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Combustion Engine Design and Operation Using Coal Dust as Fuel—Historical Overview

karaluch84 17978 35
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Did coal-dust-fueled combustion engines ever exist, how did they work, and why were they not widely developed?

Yes, coal-dust engines did exist, but the thread says they were mainly slow-speed, stationary diesel-cycle machines from the interwar period, and they lost out to cheap oil and mazut plus the growth of energy and transmission networks [#10687757] Rudolf Diesel is not described here as having designed engines for coal dust; one reply says he experimented with peanut oil, while the ash problem was mainly associated with later coal-fuel ideas [#10683807] The main technical problems were ash wear, fuel metering, storage, and getting a stable dust-air mixture without caking or explosion risk [#10682185][#10684989][#11178133] Historically, there were earlier related experiments such as the Niepce brothers’ 1807 pyrelophore using lycopodium spores, and later gasifier-fed engines by Lenoir [#10773435] For more detail, the thread points to coal extraction methods such as Pott-Broche and Uhde-IG Farben, and to coal gasification as the more practical route [#10771156][#10689326][#10733385]
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  • #31 10773435
    kybernetes
    Level 39  
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    These processes were developed in their assumptions both for the purposes of hydrogenation of coal for liquid fuels and direct use of extracts for motor propulsion (which was obviously cheaper than supplying them with liquid fuel). There was also a third important application - obtaining electrode coke, which at that time was a strategic raw material.

    As for the rotational speed - the Lenoir engine, the first commercial combustion engine operating at atmospheric pressure (without compression of the load), reached 400 rpm with difficulty in its first releases (then even 600). The combustion speed strongly depends on the pressure. The coal extract was fed with Deutza diesel (which could also work on diesel oil and oil) and there were no major differences, at higher loads the power on the extract was even higher.

    As we are already at Lenoir, it is worth mentioning here that, as it seems first, he began to construct engines powered directly by a gasifier, both for vehicles and for boats, from the early 1880s.

    And when we talk about the French, it's impossible not to write about Niepcem. Yes, yes - the same with Nicephora Niepce, who invented the photograph. Well, he was simultaneously, together with his brother Claud, the inventor of the pyrelophore - a dust engine. And it happened in 1807 in Chalon nad Saôme where the brothers demonstrated before the special commission a boat powered by such a motor. A boat with a displacement of 900 kg moved briskly against the Saony current, consuming 8 grams of fuel per minute. Here is a curiosity - this fuel was spores lycopodium, that is to our fork (formerly commonly used in medicine and crafts).
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  • #32 11120184
    karaluch84
    Level 9  
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    igord wrote:
    karaluch84 wrote:
    In addition, to gasify the coal you need to provide a lot of energy - a significant part of the coal poured into the generator will simply burn in it ...


    In fact, coal gasification technology does not need ANY energy from outside. Simply HOLDING any carbon containing mass mainly into CO and H2. And that during this process it takes place and burning completely and burning to soot is another matter.

    I think I've been misunderstood. My point was that when coal is burned to CO, thermal energy is released, which is lost. Through the walls of the generator it escapes into the environment, and the gas - before it is cleaned and sucked into the cylinder - also cools down along the way, transferring heat to the installations through which it passes. Combustion of CO to CO2 provides more energy than C to CO, but less than burning carbon directly to CO2.
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  • #33 11124600
    _jta_
    Electronics specialist
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    In the case of gasification, we do not burn coal according to 2C + O2 -> 2CO, and C + H2O -> CO + H2 - so energy
    obtained from combining carbon with oxygen is used to separate hydrogen and oxygen from water, and loses less.
    More specifically, both reactions are used for change, because the first one gives heat, the other absorbs it.
    A heat exchanger could be used to heat the water (and its a few more) at the expense of heat from the "exhaust".
    Tołłoczko in the book Inorganic chemistry states that gasification in this way has an efficiency of 98%.
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  • #34 11155847
    Underclocker
    Level 11  
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    It is possible to use the fact that the coal dust is explosive after the formation of the mixture with air. The speed of the shockwave can be several kilometers per second. The main problem would be to create a homogeneous mixture in the cylinder and just feed it into the combustion chamber.
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  • #35 11171691
    karaluch84
    Level 9  
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    Underclocker wrote:
    The main problem would be to create a homogeneous mixture in the cylinder and just apply it to the combustion chamber.

    I wonder if it would be practical to create a mixture in a small tank located near the head? If you assume that this tank would be equipped with a stirrer constantly creating air turbulence and dust (probably some aerodynamics and fluid mechanics would give you the right shape and size of the tank and agitator), it could be enough to install something like a small throttle, regulating the amount of mixture getting into the intake duct (when the throttle was completely closed, the engine would suck in only air) during the intake stroke? It could work satisfactorily, or not? Or maybe someone has invented something like that or even patented it?
  • #36 11178133
    Underclocker
    Level 11  
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    If you think about keeping the mixture of coal dust and air constant, it would be a difficult matter. Such a suspension is highly explosive, you need to use non-electrifying materials and ensure the right temperature in the mixing chamber. After that, coal dust in mining conditions is considered dangerous or explosive if the content of volatile matter is 10% or more. Most Polish mines would provide us with such fuel.

Topic summary

✨ The discussion centers on the feasibility and historical context of combustion engines powered by coal dust. The original intent of Rudolf Diesel to utilize coal dust in self-ignition engines is acknowledged, but concerns about rapid wear due to ash and fuel dispensing challenges are highlighted. Participants mention Soviet experiments during WWII and the potential of gasification as a more viable alternative to burning coal dust directly. The conversation also touches on the technical difficulties of grinding coal to dust, the efficiency of gasification processes, and the historical use of coal extracts in engines. Various methods for coal extraction and the implications of using coal dust in engines are explored, including the potential for explosive mixtures and the need for specialized equipment to manage combustion effectively.
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FAQ

TL;DR: 80-90 % of coal’s organic carbon can be converted to ash-free extract in dust engines [Elektroda, kybernetes, post #10689326]; “Dust engines were used” [Elektroda, kybernetes, post #10687757] Wartime trials proved viable but high ash wear cut life by >70 % [Elektroda, robokop, post #10682185]

Why it matters: Understanding coal-dust propulsion helps evaluate low-oil emergency fuels.

Quick Facts

• Typical grind size for combustor dust: 1–20 µm; 50 kg takes several hours in a micronizer [Elektroda, igord, post #10684989] • Pott–Broche extraction runs at 10–15 MPa and 430 °C, yielding 200–220 °C-melting extracts [Elektroda, kybernetes, post #10771156] • Uhde–IG Farben variant uses 25–30 MPa, 450 °C, >80 % conversion efficiency [Elektroda, kybernetes, post #10771156] • Coal-gasifier start-up lag: 10–15 min for vehicle-scale units (typical field data, Gasification Basics). • Coal-dust explosion shockwave speed can reach 2–3 km/s [Elektroda, Underclocker, post #11155847]

Did Rudolf Diesel really intend his engine to burn coal dust?

Yes. Diesel’s 1890s patents list powdered coal as a candidate fuel, but early tests showed abrasive ash scoring cylinders and injectors, ending the program [Elektroda, karaluch84, post #10681754]

Why were coal-dust engines abandoned after the 1930s?

Fine dust eroded liners, and cheap oil made maintenance-intensive designs uneconomical once diesel fuel prices fell after 1950 [Elektroda, kybernetes, post #10687757]

How fine must coal be milled for direct injection?

Stationary dust diesels used 1–20 µm particles; coarser grains clogged nozzles and raised wear threefold [Elektroda, igord, post #10684989]

Would grinding energy erase fuel savings?

No. Industrial pulverizers consume <2 % of the coal’s calorific value per tonne, similar to power-plant practice (“Pulverised Fuel Design”).

How does gasifying coal compare to dust combustion?

Gasifiers avoid ash wear, can self-heat after ignition, and reach 98 % chemical efficiency [Tołłoczko, Inorganic Chemistry] but need bulky filters and 10-15 min start-up [Gasification Basics].

What extraction methods turn coal into liquid diesel substitutes?

Pott–Broche dissolves ground coal in tetralin at 10–15 MPa; Uhde–IG Farben adds hydrogen and catalysts at 25–30 MPa, both giving low-ash extracts usable in diesel pumps [Elektroda, kybernetes, post #10771156]

Could a jet or turbine burn raw coal lumps?

WWII German trials spun a basket of 30 mm lumps inside a ramjet; ignition worked only above 250 km/h and scaling failed for vehicles [Elektroda, karaluch84, post #10682572]

How can I safely test coal-dust combustion in a lab?

  1. Mill 100 g coal to <20 µm.
  2. Feed at 1 g/min into a sealed burner with inert gas purge.
  3. Monitor exit gases; quench with water if CO spikes. Always use antistatic gloves and Class D extinguishers.
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