Search Results (35)

The mechanism of slagging in municipal solid waste incinerators is complex, and the slagging process is simultaneously affected by the composition, temperature, and flue gas flow. In this study, slag samples on a water-cooled wall were first analysed, and the key components and fusion temperatures were measured. Second, a gas-phase combustion model of an incinerator was established, and the temperature and velocity distributions of the flue gas inside the incinerator were calculated. Based on the incineration process, coupled with a discrete-phase model, a numerical simulation model of the slagging process on the water-cooled wall of the incinerator was constructed, considering the transport and adhesion processes of ash particles. The influence of parameters such as the ash particle size and concentration on the degree of slagging on the water-cooled wall was analysed. Smaller ash particles were less likely to adhere to water-cooled walls, with approximately 2.72% of ash particles with a particle size of 10 mm adhering to water-cooled walls. The proportion of ash particles with a particle size of 50 mm adhering to water-cooled walls was approximately three times that of those with a particle size of 10 mm. As the concentration of ash particles increased, the number of ash particles adhering to the water-cooled wall increased, and the adhesion ratio decreased. These results are of great significance for optimising the operation of incinerators and reducing slagging rates. Full article

Coal fly ash zeolites with Sodalite structure were synthesized by ultrasound-assisted double stage fusion-hydrothermal synthesis. Monometallic Ni and bimetallic Ni–Cu supported catalysts with 5 wt.% Ni and different copper contents of 1.5, 2.5 and 5.0 wt.% Cu were prepared by post-synthesis incipient wetness impregnation. The catalysts were characterized by X-ray powder diffraction, N₂ physisorption, transmission electron microscopy (TEM), Mössbauer spectroscopy and H₂ temperature programmed reduction analysis. It was found that crystalline Cu⁰ and Ni_xCu_y intermetallic nanoparticles were formed in the reduced powder and 3D printed catalysts and that they affected the reducibility of the catalytically active nickel phase. Three-dimensionally printed 5Ni2.5Cu/Sodalite catalysts were prepared via modification with metals before and after 3D printing for comparative studies. The powder and 3D printed catalysts were studied in the lignocellulosic biomass-derived levulinic acid (LA) to γ-valerolactone (GVL). The formation of NiCu alloy, which is found on the powder and 3D printed catalysts, favors their catalytic performance in the studied reaction. In contrast with powder catalysts, the preservation of the Sodalite structure was detected for all 3D printed samples and was found to have a positive influence on the metal dispersion registered in the 3D spent catalysts. The powder 5Ni2.5Cu/Sodalite catalyst showed the highest LA conversion and high GVL yield at 150 °C reaction temperature. Three-dimensionally printed catalysts show more stable catalytic activity than powder catalysts due to the preservation of the zeolite structure and metal dispersion. Full article

The aim of this study is to predict the ash fusion temperatures of the lignite ash produced in Western Macedonia, Greece, by their composition. The lignite mined in northwest Greece feeds the power plants of Agios Dimitrios, Kardia, Ptolemais, Amyntaio, and Meliti. An extensive number of samples, which were collected by the feeders of power plants during a 10-year period, were investigated. All lignite ashes were mineralogical and chemically quantitatively analyzed by XRD and XRF, respectively. Using a heating microscope, the ash fusion temperatures of the ashes were identified. According to their chemical composition, ashes can be characterized as calcareous. Indices based on the chemical composition showed that, qualitatively, the tendencies of slagging and/or fouling were found to vary mainly between medium to high. For a quantitative estimation, correlations were identified between the quantitative mineralogical composition and the ash fusion temperatures using regression analysis. The whole study focused on creating a model for the prediction of lignite behavior during combustion in power plants. The finest models achieved a mean adjusted regression coefficient of around 0.87, while the accuracy, according to root mean square errors, was less than 40 °C. Full article

Zeolites with different structures (P1, sodalite, and X) were synthesized from coal fly ash by applying ultrasonically assisted hydrothermal and fusion–hydrothermal synthesis. Bimetallic catalysts, containing 5 wt.% Ni and 2.5 wt.% Cu, supported on the zeolites, were prepared by a post-synthesis incipient wetness impregnation method. The catalysts were characterized by X-ray powder diffraction (XRPD), N₂ physisorption, transmission electron microscopy (TEM), Mössbauer and X-ray photoelectron spectroscopies (XPS), and H₂–temperature-programmed reduction (H₂-TPR) analyses. The XRPD results showed that crystalline Cu⁰ and Ni_xCu_y intermetallic nanoparticles were formed in the reduced catalysts. The presence of the intermetallic phase affected the reducibility of the nickel by shifting it to a lower temperature, as confirmed by the H₂-TPR curves. Based on the Mössbauer spectroscopic results, it was established that the iron contamination of the coal fly ash zeolites (CFAZs) was distributed in ionic positions of the zeolite lattice and as a finely dispersed iron oxide phase on the external surface of the supports. The formation of the NiFe alloy, not detectable by XRPD, was also evidenced on the impregnated samples. The catalysts were studied in the upgrading of levulinic acid (LA), derived from lignocellulosic biomass, to γ-valerolactone (GVL), in a batch reactor under 30 bar H₂ pressure at 150 and 200 °C, applying water as a solvent. The NiCu/SOD and NiCu/X catalysts showed total LA conversion and a high GVL yield (>75%) at a reaction temperature of 200 °C. It was found that the textural parameters of the catalysts have less influence on the catalytic activity, but rather the stable dispersion of metals during the reaction. The characterization of the spent catalyst found the rearrangement of the support structure. The high LA conversion and GVL yield can be attributed to the weak acidic character of the support and the moderate hydrogenation activity of the Ni-Cu sites with high dispersion. Full article

Three-dimensional printing is ideally suited to produce unique and complex shapes. In this study, the material properties of polysiloxanes, commonly named silicones, produced additively by two different methods, namely, multi-jet fusion (MJF) and material extrusion (ME) with liquid printing heads, are investigated. The chemical composition was compared via Fourier-transform infrared spectroscopy, evolved gas analysis mass spectrometry, pyrolysis gas chromatography coupled to mass spectrometry, and thermogravimetry (TGA). Density and low-temperature flexibility, mechanical properties and crosslink distance via freezing point depression were measured before and after post-treatment at elevated temperatures. The results show significant differences in the chemical composition, material properties, as well as surface quality of the tested products produced by the two manufacturing routes. Chemical analysis indicates that the investigated MJF materials contain acrylate moieties, possibly isobornyl acrylate linking branches. The hardness of the MJF samples is associated with crosslinking density. In the ashes after TGA, traces of phosphorus were found, which could originate from initiators or catalysts of the curing process. The ME materials contain fillers, most probably silica, that differ in their amount. It is possible that silica also plays a role in the processing to stabilize the extrusion strand. For the harder material, a higher crosslink density was found, which was supported also by the other tested properties. The MJF samples have smooth surfaces, while the ME samples show grooved surface structures typical for the material extrusion process. Post-treatment did not improve the material properties. In the MJF samples, significant color changes were observed. Full article

To investigate the influence of deashing on fusion characteristics, a combined method of water and acid washing with different sequences (water washing followed by acid washing, and acid washing followed by water washing) was used to treat the biochar of bamboo shoot shells (BBSSs). The results show that deashing decreased the K content of the biochar from 50.3% to 1.08% but increased the Si content from 33.48% to 89.15%. The formation of silicates and aluminosilicates from alkali metal oxides with silicon was an inevitable result of ash phase transformation at the high temperatures used to improve the fusion temperature (>1450 °C). The thermochemical behavior of ash mainly occurs at 1000 °C. The deashing treatment significantly reduced the reaction intensity during the high-temperature process. This significantly increased the thermal stability of the ash. The adjustment of the washing sequence had a slight impact on the chemical compositions, but the differences in ash micromorphology were obvious. Deashing treatments with different washing sequences can significantly improve ash fusion properties effectively and reduce the risk of scaling, slagging, and corrosion. This study provides a new and reasonable strategy for the deashing of biochar to commercially utilize bamboo shoot shell resources. Full article

The co-gasification of biomass and coal is helpful for achieving the clean and efficient utilization of phosphorus-rich biomass. A large number of alkali and alkaline earth metals (AAEMs) present in the ash system of coal (or biomass) cause varying degrees of ash, slagging, and corrosion problems in the entrained flow gasifier. Meanwhile, phosphorus is present in the slag in the form of ${\mathrm{PO}}_4^{3^{-}}$, which has a strong affinity for AAEMs (especially for Ca²⁺) to produce minerals dominated by calcium phosphates or alkaline Ca-phosphate, effectively mitigating the aforementioned problems. To investigate the changing behavior of the slag flow temperature (FT) under different CaO/P₂O₅ ratios, 72 synthetic ashes with varying CaO/P₂O₅ ratios at different Si/Al contents and compositions were prepared, and their ash fusion temperatures were tested. The effects of different CaO/P₂O₅ ratios on the FT were analyzed using FactSage thermodynamic simulation. A model for predicting slag FT at different CaO/P₂O₅ ratios was constructed on the basis of the average molar ionic potential (I_a) method and used to predict data reported from 19 mixed ashes in the literature. The results showed that I_a and FT gradually increased with a decreasing CaO/P₂O₅ ratio, and the main mineral types shifted from anorthite → mullite → berlinite, which reasonably explained the decrease in ash fusion temperatures in the mixed ash. The established model showed good adaptability to the prediction of 19 actual coal ash FTs in the literature; the deviation of the prediction was in the range of 40 °C. The model proposed between FT and I_a based on the different CaO/P₂O₅ ratios can be used to predict the low-rank coal and phosphorus-rich biomass and their mixed ashes. Full article

Solid activators based on waste glass for the manufacture of one-part alkali-activated fly ash/red mud materials were synthesized, characterized, and tested in this work. The synthesis was carried out via alkaline fusion with sodium hydroxide at different reaction temperatures and at different sodium hydroxide/waste glass mass ratios. The results showed that the reaction temperature decisively influences the properties of the obtained solid activators. Thus, the best results regarding the water solubility of solid activators were obtained for the synthesis temperature of 600 °C, regardless of the sodium hydroxide/waste glass mass ratio. Also, the use of these assortments of solid activators led to obtaining the best compressive strength of one-part alkali-activated fly ash/red mud materials. The best results were obtained for the solid activator synthesized at a temperature of 600 °C and a sodium hydroxide/glass waste mass ratio of two. Full article

Co-combustion of solid waste and biomass can alleviate biomass ash-related problems. To investigate the effects of solid waste on the ash fusion characteristics of biomass and its variation mechanisms under an oxidation atmosphere, an X-ray diffraction, thermogravimetric analyzer (TG), scanning electron microscope (SEM), and FactSage calculation were used to examine the ash fusion behaviors of sorghum straw (SS) with the addition of textile dyeing sludge (TDS) or chicken manure (CM). The ash fusion temperature (AFT) of SS increased gradually with the TDS ash addition; with CM ash addition, the AFT of SS mixtures increased rapidly (0–20%), decreased slightly (20–30%), and finally increased slowly (30–60%). The generations of high melting point (MP) minerals (e.g., KAlSi₂O₆, Fe₂O₃, and Fe₃O₄) led to an increase in the AFT of TDS-SS mixtures. The K⁺ in silicate was gradually replaced by Mg²⁺ or Ca²⁺, which caused the generations of high-MP minerals (e.g., Ca₃MgSi₂O₈, Ca₂MgSi₂O₇, and CaMgSiO₄). The TG analysis showed that the additions of TDS or CM ash slowed down the weight loss of SS mixed ash due to the formation of high-MP minerals. The SEM and FactSage calculations were also explained with the AFT change and their variation mechanisms. The result provided effective references for the AFT regulation during the co-combustion of biomass and solid waste. Full article

This study presents the synthesis of zeolites derived from coal fly ash (CFA) using the fusion-assisted alkaline hydrothermal method. The zeolites were synthesized by combining CFA and NaOH at a molar ratio of 1:1.2 under fusion temperatures of 500, 600, and 700 °C. Subsequently, the obtained zeolites were subjected to further modifications through the incorporation of magnetic (Fe₃O₄) and silver (Ag⁰) nanoparticles (NPs). The Fe₃O₄ NPs were introduced through co-precipitation of Fe(NO₃)₂ and FeCl₃ at a molar ratio of 1:1, followed by thermal curing at 120 °C. On the other hand, the Ag⁰ NPs were incorporated via ion exchange of Na⁺ with Ag⁺ and subsequent reduction using NaBH₄. The synthesized porous materials exhibited the formation of zeolites, specifically analcime and sodalite, as confirmed by X-ray diffraction (XRD) analysis. Additionally, the presence of Fe₃O₄ and Ag⁰ NPs was also confirmed by XRD analysis. The elemental composition analysis of the synthesized nanocomposites further validated the successful formation of Fe₃O₄ and Ag⁰ NPs. Nitrogen porosimetric analysis revealed the formation of a microporous structure, with the BET surface area of the zeolites and nanocomposites ranging from 48.6 to 128.7 m²/g and pore sizes ranging from 0.6 to 4.8 nm. The porosimetric characteristics of the zeolites exhibited noticeable changes after the modification process, which can be attributed to the impregnation of Fe₃O₄ and Ag⁰ NPs. The findings of this research demonstrate the effectiveness of the fusion-assisted method in producing synthetic zeolites and nanocomposites derived from CFA. The resulting composites were evaluated for their potential application in the removal of mercury ions from aqueous solutions. Among the samples tested, the composite containing Ag⁰ NPs exhibited the highest adsorption capacity, reaching 107.4 mg of Hg²⁺ per gram of composite. The composites modified with Fe₃O₄ NPs and Ag/Fe₃O₄ nanocomposites displayed adsorption capacities of 68.4 mg/g and 71.4 mg/g, respectively. Full article

The increase of global environmental restrictions concerning solid and liquid industrial waste, in addition to the problem of climate change, which leads to a shortage of clean water resources, has raised interest in developing alternative and eco-friendly technologies for recycling and reducing the amount of these wastes. This study aims to utilize Sulfuric acid solid residue (SASR), which is produced as a useless waste in the multi-processing of Egyptian boiler ash. A modified mixture of SASR and kaolin was used as the basic component for synthesizing cost-effective zeolite using the alkaline fusion-hydrothermal method for the removal of heavy metal ions from industrial wastewater. The factors affecting the synthesis of zeolite, including the fusion temperature and SASR: kaolin mixing ratios, were investigated. The synthesized zeolite was characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), particle size analysis (PSD) and N₂ adsorption-desorption. The SASR: kaolin weight ratio of 1:1.5 yields faujasite and sodalite zeolite with 85.21% crystallinity, which then shows the best composition and characteristics of the synthesized zeolite. The factors affecting the adsorption of Zn²⁺, Pb²⁺, Cu²⁺, and Cd²⁺ ions from wastewater on synthesized zeolite surfaces, including the effect of pH, adsorbent dosage, contact time, initial concentration, and temperature, have been investigated. The obtained results indicate that a pseudo-second-order kinetic model and Langmuir isotherm model describe the adsorption process. The maximum adsorption capacities of Zn²⁺, Pb²⁺, Cu²⁺, and Cd²⁺ ions onto zeolite at 20 °C were 12.025, 15.96, 12.247, and 16.17 mg·g⁻¹, respectively. The main mechanisms controlling the removal of these metal ions from aqueous solution by synthesized zeolite were proposed to be either surface adsorption, precipitation, or ion exchange. The quality of the wastewater sample obtained from the Egyptian General Petroleum Corporation (Eastern Desert, Egypt) was highly improved using the synthesized zeolite and the content of heavy metal ions was significantly reduced, which enhances the utilization of the treated water in agriculture. Full article

Agricultural and other residues are promising renewable energy sources. However, they can cause problems in combustion processes. One of these problems is also low ash melting temperatures. Except, the ash melting behavior can be impacted by many factors, such as ash preparation or used atmosphere. This article deals with comparing different atmosphere conditions during measurements of ash melting temperatures of three agricultural pellets: alfalfa, straw, and hay. The first one was oxidizing with compressed air and nitrogen. The second atmosphere was reduced with the air purge, and the last was only reduced, consisting of 60% carbon monoxide and 40% carbon dioxide. Differences between individual atmospheres were none, up to 9.8%. The most significant differences have appeared between oxidizing and reducing atmospheres. In general, the oxidizing atmosphere presents a less expensive way. More attention should be paid to the use of oxidizing atmosphere for applications in heat sources mainly due to its similarity to the combustion process. However, it would be suitable to realize more comprehensive research regarding ash preparation in different ways and with using of different types of fuel. Full article

The harmless disposal of spent cathode carbon blocks (SCCBs) has become an urgent issue in the primary aluminum industry, and the disposal of SCCBs by co-combustion in pulverized coal boilers is expected to be the most effective treatment method. A muffle furnace at 815 °C was used in this study to perform a co-combustion experiment of meager coal and SCCBs. The ash fusion characteristics (AFTs), microscopic morphology, and minerals composition of co-combustion ash were characterized. The interaction mechanism of different mineral components and the change in AFTs and viscosity-temperature characteristics were investigated using FactSage software. Results show that the change in the ash deformation temperature (DT) is correlated linearly with the SCCB addition ratio, whereas other characteristic temperatures exhibit a nonlinear relationship. The contents of SiO₂, Al₂O₃, and Na₂O collectively determine the DT in the ash, and the influence degree from high to low is in the order of SiO₂, Na₂O, and Al₂O₃. The phase diagram of Na₂O–Al₂O₃–SiO₂ is used to accurately predict the changing trend of the melting point of co-combustion ash. The ratio changes between refractory and fusible minerals in the ash, as well as the degree of low-temperature eutectic reaction between sodium- and calcium-containing minerals, are the main factors affecting the melting point of ash. When the blending amount of SCCBs is 5%, mostly complete combustion is achieved, and slagging does not occur easily. The optimal blending ratio of SCCBs is obtained using the co-combustion method from the aspect of AFTs and viscosity-temperature characteristics. This work lays a theoretical foundation for industrial application. Full article

This work investigated the effect of coal blending on ash fusibility and slurryability of Xinjiang low-rank coal. The results showed that Xinjiang low-rank coals were characterized by high internal water content, high volatile content, high ash fusing point, and poor slurryability, which can not be directly used in coal water slurry gasification. The blending method not only reduced the ash fusibility but also improved the slurryability of these low-rank coals. When the coals with low calcium and high silicon contents (KG and YK) were blended with coal with high calcium content (SH), the ash fusion temperatures of the blended coal were significantly reduced. Moreover, the SH coal showed the worst slurryability performance with a concentration of 48.56%. The slurryability of HS coal can be dramatically improved by blending with KG. When the mass fraction of KG coal reached 70%, the concentration of coal water slurry increased by 11%. For the blended coal of KG and YK, the concentration and stability of coal water slurry gradually increase with the increasing mass ratio of KG. The coal blending method can effectively improve the concentration of coal water slurry for the low-rank coals, which were difficult-to-prepare slurry. Full article

The formation of slagging and fouling during municipal solid waste (MSW) incineration not only significantly affects heat transfer, but also results in shortened operating cycles. In order to solve the issues, the effect of different additives on the migration and transformation patterns of alkali/alkaline earth metals (AAEM) and chlorine during MSW incineration is screened based on the Gibbs energy minimization method. The effect of potential additives on the ash fusion temperature and combustion reactivity of MSW char is subsequently verified and evaluated by experimental methods. The thermodynamic equilibrium analysis shows that Al(NO₃)₃, Ca(NO₃)₂, and Mg(NO₃)₂ have great potential to increase the ash fusion temperature. The experimental investigation confirms that the addition of Al(NO₃)₃, Ca(NO₃)₂, and Mg(NO₃)₂ significantly increases the ash fusion temperature. The order of increasing the ash fusion temperature by different additives is Mg(NO₃)₂ > Ca(NO₃)₂ > Al(NO₃)₃. The addition of Mg(NO₃)₂ significantly increased the initial deformation temperature, softening temperature, hemispheric temperature, and flow temperature of ash from 1180, 1190, 1200, and 1240 °C to 1220, 1230, 1240, and 1260 °C, respectively. The addition of Cu(NO3)2, Fe(NO3)3, and KMnO4 significantly decreases the temperature at the maximum weight loss rate of MSW char, while increasing the maximum weight loss rate. Additionally, Cu(NO₃)₂ shows the best performance in improving the combustion reactivity of MSW char. The addition of Cu(NO₃)₂ evidently increases the maximum weight loss rate from 0.49 to 0.54% °C⁻¹. Therefore, it is concluded that Mg(NO₃)₂ and Cu(NO₃)₂ are supposed to be the most potential candidates for efficient additives. This study presents an efficient and economical method to screen potential additives for alleviating slagging and fouling during MSW incineration. Full article