Multiphysics Design of Pet-Coke Burner and Hydrogen Production by Applying Methane Steam Reforming System

Pet-coke (petroleum coke) is identified as a carbon-rich and black-colored solid. Despite the environmental risks posed by the exploitation of pet-coke, it is mostly applied as a boiling and combusting fuel in power generation, and cement production plants. It is considered as a promising replacement for coal power plants because of its higher heating value, carbon content, and low ash. A computational fluid dynamics (CFD) computational model of methane steam reforming was developed in this research. The hydrogen production system is composed from a pet-coke burner and a catalyst bed reactor. The heat released, produced by the pet-coke combustion, was utilized for convective and radiative heating of the catalyst bed for maintaining the steam reforming reaction of methane into hydrogen and carbon monoxide. This computational algorithm is composed of three steps—simulation of pet-coke combustion by using fire dynamics simulator (FDS) software coupled with thermal structural analysis of the burner lining and a multiphysics computation of the methane steam reforming (MSR) process taking place inside the catalyst bed. The structural analysis of the burner lining was carried out by coupling the solutions of heat conduction equation, Darcy porous media steam flow equation, and structural mechanics equation. In order to validate the gaseous temperature and carbon monoxide mole fraction obtained by FDS calculation, a comparison was carried out with the literature results. The maximal temperature obtained from the combustion simulation was about 1440 °C. The calculated temperature is similar to the temperature reported, which is also close to 1400 °C. The maximal carbon dioxide mole fraction reading was 15.0%. COMSOL multi-physics software solves simultaneously the catalyst media fluid flow, heat, and mass with chemical reaction kinetics transport equations of the methane steam reforming catalyst bed reactor. The methane conversion is about 27%. The steam and the methane decay along the catalyst bed reactor at the same slope. Similar values have been reported in the literature for MSR temperature of 510 °C. The hydrogen mass fraction was increased by 98.4%.

Role of the lattice-energy from chemical-agents in the activation of highly-condensed carbons

Highly condensed carbons from pet-coke were first treated with Na/K hydroxides and carbonates and then with H2SO4. The esterification reaction of palmitic acid reached conversions up to 97 % on the yielded activated carbons. Results evince the relationship between the efficacy of Na/K hydroxides and carbonates as treatment agents and their lattice potential energy. Moreover, the analysis of carbonaceous solids confirms that both surface area and acidity are primary factors promoting activity in the esterification reaction. Furthermore, the results do not indicate a direct relationship between the activity and the oxidized species (SOx) arising from the treatment with H2SO4. The relatively low melting and decomposition temperature of Na/K hydroxides can improve their effect on the pet-coke matrix, leading to higher surface areas, acidities, and catalytic activities than treatment with carbonates. That supports an affinity between the carboxyl functions of fatty acid molecules and the polar and catalytically active centers of hydroxide-treated solid surface.

Acidophilic biodesulphurization of calcined pet coke and coal samples in iron and iron-free leaching media

Mineralogically distinct coal samples respond differently to microbial attack. In the present study, a mixed meso-acidophilic bacterial consortium predominantly comprising of Acidithiobacillus ferrooxidans strain was investigated for its biodesulphurization abilities for three distinct sulphur bearing samples (Goa CPC, Rajasthan Lignite, Assam Coal) of Indian origin in iron (9K+) and iron-free (9K−) media. A media devoid of Fe (II) iron was more effective for sulphur removal with maximum desulphurization of 45.19% for Assam coal followed by 36.8% for Rajasthan Lignite and 23.38% for CPC respectively. The proximate analysis, FTIR patterns and XRD analysis of the samples provided better insights into understanding the mineralogical and compositional changes in the coal matrix. Owing to the higher efficiency, Assam coal was additionally subjected to further optimization studies and characterization of the treated coal through TGA. The study indicated that the gross calorific values for all the samples increased following microbial treatment in 9K− media thereby providing a scope for further scale-up studies.

Direct Reduction of Fe, Ni and Cr from Oxides of Waste Products Used in Briquettes for Slag Foaming in EAF

Environmental aspects and the sustainable manufacturing of steels require producers to pay more and more attention to the efficient utilization of materials and waste products during steelmaking. This study is focused on the evaluation of possibilities for the recovery of metals (such as Fe, Ni and Cr) from waste products used for slag foaming in the Electric Arc Furnace (EAF) process. Two types of industrial briquettes were produced by mixing mill-scale from the hot rolling of stainless steels with anthracite and pet-coke, respectively. Thereafter, an assessment of the metal reduction processes in briquettes at high temperatures (1500 °C) was made by using laboratory thermo-gravimetric reduction experiments in an argon atmosphere. The amounts of metal, slag and gas obtained from the briquettes were estimated. In addition, the velocity and time for the removal of metal droplets from the liquid slag depending on the size of the metal droplets was estimated. It was found that up to 97% of metal droplets can be removed from the slag during the first 30 min. Moreover, results showed that most of the Cr, Ni and Fe (up to 93–100%) can be reduced from oxides of these metals in briquettes at 1500 °C. Moreover, the anthracite and pet-coke in the investigated briquettes have similar reduction capabilities. It was found that up to 330 kg of Fe, 28 kg of Ni and 66 kg of Cr per ton of added briquettes can be recovered from waste products by the industrial application of those briquettes for slag foaming in EAF.