the coking properties of coal at elevated pressures. - Argonne ...
the coking properties of coal at elevated pressures. - Argonne ... the coking properties of coal at elevated pressures. - Argonne ...
INTRODUCTION SULFUR CAPTURE AND NITROGEN OXIDE REDUCTION ON THE 6' X 6' ATMOSPHERIC FLUIDIZED BED COMBUSTION TEST FACILITY T. M. Modrak and J. T. Tang The Babcock & Wilcox Company Research and Development Division Alliance Research Center Alliance, Ohio 44601 C. J. Aulisio Electric Power Research Institute Palo Alto, California 94304 Atmospheric fluidized bed combustion (AFBC) is being developed as a costeffective, low-polluting method of direct coal utilization for electric power generation. An earlier state-of-the-art assessment (EPRI Final Report FP-308) concluded that the existing AFBC data base was inadequate for the design of utility-scale units -- that is, the available data vere limited in scope, and since they had been derived mainly from laboratory-scale equipment, it was doubtful whether they could be applied to the design of utility boilers. The need for a large, well- instrumented facility capable of long-term testing was clearly indicated. As a result, a 6-foot x 6-foot (6' x 6') AFBC Development Facility was built at The Babcock & Wilcox Research Center in Alliance, Ohio. A complete description of the facility design details are contained in EPKI Final Report CS-1688. PROJECT RESULTS Construction of the 6' x 6' facility was completed in October 1977. Following a 5-month startup and debugging phase, the first test series was begun in April 1978. Since then, approximately 2000 hours of testing per year have been logged at the facility. The facility has demonstrated the capability for long-term, steady- state operation, with tests typically lasting from 300 to 500 hours. The AFBC unit is large enough to result in gas-solid residence times for the various zones of the combustor that are typical of those expected for utility-scale units. A wide range of conditions can be tested at the facility. Also, the computerized data acquisition system has been shown to provide accurate, comprehensive documentation of the test results. 226
P SUMMARY OF TESTS Testing completed as of July 1981, along with a short description of each test Series is Summarized below: Test seriee __ 1 2 3 4 5 6 7 8 9 10 I1 I2 13 14 I5 16 17 18 19 20 21 22 23 - Date Hay 1978 June 1978 Augur 1978 September 1978 November 1978 February 1979 Hareh 1979 Hay 1979 June 1979 July 1979 August 1979 kcember 1979 January 1980 February 1980 April 1980 Hay 1980 June 1980 July 1980 October 1980 December 1980 January 1981 March 1981 June 1981 H0"rS Firing Coal - 277 248 278 241 204 406 171 427 298 194 96 265 318 277 382 147 344 326 365 344 170 380 485 comments lnitial characterization Long duration test to characterize performance Recycle Coal sire "Briation, temperature Variation Limestone and coal sire variation, temperature VariatiOO New distrlbvtor plate, Battelle emiseion testing - Pittsburgh t8 coal Single cod feed point - 36 ft2, bed depth variation, coal and limestone variation Recycle; underbed single point. temperature variation Coal si*e "Briatio", ternperamre variation Recycle; overbed and 4-point underbed with coal and limestone Pulverized eaal New in-bed tube bundle, new baghouse, GCA emission testing - Pittsburgh 18 coal Recycle; underbed single point. limeetme sire variation, excess transport air Recycle; underbed single point and overbed. slumped bed heat transfer study test Fuller Kinyon pump characreriration. baghouse recycle, lignite teat Turndown (slumping) tes~ Limestone size variation, center recycle New di8tribvtcir plate. 4 ftlaee characterization test 4 ftleec testing, recycle Feed nozzle design testing. 8 ftlaee Feed nozzle design testing, 8 ftlsec NO reductio. teat# 12 ftlsec testing Significant data were generated in the areas of fly ash recycle, coal particle size, limestone particle size, 5 ft/sec, 8 ft/sec, and 12 ft/sec fluidizing velocity operation, combustion of lignite, and nitrogen oxide reduction. Testing continued to emphasize fly ash recycle as a means of improving combustion efficiency and sulfur capture. In addition to center underbed recycle, overbed recycle with gravity and pneumatic feed as well as baghouse ash recycle configurations were tested. Recycled fly ash testing continued to result in combustion efficiencies on the order of 98%. The highly successful lignite test resulted in combustion efficiencies approaching 99%. The lignite test proved the capability of a fluidized bed combustor (FBC) to combust fuels which can be troublesome. One test was devoted to testing feed nozzles designed to prevent feedline pluggage during slumping. A power outage simulation test was also carried out. The test was designed to determine minimum flow rates through the in-bed tube bundle required to prevent tube overheating during a power outage. Results indicated that tube overheating may be prevented with minimal design considerations. Tests were also conducted to evaluate bed height reduction as a means of load control in an AFBC facility. These variable bed height tests provided the data needed to design an automatic load control system that will be installed on the 6' x 6' in 1982. One series of tests was devoted to two-stage combustion, i.e., allowing a portion of the forced draft air to bypass the bed, recombining with the fluidizing gas in the freeboard region. These tests, aimed at NO reduction, are discussed later in this paper. A significant amount of data covering AFBC have been generated on the 6' x 6'. Some of these data have been summarized and discussed in various technical papers 227
- Page 175 and 176: GFETC constructed a 0.2 square mete
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- Page 179 and 180: I FIG. 1. Initial ash coating on qu
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- Page 183 and 184: (4) Since the operating temperature
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- Page 199 and 200: , I B. 2 which temporarily raised t
- Page 201 and 202: -6- abrasion rate at the bottom of
- Page 203 and 204: \if F3.3 - Particulate Circulation
- Page 205 and 206: \' I/O. analog 1/13. industrial I/O
- Page 207 and 208: ACQUISITION DATA UNIT < I L- J (T)
- Page 209 and 210: SAMPLING SYSTEM FOR FLUIDIZED BED A
- Page 211 and 212: GAS SAMPLING WITH ORIGINAL PROBE-FI
- Page 213 and 214: Remove the quartz tube (gas sample
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- Page 229 and 230: I Table 1 Comparison of Sulfur Capt
- Page 231 and 232: , NITROGEN OXIDE REDUCTION Single-S
- Page 233 and 234: 0 The addition of air at the 96-inc
- Page 235 and 236: m- Y i? 4: BO n 8 c Y l0- Bo- I I I
- Page 237 and 238: E! w 2 z e Y 100 - 3 t 5 80- 0, 40
- Page 239 and 240: 0 f 0.so o'm: 0.300 0.zo - - A 5m 4
- Page 241 and 242: &e- -A \ \ \ : ERCENT OVERBED AIR I
- Page 243 and 244: PARTICLE ENTRAINMENT AND NITRIC OXI
- Page 245 and 246: i 1' 1 ! I. i Chaung (15) showed th
- Page 247 and 248: The maximum height that a large par
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- Page 251 and 252: assumed to be identical to that of
- Page 253 and 254: Nomenclature A *t cD ‘NO $3 _ _ _
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- Page 265 and 266: ! Table 2 Proximate and ultimate an
- Page 267 and 268: lb, , --pp---p-- 4 p? CHAR 1 Tu-IWO
- Page 269 and 270: I CHAR Y Y /I TIME O i ' ' ' ' 1 '
- Page 271 and 272: could not be assumed constant. Thus
- Page 273 and 274: \ greatly acknowledged. Literature
- Page 275 and 276: constructed and operated to demonst
P<br />
SUMMARY OF TESTS<br />
Testing completed as <strong>of</strong> July 1981, along with a short description <strong>of</strong> each test<br />
Series is Summarized below:<br />
Test<br />
seriee<br />
__<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
8<br />
9<br />
10<br />
I1<br />
I2<br />
13<br />
14<br />
I5<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
- D<strong>at</strong>e<br />
Hay 1978<br />
June 1978<br />
Augur 1978<br />
September 1978<br />
November 1978<br />
February 1979<br />
Hareh 1979<br />
Hay 1979<br />
June 1979<br />
July 1979<br />
August 1979<br />
kcember 1979<br />
January 1980<br />
February 1980<br />
April 1980<br />
Hay 1980<br />
June 1980<br />
July 1980<br />
October 1980<br />
December 1980<br />
January 1981<br />
March 1981<br />
June 1981<br />
H0"rS<br />
Firing<br />
Coal<br />
-<br />
277<br />
248<br />
278<br />
241<br />
204<br />
406<br />
171<br />
427<br />
298<br />
194<br />
96<br />
265<br />
318<br />
277<br />
382<br />
147<br />
344<br />
326<br />
365<br />
344<br />
170<br />
380<br />
485<br />
comments<br />
lnitial characteriz<strong>at</strong>ion<br />
Long dur<strong>at</strong>ion test to characterize performance<br />
Recycle<br />
Coal sire "Bri<strong>at</strong>ion, temper<strong>at</strong>ure Vari<strong>at</strong>ion<br />
Limestone and <strong>coal</strong> sire vari<strong>at</strong>ion, temper<strong>at</strong>ure Vari<strong>at</strong>iOO<br />
New distrlbvtor pl<strong>at</strong>e, B<strong>at</strong>telle emiseion testing - Pittsburgh t8 <strong>coal</strong><br />
Single cod feed point - 36 ft2, bed depth vari<strong>at</strong>ion, <strong>coal</strong> and limestone vari<strong>at</strong>ion<br />
Recycle; underbed single point. temper<strong>at</strong>ure vari<strong>at</strong>ion<br />
Coal si*e "Bri<strong>at</strong>io", ternperamre vari<strong>at</strong>ion<br />
Recycle; overbed and 4-point underbed with <strong>coal</strong> and limestone<br />
Pulverized eaal<br />
New in-bed tube bundle, new baghouse, GCA emission testing - Pittsburgh 18 <strong>coal</strong><br />
Recycle; underbed single point. limeetme sire vari<strong>at</strong>ion, excess transport air<br />
Recycle; underbed single point and overbed. slumped bed he<strong>at</strong> transfer study test<br />
Fuller Kinyon pump characrerir<strong>at</strong>ion. baghouse recycle, lignite te<strong>at</strong><br />
Turndown (slumping) tes~<br />
Limestone size vari<strong>at</strong>ion, center recycle<br />
New di8tribvtcir pl<strong>at</strong>e. 4 ftlaee characteriz<strong>at</strong>ion test<br />
4 ftleec testing, recycle<br />
Feed nozzle design testing. 8 ftlaee<br />
Feed nozzle design testing, 8 ftlsec<br />
NO reductio. te<strong>at</strong>#<br />
12 ftlsec testing<br />
Significant d<strong>at</strong>a were gener<strong>at</strong>ed in <strong>the</strong> areas <strong>of</strong> fly ash recycle, <strong>coal</strong> particle<br />
size, limestone particle size, 5 ft/sec, 8 ft/sec, and 12 ft/sec fluidizing velocity<br />
oper<strong>at</strong>ion, combustion <strong>of</strong> lignite, and nitrogen oxide reduction. Testing continued<br />
to emphasize fly ash recycle as a means <strong>of</strong> improving combustion efficiency and<br />
sulfur capture. In addition to center underbed recycle, overbed recycle with<br />
gravity and pneum<strong>at</strong>ic feed as well as baghouse ash recycle configur<strong>at</strong>ions were<br />
tested. Recycled fly ash testing continued to result in combustion efficiencies on<br />
<strong>the</strong> order <strong>of</strong> 98%. The highly successful lignite test resulted in combustion<br />
efficiencies approaching 99%. The lignite test proved <strong>the</strong> capability <strong>of</strong> a fluidized<br />
bed combustor (FBC) to combust fuels which can be troublesome. One test was devoted<br />
to testing feed nozzles designed to prevent feedline pluggage during slumping. A<br />
power outage simul<strong>at</strong>ion test was also carried out. The test was designed to<br />
determine minimum flow r<strong>at</strong>es through <strong>the</strong> in-bed tube bundle required to prevent tube<br />
overhe<strong>at</strong>ing during a power outage. Results indic<strong>at</strong>ed th<strong>at</strong> tube overhe<strong>at</strong>ing may be<br />
prevented with minimal design consider<strong>at</strong>ions.<br />
Tests were also conducted to evalu<strong>at</strong>e bed height reduction as a means <strong>of</strong> load<br />
control in an AFBC facility. These variable bed height tests provided <strong>the</strong> d<strong>at</strong>a<br />
needed to design an autom<strong>at</strong>ic load control system th<strong>at</strong> will be installed on <strong>the</strong><br />
6' x 6' in 1982.<br />
One series <strong>of</strong> tests was devoted to two-stage combustion, i.e., allowing a<br />
portion <strong>of</strong> <strong>the</strong> forced draft air to bypass <strong>the</strong> bed, recombining with <strong>the</strong> fluidizing<br />
gas in <strong>the</strong> freeboard region. These tests, aimed <strong>at</strong> NO reduction, are discussed<br />
l<strong>at</strong>er in this paper.<br />
A significant amount <strong>of</strong> d<strong>at</strong>a covering AFBC have been gener<strong>at</strong>ed on <strong>the</strong> 6' x 6'.<br />
Some <strong>of</strong> <strong>the</strong>se d<strong>at</strong>a have been summarized and discussed in various technical papers<br />
227