Production of Pre-Reduction of Iron Ore Nuggets with Lesser Sulphur Intake by Devolatisation of Boiler Grade Coal

Boiler coals with low fixed carbon and higher ash content have always challenged the metallurgists to develop a suitable method for their utilization. In the present study, an attempt is made to establish an energy effective method for the reduction of iron ore fines in the form of nuggets by using ‘Syngas’. By devolatisation (expulsion of volatile matter by applying heat) of boiler coal, gaseous product (enriched with reducing agents like CO, CO2, H2, and CH4 gases) is generated. Iron ore nuggets are reduced by this syngas. For that reason, there is no direct contact between iron ore nuggets and coal ash. It helps to control the minimization of the sulphur intake of the reduced nuggets. A laboratory scale devolatisation furnace designed with reduction facility is evaluated after in-depth studies and exhaustive experimentations including thermo-gravimetric (TG-DTA) analysis to find out the volatile fraction present in boiler grade coal, gas chromatography (GC) to find out syngas composition in different temperature and furnace temperature gradient measurements to minimize the furnace cost by applying one heating coil. The nuggets are reduced in the devolatisation furnace at three different temperatures and three different times. The pre-reduced nuggets are subjected to analytical weight loss calculations to evaluate the extent of reduction. The phase and surface morphology analysis of pre-reduced samples are characterized using X-ray diffractometry (XRD), energy dispersive x-ray spectrometry (EDX), scanning electron microscopy (SEM), carbon sulphur analyzer and chemical analysis method. Degree of metallization of the reduced nuggets is 78.9% by using boiler grade coal. The pre-reduced nuggets with lesser sulphur content could be used in the blast furnace as raw materials or coolant which would reduce the high quality of coke rate of the furnace due to its pre-reduced character. These can be used in Basic Oxygen Furnace (BOF) as coolant also.

Co-Disposal of Coal Ash with Mine Tailings in Surface Paste Disposal Practices: A Gold Mining Case Study

The present paper describes the study of paste tailings prepared in laboratory using gold tailings, produced in a Finnish gold mine with the incorporation of coal ash. Natural leaching tests were conducted with the original materials (tailings, fly and bottom ashes) and also with paste mixtures that were prepared with different percentages of tailings and ashes. After leaching, the solid wastes were physically and chemically characterized and the results were compared to those selected as blank – the unleached samples. The tailings and the coal ash, as well as the prepared mixtures, were characterized, in addition to the textural parameters, by the following measurements: grain size distribution, chemical composition and pH. Mixtures were also tested in order to characterize their mechanical behavior by measuring the flexural strength, the compressive strength and the consistency. The original tailing samples presented an alkaline pH because during their processing they were previously submitted to pressure oxidation with destruction of the sulfides. Therefore, it was not possible to ascertain the effect of the coal ashes in the acid mine drainage. However, it was possible to verify that the paste reactivity was affected mostly by the bottom ash and that the tailings blended with bottom ash present lower mechanical strength than when blended with a combination of fly and bottom ash. Surface paste disposal offer an attractive alternative to traditional methods in addition to the environmental benefits of incorporating large-volume wastes (e.g. bottom ash). However, a comprehensive characterization of the paste mixtures is crucial to optimize paste design in order to enhance engineer and environmental properties.

Statistical Modeling of Constituents in Ash Evolved From Pulverized Coal Combustion

Industries using conventional fossil fuels have an  interest in better understanding the mechanism of particulate  formation during combustion since such is responsible for emission  of undesired inorganic elements that directly impact the atmospheric  pollution level. Fine and ultrafine particulates have tendency to  escape the flue gas cleaning devices to the atmosphere. They also  preferentially collect on surfaces in power systems resulting in  ascending in corrosion inclination, descending in the heat transfer  thermal unit, and severe impact on human health. This adverseness  manifests particularly in the regions of world where coal is the  dominated source of energy for consumption.  This study highlights the behavior of calcium transformation as  mineral grains verses organically associated inorganic components  during pulverized coal combustion. The influence of existing type of  calcium on the coarse, fine and ultrafine mode formation mechanisms  is also presented. The impact of two sub-bituminous coals on particle  size and calcium composition evolution during combustion is to be  assessed. Three mixed blends named Blends 1, 2, and 3 are selected  according to the ration of coal A to coal B by weight. Calcium  percentage in original coal increases as going from Blend 1 to 3.  A mathematical model and a new approach of describing  constituent distribution are proposed. Analysis of experiments of  calcium distribution in ash is also modeled using Poisson distribution.  A novel parameter, called elemental index λ, is introduced as a  measuring factor of element distribution.  Results show that calcium in ash that originally in coal as mineral  grains has index of 17, whereas organically associated calcium  transformed to fly ash shown to be best described when elemental  index λ is 7.  As an alkaline-earth element, calcium is considered the  fundamental element responsible for boiler deficiency since it is the  major player in the mechanism of ash slagging process. The  mechanism of particle size distribution and mineral species of ash  particles are presented using CCSEM and size-segregated ash  characteristics. Conclusions are drawn from the analysis of  pulverized coal ash generated from a utility-scale boiler.  

Geochemistry of Coal Ash in the Equatorial Wet Disposal System Environment

The coal utilization in thermal power plants in Malaysia has increased significantly which produces an enormous amount of coal combustion by-product (CCBP) or coal ash and poses severe disposal problem. As each coal ash is distinct, this study presents the geochemistry of the coal ash, in particular fly ash, produced from the combustion of local coal from Kuching Sarawak, Malaysia. The geochemical composition of the ash showed a high amount of silica, alumina, iron oxides and alkalies which was found to be a convenient starting material for the hydrothermal synthesis of zeolites with the higher Na2O percentage being a positive factor for its alkaline activation; while the mineral phases are mainly quartz, mullite, calcium oxide, silica, and iron oxide hydrate. The geochemical changes upon alkali activation that can be predicted in a similar type of ash have been described in this paper. The result shows that this particular ash has a good potential for a high value industrial product like zeolites upon alkali activation.

Recycling for Sustainability: Plant Growth Media from Coal Combustion Products, Biosolids and Compost

Generation of electricity from coal has increased over the years in the United States and around the world. Burning of coal results in annual production of upwards of 100 millions tons (United States only) of coal combustion products (CCPs). Only about a third of these products are being used to create new products while the remainder goes to landfills. Application of CCPs mixed with composted organic materials onto soil can improve the soil-s physico-chemical conditions and provide essential plant nutritients. Our objective was to create plant growth media utilizing CCPs and compost in way which maximizes the use of these products and, at the same time, maintain good plant growth. Media were formulated by adding composted organic matter (COM) to CCPs at ratios ranging from 2:8 to 8:2 (v/v). The quality of these media was evaluated by measuring their physical and chemical properties and their effect on plant growth. We tested the media by 1) measuring their physical and chemical properties and 2) the growth of three plant species in the experimental media: wheat (Triticum sativum), tomato (Lycopersicum esculentum) and marigold (Tagetes patula). We achieved significantly (p < 0.001) higher growth (7-130%) in the experimental media containing CCPs compared to a commercial mix. The experimental media supplied adequate plant nutrition as no fertilization was provided during the experiment. Based on the results, we recommend the use of CCPs and composts for the creation of plant growth media.

On Unburned Carbon in Coal Ash from Various Combustion Units

Work is focused to the study of unburned carbon in ash from coal (and wastes) combustion in 8 combustion tests at 3 fluidised-bed power station, at co-combustion of coal and wastes (also at fluidized bed) and at bench-scale unit simulating coal combustion in small domestic furnaces. The attention is paid to unburned carbon contents in bottom ashes and fly ashes at these 8 combustion tests and to morphology of unburned carbons. Specific surface area of coals, unburned carbons and ashes and the relation of specific surface area of unburned carbon and the content of volatile combustibles in coal were studied as well.