Significant influence of self-possessed moisture of limonitic nickel laterite on sintering performance and its action mechanism

In consideration of the abundant moisture of limonitic nickel laterite mined, it is essential to determine whether the self-possessed moisture of limonitic nickel laterite after pre-dried is appropriate for sintering. Thus, based on the characterization of limonitic nickel laterite, the influence of its self-possessed moisture on sintering performance was expounded by sinter pot tests and the relevant mechanism was revealed by the systematical analyses of the granulation properties of sinter mixture, thermodynamic conditions during sintering and mineralogy of product sinter. The results indicate that the self-possessed moisture of limonitic nickel laterite indeed has significant influence on its sintering performance. At the optimum self-possessed moisture of 21 mass%, sinter indices are relatively better with tumble index, productivity and solid fuel rate of 48.87%, 1.04 t m−2 h−1 and 136.52 kg t−1, respectively, due to the superior granulation properties of sinter mixture and thermodynamic conditions during sintering, relatively large amount of silico-ferrite of calcium and alumina and tighter sinter microstructure. However, sintering performance of limonitic nickel laterite is still much poorer than that of ordinary iron ores. It is feasible to strengthen limonitic nickel laterite sintering by inhibiting the over-fast sintering speed and improving the thermodynamic conditions during sintering.

Utilization of Organic Mixed Biosludge from Pulp and Paper Industries and Green Waste as Carbon Sources in Blast Furnace Hot Metal Production

A six day industrial trial using hydrochar as part of the carbon source for hot metal production was performed in a production blast furnace (BF). The hydrochar came from two types of feedstocks, namely an organic mixed biosludge generated from pulp and paper production and an organic green waste residue. These sludges and residues were upgraded to hydrochar in the form of pellets by using a hydrothermal carbonization (HTC) technology. Then, the hydrochar pellets were pressed into briquettes together with commonly used briquetting material (in-plant fines such as fines from pellets and scraps, dust, etc. generated from the steel plant) and the briquettes were top charged into the blast furnace. In total, 418 tons of hydrochar briquettes were produced. The aim of the trials was to investigate the stability and productivity of the blast furnace during charging of these experimental briquettes. The results show that briquettes containing hydrochar from pulp and paper industries waste and green waste can partially be used for charging in blast furnaces together with conventional briquettes. Most of the technological parameters of the BF process, such as the production rate of hot metal (<1.5% difference between reference days and trial days), amount of dust, fuel rate and amount of injected coal, amount of slag, as well as contents of FeO in slag and %C, %S and %P in the hot metal in the experimental trials were very similar compared to those in the reference periods (two days before and two days after the trials) without using these experimental charge materials. Thus, it was proven that hydrochar derived from various types of organic residues could be used for metallurgical applications. While in this trial campaign only small amounts of hydrochar were used, nevertheless, these positive results support our efforts to perform more in-depth investigations in this direction in the future.

Boiler Combustion Optimization of Vegetal Crop Residues from Greenhouses

This work presents an alternative for adding value to greenhouse crop residues, used for (1) heating and (2) as a CO2 source. Both options are focused on greenhouse agricultural production, but could be applied to other applications. The influence of factors, such as the air/fuel rate and turbulence inside the combustion chamber, is studied. Our results show that for pine pellets, olive pits, tomato-crop residues, and a blend of the latter mixed with almond prunings (75–25%), the thermal losses ranged from 19.5–53.1, 20.5–58.9, 39.9–95%, and 29.4–75.5%, respectively, while the NOX emissions were 30–247, 411–1792, and 361–2333 mg/Nm3, respectively. The above-mentioned blend was identified as the best set-up. The thermal losses were 39.2%, and the CO, NOX, and SO2 concentrations were 11,690, 906, and 1134 mg/Nm3, respectively (the gas concentration values were recalculated for 0% O2). Currently, no other work exists in the literature include a similar analysis performed using a boiler with a comparable thermal output (160.46 kW). The optimal configurations comply with the relevant local legislation. This optimization is important for future emission control strategies relating to using crop residues as a CO2 source. The work also highlights the importance of ensuring a proper boiler set-up for each case considered.

Multi-Objective Load Dispatch Control of Biomass Heat and Power Cogeneration Based on Economic Model Predictive Control

This paper proposes a multi-objective load dispatch algorithm based on economic predictive control to solve the real-time multi-objective load dispatch problem of biomass heat and power cogeneration. According to the energy conservation law and production process, a real-time multi-objective load dispatch optimization model for heat and power units is established. Then, the concept of multi-objective utopia points is introduced, and the multi-objective load comprehensive objective function is defined to coordinate the conflict between the economic performance and pollutant emission performance of the units. Furthermore, using the online receding optimization characteristics of economic predictive control, the comprehensive objective function of multi-objective load dispatching is optimized online. Then, the fuel rate satisfying the economic performance and pollutant emission performance of the units is calculated to realize the economic performance and environmental protection operation of biomass heat and power cogeneration. Finally, the proposed multi-objective load dispatch control method is compared to traditional dispatch strategies by using industrial data. The results show that the method presented here can well balance the production cost and pollutant emission objective under the fluctuation of the thermoelectric load demand, and provides a feasible scheme for real-time dispatching of the multi-objective load dispatch problem of biomass heat and power cogeneration.

Current plastics pollution threats due to COVID-19 and its possible mitigation techniques: a waste-to-energy conversion via Pyrolysis

Background The extensive use and production of PPE, and disposal in the COVID-19 pandemic increases the plastic wastes arise environmental threats. Roughly, 129 billion face masks and 65 billion plastic gloves every month are used and disposed of on the globe. The study aims to identify the polymer type of face masks and gloves and sustainable plastic waste management options. Results The identification of polymers, which can help for fuel conversion alternatives, was confirmed by FTIR and TGA/DTA analysis and confirms that the polymeric categories fit for the intended purpose. Moreover, the handling technique for upcycling and the environmental impacts of the medical face mask and glove were discussed. The FTIR result revealed that face masks and gloves are polypropylene and PVC thermoplastic polymer, respectively and they can be easily transformed to fuel energy via pyrolysis. The endothermic peaks around 431 ℃ for medical glove and 175 ℃ for surgical is observed tells that the melting point of the PVC and polypropylene of plastic polymers, respectively. The pyrolysis of the face mask and glove was carried out in a closed reactor at 400 ℃ for 1 h. Conferring to lab-scale processes, liquid, and wax fuel rate of 75%, char of 10%, and the rest non-condensable gases were estimated at the end. Conclusions It can be concluded that the medical plastics can be recycled into oil due to their thermoplastics nature having high oil content and the waste to energy conversion can potentially reduce the volume of PPE plastic wastes.

DESIGN, TESTING, AND PERFORMANCE IMPACT OF EXHAUST DIFFUSERS IN AERO-DERIVATIVE GAS TURBINES FOR MECHANICAL DRIVE APPLICATIONS

The growing penetration of renewables calls for power generation and mechanical drive gas-turbine (GT) capable of quickly adjusting production and operate at part load. Aero-derivative engine architectures leverage the large experience from aircraft propulsion, have small footprint, high performance, availability and maintainability. Aircraft engines adjust power with fuel rate and shaft speed that go hand in hand. Mechanical drive engines need to change the delivered power by keeping the shaft speed under control to guarantee the operation of the driven equipment (an LNG compressor or an electric generator). Hence, the power turbine exhaust may deliver velocity and angle profiles that put the discharge diffuser in severe off-design with flow separations, high kinetic losses, and cycle performance shortfall. This paper describes Baker Hughes a GE company experience in the CFD assisted design and similitude scale-down testing of aero-derivative hot-end drive exhaust diffusers in multiple operating points. The diffuser inlet conditions reproduce power turbine exit profiles by using swirl vanes and perforated plates, the design of which is heavily CFD assisted. Predictions match measurements in terms of pressure recovery, kinetic losses, and exhaust velocity profiles. Different data post-processing and averaging are considered to properly factor in the diffuser losses into the overall turbine performance.

Tribological Study of HVOF Sprayed Tungsten Carbide Coated Stainless Steel

Corrosion and Wear, or a combination of both, are the main causes of degradation of metals used in the various industrial sectors. Degradation of the metals can be slowed down by adding a layer of resistant coating on the metal surface. This coating separates the base metal from a corrosive environment, reduces wear, and improves the appearance of the metal. The workpiece after coating becomes a composite that has properties far better than the substrate alone. There are various coating techniques, HVOF is one of the most important and widely used processes to protect the metals from wear, corrosion by providing hard and dense coatings. WC coating done by the high-velocity oxy-fuel (HVOF) spray method is the widely used method for providing a layer of corrosive resistance to a wide range of materials that are used in many different industries. In this study, Tungsten carbide (WC-12CO) Coating, HVOF Spray method was studied in great detail. Tungsten Carbide coating was done on a SUS400 Stainless steel substrate using HVOF Spray Process. An, Experiment was done to analyze the various effect of different parameters namely, oxygen rate, propane (fuel) rate, powder rate, spray distance on hardness, and surface roughness of a SUS 400 Stainless Steel substrate. Process optimization was done by using Taguchi and ANOVA methods. It was found that achieving maximum hardness was greatly dependent on propane (fuel) rate followed by powder rate, spray distance, and oxygen rate. The hardness decreases with the increasing fuel rate. And, achieving minimum surface roughness was greatly dependent on spray distance followed by oxygen rate, propane (fuel) rate, powder rate. Surface Roughness increases with increasing spray distance.

Effective Utilization of Limonitic Nickel Laterite via Pressurized Densification Process and Its Relevant Mechanism

Limonitic laterite contains low iron and nickel grades and much high smelting minerals and loss on ignition (LOI), identified as refractory iron ore for sintering. Thus, sinter pot tests of limonitic laterite via pressurized densification sintering and its intensification mechanism were conducted, and the industrial application prospect was explored. The results indicate that the sintering performance of the limonitic laterite of the new process is significantly improved with the tumble index and productivity increased by 19.2% and 18.6%, respectively, and solid fuel rate lowered by 10.3%. The external pressure field promotes the synchronization of heat front velocity and combustion front velocity for better sintering heat and mass transfer conditions, which also greatly improves the mineral compositions and microstructure of the product sinter. The microstructure is converted from large thin-wall pores into small thin-wall or large thick-wall pores with the sinter porosity decreased by 42.4%. Much close interlocking texture between hercynite and silico-ferrite of calcium and alumina (SFCA) is formed with hercynite grains aggregation and growth, and SFCA amount substantially increased. The better sintering performance will bring about a remarkable economic benefit of 282.78 million RMB/a if the industrial application is implemented. The pressurized densification sintering process is considered as one of the effective technologies for improving limonitic laterite sintering.

Researches on biofuels gasification using the Lurgi process with homogeneous air inlet over the combustion space

The experimental investigations carried out within the present research focus on a simple gasification technology dedicated to biofuels conversion according to the Lurgi procedure. Specifically, an installation with a fixed grill and a homogeneous distribution of the air inlet over the combustion space are considered. In order to provide a thorough background for the experimental research, this paper presents first the challenges related to the air distribution. If for coal gasification the difficulty of the homogeneous penetration of the air inlet within the whole combustion volume is balanced by the possibility of the direct emission of CO valorization, for biomass gasification this factor becomes fundamental. The original contribution of the technology introduced in this paper assumes an improved combustion process for Lurgi-type gas generators. The experimental installation employed has a particular design, enabling a homogeneous distribution of the air inlet over the entire combustion zone, up to the top of the embers layer. This allows achieving a maximum CO2 content in the flue gas flux, effectively reducing it inside the embers bed. The high calorific value of biofuels used favors developing an efficient combustion process, occurring at high temperatures. Thus, the reduction process of the CO2 is self-controlled. The experimental installation operates at a slow fuel rate, with discontinued supply and precise airflow control. The quality of the gas obtained is evaluated based on the resulting open flame, analyzing its composition.