The results of studies of the effect of each of the parameters of fuel preparation and combustion on the concentration of pollutants separately are presented below.
3.1. Particle size distribution
Experiments to determine the effect of the fineness of grinding on the composition of waste gases were carried out for water-coal suspensions obtained from coal enrichment waste with an average particle diameter of 35, 47, 92, 154, and 202 µm. The results of studies of the content of nitrogen and sulfur oxides in the exhaust gases are shown in Fig. 3.
When drops of CWS enter the heated chamber, the temperature of the drops increases rapidly, water vapor and volatile components are released, which leads to the effect of micro-explosion (Atal and Levendis 1994). As a result, the diameter of individual droplets decreases, and the specific surface area of the sprayed fuel increases (Fig. 2). When using large particles as raw materials (the average diameter of which is 154 and 202 µm), the effect of microexplosion becomes less noticeable, which means that for the complete combustion of such fuel, a greater amount of time is required to stay in the chamber. With constant combustion parameters, an increase in the fineness of the grinding led to an increase in the combustible losses: from 1.5 % for fuel with an average particle diameter of 35 µm; up to 11.2 % for fuels where particles with an average diameter of 202 µm were used.
An increase in the combustible losses is associated with a decrease in the concentration of pollutants in the exhaust gases with an increase in the average particle diameter. With the selected combustion parameters, suspensions with an average particle size of more than 92 µm are not completely burned out, and sulfur and nitrogen compounds remain in the organic and mineral mass of the raw material. More complete combustion of suspensions increases the energy efficiency of the fuel, reduces the danger of the resulting ash and slag waste to the environment. Also, the ash with a low content of organic mass can be used as an additive to asphalt and concrete without preliminary preparation.
3.2. Ratios of solid and liquid phases in the suspension composition
Experiments to determine the effect of the proportion of solid and liquid phases on the composition of waste gases were carried out for CWS with a mass ratio of waste coal/water equal to 50/50, 60/40, and 70/30. The results of studies of the content of nitrogen and sulfur oxides in the exhaust gases are shown in Fig. 4.
An increase in the proportion of solid components in the composition of fuel suspensions from coal processing waste from 50 to 70 % leads to an increase in the specific mass of the formation of sulfur oxides by 56 %, and nitrogen oxides by 27 %.
The presence of a large amount of water in the composition of fuel suspensions lowers the temperature in the zone of active combustion, which leads to a decrease in the amount of formed nitrogen and sulfur oxides. In addition, water vapor under the influence of high temperatures decomposes into oxygen and hydrogen. In this case, the oxygen formed during the reaction intensifies the combustion process, and hydrogen helps to reduce the levels of nitrogen oxides and sulfur in the exhaust gases:
NOx+H2 → N2 + H2O (T ≥ 200 °С) (Efstathiou and Olympiou 2017);
NOx+СО → N2 + CO2 (T ≥ 1000 °С) (Daood at al. 2014, Lee at al. 2016);
SOx+H2 → S + H2O (T ≥ 600 °С) (Feng at al. 2017);
SOx+CO → S + CO2 (T ≥ 500 °С) (Feng at al. 2017, Bacskay and Mackie 2005).
Nevertheless, a decrease in the amount of the combustible component in the composition of fuel suspensions leads to a decrease in its specific heat of combustion, reduces the stability of the flame combustion, and also increases the ignition time of the suspension droplets, which negatively affects the energy characteristics of combustion. It was found that the best combustion parameters are observed with a solid content of 55–60 wt. %.
3.3. Waste mineral oil additives
Studies to determine the effect of the addition of spent mineral engine oil to fuel suspensions on the composition of waste gases were carried out at the mass ratio of coal enrichment waste/waste oil/water: 60/0/40, 55/5/40, 50/10/40, and 45/15/40.
Used engine oil has a high specific heat of combustion, 45.8 MJ/kg. When it is used as an additive to fuel suspensions, the total specific heat of combustion increases, the droplet ignition time decreases, and the flame stability increases. When 5% of used engine oil is added to the suspension from coal enrichment wastes, the specific heat of combustion increases by 13%, with the addition of 10% by 25%, at 15% by 37%.
Table 2 shows the concentrations of the main groups of hydrocarbons formed during the combustion of CWSP using used engine oil as an additive.
Table 2
Concentration of basic hydrocarbons depending on the content of used engine oil in the suspension
Group of hydrocarbons | The concentration of hydrocarbons, depending on the mass ratio of coal waste/waste oil/water (mg/g) |
60 / 0 / 40 | 55 / 5 / 40 | 50 / 10 / 40 | 45 / 15 / 40 |
Saturated hydrocarbons | 0.42 | 0.25 | 0.21 | 0.19 |
Unsaturated hydrocarbons | 0.62 | 0.79 | 0.87 | 0.94 |
Oxygen organic compounds | 3.88 | 4.24 | 4.64 | 4.97 |
Polyaromatic hydrocarbons: Naphthalene Anthracene Phenanthrene Pyrene Benzo[a]pyrene Xylene | < 0.001 < 0.001 0.002 0.003 < 0.001 < 0.005 | 0.001 < 0.001 0.003 0.004 < 0.001 0.01 | 0.002 0.001 0.005 0.004 0.002 0.03 | 0.005 0.001 0.008 0.005 0.005 0.05 |
Amount of hydrocarbons | 4.98 | 5.35 | 5.81 | 6.22 |
The addition of waste oil to coal-water suspensions leads to an increase in the total amount of hydrocarbons in the exhaust gases. The content of unsaturated, oxygen-containing and polyaromatic hydrocarbons increases, while the content of limiting hydrocarbons decreases. Also, when adding oil in the composition of the exhaust gases, xylenes can be fixed, which were not detected when burning coal-water fuel without additives (Table 2).
The increase in the content of unsaturated hydrocarbons in the composition of the exhaust gases is presumably associated with an increase in temperature in the zone of active combustion of the flame, which leads to incomplete pyrolysis of saturated hydrocarbons, in addition, the presence of additives in the waste oil containing metals such as Zn, Mo, Cu, etc., can catalyze the reactions of intermolecular dehydrogenation of saturated hydrocarbons upon rapid cooling of a highly heated gas-air mixture (Yan at al. 2020).
The increase in the concentration of oxygenated hydrocarbons is due to the presence of esters in the waste oil. The content of PAHs in the exhaust gases increases due to an increase in the amount of volatiles in the CWSP.
To visualize the obtained data, a graph of the dependence of the specific mass of nitrogen oxides, sulfur oxides, and the amount concentration of hydrocarbons on the addition of used engine oil to fuel coal-water suspensions obtained from coal processing waste was plotted (Fig. 5).
The sulfur content of the waste oil is 0.49 %. This indicator is slightly higher than for coal enrichment waste (0.32 %). The nitrogen content in the waste oil is 0.13 %, which is lower than in coal processing waste, where this value is 1.50 %.
An increase in the content of used engine oil in the composition of fuel suspensions during combustion leads to an increase in the concentration of nitrogen oxides in the composition of exhaust gases due to an increase in temperature in the active combustion zone. Also, the content of sulfur dioxide increases slightly due to an increase in the sulfur content in the combustible mass of the fuel (Poskart and Lech 2007).
When even 5% of used engine oil is added to the suspensions, their ignition is greatly simplified due to the relatively low ignition temperature of the oil, which is 226 ° C. For coal-water suspensions, the ignition temperature is 800–850 ° C. Also, when using the additive in the form of waste oil, the sedimentation stability of the suspension significantly increased (Samoilik at al. 1990, Debadutta 2020).
Since the parameters of the coal enrichment waste generated at the enterprise can differ significantly even during one shift, for the stability of combustion and obtaining the required energy parameters, it is possible to control the characteristics of the fuel by adding used oils.
3.4. Combustion temperature
Experiments to determine the effect of the combustion temperature on the composition of waste gases were carried out for fuel CWS at temperatures of 800 ± 20 °С, 900 ± 20 °С, 1000 ± 20 °С и 1100 ± 20 °С. Table 3 shows the concentrations of the main groups of hydrocarbons formed during the combustion of fuel suspensions, depending on the temperature in the combustion chamber.
Table 3
Concentration of basic hydrocarbons depending on the temperature in the combustion chamber
Group of hydrocarbons | The concentration of hydrocarbons, depending on the temperature in the combustion chamber (mg/g) |
800 °С | 900 °С | 1000 °С | 1100 °С |
Saturated hydrocarbons | 0.73 | 0.42 | 0.34 | 0.29 |
Unsaturated hydrocarbons | 1.15 | 0.62 | 0.41 | 0.35 |
Oxygen organic compounds | 4.73 | 3.88 | 2.94 | 2.32 |
Polyaromatic hydrocarbons: Naphthalene Anthracene Pyrene Benz[a]anthracene Benzo[a]pyrene | 0.002 0.001 0.002 0.003 0.002 | < 0.001 < 0.001 0.002 0.003 < 0.001 | < 0.001 < 0.001 0.002 0.002 < 0.001 | < 0.001 < 0.001 < 0.001 < 0.002 < 0.001 |
Amount of hydrocarbons | 6.63 | 4.93 | 3.71 | 2.99 |
The specific mass of the formation of hydrocarbons at higher temperatures decreased. The ratio of saturated, unsaturated, oxygen-containing, and polyaromatic organic compounds remained practically unchanged with increasing temperature.
The graph of the change in the mass of formation of nitrogen oxides, sulfur dioxide and hydrocarbons with a change in the combustion temperature of CWS obtained from coal wastes is shown in Fig. 6.
As the temperature rises, the concentration of sulfur dioxide increases. At high temperatures, the rate of the oxidation reaction increases, and the process of interaction of fuel sulfur with oxygen intensifies (Matveeva at al. 2019).
Nitrogen oxides during fuel combustion are formed from nitrogen-containing fuel components and molecular nitrogen in the air. During the experiments, it was found that the high-temperature effect in the combustion zone has a decisive influence on the content of nitrogen oxides in the exhaust gases. The formation of thermal nitrogen oxides occurs by the Zeldovich mechanism (Zeldovich at al. 1947, Babiy at al. 1996), in which the blast nitrogen is oxidized in the zone of active flame combustion. Since the activation energy of these reactions is high, the content of nitrogen oxides in the exhaust gases strongly depends on the temperature.
3.5. Air–fuel ratio
Experiments to determine the effect of air–fuel ratio during combustion of fuel suspensions obtained from coal processing waste on the composition of waste gases were carried out at air–fuel ratio of 1.1, 1.2, 1.3, and 1.4 %. Table 4 shows the values of the concentrations of the main groups of hydrocarbons formed during fuel combustion, depending on the air–fuel ratio.
Table 4
The concentration of the main hydrocarbons, depending on the air-fuel ratio
Group of hydrocarbons | The concentration of hydrocarbons, depending on air-fuel ratio (mg/g) |
1.1 | 1.2 | 1.3 | 1.4 |
Saturated hydrocarbons | 1.12 | 0.64 | 0.42 | 0.32 |
Unsaturated hydrocarbons | 2.32 | 1.14 | 0.62 | 0.46 |
Oxygen organic compounds | 4.62 | 4.21 | 3.88 | 3.32 |
Polyaromatic hydrocarbons: Naphthalene Anthracene Pyrene Benz[a]anthracene Benzo[a]pyrene | 0.011 0.029 0.023 0.005 0.006 | 0.003 0.009 0.007 0.004 0.003 | < 0.001 < 0.001 0.002 0.003 < 0.001 | < 0.001 < 0.001 < 0.001 < 0.002 < 0.001 |
Amount of hydrocarbons | 8.20 | 6.14 | 4.93 | 4.17 |
An increase in the excess air, calculated from the stoichiometric equation of combustion of a fuel suspension, from 1.1 to 1.4 leads to a decrease in the specific gravity of the formation of hydrocarbons by almost 2 times. This also reduces the levels of carcinogenic PAHs such as anthracene, pyrene, benzo[a]pyrene, benz[a]anthracene, and naphthalene.
For visualization of the obtained data was constructed a graph of the specific gravity of the formation of nitrogen oxides, sulfur dioxide, and total hydrocarbons from the excess air ratio when burning fuel suspensions obtained from by-product coal (Fig. 7).
Figure 7 shows a significant decrease in the specific mass of the formation of hydrocarbons, but at the same time, the amount of nitrogen oxides increases. The specific gravity of the formation of sulfur dioxide is less dependent on the air-fuel ratio.
With a decrease in the air-fuel ratio, the volumes of the formed thermal nitrogen oxides also decrease. At the same time, an insufficient excess of air in the combustion zone leads to an increase in emissions of hydrocarbons and particulate matter. Also, the regulation of the formation of nitrogen oxides by changing the excess air ratio can lead to high-temperature sulfide corrosion and increase the slagging of the walls of the furnace of the boiler unit. Despite this, the combustion of fuels with a lack of air is one of the most common ways to control nitrogen oxide emissions (Li at al. 2013, Hu at al. 2000).
The lowest amount of pollutants in the exhaust gases during the combustion of fuel suspensions from coal enrichment waste is observed at an air-fuel ratio of 1.2–1.3.
3.6. Suspension droplet size
Experiments to determine the effect of the degree of suspension spraying on the composition of waste gases were carried out for water-coal suspensions obtained from coal enrichment waste with an average drop diameter of 65, 94, 128, 184, and 253 µm. The results of studies of the content of nitrogen oxides and sulfur in the exhaust gases are shown in Fig. 8.
An increase in the average droplet size when spraying the suspension leads to a decrease in the specific mass of nitrogen and sulfur oxides. This is due to the fact that with an increase in the diameter of the drop, more time is required for its heating and ignition. Larger drops during the combustion of suspensions do not have time to completely burn out, as a result of which the combustible losses increases. This is associated with a decrease in emissions of nitrogen oxides and sulfur with an increase in the diameter of the suspension droplets.
The droplets with an average diameter of 65 microns burned more intensively, as a result of which the temperature in the combustion chamber increased and because of this, there was an increase in the concentration of nitrogen oxides and sulfur oxide in the composition of the exhaust gases. The microexplosion effect less apparent for drops of this diameter (Gaber at al. 2020).
The most optimal solution is to spray CWS to droplets with an average size of 94–128 µm since this requires less energy consumption compared to a suspension dispersed to droplets with an average diameter of 65 µm. The combustible losses when spraying drops with an average diameter of 65, 94, and 128 µm were 2.5–4.9 %.