Results for “GASIFICATION” — Page 24

DOE OSTI2015

Low Cost High-H 2 Syngas Production for Power and Liquid Fuels

This report summarizes the technical progress made of the research project entitled “Low Cost High-H2 Syngas Production for Power and Liquid Fuels,” under DOE Contract No. DE-FE-0011958. The period of performance was October 1, 2013 through July 30, 2015. The overall objectives of this project was to determine the technical and economic feasibility of a systems approach for producing high hydrogen syngas from coal with the potential to reduce significantly the cost of producing power, chemical-grade hydrogen or liquid fuels, with carbon capture to reduce the environmental impact of gasification. The project encompasses several areas of study and the results are summarized here. (1) Experimental work to determine the technical feasibility of a novel hybrid polymer/metal H2-membrane to recover pure H2 from a coal-derived syngas was done. This task was not successful. Membranes were synthesized and show impermeability of any gases at required conditions. The cause of this impermeability was most likely due to the densification of the porous polymer membrane support made from polybenzimidazole (PBI) at test temperatures above 250 °C. (2) Bench-scale experimental work was performed to extend GTI's current database on the University of California Sulfur Recovery Process-High Pressure (UCSRP-HP) and recently renamed Sulfur Removal and Recovery (SR2) process for syngas cleanup including removal of sulfur and other trace contaminants, such as, chlorides and ammonia. The SR2 process tests show >90% H2S conversion with outlet H2S concentrations less than 4 ppmv, and 80-90% ammonia and chloride removal with high mass transfer rates. (3) Techno-economic analyses (TEA) were done for the production of electric power, chemical-grade hydrogen and diesel fuels, from a mixture of coal- plus natural gas-derived syngas using the Aerojet Rocketdyne (AR) Advanced Compact coal gasifier and a natural gas partial oxidation reactor (POX) with SR2 technology. Due to the unsuccessful experimental results with the hybrid polymer/metal H2 membrane, a conventional CO2 capture (single-stage Selexol) and hydrogen purification (PSA) technologies were used in the appropriate cases. In all cases, the integrated system of Advanced Compact coal gasifier, non-catalytic natural gas partial oxidation, and SR2 multicontaminant removal with state-of-the-art auxiliary system provided a 5-25% cost advantage over the base line plants using GEE coal gasifier with conventional Selexol/Claus sulfur removal and recovery. These plants also produce 18-30% less CO2 than with the conventional coal gasification plants.

08 HYDROGEN↗

DOE OSTI2016

Model-Based Sensor Placement for Component Condition Monitoring and Fault Diagnosis in Fossil Energy Systems

Design and operation of energy producing, near “zero-emission” coal plants has become a national imperative. This report on model-based sensor placement describes a transformative two-tier approach to identify the optimum placement, number, and type of sensors for condition monitoring and fault diagnosis in fossil energy system operations. The algorithms are tested on a high fidelity model of the integrated gasification combined cycle (IGCC) plant. For a condition monitoring network, whether equipment should be considered at a unit level or a systems level depends upon the criticality of the process equipment, its likeliness to fail, and the level of resolution desired for any specific failure. Because of the presence of a high fidelity model at the unit level, a sensor network can be designed to monitor the spatial profile of the states and estimate fault severity levels. In an IGCC plant, besides the gasifier, the sour water gas shift (WGS) reactor plays an important role. In view of this, condition monitoring of the sour WGS reactor is considered at the unit level, while a detailed plant-wide model of gasification island, including sour WGS reactor and the Selexol process, is considered for fault diagnosis at the system-level. Finally, the developed algorithms unify the two levels and identifies an optimal sensor network that maximizes the effectiveness of the overall system-level fault diagnosis and component-level condition monitoring. This work could have a major impact on the design and operation of future fossil energy plants, particularly at the grassroots level where the sensor network is yet to be identified. In addition, the same algorithms developed in this report can be further enhanced to be used in retrofits, where the objectives could be upgrade (addition of more sensors) and relocation of existing sensors.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2017

Evaluating the Techno-Economic Feasibility of Forward Osmosis Process Utilizing Low Grade Heat: Applications in Power Plant Water, Wastewater, and Reclaimed Water Treatment

Recovering and using uncoverted heat produced during electric power generation holds potential to significantly improve the efficiency of the electric power industry. One potential use of this low-temperature waste heat is on-site water treatment using waste heat driven processes to comply with the 2015 Effluent Limitation Guidelines for the Steam Electric Generating Sector. Ammonia-carbon dioxide forward osmosis (NH 4 HCO 3 FO) is a two-step waste heat driven process that involves a membrane separation process in which an osmotic pressure gradient created by an NH 4 HCO 3 draw solution is used to pull water across the membrane and a distillation column to regenerate the NH 4 HCO 3 draw solution. In this work we estimate the quantity, quality, and spatio-temporal availability of waste heat produced at U.S. coal, nuclear, and natural gas plants. We combine these estimates of waste heat availability with a techno-economic optimization model of NH 4 HCO 3 FO in order to assess the potential of NH 4 HCO 3 FO to treat flue gas desulfurization (FGD) wastewater, gasification wastewater, and boiler feedwater. We find that in 2012, 18.9 billion GJ of waste heat was discharged from the U.S. coal, natural gas, and nuclear fleet, although only 900 million GJ of waste heat was discharged at temperatures suitable for NH 4 HCO 3 FO. A maximum of 1.9 billion m3/yr of water could be produced using this waste heat to drive a NH 4 HCO 3 FO. The costs of waste heat driven NH 4 HCO 3 FO for FGD and gasification wastewater treatment to zero liquid discharge (ZLD) and boiler feedwater treatment are 2.20-2.40/m 3 and 0.35-0.65/m 3 , respectively. With mechanical vapor compression and crystallization for ZLD wastewater treatment and reverse osmosis for boiler feedwater treatment as the cost benchmark technologies, waste heat driven NH 4 HCO 3 FO is cost competitive for ZLD wastewater treatment, but not boiler feedwater treatment.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2018

Processing of Municipal Solid Waste (MSW) to Hydrogen Final Report CRADA No. TC-0989-94

The project objective was to develop a two-stage process for the conversion of municipal solid waste (MSW) to hydrogen. The first stage or the pre-treatment process stage was the main technical focus of the work because the overall processing approach was to use Texaco's existing gasification process with only minor modifications as the main processing stage. LLNL's main task was to develop the pre-treatment process through a scale of about 1 ton/day of feed capacity. Texaco's main task was to integrate the new pre-treatment process with its commercial gasification process and thus scale up the combined process to commercial size.

08 HYDROGEN↗

DOE OSTI2017

Improvement of Alstom's Limestone-Based Chemical Looping Combustion Process for Higher Purity Flue Gas Production

Alstom Power Inc., a wholly owned subsidiary of the General Electric Company (GE), is developing Limestone-based Chemical Looping (LCL™) Processes, utilizing limestone derived calcium sulfate as an oxygen carrier to transport oxygen from air to the fuel. The LCL™ process is a breakthrough technology with the potential to capture CO 2 and SO 2 from new and existing coal-fired power plants at reduced costs while maintaining high plant power generation efficiency. Chemical looping is a next generation advancement to oxy-combustion which would not require the significant investment in a cryogenic distillation type oxygen production plant. Instead of the energy-consuming oxygen plant, chemical looping uses a benign material to directly remove oxygen from the air and bring that oxygen into contact with the fuel. This "game changing" technology is the lowest cost-of-electricity technical approach that GE Power has identified to date for coal power with carbon capture. The technology has significantly lower capital costs compared to a conventional steam power plant with first generation carbon capture technologies. This new power plant concept is based on a hybrid combustion-gasification process utilizing high temperature chemical and thermal looping technology. In the air reactor, a solid oxygen carrier picks up oxygen from air through an oxidation reaction and leaves nitrogen behind. The hot oxygen-carrying solid carrier is then transported to a fuel reactor, where it releases oxygen. The released oxygen then converts the coal in the fuel reactor into combustion gases. The solid carrier is recycled back to the air reactor for regeneration completing the “chemical loop.” The regeneration step produces heat from which steam is produced for power generation while the process results in a concentrated carbon dioxide stream in which the carbon is captured for use or sequestration (CCUS). Limestone as a precursor for the oxygen carrier is abundant, benign, low cost, and is used in CFB and PC boilers for sulfur control. Challenges associated with this carrier include a complex reaction mechanism with possible side reactions leading to the release of SO 2 . The present project (DOE/NETL Cooperative Agreement No. DE-FE0025073) report focuses on coal-fired Limestone Chemical Looping Combustion (LCL-C™) processes that can produce a higher purity flue gas stream and achieve an improved overall performance that will meet the stated DOE goal of generating power from coal while achieving greater than 90% CO2 removal at less than 35% increase in the Levelized Cost of Electricity (LCOE). It builds on the concurrent and synergistic limestone-based chemical looping combustion (LCL-C™) and gasification (LCL-G™) projects with the Department of Energy, that were executed in parallel with the present project. In this report, the LCL-C™ experimental testing from the electrically-heated, once-through, 100 kW Pilot-Scale Test Facility (PSTF) is analysed and reviewed. The PSTF Oxidizer is a 50-foot tall, 100-mm diameter transport reactor, while the PSTF Reducer reactor is based upon a bubbling-bed design. The experimental data from designated test periods (denoted “Weeks”) are reviewed and discussed. The application of high sulfur release in the Reducer (with proper sulfur management) exceeded the LCL-CTM performance targets. Furthermore, the ilmenite blend came within 1 percentage point of meeting all of the performance targets.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2019

Improved Reliability of Solid Oxide Fuel Cell Systems. Final scientific/technical report

This program is furthering the development of SOFC technology to meet the durability requirements required by the market for the service life and costs for such a power generation technology. SOFC technology provides an environmentally friendly and highly efficient power generation. LGFCS is developing a 1MW pressurized SOFC system for distributed power generation. The planned commercial product is expected to have an efficiency of ~60% (net AC) and fueled by natural gas. The lower carbon content of natural gas combined with the efficient power generation results in significant environmental benefits (lower CO2 greenhouse emissions). The SOFC technology provides a means for efficient utilization of the large US reserves of natural gas and enhances national energy independence. The SOFC technology will initially serve the distributed power generation market and gain market acceptance and smaller power system sizes. The technology is well suited to carbon sequestration given the separated air and fuel streams. The Department of Energy (DOE) envisions a centralized power generation technology that could use coal gasification as an integrated gasification fuel cell (IGFC) power plant at the >100MW scale with CO2 capture.

25 ENERGY STORAGE↗

DOE OSTI2019

Raman Spectroscopy for the On-Line Analysis of Oxidation States of Oxygen Carrier Particles (Final Report)

The need for cleaner energy systems, including CO 2 capture technologies, is driving the current development of chemical looping technologies such as chemical looping combustion (CLC) and chemical looping gasification (CLG). Specific processes that are under development for using solid fuels are in-situ Gasification Chemical-Looping Combustion (iG-CLC) and Chemical Looping with Oxygen Uncoupling (CLOU). Chemical looping is based on using oxygen carriers (e.g., iron oxides, copper oxides, calcium sulfates, etc.) to provide the oxygen for the reaction with the fuel. In order to optimize the overall process performance, it is critical that the properties of the oxygen carriers are well-defined and maintained for their specific purpose during the different stages of the CLC process. One of the critical properties of the oxygen carrier is its oxidation state (e.g., content of Fe 2 O 3 vs. Fe 3 O 4 ) as it affects the fundamental operation of the CLC process. Unfortunately, the ability to make on-line measurements of the oxidation state of oxygen carriers is lacking and new sensors need to be developed. The goal of this project was to evaluate the potential of Raman spectroscopy as a sensor for the on-line analysis of the oxidation state of oxygen carrier particles. Oxygen carrier particles (OCPs) of interest include iron oxides, copper oxides, calcium sulfite, and calcium sulfate, with particle sizes typically less than 0.5 mm diameter. The expected operating conditions of the sensor include OCP temperatures in the range of 800 °C to 1000 °C, and pressures of about 10 atm. We evaluated continuous wave (cw), Quasi cw, pulsed, and time-gated Raman spectroscopy at multiple wavelengths (355 nm, 360 nm, 532 nm, 633 nm, 785 nm). Samples included iron oxides, copper oxides, calcium sulfate, and a custom sample provided by NETL for temperatures beyond 1000 °C. Our findings can be summarized as follows: Calcium sulfate can be detected via cw and pulsed 532 nm Raman spectroscopy at temperatures above 1100 °C.; Hematite (Fe 2 O 3 ) Raman spectra can be detected at temperatures of 700 °C via cw 360 nm, 1089 °C with cw 532 nm, 400 °C with cw 633 and 600 °C with cw 785 nm lasers; Magnetite (Fe 3 O 4 ) can be detected via cw 532 nm Raman spectroscopy up to 600 °C; Mixtures of Fe2O3 and Fe 3 O 4 can be distinguished for temperatures up to 600 °C using 532 nm; Copper oxides did not yield suitable signals at elevated temperatures; The custom NETL samples did not yield suitable signals at elevated temperatures. Raman spectroscopy would be a suitable approach for calcium sulfate as this material provides a very strong Raman signal at high temperatures. Oxygen carrier particles of higher interest such as metal oxides, however, do not yield a strong-enough signal at elevated temperatures. As such, Raman spectroscopy is not suitable to differentiate the oxidation state of these materials at temperatures above 600 °C.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2017

Hydrogen Energy California (Final Scientific and Technical Report)

Hydrogen Energy California ("HECA") is an Integrated Gasification Combined-Cycle (IGCC) “polygeneration” project. The Project gasifies a 75 percent coal and 25 percent petroleum coke (petcoke) fuel blend to produce synthesis gas (syngas). Syngas produced via gasification is purified to hydrogen-rich fuel, which is used to generate low-carbon baseload electricity in a Combined Cycle Power Block, low-carbon nitrogen-based products in an integrated manufacturing Complex, and carbon dioxide (CO 2 ) for use in enhanced oil recovery (EOR). The power and products produced by HECA have a lower carbon footprint compared to power and products produced from more traditional fossil fuel facilities. This low-carbon footprint is achieved by capturing more than 90 percent of the CO 2 in the production of the hydrogen fuel and transporting it for use in EOR, which results in simultaneous sequestration (storage) of the CO 2 in a secure geologic formation in the adjacent Elk Hills Oil Field (EHOF), a hydrocarbon producing area. Highlights of HECA as conceived during the execution of FEED are as follows: The Project is designed to operate on a fuel blend consisting of 75 percent western subbituminous coal and 25 percent California petcoke based on thermal input to the gasifier on a higher heating value (HHV) basis; The feedstocks are gasified to produce syngas that is further processed and cleaned to produce hydrogen-rich fuel; More than 90 percent of the carbon in the raw syngas is captured in a high-purity CO 2 stream during steady-state operation; High purity CO 2 is compressed and transported by pipeline to the EHOF for injection into deep underground hydrocarbon reservoirs for CO 2 EOR; The Combined Cycle Power Block produces over 420 megawatts (MW) of gross power, which yields during periods of maximum power production over 270 MW of low-carbon baseload electricity to the grid; An integrated Manufacturing Complex produces approximately 1 million tons per year of low-carbon nitrogen-based products, including urea, urea ammonium nitrate (UAN), and anhydrous ammonia, to be used in agricultural, transportation, and industrial applications.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2018

Development of a Pre-combustion CO 2 Capture Process Using High-Temperature PBI Hollow-Fiber Membranes

The overall goal of this research project was to develop a high-temperature, membrane-based CO 2 capture technology for coal gasification facilities and make progress toward meeting overall fossil energy performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) 30% less than baseline capture approaches. The primary objectives of the project were to evaluate, at a bench-scale size, a technically and economically viable CO 2 capture system based on a high-temperature polybenzimidazole (PBI) polymer hollow-fiber membrane (HFM) separation system, and to optimize the process for integration of that system into an integrated gasification combined cycle (IGCC) plant. The specific objectives of the proposed project are to: (1) fabricate high-performance PBI-HFMs for H 2 /CO 2 separation; (2) collect laboratory data for separating hydrogen from simulated synthesis gas using PBI-based membrane modules; (3) transfer the membrane fabrication technology to an industrial firm that specializes in the manufacture of HFMs; (4) fabricate membrane modules to process a syngas stream (50 kWth) equivalent to that of shifted gas from an oxygen-blown gasifier; (5) obtain design and steadystate performance data for membrane modules using syngas from an operating coal gasifier; (6) estimate the cost of CO 2 capture from pre-combustion gas streams integrated into a 550-MW (net) power plant; and (7) conduct a process environmental health & safety (EH&S) assessment.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2019

Raman Spectroscopy for the On-Line Analysis of Oxidation States of Oxygen Carrier Particles

The need for cleaner energy systems, including CO 2 capture technologies, is driving the current development of chemical looping technologies such as chemical looping combustion (CLC) and chemical looping gasification (CLG). Specific processes that are under development for using solid fuels are in-situ Gasification Chemical-Looping Combustion (iG-CLC) and Chemical Looping with Oxygen Uncoupling (CLOU). Chemical looping is based on using oxygen carriers (e.g., iron oxides, copper oxides, calcium sulfates, etc.) to provide the oxygen for the reaction with the fuel. In order to optimize the overall process performance, it is critical that the properties of the oxygen carriers are well-defined and maintained for their specific purpose during the different stages of the CLC process. One of the critical properties of the oxygen carrier is its oxidation state (e.g., content of Fe 2 O 3 vs. Fe 3 O 4 ) as it affects the fundamental operation of the CLC process. Unfortunately, the ability to make on-line measurements of the oxidation state of oxygen carriers is lacking and new sensors need to be developed. The goal of this project was to evaluate the potential of Raman spectroscopy as a sensor for the on-line analysis of the oxidation state of oxygen carrier particles. Oxygen carrier particles (OCPs) of interest include iron oxides, copper oxides, calcium sulfite, and calcium sulfate, with particle sizes typically less than 0.5 mm diameter. The expected operating conditions of the sensor include OCP temperatures in the range of 800 °C to 1000 °C, and pressures of about 10 atm. We evaluated continuous wave (cw), Quasi cw, pulsed, and time-gated Raman spectroscopy at multiple wavelengths (355 nm, 360 nm, 532 nm, 633 nm, 785 nm). Samples included iron oxides, copper oxides, calcium sulfate, and a custom sample provided by NETL for temperatures beyond 1000 °C. Our findings can be summarized as follows: Calcium sulfate can be detected via cw and pulsed 532 nm Raman spectroscopy at temperatures above 1100 °C. Hematite (Fe 2 O 3 ) Raman spectra can be detected at temperatures of 700 °C via cw 360 nm, 1089 °C with cw 532 nm, 400 °C with cw 633 and 600 °C with cw 785 nm lasers. Magnetite (Fe 3 O 4 ) can be detected via cw 532 nm Raman spectroscopy up to 600 °C. Mixtures of Fe 2 O 3 and Fe 3 O 4 can be distinguished for temperatures up to 600 °C using 532 nm. Copper oxides did not yield suitable signals at elevated temperatures. The custom NETL samples did not yield suitable signals at elevated temperatures. Raman spectroscopy would be a suitable approach for calcium sulfate as this material provides a very strong Raman signal at high temperatures. Oxygen carrier particles of higher interest such as metal oxides, however, do not yield a strong-enough signal at elevated temperatures. As such, Raman spectroscopy is not suitable to differentiate the oxidation state of these materials at temperatures above 600 °C.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

CO 2 Source Assessment, Wabash CarbonSAFE Subtask 10.1 (Technical Report)

This document describes the CO 2 source at Wabash Valley Resources, namely the gasification process and configuration of the facility, and separation of the hydrogen product from the CO 2 byproduct which will be captured for subsurface storage. This document then presents a summary of CO 2 storage considerations and estimated project expenses for adding CO 2 capture and sequestration to the existing gasification plant.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Comparison of Commercial, State-of-the-Art, Fossil-Based Hydrogen Production Technologies

This report presents an independent assessment of the cost and performance of select hydrogen production plants utilizing fossil fuel resources as the primary feedstocks – specifically, natural gas (NG), steam methane reforming (SMR), NG autothermal reforming (ATR), coal gasification, and coal/biomass co-gasification – using a systematic, transparent technical and economic approach. Study cases were selected to reflect the capabilities of current, commercial technologies within plant configurations, and at scales, representative of next commercial offerings facing no fundamental research and development (R&D) obstacles. Additionally, several areas of R&D are identified as potential pathways for performance improvements and cost reductions.

08 HYDROGEN↗

DOE OSTI2018

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 OSTI2017

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 OSTI2019

Sub-micron Ash Aerosol Formation in Oxycoal Combustion at Atmospheric and Elevated Pressures

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 OSTI2019

Design, Construction, and Assessment of Dry Coal Feeding in a High Pressure Oxy-coal System

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 OSTI2019

Sub-micron Ash Aerosol Formation in Oxycoal Combustion at Atmospheric and Elevated Pressures

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 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↗