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The Science and Technology of Coal and Coal Utilization PDF

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The Science and Technology of Coal and Coal Utilization The Science and Technology of Coal and Coal Utilization EDITED BY BERNARD R. COOPER West Virginia University Morgantown, West Virginia AND WILLIAM A. ELLINGSON Argonne National Laboratory Argonne, Illinois PLENUM PRESS • NEW YORK AND LONDON Library of Congress Cataloging in Publication Data Main entry under title: The Science and technology of coal and coal utilization. Includes bibliographical references and index. Contents: Introduction to the science and technology of coal and coal utiliza- tion/Bernard R. Cooper and William A. Ellingson-Coal characterization/Heinz H. Damberger ... et al. -Coal preparation and cleaning/T.D. Wheelock and R. Markuszewski- etc. 1. Coal-Addresses, essays, lectures. I. Cooper, Bernard R. II. El- lingson, W. A. TP325.S36 1984 83-26189 ISBN-13: 978-1-4684-4582-4 e-ISBN-13: 978-1-4684-4580-0 DOl: 10.1007/978- I -4684-4580-0 © 1984 Plenum Press, New York Softcover reprint of the hardcover 15t edition 1984 A Division of Plenum Publishing Corporation 233 Spring Street, New York, N.Y. 10013 All rights reserved No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, microfilming, recording, or otherwise, without written permission from the Publisher We dedicate this volume to the memory of our colleague and fellow author Leon Polinski Preface Filling the need for new and improved energy sources is an area where societal effects of science and technology will surely increase. The editors and authors have attempted in this volume to present the most current work on the science and technology of coal and coal utilization. Serious disagreement exists on several key issues such as carbon dioxide release and acid rain. At the same time, however, coal is the world's most abundant fossil fuel and will have to be used to supply the world's energy needs for the next several decades. The 1979 National Research Council Report, "En- ergy in Transition: 1985-2010," has estimated that the United States alone may go from a 1979 coal consumption of 14 QUADS per annum (approximately 750 million tons per year) to approximately 40-50 QUADS per annum (approximately 2 billion tons per year) by the year 2010. If this scale of coal utilization is to become a reality, a significant level of research and development will be necessary to establish advanced process technologies and to improve related areas such as materials and instrumentation. The editors hope that this volume will allow a technically educated person to become aware of the several aspects of coal utilization, from characterization of coal itself to the processes of coal utilization. B. R. Cooper and W. A. Ellingson March, 1983 vii Contents 1. THE SCIENCE AND TECHNOLOGY OF COAL AND COAL UTILIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Bernard R. Cooper and William A. Ellingson 2. COAL CHARACTERIZATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Heinz H. Damberger, Richard D. Harvey, Rodney R. Ruch, and Josephus Thomas, Jr. 1. Introduction ......................................... . 7 2. Samples and Their Analyses ........................... . 10 3. Megascopic and Microscopic Characterization of Coal ...... . 11 3.1. Megascopic Characterization ...................... . 12 3.2. Microscopic Characterization ...................... . 13 4. Mineral Matter in Coals ............................... . 21 5. Standard Chemical Analyses and Some Special Evaluation Tests ............................................... 25 6. Analyses of Major, Minor, and Trace Ash-Forming Elements 26 7. Isotopic Studies ...................................... . 30 8. Physical Properties of Coal ............................ . 31 8.1. Porosity and Internal Surface Area ................. . 31 8.2. Permeability ................................... . 36 8.3. Structure and Density ............................ . 36 8.4. Spontaneous Combustion ......................... . 37 8.5. Electrical Conductivity ........................... . 38 8.6. Optical Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39 8.7. Grindability, Hardness, Strength . . . . . . . . . . . . . . . . . . .. 39 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39 ix x CONTENTS 3. COAL PREPARATION AND CLEANING .................. 47 T. D. Wheelock and R. Markuszewski 1. Introduction.......................................... 47 2. Present Coal-Cleaning Practice .......................... 52 2.1. Basic Cleaning Process. . . . . . . . . . . . . . . . . . . . . . . . . . .. 52 2.2. Washability Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 54 2.3. Beneficiation Methods ............................ 57 2.4. Separation Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60 2.5. Industrial Plant Performance ....................... 65 3. Experimental Coal-Cleaning Plants. . . . . . . . . . . . . . . . . . . . . .. 68 4. New Developments in Physical Cleaning. . . . . . . . . . . . . . . . .. 74 4.1. Chemical Comminution ... . . . . . . . . . . . . . . . . . . . . . . .. 75 4.2. Screening....................................... 77 4.3. Hydraulic Separation ............................. 78 4.4. Heavy Media Separation .......................... 79 4.5. Separations Based on Surface Properties. . . . . . . . . . . . .. 81 4.6. Magnetic Cleaning .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 87 4.7. Electrostatic Separation ........................... 92 5. Development of Chemical Cleaning Methods. . . . . . . . . . . . . .. 94 5.1. Oxidative Desulfurization . . . . . . . . . . . . . . . . . . . . . . . . .. 96 5.2. Caustic Treatments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 101 5.3. Reductive Desulfurization ......................... 105 5.4. Miscellaneous Methods ........................... 106 5.5. Economics of Chemical Coal Cleaning. . . . . . . . . . . . . .. 107 6. Research on Bacterial Desulfurization . . . . . . . . . . . . . . . . . . . .. 108 7. Summary and Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 109 Conversion Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 113 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 113 4. ROLE OF IMPURITIES .................................. 125 P. A. Montano, B. Granoff, and T. D. Padrick 1. Impurities in Coal: Introduction. . . . . . . . . . . . . . . . . . . . . . . . .. 125 1.1. Physical and Chemical Properties of the Major Minerals 126 1.2. Trace Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 128 1. 3. Identification and Characterization of Minerals and Trace Elements in Coal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 129 2. Role of Impurities in Coal Mining ....................... 133 3. Coal Combustion ..................................... 133 4. Coke ............................................... 134 CONTENTS xi 5. Coal Liquefaction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 135 5.1. Kinetics of Pyrite Decomposition ................... 137 5.2. Pyrrhotites ...................................... 140 5.3. Active Catalytic Sites. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 143 5.4. Slurry Phase Catalysts ............................ 147 6. Coal Gasification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 150 6.1. Introduction..................................... 150 6.2. Rapid Devolatilization ............................ 150 6.3. Char Gasification ................................ 153 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 159 5. GASIFICATION AND INDIRECT LIQUEFACTION. . . . . . . .. 163 James C. W. Kuo 1. Introduction.......................................... 163 2. Coal Gasification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 165 2.1. Introduction ..................................... 165 2.2. Chemistry of Coal Gasification. . . . . . . . . . . . . . . . . . . .. 166 2.3. Classification of Coal Gasifiers ...... . . . . . . . . . . . . . .. 170 2.4. Commercial Gasifiers. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 178 2.5. Gasifiers under Development ....................... 181 3. Synthesis Gas Purification and Water-Gas Shift Processes. . .. 190 3. 1. Introduction..................................... 190 3.2. Commercial Synthesis Gas Purification Processes ...... 191 3.3. Water-Gas Shift Processes ......................... 197 4. Indirect Liquefaction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 199 4.1. Introduction..................................... 199 4.2. Methanol Synthesis ............................... 200 4.3. Methanol-to-Gasoline Conversion ................... 205 4.4. Fischer-Tropsch Synthesis ......................... 210 4.5. Fischer-Tropsch Product Upgrading ................. 221 5. Summary and Conclusion ............................... 224 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 226 6. DIRECT LIQUEFACTION ............................... 231 Michael G. Thomas 1. Introduction.......................................... 231 1.1. Historical Perspective . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 231 xii CONTENTS 1.2. Definition of Processes. . . . . . . . . . . . . . . . . . . . . . . . . . .. 232 1.3. Types of Coals .................................. 233 1.4. Objectives ...................................... 234 2. Thermal Chemistry .................................... 234 2. 1. Concepts ....................................... 234 2.2. Stoichiometry ................................... 236 2.3. Mechanisms ..................................... 238 2.4. Effects of Independent Variables .................... 240 2.5. Current Concepts on Rates and Activation Energies .... 241 3. Catalytic Chemistry ................................... 248 3.1. Objectives ...................................... 248 3.2. Effects on Coal Dissolution ........................ 249 3.3. Effects on Preasphaltene Decomposition .............. 250 3.4. Synergistic Effects with Catalysts . . . . . . . . . . . . . . . . . .. 251 3.5. Catalytic Mechanisms ............................. 254 4. Direct Liquefaction Technology .......................... 255 4.1. Current Status ................................... 255 4.2. Advanced Concepts .............................. 257 5. Summary ............................................ 259 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 7. FLUIDIZED-BED COMBUSTION . ........................ 263 Walter F. Podolski 1. Introduction.......................................... 263 2. Fluidization Background ................................ 265 3. FBC System Description ............................... 267 3.1. Atmospheric Fluidized Bed Combustors . . . . . . . . . . . . .. 267 3.2. Pressurized Fluidized Bed Combustors ............... 268 3.3. Comparison to Conventional Combustors ............. 269 4. FBC Design .......................................... 271 4.1. Mechanical Design Consideration ................... 274 4.2. Environmental Considerations ...................... 285 5. Analytical System Performance Modeling ................. 295 5.1. Hydrodynamics .................................. 296 5.2. Combustion Process .............................. 297 6. Concluding Remarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 300 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

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