Results for “OEM” — Page 8

DOE OSTI2020

Validation of an Advanced High-Pressure PEM Electrolyzer and Composite Hydrogen Storage

One of the challenges associated with transitioning our nation’s transportation economy to any alternative fuel is bringing fuel production, storage, transportation, and end-customer delivery infrastructure online. There are challenges associated with planning and implementing hydrogen fueling stations at locations relevant to the parallel effort of bringing the related transportation vehicles into the market. There are additional challenges associated with the operation of hydrogen fueling stations and reducing operating costs through energy reduction. Through calculation and design efforts it was concluded that elevating the pressure of a PEM cell stack and further developing hydrogen processing equipment that support elevated pressures while maintaining similar characteristics to their current production counterparts will yield in energy savings and by extension cost reductions. In this report, the design of a 57-bar (827-psig) electrolysis system and electrolysis cell stack is described. Furthermore, the fabrication, component verification, and integrated testing are summarized. Prior to this development effort, Proton had demonstrated thousand of hours of durability on 30-bar (435-psig) differential pressure PEM electrolysis hardware. Proton has sold and installed many of these 30-bar devices at customer sites. Through this project, Proton has developed and tested 57-bar PEM electrolysis, thereby extending the proven capability of PEM electrolysis as a hydrogen generation and electrochemical compression device. A design and validation effort to arrange hydrogen processioning equipment for refueling OEM vehicles was also undertaken within this project. By arranging equipment within two 6-meter ISO shipping containers and further developing NFPA 2 Hydrogen Technologies Code to support containerized hydrogen equipment, efforts to site, install, and commission, and approve hydrogen fueling stations were reduced and now provide a groundwork for future installations.

08 HYDROGEN↗

DOE OSTI2021

Off-Road Vehicle Energy-Saving Potential

The U.S. Department of Energy’s (DOE’s) Vehicle Technology Office (VTO) has played a critical role in enabling electrification and reducing fuel consumption in the automotive sector. However, the off-road vehicle sector accounts for 8% of transportation fuel, and that share is likely to increase over time as onroad vehicles move towards electrification. DOE can again play a key role in the off-road vehicle market by providing tools that can be used by academia and the industry to evaluate the impact of advanced technologies. The need for a pre-competitive simulation tool was also identified during a 2019 DOE-led workshop at Argonne National Laboratory that included OEMs and suppliers to this market. Autonomie, a powerful and robust system simulation tool for vehicle energy consumption and performance analysis, was developed by Argonne National Laboratory in collaboration with General Motors. Its application covers energy consumption and performance analysis throughout the entire vehicle development process by leveraging its plug-and-play powertrain and vehicle model architecture and development environment

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Bridge Seismic Screening Tool (BSST), Version 2.0

The Regional Resiliency Assessment Program (RRAP) is a cooperative assessment of specific critical infrastructure within a designated geographic area and a regional analysis of the surrounding infrastructure that addresses a range of infrastructure resilience issues that could have regionally and nationally significant consequences. In 2018, DHS’s Cybersecurity and Infrastructure Security Agency (CISA) sponsored the Oregon Transportation Systems RRAP project in coordination with the Office of the Governor (under the oversight of the state resilience officer), the Oregon Office of Emergency Management (OEM), the Oregon Department of Transportation (ODOT), and other regional stakeholders (CISA 2021). This project focuses on assessing the impacts of a Cascadia Subduction Zone (CSZ) earthquake on state transportation systems and, in particular, how those impacts may affect the ability of emergency response efforts to move supplies into the region. The intended outcome of this analysis is the prioritization of transportation routes and modes for additional planning, investment, hardening, or other activities to enhance their resilience—and therefore, to enhance their ability to support response and recovery efforts following a CSZ earthquake. An important part of this transportation system-level assessment has been to assess the seismic vulnerability of the state highway system. In doing so, the RRAP project team used the Bridge Seismic Screening Tool (BSST) to assess, at a system-level, the potential impacts that a CSZ earthquake could have on state highway bridges (Bergerson et al. 2019).1 Argonne National Laboratory (Argonne), in collaboration with the Washington State Department of Transportation (WSDOT), originally developed the BSST as part of the 2017 Washington State Transportation Systems RRAP project, a sister project to the 2018 Oregon Transportation Systems RRAP project. Argonne updated the BSST during this more recent project in Oregon based on feedback from stakeholders and subject matter experts (SMEs) on the original version of the tool. The first step in the BSST is to assess the seismic vulnerability of roadway bridges following a CSZ earthquake to determine a projected or potential damage state. Damage states then help determine approximate reopening times for bridge crossings.2 This document provides details on the BSST methodology, the implementation of that tool to analyze the projected damage incurred in a CSZ earthquake scenario, and the determination of corresponding reopening times of interstate, state highway, and local bridges following such an event.

58 GEOSCIENCES↗

DOE OSTI2021

Report on High-Fidelity Dynamic Modeling of a Coal-Fired Steam Power Plant

As a result of the growth of renewables including solar and wind energy with fluctuating production, fossil fuel power plants are being required to cycle between high and low power production. This cycling is both at a greater frequency and over a wider range than in the past. In many cases, power plants are not designed for this type of cycling operation but can nonetheless endure these challenging operation requirements under the right conditions. In this project, optimal solution for enhanced flexible operations are being investigated using model based estimation and control techniques. To support the development of model-based estimator and model-based controls at GE Global Research, GE Steam Power configured a dynamic model using a reference steam plant design including the boiler, turbine, and water/steam conditioning systems as well as the controls needed for plant cycling with stability and reliability. The dynamic model was built using the APROS® software from VTT, and then calibrated to multiple load conditions from full load (100%TMCR) to partial loads (75%TMCR, 50%TMCR and 25%TMCR) based on internally developed steady state heat balance models at the unit level. These internal heat balance models are based on first principles and extensive engineering experiences from GE Steam Power as an OEM and a services provider. This topical report presents the structure of the unit level dynamic model, the tuning process, and representative simulation results from typical load cycling simulations using the dynamic model.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Vehicle-Cycle Inventory for Medium- and Heavy-Duty Vehicles

The United States has witnessed multiple attempts to improve fuel economy and reduce pollutant emissions in the transportation sector, guided chiefly via technological interventions by original equipment manufacturers (OEMs) and by specific policies of the U.S. Federal Government, like Corporate Average Fuel Economy (CAFE) norms (Burnham et al., 2006; U.S. DoT, 2013). These efforts have resulted in the growing adoption of alternatives to conventional materials, fuels, and vehicle propulsion technologies across various transportation modes, while also helping to lower global pollution (greenhouse gas, or GHG, emissions). Yet, a holistic evaluation of the ecofriendliness of these alternatives, particularly their energy use and emissions, merits detailed focus on their entire life-cycle, and thereby, on the life-cycle of associated transport modes. This is vital since alternative fuels and materials can differ vastly in energy sources and production methods employed for their processing vis-à-vis their existing counterparts — and this difference causes significant variation in their respective upstream emissions.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Global Ethanol-Blended-Fuel Vehicle Compatibility Study

The objective of this study is to understand the impact of ethanol-blended fuel at various blending levels (10%, 15%, and 20% vol.) on "in-operation" vehicles built to differing emissions and manufacturing standards around the world. The study focuses on vehicles used in Canada, China, India, Indonesia, Japan, South Korea, and Mexico. Historical experience in the United States and Brazil informs the analysis. The primary study question is: Are vehicles in targeted countries physically and operationally compatible with ethanol blended fuel? For a fuel to be compatible with a vehicle, the fuel must perform its function as part of the integrated fuel-vehicle system, meaning: the car should start easily and drive normally, the fuel should not cause catastrophic fuel system leaks, the fuel should not cause corrosion or degradation of any engine or fuel system components (including emissions control components). The history of E10 use in the United States, beginning in 1978, was evaluated and shows no reliability or operability issues for cars dating back to pre-emissions-control times -- and likely included many cars manufactured in the 1960s. This strongly supports the contention that fuel chemistry and property differences between E0 and E10 are so small that any car made to international standards in the last 50 years will have a very high probability of being fully compatible with E10. This conclusion is supported by the experience in Brazil in the 1970s, where E10 was also introduced, and ethanol blending for conventional cars rapidly ramped up to even higher blend levels. A limited number of fuel system and component manufacturers supply the global market, including Bosch, Continental, Denso, Delphi, and Visteon. To reduce complexity, ethanol-compatible materials began to be integrated in fuel system designs globally. Fuel systems evolved over the following decades to incorporate ethanol-compatible materials with core subsystem families, such as in-tank fuel pumps used across several global vehicle original equipment manufacturers (OEMs). A similarly compelling case can be made that all cars at the Tier 1 (or equivalent) emissions-control technology level or higher are fully compatible with E15 blends, based on the data evaluated by the U.S. Environmental Protection Agency (EPA) and Ricardo in 2010. For cars at this technology level, the minor differences in fuel chemistry and properties between E10 and E15 are not significant. For E20, studies are not as extensive but are still highly significant. A long-term durability study conducted on mileage accumulation dynamometers presents convincing evidence that Tier 2 technology level cars have materials of construction and engine control authority for compatibility with E20, although this conclusion is not as strong as those drawn for E10 and E15, which are also partly based on real-world experience.

09 BIOMASS FUELS↗

DOE OSTI2021

Cost targets to achieve commercially viable thermal storage in buildings

To mitigate the variation in demand on the electric grid, thermal energy storage (TES) is an alternative to electric batteries or installing new peaking power plants. Stakeholders and policy makers across the United States have expressed interests in promoting TES, as demonstrated by the US Department of Energy’s Grid-Interactive Efficient Buildings program and the efforts of various state legislatures. However, the cost value provided by TES are unclear. If reliable cost benefits were determined, stakeholders would have a clearer picture of the financial returns that can be gained from their investment in TES. In this report, EnergyPlus was used to perform whole-building simulations for two residential buildings in Indianapolis and Atlanta. The HVAC system in both buildings were equipped with phase change material TES. The TES tank was charged in off-peak hours and discharged in peak hours to perform load shifting. First, the economic value implied by existing time-of-use (TOU) rates offered by utility companies was analyzed via whole-building simulation. Second, existing demand reduction (DR) incentives sourced from 3 different electrical grid administrators (i.e., California, Texas, and New England region) were surveyed to determine their implied value. Lastly, the economic value implied by different types of deferred peak power plants were reviewed. The full value of TES to the entire society consists of value to the utility, OEMs, facility installers, and other stakeholders. This report focuses on the value to the utility with emphasis on the deferred capital of peak power plant. The value from the deferred capital of peak power plant is manifested to the customer in the form of demand reduction program and Time-of-Use utility rate program. In this report, an initial proxy of the value of TES is made by assuming the deferred capital cost of power plant is the full value to reduce peak demand. Three levels of financial value of TES systems were assessed. Two are currently available to some residential customers: (1) the benefit from TOU pricing alone and (2) the benefit from TOU pricing in combination with DR incentive programs. The third level was computed as the full cost of deferred capital cost of peaking power plants. This represents the potential value that could be gained by the utilities or conceivably be offered to consumers.

25 ENERGY STORAGE↗

DOE OSTI2022

Barriers to Broader Utilization of Fault Detection Technologies for Improving Residential HVAC Equipment Efficiency

Faults in residential heating, ventilating, and air conditioning (HVAC) equipment may occur due to poor installation practices or develop over time, and these faults can negatively impact system efficiency, thermal comfort, and equipment lifespan. Automated fault detection and diagnostic (AFDD) technologies identify energy wasting HVAC faults, such as low indoor airflow and improper refrigerant charge, and guide technicians in improving system efficiency. For residential HVAC, AFDD consists of a range of fault detecting and diagnostic capabilities, sensor configurations, and target applications. AFDD technology can either be permanently installed by the original equipment manufacturer (OEM) using embedded sensors or as an add-on product either during or after installation. Additionally, several advanced installation tools and refrigerant gauge sets include AFDD features for temporary use during equipment installation and tune-ups. Some technologies can detect a fault but have limited diagnostic capabilities. For example, a single-point measurement from the home's thermostat or energy monitor can provide certain fault detection capability by analyzing the equipment runtime or energy consumption. These technologies, though limited at determining the cause of a given fault, may have significant energy savings potential due to their low cost and prevalence in the residential HVAC market. Despite the potential benefits, fault detection technologies face many technical and market barriers preventing broad adoption. Beyond the cost barriers due to the added sensor requirements and technology development, fault detection technologies face many implementation and adoption barriers such as installer training, customer awareness, standardized communication protocols, and methods of test for evaluating accuracy. The purpose of this whitepaper is to characterize market and technical barriers impeding broader utilization of fault detection technology for residential HVAC energy efficiency applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Highly Recyclable Thermosets for Lightweight Composites: CRADA 517 [Abstract only]

Lightweight composites are of increasing need to enable reduced fuel usage, reduced carbon emissions and increased range in air and ground transportation. The superior weight savings of carbon fiber thermoset composites are impeded by material and production costs and the limited options available for composite repair and recycle. The materials recovery and recycling sector is currently overwhelmed by an abundance of low-value materials and limited market opportunities for downcycled content, rendering landfilling a more attractive alternative. Vitrimers represent a new paradigm for repairable and recyclable thermosets, but this relatively new technology will require development, including government investment, to reduce risks for its adoption by aerospace and automotive OEMs. The overall goal of the project is to create recyclable carbon fiber composites using vitrimer resins that are more energy efficient to produce and have improved properties over baseline technology. The targeted composites will retain their tensile strength after multiple recycling and reprocessing steps. In addition, monomer will be recoverable through depolymerization and re-usable carbon fibers will be retrieved.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Clean Condensing Gas Furnace

Natural gas furnaces are the most common space heating equipment in the U.S. residential and commercial building markets. However, current residential natural gas condensing furnaces generate substantial acidic condensate as well as significant emissions of sulfur oxides (SOx), nitrogen oxides (NOx), carbon monoxide (CO), hydrocarbons (HC), and methane (CH 4 ) contributing to environmental degradation of air, water, and soil. This report describes a novel solution to reduce the environmental impact of natural gas condensing furnaces based on the technology of a monolithic acidic gas reduction (AGR) catalyst for SOx trapping, NOx redox to nitrogen, and oxidation of formic acid, CO, HC, and CH 4 . The AGR technology offers the following benefits: (1) a neutral furnace condensate with a pH of ~7, allowing its safe release into the sewer system thus eliminating a second drainage system; (2) trapping and removing nearly all SOx emissions; (3) NOx emissions nearly at nearly 1-2 ng/J, more than 95% lower than new emissions standards in California; (4) the use of a low-cost heat exchanger as a condensing heat exchanger (HX) since the condensate is not acidic, avoiding the need for expensive stainless steel alloys; and (5) unburnt fuel energy recovery to boost efficiency.The AGR component and AGR-enabled furnace performance were broadly tested to determine their effects on long-term reliability and durability, as well as SOx storage and regeneration activity. The AGR regeneration does not impair the performance in achieving neutral condensate and ultra-low NOx emissions, and the AGR catalyst subjected to regeneration activities continued to function well and achieved slightly better annual fuel utilization efficiency (AFUE). The 400-hour reliability and durability test of the retrofitted condensing furnace with the AGR component shows that the furnace unit still achieves a neutral furnace condensate with a pH of ~7 and enables 0~3 ng/J of NOx emissions. However, the 400-hour operation slightly degraded the AFUE because of soot particle accumulation caused by frequent incomplete combustion owing to inappropriate condensate drainage during testing. Thus, proper condensate drainage is critical for AGR-enabled furnaces. Furthermore, neutron computed tomography was employed to survey the aged AGR component and demonstrate high-resolution 2D and 3D representations for the nondestructive diagnosis of the AGR component. The tomography showed that the AGR component did not deform or suffer broken AGR channels. A new AGR catalyst with low precious metal loading was preliminarily explored to identify a pathway of optimizing AGR material loading and maximizing acidic gas reduction at low cost. The new AGR component can reduce precious metal loading by 38% and still achieve neutral condensate and ultralow NOx emissions. The furnace with the AGR component of low Pt/Rh loading enables a maximum AFUE of 97%, which is meaningfully higher than the original furnace. Long-duration testing for the furnace enabled with the low precious metal loading AGR component will be vital in future research. Although the current work demonstrates a proof of concept for the AGR-enabled furnace, the AGR assembly needs to be optimized and integrated into the design of new OEM furnace products. Furthermore, the AGR technology can be applied not only for residential gas furnaces, but also for commercial rooftop units, gas heat pumps, gas-fired water heaters, combustion boilers, and other systems.

03 NATURAL GAS↗

DOE OSTI2022

Cybersecurity for Electric Vehicle Charging Infrastructure

As the U.S. electrifies the transportation sector, cyberattacks targeting vehicle charging could impact several critical infrastructure sectors including power systems, manufacturing, medical services, and agriculture. This is a growing area of concern as charging stations increase power delivery capabilities and must communicate to authorize charging, sequence the charging process, and manage load (grid operators, vehicles, OEM vendors, charging network operators, etc.). The research challenges are numerous and complicated because there are many end users, stakeholders, and software and equipment vendors interests involved. Poorly implemented electric vehicle supply equipment (EVSE), electric vehicle (EV), or grid operator communication systems could be a significant risk to EV adoption because the political, social, and financial impact of cyberattacks — or public perception of such — would ripple across the industry and produce lasting effects. Unfortunately, there is currently no comprehensive EVSE cybersecurity approach and limited best practices have been adopted by the EV/EVSE industry. There is an incomplete industry understanding of the attack surface, interconnected assets, and unsecured inter faces. Comprehensive cybersecurity recommendations founded on sound research are necessary to secure EV charging infrastructure. This project provided the power, security, and automotive industry with a strong technical basis for securing this infrastructure by developing threat models, determining technology gaps, and identifying or developing effective countermeasures. Specifically, the team created a cybersecurity threat model and performed a technical risk assessment of EVSE assets across multiple manufacturers and vendors, so that automotive, charging, and utility stakeholders could better protect customers, vehicles, and power systems in the face of new cyber threats.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

High Frequency Transverse Instabilities in Low NOx Gas Turbines

This program addresses the topic of combustion instabilities under the goal of developing “Low-NOx Combustion Technology for ‘Air-Breathing’ Advanced Turbines”. With recent advances in high-temperature withstanding materials, the push towards higher efficiency has resulted in efforts to design high temperature, low NOx gas turbines. The development of such low NOx systems is often plagued with combustion instabilities. These instabilities manifest with acoustic modes that are longitudinal, transverse or both. A large body of literature and work exists addressing the underlying mechanisms and models for longitudinal instabilities and these have been successfully implemented in the design tools for low NOx gas turbines. The flame response aspect of the thermoacoustic feedback loop was often modeled in an acoustically compact framework since for low frequencies, the flame length scale was small compared to the acoustic wavelength. This enabled simplification where the modeling focused only on the overall flame response and not the local spatial distribution of the flame response. In addition, additional mechanisms such as the direct effect of pressure fluctuations on the flame response could be neglected. In contrast, high frequency instabilities which often are transverse in nature, have received relatively less attention in the literature. The flame is no longer acoustically compact and thus the local distribution of heat release must be accurately understood. The flame responds to velocity fluctuations, equivalence ratio fluctuations as before, but also to pressure fluctuations through kinetic effects. These aspects of high-frequency instabilities make it a challenging problem that requires a detailed elucidation of the underlying mechanisms and creating models for them. In this program we significantly improved the understanding of these instabilities through a combination of experiments (informed by interactions with OEMs), modeling of measured data and reduced order modeling of flame response. The results from the program can be used as basis for robust design tools that are essential for successfully developing gas turbines that operate in an environmentally acceptable manner with mitigation strategies for high-frequency instabilities.

08 HYDROGEN↗

DOE OSTI2022

Innovative SCR Materials and System for Low Temperature Aftertreatment

US automotive OEMs are required to meet the twin challenge of corporate average fleet fuel economy of 54.5 mpg and stringent Bin30/SULEV30 emissions standards for light duty vehicles by 2025. This creates a heavy burden on the R&D community to discover and develop the necessary enabling technologies by 2023 to integrate into powertrain systems intended for 2025. Further amplifying the emissions challenge is the reduction in engine exhaust energy resulting from more fuel-efficient powertrains and the regulatory requirement of 15-year system performance. This forces aftertreatment systems to continue to push their operational limits to increasingly lower temperatures. This CRADA will focus on a broad and very important area of critical relevance to DOE and Stellantis, i.e., development of low temperature aftertreatment approaches, while not sacrificing durability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

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↗