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At least 37 records · Page 2

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↗

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↗

An improved semi-global intrinsic kinetics model for high temperature carbon oxidation

Measurements of the oxidation rates of various forms of carbon (soot, graphite, coal char) have often shown an unexplained attenuation with increasing temperatures in the vicinity of 2000 K, even when accounting for diffusional transport limitations and gas-phase chemical effects (e.g. CO 2 dissociation). With the development of oxy-fuel combustion approaches for pulverized coal utilization with carbon capture, high particle temperatures are readily achieved in sufficiently oxygen-enriched environments. Here, in this work, a new semi-global intrinsic kinetics model for high temperature carbon oxidation is created by starting with a previously developed 5-step mechanism that was shown to reproduce all major known trends in carbon oxidation, except for its high temperature kinetic falloff, and incorporating a recently discovered surface oxide decomposition step. The predictions of this new model are benchmarked by deploying the kinetic model in a steady-state reacting particle code (SKIPPY) and comparing the simulated results against a carefully measured set of pulverized coal char combustion temperature measurements over a wide range of oxygen concentrations in N 2 and CO 2 environments. The results show that the inclusion of the spontaneous surface oxide decomposition reaction step significantly improves predictions at high particle temperatures. Furthermore, the simulations reveal that O atoms released from the oxide decomposition step enhance the radical pool in the near-surface region and within the particle interior itself. Incorporation of literature rates for O and OH reactions with the carbon surface results in a reduction in the predicted radical pool concentrations and a very minor enhancement of the overall carbon oxidation rate.

33 ADVANCED PROPULSION SYSTEMS↗

Development of a health monitoring framework: Application to a supercritical pulverized coal-fired boiler

In this study, this work details the development of a physics-based equipment health monitoring framework for a supercritical boiler, using first-principles models to estimate the remaining useful life (RUL) of its components. The framework accounts for fatigue and creep life consumption, generating spatio-temporal variations in mechanical and thermal stress. Analysis of the stress profile throughout the boiler highlights the finishing superheater inlet steam header as a vulnerable location susceptible to damage from cycling operation. The framework also yields quantified uncertainty in the RUL projection for specific locations, accounting for uncertainties in material properties and boiler operation. Results indicate that operational uncertainties (e.g., seasonal variation and operational strategy) and material properties (e.g., rupture time coefficients, Young’s modulus, yield strength, and coefficient of thermal expansion) significantly impact the RUL of the finishing superheater inlet steam header. Additionally, case studies demonstrate the use of the health monitoring framework as a predictive tool for operational planning under uncertainty, including scenarios with and without updates on the operation of the boiler.

20 FOSSIL-FUELED POWER PLANTS↗

Extended Low Load Boiler Operation to Improve Performance and Economics of an Existing Coal Fired Power Plant (Final Report)

The overall goal is to improve the performance and economics of existing coal fired power plants by extending low load boiler operation to lower loads than is currently achievable. The objective of this program is to develop and validate sensor hardware and analytical algorithms to lower plant operating expenses (OPEX) for the currently operating pulverized coal utility boiler fleet. Coal fired utility boilers are increasingly under grid dispatch pressure. In some cases, the coal fired cost of generation is noncompetitive with respect to natural gas generation and subsidized renewable sources. To remain profitable and remain fully compliant with existing environmental regulations, the installed coal fired fleet must find technologies which allow it to move into a more flexible cyclic load dispatch model. Today the installed coal fired utility fleet must be cost of generation competitive, fully emissions compliant, and responsive to the variability inherent in renewable energy generation sources. In the Phase I of the project, GE Steam Power, Inc. (GE) performed modeling of different operating scenarios for low load operation using an existing full plant dynamic model developed for a 660MW steam power plant. Sensors and analytic algorithms to enable a stable and steady coal supply for low load pulverizer operation were identified and tested at the Pulverizer Development Facility (PDF) at GE’s Clean Energy Center in Bloomfield, Connecticut. Sensors and analytic algorithms to enable stable combustion for low load operation were identified and tested at the 15 MWth Industrial Scale Burner facility (ISBF) at GE’s Clean Energy Center. A concept was developed to test the sensors and control algorithms, down selected after testing, at a full-scale coal fired power plant. A budget estimate was then developed, and the concept was implemented at an existing utility power plant. The specific objectives of the experimental work were to: • Identify and select sensors and analytic algorithms for monitoring coal pulverizer operation at lower loads to provide stable operation and appropriate coal fineness at lower coal throughput; Identify and select sensors and analytic algorithms for a Boiler Flame Stability Monitor to better balance air and fuel at each burner. This enables a reduction in a coal boiler’s safe low load power level while maintaining stable flame characteristics; Develop a concept in Phase I for low load operation of a full-scale power plant and develop a budget estimate for testing and execute the test plan at an existing plant in Phase II; Validate the capability of the extended low load boiler system to extend the minimum load operating point in a safe and reliable manner on an existing full-scale utility boiler. At the completion of this experimental study, GE has developed a set of sensors and analytic algorithms, down selected after testing, that have the potential to enable safe low load operation of a utility boiler. GE has also identified a host site for testing these identified sensors and analytic algorithms. GE has generated a full set of deliverables that provide sufficient information to proceed with the next step of testing at a host site. This includes a potential host site and budget estimate for concept testing at host site. In the Phase II of the project, a series of field tests were completed to validate the extended low load boiler operation, which consisted of detailed engineering, installation, commissioning, and testing the additional sensors and analytics for the coal-fired combustion system on an existing full-scale utility boiler. The optimization work has been supported by the host plant and endorsed by their engineering and operation staff.

01 COAL, LIGNITE, AND PEAT↗

Boiler Health Monitoring Using a Hybrid First Principles-Artificial Intelligence Model

Due to increased penetration of the intermittent renewables to the grid, pulverized coal (PC) plants are being forced to cycle their load frequently and rapidly, operate at low load condition for sustained period, and start up and shut down several hundred times in a year in the worst case. These severe operations are causing substantial damage to the boiler components compromising the reliability of PC plants. An online health monitoring tool can be instrumental in understanding the impacts of load-following and can eventually help PC plants to develop advanced process control strategies for improved flexibility without compromising safety nor reliability.

20 FOSSIL-FUELED POWER PLANTS↗

Analysis of thermal radiation of a gas-particulate-cloud in a pressurized oxy-coal combustor

Pressurized oxy-combustion (POC) aims to reduce carbon emissions from coal-fired power plants. In the POC process, pulverized coal is burned at elevated pressure in an O2-CO2 environment. The elevated pressure and high CO2 and H2O concentrations strongly impact thermal radiation, thereby significantly distinguishing POC system from conventional atmospheric-pressure air-fired and oxy-fuel combustion. Consequently, a thorough understanding of thermal radiation in POC is required to promote the development of novel combustors. The present computational work analyzes thermal radiation of the gaseous and particle phases in the pilot-scale POC combustor in Washington University in St. Louis. Particularly, the radiation characteristics of the gaseous and particulate cloud were estimated by employing the statistical narrow band model and the large-particle model. It is found that thermal radiation of a particulate cloud dominates in the combustor under the conditions of a furnace temperature of 1500 K and no substantial particle loss. Another important result is that the gas-and-particulate cloud can be approximately treated as a graybody under the same conditions. To be more specific, the results of spectral radiation intensity of a gas comprised of 40% (vol) H2O and 60% CO2 show that when the pressure is increased to 15 bar, and the radiation pathlength to 100 cm, the spectral radiation profile of the gas phase approaches that of a blackbody at the respective temperature. In addition, the emissivity of the particulate cloud has been evaluated as a function of the particle concentration and diameter by means of the large particle model. It is shown that the emissivity grows with the particle concentration but decreases with the particle size for the same mass of a particulate cloud. The emissivity of a particulate cloud in oxy- combustion exceeds that in air-fired combustion. This work could be used to validate the assumption of the gray gas model adopted in numerical simulations.

Li, Lei↗

Update to Techno-economic Analysis of BECCS Systems

Presentation of updated cost and performance results for coal and biomass co-firing in a pulverized coal power plant both with and without CO2 Capture at the Clearwater Clean Energy Conference. Update includes a 100% biomass fired case with and without capture.

Fout, Timothy↗

High CO2 Capture Rate Cost and Performance for F- and H-Class Natural Gas Combined Cycles (NGCC)

The National Energy Technology Laboratory (NETL) is updating its study titled “Cost and Performance Baselines for Fossil Energy Plants, Volume 1: Bituminous Coal and Natural Gas to Electricity.” Revision 4 was published in 2019. Pulverized coal (PC) and natural gas combined cycle (NGCC) cases with carbon capture in that study capture carbon dioxide (CO2) at 90% efficiency. Field-testing of post-combustion CO2 capture technology as well as vendor and industry feedback on projects currently in the planning stages (including FEED projects sponsored by DOE) indicate that capture rates as high as 95% are feasible for both coal- and natural gas-fueled electricity generating units. Technology suppliers (as reflected in vendor-supplied information provided to DOE for this study that included cost and performance estimates for both NGCC (97%) and PC (99%) study cases) as well as subject matter experts acknowledge and support that solvent-based post-combustion CO2 capture technologies are capable of achieving CO2 removal rates beyond 95% on low-purity streams representative of fossil-fueled combustion; however, the relatively limited experience with design and operation of capture systems that can routinely, reliably, and economically achieve very high removal rates (e.g., 97% for NGCC flue gas) requires further study. This presentation will address performance and cost estimates for 90%, 95%, and 97% capture for F- and H-class NGCC plants. This presentation was given at the 2022 Pittsburgh Coal Conference.

Fout, Timothy↗

Mass transfer intensification through increased surface wetting and liquid turbulence using 3D printing structured packing for CO2 capture

The absorber column is one of the most expensive pieces of equipment to construct in the solvent-based post-combustion carbon capture unit. In order to decrease the absorber size and reduce capital costs, novel polymer packings were proposed by enhancing surface wettability and local turbulence within liquid solvent. The novel packings intensify the mass transfer in CO2 absorption and show better separation efficiency than traditional structured packings. In this work, the economic influence of applying the more efficient packing with a shorter absorber column is studied in a techno-economic analysis for a carbon capture unit at a coal-fired power plant. The baseline case includes CO2 capture unit in a supercritical pulverized coal power plant to generate 650 MWe (net) of electricity, where the additional CO2 capture unit leads to 63.4% increase of LCOE. While implementing UK PCC with traditional and novel packings, there will be 47.2% and 46.4% LCOE increase separately, both of which are lower than the baseline value. Applying more efficient packing and smaller absorber could further lessen the LCOE increase. The UK PCC with traditional packings reduces CO2 capture cost by 23.4% and the application of the advanced packings allows to the reduction increases to 24.4%.

60 APPLIED LIFE SCIENCES↗

Cost and Performance Baseline for Fossil Energy Plants Volume 3: Low Rank Coal and Natural Gas to Electricity

This report presents an independent assessment of the cost and performance of select fossil energy power systems—pulverized coal (PC), circulating fluidized bed (CFB), and natural gas combined cycle (NGCC) plants—using a systematic, transparent technical and economic approach. This is Volume 3 of a five-volume series, which comprise the following reports: Volume 1: Bituminous Coal and Natural Gas to Electricity; Volume 2: Coal to Synthetic Natural Gas and Ammonia (Various Coal Ranks); Volume 3: Low Rank Coal and Natural Gas to Electricity; Volume 4: Bituminous Coal to Liquid Fuels; and Volume 5: Natural Gas Electricity Generating Units for Flexible Operation. The cost and performance of fossil fuel-based generation technologies represented in this report (and the series at large) are important inputs to assessments and determinations of technology combinations to be utilized to meet the projected demands of future power markets. In addition to informing technology comparisons, the reference plant configurations found in this report provide perspective for regulators and policy makers. From a research and development perspective, this report is used to assess goals and metrics and to provide a consistent basis for comparing developing technologies.

20 FOSSIL-FUELED POWER PLANTS↗

Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity

This report presents an independent assessment of the cost and performance of select fossil energy power systems—pulverized coal (PC) and natural gas combined cycle (NGCC) plants—using a systematic, transparent, technical, and economic approach. This is Volume 1 of the baseline series: Bituminous Coal and Natural Gas to Electricity. The cost and performance of fossil fuel‐based generation technologies represented in this report are important inputs to assessments and determinations of technology combinations to be utilized to meet the projected demands of future power markets. From a research and development perspective, this report is used to assess goals and metrics and to provide a consistent basis for comparing developing technologies. The main report consists of fifteen power plant configurations, six PC cases (with and without carbon capture) nine NGCC cases (with and without carbon capture) and few additional cases of higher capture rate, for both PC and NGCC plants in the appendix. In addition to the report, an interactive tool was developed that allows users to manipulate six key study parameters simultaneously for each case and visualize the impact on three metrics: 1) levelized cost of electricity (LCOE), 2) cost of CO 2 capture (CCC), and 3) cost of CO 2 avoided (CCA). Following is the link to the interactive tool: https://netl.doe.gov/NETLVol1BaselineTool

20 FOSSIL-FUELED POWER PLANTS↗

Numerical analysis of particle dispersion and deposition in coal combustion using large-eddy simulation

High-fidelity modeling provides a useful approach to investigate the particle dispersion and deposition mechanism in pulverized coal combustion. To be able to analyze these detailed mechanisms, this work couples detailed multiphysics models for poly-dispersed turbulent, particle-laden flow, particle and gas phase reaction chemistry, convective, conductive and radiative heat transfer, ash formation and deposition with a Large-Eddy Simulation (LES) approach to numerically simulate coal combustion in a downfired self-sustained oxy-fuel combustor (OFC). It is necessary to explicitly capture all but the highest frequency dynamics of the turbulence and its coupling with each of the other physical phenomena using LES. Effects of subgrid-scale unresolved turbulence on the particle motions are also analyzed by a novel Stokes number analysis. Due to the inherent relation ship between coal combustion and ash deposition, this study integrates the improved ash deposition model into the numerical simulation. Overall simulation results are compared with experimentally measured data from the OFC. The simulation and measured data for the averaged gas temperature and deposition rates agree with 5% and 28%. This study shows that high-fidelity LES coupled with other detailed multiphysics models running on a exascale computing facility can provide a good representation of complex coal combustion and deposition in a laboratory-scale furnace.

multiphysics model↗

Gasification of Coal/Plastic Mixtures: Fundamental Studies in a Laminar Entrained Flow Reactor

There is interest in leveraging entrained-flow coal gasification for co-processing plastic waste. However interactions between plastic and coal, particularly possible competition between coal volatiles and plastic vapors for oxygen, are not well understood. This study explores co-gasification of pulverized coal and plastic granules in a lab-scale entrained-flow reactor. Conversion and CO/CO2 ratio are given special attention.

Kareem, Afeez↗

Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity

This revised report presents an independent assessment of the cost and performance of select fossil energy power systems—integrated gasification combined cycle (IGCC), pulverized coal (PC), and natural gas combined cycle (NGCC) plants—using a systematic, transparent technical and economic approach. The cost and performance of fossil fuel-based generation technologies represented in this report (and the series at large) are important inputs to assessments and determinations of technology combinations to be utilized to meet the projected demands of future power markets. In addition to informing technology comparisons, the reference plant configurations found in this report provide perspective for regulators and policy makers. From a research and development perspective, this report is used to assess goals and metrics and to provide a consistent basis for comparing developing technologies.

01 COAL, LIGNITE, AND PEAT↗

AOI [1] Advanced Manufacturing of Ceramic Anchors with Embedded Sensors for Process and Health Monitoring of Coal Boilers

Researchers at West Virginia University (WVU) developed methods to fabricate and test ceramic anchors with an embedded sensor technology for monitoring the health and processing conditions within pulverized coal (PC) and fluidized-bed combustion (FBC) boiler systems. The technology included the development of advanced manufacturing processes for 2D/3D printing electroceramic (conductive ceramic) sensor designs within the ceramic anchor microstructure during the manufacturing process. This advanced manufacturing process would allow for the precise control of local microstructure and composition in order to engineer layer-by-layer any protective and electrically active materials within the refractory anchor. This 3D printing technology would permit the rapid and controlled design of the refractory microstructure and embedded sensor design throughout the volume of the ceramic anchor. The work also included a method to interconnect the sensors to boiler shell through the anchor clamp, where the sensor signals will be processed by low-power electronics and transmitted wirelessly to a central processing hub. The end-goal of the program was to produce a ceramic anchor sensor system which would be ready for implementation within a coal boiler, and/or other similar refractory liner systems (such as that in the glass and metal manufacturing areas). The project objectives were to: 1) Define the chemical and microstructural stability, in addition to the electrical properties, of oxide and non-oxide ceramic composites to be embedded within the ceramic anchor compositions that may operate up to 1400ºC; 2) Develop and implement the 2D/3D printing technology to pattern and control the microstructure of the ceramic anchor and embedded sensor circuits; 3) Develop an interconnect technology which will permit easy installation of the ceramic anchors and signal collection at the boiler shell; 4) Develop low power analog electronics and wireless communication hardware to efficiently collect the sensor signal at each processing unit and transmit data to a central hub for data analysis; 5) Demonstrate the smart ceramic anchor system for temperature and liner fracture within a high-temperature processing unit, such as a boiler furnace or glass melting furnace floor/wall liner.

20 FOSSIL-FUELED POWER PLANTS↗

Cost and Performance Baseline for Fossil Energy Plants Supplement: Sensitivity to CO 2 Capture Rate In Coal-Fired Power Plants

The cost and performance of various plants designed to meet a range of carbon dioxide (CO 2 ) emission limits are evaluated in this report by varying the CO 2 capture rate. The base cases for these designs are the supercritical (SC) pulverized coal (PC) plant and the General Electric Power (GEP) integrated gasification combined cycle (IGCC) plant from the Department of Energy (DOE) National Energy Technology Laboratory (NETL) report “Cost and Performance Baseline for Fossil Energy Plants, Volume 1: Bituminous Coal and Natural Gas to Electricity, Revision 4” (“Bituminous Baseline”).

20 FOSSIL-FUELED POWER PLANTS↗

The Co-Firing of Pine Biomass and Waste Coal in 100 and 600 MW Power Plants: A Sustainable Approach to Reduce GHG Emissions

Climate change is a global issue that has gained much attention recently. Co-firing biomass with coal/waste coal reduces the electricity sector’s GHG emissions sustainably. This study uses commercial software to model waste coal and biomass co-firing in 100 MW and 600 MW power plants. The objective is to assess the effects of fluid types (subcritical and supercritical), plant capacities (100 MW and 600 MW), boiler types (pulverized coal and circulating fluidized bed boilers), biomass and waste coal co-firing ratios (0:100, 20:80, 40:60, 60:40, 80:20, and 100:0), and carbon capture and storage efficiencies (0%, 90%, 95%, and 97%) on performance parameters such as net plant efficiency, heat rate, net plant CO2 and SO2, and particulate matter emissions. The feedstocks selected for this investigation include anthracite waste coal and loblolly pine biomass. As the biomass fraction increases from 0% to 100%, co-fired power plants net efficiency increases by 3–8%. Supercritical plants had a 6% higher net plant efficiency than the subcritical plants. The study found that the biomass’s high heating value decreased the fuel flow rate and reduced plant CO2 emissions by 10–16%. With 100% biomass power plant feed and 90% carbon capture and storage efficiency, CO2 emissions drop by 83% and SO2 and PM emissions drop to zero.

Bhoi, Prakashbhai R. (ORCID:0000000333104888)↗