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Article history: The present study aims to evaluate the chemical and mineralogical compositions of coal samples collect-
Received 23 September 2014 ed from three different seams of a particular borehole of Samaleswari Block, Ib river coalfield, Odisha,
Received in revised form 4 February 2015 India. Different experimental and theoretical studies were conducted to predict and correlate the chemi-
Accepted 5 February 2015
cal and mineral composition of coal ash to ash fusion temperatures. The experimental techniques used
Available online 16 February 2015
include proximate analysis, ultimate analysis, gross calorific value determination and chemical analysis
of coal ash for quantification of major oxides such as SiO2, Al2O3, Fe2O3, CaO, MgO, Na2O, K2O, SO3 and
Keywords:
TiO2. In addition, X-ray diffraction (XRD) and electron probe micro analysis (EPMA) techniques were used
Indian coal
Coal ash
to identify the mineral phases present in coal and ash samples. Finally, FactSage Thermodynamics Model
Ash fusion temperatures (FactSage 6.3) was used to understand the ash fusion behavior and to predict the phase transformations
Coal mineralogy that occur during the process of coal combustion.
FactSage Ó 2015 Elsevier Ltd. All rights reserved.
1. Introduction of coal gets worsen with increasing depth [1,2]. Although some
preliminary studies have been carried out on petrographic charac-
Coal is the dominant energy source and one of the major natural teristics and mineral matter content of Indian coals [3–6], little
resources available in India. Nearly 55% of country’s primary com- information has been published on the nature and relative propor-
mercial energy supply and about 70% of total electricity generation tions of the individual minerals, the modes of mineral occurrence,
is from coal [1,2]. Therefore, detail information on elemental and and the associations between the different groups of minerals pre-
mineralogical composition of Indian coal is essential to optimize sent within the Indian coals.
coal utilization technologies such as combustion, gasification, liq- During burning of coal, minerals undergo thermal decomposi-
uefaction and coking as well as for environment considerations. tion, fusion, disintegration and agglomeration. This causes major
The quality of Indian coal is generally poor having high ash content industrial problems such as ash clinkering, slagging, fouling,
(ranging from 30% to 50%), high moisture content (4–20%), low agglomeration, and deposition on heat exchange surfaces. The nat-
sulfur content (0.2–0.7%), and low calorific values (between 10.5 ure and distribution of mineral matter in coal determines the
and 20.9 MJ/kg) [1,2]. Indian coal seams are generally inter-banded degree to which these problems are likely to occur during coal com-
with mineral sediments and amount of ash in coal increases as one bustion [7]. Ash fusion temperatures (AFTs) are the parameters
move from the core of the coal seam to its floor, hence, the quality commonly used to predict the behavior of coal ash (ash fusibility
and melting behavior) during the processes of coal combustion,
gasification, liquefaction and ash utilization. It is more or less estab-
⇑ Corresponding author. Tel.: +91 657 2345063.
lished that AFTs depend strongly on the chemical composition of
E-mail address: sanchita@nmlindia.org (S. Chakravarty).
http://dx.doi.org/10.1016/j.fuel.2015.02.015
0016-2361/Ó 2015 Elsevier Ltd. All rights reserved.
S. Chakravarty et al. / Fuel 150 (2015) 96–101 97
coal ash and a number of studies have found empirical and statisti-
cal correlations between coal ash compositions and AFTs [8–11].
Many experimental techniques like scanning electron microscope
(SEM), energy dispersive X-ray spectroscopy analyzer (EDX),
C1
X-ray diffractometry, thermogravimetric analyzers [12–17] and
some theoretical models like thermodynamic computer package
FactSage, partial least-squares regression method, back propaga-
tion neural network model [18–20] have been used to either predict
or calculate AFTs from chemical composition of coal ash. However,
correlation between mineral matter composition and ash fusion
temperatures has not been reported so far for Indian coals.
The present study aims to evaluate the chemical and miner-
alogical compositions of coal samples collected from three differ-
ent seams of a particular borehole of Samaleswari Block, Ib river
coalfield, Odisha, India. Subsequently, different experimental and
theoretical studies were conducted to predict and correlate the
chemical and mineral composition of coal ash to AFTs. The
experimental techniques used include proximate analysis, ulti-
mate analysis, gross calorific value determination and chemical
analysis of coal ash for quantification of major oxides such as C15
SiO2, Al2O3, Fe2O3, CaO, MgO, Na2O, K2O, SO3 and TiO2. In addition,
X-ray diffraction (XRD) and electron probe micro analysis (EPMA)
techniques were used to identify the mineral phases present in
coal and ash samples. Finally, FactSage Thermodynamics Model
(FactSage 6.3) was used to understand the ash fusion behavior
and to predict the phase transformations that occur during the
process of combustion.
2. Geological setting
900 °C and then changing the heating rate to 5 °C min1. During different coal ashes at various temperature ranging from 700 °C
the process of AFT measurement, the initial deformation tem- to 1500 °C at a pressure of 1 atm. The thermodynamic phase equi-
perature (DT), softening temperature (ST), hemispherical tem- libria package used in this work was FactSage, version 6.3.
perature (HT) and fluid temperature (FT) were recorded Databases used for calculations of compounds were FactPS, ELEM,
according to the specific shape of the ash cone. FTmisc and FToxide. The elemental concentrations of coal ash were
used as input data for thermodynamic calculations.
3.5. Thermodynamic calculations
4. Results and discussions
A thermodynamic equilibrium calculation based on FactSage
computer software using ‘‘equilibrium module’’ was used for 4.1. Coal quality and mineralogy
predicting the multi-phase equilibria and their proportions for
For Indian coal, it is generally observed that quality of coal var-
ies significantly as one move from one seam to other within the
Table 1 same borehole [2]. In the present study, quality of the coal samples
Proximate (air dry basis), ultimate, GCV and forms of sulfur analysis of coal samples.
C1, C15 and C96 collected from three different seams of a par-
Component C1 C15 C96 ticular borehole of Samaleswari block of Ib valley coal field, Odisha,
Moisture (%) 3.87 3.18 4.04 India was evaluated by performing proximate, ultimate and gross
Ash (%) 31.6 44.4 35.42 calorific value (GCV) analysis. The result (on air dried basis) is pre-
Volatile matter (%) 24.7 29.68 26.53 sented in Table 1. Coals of all the three seams are of poor quality
Fixed carbon (%) 39.83 22.74 34.01
having high ash content (31.6–44.4%), low fixed carbon content
Gross calorific value (cal/g) 4988 3892 4110
C (total) (%) 44.91 35.71 39.32 (22.74–39.83%) and GCV in the range of 3892–4988 cal/g. Howev-
H (%) 1.99 2.26 2.12 er, the total sulfur content is relatively low (0.36–0.78%) and
N (%) 1.14 0.71 1.03 majority of the sulfur is associated with the coal macerals i.e.
S (total) (%) 0.36 46.74 0.78
organically associated sulfur. The volatile matter content of the
Water soluble S (ppm) 73.0 0.48 100
Pyritic S (%) 0.02 0.18 0.1
coals of all the three seams is more or less same (24.7–29.68%).
Organic S (%) 0.33 0.5 0.37 Among the three seams, coal of the seam C1 is of better quality
with highest fixed carbon content (39.83%) and has highest GCV
(4988 cal/g).
Mineralogy of the inorganic components of coal samples was
studied using X-ray powder diffraction technique. Knowledge of
the mineral matter present in coal helps in solving industrial prob-
lems such as boiler erosion, ash formation and slagging, coal pro-
cessing and coal utilization. Powder XRD diffractogram of the C1,
C15, and C96 coal samples (Fig. 2) indicates that quartz and kaolin-
ite are the major minerals present in all the three coals. Minor
amounts of feldspar, pyrite, whitlockite and siderite minerals were
also observed. Presence of iron containing minerals pyrite [FeS2]
and siderite [FeCO3] suggests that the ash fusion temperatures
(AFTs) of these coals could be low. The coal mineralogy and their
modes of occurrence were further investigated using electron
probe micro analyzer (EPMA). EPMA is a useful technique in deter-
mining location and size of mineral grains inside coal matrix and
its chemical composition. Representative micrographs obtained
for C1 and C15 coal samples using EPMA (Fig. 3) shows presence
of mineral grains of about 150–200 lm size inside the coal matrix.
Localized analysis of chemical compositions at different points
reveals presence of quartz, kaolinite, pyrite, and feldspar minerals
Fig. 2. XRD diffractogram of C1, C15 and C96 coal samples. (Q – quartz; K – kaolinite in both of C1 and C15 coal samples. The result of EPMA analysis
F – feldspar; P – pyrite; W – whitlockite; Sd – siderite).
matches well with XRD analysis.
4.2. Coal ash chemistry and mineralogy samples are in the order of C15 > C96 > C1. The amounts of CaO,
MgO, Na2O, K2O and P2O5 are below 2.33%.
Chemical analysis of coal ash samples was performed to ascer- XRD analysis of ash samples was carried out to identify the min-
tain the chemical composition of the coal ash which could be used eral phases present in these samples. The objective was to get infor-
to predict AFTs. Table 2 contains the chemical analysis data for C1, mation on mineral phase transformations that occurred during
C15 and C96 coal ash samples. Data in Table 2 indicates that SiO2, ashing of coal samples. The XRD patterns of the ash samples
Al2O3, and Fe2O3 are the predominant minerals present in coal ash. (Fig. 4) indicate that quartz is the major mineral present in all ash
While Al2O3 content is similar for all the three ash samples (21%), samples. It should be noted that XRD patterns of coal ash samples
the SiO2 and Fe2O3 content varied widely between the seams. The are significantly different from that of the original coal samples
SiO2 content varied between 48.32% and 62.59% and Fe2O3 content (Fig. 2). During combustion of coal in natural atmospheric condi-
varied within 5.51% to 21.47%. The amount of Fe2O3 in three tions, some mineral phases got transformed to new phases. For
example, kaolinite phases present in original coal samples (Fig. 2)
are absent in ash samples. Similarly, mineral phases of Fe (Goethite
Table 2
Chemical analysis of coal ash samples.
and Siderite) were transformed to hematite in coal ash samples.
EPMA analysis of C1 and C15 coal ash samples (Fig. 5) further cor-
Ash composition (wt%) C1 C15 C96
roborate the findings of XRD analysis. Mineral compositions of
Al2O3 21.46 20.55 21.29 the ash samples were estimated from the oxide composition of coal
SiO2 62.59 48.32 56.54 ash and presented in Table 3. The compositions of mineral phases
Fe2O3 5.51 21.47 13.44
CaO 1.73 1.98 2.33
were derived from the chemical composition data of coal ash
MgO 0.60 0.50 1.05 (Table 2) and the FactSage data described later.
Na2O 0.11 0.14 0.16
K2O 1.05 1.21 1.14
4.3. Ash fusion temperatures
P2O5 1.57 1.67 1.02
TiO2 1.72 1.44 1.65
SO3 0.06 0.04 0.15 AFTs of a coal give an indication of the extent to which ash
clinkering and ash agglomeration are likely to occur during coal
combustion and gasification. AFT determination involves identifi-
cation of four temperatures i.e. initial deformation temperature
(IDT), softening temperature (ST), hemispherical temperature
(HT), and the melting temperature (MT) which reflects different
phases of the ash ‘melting’ process. The experimentally determined
AFTs of C1, C15 and C96 coal ash samples are tabulated in Table 4.
One important observation from data in Table 4 is that the IDT of
all the three ash samples are practically same (1150 °C) whereas
the ST, HT and MT values decreases in the order C1 > C96 > C15.
The trend can be explained considering the mineral composition
of the ash samples. Although the three coal samples are collected
from three seams of the same borehole there is a marked difference
in the chemical composition of their ashes (Table 2). Liu et. al. have
reported that three major chemical compositions that affect the
AFTs of coal samples are CaO, and Fe2O3 content and SiO2/Al2O3
ratio (S/A) [21]. AFTs decreases with increase of CaO and Fe2O3
content and increase of S/A ratio till 1.5. Beyond the S/A value of
2.0, AFTs decrease marginally or remain unchanged [21]. In the
present case, the S/A ratio of all the three samples are higher than
2.0 and very close to each other (2.92, 2.35, and 2.65 for C1, C16
and C96, respectively); therefore it does not have significant affect
on AFTs. However, the Fe2O3 content of C15 sample is very high
Fig. 4. XRD patterns of coal ash. Q – quartz, H – Hematite, Py – pyrrhotite, (21.47%) compared to C96 and C1 samples (13.44% & 5.51%,
A – Apatite, S – Siderite, L – Leucite, R – Rutile, C – Corderite. respectively), resulting in lowest AFTs for C15 sample.
Table 3
Mineral phase composition (%) of coal ashes estimated from oxide composition.
Table 4
Experimentally determined Ash Fusion Temperature (AFT) of coal samples and
percentage of liquid phase at that temperature predicted by FactSage.
Acknowledgements