WO2007048198A1 - Procédé, système et appareillage servant à passiver des matières carbonées - Google Patents

Procédé, système et appareillage servant à passiver des matières carbonées Download PDF

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Publication number
WO2007048198A1
WO2007048198A1 PCT/AU2006/001604 AU2006001604W WO2007048198A1 WO 2007048198 A1 WO2007048198 A1 WO 2007048198A1 AU 2006001604 W AU2006001604 W AU 2006001604W WO 2007048198 A1 WO2007048198 A1 WO 2007048198A1
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WIPO (PCT)
Prior art keywords
carbonaceous material
process according
dried
volatile matter
gas stream
Prior art date
Application number
PCT/AU2006/001604
Other languages
English (en)
Inventor
James Coleman
David Cork
Original Assignee
Devereaux Holdings Pty Ltd
Corky's Carbon And Combustion Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2005905934A external-priority patent/AU2005905934A0/en
Application filed by Devereaux Holdings Pty Ltd, Corky's Carbon And Combustion Pty Ltd filed Critical Devereaux Holdings Pty Ltd
Priority to US12/091,503 priority Critical patent/US20090217574A1/en
Priority to EP06790435A priority patent/EP1951849A4/fr
Priority to BRPI0618018-3A priority patent/BRPI0618018A2/pt
Priority to EA200801191A priority patent/EA200801191A1/ru
Priority to AU2006308519A priority patent/AU2006308519A1/en
Publication of WO2007048198A1 publication Critical patent/WO2007048198A1/fr

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Classifications

    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10LFUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L5/00Solid fuels
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10LFUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L9/00Treating solid fuels to improve their combustion
    • C10L9/08Treating solid fuels to improve their combustion by heat treatments, e.g. calcining
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10LFUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L9/00Treating solid fuels to improve their combustion
    • C10L9/10Treating solid fuels to improve their combustion by using additives

Definitions

  • the present invention relates to a process, system and apparatus for passivating carbonaceous materials against spontaneous combustion.
  • An apparatus for heating oxygen sensitive carbonaceous material in a controlled oxygen environment is also described.
  • Coal pyrolysis occurs upon heating coal to produce gases, liquids, and a solid residue (char or coke) . Pyrolysis occurs in all coal utilisation processes, including combustion, gasification, liquefaction, and carbonisation.
  • char and coke The principal difference between char and coke is that the parent coal for char has high oxygen content and a non- aromatic structure and therefore the char particles do not tend to agglomerate during pyrolysis.
  • the parent coal for coke has much lower oxygen content and an aromatic structure.
  • Coke feed stock undergoes a plastic phase and agglomerates during pyrolysis. Feed stock that normally produces coke can be used to produce char by pyrolysis thereof in an atmosphere with a slight to moderate oxygen content.
  • char has been an undesirable by-product of a smokeless fuel plant, coke works or coal gasification plant, although smaller scale plants produce char for activated carbon and micro blast furnaces.
  • One of the least desirable characteristics of some dried chars is that they can be pyrophoric when exposed to an oxygen-containing atmosphere.
  • This tendency to spontaneously combust is promoted by rapid adsorption of water vapour and oxygen by dried char.
  • Oxygen physically adsorbs onto the surface of the dried char and chemically reacts in an exothermic oxidation reaction with the organic molecules within the char.
  • the heat release if not dissipated, will promote a self-accelerating oxidation process, causing the temperature of the char to rise progressively until the char spontaneously ignites.
  • the rise in temperature of the char is also promoted by latent heat of vaporization released by adsorption of water onto the char particles.
  • US Patent No. 5,601,692 describes a continuous process for treating a non-caking coal to form stable char. The process involves several sequential steps including drying the coal to remove moisture therefrom and pyrolysing the dried coal to vaporise and remove low end volatile materials from the coal to form char and to mobilize at least a portion of high end volatile materials within the char and at least partially collapse micropores within the char.
  • the char is then cooled to a temperature sufficient to demobilize the volatile materials within the partially collapsed micropores of the char to pyrolytically passivate the char, and is subsequently treated with an oxygen containing gas to oxidatively passivate the coal by chemisorption of oxygen.
  • the oxidatively passivated char is then simultaneously rehydrated and cooled. It would be advantageous to dry coals and process them in such a manner that the dried coal or char particles are passivated against spontaneous combustion without the need for externally supplied coating materials or subsequent multi-step treatment processes.
  • the present invention seeks to overcome at least some of the aforementioned disadvantages.
  • the invention increases the specific energy of the treated carbonaceous material making it a more commercially attractive product, particularly for shipping. Additionally, the organic sulfur content thereof is also reduced.
  • a carbonaceous material feed stream may be dried and carbonised ,to produce char, both processes being conducted simultaneously in a single vessel or, alternatively, the drying and carbonisation processes may be conducted sequentially in two separate vessels.
  • the volatile matter evolved from the carbonaceous material feed stream during carbonisation often referred to as coal gas, generally has a high calorific content and contains tars.
  • attention has been directed to separating the coal gas from the char and improving the high calorific content of the coal gas generated during carbonisation so that its commercial potential can be fully exploited.
  • the present invention is based on the realisation that it is possible to passivate carbonaceous material by treating the dried carbonaceous material with the volatile matter evolved during low temperature and/or medium temperature devolatilisation of the carbonaceous material.
  • a process for preparing a passivated carbonaceous material comprising the steps of : a) drying a carbonaceous material feed stream,- b) treating the dried carbonaceous material with volatile matter,- and c) devolatilising the dried carbonaceous material feed stream and forming the passivated carbonaceous material and volatile matter.
  • the step of treating the dried carbonaceous material feed stream comprises contacting the dried carbonaceous material feed stream with a gas stream containing volatile matter.
  • tars and other organic compounds contained in the volatile matter coat particles of the carbonaceous material, plugging the micropores of the particles and thereby reducing the adsorption of water and oxygen.
  • the tars and organic compounds undergo pyrolysis. Pyrolytic rupture of functional groups attached to aromatic and hydroaromatic moieties on the carbonaceous material leads to release of low molecular weight reactive free radical fragments and stabilization of the former fragment sites by hydrogen. They hydrophilic polar functional groups are thereby converted to, and replaced by, an hydrophobic aromatic coating, thus passivating the dried carbonaceous material against spontaneous combustion.
  • the gas stream containing volatile matter is directed in a counter current flow relative to the dried carbonaceous material .
  • the volatile matter contained in the gas stream comprises volatile matter evolved during step c) .
  • the volatile matter evolved during devolatilisation of the dried carbonaceous material is augmented by doping the carbonaceous material feed stream with materials containing large amounts of hydrophobic aromatic moieties that would enrich the volatile matter with these species during devolatilisation. Suitable examples of such materials containing large amounts of hydrophobic aromatic moieties will be well known to those skilled in the art and include, but are not limited to, waste rubber, in particular vehicle tyres, and plastics materials.
  • the volatile matter contained in the gas stream comprises volatile matter evolved from devolatilisation of a volatile matter feedstock, distinct and separate from the carbonaceous material feed stream of the present process.
  • the volatile matter feedstock comprises materials containing large amounts of hydrophobic aromatic moieties as described above.
  • the volatile matter contained in the gas stream comprises volatile matter evolved during step a) .
  • the step of drying the carbonaceous material feed stream comprises heating the carbonaceous material feed stream from about 100 0 C to 400 0 C.
  • the drying step is conducted under a low oxygen (0-5% O 2 v/v) and high moisture (up to 50% v/v) atmosphere.
  • the carbonaceous material feed stream may be heated directly or indirectly to the temperatures at which the drying step is performed.
  • direct heating or "heated directly” as used herein refer to a manner of heating the carbonaceous material feed stream wherein a hot gas stream, from a local or a remote source, at a pre-determined temperature is arranged to come into contact with the particles of carbonaceous material of the carbonaceous material feed stream to facilitate a gas- solid heat exchange.
  • directly heating encompass a manner of heating the carbonaceous material feed stream wherein a gas stream from a local or a remote source, at a pre-determined temperature is prevented from coming into contact with the particles of the carbonaceous material feed stream, but is used instead to heat the vessel containing the carbonaceous material feed stream.
  • directly heating or “heated indirectly” also encompass any manner of heating the vessel containing the carbonaceous material feed stream so as to heat the carbonaceous material feed stream to a desired temperature, as would be understood and known to a person skilled in the art.
  • the carbonaceous material feed stream is directly heated.
  • the carbonaceous material feed stream is directly heated by contacting the carbonaceous material feed stream with a hot gas stream having a low oxygen content.
  • the oxygen content of the hot gas stream is less than 5% v/v, and preferably less than 1% v/v.
  • the hot gas stream is contacted with the carbonaceous material feed stream in a countercurrent direction relative to the carbonaceous material feed stream.
  • the step of contacting the dried carbonaceous material with a gas stream containing volatile matter is facilitated by directing a countercurrent flow of the hot gas stream relative to the dried carbonaceous material, wherein the hot gas stream is used to heat the carbonaceous material feed stream to temperatures at which step a) is performed.
  • the step of devolatilising the dried carbonaceous material comprises heating the dried carbonaceous material from about 400 0 C to 900 0 C, preferably 600°C to 800 0 C.
  • the devolatilising step is conducted under a low oxygen (0-5% O 2 v/v) atmosphere.
  • the dried carbonaceous material is directly heated.
  • the dried carbonaceous material is directly heated by contacting the dried carbonaceous material with a hot gas stream having a low oxygen content.
  • the oxygen content of the hot gas stream is less than 5% v/v, and preferably less than 1% v/v.
  • the hot gas stream is contacted with the dried carbonaceous material in a countercurrent direction relative to the dried carbonaceous material .
  • Volatile matter evolves at the temperatures at which the dried carbonaceous material undergoes devolatilisation in step c) .
  • the same hot gas stream is used in step c) and then subsequently in step a) .
  • the volatile matter mixes with the hot gas stream and is directed in a countercurrent flow relative to the dried carbonaceous material, and subsequently contacts the dried carbonaceous material located upstream, thereby pre-conditioning the dried carbonaceous material before it is devolatilised.
  • the passivated carbonaceous material feed stream produced by the process of the present invention has its moisture content reduced to between 0-20% moisture and its volatile matter -content reduced to 0-25% in comparison with the moisture and volatile matter content of the carbonaceous material feed stream.
  • the process further comprises the step of quenching the passivated carbonaceous material.
  • the passivated carbonaceous material is quenched with water and/or cool inert gas.
  • the quenched passivated carbonaceous material can then be cooled to ambient temperature, stockpiled and loaded out.
  • the passivated carbonaceous material is quenched with untreated carbonaceous material, including but not limited to wet screened coal .
  • a system for preparing passivated carbonaceous materials comprising : a dryer for drying a carbonaceous material feed stream; a pyrolyser for devolatilising dried carbonaceous material and forming passivated carbonaceous material and volatile matter; and a carrier vehicle for facilitating contact of volatile matter with the dried carbonaceous material .
  • a dryer examples include, but are not limited to, a rotary kiln, a multiple hearth furnace (MHF) , flash dryer, or a circulating fluid bed (CFB) .
  • the dryer comprises a rotary kiln.
  • the dryer comprises a circulating fluidized bed, preferably a differentially circulating fluidized bed.
  • the rotary kiln is configured at an angle of up to 10° , preferably 2-5°, above the horizontal to facilitate passage of the carbonaceous material feed stream through the rotary kiln under gravity.
  • the rotary kiln is provided with a means to rotate the rotary kiln about its central longitudinal axis, and the rotational speed thereof is typically selected to correspond with the length of the rotary kiln such that a residence time of the carbonaceous material feed stream in the rotary kiln is about 15-40 minutes .
  • the dryer is arranged to heat the carbonaceous material feed stream to 100 0 C to 400 0 C.
  • the dryer is heated by a hot gas stream (400 0 C to 800 0 C) having a low oxygen content.
  • the oxygen content of the hot stream of gas is less than 5% v/v and prefei-ably less than 1% v/v.
  • Oxygen is preferably substantially excluded from the carbonaceous material feed stream, or at least at a controlled low concentration, throughout its residence time within the dryer.
  • the pyrolyser for devolatilising the dried carbonaceous material feed stream and forming the passivated carbonaceous material and volatile matter comprises any one or more in combination of a rotary kiln, multiple hearth furnace (MHF) , or a circulating fluid bed (CFB) .
  • MHF multiple hearth furnace
  • CFB circulating fluid bed
  • the pyrolyser comprises a multiple hearth furnace .
  • the dried carbonaceous material feed stream in the multiple hearth furnace is directly heated with a hot gas stream having a low oxygen content to temperatures of about 600°C-800°C.
  • the oxygen content of the hot gas stream is less than 5% v/v and preferably less than 1% v/v.
  • the hot gas stream comprises combustion gas generated from an external burner.
  • the system is further provided with an external burner to generate a hot gas stream used for directly heating the pyrolyser and heating the dryer of the system, respectively.
  • the carbonaceous material feed stream may be heated in the dryer and/or the pyrolyser at a controlled temperature and oxygen concentration.
  • Oxygenated hot gas is not unnecessarily mixed with the carbonaceous material feed stream unless combustion is required.
  • the hot gas stream is directed in counter current flow against the dried carbonaceous material in the pyrolyser.
  • the hot gas stream combines with the volatile matter evolved in the pyrolyser and thus acts as a carrier vehicle for the volatile matter.
  • the volatile matter is directed in counter current flow against the dried carbonaceous material in the pyroliser to facilitate contact of the volatile matter with the dried carbonaceous material.
  • the system further comprises a means for feeding the dried carbonaceous material from the dryer to the pyrolyser.
  • the means for feeding the dried carbonaceous material to the pyrolyser comprises a closed pneumatic system.
  • a process for reducing inherent moisture in and/or increasing a specific energy of a carbonaceous material comprising the steps of : a) drying a carbonaceous material feed stream; and b) carbonising the dried carbonaceous material by- contacting the dried carbonaceous material with a counter current gas stream having a low oxygen content .
  • the oxygen content of the gas stream is less than 5%. Typically, the oxygen content of the gas stream is less than 1%.
  • the gas stream having the low oxygen content is produced by the combustion of a carbon source. Typical examples of such carbon sources include, but are not limited to, coal gas, pulverized coal, char or coke .
  • the gas stream having a low oxygen content is contacted with the dried carbonaceous material at a temperature of between 400 0 C and 800 0 C.
  • steps a) and b) are both carried out by contacting the carbonaceous material with the gas stream having a low oxygen content whereby said gas stream initially dries the carbonaceous material and then proceeds to carbonise the carbonaceous material .
  • the gas stream contains volatile matter.
  • the volatile matter evolves during step b) and mixes with the gas stream.
  • the volatile matter evolves during step a) and mixes with the gas stream.
  • the volatile matter coats the carbonaceous material and provides the aforementioned advantages.
  • a process for improving the coking characteristics of non-coking carbonaceous material comprising the steps of: a) drying a non-coking carbonaceous material feed stream; b) treating the dried non-coking carbonaceous material with volatile matter; and c) devolatilising the treated dried non-coking carbonaceous material and forming a carbonaceous material with improved coking characteristics and volatile matter.
  • hot char produced in a carbonising process is typically quenched with water and/or inert gases to lower the temperature of the particles to below 100 0 C.
  • Carefully controlled conditions for the quenching process and subsequent storage of the quenched char are required because of the tendency of char to spontaneously combust under conditions where oxygen and/or water adsorption onto the char particles is allowed to occur, as described above.
  • the present invention is based on the realisation that passivated char does not tend to spontaneously combust when exposed to conditions under which water and/or oxygen adsorption occur, and thus it is possible to quench hot passivated char by contacting the hot passivated char with a particulate material under ambient conditions to facilitate solid-solid heat transfer. Precautions against exposing the char to conditions under which oxygen and/or water adsorption occur, to prevent spontaneous combustion of the char, are no longer required.
  • a process for quenching hot passivated char comprising contacting the hot passivated char with a particulate material .
  • the step of contacting the hot passivated char with the particulate material comprises mixing the hot passivated char with the particulate material and facilitating a solid-solid heat exchange between particles of the hot passivated char and the particulate material.
  • the particulate material will be at ambient temperature.
  • the hot passivated char and the particulate material blend can be further mixed with a cool inert gas stream to facilitate further quenching thereof.
  • the particulate material is a carbonaceous material, in particular wet screened coal.
  • the temperature of the hot passivated char is lowered by direct heat transfer to the wet screened coal at ambient temperature. Additionally, thermal energy contained in the hot passivated char will also be employed in removing moisture from the wet screened coal .
  • the step of blending the carbonaceous material and passivated char is conducted in a substantially oxygen-free atmosphere.
  • the present invention provides an apparatus, for use in a continuous process, for passivating carbonaceous material, the apparatus comprising:
  • an apparatus for heating oxygen sensitive carbonaceous material in a controlled oxygen environment comprising:
  • Figure 1 shows a block diagram illustrating the steps involved in a process for preparing passivated carbonaceous material in accordance with the present invention
  • Figure 2 shows schematically a process flow diagram in accordance with a process for preparing passivated carbonaceous material under low temperature carbonisation conditions
  • Figure 3 shows a schematic diagram of a dryer comprised in an apparatus for preparing passivated carbonaceous material in accordance with the present invention.
  • Figure 4 shows schematically a process flow diagram in accordance with a process for preparing passivated carbonaceous material under medium temperature carbonisation conditions.
  • a hopper, a conveyor, a bag house filter, a cyclone, a multi-hearth furnace, flues, blowers and valves may be any such known commercially available components with the exception that such components may be modified as necessary by one skilled in the art to be employed in the overall process of the present inventions discussed herein.
  • many control devices which are conventional and standard in chemical processing have been omitted for clarity of illustrating and describing the invention.
  • control valves, thermocouples, thermistors, coupled with suitable servo circuits are readily available and conventionally used for measuring and controlling temperature and process flow.
  • Figure 1 there is shown a block diagram of the steps of a process 10 for preparing a passivated carbonaceous material .
  • the steps of the process 10 include drying 2 a carbonaceous material feed stream, treating 3 the dried carbonaceous material with volatile matter, and devolatilising 4 the dried carbonaceous material and forming passivated carbonaceous material.
  • devolatilisation or “devolatilising” as used herein refers to a process that involves thermal decomposition of carbonaceous material, typically coal, in a controlled oxygen atmosphere with production of volatile matter, liquor (low molecular weight liquids) , tar (high molecular weight liquids), and char or coke. There is some variation of the product distribution with the temperature of thermal decomposition. It will be appreciated that the process of carbonisation of carbonaceous materials undertaken at low, medium or high temperature conditions is encompassed by the terms “devolatilisation” and “devolatilising” .
  • volatile matter refers to those products described previously, exclusive of moisture, given off as gas and vapour.
  • the content of volatile matter in coal can be determined by definite prescribed methods (ASTM, 1981, D2361-66, D3761-79, D3175-77, D3175-77, D3176-74, D3178-73, and D3179-73, and will vary according to the composition of the coal or feedstock materials for the volatile matter.
  • passivated carbonaceous material refers to carbonaceous material which has been treated to be resistant to spontaneous combustion in conditions where carbonaceous material would be reasonably expected to spontaneously combust .
  • carbonaceous material as used herein is defined in the broadest terms and includes coal, coal -based products, charcoal, activated carbon, wood, wood chips, sawdust, biomass, waste rubber including but not limited to vehicle tyres, waste plastic materials, contaminated soils, mixtures thereof and mixtures of said carbonaceous materials with other substances.
  • the carbonaceous material feed stream comprises a plurality of particles of non-agglomerating coal including but not limited to lignite, sub-bituminous coal, bituminous coal, anthracite, and a blend of two or more thereof.
  • Anthracite is a class of non-agglomerating coals as defined by the American Society for Testing and Materials having more than 86 percent fixed carbon and less than 14 percent volatile matter on a dry, mineral-matter-free basis.
  • Bituminous coal is a class of coals as defined by the American Society for Testing and Materials high in carbonaceous matter, having less than 86 percent fixed carbon, more than 14 percent volatile matter on a dry, mineral-matter-free basis, a moisture content from 1.5 to 7 percent, and more than 10,500 Btu/lb (29.68 MJ/kg) on a moist, mineral-matter-free basis. Bituminous coals may be either agglomerating or non-agglomerating coals.
  • Sub- bituminous coal is a class of non-agglomerating coals with a carbon content between 71 and 77 percent and a moisture content to 10 percent, and having a heat value content of more than 8,300 Btu/lb and less than 11,500 Btu/lb on a moist, mineral-mater-free basis.
  • Lignite is a class of brownish-black, low-rank coal defined by the American Society for Testing and Materials as having less than 8,300 Btu/lb (23.46 MJ/kg) on a moist, mineral-matter-free basis.
  • lignites or brown coal have high oxygen content
  • the carbonaceous material feed stream can also comprise a plurality of particles of agglomerating coal (or coking coal) in combination with an anti -caking agent to reduce swelling and agglomeration of the coal particles during carbonization.
  • the process of the present invention is particularly suited in respect of a carbonaceous material feed stream comprising a plurality of coal particles of low rank coal with a high moisture content, such as lignite, sub-bituminous coal, and bituminous coal with a moisture content of 10% - 70%.
  • the process 10 of the present invention is particularly suited for sub-bituminous coal from the Ewington mine in Western Australia having approximately the following composition by weight: 44% fixed carbon, 6% ash, 25% moisture, and 27% volatile matter.
  • the process 10 with reference to Figures 1, 2 and 4 refers to performing the invention with respect to sub- bituminous coal or lignite
  • the process 10 the present invention may be used to prepare passivated dried coal or passivated char from other types of coals, biomass, waste rubber products such as for example tyres, woodchips, and other carbonaceous materials.
  • the process may be used to dry other oxygen sensitive, flammable substances, for example thermal desorption of activated carbon or even contaminated soil.
  • the particles of carbonaceous material are sized less than 50 mm, preferably less than 20 mm, and even more preferably less than 15 mm.
  • the particles of carbonaceous material do not tend to suffer excessive stress due to shrinkage and subsequent decrepitation when dried, or at temperatures under which devolatilisation and/or carbonization occurs.
  • the percentage particle breakdown throughout the process is typically ⁇ 15%.
  • the particles do not tend to suffer excessive transient heat transfer.
  • the temperature at the centre of the particle is similar to the temperature at the surface of the particle, and thus each particle can be rapidly heated or cooled.
  • the carbonaceous material feed stream is prepared by washing, crushing and classifying to provide coal of suitable quality, quantity and particle size.
  • the carbonaceous material feed stream is fed into a dryer 12 at ambient temperature via a screw conveyor 14, typically at a rate of 90-100 tph.
  • the dryer 12 is shown in more details in Figure 3.
  • the dryer 12 comprises two 20 m long, 3m diameter co-axial rotary kilns 12a, 12b in fluid communication with one another.
  • the dryer 12 is operated as if it were a single rotary kiln, the dual configuration of the rotary kilns 12a, 12b being arranged merely to facilitate control of operating conditions within each rotary kiln 12a, 12b and ensure safe operating conditions.
  • the rotary kilns 12a, 12b are disposed on an angle of 0-10°, preferably 2-5° above the horizontal which facilitates passage of the carbonaceous material feed stream therethrough by gravity.
  • Each rotary kiln 12a, 12b is rotated via its own gearbox and motor.
  • the dryer running gear has a temperature transmitter and a local temperature indicator to the monitor lubricant temperature to ensure the bearings operate properly.
  • each rotary kiln 12a, 12b there is a temperature indicator and temperature transmitter PLC instrumentation.
  • the dried carbonaceous material feed stream exiting each rotary kiln 12a, 12b of the dryer 12 is monitored to ensure that the temperature of the dried carbonaceous material feed stream does not increase more than 10 0 C per second, which would indicate imminent spontaneous combustion.
  • a rapid temperature rise means are provided for water to be sprayed on the dried carbonaceous material feed stream. Explosion flaps are also provided at each transfer box to vent the dryer 12 should the internal pressure exceed 2OkPa (g) .
  • Each co-axial rotary kiln 12a, 12b houses an internal tube 20a, 20b having a diameter of 1.5m and 1.8 m, respectively.
  • the external diameter of each co-axial rotary kiln 12a, 12b is about 3 m.
  • the internal tubes 20a, 20b are provided with a thick wall to withstand high temperature conditions. For example, the strength of steel at 65O 0 C is approximately 30% of its original strength at ambient temperature. Thus the internal tubes 20a, 20b are provided with the thick wall to prevent creep in the steel at temperatures of 65O 0 C and above .
  • the co-axial rotary kilns 12a, 12b are configured to receive the carbonaceous material feed stream in an outer passage 22 between an outer shell of the co-axial rotary kilns 12a, 12b and the internal tubes 20a, 20b.
  • the carbonaceous material feed stream is fed into the outer passage in rotary kiln 12a by a screw conveyor (not shown) .
  • the carbonaceous material feed stream then travels through the outer passage 22 of rotary kiln 12a.
  • Typical residence time of the carbonaceous material feed stream in the rotary- kilns 12b, 12a is about 30 minutes.
  • the carbonaceous material feed stream is heated so that the temperature of the carbonaceous material feed stream progressively increases from ambient temperatures to between 100-400 0 C, under which temperature conditions the carbonaceous material feed stream is dried. At temperatures >100°C low temperature devolatilisation commences. Volatile matter is thus evolved from the carbonaceous material feed stream in the dryer 12.
  • the carbonaceous material feed stream is heated to temperatures of about 100°C-400°C by a counter current flow of a gas stream with low oxygen content at temperatures of 400 0 C to 900 0 C, preferably 600 0 C to 800 0 C.
  • the volatile matter evolved in the dryer 12 mixes with the gas stream in the outer passage 22 and is directed in a counter current flow relative to the carbonaceous feed stream.
  • Tar and other organic compounds contained in the volatile matter coat the particles of the carbonaceous material in the dryer 10-, plugging the micropores of the particles, thereby passivating the particles against spontaneous combustion.
  • the gas stream has a low oxygen (0-5% O 2 v/v) , high moisture (up to 50% moisture) content.
  • the gas stream is generated from an external burner 30 and fed to the outer passage 22 of the rotary kiln 12a via conduit 28, and then from the outer passage 22 of rotary kiln 12a to the outer passage 22 of rotary kiln 12b.
  • the gas stream flows at approximately at 33 m 3 /s i.e. 37500 kg/h.
  • the heat load capacity of the external burner 30 is selected according to the moisture content of the carbonaceous material feed stream. In, this particular embodiment the heat load of the external burner 30 is about 18 -20MW.
  • the external burner 30 may be fuelled by LPG combustion, and/or pulverised coal can be conveyed into the combustion chamber thereof, where it mixes with preheated secondary combustion air and combustion takes place. Later in the process, it will be understood that coal gas generated during devolatilisation of the carbonaceous material feed stream can be diverted and fed to the external burner 30 and combusted for heating purposes as a replacement fuel for LPG or PCI.
  • the gas stream with a low oxygen content is supplied to the external passages 22b, 22a of the rotary kilns 12a, 12b and comprises the hot combustion gases produced by the external burner 30.
  • the hot combustion gases pass through a heat exchanger 32 which transfers some of the heat to ambient air to produce a hot air stream.
  • the ambient air that is passed through the heat exchanger 32 is supplied by two fans, a Variable Speed Drive (VSD) fan and a soft start fan.
  • VSD Variable Speed Drive
  • the hot air stream leaves the heat exchanger at 650 0 C and a flow rate of 33m 3 /s through a conduit 26 which is typically a 1.5m diameter stainless steel duct.
  • Conduit 26 is provided with a butterfly valve to bleed off excess hot air.
  • the hot combustion gases leaves the heat exchanger 32 at 400°C-800°C, typically 650 0 C, at a flow rate of 33m 3 /s.
  • the hot combustion gases travel through conduit 28 which is typically a 1.8m diameter refractory lined steel pipe.
  • a refractory lining is used to protect the pipe because the hot combustion gas is low in oxygen content and could potentially decarbonise the steel.
  • the hot combustion gas tends to cool as it traverses the external passage 22 of the dryer 12 in counter current flow to the carbonaceous material feed stream by virtue of gas- solid heat exchange.
  • the hot air stream produced by heat exchanger 32 is fed simultaneously to the internal tubes 20a, 20b of the dryer 12 via conduit 26.
  • the hot air stream is 400 0 C to 800 0 C, preferably about 600°C-700°C, and flows at 33m 3 /s through the internal tubes 20a, 20b in the same direction as the hot combustion gas.
  • One portion of the hot air stream is fed into the internal tube 20a of the rotary kiln 12a and the other portion of the hot air stream is fed into the internal tube 20b of the rotary kiln 12b.
  • the dryer 12 is externally heated and oxygen is substantially excluded from contact with the carbonaceous material feed stream and the dried carbonaceous material feed stream produced in the dryer 12.
  • Fine dried coal particles (approximately -2mm) are entrained in the hot combustion gas and exit the dryer 12 with this gas through conduit 36.
  • the hot inert gas and fine dried coal particles are separated after leaving the dryer 12 with a plurality of cyclones (not shown) .
  • the cyclones have two induced draft fans, a VSD fan and a soft start fan.
  • the fine dried coal particles are removed and stored in a fine coal bin, and can be subsequently briquetted in accordance with a briquetting process described in WO2004/072212.
  • the separated combustion gas is now warm, humid and corrosive. After passing through the cyclones the hot combustion gas travels to two heat recovery regenerators where trace amounts of volatile materials are thermally destroyed in an oxidising environment. These after burners are designed so that around 70% of the heat used in the combustion of these volatiles is regenerated; the remaining heat comes from the air blown through' the heat exchanger that arrives at about 650 0 C.
  • the combustion gas then flows to a scrubber by two scrubber fans, a VSD fan and a soft start fan.
  • the scrubber is chemically active towards acidic gases, in particular SO x , NO x , and PO x . Thickened sludge flows out of the bottom of the scrubber which is sent to the tailings pond .
  • the dried carbonaceous material feed stream can be cooled, stockpiled and stored, or it can undergo further pyrolysis.
  • the dried carbonaceous material feed stream is ⁇ transferred from the dryer 12 by a conveyor 16 which takes the dried coal feed stream to a further two conveyors .
  • the dried coal feed stream travels at a " nominal 100 tph along the conveyors to a coal holding bin 54 disposed above a cooler 50, such as, for example, a multi hearth fluidised bed cooler.
  • Each of the conveyors is provided with temperature transmitters to monitor the temperature of the dried carbonaceous material feed stream.
  • the coal holding bin 54 disposed above the cooler 50 there are local instruments consisting of a low level switch and a high level switch.
  • the PLC instruments include a level high alarm, a high level sensor and a low level sensor.
  • the dried carbonaceous material feed stream is then fed into the cooler 50 by a screw conveyor 56.
  • the dried carbonaceous material typically dried low rank coals
  • the dried carbonaceous material are then cooled by mixing the dried carbonaceous material with ambient particulate matter, preferably wet screened coal to produce a solid-solid heat exchange between the two materials.
  • ambient particulate matter preferably wet screened coal
  • the inherent heat of the dried carbonaceous material is not only transferred to the particulate matter to facilitate thermal equilibrium, but the thermal energy of the dried carbonaceous material is also utilized to dry the particulate matter and therefore facilitate moisture equilibrium.
  • Cool inert gas typically comprising N 2 , CO 2 , and Ar,. is also blown through the fluidised bed cooler to help bring the mixed materials to thermal and moisture equilibrium.
  • the mixed carbonaceous material is eventually discharged onto a conveyor at a nominal rate of 100 tph, and transported to stockpiling.
  • the cool inert gas which has circulated through the cooler is then passed through six Im diameter cyclones to remove fine coal particles (-2mm) entrained in the cool inert gas.
  • the fine coal particles are stored and then transported in a pneumatic conveyor.
  • the de-dusted air is returned as exhaust to the atmosphere via a bag house.
  • the dried carbonaceous feed material produced in the dryer 12 may undergo further devolatilisation, such as medium temperature carbonization, to produce passivated char.
  • the dried carbonaceous material feed stream is fed from the dryer 12 by a screw conveyor 16 onto one or more pneumatic conveyors 18.
  • the dried carbonaceous material feed stream is already heated to 100- 400 0 C, which reduces the heating load required during carbonization and improves thermal efficiencies in the system.
  • the dried carbonaceous material feed stream is transported by the pneumatic conveyor (s) 18 in a substantially oxygen free atmosphere (0-5% O 2 ) composed mostly of N 2 , CO 2 , and Ar with traces of CO, H 2 and CH 4 , at a temperature of 100 0 C - 500 0 C, typically 300 0 C.
  • the inert gas is pressurized via a compressor before being heated.
  • the transport fans exert high pressures on both the inlet and the outlet of the pneumatic conveyor so as only to overcome any pressure drops associated with transport of the dried carbonaceous material feed stream, line losses, cyclones and multi-clones .
  • Dried carbonaceous material feed stream is then fed into a large cyclone 34 disposed above a pyrolyser 40, in this instance a multi-hearth furnace 40.
  • the feed rate of dried carbonaceous material into the pneumatic transport system is controlled by the pressure drop across the cyclone 34.
  • the inert gas is re-circulated at 20 m/s through the system except in the portion of the system immediately before the cyclone 34 where the flow rate is 12 m/s.
  • the cyclone 34 removes particles -1.5mm thus preventing fine particles being fed to the pyrolyser 40.
  • the separated inert gas is recirculated and the fines are fed to either the external burner 30 or to a briquette plant.
  • one or more multi -hearth furnaces 40 are employed as the pyrolyser.
  • the hot dried carbonaceous material feed stream cascades down through the multi-hearth furnace 40 against a counter current flow of hot gases which rise to the top of the multi -hearth furnace 40.
  • the hot gases comprise coal gas evolved from the devolatilised carbonaceous material feed stream (i.e. volatile matter) , combustion product gas arising from instances of combustion ' of the carbonaceous material feed stream that occur in the multi-hearth furnace 40, and hot inert gases fed from the external burner 30 by conduit 38.
  • the hot inert gases are preheated in the external burner 30 to 650 0 C before being delivered to the multi-hearth furnace 40. However, the majority of the heat for carbonisation will be derived from the combustion of coal gas in the external burner 30.
  • the dried carbonaceous material feed stream cascades down through each of the hearths in counter current flow with a- stream of gas with a low oxygen content of less than 5% and preferably less than 1% comprising hot combustion fuel gases generated in each of the hearths and/or an external burner.
  • the dried carbonaceous material feed stream thermally decomposes to form char and a gas product stream containing volatile matter.
  • the gas product stream mixes with the hot combustion fuel gases and is directed in a counter current flow through the multi-hearth furnace.
  • volatile matter contained in the gas product stream is brought into contact with the dried carbonaceous material feed stream immediately prior to its ingress to the multi- hearth furnace, as described above, and additionally as the dried carbonaceous material feed stream cascades through the multi -hearth furnace and undergoes carbonization.
  • Hydrophobic species in the volatile matter coat the particles in the dried carbonaceous- material feed stream, plug the micropores of the dried particles as described above, and passivate the particles of dried . carbonaceous material against adsorption of water and oxygen, and thus spontaneous combustion.
  • the dried carbonaceous material feed stream traverses the multi-hearth furnace 40, the dried carbonaceous material feed stream is heated to temperatures of about 600°C-850°C by a counter current flow of hot gases as described above, at which temperatures the dried carbonaceous material feed stream is carbonized and converted to char.
  • Volatile matter is also evolved from the dried carbonaceous material feed stream at these temperatures.
  • the volatile matter mixes with the hot gases and is subsequently directed in a counter current flow against the dried carbonaceous material feed stream.
  • the volatile matter coats the dried particles, plugging the micropores, and reducing the absorption of water and oxygen.
  • the tar and the particles undergo pyrolysis. Pyrolytic rupture of functional groups attached to aromatic and hydro-aromatic units of the coal particle structure leads to the release of low molecular weight, reactive, free radicals (fragments) and stabilisation of the former fragment sites by hydrogen.
  • hydrophilic polar- functional groups are removed from the coal particles and replaced by hydrophobic aromatic coating.
  • this process can produce a passivated carbonaceous material with similar properties to a reduced sulphur, pseudo-bituminous coal from low rank coal.
  • the passivated carbonaceous material may be as chemically stable as any other naturally occurring bituminous coal.
  • the tar coating mobilises and in the subsequent pyrolysis phase the tar provides the hydrogen used to stabilise more radical sites on the coal particle thus producing a passivated char with similar properties to a reduced sulphur, pseudo anthracite coal.
  • the mixed coal and combustion gases produced and used in the multi -hearth furnace can be processed in several ways including but not limited to combustion to produce electricity, or used to make fertilizer. Additionally, as described above, the coal gas can be used as an alternative fuel source for the external burner 30. Regardless of the method of gas utilization, there is provided a safe and environmentally acceptable method of flaring the mixed gases generated in the multi-hearth furnace .
  • the passivated char exits the multi-hearth furnace and can be quenched by water and cool inert gas in a manner well known to a person skilled in the art, including using a multi- hearth cooler 50 as described above, before being cooled to ambient temperature, stockpiled and loaded out.
  • the passivated char produced in the pyroliser is at greater temperatures than the passivated dried carbonaceous material produced in the dryer 12.
  • liquid water is not introduced to the cooler 50 as a quenching medium until the temperature of the passivated char is below 200 0 C.
  • the passivated char produced by the above described process from the above described coal feedstock has approximately the following composition by weight: 81.3% fixed carbon, 11.9% ash, 2% moisture, and 5% volatile matter.
  • the hot passivated char is blended with wet screened coal of the above described composition to produce a blended carbonaceous material with the following composition by weight: 64.8% fixed carbon, 9.2% ash, 10% moisture, and 14.7% volatile matter.
  • the process 10 of the present invention can also be conducted under conditions wherein the carbonaceous feed material undergoes high temperature carbonisation, as described in the following example.
  • coal in the fluidised bed dryer is heated with a flow (28,500 kg/h) of waste gas containing 1.6% (m/m) O 2 at temperatures of 800 0 C produced in a 10 MW burner.
  • the coal feed stream has a residence time of 9 to 10 minutes in the dryer.
  • the last cell of the dryer is heated by the off gas generated from the pyrolising means in this system.
  • Hot (150 0 C) dry coal is fed to a 13.2-m long refractory lined carboniser via a gas lock feeder.
  • the dried coal is heated to 1,300 0 C.
  • These high temperatures are generated by feeding hot air (800 0 C) to the carboniser which combusts with some of the coal gas evolved during pyrolisis.
  • the coal gas flows in a counter-current direction to the flow of the coal/char feed stream.
  • the total residence time of the char feed stream held above 900 0 C is between 11 and 12 minutes. Approximately 24,500 kg/h of dry char is produced. Excess coal gas and combustion gases are collected.
  • the carboniser feeds three 9.9-m long refractory lined coolers which depress the char temperature from 1,300 0 C to less than 500 0 C. These coolers are fed a counter-current flow of coal inert gas. The quenched char is then fed to a further six steel refractory coolers which reduce the gas temperature to below 70 0 C. The moisture content of the char is raised to about 6% to suppress dust.
  • the above-described high temperature carbonisation system has a nominal capacity of 190,000 tpa of passivated char with 6% moisture, 2% volatile matter content.
  • Collie coal with 24% moisture, was pre-dried in an oven under nitrogen at 120 0 C. This coal was then heated at 5°C/min until it reached 300 0 C. The mass lost was 0.6% and the equilibrium moisture was 6.5%. The same dried coal was placed in an oven for 10 minutes at 400 0 C. The resulting mass loss was 2.6% and the equilibrium moisture was 4.5%.
  • the feed coal typically has an equilibrium moisture of about 13%.
  • the overall yield was 65.6% on wet basis or 82.8% yield on dry basis.
  • the increase in specific energy was 28.8% and the reduction in sulfur was 215%.
  • the drying and carbonization energy was 15.5% of total energy throughput.
  • the overall yield was 57.1% on wet basis or 65.7% yield on dry basis.
  • the increase in specific energy was 53% and the reduction in sulfur was 37%.
  • the drying and carbonization energy was 12.6% of total energy throughput.
  • coal gas containing volatile matter is also burnt outside the carboniser to provide heat for the process.
  • the process can use a variety of feed stocks but in particular it is readily suited to removing oxygen and organic sulphur from lignite, sub-bituminous and bituminous coals .
  • Drier, pneumatic transport and coal gases are separated where possible and are controlled in terms of temperature, flow and pressure independently
  • the process is not equipment limited as it could employ fluidised beds, multi-hearth furnaces or rotary kilns or a combination of these unit operations.
  • the activity of the tarry material in the coal gas is greatly increased by pre-drying the coal and not combining this drier gas with the carbonizing gas. Thus the effect of moisture stabilization can occur at lower temperature if there is a pre-drying step due to less coal gas being required.
  • the process of the present invention can be applied to other heat sensitive, flammable substances, for example thermal desorption of activated carbon or even contaminated soil .

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Solid Fuels And Fuel-Associated Substances (AREA)
  • Carbon And Carbon Compounds (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)

Abstract

L'invention concerne un procédé, un système et un appareillage servant à passiver une matière carbonée contre la combustion spontanée. Le procédé consiste à sécher la matière carbonée dans un environnement à faible teneur en oxygène et à prétraiter la matière carbonée en la mettant en contact avec une matière volatile contenue dans un courant de gaz à contre-courant. La matière volatile recouvre les particules de matière carbonée séchée et bouche les micropores de la matière carbonée séchée, ce par quoi elle la passive contre l'adsorption d'eau et d'oxygène et donc contre la combustion spontanée. La matière séchée prétraitée subit ensuite un dégazage à des températures auxquelles la matière volatile se dégage. La matière volatile dégagée se mélange au courant de gaz à contre-courant et est utilisée pour prétraiter la matière carbonée séchée située en amont.
PCT/AU2006/001604 2005-10-26 2006-10-26 Procédé, système et appareillage servant à passiver des matières carbonées WO2007048198A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US12/091,503 US20090217574A1 (en) 2005-10-26 2006-10-26 Process, system and apparatus for passivating carbonaceous materials
EP06790435A EP1951849A4 (fr) 2005-10-26 2006-10-26 Procédé, système et appareillage servant à passiver des matières carbonées
BRPI0618018-3A BRPI0618018A2 (pt) 2005-10-26 2006-10-26 processo e sistema para a preparação de um material carbonáceo apassivado, processos para reduzir umidade inerente e/ou aumentar uma energia especìfica de um material carbonáceo, para aperfeiçoar as caracterìsticas de coqueificação de material carbonáceo não-coqueificado, para resfriar bruscamente carbonizado apassivado quente e aparelho para apassivar material carbonáceo
EA200801191A EA200801191A1 (ru) 2005-10-26 2006-10-26 Способ, система и установка для пассивирования углеродсодержащих материалов
AU2006308519A AU2006308519A1 (en) 2005-10-26 2006-10-26 Process, system and apparatus for passivating carbonaceous materials

Applications Claiming Priority (4)

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AU2005905934A AU2005905934A0 (en) 2005-10-26 Process and/or apparatus for reducing the inherent moisture content and raising the specific energy of a carbon based particulate substance
AU2005905934 2005-10-26
AU2005906808 2005-12-05
AU2005906808A AU2005906808A0 (en) 2005-12-05 Process, system and apparatus for passivating carbonaceous materials

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CN101985559B (zh) * 2010-08-19 2011-08-17 西峡龙成特种材料有限公司 电热式粉煤分解设备
US10011792B2 (en) * 2010-08-16 2018-07-03 Nikhil Manubhai Patel Sandwich gasification process for high-efficiency conversion of carbonaceous fuels to clean syngas with zero residual carbon discharge
FR2985735B1 (fr) * 2012-01-18 2014-09-12 Cirad Carburant solide sous forme d'une poudre comprenant un constituant lignocellulosique
CA2896621A1 (fr) 2013-01-09 2014-07-17 C2O Technologies, Llc Procede pour le traitement de charbon pour ameliorer la recuperation de liquides issus du charbon condensables
JP6017366B2 (ja) * 2013-04-16 2016-10-26 株式会社神戸製鋼所 無灰炭の製造方法
EP2843032A1 (fr) * 2013-09-02 2015-03-04 Kunimichi Sato Procédé d'augmentation de la valeur calorifique de charbons maigres
CN104119981B (zh) * 2014-07-03 2017-02-01 广东电网公司电力科学研究院 一种采用有机复合阻燃剂防止煤堆自燃的方法
AU2014409609B2 (en) 2014-10-23 2018-11-29 Thiessen Jr, Lavoy M. Rotating and movable bed gasifier producing high carbon char
KR101755396B1 (ko) * 2015-12-10 2017-07-11 주식회사 포스코 탄재 개질 방법 및 그 장치
JP7325948B2 (ja) * 2018-11-21 2023-08-15 三菱重工業株式会社 微粉炭機の微粉炭乾燥システム及びその微粉炭乾燥方法並びに微粉炭乾燥プログラム、微粉炭機、ガス化複合発電設備
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EP1951849A1 (fr) 2008-08-06
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US20090217574A1 (en) 2009-09-03
EA200801191A1 (ru) 2009-02-27
EP1951849A4 (fr) 2010-05-26

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