Professional Documents
Culture Documents
Dr. N. B. Dhokey
Professor
Department of Metallurgical and Materials Science,
College of Engineering, Pune Shivajinagar, Pune 411005
1
CERTIFICATE
This is to certify that the report entitled “Development of Sustainable Process for
Clean Energy Generation using Iron Powder” submitted by Suyash Peshave and
Shubham Kodare in the partial fulfillment of the requirement for the award of degree
of Bachelor of Technology (Metallurgical Engineering) of College of Engineering Pune
affiliated to the Savitribai Phule Pune University, is a record of their own work.
Dr. N. B. Dhokey
Professor
Department of Metallurgy and Materials Science
College of Engineering, Pune
Date:
Place:
2
DECLARATION
We declare that this written submission represents our ideas in our own words and
where others ideas or words have been included; we have adequately cited and
referenced the original sources. We also declare that we have adhered to all principles of
academic honesty and integrity and have not misrepresented or fabricated or falsified
any idea/data/fact/source in our submission. We understand that any violation of the
above will be cause for disciplinary action by the Institute and can also evoke penal
action from the sources which have thus not been properly cited or from whom proper
permission has not been taken when needed.
Date:
Place:
3
TABLE OF CONTENTS
1.0 ABSTRACT...................................................................................................................................5
2.0 INTRODUCTION.........................................................................................................................6
3.0 BACKGROUND AND MOTIVATION.......................................................................................7
4.0 PROOF OF CONCEPT.................................................................................................................9
5.0 AIM AND OBJECTIVES...........................................................................................................10
6.0 THEORETICAL ANALYSIS.....................................................................................................11
6.1 Enthalpy Calculation:..............................................................................................................11
6.2 Energy Balance....................................................................................................................... 13
6.3 Effect of surface of iron powder.............................................................................................13
7.0 DESIGN AND DRAWING.........................................................................................................15
7.1 Setup of Boiler fired with iron powder and air.......................................................................15
7.2 Setup of Gas turbine fired with iron powder and air..............................................................16
7.3 Setup for Iron powder as a fuel – Boiler assembly –With pure oxygen (Main Sketch)...........17
7.3.1 Roll of Sprayers in the reactor………………………………………………………………………………………18
7.4 Phase diagram of iron-oxygen system....................................................................................18
7.5 Regeneration of Iron powder from Rust................................................................................19
7.5.1 Way to generate H2 for reduction of rust……………………………………………………………………..19
7.5.2 Processes of regeneration of iron powder……………………………………………………………………20
7.6 Efficiency Calculations............................................................................................................ 21
8.0 CONCLUDING REMARKS.......................................................................................................22
9.0 REFERENCES............................................................................................................................23
ACKNOWLEDGEMENT.................................................................................................................25
4
1.0 ABSTRACT
Fig. 1.1: Three pillars of Sustainability – Environment, Society & Economics [10]
This report proposes a novel concept for power generation in which iron powder
fuels are burned with oxygen in a combustor to provide clean, high-grade heat. The
metal-fuel combustion heat can be used directly for industrial or residential heating for a
development of sustainable process.
5
2.0 INTRODUCTION
6
3.0 BACKGROUND AND MOTIVATION
India has an ever-growing appetite for power & historically it is satisfied with use
of traditional methods of power generation mainly coal fired power plants. Hence, many
more of such power plants are sanctioned. However it is speculated that once
commissioned these will cause additional pollution. According to a study Operational
coal fired power plants already contribute to around 70% of India’s total power
generation which is bound to go upward in aforementioned scenario. [11] Every year India
faces problems due to pollution which has created a bad image of India in terms of
factors such as air quality. Most importantly pollution leads to loss of lives.
One of the ways to look at pollution is by calculating the carbon footprint of the
region or country. Carbon footprint tells us about the amount of carbon emission from
various activities in the country. Fig. 3.1 shows some estimates done by a study about
carbon footprint of India in upcoming years. The trend shown in the graph below is
quite haunting.
Fig. 3.1: Trend of CO2 emission in India from years 2001-02 to 2020-21 (Trend from
2001-02 to 2009-10 is based on data collected and 2010-11 to 2020-21 was estimated in
the report) [2]
Paris agreement of 2015 has set a target for each country and to fulfill the
commitments India has to start looking at alternative sources. Given the variety in socio-
economic terms evident in India, problems are plenty in each type of alternative
methods of power generation. We see protests day-in-day-out when it comes to setting
up of hydro or nuclear based power plants. India spans in tropical and sub-tropical
7
region and thus, has a huge potential for solar based power generation. But this option
has lags in terms of efficiency, which translates to huge land requirement. India can’t
afford to use up land when it is already a scarce resource.
Considering all this India must start looking for cleaner, efficient and feasible
ways of power generation. One option to look at is power generation using metal
powder. If we look at the problems in options available this source overcomes most of
them. For example, the reactions involved in power generation are totally environment
friendly and byproduct formed is only water. The fuel used i.e. metal powder is totally
recoverable. However it may take time to industrialize this fuel and use it in all possible
applications as technology necessary for running a plant using metal powder is yet to be
developed.
In this mini project we have proposed a method to employ abovementioned
technology. Here we have shown with the help of simple calculations that the
technology can be a game changer in a fight against climate change.
8
4.0 PROOF OF CONCEPT
a) b)
Fig. 4.1: a) Comparison of different fuels as graph of energy density vs specific energy, b)
Histogram for energy densities for different fuels [1][3]
Iron has energy density of about 11.3kWh/L which is better than gasoline and
carbon which are generally used as fuel in thermal power plants.
But, its specific energy is relatively poor 1.4kWh/kg, meaning that for given
amount of energy, iron powder will take up a little bit space than gasoline but it’ll
be almost ten times heavier.
Hence, one can use iron powder as fuel in industrial processes or thermal power
plants. Iron powder is easily available in abundant, Iron fuel can be burned to
form iron oxide, better known as rust. In this process, a large amount of thermal
energy are released that can be used in industrial processes. The
resulting iron oxide is a solid material, so it can be captured after the combustion
process. Hence, iron powder can be used as fuel.
9
5.0 AIM AND OBJECTIVES
The aim of the project is to produce clean energy from iron powder. The activities
are itemized as follows:-
10
6.0 THEORETICAL ANALYSIS
Similarly,
Table 6.2 Values of Enthalpy for Equn A & C higher temperatures
12
2) Energy consumed in Equn C per mole of FeO consumed is +24.2 KJ.
3) Net heat released= -266 + 24.2 = -241.8 KJ.
For solids, whether the particles are spherical or jagged, the particle size is
important for performance evaluation. In this study, it is assumed that a particle size
refers to the diameter of a hypothetical sphere of the same mass. As shown in Fig., the
test results demonstrate that the temperature at which the reaction peaks increases with
the particle size. This is presumably caused by having a larger surface area per particle
that is readily exposed to the oxygen for a more complete oxidation. Furthermore, a
fixed total system volume, containing larger size particles will have a higher void
fraction than that of a system with small size particles. Therefore, larger size particles
require less initial heat to bring the reacting system up to its activation state, less
activation energy, compared to that of the smaller size particles leading to a larger
13
amount of net heat released by the exothermic reaction (larger ∆H). In other words, a
decrease in particle size requires a higher amount of instantaneous heat flowing into the
system to bring it to the activation state, and therefore it has a less net amount of heat
released by exothermic reaction (smaller ∆H).
14
7.0 DESIGN AND DRAWING
A detailed calculation on enthalpy change has been carried out in the previous
section. On oxidation of iron, there is surplus heat left out which can be usefully
converted into generation of electricity or mechanical work. In this report, we are
proposing three possible designs that can covert chemical energy formed from
combustion of iron to the usable form of energy.
Cyclone Separation
technology
Iron powder and compressed air reacted together and burns inside the burner.
Then hot nitrogen and FeO particles passes through Cyclone Separation technology to
separate FeO particles. Then hot nitrogen passes from tubes of fire tube boiler for
production of electricity. As nitrogen and FeO particles are by-products so this is
environmental friendly process.
15
7.2 Setup of Gas turbine fired with iron powder and air
Cyclone Separation
technology
Iron powder and air reacted together and burns inside the burner located for
running of gas turbine. Hot nitrogen and FeO particles passes through Cyclone
Separation technology to separate FeO particles. Then hot nitrogen passes towards gas
turbine to run the turbine for production of electricity. As nitrogen and FeO particles are
by-products so this is environmental friendly process.
16
7.3 Setup for Iron powder as a fuel – Boiler assembly –With pure
oxygen (Main Sketch)
Steam
Boiler
Water
Flame
FeO
Iron Burner
Collect
Powder
Pure O2
In the first step iron powder with desirable particle size is filled in the container.
Then pure oxygen supply is started. As iron powder and oxygen mix and react together
as per the equn A and release heat in the form of flame heating and FeO particles. This
heat is used to heat the boiler and FeO is collected by means of Cyclone separation
technology.
Flame
Collection
of FeO
particles
For figures 7.1 & 7.2, air is used as a source of oxygen for combustion. Air
contains 23% of oxygen by weight and we are operating the burner in the region
between 400 – 500oC for the maximum heat flow as shown in the above figure. From the
above figure, it is clear that stable product at temperature range between 400-500 oC and
23% of oxygen is FeO.
18
Fig. 7.6: Ellingham diagram for different oxide product [5]
For figure 7.3, pure oxygen is used as a source of oxygen for combustion. So it is
clear from the Ellingham diagram that the stable oxide product of iron between 400 –
500oC temperature range is FeO and not Fe2O3
19
7.5.2 Processes of regeneration of iron powder
There are a variety of different ways of using electricity to turn rust back into iron
as given in the equn C, three different technologies based on hot hydrogen reduction
(which turns iron oxide and hydrogen into iron and water) [12]:
Mesh Belt Furnace: In the mesh belt furnace, the iron oxide is transported by a
conveyor belt through a furnace in which hydrogen is added at 800-1000°C. The
iron oxide is reduced to iron, which sticks together because of the heat, resulting
in a layer of iron. This can then be ground up to obtain iron powder.
Fluidized Bed Reactor: This is a conventional reactor type, but its use in
hydrogen reduction of iron oxide is new. In the fluidized bed reactor, the reaction
is carried out at lower temperatures around 600°C. This avoids sticking of iron
and iron oxide, but time required for the reaction increases.
Entrained Flow Reactor: The entrained flow reactor is an attempt to implement
flash iron making technology. This method performs the reaction at high
temperatures, 1100-1400°C, by blowing the iron oxide through a reaction
chamber together with the hydrogen flow to avoid sticking. This might be a good
solution, but it is a new technology and has yet to be proven.
20
7.6 Efficiency Calculations
Let us calculate the difference in the efficiencies of boilers when coal is used and when
iron powder is used. Boiler has an efficiency of around 75-80%. [6]
For Pulverized coal fired boiler,
Coal as a fuel has an efficiency of 37%
So,
Efficiency of coal fired boiler = 0.37 × 0.8
= 29.6%
= 74.46 %
Hence,
The efficiencies calculated above doesn’t account for the heat losses that would
occur. Therefore practical efficiency of coal fired boiler drops down to around 20% and
similarly practical efficiency of iron powder fired boiler might drop down to 65-70%.
21
8.0 CONCLUDING REMARKS
Iron powder can be used as alternative fuel which is sustainable than the
conventional fuels due to their high energy densities and the high collection and
recycling efficiencies enabled by the solid combustion products.
Due to high exothermicity of iron powder, it provides ample opportunity to use it
as fuel to minimize carbon footprint and promise to make process self-
sustainable.
Fine iron powder, of size less than 10 μm, has greater surface area which implies
higher flammability.
Binary phase diagram of iron-oxygen system suggests that wustite phase (FeO) is
likely to form on oxidation of iron. It is hypothesized that those iron oxide
particles may be reduced inflight by hydrogen.
The efficiency of coal fired boiler is around 20%. Whereas that of iron fuel
powder boiler would be around 65-70%.
22
9.0 REFERENCES
Journal reference
Books
23
Articles in newspapers & internet
Patents
14. James K. Mcnight inventor, powdered fuels dispersion and combustion devices
related, patent KR20090105916A.
Link –
https://patents.google.com/KR20090105916A/en?
q=Metal+powder+fuels&oq=Metal+powder+fuels
24
ACKNOWLEDGEMENT
We express our deep feelings of gratitude to our guide Dr. N. B. Dhokey, Professor of
Department of Metallurgy and Materials Science, College of Engineering, Pune, for the
valuable advice and guidance in the completion of this project work.
We are greatly indebted to him for instilling in us the idea and structure of this project
report. We would like to acknowledge our collaborators and colleagues, who have
constantly helped, encouraged, boosted our morale and have worked with us in
completing this dissertation work.
Sincerely,
Suyash Peshave
Shubham Kodare
25