Injectant Coal Gasification, Char Formation and Char Utilisation at High Injection Rates

Injectant Coal Gasification, Char Formation and Char Utilisation at High Injection Rates
Author: European Communities
Publisher:
Total Pages:
Release: 2004
Genre:
ISBN:

The aim of this project was to carry out an integrated laboratory, pilot and plant scale investigation of injectant coal gasification, char formation and properties, the effect of char on melting zone behaviour and the utilisation of char in terms of top gas dust carryover at high levels of injection. Laboratory-scale studies undertaken by Corus and Imperial College of Science, Technology and Medecine (ICSTM), focused on the degree of burnout of injectant coals, morphology and reactivity of resultant chars and an evaluation of the potential for the formation of soot precursors. Extents of gasification were related to parent coal properties and correlations between char morphology and parent coal VM content were established. The experiments also determined rates of particle mass loss under the variety of conditions that exist within the coal injection plume and made a significant contribution to the understanding of how and where volatiles are released and whether chars will be completely gasified. Centra Sviluppo Materiali (CSM) concentrated on the influence of char particles on the rheological properties of the ferrous materials in the blast furnace burden. Laboratory-scale tests under simulated blast furnace conditions on mixtures of ferrous burden, coke and char were conducted in the SMEDRA (Softening MElting DRipping Apparatus). The presence of char in the ferrous materials caused changes to the extent of initial dripping and to the starting temperature of this phenomenon. These changes correlated to the amount of char added and to the characteristics of the parent coal (the VM content and whether pulverised or granular grade) and would affect the position and the shape of the melting zone in the blast furnace. At the plant scale , ThyssenKrupp Stahl sampled blast furnaces operating with coal injection and characterised the dust collected. Tests were carried out based on the knowledge that increased graphitisation of carbon occurs with rising temperature, allowing the source of the carbon to be identified. With a new analytical method, Microwave-Assisted Dissolution, it was possible to exactly quantify the smallest quantities of graphite in top gas dust. The amount of dust discharged through the furnace top was largely determined by the percentage of non-carbonaceous components, but a clear correlation between the quantity of discharged dust and the quantity of carbonaceous components was also found. The findings also indicated that the carbon in the dust from the centre of the furnace comes mainly from ungasified injectant coal char.

Char Formation, Transportation and Consumption in the Blast Furnace and Its Impact on Coke Rate (Charfoco)

Char Formation, Transportation and Consumption in the Blast Furnace and Its Impact on Coke Rate (Charfoco)
Author:
Publisher:
Total Pages:
Release: 2019
Genre:
ISBN: 9789279983245

In the past, blast furnace coal injection research mainly focused on combustion of injection coal in the raceway. However, it could be assumed that coal is anyway not able to fully combust, particularly at high injection rates, and unburnt residues leave the raceway as char. The char evolution and subsequent consumption depends on the raceway characteristics, which depend on coal conversion. Both groups of factors were investigated with conversion tests, as well as raceway measurements. Generally, the char evolution is seen to manifest itself as a negative impact, but this may depend on the blast furnace conditions and injection coal characteristics. Char effects might deteriorate the blast furnace operation and stability (i.e. lower burden permeability or higher carbon losses in the flue dust). Nonetheless, char could also be advantageous by contributing toward the increase in coke reactivity thereby lowering the thermal reserve zone temperature. It was shown that the coal combustion highly depends on coal grain size and only marginally on oxygen enrichment. Effects of oxygen enrichment on maximum coal injection rate might be more related to char consumption, rather than coal conversion. Despite low conversion of granular coal under blast furnace raceway simulation conditions, granular coal injection is possible at high rates, obviously due to its consumption outside the raceway. Blast furnace operation experience with coals, like operational benefits or transport behaviour could be confirmed. Char impact on ferrous burden behaviour highly depends on temperature and gas composition and is difficult to predict from the performed tests. Several raceway measurement techniques were successfully developed and applied at pilot scale and at a real blast furnace. Raceway size, temperature and changes in the gas composition could be shown. The raceway size depends on the location of the tuyère in relation to blast inlet and tap hole and changes significantly over time, indicating raceway collapses. Gas and temperature measurements of the BF interior were performed: New insights regarding the impact of high coal injection rates on the blast furnace inner state were gained by gas and temperature measurements of the blast furnace inside and confirmed with mathematical modelling.

Structural Characteristics and CO2 Reactivity of Partially Gasified Pittsburgh No.8 Coal Chars Generated in a High-pressure, High-temperature Flow Reactor

Structural Characteristics and CO2 Reactivity of Partially Gasified Pittsburgh No.8 Coal Chars Generated in a High-pressure, High-temperature Flow Reactor
Author: Vijayaragavan Krishnamoorthy
Publisher:
Total Pages:
Release: 2018
Genre:
ISBN:

Integrated gasification combined cycle (IGCC) is an advanced power generation technology based on gasification of coal or solid fuels. Despite many commercial operations, the knowledge of char gasification rates at high pressures and temperatures, crucial to the design and troubleshooting of the gasifiers, are relatively unknown. While many kinetic studies have been performed at atmospheric pressure and low heating rates, there are few studies that examined the reactivity of chars generated at high temperatures and elevated pressuresGasification rate of chars in entrained-flow gasifiers is dependent on both intrinsic reactivity and the gas diffusion rate of reactants into pores. Therefore, the knowledge of intrinsic reaction rate and the structural features of the char are necessary for developing a kinetic model. The aim of the thesis is to determine the intrinsic reactivity and the structural features of the chars generated at elevated pressures and temperatures pertinent to conditions of the entrained-flow gasifiers. A series of interrelated studies were conducted to characterize the gasification behavior of a widely used Pittsburgh No,8 coal. To generate chars under conditions similar to that of the gasifier, a 20 kW high-pressure, high-temperature flow reactor (HPHTFR) was designed to operate up to 1650C and 30 bar. The chars obtained at various temperatures, pressures, and pyrolysis atmospheres were characterized for physical and chemical structure using surface area analyzer, XRD, Raman, and morphological analysis. The CO2 kinetics on chars were obtained using a high pressure thermogravimetric analyzer (HPTGA). The structural properties and intrinsic kinetics of chars widely reported in the literature were generated in inert atmospheres. However, the pyrolysis of feedstock occurs in the presence of reaction gas. This difference can affect char structural properties and intrinsic reactivity. To determine the role of pyrolysis atmosphere, chars were generated in three different atomspheres-CO2/N2, Ar and N2- at 1100C and 6.2 bar. The chars generated in the CO2/N2 atmosphere showed higher conversion compared to that of chars generated in N2 and Ar atmospheres. The increased conversion in the CO2/N2 atmosphere was attributed to increased gasification of tar/soot. While the volatile yield showed some difference, char properties such as surface area, swelling ratio, defects to graphitic band ratio and crystallite sizes showed no difference. The kinetic parameters of the chars were obtained using the nth order model. The activation energy was found to be independent of pyrolysis atmospheres. The order of reaction was found to be significantly affected by the pyrolysis atmosphere. The order of reaction followed the trend: CO2/N2> N2 Ar. The order of the reaction was found to correlate with surface area evolution.Gasification of coal can be impacted by the organic and inorganic compositional heterogeneity, which further impact the char morphology, and the intrinsic reactivity. To account for the compositional heterogeneity, chars were generated from various size fractions (-106+75, -150+106, -212+150, -420+212 m at 1300C and 11.3 bar) and density fractions (1.3 g/cc, 1.3-1.6 g/cc, 1.6g/cc of -106+75 m at 1300C and 11.3 bar). Chars were also generated over a range of temperatures (1100, 1300, and 1400C at 11.3 bar for the -150+106 m fraction), pressures (3.4, 6.2, 11.3, 15.5, and 21.7 bar at 1300C for -150+106 m fraction) to study the effect of temperature and pressure on char structures and reactivity. Chars were characterized for morphology, pore structure (i.e. surface area and pore volume), reflectance, and reactivity using oil immersion microscopy, N2 adsorption technique, reflectance microscopy, and thermogravimetric analyzer, respectively. The swelling ratio, pore volume, and surface area increased up to certain pressure while these parameters decreased with particle size and density fraction. The intrinsic reactivity of chars increased with inorganic matter and feed particle size, while it decreased with increase in char generation temperature. The intrinsic gasification rate is an important parameter for designing a kinetic model. Chars were obtained by partially gasifying Pittsburgh No.8 coal in CO2 atmosphere at 1300C and over a range of pressures (3.4, 6.2, 11.3, 15.5, and 21.7 bar) in the HPHTFR. The intrinsic reaction rate of those chars with CO2 was obtained at the char generation pressure using the HPTGA. The kinetic parameters were obtained using the nth order model. The intrinsic reaction rate, and activation energy were found to be independent of the char generation pressure. The order of reaction was obtained by varying CO2 partial pressures. The order of reaction decreased with increase in char generation pressure. The comparison of initial char with the char obtained at ~20% conversion in the HPTGA for surface area and pore volume showed that the reaction primarily occurs in microporous regions. The order of reaction also closely followed the surface area during gasification in the HPTGA.Through this research, a comprehensive assessment of the entrained-flow gasification behavior of Pittsburgh No.8 coal has been performed using proven experimental techniques under conditions of industrial interest. The structural features and kinetics were obtained. The generated data provide optimum, and trends that can be used as direct inputs to kinetic modelling and gasifier design applications.

Effects of Pressure on the Properties of Coal Char Under Gasification Conditions at High Initial Heating Rates

Effects of Pressure on the Properties of Coal Char Under Gasification Conditions at High Initial Heating Rates
Author: Randy Clark Shurtz
Publisher:
Total Pages: 0
Release: 2011
Genre:
ISBN:

The effects of elevated pressure and high heating rates on coal pyrolysis and gasification were investigated. A high-pressure flat-flame burner (HPFFB) was designed and built to conduct these studies. The HPFFB was designed to provide an environment with laminar, dispersed entrained flow, with particle heating rates of ~10^5 K/s, pressures of up to 15 atm, and gas temperatures of up to 2000 K. Residence times were varied from 30 to 700 ms in this study.

Effects of Pressure on the Properties of Coal Char Under Gasification Conditions at High Initial Heating Rates

Effects of Pressure on the Properties of Coal Char Under Gasification Conditions at High Initial Heating Rates
Author: Randy Clark Shurtz
Publisher:
Total Pages: 316
Release: 2011
Genre: Electronic dissertations
ISBN:

The effects of elevated pressure and high heating rates on coal pyrolysis and gasification were investigated. A high-pressure flat-flame burner (HPFFB) was designed and built to conduct these studies. The HPFFB was designed to provide an environment with laminar, dispersed entrained flow, with particle heating rates of ~10^5 K/s, pressures of up to 15 atm, and gas temperatures of up to 2000 K. Residence times were varied from 30 to 700 ms in this study.