Catalytic Effect of Reactive Extraneous Mineral Composites on Char and Tar Distribution during Pyrolysis of Highveld Partially Oxidized Fine-Coal Reject and Its Beneficiated Residues

Abstract

In this study, the South African partially oxidized fine-coal reject (FCR), which is associated with human health and environmental problems and sustains high disposal expenses, was subjected to density-separation, chemical fractionation, and demineralization experiments to isolate and evaluate the mode of occurrence of mineral-matter (MM) effects on the FCR pyrolysis. A unique composite of two reactive oxides (i.e., MgO and Fe2O3) and a hydrated oxide [i.e., Ca(OH)2] representing major extraneous coal–minerals were blended with either FCR, demineralized FCR, and its beneficiated samples to evaluate the yields of pyrolytic products and activation energy following a novel procedure. The properties of FCR samples and their pyrolytic products were determined by different analyses. Results indicate that the reactive oxides and a hydrated oxide composite addition increased the average activation energy (332.0–476.5 kJ/mol) for FCR due to the initial Ca(OH)2 decomposition and Fe2O3 reduction that took place under pyrolysis conditions. The FCR mineral-rich sink fractions achieved the highest carbon conversion (char yield = 78.8% and tar yield = 5.1%) compared to those of other samples (e.g., <1.9 g/cm3 float char yield = 87.3% and tar yield = 2.3%) evaluated due to higher proportions of calcite/dolomite/pyrite cleats and nonmineral inorganics (Ca, Mg, Na, and Fe) which catalyzed the pyrolysis reactions. On the other hand, CaCO3, CaMg(CO3)2, and metakaolinite formations in the char derived from a blend of reactive oxides and a hydrated oxide composite and FCR interfere with the pyrolysis reactions. Also, deoxygenation reactions were impeded by oxygen present in the reactive oxides and a hydrated oxide composite. The potent catalytic effects of cleat minerals and the extraneous minerals associated with cracking of heavy tars to lighter fractions open opportunities to further understand the mode of occurrence of MM present in FCR during utilization in global pyrolysis. This may reduce waste disposal costs, health-hazards, air-pollution, and FCR volumes and augments feed-coals.