Environmental Performances of Various CCU Options in the Framework of an Integrated Chemical Plant.

Several carbon capture processes are investigated to separate a part of the CO2 contained in the flue gas of a coal-fired power plant located in a chemical integrated plant, with the objective of using it as a raw material in a production process. The expected results are to reduce the impact on global warming potential (GWP) and to increase the productivity of the plant. The study is based on the modelling of the combination of systems in the plant using a process simulation software and using life cycle assessment to evaluate both technical feasibility and environmental aspects. Models for the power plant, the production processes, amine chemical absorption, membrane separation and adsorption on activated coal are developed and validated against industrial and literature data. The life cycle inventory is obtained from the mass and energy balances given by the systems model. A first set of calculations is launched with a high purity requirement for the CO2 stream (95%) recycled into the process. Those calculations show a 12% increase in productivity for the chemical process considered, but result in no significant gain in terms of GWP. Conversely, scenarios with a lower CO2 purity (40%) show a drop around 9% of the impacts on GWP using membrane separation and activated coal adsorption, while keeping the other impacts at about the same level.

Some Aspects of the Thermochemical Route for the Valorization of Plastic Wastes, Part I: Reduction of Iron Oxides by Polyvinyl Chloride (PVC).

The mass production of synthetic plastics began in the last century and today they have become one of the most abundant man-made materials. The disposal or the beneficiation of end-of-life plastics represent a great challenge for society especially in the case of polyvinyl chloride (PVC). This study is focused on the use of PVC waste as a useful agent for the direct reduction of hematite (Fe2O3) after a thermal treatment at 300 °C for removing the chlorine contained in PVC. Thermal reduction tests were conducted from 600 °C to 1100 °C with (Fe2O3 + PVC + clay) pellet mixtures in which clay was used as plasticizing and binder agent of the pellets. The starting samples and treatment residues were analyzed by scanning electron microscopy through energy dispersive spectroscopy (SEM-EDS) and X-ray diffraction (XRD) to monitor the chemical behavior and reactivity of the pellet constituents during their thermal treatment. The stepwise reduction of hematite up to metallic iron was achieved at temperatures approaching 1000 °C, confirming the capability of using PVC waste for the direct reduction of iron oxides.

Reactivity of Low-Grade Chromite Concentrates towards Chlorinating Atmospheres.

The most economically important iron-chromium bearing minerals is chromite. In natural deposits, iron(II) is frequently substituted by magnesium(II) while chromium(III) is replaced by aluminum(III) and/or iron(III) forming a complex chromium bearing material. The majority of mined chromite is intended for the production of ferrochrome which requires a chromite concentrate with high chromium-to-iron ratio. Found mostly in the spinel chromite structure, iron cannot be removed by physical mineral processing methods. In this frame, the present work deals with the reaction of chlorine and chlorine+oxygen with selected samples of chromite concentrates for assessing the reactivity of their components towards chlorinating atmosphere, allowing the preferential removal of iron, hence meeting the chromite metallurgical grade requirements. Isothermal thermogravimetric analysis was used as a reliable approach for the kinetic reactivity investigation. Results indicated a wide difference in the thermal behavior of chromite constituents in a chlorinating atmosphere when considering their respective values of apparent activation energy oscillating from about 60 to 300 kJ/mol as a function of the sample reacted fraction. During the chromite treatment by chlorine in presence of oxygen, chromium was recovered as liquid chromyl chloride by condensation of the reaction gas phase.

Thermochemical Route for Extraction and Recycling of Critical, Strategic and High-Value Elements from By-Products and End-of-Life Materials, Part II: Processing in Presence of Halogenated Atmosphere.

During the treatment of copper anode slime (CAS) under an air atmosphere, several aspects of the interactions of its main components (CuAgSe, Cu2-xSeyS1-y, Ag3AuSe2) with oxygen were described in Part I. As a comparative and complementary study, this work deals with the thermal behavior of CAS under air in the presence of polyvinyl chloride (PVC) between 195 and 770 °C. The preliminary thermal treatment of an e-waste sample containing brominated substances was also performed. The reaction products were systematically analyzed by scanning electron microscopy through energy-dispersive spectroscopy (SEM-EDS) and X-ray diffraction (XRD) to investigate the thermal behaviors of the studied samples in a halogenated medium. At low temperatures, the copper, silver and selenium compounds of the CAS reacted with the HCl, issued from PVC degradation, leading to the formation of their respective chlorides. Bromides of valuable metals (Cu, Pb, Sn…) were synthesized during the e-waste treatment at 500 °C and they were distributed between the solid residue and gaseous phase. The data obtained give an insight into the reactivity of several metals towards halogenated substances, which may be valuable information for conducting the extraction and recycling of targeted elements from industrial by-products and end-of-life materials by a thermochemical route.

Green Process for Industrial Waste Transformation into Super-Oxidizing Materials Named Alkali Metal Ferrates (VI).

The investigation presented here features the design of a cleaner and greener chemical process for the conversion of industrial wastes into super-oxidizing materials. The waste of interest is the iron sulfate heptahydrate (FeSO4·7H2O) mainly generated through the sulfate route used for titanium dioxide industrial production. The products of this transformation process are alkali ferrates (A2FeO4, A = Na, K) containing iron in its hexavalent state and considered as powerful oxidants characterized by properties useful for cleaning waters, wastewaters, and industrial effluents. The proposed process includes two steps: (i) The first step consisting of the pre-mixing of two solids (AOH with FeSO4·xH2O) in a rotary reactor allowing the coating of iron sulfate in the alkali hydroxides through solid-solid reactions; and (ii) the second step involves the synthesis of alkali ferrates in a fluidized bed by oxidation of the single solid obtained in the first step in diluted chlorine. The chemical synthesis of alkali ferrates can be carried out within a timeframe of a few minutes. The usage of a fluidized bed enhanced the energy and mass transfer allowing a quasi-complete control of the ferrate synthesis process. The alkali ferrate synthesis process described here possesses many characteristics aligned with the principles of the "green chemistry".

Thermochemical Route for Extraction and Recycling of Critical, Strategic and High Value Elements from By-Products and End-of-Life Materials, Part I: Treatment of a Copper By-Product in Air Atmosphere.

Development of our modern society requests a number of critical and strategic elements (platinum group metals, In, Ga, Ge…) and high value added elements (Au, Ag, Se, Te, Ni…) which are often concentrated in by-products during the extraction of base metals (Cu, Pb, Zn…). Further, recycling of end-of-life materials employed in high technology, renewable energy and transport by conventional extractive processes also leads to the concentration of such chemical elements and their compounds in metallurgical by-products and/or co-products. One of these materials, copper anode slime (CAS), derived from a copper electrolytic refining factory, was used for this study. The sample was subjected to isothermal treatment from 225 to 770 °C under air atmosphere and the reaction products were systematically analyzed by scanning electron microscopy through energy dispersive spectroscopy (SEM-EDS) and X-ray diffraction (XRD) to investigate the thermal behavior of the treated sample. The main components of the anode slime (CuAgSe, Cu2-xSeyS1-y, Ag3AuSe2) react with oxygen, producing mostly copper and selenium oxides as well as Ag-Au alloys as final products at temperatures higher than 500 °C. Selenium dioxide (SeO2) is volatilized and recovered in pure state by cooling the gaseous phase, whilst copper(II) oxide, silver, gold and tellurium remain in the treatment residue.

Detailed Modeling of the Direct Reduction of Iron Ore in a Shaft Furnace.

This paper addresses the modeling of the iron ore direct reduction process, a process likely to reduce CO2 emissions from the steel industry. The shaft furnace is divided into three sections (reduction, transition, and cooling), and the model is two-dimensional (cylindrical geometry for the upper sections and conical geometry for the lower one), to correctly describe the lateral gas feed and cooling gas outlet. This model relies on a detailed description of the main physical⁻chemical and thermal phenomena, using a multi-scale approach. The moving bed is assumed to be comprised of pellets of grains and crystallites. We also take into account eight heterogeneous and two homogeneous chemical reactions. The local mass, energy, and momentum balances are numerically solved, using the finite volume method. This model was successfully validated by simulating the shaft furnaces of two direct reduction plants of different capacities. The calculated results reveal the detailed interior behavior of the shaft furnace operation. Eight different zones can be distinguished, according to their predominant thermal and reaction characteristics. An important finding is the presence of a central zone of lesser temperature and conversion.

Optimization of the Iron Ore Direct Reduction Process through Multiscale Process Modeling.

Iron ore direct reduction is an attractive alternative steelmaking process in the context of greenhouse gas mitigation. To simulate the process and explore possible optimization, we developed a systemic, multiscale process model. The reduction of the iron ore pellets is described using a specific grain model, reflecting the transformations from hematite to iron. The shaft furnace is modeled as a set of interconnected one-dimensional zones into which the principal chemical reactions (3-step reduction, methane reforming, Boudouard and water gas shift) are accounted for with their kinetics. The previous models are finally integrated in a global, plant-scale, model using the Aspen Plus software. The reformer, scrubber, and heat exchanger are included. Results at the shaft furnace scale enlighten the role of the different zones according to the physico-chemical phenomena occurring. At the plant scale, we demonstrate the capabilities of the model to investigate new operating conditions leading to lower CO2 emissions.

Assessing the fate of nutrients and carbon in the bioenergy chain through the modeling of biomass growth and conversion.

A forest growth model was coupled to a model of combined heat and power (CHP) production in a gasification plant developed in Aspen Plus. For a given production, this integrated forest-to-energy model made it possible to predict the annual flows in wood biomass, carbon, and nutrients, including N, S, P, and K, from the forest to the air emissions (NOx, SOx, PAH, etc.) and ash flows. We simulated the bioenergy potential of pure even-aged high-forest stands of European beech, an abundant forest type in Northeastern France. Two forest management practices were studied, a standard-rotation and a shorter-rotation scenario, along with two wood utilizations: with or without fine woody debris (FWD) harvesting. FWD harvesting tended to reduce the forested area required to supply the CHP by 15­22% since larger amounts of energy wood were available for the CHP process, especially in the short-rotation scenario. Because less biomass was harvested, the short-rotation scenario with FWD decreased the nutrient exports per hectare and year by 4­21% compared to standard practices but increased the amount of N, S, and P in the CHP process by 2­9%. This increase in the input nutrient flows had direct consequences on the inorganic air emissions, thus leading to additional NOx and SO2 emissions. This model is a valuable tool for assessing the life cycle inventories of the entire bioenergy chain.

Hydrazinium lanthanide oxalates: synthesis, structure and thermal reactivity of N2H5[Ln2(C2O4)4(N2H5)]·4H2O, Ln = Ce, Nd.

New hydrazinium lanthanide oxalates N2H5[Ln2(C2O4)4(N2H5)]·4H2O, Ln = Ce (Ce-HyOx) and Nd (Nd-HyOx), were synthesized by hydrothermal reaction at 150 °C between lanthanide nitrate, oxalic acid and hydrazine solutions. The structure of the Nd compound was determined from single-crystal X-ray diffraction data, space group P21/c with a = 16.315(4), b = 12.127(3), c = 11.430(2) Å, ß = 116.638(4)°, V = 2021.4(7) Å(3), Z = 4, and R1 = 0.0313 for 4231 independent reflections. Two distinct neodymium polyhedra are formed, NdO9 and NdO8N, an oxygen of one monodentate oxalate in the former being replaced by a nitrogen atom of a coordinated hydrazinium ion in the latter. The infrared absorption band at 1005 cm(-1) confirms the coordination of N2H5(+) to the metal. These polyhedra are connected through µ2 and µ3 oxalate ions to form an anionic three-dimensional neodymium-oxalate arrangement. A non-coordinated charge-compensating hydrazinium ion occupies, with water molecules, the resulting tunnels. The N-N stretching frequencies of the infrared spectra demonstrate the existence of the two types of hydrazine ions. Thermal reactivity of these hydrazinium oxalates and of the mixed isotypic Ce/Nd (CeNd-HyOx) oxalate were studied by using thermogravimetric and differential thermal analyses coupled with gas analyzers, and high temperature X-ray diffraction. Under air, fine particles of CeO2 and Ce(0.5)Nd(0.5)O(1.75) are formed at low temperature from Ce-HyOx and CeNd-HyOx, respectively, thanks to a decomposition/oxidation process. Under argon flow, dioxymonocyanamides Ln2O2CN2 are formed.

Kinetic rate laws of Cd, Pb, and Zn vaporization during municipal solid waste incineration.

The kinetic rate laws of heavy metal (HM) vaporization from municipal solid waste during its incineration were studied. Realistic artificial waste (RAW) samples spiked with Pb, Zn, and Cd were injected into a fluidized bed reactor. Metal vaporization wastracked by continuous measure ofthe above metals in exhaust gases. An inverse model of the reactor was used to calculate the metal vaporization rates from the concentration vs time profiles in the outlet gas. For each metal, experiments were carried out at several temperatures in order to determine the kinetic parameters and to obtain specific rate laws as functions of temperature. Temperature has a strong influence on the HM vaporization dynamics, especially on the vaporization kinetics profile. This phenomenon was attributed to internal diffusion control of the HM release. Two types of kinetic rate laws were established based on temperature: a fourth- or fifth-order polynomial rate law (r(x) = k0e(-E(A)/RT)p(x)) for temperatures lower than 740 degrees C and a first-order polynomial (r(x) = k0e(-E(A)/ RT(q-q(f) for temperatures higher than 740 degrees C.