Spray drying has
gradually become an effective method for large-scale
preparation of oxygen carriers as a result of its unique advantages
(high efficiency, scalable production, etc.). However, expensive chemical
or commercial powder is usually used as raw material in spray drying
granulation. The main objective of this work is to reduce the cost
of a spray-drying-derived oxygen carrier through using cheap natural
ores as raw materials and optimizing the preparation process. Considering
that hematite is cheap but less active in chemical looping combustion
(CLC) processes, while copper ore has high oxygen carrying capacity
and good reactivity but suffers from sintering at a high temperature,
the bi-ore oxygen carrier is prepared by the spray drying granulation
method in this work using copper ore and hematite fine powders as
raw materials with the addition of a suitable dispersant and binder.
Two kinds of oxygen carriers are successfully prepared by the spray
drying method, Fe100 (the mass ratio of hematite is 100%) and Cu20Fe80
(the mass ratio of copper ore/hematite is 20:80%), and their performance
is evaluated in a batch fluidized bed reactor. The reactivity of Cu20Fe80
is superior than that of Fe100 to char gasification products. The
effects of the temperature, oxygen/fuel ratio, and coal rank on the
coal-derived CLC performance of Cu20Fe80 are further examined. The
temperature of 950 °C is the optimal choice with the highest
reaction rate and CO2 yield. The gasification rate is fast
using the low-rank coals as fuels, i.e., Chifeng lignite and Shenhua
bituminous coal. Moreover, Cu20Fe80 exhibits good stability during
the redox test of more than 10 cycles. The used oxygen carrier particles
still maintain the abundant pore structure well without the sintering
phenomenon. Additionally, the results of scanning electron microscopy
with energy-dispersive spectrometry indicate that there is almost
no decrease in the relative content of Cu elements after the cyclic
tests. This work demonstrates that the spray-drying-derived Cu20Fe80
particle is a promising choice as an oxygen carrier for industrial
application of the CLC process.