the influence of specific gravity distributions on fuel properties
DESCRIPTION
The Influence of Specific Gravity Distributions on Fuel Properties. Pete Rozelle U.S. Department of Energy ARIPPA, October 31, 2006. The Influence of Specific Gravity Distributions on Fuel Properties. Ash Content Distributions in Coal Refuse by Specific Gravity - PowerPoint PPT PresentationTRANSCRIPT
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The Influence of Specific Gravity Distributions on Fuel Properties
Pete Rozelle
U.S. Department of Energy
ARIPPA, October 31, 2006
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The Influence of Specific Gravity Distributions on Fuel Properties
• Ash Content Distributions in Coal Refuse by Specific Gravity
• Distributions of Mineral and Ash Components
• Example of Using these Things to get a Cost Advantage for a CFB Power Plant
• Turning Bad Material into Useful Fuel (an Example)
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Attributes that Vary with Specific Gravity
• Ash Content
• Mineral Content
• Particle Density
• Ash Chemistry
• Ash Fusion Characteristics
• Where the Stuff Ends up in a CFB Boiler (Ash Split)
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The Math of Summing Fuel Properties - an Example Using Ash Content
Run of Mine Refuse Dump Cogen Fuel
250 Tons 750 Tons 1000 Tons
15% Ash
1.4% S
50% Ash
3.5% S
41.3% Ash
3.0% S
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The Math of Summing Fuel Properties - an Example Using Ash Content
Fraction Run of Mine
(M1)
Fraction Refuse Dump
(M1)
1 Mass of Cogen Fuel
iMCogenFuel
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The Math of Summing Fuel Properties - an Example Using Ash Content
Fraction Run of Mine X Ash Content of
Run of Mine
(M1A1)
Fraction Refuse Dump X Ash Content of
Refuse Dump
(M2A2)
Ash Content of Cogen Fuel
iiAMAshCogenFuel %_
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The Specific Gravity Distribution of Ash Content- the Float Sink Table
Direct Cumulative Float
Sink Float Wt% Ash% Sulfur% Wt% Ash% Sulfur%
1.30 25.12% 4.03% 1.19% 25.12% 4.03% 1.19%
1.30 1.40 36.29% 8.25% 1.46% 61.41% 6.52% 1.35%
1.40 1.50 7.66% 18.76% 2.26% 69.07% 7.88% 1.45%
1.50 1.60 2.70% 28.13% 3.24% 71.77% 8.64% 1.52%
1.60 28.23% 47.37% 5.33% 100.00% 19.57% 2.59%
B Seam Run of Mine, Cambria County, Pa
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The Specific Gravity Distribution of Ash Content- One Way to Look at it
B Seam Run of Mine, Cambria County, Pa
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
1.29 1.35 1.45 1.55 2.7
Mean Specific Gravity
Wt% Direct Wt%
CumulativeAsh%
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The Specific Gravity Distribution of Ash Content
B Seam Refuse Dump, From the ROM in the Last Slide
Direct Cumulative
Sink Float Wt% Ash% S% Wt% Ash% S%
1.40 15.9% 6.9% 1.4% 15.9% 6.9% 1.4%
1.40 1.50 2.5% 19.7% 3.3% 18.4% 8.6% 1.6%
1.50 1.60 2.4% 29.3% 2.9% 20.8% 11.0% 1.8%
1.60 1.70 3.6% 38.9% 2.2% 24.4% 15.1% 1.9%
1.70 1.80 6.9% 49.0% 1.5% 31.3% 22.6% 1.8%
1.80 2.00 17.7% 58.1% 1.6% 49.0% 35.4% 1.7%
2.00 51.0% 78.9% 5.0% 100.0% 57.6% 3.4%
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The Specific Gravity Distribution of Ash Content- One Way to Look at it
B Seam Refuse Dump, Cambria County, Pa
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
1.3 1.45 1.55 1.65 1.75 1.9 3.5
Direct Wt%
Cumulative Float Ash
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Float Sink Tables for Refuse Dumps
• The Good:– Deep Mined, Flat Coal
– Not Dense Medium Cleaned
– Old
• The Bad:– Newer
– Refuse Quality wasn’t under the Microscope
• The Ugly:– Surface Mining of Old Workings
– Pitched Coal
– Dense Medium Cleaning
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The Specific Gravity Distribution of Ash Content- The Good
B Seam Refuse Dump, Cambria County, Pa
Direct Cumulative
Sink Float Wt% Ash% S% Wt% Ash% S%
1.40 8.5% 6.5% 1.1% 8.5% 6.5% 1.1%
1.40 1.50 5.7% 21.8% 1.5% 14.2% 12.6% 1.2%
1.50 1.60 15.6% 31.2% 1.4% 29.7% 22.4% 1.3%
1.60 1.70 21.7% 39.6% 1.5% 51.5% 29.7% 1.4%
1.70 1.80 13.6% 47.9% 1.6% 65.0% 33.5% 1.4%
1.80 2.00 11.8% 55.3% 2.7% 76.8% 36.8% 1.6%
2.00 23.5% 67.2% 11.6% 100.3% 43.9% 4.0%
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The Specific Gravity Distribution of Ash Content- The Good
B Seam Refuse Dump, Cambria County, Pa
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
45.0%
50.0%
1.3 1.45 1.55 1.65 1.75 1.9 3.5
Direct Wt%
Cumulative Ash %
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The Specific Gravity Distribution of Ash Content- The Bad
Pittsburgh Seam Refuse Dump (Old)
Direct Cumulative
Sink Float Wt% Ash% S% Wt% Ash% S%
1.40 18.6% 9.2% 1.5% 18.6% 9.2% 1.5%
1.40 1.50 4.1% 21.3% 3.8% 22.7% 11.3% 1.9%
1.50 1.60 3.2% 27.7% 3.9% 25.9% 13.4% 2.2%
1.60 1.70 2.9% 37.5% 4.3% 28.7% 15.8% 2.4%
1.70 1.80 2.1% 43.1% 4.2% 30.9% 17.7% 2.5%
1.80 2.00 3.7% 52.8% 4.9% 34.6% 21.5% 2.8%
2.00 65.4% 86.2% 3.7% 100.0% 63.8% 3.4%
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The Specific Gravity Distribution of Ash Content- The Bad
Pittsburgh Seam Refuse Dump (Old)
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
1.35 1.45 1.55 1.65 0.175 1.9 2.5
Mean Specific Gravity
Wt%
Direct Wt%
Cumulative Wt%Ash
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The Specific Gravity Distribution of Ash Content- The Ugly
Anthracite Refuse (Active Mine in 1960’s)
Direct Cumulative
Sink Float Wt% Ash% S% Wt% Ash% S%
1.60 1.4% 9.4% 0.8% 1.4% 9.4% 0.8%
1.60 1.70 1.0% 26.4% 1.1% 2.4% 16.4% 0.9%
1.70 1.80 5.5% 37.3% 1.0% 7.9% 30.9% 1.0%
1.80 2.00 19.2% 49.7% 1.2% 27.1% 44.2% 1.1%
2.00 72.9% 81.3% 1.4% 100.0% 71.2% 1.3%
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The Specific Gravity Distribution of Ash Content- The Ugly
Anthracite Refuse (Active Mine in 1960’s)
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
1.55 1.65 1.75 1.9 2.8
Mean Specific Gravity
Wt% Direct Wt%
Cumulative Wt% Ash
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Minerals in Coal Waste
• Illite:
– K3(Al6FeMg)(Si14Al2)O40(OH)8
• Kaolinite
– Al2O3·2SiO2·2H2O
• Pyrophyllite
– Al2O3·2SiO2·H2O
• Pyrite
– FeS2
• Rutile
– TiO2
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Minerals in Coal WasteExample of Mineral Content Variations by
Specific Gravity- An Anthracite Bank
Wt% of Mineral Matter
Sink Float Wt% Illite KaolinitePyrophylliteKaolinite Quartz Pyrite Rutile
1.60 1.4% 26.8% 66.2% - 2.4% 1.3% 3.3%
1.60 2.00 12.7% 37.4% 49.4% - 9.2% 1.5% 2.5%
2.00 2.40 42.9% 39.9% 41.8% - 14.8% 1.9% 1.6%
2.40 2.60 32.8% 28.7% - 30.8% 36.7% 2.9% 0.9%
2.60 10.2% 45.1% - 38.4% 7.2% 8.3% 1.0%
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Minerals in Coal WastePittsburgh Seam Refuse- Specific Gravity Variations in Ash
AnalysisWt% of Ash
Sink Float Wt% Wt% Ash SiO2 Al2O3 Fe2O3 CaO MgO
1.4 17.0% 7.8% 58% 26% 12% 1.6% 0.1%
1.4 1.6 4.9% 17.7% 50% 18% 20% 2.7% 0.1%
1.6 1.8 5.9% 40.0% 42% 17% 16% 11.0% 1.5%
1.8 2 2.8% 50.7% 44% 17% 17% 11.0% 1.4%
2 2.2 2.7% 59.3% 51% 16% 21% 4.0% 0.1%
2.2 2.4 4.6% 69.6% 54% 19% 20% 4.0% 0.1%
2.4 2.6 10.7% 82.4% 61% 23% 12% 1.8% 0.1%
2.6 2.8 45.2% 88.7% 57% 22% 6% 1.7% 0.1%
2.8 2.96 1.6% 66.1% 24% 9% 60% 1.7% 0.0%
2.96 4.6% 61.3% 11% 2% 83% 1.2% 1.6%
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Minerals in Coal WasteAnthracite Refuse
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
1.5 1.7 1.9 2.1 2.3 3.5
Mean Specific Gravity
Wt% Direct Wt%
Cumulative Wt% Ash
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Minerals in Coal WasteAnthracite Refuse- Specific Gravity Variations in Ash
Analysis
Wt% of Ash
Sink Float Wt% Wt% Ash SiO2 Al2O3 Fe2O3 CaO MgO
1.6 4.9% 17.7% 54% 25% 11% 0.7% 0.1%
1.6 1.8 5.9% 40.0% 55% 24% 6% 0.3% 0.6%
1.8 2 2.8% 50.7% 55% 27% 6% 0.3% 0.1%
2 2.2 2.7% 59.3% 55% 24% 5% 0.3% 0.1%
2.2 2.4 4.6% 69.6% 55% 29% 4% 0.5% 0.1%
2.4 2.6 10.7% 82.4% 55% 28% 4% 0.7% 0.1%
2.6 2.8 45.2% 88.7% 55% 27% 6% 0.8% 0.1%
2.8 2.96 1.6% 66.1% 31% 13% 54% 2.8% 2.1%
2.96 4.6% 61.3% 12% 3% 75% 1.5% 1.7%
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Minerals in Coal WasteWest Virginia Refuse
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
1.35 1.5 1.7 1.9 2.1 3
Mean Specific Gravity
Wt% Direct Wt%
Cumulative Wt% Ash
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Minerals in Coal WastePittsburgh Seam Refuse- Specific Gravity Variations in Ash
AnalysisWt% of Ash
Sink Float Wt% Wt% Ash SiO2 Al2O3 Fe2O3 CaO MgO
1.4 17.0% 7.8% 50% 28% 17% 2.0% 0.1%
1.4 1.6 4.9% 17.7% 54% 26% 13% 1.4% 0.1%
1.6 1.8 5.9% 40.0% 55% 26% 11% 1.9% 0.1%
1.8 2 2.8% 50.7% 56% 25% 10% 1.2% 0.1%
2 2.2 2.7% 59.3% 57% 23% 7% 1.1% 0.1%
2.2 2.4 4.6% 69.6% 58% 25% 7% 0.6% 1.1%
2.4 2.6 10.7% 82.4% 56% 23% 6% 0.3% 1.5%
2.6 2.8 45.2% 88.7% 57% 24% 6% 0.2% 1.5%
2.8 2.96 1.6% 66.1% 26% 9% 52% 1.1% 0.5%
2.96 4.6% 61.3% 7% 2% 90% 0.4% 0.0%
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Mineral and Ash Analyses Vary with Specific Gravity- What about Fusion
Temperatures?Degrees F
Sink FloatWt%Ash
Initial Deformation Temperature
SofteningTemperature Fluid Temperature
1.45 1.7% 2,720 2,720 2,820
1.45 1.50 2.8% 2,890 2,910+ -
1.50 1.55 7.8% 2,910+ - -1.55 1.60 15.7% 2,360 2,410 2,460
1.60 1.65 16.2% 2,340 2,390 2,490
1.65 1.70 24.3% 2,250 2,300 2,350
1.70 1.75 26.7% 2,190 2,250 2,300
1.75 1.80 31.6% 2,210 2,260 2,310
1.80 1.85 34.5% 2,340 2,390 2,490
1.85 1.90 42.9% 2,520 2,570 2,700
1.90 69.7% 2,120 2,160 2,200
Anthracite
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An Example of Getting a Cost Advantage for a CFB Power Plant
• Not all Potential Fuel is Located Close to the Power Plant
• Low Quality Materials May not Make Sense to Truck Long Distances
• Improved Fuel Quality can:– Reduce Transportation Costs– Reduce Limestone requirements– Reduce Ash Disposal Costs– Increase Mean Bed Residence Time
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Economics of Waste Coal Reprocessing
)Y1(CY
)CC(C r
ofp
Cp Product Cost/tonCf Feedstock Cost/tonCo Plant Operating Cost/ton FeedCr Refuse Disposal Cost/ton
Y Plant Yield
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Example of the Effect of Product Quality on Production Cost
$-
$5.00
$10.00
$15.00
$20.00
$25.00
$30.00
$35.00
$40.00
15 20 25 30 35 40 45
Product Wt% Ash
Pro
duct
ion
Cos
t P
er T
on
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Effect of Fuel Quality on Tonnage Requirements (100 MW CFB Power Plant)
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
15 20 25 30 35 40 45
Fuel Wt% Ash
Ton
s pe
r Y
ear
FuelLimestoneAsh
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Fuel, Limestone, and Ash Costs for a 100 MW CFB Power Plant (Example)
$-
$2,000,000
$4,000,000
$6,000,000
$8,000,000
$10,000,000
$12,000,000
$14,000,000
15 20 25 30 35 40 45Fuel Wt% Ash
An
nu
al C
ost
Fuel Cost
Limestone Cost
Ash Cost
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Fuel, Limestone, Ash Total Cost for 100 MW CFB Power Plant (Example)
$-
$2,000,000
$4,000,000
$6,000,000
$8,000,000
$10,000,000
$12,000,000
$14,000,000
15 20 25 30 35 40 45
Fuel Wt% Ash
An
nu
al C
ost
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Fuel, Limestone, Ash Total Cost for 100 MW CFB Power Plant (Example)
$-
$2,000,000
$4,000,000
$6,000,000
$8,000,000
$10,000,000
$12,000,000
$14,000,000
15 20 25 30 35 40 45
Fuel Wt% Ash
An
nu
al C
ost
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Examples of the Application of Coal Preparation Vessels to Coal Refuse
• Dense Medium Cyclone- Commonwealth of Pennsylvania, 1960’s:– Feed Ash Content: 56 wt%– Cyclone Feed Gravity =1.80, Product = 20%
Yield, 38% Ash– Cyclone Feed Gravity = 1.90, Product = 28%
Yield, 42% Ash
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Examples of the Application of Coal Preparation Vessels to Coal Refuse
• Horsfall, Grobelaar, and Van Eck and Lurie (South Africa)– High Gravity Separations for Rerunning Coal
Refuse• Dense Medium Vessels
• Dense Medium Cyclones
• Other Systems
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Examples of the Application of Coal Preparation Vessels to Coal Refuse
• Water Only Cyclone- Penn State University– Feed: up to 30% Ash– Product at 30% Ash Feed = 20% Ash
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Potential Economics of Prepared Fuel from Low Quality Coal Refuse
• Simulation for the Following:– Coarse Coal Dense Medium Vessel (1.60 to 1.80
Gravity)– Dense Medium Cyclones (1.60-1.90 Feed Gravity)– Generic Process for Recovery of -28 Mesh
Material
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Potential Economics of Prepared Fuel from Low Quality Coal Refuse Dump
• Assumptions:– Royalty = $1.00/Raw Ton– Load and Carry Cost = $1.00/Raw Ton– Prep Plant Cost= $2.50/Raw Ton– Prep Plant refuse Cost = $0.50/Ton
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The Specific Gravity Distribution of Ash Content- The Bad
Pittsburgh Seam Refuse Dump (Old)
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
1.35 1.45 1.55 1.65 0.175 1.9 2.5
Mean Specific Gravity
Wt%
Direct Wt%
Cumulative Wt%Ash
64 Wt% Ash
3.3 Wt% S
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Potential Economics of Prepared Fuel from Low Quality Coal Refuse Dump (Pittsburgh)
• Results:– 24 Wt% Ash– 2.5 Wt% S– ~$0.72/MM BTU Production Cost
• Blended with Run of Bank (65/35) Yields:– 34 Wt% Ash– 2.8 Wt% S– ~$0.60/MM BTU Production Cost
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The Specific Gravity Distribution of Ash Content
B Seam Refuse Dump, Cambria County, Pa
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
1.3 1.45 1.55 1.65 1.75 1.9 3.5
Direct Wt%
Cumulative Float Ash
64 Wt% Ash
3.3 Wt% S
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Potential Economics of Prepared Fuel from Low Quality Coal Refuse Dump (B Seam)
• Results:– 30 Wt% Ash– 2.1 Wt% S– ~$0.62/MM BTU Production Cost
![Page 42: The Influence of Specific Gravity Distributions on Fuel Properties](https://reader030.vdocuments.mx/reader030/viewer/2022032607/56813061550346895d962eab/html5/thumbnails/42.jpg)
What about Currently Produced Prep Plant Refuse?
• Pittsburgh Bed Refuse from Active Operation in 1988- As Sampled:– 49 Wt% Ash– 5.5 Wt% Sulfur
![Page 43: The Influence of Specific Gravity Distributions on Fuel Properties](https://reader030.vdocuments.mx/reader030/viewer/2022032607/56813061550346895d962eab/html5/thumbnails/43.jpg)
What about Currently Produced Prep Plant Refuse?
• Pittsburgh Bed Refuse from Active Operation in 1988- As Sampled:– 49 Wt% Ash– 5.5 Wt% Sulfur
• After a Laboratory Process:– 65% Yield– 41 Wt% Ash– 3.9 Wt% Sulfur
![Page 44: The Influence of Specific Gravity Distributions on Fuel Properties](https://reader030.vdocuments.mx/reader030/viewer/2022032607/56813061550346895d962eab/html5/thumbnails/44.jpg)
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0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
1.35 1.45 1.55 1.65 0.175 1.9 2.5
Mean Specific Gravity
Wt%
Direct Wt%
Cumulative Wt%Ash
Makes Bottom AshMakes Flyash