COAL-WATER SLURRY FUEL COMBUSTON TESTNG N AN OL-FRED NDUSTRAL BOLER Semannual Techncal Progress Report for the Perod 2/15/1994 to 8/15/1994 Bruce G. Mller, Co-Prncpal nvestgator Alan W. Scaron, Project Manager November 3,1994 Work Performed Under Cooperatve Agreement No. DE-FC22-89PC88697 For US. Department of Energy Pttsburgh Energy Technology Center Pttsburgh, Pennsylvana BY Energy and Fuels Research Center The Pennsylvana State Unversty Unversty Park, Pennsylvana DSCLAMER Ths report was prepared as an account of work sponsored by an agency of the Unted States Government. Nether the Unted States Government nor any agency thereof, nor any of ther employees, makes any warranty, express or mpled, or assumes any legal lablty or responsblty for the accuracy, completeness, or usefulness of any nformaton, apparatus, product, or process dsclosed, or represents that ts use would not nfrnge prvately owned rghts. Reference heren to any specfc commercal product, process, or servce by trade name, trademark, manufacturer, or otherwse does not necessarly consttute or mply ts endorsement, recommendaton, or favorng by the Unted States Government or any agency thereof. The vews and opnons of authors expressed heren do not necessarly state or reflect those of the Unted States Government or any agency thereof.
.* :. - DSCLAMER Ths report was prepared as an account of work sponsored by the Unted States &vemrnent. Nether the Unted States Governmentnor the Unted States Department of Energy, nor any of ther employees, nor any of ther contractors, subcontractors, or ther employees makes any warranty, express or mpled, or assumes any 1egal.labty or responsblty for the accuracy, completeness, or usefulness of any nformaton, apparatus, product, or process dsclosed, or represents that ts use would not nfrnge prvately owned rghts... ll
DSCLAMER Portons of ths document ma be llegble n electronc mage products. mages are produced from the best avalable orgnal document.
* TABLE OF CONTENTS...... ~ C u T v SUMMARY E 1. NTRODUCTON... 2. PHASEV: ADVANCEDSYSTEMTESTS... 2.1 Task 1. Procurement and nstallaton of a Burner and Superheater... 2.2 Task 2. Constructon of a CWSF Preparaton Faclty... 2.3 Task 3. nstallaton of an Advanced Flue Gas Treatment System.. 3. NEXT SEMANNUAL PEROD A(3TvTES... 4. REFERENCES...... 5. ACKNOWLEDGMENTS.... F w 2 v 1 3
v EXECUTVE SUMMARY The Pennsylvana State Unversty s conductng a coal-water slurry fuel (CWSF) program for the Unted States Department of Energy (DOE)and the Commonwealth of Pennsylvana wth the objectve of determnng the vablty of frrng CWSF n an ndustral boler desgned for heavy fuel ol. Penn State and DOE have entered nto a cooperatve agreement to determne f CWSFs prepared from cleaned coal (contanng approxmately 3.5 wt.% ash and.9 wt.% sulfur) can be burned effectvely n a heavy fuel oldesgned ndustral boler wthout adverse mpact on boler ratng,mantanablty, relablty, and avalablty. The project wll also provde nformaton to help n the desgn of new systems specfcally confgured to fre these clean coal-based fuels. The project conssts of four phases: (1) desgn, permttng, and test plannng, (2) constructon and start up, (3) demonstraton and evaluaton (1,-hour demonstraton), and (4) expanded demonstraton and evaluaton (nstallng a CWSF preparaton crcut, conductng an addtonal 1,OOO hours of testng, and nstallng an advanced flue gas treatment system). The boler testng and evaluaton w determne f the CWSF combuston characterstcs, heat release rate, foulng and slaggng behavor, corroson and eroson tendences, and fuel transport, storage, and handlng characterstcs can be accommodatedn a boler system desgned to fre heavy fuel ol. n addton, the proof-of-concept demonstraton wll generate data to determne how the propertes of a CWSF and ts parent coal affect boler performance. The economc factors assocated wth retrofttng bolers wll also be evaluated.. The CWSF demonstraton program s beng conducted on the 15, lb steam/h demonstraton boler located at Penn State. The approach used n the program was as follows: 1. A natural gas/fuel oldesgned package boler was nstalled and baselne data frng natural gas generated. 2. The system was then shaken down wth CWSF and 1,OOO hours of testng was conducted usng the burner/atomzer system provded wth the boler. The 1,OOO-hour demonstraton conssted of boler optmzaton testng and combuston performance evaluaton usng CWSF preheat, a range of atomzng ar pressures (up to 2 psg), and the use of steam as the atomzng medum. 3. f the combuston performance was not acceptable based on the combuston effcency obtaned and the level of gas support necessary to mantan flame stablzaton, then low-cost modfcatons were to be mplemented, such as nstallng a quarl and testng alternatve atomzers. 4. f acceptable combuston performance was not obtaned wth the low-cost modfcatons, then the frst demonstraton was to be termnated and the burner system replaced wth one of proven CWSF desgn.
V 5. n addton to the advanced burner system, a superheater tube and advanced fluegas cleanup system were to be nstalled for the second 1,OoO-hourdemonstraton. The frst three steps (Le., the frst demonstraton) have been completed and the combuston performance of the burner that was provded wth the boler has been determned to be unacceptable. Consequently, the frst demonstraton has been concluded at 5 hours. The second demonstraton (phase V)wll be conducted after a proven CWSFdesgnedburner s nstalled on the boler. Pror to the second demonstraton, a CWSF preparaton crcut s beng constructed. Durng ths reportng perod, the constructon of the CWSFpreparaton crcut (as well as a dry, mcronzed coal crcut) contnued. The CWSF preparaton crcut wll be completed by November 1,1994. Addtonal actvtes ncluded recevng a coal-desgned burner and nstallng t on the demonstraton boler; and workng wth DOE n selectng polluton control systems to nstall on the boler.
1. NTRODUCTON The Pennsylvana State Unversty s conductng a coal-water slurry fuel (CWSF) program for the Unted States Department of Energy (DOE) and the Commonwealth of Pennsylvana wth the objectve of determnng the vablty of frng CWSF n an ndustral boler desgned for heavy fuel ol. Penn State and DOE have entered nto a cooperatve agreement to determne f CWSFs prepared from cleaned coal (contanng approxmately 3.5 wt.% ash and.9 wt.% sulfur) can be burned effectvely n a heavy fuel oldesgned ndustral boler wthout adverse mpact on boler ratng, mantanablty, refablty, and avalablty. The project wll also provde nfoxmaton to help n the desgn of new systems specfcally confgured to fre these clean coal-based fuels. The project conssts of four phases: (1) desgn, permttng, and test plannng, (2) constructon and start up, (3) demonstraton and evaluaton (1,-hour demonstraton), and (4) expanded demonstraton and evaluaton (addtonal 1,oO hours of testng). The boler testng and evaluaton wll determne f the CWSF combuston characterstcs, heat release rate, foulng and slaggng behavor, corroson and eroson tendences, and fuel transport, storage, and handlng characterstcs can be accommodated n a boler system desgned to fre heavy fuel ol. n addton, the proof-of-concept demonstraton wll generate data to determne how the propertes of a CWSF and ts parent coal affect boler performance. The economc factors assocated wth retrofttng bolers wll also be evaluated. The project conssts of four phases as prevously mentoned. Followng s an outlne of the project tasks that comprse the four phases: Phase : Desgn, Permttng, and Test Plannng Task 1. Desgn Task2 Permttng Task 3. Test Plannng Phase : Constructon and Start Up Task 1. Host Ste ReadnesdBoler Retroft Task 2. CWSF Preparaton Task 3. Boler Performance Predcton Task 4. Shakedown Testng Phase : Demonstraton and Evaluaton Task 1. Test Burn Subtask 1.a. CWSF combuston performance Subtask 1.b. Slaggng/foulng propensty; corroson characterstcs Subtask 1.c. Eroson characterstcs Subtask 1.d. Fuel transport, storage, and handlng characterstcs Task 2. Evaluaton of Retroft Economcs
e Task 3. Project Report Phase V: Advanced System Tests Task 1. Procure and nstall Burner and Superheater Task 2. Constructon of a CWSF Preparaton Faclty Task 3. nstallaton of an Advanced Flue Gas Treatment System Task 4. 1,-How Test Task 5. Fnal Report Penn State began a coal-water slurry fuel (CWSF) research and developmentprogram n 1984 wth the ultmate goal of facltathg the replacement of petroleum-based fuels wth coal-based fuels n fuel ol-fred (desgned) bolers. The Pennsylvana legslature approprated funds n 1984 for the constructon of a demonstraton CWSF boler wth a capacty of approxmately 15, lb steam/h at 3 psg on the Unversty Park campus of Penn State. The project goal was to conduct a demonstraton of the use of CWSF derved from Pennsylvana coal. The boler performance was requred to be envronmentally acceptable and the testng was to evaluate the effects of long-term frng wth CWSF on boler performance. From a commercalzaton vewpont, t was consdered necessary to demonstrate at the ndustral scale the techncal feasblty of retrofttng exstng fuel ol-fred unts to bum CWSF,partcularly n the commercal and lght-ndustral sectors. State fundng was also provded for the nstallaton of a 1, lb steam/h (nomnally rated) Cleaver-Brooks A-frame watertube boler (Knneman et al, 1988) to nvestgate: the effect of boler operatng parameters on combuston performance (Mller et al, 1988); automaton of the frng of CWSF,partcularly wth respect to start up and shutdown procedures but also for optmzng boler performance (Wncek et al, 1989); testng canddate CWSFs (Mller et al, 1991); and provdng the necessary research support and operator tranng pror to start up of the demonstraton unt. The CWSF demonstraton program s beng conducted on the 15, lb steam/h demonstraton boler. The approach used n the program was as follows: 1. nstall a natural gadfuel oldesgned package boler and generate baselne data fung natural gas. 2. Shake down the system wth CWSF and begn the frst 1,OOO hours of testng usng the burner/atomzer system provded wth the boler. The frst 1,OOO-hourdemonstraton was to consst of boler optmzaton testng and combuston performance evaluaton usng CWSF preheat, a range of atomzng ar pressures (up to 2 psg as compared to the 1 psg boler manufacturer desgn pressure), and usng steam as the atomzng medum. 3. f the combuston performance was not acceptable based on the combuston effcency obtaned and the level of gas support necessary to mantan flame stablzaton, then 2
e lowcost modfcatons were to be mplemented, such as nstallng a qual and testng alternatve atomzers. 4. f acceptable combuston performance was not obtaned wth the lowcost modfcatons, then the fmt demonstraton was to be texmnated and the burner system replaced wth one of proven CWSF desgn. 5. n addton to the advanced burner system, a superheater tube and advanced flue gas cleanup system were to be nstalled for the second 1,OOo-hourdemonstraton. The fmt three steps (Le., the fmt demonstraton) have been completed and the combuston performance of the burner that was provded wth the boler has been determned to be unacceptable. Consequently, the fmt demonstraton (Phases -m) has been concluded at 5 hours and the results have been presented elsewhere (Mller, et al 1993). The second demonstraton (Phase V)wll be conducted after a proven CWSFdesgned burner s nstalled on the boler. A summary of Phase V s presented n Secton 2.. Actvtes planned for the next semannual perod are gven n Secton 3.. References are contaned n Secton 4. and acknowledgments are gven n Secton 5.. The mlestone schedule for Phase V s shown n Fgure 1, and Table 1 contans the mlestone descrpton for the entre project. 2. ADVANCED SYSTEM TESTS 2. 1 Task 1. Procurement and nstallaton of a Burner and Superheater Durng ths reportng perod, a burner was procured from Energy and Envronmental Research Corporaton (n conjuncton wth another program (Cooperatve Agreement No. DEFC22-92PC92162) that has the capablty of frng natural gas and CWSF or dry,mcronzed coal. t s a low-no, burner and a sectonal vew s shown n Fgure 2. Detals of the burner were gven n the prevous semannual report (Mller et al., 1994). Currently the burner s beng operated n ts dry,mcronzed coal mode for another program (Cooperatve Agreement No. DE-FC2292PC92162). The atomzer wll be nstalled pror to the Phase V test (frst and second quarter of 1995). No work was conducted on the procurement and nstallaton of the superheater ths reportng perod. The superheater wll be nstalled pror to the Phase N test. 2. 2 Task 2. Constructon of CWSF Preparaton Faclty Constructon of the CWSF preparaton crcut contnued durng ths reportng perod. Fgure 3 s a schematc dagram of the CWSF preparaton crcut. The nstallaton of the CWSF crcut s beng conducted n conjuncton wth another program (Cooperatve Agreement No. DEFC22-92PC92162). tems that have been, or are n the process of beng, nstalled or constructed are lsted below: 3
4 Water lnes and nozzles (to clean the ppe trench) have been nstalled n the ppe trench; CWSF tank stands were constructed for Tanks T1 and T4; Tanks T1 and T4 were mounted on the stands; Mxer mounts were constructed for Tanks T1 and T4 and a mxer was mounted on Tank T1; Electrcal condut was nstalled and the mxers were wred; Ppng for compressed ar and water lnes was nstalled to the areas n the Fuel Preparaton Faclty (FPF)where each major pece of equpment (pumps, tanks,sand mll, etc.) wll be sted; CWSF lnes were nstalled n the FPF and from the FPF to the boler room; A flush water (water/coal mxture produced h m purgng lnes n the boler room) return lne was nstalled from the boler room to Tank T4; Ppng for the sand mll was started; Moyno pumps that were receved from OXCE Fuel Company were dentfed for Tanks T1 and T4 and put nto place; Refurbshng of the 4 x 8' Centrx ball mll has begun. Alls Mneral Systems of York, Pennsylvanas currently fabrcatnga new man bearng for the ball mll. Orders for a new lubrcaton system and 5 hp motor have been placed. nstallaton of these components and controls for the ball mll wll be subcontracted to the Betzel Corporaton; Pneumatc valves for tanks T1, T2, T3, and T4 have been ordered; Materal was receved for, and constructon began on the sump for the bdl mll; The hydraulc system for the Morehouse Mll, whch was donated by OXCE Fuel Company, could not be repared and a new hydraulc system was ordered; e The Qualty Assurance (QA) mom was set up whch ncluded mountng cabnets, nstallng a snk, and settng up a computer, and A ladder was constructed and nstalled for access to a storage area above the QA room. Orders have been placed for the remanng major peces of equpment (tanks,moyno pumps, mxers). These equpment wll be nstalled upon recept. 2.3 Task 3. nstallaton of an Advanced Flue Gas Treatment System t was the orgnal ntenton of ths task was to ntegrate an advanced flue gas treatment system wth the boler. However, after recevng proposals from potental supplers and revewng them wth DOE, t became apparent that there were not any advanced systems that were both. techncally and economcally vable for nstallaton on ndustral bolers. Consequently, t was. decded to nstall commercalno, and SO2 systems on the boler. Work started n dentfyng the approprate emssons control technologes.
NEXT SEMANNUAL PEROD ACTVTES Durng the next reportng perod, the followng wll be completed nstallaton and shakedown of the CWSF preparaton crcut, and nstallaton of the superheater. 4. REFERENCES Knneman, W.P., R.T. Wncek, B.G. Mller, A.W. Scaron, and R.G. Jenkns, "Converson of a lo lb/h Steam Boler to Fre Coal Water Slurry Fuel," Thrteenth nr. Con$ on Coal culcl Slurry Tech., Denver, Colorado, p.725 (Aprl 12-15, 1988). Mller, B.G., R.T. Wncek, A.W. Scaron, W.P. Knneman, and R.G. Jenkns, "Combuston of CWSF n a lo lb Steam/h Watertube Boler," ThrteenthZnt. Con$ on Coal Md Slurry Tech., Denver, Colorado, p. 119 (Aprl 12-15, 1988). Mller, B.G., J.L. Morrson, J.T. Elston, P.M. Walsh, H.H. Schobert, and A.W. Scaron, "Superclean Coal-Water Slurry CombustonTestng n an Ol-Fred Boler," Semannual Techncal Progress Report for the Perod 8/15/199 to 2/15/1991, Pttsburgh Energy Technology Center, Pttsburgh, Pennsylvana, May 15, 1991, DE-FC22-89PC88697. Mller, B.G., A.W. Scaron, S.A. Brtton, D.A. Clark, J.L. Morrson, S.V. Psupat, R.L. Poe, P.M. Walsh, R.T. Wncek, and J. Xe, "Coal-Water Slurry Fuel Combuston Testng n an Ol-Fred ndustral Boler, Techncal Report for Phases -", Pttsburgh Energy Technology Center, Pttsburgh, Pennsylvana, June 2 1, 1993, DE-FC22-89PC88697. Mller, B.G., J.L. Morrson, R.L. Poe, and A.W. Scaron, "Coal-Water Sluny Fuel CombustonTestng n an Ol-Fred ndustral Boler," Semannual Techncal Progress Report for the Perod 8/15/1993 to 2/15/1994, Pttsburgh Energy Technology Center, Pttsburgh, Pennsylvana, March 28, 1994, DE-FC22-89PC88697. Wncek, R.T., W.P. Knneman, B.G. Mller, A.W. Scaron, D. Shefet, and F. Kal, "Combuston Control System for a Coal-Water Slurry Fuel-Fred Boler," AChE Sprng Natonal Meetng, Houston, Texas (Aprl 2-6, 1989). 6. ACKNOWLEDGMENTS The authors acknowledgethe followng personnel for ther contrbutons to the project durng ths reportng perod: Mchael Anna - Research Technologst Davd Bartley - Research Technologs Howaqd R. Glunt - Research Techncan Ruth Krebs - Research Assstant Scott Lyons - Research Techncan Bradley Maben - Research Techncan Joel L. Morrson - Research Assstant Roger L. Poe - Research Assstant Chrstopher Snyder - Research Techncan 3.
Table 1. Mlestone Descrpton Planned Jvllestone Phase Task 1, No. Task 2, No. 1 Task 3, No. 1 Phase 1 Task 1, No. 1 Task 1, No. 2 Task, No. 3 Task 2, No. 1 Task 2, No. 2 Task 3, No. 1 Task 4, No. 1 Task 4, No. 2 Phase Task 1, No. 1 Subtask la, No. 1 Subtask la, No. 2 Subtask la, No. 3 Subtask lb, No. 1 Subtask lb, No. 2 Subtask lb, No. 3 Subtask lb, No. 4 ComDletoq w Q& dentfy equpment and dagnostc nstrumentaton Revew present permt Develop CWSF specfcatons, dentfy operatng procedures, prepare detaled test plan 9/15/89 9115/89 1/15/89 9115/89 9/15/89 2/15/93 Buldnghler constructon and nstallaton let for bds Buldnglboler constructon and nstallaton awarded Prepare ste, nstall boler and auxlary equpment dentfy coal for CWSF preparaton Prepare CWSF for demonstraton Predct boler performance Shakedown boler and auxlary equpment Generate baselne data on gas 1118/89 1331/89 4/1/91 9/3/9 4/1/91 6/15/9 1 4131191 513 1191 1118/89 3/23/9 1/31/92 9/3/9 1113/92 OD 1/92 6/3/92 9/3/91 7131/92 1131/92 1/15/93 1O/15/89 6/1/9 1/1/9 111191 713 1/92 11/13/92 1/15/93 1115/89 8/ 1/9 11 1/9 2/15/91 8131191 8115/92 1/31/92 1/15/93 1115/89 81 19 11 19 111191 51 1191 1/15/93 1115/89 8115/9 11/3/92 1/15/93 31 193 11/13/92 1/15/93 1115/89 8/1/9 1/1/9 OU15/91 1/15/91 6115/93 1115/89 9/15/9 11/3/92 1115/93 6l2 1/93 Subtask b, No. 6 Subtask lb, No. 7 Subtask C, No. 1 Subtask C, No. 2 Subtask C, No. 3 Subtask C, No. 4 Subtask C,No. 5 Subtask C, No. 6 Subtask d, No. 1 Subtask d, No. 2 Subtask d, No. 3 Task 2, No. 1 Task3,No. 1 Perform demonstraton 3-hour demonstraton mlestone 5-hour demonstratonmlestone Redefne CWSF specfcatons Develop deposton and corroson test plan Desgn sucton pyrometer Construct sucton pyrometer Deposton characterzaton equpmentdesgn and specfcaton Acquston of baselne data for spectroscopc analyss of deposts; acquston of baselne data for corroson of tubes by ash components Coupon testng n boler Complete deposton and corroson testng Develop eroson test plan Complete research boler eroson evaluaton Full-scale eroson technque decson Desgn probe for full-scale eroson study Construct eroson probe Complete eroson modelng dentfy vscometer Complete prelmnary vscosty and stablty tests Complete vscosty and stablty tests Complete economc evaluaton Complete project report Phase V Task 1, No. 1 Task 1, No. 2 Task2,No. 1 Task 2, No. 2 Task 3, No. 1 Task 4, No. 1 Task 5, No, 1 Procure and nstall burner Procure and nstall superheater Complete constructon of Fuel Preparaton Faclty nstall and shake down CWSF preparaton crcut nstall flue gas treatment system Complete 1,OOO-hr test Complete fnal report Subtask lb, No. 5 Actual ComDetoq 4115/94 12/31/94 813 1/93 11/1/94 12/31/94 6/3/95 91 1/95 5/9/94 8131/93
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