A mathematical model for entrained flow coal gasification was developed with the objective of predicting the influence of coal properties and gasification conditions on the performance of entrained flow gasifiers operating at pressures up to 21 atmospheres (2.1MPa). The model represents gasifiers as plug flow reactors and therefore neglects any mixing or turbulence effects. Coal properties were predicted through use of correlations from a variety of literature sources and others that were developed from experimental data in the literature. A sensitivity analysis of the model indicated that errors in the calculated values of coal volatile yield, carbon dioxide gasification reactivity and steam gasification may significantly affect the model predictions. Similarly errors in the input values for gasifier wall temperatures and gasifier diameter, when affected by slagging, can cause model prediction errors. Model predictions were compared with experimental gasification results for a range of atmospheric and high pressure gasifiers, the majority of the results being obtained by CSIRO at atmospheric pressure for a range of coals. Predictions were accurate for the majority of atmospheric pressure results over a large range of gas feed mixtures. Due to the limited range of experimental data available for high pressure gasification the capability of the model is somewhat uncertain, although the model provided accurate predictions for the majority of the available results. The model was also used to predict the trends in particle reactions with gasification and the influence of pressure, gasifier diameter and feed coal on gasifier performance. Further research on coal volatile yields, gasification reactivities and gas properties at high temperatures and pressures was recommended to improve the accuracy of model inputs. Additional predictions and model accuracy improvements could be made by extending the model to include fluid dynamics and slag layer modelling. / PhD Doctorate

One of the major issues facing the coal industry today is the decline in economically recoverable reserves, especially in the Witbank 1 Mpumalanga region of South Africa. This necessitates a critical review of alternate coal sources. One such source was identified as previously discarded and currently arising coal fines. It is well known that great value lies within these fines, but that the high moisture content associated with fine coal leads to thermal inefficiencies, handling problems and increased transport cost. This study will investigate thermal drying as a feasible solution to effectively remove this moisture. During thermal drying coal is fed into a high temperature environment; this can influence the physical and mechanical properties of the coal. The effects include swelling, caking, cracking, loss of water, loss of volatiles, and many more. These effects are investigated by means of thennogravimetric analysis, scanning electron microscopy with a heating stage, proximate analysis and mercury intrusion. Coal samples with an average particle size of 500 um were selected for this study. It was found that: The rate of moisture loss up to temperatures between 150 and 200°C is at a maximum where after the rate declines up to temperatures between 350 and 450°C when primary devolatilisation initiates. No visual changes in the coal are observed up to temperatures between 350 and 450°C. A limited amount of volatiles evolve at a constant rate up to 250°C; this is not significant enough to decrease the calorific value of the coal. Porosity changes in the coal are observed from temperatures as low as 250°C. Thermal drying was found to be a feasible alternative to currently employed drying methods with 150°C selected as the optimal drying temperature. A thermal drying plant is proposed with recommendations for future work needed to realise such a plant. / Thesis (M.Ing. (Chemical Engineering))--North-West University, Potchefstroom Campus, 2010

One of the major issues facing the coal industry today is the decline in economically recoverable reserves, especially in the Witbank 1 Mpumalanga region of South Africa. This necessitates a critical review of alternate coal sources. One such source was identified as previously discarded and currently arising coal fines. It is well known that great value lies within these fines, but that the high moisture content associated with fine coal leads to thermal inefficiencies, handling problems and increased transport cost. This study will investigate thermal drying as a feasible solution to effectively remove this moisture. During thermal drying coal is fed into a high temperature environment; this can influence the physical and mechanical properties of the coal. The effects include swelling, caking, cracking, loss of water, loss of volatiles, and many more. These effects are investigated by means of thennogravimetric analysis, scanning electron microscopy with a heating stage, proximate analysis and mercury intrusion. Coal samples with an average particle size of 500 um were selected for this study. It was found that: The rate of moisture loss up to temperatures between 150 and 200°C is at a maximum where after the rate declines up to temperatures between 350 and 450°C when primary devolatilisation initiates. No visual changes in the coal are observed up to temperatures between 350 and 450°C. A limited amount of volatiles evolve at a constant rate up to 250°C; this is not significant enough to decrease the calorific value of the coal. Porosity changes in the coal are observed from temperatures as low as 250°C. Thermal drying was found to be a feasible alternative to currently employed drying methods with 150°C selected as the optimal drying temperature. A thermal drying plant is proposed with recommendations for future work needed to realise such a plant. / Thesis (M.Ing. (Chemical Engineering))--North-West University, Potchefstroom Campus, 2010

Advances in the knowledge of chemical structure of coal and development of high performance computational techniques led to more than hundred and thirty four proposed molecular level representations (models) of coal between 1942 and 2010. These models were virtually on the carboniferous coals from the northern hemisphere. There are only two molecular models based on the inertinite- and vitrinite-rich coals from the southern hemisphere. The current investigation is based on the chars derived from the Permian-aged coals in two major South African coalfields, Witbank #4 seam and Waterberg Upper Ecca. The two coals were upgraded to 85 and 93% inertinite- and vitrinite-rich concentrates, on visible mineral matter free basis. The coals were slow heated in inert atmosphere at 20 ℃ min-1 to 450, 700 and 1000 ℃ and held at that temperature for an hour. After the HCl-HF treatment technique at ambient temperatures, the characteristics of the coals and chars were examined with proximate, ultimate, helium density, porosity, surface area, petrographic, solid-state 13C NMR, XRD and HRTEM analytical techniques. The results largely showed that substantial transitions occurred at 700-1000 ℃, where the chars became physically different but chemically similar. Consequently, the chars at the highest temperature (1000 ℃) drew attention to the detailed study of the atomistic properties that may give rise to different reactivity behaviours with CO2 gas. The H/C atomic ratios for the inertinite- and vitrinite-rich chars were respectively 0.31 and 0.49 at 450 ℃ and 0.10 and 0.12 at 1000 ℃. The true density was respectively 1.48 and 1.38 g.cm-3 at 450 ℃ and 1.87 and 1.81 g.cm-3 at 1000 ℃. The char form results from the petrographic analysis technique indicated that the 700-1000 ℃ inertinite-rich chars have lower proportions of thick-walled isotropic coke derived from pure vitrinites (5-8%) compared with the vitrinite-rich chars (91-95%). This property leads to the creation of pores and increases of volume and surface area as the softening walls expand. It was found that the average crystallite diameter, La, and the mean length of the aromatic carbon fringes from the XRD and HRTEM techniques, respectively, were in good agreement and made a definite distinction between the 1000 ℃ inertinite- and vitrinite-rich chars. The crystallite diameter on peak (10) approximations, La(10), of 37.6Å for the 1000 ℃ inertinite-rich chars fell within the HRTEM’s range of minimummaximum length boundary of 11x11 aromatic fringes (27-45Å). The La (10) of 30.7Å for the vitrinite-rich chars fell nearly on the minimum-maximum length range of 7x7 aromatic fringes (17-28Å.) The HRTEM results showed that the 1000 ℃ inertinite-rich chars comprised a higher distribution of larger aromatic fringes (11x11 parallelogram catenations) compared with a higher distribution of smaller aromatic fringes (7x7 parallelogram catenations). The mechanism for the similarity between the 700-1000 ℃ inertinite- and vitrinite-rich chars was the greater transition occurring in the vitrinite-rich coal to match the more resistant inertinite-rich coal. This emphasised that the transitions in the properties of vitrinite-rich coals were more thermally accelerated than those of the inertinite-rich coals. The similarity between the inertinite- and vitrinite-rich chars was shown by the total maceral reflectance, proximate, ultimate, skeletal density and aromaticity results. Evidence for this was the carbon content by mass for the inertinite- and vitrinite-rich chars of respectively 90.5 and 85.3% at 450 ℃ and 95.9 and 94.1% at 1000 ℃. The aromaticity from the XRD technique was respectively 87 and 77% at 450 ℃ and 98 and 96% at 1000 ℃. A similar pattern was found in the hydrogen and oxygen contents, the atomic O/C ratios and the aromaticity from the NMR technique. The subsequent construction of large-scale molecular structures for the 1000 ℃ inertinite-rich chars comprised 106 molecules constructed from a total of 42929 atoms, while the vitrinite-rich char model was made up of 185 molecules consisting of a total of 44315 atoms. The difference between the number of molecules was due to the inertinite-rich char model comprising a higher distribution of larger molecules compared with the vitrinite-rich char model, in agreement with the XRD and HRTEM results. These char structures were used to examine the behaviour on the basis of gasification reactivity with CO2. The density functional theory (DFT) was used to evaluate the interactions between CO2 and the atomistic representations of coal char derived from the inertinite- and vitrinite rich South African coals. The construction of char models used the modal aromatic fringes (fringes of highest frequencies in size distributions) from the HRTEM, for the inertinite- and vitrinite-rich chars, respectively (11x11 and 7x7 parallelogram-shaped aromatic carbon rings). The structures were DFT geometrically optimized and used to measure reactivity with the Fukui function, f+(r) and to depict a representative reactive carbon edge for the simulations of coal gasification reaction mechanism with CO2 gas. The f+(r) reactivity indices of the reactive edge follows the sequence: zigzag C remote from the tip C (Czi = 0.266) > first armchair C (Cr1 = 0.087) > tip C (Ct = 0.075) > second armchair C (Cr2 = 0.029) > zigzag C proximate to the tip C (Cz = 0.027). The DFT simulated mean activation energy, ΔEb, for the gasification reaction mechanism (formation of second CO gas molecule) was 233 kJ mol-1. The reaction for the formation of second CO molecule is defines gasification in essence. The experimental activation energy determined with the TGA and random pore model to account essentially for the pore variation in addition to the gasification chemical reaction were found to be very similar: 191 ± 25 kJ mol-1 and 210 ± 8 kJ mol-1; and in good agreement with the atomistic results. The investigation gave promise towards the utility of molecular representations of coal char within the context of fundamental coal gasification reaction mechanism with CO2. / PhD (Chemical Engineering), North-West University, Potchefstroom Campus, 2015

Advances in the knowledge of chemical structure of coal and development of high performance computational techniques led to more than hundred and thirty four proposed molecular level representations (models) of coal between 1942 and 2010. These models were virtually on the carboniferous coals from the northern hemisphere. There are only two molecular models based on the inertinite- and vitrinite-rich coals from the southern hemisphere. The current investigation is based on the chars derived from the Permian-aged coals in two major South African coalfields, Witbank #4 seam and Waterberg Upper Ecca. The two coals were upgraded to 85 and 93% inertinite- and vitrinite-rich concentrates, on visible mineral matter free basis. The coals were slow heated in inert atmosphere at 20 ℃ min-1 to 450, 700 and 1000 ℃ and held at that temperature for an hour. After the HCl-HF treatment technique at ambient temperatures, the characteristics of the coals and chars were examined with proximate, ultimate, helium density, porosity, surface area, petrographic, solid-state 13C NMR, XRD and HRTEM analytical techniques. The results largely showed that substantial transitions occurred at 700-1000 ℃, where the chars became physically different but chemically similar. Consequently, the chars at the highest temperature (1000 ℃) drew attention to the detailed study of the atomistic properties that may give rise to different reactivity behaviours with CO2 gas. The H/C atomic ratios for the inertinite- and vitrinite-rich chars were respectively 0.31 and 0.49 at 450 ℃ and 0.10 and 0.12 at 1000 ℃. The true density was respectively 1.48 and 1.38 g.cm-3 at 450 ℃ and 1.87 and 1.81 g.cm-3 at 1000 ℃. The char form results from the petrographic analysis technique indicated that the 700-1000 ℃ inertinite-rich chars have lower proportions of thick-walled isotropic coke derived from pure vitrinites (5-8%) compared with the vitrinite-rich chars (91-95%). This property leads to the creation of pores and increases of volume and surface area as the softening walls expand. It was found that the average crystallite diameter, La, and the mean length of the aromatic carbon fringes from the XRD and HRTEM techniques, respectively, were in good agreement and made a definite distinction between the 1000 ℃ inertinite- and vitrinite-rich chars. The crystallite diameter on peak (10) approximations, La(10), of 37.6Å for the 1000 ℃ inertinite-rich chars fell within the HRTEM’s range of minimummaximum length boundary of 11x11 aromatic fringes (27-45Å). The La (10) of 30.7Å for the vitrinite-rich chars fell nearly on the minimum-maximum length range of 7x7 aromatic fringes (17-28Å.) The HRTEM results showed that the 1000 ℃ inertinite-rich chars comprised a higher distribution of larger aromatic fringes (11x11 parallelogram catenations) compared with a higher distribution of smaller aromatic fringes (7x7 parallelogram catenations). The mechanism for the similarity between the 700-1000 ℃ inertinite- and vitrinite-rich chars was the greater transition occurring in the vitrinite-rich coal to match the more resistant inertinite-rich coal. This emphasised that the transitions in the properties of vitrinite-rich coals were more thermally accelerated than those of the inertinite-rich coals. The similarity between the inertinite- and vitrinite-rich chars was shown by the total maceral reflectance, proximate, ultimate, skeletal density and aromaticity results. Evidence for this was the carbon content by mass for the inertinite- and vitrinite-rich chars of respectively 90.5 and 85.3% at 450 ℃ and 95.9 and 94.1% at 1000 ℃. The aromaticity from the XRD technique was respectively 87 and 77% at 450 ℃ and 98 and 96% at 1000 ℃. A similar pattern was found in the hydrogen and oxygen contents, the atomic O/C ratios and the aromaticity from the NMR technique. The subsequent construction of large-scale molecular structures for the 1000 ℃ inertinite-rich chars comprised 106 molecules constructed from a total of 42929 atoms, while the vitrinite-rich char model was made up of 185 molecules consisting of a total of 44315 atoms. The difference between the number of molecules was due to the inertinite-rich char model comprising a higher distribution of larger molecules compared with the vitrinite-rich char model, in agreement with the XRD and HRTEM results. These char structures were used to examine the behaviour on the basis of gasification reactivity with CO2. The density functional theory (DFT) was used to evaluate the interactions between CO2 and the atomistic representations of coal char derived from the inertinite- and vitrinite rich South African coals. The construction of char models used the modal aromatic fringes (fringes of highest frequencies in size distributions) from the HRTEM, for the inertinite- and vitrinite-rich chars, respectively (11x11 and 7x7 parallelogram-shaped aromatic carbon rings). The structures were DFT geometrically optimized and used to measure reactivity with the Fukui function, f+(r) and to depict a representative reactive carbon edge for the simulations of coal gasification reaction mechanism with CO2 gas. The f+(r) reactivity indices of the reactive edge follows the sequence: zigzag C remote from the tip C (Czi = 0.266) > first armchair C (Cr1 = 0.087) > tip C (Ct = 0.075) > second armchair C (Cr2 = 0.029) > zigzag C proximate to the tip C (Cz = 0.027). The DFT simulated mean activation energy, ΔEb, for the gasification reaction mechanism (formation of second CO gas molecule) was 233 kJ mol-1. The reaction for the formation of second CO molecule is defines gasification in essence. The experimental activation energy determined with the TGA and random pore model to account essentially for the pore variation in addition to the gasification chemical reaction were found to be very similar: 191 ± 25 kJ mol-1 and 210 ± 8 kJ mol-1; and in good agreement with the atomistic results. The investigation gave promise towards the utility of molecular representations of coal char within the context of fundamental coal gasification reaction mechanism with CO2. / PhD (Chemical Engineering), North-West University, Potchefstroom Campus, 2015