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Title: SECOND GENERATION PFBC SYSTEMS R AND D - PHASE 2 AND 3

Abstract

When DOE funds were exhausted in March 1995, all Phase 2 activities were placed on hold. In February 1996 a detailed cost estimate was submitted to the DOE for completing the two remaining Phase 2 Multi Annular Swirl Burner (MASB) topping combustor test campaigns; in August 1996 release was received from FETC to proceed with the two campaigns to: (1) test the MASB at proposed demonstration plant full to minimum load operating conditions; (2) identify the lower oxygen limit of the MASB; (3) demonstrate natural gas to carbonizer fuel gas switching; and (4) demonstrate operation with ''low temperature'' compressor discharge air rather than high temperature ({approx}1600 F) vitiated air.

Authors:
Publication Date:
Research Org.:
Federal Energy Technology Center, Morgantown, WV (US); Federal Energy Technology Center, Pittsburgh, PA (US)
Sponsoring Org.:
US Department of Energy (US)
OSTI Identifier:
14003
Report Number(s):
DE-AC21-86MC21023-71
TRN: AH200136%%345
DOE Contract Number:
AC21-86MC21023
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 5 Aug 1999
Country of Publication:
United States
Language:
English
Subject:
03 NATURAL GAS; AIR; BURNERS; COMBUSTORS; COMPRESSORS; DEMONSTRATION PLANTS; FUEL GAS; NATURAL GAS; OXYGEN

Citation Formats

A. Robertson. SECOND GENERATION PFBC SYSTEMS R AND D - PHASE 2 AND 3. United States: N. p., 1999. Web. doi:10.2172/14003.
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A. Robertson. SECOND GENERATION PFBC SYSTEMS R AND D - PHASE 2 AND 3. United States. doi:10.2172/14003.
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A. Robertson. Thu . "SECOND GENERATION PFBC SYSTEMS R AND D - PHASE 2 AND 3". United States. doi:10.2172/14003. https://www.osti.gov/servlets/purl/14003.
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@article{osti_14003,
title = {SECOND GENERATION PFBC SYSTEMS R AND D - PHASE 2 AND 3},
author = {A. Robertson},
abstractNote = {When DOE funds were exhausted in March 1995, all Phase 2 activities were placed on hold. In February 1996 a detailed cost estimate was submitted to the DOE for completing the two remaining Phase 2 Multi Annular Swirl Burner (MASB) topping combustor test campaigns; in August 1996 release was received from FETC to proceed with the two campaigns to: (1) test the MASB at proposed demonstration plant full to minimum load operating conditions; (2) identify the lower oxygen limit of the MASB; (3) demonstrate natural gas to carbonizer fuel gas switching; and (4) demonstrate operation with ''low temperature'' compressor discharge air rather than high temperature ({approx}1600 F) vitiated air.},
doi = {10.2172/14003},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Thu Aug 05 00:00:00 EDT 1999},
month = {Thu Aug 05 00:00:00 EDT 1999}
}
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Technical Report:
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DOI:  10.2172/14003
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  • When DOE funds were exhausted in March 1995, all Phase 2 activities were placed on hold. In February 1996 a detailed cost estimate was submitted to the DOE for completing the two remaining Phase 2 Multi Annular Swirl Burner (MASB) topping combustor test campaigns; in August 1996 release was received from FETC to proceed with the two campaigns to: (1) test the MASB at proposed demonstration plant full to minimum load operating conditions; (2) identify the lower oxygen limit of the MASB; (3) demonstrate natural gas to carbonizer fuel gas switching; and (4) demonstrate operation with low temperature compressor dischargemore » air rather than high temperature ({approx} 1,600 F) vitiated air. The 18 in. MASB was last tested at the University of Tennessee Space Institute (UTSI) in a high-oxygen configuration and must be redesigned/modified for low oxygen operation. A second-generation PFB combustion plant incorporating an MASB based topping combustor will be constructed at the City of Lakeland's McIntosh Power Plant under the US DOE Clean Coal V Demonstration Plant Program. This plant will require the MASB to operate at oxygen levels that are lower than those previously tested. Preliminary calculations aimed at defining the operating envelope of the demonstration plant MASB have been completed. Phase 3--Commercial plant design update: The Second-Generation PFB Combustion Plant conceptual design prepared in 1987 is being updated to reflect the benefit of pilot plant test data and the latest advances in gas turbine technology. The updated plant is being designed to operate with 95% sulfur capture and a single Westinghouse 501G gas turbine. The 1987 study investigated two coal feeding arrangements, e.g., dry and paste feed. Paste feeding resulted in a lower cost of electricity. Paste, however, increases the water content of the carbonizer generated syngas; this increases the equilibrium partial pressure of hydrogen sulfide gas over calcium oxide/calcium carbonate and thereby reduces the carbonizer sulfur capture efficiency. Recognizing that the carbonizer and the CPFBC work together to control the plant overall sulfur capture efficiency, the higher CPFBC efficiency can compensate for the carbonizer's lower sulfur capture efficiency depending upon the amount of coal and/or char being fed to each unit. Since the latter are determined by the overall plant heat and material balance, they prepared a balance for each feed case to enable selection of the plant coal feed system.« less

  • When DOE funds were exhausted in March 1995, all Phase 2 activities were placed on hold. In February 1996 a detailed cost estimate was submitted to the DOE for completing the two remaining Phase 2 Multi Annular Swirl Burner (MASB) topping combustor test campaigns; in August 1996 release was received from FETC to proceed with the two campaigns to: (1) test the MASB at proposed demonstration plant full to minimum load operating conditions; (2) identify the lower oxygen limit of the MASB; (3) demonstrate natural gas to carbonizer fuel gas switching; and (4) demonstrate operation with low temperature compressor dischargemore » air rather than high temperature ({approx} 1,600 F) vitiated air. The 18 in. MASB was last tested at the University of Tennessee Space Institute (UTSI) in a high-oxygen configuration and must be redesigned/modified for low oxygen operation. A second-generation PFB combustion plant incorporating an MASB based topping combustor will be constructed at the City of Lakeland's McIntosh Power Plant under the US DOE Clean Coal V Demonstration Plant Program. This plant will require the MASB to operate at oxygen levels that are lower than those previously tested. Preliminary calculations aimed at defining the operating envelope of the demonstration plant MASB have been completed. Phase 3--Commercial plant design update: The Second-Generation PFB Combustion Plant conceptual design prepared in 1987 is being updated to reflect the benefit of pilot plant test data and the latest advances in gas turbine technology. The updated plant is being designed to operate with 95% sulfur capture and a single Westinghouse 501G gas turbine. The 1987 study investigated two coal feeding arrangements, e.g., dry and paste feed. Paste feeding resulted in a lower cost of electricity. Paste, however, increases the water content of the carbonizer generated syngas; this increases the equilibrium partial pressure of hydrogen sulfide gas over calcium oxide/calcium carbonate and thereby reduces the carbonizer sulfur capture efficiency. Recognizing that the carbonizer and the CPFBC work together to control the plant overall sulfur capture efficiency, the higher CPFBC efficiency can compensate for the carbonizer's lower sulfur capture efficiency depending upon the amount of coal and/or char being fed to each unit. Since the latter are determined by the overall plant heat and material balance, they prepared a balance for each feed case to enable selection of the plant coal feed system.« less

  • When DOE funds were exhausted in March 1995, all Phase 2 activities were placed on hold. In February 1996 a detailed cost estimate was submitted to the DOE for completing the two remaining Phase 2 Multi Annular Swirl Burner (MASB) topping combustor test campaigns; in August 1996 release was received from FETC to proceed with the two campaigns to: (1) test the MASB at proposed demonstration plant full to minimum load operating conditions; (2) identify the lower oxygen limit of the MASB; (3) demonstrate natural gas to carbonizer fuel gas switching; and (4) demonstrate operation with ''low temperature'' compressor dischargemore » air rather than high temperature ({approx} 1600 F) vitiated air. The 18 in. MASB was last tested at the University of Tennessee Space Institute (UTSI) in a high-oxygen configuration and must be redesigned/modified for low oxygen operation. A second-generation PFB combustion plant incorporating an MASB based topping combustor has been proposed for construction at the City of Lakeland's McIntosh Power Plant under the U.S. DOE Clean Coal V Demonstration Plant Program. This plant will require the MASB to operate at oxygen levels that are lower than those previously tested. Preliminary calculations aimed at defining the operating envelope of the demonstration plant MASB have been completed. The previous MASB tests have been performed at UTSI in a facility constructed to support the development of MHD power generation. Because of a loss of MHD funding, the UTSI facility closed October 1998. On February 2, 1999, Siemens Westinghouse proposed a 12-week study that would identify the cost of modifying the MASB for Lakeland low oxygen operation conditions and conducting tests 3 and 4 above at the Arnold Engineering Development Center (AEDC). On February 22, 1999, Siemens Westinghouse was given release to proceed with this study and results/recommendations were received on April 22, 1999. Siemens Westinghouse recommended a two-phase test effort. The first test effort would entail two 6-hour tests beginning November 1999 with the MASB operated with natural gas and ''cold'' compressor air. The MASB would be tested at full Lakeland pressure using the physical configuration planned for operation at lower pressure at Wilsonville in September 1999. As a result, the MASB test specimen would be a totally new unit (not a modification of a previously UTSI tested unit). The MASB would be installed in an existing AEDC test shell as shown in Fig. 1. Although the internals currently installed within the shell would have to be removed and reinstalled at the completion of the first test phase, no major facility modifications external to the shell are needed; this first test effort was estimated to cost $1.2 million. Although the second test effort was not the subject of this initial study, Siemens Westinghouse envisioned it being conducted in another AEDC test cell that is currently mothballed. The facility has been well preserved and it would be modified to permit syngas testing with both cold and hot vitiated air; these tests would not be conducted until the fall 2000 and were estimated to cost $3.2 million. Written questions were submitted to Siemens Westinghouse regarding their proposed test programs; their responses and cost estimates were transmitted to FETC on April 30, 1999. Review of the proposed programs by FETC revealed that they exceeded existing funding limits, and all further Phase 2 work was put on hold until additional funding becomes available.« less

  • No work was performed; the two remaining Multi Annular Swirl Burner test campaigns are on hold pending selection of a new test facility (replacement for the shut down UTSI burner test facility) and identification of associated testing costs. The Second-Generation PFB Combustion Plant conceptual design prepared in 1987 is being updated to reflect the benefit of pilot plant test data and the latest advances in gas turbine technology. The updated plant is being designed to operate with 95 percent sulfur capture and a single Siemens Westinghouse (SW) 501G gas turbine. Using carbonizer and gas turbine data generated by Foster Wheelermore » (FW) and SW respectively, Parsons Energy and Chemicals Group prepared preliminary plant heat and materials based on carbonizer operating temperatures of 1700 and 1800 F and found the former to yield the higher plant efficiency. As a result, 1700EF has been selected as the preferred operating condition for the carbonizer. The previous first cut plant heat and material balance was refined and it predicts a 47.7% plant efficiency (HHV) with a net power output of 421 MWe. The latter includes a plant auxiliary load estimated to be 23.48 MWe or 5.26% of the gross plant power and a transformer loss of 1.52 MWe. Coal drying is through natural gas combustion, and the thermal energy input of the natural gas has also been included in the heat rate calculation. Figure 1 presents the plant preliminary full load heat and material balance. In this arrangement, evaporation and primary steam superheating tube surfaces are placed in both the pressurized circulating fluidized bed boiler (PCFB) and the gas turbine heat recovery steam generator (HRSG). The superheated steam from these units is mixed and then heated to 1050 F in the PCFB finishing superheater. With regard to steam reheating, the primary stage is located at the front of the HRSG and the final stage is located in the PCFB. Although this circuitry arrangement appears workable at full load, minimum load must be checked next to see if rearrangement is needed. Plant start up and load following discussions indicated that below about 15 percent gas turbine load, the latter would transition from steam to air cooling. Keeping the gas turbine at 15 percent load to avoid this transition, a minimum load heat and material balance will be prepared next; gas turbine performance data for this condition was being generated by SW as the reporting period ended.« less