Results for “Pulverization” — Page 8

DOE OSTI2021

High-Temperature Multi-Process Sensor Development for a PC-Fired Unit

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2022

Real-time sensor measurements to evaluate impacts of load cycling on high-temperature fire-side corrosion in a PC boiler

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2021

High-Temperature Multi-Process Sensor Development and Demonstration at Coalfired Power Plants

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2022

Full-scale Demonstration of Multi-process Sensor at a Cycling PC-fired Boiler

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2024

Combustion Performance and Emissions Optimization Through Integration of a Miniaturized High-Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution of wall conditions in utility boilers. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of a coal-fired utility boiler in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

42 ENGINEERING↗

DOE OSTI2023

Advanced Multiscale Microscopy Characterization of High Burnup LWR UO 2 Before and After LOCA Testing

Previous microscopy work within the campaign has observed increased porosity coupled with subgrain formation in the mid-radial region of the fuel. However, examinations of high burnup fuel taken from multiple reactors with different operating conditions have shown that this structure can move radially inward depending on the fuel operating conditions. It is currently theorized that inter- and intragranular fission gas bubble nucleation is precursory to the grain subdivision observed in the mid-radial and central regions of the fuel. Characterization of samples after loss-of-coolant accident (LOCA) testing has revealed that these restructured regions with a high density of bubbles and subgrains pulverize during the transient test. It appears that the increase in fission gas bubbles coupled with grain subdivision renders the fuel mechanically weaker during a LOCA transient and thus susceptible to fuel fragmentation relocation and dispersal (FFRD). Work this past fiscal year has prioritized understanding this behavior by using advanced microscopy to investigate fission gas behavior in the as-irradiated and post-LOCA state. Additional work has been performed to verify the theory described above by analyzing multiple post-LOCA optical micrographs and comparing that to as-irradiated microstructural data. This document reports progress in the post-irradiation characterization of high burnup nuclear fuel with emphasis on the restructured fuel regions, particularly how microstructural features influence FFRD and fission gas release behavior in LOCA conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Triaxial Shear Tests on Simulated Sierra White Fault Gouge & Borehole Simulation in Sierra White Gouge

Laboratory shear tests were conducted on pulverized Sierra White granite (SWG) to investigate slip mechanisms in naturally occurring faults. Synthetic fault geometries were constructed by sandwiching fine grained SWG powder in between steel forcing blocks. For dry experiments, ~3.5 g of SWG powder was poured onto the face of the lower steel forcing block and leveled. For saturated experiments, enough fluid was added to the ~3.5 g of Sierra White granite powder to form a slurry. This slurry was applied to the lower forcing block and leveled. Inclined forcing blocks with 25.4 mm diameter and 35° faces, which were machined from ground steel rods with fine teeth on the faces, help to hold the gouge in place and prevent delamination at the interface. The top forcing block had a 2.03 mm centered hole to allow pore fluid access to the gouge. A fine steel mesh prevented back flow of the gouge into pore fluid lines. Samples were isolated from the confining medium using three layers of heat shrink polyolefin, as shown in Figure 1. The outer layer was shrunk over the o-rings on the end caps to form an impermeable seal, which was reinforced with steel tie wires on both sides of the o-rings. Hardened steel spacers and copper shim stock was placed between the steel forcing blocks and the end caps to preserve the parallelism of the Hastelloy wetted parts. For dry samples, the end caps were plugged, while the end caps for the saturated samples were connected to pore lines.

58 GEOSCIENCES↗

DOE OSTI2024

Development and Refinement of Bison Models for Higher Burnup Application

Electric Power Research Institute (EPRI) is an international research organization funded by organizations in the energy and government sectors. The company conducts research to tackle the energy challenges of its member organizations. In support of the U.S. nuclear industry, EPRI and Idaho National Laboratory were awarded a U.S. Department of Energy Technology Commercialization Fund to develop a loss of coolant accident (LOCA) analysis tool. This tool was developed to support burnup extension activities by supplementing the existing capabilities of operators of existing large light-water reactor plants. The tool couples INL developed codes Bison and RELAP5-3D for advanced simulation of LOCA behavior. The project consists of seven major tasks, one of which is the development and refinement of Bison models for higher burnup applications. This task is broken down into six targeted areas of development and refinement including: formation of high burnup structure, fuel fracture and pulverization, transient fission gas release, axial gas communication within a fuel rod, cladding ballooning and burst, and axial fuel relocation. This report summarizes the models for both the fuel and cladding in Bison for high burnup application, identifies the areas of development and refinement necessary to enhance the Bison capabilities to be used in the coupled simulation tool with RELAP5-3D. Integration and regression testing to demonstrate proper implementation of the new features in Bison is highlighted.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

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

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

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

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

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

Kareem, Afeez↗

DOE OSTI2025

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

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

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Status of the Fuel Fragment Dispersal Studies at Oak Ridge National Laboratory

During a loss-of-coolant accident, a nuclear fuel rods undergo balloon and burst. High burnup fuel is known to fragment and pulverize leading to the potential for the fuel to disperse through the burst opening either during the initial burst or following the burst during the reflood event. This milestone summarizes the design and assembly of a system to study dispersal in a postburst event. Surrogate fuel material (HfO 2 , tungsten, and yttria-stabilized zirconia [YSZ]) dispersing from as-burst loss-of-coolant accident (LOCA) test specimens was extensively investigated, along with dispersal of actual nuclear fuel following a LOCA Severe Accident Test Station (SATS) test.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Transformational Sorbent System for Post-Combustion Carbon Capture (Final Report)

As part of this DOE Contract (Transformational Sorbent System for Post-Combustion Carbon Capture, DE-FE0031734),TDA Research Inc. developed a transformational sorbent system for post combustion CO 2 capture process that captures more than 95% of CO 2 emissions from a coal fired power plant, recovering CO 2 at 95% purity with a cost of CO 2 capture significantly lower than with amine-based system (~$30 per tonne (MT) of CO 2 captured). TDA’s transformational sorbent system uses a novel, highly stable, high-capacity metal organic framework (MOF) based CO 2 sorbent in a new vacuum/concentration swing adsorption (VCSA) process that allows us to use high efficiency vacuum pumps with a low auxiliary load. A pulverized coal fired power plant equipped with TDA’s transformational sorbent system for post combustion CO 2 capture is expected to efficiently produce electricity with a low Cost of Electricity (COE) and capture greater than 95% of the CO 2 from the power plant exhaust.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Status of the Fuel Fragment Dispersal Studies at Oak Ridge National Laboratory

During a loss-of-coolant accident, a nuclear fuel rods undergo balloon and burst. High burnup fuel is known to fragment and pulverize leading to the potential for the fuel to disperse through the burst opening either during the initial burst or following the burst during the reflood event. This milestone summarizes the design and assembly of a system to study dispersal in a postburst event. Surrogate fuel material (HfO2, tungsten, and yttria-stabilized zirconia [YSZ]) dispersing from as-burst loss-of-coolant accident (LOCA) test specimens was extensively investigated, along with dispersal of actual nuclear fuel following a LOCA Severe Accident Test Station (SATS) test. Surrogate material tests spanned a variety of burst geometries, particle types, particle size distributions, and rod oscillation loadings (frequency and amplitude combinations).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Development of Next Generation Hierarchical Hybrid Cu-Si anode Batteries via Direct-Ink Writing Application: End of (6th) Month Report - November 2025

Sustainable renewable energy continues to be in dire need to effectively combat global warming. Emerging technology for electric vehicles/ devices remains in high demand that is not only lower in cost, more efficient, but safer in comparison to commercial materials on the market. Although first-generation lithium-ion batteries have exhibited extensive commercial application, conventional graphite no longer meets this increasing demand as an efficient anode material. Due to the fact that graphite has a subpar theoretical specific capacity (372 mAh g -1 ), thus significant limitations in rate capability (for potential faster charging at higher C-rates currently commercially available.). Alternatively, silicon has gained significant attention as a superior candidate to potentially surpass graphite. Due to silicon’s exceedingly high theoretical capacity (4,200 mAh g -1 ) in comparison to standard graphite, its abundance thus in turn it’s low-cost, in addition to exhibiting a significantly low working potential (< 0.4 V vs Li/Li + ). However, one of the main (and most detrimental) challenges is silicon’s tendency to expand in volume (> 300%) upon discharge as it begins the lithiation process. As a direct result, it causes not only for the particles to both crack and pulverize under mechanical stress as the volume continues to expand and contract during cycling. Upon assembling the cell, it needs to undergo ‘charging’ for initially discharging/ ‘activating’ the cell, otherwise commonly known as the ‘formation’ step. As a result a solid electrolyte interface (SEI) layer begins to form at the anode surface because some of the electrolyte begins to react during the formation process. However, this (SEI) layer is deemed as a ‘protective’ interlayer because in theory it prevents further reaction as the cell continues to cycle. However, due to the volume change it causes significant degradation at the interface. As cracking starts to occur at the anode surface, it results in a ‘new’ altered surface with each cycle that causes further reaction with the electrolyte as a byproduct quickly consuming active Li/ and more electrolyte. Thus, fracturing this ‘protective layer,’ causing significantly higher impedance as a result, and in turn a decline in capacity due to active Li-loss. In addition to the active material exfoliating off from the current collector, further contributing to the steady decline in capacity and overall performance. Current state of the art Si-anode batteries on the market range between a maximum content of 5-10 Si wt%. It has been previously reported Tesla has utilized SiO x -C anodes containing 5 wt% Si within their ‘Model 3/ Model X’ electric vehicles. However, more recent ‘Model 3’ vehicles have started to incorporate 10 Si wt%, in which they were able to increase their energy density upwards by approximately 30%. Recent effort has been focused on continuing to increase the wt% of Si being utilized, eventually to 100 wt% of Si, to maximize the energy density even further.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Process Design and Techno-Economic Analysis of the Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Biomass

This work describes the process design and techno-economic analysis (TEA) of the modular SPOC power plant for biomass firing and coal-biomass co-firing. Two Rankine cycles were considered: a supercritical steam cycle (242 bar, 593°C, 593°C) with 550 MWe net output and a subcritical cycle (166 bar, 566°C, 566°C) with 200 MWe net output. For both cases, 95% carbon capture was modeled, and hybrid poplar biomass was chosen to generate carbon-negative power. In addition, the supercritical 500 MWe case included a 25% biomass co-firing (carbon neutral) case. For both cycles, a 100% Powder River Basin coal firing case was used for comparison purposes. In the SPOC process, oxygen is produced via a cryogenic air separation unit (ASU) and the heat generated from the compression of air is integrated into the steam cycle and utilized for boiler feed water pre-heating. Unique to the SPOC process, the boilers are pressurized and arranged in a series-parallel configuration, with minimized flue gas recirculation. The flue gas is cooled and scrubbed in the direct-contact cooler (DCC) column, and the moisture in the flue gas is condensed, leaving the bottom of the DCC at a sufficiently high temperature such that it can be used for boiler feed water pre-heating, improving plant thermal efficiency. Following drying and purification, CO2 in the flue gas is at the purity required for storage or utilization. The performance data were obtained from process modelling via Aspen Plus®. The stream data from Aspen Plus® were used as an input for the AACE Class 5 cost study. Ultimately, the capital costs, Levelized Cost of Electricity (LCOE), and cost of CO2 captured and avoided were obtained. The HHV efficiency of the carbon negative 550 MWe supercritical SPOC case (34.8%) was clearly above those reported by NETL for the BECCS baseline cases of supercritical pulverized coal with capture (B12B, 31.5%) and the 49% biomass co-firing case with capture (PA3, 29.2%). The HHV efficiency of the carbon-negative subcritical plant is also higher than the subcritical baseline PC plant with capture (case B11B.95) presented by NETL (32% vs 29.7%). The LCOE for the SPOC 100% biomass case was similar to the LCOE for the BECCS 49% biomass with carbon capture case ($147/MWh), and the SPOC carbon neutral case LCOE was lower ($110/MWh) than the cost for the NETL baseline SC coal firing case with 90% carbon capture ($114/MWh).

Magalhaes, Duarte↗

DOE OSTI2023

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

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

Li, Lei↗

DOE OSTI2023

A numerical investigation of coal particle modeling for the inlet section of a pressurized oxy-combustion burner

Concerns over climate change have led to numerous efforts to develop low-carbon technologies, and pressurized oxy-combustion (POC) is a promising candidate to reduce carbon emissions in the power industry. Designing an effective burner for such technologies is vital for the development of these and other coal combustion technologies. Because of the high pressure, the volume fraction of coal particles at the fuel inlet of the pressurized oxy-combustor burner is close to or even higher than the maximum limit for commercial CFD codes (e.g., ANSYS FLUENT). At these high particle volume fractions, the interactions among particles, fluid flow and wall need to be re-evaluated. The present computational work is a first step in a systematic analysis of the influence of various parameters, like method of particle release, release location, and particle size, in a pilot-scale POC combustor, developed at Washington University in St. Louis (WUSTL). In the POC process, pulverized coal is burned under elevated pressure in an O2-CO2 environment. Specifically, a 15-bar, 100 kWth, POC combustor is modeled employing Ansys FLUENT commercial sodtware using the Reynolds-Averaged Navier-Stokes (RANS) approach. It is revealed that for this pilot-scale, pressurized burner, velocity profiles in the near-wall region exhibit some anomalies. In order to investigate the influence of particle loading in the near-wall region, particle release location was investigated. The numerical simulations incorporate the coupling between the turbulent flow and the particles. A sensitivity investigation of particle release location found that by tuning the release location, the velocity profile can be consistent with the pure gas flow velocity profile. More importantly, the particle releasing location also affects flame stability. Particle size was also found to have a significant impact on particle trajectory, flame stability and temperature. Finally, Large Eddy Simulations (LES) were performed and compared with the results from two-dimensional RANS.

Li, Lei↗