A modified approach to equilibrium modelling of coal gasification is presented, based on global thermodynamic analysis of both homogeneous and heterogeneous reactions occurring during a gasification process conducted in a circulating fluid bed reactor. The model is based on large-scale experiments (ca. 200 kg/h) with air used as a gasification agent and introduces empirical modifications governing the quasi-equilibrium state of two reactions: water-gas shift and Boudouard reaction. The model predicts the formation of the eight key gaseous species: CO, CO2, H2O, H2, H2S, N2, COS and CH4, volatile hydrocarbons represented by propane and benzene, tar represented by naphthalene, and char containing the five elements C, H, O, N, S and inorganic matter.
Any complete CFD model of pulverised coal-fired boiler needs to consider ash deposition phenomena. Wall boundary conditions (temperature and emissivity) should be temporally corrected to account for the effects of deposit growth on the combustion conditions. At present voluminous publications concerning ash related problems are available. The current paper presents development of an engineering tool integrating deposit formation models with the CFD code. It was then applied to two tangentially-fired boilers. The developed numerical tool was validated by comparing it with boiler evaporator power variation based on the on-line diagnostic system with the results from the full CFD simulation.
The most important and the most frequently used plastics are polyethylene (PE) and polypropylene (PP). They are characterised with high heating values (approximately 40 MJ/kg). Moreover, their chemical composition, based mainly on carbon and hydrogen, allows to use them in industrial processes. One of the methods of utilisation of plastic waste can be its use in the metallurgical industry. This paper presents results of thermal decomposition of waste PE/PP. Chemical and thermal analysis (TG) of studied wastes was carried out. Evolved gaseous products from the decomposition of wastes were indentified using mass spectrometry (TG-MS). This paper also presents an application of plastic wastes as supplemental fuel in blast furnace processes (as a substitute for coke) and as an addition in processes of coking coal.
The paper covers problems of the owners of a fleet of long-operated conventional power plants that are going to be decommissioned soon in result of failing to achieve new admissible emissions levels or exceeding pressure elements design lifetime. Energoprojekt-Katowice SA, Siemens AG and Rafako SA presents their joint concept of the solution which is a 2on1 concept – replacing two unit by two ultra-supercritical boilers feeding one turbine. Polish market has been taken as an example.
The research was aimed at examining the impact of the petrographic composition of coal from the Janina mine on the gasification process and petrographic composition of the resulting char. The coal was subjected to fluidized bed gasification at a temperature below 1000°C in oxygen and CO2 atmosphere. The rank of coal is borderline subbituminous to bituminous coal. The petrographic composition is as follows: macerals from the vitrinite (61.0% vol.); liptinite (4.8% vol.) and inertinite groups (29.0% vol.). The petrofactor in coal from the Janina deposit is 6.9. The high content of macerals of the inertinite group, which can be considered inert during the gasification, naturally affects the process. The content of non-reactive macerals is around 27% vol. The petrographic analysis of char was carried out based on the classification of International Committee for Coal and Organic Petrology. Both inertoid (34.7% vol.) and crassinetwork (25.1% vol.) have a dominant share in chars resulting from the above-mentioned process. In addition, the examined char contained 3.1% vol. of mineroids and 4.3% vol. of fusinoids and solids. The calculated aromaticity factor increases from 0.75 in coal to 0.98 in char. The carbon conversion is 30.3%. Approximately 40% vol. of the low porosity components in the residues after the gasification process indicate a low degree of carbon conversion. The ash content in coal amounted to 13.8% and increased to 24.10% in char. Based on the petrographic composition of the starting coal and the degree of conversion of macerals in the char, it can be stated that the coal from the Janina deposit is moderately suitable for the gasification process.
In recent years, more and more attention has been paid to the quality of produced coal size categories for energy purposes. This is important from the perspective of promoting clean coal technologies which aim at changing the perception of coal as a fuel friendly for the environment. This is specifically because hard coal resources in Poland allow the national energy security to be guaranteed on the basis of energy production based on hard coal. Fine coals upgraded at coal processing facilities in the separation process in fine coal jigs are mainly used in energy production from coal. In the article, an analysis of hard coal upgrading in a jig regarding the optimum recovery of a useful fraction in the concentrate (combustible and volatile matter) and non-useful fraction in tailings (ash and sulfur) was conducted. Based on the industrial testing of a fine coal jig, the granulometric and densimetric analysis of the taken samples of concentrate, middlings and tailings of coal was conducted in laboratory conditions. Yields of products were calculated in separated size-fractions of separation products, and ash content and total sulfur content were determined in them. Based on the results of granulometric, densimetric and chemical analyses of the obtained size-fractions, the balance of separation products and appropriate calculations, Fuerstenau upgrading curves which allowed the process to be evaluated and a comparison of the results of hard coal upgrading regarding the optimum recovery of the organic phase in the concentrate and mineral components in tailings to be drawn. The obtained results were evaluated on the basis of different criteria for changing the device’s hydrodynamic operational conditions. The ash content and total sulfur content were analyzed as non-useful substances.
In the present paper, the one-dimensional model for heat and mass transfer in fixed coal bed was proposed to describe the thermal and flow characteristics in a coke oven chamber. For the purpose of the studied problem, the analysis was limited to the calculations of temperature field and pyrolytic gas yield. In order to verify the model, its theoretical predictions for temperature distribution during wet coal charge carbonization were compared with the measurement results found in the literature. In general, the investigation shows good qualitative agreement between numerical and experimental data. However, some discrepancy regarding the temperature characteristics at the stage of evaporation was observed.
The paper presents current reports on kinetics and mechanisms of reactions with mercury which take place in the exhaust gases, discharged from the processes of combustion of solid fuels (coals). The three main stages were considered. The first one, when thermal decomposition of Hg components takes place together with formation of elemental mercury (Hg0). The second one with homogeneous oxidation of Hg0 to Hg2+ by other active components of exhaust gases (e.g. HCl). The third one with heterogeneous reactions of gaseous mercury (the both - elemental and oxidised Hg) and solid particles of fl y ash, leading to generation of particulate-bound mercury (Hgp). Influence of exhaust components and their concentrations, temperature and retention time on the efficiency of mercury oxidation was determined. The issues concerning physical (gas-solid) and chemical speciation of mercury (fractionation Hg0-Hg2+) as well as factors which have influence on the mercury speciation in exhaust gases are discussed in detail.
This article presents the use of a multi-criterion Analytic Hierarchy Process (AHP) method to assess geological and mining condition nuisance in longwall mining operations in selected coal mines in Poland. For this purpose, a methodology has been developed which was used to calculate the operational nuisance indicator (WUe) in relation to the cost of mining coal in individual longwalls. Components of the aggregate operational nuisance indicator include four sub-indicators: the natural hazards indicator (UZN), an indicator describing the seam parameters (UPZ), an indicator describing the technical parameters (UT) and an environmental impact indicator (UŚ). In total, the impact of 28 different criteria, which formed particular components of the nuisance indicators were analysed. In total 471 longwalls in 11 coal mines were analysed, including 277 longwalls that were mined in the period of 2011 to 2016 and 194 longwalls scheduled for exploitation in the years 2017 to 2021. Correlation analysis was used to evaluate the relationships between nuisance and the operating costs of longwalls. The analysis revealed a strong correlation between the level of nuisance and the operating costs of the longwalls under study. The design of the longwall schedule should therefore also take into account the nuisance arising from the geological and mining conditions of the operations. Selective operations management allows for the optimization of costs for mining in underground mines using the longwall system. This knowledge can also be used to reduce the total operating costs of mines as a result of abandoning the mining operations in entire longwalls or portions of longwalls that may be permanently unprofitable. Currently, underground mines do not employ this optimization method, which even more emphasizes the need for popularizing this approach.
The environment is the greatest good for the people. Everyone wants to breath air of the best possible quality, whether living in the city center of a metropolis or in a rural area. Air polluted with very fine particles contribute to the negative effect on people’s health and the whole environment. A significant part of air dust pollution comes from the so-called low emissions sources which include: non-standard furnaces, fireplaces, low-efficiency outdated boilers and local heat sources. Since the beginning of Polish Mining Group’s existence, the company actively participates and supports many activities, the aim of which is to improve the air quality by producing and supplying high quality coal for the residential sector. The company has undertaken pro-ecological activities towards creating a new, pro-ecological strategy as well as product offer. The production of an ecological coal assortment is systematically developing but new coal products are also being launched on the market. One of the company’s priorities is the production of thermal coal for the residential sector. Many organizational and technological changes have been made In that area (e.g. the establishmsnt of the Eco-Fuels Production Plant) to ensure a suitable level of production of the highest quality thermal coal.
The petrographic composition of coal has a significant impact on its technological and sorption properties. That composition is most frequently determined by means of microscope quantitative analyses. Thus, aside from the purely scientific aspect, such measurements have an important practical application in the industrial usage of coal, as well as in issues related to the safety in underground mining facilities. The article discusses research aiming at analyzing the usefulness of selected parameters of a digital image description in the process of automatic identification of macerals of the inertinite group using neural networks. The description of the investigated images was based on statistical parameters determined on the basis of a histogram and co-occurrence matrix (Haralick parameters). Each of the studied macerals was described by means of a 20-element feature vector. An analysis of its principal components (PCA) was conducted, along with establishing the relationship between the number of the applied components and the effectiveness of the MLP network. Based on that, the optimum number of input variables for the investigated classification task was chosen, which resulted in reduction of the size of the network’s hidden layer. As part of the discussed research, the authors also analyzed the process of classification of macerals of the inertinite group using an algorithm based on a group of MLP networks, where each network possessed one output. As a result, average recognition effectiveness of 80.9% was obtained for a single MLP network, and of 93.6% for a group of neural networks. The obtained results indicate that it is possible to use the proposed methodology as a tool supporting microscopic analyses of coal.
The article compares the management of energy resources in Poland and Ukraine over the period 2000–2017. The analysis took changes in the volume of coal, oil and natural gas resources into consideration. The indicators of supplies of these fuels for Poland and Ukraine have additionally been compared with selected EU countries. In order to assess energy security of Poland and Ukraine, the changes in the primary energy consumption have been analyzed in general in first order, then the possibilities of meeting the demand for natural gas, coal and oil have been determined based on the domestic extraction of individual energy resources. Such a comparison indicates the dominant role of coal in Poland while the extraction of oil and natural gas meets the domestic demand to a greater extent in Ukraine. Over the period 2000-2017, trends in primary energy consumption were different; a 17% increase was noted in Poland, while a nearly 40% decline was noted in Ukraine. The main factors responsible for radical changes in fuel and energy management in Ukraine have been identified: military operations in the east of the country and the annexation of Crimea, demographic changes. These events had a negative impact especially on the volume of hard coal mining in Ukraine; the significant increase in imports from 5.36 to 19.14 million tons in 2011-2017 was necessary for balancing. The balance of foreign exchange for electricity was also compared. Over the past years, this comparison has been favorable for Ukraine, where the dominance of electricity exports over imports is noticeable, which generated revenues of over USD 200 million in 2017.
To investigate the effect of different proximate index on minimum ignition temperature(MIT) of coal dust cloud, 30 types of coal specimens with different characteristics were chosen. A two-furnace automatic coal proximate analyzer was employed to determine the indexes for moisture content, ash content, volatile matter, fixed carbon and MIT of different types of coal specimens. As the calculated results showed that these indexes exhibited high correlation, a principal component analysis (PCA) was adopted to extract principal components for multiple factors affecting MIT of coal dust, and then, the effect of the indexes for each type of coal on MIT of coal dust was analyzed. Based on experimental data, support vector machine (SVM) regression model was constructed to predicate the MIT of coal dust, having a predicating error below 10%. This method can be applied in the predication of the MIT for coal dust, which is beneficial to the assessment of the risk induced by coal dust explosion (CDE).
Work is being carried out on possibilities of limiting the content of mercury in hard coal products by gravity concentration of run-of-mine coal in the Branch of the Institute of Mechanized Construction and Rock Mining in Katowice and on the Faculty of Energy and Fuels of the AGH University of Science and Technology in Krakow. Under domestic industrial conditions, gravity concentration is carried out with heavy medium liquids and in jigs. Preliminary - pilot studies have shown the possibility of mercury removal also by using the dry deshaling method involving vibratory air separators. Mercury is mainly found in the pyrite and the rubble formed by the mineral carbon, but also in the organic carbon. Some of it is located in layers of coal roof fields, which in the course of their exploitation go to coal. The mercury removal efficiency during the gravity concentration process will depend on the decomposition of the listed components in the density fractions. The paper presents the results of investigations of total mercury and total sulphur content in the separated coal fractions from four mines. These contents were determined in fractions: –1.5 g/cm3 (conventionally clean coal – concentrate), 1.5–1.8 g/cm3 (conventionally middlings) and +1.8 g/cm3 (conventionally rock – waste). The results are summarized in Tables 3–5 and in Charts 1–4. Conversely, graphs 5-8 show the relationship between mercury content and total sulphur content in the tested coal samples. The study, which can be called a preliminary analysis of the susceptibility of the coals to gravity concentration, showed that the dry deshaling method on the vibratory air separators would allow significant amounts of mercury accumulated in the middlings and waste fractions to be removed.
In the process of extraction and enrichment of coal waste, considerable quantities of waste material are produced, mainly the gangue and coal sludge, considered as waste or raw material. The main directions of the management development of the waste rock are the production of aggregates, the production of energy products and the liquidation works in hard coal mines and the filling of excavations. The paper proposes the extension of these activities to the use of waste material. The possibility of using aggregates or extractive waste to fill open-pit excavations has been proposed, also in areas within the reach of groundwater and the possibility of building insulation layers of waste material and the production of mixtures of hard coal sludge and sewage sludge to produce material with good energy properties. The analysis was based on the author’s own research and literature data related to selected parameters of waste material. This paper presents our own preliminary studies on the amount of combustion heat and the calorific value of coal sludge combined with other wastes such as sewage sludge. The proposed methods and actions are part of the current directions of development, but they allow the extension of the scope of use of both extractive waste and products produced on the basis of gangue or coal sludge. Due to the frequent lack of the stable composition of these materials, their current properties should be assessed each time before attempting to use them. The fact that it is important to continue research to promote existing economic use and to seek new activities or methods has been concluded.
In the extra-thick coal seams and multi-layered hard roofs, the longwall hydraulic support yielding, coal face spalling, strong deformations of goaf-side entry, and severe ground pressure dynamic events typically occur at the longwall top coal caving longwall faces. Based on the Key strata theory an overburden caving model is proposed here to predict the multilayered hard strata behaviour. The proposed model together with the measured stress changes in coal seam and underground observations in Tongxin coal mine provides a new idea to analyse stress changes in coal and help to minimise rock bursts in the multi-layered hard rock ground. Using the proposed primary Key and the sub-Key strata units the model predicts the formation and instability of the overlying strata that leads to abrupt dynamic changes to the surrounding rock stress. The data obtained from the vertical stress monitoring in the 38 m wide coal pillar located adjacent to the longwall face indicates that the Key strata layers have a significant influence on ground behaviour. Sudden dynamically driven unloading of strata was caused by the first caving of the sub-Key strata while reloading of the vertical stress occurred when the goaf overhang of the sub-Key strata failed. Based on this findings several measures were recommended to minimise the undesirable dynamic occurrences including pre-split of the hard Key strata by blasting and using the energy consumption yielding reinforcement to support the damage prone gate road areas. Use of the numerical modelling simulations was suggested to improve the key theory accuracy.
As one of the key techniques in the fully mechanized mining process, equipment selection and matching has a great effect on security, production and efficiency. The selection and matching of fully mechanized mining equipment in thin coal seam are restricted by many factors. In fully mechanized mining (FMM) faced in thin coal seams (TCS), to counter the problems existing in equipment selection, such as many the parameters concerned and low automation, an expert system (ES) of equipment selection for fully mechanized mining longwall face was established. A database for the equipment selection and matching expert system in thin coal seam, fully mechanized mining face has been established. Meanwhile, a decision-making software matching the ES was developed. Based on several real world examples, the reliability and technical risks of the results from the ES was discussed. Compared with the field applications, the shearer selection from the ES is reliable. However, some small deviations existed in the hydraulic support and scraper conveyor selection. Then, the ES was further improved. As a result, equipment selection in fully mechanized mining longwall face called 4301 in the Liangshuijing coal mine was carried out by the improved ES. Equipment selection results of the interface in the improved ES is consistent with the design proposal of the 4301 FMM working face. The reliability of the improved ES can meet the requirements of the engineering. It promotes the intelligent and efficient mining of coal resources in China.
Trace metal composition of snowpack, snow-melt filter residues and top-soils were determined along transects through industrial towns in the Usa River Basin: Inta, Usinsk and Vorkuta. Elevated concentrations of deposition elements and pH in snow and soils associated with alkaline coal ash within 25-40 km of Vorkuta and Inta were found. Atmospheric deposition in the vicinity of Vorkuta and Inta, added significantly to the soil contaminant loading as a result of ash fallout. The element concentrations in soils within 20-30 km of Vorkuta do not reflect current deposition rates, but instead, reflect an historical pollution legacy, when coal mining activity peaked in the 1960s. There is little evidence of anthropogenic metal deposition around the gas and oil town of Usinsk.
Combustion technology of the coal-water suspension creates a number of new possibilities to organize the combustion process fulfilling contemporary requirements, e.g. in the environment protection. Therefore the in-depth analysis is necessary to examine the technical application of coal as a fuel in the form of suspension. The research undertakes the complex investigations of the continuous coal-water suspension as well as cyclic combustion. The cyclic nature of fuel combustion results from the movement of the loose material in the flow contour of the circulating fluidized bed (CFB): combustion chamber, cyclone and downcomer. The experimental results proved that the cyclic change of oxygen concentration around fuel, led to the vital change of both combustion mechanisms and combustion kinetics. The mathematical model of the process of fuel combustion has been presented. Its original concept is based on the allowance for cyclic changes of concentrations of oxygen around the fuel. It enables the prognosis for change of the surface and the centre temperatures as well as mass loss of the fuel during combustion in air, in the fluidized bed and during the cyclic combustion.
The technology for gob-side entry retaining in steep coal seams is still in the development stage. The analysis results of the caving structure of main roof, low influence of gateway’s stability because of long filling distance and weak dynamic effect of the gateway, and the low stress redistribution environment indicate that using this technology in steep coal seams has significant advantages. Moreover, to reinforce the waste rock and the soft floor and to better guard against the impact of the waste rock during natural filling, a rock blocking device and grouting reinforcement method were invented, and theoretical calculations result show that the blocking device has high safety factor. In addition, we also developed a set of hydraulic support devices for use in the strengthening support zone. Furthermore, because the retaining gateway was a systematic project, the selection of the size and shape of the gateway cross section and its support method during the initial driving stage is a key step. Thus, first, a section the size of bottom width and roof height of a new gateway was determined to meet any related requirements. Then, according to the cross sections of 75 statistical gateways and the support technique, it chosen a trapezoidal cross section when the dip of the coal seam is 35° < α ≤ 45°, a special and an inclined arch cross section when 45° < α ≤ 55°. Eventually, a support system of bolts and cables combined with steel mesh and steel belts was provided. The support system used optimized material and improved parameters, can enhanced the self-bearing ability of the surrounding coal and rock masses.
Geodesic measurements of mining area deformations indicate that their description fails to be regular, as opposed to what the predictions based on the relationships of the geometric-integral theory suggest. The Knothe theory, most commonly applied in that case, considers such parameters as the exploitation coefficient a and the angle of the main influences range tgβ, describing the geomechanical properties of the medium, as well as the mining conditions. The study shows that the values of the parameters a = 0.8 and tgβ = 2.0, most commonly adopted for the prediction of surface deformation, are not entirely adequate in describing each and every mining situation in the analysed rock mass. Therefore, the paper aims to propose methodology for determining the value of exploitation coefficient a, which allows to predict the values of surface subsidence caused by underground coal mining with roof caving, depending on geological and mining conditions. The characteristics of the analysed areas show that the following factors affect surface subsidence: thickness of overburden, type of overburden strata, type of Carboniferous strata, rock mass disturbance and depth of exploitation. These factors may allow to determine the exploitation coefficient a, used in the Knothe theory for surface deformation prediction.
In this work problems associated with requirements related to pollution emissions in compliance with more restrictive standards, low-emission combustion technology, technical realization of the monitoring system as well as algorithms allowing combustion process diagnostics are discussed. Results of semi-industrial laboratory facility and industrial (power station) research are presented as well as the possibility of application of information obtained from the optical fibre monitoring system for combustion process control. Moreover, directions of further research aimed to limit combustion process environmental negative effects are presented.
As part of the presented work, tests were carried out to check the possibility of replacing of conventional reducers used in the lead pyrometallurgical processes by cheaper, but equally effective substitutes. For research of lead oxide reduction, the following fine-grained carbonaceous materials were used, ie anthracite dust and coal flotation concentrate, as well as traditional used coke breeze for comparison. The obtained test results indicate a similar ability to reduce the lead oxide of all studied carbonaceous materials.