Impact of Mineral Impurities in Solid Fuel Combustion PDF
Preview Impact of Mineral Impurities in Solid Fuel Combustion
Impact of Mineral Impurities in Solid Fuel Combustion Impact of Mineral Impurities in Solid Fuel Combustion Edited by R. P. Gupta CRC for Black Coal Utilisation University of Newcastle NSW, Australia T. F. Wall CRC for Black Coal Utilisation University of Newcastle NSW, Australia and L. Baxter Sandia National Laboratories Livermore, California KLUWER ACADEMIC PUBLISHERS NEW YORK, BOSTON, DORDRECHT, LONDON, MOSCOW eBook ISBN: 0-306-46920-0 Print ISBN: 0-306-46126-9 ©2002 Kluwer Academic Publishers New York, Boston, Dordrecht, London, Moscow Print ©1999 Kluwer Academic / Plenum Publishers New York All rights reserved No part of this eBook may be reproduced or transmitted in any form or by any means, electronic, mechanical, recording, or otherwise, without written consent from the Publisher Created in the United States of America Visit Kluwer Online at: http://kluweronline.com and Kluwer's eBookstore at: http://ebooks.kluweronline.com PREFACE This book contains papers presented at the Engineering Foundation Conference on mineral matter in fuels held on November 2-7, 1997 in Kona, Hawaii. The conference is one of a continuing series that was initiated by the CEGB March- wood Engineering Laboratories in 1963. The conference was to be eventually organised by the Engineering Foundation as the need for multi-disciplinary work related to con- trolling ash effects in combustors became apparent. The conference covers both the science and the applications. The papers also present case histories, particularly for current fuel technologies, developments in advanced technologies for power generation and mathematical modelling of these processes. Developments since 1963 have been slow, but steady, due to the complexity of the chemical and physical processes involved. However, the research presented here displays great improvement in our understanding of the mechanisms by which mineral matter will influence fuel use. Steve Benson from EERC presented a review and current status of issues related to ash deposition in coal combustion and gasification. The application of new analytical tools, which have been detailed in the previous conferences, is presented. These include CCSEM, as well as new techniques for charac- terising sintering of ash, such as TMA, image analysis, X-ray diffraction crystallography and thermal analysis. The new analytical techniques were extended to encompass widely differing fuels such as biomass. Ole H Larsen from ELSAM Denmark presented a review of these advanced techniques. Thermodynamic equilibrium calculations and knowledge of mineralogy has helped in understanding ash reaction mechanisms and evaporation of alkali species during com- bustion and gasification. Together with the analytical tools, and mathematical models based on these mechanisms, the leap to practical predictions is now possible. Several examples of this approach are detailed. For example, Jouni Pyykonen from VTT mod- elled ash deposition in a boiler using the mineral distribution from CCSEM and FLUENT, a computational fluid dynamics code. John Harb and his group from BYU extended the models to predict the changes in heat transfer in boilers with deposit growth. There has not been enough emphasis in the past on the estimates of thermal properties of ash. A review article on thermal conductivity of ash like materials presented by Raj Gupta from CRC Black Coal is a significant step in the direction to rectify this problem. Thermal properties of deposits are shown to be strongly influenced by the deposit struc- ture. A greater integration of data from advanced analytical techniques, mechanistic models and sophisticated CFD codes is expected in the future in order to predict the thermal performance of boilers. The conference is truly an international one, with participants representing all major laboratories working in this technical area. Many papers outline collaborative efforts, which have become a feature of modern research. This requires a special mention V vi Preface of the ELSAM project involving collaboration between Danish, US and Japanese researchers. The fuels of interest are somewhat continent-specific. In Europe, there is major interest in the use of biomass and its blending with other fuels. Larry Baxter from Sandia Laboratories reviewed the issues related to ash deposition in co-firing of biomass with coal. In Australia, the major interest is in coal. In Japan and the USA, all fuels are of interest. There were several studies on large power station boilers and pilot scale plants spe- cially related to advanced technologies. The technologies considered include pulverised fuel, co-firing aid advanced power systems, such as PFBC and IGCC. FBC technology is highly suitable for low rank and low grade coals. The economic is pushing the usage of such fuels. A complete session was devoted to the ash problems and their solutions in FBC such as agglomeration and additives. There were a number of reviews and keynote papers in the field of FBC and other advanced technologies (Basu from BHEL India, Zhang from CRC Low Rank Coal and Ohman from ETC Sweden). The conference presents research in traditional atmospheric pressure systems but also considers newer systems where higher pressures are used and where the mineral matter in the fuel might be extracted as slag rather than the ash, which has been the traditional combustion product. Mr Sadayuki Shinozaki from CCUJ presented an extensive review of the advanced clean coal technologies. The Bryers Award for the best paper was presented to Lone Hansen of the Tech- nical University of Denmark for her paper on “Ash Fusion Quantification by Use of Thermal Analysis”, and Raj Gupta of The CRC for Black Coal Utilisation on his paper on “The Thermal Conductivity of Ash Deposits: Particulate and Slag Structures”. We also noted two excellent papers presented by Tim Heinzel of the University of Stuttgart and Bengt-Johan Skrifvars of Abo Akademi University, Finland. It was particularly gratifying to have Richard Bryers at the conference to present the award named after him and also to give a keynote paper. We would like to thank a number of sponsors who provided support to allow the attendance of delegates who would otherwise not have been able to attend. The sponsors were: Cooperative Research Centre for Black Coal Utilisation, Australia; Cooperative Research Centre for Power Generation from Low-Rank Coal, Australia; Centre for Coal Utilisation, Japan; Idemitsu Kosan Co. Ltd., Japan; EBARA Corporation, Japan; IHI Co. Ltd., Japan; Kawasaki Heavy Industries, Japan; Electric Power Development Company, Japan and Japan Cement Association, Japan. We would also like to thank the Engineering Foundation for their assistance, par- ticularly Richard Fein and Rosa Landinez who provided on-site support during the con- ference. We are grateful to all the session chairpersons for organising their sessions and reviewing the papers. In addition, Hongwei Wu and Chris Bailey, two PhD students from the CRC for Black Coal Utilisation, helped with arrangements. We would also like to thank Susan Safren of Plenum Publishing for her care, help and forbearance in the prepa- ration of this book. R. P. Gupta T. F. Wall L. Baxter CONTENTS Keynote Papers Ash-Related Issues During Combustion and Gasification . . . . . . . . . . . . . . . . . . . 1 Steven A. Benson and Everett A. Sondreal Mineral Characterization for Combustion: The Contribution from the Geological Sciences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Colin R. Ward The Development of Power Technologies for Low-Grade Coal . . . . . . . . . . . . . . 33 K. Basu Low-Rank Coal and Advanced Technologies for Power Generation . . . . . . . . . . . 45 Dong-ke Zhang, Peter J. Jackson, and Hari B. Vuthaluru The Thermal Conductivity of Ash Deposits: Particulate and Slag Structures . . . 65 R. P. Gupta, T. F. Wall, and L. Baxter The Development of Advanced Clean Coal Technology in Japan: Mineral Matter Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Sadayuki Shinozaki Factors Critically Affecting Fireside Deposits in Steam Generators . . . . . . . . . . 105 Richard W. Bryers SECTION I Mineral Matter, Ash and Slag Characterisation Advanced Analytical Characterization of Coal Ashes—An Idemitsu Kosan—Elsam Cooperation Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Ole Hede Larsen, Flemming J. Frandsen, Lone A. Hansen, Signe Vargas, Kim Dam-Johansen, Karin Laursen, Takeo Yamada, and Tsuyoshi Teramae vii viii Contents A Novel Application of CCSEM for Studying Agglomeration in Fluidised Bed Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Mika E. Virtanen, Ritva E. A. Heikkinen, H. Tapio Patrikainen, and Risto S. Laitinen Thermomechanical Analysis and Alternative Ash Fusibility Temperatures . . . . . 155 S. K. Gupta, R. P. Gupta, G. W. Bryant, L. Juniper, and T. F. Wall Ash Fusibility Detection Using Image Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Klaus Hjuler Ash Fusion Quantification by Means of Thermal Analysis . . . . . . . . . . . . . . . . . 181 Lone A. Hansen, Flemming J. Frandsen, and Kim Dam-Johansen Sticking Mechanisms in Hot-Gas Filter Ashes . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 John P. Hurley, Bruce A. Dockter, Troy A. Roling, and Jan W. Nowok Classification System for Ash Deposits Based on SEM Analysis . . . . . . . . . . . . 205 Karin Laursen and Flemming J. Frandsen Determination of Amorphous Material in Peat Ash by X-Ray Diffraction . . . . 217 Minna S. Tiainen, Juha S. Ryynänen, Juha T. Rantala, H. Tapio Patrikainen, and Risto S. Laitinen System Accuracy for CCSEM Analysis of Minerals in Coal . . . . . . . . . . . . . . . . 225 R. P. Gupta, L. Yan, E. M. Kennedy, T. F. Wall, M. Masson, and K. Kerrison The Microstructure and Mineral Content of Pulverised Coal Chars . . . . . . . . . 237 F. Wigley and J. Williamson SECTION II The Use of Low-rank and Low-grade Coals and Cofiring Fireside Considerations when Cofiring Biomass with Coal in PC Boilers . . . . . 247 Allen L. Robinson, Larry L. Baxter, Gian Sclippa, Helle Junker, Karl E. Widell, Dave C. Dayton, Deirdre Belle-Oudry, Mark Freeman, Gary Walbert, and Philip Goldberg Summary of Recent Results Obtained from Using the Controlled Fluidised Bed Agglomeration Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Marcus Öhman and Anders Nordin Deposition and Corrosion in Straw- and Coal-straw Co-fired Utility Boilers: Danish Experiences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Flemming J. Frandsen, Hanne P. Nielsen, Peter A. Jensen, Lone A. Hansen, Hans Livbjerg, Kim Dam-Johansen, Peter F. B. Hansen (1) and Karin H. Andersen (2), Henning S. Sørensen, Ole H. Larsen, Bo Sander, Niels Henriksen, and Peter Simonsen Contents ix Development of Blast-Furnace Gas Firing Burner for Cofiring Boilers with Pulverized Coal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Takashi Kiga, Takehiko Ito, Motoya Nakamura and Shinji Watanabe Changes in Slagging Behaviour with Composition for Blended Coals . . . . . . . . 297 Nicholas J. Manton, Jim Williamson, and Gerry S. Riley Role of Inorganics During Fluidised-Bed Combustion of Low-Rank Coals . . . 309 Hari Babu Vuthaluru and Dong-ke Zhang Role of Additives in Controlling Agglomeration and Defluidization During Fluidised Bed Combustion of High-Sodium, High-Sulphur Low-Rank Coal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Temi M. Linjewile and Alan R. Manzoori The Agglomeration in the Fluidized Bed Boiler During the Co-Combustion of Biomass with Peat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 Ritva E. A. Heikkinen, Mika E. Virtanen, H. Tapio Patrikainen, and Risto S. Laitinen Ash Fusion and Deposit Formation at Straw Fired Boilers . . . . . . . . . . . . . . . . . 341 Lone A. Hansen, Flemming J. Frandsen, Henning S. Sørensen, Per Rosenberg, Klaus Hjuler, and Kim Dam-Johansen SECTION III Case Studies in Conventional and Advanced Plant Influence of Metal Surface Temperature and Coal Quality on Ash Deposition in PC-Fired Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Karin Laursen, Flemming J. Frandsen, and Ole Hede Larsen Full Scale Deposition Trials at 150MWE PF-Boiler CO-Firing Coal and Straw: Summary of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 Karin H. Andersen, Flemming J. Frandsen, Peter F. B. Hansen, and Kim Dam-Johansen Slagging Tests on the Suitability of Alternative Coals in a 325 MWE PC Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 Timm Heinzel, Jörg Maier, Hartmut Spliethoff, Klaus R. G. Hein. and Werner Cleve Predicting Superheater Deposit Formation in Boilers Burning Biomasses . . . . . . 405 Rainer Backman, Mikko Hupa, and Bengt-Johan Skrifvars Deposit Formation in the Convective Path of a Danish 80 MWTH CFB-Boiler CO-Firing Straw and Coal for Power Generation . . . . . . . . . . 417 Peter F. Binderup Hansen Research on the Melting Points of Some Chinese Coal Ashes . . . . . . . . . . . . . . 433 Shen Xianglin, Chen Ying, and Liu Haibin x Contents Computer Controlled Scanning Electron Microscopy (CCSEM) Analysis of Straw Ash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 Henning Sund Sørensen Prognosis of Slagging and Fouling Properties of Coals Based on Widely Available Data and Results of Additional Measurements . . . . . . . . . . . . . . 455 Alexander N. Alekhnovich, Natalja V. Artemjeva, Vladimir V. Bogomolov, Vyacheslav I. Shchelokov, and Vasilij G. Petukhov The Slagging Behaviour of Coal Blends in the Pilot-Scale Combustion Test Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471 Alexander N. Alekhnovich, Vladimir V. Bogomolov, Natalja V. Artemjeva, and Vladimir E. Gladkov SECTION IV Studies at Rig Scale (Including Corrosion) In Situ Measurements of the Thermal Conductivity of Ash Deposits Formed in a Pilot-Scale Combustor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485 Allen L. Robinson, Steven G. Buckley, Gian Sclippa, and Larry L. Baxter Low Corrosivity of Coal Chlorine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497 Elliott P. Doane and Murray F. Abbott Laboratory Studies on the Influence of Gaseous HCl on Superheater Corrosion 513 Keijo Salmenoja, Mikko Hupa, and Rainer Backman The Role of Alkali Sulfates and Chlorides in Post Cyclone Deposits from Circulating Fluidized Bed Boilers Firing Biomass and Coal . . . . . . . . . . . . 525 Bengt-Johan Skrifvars, Tor Laurén, Rainer Backman, and Mikko Hupa Fly Ash Deposition onto the Convective Heat Exchangers during Combustion of Willow in a Circulating Fluidized Bed Boiler . . . . . . . . . . . . . . . . . . . . . . 541 Terttaliisa Lind, Esko I. Kauppinen, George Sfiris, Kristina Nilsson, and Willy Maenhaut Ash Behaviour in Biomass Fluidised-Bed Gasification . . . . . . . . . . . . . . . . . . . . . 555 Antero Moilanen, Esa Kurkela, and Jaana Laatikainen-Luntama Bench-Scale Biomass/Coal Cofiring Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569 Deirdre Belle-Oudry and David C. Dayton Iron in Coal and Slagging: The Significance of the High Temperature Behaviour of Siderite Grains During Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581 Gary Bryant, Christopher Bailey, Hongwei Wu, Angus McLennan, Brian Stanmore, and Terry Wall Contents xi SECTION V Develpments in Advanced Coal Technologies Fractionated Heavy Metal Separation in Biomass Combustion Plants—Possibilities, Technological Approach, Experiences . . . . . . . . . . . . . 595 Ingwald Obernberger and Friedrich Biedermann Distributions of Major and Trace Elements in Entrained Slagging Coal Gasification Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609 Kenichi Fujii, Masamitsu Suda, Tadayoshi Muramatsu, and Masahiro Hara Behavior of Inorganic Materials During Pulverized Coal Combustion . . . . . . . . 621 Tsuyoshi Teramae, Toru Yamashita, and Takashi Ando Energy Production from Contaminated Biomass: Progress of On-Going Collaboration Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635 Alexandre Grebenkov, Anatoli Iakoushev, Larry Baxter, Dave Allen, Helle Junker, and Jørn Roed Triboelectrostatic Coal Cleaning: Mineral Matter Rejection In-Line Between Pulverizers and Burners at a Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645 John M. Stencel, John L. Schaefer, Heng Ban, TianXiang Li, and James K. Neathery Development of Advanced PFBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653 Makoto Takai and Masahiro Hara Operating Experiences of 71 MW PFBC Demonstration Plant . . . . . . . . . . . . . . . 663 Hideki Goto and Syoichi Okutani Development of an Innovative Fluidized Bed Cement Kiln System . . . . . . . . . . . 675 Sadayuki Shinozaki, Isao Hashimoto, Katsuji Mukai, and Kunio Yoshida The Influence of Pressure on the Behaviour of Fuel Carbonates . . . . . . . . . . . . . 685 Arvo Ots, Tõnu Pihu, and Aleksander Hlebnikov SECTION VI Modeling of Ash Behaviour and Ash Deposition Modeling of Ash Deposit Growth and Sintering in PC-Fired Boilers . . . . . . . . . 697 Huafeng Wang and John N. Harb Predicting Ash Behavior in Conventional Power Systems: Putting Models to Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 709 Christopher J. Zygarlicke Thermodynamic Modelling of the System to Characterise Coal Ash Slags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723 Evgueni Jak, Sergei Degterov, Arthur D. Pelton, Jim Happ, and Peter C. Hayes
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