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Laboratory studies on cavity growth and product gas composition in the context of underground coal gasification

Systematic laboratory scale experiments on coal blocks can provide significant insight into the underground coal gasification (UCG) process. Our earlier work has demonstrated the various features of the early UCG cavity shape and rate of growth through lab-scale experiments on coal combustion, wherein the feed gas is oxygen. In this paper, we study the feasibility of in situ gasification of coal in a similar laboratory scale reactor set-up, under conditions relevant for field practice of UCG, using an oxygen-steam mixture as the feed gas. By performing the gasification reaction in a cyclic manner, we have been able to obtain a product gas with hydrogen concentrations as high as 39% and a calorific value of 178 kJ/mol. The effect of various operating parameters such as feed temperature, feed steam to oxygen ratio, initial combustion time and so on, on the product gas composition is studied and the optimum operating conditions in order to achieve desired conversion to syngas, are determined. We also study the effect of various design and operating parameters on the evolution of the gasification cavity. Empirical correlations are proposed for the change in cavity volume and its dimensions in various directions. The results of the previous study on the combustion cavity evolution are compared with this gasification study.     

Influence of functional group structures on combustion behavior of pulverized coal particles

The ignition and combustion behavior of pulverized coal was studied with respect to coal rank in a custom-designed visual drop tube furnace. The results showed that low-rank coals were ignited in a shorter time, mainly due to the presence of larger amounts of functional groups, while the ignition delay time of high-rank coals was longer. With increasing temperature and particle size, the ignition mode of coals shifted from heterogeneous into homogeneous, which was related to the increased yield of volatile matter. The chemical percolation devolatilization analysis results showed a clear relationship between the yield and composition of volatile matter and the amount and type of functional groups in coal. In addition, the tar yield was consistent with the amount of aliphatic hydrocarbons and the length of aliphatic chains, which explained the tailing combustion mode of the bituminous coal. The findings of the study showed that the yield and composition of volatiles in coal had a significant impact on the ignition behavior, which depended on the composition of functional groups, particle size, and the combustion environment.     

Effects of coal syngas impurities on anodes of solid oxide fuel cells

A literature review is conducted to summarize the studies on the identification of impurities in coal syngas and their effects on the performance of Ni-yttria stabilized zirconia (Ni-YSZ) anode of solid oxide fuel cells (SOFCs). Coal syngas typically contains major species, CO, H₂, CO₂, H₂O, CH₄, N₂, and H₂S as well as trace impurities. Thermodynamic equilibrium calculations have indicated that trace impurities species such as Be, Cr, K, Na, and V in the coal syngas form condensed phases under warm gas cleanup conditions and can be effectively removed by the cleanup processes. For meaningful data comparison, a practical parameter is formulated to quantify the level of degradation normalized with respect to the relevant experimental parameters. Experimental results show that the existence of Hg, Si, Zn and NH₃ in the coal syngas does not significantly affect the performance of the Ni-YSZ anode. The presence of Cd and Se in the syngas impacts the SOFC anode performance to some extent. Impurity species such as Cl, Sb, As, and P cause severe cell voltage degradation due to attack on the Ni-YSZ anode. Sb, As and P have the potential to react with Ni to form secondary phases in the Ni-YSZ anode, which deteriorate the catalytic activity of the anode.     

Performance and cost of wet and dry cooling systems for pulverized coal power plants with and without carbon capture and storage

Thermoelectric power plants require significant quantities of water, primarily for the purpose of cooling. Water also is becoming critically important for low-carbon power generation. To reduce greenhouse gas emissions from pulverized coal (PC) power plants, post-combustion carbon capture and storage (CCS) systems are receiving considerable attention. However, current CO₂ capture systems require a significant amount of cooling. This paper evaluates and quantifies the plant-level performance and cost of different cooling technologies for PC power plants with and without CO₂ capture. Included are recirculating systems with wet cooling towers and air-cooled condensers (ACCs) for dry cooling. We examine a range of key factors affecting cooling system performance, cost and plant water use, including the plant steam cycle design, coal type, carbon capture system design, and local ambient conditions. Options for reducing power plant water consumption also are presented.     

Effects of high-temperature oxygen-deficient oxidation on the surface properties of sub-bituminous coal

The air oxidation of coal releases heat which increases coal temperature, as a result, the spontaneous combustion of coal happens. Generally, coal spontaneous combustion needs to be prevented artificially, however, most of the coal particles still suffer a high-temperature heating process under the oxygen-deficient condition. This paper aims to investigate the effect of high temperature (500°C, 600°C, and 700°C) oxygen-deficient (3% oxygen and 97% nitrogen) oxidation on the surface properties of sub-bituminous coal. SEM and XPS were applied to show the changes of surface properties of sub-bituminous coal. SEM results showed the number of pores and cracks on coal surface increased with the increasing heating temperature, and XPS results showed the content of hydrophobic functional groups on coal surface reduced whereas the content of hydrophilic oxygen-containing functional groups increased after the oxygen-deficient oxidation.     

An assessment of the physical,mineral, and rheological properties of fly ash for stowing in coal mines

With increasing environmental awareness, utilization of fly ash has become an attractive alternate to disposal. The objective of the present study was to investigate the physical, chemical, mineral, and rheological characteristics of fly ash for their potential utilization in stowing operation. The study was conducted with fly ash collected from the ash disposal system of Guru Govind Singh thermal power plant, Ropar, Punjab, India. From the characterization of the fly ash sample, it was found that the ash sample is enriched predominantly in silica; alumina and iron oxides fall under the category of F-type fly ash. The major mineral crystalline phase identified in the ash sample is quartz and mullite. Because of the properties of fly ash, it can be used as a stowing material in coal mines. The data obtained for critical velocity will help design a slurry pipeline system for the hydraulic stowing of fly ash slurry at any concentration and pipe size.     

Formation of the structure of chars during devolatilization of pulverized coal and its thermoproperties: A review

The paper provides an overview of current studies on the behaviour of coal during devolatilization, especially the experimental studies and modelling efforts on the formation of char structure of bituminous coals in the open literature. Coal is the most abundant fossil fuel in the world. It dominates the energy supply in the future and plays an increasing role particularly in the developing countries. Coal utilization processes such as combustion or gasification generally involve several steps: i.e., the devolatilization of organic materials, homogeneous reactions of volatile matter with the reactant gases and heterogeneous reactions of chars with the reactant gases. The devolatilization process exerts its influence throughout the life of the solid particles from the injection to the burnout, therefore is the most important step which needs to be understood. When volatile matter is generated, the physical structure of a char changes significantly during the devolatilization, some accompanying a particle's swelling. The complexity of a char's structure lies in the facts that the structure of a char itself is highly heterogenous inside an individual particle and between different particles and the chemistry of a char is strongly dependent on the raw coal properties. A char's structure is strongly dependent on the heating conditions such as temperature, heating rate and pressure. Understanding the swelling of coal and the formation of char's pore structure during the devolatilization of pulverized coal is essential to the development of advanced coal utilization technologies. During combustion and gasification of pulverized coal, the behaviour of individual particles differs markedly due to the variation of their maceral composition. Particles with different maceral constituents generate different types of char structure. The structure of a char has a significant impact on its subsequent heterogeneous reactions and ash formation. The review also covers the most recent studies carried out by the authors, including the experimental observations of the thermoplastic behaviour of individual coal particles from the density fractions using a single-particle reactor, the experimental analysis on chars prepared in a drop tube furnace using the density-separated coal samples, the development of a mathematical model for the formation of char's pore structure based on a simplified multi-bubble mechanism and the investigation on the effect of pressure on char formation in a pressurized entrained-flow reactor.     

The effect of sludge from coal to oil process on the stability of coal/sludge water slurries

Sludge produced from coal to oil process contains larger content of tar, phenols, ammonia components, and ashes. It cannot be treated by using traditional disposal methods as landfill or incineration. A promising solution is to blend sludge with coal for preparation of sludge/coal-water slurries. The new slurry fuels could be used in commercial gasifiers for syngas generation. In this process, the first goal is to form a stable slurry. In the research project, the addition of sludge on the stability of coal-water slurries was investigated. Results show that the addition of sludge can improve the static stability for slurries prepared by lean coal, coking coal, and lignite. The effect on stability of coking coal-water slurry is the most significant. The proportion of sludge to lean coal added in the slurry can be maintained at 10% to 15%.     

Catalytic steam reforming of bio-oil model compounds for hydrogen production over coal ash supported Ni catalyst

The development of a high performance and low cost catalyst is an important contribution to clean hydrogen production via the catalytic steam reforming of renewable bio-oil. Solid waste coal ash, which contains SiO₂, Al₂O₃, Fe₂O₃ and many alkali and alkaline earth metal oxides, was selected as a superior support for a Ni-based catalyst. The chemical composition and textural structures of the ash and the Ni/Ash catalysts were systematically characterized. Acetic acid and phenol were selected as two typical bio-oil model compounds to test the catalyst activity and stability. The conversion of acetic acid and phenol reached as much as 98.4% and 83.5%, respectively, at 700 °C. It is shown that the performance of the Ni/Ash catalyst was comparable with other commercial Ni-based steam reforming catalysts.     

Numerical investigation of influence of homogeneous/heterogeneous ignition/combustion mechanisms on ignition point position during pulverized coal combustion in oxygen enriched and recycled flue gases atmosphere

It is expected that pulverized coal combustion will continue to play a major role in electricity generation for the foreseeable future. Oxy-fuel coal combustion is actively being investigated, as alternative to conventional pulverized-coal combustion, due to its potential to easier carbon dioxide sequestration. This paper presents experimental and numerical analysis of ignition phenomena in oxy-fuel conditions. A modification of standard sequential coal combustion model is proposed. The new model is developed following the criteria for the particle ignition mechanism as the function of surrounding conditions. The implemented model was validated based on ignition point position obtained from the drop tube facility experiments in various O₂-N₂ and O₂-CO₂ conditions. The obtained numerical results showed a much better agreement with the experimental results when compared with the simulations performed with the default FLUENT sub-models for coal particle ignition/combustion, thus enabling a quantitative determination of pulverized coal flame ignition point position using numerical analysis.     

Effects on enrichment characteristics of trace elements in fly ash by adding halide salts into the coal during CFB combustion

The effects on enrichment characteristics of trace elements (TEs) in fly ash by adding halide salts into the coal during coal combustion were conducted on a 6 kW_th circulating fluidized bed (CFB) experimental device. Results show that unburn carbon content in fly ash has little relationship with the concentration of TEs namely Hg, As, Pb, Cr and Mn. All the TEs are enriched in fly ash for the raw coal CFB combustion. Concentration of Hg and Mn increases with increasing the addition amount of CaCl₂, NH₄Cl and NH₄Br. As, Pb and Cr enrich in fly ash more strongly when adding more CaCl₂ into the coal while more addition of NH₄Cl and NH₄Br leads to the decrease of their enrichment compared to addition amount of 0.1 wt%. On the whole, putting halide salts into the coal results in the TEs enriched in fly ash, which benefits for TEs removal during the coal combustion. Combining this method with the chemical sequential extraction or thermal treatment of the fly ash will be a promising way to realize the TEs removal and their recovery.     

Effects of coal syngas major compositions on Ni/YSZ anode-supported solid oxide fuel cells

This paper presents a systematical evaluation of the effects of CO₂, H₂O, CO, N₂ and CH₄ in the coal syngas on the properties of typical Ni/YSZ anode-supported solid oxide fuel cells (SOFCs). The results show that CO₂, H₂O, CO, N₂ and CH₄ have complicated effects on the cell performance and the electrochemical impedance spectra (EIS) analysis reveals the addition of these gases influences electrode processes such as the oxygen ion exchange from YSZ to anode TPBs, the charge transfer at the anode TPBs, gas diffusion and conversion at the anode. Two kinds of mixture gases with different compositions are thus constituted and used as fuel for aging test on two cells at 750 °C. No degradation or carbon deposition is observed for the cell fueled with 40% H₂-20% CO-20% H₂O-20% CO₂ for 360 h while the cell fueled with 50% H₂-30% CO-10% H₂O-10% CO₂ exhibits an abrupt degradation after 50 h due to the severe carbon deposition.     

Influence of coal co-firing on the particulate matter formation during pulverized biomass combustion

Biomass is regarded as CO₂-neutral, while the high contents of potassium and chlorine in biomass induce severe particulate matter emission, ash deposition, and corrosion in combustion facilities. Co-firing biomass with coal in pulverized-combustion (PC) furnaces is able to solve these problems, as well as achieve a much higher generating efficiency than grate furnaces. In this work, the particulate matter (PM) emission from biomass co-firing with coal was studied in an entrained flow reactor at a temperature of 1623 K simulating PC furnace condition. PMs were sampled through a 13-stage impactor, and their morphology and elemental composition were characterized by scanning electron microscopy and electron dispersive X-ray spectroscopy. SO₂ emissions were measured to interpret the possibility of potassium sulfation during co-firing. Results show that PMs from the separated combustion of both biomass and coal present a bimodal particle size distribution (PSD). The concentration and size of fine-mode submicron particles (PM_1.0) from biomass combustion are much higher than those from coal combustion because of the high potassium content in biomass. For the co-firing cases, with the coal ratio increasing from 0% to 50%, the PM_1.0 yield is reduced by more than half and the PM_1.0 size becomes smaller, in contrast, the concentration of coarse-mode particles with the size of 1.0–10 μm (PM_1.0-10) increases. The measured PM_1.0 yields of co-firing are lower than the theoretically weight-averaged ones, which proves that during the biomass and coal co-firing in PC furnaces, the vaporized potassium from biomass can be efficiently captured by these silicon-aluminate oxides in coal ash. In the studied range of coal co-firing ratio (≤50 wt.%), the chlorides and sulfates of alkali metals from biomass burning are the dominating components in PM_1.0, and a certain amount of silicon is observed in PM_0.1-1. The analysis of chemical composition in PM_1.0, together with that of SO₂ emission, indicates a marginal sulfation of alkali metal chloride occurring at high temperatures in PC furnaces.     

On the influence of the char gasification reactions on NO formation in flameless coal combustion

Flameless combustion is a well known measure to reduce NO_x emissions in gas combustion but has not yet been fully adapted to pulverised coal combustion. Numerical predictions can provide detailed information on the combustion process thus playing a significant role in understanding the basic mechanisms for pollutant formation. In simulations of conventional pulverised coal combustion the gasification by CO₂ or H₂O is usually omitted since its overall contribution to char oxidation is negligible compared to the oxidation with O₂. In flameless combustion, however, due to the strong recirculation of hot combustion products, primarily CO₂ and H₂O, and the thereby reduced concentration of O₂ in the reaction zone the local partial pressures of CO₂ and H₂O become significantly higher than that for O₂. Therefore, the char reaction with CO₂ and H₂O is being reconsidered. This paper presents a numerical study on the importance of these reactions on pollutant formation in flameless combustion. The numerical models used have been validated against experimental data. By varying the wall temperature and the burner excess air ratio, different cases have been investigated and the impact of considering gasification on the prediction of NO formation has been assessed. It was found that within the investigated ranges of these parameters the fraction of char being gasified increases up to 35%. This leads to changes in the local gas composition, primarily CO distribution, which in turn influences NO formation predictions. Considering gasification the prediction of NO emission is up to 40% lower than the predicted emissions without gasification reactions being taken into account.     

On the deduction of single coal particle combustion temperature from three-color optical pyrometry

Temperature–time histories of burning single coal particles can be obtained with multi-color (multi-wavelength) optical pyrometry. With this method, a number of different temperatures can be deduced from the resulting number of two-color ratios. However, these two-color temperatures do not always agree, causing considerable uncertainty in the temperature measurement. This work used a three-color pyrometer and focused on identifying and minimizing the causes of disparity among the three deduced temperatures. Components of the pyrometer (such as dichroic filters, interference filters and photo-detectors) were modeled mathematically, taking into account their wavelength-dependent properties. The pyrometer was calibrated with both a high-temperature pre-calibrated tungsten lamp, and a moderately-high temperature blackbody cavity, to span the temperature range of interest in pulverized coal combustion. Temperatures were deduced based not only on a suitably-modified pyrometric signal ratio method but also, on a similarly modified pyrometric signal non-linear least-square method, to provide comparison. Results are exemplified by presenting radiation-signal-time and temperature–time profiles of single particles burning in air. The variation of the projected luminous area of burning particles was also computed using both methods, and area–time profiles are presented herein. The char particle emissivity was either treated as a quantity independent of the wavelength (i.e., assuming gray-body behavior), or as a quantity assumed to depend linearly on the wavelength and using pertinent published emissivity data. Finally, a sensitivity analysis was performed to investigate individual effects of parameters, such as the calibration method, the wavelength dependencies of filter transmissivities, and the photo-detector responsivities on the pyrometric signal ratio method temperature consistency.     

Research on the combustion characteristics of anthracite and blended coal with composite catalysts

Composite catalysts composed of different proportion of chemical reagents and steel industrial wastes were used as coal-burning additives. The effects of additives on combustion characteristics of anthracite coal and blended coal were studied by thermogravimetric analysis (TGA). The results showed that appropriate amount and proportion between chemical reagents and waste slag used as composite catalysts had good performances on the characteristics of coal combustion including ignition temperature, burnout temperature and burnout index, this will improve the coal combustion efficiency and also facilitate the comprehensive utilization of steel industrial waste slag.     

Experiments on chemical looping combustion of coal with a NiO based oxygen carrier

A chemical looping combustion process for coal using interconnected fluidized beds with inherent separation of CO₂ is proposed in this paper. The configuration comprises a high velocity fluidized bed as an air reactor, a cyclone, and a spout-fluid bed as a fuel reactor. The high velocity fluidized bed is directly connected to the spout-fluid bed through the cyclone. Gas composition of both fuel reactor and air reactor, carbon content of fly ash in the fuel reactor, carbon conversion efficiency and CO₂ capture efficiency were investigated experimentally. The results showed that coal gasification was the main factor which controlled the contents of CO and CH₄ concentrations in the flue gas of the fuel reactor, carbon conversion efficiency in the process of chemical looping combustion of coal with NiO-based oxygen carrier in the interconnected fluidized beds. Carbon conversion efficiency reached only 92.8% even when the fuel reactor temperature was high up to 970 °C. There was an inherent carbon loss in the process of chemical looping combustion of coal in the interconnected fluidized beds. The inherent carbon loss was due to an easy elutriation of fine char particles from the freeboard of the spout-fluid bed, which was inevitable in this kind of fluidized bed reactor. Further improvement of carbon conversion efficiency could be achieved by means of a circulation of fine particles elutriation into the spout-fluid bed or the high velocity fluidized bed. CO₂ capture efficiency reached to its equilibrium of 80% at the fuel reactor temperature of 960 °C. The inherent loss of CO₂ capture efficiency was due to bypassing of gases from the fuel reactor to the air reactor, and the product of residual char burnt with air in the air reactor. Further experiments should be performed for a relatively long-time period to investigate the effects of ash and sulfur in coal on the reactivity of nickel-based oxygen carrier in the continuous CLC reactor.     

Experimental studies of ash film fractions based on measurement of cenospheres geometry in pulverized coal combustion

In pulverized coal particle combustion, part of the ash forms the ash film and exerts an inhibitory influence on combustion by impeding the diffusion of oxygen to the encapsulated char core, while part of the ash diffuses toward the char core. Despite the considerable ash effects on combustion, the fraction of ash film still remains unclear. However, the research of the properties of cenospheres can be an appropriate choice for the fraction determination, being aware that the formation of cenospheres is based on the model of coal particles with the visco-plastic ash film and a solid core. The fraction of ash film X is the ratio of the measuring mass of ash film and the total ash in coal particle. In this paper, the Huangling bituminous coal with different sizes was burnt in a drop-tube furnace at 1273, 1473, and 1673 K with air as oxidizer. A scanning electron microscope (SEM) and cross-section analysis have been used to study the geometry of the collected cenospheres and the effects of combustion parameters on the fraction of ash film. The results show that the ash film fraction increases with increasing temperature and carbon conversion ratio but decreases with larger sizes of coal particles. The high fraction of ash film provides a reasonable explanation for the extinction event at the late burnout stage. The varied values of ash film fractions under different conditions during the dynamic combustion process are necessary for further development of kinetic models.     

Effect of oil type on the recovery of coal fines from coal waste slurry by the oil agglomeration process

The coal fines from slurry waste discarded from the Jamadoba coal preparation plant were used for the recovery of significant energy value coal fines. The effect of oil type was investigated using different oils (edible oil and nonedible oil) at constant pulp density (PD) and agglomeration time (AT) and varying oil dosages. (ODs) The results were evaluated based on % organic matter recovery (% OMR) and % ash rejection (% AR).