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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Computational simulation of a 100 kW dual circulating fluidized bed reactor processing coal by chemical looping with oxygen uncoupling

Chemical looping with oxygen uncoupling (CLOU) is a promising carbon capture technology that utilizes two interconnected fluidized-bed reactors to separate oxygen from air using a metal oxide, and then to use that oxygen to combust fuel in a nitrogen-free environment. CLOU is particularly well suited for solid fuels such as coal since released O 2 will readily combust with solid char. This study presents simulations of the University of Utah's dual fluidized bed chemical looping process development unit (PDU) operating as a CLOU system at 100 kW th , using CPFD Software's Barracuda-VR™ CFD modeling program. A full 3D model of the PDU was used including both reactors, as well as loop seals and cyclone separators. Hydrodynamic settings and the drag model are based on previous cold-flow validation experiments. Mechanisms describing CLOU reaction kinetics for cuprous oxide oxidation in the air reactor and cupric oxide reduction in the fuel reactor were adapted from previously completed experimental work. Coal char kinetics were based on the carbon-hydrogen-nitrogen-oxygen-sulfur, CHNOS, method. Submodels for devolatilization, gasification, and homogenous gas-phase reactions used relationships from the literature. Results predict volatile burnout almost immediately, though coal combustion continues into the upper portions of the fuel reactor and cyclone. Lastly, nitrogen gas leakage into the fuel reactor is shown to be mostly carryover from the air reactor

42 ENGINEERING↗
DOE OSTI2013

Computational Modeling of Circulating Fluidized Bed Reactors

Details of numerical simulations of two-phase gas-solid turbulent flow in the riser section of Circulating Fluidized Bed Reactor (CFBR) using Computational Fluid Dynamics (CFD) technique are reported. Two CFBR riser configurations are considered and modeled. Each of these two riser models consist of inlet, exit, connecting elbows and a main pipe. Both riser configurations are cylindrical and have the same diameter but differ in their inlet lengths and main pipe height to enable investigation of riser geometrical scaling effects. In addition, two types of solid particles are exploited in the solid phase of the two-phase gas-solid riser flow simulations to study the influence of solid loading ratio on flow patterns. The gaseous phase in the two-phase flow is represented by standard atmospheric air. The CFD-based FLUENT software is employed to obtain steady state and transient solutions for flow modulations in the riser. The physical dimensions, types and numbers of computation meshes, and solution methodology utilized in the present work are stated. Flow parameters, such as static and dynamic pressure, species velocity, and volume fractions are monitored and analyzed. The differences in the computational results between the two models, under steady and transient conditions, are compared, contrasted, and discussed.

42 ENGINEERING↗
DOE OSTI2022

Design of a gas-solid-solid separator to remove ash from circulating fluidized bed reactors

Cyclones are one of the most common types of gas-solid separators used in circulating fluidized bed boilers. However, cyclones typically do not allow ash to leave the system through the cyclone exit, causing ash to build up in the fluidized bed and necessitating additional systems to remove ash that builds up in the bed. In this study, an alternative “disengager” gas-solid separator is proposed as a way of inherently separating small and large solids, resulting in a gas-solid-solid separation system where ash is allowed to leave the system along with gas while the desired fluidized bed material is retained. Unlike cyclones, which rely on centrifugal force to separate solids and gas, the disengager separates based on entrainment velocity of the particles. Upwards-flowing gas and particles strike a deflection plate and enter the disengaging chamber where particles with low terminal velocity such as ash fines flow with the gas, while larger particles such as sand fall to the bottom of the separator and are returned to the fluidized bed. In this study, several different proposed disengager configurations are simulated and compared to a typical cyclone using computational fluid dynamic (CFD) simulations. Furthermore, it was found that separation efficiency in the disengager is strongly influenced by the size of the deflection plate, rather than by the size of the unit itself. The predicted separation efficiency showed that compared to a cyclone, the disengager design allows significantly more ash to exit the system but retains a similar amount of desirable material. Additionally, the disengager was predicted to not suffer significantly more erosion that a cyclone.

42 ENGINEERING↗
DOE OSTI2025

Design Approach for Circulating Fluidized Bed Riser Reactors such as NETL ASURE: A Review for Clustering Flow

Circulating fluidized bed riser reactors have been a commercial reality for some 80 to 90 years. Through all this time and hundreds if not thousands of research papers on the topic, no clear understanding exists on what is required to design and build a process reactor. There are numerous reasons for this, but the most significant reason is likely that riser reactors are chaotic in nature and unless this chaotic behavior is accounted for, there will be wide discrepancies in the predicted performance and in attempts to scale these reactors without significant trial and error. This work puts forth a new methodology to design riser reactors based upon the desired operating range using the chaotic microstructure behavior. This is accomplished through the use of a nondimensional regime map that was developed using chaotic parameters of memory and order/disorder along with higher moments of skewness and kurtosis. Validation of the approach is provided with circulating fluidized bed combustors and applied to the design of the NETL ASURE facility.

42 ENGINEERING↗
DOE OSTI2019

Process for generating hydrogen from heavy oil or hydrocarbons

The present invention provides a steam reforming process for heavy oil or hydrocarbons using a circulating fluidized bed reactor, the process having a reforming step and a regeneration step, wherein the reforming step and the regeneration step comprise a bubbling fluidized reactor containing a fluidizable nickel-containing reforming catalyst and produce hydrogen as a product of the reforming bed. The API gravity of the feedstock may be between −11 and 54, preferably between −11 and 20. The present invention also provides a fluidized bed hydrocarbon steam reforming process using a regenerable catalyst to produce hydrogen, wherein a circulating bed reactor is operated in an alternating manner, switching between two steps: reforming and regeneration; using a mixture of a fluidizable solid and a fluidizable nickel-containing reforming catalyst; producing hydrogen as a product of the reforming step with a minimum hydrogen content of 25 volume percent, preferably at least 60 volume % and more preferably at least 70 volume percent on a dry weight basis.

Srinivas, Girish↗
DOE OSTI2015

Apparatus, components and operating methods for circulating fluidized bed transport gasifiers and reactors

The improvements proposed in this invention provide a reliable apparatus and method to gasify low rank coals in a class of pressurized circulating fluidized bed reactors termed "transport gasifier." The embodiments overcome a number of operability and reliability problems with existing gasifiers. The systems and methods address issues related to distribution of gasification agent without the use of internals, management of heat release to avoid any agglomeration and clinker formation, specific design of bends to withstand the highly erosive environment due to high solid particles circulation rates, design of a standpipe cyclone to withstand high temperature gasification environment, compact design of seal-leg that can handle high mass solids flux, design of nozzles that eliminate plugging, uniform aeration of large diameter Standpipe, oxidant injection at the cyclone exits to effectively modulate gasifier exit temperature and reduction in overall height of the gasifier with a modified non-mechanical valve.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Development and Scale-Up of Copper-Based Chemical Looping with Oxygen Uncoupling

The University of Utah has been researching chemical looping with oxygen uncoupling of coal since 2007, focusing on copper-based carriers and a system configuration based on two interconnected circulating fluidized bed reactors. R&D has combined fundamental, lab-scale systems with operation of CLOU reactor systems at various scales and computational simulations for performance evaluation and reactor scale-up. Development has progressed from small lab scale through bench scale with a 10 kW dual bed research reactor to semi-pilot scale with a recently-inaugurated 220 kW chemical looping combustion process development unit. One of the challenges of scaling up copper-based CLOU technology is acquiring enough oxygen carrier material to support operation in larger reactor systems. The UofU CLC PDU, for example, requires 150-200 kg of inventory, so the oxygen carrier must be readily available in large quantities at comparatively low cost. Because no supplier capable of delivering 1+ tons of copper-based oxygen carrier material could be identified, an inexpensive oxygen carrier material was developed in-house and the carrier production process was scaled to produce large quantities of material sufficient for the CLC PDU. This presentation describes development of the CLOU process at the University of Utah, including evaluation of fundamental processes key to performance of CLOU, modeling and scale-up of the process, large-scale production of copper based oxygen carrier material and experience to date with the world’s largest dedicated CLOU reactor.

Whitty, Kevin J.↗
DOE OSTI2021

Process for generating high purity synthesis gas hydrogen from heavy oil or hydrocarbons

The present invention provides a steam reforming process for heavy oil or hydrocarbons using a circulating fluidized bed reactor, the process having a reforming step and a regeneration step, wherein the reforming step and the regeneration step comprise a fluidized reactor containing a fluidizable nickel-containing reforming catalyst and produce hydrogen as a product of the reforming bed. The invention produces high purity hydrogen in the synthesis gas product stream and avoids irreversible fouling on the catalyst.

Srinivas, Girish↗
DOE OSTI2019

Dover Light & Power 10 MWe Coal Direct Chemical Looping (CDCL) (Large Pilot Plant Test - Phase I Feasibility)

A feasibility study was conducted to install a 10 MWe coal direct chemical looping large pilot plant at a host site. The coal direct chemical looping technology was based on The Ohio State University and Babcock & Wilcox iron-based metal oxide technology coupling a moving bed reduction reactor with a circulating fluidized-bed oxidation reactor. The host site was the Dover Light & power Plant in Dover, Ohio. The Electric Power Research Institute performed the host site evaluation. Trinity Consultants prepared the Environmental Information Volume. WorleyParsons Group performed the civil engineering. Clear Skies Consulting served as lead on the Industrial Advisory Committee.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Transient Cold Flow Simulation of Fast Fluidized Bed Fuel Reactors for Chemical-Looping Combustion

Circulating fluidized bed in chemical-looping combustion (CLC) is a recent technology that provides great advantage for gas–solid interaction and efficiency. In order to obtain a thorough understanding of this technology and to assess its effectiveness for industrial scale deployment, numerical simulations are conducted. Computational fluid dynamics (CFD) simulations are performed with dense discrete phase model (DDPM) to simulate the gas–solid interactions. CFD commercial software ansysfluent is used for the simulations. Two bed materials of different particle density and diameter, namely the molochite and Fe100, are used in studying the hydrodynamics and particle behavior in a fuel reactor corresponding to the experimental setup of Haider et al. (2016, “A Hydrodynamic Study of a Fast-Bed Dual Circulating Fluidized Bed for Chemical Looping Combustion,” Energy Technol., 4(10), pp. 1254–1262.) at Cranfield University in the UK. Both the simulations show satisfactory agreement with the experimental data for both the static pressure and volume fraction at various heights above the gas inlet in the reactor. It is found that an appropriate drag law should be used in the simulation depending on the particle size and flow conditions in order to obtain accurate results. Furthermore, the simulations demonstrate the ability of CFD/DDPM to accurately capture the physics of circulating fluidized bed-based CLC process at pilot scale which can be extended to industrial scale projects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Saturation Carrying Capacity for Group A Particles in a Circulating Fluidized Bed

Empirical models continue to play a significant role in the design process of multiphase chemical reactors, particularly riser reactors in circulating fluidized bed (CFB) processes. It is imperative that accurate, industrial relevant correlations are developed to aid these design efforts. Using poor correlations could result in startup issues and significant redesign work. In this work, a new correlation is proposed to predict the saturation carrying capacity of Geldart Group A particles. This new correlation improves upon the currently available correlations for these materials and covers a broad range of Geldart Group A particles (particle diameters from 52 to 70 µm, and Archimedes numbers ranging from 5 to 20), superficial gas velocities (1 to 4 m/s), and riser diameters (0.066 to 0.3048 m). The new correlation has an Absolute Average Percent Deviation of only 17.6%, making it the most accurate correlation for Geldart Group A particles in the current literature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Experience with Chemical Looping Combustion of Coal in a 200 kW Dual Fluidized Bed Reactor

The University of Utah recently commissioned a dual fluidized bed process development unit (PDU) for investigating chemical looping combustion (CLC) and chemical looping with oxygen uncoupling (CLOU) of coal. The reactors and supporting systems were sized to support at least 200 kW of coal input based on available reaction rate data. Both the air reactor and fuel reactor are circulating fluidized beds and bed material passes between the reactors via loop seals. The reactors are refractory-lined rather than electrically heated, so the system must be preheated with natural gas before chemical looping combustion can begin. Air and steam are preheated through a combination of electric heating and natural gas burners and reactor product gas flows through heat exchangers and bag houses to cool and clean the gas of particulate. As is typical with pilot-scale systems, several operational challenges were encountered as the system was brought online and operation progressed from heatup and initial testing with gaseous fuels towards full CLOU processing of coal. The system hardware and operational procedures have undergone several modifications, but the PDU can now reliably be preheated to the operating temperature and coal can be fed at the target feed rate. This paper presents the PDU, describes the procedures for evaluating carbon conversion, CO2 capture and CO2 purity, and presents initial results from chemical looping combustion of coal with non-CLOU and CLOU carriers. General experience of operating the plant and notable challenges and solutions are also presented.

Whitty, Kevin J.↗
DOE OSTI2013

Phase shift method to estimate solids circulation rate in circulating fluidized beds

While solids circulation rate is a critical design and control parameter in circulating fluidized bed (CFB) reactor systems, there are no available techniques to measure it directly at conditions of industrial interest. Cold flow tests have been conducted at NETL in an industrial scale CFB unit where the solids flow has been the topic of research in order to develop an independent method which could be applied to CFBs operating under the erosive and corrosive high temperatures and pressures of a coal fired boiler or gasifier. The dynamic responses of the CFB loop to modest modulated aeration flows in the return leg or standpipe were imposed to establish a periodic response in the unit without causing upset in the process performance. The resulting periodic behavior could then be analyzed with a dynamic model and the average solids circulation rate could be established. This method was applied to the CFB unit operated under a wide range of operating conditions including fast fluidization, core annular flow, dilute and dense transport, and dense suspension upflow. In addition, the system was operated in both low and high total solids inventories to explore the influence of inventory limiting cases on the estimated results. The technique was able to estimate the solids circulation rate for all transport circulating fluidized beds when operating above upper transport velocity, U{sub tr2}. For CFB operating in the fast fluidized bed regime (i.e., U{sub g}< U{sub tr2}), the phase shift technique was not successful. The riser pressure drop becomes independent of the solids circulation rate and the mass flow rate out of the riser does not show modulated behavior even when the riser pressure drop does.

42 ENGINEERING↗
DOE OSTI2013

Mass transfer effects in a gasification riser

In the development of multiphase reacting computational fluid dynamics (CFD) codes, a number of simplifications were incorporated into the codes and models. One of these simplifications was the use of a simplistic mass transfer correlation for the faster reactions and omission of mass transfer effects completely on the moderate speed and slow speed reactions such as those in a fluidized bed gasifier. Another problem that has propagated is that the mass transfer correlation used in the codes is not universal and is being used far from its developed bubbling fluidized bed regime when applied to circulating fluidized bed (CFB) riser reactors. These problems are true for the major CFD codes. To alleviate this problem, a mechanistic based mass transfer coefficient algorithm has been developed based upon an earlier work by Breault et al. This fundamental approach uses the local hydrodynamics to predict a local, time varying mass transfer coefficient. The predicted mass transfer coefficients and the corresponding Sherwood numbers agree well with literature data and are typically about an order of magnitude lower than the correlation noted above. The incorporation of the new mass transfer model gives the expected behavior for all the gasification reactions evaluated in the paper. At the expected and typical design values for the solid flow rate in a CFB riser gasifier an ANOVA analysis has shown the predictions from the new code to be significantly different from the original code predictions. The new algorithm should be used such that the conversions are not over predicted. Additionally, its behaviors with changes in solid flow rate are consistent with the changes in the hydrodynamics.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2017

Moving Bed Chemical Looping Combustion Fuel Reactor Modeling and Sensitivity Analysis

Chemical looping combustion (CLC) is a novel, coal-based power generation technology that has currently achieved only small-scale, non-integrated development status, with the fuel reactor being the key developmental component in the CLC process. Both circulating fluidized bed (CFB) and moving bed fuel reactors have been the subjects of ongoing development campaigns. The objective of the effort described in this report is to characterize a moving bed fuel reactor by applying more detailed, reaction kinetics-based models that represent the nature of this reactor with a more fundamental foundation than has previously been reported by developers. This report describes the modeling basis, and a “base” fuel reactor’s design and performance characteristics resulting from the model. A major focus of the evaluation has been placed on studies of the sensitivity of the base moving bed fuel reactor performance, design, and CLC power plant cost implications to the key parameters.

20 FOSSIL-FUELED POWER PLANTS↗