Flash pyrolysis of coals. Devolatilization of bituminous coals in a small fluidized-bed reactor

The devolatilization behaviour of ten bituminous coals was investigated under rapid heating conditions using a small-scale fluidized-bed pyrolyser. The pyrolyser operated continuously, coal particles being injected at a rate of 1–3 g h^?1 directly into a heated bed of sand fluidized by nitrogen. Yields of tar, C₁–C₃ hydrocarbon gases, and total volatile-matter and an agglomeration index are reported for all coals. Maximum tar yields were obtained at about 600 °C and were always substantially higher than those from the Gray-King assay. Total volatile-matter yields were also substantially higher than the proximate analysis values. The maximum tar yields appear to be directly proportional to the coal atomic $\text{H}\text{C}$ ratio. The elemental analysis of the tar is strongly dependent on pyrolysis temperature. The tar atomic $\text{H}\text{C}$ ratio is proportional to that of the parent coal. The effect on the devolatilization behaviour of two coals produced by changes in the pyrolyser atmosphere and the nature of the fluidized-bed material were also investigated. Substituting an atmosphere of hydrogen, helium, carbon dioxide or steam for nitrogen, has no effect on tar yield and, with one exception, little effect on the hydrocarbon gas yields. In the presence of hydrogen the yield of methane was increased at temperatures above 600 °C. Tar yields were significantly reduced on substituting petroleum coke for sand as the fluid-bed material. A fluidized bed of active char virtually eliminated the tar yield.     

Preliminary studies on the aromaticity of Australian coals: Solid state n.m.r. techniques

The aromaticities of samples from nine Australian coal seams, including pairs of hand-picked vitrains and durains, have been determined by ¹³C cross-polarization n.m.r. spectroscopy with magic angle sample spinning. The results clearly show that the aromaticity (f_a) of the coals increases with increase in vitrinite reflectance and carbon content and decrease in atomic H/C ratio. For a given coal seam, durain (inertinite-rich coal) has a higher f_a value than vitrain (vitrinite-tich coal). The trends for carbon content and atomic H/C are in good agreement with results from North American coals, although the aromaticities of Australian coals obtained in this study appear to be slightly lower than some of those reported for North American coals of similar carbon content.     

Flash pyrolysis of coals: influence of cations on the devolatilization behaviour of brown coals

The influence of cations on the pyrolysis behaviour of brown coals under flash heating conditions was investigated by means of a small fluidized-bed pyrolyser. A stream of coal particles in nitrogen was injected at rates of 1–3 g coal/h directly into a heated bed of sand fluidized by nitrogen. Yields of tar, C₁–C₃ hydrocarbons and total volatile matter from four Gelliondale brown coals and a Montana lignite were determined as a function of pyrolysis temperature. With all coals the maximum tar yield was obtained at 600 °C. Removal of cations present in the coals markedly increased the yields of tar and total volatile matter, with little effect on the yields of hydrocarbon gases. The converse was also observed in that the addition of Ca²⁺ to a cation-free coal decreased the yields of tar and total volatile matter. The extent of the reduction in tar yield at 600 °C in the presence of cations was found to be similar for all coals. After acid washing, tar yields appear to correlate with the atomic $\text{H}\text{C}$ ratios of the coals in a manner similar to that observed previously with bituminous coals.     

Mechanisms leading to process improvements in lignite liquefaction using CO and H2S

Optimum distillate yields from US lignites can be as high on a dry, ash-free basis as those obtained from bituminous coals, but only if the vacuum bottoms are recycled. Lignites are more readily liquefied if the reducing gas contains some carbon monoxide and water, which together with bottoms recycle has proven to yield the highest conversions and the best bench-unit operability. The recycle solvent in the reported tests consisted of unseparated product slurry, including coal mineral constituents. Variability in coal minerals among nine widely representative US low-rank coals did not appear to correlate with liquefaction behaviour. Addition of iron pyrite did, however, improve yields and product quality, as measured by hydrogen-to-carbon ratio. Future improvements in liquefaction processes for lignite must maintain high liquid yields at reduced levels of temperature, pressure, and reaction time whilst using less reductant, preferably in the form of synthesis gas (CO + H₂) and water instead of the more expensive pure hydrogen. Understanding the process chemistry of carbon monoxide and sulphur (including H₂S) during lignite liquefaction is a key factor in accomplishing these improvements. This Paper reviews proposed mechanisms for such reactions from the viewpoint of their relative importance in affecting process improvements. The alkali formate mechanism first proposed to explain the reduction by CO does not adequately explain its role in lignite liquefaction. Other possible mechanisms include an isoformate intermediate, a formic acid intermediate, a carbon monoxide radical anion, direct reaction with lignite, and the activation of CO by alkali and alkaline earth cations and by hydrogen sulphide. Hydrogen sulphide reacts with model compounds which represent key bond types in low-rank coal in the following ways: (1) hydrocracking; (2) hydrogen donor; (3) insertion reactions in aromatic rings; (4) hydrogen abstraction, with elemental sulphur as a reaction intermediate; and (5) catalysis of the water-gas shift reaction. It appears that all of these reaction pathways may be operative when catalytic amounts of H₂S are added during liquefaction of lignite. In bench recycle tests, the addition of H₂S as a homogeneous catalyst reduced reductant consumption as much as three-fold whilst maintaining high yield levels when the reaction temperature was reduced by 60°C. Attainment of the high distillate yield at 400°C was accompanied by a marked decrease in the production of hydrocarbon gases, which normally is a major cause of unproductive hydrogen consumption and solvent degradation via hydrocracking. Processing with synthesis gas and inherent coal moisture using bottoms recycle and H₂S as a catalyst appears to be the most promising alternative combination of conditions for producing liquids from lignite at reduced cost.     

Pyrolysis of coal and iron oxides mixtures. 2. Reduction of iron oxides

The reduction of iron oxides during the pyrolysis of blends of coal and iron oxides on a laboratory scale, has been studied. The pyrolysis of blends of bituminous coal and 30 wt% of magnetite or hematite has been studied by thermogravimetry and analysis of gases, using a heating rate of 3.2 K min^?1. The state of iron in ferrocoke has been established by X-ray diffraction. A primary reduction by hydrogen and carbon monoxide of the hematite has been observed at between 400 °C and 500 °C, but hidden in thermogravimetric measurements by primary volatilization of the coal. At ≈600 °C magnetite is progressively reduced to wustite and then to iron. This reduction starts a little earlier if the heating rate is slow and the coal rank is low and progresses more rapidly when using hematite. Except for higher heating rates in the coal-magnetite blends, the reduction is complete at 1000 °C. The reductants are H₂ and CO, with production of H₂O and CO₂. When the temperature is increased the reduction by CO becomes of increasing importance, being mainly produced from the coke by the Boudouard reaction. The consumption of coke for the reduction of iron oxides is therefore more important at higher temperatures. Lignite is clearly a better reducing agent than the other coals, because of larger quantities of CO produced from the start of its pyrolysis, and the good reactivity of its char towards CO₂ and H₂O.     

Effect of iron on the gasification of Victorian brown coal with steam:enhancement of hydrogen production

This paper reports the significant enhancement of hydrogen production during the gasification of Victorian brown coal with steam using iron as a catalyst. Iron was loaded into the acid-washed Loy Yang brown coal using ferric chloride aqueous solution. Gasification experiments were carried out using a quartz reactor at a fast particle heating rate. The yield of char was determined by directly weighing the reactor before and after each experiment. Gases were analysed using a GC with dual columns. The overall gasification rate of a char increases greatly in the presence of iron. The transformation of iron species during pyrolysis and gasification was examined using X-ray diffraction (XRD) and scanning electron microscopy (SEM). The results show that both reduced-iron (α-Fe and γ-Fe) and magnetite (Fe₃O₄) highly dispersed in a char can catalyse the gasification of the char with steam. In particular, the char from iron-loaded coal samples gives much higher yields of H₂ than a char from the acid-washed coal under similar conditions. The mechanism for the enhancement of hydrogen production in the presence of iron is discussed.     

Hydroliquefaction of low-sulfur coals using iron carbonyl complexes—Sulfur as catalysts

Hydroliquefaction of low-sulfur Australian coals (Wandoan and Yallourn) was studied using iron carbonyl complexes as catalyst. The addition of Fe(CO)₅ (2.8 wt% Fe of coal) increased coal conversion from 48.6 to 85.2% for Wandoan coal, and from 36.7 to 69.7% for Yallourn coal in 1-methylnaphthalene at 425°C under an initial hydrogen pressure of 50 kg cm^?2. When molecular sulfur was added to iron carbonyls (Fe(CO)₅, Fe₂(CO)₉ and Fe₃(CO)₁₂), higher coal converions ( > 92%) and higher oil yields (>46%) were obtained, along with an increase in the amount of hydrogen transferred to coal from the gas phase (0.2 to 2.8%, d.a.f. coal basis). In the liquefaction studies using a hydrogen donor solvent, tetralin, Fe(CO)₅S catalyst increased the amount of hydrogen absorbed from the gaseous phase and decreased the amount of naphthalene dehydrogenated from tetralin. The direct hydrogen transfer reaction from molecular hydrogen to coal fragment radicals seems to be a major reaction pathway. Organic sulfur compounds, dimethyldisulfide and benzothiophene, and inorganic FeS₂ and NiS were found to be good sulfur sources to Fe(CO)₅. From X-ray diffraction analyses of liquefaction residues, it is concluded that Fe(CO)₅ was converted into pyrrhotite (Fe_1?xS) when sulfur was present, but into Fe₃O₄ in the absence of sulfur.     

Exploring the possibilities of using Brazilian subbituminous coals for blast furnace pulverized fuel injection

The current study investigates the combustion and blast furnace injection performance of three Brazilian subbituminous coals (Mina do Recreio) and their beneficiation products using laboratory scale combustion tests. The coals have relative high ash yields (up to 40 wt%) that were reduced stepwise to levels as low as 12 wt%, dry basis. The reduction of ash yields is paralleled by a significant decrease in sulphur and inertinite contents.The combustion tests were performed in a drop tube reactor operating at 1300 °C using two different atmospheres (2.5 and 5% O₂). The chars exhibited preferentially rounded shapes with thick walls and abundant secondary porosity for the 2.5% O₂ chars, whereas the 5% O₂ chars showed very thin walls as a consequence of extensive burnout. The intrinsic reactivities of both set of chars were similar. The differences in conversion between the two working atmospheres were 24-37% and roughly tend to increase with increasing mineral matter content. Conversions as high as 76-81% were reached operating under 5% O₂ indicating that the coals are easy to burn. The small differences in burnout among the coals and their beneficiation products cannot be clearly attributed neither to mineral matter or inertinite content. A rough inverse relationship was found between the intrinsic reactivity of the chars and the inertinite content of the parent coal indicating that the char material derived from inertinite was intrinsically less reactive than that derived from vitrinite. These differences were no longer relevant at high temperature.Blast furnace injection performance was studied through thermobalance experiments using CO₂ atmosphere and 1050 °C temperature. It is apparent that the beneficiation process has no effect on the reactivity of the coals from Recreio Mine. The only exception is the low ash coal-2-LabB (11.5 wt%), for which a higher reactivity is indicated. The reactivity tests show also that the coals have adequate properties to be used together with imported coal blends in pulverized coal injection in the blast furnace (PCI).     

Catalytic activity of cobalt and iron phthalocyanines or porphyrins supported on different carbon nanotubes towards oxygen reduction reaction

Non-noble metal catalysts for O₂ reduction were prepared by dispersing iron(II) phthalocyanine, cobalt(II) tetra-tert-butylphthalocyanine, cobalt(II) 2,3,7,8,12,13,17,18-octaethyl-porphine, and cobalt(II) 5,10,15,20-tetrakis(4-tert-butylphenyl)-porphyrine on carbon nanotubes (CNTs) used as high surface area support. Different types of CNTs (SWCNTs, DWCNTs and MWCNTs) were investigated as an effective substitute for commonly used carbon black in carbon-supported phthalocyanines and porphyrins. The oxygen reduction reaction (ORR) activity of those CNT-supported catalysts in alkaline and acidic solutions was studied. The results show that: (i) all catalytic systems including MWCNTs are more efficient for O₂ reduction than those with SWCNTs and DWCNTs, (ii) the oxidative chemical treatment of the CNTs increases the electrocatalytic performance of the corresponding CNT-supported catalysts, (iii) similarly to Vulcan-supported catalysts, iron(II) phthalocyanine gives the best electroactivity among the investigated CNT-supported materials and (iv) finally, the MWCNT-supported iron(II) phthalocyanine catalyst chemically treated in oxidative conditions shows an ORR catalytic activity comparable to a commonly used Pt/C catalyst with similar current densities and a very low overpotential (60 mV).     

Studies of inorganics added to low-rank coals for catalytic gasification

Inorganic complexes were added to low-rank coals by step-wise pH adjustment of a mixture of inorganic solution and brown coal while avoiding the formation of precipitates. The nature and amounts of the added inorganic depend on the pH of the coal/solution mixture and concentration of inorganic salts. The amount of hydroxide added for high loading of iron to coal is consistent with added multinuclear complexes. Computer generated models of brown coal with multi-iron species account for observed OH/Fe ratios. X-ray photoelectron spectroscopy (XPS) data for these samples are consistent with multi-iron species in coal. Computer molecular modelling of two brown coal models with added inorganics shows monodentate carboxyl coordination to metals is sterically favoured. Mononuclear Fe(III) with bidentate carboxyl coordination form distorted structures and are energetically unfavoured. Modelling indicates significant reductions in partial charges on metal centres, consistent with a redistribution of electron density on complexation. Low temperature pyrolysis of brown coals with added inorganics provides increased yields of gases, no detectable tar and lower char, compared with acid washed coals. Gasification of these coals using a nitrogen/oxygen mix at 150–200 °C yields CO, while steam gasification at 250–450 °C yields CO₂, CO and CH₄. Iron oxide/carbonate complexes are postulated during the pyrolysis and gasification.     

Difference in chemical composition of carbon disulfide-extractable fraction between vitrinite and inertinite from Shenfu-Dongsheng and Pingshuo coals

Vitrinite- and inertinite-rich samples separated from Shenfu-Dongsheng (SD) and Pingshuo (PS) coals were extracted with CS₂ and the extraction solutions were analyzed with GC/MS. The results show that extract yields of the two maceral-rich samples (MRSs) from PS coal are much higher than those from SD coal; for MRSs from the same coal, the yield of vitrinite-rich sample is larger than that of inertinite-rich sample; there is no remarkable difference in chemical composition from the extraction solutions between the two MRSs separated from PS coal, whereas the difference between those separated from SF coal is significant.     

Correlation of coal volatile yield with oxygen and aliphatic hydrogen

An interesting correlation has been observed between the volatile yield for three coal conversion processes and the oxygen and aliphatic hydrogen (H_al) content of the coal. The three processes are: (1) rapid pyrolysis in vacuum, (2) hydropyrolysis at ≈10 MPa hydrogen, and (3) liquefaction with tetralin at 400 °C. The volatile yield for the first two processes and for low sulphur coals studied in the third process may be predicted with the equation: Yield≈0.8 O_T+15 H_al where: O_T, the organic oxygen concentration measured by ultimate analysis; and H_al is the aliphatic hydrogen concentration determined from Fourier Transform infrared (FTIR) measurements. The similarity of yields for these processes suggests that they are basically controlled by thermal decomposition. Justification for the above equation is offered by considering a recently developed model for thermal decomposition of coal. The correlation does not fit a group of high sulphur coals studied in the liquefaction programme. These coals have extremely high volatile yields which may be a result of catalytic activity.     

Differences in the behaviour of US bituminous and subbituminous coals during short contact time liquefaction

The short contact time (SCT) liquefaction of Belle Ayr subbituminous coal has been compared with that of Illinois No. 6 and Pittsburgh seam bituminous coals. Each bituminous coal was highly solubilized (90 wt%, daf coal) in 3–4 min at 450 °C and 13–16 MPa hydrogen pressure. More than 80 wt% of each coal was converted to solvent-refined coal (SRC, pyridine-soluble residuum), with only small quantities of distillate oil and C₁–C₄ gas being formed. A longer reaction (up to 30 min) gave only a small increase in total conversion, but gas and distillate yields increased significantly. Iron sulphides did not appear to catalyse coal solubilization. By contrast, only 65 wt% of the Belle Ayr coal dissolved rapidly in SCT liquefaction and pyrite addition catalysed the conversion of the remaining insoluble organic matter (IOM). With an equivalent amount of pyrite present the Belle Ayr coal also gave more C₁–C₄ gas and substantially more distillate in SCT liquefaction than the bituminous coals. These differences in product distributions obtained from bituminous and subbituminous coals in SCT liquefaction can be rationalized on the basis of differences in the structures of the starting coals. However, the origin of high IOM yields with the Belle Ayr coal remains unclear.     

Flash hydrogenation of coal. 3. A sample of US coals

The susceptibility of a group of US coals to the production of light gaseous and liquid hydrocarbons during flash hydrogenation is examined. Eight coals ranging from lignite to high-volatile A bituminous and representing five provinces, have been flash heated in 101.3 MPa of flowing hydrogen using a bench scale reactor. A 0.6 s gas phase residence time was provided to hydrocrack the vapour products. Temperatures ranged from 750 to 850°C, where maximum yields of ethane and BTX (benzene+toluene + xylene) are found. The carbon conversion decreased with increasing rank at fixed reaction conditions. Methane yields are highest for lignite. Peak ethane yields range from 6.4 to 9% carbon conversion. BTX yields have a shallow maximum at intermediate ranks, decreasing towards high and low rank coals. Total liquid yields range from 14 to 43%. Although a definite variation of yield with rank is evident, the trends, especially total liquid yields, are attended by considerable scatter. Rank is not the only, and indeed may not be the most significant variable in determining the yield of individual species in flash hydrogenation. To establish the significant variables a stepwise regression procedure was applied to the experimental data using information from the elemental, proximate and petrographic compositions of the coals as independent variables. Two variables are adequate in all cases to correlate species yield and coal properties. Exinite appears to be capable of increasing the amount of liquid obtained from other macerals.     

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.     

Coal liquefaction using iron complexes as catalysts

Hydroliquefaction of Japanese Miike and Taiheiyo coals was carried out using various iron complexes as catalysts in tetralin at 375–445 °C. Iron pentacarbonyl (Fe(CO)₅) showed the highest catalytic activity, increasing coal conversion by about 10% at 425 °C under an initial hydrogen pressure of 5 MPa. Amounts of hydrogen transferred to coal increased from 1.4–2.3 wt% of daf coal in the absence of the catalyst to 2.5–4.2 wt% of daf coal in the presence of Fe(CO)₅ at 425 °C.     

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.     

Continuous hydrothermal synthesis of HT-LiCoO2 in supercritical water

A detailed investigation was made into the production of high temperature lithium cobalt oxide (HT-LiCoO₂) particles by continuous hydrothermal synthesis via the reaction of cobalt nitrate, lithium hydroxide, and hydrogen peroxide. The experiments were carried out in both subcritical and supercritical water, at temperatures ranging from 300 to 411 °C, with residence times less than 1 min in all instances. Although Co₃O₄ particles were synthesized in subcritical water at similar reaction conditions designed for comparison, well-ordered particles of HT-LiCoO₂ were obtained in supercritical water. In supercritical conditions, the variations in temperature and residence time did not have significant impacts on the average particle size, particle size distribution, or morphology of obtained HT-LiCoO₂. However, it was important to supply excessive lithium hydroxide and hydrogen peroxide in order to synthesize single-phased HT-LiCoO₂ particles without undesired by-products. The hydrothermal synthetic route for LiCoO₂, CoO, and Co₃O₄ in both subcritical and supercritical conditions was postulated.     

Effect of coal soluble constituents on caking property of coal

Three cokemaking bituminous coals were extracted by the CS₂/NMP mixed solvents with different content of NMP, and the effect of the amount and the component of coal soluble constituents on the caking property of the extracted residues of coals were investigated in this study. The CS₂/NMP mixed solvent (1:1 by volume) was found to give the maximal extraction yields for the three coals, and the fat coal gave the highest extraction yield of 78.6% (daf) corresponding to its highest caking index of 101. It was found that for coking coal, when the extraction yield got to the maximum of 25.3% in the 1:1 by volume of CS₂/NMP mixed solvent, the residue extracted still had caking property with the caking index of 19. This means parts of the caking constituents of coal are un-extractible because of covalent bonding or strong associative cross-links. The soluble components extracted by the CS₂/NMP mixed solvent and their effects on the caking indexes of the residues at a similar extraction yield quite differed depending on the NMP content in the mixed solvent. The coal solubles extracted by the CS₂/NMP mixed solvent with NMP less than 50% contained less light constituents with less of oxygen groups. This may lead to the decrease in the caking indexes for the residues obtained at the similar extraction yields compared to those of the CS₂/NMP mixed solvent with NMP more than 50%.