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Catalytic Gasification of Coal Using Eutectic Salt Mixtures.
Final Technical Report for the Project Duration:  October 1997 to September 2001

Yeboah, Dr. Yaw D. and Xu, Dr. Yong
Clark Atlantic University

Sheth, Dr. Atul
University of Tennessee Space Institute

Agrawal, Dr. Pradreep
Georgia Institute of Technology

In this pdf format, this document has 134 pages and is 2.47 MB.

Table of Contents

Executive Summary

2

List of Figures

8

List of Tables

12

1.

Chapter 1:  Introduction and Objectives

14

1.1

Introduction

14

1.2

Scientific Background

15

1.2.1

Literature Review

15

1.2.1.1

Alkali metal Salts

15

1.2.1.2

Alkaline-Earth Metal Oxides

16

1.2.1.3

Transition and other metals, their oxides and salts

18

1.2.1.4

Mineral Substances or ash in coal

19

1.2.1.5

Eutectic Salt Mixtures

19

1.2.2

Catalytic coal gasification by eutectic salt mixtures

20

1.3

Research Needs

22

1.4

Project Objectives

23

1.4.1

Research Objectives

23

1.4.2

Educational Objectives

23

1.5

References

24

2.

Chapter Two:  Technical Approach

27

2.1

Methodology and Tasks

27

2.1.1

Selection of Eutectic salt Mixtures

27

2.1.2

Evaluation of gasification performance in a bench-scale fixed-bed reactor

27

2.1.3

Data analysis and reporting

27

2.2

Materials

27

2.2.1

Coal

27

2.2.2

Reagents and Chemicals

28

2.3

Preparation

28

2.3.1

Preparation of eutectic catalysts

28

2.3.2

Sample Preparation (coal + catalyst)

28

 

2.3.2.1

Physical Mixing Technique (M1 method)

28

2.3.2.2

Incipient wetness method for mixture of individual salts (M2 method)

28

2.3.2.3

Incipient wetness method for mixture of individual Salts (M3 Method)

28

2.3.2.4

Drying

28

2.3.2.5

Devolatilization/pyrolysis

29

2.3.2.6

Sieving

29

2.4

Gasification test by TGA in CO2

29

2.4.1

Gasification test by fixed-bed reactor

30

2.5

Zeta Potential measurements

31

2.6

Free-Swelling index tests

32

2.7

X-ray diffraction experiments

32

2.8

SEM measurements

32

2.9

References

33

3.0

Chapter 3:  Identification of Appropriate Eutectic Salt Mixtures

34

3.1

Selection of eutectic salt mixtures

34

3.2

Results and Discussion

38

3.2.1

Study on TGA reproducibility

39

3.2.2

Study on single salt for the gasification

40

3.2.3

Study on binary and ternary eutectics

45

3.2.3.1

Measurements of melting point of binary and ternary eutectics

45

3.2.3.2

Study of the effect of preparation conditions on the catalytic activity

45

3.2.4

Evaluation of the effect of preparation conditions on the catalytic activity

51

3.3

Conclusions

52

3.4

References

54

4.0

Chapter 4:  Gasification of Coal in Steam by Bench Scale Fixed-Bed Reactor

55

4.1

Introduction

55

4.2

Evaluation of catalyst addition techniques

55

4.3

Comparative study of single, binary, and ternary salt catalysts

58

4.4

Study of the effects of process variables on the performance of gasifiers

60

4.4.1

Effect of Temperature

60

4.4.2

Effect of Pressure

61

4.4.3

Effect of Catalyst Loading

64

4.4.4

Effect of steam/water flow rate

66

4.5

Reaction kinetics modeling using binary and ternary eutectic catalysts in steam

68

4.5.1

Overview

68

4.5.2

Kinetic Modeling

70

4.6

Conclusions

76

4.7

References

78

5.0

Chapter 5:  Reaction Kinetics for Hydrogasification

79

5.1

Introduction

80

5.2

Hydrogasification

80

5.3

Study of the effects of process variables of the gasification of coal

 

5.3.1

Effect of partial pressure of hydrogen

81

5.3.2

Effect of average particle size of sample

83

5.3.3

Reproducibility of experiments

87

5.4

Kinetic Modeling

87

5.5

Conclusions

92

5.6

References

95

6.0

Recovery, Regeneration and Recycle of Spent Eutectic catalysts and Economic Analysis

96

6.1

Introduction

98

6.2

Water Extraction

98

6.2.1

Effect of solvent-to-char ratio

98

6.2.2

Effect of mixing time

99

6.2.3

Effect of temperature

100

6.3

Sulfuric acid extraction

100

6.4

Acetic acid extraction

103

6.5

Comparison of catalyst recovery results for LNK and NK catalysts

105

6.6

Catalyst Regeneration

105

6.7

Economic analysis and cost estimation

108

6.8

Sensitivity analysis

110

6.9

Conclusions

111

6.10

References

112

7.0

Chapter 7:  Characterizations of Coal/Char with/without Catalysts

114

7.1

Study of the surface property of the coal with/without catalyst

114

7.2

Free swelling index studies

114

7.3

X-ray diffraction experiments

116

7.4

Scanning Electron Microscopy (SEM)

123

7.5

Conclusions

123

7.6

References

126

8.0

Chapter 8:  Other Program Accomplishments

127

8.1

Students supported on the project at Clark Atlanta University

127

8.2

Students supported at the University of Tennessee Space Institute (USTI)

127

8.3

Students supported at the Georgia Institute of Technology

127

8.4

Student Thesis Produced

128

8.5

Publications and presentations

128

8.5.1

Publications

128

8.5.2

Presentations

128

9.0

Chapter 9:  Conclusions and Acknowledgements

129

9.1

Conclusions

129

9.2

Acknowledgements

132

10.0

Chapter 10:  Suggestions for Future Studies

133