Search Results (110)

The oxygen blast furnace (OBF) process presents a promising low-carbon pathway for the smelting of vanadium–titanium magnetite (VTM). This study develops an innovative mathematical model based on mass and heat balance principles, specifically tailored to the OBF smelting of VTM. The model systematically investigates the effects of key parameters—including pulverized coal injection ratio, recycling gas volume, hydrogen content in the recycling gas, and charge composition—on furnace productivity, hearth activity, and the tuyere raceway zone. The results show that increasing the pulverized coal injection ratio slightly reduces productivity and theoretical flame temperature: for every 25 kg/tHM increase in the coal ratio, the theoretical flame temperature decreases by 21.95 °C; moreover, indirect reduction is enhanced and the heat distribution within the furnace is significantly improved. A higher recycling gas volume markedly increases productivity and optimizes hearth thermal conditions, accompanied by enhanced blast kinetic energy and an expanded tuyere raceway zone, albeit with a notable drop in combustion temperature. Increased hydrogen content in the recycling gas promotes productivity, but may weaken blast kinetic energy and reduce the stability of the raceway zone. Furthermore, a higher titanium content in the charge increases the difficulty of iron oxide reduction, resulting in lower CO utilization and reduced productivity. Full article

Ammonia is a carbon-free fuel with strong potential for emission reduction. However, its high auto-ignition temperature and low reactivity lead to poor ignitability and unstable combustion. In contrast, coal-to-liquid (CTL) fuel offers high cetane number, low sulfur content, and low aromaticity, making it a clean fuel with excellent ignition performance. Blending CTL with ammonia can effectively compensate for ammonia’s combustion limitations, offering a promising pathway toward low-carbon clean combustion. This study explores the effects of post-injection strategies on combustion and emission characteristics of a CTL–ammonia dual-fuel engine under different levels of ammonia energy fractions (AEFs). Results show that post-injection significantly improves combustion and emission performance by expanding ammonia’s the favorable reactivity range of ammonia and enhancing NH₃ oxidation, particularly under moderate AEF conditions (5–10%) where ammonia and CTL demonstrate strong synergy. For emissions, moderate post-injection notably reduces CO at low AEFs, while NO_X emissions consistently decrease with increasing post-injection quantity, with greater suppression observed at higher AEFs. Soot emissions are also effectively reduced under post-injection conditions. Although total hydrocarbon (THC) emissions increase due to ammonia’s low reactivity, post-injection mitigates this accumulation trend to some extent, demonstrating overall co-benefits for emission control. Comprehensive evaluation indicates that the combination of 5–10% AEF, 8–12 mg post-injection quantity, and post-injection timing of 10–15 °CA achieves the most favorable balance of combustion efficiency, emissions reduction, and reaction stability, confirming the potential of the CTL–ammonia dual-fuel system for clean and efficient combustion. Full article

Under China’s “dual carbon” goals (carbon peaking and carbon neutrality), the utilization of high-chlorine coal faces significant challenges due to its abundant reserves in regions such as Xinjiang and its notable environmental impacts. This study systematically investigates the combustion characteristics, environmental risks, and control strategies for high-chlorine coal. Key findings reveal that chlorine release occurs in three distinct stages, namely low-temperature desorption, medium-temperature organic bond cleavage, and high-temperature inorganic decomposition, with release kinetics governed by coal metamorphism and the reaction atmosphere. Chlorine synergistically enhances mercury oxidation through low-activation-energy pathways but exacerbates boiler corrosion via chloride–sulfate interactions. Advanced control technologies—such as water washing, calcium-based sorbents, and integrated pyrolysis–gasification systems—demonstrate substantial emission reductions. However, challenges remain in addressing high-temperature corrosion and optimizing multi-pollutant synergistic control. This study provides critical insights into the clean utilization of high-chlorine coal, supporting sustainable energy transitions. Full article

This study evaluates the potential of biomass fuels (10 wt% and 20 wt%) as partial coal replacements in combustion and their effects on clinker performance. Cement was produced by co-grinding clinker with gypsum, and hydration products were analyzed. Potassium and sodium carbonates were introduced to create highly alkaline conditions, thereby simulating the effect of alkali metals in biomass-derived fuel ash on the mineral phases of clinker under high substitution ratios. The results showed biomass fuels’ low ignition point and high volatile matter content improved mixed fuels combustion, increasing the average combustion rate by 0.52%~2.28% and reducing the ignition temperature by up to 56 °C. At low substitution levels, biomass ash did not adversely affect clinker mineral composition or cement properties. However, the highly alkaline environment suppressed the formation of tricalcium silicate (C₃S) in the clinker, resulting in an increased content of free calcium oxide(f-CaO). Simultaneously, it promotes the formation of sulfates (K₂SO₄, Na₂SO₄) and sodium silicate (Na₂Si₂O₅). Full article

The accelerated urbanisation that is occurring in many regions of the world is resulting in a corresponding increase in the volume of sewage sludge. This sludge is then stored in specialised landfills, the area of which is increasing annually. One of the methods of utilising this sludge is through its combustion in power plants, where it serves to generate heat. However, due to the low calorific value of sewage sludge, it is recommended to combust it in conjunction with high-calorific fuel. To improve energy efficiency of sewage residue biomass utilisation by co-combustion with coal, it is necessary to determine the main combustion parameters and mass fraction in the mixture. The objective of this study is to estimate the primary parameters of combustion of sewage sludge and coal by employing the synchronous thermal analysis method, in addition to determining the concentrations of gaseous substances formed during the combustion process. A comprehensive technical and elemental analysis of the fuels was conducted, and their thermal properties were thoroughly determined. The inorganic residue from sewage sludge combustion was analysed by scanning electron microscopy for the content of trace elements and basic oxides. Thermogravimetric analysis (TGA) of fuels was conducted in an oxidising medium, utilising a 6 mg suspension with a heating rate of 20 °C/min. The profiles of TG, DTG, and DSC curves were then utilised to determine the ignition and burnout temperatures, maximum mass loss rate, combustion index, and synergistic effects. The mixture of coal with 25% sewage sludge was found to have the most energy-efficient performance compared to other mixtures, with a 3% reduction in ignition temperature compared to coal. Concentrations of carbon dioxide, carbon monoxide, nitrogen oxides, and sulphur oxides were also determined. Full article

The hydrothermal dewatering (HTD) of lignite results in noticeable variations in the low-temperature oxidation process. Consequently, this study was made on the gas release and temperature change characteristics to investigate the oxidation kinetics and mechanism of HTD coal samples. In this study, a lignite from Inner Mongolia in China was upgraded by HTD. N₂ adsorption, SEM, FT-IR, and chemical titration experiments were also carried out on raw and HTD coal samples to relate the physico-chemical structure properties with low-temperature oxidation characteristics. Results show that HTD coal samples have higher low-temperature oxidation activities and lower critical ignition temperatures compared with raw coal. According to the change in activation energy by kinetic analysis, the low-temperature oxidation process in the temperature range 35–140 °C could be divided into the stage I (oxygen adsorption stage) and stage II (accelerated oxidation stage). The correlation analysis indicates that the oxygen adsorption stage is controlled by the aliphatic and surface structures, while the accelerated oxidation stage is jointly affected by the competition of physico-chemical structures. The oxygen adsorption stage promotes the progress in accelerated oxidation stage. Full article

This article presents the results of laboratory studies on the smelting of nickel–chromium-containing ferroalloys from low-grade nickel ores from Kazakhstan. X-ray phase analysis was performed on raw materials, which included quartz, nontronite, chromium metahydroxide, goethite, magnetite, iron chromite, and nickel (II) silicate. The reduction reactions of metal oxides with carbon and carbon monoxide were studied as the temperature increased. Experimental smelting was carried out in a Tammann furnace at 1500–1550 °C using three types of reducing agent: RK coke, as well as its mixtures with low-ash Shubarkol coal, in ratios of 75:25 and 50:50. The second option demonstrated the highest economic efficiency, achieving a 91% nickel recovery rate, reduced coke consumption, and a slag-to-metal ratio of 3.07. Chemical analysis showed that the nickel content in the obtained alloys ranged from 2.5% to 6.5%, while chromium content ranged from 2.6% to 4.5%. X-ray phase analysis confirmed the presence of Fe₂Ni_0.6Si, Fe₅Si₃, and Fe₂CrSi phases in the alloy structure. Local element concentrations varied within the following ranges: Fe—55–59%, Ni—2–10%, Cr—2–7%, and Si—29–35%. The results of this study confirmed the feasibility of producing a nickel–chromium-containing alloy with a nickel content of 2–10% and a chromium content of 2–7%. Full article

Coal mining and washing processes generate substantial amounts of coal gangue, posing significant environmental challenges. Coal gangue as a solid waste is rich in SiO₂ and Al₂O₃, with the SiO₂/Al₂O₃ molar ratio closely aligned with the ideal composition of 4A molecular sieves. In this study, through a synergistic pretreatment process involving low-temperature oxidation and hydrochloric acid leaching, the Fe₂O₃ content in coal gangue was reduced from 7.8 wt% to 1.1 wt%, markedly enhancing raw material purity. The alkali fusion–hydrothermal synthesis parameters were optimized via orthogonal experiments—calcination (750 °C, 2 h), aging (60 °C, 2 h), and crystallization (95 °C, 6 h) to maintain cubic symmetry, yielding highly crystalline 4A zeolite. Characterization via XRD, calcium ion adsorption capacity, SEM, and FTIR elucidated the regulatory mechanism of calcination on kaolinite phase transformation and the critical role of alkali fusion in activating silicon–aluminum component release. The as-synthesized zeolite exhibited a cubic morphology, high crystallinity, and sharp diffraction peaks consistent with the 4A zeolite phase. The pH of the zero point charge (pH_ZPC) of the 4A molecular sieve is 6.13. The 4A molecular sieve has symmetry-driven adsorption sites, and the adsorption of Cu²⁺ follows a monolayer adsorption mechanism (Langmuir model, R² = 0.997) with an average standard enthalpy change of 38.96 ± 4.47 kJ/mol and entropy change of 0.1277 ± 0.0148 kJ/mol, adhering to pseudo-second-order kinetics (R² = 0.999). The adsorption process can be divided into two stages. This study provides theoretical and technical insights into the high-value utilization of coal gangue. Full article

The chemical composition and molecular structure of the pitch-like products obtained by liquid-phase reaction of bituminous coal with heavy hydrocarbon fractions of coal and petroleum origin as solvents at a moderate temperature were comprehensively characterized in terms of a new aromatic feedstock for needle coke and other valuable high-tech carbon materials. The molecular parameters of the products were characterized by using FTIR, ¹H NMR, ¹³C NMR and XPS. Liquid-phase chromatography was used to analyze benzo(a)pyrene (BaP) as a carcinogenicity marker. The chemical composition and the characteristics of the molecular structure of the products were shown to depend greatly on the solvent used. The product obtained using coal tar as a solvent was highly aromatic, its polyaromatic nuclei consisted predominantly of protonated and pericondensed cycles sparsely substituted by CH₃ and occasionally CH₂ groups. The product obtained using petroleum-derived heavy gas oil as solvent was much less aromatic and prone to autogenous surface oxidation. Its aromatic nuclei contained mainly protonated and highly alkylated catacondensed chains. The intermediate structural parameters were characteristic of the product obtained using binary solvent. A remarkable feature of the pitch-like products obtained was a reduced BaP concentration (up to 40 times compared to typical coal-tar pitch). In terms of the molecular structure, the pitch-like products obtained by low-temperature dissolution of coal can serve as a new polyaromatic feedstock with a reduced carcinogenicity for the production of valuable high-tech carbon materials, needle coke, in particular. Full article

As part of the transition to low-carbon energy and for the sustainable utilisation of resources, it is necessary to seek a replacement for solid fossil fuels, but unfortunately, it is impossible to completely abandon them for various reasons at the moment, so only partial replacement with new, high-calorific, biomass-based fuels is possible. The purpose of this work is to determine the typical parameters of the co-combustion of carbonisate, coal and their mixtures, taking into account the synergetic effects influencing the combustion intensity of the mixture. Carbonisate was obtained in the process of the gasification of pinewood through the counter-blowing method at a temperature of 800–900 °C, while air was used as an oxidant. Basically, this method of gasification is used for coal in order to obtain high-calorific coke for the metallurgical industry. Also, in this study, for the first time, carbonisate was obtained from 50% pinewood and 50% lignite. The O/C and H/C ratios were determined for carbonisate. A technical and elemental analysis of the investigated fuels was carried out. A thermal analysis in oxidising medium was applied to determining the typical combustion parameters in the process of slow heating of the fuels under study. According to the results of this thermal analysis, typical heating parameters such as the ignition temperature, burnout temperature, maximum mass loss rate, combustion index, etc., were determined. It was noted that the calorific value of carbonised wood is two times higher than that of coal. The combustion index of carbonisates is 2.5–36% lower compared to that of coal. According to the results of the analysis of the interaction of the components among themselves (in the process of their joint combustion), the presence of synergetic interactions between the components was determined, which affected the change in the combustion intensity and heat release intensity. The results of this study may be useful for retrofitting coal-fired boilers to run on a mixture containing carbonisate and lignite. If carbonisate is produced from biomass, the resulting gas could be used as an energy fuel by burning it in a coal-fired boiler. Full article

This study systematically explores and expands upon the research questions, revealing the scientific principles and engineering value of chromium–aluminum (Cr-Al) co-diffusion coatings in enhancing high-temperature friction performance. This study addresses the critical need for wear resistance in GH5188 cobalt-based alloy stator bushings operating in high-temperature environments. The high-temperature wear resistance mechanism of aluminized coatings modified with Cr elements on the GH5188 alloy, based on thermal diffusion technology, was investigated. The experimental results indicate that the high-temperature wear resistance of the samples was directly related to the type and content of oxides in the wear scars and debris. After friction at 700 °C, the aluminized coating on the GH5188 alloy showed the lowest oxide content in the wear scars, primarily composed of CoAl₂O₄. The oxides in the wear scars of the GH5188 alloy and Al-Cr co-aluminized coatings were mainly CoCr₂O₄ and Cr₂O₃, with the Al-Cr co-aluminized coating showing the highest amount of wear debris. The Cr-rich oxide debris not only has high thermodynamic stability but also exhibits relatively low high-temperature growth stress, making it difficult to spall. Additionally, the higher diffusion coefficient of Cr³⁺ accelerates the reoxidation of wear debris pits, resulting in excellent high-temperature wear resistance. The wear rate of the Al-Cr co-aluminized coating was reduced by 30% compared with the GH5188 substrate and by 69% compared with the aluminized coating. In summary, the key findings are not only applicable to cobalt-based alloys but can also be extended to a broader range of material systems and engineering applications. This provides new perspectives and methodologies for the design of high-temperature coatings, the development of materials for extreme conditions, and interdisciplinary applications. Full article

Due to the gradual depletion of traditional metallic mineral resources, the search for new potential sources is an important issue. One such source is coal deposits. The extraction of metals from coal is a way to produce clean energy. This study presents the results of detailed research on geochemical features and mineralogy to understand the processes of microelement enrichment in the coal-bearing deposit of Shubarkol, in Central Kazakhstan. Modern analytical techniques were used to obtain information about the conditions and processes of trace element accumulation in coal, as well as the modes of occurrence of these elements. Geochemical data were analyzed using multidimensional statistical methods, including correlation, clustering, and factor analysis, which allowed us to draw several scientific conclusions. Numerous factors indicate that the enrichment of trace elements in sediments is controlled by clastic terrigenous material and low-temperature hydrothermal solutions circulating in the coal basin. The main sources of removal of trace elements from coal are ancient igneous rock complexes located within deposits that were directly involved in coal enrichment through secondary geological processes. According to estimates, the degree of enrichment of Jurassic coals at Shubarkol was close to the average value for world coals (0.5 < CC < 2), and coal seams were enriched with lithophilic and chalcophilic elements such as Ba, U, Yb, Co, La, Nb, Hf, Sc, V, Sr, Cu, and Zn. A correlation analysis of coal deposits revealed a significant correlation between main oxides and rare earth elements (REEs). The strongest correlation was between Zr, Hf, Th/Ta, and REEs. The positive correlations between Zr and Al₂O₃, Nb and Al₂O₃ indicate that these elements (Zr, Hf, Nb, Ta, and REY) are probably related to Al. The results obtained make it possible to consider coal as a potential mineral resource for the production of rare metals and serve as a guide for the industrial processing of the most important elements found in coal. Full article

The recycling of coal gangue has considerable potential to produce secondary environmental hazards, which significantly influence the high-end application of coal gangue in practical engineering. The present study investigates the effects of activation treatment on the physical, chemical properties and leaching behavior of coal gangue. The mineral composition, micro-pore structure and element leaching were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), Thermogravimetry Analysis (TG), Low-Temperature Nitrogen Adsorption (LTNA) and Inductively Coupled Plasma (ICP). The results indicate that kaolinite and pyrite in coal gangue experienced reconstruction after 600 °C during thermal activation. The density of thermally activated coal gangue is increased with the calcination temperature as well as the alkalinity (from 4.8–7.1) due to the burning of organic and the oxidation of pyrite. The calcination treatment induced the reduction in macropore volume (>50 nm), and enhancement in mesopore (<5 nm) volume. Leachable Ni, Cd, Mn, Cu, Zn and Pd decreased by 99%, 67%, 86%, 40%, 99% and 93% after calcination at 800 °C, respectively. The Si and Al in 800 °C calcined coal gangue exhibited a high leaching ability in alkalinity solution; leachable Al reached 106.4 mg/kg, while leachable Si reached 86.1 mg/kg after 48 h of dynamic leaching. Full article

We report the results of a zinc oxide (ZnO) low-power microsensor for sub-ppm detection of NO₂ and H₂S in air at 200 °C. NO₂ emission is predominantly produced by the combustion processes of fossil fuels, while coal-fired power plants are the main emitter of H₂S. Fossil fuels (oil, natural gas, and coal) combined contained 74% of USA energy production in 2023. It is foreseeable that the energy industry will utilize fossil-based fuels more in the ensuing decades despite the severe climate crises. Precise NO₂ and H₂S sensors will contribute to reducing the detrimental effect of the hazardous emission gases, in addition to the optimization of the combustion processes for higher output. The fossil fuel industry and solid-oxide fuel cells (SOFCs) are exceptional examples of energy conversion–production technologies that will profit from advances in H₂S and NO₂ sensors. Porosity and surface activity of metal oxide semiconductor (MOS)-based sensors are both vital for sensing at low temperatures. Oxygen vacancies (${\mathbf{V}}_{\mathbf{O}}^{••}$) act as surface active sites for target gases, while porosity enables target gases to come in contact with a larger MOS area for sensing. We were able to create an open porosity network throughout the ZnO microstructure and simultaneously achieve an abundance of oxygen vacancies by using a heat treatment procedure. Surface chemistry and oxygen vacancy content in ZnO were examined using XPS and AES. SEM was used to understand the morphology of the unique characteristics of distinctive grain growth during heat treatment. Electrical resistivity measurements were completed. The valance band was examined by UPS. The Engineered Porosity approach allowed the entire ZnO to act as an open surface together with the creation of abundant oxygen vacancies (${\mathbf{V}}_{\mathbf{O}}^{••}$). NO₂ detection is challenging since both oxygen (O₂) and NO₂ are oxidizing gases, and they coexist in combustion environments. Engineered porosity ZnO microsensor detected sub-ppm NO₂ under O₂ interference, which affects mimicking realistic sensor operation conditions. Engineered porosity ZnO performed better than the previous literature findings for H₂S and NO₂ detection. The exceptionally high sensor response is attributed to the high number of oxygen vacancies (${\mathit{V}}_{\mathit{O}}^{••}$) and porosity extending through the thickness of the ZnO with a high degree of tortuosity. These features enhance gas adsorption and diffusion via porosity, leading to high sensor response. Full article

The oxidation characteristic parameters of residual coal in working face change with the advance of coal seam. To explore the influence of dynamic oxygen-consuming environments, we examined the influence of reducing the oxygen concentration on the formation characteristics and characteristic parameters of coal oxidation products, conducted with temperature-programmed experiments under staged oxygen consumption. The correlation between the characteristic oxidation parameters was determined, and the critical oxygen concentration that determined the gas yield was obtained. The results show that after staged oxygen-consumption, the oxidation of coal is stronger than that under constant low oxygen, the oxidation products are greatly affected, and the influence of pyrolysis gas is small. The oxidation characteristic parameters such as gas product volume fraction, production rate, and heat release intensity are positively correlated with the oxygen-consumed temperature. We found that the oxidation reaction heat of coal is 180~330 kJ·mol⁻¹, and the maximum and minimum exothermic intensities are significantly linearly correlated with the oxygen consumption rate. Finally, the critical oxygen concentrations for gas production rate under oxygen-consumed conditions were 17, 9, and 5%. These results have practical significance for strengthening the prevention and control of spontaneous combustion disasters in goafs. Full article