2014 Volume 54 Issue 11 Pages 2439-2445
The present study focuses on examining the fate of coal-S and coal-N during carbonization in detail and making clear the effects of these elements on coal fluidity and coke strength. When eight kinds of caking coals with 80–88 mass%-daf C are carbonized in high-purity He at 3°C/min up to 1000°C with a quartz-made fixed bed reactor, 50–75% of coal-S remains as FeS and organic-S in the coke, and the rest is released as tar-S and H2S. Most of coal-N is also retained in the coke, and the remainder is converted to tar-N, HCN, NH3 and N2. The eight coals give Gieseler maximum fluidity values between 435 and 480°C, and the value tends to be larger at a smaller sulfur content in coal or in the carbonaceous material recovered after carbonization at 450°C. It also seems that the value increases with increasing nitrogen content in coal or total amount of either HCN or NH3 formed up to 450°C. Furthermore, the addition of S-containing compounds to an Australian bituminous coal lowers coal fluidity and coke strength considerably, whereas indole gives the reverse effect on them. On the basis of these results, it is suggested that coal-S or some coal-N has a negative or positive effect on the two properties, respectively.
When caking coal is fed into a coke oven, the softening and swelling occur around 400–500°C, and the resulting carbonaceous materials are subsequently resolidified to provide coke. It has been well-accepted that the degree of softening and swelling is one of the crucial factors determining the physicochemical properties (e.g., strength and reactivity) of the coke formed. The thermoplastic behavior of coal particles during carbonization has thus been studied extensively with several types of analysis techniques and different kinds of coals.1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16) Some researchers exhibit that coal thermoplasticity depends strongly on the amounts of chloroform solubles naturally-present in coal,1,4,6) low-molecular-weight compounds (metaplasts)2,3) and/or transferable hydrogen7,10) formed upon carbonization. It has also been reported that the sulfur and nitrogen present in coal, denoted as coal-S and coal-N, respectively, affect coal fluidity,17,18,19,20) and that the addition of denzo-[c]-acridine (C17H11N) to a coal blend, even at a small amount of 3 mass%, enhances the tensile strength of the coke after carbonization by a factor of about 1.2.21) It is of interest to investigate the influences of S and N elements on coal fluidity and coke strength in more detail. In the present paper, therefore, we first examine the fate of coal-S and coal-N during carbonization of several caking coals with different carbon contents, then investigate the effect of addition of some S- or N-containing compounds on coal fluidity and follow the change in the tensile strength of the coke produced.
Eight kinds of caking coals with size fraction of less than 215 μm were used in the present study. The as-received sample was stored in a N2-filled plastic bag kept in a freezer to avoid air oxidation in coal storage. The ultimate and proximate analyses are given in Table 1, where Al, Si, Ca and Fe contents of all coals are also shown, and Na, Mg and K are excluded because of trace amounts. The C, S and N contents in the eight samples ranged 80–88, 0.55–1.8 and 1.2–2.3 mass% on a dry, ash-free basis (daf), respectively.
Coal | Countrya | Ultimate analysis (mass%-daf) | Proximate analysis (mass%-dry) | Metal content (mass%-dry) | |||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
C | H | S | N | Ob | Ash | VMc | FCb, d | Al | Si | Ca | Fe | ||
LL | AUS | 79.9 | 5.7 | 0.57 | 2.1 | 11.7 | 9.2 | 35.2 | 55.6 | 0.63 | 3.0 | 0.14 | 0.25 |
RW | AUS | 81.8 | 5.8 | 0.65 | 2.0 | 9.8 | 8.7 | 37.1 | 54.2 | 0.84 | 2.4 | 0.16 | 0.30 |
GY | AUS | 82.8 | 5.6 | 0.70 | 2.3 | 8.6 | 7.6 | 31.8 | 60.6 | 0.97 | 2.3 | 0.04 | 0.17 |
NW | NZL | 83.5 | 5.3 | 1.8 | 1.2 | 8.2 | 3.1 | 30.8 | 66.1 | 0.57 | 0.72 | 0.06 | 0.19 |
GA | AUS | 85.6 | 5.3 | 0.62 | 2.0 | 6.5 | 8.5 | 25.4 | 66.1 | 1.1 | 2.4 | 0.01 | 0.30 |
TR | USA | 86.4 | 5.2 | 1.4 | 1.6 | 5.4 | 8.5 | 23.8 | 67.7 | 0.96 | 2.2 | 0.03 | 0.52 |
SI | AUS | 87.3 | 4.9 | 0.75 | 2.0 | 5.0 | 10.2 | 18.4 | 71.4 | 1.9 | 2.7 | 0.05 | 0.33 |
GC | AUS | 87.5 | 4.9 | 0.55 | 2.1 | 4.9 | 9.4 | 19.0 | 71.6 | 1.1 | 2.3 | 0.08 | 0.61 |
aAUS, Australia; NZL, New Zealand; USA, United States of America. bEstimated by difference.
cVM, volatile matter. dFC, fixed carbon.
To investigate the effects of sulfur and nitrogen on coal fluidity, a mixture of RW coal and a S- or N-containing compound was prepared by the impregnation method. The procedure has been reported in detail elsewhere19) and is thus simply explained below. Two inorganic sulfur, three organic sulfur and six organic nitrogen compounds were selected according to earlier studies on S- and N-functional forms in coal.22,23,24,25,26,27,28) Each compound was added to RW coal by mixing in benzene at room temperature, followed by dryness under vacuum at 38°C. As reported previously,19) the influence of the impregnation in benzene on coal fluidity was negligibly small. The S or N loading in the dried sample was 1.0 mass%, unless otherwise stated.
2.3. CarbonizationAll runs were performed with a quartz-made fixed bed reactor. The details of the apparatus have been described elsewhere.29) In a typical experiment, about 0.50 g of the as-received coal was first charged into a rectangular quartz cell on a quartz holder in the reactor. After prudent precautions against leakage, the reactor was then heated electrically at 3°C/min up to 350–1000°C in a stream of high-purity He (> 99.99995%) and finally quenched to ambient temperature. The temperature was measured with a thermocouple (Ni/Cr:Ni/Al) inserted at the bottom of the cell.
2.4. Sulfur and Nitrogen AnalysisCarbonization products were separated into gas, tar and coke (or semicoke) in the same manner as reported previously.29) With the gas, H2S was analyzed at intervals of 50°C by the Gastec standard detector tube. On the other hand, N2 was determined online at 13°C intervals with a high-speed micro-gas chromatograph, and HCN and NH3 were measured at 9°C intervals with a photoacoustic multi-gas monitor. The reproducibility was within ± 3% for H2S, ± 2% for N2 and ± 4% for HCN or NH3. Although CS2 and COS were also analyzed by the Gastec standard tube, no appreciable amounts of them were detectable in all cases. The S and N in the tar, denoted as tar-S and tar-N, respectively, were determined with separate combustion-type analyzers. These elements in the coke (coke-S and coke-N) were also measured with conventional elemental analyzers. The reproducibility of the tar-S, tar-N, coke-S or coke-N measurement was within ± 3, ± 5, ± 2 or ± 2%, respectively.
The modes of occurrence of coal- and coke-S were investigated by the ASTM D 2492 method and Gladfelter-Dickerhoof technique,30) whereas coal- and coke-N functionalities were determined by the N 1s X-ray photoelectron spectroscopy (XPS) method. The detailed procedure for each analysis has been described in the previous paper.31,32)
2.5. Fluidity MeasurementThe fluidity analyses of the as-received coal and mixture of RW coal and S- or N-containing compound were carried out according to the constant-torque Gieseler plastometer method (JIS M 8801).20) In the experiments, about 4.5 g of the sample charged into a stainless steel crucible was placed into a lead solder bath in a plastometer, then heated at 3°C/min from 270 to 500–550°C in laboratory air and finally quenched to ambient temperature. Every sample was stirred at a constant torque during heating, and the fluidity was recorded in dial divisions per minute (ddpm) against temperature.
2.6. Tensile Strength AnalysisThe strength measurements of coke samples were conducted with a conventional automatic extensometer employing the indirect tensile mthod.33,34) About 40 g of RW coal without and with benzothiophene or indole added was first carbonized in a flow of N2 at 1000°C for 30 min, and the resulting sample was cut into three cylindrically-shaped pellets (13 mm diameter, 9 mm thickness) and then supplied to the extensometer. Each strength data observed was subjected to the Weibull analysis, and the value at the Weibull failure probability of 63.2% was taken as the coke strength throughout the present paper.
Figure 1 shows the temperature dependency of sulfur distribution during carbonization of all coals used. Since sulfate (SO42–) and sulfite (SO32–) minerals were approximately 1–2% of total sulfur in feed coal, such data were not shown. Sulfur mass balances for all runs fell within the reasonable range of 95–105%. At 200–350°C, as seen in Fig. 1, more than 90% of coal-S was retained as pyrite (FeS2) and organic-S in solid phase, irrespective of the kind of coal, and most of the rest was released as tar-S. Small amounts of hydrogen sulfide (H2S) were also observed with LL, RW, GY, NW and TR coals. When the temperature was increased from 350 to 650°C, the almost complete transformation of FeS2 into pyrrhotite (FeS) and the significant decrease in organic-S took place with many coals, and the formation of H2S and tar-S became more remarkable. Part of the H2S observed may be formed via the reaction (Eq. (1)) of FeS2 with H2 evolved during carbonization.
(1) |
Temperature change in sulfur distribution during carbonization of coals examined.
Figure 2 presents the temperature dependency of nitrogen distribution under the same experimental conditions as in Fig. 1. The nitrogen mass balance was in the reasonable range of 95–105% in every case. Tar-N was the only N species evolved below 350°C, regardless of the type of coal, indicating that tar-N is a primary volatile product under the present conditions. When the temperature was raised from 350 to 650°C, not only tar-N but also HCN, NH3 and N2 were formed, and the extent of the formation tended to be larger at a higher temperature in all cases. It has been reported that HCN come from secondary decomposition reactions of tar-N,27,36,37,38) and that a larger degree of secondary reactions between volatiles and char leads to higher conversion of HCN to NH3.37,38) As seen in Fig. 2, NH3 was the predominant product among N species evolved at 350–650°C for all coals, suggesting the significance of secondary reactions of volatile nitrogen (tar-N, HCN and NH3) under the conditions applied. Some of the N2 produced may arise from HCN (Eq. (2)) and/or NH3 (Eq. (3)), because ΔG values for Eqs. (2) and (3) at 350–650°C are as small as –4.3 to –4.0 kcal/mol and –4.4 to –13 kcal/mol, respectively.
(2) |
(3) |
Temperature change in nitrogen distribution during carbonization of coals examined.
As provided in Fig. 2, about 60–80% of coal-N was retained in the 1000°C-cokes. It is of interest to evaluate coke-N functionality quantitatively. The N forms of the 1000°C-cokes estimated by the XPS method are summarized in Fig. 3, where those of the as-received raw coals are also given for comparison. Pyrrolic-N was the main N form, irrespective of the coal type, and the proportion was in the range of 50–60 mol%, followed by pyridinic-N in many cases. Quaternary-N also existed in all the coals in the range of 15–30 mol%. It has been proposed that the quaternary-N in coal can be assigned to pyridinic-N associated with the hydroxyl groups from phenols and/or carboxyl acids.28) When each coal was carbonized at 1000°C, as shown in Fig. 3, nitrogen functionality changed dramatically, and quaternary-N became the predominant form, the proportion being between 40 and 50 mol%. On the other hand, pyrrolic-N and pyridinic-N decreased considerably. Although oxidized-N was observed with all the cokes examined, this species might be formed during exposure to laboratory air for coke recovery from the reactor.41) According to earlier work about the XPS analysis using char samples after pyrolysis at 500–800°C of Argonne premium coals,42) it has been reported that the quaternary-N present in the samples differs from that proposed for coals, and it can be assigned to nitrogen atoms incorporated in the interior of the char matrix. It is thus possible that the N in the cokes shown in Fig. 3 may exist mainly in the interior of condensed aromatic structures.
Nitrogen functional forms of coal and 1000°C-coke samples estimated by XPS measurements.
Figure 4 illustrates Gieseler fluidity profiles for the as-received coals, and Table 2 summarizes the fluidity data for each sample. The coals started to soften at about 375–435°C, gave the maximum fluidity (MF) values between 435 and 480°C, and resolidified beyond 465–505°C. The MF value depended strongly on the kind of coal and ranged 13–13000 ddpm [1.1–4.1 log(ddpm)]. It should be noted that GY and NW coals give the highest and lowest values, respectively, in spite of containing the similar C contents (Table 1). In other words, the degree of coal fluidization had no distinct relationship with C%.
Gieseler fluidity profiles for eight coals investigated.
Coal | ISTa | MFTb | RSTc | MFd | |
---|---|---|---|---|---|
(°C) | (°C) | (°C) | (ddpm) | [log(ddpm)] | |
LL | 395 | 437 | 467 | 280 | 2.4 |
RW | 389 | 433 | 460 | 150 | 2.2 |
GY | 377 | 445 | 475 | 13000 | 4.1 |
NW | 418 | 456 | 480 | 13 | 1.1 |
GA | 413 | 460 | 502 | 670 | 2.8 |
TR | 380 | 461 | 500 | 1300 | 3.1 |
SI | 432 | 477 | 504 | 67 | 1.8 |
GC | 436 | 478 | 500 | 100 | 2.0 |
aInitial softening temperature. bMaximum fluidity temperature.
cResolidification temperature. dMaximum fluidity.
Figure 5 illustrates the MF value (Table 2) as a function of S content (S%) or N content (N%) in coal (Table 1). Although some data were scattered, the MF value tended to be larger at a lower S% (Fig. 5(a)) or at a higher N% (Fig. 5(b)). In addition, the value decreased with increasing content of the S remaining in the carbonaceous material recovered after carbonization at 450°C, whereas it tended to increase with increasing total amount of HCN or NH3 evolved up to this temperature, as recently reported.19,20) These observations suggest that sulfur or nitrogen has a negative or positive effect on coal fluidity, respectively. The next section thus focuses mainly on examining the effect of addition of S- or N-containing compounds on the fluidity.
Effect of sulfur (a) or nitrogen (b) content in coal on Gieseler maximum fluidity.
The results for the Gieseler fluidity analyses of RW samples with several types of S-containing compounds added are given in Table 3, where the choices of four S compounds, such as pyrite (FeS2), diphenyl disulfide (C12H10S2), benzothiophene (C8H6S) and dibenzothiophene (C12H8S), are made according to previous studies,22,23,24,25) and elemental sulfur is also used. The comparison of Tables 2 and 3 exhibited that the five S species impregnated with RW coal did not affect the initial softening, maximum fluidity and resolidification temperatures significantly, but they lowered the MF value considerably: the value decreased from the original 150 to 25–90 ddpm (Table 3). On the other hand, the S content in the carbonaceous material recovered after carbonization at 390°C increased from 0.69 mass%-daf without any S species added to 0.72–1.5 mass%-daf. It has been reported that the amount of transferable hydrogen formed during coal carbonization is one of the important factors determining MF value, and there is an almost linear correlation between the two.7,10) On the basis of this information, the decrease in the MF observed in Table 3 may be caused by the reaction of transferable hydrogen produced with each S compound added. If transferable hydrogen can be regarded as atomic hydrogen (H*) according to earlier work,7) the reactions with the five S species may be expressed as follows (Eqs. (4), (5), (6), (7), (8)):
(4) |
(5) |
(6) |
(7) |
(8) |
Sulfur compound | ISTa | MFTb | RSTc | MFd | |
---|---|---|---|---|---|
(°C) | (°C) | (°C) | (ddpm) | [log(ddpm)] | |
Elemental sulfur | 405 | 440 | 458 | 25 | 1.4 |
Pyrite (FeS2) | 405 | 440 | 461 | 25 | 1.4 |
Diphenyl disulfide (C12H10S2) | 395 | 436 | 457 | 70 | 1.8 |
Benzothiophene (C8H6S) | 397 | 439 | 466 | 90 | 2.0 |
Dibenzothiophene (C12H8S) | 397 | 436 | 463 | 90 | 2.0 |
aInitial softening temperature. bMaximum fluidity temperature.
cResolidification temperature. dMaximum fluidity.
Figure 6 presents the profiles for the fluidity of RW samples with N-containing compounds added. As seen in Fig. 6(a), pyrrole (C4H5N) or pyridine (C5H5N) mixed with RW coal did not affect the profile significantly. Such a trend were also observed with the mixture of RW and isoquinoline (C9H7N) (Fig. 6(b)), carbazole (C12H9N) (Fig. 6(c)) or phenanthroline (C12H8N2) (Fig. 6(c)). On the other hand, the addition of indole (C8 H7N) to the coal enhanced the fluidity remarkably, and the MF value increased from 150 ddpm without any additives to 400 ddpm (Fig. 6(b)). When indene (C9H8) was mixed with the coal, the value was approximately 250 ddpm, which was much smaller than that for the indole added coal. As is well-known, five-membered N-containing heterocycles, such as pyrrole, indole and carbazole, are π-electron rich aromatics, which have higher reactivity than π-electron deficient aromatics (e.g., pyridine, isoquinoline and phenanthroline) toward electrophilic substitution reactions. It has also been shown by the in situ 1H nuclear magnetic resonance (NMR) imaging analyses during heating that the proportion of mobile component present in coal increases gradually beyond 220–230°C, but it decreases steeply after the maximal value at about 450°C.43) It may be noteworthy that the former temperature is close to the boiling point (253°C) of indole. This similarity suggests that the externally added indole might play an important role in the formation of mobile component at the initial stage of coal carbonization. Further, the H atom attached to the N in indole as well as coal-derived transferable hydrogen might affect the transformation of immobile component into mobile component. A detailed mechanism for the indole-enhanced coal fluidity should be clarified in future work.
Gieseler fluidity profiles for RW samples with N-containing compounds added: (a) monocyclic, (b) bicyclic and (c) tricyclic aromatic compounds.
Figure 7 illustrates Weibull failure probability plots for the tensile strength of 1000°C-cokes from RW samples without and with benzothiophene or indole added. Although the data points are insufficient, it seems that the strength data of each sample investigated can fall on or around a straight line on the Weibull plot. In the absence of any additives, as provided in Fig. 7, the strength (η) value at the failure probability of 63.2% was estimated to be 3.9 MPa. As expected from the results in Table 3 and Fig. 6, the addition of benzothiophene and indole to RW coal changed the strength significantly: the former compound drastically decreased the η value from 3.9 to 1.6 MPa, whereas the latter one exhibited the reverse effect on the strength, and the η value reached about 6.0 MPa (Fig. 7). It is thus evident that the added benzothiophene or indole has a negative or positive effect on coke strength, respectively. The η value of the indene-added coal was ≤ 5.5 MPa.
Weibull failure probability plots for the tensile strength of 1000°C-cokes derived from RW coal without and with benzothiophene or indole added.
On the basis of the results described in section 3.4, it is suggested that most of coal-S lowers coal fluidity and coke strength, but contrarily part of coal-N can enhance the two properties. The results obtained in the present study may elucidate the fate of these elements in coke ovens, help us to understand the chemistry of coal fluidization, and contribute to the development of a novel technique of producing high-strength coke from low-rank coals and/or unused carbon resources.
Carbonization of eight caking coals with carbon contents of 80–88 mass%-daf has been studied with a quartz-made fixed bed reactor to make the fate of coal-S and coal-N clear and to investigate the influences of these elements on coal fluidity and coke strength. The principal conclusions are summarized as follows:
(1) When the coals are heated in high-purity He at 3°C/min up to 1000°C, more than half of coal-S and coal-N are retained in the coke, the remainder being released as tar, H2S, HCN, NH3 and N2.
(2) The coals provide 1.1–4.1 log(ddpm) of Gieseler maximum fluidity, and the value tends to be larger at a lower sulfur or higher nitrogen content in coal.
(3) The addition of S-containing compounds to an Australian bituminous coal lowers the maximum fluidity considerably, whereas indole shows the reverse effect on it.
(4) The tensile strength of the coke formed decreases significantly by benzothiophene addition, but contrarily it increases by indole addition, the increment factor at the Weibull failure probability of 63.2% being approximately 1.5.
(5) On the basis of the above results, it is suggested that coal-S and some coal-N have the reverse effects on the changes in coal fluidity and coke strength.
This work was carried out as a part of research activities - Development of Cokemaking Technology for Low-Quality Coals and Unused Carbon Resources - undertaken by the Iron and Steel Institute of Japan (ISIJ). The authors are indebted to Ms. Aya Amikura for her assistance in carrying out experiments.