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Title: Second Generation PFBC Systems R&D

Abstract

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 Wheeler (FW) and SW respectively, Parsons Infrastructure & Technology prepared preliminary plant heat and material balances based on carbonizer operating temperatures of 1700 and 1800 F; the former yielded the higher plant efficiency and has been selected for the design update. The 501G gas turbine has an air compressor discharge temperature of 811EF and an exhaust temperature of 1140 F. Both of these streams represent high sources of heat and must be cooled, the air to 600 F to be compatible with a 650 F PCFB pressure vessel design temperature and the exhaust for a 275 F stack gas temperature. Becausemore » of their relatively high temperature, they can be used for feed water heating, steam generation and/or steam superheating and reheating. As a result, the plant could have one boiler (the PCFB boiler), or as many as three boilers if their cooling is used to generate steam. Three different plant arrangements using one, two and then three boilers were considered with the three-boiler arrangement minimizing the feedwater flow/steam turbine size and maximizing the plant efficiency. After reviewing the three arrangements it was felt the operating complexity associated with a three-boiler plant did not justify the 1/2 point increase in plant efficiency it provided and a two-boiler plant was selected.« less

Authors:
Publication Date:
Research Org.:
Foster Wheeler Development Corporation
Sponsoring Org.:
USDOE
OSTI Identifier:
882012
DOE Contract Number:
AC21-86MC21023
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; FLUIDIZED BED BOILERS; BURNERS; GAS TURBINES; PILOT PLANTS; STEAM GENERATION; SULFUR; AIR POLLUTION CONTROL; DESIGN

Citation Formats

Archie Robertson. Second Generation PFBC Systems R&D. United States: N. p., 2000. Web. doi:10.2172/882012.
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Archie Robertson. Second Generation PFBC Systems R&D. United States. doi:10.2172/882012.
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Archie Robertson. Thu . "Second Generation PFBC Systems R&D". United States. doi:10.2172/882012. https://www.osti.gov/servlets/purl/882012.
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@article{osti_882012,
title = {Second Generation PFBC Systems R&D},
author = {Archie Robertson},
abstractNote = {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 Wheeler (FW) and SW respectively, Parsons Infrastructure & Technology prepared preliminary plant heat and material balances based on carbonizer operating temperatures of 1700 and 1800 F; the former yielded the higher plant efficiency and has been selected for the design update. The 501G gas turbine has an air compressor discharge temperature of 811EF and an exhaust temperature of 1140 F. Both of these streams represent high sources of heat and must be cooled, the air to 600 F to be compatible with a 650 F PCFB pressure vessel design temperature and the exhaust for a 275 F stack gas temperature. Because of their relatively high temperature, they can be used for feed water heating, steam generation and/or steam superheating and reheating. As a result, the plant could have one boiler (the PCFB boiler), or as many as three boilers if their cooling is used to generate steam. Three different plant arrangements using one, two and then three boilers were considered with the three-boiler arrangement minimizing the feedwater flow/steam turbine size and maximizing the plant efficiency. After reviewing the three arrangements it was felt the operating complexity associated with a three-boiler plant did not justify the 1/2 point increase in plant efficiency it provided and a two-boiler plant was selected.},
doi = {10.2172/882012},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Thu Aug 31 00:00:00 EDT 2000},
month = {Thu Aug 31 00:00:00 EDT 2000}
}
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DOI:  10.2172/882012
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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}1600 F) vitiated air.« 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} 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

  • No work was performed on Phase 2; 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. Phase 3 of 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 Siemens Westinghouse (SW) 501G gas turbine. Using carbonizer and gas turbinemore » data generated by Foster Wheeler (FW) and SW respectively, Parsons Infrastructure and Technology prepared preliminary plant heat and material balances based on carbonizer operating temperatures of 1,700 and 1,800 F, the former yielded the higher plant efficiency and has been selected for the design update. The 501G gas turbine ha san air compressor discharge temperature of 811 F and an exhaust temperature of 1,140 F. Both of these streams represent high sources of heat and must be cooled, the air to 600 F to be compatible with a 650 F PCFB pressure vessel design temperature and the exhaust for a 275 F stack gas temperature. Because of their relatively high temperature, they can be used for feed water heating, steam generation and/or steam superheating and reheating. As a result, the plant could have one boiler (the PCFB boiler), or as many as three boilers if their cooling is used to generate steam. Three different plant arrangements using one, two and then three boilers were considered with the three-boiler arrangement minimizing the feedwater flow/steam turbine size and maximizing the plant efficiency. After reviewing the three arrangements it was felt the operating complexity associated with a three-boiler plant did not justify the 1/2 point increase in plant efficiency it provided and a two-boiler plant was selected.« less