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Number of results: 24
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Abstract

The article presents the directions of foundry waste management, mainly used for spent foundry sands (SFS) and dust after the reclamation of this waste. An important aspect of environmental protection in foundry production is the reduction of the amount of generated waste as a result of SFS regeneration. The advantage is the reuse of waste, which reduces the costs of raw materials purchase and environmental fees for landfilling. Non -recycled spent foundry sands can be used in other industries. SFS is most often used in road and construction industries as well as inert material in closed mines (Smoluchowska and Zgut 2005; Bany-Kowalska 2006). An interesting direction of using SFS is its application in gardening and agriculture. The article presents the advantages and disadvantages of such use. It was found that spent foundry sands can be useful for the production of soil mixtures for many agricultural and horticultural applications. Due to the possibility of environmental pollution with heavy metals and organic compounds, such an application is recommended for the so-called green sands, i.e. SFS with mineral binders. In addition, an innovative solution for the energy use of dusts after spent foundry sands reclamation with organic binders has been discussed and proposed by some researchers. It was shown that dust from reclaimed SFS with organic binders can be used as an alternative fuel and raw material in cement kilns, due to the high percentage of organic substances which determine their calorific value and silica.
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Abstract

Explosions of coal dust are a major safety concern within the coal mining industry. The explosion and subsequent fires caused by coal dust can result in significant property damage, loss of life in underground coal mines and damage to coal processing facilities. The United States Bureau of Mines conducted research on coal dust explosions until 1996 when it was dissolved. In the following years, the American Society for Testing and Materials (ASTM) developed a test standard, ASTM E1226, to provide a standard test method characterizing the “explosibility” of particulate solids of combustible materials suspended in air. The research presented herein investigates the explosive characteristic of Pulverized Pittsburgh Coal dust using the ASTM E1226-12 test standard. The explosibility characteristics include: maximum explosion pressure, (Pmax); maximum rate of pressure rise, (dP/dt)max; and explosibility index, (Kst). Nine Pulverized Pittsburgh Coal dust concentrations, ranging from 30 to 1,500 g/m3, were tested in a 20-Liter Siwek Sphere. The newly recorded dust explosibility characteristics are then compared to explosibility characteristics published by the Bureau of Mines in their 20 liter vessel and procedure predating ASTM E1126-12. The information presented in this paper will allow for structures and devices to be built to protect people from the effects of coal dust explosions.
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Abstract

Significant quantities of coal sludge are created during the coal enrichment processes in the mechanical processing plants of hard coal mines (waste group 01). These are the smallest grain classes with a grain size below 1 mm, in which the classes below 0.035 mm constitute up to 60% of their composition and the heat of combustion is at the level of 10 MJ/kg. The high moisture of coal sludge is characteristic, which after dewatering on filter presses reaches the value of 16–28% (Wtot r) (archival paper PG SILESIA). The fine-grained nature and high moisture of the material cause great difficulties at the stage of transport, loading and unloading of the material. The paper presents the results of pelletizing (granulating) grinding of coal sludge by itself and the piling of coal sludge with additional material, which is to improve the sludge energy properties. The piling process itself is primarily intended to improve transport possibilities. Initial tests have been undertaken to show changes in parameters by preparing coal sludge mixtures (PG SILESIA) with lignite coal dusts (LEAG). The process of piling sludge and their mixtures on an AGH laboratory vibratory grinder construction was carried out. As a result of the tests, it can be concluded that all mixtures are susceptible to granulation. This process undoubtedly broadens the transport possibilities of the material. The grain composition of the obtained material after granulation is satisfactory. Up to 2 to 20 mm granules make up 90–95% of the product weight. The strength of the fresh pellets is satisfactory and comparable for all mixtures. Fresh lumps subjected to a test for discharges from a height of 700 mm can withstand from 7 to 14 discharges. The strength of the pellets after longer seasoning, from the height of 500 mm, shows different values for the analyzed samples. The values obtained for hard coal sludge and their blends with brown coal dust are at the level from 4 to 5 discharges. The strength obtained is sufficient to determine the possibility of their transport. At this stage of the work it can be stated that the addition of coal dust from lignite does not cause the deterioration of the material’s strength with respect to clean coal sludge. Therefore, there is no negative impact on the transportability of the granulated material. As a result of mixing with coal dusts, it is possible to increase their energy value (Klojzy-Karczmarczyk at al. 2018). The cost analysis of the analyzed project was not carried out.
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Abstract

To investigate the effect of different proximate index on minimum ignition temperature(MIT) of coal dust cloud, 30 types of coal specimens with different characteristics were chosen. A two-furnace automatic coal proximate analyzer was employed to determine the indexes for moisture content, ash content, volatile matter, fixed carbon and MIT of different types of coal specimens. As the calculated results showed that these indexes exhibited high correlation, a principal component analysis (PCA) was adopted to extract principal components for multiple factors affecting MIT of coal dust, and then, the effect of the indexes for each type of coal on MIT of coal dust was analyzed. Based on experimental data, support vector machine (SVM) regression model was constructed to predicate the MIT of coal dust, having a predicating error below 10%. This method can be applied in the predication of the MIT for coal dust, which is beneficial to the assessment of the risk induced by coal dust explosion (CDE).
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Abstract

The cement production process is associated with the emission of dust. These are mainly CKD (cement kiln dust) and BPD (by-pass dust), classified as wastes from group 10 – Wastes from thermal processes, subgroups 10 and 13 – wastes from manufacture of cement, lime and plaster and articles and products made from them. Cement kiln dust is a waste of variable composition and properties, which makes it a difficult material to recover. The main directions of recovery presented in the world literature indicate the use of dust from cement kilns in cement, mortar and concrete production, the production of bricks and in order to improve soil quality and wastewater treatment. Factors affecting chemical and phase compositions of dust from cement kilns are the reason why each waste should be analyzed individually. The paper presents the results of the analysis of the cement kiln dust after dedusting cement kilns and two bypass dusts. Analysis of the chemical composition has shown significant concentrations of chlorine, potassium and calcium in all wastes. The content of: Si, S, Ti, V, Cr, Mn, Fe, Ni, Cu, Zn, Zr, Pb, and Bi has also been confirmed. The analyzed dusts were characterized by the presence of carbonates (calcite, dolomite, and arcanite), quartz, alite, belite, sylvine, anhydrite, and portlandite in their phase composition. The leachates which were characterized by an alkaline reaction. In terms of leachability, high concentrations of chlorine ions in the analyzed dust leachates were confirmed, which significantly limits their use.
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Abstract

The article presents research results of physico-chemical and environmental issues for the dust generated during dedusting of the installation for the processing and preparation of moulding sand with bentonite. Particular attention was paid to the content of heavy metals and emission of gases from the BTEX group, which is one of the determinants of the moulding sands harmfulness for the environment. The analysis of heavy metals in the test samples indicate that there is an increase of the content of all metals in the dust compared to the initial mixture of bentonite. The most significant (almost double) increase observed for zinc is probably related to the adsorption of this element on the dust surface by contact with the liquid metal. The study showed, that dust contained more than 20% of the amount of montmorillonite and had a loss on ignition at a similar level. The addition of 1% of dust to the used moulding sand results in almost 30% increase in the total volume of gases generated in casting processes and nearly 30% increase of the benzene emission.
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Abstract

Foundry dust from blasting and grinding of castings contain a high amount of iron, ergo it is possible its recycling in foundry process. Dust was compacted by briquetting, two kinds of briquettes were prepared (A contained 95% magnetic part of dust from casting blasting +5% bentonite and B contained 95% mixture of dust from casting grinding and magnetic part of dust from casting blasting + 5% bentonite) and used as a part of charge into the electric induction furnace. It was found that addition of briquettes has had an influence of a chemical composition of cast iron above all on content of sulphur, phosphorus and silicon. It was not reflected in decrease in tensile strength and in microstructure. Yield of metal from briquettes was not lower then 70%.
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Abstract

In this study, solidification/stabilization (S/S) of electric arc furnace dust (EAFD) which is generated during the production of steel from scrap metals and classified as hazardous waste were investigated by using different ratios of cement and low grade MgO (LG MgO) as binding agents. Type I PC 42.5 R portland cement and LG MgO which contains 70–80% MgO were used. S/S blocks that contain different ratios of binding agents which have 1/0.5 – 1/1 – 1/2 – 1/3 – 1/4 – 1/5 cement/LG MgO ratio and S/S blocks which contain only cement and no LG MgO agents were prepared. These blocks, which contain 3 different waste ratios according to weight, 20%, 30% and 40% respectively, were produced and exposed to 28-day water purification. At the end of the purification process, S/S blocks were extracted using TCLP (Toxicity Characteristic Leaching Procedure) tests in order to determine the leaching behavior of Zn, Pb, and Cd in S/S blocks. By the end of this study, it was concluded that the recovery of EAFD is possible and applicable by immobilization. The findings of the study concluded that environmental performances or structural properties of blocks contain 30% waste by weight are suitable. This method is a proper one for recovering and treatment of EAFD with mixture of cement and LG MgO.
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Abstract

The article concerns investigations over benefits of application of HRC devices into sulphide copper ore processing plant. High pressure comminution appears to be very effective technology in hard ore processing circuits, especially in terms of energy consumption. This can be particularly observed in downstream grinding and beneficiation operations. A series of pilot-scale crushing tests in HRC roller press for various levels of operating pressure, were performed. HRC crushing effectiveness along with downstream grinding process course for each crushing product were also under analysis. The investigations were supplemented by analysis of flotation process effectiveness and impact of the process of high-pressure comminution on environment (dust emission). The results of investigation show that operating pressure level influences the obtained comminution results (comminution degree, yield of finest particle size fractions). The grinding effectiveness, measured through production of the finest particle size fractions was significantly influenced by the operating pressure. The results show that higher values of operating pressure (4.0 and 4.5 N/mm2) are not as efficient within this scope as the pressure 3.5 N/mm2. Dust emission is also correlated with the operating pressure value.
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Abstract

Environmental risks associated with Co, Cr, Cu, Mn, Ni, Pb, V and Zn in street dust collected from Baotou, a medium-sized industrial city in a semi-arid area of northwest China, were assessed by using enrichment factor and the potential ecological index. Their spatial distributions and sources in the dust were analyzed on the basis of geostatistical methods and multivariate statistical analysis, respectively. The results indicate that street dust in Baotou has elevated heavy metal concentrations, especially of Co, Cr, Cu, Pb and Zn. Co in the dust was significantly enriched. Cr and Pb were from moderate to significant enrichment. Cu and Zn were from minimal to moderate enrichment, whereas Mn, Ni and V in the dust were from deficient to minimal enrichment. The ecological risk levels of Co and Pb in the dust were moderate to considerable and low to moderate, respectively, whereas those of other heavy metals studied in the dust presented low ecological risk. Different distribution patterns were found among the analyzed heavy metals. Three main sources of these heavy metals were identified. Cr, Mn, Ni and V originated from nature and industrial activities. Cu, Pb and Zn derived mainly from traffic sources, and Co was mainly from construction sources.
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Abstract

Until now, dust arising from lime manufacture has been considered harmless to the environment so it has been investigated marginally from the standpoint of environmental protection, especially when it came to magnetic properties and heavy metal content. The aim of the research was filling the gap in this area. The research comprised measurements of magnetic susceptibility, the content of heavy metals, reaction (pH) and specific conductivity of lime dust and also raw material and fuel used for lime production. The samples were taken from one of the lime plants located in Opole Province. Similar investigations were also performed for dust taken from the nearby cement plant using dry method of cement production. It was proven that magnetic susceptibility, heavy metal content and conductivity of lime dust was lower in comparison to cement dust, which resulted from the fact that the lime plant used neither low raw materials nor additives. Due to the high atmosphere dust level in the vicinity of the investigated plants, extremely basic reaction of the tested dust and high content of metals, the studied dust cause alkalization of soils and contribute to the increase of heavy metal content in soils, posing a threat to the environment.
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Abstract

The results of investigations of the granulation process of foundry dusts generated in the dry mechanical reclamation process of used sands, where furan resins were binders are presented in the paper. Investigations concerned producing of granules of the determined dimensions and strength parameters. Granules were formed from the dusts mixture consisting in 50 mass% of dusts obtained after the reclamation of the furane sands and in 50 mass % of dusts from sands with bentonite. Dusts from the bentonite sands with water were used as a binder allowing the granulation of after reclamation dusts from the furane sands. The following parameters of the ready final product were determined: moisture content (W), shatter test of granules (Wz) performed directly after the granulation process and after 1, 3, 5, 10 days and nights of seasoning, water-resistance of granules after 24 hours of being immersed in water, surface porosity ep and volumetric porosity ev. In addition the shatter test and water-resistance of granulate dried at a temperature of 105oC were determined. Investigations were performed at the bowl angle of inclination 45o, for three rotational speeds of the bowl being: 10, 15, 20 rpm. For the speed of 10 rpm the granulation tests of dusts mixture after the preliminary mixing in the roller mixer and with the addition of water-glass in the amount of 2% in relation to the amount of dust were carried out. The obtained results indicate that the granulator allows to obtain granules from dusts originated from the reclamations of moulding sands with the furane resin with an addition of dusts from the bentonite sands processing plants.
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Abstract

Dust generated at an electric arc furnace during steel production industry is still not a solved problem. Electric arc furnace dust (EAF) is a hazardous solid waste. Sintering of well-prepared briquetted mixtures in a shaft furnace is one of possible methods of EAFD utilisation. Simultaneously some metal oxides from exhaust gases can be separated. In this way, various metals are obtained, particularly zinc is recovered. As a result, zinc-free briquettes are received with high iron content which can be used in the steelmaking process. The purpose of the research was selecting the appropriate chemical composition of briquettes of the required strength and coke content necessary for the reduction of zinc oxide in a shaft furnace. Based on the results of the research the composition of the briquettes was selected. The best binder hydrated lime and sugar molasses and the range of proper moisture of mixture to receive briquettes of high mechanical strength were also chosen and tested. Additionally, in order to determine the thermal stability for the selected mixtures for briquetting thermal analysis was performed. A technological line of briquetting was developed to apply in a steelworks.
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Abstract

The problem related to the management of post reclamation dusts generated in the reclamation process of waste moulding sands with organic binders is presented in the hereby paper. Waste materials generated in this process are products hazardous for the environment and should be utilised. The prototype stand for the utilisation of this dangerous material in its co-burning with coal was developed and patented in AGH in Krakow. The stand was installed in one of the domestic casting houses. As the utilisation result the transformed waste product is obtained and its management in the production of ceramic materials constitutes the subject of the presented publication.
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Abstract

Manual measurements of distribution of gas velocity in conduits of flue gas installations using systems with differential pressure sensors of velocity are often performed for the requirements of determining emissions of dust pollutants from industrial process plants to the atmosphere. The aim is to determine an axial velocity profile. Flows in measuring sections are not always coaxial along the run of the duct; they are characterized by different directions of the velocity vector at various measuring points. The determination of actual directions of vectors of local velocities giving a guarantee of an accurate calculation of the axial velocity is often not possible from the technical point of view and the measurement of the velocity is carried out with the parallel setting of the sensor head in relation to the axis and the walls of the conduit. Then the knowledge of the directional sensitivity of the applied velocity sensor allows either to eliminate the axial velocity measurement error or to take it into account by the uncertainty of this measurement. For specific situations of two-dimensional variation of direction of the velocity vector, the directional sensitivity characteristics and in consequence the characteristics of error have been determined for three sensors adopted to tests: a zero pressure dust sampling probe with the anemometric function as an element of the gravimetric dust sampler and comparatively - two commonly used Pitot tubes: types S and L.
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Abstract

This paper presents an effect of general dimensions of a reverse flow mini-cyclone with a tangential inlet on its separation efficiency. Several mini-cyclone design modifications are presented and evaluated for use in the air filtration systems of motor vehicles. Local design improvements of three components of a reverse flow mini-cyclone with a tangential inlet D-40 of an air filter fitted in an all-terrain vehicle engine were introduced. An asymmetric curvilinear shape of an outlet port was used instead of a symmetrical shape. An outlet vortex finder inlet port shape was streamlined, and a cylindrical outlet vortex finder of the cyclone was replaced with a conical one. Experimental evaluation of the effects of the design improvements of mini-cyclone on its separation efficiency and performance as well as flow resistance was carried out. Separation efficiency of the cyclone was determined using the mass method as a product of dust mass retained by the mini-cyclone and supplied to the mini-cyclone in a specified time. Separation performance of the cyclone was determined as the largest dust particle dz =dzmax in a specific test cycle in the cyclone outlet air stream. A polydisperse PTC-D test dust used in Poland, a substitute for AC-fine test dust was used. Dust concentration at the mini-cyclone inlet was kept at 1 g/m3. The size and total number of dust particles in the air stream at the outlet of the original mini-cyclone and at the outlet of the improved mini-cyclone was determined using a particle counter.
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Abstract

In this research, the high arsenic content dust of copper smelting, as a raw material, the extraction of copper and arsenic from the high arsenic content dust in the leaching system containing acidic and alkaline compounds was investigated. Meanwhile, the effects of acid/alkaline initial concentration, liquid to solid ratio, leaching temperature, leaching time on the leaching rate of copper and arsenic were studied. The optimum conditions for the leaching of high arsenic content dust and preparation of copper arsenate were determined. The results showed that acidic/alkaline leaching of high arsenic content dust was particularly effective. 93.2% of the copper, and 91.6% of the arsenic were leached in an acidic leaching process and 95% of the arsenic, while less than 3% of the copper, less than 5% of the antimony, less than 2% of the bismuth was also leached in an alkaline leaching process. A new method (the parallel flow drop precipitate method) was developed in the synthesis of copper arsenate process. The parallel flow drop method was employed to adjust the molar ratio (copper to arsenic) of the mixed solution of the acid-leaching solution and the alkali-leaching solution by taking the drop acceleration of an acidic leaching solution and an alkaline leaching solution at 10 mL/min and 12 mL/min, at a temperature of 60°C and a reaction time of 1 h. Copper arsenate was prepared by mixing an acidic leaching solution and an alkaline leaching solution. The main phases of copper arsenate were CuHAsO4·1.5H2O and Cu5As4O15·9H2O. Copper arsenate contained 30.13% copper and 31.10% arsenic.
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Abstract

A technology of sands with water glass hardened by liquid esters is a cheap and ecologic method of producing moulding sands. Due to these advantages, this technology is still very important in several foundry plants for production of heavy iron and steel castings. Reclamation of the mixed moulding and core sands generates significant amounts of dusts, which require further treatments for their reuse. The results of investigations of a pressureless granulation of dusts generated in the dry mechanical reclamation process of the mixture consisting in app. 90 % of moulding sands from the Floster S technology and in 10 % of core sands with phenolic resin resol type, are presented in the hereby paper. Investigations were aimed at obtaining granulates of the determined dimensional and strength parameters. Granules were formed from the mixture of dusts consisting of 75 mass% of dusts after the reclamation of sands mixture and of 25 mass% of dusts from bentonite sands processing plant. Wetted dusts from bentonite sands were used as a binding agent allowing the granulation of after reclamation dusts originated from the mixed sands technology.
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Abstract

Zinc is present in electric arc furnace dust (EAFD) mainly in two basic minerals, namely as franklinite ZnFe2O4 and/or zincite ZnO. While zincite is relatively reactive and easily treatable, franklinite is considerably refractory, which causes problems during EAFD processing. In this work EAFD containing 18.53% Zn was leached in water solution of ammonium carbonate. This leaching solution selectively leaches zincite, while franklinite is refractory and stable against leaching in this case. The temperature dependence of zinc leaching from EAFD was studied and the activation energy EA was determined by two methods: 1.) classically based on zinc chemical analyses from the leaching solution and 2.) by using of X-Ray diffraction qualitative phase analyses of leaching residues. The determined values of activation energies 37.41 and 38.55 kJmol–1 match perfectly, which show the excellent possibility of using X-Ray diffraction toward the study of leaching kinetics at properly chosen experimental conditions. The important result is the determination of the amount zincite and franklinite in EAFD, which is not possible by using of classical chemical methods.
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Abstract

As part of the presented work, tests were carried out to check the possibility of replacing of conventional reducers used in the lead pyrometallurgical processes by cheaper, but equally effective substitutes. For research of lead oxide reduction, the following fine-grained carbonaceous materials were used, ie anthracite dust and coal flotation concentrate, as well as traditional used coke breeze for comparison. The obtained test results indicate a similar ability to reduce the lead oxide of all studied carbonaceous materials.
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Abstract

Concentrations and elemental composition of fine (PM2.5) and coarse (PM2.5-10) ambient particles, at two sampling points located at the same urban background sites, were investigated. The points were 20 m distant from each other and at various heights (2 and 6 m) above the ground. A dichotomous sampler, equipped with a virtual impactor, and a cascade impactor were used to sample the dust. An X-ray fluorescence spectrometer was used in the elemental analyses. The investigations revealed heterogeneity of the spatial distribution and the elemental composition of suspended dust at the investigated urban background site. Coarse dust, whose concentration at 2.0 m above the ground was affected by secondary emission from roads, soil and other local low-level sources in some periods, appeared more heterogeneous.
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Abstract

The new legislative provisions, regulating the solid fuel trade in Poland, and the resolutions of provincial assemblies assume, inter alia, a ban on the household use of lignite fuels and solid fuels produced with its use; this also applies to coal sludge, coal flotation concentrates, and mixtures produced with their use. These changes will force the producers of these materials to find new ways and methods of their development, including their modification (mixing with other products or waste) in order to increase their attractiveness for the commercial power industry. The presented paper focuses on the analysis of coal sludge, classified as waste (codes 01 04 12 and 01 04 81) or as a by-product in the production of coals of different types. A preliminary analysis aimed at presenting changes in quality parameters and based on the mixtures of hard coal sludge (PG SILESIA) with coal dusts from lignite (pulverized lignite) (LEAG) has been carried out. The analysis of quality parameters of the discussed mixtures included the determination of the calorific value, ash content, volatile matter content, moisture content, heavy metal content (Cd, Tl, Hg, Sb, As, Pb, Cr, Co, Cu, Mn, Ni, and W), and sulfur content. The preliminary analysis has shown that mixing coal sludge with coal dust from lignite and their granulation allows a product with the desired quality and physical parameters to be obtained, which is attractive to the commercial power industry. Compared to coal sludge, granulates made of coal sludge and coal dust from lignite with or without ground dolomite have a higher sulfur content (in the range of 1–1.4%). However, this is still an acceptable content for solid fuels in the commercial power industry. Compared to the basic coal sludge sample, the observed increase in the content of individual toxic components in the mixture samples is small and it therefore can be concluded that the addition of coal dust from lignite or carbonates has no significant effect on the total content of the individual elements. The calorific value is a key parameter determining the usefulness in the power industry. The size of this parameter for coal sludge in an as received basis is in the range of 9.4–10.6 MJ/kg. In the case of the examined mixtures of coal sludge with coal dust from lignite, the calorific value significantly increases to the range of 14.0–14.5 MJ/kg (as received). The obtained values increase the usefulness in the commercial power industry while, at the same time, the requirements for the combustion of solid fuels are met to a greater extent. A slight decrease in the calorific value is observed in the case of granulation with the addition of CaO or carbonates. Taking the analyzed parameters into account, it can be concluded that the prepared mixtures can be used in the combustion in units with flue gas desulfurization plants and a nominal thermal power not less than 1 MW. At this stage of work no cost analysis was carried out.
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