米颗粒主要来自无机物的气化-凝结过程，在高温条件下无机矿物首先以氧化物、次氧化物或原子的形式气化，当温度降低时，无机蒸气通过均相成核、异相冷凝、凝并、团聚等过程形成细微颗粒．残灰由残留在焦炭颗粒中的矿物转化而成，焦炭破碎和表面灰的聚合是决定残灰最终粒径分布的主要过程，除此之外，对于含外来矿物较多的煤种，矿物破碎对残灰颗粒的形成也有十分重要的影响．最后对燃煤过程中颗粒物的形成机理研究提出了建议．     

Classification of carbon in Canadian fly ashes and their implications in the capture of mercury

Fly ashes produced from Canadian power plants using pulverized coal and fluidized bed combustors were examined for their carbon content to determine their ability to capture mercury. The feed coal used in these power plants were lignite, subbituminous, high and medium volatile bituminous, their blends, and also blends of coal with petroleum coke (Petcoke). The carbon and mercury content of the coals and fly ashes were determined using the ASTM standard method and by the cold vapour atomic absorption spectrometry method. The carbon content of the fly ash was concentrated by strong acid digestion using HCl and HF. The quantitative and qualitative analyses of the carbon concentrate were made by using a reflected light microscope. The results show that the carbon content of fly ash appears to be partially related to depositional environment during coalification and to the rank of the coal. The Hg captured by the fly ash depends on the rank and blend of the feed coals and the type of carbon in the fly ash. The isotropic vitrinitic char is mostly responsible for the capture of most Hg in fly ash. The inadvertent increase in carbon content due to the blending of coal with petroleum coke did not increase the amount Hg captured by the fly ash. The fly ash collected by the hot side electrostatic precipitator has a low Hg content and no relation between the Hg and carbon content of the ash was observed. These results indicate that the quantity of carbon in the fly ash alone does not determine the amount Hg captured. The types of carbon present (isotropic and anisotropic vitrinitic, isotropic inertinitic and anisotropic Petcoke), the halogen content, the types of fly ash control devices, and the temperatures of the fly ash control devices all play major roles in the capture of Hg.     

高效煤粉锅炉粉煤灰在熟料生产中的应用

山东东华水泥有限公司目前有两条5 000 t/d熟料生产线, 处理我市高效环保煤粉锅炉的产生的粉煤灰。通过增加高效煤粉锅炉粉煤灰的储存、计量和输送设备,实现了高效煤粉锅炉粉煤灰计量可控的掺加到生料中,并随生料一起进入回转窑煅烧的工艺途径,成功地解决了高效煤粉锅炉粉煤灰因成分波动大、烧失量高导致的水泥磨消耗量有限的处置瓶颈。     

煤粉炉和循环流化床锅炉飞灰特性对其汞吸附能力的影响

通过分析两台容量相近的循环流化床锅炉和煤粉锅炉飞灰样品的粒径分布、表面结构特性、未燃尽碳含量、反应性和汞含量，探究两种类型锅炉飞灰特性差异及其与飞灰汞吸附能力的关系。结果表明：循环流化床和煤粉锅炉尾端除尘设备排灰口飞灰汞的含量分别为1584.0 ng/g和503.7 ng/g，其原因与飞灰粒径、未燃尽碳含量和表面特性相关。对于循环流化床锅炉，飞灰中汞含量随其粒径和反应性温度的减小而增加，随未燃尽碳含量增加而增加，且与比表面积和吸附量呈正相关关系。对于煤粉锅炉，粒径为75～53 μm的飞灰对汞吸附能力较强，未燃尽碳含量明显小于循环流化床所产生飞灰的含量，飞灰比表面积随粒径变化不大，由此导致煤粉锅炉除尘设备排灰口所取样品对汞的吸附能力远低于循环流化床锅炉相对应位置飞灰对汞的吸附能力。