Impact of co-combustion of petroleum coke and coal on fly ash quality: Case study of a Western Kentucky power plant

Abstract

Petroleum coke has been used as a supplement or replacement for coal in pulverized-fuel combustion. At a 444-MW western Kentucky power station, the combustion of nearly 60% petroleum coke with moderate- to high-sulfur Illinois Basin coal produces fly ash with nearly 50% uncombusted petroleum coke and large amounts of V and Ni when compared to fly ash from strictly pulverized coal burns. Partitioning of the V and Ni, known from other studies to be concentrated in petroleum coke, was noted. However, the distribution of V and Ni does not directly correspond to the amount of uncombusted petroleum coke in the fly ash. Vanadium and Ni are preferentially associated with the finer, higher surface area fly ash fractions captured at lower flue gas temperatures. The presence of uncombusted petroleum coke in the fly ash doubles the amount of ash to be disposed, makes the fly ash unmarketable because of the high C content, and would lead to higher than typical (compared to other fly ashes in the region) concentrations of V and Ni in the fly ash even if the petroleum coke C could be beneficiated from the fly ash. Further studies of co-combustion ashes are necessary in order to understand their behavior in disposal.