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Introduction

For many millions of years, nature has accumulated the richest reserves of carbon in the form of coal, oil and natural gas. Now these fossil fuels are used by man for energy and chemical products.

At the end of the past - the beginning of this century, most products of organic chemistry were made from coal. As oil production increased, coal-based chemicals began to be superseded by petrochemical synthesis products produced by simpler and less energy-intensive methods. However, an assessment of the world's proven reserves of various types of fossil organic materials leads to the conclusion that oil and gas deposits will be largely exhausted already at the beginning of the first decades of the 21st century. Coal reserves should be enough for the next several hundred years. The conclusion about the need to constantly increase the use of coal in the energy and industry is confirmed by data on the comparison of oil and gas reserves,

Coal is one of the main sources of thermal energy, and also represents a valuable raw material for chemical processing in order to obtain the necessary products for industry. world production of all types of fossil fuels, reaching about 6 billion tons per year (in terms of equivalent fuel) for solid fossil fuels (coal, peat, oil shale) accounts for 48%, about 35% is extracted oil and 17% natural combustible gases .

In the balance of world reserves of combustible minerals, the share of coal and oil shale is 90%, peat - 5%, oil and natural gas - 5%.

Most of the coal mined is used for energy purposes, and the most valuable coals are subjected to thermal processing - semi-coking, coking, gasification and hydrogenation.

Currently, there are over 350 valuable products of various kinds derived from coal used by industry and agriculture. In the coke industry, when producing synthetic fuels, carbon materials and a number of chemical compounds, the quality of the target product, and sometimes the very possibility of its production, entirely depends on the material composition and properties of the processed coal. In this regard, great importance is attached to the study of quality and the development of methods for assessing the suitability of coal for various industries.

To provide various industries with coals of appropriate quality, the latter are usually subjected to preliminary mechanical processing - enrichment to remove mineral impurities from coal, briquetting, and size classification.

The rational scheme of coal processing should include not only the full use of all components of the organic mass of coal, but also mineral impurities in coal, including rare and dispersed elements (in total, more than 70 valuable chemical elements included in these or those connections). An essential issue for practice is also the extraction by enrichment of coals of the iron sulfides contained in them, used for the production of sulfuric acid.

Coals also contain elements suitable for agricultural needs. Microelements such as molybdenum, zinc, manganese, copper, etc., are valuable as plant growth stimulants, and alkaline ash from coal are very useful additives for acidic soils, increasing the yield of legumes and other crops.

1. Types, origin, extraction and stocks of solid fuels

Solid fuels used as a source of energy and raw materials for chemical production are divided into fuels of natural origin - natural - and synthetic fuels. Natural fuels include peat, brown and hard coal, anthracite, oil shale. They are also called fossil fuels. Artificial fuels are coal, peat and petroleum coke obtained by the pyrogenetic processing of various types of natural fuels, as well as briquettes and coal dust - products of the mechanical processing of solid fuels.

Solid fossil fuels (solid fossil fuels) are called natural solid combustible substances of organic origin, formed from the remains of dead plants and plankton as a result of bacterial exposure. In the earth's crust, solid fossil fuels are in the form of carbonaceous sedimentary rocks that form deposits or basins. All fossil fuels based on the material from which they were formed are divided into sapropelites and gummolites.

Sapropelites arose as a result of the reductive decomposition of sapropel residues - silty sediments formed at the bottom of water basins from plankton and lower plants. Sapropelites include oil shale and some other minerals.

Gummolytes arose as a result of oxidative decomposition of the remains of higher plants. They are divided into:

- gummites, consisting mainly of humic substances;

- lintobioliths formed from persistent structural elements of lower plants (spores, pollen, etc.).

The main types of fossil solid fuels (peat, brown and hard coal, anthracite) are classified as gummites.

The depth of conversion of the source of biogenic materials as a result of coal formation into solid fuels is characterized by the so-called degree of coalification (metamorphism), which is understood as the average carbon content in the fuel (in wt.%, Or fraction). As the degree of coalification increases, solid gummitic fuels form a genetic series:

Peat> Lignite> Coal> Anthracite

The degree of coalification is given in table 1

Table 1. The degree of coalification of fossil solid fuels

Fuel

Peat

Brown coals

Coal

Anthracite

The degree of coalification, wt.%

58-62

15-61

16-92

93-96

Solid fuels make up the bulk of the world's known fossil fuels. Their total reserves are several orders of magnitude superior to the reserves of liquid (oil) and gaseous fuels. [3]

In Russia, to characterize the consumer value of coal, the Unified Classification of Coals developed in the USSR in accordance with GOST 25543-88 (ЕК - 88) is used. According to the EC, brown coal, stone and anthracite are distinguished by the degree of metamorphism (changes in the structure, mineral and chemical composition of the rock). For tax purposes, coal is typologized by type, and coking and other coal also by brand: anthracite, coking coal (8 grades), brown coal, other coal (7 grades).

Brown coal is a transitional form from peat to coal. In comparison with peat in brown coal, the fraction of distinguishable plant residues is lower, and in comparison with hard coal, brown coal is more humid (up to 40% or more). In brown coal, the carbon content is 55.0--78.0%, hydrogen is 4.0--6.5%, and oxygen is 15.0--30.0%. Color from brown to black. The thickness of the layers is 60--90 meters, some are favorable for open mining. Brown coal is used as fuel for thermal power plants, as well as chemical raw materials for the production of liquid fuel, synthetic substances, gas and fertilizers.

Coal is denser and less moist compared to brown coal, has a black or gray-black color. The carbon content in coal is 75.0--97.0% or more, hydrogen is 1.5--5.7%, oxygen is 1.5--15.0%, sulfur is 0.5--4.0%, nitrogen up to 1.5%, moisture 4-14%. The thickness of the layers is from fractions of a meter to several tens of meters. Depth of seams - from the exit to the surface to 2-2.5 km and deeper. Coal is used as fuel in everyday life, in the metallurgical and chemical industries, including for the extraction of rare and trace elements from it. fuel coal coking

Coking coals - capable of sintering at a temperature of 500-700 ° C and more, having high heat of combustion and low content of volatile substances and mineral impurities, coal, of which during coking (13-18 hours of heating coal without air to 950-1050 ° C) it is possible to obtain coke - coal of increased strength. Coke is mainly used in the iron and steel industry for smelting cast iron, while being not only fuel, but also a reducing agent of iron ore. Less commonly, coke is used in foundry, chemical industry, non-ferrous metallurgy and some other processes. In coke, the carbon content is more than 96%, moisture 0.5-4.0%

Anthracite - from the point of view of consumer properties, the highest quality, humus coal of the highest degree of metamorphism, plant residues in anthracites are difficult to distinguish even under a microscope. Black, often with a grayish tint and a mandatory metallic sheen, anthracite has the highest hardness on the mineralogical scale, good electrical conductivity, high viscosity and does not sinter. In anthracite, the carbon content is 93.5--97.0%, hydrogen is 1.0--3.0%, oxygen is 1.5--2.0%, nitrogen is 1.5--2.0%, moisture is 1, 0--3.0%. The thickness of the layers is mainly small (up to 1.3 meters) and medium (1.3-3.5 meters), rarely 10-40 meters. Anthracites are used as high-quality energy fuel in the chemical and metallurgical industries.

The main methods of coal mining are indoor and outdoor. Enterprises for closed coal mining are called mines, for open - quarries, or, in the professional terminology of coal miners, opencasts. In addition to open pits and mines, in the coal industry there are enterprises for the processing of coal - enrichment plants.

The mine is a complex mining enterprise for coal mining underground. Depending on the thickness of the coal seam, the mine has been operating on average about 40 years, and on particularly powerful seams, up to 50-70 years. Coal mining is carried out in layers (the so-called "mining horizons"), each layer is removed for about 10 years, after which the horizon is reconstructed and the next, deeper layer is developed. The reconstruction process is required to ensure the environmental safety of the environment and people working in the faces, this is a prerequisite for the existence of the mine. Taking into account the processes of reconstruction and the average life of the mines, in order to maintain the level of production, it is necessary to constantly build new mines - annually 5-7 developed enterprises are left in the industry.

The section produces coal excavation with ledges and successive strips. The upper ledges are ahead of the lower ones and expand the space developed by the cut.

The total geological (forecast) coal reserves in Russia are 4 trillion. t, this is 30% of the world's coal reserves. The explored (balance) reserves are estimated at 190 billion tons. The production volume is limited by the total production capacity of mining enterprises. In 2010, 91 mines and 137 opencast mines with a total annual capacity of 380 million tons were mined. In fact, in 2010, 323 million tons of coal were produced on the mountain.

Russian coal deposits are unequal in quality of coal, the amount of its reserves, as well as the occupied area, and are located in different regions of the country. Currently, Russian coal is mined in ten major coal basins. The largest developed brown coal deposit is the Kansk-Achinsky basin, coal and coking coal - the Kuznetsk coal basin (Kuzbass), anthracites - East Donbass and Gorlovsky basin.

Kuznetsk Coal Basin (Kuzbass) is the largest in Russia and one of the largest in the world. Located in the Kemerovo region, most mining enterprises are concentrated in the south of the region. Methods of production: open (36 cuts) and closed (58 mines). The total geological reserves of coal are estimated at 693 billion tons, of which coking 207 billion tons.

The Kansk-Achinsk coal basin is located mostly in the center of the Krasnoyarsk Territory, and also occupies a small territory of the Kemerovo and Irkutsk Regions. Method of extraction: open. Total geological reserves: 638 billion tons, coal is mainly brown. The thickness of the layers is 2-56 meters.

The Pechora coal basin is located within the Republic of Komi and the Nenets Autonomous Okrug and covers an area of ​​90 thousand km ?. Method of production: closed, the depth of the beds up to 298 meters. Total geological reserves of coal: 344.5 billion tons, including coking 9 billion tons. Powerful East Donbass. The main part of the Donetsk coal basin (Donbass) is territorially located in Ukraine, and its Russian part (East Donbass) is completely located within the Rostov Region. In general, the Donbass possesses geological reserves of coal of 140.8 billion tons, of which 60% are stone, 18% are coking (25 billion tons), and 22% are anthracites. Method of extraction: mostly closed. The thickness of the layers is 0.6-1.2 meters. Eastern Donbass has 24.2 billion tons of total geological reserves of coal, of which 90% are anthracites, 5% coking. Explored reserves of industrial categories: anthracite 298.7 million tons, coking coal 16 million tons.

The Ulug-Khem coal basin in Tuva is one of the most attractive for development and, at the same time, the least developed, since there is no railway for transporting coal. The area of ​​the basin is 2.3 thousand km ?. Method of extraction: open. The total geological reserves are estimated at about 14 billion tons. Coal, mainly coking. The thickness of the layers is 0.6-12 meters.

The coal basin near Moscow with a total area of ​​120 thousand km? affects the territories of the Leningrad, Novgorod, Tver, Smolensk, Moscow, Kaluga, Tula and Ryazan regions. Total geological reserves: 11.8 billion tons of brown coal. The depth of the beds reaches 200 meters.

The Irkutsk coal basin is located in the south of the Irkutsk region on an area of ​​42.7 thousand km ?. Total geological reserves of coal: 9 billion tons, of which 94% is stone (partially coking) and 6% is brown. The thickness of the layers is 1-10 meters.

The South Yakut coal basin is located in Yakutia and covers a total area of ​​25 thousand km. Method of extraction: open. Explored reserves: 3.0 billion tons. Coal. The thickness of the layers is from 1-3 to 10-60 meters. the bed of the strata is average, about 1.53 meters.

The Minusinsk coal basin is located in the administrative borders of the Republic of Khakassia. Production methods: open (5 cuts) and closed (2 mines). The balance reserves are estimated at 2.7 billion tons, coal is mainly hard.

The Gorlovsky coal basin is located in the Novosibirsk region on the territory of the Iskitim district. Production methods: open (2 cuts) and closed (1 mine). Explored reserves: 303 million tons. 100% of the reserves are anthracite. The thickness of the layers is up to 41 meters.

2. Coal

2.1 Structure and properties of coal

Coal of various nature is the most common type of solid fossil fuel. These are heterogeneous solids of black or black-gray color, including four types of macro-ingredients, which differ in gloss, appearance and composition: brilliant (vitren), semi-brilliant (clarin), matte (duren) and wavy (fusen). The ratio of these ingredients that make up the organic mass of fossil fuels characterizes their structure, chemical and mineralogical composition and determines their diversity and difference in properties.

The organic part of fossil fuels includes bitumen, humic acids and residual coal. The molecular structure of the organic part of coal is a rigid three-dimensional polymer of irregular structure containing a mobile phase in the form of various monomolecular compounds. Both phases are built of separate fragments, including aromatic, including multinuclear and hydrogenated systems with aliphatic substituents, and nitrogen-containing heterocycles connected by C-C, C-O-C, CSC and C-NH-C bridge bonds. The degree of condensation of the fragments (n) depends on the degree of coalification of coal. So, with a degree of coalification of 18% n = 2, with a degree of 90% n = 4, for anthracite n = 12. The presence of various functional groups was also found in the composition of fossil fuels: hydroxyl (alcohol and phenolic), carbonyl, carboxyl and sulfur-containing groups - SR - and - SH. [7]

The most important characteristics of fossil fuels, on which the possibility and effectiveness of their use depend, are ash content, humidity, sulfur content, volatiles yield and mechanical properties, and for fossil fuels used as raw materials for thermochemical processing, also sintering and coking properties.

Ash content. Ash is called the non-combustible part of coal, consisting of minerals contained in the fuel. The composition of the ash includes oxides of aluminum, silicon, iron (III), calcium and magnesium. High ash content reduces the heat of combustion of coal and degrades the quality of the resulting coke. The ash content of coal varies from 3 to 30% and can be reduced by their enrichment. Coals used for coking should have an ash content not exceeding 1-1.5%.

Humidity. The total moisture content of coal consists of the external, forming droplets or films on the surface, and the internal (pyrogenetic) released during the coking process. Moisture, being a ballast, increases the cost of coal transportation, complicates its preparation for coking, storage and dosage, and also increases the heat consumption for coking and increases the coking time. The moisture content of coals used for thermochemical processing should not exceed 1%.

Sulfur Sulfur in fossil fuels is in the form of pyrite, sulfate and organic. The total sulfur content in coal ranges from 0.4 to 8%. Since during the coking process, most of the sulfur remains in the coke and can, when cast iron is smelted, pass into the metal, causing its red breaking, the coal must be desulphurized by enrichment.

Volatiles yield. Volatile substances of coal are called vaporous and gaseous substances released from coal when it is heated without air at a certain fixed temperature. The yield of volatile substances depends on the conditions of formation, chemical composition and degree of coalification of coal, as well as on temperature, heating rate and exposure at a given temperature. With increasing degree of coalification, the yield of volatile substances decreases. So, for peat it is about 10%, for brown coals - 65-45%, hard coal - 45-10%, for anthracite - less than 10%. The volatiles release procedure is standardized. It is determined by heating a sample of coal at 850? C and keeping at this temperature for seven minutes. [8]

2.2 Classification of fossil fuels

The technological classification of fossil fuels is based on the yield of volatile substances and the thickness of the plastic layer formed by heating. Table 2 shows the technological classification of the coals of one of the basins, according to which they are divided into 1 grades (classes). [4]

Table 2. Technological classification of coal

Coal grade

The yield of volatiles,%

Plastic layer thickness

Name

Designation

Long flame

Gas

Fatty

Coke

Sintered sintering.

Skinny

Anthracite

D

G

F

TO

OS

T

A

42

35

35-21

21-18

22-14

11-19

9

-

6-15

13-20

14-20

6-13

2.3 Fossil coals as chemical raw materials

A significant part of fossil coals is subjected to high-temperature (pyrogenetic) processing, that is, it is a chemical raw material. The purpose of such processing is to obtain valuable secondary products from coal used as fuel and intermediates in basic organic synthesis.

All methods for processing fossil coal are based on heterogeneous, in most cases non-catalytic processes occurring in a multiphase system at high temperatures. Under these conditions, the coal material undergoes profound changes, leading to the formation of new solid, liquid and gaseous products. According to the purpose and conditions, the processes of pyrogenetic processing of solid fuels are divided into three types: pyrolysis, gasification and hydrogenation.

Pyrolysis, or dry distillation, is the process of heating solid fuel without access of air in order to obtain from it solid, liquid and gaseous products for various purposes. Depending on the process conditions and the nature of the secondary products, low-temperature pyrolysis, or semi-coking, and high-temperature pyrolysis, or coking, are distinguished. According to the scale of production, the volume and variety of manufactured products, the coking process takes first place among all solid fuel processing processes.

Semi-coking is carried out at 500-580 ° C in order to obtain artificial liquid and gaseous fuel transportable and more valuable than the original solid fuel. Semi-coking products - combustible gas used as fuel with high heat of combustion and raw materials for organic synthesis, resin, which serves as a source of motor fuels, solvents and monomers, and semi-coke, used as local fuel and an additive to the charge for coking. Raw materials for semi-coking are low-grade coals with a high ash content, brown coals and oil shales. [14]

The hydrogenation and gasification processes aim to obtain from solid fuels, respectively, liquid products used as motor fuels and combustible gases. The introduction of these processing methods increases the importance of solid fuels and coal, in particular, in the fuel balance of the country.

To date, the most popular methods for processing coal:

- pyrolysis

- hydrogenation

- hydrogenation

processing of coal into synthetic liquid fuels

The term pyrolysis of coal is understood to mean the totality of processes that occur when coal is heated, provided that there are no reagents. However, in recent years, under the pyrolysis of coal, they also began to mean processes that occur with the action of any additional reagent (the so-called hydropyrolysis and oxidative pyrolysis).

Often, the term pyrolysis also refers to the procedure for coal gasification, although this is not entirely true, since additional reagents are also used.

The thermal processing of coal is widely used to produce various carbonaceous solid materials, and liquid and gaseous products. In this regard, depending on the purpose of the final pyrolysis products, almost any coal can be the feedstock for processing. This is very convenient, since all the coal mined can go to processing, and not to the plant for processing municipal solid waste.

Coal pyrolysis

The processes of coal pyrolysis have been used by mankind since the end of the XVIII. At that time, coal was processed to obtain materials such as:

Coal coke used in metallurgy

Refined charcoals for smokeless burning in furnaces

Lighter gas used for street lighting

Of course, the technology and process of coal pyrolysis has not practically changed since then, but the equipment used for this process, on the contrary, has been improved. Today, as a result of a long evolution of hardware and technical solutions, the process of coal pyrolysis is characterized by rather high energy and environmental indicators.

However, at the same time, one should take into account the fact that the products of coal pyrolysis, especially liquid ones, contain large amounts of organic compounds that contain oxygen, nitrogen, and sulfur. For this reason, the liquid products of coal pyrolysis cannot be used as a synthetic analogue of liquid hydrocarbon fuels without additional purification. Therefore, thermal processing of coal is rarely used to obtain liquid synthetic fuel as the final product of pyrolysis.

How does the process of coal pyrolysis proceed?

As we mentioned earlier, the process of pyrolysis of coal is based on heating coal to a certain temperature without access of oxygen for the purpose of its thermal destruction. During this process, the following groups of chemical reactions occur:

Depolymerization of the organic mass of coal to form organic molecules with a lower molecular weight

Secondary reactions of transformations of products formed during the pyrolysis process, including:

condensation

polymerization

aromatization alkylation

Both groups of chemical reactions occur both sequentially and in parallel. The final result of the totality of these thermochemical transformations is the formation of liquid gaseous and solid products.

It should be noted that coal pyrolysis is carried out in various temperature ranges. The choice of pyrolysis temperature depends on the type of products that you need to get in the end. Low-temperature pyrolysis (or semi-coking) is usually performed at 500 - 600 degrees Celsius, and high-temperature pyrolysis (or, as it is also called, coking) is performed at 900 - 1100 degrees Celsius.

3. Products of coal pyrolysis

So, at the very beginning of our article, we mentioned that by pyrolysis from coal you can get products of the following types:

Solid

Liquid

Gaseous

Hydrogenation of coal is carried out at 400 - 600 C under a hydrogen pressure of up to 2 5 - 10 Pa (250 atm) in the presence of a catalyst - iron oxides. In this case, a liquid mixture of hydrocarbons is formed, which is usually subjected to destructive hydrogenation on nickel or other catalysts.

The coal hydrogenation reaction is carried out at 560 C and 3 79 MPa. Hydrocarbon vapors and gas are discharged through the top of the reactor, and the carbon residue is discharged through the bottom. After cooling to 316 ° C, the carbon residue is discharged through discharge bins and freed from hydrocarbons. It is finally cooled to about 93 ° C, converted to pulverized fuel and fed to steam boilers or to a hydrogen production unit using partial coal gasification.

The coal hydrogenation reaction is exothermic and the temperature is controlled by the supply of cold hydrogen, supplied at six points along the height of the columns. The columns do not have internal nozzles, but their walls are internally protected from overheating by a thermally insulating lining. The paste passes the columns from the bottom up with a total residence time of about 1 hour in the block and then gets into the hot separator.

The mechanism of coal hydrogenation can be represented as follows:

1) diffusion of hydrogen to coal (310 - 350);

2) primary decomposition of coal by graphite bonds and the formation of two-dimensional macromolecules (350 - 370);

3) hydrogenation and gradual decomposition of six-membered rings associated with the formation of simpler systems.

When hydrogenating coal using the Bergius method, a solid residue is obtained, the organic substance of which consists mainly of fusite. Analysis of the sample of such a product showed that the organic mass consists almost entirely of fusite. Coal hydrogenation plants produce relatively large amounts of ethane, which is the feedstock for the production of high-quality oils. The gasoline obtained from the hydrogenation of coal contains approximately 14 - 16% H2 and 81 - 84% C.

4. Coal processing into synthetic liquid fuels

The physicochemical properties of the resulting liquid hydrocarbon mixture are close to oil.

Further processing of liquid brown coal is carried out under conditions similar to oil refining processes.

The content of minerals in brown coal exceeds their content in oil raw materials. When processing brown coal into synthetic liquid fuel, it is necessary to use perfect processes of fractionation and separation of hydrocarbon and mineral components.

At the second stage, liquid brown coal is purified from mechanical impurities, suspended particles, salts, sulfur and other components to be removed.

The third stage is the in-depth processing of liquid brown coal into synthetic liquid fuel.

The first synthetic fuel from coal appeared in Germany - in 1911, the German chemist F. Bergius received gasoline from coal. The fact is that Germany did not have its own oil fields, and the demand for fuel increased. But there were some of the largest brown coal deposits in Europe, which prompted research to obtain fuel from this particular fossil. The problem was successfully solved by the efforts of German chemists, and already by 1941 Germany was producing up to 4 million tons of liquid fuel per year.

At the beginning of the 70s, a group of Sasol plants was established in South Africa for the processing of coal into synthetic liquid fuel, which allowed the embargo on oil products to be survived with less losses. Today, Sasol processes about 47 million tons of coal per year, producing about 7 million tons of liquid fuel and having an annual profit of hundreds of millions of dollars. It is to this South African company that the highest indicators are attributed in terms of the level of technology and the development of the scale of production.

After South Africa, the United States began to synthesize motor fuel the most large-scale and high-tech. Eight projects at various stages of implementation are ongoing in China, all of which are intended to completely replace traditional fuels. In general, in Nigeria, Qatar, Malaysia and the USA, about 50 objects with a total capacity of more than 300 million tons of fuel per year are at the design and construction stage. Japan, India, Poland, Indonesia, and Pakistan joined the problem. The total volume of officially announced investments in this area exceeded $ 15 billion, and the production of synthetic fuel reached 20 million tons per year.

The technology for producing emulsion fuel includes the following main stages: liquefaction of brown coal, stabilization of the emulsion system and purification of the emulsion system from mechanical impurities and suspended particles.

At the first stage, the process of liquefying brown coal is carried out.

The second stage is the stabilization of the emulsion system in a cavitation reactor.

At the third stage, the emulsion system is cleaned of mechanical impurities and suspended particles. Cleaning is carried out in an original, unparalleled way - by thermo-gravity cleaning.

The resulting emulsion has all the necessary regulated physicochemical properties. Such properties include: stability of the fuel system for a long time, technologically acceptable values ​​of rheological parameters - low viscosity, low yield stresses, the absence of pronounced thixotropic properties, ultimate uniformity of coagulation structures.

The emulsion meets the basic requirement for emulsion fuels - the emulsion contains a high concentration of combustible base, sufficient to ensure high calorific value of the fuel.

Emulsion fuel is an environmentally friendly type of alternative liquid fuel also because, in addition to reducing the above-mentioned harmful emissions in exhaust gases, the concentration of nitrogen and sulfur oxides is significantly reduced during its combustion.

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