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Ducting arrangement with injector assemblies arranged in an expanding cross-sectional area of a downstream combustion stage in a gas turbine engine
A ducting arrangement (10) in a combustion stage downstream of a main combustion stage of a gas turbine engine is provided. A duct (18) is fluidly coupled to receive a cross-flow of combustion gases from the main combustion stage. Duct (18) includes a duct segment (23) with an expanding cross-sectional area (24) where one or more injector assemblies (26) are disposed. Injector assembly (26) includes one or more reactant-guiding structures (27) arranged to deliver a flow of reactants into the downstream combustion stage to be mixed with the cross-flow of combustion gases. Disclosed injector assemblies are arranged in expanding cross-sectional area (24) to reduce total pressure loss while providing an effective level of mixing of the injected reactants with the passing cross-flow. Respective duct components or the entire ducting arrangement may be formed as a unitized structure, such as a single piece using a rapid manufacturing technology, such as 3D Printing/Additive Manufacturing (AM) technologies.
Staged combustion with piston engine and turbine engine supercharger
A combustion engine method and system provides increased fuel efficiency and reduces polluting exhaust emissions by burning fuel in a two-stage combustion system. Fuel is combusted in a piston engine in a first stage producing piston engine exhaust gases. Fuel contained in the piston engine exhaust gases is combusted in a second stage turbine engine. Turbine engine exhaust gases are used to supercharge the piston engine.
A semi-empirical NO x model for LES in pulverized coal air-staged combustion
Numerical simulation of pulverized coal combustion with the large eddy simulation (LES) method can provides important instructions on the design optimization of boilers. Because of its huge computational cost, a simple but reliable NO x prediction model is required in LES. Through the air-staged combustion experiments of six kinds of coals which conducted in an electric heated down-fired furnace (DFF), the relationship between NO x reduction and CO+H 2 generation in the fuel-rich zone was identified. Based on this observation, a semi-empirical modeling strategy was proposed: instead of CHi which is difficult to calculate, the concentration of CO+H 2 is used to quantify NO homogeneous reduction. An integrated NO x prediction model was proposed and implemented into LES simulation. Here, the results proved the new model can accurately predict different NO x evolution characteristics under various conditions. Furthermore, the comparison indicated the LES method performs better on NO x prediction than the RANS method, especially in the area where the turbulent fluctuation is relatively stronger.
Lean-rich axial stage combustion in a can-annular gas turbine engine
An apparatus and method for lean/rich combustion in a gas turbine engine (10), which includes a combustor (12), a transition (14) and a combustor extender (16) that is positioned between the combustor (12) and the transition (14) to connect the combustor (12) to the transition (14). Openings (18) are formed along an outer surface (20) of the combustor extender (16). The gas turbine (10) also includes a fuel manifold (28) to extend along the outer surface (20) of the combustor extender (16), with fuel nozzles (30) to align with the respective openings (18). A method (200) for axial stage combustion in the gas turbine engine (10) is also presented.
Extending the Operating Envelope for an Extremely Low NOx Axial Stage Combustion System
The overall goal of this program is to develop a low NOx combustion system which enables a gas turbine combined cycle efficiency of > 65%. The proposed combustion system is a combination of three advanced technologies under development by the Recipient: advanced transition design, the Distributed Combustion System (DCS), and advanced head end. Of note is that the DCS and advanced transition were initially developed with DOE funding under previous Cooperative Agreements. The continued development of these designs has resulted in a proof of concept design which was successfully tested in the Recipient’s state-of-the-art high-pressure rig. The initial rig testing indicated a substantial benefit with respect to high firing temperature operation as well as low NOx operation for the advanced transition and the DCS. Even lower NOx and higher firing temperatures are possible with the addition of the advanced head end to the design. Potential hurdles to the combustion design have been identified, such as high pressure drop and acoustics. The goal of this program is to develop variations of this design which address these hurdles and create an optimized design for implementation into the Recipient’s new high efficiency gas turbine engine.
Improving Flexibility and Performance of Staged Pressurized Oxy-Combustion
Staged pressurized oxy-combustion (SPOC) is a novel coal combustion power technology being developed by Washington University in St. Louis (WUSTL) that offers the potential to deliver low-carbon power at a reduced cost. Oxy-combustion plants operate by removing most of the nitrogen contained in air prior to combustion, thereby burning fuel in a near-pure oxygen stream instead of air. This combustion produces a flue gas containing primarily carbon dioxide (CO 2 ) and water vapor that allows relatively straightforward CO 2 capture. First-generation, atmospheric oxy-combustion technology relies on a flue gas recycle (FGR) diluent to reduce the peak temperatures achieved and the resulting high thermal radiation levels that would otherwise occur in a fuel/oxygen only flame. In contrast, by staging the combustion in several steps, SPOC reduces the peak temperatures of combustion without resorting to a high degree of FGR to control flame temperatures. The SPOC process operates by utilizing two or more pressurized boiler modules connected in series to produce fuel staging; hence, only a portion of the fuel is combusted in any given combustion module. Subsequently the thermal energy released at each stage can be captured and removed from the gases prior to subsequent stages, when more fuel is introduced. This allows the SPOC process to operate with minimal FGR, avoiding the associated efficiency losses and additional costs. While the staging controls the heat release profile in SPOC, operating in a pressurized condition yields a more compact system, reducing modular boiler size and delivering enhanced heat transfer. Additionally, operating at elevated pressures ensures that the latent heat of moisture available from moisture in the fuel and generated by the combustion of the hydrogen content in the fuel can be captured as useful thermal energy for steam turbine integration. This is possible due to elevated dew point from the high partial pressure of the moisture generated in this process, which allows substantial feedwater heater bypassing to be achieved. The inclusion of this thermal energy, normally lost to the atmosphere in traditional combustion processes or to cooling systems in atmospheric oxy-combustion, allows the resultant net efficiency of the SPOC system to be up to 6 percentage points greater than first-generation systems. To begin the process of developing this technology for full-scale application, the Electric Power Research Institute, Inc. teamed up with WUSTL, American Air Liquide, Doosan Babcock, and the U.S. Department of Energy to investigate a practical and workable boiler design concept that would minimize process risks where possible. The SPOC system offers unique process flexibility opportunities due to the staged nature of the combustion, making it a prime candidate for future primary energy delivery where the ability to operate at reduced load in an efficient manner and ramp rapidly will be valuable for balancing intermittent renewable electricity generation. The efficiency of traditional coal-fired power plants is lower at reduced loads below the steam temperature control range due to the challenges in balancing the heat pickup between radiative and convective superheater and reheater surface. Introducing additional heating surface for optimal extended controlled low load operation will likely lead to excessive attemperation at high loads, ultimately leading to a poorer overall cycle efficiency. The SPOC process can facilitate the adjustment of fuel firing rates between stages, targeting heat pickup to where it is most needed and potentially can shut down stages for low-load operation, facilitating an increased steam temperature control range on turndown. The boiler design concept assessment is being carried out to identify the maximum permissible compactness of the SPOC boiler heating surfaces. The assessment will determine the minimum overall height that will deliver appropriate tube operating metal temperatures at full load and achieve rated reheat steam temperatures at low operating loads, balanced against the needs of efficient coal combustion, and the potential resultant slagging and ash environments. The design parameters are being validated by combustion testing in the 100-kWth pressurized combustion test rig at WUSTL. Parameters being investigated include flame stability, fuel burnout, ash composition, radiative heat flux, and temperature profiles. These are being carried out for a range of inlet gas conditions and compositions and at multiple load conditions to investigate combustion stability at reduced load. The results of this testing inform the modeling of the large-scale system, that was sized at 550 MWe to allow direct comparison with the National Energy Technology Laboratory baseline cases for atmospheric oxy-combustion, air firing, and air firing with post-combustion capture.
Performance and flexibility improvements of Staged Pressurized Oxy-Combustion
Staged Pressurized Oxy-Combustion (SPOC) is a low-carbon coal combustion power technology being developed by Washington University in St. Louis (WUSTL). Oxy-combustion plants enable straightforward capture of carbon dioxide (CO 2 ) by removing most of the nitrogen in the combustion air prior to use, thereby burning fuel in near-pure oxygen instead of air, producing a flue gas containing primarily CO 2 and water. CO 2 capture at amounts > 90% is possible, often using cryogenic air separation. Oxy-combustion typically relies on flue gas recycle (FGR) to reduce the peak temperature and radiation that would otherwise occur in a fuel/oxygen only flame. SPOC reduces the peak temperatures of combustion by utilizing two or more pressurized boiler modules connected in series to produce fuel staging; hence, only a portion of the fuel is combusted in any given furnace module. This means that the thermal energy released at each stage can be captured and removed from the gases prior to subsequent stages, when more fuel is introduced. This allows the SPOC process to operate with minimal FGR, avoiding the associated efficiency losses and additional costs. Also, the process operates at an elevated gas-side pressure, reducing boiler size, enhancing heat transfer to achieve a compact boiler configuration as compared to an atmospheric-pressure boiler design, and allowing for recovery of the latent heat of the water from the flue gas at a temperature useful to the steam cycle. The resultant net efficiency of the system is over 3 percentage points greater than traditional atmospheric-pressure oxy-combustion, and 7 percentage points greater than the post combustion variant, representing a step-change improvement over first-generation capture technologies. To further develop the concept, WUSTL and the Electric Power Research Institute, Inc., organized a project with American Air Liquide, Inc., Doosan Babcock Limited, and the U.S. Department of Energy to investigate a practicable and workable boiler design. The team has identified the potential for enhanced process flexibility for controlling power generation over a wider load range than is normally available to conventional coal-fired power plants due to the staged nature of the heat release. With increasing intermittent renewable generator contribution, on-demand generators need to be highly flexible to participate in the future energy market, requiring extensive operation at reduced load. Conventional coal-fired steam generators typically face challenges in maintaining temperature control of the reheat steam and main steam at reduced loads. This results in inefficient operation, both in terms of the boiler efficiency and steam turbine heat rate. The results of this project show the SPOC process is capable of exceptional turndown, both on a stage basis and with the ability to bypass entire stages. Oxygen-supply flexibility was also investigated, as this is also a key consideration for the overall flexibility of the SPOC process given the operating constraints of conventional air separation units. A boiler design concept assessment was conducted and was focused on delivering compact and constructible design. The assessment checked appropriate tube operating metal temperatures at full load and at lower operating loads, balanced against the needs of efficient coal combustion, and the resultant slagging and ash environments. Combustion testing in the 100-kWth pressurized combustion test rig at WUSTL was carried out to validate the combustion, heat flux profiles and burnout at multiple loads. Combustion parameters investigated were flame stability, fuel burnout, ash composition, radiative heat flux, and temperature profiles. The results of these tests formed the basis of a full-scale boiler design that will encompass improvements in both efficiency and flexibility over conventional oxy-combustion processes. The air separation unit flexibility was investigated, and associated cost implications were addressed. Detailed economic assessment results for a 550 MWe net power block are also provided, allowing for a comparison against the baseline NETL oxy-combustion and post combustion capture cases.
COMBUSTION AND EMISSION CHARACTERISTICS OF A LEAN AXIAL-STAGE COMBUSTOR
Gas turbine engines with high operational flexibility represent an important area of research. In support of this, the reduction of NOx emissions at high-temperature, full-load conditions are the main target of this research study. To overcome the challenge of decreasing the residence time of hot exhaust gas in the burner, the approach of axial-staged combustion has been used, which aims to burn at lean conditions. A main combustion stage with a conventional burner is followed by a jet-in-crossflow (JIC) stage downstream. This second combustion stage, the test section, burns well over a third of the total fuel amount, which is added by a jet inlet. A steady Computational Fluid Dynamics (CFD) model in Star-CCM+ was created to analyze the JIC stage. A structured mesh grid with 1.7 million cells and local refinement domains was used along with RANS equations, Realizable k-ε turbulence, Complex Chemistry model with Laminar Flame Concept (LFC) applied. The findings of the computational model include a detailed description of the flow field, focusing on vortex formation and penetration depth. Three vortex types and local pressure losses of up to 6% in the mixing domain were identified. Results were compared with similar data from literature and a very good match was yielded. Optical laser diagnostics should work well to capture the predicted flow penetration. The highest local reaction rates were observed inside a thin flame front, 4 to 6 diameters downstream of the jet. The jet showed a limited expansion into the available channel domain, resulting in low heat release and a methane conversion of only 52%. Providing an enhanced amount of oxygen was proven to increase the CH4 conversion significantly. Emissions were analyzed for an estimated species composition from the main burner. A CO production of 9.85‰ and the reduction of an incoming NOx amount by 15% were determined, outlining the potential of axial-staged combustion. Further numerical investigation along with experimental verification is in progress.
A cost-benefit analysis of a pellet boiler with electrostatic precipitator versus conventional biomass technology: A case study of an institutional boiler in Syracuse, New York
Background: Biomass facilities have received increasing attention as a strategy to increase the use of renewable fuels and decrease greenhouse gas emissions from the electric generation and heating sectors, but these facilities can potentially increase local air pollution and associated health effects. Comparing the economic costs and public health benefits of alternative biomass fuel, heating technology, and pollution control technology options provides decision-makers with the necessary information to make optimal choices in a given location. Methods: For a case study of a combined heat and power biomass facility in Syracuse, New York, we used stack testing to estimate emissions of fine particulate matter (PM{sub 2.5}) for both the deployed technology (staged combustion pellet boiler with an electrostatic precipitator) and a conventional alternative (wood chip stoker boiler with a multicyclone). We used the atmospheric dispersion model AERMOD to calculate the contribution of either fuel-technology configuration to ambient primary PM{sub 2.5} in a 10 km×10 km region surrounding the facility, and we quantified the incremental contribution to population mortality and morbidity. We assigned economic values to health outcomes and compared the health benefits of the lower-emitting technology with the incremental costs. Results: In total, the incremental annualized cost of the lower-emitting pellet boiler was $190,000 greater, driven by a greater cost of the pellet fuel and pollution control technology, offset in part by reduced fuel storage costs. PM{sub 2.5} emissions were a factor of 23 lower with the pellet boiler with electrostatic precipitator, with corresponding differences in contributions to ambient primary PM{sub 2.5} concentrations. The monetary value of the public health benefits of selecting the pellet-fired boiler technology with electrostatic precipitator was $1.7 million annually, greatly exceeding the differential costs even when accounting for uncertainties. Our analyses also showed complex spatial patterns of health benefits given non-uniform age distributions and air pollution levels. Conclusions: The incremental investment in a lower-emitting staged combustion pellet boiler with an electrostatic precipitator was well justified by the population health improvements over the conventional wood chip technology with a multicyclone, even given the focus on only primary PM{sub 2.5} within a small spatial domain. Our analytical framework could be generalized to other settings to inform optimal strategies for proposed new facilities or populations. - Highlights: • PM{sub 2.5} emissions vary greatly across alternative biomass fuels and technologies. • A pellet boiler had a factor of 23 lower emissions than a conventional alternative. • The incremental annualized cost of the lower-emitting technology was $190,000. • The monetary value of annual health benefits of reduced emissions was $1.7 million. • Our analytical framework provides insight about optimal biomass technologies.
Evaluation of Spray and Combustion Models for Simulating Dilute Combustion in a Direct-Injection Spark-Ignition Engine
Dilute combustion in spark-ignition engines has the potential to improve thermal efficiency by mitigating knock and by reducing throttling and wall heat losses. However, ignition and combustion processes can become unstable for dilute operation due to a lowered laminar flame speed, resulting in excessive cycle-to-cycle variability (CCV) of the combustion process. To compensate for the slower combustion in less reactive mixtures, a modified intake port geometry can be employed to generate a strong tumble flow in the cylinder and elevate turbulence levels around the spark plug, thereby promoting a faster transition to turbulent deflagration. Consequently, optimizing combustion chamber geometry and operating strategy is crucial to maximizing the benefits of using dilute combustion with enhanced in-cylinder turbulence across a wide range of operating conditions. Computational fluid dynamics (CFD) simulations can be utilized for virtual engine optimization tasks, but this would require the models to be truly predictive regarding the impact of changes to the engine design and operational parameters.In this study, multicycle large-eddy simulations (LES) are performed for a direct-injection spark-ignition engine to investigate the model performance in predicting engine combustion characteristics with respect to changes in the intake configuration. A tumble plate that blocks the lower part of the intake port inlet is used to vary the tumble. A set of CFD models that have been recently developed are employed, which takes into account the drag of nonspherical droplets, flash-boiling behavior of liquid sprays, spray-wall interaction, surrogate formulation of a research-grade E10 gasoline, and fast chemical kinetic solvers. Simulation results are compared to experimental engine data in terms of cylinder pressure, apparent heat release rate, mass fraction burned timing, and flame images. It is found that LES employing the state-of-the-art CFD models are capable of properly predicting the spray processes and reproducing the measured mean cylinder pressure for the case with the tumble plate. On the other hand, the LES over-predicts the combustion rate during the early combustion stage and under-estimates the CCV, and these discrepancies become larger when the tumble plate is removed.
Consequences of sludge composition on combustion performance derived from thermogravimetry analysis
Highlights: • Volatiles, particularly proteins, play a key role in sludge combustion. • Sludge combustion performance varies with different sludge organic concentrations. • Carbohydrates significantly affect the combustion rate in the second stage. • Combustion performance of digested sludge is more negative compared with others. - Abstract: Wastewater treatment plants produce millions of tons of sewage sludge. Sewage sludge is recognized as a promising feedstock for power generation via combustion and can be used for energy crisis adaption. We aimed to investigate the quantitative effects of various sludge characteristics on the overall sludge combustion process performance. Different types of sewage sludge were derived from numerous wastewater treatment plants in Beijing for further thermogravimetric analysis. Thermogravimetric–differential thermogravimetric curves were used to compare the performance of the studied samples. Proximate analytical data, organic compositions, elementary composition, and calorific value of the samples were determined. The relationship between combustion performance and sludge composition was also investigated. Results showed that the performance of sludge combustion was significantly affected by the concentration of protein, which is the main component of volatiles. Carbohydrates and lipids were not correlated with combustion performance, unlike protein. Overall, combustion performance varied with different sludge organic composition. The combustion rate of carbohydrates was higher than those of protein and lipid, and carbohydrate weight loss mainly occurred during the second stage (175–300 °C). Carbohydrates have a substantial effect on the rate of system combustion during the second stage considering the specific combustion feature. Additionally, the combustion performance of digested sewage sludge is more negative than the others.
Fireside Corrosion
Oxy-fuel fireside research goals are: (1) determine the effect of oxyfuel combustion on fireside corrosion - flue gas recycle choice, staged combustion ramifications; and (2) develop methods to use chromia solubility in ash as an ash corrosivity measurement - synthetic ashes at first, then boiler and burner rig ashes.
Development of Computational Capabilities to Predict the Corrosion Wastage of Boiler Tubes in Advanced Combustion Systems
A comprehensive corrosion research project consisting of pilot-scale combustion testing and long-term laboratory corrosion study has been successfully performed. A pilot-scale combustion facility available at Brigham Young University was selected and modified to enable burning of pulverized coals under the operating conditions typical for advanced coal-fired utility boilers. Eight United States (U.S.) coals were selected for this investigation, with the test conditions for all coals set to have the same heat input to the combustor. In addition, the air/fuel stoichiometric ratio was controlled so that staged combustion was established, with the stoichiometric ratio maintained at 0.85 in the burner zone and 1.15 in the burnout zone. The burner zone represented the lower furnace of utility boilers, while the burnout zone mimicked the upper furnace areas adjacent to the superheaters and reheaters. From this staged combustion, approximately 3% excess oxygen was attained in the combustion gas at the furnace outlet. During each of the pilot-scale combustion tests, extensive online measurements of the flue gas compositions were performed. In addition, deposit samples were collected at the same location for chemical analyses. Such extensive gas and deposit analyses enabled detailed characterization of the actual combustion environments existing at the lower furnace walls under reducing conditions and those adjacent to the superheaters and reheaters under oxidizing conditions in advanced U.S. coal-fired utility boilers. The gas and deposit compositions were then carefully simulated in a series of 1000-hour laboratory corrosion tests, in which the corrosion performances of different commercial candidate alloys and weld overlays were evaluated at various temperatures for advanced boiler systems. Results of this laboratory study led to significant improvement in understanding of the corrosion mechanisms operating on the furnace walls as well as superheaters and reheaters in coal-fired boilers resulting from the coexistence of sulfur and chlorine in the fuel. A new corrosion mechanism, i.e., “Active Sulfidation Corrosion Mechanism,” has been proposed to account for the accelerated corrosion wastage observed on the furnace walls of utility boilers burning coals containing sulfur and chlorine. In addition, a second corrosion mechanism, i.e., “Active Sulfide-to-Oxide Corrosion Mechanism,” has been identified to account for the rapid corrosion attack on superheaters and reheaters. Both of the newly discovered corrosion mechanisms involve the formation of iron chloride (FeCl2) vapor from iron sulfide (FeS) and HCl, followed by the decomposition of FeCl2 via self-sustaining cycling reactions. For higher alloys containing sufficient chromium, the attack on superheaters and reheaters is dominated by Hot Corrosion in the presence of a fused salt. Furthermore, two stages of the hot corrosion mechanism have been identified and characterized in detail. The initiation of hot corrosion attack induced by molten sulfate leads to Stage 1 “acidic” fluxing and re-precipitation of the protective scale formed initially on the deposit-covered alloy surfaces. Once the protective scale is penetrated, Stage 2 Hot Corrosion is initiated, which is dominated by “basic” fluxing and re-precipitation of the scale in the fused salt. Based on the extensive corrosion information generated from this project, corrosion modeling was performed using non-linear regression analysis. As a result of the modeling efforts, two predictive equations have been formulated, one for furnace walls and the other for superheaters and reheaters. These first-of-the-kind equations can be used to estimate the corrosion rates of boiler tubes based on coal chemistry, alloy compositions, and boiler operating conditions for advanced boiler systems.
Fireside Corrosion USC Steering
Oxy-Fuel Fireside Research goals are: (1) Determine the effect of oxy-fuel combustion on fireside corrosion - (a) Flue gas recycle choice, Staged combustion ramifications, (c) JCOAL Collaboration; and (2) Develop methods to use chromia solubility in ash as an 'ash corrosivity' measurement - (a) Synthetic ashes at first, then boiler and burner rig ashes, (b) Applicable to SH/RH conditions.
Detection of low Temperature heat release (LTHR) in the standard Cooperative Fuel Research (CFR) engine in both SI and HCCI combustion modes
To this date, extensive research has been conducted to understand the low-temperature auto-ignition chemistry of gasoline. The detection of low-temperature chemical reactions under Spark Ignition (SI) combustion cannot be detected, as they are hidden by the flame propagation. Alternatively, Homogeneous Charge Compression Ignition (HCCI) combustion has a two-stage combustion involving low and high-temperature heat release (LTHR and HTHR respectively). Both Knocking SI and HCCI combustion involve auto-ignition and are governed by fuel characteristics and the pressure-temperature (P-T) history. Therefore, HCCI combustion might provide an alternative to understand the knocking behavior and LTHR in modern SI engines. A standard Cooperative Fuel Research (CFR) engine was operated at lean HCCI conditions (lambda 3), as well as SI conditions at stoichiometry. For SI combustion, the CFR engine was operated with RON-like conditions, but at late spark timing to induce LTHR prior to flame propagation. Three RON 90 binary fuel blends were investigated, being composed of n-heptane with isooctane, toluene, or ethanol. This work demonstrated that the CFR engine under stoichiometric SI with late spark timing and HCCI combustion mode can help to detect LTHR which is not possible in the standard RON test. The intake pressure and temperature sweeps showed similar effects on LTHR for both combustion modes. The linking of auto-ignition behavior of SI and HCCI was dependent primarily on intake valve closing (IVC) conditions. In conclusion, the high exhaust temperature in SI lead to high IVC temperatures. In order to match the IVC temperatures and to overlap the P-T trajectories, the intake temperature for HCCI was increased.
Enabling Staged Pressurized Oxy Combustion (SPOC): Improving Flexibility and Performance at Reduced Cost
Staged Pressurized Oxy-Combustion (SPOC) is a coal combustion power technology being developed by Washington University in St. Louis (WUSTL) that offers the potential to deliver low-carbon power at a reduced cost. Traditional oxy-combustion plants remove most of the nitrogen in air prior to combustion, thereby burning fuel in oxygen instead of air, producing a flue gas containing primarily CO 2 and water that allows relatively simple CO 2 capture at amounts > 90%. This technology relies on flue gas recycle (FGR) to reduce the peak temperature and radiation that would otherwise occur in a fuel/oxygen only flame. SPOC reduces the peak temperatures of combustion by utilizing two or more pressurized boiler modules connected in series to produce fuel staging; hence, only a portion of the fuel is combusted in any given furnace module. This means that the thermal energy released at each stage can be captured and removed from the gases prior to subsequent stages, when more fuel is introduced. This allows the SPOC process to operate with minimal FGR, avoiding the associated efficiency losses and additional costs. The SPOC process operates at an elevated gas-side pressure, reducing boiler size, enhancing heat transfer to achieve a compact boiler configuration as compared to an atmospheric-pressure boiler design, and allowing the recovery of the latent heat of the water from the flue gas at a temperature useful to the steam cycle. The resultant net efficiency of the system is up to 6 percentage points greater than traditional atmospheric-pressure oxy-combustion, representing a step-change improvement over first-generation oxy-combustion technologies. WUSTL has teamed up with the Electric Power Research Institute, Inc., American Air Liquide, Inc., Doosan Babcock Limited, and the U.S. Department of Energy to develop a practicable and workable boiler design concept associated with the application of SPOC. In particular, due to the staged nature of the heat release, the team has identified the potential for enhanced process flexibility for controlling power generation over a wider load range than is normally available to conventional coal-fired power plants. Improved flexibility is a critical need as coal power plants are being tasked with providing grid stability to balance the growth of intermittent renewables. Not only is flexible operation important, achieving efficient power generation at reduced loads will be key as the plants are likely to operate in this regime for significant periods of time as more renewables become available. At reduced loads, coal-fired steam generators typically face challenges in maintaining temperature control of the reheat steam and to a lesser extent the main steam due to the heat transfer characteristics of these circuits when flue gas quantities are lower. This results in inefficient operation, both in terms of the boiler efficiency and steam turbine heat rate. Since the SPOC process can be configured to deliver targeted heat input to each boiler circuit by adjusting the relative fuel firing rate of each stage, better temperature control can be achieved during dynamic conditions. Oxygen supply flexibility is also a key consideration for the overall flexibility of the SPOC process given the operating constraints of conventional air separation units. The boiler design concept assessment is being carried out to identify the maximum permissible compactness of the SPOC boiler heating surfaces. The assessment will determine the minimum overall height that will deliver appropriate tube operating metal temperatures at full load and achieve rated reheat steam temperatures at low operating loads, balanced against the needs of efficient coal combustion, and the resultant slagging and ash environments. The design parameters are being validated by combustion testing in the 100-kWth pressurized combustion test rig at WUSTL. Testing results and model validation that form the basis of a full-scale boiler design that will encompass both efficiency and flexibility improvements over conventional oxy-combustion processes will be presented.
Low-Temperature Combustion of High Octane Fuels in a Gasoline Compression Ignition Engine
Gasoline Compression Ignition (GCI) has been shown as one of the advanced combustion concepts that could potentially provide a pathway to achieve cleaner and more efficient combustion engines. Fuel and air in GCI are not fully premixed as compared to homogeneous charge compression ignition (HCCI) which is a completely kinetic-controlled combustion system. Therefore, the combustion phasing can be controlled by the time of injection, usually post injection in a multiple-injection scheme, to mitigate combustion noise. Gasoline fuels ignite more difficult than Diesel. The autoignition quality of gasoline can be indicated by research octane number (RON). Fuels with high octane tend to have more resistance to auto-ignition, hence more time for fuel-air mixing. In this study, three fuels, namely, Aromatic, Alkylate, and E30, with similar RON value of 98 but different hydrocarbon compositions were tested in a multi-cylinder engine under GCI combustion mode. Considerations of EGR, start of injection (SOI), and boost were investigated to study the sensitivity of dilution, local stratification, and reactivity of the charge, respectively, for each fuel. Combustion phasing was kept constant during the experiments to the changes in ignition and combustion process before and after 50% of the fuel mass is burned. Emission characteristics at different levels of EGR and lambda were revealed for all fuels with E30 having the lowest filter smoke number (FSN) and was also most sensitive to the change in dilution. Reasonably low combustion noise (< 90 dB) and stable combustion (COVIMEP < 3%) were maintained during the experiments. The second part of this paper contains visualization of the combustion process obtained from endoscope imaging for each fuel at selected conditions. Soot radiation signal from GCI combustion were strong during late injection, and also more intense at low EGR conditions. Furthermore, soot/temperature profiles indicated only the high-temperature combustion period, while cylinder pressure-based heat release rate (HRR) showed a two-stage combustion phenomenon.