Volatilisation and catalytic effects of alkali and alkaline earth metallic species during the pyrolysis and gasification of Victorian brown coal. Part IV. Catalytic effects of NaCl and ion-exchangeable Na in coal on char reactivity

The purpose of this study is to investigate the catalytic effects of Na as NaCl or as sodium carboxylates (-COONa) in Victorian brown coal on the char reactivity. A Na-exchanged coal and a set of NaCl-loaded coal samples prepared from a Loy Yang brown coal were pyrolysed in a fluidised-bed/fixed-bed reactor and in a thermogravimetric analyser (TGA). The reactivities of the chars were measured in air at 400 °C using the TGA. The experimental data indicate that the Na in coal as NaCl and as sodium carboxylates (-COONa) had very different catalytic effects on the char reactivity. It is the chemical form and dispersion of Na in char, not in coal, that govern the catalytic effects of Na. For the Na-form (Na-exchanged) coal, the char reactivity increased with increasing pyrolysis temperature from 500 to 700 °C and then decreased with pyrolysis temperature from 700 to 900 °C. The increase in reactivity with pyrolysis temperature (500-700 °C) is mainly due to the changes in the relative distribution of Na in the char matrix and on the pore surface. For the NaCl-loaded coals, when Cl was released during pyrolysis or gasification, the Na originally present in coal as NaCl showed good catalytic effects for the char gasification. Otherwise, Cl would combine with Na in the char to form NaCl during gasification, preventing Na from becoming an active catalyst. Controlling the pyrolysis conditions to favour the release of Cl can be a promising way to transform NaCl in coal into an active catalyst for char gasification.     

Volatilisation and catalytic effects of alkali and alkaline earth metallic species during the pyrolysis and gasification of Victorian brown coal. Part VI. Further investigation into the effects of volatile-char interactions

The purpose of this study is to further investigate the effects of volatile-char interactions on the volatilisation and dispersion of alkali and alkaline metallic species and changes in char structure during pyrolysis. Ion-exchanged (H-form, Na-form and Ca-form) Loy Yang brown coal samples were pyrolysed in a novel two-stage fluidised-bed/fixed-bed reactor over a wide temperature range of 500-930 °C. Our results indicate that soot formation and destruction on char (pore) surface during volatile-char interactions could be catalysed by Na and, to a lesser extent, Ca on char. Volatile-char interactions caused additional volatilisation of Na at temperatures higher than 700 °C although there are no effects on the volatilisation of Ca. The formation and simultaneous (catalytic) destruction of soot on char surface are closely linked to the volatilisation of Na from the char. Volatile-char interactions have also caused changes in char structure and/or changes in Na/Ca dispersion, as is reflected by the reduction in char reactivity. These results indicate that the volatile-char interactions are not limited on the char surface. It appears that H radicals must have penetrated into the char structure during volatile-char interactions.     

Volatilisation and catalytic effects of alkali and alkaline earth metallic species during the pyrolysis and gasification of Victorian brown coal. Part III. The importance of the interactions between volatiles and char at high temperature

A novel two-stage fluidised-bed/fixed-bed reactor was designed to investigate the effects of volatile-char interactions on the volatilisation of alkali and alkaline earth metallic (AAEM) species during the pyrolysis of Victorian brown coal at 900 °C. With the two-stage reactor configuration, the AAEM-free volatiles generated from the pyrolysis of the H-form coal in the fluidised bed came into direct contact with the char from NaCl-loaded or Na-form coals in the fixed bed. The results indicated that the interactions between the volatiles, especially free radicals in the volatiles, and the char particles enhanced the volatilisation of Na from the char drastically. However, such radical-char interactions resulted in little volatilisation of Mg and Ca, indicating the importance of valence of the AAEM species. The degree of the volatile-char interactions was also related to the ageing of the char and the chemical form of AAEM species in the coal substrate. The volatiles interacted more strongly with the nascent char than the aged char, indicating that the AAEM species existed in the aged char in more stable forms than in the nascent char.     

Volatilisation and catalytic effects of alkali and alkaline earth metallic species during the pyrolysis and gasification of Victorian brown coal. Part IX. Effects of volatile-char interactions on char-H2O and char-O2 reactivities

Volatile-char interactions are an important consideration in the design and operation of a gasifier. This study aims to investigate the effects of volatile-char interactions on the in situ char-steam reactivity at 800 °C and the ex-situ char-O₂ reactivity at 400 °C. A Victorian brown coal was gasified in 15% steam at 800 °C in a one-stage novel fluidised-bed/fixed-bed quartz reactor, in which the extent of volatile-char interactions could be controlled. The chars after varying extents of volatile-char interactions and/or varying extents of char conversion in steam were also collected for the measurement of their reactivity with air at 400 °C in a thermogravimetric analyser. Our results show that the char-steam gasification reactions were greatly inhibited by the volatile-char interactions. It is believed that the H radicals generated from the thermal cracking/reforming of volatiles slowed the char gasification in three ways: occupying the char reactive sites, causing the char structure to re-arrange/condense and enhancing the release of catalytic species inherently present in the brown coal. The importance of volatile-char interactions to char-steam reactivity was further confirmed by the char-air reactivity.     

Volatilisation and catalytic effects of alkali and alkaline earth metallic species during the pyrolysis and gasification of Victorian brown coal. Part VIII. Catalysis and changes in char structure during gasification in steam

The purpose of this study is to investigate the major factors influencing the Na-catalysed and non-catalysed gasification reactivity of a Victorian brown coal in steam. An acid-washed (H-form) sample and a Na-exchanged (Na-form) sample prepared from the same Loy Yang brown coal were gasified in 15% steam in a novel two-stage fluidised-bed/fixed-bed reactor. All C-containing species in the gasification product gas were converted into CO₂ that was monitored with a mass spectrometer continuously to determine the in situ gasification reactivity. While the volatile-char interactions were responsible for the volatilisation of Na when the coal was continuously fed into the reactor, the physical entrainment by gas of agglomerated Na-containing crystalline species (likely to be Na₂CO₃ or Na₂O) from char surface was the main mechanism for the loss of Na during char gasification. The Raman spectroscopy of char showed the preferential release of smaller aromatic ring system to be more significant during the non-catalysed char gasification than the Na-catalysed gasification. The dispersion of Na in char appeared to deteriorate with the enrichment of large aromatic ring systems in char, greatly affecting the char gasification reactivity. The char gasification reactivity showed a maximum with increasing conversion with the maximum to shift towards lower conversion with increasing temperature. Increasing temperature does not always lead to increases in the in situ char gasification reactivity.     

Volatilisation and catalytic effects of alkali and alkaline earth metallic species during the pyrolysis and gasification of Victorian brown coal. Part I. Volatilisation of Na and Cl from a set of NaCl-loaded samples

A set of NaCl-loaded coal samples was prepared by physically impregnating NaCl into a Victorian (Loy Yang) brown coal. This set of brown coal samples was pyrolysed in a thermogravimetric analyser and in a novel fluidised-bed/fixed-bed reactor. The latter reactor has some features of both a fluidised-bed reactor and a fixed-bed reactor. The reactor configuration allowed the volatilised Na to be swept away by carrier gas from the bed of char particles, avoiding the re-condensation of the volatilised Na on the char particles at lower temperatures. The volatilisation of Na and of Cl during pyrolysis was quantified simultaneously. The results indicated that a significant proportion of Cl could be volatilised at temperatures around 200°C. The volatilisation of Cl increased drastically with increasing temperature, from 200 to about 500°C. At higher temperatures with a fast heating rate, Cl could interact with the nascent char to be retained in the char. The volatilisation of Na followed a different trend from that of Cl and increased monotonically with increasing temperature. The loading of NaCl into the brown coal had negligible effects on the total volatile yields and on the volatilisation of Mg and Ca during pyrolysis. It is concluded that NaCl in the brown coal was mainly released as Na and Cl separately rather than as NaCl molecules. Reactions involving radicals play important roles in the volatilisation of Na and Cl.     

Effects of volatile-char interactions on the evolution of char structure during the gasification of Victorian brown coal in steam

The purpose of this study is to investigate the effects of volatile-char interactions on the evolution of char structure during the gasification of Victorian brown coal in steam. A novel one-stage fluidised-bed/fixed-bed quartz reactor was employed to carry out the experiments in the presence and absence of volatile-char interactions. The effects of thermal annealing on char structure were also investigated under similar conditions. The structural features of char were evaluated using FT-Raman spectroscopy. The results indicate that the char structural features were considerably affected by volatile-char interactions, which was shown from the Raman band area or the ratios between the band areas. H radicals from the thermal cracking/reforming of volatiles are believed to play a vital role in the changes in char structure due to the volatile-char interactions. H radicals could penetrate into char matrix and favour the condensation of aromatic rings, which was the main reason for the decrease in the ratio of small (less than 6 fused rings) to large aromatic rings during the volatile-char interactions. The volatile-char interactions also greatly affected the concentrations of O-containing groups in char and thus significantly altered the observed Raman intensity of the char.     

Effects of volatile-char interactions on the volatilisation of alkali and alkaline earth metallic species during the pyrolysis of biomass

An important feature of a fluidised-bed gasifier is the continuous contact between volatiles and char. The aim of this study is to experimentally investigate the effects of volatile-char interactions on the volatilisation of AAEM species during pyrolysis of two sugarcane industry wastes, bagasse and cane trash. A two-stage quartz fluidised-bed/fixed-bed reactor was used for this fundamental study. Our results indicate that the volatile-char interactions could lead to the additional volatilisation of alkali and alkaline earth metallic (AAEM) species, particularly if the volatile-char interactions have resulted in additional char weight losses. The monovalent Na and K behaved differently from the divalent Mg and Ca in biomass. Our results provide circumstantial but clear evidence that the AAEM species in biomass could behave distinctly differently from those in brown coal, largely due to the differences in the structure and composition between biomass and coal. The development of biomass gasification technologies must consider the special thermochemical characteristics of biomass. Furthermore, even the bagasse and cane trash grown in the same area behave drastically differently, at least partly due to the different microstructures of bagasse and cane trash.     

Formation of NOx precursors during the pyrolysis of coal and biomass. Part IX. Effects of coal ash and externally loaded-Na on fuel-N conversion during the reforming of coal and biomass in steam

Ash interacts strongly with char and volatiles in a gasifier, especially in a fluidised-bed gasifier. This study aims to investigate the effects of ash or ash-forming species on the conversion of fuel-N during gasification. A Victorian (Loy Yang) brown coal and a sugar cane trash were gasified in two novel fluidised-bed/fixed-bed reactors where the interactions of ash with char and/or volatiles could be selectively investigated. Our results show that the interaction of ash with char and/or volatiles could lead to increases in the yield of NH₃ and decreases in the yield of HCN although the increases were not always matched exactly by the decreases. Loading NaCl or Na₂CO₃ into the brown coal was also found to affect the formation of HCN and NH₃ during gasification. In addition to the possible catalytic hydrolysis of HCN into NH₃ particularly at high temperatures, two other causes were identified for the changes in the HCN and NH₃ yields. It is believed that some ash species could migrate into the char matrix to affect the local availability of H radicals or to catalyse the formation of NH₃ selectively. The interactions of ash (or Na loaded into the coal) with volatiles could enhance the formation of soot-N, which would be gasified favourably to form NH₃.     

Formation of NOx precursors during the pyrolysis of coal and biomass. Part X: Effects of volatile-char interactions on the conversion of coal-N during the gasification of a Victorian brown coal in O2 and steam at 800 °C

A novel fluidised-bed/fixed-bed reactor was used to study the effects of volatile-char interactions on the conversion of coal-N during the gasification of a Victorian brown coal at 800 °C. The reactor has the capability of controlling the extent and length of the interactions between volatiles and char. Our results indicate that in the absence of volatile-char interactions during gasification in O₂, the lack of abundant H radicals led to negligible formation of NH₃ and HCN from char-N. The presence of volatile-char interactions during the gasification of Victorian brown coal in O₂ at 800 °C drastically enhanced the formation of NH₃ and, albeit to a lesser extent, the formation of HCN. The enhanced conversion of char-N into NH₃ (and HCN) due to the volatile-char interactions is attributed to the presence of H radicals in the volatiles. H radicals in volatiles could “die off” as they pass through the nascent char bed during the course of volatile-char interactions.     

Volatilisation and catalytic effects of alkali and alkaline earth metallic species during the pyrolysis and gasification of Victorian brown coal. Part V. Combined effects of Na concentration and char structure on char reactivity

A set of NaCl-loaded Loy Yang brown coal was pyrolysed in a thermogravimetric analyser between 600 and 900 °C. The char sample after pyrolysis was cooled down directly for in situ reactivity measurement with air. The results indicated that the volatilisation of Na during pyrolysis is an important reason for the existence of catalyst loading saturation level with Na as a catalyst in char because the char prepared at high temperature had a limited holding capacity for Na. Under the experimental conditions in this study, the char reactivity showed good linear correlation with the Na concentration in the reacting char. Peak pyrolysis temperature, affecting the release of Cl and distribution of Na in char, is an important factor governing the correlation between the char reactivity and Na concentration in char. The catalytic activity of Na is a result of the interaction between Na and char and thus is greatly dependent on the char/carbon structure. At high char conversion levels where the char structure is more inert and highly condensed, the catalytic activity of Na is reduced compared with its activity at low char conversion levels. The catalytic activity of Na depends on the structure of char.     

Changes in char reactivity and structure during the gasification of a Victorian brown coal: Comparison between gasification in O2 and CO2

Char reactivity is an important factor influencing the efficiency of a gasification process. As a low-rank fuel, Victorian brown coal with high gasification reactivity is especially suitable for use with gasification-based technologies. In this study, a Victorian brown coal was gasified at 800 °C in a fluidised-bed/fixed-bed reactor. Two different gasifying agents were used, which were 4000 ppm O₂ balanced with argon and pure CO₂. The chars produced at different gasification conversion levels were further analysed with a thermogravimetric analyser (TGA) at 400 °C in air for their reactivities. The structural features of these chars were also characterised with FT-Raman/IR spectroscopy. The contents of alkali and alkaline earth metallic species in these chars were quantified. The reactivities of the chars prepared from the gasification in pure CO₂ at 800 °C were of a much higher magnitude than those obtained for the chars prepared from the gasification in 4000 ppm O₂ also at 800 °C. Even though both atmospheres (i.e. 4000 ppm O₂ and pure CO₂) are oxidising conditions, the results indicate that the reaction mechanisms for the gasification of brown coal char at 800 °C in these two gasifying atmospheres are different. FT-Raman/IR results showed that the char structure has been changed drastically during the gasification process.     

FT-Raman spectroscopic study of the evolution of char structure during the pyrolysis of a Victorian brown coal

FT-Raman spectroscopy with a 1064 nm laser was used to investigate chemical structural changes of char during the pyrolysis of Victorian Loy Yang brown coal samples. The chars were diluted with KBr in order to record Raman spectra with acceptable quality. The interpretation of the Raman spectral data for these highly disordered and heterogeneous chars differs distinctly from that for the highly condensed/graphitised carbon materials. The FT-Raman spectra of chars in this study over the range of 800–1800 cm⁻¹ were curve-fitted with 10 bands representing major structures in the chars. This has given information about the size of aromatic rings and the nature of substitutional groups and cross-links in char. The observed Raman intensity of a char is governed by its Raman scattering ability and its light absorptivity for both excitation laser and Raman scattering. The overall Raman intensity (peak area) as well as the ratios among the intensities of some major Raman bands has allowed some semi-quantitative evaluation of changes in char structure with increasing temperature during pyrolysis. The presence of ion-exchangeable Na and Ca in brown coal greatly affects the char-forming reactions during pyrolysis.     

Effects of alkaline metal on coal gasification at pyrolysis and gasification phases

A Chinese high-rank coal was acid-washed and ion-exchanged with Na and K to prepare the H-form, Na-form and K-form coals. After pyrolysis, H-form, Na-form and K-form chars and two additional H-form chars (acid washed Na-form and K-form chars) were prepared to investigate the effects of alkaline metal (AM) on coal gasification at the pyrolysis and gasification phases. The H-form char had the highest pryolysis rate; the H-form char had a relative low gasification rate. The AM loaded coals exhibited relative low pyrolysis rate, while the corresponding chars had high gasification reactivity. Acid-washing reduced the reactivities of Na-form and K-form chars. AM inhibited the progress of graphitization of the base carbon resulting in a more reactive char of less ordered crystalline carbon structure. A kinetic model incorporating AM-catalyzed gasification and non-catalytic gasification was developed to describe the gasification rate changes in the char conversion for AM-catalyzed gasification of chars.     

Formation of NOx precursors during the pyrolysis of coal and biomass. Part VIII. Effects of pressure on the formation of NH3 and HCN during the pyrolysis and gasification of Victorian brown coal in steam

Effects of pressure on the formation of HCN and NH₃ during the pyrolysis and gasification of Loy Yang brown coal in steam were investigated using a pressurised drop-tube/fixed-bed reactor. The NH₃ yield increased with increasing pressure during both pyrolysis and gasification. Increasing pressure selectively favours the formation of NH₃ at the expenses of other N-containing species. The changes in the yield of NH₃ with increasing pressure were mainly observed in the feeding periods both during pyrolysis and gasification and were closely related to the formation and subsequent cracking of soot both as a result of intensified thermal cracking of volatile precursors inside the particles and as a result of volatile-char interactions after the release of volatiles. While the corresponding HCN yield during pyrolysis showed little sensitivity to changes in pressure, the HCN yield during gasification in steam showed some increases with increasing pressure. Our data indicate that the direct hydrogenation of char-N by H radicals, favoured by the presence of steam, is the main route of NH₃ formation during pyrolysis and gasification. The direct conversion, either through hydrogenation or hydrolysis, of HCN into NH₃ on char surface during the pyrolysis and gasification of brown coal is not an important route of NH₃ formation.     

Reactivities of 34 coals under steam gasification

The reactivities of 34 coal chars of varying rank with H₂O have been determined to examine the effect of coal rank on the gasification rate of coal char. The reactivities of chars derived from caking coals and anthracites (carbon content > 78 wt%, daf) were very small compared with those from non-caking (lower-rank) coals. The reactivities of low-rank chars do not correlate with the carbon content of the parent coals. To clarify which factor is more important in determining the reactivity, the evolution of CO and CO₂ from char, the moisture content of char and the amount of exchangeable cations were determined for these low-rank coals or their chars. These values were considered to represent the amount of active carbon sties, the porosity and the catalysis by inherent mineral matters, respectively. It was concluded that the amount of surface active sites and/or the amount of exchangeable Ca and Na control the reactivity of low-rank chars in H₂O.     

Factors affecting steam gasification rate of low rank coal char in a pressurized fluidized bed

A high-pressure bubbling fluidized bed reactor was used to study the steam gasification of coal char under pressure. Indonesian sub-bituminous coal char (Adaro) and Australian lignite char (Loy Yang) were gasified with steam in the reactor at temperatures below 1173 K and at total pressures ranging from 0.1 to 0.5 MPa. The steam gasification rates of the coal chars were determined by analysis of the gaseous products. Activation energies for the steam gasification of the chars were as high as about 250 kJ/mol, which suggests that the temperature dependence of the gasification was substantial. The apparent gasification rates under the study conditions were described by a Langmuir–Hinshelwood (L–H)-type equation. Analysis of the reaction kinetics on the basis of the L–H equation indicated that increasing steam pressure effectively increased the gasification rate.     

Flash pyrolysis of coals: comparison of results from 1 g h−1 and 20 kg h−1 reactors

The performances of 1 g h^?1 and 20 kg h^?1 flash pyrolysers are compared for three Australian coals: Loy Yang brown coal (Victoria), Liddell bituminous coal (New South Wales), and Millmerran sub-bituminous coal (Queensland). The two reactors gave comparable yields of tar, char and C₁–C₃ hydrocarbon gases over a range of operating conditions for each particular coal. The yield of total volatile matter from Millmerran coal was similar from both reactors, as were the compositions of chars from Loy Yang coal and tars from the Liddell and Millmerran coals. For Millmerran coal, the yields of tar, C₁–C₃ gases and volatiles from the large reactor below 650 °C, were slightly lower than for the small reactor, possibly owing to a shorter retention time of Millmerran coal particles in the large-scale reactor. At a temperature near 600 °C tar yields were independent of tar concentration in the effluent gas, over a range 0.0025–0.1 kg m^?3 for Liddell coal, 0.005–0.26 kg m^?3 for Millmerran coal and 0.0045–0.09 kg m^?3 for Loy Yang coal. The tar yields from Millmerran and Liddell coals at 600 °C in the large reactor, correlate directly with the atomic $\text{H}\text{C}$ ratio of the parent coal, in the same manner as that found for a wider range of bituminous coals in the small-scale reactor.     

Thermogravimetric determination of the carbon dioxide reactivity of char from some New Zealand coals and its association with the inorganic geochemistry of the parent coal

Thermogravimetrically-determined carbon dioxide reactivities of chars formed from New Zealand coals, ranging in rank from lignite to high volatile bituminous, vary from 0.12 to 10.63 mg/h/mg on a dry, ash-free basis. The lowest rank subbituminous coal chars have similar reactivities to the lignite coal chars. Calcium content of the char shows the strongest correlation with reactivity, which increases as the calcium content increases. High calcium per se does not directly imply a high char reactivity. Organically-bound calcium catalyses the conversion of carbon to carbon monoxide in the presence of carbon dioxide, whereas calcium present as discrete minerals in the coal matrix, e.g., calcite, fails to significantly affect reactivity. Catalytic effects of magnesium, iron, sodium and phosphorous are not as obvious, but can be recognised for individual chars. The thermogravimetric technique provides a fast, reliable analysis that is able to distinguish char reactivity differences between coals, which may be due to any of the above effects.     

Some recent advances in the understanding of the pyrolysis and gasification behaviour of Victorian brown coal

The brown coal in the Latrobe Valley, Victoria, Australia, has many unique structural features and properties. The brown coal has a very low ash yield and contains highly dispersed alkali and alkaline earth metallic (AAEM) species, either as carboxylates forming part of its organic matter or as NaCl dissolved in its moisture. Owing to its unique structural features and properties, the brown coal behaves very differently from many other solid fuels such as biomass, bituminous coals and anthracites. For example, the highly reactive nature of its volatiles, the vulnerable nature of its nascent char and the presence of finely distributed AAEM species mean that the volatile–char interactions, a common phenomenon in all gasifiers, especially in the fluidised-bed gasifiers, would influence almost every aspect of its pyrolysis and gasification behaviour. Some recent progress in the understanding of the pyrolysis and gasification behaviour of Victorian brown coal will be reviewed in this paper. After a brief account of the effects of AAEM species on the pyrolysis yields, the factors influencing the volatilisation of AAEM species will be summarised. This will be followed by the discussion of the factors influencing the reactivity of brown coal char and the catalytic reforming/cleaning of volatiles and gasification products by char-supported catalysts. The effects of dewatering/drying on the pyrolysis behaviour of Victorian brown coal and the conversion of pollutant-forming elements will be mentioned briefly. The progress in the fundamental understanding of the pyrolysis and gasification behaviour of Victorian brown coal has laid solid foundation for the further development of advanced gasification technologies for the clean and efficient utilisation of this cheap but important resource.