The Science and Technology of Coal and Coal Utilization

Transcription

1 The Science and Technology of Coal and Coal Utilization

2 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

3 Main entry under title: Library of Congress Cataloging in Publication Data 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 utilization/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. Ellingson, W. A. TP325.S ISBN-13: DOl: /978- I e-isbn-13: 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 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

4 We dedicate this volume to the memory of our colleague and fellow author Leon Polinski

5 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, "Energy in Transition: ," 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 QUADS per annum (approximately 2 billion tons per year) by the year 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

6 Contents 1. THE SCIENCE AND TECHNOLOGY OF COAL AND COAL UTILIZATION Bernard R. Cooper and William A. Ellingson 2. COAL CHARACTERIZATION Heinz H. Damberger, Richard D. Harvey, Rodney R. Ruch, and Josephus Thomas, Jr. 1. Introduction Samples and Their Analyses Megascopic and Microscopic Characterization of Coal Megascopic Characterization Microscopic Characterization Mineral Matter in Coals Standard Chemical Analyses and Some Special Evaluation Tests Analyses of Major, Minor, and Trace Ash-Forming Elements 26 Isotopic Studies Physical Properties of Coal Porosity and Internal Surface Area Permeability Structure and Density Spontaneous Combustion Electrical Conductivity Optical Properties Grindability, Hardness, Strength References ix

7 x CONTENTS 3. COAL PREPARATION AND CLEANING T. D. Wheelock and R. Markuszewski 1. Introduction Present Coal-Cleaning Practice Basic Cleaning Process Washability Tests Beneficiation Methods Separation Efficiency Industrial Plant Performance Experimental Coal-Cleaning Plants New Developments in Physical Cleaning Chemical Comminution Screening Hydraulic Separation Heavy Media Separation Separations Based on Surface Properties Magnetic Cleaning Electrostatic Separation Development of Chemical Cleaning Methods Oxidative Desulfurization Caustic Treatments Reductive Desulfurization Miscellaneous Methods Economics of Chemical Coal Cleaning Research on Bacterial Desulfurization Summary and Conclusions Conversion Factors References ROLE OF IMPURITIES P. A. Montano, B. Granoff, and T. D. Padrick 1. Impurities in Coal: Introduction Physical and Chemical Properties of the Major Minerals Trace Elements Identification and Characterization of Minerals and Trace Elements in Coal Role of Impurities in Coal Mining Coal Combustion Coke

8 CONTENTS xi 5. Coal Liquefaction Kinetics of Pyrite Decomposition Pyrrhotites Active Catalytic Sites Slurry Phase Catalysts Coal Gasification Introduction Rapid Devolatilization Char Gasification References GASIFICATION AND INDIRECT LIQUEFACTION James C. W. Kuo 1. Introduction Coal Gasification Introduction Chemistry of Coal Gasification Classification of Coal Gasifiers Commercial Gasifiers Gasifiers under Development Synthesis Gas Purification and Water-Gas Shift Processes Introduction Commercial Synthesis Gas Purification Processes Water-Gas Shift Processes Indirect Liquefaction Introduction Methanol Synthesis Methanol-to-Gasoline Conversion Fischer-Tropsch Synthesis Fischer-Tropsch Product Upgrading Summary and Conclusion References DIRECT LIQUEFACTION Michael G. Thomas 1. Introduction Historical Perspective

9 xii CONTENTS 1.2. Definition of Processes Types of Coals Objectives Thermal Chemistry Concepts Stoichiometry Mechanisms Effects of Independent Variables Current Concepts on Rates and Activation Energies Catalytic Chemistry Objectives Effects on Coal Dissolution Effects on Preasphaltene Decomposition Synergistic Effects with Catalysts Catalytic Mechanisms Direct Liquefaction Technology Current Status Advanced Concepts Summary References FLUIDIZED-BED COMBUSTION Walter F. Podolski 1. Introduction Fluidization Background FBC System Description Atmospheric Fluidized Bed Combustors Pressurized Fluidized Bed Combustors Comparison to Conventional Combustors FBC Design Mechanical Design Consideration Environmental Considerations Analytical System Performance Modeling Hydrodynamics Combustion Process Concluding Remarks References

10 CONTENTS xiii 8. COAL-FIRED OPEN-CYCLE MHD PLANTS George R. Seikel 1. Introduction Plant Concept Historical Perspective MHD Generator MHD Plants Types of MHD Plants MHD Plant Efficiency Summary of MHD Plant Performance Early Commercial MHD Plant Designs Alternative Disk Generator Plants Nonutility MHD Plants Status and Cost of MHD Plant Systems Concluding Remarks References FUEL CELL POWER PLANT SySTEMS Marvin Warshay 1. Summary Introduction Brief History Fuel Cell Basic Concepts Fuel Cell Power Plant System Characteristics Predicted Performance and Cost of Fuel Cell Systems Operating on Coal-Derived Fuels Low-Temperature Fuel Cells High-Temperature Fuel Cells Discussion Study Assumptions and Sensitivity Fuel Cell Problems, Solution Prospects, and Commercialization Concluding Remarks References CATALYSIS AND CATALYTIC DEACTIVATION Leon M. Polinski, V. Udaya S. Rao, and John M. Stencel 1. Preface Instrumental Analysis of Liquefaction Catalysts

11 xiv CONTENTS 2.1. Introduction Analytical Techniques for Catalyst Characterization Indirect Liquefaction Direct Liquefaction Catalysts for the Indirect Liquefaction of Coal Possible Routes for Indirect Liquefaction of Coal Aspects of Hydrocarbon Synthesis (Polymerization Kinetics) Catalysts for Alcohol Synthesis Zeolite Catalysts for Methanol to Gasoline Process Fischer-Tropsch Catalysts Catalysts for the Direct Liquefaction of Coal Overview of Direct Coal Liquefaction General Problems of Catalytic Systems for Coal Liquefaction Processes Conversion Measurement History of Supported Catalyst Coal Conversion Process Investigations Variations in Test Procedures for Catalyst Evaluation by Investigations Catalytically Active (Co/MoIAI 20 3, Ni/MoiAlz0 3 and SnClz)Ingredients and Some Experimental Results Indicating the Importance of Metal-to-Metal and Metal- Support Interactions Catalyst Preparation Pore Size Distribution-Selectivity and Activity Effects H-Coal Catalyst Process Behavior Analysis of the Types of Catalyst Aging and of Aging Dynamics Catalyst Diameter Effect Coal-Liquids-Upgrading Catalysis-Recent Work Heteroatom Removal Characteristics of Catalysts Slurry Phase Catalysts Concluding Remarks References MATERIALS OF CONSTRUCTION W. A. Ellingson, K. Natesan, and T. Vojnovich 1. Introduction Low-Temperature Corrosion Aqueous Corrosion Stress Corrosion Cracking Steam Corrosion

12 CONTENTS xv 2.4. Hydrogen Attack High-Temperature Corrosion :3.1. Gaseous Corrosion Corrosion of Refractories by Coal Slag Molten Salt Corrosion Deposit-Induced Corrosion Erosive Wear Erosion by Solid Particles Entrained in Gas Streams Consideration of Fluid Mechanics on Erosive Wear Processes Erosive Wear by Solid Particles Entrained in Liquid Streams (Slurry Erosion) Cavitation Erosion Mechanical Properties Tensile Properties Creep and Creep-Rupture Properties Impact Properties Low-Cycle Fatigue Properties Susceptibility to Stress-Corrosion Cracking Materials-Design Interface Pressure Vessels Refractory Linings Heat Exchangers Turbines Nondestructive Evaluation Pressure Vessel Inspection Refractory Lining Inspection Steam Boiler and Heat Exchanger Inspection Monitoring Methods Summary References INSTRUMENTATION AND MONITORING Nancy M. O'Fallon 1. Introduction Types of Instrumentation Difficulties in Instrumenting Coal Utilization Systems Multiphase Flow Measurement Description of Available Multiphase Flow Instruments Multiphase Flowmeters under Development Temperature Measurement Description of Available Temperature Instruments Temoerature Instrumentation under Development

13 xvi CONTENTS 4. Gas Stream Analysis Description of Available Gas Stream Analyzers Gas Stream Analyzers under Development Particulate Monitors Description of Available Particulate Monitors Particulate Monitoring Systems under Development Solid and Slurry Stream Analysis Description of Available Solid and Slurry Stream Analyzers Solid and Slurry Stream Analyzers under Development Level Detection Description of Available Level Detection Instruments Level Detection Instruments under Development Nondestructive Evaluation Instruments INDEX