C. Saha, A.A. Raisi, S.

Bhattacharya

COAL DIRECT CHEMICAL LOOPING COMBUSTION:

EXPERIMENTAL INVESTIGATION AND ASSESMENT OF
OPERATING CONDITIONS
Chiranjib Saha, Asma Ismail AL Raisi, Sankar Bhattacharya*

Department of Chemical Engineering

Monash University, Clayton Campus, Victoria 3800
*Email address: sankar.bhattacharya@monash.edu
ABSTRACT
Chemical-Looping combustion (CLC) is a novel technique where a metal oxide is used
to transfer oxygen from the combustion air to the coal. Two inter-connected fluidized
beds are used as fuel and air reactor for this purpose. The metal oxide is reduced by
reaction with coal in fuel reactor and then transported to the air reactor for (re)oxidation.
Thus the direct contact between air and coal is avoided and the fuel reactor outlet gas
consists of almost pure stream of CO2 ready for sequestration, when water vapour is
condensed. This paper reports the first known investigation of CLC with Victorian
brown coal using Fe2O3 as oxygen carrier. Victoria has large resources of brown coal
(>500 years at current consumption rate) and therefore there is a strong incentive for
development of technologies, such as chemical looping, that makes CO2 capture
potentially easier. Multiple reduction and reoxidation experiments with well
characterized Fe2O3 and Loy Yang Victorian brown coal has been performed using a
Thermogravimetric analyser (TGA). The reactivity, mechanical and chemical stability
of the oxygen carrier particles has been investigated. The results show good
performance of Iron oxide as oxygen carrier over multiple cycles. In addition a coal
direct chemical looping (CDCL) process, advantageous over syngas chemical looping
(SCL) process due to removal of gasification step, is developed using ASPEN plus
package. The performance parameters are optimized using Loy Yang coal and Fe2O3 as
fuel and oxygen carrier respectively. It was found that the general trends predicted by
the present model matched well with the results reported in the literature.
Key Words: Chemical Looping, Combustion, Gasification, Brown coal, TGA, ASPEN
Plus
INTRODUCTION
Conventional coal based power generation involving combustion requires direct contact
between air and coal. This dilutes the resulting gases due to the presence of nitrogen
(N2) in air. So the concentration of CO2 is reduced in flue gases which make CO2
separation and capture energy intensive. Chemical looping combustion (CLC) is one of
the most promising technologies to carryout potentially easier CO2 capture. In chemical
looping combustion, an oxygen carrier; preferably metal oxides, is used to transfer
oxygen from combustion air to fuel. The CLC system is composed of two reactors: an
air reactor and a fuel reactor. In the fuel reactor, the coal particles are reduced by the
lattice oxygen of the metal oxide and reduced metal oxide is re-oxidized in the air
reactor to be used in the next cycle. The main advantage of this system is that a
concentrated stream of CO2, free from dilution with nitrogen, can be obtained from fuel

C. Saha, A.A. Raisi, S. Bhattacharya

reactor after condensing the water vapour. A generalized description of the overall
system is given in Figure 1. Reaction stoichiometry is given by the equations below:
(2n+m) MyOx + CnH2m (2n+m) MyOx-1 + mH2O + nCO2
(1)
However, in case of coal direct chemical looping combustion experiments explained in
this work, the reaction 1 can be subdivided as the followings:
C+CO2 2CO
(1a)
CO+ MyOx MyOx-1 + CO2
(1b)
MyOx-1 + O2 MyOx
(2)
where M stands for metal and MyOx as metal oxide.
Chemical looping concept has been widely studied and important progress has been
made for combustion of natural gas (Adanez et al., 2010).The Chemical looping
methodology has been investigated previously with synthesis gas, derived from coal, as
feedstock (Diego et al., 2004; Lyngfelt et al., 2008). However, only a few studies have
been conducted directly using combustion of solid fuels, such as coal (Siriwardane et al.,
2009). Two major approaches are researched in chemical looping combustion of coal.
One approach is to use syngas derived from coal gasification or ex-situ coal gasification
products in the fuel reactor. The other approach is introduction of the coal directly to the
fuel reactor where the gasification (in-situ) of the coal and the subsequent reactions with
the metal oxide particles will occur simultaneously in the same reactor (Mattisson et al.,
2007). This in-situ or direct coal combustion using chemical looping process is
potentially advantageous over the syngas chemical looping as it eliminates the need for
energy intensive air separation unit (Fan et al., 2008; Gnanapragasam et al., 2009).
From literature it is evident that limited number of investigations has been performed on
chemical looping using lignites. In-situ process has been experimentally investigated
using Hambach German Lignite, #6 Illinois coal (Dennis & Scott 2009; Siriwardane et
al., 2009). Prediction of optimized system operating conditions is performed using coal
direct chemical looping (CDCL) process simulation models (Gnanapragasam et al.,
2009).

C. Saha, A.A. Raisi, S. Bhattacharya

N2/O2

CO2/H2O

MyOx

Air

Fuel

Reactor

Reactor
MyOx-1

Air

Coal

Fig. 1: Schematic of Chemical Looping Combustion

But Victorian brown coals are never investigated, neither experimentally nor modelling,
for coal direct chemical looping process. This project is the first ever experimental
investigation and models prediction study reported on coal direct chemical looping
process with Victorian Brown coal. Victoria has large resources of brown coal, (over
500 years at current consumption rate) which has a very low ash content, but and high
in minerals; and these characteristics separate it from other coals, in particular black
coals... Therefore there is a strong incentive for the development of efficient
technologies, such as chemical looping, for power generation from Victorian brown
coal.
Metal oxides of Nickel, Copper, Cobalt, Manganese and Cadmium have been discussed
in literature for Chemical looping combustion of gaseous fuels such as natural gas and
CH4 (Rubel et al., 2009). Pure Hematite (Fe2O3) and externally impregnated support
metal oxides with this has been investigated for application in chemical looping mostly
with gaseous fuel (Lyngfelt et al., 2008). Coal gasification experiments in a fluidized
bed proved the feasibility of coal CLC with Fe2O3 as the oxygen carrier. It was
observed the amount of CO and CO2 produced is consistent with the amount of coal
added (Siriwardane et al., 2009; Lyon et al., 2000). Natural iron titanium oxide or
Ilmenite has been investigated as oxygen carrier with South African Coal and Petroleum
coke by Berguerand & Lyngfelt (Berguerand et al., 2008 & 2009). Synthetic particle of
60% active Fe2O3 and 40% MgAl2O4 has also been investigated with solid fuel by Leion
et al. (Leion et al., 2008). Dennis & Scott reported gasification of lignite char under
steam and CO2 atmosphere with Fe2O3 as oxygen carrier (Dennis & Scott 2009). It is
evident that application of Fe2O3 as oxygen carrier for CLC of lignites has not been
investigated widely. Moreover iron oxide is inexpensive in Australia and when used in
CLC it is expected to generate concentrated stream of CO2 and H2.
The reduction and re-oxidation kinetics of Fe2O3 in multiple cycles operation for direct
coal chemical looping combustion have been determined in a Thermo gravimetric
Analyser (TGA). The reactivity, conversion and oxygen transfer capability of iron oxide
during CDCLC of Loy Yang Victorian brown coal are reported in this paper. The

C. Saha, A.A. Raisi, S. Bhattacharya

preliminary prediction of ash agglomeration has also been made. Also a CDCL process
has been developed using ASPEN plus simulation package to predict the optimized
resource requirements. Predictions of the present model have been compared with that
in literature. This paper outlines the experimental works and the developed model,
discusses the results and new work being undertaken based on these experiences.
EXPERIMENTAL SECTION
Materials
The experiments have been performed with a dried Victorian brown coal - Loy Yang of
100-150 m particle size. Drying was done in an oven for 6 hours at 105C. The
composition of the dried Loy Yang Victorian brown coal used in this study can be
found in literature (Saha et al., 2011). The oxygen carrier used in this study is Fe2O3
powder with 99% purity of 100-150 m size. These were thoroughly mixed with the
dried coal particles prior to the experiments. The metal oxide / coal mass ratio used in
the experiments was 6:1 which correspond to stoichiometric oxygen supply. 20 mg coal
samples have been used for reduction in every cycle. Same amount of coal has been
mixed with reacted metal oxide and ash in the TGA crucible after each re-dox cycle.
Ash could not be separated after each cycle because the coal quantity used was too
small and so was the accumulated ash after each cycle.

Chemical Looping Experiments

Tests were conducted using Thermo gravimetric analyser (TGA) apparatus. Scanning
electron microscope (SEM) and Energy Dispersive X-rays (EDX) was used for solids
characterization. The solid residue samples were collected carefully after each test for
SEM analysis.
The effect of consecutive reduction-oxidation cycles on the reactivity of metal oxides in
CO2 gas composition was assessed in the TGA. Experiments were carried out in
alumina crucibles. The coal and Fe2O3 mixture was heated from ambient temperature to
950C at a heating rate of 10C/min under CO2 gas composition. During an experiment,
the sample was heated to 950C in CO2 atmosphere, and maintained at that condition for
one hour, following which air was introduced to oxidize the reduced particles for
another hour. The reducingin-situ gasification environment used for experimentcoal
gasification was 20%CO2 + 80% N2 gas mixture during reduction. The metal oxide
particles have been re-oxidized using air.
TGA weight change data was also used to calculate the percentage of combustion.
Percent Combustion =

Actual Weight Loss of coal from TGA

100
Theoretica l weight loss based on the carbon content in the coal sample
(3)

C. Saha, A.A. Raisi, S. Bhattacharya

COAL DIRECT CHEMICAL LOOPING PROCESS SIMULATION
The schematic of coal direct CLC combined cycle plant with CO2 capture using Fe2O3
as oxygen carrier is shown in Figure 2. There are four basic sections in this type of
power plant. Fe2O3 is circulated between the three reactors (AR- Air reactor, FR-Fuel
reactor and SR-Steam reactor) for chemical looping combustion and hydrogen
production. The hot oxygen depleted air from air reactor expands in a gas turbine (GTGas turbine). The flue gases from gas turbine then passes through the heat recovery
steam generator (HRSG) for power generation using steam cycle. The hot CO2-Steam
mixture stream from fuel reactor expands in a CO2-turbine (CO2-T) for power
generation. After compressing this cold utility steam is removed and further
compression provides liquid CO2 for capture and storage. In this way a direct contact
between air and fuel is avoided. Hence a near pure stream of CO2 can be achieved for
sequestration with minimum energy penalty as installation of air separation unit is
avoided. Also the amount of NOX produced in such a plant is negligible.
In this present study the coal direct chemical looping combustion process has been
modelled (the red dotted box section) using ASPEN plus software package. The system
operating conditions are assessed. The operating variables considered as part of this
study are inlet conditions to different reactors and minimum resource requirements.
Emphasis is given on correct prediction of amount of hydrogen production and CO2
emissions. Detailed study has been performed on resource requirements such as air,
steam and iron oxide and compared with the rates of specific hydrogen production. This
paper will report some of the predictions and discuss the practical implications.
H2O

STEAM CYCLE

STACK

POWER GENERATION

COMPRESSOR

HRSG
HP

COMPRESSOR

CO2-T

LIQUID
CO2

GT

IP
CONDENSER

CYCLONE

N2/O2

CO2+H2O

COAL
FEEDER

FR

PUMP

FeO/Fe

AR

H2 TO STORAGE

SR

Fe2O3
STEAM
Fe3O4

AIR

AIR

COMPRESSOR
CHEMICAL LOOPING COMBUSTION AND
HYDROGEN PRODUCTION

CYCLONE

ST

PUMP
CO2 CAPTURE

C. Saha, A.A. Raisi, S. Bhattacharya

Fig.2: Chemical Looping Combustion combined cycle with CO2 capture
RESULTS AND DISCUSSION
The feasibility of using different oxygen carriers in chemical looping combustion with
Victorian brown coal is one of the major objectives of the ongoing study. Experimental
results pertaining to application of Fe2O3 as oxygen carrier with Loy Yang Victorian
brown coal in CLC is reported in this section.
TGA weight loss experiment of coal and metal oxide mixture
The TGA weight loss and the corresponding reactivity of Fe2O3-Coal mixture during
heating upto 950C in CO2 have been plotted in Fig. 3 (A). A continuous weight loss
can be observed for metal oxide-coal mixture. Coal devolatilization starts from 250C
and proceeds until 650C with a peak around 550-600C for the case studied. The
reactivity curve in presence of CO2 indicates the start of combustion peak at 700C and
reaches maximum at around 940C. This observation indicates that Fe2O3 contributes to
the combustion of the coal after volatilization and weight loss corresponds to coal
combustion in presence of both the gasification agents. The maximum combustion rate
for Fe2O3-mixture reported in literature (Siriwardane et al., 2009) under CO2 gas
composition occurred at 905C. It is possible to achieve 95% combustion of coal with
Fe2O3 as calculated by equation 3. . In reality this number indicate the percentage of
actual amount of weight loss of coal in a coal and metal oxide mixture from TGA
experiments to the theoretical weight loss based on carbon content in coal sample. This
means that TGA plots show 95% of coal mass loss with respect to ideal case based on
carbon content when Fe2O3 is used as oxygen carrier. The oxidation segment of Fe2O3
oxide after reduction under CO2 is shown in Fig. 3 (B). The final weight gain during
oxidation, as measured after the experiment, is almost same as compared to the initial
mass of the oxygen carrier used in Fe2O3-Loy Yang coal mixture. The result of the EDX
analysis (explained later) also strengthens this observation. It is clearly seen from the
Fig. 3 (B) that re-oxidation of reduced iron oxide in presence of air occurs in two steps.
The process simulation on coal direct chemical looping for CO2 capture and hydrogen
production, as described in Fig. 2 and explained later on, also predicts that Fe2O3 is first
reduced to Fe/FeO in the reducer. Then it is re-oxidized to Fe3O4 in oxidizer with steam
to produce H2. Finally it is fully oxidized to Fe2O3 in combustor with contact of fresh air
and can be reused in next cycle. In Fig. 3(B) the two steps oxidation in air is expected
because Fe2O3 is reduced to Fe/FeO (as predicted by FACTSAGE simulation also) and
consecutively re-oxidized to Fe3O4 and Fe2O3 in two steps.

C. Saha, A.A. Raisi, S. Bhattacharya

Fe2O3 mass gain during oxidation in air

Fe2O3 and Loy Yang Coal M ass loss in CO2

Fe2O3 and Loy Yang Coal Reactivity in CO2

Fe2O3 reactivity during oxidation in air

100

0 . 00004

85
0 . 00015

0 . 00005

80

M ass gain (%)

0 . 00010
85

Reactivity (per min)

90

0 . 00003
84
83

0 . 00002

82
0 . 00001

React ivity (p er m in )

95

M ass Loss (%)

86

0 . 00020

81

75

0 . 00000
0

200

400

600

800

1000

80

0 . 00000

7500

8500

9500

Temperature (deg C)

10500

11500

12500

13500

Time (s)

(A)
(B)
Fig.3: (A) Weight loss and reactivity of Loy Yang coal with Fe2O3 (B) Weight gain and
reactivity of Fe2O3 during oxidation in air.
100

Reactivity Comparison

Reduction and Oxidation of Fe2O3 and Loy Yang

Maximum Reactivity during oxidation

Maximum Reactivity during Reduction

0.012

Weight Loss (%)

95
0.01
0.008

90

Reactivity (Per 0.006

Min)
0.004
0.002

85

0
1

3
Cycle

80
0

200

400

600

800

1000

1200

Time (Min)

Fig.4: Five (5) cycles TGA redox

test of Loy Yang coal with Fe2O3

Fig. 5: Maximum Reactivity Comparison of

Fe2O3 with Loy Yang Coal during Redox in
CO2 environment
Multi cycle redox TGA tests of metal oxides and coal
A five cycle TGA test was conducted with Fe2O3-Loy Yang coal mixture in CO2
environment to evaluate the coal combustion and metal re-oxidation process. After each
re-oxidation process at 950C, reacted metal oxide/ash was mixed with same amount of
coal used in previous cycles. Ash could not be separated after each cycle and hence
accumulated TGA crucible. The results of redox cycles in CO2 gas are shown in Fig. 4.
The extent of coal combustion and re-oxidation of metal oxides, as shown by the weight
loss and weight gain respectively, during TGA tests show a small decrease for the
Fe2O3-coal mixture. The attrition rate of iron oxide was very less or negligible.
However, even with sample ash accumulation in TGA crucible in each cycle the
percentage of combustion at fifth cycle is 89% for Fe2O3 oxygen carrier. The maximum
reactivity during reduction and re-oxidation of oxygen carrier in each cycle is plotted in
Fig. 5. The reduction reactivity is maximum at second cycle and shows a decrease in
trend in consecutive cycles. This can be attributed to the fact that the oxygen carrier

C. Saha, A.A. Raisi, S. Bhattacharya

particles give off oxygen more easily for combustion at second cycle due to the
structural changes during operation in first cycle. But during progressive cycles the
continuous ash accumulation in the TGA crucible may restrict the contact between fresh
coal and the re-oxidized metal oxide. The maximum reactivity in each re-oxidation
cycle for Fe2O3 shows maximum value at second cycle similar to maximum reduction
reactivity curve. But after that reactivity is almost constant as ash accumulation does not
play any role during reaction of oxygen carrier and fresh air.
EDX analysis of fresh and used oxygen carriers:
The EDX analysis provides semi-quantitative weight composition of the major elements
detected on the surface of the fresh and used oxygen carrier particles. For the fresh
particles of Fe2O3, Fe and O are detected and the weight percentages are 18.18 and
81.82 respectively as shown in figure 6A. For used Fe2O3 particles (after five redox
cycles) these weight percentages are 17.76 and 82.24 as can be seen from Fig. 6B. This
indicates that there is little ash deposition on the used particles of Fe2O3 under the
conditions of the experiments. However, long term experiments are in progress.
Coal Direct Chemical Looping (CDCL) process modelling:
The three reactor steam-iron oxide process has been developed using Aspen plus
package for H2 and concentrated stream of CO2 production by direct CLC of Loy Yang
coal. The H2 and CO2 production and resources requirement predicted by the present
model for Loy Yang coal combustion is compared with that of literature with Pittsburgh
#8 coal (Gnanapragasam et al., 2009). Aspen Plus has a built in sensitively analyser
which records the effect of variation of one process variable on another variable. This
analyser was used to study the effect of increasing pure oxygen on the amounts of
resources required (Fe2O3, steam and re-oxidation air) and the products produce (H2,
CO2).
Two processes occur in the Fuel reactor. The first is partial combustion using pure
oxygen and the second is the reduction reaction of the iron oxide. Initial partial
combustion is required because the reduction reaction of Fe2O3 is highly endothermic;
therefore heat needs to be supplied to balance that. The source of heat is assumed to be
from the partial combustion process. For the developed model 5 kg/s of coal is fed to
the fuel reactor. To transport the coal to the reactor 10kg/s of CO2 is used as coal carrier
gas (CCG). The amount of oxygen fed was varied form 3.5-5.5 kg/s for all models. The
detailed reactions occurring in all the three reactors (Figure 2, red dotted box) can be
found in literature (Fan et al., 2008; Gnanapragasam et al., 2009). The products from
partial combustion reduce Fe2O3. The gaseous products are separated from the reduced
metal oxide FeO/Fe. The gas product gets cooled down to separate water from CO2 and
the reduced iron oxides are fed into a hydrogen reactor where they react with steam to
produce hydrogen. After the partial oxidation of the metal oxide they enter an air reactor to
fully re-oxidise iron based compounds to hematite (Fe2O3). The results are presented in
Figures 7. It can be seen from Figure 7A that as oxygen mass flow rate increases from
3.5 to 5.5 kg/s in the partial combustor of the fuel reactor, the hydrogen production
decreases from 69 Nm3/hr to 47.65 Nm3/hr for Loy Yang coal. Similar decreasing trend

C. Saha, A.A. Raisi, S. Bhattacharya

can also be observed for Pittsburgh #8 coal. Loy Yang coal produces less hydrogen
compared to Pittsburgh #8 coal. Loy Yang coal has lower carbon content than the
Pittsburgh #8 coal (~84%) and hence, the decreasing trend is observedThe carbon
content of Loy Yang coal is less as compared to Pittsburgh #8 coal (~84%) and hence is
this decrease. It was found that amount of hydrogen production is proportional to the
amount of CO and CH4 produced from the partial combustion process. Since in partial
combustion oxygen was kept constant for both the models, Loy Yang coal will
encounter more combustion initially with pure oxygen (since lower carbon content)
leading to lower CO, CH4 and H2 production.

(A)
(B)
Fig. 6: EDX spectrum of (A) fresh Fe2O3 and (B) 5 redox cycle with Loy Yang Coal
used Fe2O3 particles
H2 Pittsburgh #8 coal

H2 Loy Yang coal

CO2 Pittsburgh #8 coal

CO2 Loy Yang coal

100

Products (Nm3/hr)

90

80

70

60

50

40
3

3.5

4.5

5.5

Oxygen (kg/s)

(A)
Air-Pittsburgh #8

Air-Loy Yang

Fe2O3-Pittsburgh #8

Fe2O3-Loy Yang

Steam-Pittsburgh #8

Steam-Loy Yang

35

Resources Required (kg/s)

30
25

20

15

10
5

0
3

3.5

4.5
Oxyge n (kg/s)

(B)

5.5

C. Saha, A.A. Raisi, S. Bhattacharya

Fig. 7: (A) H2 and CO2 production (B) Resources requirement Vs oxygen flow at inlet
The maximum carbon dioxide produced for Loy Yang is 55.54 Nm3/hr. This value was
further verified through manual calculation. The CO2 values obtained for both the
models did not vary as O2 increased because complete combustion was maintained in all
runs. It is seen from Figure 7B that as oxygen flow increases to the partial combustion
reactor, the amount of iron oxide required decreases. This is obvious because with more
initial combustion, less oxygen supply through iron oxide will be required in the fuel
reactor for complete combustion. Therefore, the iron-oxide required is inversely
proportional to the oxygen fed to the partial combustor. The reason why Pittsburgh #8
requires relatively higher Fe2O3 is because it contains higher carbon content hence,
more oxygen will be required to combust the coal.
CONCLUSIONS
The feasibility of coal direct CLC was investigated experimentally with Loy Yang
Victorian brown coal and Fe2O3 as fuel and oxygen carrier respectively. The three
reactor coal direct steam-iron CLC process was also simulated using ASPEN plus
package. Fe2O3 showed a high coal combustion percentage of more than 90% in each of
the cycles of a multiple cyclic operation. No agglomeration between ash and Fe2O3 mass
loss of Fe2O3 particles was observed. The prediction of H2 and CO2 production trends
were very similar to the reported results in literature and so were the resources
requirement. However, the exact values were relatively less for Loy yang coal
combustion as compared to the Pittsburgh #8 coal due to less carbon content in the
former coal. The addition of coal dryer in the model and overall integration of the
process to the combined cycle power plant with CO2 capture is in progress.
ACKNOWLEDGEMENTS
The authors acknowledge the support of Brown Coal Innovation Australia (BCIA) for
this work. Chiranjib Saha acknowledges Monash University for his scholarships and
Monash Centre for Electron Microscopy (MCEM) for electron microscopy work..
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