Separation of Nonmagnetic Fine Narrow Fractions of PM10 from Coal

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Separation of Nonmagnetic Fine Narrow Fractions of PM10 from Coal Fly Ash and Their Characteristics and Mineral Precursors Elena V. Fomenko,*,† Natalia N. Anshits,† Olga A. Kushnerova,† Galina V. Akimochkina,† Sergey V. Kukhtetskiy,† and Alexander G. Anshits*,†,‡ †

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Institute of Chemistry and Chemical Technology SB RAS, Federal Research Center “Krasnoyarsk Science Center SB RAS”, Akademgorodok 50/24, Krasnoyarsk 660036, Russia ‡ Siberian Federal University, Svobodnyi pr. 79, Krasnoyarsk 660041, Russia ABSTRACT: Nonmagnetic fine narrow fractions of particles with mean diameters of 2, 3, 6, and 10 μm were for the first time separated from fly ash produced by pulverized combustion of Ekibastuz coal using aerodynamic classification with subsequent magnetic separation. These fractions were characterized by the size distribution, bulk density, and chemical and phase compositions. The particle size distributions correspond to d50 values of 1.9, 2.3, 5.1, and 9.2 μm. As the fraction particle size increases, the bulk density was found to rise gradually from 0.90 to 1.07 g/cm3. The main components of the chemical composition were SiO2 (65−70 wt %) and Al2O3 (23−28 wt %). The phase composition was represented by the glass phase (64−69 wt %), mullite (17−21 wt %), and quartz (10−18 wt %). The main morphological particle types were microspheres with a nonporous smooth surface and microspheres with a porous shell. With an increase in the fraction particle size, the percentage of microspheres with a porous shell increases. The largest fraction contains particles with a network structure. Singleparticle scanning electron microscopy−energy dispersive X-ray spectroscopy analysis of nonporous microspheres with a diameter of 1−2 μm, approximate in composition to the internal coal minerals, indicated that, depending on the content of SiO2, Al2O3, and FeO, they form several groups differing in mineral precursors. Thus, for microspheres of group 1 (SiO2 + Al2O3 > 95 wt %), the mineral precursors are NH4-illite and montmorillonite; group 2 (SiO2 + Al2O3 = 90−95, FeO ≤ 4 wt %)minerals of the isomorphic montmorillonite-illite series, including phases with a low level of iron cation substitution; group 3 (SiO2 + Al2O3 = 90−95, 4 < FeO ≤ 6 wt %) and group 4 (SiO2 + Al2O3 < 90, 3 < FeO ≤ 9 wt %)minerals of the illite-montmorillonite series, with a high level of iron cation substitution and with Fe3+ in interlayer sites.



Depending on the coal type and combustion conditions, fly ash contains, along with large particles, 8−42% of particles less than 10 μm in size.2,20−22 These dispersed particles belong to the particulate matter PM10. A particular environmental hazard is fine particulate matter PM2.5 with particles of less than 2.5 μm in size, which are suspended in the atmosphere for a long time and difficult to remove from the human lungs. In many countries, emission of these particles into the atmosphere is restricted and under tight control.23,24 On the other hand, fine ash particles are potentially suitable for creating materials with improved properties for various applications. In this case, they should meet certain requirements for particle size as well as chemical and phase compositions. For example, the use of class F fly ash [according to the standard specification for coal fly ash (ASTM C618)] as an additive to concrete increases its strength characteristics. For these purposes,25,26 ash with dav = 3 μm, 54 wt % SiO2, and 28 wt % Al2O3 as well as d50 = 7 μm, 50 wt % SiO2, and 19 wt % Al2O3 has been successfully used. High calcium ash (29 wt % SiO2, 13 wt % Al2O3, 26 wt % CaO, dav = 8.5 μm) was shown to be promising in production of homogeneous and hard geopolymers.27 Aluminosilicate ash (47 wt % SiO2, 41 wt % Al2O3, d50 = 2.53 μm) was used to synthesize ceramic membrane supports.28 Ash with d50 = 4 μm,

INTRODUCTION Currently, coal-fired power plants produce about 37% of the world’s electricity.1 The amount of fly ash generated during coal combustion is estimated at ∼1 billion tons per year,2,3 and its worldwide recycling is about 25%.2,4 Fly ash produced by thermal power plants is considered as technogenic raw material of a low technological level because of a wide variability in the particle size, variable chemical and mineral-phase compositions, and uncontrolled properties. The main directions of ash recycling in the world include the traditional large-scale use of raw ash, without preclassification, in the construction industry, agriculture, and road construction.2,3,5,6 High-quality separation of ash into fractions with a certain size and composition and with predictable properties enables conversion of large-scale waste of thermal power plants into valuable mineral raw materials of technogenic origin. In recent years, production of functional materials based on individual fly ash components, such as adsorbents, catalysts, carriers, ceramic materials, and zeolites, has attracted great interest of researchers.2,3,5,7−9 For example, narrow fractions of 50−250 μm hollow aluminosilicate microspheres (cenospheres) separated from fly ash10−12 were used to fabricate hydrogen storage containers and highly selective membranes for diffusion-based extraction of helium,13−15 emulsion explosive sensitizers,16 encapsulated pH-sensitive spin probes for studying biological objects,17 and composite sorbents for extraction of radionuclides from liquid radioactive waste.18,19 © XXXX American Chemical Society

Received: January 9, 2019 Revised: February 18, 2019 Published: March 13, 2019 A

DOI: 10.1021/acs.energyfuels.9b00097 Energy Fuels XXXX, XXX, XXX−XXX

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Figure 1. Schematic diagram of a 50 ATP aerodynamic classifier (Hosokawa ALPINE, Germany): 1fan, 2bag filter, 3fine-grained product hopper, 4loading hopper, 5screw feeder, 6coarse product hopper, 7air supply, 8filter cleaning, 9compressed air for rotor cleaning, 10compressed air for classifier bearing system, 11cyclone, 12suction pipe, 13classifier.

density, chemical and phase compositions, as well as identification of mineral precursors whose thermochemical transformations lead to the formation of fine particles.

58 wt % SiO2, and 23 wt % Al2O3 was used for fabrication of fire-resistant panels with high insulating properties.29 Ash with dav = 4.6 μm, 49 wt % SiO2, and 34 wt % Al2O3 was found to be a promising polymer filler.30 In these cases, raw fly ash was used without preseparation, but it was noted that the presence of fine particles 20, Si + Al ≥ 80, K ≤ 5, Ca ≤ 5, Fe ≤ 5), Fe−Al-silicate (Na ≤ 5, Al ≥ 15, Si > 20, S ≤ 5, K ≤ 5, Ca ≤ 5, Fe > 5, Fe + Al + Si ≥ 80), and others (Ca−Al-silicate, gypsum, dolomite: Ca ≥ 5, Ca > 10, Ti > 5).55,56 Dominant mineral categories among the analyzed microspheres were Si-rich, Montmorillonite, and Fe−Al-silicate, accounting for 25, 29, and 30% of globules, respectively (Figure 5). The content of microspheres classified to the

Figure 6. Dependence of the SiO2 content on the Al2O3 content for nonporous microspheres in the nonmagnetic fine narrow fraction HMR-2. The mineral composition corresponds to the stoichiometric formula from refs39,60,61 after conversion to the dehydroxylated phase.

interval of changes in the contents of SiO2, Al2O3, FeO, and impurity oxides. Table 4 presents the minimum and maximum values of oxide contents in the composition of studied microspheres assigned to different groups (Table 4). For example, in group 1, comprising 20% of microspheres, the concentrations of SiO2 and Al2O3 vary in the range of 57− 87 and 11−39 wt %, respectively, the sum of SiO2 and Al2O3 exceeds 95 wt %, the FeO content is not more than 3 wt %, and the amount of impurity oxides is minimal. Group 2 includes the main amount (50%) of studied globules; the range of changes in SiO2 and Al2O3 concentrations is 57−81 and 13−36 wt %, respectively; (SiO2 + Al2O3) = 90−95 wt %; the FeO concentration is increased to 4 wt %. For group 3 microspheres (21% of globules), the range of changes in concentrations of SiO2 and Al2O3 noticeably reduces, amounting to 54−72 and 20−36 wt %, respectively; FeO increases to 6 wt %. For group 4 microspheres (8% of globules), the range of changes in SiO 2 and Al 2 O 3 concentrations does not exceed 54−62 and 26−33 wt %, respectively; ∑(SiO2 + Al2O3) is < 90 wt %; FeO increases to 9 wt %. When going from group 1 to group 4 microspheres, the content of TiO2 and CaO gradually increases (Table 4). Single globules (about 3%) are characterized by a high content of TiO2 (up to 13 wt %), CaO (up to 11 wt %), and MgO (up to 4 wt %).

Figure 5. Mineral species for nonporous microspheres in the nonmagnetic fine narrow fraction HMR-2 according to the elemental composition criteria from ref 55.

kaolinite category was minimal (9%). Compositions of single microspheres (Figure 5, others3%) with high contents of calcium, magnesium, and titanium corresponded to Ca−Alsilicate, gypsum, and dolomite mineral categories, respectively. The nature of mineral precursors whose thermochemical transformations lead to the formation of microspheres can be determined by a comparative analysis of the relationship of F

DOI: 10.1021/acs.energyfuels.9b00097 Energy Fuels XXXX, XXX, XXX−XXX

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Table 4. Minimum and Maximum Oxide Contents (wt %) in Nonporous Microspheres of the Nonmagnetic Fine Narrow Fraction HMR-2 (Analysis of 282 Globules with d = 1−2 μm)

compositions of montmorillonite and K-illite are well fit with the dependencies (2) and (3), respectively. The systematic study of the compositions of 1−2 μm nonporous microspheres suggests that mineral precursors of the most (∼90%) globule are genesis products of main clay minerals, which undergo thermochemical transformations during combustion. A distinctive feature of clay minerals, which is related to their layered structure, is their ability for isomorphic substitutions and interlayer cation exchange, which leads to variable compositions of mixed-layered phases, including two- and three-component mixtures of kaolinite, montmorillonite, and illite, as well as to transformation of one mineral to another. These transformations include conversion of montmorillonite, which belongs to smectite-type layered silicates, to K-illite (eq 5),62 kaolinite to NH4-illite (eq 6),60 and K-illite to NH4-illite (eq 7)62

Aluminosilicate compositions of microspheres in various groups are described by functional dependencies with high correlation coefficient values (Figure 6) Group 1: [SiO2 ] = 96.02 − 1.03[Al 2O3] , r = − 1.00

(1)

Group 2: [SiO2 ] = 93.76 − 1.02[Al 2O3] , r = −0.99

(2)

Group 3: [SiO2 ] = 92.16 − 1.04[Al 2O3] , r = −0.99

(3)

Group 4: [SiO2 ] = 85.89 − 0.91[Al 2O3] , r = −0.94

(4)

The linear regression given in eqs 1−4 differs in the free term, with the slope values being similar, which is graphically reflected as a parallel shift of the lines when going from one group of microspheres to another, indicating changes in mineral precursors. The functional dependencies SiO2 = f(Al2O3) for microspheres in different groups are related to the aluminosilicate compositions of dehydroxylated clay minerals and products of their genesis (Figure 6). The average stoichiometric formulas for the minerals are as follows: NH 4 -Illite(NH 4 0 . 6 7 ,K 0 . 1 1 )(Al 1 . 9 0 ,Fe 0 . 0 6 ,Mg 0 . 0 4 )(Al0.68,Si3.32)O10(OH)2;60 MontmorilloniteNa0.33(Al1.67Mg0.33)Si4O10(OH)2;61 K-IlliteK1.5Al4(Si6.5Al1.5)O20(OH)4;61 KaoliniteAl2Si2O5(OH)4.39,61 The compositions of NH4-illite and montmorillonite satisfactorily correspond to the dependence (1), and the

Smectite + K+ → K‐illite + Si4 +

(5)

Kaolinite + NH 4 + → NH4‐illite + H 2O

(6)

K‐Illite + NH 4 + → NH4‐illite + K+

(7)

Possible thermochemical mineral transformations during coal combustion include the following reactions (refs 39 and 55) Montmorillonite → melilite + Fe3O4 + SiO2 G

(8)

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Energy & Fuels Illite → K 2O + mullite + SiO2 Kaolinite → mullite + SiO2

Notes

(9)

The authors declare no competing financial interest.



(10)

ACKNOWLEDGMENTS This study was supported by the Russian Foundation for Basic Research, Government of Krasnoyarsk Territory, and Krasnoyarsk Regional Fund of Science (project no. 18-43-240002 Development of lightweight high-strength proppants based on microsphere narrow fractions of coal fly ash) and the Siberian Branch of the Russian Academy of Sciences (project no. V.45.3.3 Formation of new functional microspherical and composite materials with desired properties). We are grateful to staff members of the Institute of Chemistry and Chemical Technology of the Siberian Branch of the Russian Academy of Sciences (Krasnoyarsk), L. A. Solov’ev for quantitative X-ray diffraction analysis and result interpretation and A. M Zhizhaev for SEM−EDS analysis of microspheres.

Group 1 microspheres are formed during the thermochemical transformation of NH4-illite with partial involvement of montmorillonite. Precursors of most group 2 microspheres are mixed-layered minerals of the montmorillonite-illite series. The presence of iron in their composition is associated with isomorphic substitution of octahedral Mg2+ cations of lower valency by Fe3+ cations of higher valency, and, in the case of an elevated iron content, with substitution of Al in octahedra and partial substitution of Si in tetrahedra as well as with the entry of Fe3+ into interlayer sites.63 The maximum FeO content of ∼4 wt % (Table 4) is controlled by possible iron content in illites with a low degree of aluminum substitution by iron cations.64 For mineral precursors of group 3 and group 4 microspheres, in which the FeO content reaches 6 and 9 wt %, respectively (Table 4), the level of iron cation substitution and Fe3+ entry into interlayer sites of mixed-layered clay minerals of the isomorphic illite-montmorillonite series increases gradually. Individual globules with a high content of calcium, magnesium, titanium, and iron are formed with involvement of impurity minerals of the initial coal, such as calcite, dolomite, gypsum, magnesite, rutile, and siderite.





CONCLUSIONS The present study leads to the following conclusions. Nonmagnetic fine narrow fractions of PM10 with d50 of 1.9, 2.3, 5.1, and 9.2 μm can be successfully separated from fly ash produced by pulverized combustion of Ekibastuz coal at the Reftinskaya GRES using aerodynamic and magnetic separation. The separated fractions have the bulk density from 0.90 to 1.07 g/cm3. The chemical composition mainly represented by SiO2 and Al2O3 in the amount of 65−70 and 23−28 wt %. The phase composition includes the amorphous glass phase 64−69 wt % and crystalline phases of mullite and quartz17−21 and 10−18 wt %, respectively. The main morphological particle types are microspheres with a nonporous smooth surface and microspheres with a porous shell. As the fraction particle size increases, the proportion of microspheres with the porous shell rises, the largest fraction is characterized by the presence of particles with a network structure. Analysis of the relationship of macrocomponent concentrations for nonporous microspheres of 1−2 μm revealed correlation dependencies and suggested that the mineral precursors of the main fine microspheres are the genesis products of mixed-layered clay minerals with varying levels of iron cation substitution. Because of certain physicochemical parameters, the separated fine fractions of fly ash are promising for the production of materials with predictable properties (ultrahigh performance concrete, ceramic membrane substrates, fire-resistant panels, polymer composites, etc.).



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AUTHOR INFORMATION

Corresponding Authors

*E-mail: [email protected] (E. V. F.). *E-mail: [email protected]. Phone: +7 391 205 19 43. Fax: +7 391 249 41 08 (A.G.A.). ORCID

Elena V. Fomenko: 0000-0003-0929-807X Alexander G. Anshits: 0000-0002-5259-0319 H

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DOI: 10.1021/acs.energyfuels.9b00097 Energy Fuels XXXX, XXX, XXX−XXX

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DOI: 10.1021/acs.energyfuels.9b00097 Energy Fuels XXXX, XXX, XXX−XXX