Teve como objetivo verificar e comparar a alteração das características do carvão antracitoso e do carvão betuminoso utilizados em meio filtrante, devido ao efeito abrasivo causado entre os grãos decorrentes de lavagens exclusivamente com água e lavagens independentes com ar e água. Foram estudados dois tipos de carvão antracitoso e um tipo de carvão betuminoso, para os quais foram determinadas suas características químicas e físicas. Os ensaios foram realizados em uma instalação ao piloto montada na escola de engenharia de São Carlos-EESC, USP, na qual foram feitas simulações de lavagens admitindo-se uma lavagem diária durante um ano para cada método, de modo intermitente, em que o meio granular era compactado ao final de cada lavagem, e continuo, sem compactação do meio granular. A velocidade ascensional utilizada para cada simulação de lavagem foi de 0,9 m/min, promovendo expansão no meio granular de 35 a 40%. A taxa de ar utilizada para as simulações de lavagens com aplicação de ar foi de 15 l/sm2. Após o término das 365 lavagens, foram determinados os valores médios do coeficiente de esfericidade e da porosidade do meio granular estratificado e construída a curva de distribuição granulométrica das amostras utilizadas nos ensaios. Conclui-se que o carvão betuminoso apresentou comportamento semelhante ao dos carvões antracitosos e que a metodologia de lavagem continua produz praticamente o mesmo efeito abrasivo comparada a de lavagem intermitente. / This work had the objetive to verify and to compare the alterations on the properties of Anthracite coal and Betuminous coal, due to the abrasive effect caused between the grains resulted from washing exclusively with water and independent washing with air and water. There were studied two types of Anthracite coal and one type of Betuminous coal, their chemical and physical properties were determined. The tests were performed at a pilot instalation setted at the School of Engineering of São Carlos - EESC,USP; where, were done simulations of washing, it was admitted one washing a day during one year (365 washing) for each method, in an intermitent way, in which the granular medium was compacted at the end of each washing, and continous without compactation of the granular medium. The ascending speed used for each simulation of washing was 0,9 m/min, promoting an expansion in the granular medium of 35 to 40%. The rate of air used for the simulations of washing with the aplication of air was 15 I/sm2. After the last of the 365 washing, were determined the average values of the coefficient of sphericity and porosity of the granular estratified medium and was constructed a curve of the granulometric distribution of the samples used during the tests. It was conclued that Betuminous coal shows similar behaviour as Anthracite coaI and the continous method produce the same effect abrasive compared intermitent method.

D.Phil. (Geology) / Please refer to full text to view abstract

M.Sc. / The study site for this project is New Clydesdale Colliery situated in the Witbank Coalfield, South Africa. The Witbank Coalfield is located within the northern part of the Karoo Basin where the major coal deposits in South Africa are located. Optimum ash fusion temperatures derived from coal in this region are approximately 1400°C, and higher, although temperatures above 1300°C are also acceptable. In certain coal seams the ash fusion temperatures drop well below this optimum temperature, leading at times to problems in the user industry. Ash fusion temperature which is the temperature at which the mineral matter in coal begins to soften, flow and fuse, is an important aspect relating to coal utilization but is little understood and under-studied in South Africa. The objective of this thesis is to attempt to determine what factors, mineralogical or inorganic chemical, influence variations in the ash fusion temperatures in certain coal samples. An understanding of this problem will have a bearing on the ultimate assessment of a coal for utilization purposes, in general, and ash deposition prediction in future boiler plants in particular. This study is somewhat pioneering as no detailed studies have been undertaken or published previously. Samples were collected at four sites from New Clydesdale Colliery. The sample sites were selected based on pre-existing knowledge of the ash fusion temperatures obtained from company analytical sheets. The sites were therefore representative of low and high ash fusion temperature coal. The first two sites were located in the opencast area where the No. 2 seam is actively being mined. The other two sites were located underground where mining has ceased. Conventional analyses conducted on the samples include proximate analyses, calorific values, percentage sulphur, and ash fusion temperatures. Further analyses performed included ash analyses (composition of ash), X-ray diffraction, scanning electron microscopy and petrographic studies. It was found that although complex relationships exist between ash fusion temperature and the various geological and coal parameters, positive results were obtained. These indicate a possible relationship between low ash fusion temperatures and i) finer size fractions, ii) an increase in iron content present in the form of pyrite and iii) the form in which pyrite is present, namely cleats. High ash fusion temperatures tend to correlate with i) the absence of pyrite or ii) pyrite present as framboids.

M.Phil. / Coal is today providing more than seventy-five percent of South Africa's energy requirements and will, to a large extent, remain so in the future. It is thus important to evaluate the adequacy of the country's available coal resources against expected future demand. The main objective of this study, which was done under the supervision of Prof. D. J. Kotze, was therefore to analyse the specific consumption of coal in the various consumption sectors in order to establish historical trends. The specific comsumption of coal is defined as the amount of coal used to produce a unit of final product. The factors attributing to these observed trends were determined and their future role evaluated in order to establish whether it was possible to extrapolate historical trends into the future. By means of curve fitting to the observed data and extrapolation it was possible to obtain future values of specific coal consumption for each of the sectors. These values, together with the production output forecasts for the various sectors were then used to calculate the total coal requirements for three reference years, namely, 1990, 1995 and 2000. The role of coal prices in explaining trends in specific coal consumption of various sectors was also analised separately. Information to conduct the study was obtained mainly from the various coal producers' associations as well as from individual producers and other organizations such as Escom, Sasol and Iscor, the Department of Hineral and Energy Affairs and the Hinerals Bureau. In some instances private firms and producers' associations were also consulted as well as a wide variety of literature on the subject. The principal finding of the study was that coal was substituted or was still being substituted by electricity in most final applications because of the convenience of use. Coal, however, still plays and probably will continue to play an important role in future in basic industries such as the metallurgical industry. Coal prices have not up to now played a very important role in the overall specific consumption of coal which can probably be attributed to the relatively low prices of coal on the inland market. It was also found that it was not desirable to do away with the present system of price control entirely as a certain measure of control was still necessary to safeguard the usuage of coal in certain applications for which there were no other substitutes. It was further concluded that South Africa does not have the vast quantities of coal commonly thought and that measures have to be taken in order to ensure that the country's coal resources are conserved and that optimum use is made of available resources.

Please read the abstract in the section 00front of this document / Dissertation (M Eng (Mechanical Engineering))--University of Pretoria, 2007. / Mechanical and Aeronautical Engineering / unrestricted

The Refcoal process is being developed to produce graphite from coal. Coal is dissolved in dimethylformamide (DMF) and sodium hydroxide (NaOH) is used as additive. After separation, the extracted coal (Refcoal) is precipitated with water and dried. The extraction process and subsequent solid-liquid separation processes have to be as efficient and cost-effective as possible. The purpose of the study was therefore to complete research on various unresolved aspects of the processes as identified by the candidate and supervisor. Extraction at 95 °C (DMF:coal:NaOH = 100:10:1), has an induction period of approximately 60 minutes observed, after which the reaction rate increases considerably. The reaction reaches completion after 360 minutes. An increase in stirring rate decreases extraction time due to the elimination of external mass-transfer limitations. The progress curves obtained for extraction at 135 °C with lower solvent-to-coal ratios differ dramatically from those obtained in previous studies, which indicates that changes in the raw materials and the experimental set-up have a great influence on the extraction at higher temperatures and concentrations. These extractions at higher temperatures using DMF:coal:NaOH ratios between 100:30:3 and 100:30:2 take approximately 360 minutes to complete and do not have an induction period as is the case with the extractions at 95 °C. It was found that the optimum DMF:coal ratio for an operating temperature of 135 °C, is 10:3. The high-temperature extractions reach completion in different time periods, depending on the amount of NaOH added to the reaction mixture. When very low concentrations of NaOH are added, the extraction will take much longer to complete and vice versa. The amount of NaOH used influences various aspects of the process. The cost analysis of the process falls beyond the scope of this investigation, but it is recommended that a thorough financial study is done to determine the optimum balance between raw materials, heat load and plant availability. The relationships between the concentration of Refcoal in the Refcoal solution and the absorbance values measured are polynomial expressions ending in downward concaves. The kinetics for the low-concentration (DMF:coal:NaOH = 100:10:1) extraction are best described by an autocatalytic reaction rate equation which is a function of coal, coal complex and NaOH concentration. A good fit was also obtained for the high temperature extractions. The rate expression is a function of both the coal and NaOH concentrations, but not of the coal complex. The sedimentation test showed promising results. The use of a thickener instead of a centrifuge to separate the insoluble material from the Refcoal solution would be a feasible cost-saving method. Filtration of the Refcoal solution (after centrifugation) using suitable filter media decreases the amount of impurities in the Refcoal. Filtration constants were determined for the best filter medium. The use of a hydrocyclone to separate the insoluble material from the extract is not recommended as it did not give the required efficiency to make the process viable. It is recommended that more tests be done under different conditions. Useful expressions were obtained for the change in viscosity with temperature for three different concentrations of Refcoal solution. It was determined that the viscosity of the Refcoal solution increases with time and it is therefore recommended that this be taken into account when equipment is being designed and plant scheduling is being done. / Dissertation (MEng (Chemical Engineering))--University of Pretoria, 2007. / Chemical Engineering / MEng / unrestricted

No description available.

>Magister Scientiae - MSc / Fly ash is the major waste material produced by power plants in the combustion of coal to generate electricity. The main constituents of fly ash are Si, Al, Fe and Ca with smaller amount of S, Mn, Na, K, and traces of many other elements such as Co, Cd, As, Se, Zn, Mo, Pb, B, Cu and Ni. Fly ash is usually disposed either by dry or wet disposal methods. These disposal methods have raised major environmental concerns due to the potential leaching of chemical species from the ash heap by ingress of rainfall and brine used to transport the fly ash to the dam. This study focuses on the changes in chemical composition, morphology and mineral phases due to weathering, of coal fly ash co-disposed with brine over 20 years at Sasol Secunda ash dump in Mpumalanga Province, South Africa. The design and operation of the Secunda ash dump presupposes that the ash dump may act as a sink for the salts which originated from chemicals used for normal operation in the plants. The majority of these salts come from the brines generated during desalination and raw water regeneration. The aim of this study is to ascertain if the ash dump could serve as a sustainable salt sink.Samples were drawn along the depth of two drilled cores (S1 and S3) from the weathered Secunda ash dump and analysed in conjunction with the fresh (unweathered) Secunda fly ash taken from the fly ash hoppers for comparative analysis. Scanning electron microscopy (SEM), X-ray diffractive (XRD) and X-ray fluorescence (XRF) spectrometry were employed to obtain a detailed morphological, mineralogical and bulk chemical composition of all the samples. Pore water analysis was used to determine the pH, EC and moisture content of fly ash samples. A five step sequential chemical extraction procedure was used to establish the geochemical association of particular elements with various mineral phases. The total acid digestion test was also used to determine the total elemental compositions of the Secunda fly ash samples. The SEM results showed that the fly ashes consist of irregular and numerous spherically shaped particles. Changes (encrustations, etchings and corrosion) in the morphologies of the weathered ash particles were also observed. The XRD results revealed quartz, mullite, lime and calcite as the major mineral phases. Other minerals identified in very minor quantities in the drilled Secunda ash core that were dried prior to analysis were halite, kaolinite, nitratine, bassanite, microline. and hydrophitte. These phases may have formed during sample handling. XRF investigation revealed that the major oxides present in the dumped ash samples were SiO₂, A₂2O₃, CaO, Fe₂O₃, MgO, Na₂O, TiO₂ and the minor elements present were K₂O, P₂O₅, SO₃ and MnO. The sum of the mean values of the % composition of SiO₂, Al₂O₃, and Fe₂O₃ was 70.19 %, and 72.94 % for the two drilled ash core samples (S1 and S3) respectively, and 78.67 % for the fresh ash which shows the significant alteration of the Si, Al and Fe content in the ash matrix over time. The fly ash is classified as Class F using the ASTM C 618 standards. The loss on ignition (LOI) which is an indication of unburned carbon or organic content was 4.78 %, 13.45 % and 8.32 % for the fresh ash, drilled ash cores S1 and S3 respectively. The high LOI values for the drilled ash cores could indicate high hydrocarbon content in the ash dump because of co-disposal practises where hydrocarbon waste are included in the brine stream for disposal on the ash. While the ash samples from the surface appeared dry, moisture content (MC) analysis showed that there is considerable water entrained in the fly ash dump. The fresh ash MC was 1.8 % while core S1 ranged from 41.4 – 73.2 %; core S3 ranged from 21.7 – 76.4 %. The variations in the MC values can be attributed to uneven flow paths due to inconsistent placement conditions or variations in ambient weather conditions during placement. The fresh fly ash (n=3) had a pH of 12.38±0.15, EC value of 4.98±0.03 mS/cm and TDS value of 2.68±0.03 g/L, the pH of the drilled ash core S1 (n=35) was 10.04 ±0.50, the EC value was 1.08±0.14 mS/cm and the TDS value was 0.64 ±0.08 g/L. Core S3 (n=66) had pH of 11.04±0.09; EC was 0.99 ±0.03 and TDS was 0.57 ± 0.01. The changes in pH values can be attributed to the dissolution and flushing out from the dump basic alkaline oxides like CaO and MgO These variations in pH values shows that the fly ash is acidifying over time and metal mobility can be expected under these conditions. The large decrease of EC in the drilled ash cores S1 and S3 compared to the fresh ash indicated a major loss of ionic species over time in the ash dump. The sequential extraction scheme revealed that the elements Al, Si, Ca, Mg, Ba, Sr, Fe, Mn, Na, K, As, Pb, Cr, Mo, Cu, Ni and Zn are present in Secunda fresh and weathered fly ash and are partitioned between the water soluble, exchangeable, carbonate, iron and manganese, and residual fractions of the coal fly ash. It also showed that the trace elements As, Pb, Cr, Mo, Cu, Ni and Zn do not show permanent association with particular mineral phases as a continuous partitioning between different mineral phases was observed in the weathered drilled core. Generally, all the elements had the highest concentration in the residual fraction. But it was evident that the labile phase (water soluble, exchangeable and carbonate fractions) had fairly high concentrations of Si (± 6.5 %), Al (± 6.5 %), Ca (±10 %), Mg (± 5.5 %), Ba (± 7.5 %),Sr (± 7.5 %), Na (± 12 %) and K (± 12 %) for the Secunda drilled ash core (S1 and S3) and fresh fly ash samples. This indicates that these species can leach easily upon water ingress and could pose a danger to the environment. Na and K had the highest concentrations leached out in the labile phase in all the ash samples. The amount of Na leached out of the drilled Secunda ash core in the labile phase was 13.21 % of 18584.26 mg/kg in the five geochemical phases of core S1; and 9.59 % of 11600.17 mg/kg in the five geochemical phases of core S3 while the fresh Secunda fly ash leached out 11.28 % of 16306.30 mg/kg of Na in the five geochemical phases. This study provided significant insight into the pore water chemistry, morphology, mineralogy and chemical composition and the elemental distribution pattern of the major and trace elements in the Secunda fly ash and weathered drilled Secunda ashm core S1 and S3. Though results from XRF analysis and the sequential extraction scheme shows that Na, K, S, Ca and Mg were slightly captured from the co-disposed brine by the Secunda fly ash, these species were however released in the labile phase. Hence there was no significant retention of these species in the ash dump. The amount of these species retained in the weathered ash were (0.26 % and 0.55 %) for Na, (0.02 % and 0.34 %) for K, (0.08 % and 0.06 %) for S, (0.94 % and 0.01 %) for Ca and (0.37 % and 0.96 %) for Mg in drilled ash cores S1 and S3 respectively. This poor retention of Na K, S, Ca and Mg which are major components of Sasol Secunda brine in the drilled ash cores S1 and S3 clearly shows the unsustainability of the Secunda fly ash dump as a salt sink.

CFD simulations are valuable tools in evaluating and deploying oxy-fuel and other carbon capture technologies either as retrofit technologies or for new construction. However, accurate predictive simulations require physically realistic submodels with low computational requirements. In particular, comprehensive char oxidation and gasification models have been developed that describe multiple reaction and diffusion processes. This work extends a comprehensive char conversion code (the Carbon Conversion Kinetics or CCK model), which treats surface oxidation and gasification reactions as well as processes such as film diffusion, pore diffusion, ash encapsulation, and annealing. In this work, the CCK model was thoroughly investigated with a global sensitivity analysis. The sensitivity analysis highlighted several submodels in the CCK code, which were updated with more realistic physics or otherwise extended to function in oxy-coal conditions. Improved submodels include a greatly extended annealing model, the swelling model, the mode of burning parameter, and the kinetic model, as well as the addition of the Chemical Percolation Devolatilization (CPD) model. The resultant Carbon Conversion Kinetics for oxy-coal combustion (CCK/oxy) model predictions were compared to oxy-coal data, and further compared to parallel data sets obtained at near conventional conditions.

The integrated gasification combined cycle (IGCC) is the most environmentally friendly coal-fired power generation technology that offers near zero green house gas emissions. This technology has higher thermal efficiency compared to conventional coal-fired power generation plants and uses up to 50% less water. This work involves the optimization of IGCC power plants by applying process integration techniques to maximize the use of energy available within the plant. The basis of this project was the theoretical investigations which showed that optimally designed and operated IGCC plants can achieve overall thermal efficiencies in the regions of 60%. None of the current operating IGCC plants approach this overall thermal efficiency, with the largest capacity plant attaining 47%. A common characteristic in most of these IGCC plants is that an appreciable amount of energy available within the system is lost to the environment through cold utility, and through plant irreversibility to a smaller extent. This work focuses on the recovery of energy, that is traditionally lost as cold utility, through application of proven process integration techniques. The methodology developed comprises of two primary energy optimization techniques, i.e. pinch analysis and the contact economizer system. The idea behind using pinch analysis was to target for the maximum steam flowrate, which will in turn improve the power output of the steam turbine. An increase in the steam turbine power output should result in an increase in the overall thermal efficiency of the plant. The contact economizer system is responsible for the recovery of low potential heat from the gas turbine exhaust en route to the stack to heat up the boiler feed water (BFW). It was proven in this work that a higher BFW enthalpy results in a higher overall efficiency of the plant. A case study on the Elcogas plant illustrated that the developed method is capable of increasing the gross efficiency from 47% to 55%. This increase in efficiency, however, comes at an expense of increased heat exchange area required to exchange the extra heat that was not utilized in the preliminary design. / Dissertation (MEng)--University of Pretoria, 2011. / Chemical Engineering / unrestricted