Results for “Electric boilers” — Page 2

DOE OSTI2024

Utilization of an Advanced Sensor network to determine fuel heating value and Real-Time net unit heat rate during transient operation

Coal-fired utility boilers are being increasingly used as variable electricity generation to resolve the imbalance in the energy market from the expansion of intermittent renewable energy. The frequent transient operation required to meet residual energy demand has created a challenge for coal-fired units to operate efficiently. This work utilizes an advanced sensor network (ASN) to calculate net unit heat rate (NUHR) of a coal-fired boiler in real time through combustion calculations and statistical correlations to provide the tools for optimizing dynamic operation. Real-time heating values that were necessary to determine fuel input energy to calculate accurate NUHR were found using both fundamental and data-driven methods. Real-time NUHR shows distinct shifts that reflect changes in process conditions that will improve the ability to optimize transient operation. Data-driven heating value correlations had 24% lower root mean square error (RMSE) than the fundamental combustion calculation approach when compared to daily retrospective proximate analysis. Furthermore, the data-driven method RMSE improved by 7% with the inclusion of ASN data. Future work is to validate by comparing unit performance with and without the inclusion of NUHR as a control parameter for the dynamic neural network.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Characterizing Impacts of Dry Coal Feeding in High Pressure Oxy-Coal Combustion Systems

Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Characterizing Impacts of Dry Coal Feeding in High Pressure Oxy-Coal Combustion Systems

Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.

pressurized oxy-coal combustion, sub-micron ash ae↗

DOE OSTI2022

Characterizing Impacts of Dry Coal Feeding in High Pressure Oxy-Coal Combustion Systems

Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Full Scale 3D Computational Model of the Industrial -Scale Coal Fired Boiler Performance for Temperature Sensor Installation Guidance

Abstract Nearly 30% of the electricity is generated by using coal as the primary fuel in the US. One of the major concerns in coal-fired power plants is the failure of boiler tubes that leads to unscheduled maintenance and has a huge economical and societal impact. High temperature flue gas along with ash pass over the boiler tubes, which over time leads to tube failure. Therefore, developing temperature sensors for harsh environments and install them for temperature sensing and boiler tube lifetime prediction is an urgent need. On the side of sensor development, the location of the sensor installation is important for stable sensing performance and easy calibration. In this study, computational fluid dynamics and heat transfer modeling are adopted to establish a full-scale 3-dimensional model of a coal-fired boiler to investigate the flue gas temperature distribution within the boiler and identify the proper locations for sensor installation. We proposed three criteria to select the temperature sensor installation location: (1) select the boiler tube panel away from the sidewalls, (2) select the boiler tube section closer to the top wall of the boiler; and (3) select the boiler tube on the back of the boiler panel (not directly facing the flue gas flow). In these regions, the flue gas temperature is stable, providing an ideal environment for stable temperature sensing and calibration.

Gupta, Tanuj↗

DOE OSTI2022

Electrification potential of U.S. industrial boilers and assessment of the GHG emissions impact

Electrification is a key strategy for decarbonizing the industrial sector. Industrial process heating, which still relies heavily on fossil fuel combustion and accounts for the majority of sector wide GHG emissions, is a particularly attractive electrification target. Electrifying industrial boilers represents a cross-cutting opportunity for GHG emissions reductions, given their widespread use in most manufacturing industries. Yet, there are gaps in the understanding of the current population of conventional industrial boilers in the United States that preclude a characterization of boiler electrification's technical potential to reduce fuel consumption and GHG emissions. In this study, we develop an up-to-date dataset of the industrial boiler population in the U.S. and quantify the county-level electricity requirements and net changes in fuel use and GHG emissions under the current electric grid and theoretical future grid scenarios. Our results show an increase of 105 MMmtCO 2 e and 73 MMmtCO 2 e in GHG emissions from boiler electrification, with and without the replacement of byproduct fuels, respectively, under the current electric grid, and a reduction of 19 MMmtCO2e and 7 MMmtCO2e in GHG emissions under a future high renewables electric grid. GHG emissions savings are currently possible only in certain regions of the U.S. unless future grids are decarbonized. We also provide discussion that could be useful for policy makers and manufacturing facilities for advancing the electrification of industrial boilers in locations and industries toward fuel savings and GHG emissions reductions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Development of novel dynamic machine learning-based optimization of a coal-fired power plant

The increasing fraction of intermittent renewable energy in the electrical grid is resulting in coal-fired boilers now routinely ramp up and down. The current state-of-the-art operation for such boilers is to apply steady-state, neural network-based optimization to make control decisions in real-time, and this report demonstrates the feasibility of extending this to dynamic, neural network-based optimization using a long short-term memory neural network. A simplified numerical simulation of a t-fired coal boiler and supporting equipment is used to represent a real plant subjected to both steady-state, neural network-based optimization and dynamic, neural network-based optimization. Using the same intervals and a particle swarm optimization algorithm, the dynamic optimization outperforms the steady-state optimization and realizes up to 4.58% improvement in thermal efficiency. Dynamic optimization with a long short-term memory neural network is shown to both be feasible and beneficial for operation of a coal-fired boiler under changing load.

42 ENGINEERING↗

DOE OSTI2020

10 MWE CDCL Large Pilot Plant – pre-FEED Study (Final Report)

The Following Document is the Final Technical Scientific Report for the project tittle “10 MWE CDCL Large Pilot Plant – pre-FEED Study” performed by The Babcock & Wilcox Company in collaboration with The Ohio State University, Johnson & Matthey, The Electric Power Research Institute, and the Dover Light & Power Municipal Power Plant. The project Team performed a pre-Front End Engineering Design study of a 10 MWe Coal-Direct Chemical Looping power plant to be hosted at the Dover Light & Power Municipal Plant. As part of the pre-FEED study, the project Team performed multiple pilot test campaigns to obtain design and performance information at the 250 kWth CDCL pilot facility at the Babcock & Wilcox Company’s Research Center. The Techno-Economic analysis was updated based on the FEED study and the pilot tests results. The study shows that the CDCL process is a promising carbon-friendly technology capable of producing electricity with a high efficiency with a cost of electricity of $83.3 / MWh, which corresponded to less than 30% increase in cost of electricity compared to the cost of electricity of a base case study of a supercritical PC boiler.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Material Selection and Sizing of a Thermoelectric Generator (TEG) for Power Generation in a Self-Powered Heating System

By employing the high temperature heat source to directly generate the electricity needed to power auxiliary systems in a natural gas furnace, boiler or hot water heater, a “self-powered” heating system can provide several benefits. Compared with a traditional furnace, boiler or hot water heater, when overall fuel utilization is kept constant, the self-powered system will have a higher primary energy efficiency, lower operating costs, and dramatically improved building safety and resilience during electric grid outages. Furthermore, a self-powered heating system only has a single utility connection – natural gas, without an electric connection – thus simplifying installation. A thermoelectric generator can be used for direct energy conversion of thermal energy to electricity with no moving parts, which offers a very simple means to provide power for the self-powered heating system, and the operation is without noise or vibration and can thus provide a very long system life. This paper provides an analysis focused on materials selection and the thermal power requirements for a thermoelectric generator (TEG) for use in a self-powered heating system. The dimensionless figure of merit for thermoelectric materials, zT, is used to estimate the optimal efficiency that can be achieved with a TEG to produce the electric power required in such an application. Comparisons of the predicted efficiency, the required heat transfer rate to the TEG and the heat transfer area needed for sustained operation under thermal conditions relevant to the self-powered heating application are made for several potential thermoelectric materials. This analysis was used to develop system requirements for a self-powered hot water heater using a TEG for electric power generation.

Laclair, Tim↗

DOE OSTI2023

Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler

The growth of renewable energy sources presents a pressing challenge to the operation and maintenance of existing fossil fuel power plants, given that fossil fuel remains the predominant fuel source, responsible for over 60% of electricity generation in the United States. One of the main concerns within these fossil fuel power plants is the unpredictable failure of boiler tubes, resulting in emergency maintenance with significant economic and societal consequences. A reliable high-temperature sensor is necessary for in situ monitoring of boiler tubes and the safety of fossil fuel power plants. In this study, a comprehensive four-stage multi-physics computational framework is developed to assist the design, optimization installation, and operation of the high-temperature stainless-steel and quartz coaxial cable sensor (SSQ-CCS) for coal-fired boiler applications. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. With the simulation-guided sensor installation plan, the newly designed SSQ-CCSs have been employed for field testing for more than 430 days. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.

42 ENGINEERING↗

DOE OSTI2020

Conceptual Design Study of a Thermal Energy Storage System Using Granular Solids for Coal-fired Boilers

<span style="font-size: 12pt;">Presentation for the 2020 International Pittsburgh Coal Conference held virtually from September 8-11, 2020.</span><span style="font-size: 12pt;">Abstract: As electricity from various renewable energy sources is increasingly supplied to the power grid, the grid’s stability will be challenged. Proposed grid-stability solutions will need to address variability of sources, such as solar and wind energy, in order to alleviate problems such as overgeneration and ramping. In regions where increases in solar energy are prominent, such as California, the net power demand curve often referred to as “the Duck Curve,” has caused problems for energy dispatchers, due to over-generation and fast ramping demands. In this project, we investigated a conceptual design for a Thermal Energy Storage System (TESS) integrated into a coal-fired power plant to support grid-scale storage. Implementing a TESS into power plants can allow for an increase in renewable sources, increase grid resilience, and allow conventional coal-fired plants to operate more efficiently. For this project, a TESS using granular solids as the energy-storage media is integrated into a conventional coal-fired power plant. The purpose of the TESS is to store energy from the flue gas during low demand periods and transfer the energy to steam during peak demand periods. The storage allows the stabilization of combustion and related boiler components at low loads and provides the opportunity to avoid some shutdowns. This study uses thermodynamic properties of several candidate thermal storage materials to estimate the size of storage system required for several operating scenarios. </span>

Huckaby, E. David↗

DOE OSTI2022

Application of a Novel Heat Pump Model for Estimating Economic Viability and Barriers of Heat Pumps in Dairy Applications in the United States

Heat pumps represent an important opportunity for energy savings and decarbonization. This work investigates the techno-economic performance of high-temperature heat pumps (HTHPs) for use in the U.S. dairy industry. The studied heat pump performs a 50 °C temperature lift on a waste heat stream of cleaning water and applies the upgraded heat stream to a fluid milk pasteurization process. This work involved the creation of a HTHP model that estimated the coefficient of performance (COP), internal rate of return (IRR), net present value (NPV), and payback period (PBP), and emissions saved for a heat pump replacing a natural gas boiler. Capital costs, operations, and maintenance (O&M) cost, heat pump lifetime, electricity prices, natural gas prices, and a cost of carbon were varied to perform a parametric study on the factors affecting the break-even price of HTHPs. The results show that HTHP economics are highly sensitive to COP and energy price environment, and less sensitive to capital and O&M cost variance, leading to a large scatter of positive and negative NPVs based on U.S. location. PBPs demonstrate a defined threshold, based on energy price environment, below which favorable two-to-three-year PBPs predominate. This work is focused on the U.S. dairy industry, but international application in relation to fossil vs. electricity price regimes. Heat pumps have seen wider adoption in regions with a high ratio of fossil energy to electricity prices ($/MMBTU vs. $/kWh). The U.S. has plentiful natural gas resulting in lower fossil energy prices which has reduced heat pump adoption. This paper identifies potential first mover industries for HTHP adoption and their associated price regimes even in regions with lower ratios of fossil energy to electricity prices that exist many places globally.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION,↗

DOE OSTI2021

State-by-State comparison of combined heat and power to photovoltaic installations at manufacturing facilities with heat and power loads

Manufacturing facilities with large electricity and steam loads commonly meet those loads with a grid and boiler (GB) system configuration. In this study, two alternatives, a natural gas turbine cycle driven combined heat and power (CHP) system configuration and a grid boiler system augmented with photovoltaics (GB-PV), are investigated sustainable manufacturing in reference to the GB system configuration. For this purpose, their discounted payback period (DPP), carbon dioxide (CO 2 ) and nitrogen oxides (NO x ) emission reductions, and primary fossil energy impacts are calculated. The major contribution of this study is that it directly compares the application of both CHP and PV technologies at an assumed manufacturing facility in all 50 states of the United States. This highlights the location-specific impacts of the facility. The examined manufacturing facility utility requirements are 5 MW of power and over 12,000 kg/h of 250 kPa and 400 K saturated steam. A DPP of less than 25 years, the technology lifetime, is found in 44 states for the CHP system configuration and 6 states for the GB-PV system configuration. GB-PV and CHP cost-effectively reduce CO 2 in 44 and 38 states, respectively. CHP is better for NO x reduction, whereas GB-PV is better for primary fossil energy reduction.

14 SOLAR ENERGY↗

DOE OSTI2020

Combined Heat and Power Deployment Program

Combined heat and power (CHP) is an efficient and clean approach to generating on-site electric power and useful thermal energy from a single fuel source. Instead of purchasing electricity from the distribution grid and burning fuel in an on-site furnace or boiler to produce thermal energy, CHP provides both energy services to a facility in one energy-efficient step.

CHP↗

DOE OSTI2023

Nexus of electrification and energy efficiency retrofit of commercial buildings at the district scale

Rapid electrification of buildings at the district scale is needed for cities to achieve climate change mitigation goals. However, most electrification studies focus on either the single building level or the city/region building stock level, and depend on the slow and uncertain process of requesting personally identifiable customer energy usage data from utilities. To answer a key question facing local policymakers: “Where can electrification proceed at scale without first upgrading the grid?” this study aims to quantify and inform building electrification impacts at the district scale using detailed building energy modeling and based on public records datasets. We explore how energy efficiency retrofits can help mitigate increased peak electric demand, and quantify impacts to energy use and carbon emissions. Building energy models of a baseline, and scenarios of simple electrification, energy retrofits, and electrification in combination with retrofits were created and simulated for 54 commercial buildings in two contiguous districts of San Francisco. A simple electrification scenario increased annual electricity consumption but reduced annual site energy usage by 15% to 17%, mainly due to replacing inefficient gas furnaces and boilers with more efficient heat pumps. Peak demand increased 7.4% for Fisherman's Wharf (e.g. within the capacity of the existing power grid), while the Design District showed a marginal decrease. Annual carbon emissions were reduced by 46% and 37%. Combining electrification with efficiency upgrades reduced peak demand by 26% and 40%, and annual carbon emissions by 63% and 64% for the two districts. Furthermore, these results indicate that impacts of electrification depend on the mix of building uses within a district, and coupling electrification with energy efficiency upgrades is an effective strategy to decarbonize buildings while maintaining or reducing the peak electric demand.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

INSTANTANEOUS, 2-PHASE FLOW SENSOR FOR PULVERIZED COAL MASS FLOW RATE AND DISTRIBUTION FOR INCREASED RELIABILITY OF A COAL BOILER DURING STEADY AND TRANSIENT OPERATIONS

Explore the source record for details and available documents.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

Geothermal district energy systems coupled with seasonal underground thermal energy storage: a U.S. techno-economic screening by climate and geology

In the United States, cooling-dominated commercial building loads can cause geothermal heat pump-based district energy systems to accumulate a long-term subsurface thermal imbalance, motivating the incorporation of seasonal underground thermal energy storage. We developed a transferable workflow to evaluate geothermal district systems that pair ground heat exchangers with seasonal underground thermal energy storage. Using standardized hourly loads for seven commercial buildings and a uniform cost framework, we simulated ten U.S. cities with a physics-based ground heat exchanger model, subsurface storage simulations, and economic assessment to isolate the roles of climate and hydrogeology. In cooling-dominated cities, underground thermal energy storage supplied the majority of annual cooling, cutting electricity use and summer peaks substantially while achieving levelized costs comparable to or below conventional chiller-boiler plants. In cooler climates, the storage share shrunk, required borefield size and costs rose, and levelized cost of energy increased nearly linearly with declining underground thermal energy storage fraction, indicating storage fraction as the primary economic lever. Sensitivity analysis showed capital risk dominated by borefield drilling and surface heating, ventilation, and air-conditioning and piping, with underground thermal energy storage costs secondary. This workflow provides a transparent foundation for site-specific design and screening of next-generation geothermal district energy systems.

25 ENERGY STORAGE↗

DOE OSTI2023

Ultrasonic Measurements of Temperature Profile and Heat Fluxes in Coal-Fired Power Plants (Final Report)

Many industrial processes are inaccessible or inhospitable to characterization by traditional temperature measurement methods, such as thermocouples, especially over prolonged exposure to harsh environments. Ultrasound is an established characterization technology with diverse applications ranging from medical imaging to therapies to flaw detection to nondestructive evaluation. Ultrasound may characterize solid materials and components noninvasively as a nondestructive evaluation modality and obtain internal measurements of material properties. For example, the speed of ultrasound propagation changes with Young’s modulus and Poisson’s ratio, which can be found from its measurements. Traditional ultrasonic characterization assumes all material properties remain constant with the position. When this assumption holds, a property of interest may be measured by relating it to the speed of ultrasound propagation (or a speed of sound, SOS) and measuring the SOS by timing the ultrasound propagation through a known distance. However, when a property of interest is spatially distributed, the propagation time depends on the SOS changing with the position along the ultrasound propagation path. The multiple temperature distributions may lead to an identical time of flight (TOF). Temperature is one property that impacts the speed of ultrasound and often cannot be assumed to remain constant with the position. Previously, in the context of temperature, we addressed the challenge of ultrasonic characterization of spatially distributed properties by developing a method for measuring segmental temperature distributions (MSTD). This method divides the ultrasonic propagation into segments bound by echogenic features. These features provide ultrasonic interfaces where some energy is reflected toward the receiving transducer, and the rest continues through the medium. The time-of-flight between the echoes reflected from echogenic features characterizes the spatial distribution in the properties of interest in the corresponding segment of the ultrasonic propagation path. This project demonstrated the application of the MSTD method in industrial conditions of the coal-fired power plant. We implemented the MSTD using metals and alloys waveguides, which may be the existing structure for which the temperature distribution is characterized or purposefully designed waveguides added to the structure by welding or other means specifically to quantify thermal properties using the MSTD method. Previous iterations of the MSTD method used ceramic and cementitious waveguides, which significantly attenuate ultrasound. On the other hand, low attenuation in metallic waveguides creates interactions between echogenic features which compilates the signal analysis in the segmental TOF measurements. We have established the WG design principles that minimize the interferences between trailing and primary echoes and, in some cases, eliminate them. The waveguides in which echoes do not interfere improve the timing accuracy and the robustness of ultrasonic measurements of the spatial distributions in material properties. Our emphasis remained on the estimation of the temperature distributions. We have developed general recommendations for designing ultrasonically segmented waveguides with the reduced influence of trailing echoes. Two of our waveguide designs were tested in the industry. The first waveguide was designed for insertion into a combustion zone of the utility-scale coal-fired power plant boiler. The second design allows the characterization of temperature distribution in the direction normal to the boiler’s water wall, a large heat exchanger converting the chemical energy released during combustion to the steam driving the electrical power generation turbines. These waveguides were designed to operate within a restrictive space of thermally insulated water wall and incorporate densely located echogenic features while combatting the influence of trailing echoes. The project has successfully demonstrated the feasibility of using the developed method for accurate, continuous, and robust temperature measurements in extreme environments of power generation and other industrial processes. It, therefore, has achieved its overarching goal of advancing the technology readiness level of the novel Ultrasound Measurements of Segmental Temperature Distribution (US-MSTD) method for real-time measurements of the temperature distribution and heat fluxes closer to commercial availability, developing a prototype multipoint measurement system, and validating its performance on coal-fired utility boilers. The success of this project was achieved in collaboration with the power generator, Rocky Mountain Power, and set the stage for the transfer of this technology from the laboratory to the industry.

01 COAL, LIGNITE, AND PEAT↗