COAL AND COAL CHEMICALS

BY:- 14BCH065
15BCH152
15BCH153
15BCH154
15BCH155

What is a Coal?
Coal is carbonaceous solid black or

brownish black sedimentary rock matter.

Coal is composed of chiefly carbon and
other elements like hydrogen, sulphur,
oxygen, nitrogen, moisture and noncombustible inorganic matter containing,
silica, iron, calcium, magnesium, mercury
etc.

Formation of Coal

Transportation of Coal
Trucks
Trains
Barges(waterways)
Slurry pipelines
Log pipelines

Barges

Coal Pipeline

Uses of Coal
Generation of electricity
Steel production
Cement manufacturing
As a liquid or gaseous fuel

Harmful Effects of Coal

Global warming
Water pollution
Air pollution
Respiratory problems like Chronic

bronchitis, asthma attacks, etc.

Coal combustion contributes to smog.

Importance of Coal

TYPES OF COAL
1. Anthracite
2. Bituminous
3. Lignite
4. peat

ANTHRACITE : This is the highest ranked, hardest, oldest and least

common type of coal.

High percentage of carbon is ( >85%) , and energy content of 25 million
BTU/ton (11300 BTU/lb).
BITUMINOUS : This is the second rank of coal, softer and younger then
anthracite.
Lower percentage of carbon is (45-85%) ,and energy content of 24 million
BTU/ton (10900 BTU/lb) in the US.
SUB-BITUMINOUS : third rank of coal, possessing 35 45% carbon and
moisture then bituminous .
Energy content of 17 18 million BTU/ton (7700 8300 BTU/lb) in the US.
LIGNITE : This is the softest, youngest and wettest rank of coal, often
referred to as brown coal.
Carbon content of only 25 35% and correspondingly lower energy content.
PEAT : It is generally considered a precursor of coal, composed of over 60%
organic matter; typically, ferns and vegetation found in swamp. It's a very
soft brown coal.

Mining of Coal
Surface mining

Upto 30 metres from ground level.

Underground mining

More than 30 metres from ground level.

COKING OF COAL
It involves carbonization of coal at high

temperature (1100C) in absence of oxygen

to concentrate carbon.
As the temperature rises the fluidity of
mass reaches the maximum and then the
mass solidifies to form coke.

FEED
Coking coal or metallurgical coal is used as

feed.
It starts softening at 300C
ECONOMICS
1 ton of coal :1500 pounds of coke,
15 gallons of liquid products.

CHEMICAL REACTION
4(C3H4)n
+ nCH4
coal
Lighter hydrocarbon

nC 6H6+ 5nC + 3nH2

Benzene

Coke

The coking of coal is considered to follow the

approximate equation.

PROCESS UNITS
Coal crusher and

screening
Coke oven
Gas generator
Quenching car
Coke crusher and
screening
Condenser
Tar extractor
Reheater

Tar seperator
Lime still
Saturator
Centrifuge
Cooler
Oil scrubber
Oil still
Oxide purifier

Figure 1: "Coke Side" of a By-Product Coke Oven Battery

 Figure 2: Incandescent coke in the

oven waiting to be "pushed".

MAJOR ENGINEERING
PROBLEMS
Maintenance of refractory and brickwork at

high operating temperatures, imposing

severe thermal strain.
Maintenance of uniform coking

temperatures by proper heating and waste

gas circulations

USES OF COKE
Coke is used as a fuel and as a reducing agent

in smelting iron ore in a blast furnace.

Coke is sometimes used as a filter in whiskey
distilleries in which a mixture of coal and peat is used.
Discovered by accident to have superior heat
shielding properties when combined with other
materials.

MAJOR INDUSTRIES
Arr Vee International-New Delhi
Sharif International Trading Company

-Karnataka
Maha Laxmi Industries-Jharkhand
Siddhi Vinayak Impex-Gujarat
Arafath Trading Company-Tamil Nadu
Niko Metaliks-West Bengal

GASIFICATION OF COAL
Coal gasification offers one of the most versatile

and clean ways to convert coal into electricity,

hydrogen, and other valuable energy products.
coal gasification will be at the heart of future
generations of clean coal technology plants.
Rather than burning coal directly, gasification
breaks down coal into its basic chemical
constituents.
In gasifier amounts of air or oxygen under high
temperatures and pressures.
Gasification may be one of the most flexible
technologies and having vast applcations..

COAL GASIFICATION
REACTIONS
C (s) + H2O (g) = CO (g) + H2 (g) H298 = 131.3

kJ/mol
C (s) + CO2 (g) = 2 CO (g) H298 = 172.5 kJ/mol
C (s) + 2 H2 (g) = CH4 (g) H298 = 74.8 kJ/mol
C (s) + O2 (g) = CO2 (g) H298 = 393.5 kJ/mol
C (s)+ 1/2 O2 (g) = CO (g) H298 = 111.4 kJ/mol

CLASSIFICATION OF GASIFICATION PROCESSES

The gasification processes can be classified basically in two general ways:

(1) by the Btu content of the product gas
(2) by the type of the reactor hardware configuration, as well as by whether the reactor system is operated
under pressure or not.
Medium- or High-Btu Gas Gasification Processes

1. Lurgi gasifier
2. Synthane gasifier
3. Atgas molten iron coal gasifier
Low- or Medium-Btu Gas Gasification Processes

1. Koppers-Totzek gasifier
2. Texaco gasifier
3. Shell gasifier
4. Kelloggs molten salt gasifier
5. CO2-acceptor gasification process
6. U-gas process
Low-Btu Gas Only Gasification Process

1. Underground in situ gasification process

Based on the reactor configuration, as well

as by the method of contacting gaseous

and solid streams, gasification processes
can also be categorized into the following
four types:
Fixed or moving bed
Fluidized bed
Entrained bed
Molten salt bath reactor

LUGRI GASIFICATION
Typical Lurgi Gas
Products
Species
Percentage
CO
16.9
H2
39.4
CH4
9.0
C2H6
0.7
C2H4
0.1
CO2
31.5
H2S + COS
0.8
N2 +Ar
1.6

Mole

ENVIRONMENTAL BENEFITS
The environmental benefits of gasification stem from the capability to

achieve extremely low SOx, NOx and particulate emissions from burning
coal-derived gases.
In an Integrated Gasification Combined-Cycle (IGCC) plant, the syngas

produced is virtually free of fuel-bound nitrogen. NOx from the gas turbine
is limited to thermal NOx. Diluting the syngas allows for NOx emissions as
low as 15 parts per million.
Selective Catalytic Reduction (SCR) can be used to reach levels comparable
to firing with natural gas if required to meet more stringent emission levels.
Other advanced emission control processes are being developed that could
reduce NOx from hydrogen fired turbines to as low as 2 parts per million.
Coal gasification may offer a further environmental advantage in addressing
concerns over the atmospheric buildup of greenhouse gases, such as
carbon dioxide. If oxygen is used in a coal gasifier instead of air, carbon
dioxide is emitted as a concentrated gas stream in syngas at high pressure.
In this form, it can be captured and sequestered more easily and at lower
costs. By contrast, when coal burns or is reacted in air, 79 percent of which
is nitrogen, the resulting carbon dioxide is diluted and more costly to
separate.

EFFICIENCY BENEFITS
Efficiency gains are another benefit of coal gasification. In a typical coal

combustion-based power plant, heat from burning coal is used to boil

water, making steam that drives a steam turbine-generator. In some coal
combustion-based power plants, only a third of the energy value of coal is
actually converted into electricity.
A coal gasification power plant, however, typically gets dual duty from

the gases it produces. First, the coal gases, cleaned of impurities, are
fired in a gas turbine - much like natural gas - to generate one source of
electricity. The hot exhaust of the gas turbine, and some of the heat
generated in the gasification process, are then used to generate steam
for use in a steam turbine-generator. This dual source of electric power,
called a "combined cycle," is much more efficient in converting coal's
energy into usable electricity. The fuel efficiency of a coal gasification
power plant in this type of combined cycle can potentially be boosted to
50 percent or more.

Future concepts that incorporate a fuel cell or a fuel cell-gas turbine hybrid

could achieve efficiencies nearly twice today's typical coal combustion

plants. If any of the remaining heat can be channeled into process steam or
heat, perhaps for nearby factories or district heating plants, the overall fuel
use efficiency of future gasification plants could reach 70 to 80 percent.
Higher efficiencies translate into more economical electric power and

potential savings for ratepayers. A more efficient plant also uses less fuel to
generate power, meaning that less carbon dioxide is produced. In fact, coal
gasification power processes under development by the Energy Department
could cut the formation of carbon dioxide by 40 percent or more, per unit of
output, compared to today's conventional coal-burning plant.
The capability to produce electricity, hydrogen, chemicals, or various

combinations while eliminating nearly all air pollutants and potentially

greenhouse gas emissions makes coal gasification one of the most
promising technologies for energy plants of the future.

Hydrogenation of Coal
Introduction
Coal

or hydrogenation of coal involves raising the atomic

hydrogen to carbon ratio. Coal can be converted to liquid and
gaseous fuels by direct and indirect processing. Hydrogenation of
coal is also called liquefaction of coal. The source of coal is from
various coal mines.

Hydrogenation reaction:

4(C3H4)n +nH2
Powedered coal

nC6H6 + 5nC + nCH4

Aromatic liquid

( This is highly exothermic reaction

hydrocarbon

Process flow sheet:

Technical question:
1. What are the various ways for coal to be fed to hydrogenation process?
2. In the changing energy scenarios of the world, in what way hydrogenation
of coal is beneficial?

Major engineering problems:

Hydrogen embrittlement of reactor steels.

complex separation process is involved in separating multicomponent mixtures of
aromatics hydrocarbons, nitrogen compound and phenol.

Economics:
The hydrogenation of coal can produce 60 to 70 gallons of liquid product per ton of
coal, some 4 to 5 times the yield of straight high temperature coking process.
Several major petroleum companies have bought or leased coal properties and are
reevaluating this coal hydrogenation techniques.

Oxidation and Hydrolysis Process

Have

been used for producing aromatic

derivatives directly from coal.
Oxidation reagents used are nitric acid,
potassium permanganate, ozone and oxygen .

Coal Tar
It is a black to brown oily and viscous fluid

of characteristic odor produced during high

or low temperature carbonization of coal
during coke manufacture.
It is a complex and variable mixture of
phenols, polycyclic aromatic hydrocarbons
(PAHs), and heterocyclic compounds, about
200 substances in all.
2 types of coal tar:1) Low temperature tar
2) High temperature tar

Why we need to distillate coal

tar???
Contains around 200 chemicals.
To recover important chemicals like

naphthalene, phenol, benzol, creosote,

pyridine, anthracene, etc.

Composition of Coal tar

Distillation of Coal Tar

Major Engineering Problems

Corrosion and erosion

Two new techniques used to improve purity

of products. They are:1) Hydrodesulfurization
2) Solvent extraction

Uses of Coal Tar

Making of roads.
Being flammable, coal tar is sometimes

used for heating or to fireboilers

Coal tar is also used to manufacture paints,
synthetic dyes, and photographic materials.
Coal tar is still used to treat a variety of
skin disorders.
It can be used in medicatedshampoo, soap
and ointment.

Coal Reserves Worldwide

Coal Consumption Worldwide

China is the largest consumer of coal since

2005.
United States is the second largest
consumer of coal.
India is ranked 3rd in terms of coal
consumption.

Coal Reserves in India

Majority of the coal producing states are

found in the eastern part of India

comprising part of Jharkhand, Orissa,
Chhattisgarh and West Bengal.
Jharkhand is the largest coal producing
state in the country followed by Orissa,
Chhattisgarh, West Bengal, Madhya
Pradesh, Telangana (previous part of
Andhra Pradesh) and Maharashtra.

Coal Consumption in India

REFERENCES
1) Austin G. T., "Shreves Chemical Process Industries", Fifth edition, Tata

McGraw Hill, NY.

2) Kent J.A., "Riegel's Handbook of Industrial Chemistry, CBS
Publishers.
3) Gopala Rao M. & Marshall Sittig, "Drydens Outlines of Chemical
Technology for the 21st Century", Affiliated East West Press, New Delhi.
4) Mall I. D., "Petrochemical Process Technology", Macmillan India Ltd.,
New Delhi.
5) https://en.wikipedia.org/wiki/Coal#Formation
6) http://energy.gov/fe/how-coal-gasification-power-plants-work
7) http://www.britannica.com/science/coking-coal
8) http://www.ncbi.nlm.nih.gov/pmc/articles/PMC1475092/
9) http://pubs.acs.org/doi/abs/10.1021/i650473a753?journalCode=iechad
10) http://www.sciencedirect.com/science/article/pii/S036012850300042X