Steam reactivation of 16 bed and fly ashes from industrial-scale coal-fired fluidized bed combustors

The hydration behaviour of sixteen ashes, obtained from different commercial-scale fluidized bed combustors, has been investigated. Hydration is important for both ash disposal and reactivation of excess lime present in the ashes for further use in flue gas desulphurization. The techniques used were instrumental and conventional chemical analysis, thermogravimetry and X-ray diffraction. The ashes comprised both fly ash and bottom ash, with particle size less than 2 mm. The ashes were heat treated in air to oxidize free carbon and then hydrated with pressurized steam at about 170 °C, alone and with addition of pure CaO.It has been shown that steam hydration is effective in quantitatively converting CaO to Ca(OH)₂, but in most cases the free lime content (i.e. CaO+Ca(OH)₂), expressed as CaO, decreases and added CaO enters into pozzolanic reactions with coal ash components, in part or even completely. Both the chemical evidence and X-ray phase analyses indicate that hydrated silicates and silicoaluminates are formed. The hydrated ashes are all able to take up additional SO₂ and it appears that the presence of amounts of Ca(OH)₂ detectable by phase analysis is not necessary for such capture.     

Elemental mercury vapor capture by powdered activated carbon in a fluidized bed reactor

A bubbling fluidized bed of inert material was used to increase the activated carbon residence time in the reaction zone and to improve its performance for mercury vapor capture. Elemental mercury capture experiments were conducted at 100 °C in a purposely designed 65 mm ID lab-scale pyrex reactor, that could be operated both in the fluidized bed and in the entrained bed configurations. Commercial powdered activated carbon was pneumatically injected in the reactor and mercury concentration at the outlet was monitored continuously. Experiments were carried out at different inert particle sizes, bed masses, fluidization velocities and carbon feed rates. Experimental results showed that the presence of a bubbling fluidized bed led to an increase of the mercury capture efficiency and, in turn, of the activated carbon utilization. This was explained by the enhanced activated carbon loading and gas-solid contact time that establishes in the reaction zone, because of the large surface area available for activated carbon adhesion/deposition in the fluidized bed. Transient mercury concentration profiles at the bed outlet during the runs were used to discriminate between the controlling phenomena in the process. Experimental data have been analyzed in the light of a phenomenological framework that takes into account the presence of both free and adhered carbon in the reactor as well as mercury saturation of the adsorbent.     

Removal of victoria blue from aqueous solution by fly ash

The use of fly ash for the removal of victoria blue (C126, 44045) from aqueous solution at different concentrations and pH has been investigated. The process follows first order adsorption rate expression and the rate constant was found to be 1.70 × 10^?2 min^?1 at a victoria blue concentration of 1.0 × 10^?4 M and 25°C. The uptake of victoria blue by fly ash is diffusion controlled and the value of mass transfer coefficient is 1.25 × 10^?5 cm sec^?1. The equilibrium data fit well in the Langmuir model of adsorption. Maximum removal was noted at pH 8.0. Low desorption of dye from adsorbent surface indicates that the process may not be essentially a reversible one.     

Activated carbon for mercury control: Implications for fly ash management

As more utilities begin to use activated carbon injection (ACI) for mercury control, the potential for the presence of elevated concentrations of mercury, other air toxic elements, and activated carbon to impact fly ash management needs to be evaluated. Several Energy & Environmental Research Center (EERC) projects have allowed the collection of comparative baseline fly ash samples and associated fly ash–activated carbon (AC) samples from full-scale demonstrations of ACI for mercury emission control. These samples were evaluated for mercury and air toxic element content and mobility and for performance criteria to facilitate a better understanding of the impact of these components to specific utilization applications, including use as a mineral admixture in concrete. These data are compared with published data from samples collected at similar large-scale mercury emission control tests.     

Leaching characteristics of fly ash from fluidized bed combustion thermal power plant: Case study: Çan (Çanakkale-Turkey)

It is known that the concentration of elements of fly ash varies due to the used-coal and the used-lime qualities varying in different periods. In the Çan Thermal Power Plant (CTPP) located at northwestern Turkey, Çan (Çanakkale) basin coals, which are classified as lignite to sub-bituminous C coal with high total sulphur (0.4-12.22%) and a broad range of ash contents (3.2-44.6%) are mainly used. Performed studies reveal that some toxic elements exit in the coal, including As, U and V. Also, while the As, Cu, Co and Hg contents in coal increases, the sulphur contents in coal also increase. Additionally, trace elements that have inorganic compounds in coal are mobilized into air during the combustion process. This poses a big risk for human health and keeping the environment when Çan Basins low quality lignite is burned, it's the fly ash that contains several toxic elements which can leach out and contaminate the water resources.In this study, toxicity tests were conducted on the fly ash samples that were obtained from the fluidized bed combustion of Çan Thermal Power Plant. The results showed that water temperature, pH and the quality of the limestone used were the most important factors affecting the leaching properties. Concentration of some toxic elements found in the fly ash, such as; As, Cd, Cr, Pb, Se and Zn were analyzed. Concentration richness of some heavy metals were attributed to the increase of water temperature, especially when pH is lower than 5. At pH = 5 value, there is no clear explanation of each heavy metal presence in the fly ash from fluidized bed combustion thermal power plant.     

Thermal stability of mercury captured by ash

The thermal stability of mercury captured by ash was studied by sampling ash throughout the collection train of two Kentucky power plants. Sampling occurred over multiple years and involved both fresh and archived samples. During one ash collection episode, sampling was from the combustion of a single pulverized coal feed. The other collections involved ash from blended feeds. Ash was collected from economizer, mechanical and electrostatic precipitator hoppers. Feed coals, rejects and bottom ash were also sampled. Fractions of all the samples were heated in a thermal analyzer to maximum temperatures increased sequentially from 100 to 500 °C in 100 °C increments. The mercury content of the spent material was then determined by analysis of the solids for Hg. From this data the thermal decomposition temperature of the captured mercury was determined. The total mercury captured by each sample, thermal stability of the mercury in relation to collection site, and correlations between mercury capture and chemical composition of the sample were also determined. The data showed that mercury was released between 300–400 °C for all ash samples. The thermal release of Hg between 300–400 °C was studied in greater detail by following the Hg release in several samples at 25 °C intervals from 300–400 °C. The concentration of mercury captured in the ESPs hoppers was greater than in the ash collected from the economizer or mechanical separators.     

不同负荷下循环流化床锅炉粉煤灰的理化性质研究

为拓展循环流化床锅炉粉煤灰的利用途径,开发粉煤灰综合利用技术,研究了不同负荷下循环流化床(CFB)锅炉粉煤灰的粒径分布、化学组成、物相组成、Al_2O_3溶出特性和微观形貌等理化性质,考察了锅炉负荷对粉煤灰理化性质的影响。结果显示,CFB锅炉负荷对粉煤灰的粒径分布、化学组成和物相组成等性质影响较小,对粉煤灰中Al_2O_3溶出率影响较大,Al_2O_3溶出率与样品颗粒的微观形貌有关,颗粒表面孔隙和裂缝越多,Al_2O_3溶出率越高。CFB锅炉粉煤灰中的无定形相含量较高,在70%以上;CaO在粉煤灰中的主要存在形式有3种:硬石膏、生石灰和无定形CaO。Al_2O_3均是以无定形氧化物的形式存在,煤样中的Al_2O_3在燃烧过程中更容易以飞灰的形式排出;石英和硬石膏更容易以底渣的形式排出。     

Heavy metal characterization of CFB-derived coal fly ash

The present study investigates the heavy metal content of coal fly ash (FA) samples coming from three different sampling points (secondary cyclone, cooler and filter) of a pilot plant combustion facility. The combustion experiments were carried out in a 0.1 MW Circulated Fluidized Bed (CFB) boiler using South African coal, with the addition of limestone for sulfur capture. FA was tested for the presence of selected heavy metals using inductively coupled plasma optical emission spectrometry (ICP-OES); batch leaching tests were conducted as well. The samples were also characterized in terms of their microstructure, chemical and mineralogical composition, total surface area and particle size distribution. Most of the studied metals (Cd, Cr, Cu, Ni, Mn, Zn) showed enrichment in the fine, filter FA particles, while Pb was mostly concentrated in the cooler sample. Regarding leaching characteristics of the examined samples, Cr was found to occur in considerable amounts. Although the use of CFB technology for the combustion of solid fuels steadily gets bigger worldwide, only a very limited number of studies have environmentally assessed CFB-coal FAs to date. Thus, the current study aims to contribute toward building a more integrated knowledge on the environmental impact of this abundant power production by-product.     

Hydrothermal synthesis of zeolitic material from circulating fluidized bed combustion fly ash for the highly efficient removal of lead from aqueous solution

The utilization of coal fly ash derived from circulating fluidized bed combustion(CFBFA) still faces great challenges because of its unique characteristics. In this study, a zeolitic material with Na-P1 zeolite as the main phase was successfully synthesized via a hydrothermal method by using CFBFA as the raw material.The effects of hydrothermal temperature, time, and added CTAB amount on the characterizations of synthesized materials were investigated by XRD, SEM, and XPS. The properties of the ...     

The leachability of heavy metals in hardened fly ash cement and cement-solidified fly ash

The effect of mix proportion, leachant pH, curing age, carbonation and specimen making method etc. on the leaching of heavy metals and Cr(VI) in fly ash cement mortars and cement-solidified fly ashes has been investigated. In addition, a method for reducing the leaching of Cr(VI) from cement-solidified fly ashes is proposed. The results mainly indicate that: (1) either Portland cement or fly ash contains a certain amount of heavy and toxic metals, and the leaching of them from hardened fly ash incorporated specimens exists and is increased with fly ash addition and water to cement ratio; (2) the leachability of some heavy metals is greatly dependent on leachant pH; (3) when carbonation of cement mortars occurs the leaching of chromium ions is increased; (4) the amount of heavy metals leached from cement-solidified fly ashes depends more on the kind of fly ash than their contents in fly ash; and (5) with ground granulated blast furnace slag addition, the leaching of Cr(VI) from solidified fly ashes is decreased.     

Electron microscopy and phase analysis of fly ash from pressurized fluidized bed combustion

The characterization of the typical fly ashes from pressurized fluidized bed combustion system (PFBC) in Japan and Europe was carried out by electron microscopy and phase analysis using energy-dispersive X-ray spectroscopy (EDX). The purity of limestone as in-bed sulfur removal sorbent influences the desulfurization reaction. The high-purity limestone yielded both hydroxyl ellestadite and anhydrite in Japanese PFBC ashes, while dolomite-rich limestone yielded anhydrite in European PFBC ashes. When the high-purity limestone was used, hydroxyl ellestadite particles were observed as the independent particles or the rim around limestone particles. The Al₂O₃ content in the glassy phase was inversely proportional to the CaO content in the glassy phase, suggesting that the glassy phases were formed from metakaoline and calcite as end members. Since hydroxyl ellestadite, glassy phase and metakaoline are reactive under hydrothermal conditions, PFBC ashes are expected to be used as raw materials for autoclaved products.     

The removal of phosphate ions from aqueous solution by fly ash, slag, ordinary Portland cement and related blends

Phosphate ions have been removed from aqueous solution by fly ash, slag, ordinary Portland cement (OPC) and related cement blends. The rate and efficiency of PO₄³⁻ removal were found to increase in the order: fly ash, slag, OPC, apparently mimicking the order of increasing percent CaO in the adsorbents. Blending OPC with fly ash or slag evidently results in diminished PO₄³⁻ removal efficiency. Better removal was obtained at higher solute concentration, acidic pH and higher temperature. The effect of particle size and the speed of mixing were found not to be significant. A first-order kinetic model was used to obtain values for overall sorption rate constants and intraparticle diffusion constants. The Frumkin isotherm was found to be the appropriate equation for modelling isotherms from the experimental adsorption data, and values have been obtained for the isotherm constants. A 400-mg/l PO₄³⁻ (as P) solution was fed at a steady velocity of 2.0 cm/min through a 2.0-cm fixed-bed column (at pH 9.0 and 25 °C), and breakthrough curves were constructed to obtain estimated adsorption capacity values of 32, 60, 75, 78 and 83 mg PO₄³⁻/g adsorbent for fly ash, slag, OPC+fly ash, OPC+slag and OPC, respectively.     

Removal of boron from coal fly ash by washing with HCl solution

Boron as an environmentally regulated substance is well known to condense in the coal fly ash generated from coal combustion plants. Since boron in the coal fly ash tends to elute into the soil easily, a technology for its stabilization or removal from fly ash is required. An acid washing process is proposed and studied as one of the candidate technologies for the removal of boron from coal fly ash. A laboratory-scale investigation is conducted on the dissolution behavior of boron in the coal fly ash in a diluted HCl solution. The dissolution of boron and alkaline species is considerably fast and exhibits a behavior different from that of aluminum and silicon, which are major components of the ash. From the kinetic model, it is expected that boron in the ash may mainly be in the form of alkaline or alkaline earth borates that are deposited on the surface of relatively large ash particles of alumino-silicate or may be precipitated as fine particles during coal combustion. This acid washing process is extended to a bench-scale plant and boron is successfully removed from the coal fly ash until its content is less than the regulation limit.     

Influence of the co-firing on the leaching of trace pollutants from coal fly ash

The (co)-firing of low-cost alternative fuels is expected to increase in the forthcoming years in the EU because of the economic and environmental benefits provided by this technology. This study deals with the impact of the different coal/waste fuel ratio of the feed blend on the mineralogy, the chemical composition and especially on the leaching properties of fly ash. Different blends of coal, petroleum coke, sewage sludge, wood pellets, coal tailings and other minor biomass fuels were tested in PCC (pulverised coal combustion) and FBC (fluidized bed combustion) power plants. The co-firing of the studied blends did not drastically modify the mineralogy, bulk composition or the overall leaching of the fly ash obtained. This suggests that the co-firing process using the alternative fuels studied does not entail significant limitations in the re-use or management strategies of fly ash.     

The influence of carbon particle type in fly ashes on mercury adsorption

Recent research has shown that certain fly ash materials produced in coal combustion for power generation have an affinity for the mercury compounds present in flue gases. However, the exact nature of Hg-fly ash interactions is still unknown and the different variables that influence mercury adsorption need to be identified. In this work the microscopic components of fly ashes derived from the combustion of different types of feed blends of different coal rank and mercury adsorption were investigated. The aim of this research was to establish relationships between Hg retention and the type of unburned carbons present in various fly ashes. The fly ashes and fly ash fractions studied were used as sorbent beds for high mercury concentrations, conditions in which mercury retention is highly favored. From the results obtained it was confirmed that the role of the unburned carbon components in mercury capture may depend, among other factors, on the type of unburned carbon. Fly ashes capture different species of mercury depending on their nature and the type of anisotropic particles.     

Aluminium extraction and leaching characteristics of Talcher Thermal Power Station fly ash with sulphuric acid

Although fly ash disposal is of environmental concern the quality of residues can be improved with respect to high value applications. Fly ash is considered as a potential source of aluminium and other strategic metals. Leaching and metal extraction behaviour of fly ash collected from Talcher Thermal Power Station have been thoroughly studied using sulphuric acid as extractant. The chemical and mineralogical composition of post-leached samples have been determined. Aluminium extraction by direct leaching at low acid concentration and ambient temperature is not suitable for high recovery. The extraction efficiency of aluminium increases significantly at a higher solid:liquid ratio. It is evident that the leachability of metals from fly ash depends on the nature of leaching medium, solid:liquid ratio, temperature and leaching time.     

Study on the phosphate removal from aqueous solution using modified fly ash

In this work the fly ash was modified by sulfuric acid for the removal of phosphate. It was found that modification of fly ash could significantly enhance the phosphate immobilization ability of the fly ash. The specific surface area of the fly ash increased from 8.8 to 32.5 m²/g after treated with sulfuric acid. The modification of the fly ash also resulted in the mobilization of acid-soluble metal ions due to partial or complete dissolution of the metals under the acidic conditions. Both adsorption and precipitation contributed to the removal of phosphate by the modified fly ash but precipitation was a major mechanism of phosphate removal. The experimental results showed that adsorption of phosphate by the modified fly ash was rapid, the removal percentage of phosphate could reach maximum in 5 min. In the range of 5–9, pH did not significantly affect the removal of phosphate and the removal percentage of phosphate increased with the increase of adsorbent dosage. The adsorption of phosphate by the modified fly ash could be described well by Langmuir isotherm equation, the Langmuir constant Q₀ was 9.15 mg g⁻¹. The XRD patterns and the SEM images of modified fly ash after sorption revealed that CaHPO₄·2H₂O was formed in the removal of phosphate. In addition, phosphate also formed precipitate with aluminum and iron.     

The Silicate/non-silicate distribution of metals in fly ash and its effect on solubility

In a study at DOE's National Energy Technology Laboratory, 32 Class F fly ash samples from pulverized coal (PC) power plants were dissolved in concentrated nitric acid and in hydrofluoric acid to estimate the distribution of metals in non-silicate and silicate matrices. Nineteen cations occurred to some extent in both phases. Using a column leaching method, the release of the metals was determined with four leachant solutions; the pH of the leachants ranged between 1.2 and 12. Although the amount of an element extracted from the fly ash was low, solubility in alkaline leachants was correlated with elements in non-silicate compounds. Solubility in acid solutions was correlated more strongly with silicate phase concentration.     

Removal of phenols by adsorption on fly ash

Adsorption of phenol and cresol and their mixtures from aqueous solutions on activated carbon and fly ash has been investigated. The effects of contact time and initial solute concentration have been studied and isotherm parameters are evaluated. The Freundlich isotherm has been found to be more suitable for all the systems investigated.     

Influence of iron species present in fly ashes on mercury retention and oxidation

The aim of this study was to assess the effect of iron species present in fly ashes produced from coal combustion on mercury retention and oxidation. To achieve this objective the work was divided into two parts. In the first part the relationship between the mercury and iron content in fly ashes of different origin and characteristics was evaluated. In the second, a series of fractions enriched in iron oxides were separated from the fly ashes to determine the effect of increasing iron content on mercury retention and oxidation. Special attention was paid to the influence of iron on mercury behavior in enriched carbon particles in fly ashes. From the results obtained it can be inferred that, in the range of fly ashes studied, iron species do not affect the retention of mercury and do not play any role in heterogeneous mercury oxidation.