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SCALING PARAMETERS FOR PFBC CYCLONE SEPARATOR<br />

SYSTEM ANALYSIS<br />

Antonia Gil, Luis M. Romeo and Cristóbal Cortés<br />

CIRCE, Centro de Investigación del Rendimiento de Centrales Eléctricas<br />

Centro Politécnico Superior. María de Luna, 3.<br />

50015 Zaragoza (Spain)<br />

email: antgilma@posta.unizar.es, luismi@posta.unizar.es, tdyfqdb@posta.unizar.es<br />

ABSTRACT<br />

Laboratory-scale cold flow models have been used extensively to study the behaviour<br />

of many installations. In particular, fluidized bed cold flow models have allowed developing<br />

the knowledge of fluidized bed hydrodynamics. In order <strong>for</strong> the results of the research to be<br />

relevant to commercial power plants, cold flow models must be properly scaled.<br />

Many ef<strong>for</strong>ts have been made to understand the per<strong>for</strong>mance of fluidized beds, but up<br />

to now no attention has been paid in developing the knowledge of <strong>cyclone</strong> <strong>separator</strong> <strong>system</strong>s.<br />

CIRCE has worked on the development of <strong>scaling</strong> <strong>parameters</strong> to enable laboratory-scale<br />

equipment operating at room temperature to simulate the per<strong>for</strong>mance of <strong>cyclone</strong> <strong>separator</strong><br />

<strong>system</strong>s. This paper presents the simplified <strong>scaling</strong> <strong>parameters</strong> and experimental comparison<br />

of a <strong>cyclone</strong> <strong>separator</strong> <strong>system</strong> and a cold flow model constructed and based on those<br />

<strong>parameters</strong>. The cold flow model has been used to establish the validity of the <strong>scaling</strong> laws <strong>for</strong><br />

<strong>cyclone</strong> <strong>separator</strong> <strong>system</strong>s and permits detailed room temperature studies (determining the<br />

filtration effects of varying operating <strong>parameters</strong> and <strong>cyclone</strong> design) to be per<strong>for</strong>med in a<br />

rapid and cost effective manner. This valuable and reliable design tool will contribute to a<br />

more rapid and concise understanding of hot gas filtration <strong>system</strong>s based on <strong>cyclone</strong>s.<br />

The study of the behaviour of the cold flow model, including observation and<br />

measurements of flow patters in <strong>cyclone</strong>s and diplegs will allow characterising the<br />

per<strong>for</strong>mance of the full-scale ash removal <strong>system</strong>, establishing safe limits of operation and<br />

testing design improvements.<br />

1


INTRODUCTION<br />

Hot gas cleaning plays an essential role in the development of new power generation<br />

technologies such as Integrated Gasification Combined Cycle (IGCC) or Fluidized Bed<br />

Combustion (FBC). The removal of solid particles from the combustion flue gases is essential<br />

in order to maintain gas turbine working conditions and particle emissions in safe limits. In<br />

particular, in PFBC power stations the entrainment of bed particles may lead to erosion and<br />

fouling in downstream equipment. Special importance is the damage of gas turbine blades. In<br />

addition, fly ash can also produce corrosion due to metal alkali compounds.<br />

Cyclone <strong>separator</strong> <strong>system</strong>s offer nowadays one of the best solution <strong>for</strong> removing<br />

particles from high temperature high pressure installations. Combustion gases from<br />

pressurized beds are an example of this harsh environment, and <strong>cyclone</strong>s are, nowadays, the<br />

only solution commercially available <strong>for</strong> these power stations. These <strong>system</strong>s are simple, low<br />

cost and maintenance with relatively high collection efficiency. Its main disadvantages are the<br />

complex hydraulic behaviour and a efficiency decrease <strong>for</strong> small particles (below 5 μm). In<br />

Escatrón PFBC power plant, the hot gas filtration equipment is a two-stage process per<strong>for</strong>med<br />

in nine streams between the fluidized bed and the gas turbine. The <strong>cyclone</strong>s are high<br />

efficiency, Van Tongeren´s type, with a tangential inlet, cylindrical body, conical base, and an<br />

axial outlet <strong>for</strong> clean gases and outlet port <strong>for</strong> solid particles in the lower part. The solid<br />

extraction bin has been replaced by a dipleg (similar to those found in catalytic cracking) and<br />

a suction nozzle through which collected particles are evacuated along with some amount of<br />

transport gas. In contrast with other devices, such as series of pressure-tight lockhooppers, the<br />

solid extraction by pneumatic conveying improves <strong>cyclone</strong> efficiency and allows reliable<br />

handling and cooling of ash particles with low cost.<br />

Ash and combustion gases exit the pressurized bed at nearly 800 °C and 11 bar(g). The<br />

gas and solid mass flow rates depend on load, coal and sorbent characteristics and other<br />

operating variables, in particular those related with fluidisation. These <strong>parameters</strong> have a<br />

strong influence on the separation efficiency of the <strong>cyclone</strong>s, and there are not well<br />

established theories able to achieve an accurate and complete prediction. Operating<br />

experience at Escatrón have shown sintered deposits and unsteadiness in the dipleg and the<br />

suction nozzle that modify <strong>cyclone</strong> separation efficiency and affect the <strong>cyclone</strong> per<strong>for</strong>mance<br />

and the capacity of ash conveying lines.<br />

The possibility of achieving analyses to establish the influence of different variables in<br />

a real installation is limited due to a non-controlled operating conditions and a lack of data to<br />

2


obtain conclusions. Laboratory-scale cold flow models have been used extensively to study<br />

the behaviour of many installations. In particular, fluidized bed cold flow models have<br />

allowed developing the knowledge of fluidized bed hydrodynamics. In order <strong>for</strong> the results of<br />

these researches to be relevant to commercial power plant, cold flow models have to be<br />

properly scaled. In the present study, <strong>scaling</strong> <strong>parameters</strong> have been developed to build a<br />

dipleg and <strong>cyclone</strong> cold flow model of a PFBC power plant. The cold flow model permits<br />

detailed room temperature studies, such as determining the filtration effects of varying<br />

operating <strong>parameters</strong> and <strong>cyclone</strong> designs.<br />

The study of the behaviour of the cold flow model, including observation and<br />

measurements of flow patterns in <strong>cyclone</strong> and dipleg, will allow characterising the<br />

per<strong>for</strong>mance of the full-scale ash removal <strong>system</strong>, establishing safe limits of operation, testing<br />

design improvements and determining the filtration effects of varying operating <strong>parameters</strong>.<br />

This paper presents the most relevant <strong>scaling</strong> <strong>parameters</strong> <strong>for</strong> a <strong>cyclone</strong> <strong>separator</strong> <strong>system</strong> and<br />

an experimental comparison of a PFBC <strong>cyclone</strong> <strong>separator</strong> <strong>system</strong> and a cold flow model<br />

constructed based on those <strong>parameters</strong>.<br />

CYCLONE SCALING PARAMETERS<br />

Collection efficiency and <strong>cyclone</strong> pressure drop are the most important variables in<br />

<strong>cyclone</strong> behaviour. Criteria <strong>for</strong> <strong>cyclone</strong> <strong>scaling</strong> <strong>parameters</strong>, based on maintain collection<br />

efficiency, have been proposed by several researchers (Cheremisinoff and Cheremisisnoff,<br />

1986; Dirgo and Leith, 1986; Svarovsky, 1981, 1986; Leith and Litch, 1972; Abrahanson et<br />

al., 1978). It is generally assumed the necessity of maintain, at least, Stokes number in order<br />

to maintain collection efficiency. Cheremisinoff and Cheremisinoff (1986) developed the<br />

<strong>scaling</strong> <strong>parameters</strong> by analysing the <strong>for</strong>ces that influence a particle within the <strong>cyclone</strong>. They<br />

proposed to maintain Froude,<br />

ratio between densities and lengths, equation 1.<br />

Fr = gD v , and Reynolds numbers, Re = dvρ<br />

s μ g , and a<br />

2<br />

in<br />

⎛ ⎞<br />

⎜<br />

ρs<br />

D<br />

η = f Fr,<br />

Re, ⎟<br />

(1)<br />

⎜ ⎟<br />

⎝ ρ gd<br />

p ⎠<br />

For the laminar regime of flow (Re


and Stokes numbers. He has developed these <strong>parameters</strong> from the equation <strong>for</strong> accelerated,<br />

three-dimensional particle motion with the main assumption of Stokes regime, equation 2:<br />

Re<br />

p<br />

d pρ<br />

=<br />

μ<br />

g<br />

g<br />

v<br />

r<br />

Other authors only mention the importance of maintaining Stokes number especially at low<br />

solid concentrations (Dirgo and Leith, 1986), or suggest that is the Stokes number the main<br />

variable in <strong>cyclone</strong> efficiency (Svarovsky, 1981; Leith and Licht, 1972). Finally, Chao (1982)<br />

<strong>for</strong> a dilute flow as the freeboard of a PFBC power plant, has suggested as <strong>scaling</strong> <strong>parameters</strong><br />

the Stokes and Froude number and a particle Reynolds number. The last number is necessary<br />

when the flow regime is different from Stokes regime. Although these authors have proposed<br />

different theories <strong>for</strong> <strong>cyclone</strong> <strong>scaling</strong>, none of them has verified their proposals in a real<br />

installation. So, as first approximation <strong>cyclone</strong> behaviour depends on the following variables,<br />

figure 1<br />

< 1<br />

( , ρ , μ , d , V , D,<br />

g,<br />

C )<br />

f g s g p50<br />

in<br />

s _ in<br />

(2)<br />

ρ (3)<br />

Figure 1. Parameters affecting <strong>cyclone</strong> behaviour<br />

Where dp50 has been selected as variable to take into account the particle size distribution at<br />

<strong>cyclone</strong> inlet. Selecting vin, ρg and dp50 as independent variables in order to identify<br />

dimensionless groups:<br />

ΔP<br />

Vin<br />

Cs<br />

ρs<br />

ρg<br />

μg<br />

dp<br />

η<br />

1-η<br />

D<br />

g<br />

4


⎛<br />

⎜<br />

gD ρ g DV<br />

f ,<br />

⎜ 2<br />

⎝V<br />

in μ g<br />

in<br />

2<br />

where = V gD is the Froude number. With the approximation of a flow regime with low<br />

Fr in<br />

relative velocity <strong>for</strong> the particles in the <strong>cyclone</strong> and considering the influence of the<br />

aerodynamic <strong>for</strong>ces by means of the Stokes number (which is a combination of three of the<br />

previous numbers, equation 5).<br />

Stk<br />

Finally, equation (4) is rearranged to read:<br />

,<br />

D<br />

d<br />

p50<br />

ρ<br />

,<br />

ρ<br />

s<br />

g<br />

g<br />

C<br />

,<br />

ρ<br />

s _ in<br />

s<br />

⎞<br />

⎟<br />

⎠<br />

g<br />

(4)<br />

2<br />

2<br />

ρ g DVin<br />

⎛d<br />

p50<br />

⎞ ρ ρ s sd<br />

p50Vin<br />

= ⎜ ⎟ =<br />

(5)<br />

μ<br />

g<br />

⎜<br />

⎝<br />

⎛<br />

⎜<br />

ρ<br />

f Fr,<br />

Re, St,<br />

⎜<br />

⎝ ρ<br />

g<br />

D<br />

⎟<br />

⎠<br />

s s _ in C<br />

,<br />

Froude number takes into account the relation between gravitational and inertia <strong>for</strong>ces.<br />

When particle diameter is small, less than 10 μm, some authors neglect this number due to the<br />

fact that gravitational <strong>for</strong>ces are small compared with inertia <strong>for</strong>ces (Mothes and Löffler,<br />

1985). In our case, more than 80% of the particles are bigger than 10 μm so, it seems<br />

necessary to maintain Froude number.<br />

Reynolds number is not considered to analyse <strong>cyclone</strong> collection efficiency.<br />

Generally, its influence is near negligible due to Reynolds number is high enough. According<br />

to experiments at different temperatures and pressures, from 1 to 6 bars, and from 293 to<br />

1123ºC, Reynolds influence is significant <strong>for</strong> values from 10 3 to 10 5 . The tendency observed<br />

is that Reynolds higher than 10 5 does not influence <strong>cyclone</strong> behaviour (Morweiser and<br />

Bohnet, 1996).<br />

Most of the authors take into account Stokes number to analyse <strong>cyclone</strong> collection<br />

efficiency. Stokes number relates the inertia <strong>for</strong>ces with aerodynamic <strong>for</strong>ces in a flow field.<br />

Stokes number and <strong>cyclone</strong> efficiency are closely related. Generally, researchers consider<br />

laminar flow or assume Stokes´ law (Rep


with Stokes number <strong>for</strong> dp50, but it does not give an exact idea of the PSD conservation. It is<br />

possible to have a wide PSD, and a narrow PSD with the same dp50 and the <strong>cyclone</strong> behaviour<br />

would be completely different. Finally, from a practical point of view, it is impossible to<br />

achieve a scaled PSD. In Escatrón PFBC less than 1% of particles are smaller than 0.4 μm,<br />

that is the limit <strong>for</strong> Rep


<strong>parameters</strong> that were used to calculate the values of the <strong>cyclone</strong> <strong>scaling</strong> <strong>parameters</strong>, and the<br />

dimensions of the 1/5 scaled <strong>cyclone</strong>. The real <strong>cyclone</strong> mean particle diameter, dp50, has been<br />

taken from design data, since to it is not possible to obtain a particle sample from the <strong>cyclone</strong><br />

inlet. Table 2 shows a comparison between the values of the dimensionless <strong>scaling</strong> <strong>parameters</strong><br />

<strong>for</strong> the two <strong>cyclone</strong> <strong>system</strong>s.<br />

Table 1. Comparison between Escatrón PFBC and laboratory cold flow model <strong>parameters</strong> of<br />

the <strong>cyclone</strong> <strong>separator</strong> <strong>system</strong><br />

REAL CYCLONE<br />

SEPARATOR SYSTEM<br />

LABORATORY COLD<br />

FLOW MODEL SYSTEM<br />

D (mm) 1000 200<br />

T (K) 1030 293<br />

P (bar a) 11.14 3.22<br />

μg (kg/m s) 4.25e-5 1.82e-5<br />

ρg (kg/m 3 ) 3.8 3.8<br />

ρs (kg/m 3 ) 2800 2800<br />

dp50 (μm) 40 23<br />

Vin (m/s) 30 13.4<br />

Cs_in (g/m 3 ) 290 290<br />

Mair (kg/s) 10.6 0.19<br />

Mash (g/s) 800 14<br />

Table 2. Comparison of Escatrón PFBC and cold flow dimensionless <strong>scaling</strong> <strong>parameters</strong><br />

Froude number<br />

Reynolds number<br />

Stokes number<br />

Density ratio<br />

REAL CYCLONE<br />

SEPARATOR SYSTEM<br />

LABORATORY COLD<br />

FLOW SYSTEM<br />

2<br />

Fr = vin<br />

gD<br />

91.74 91.79<br />

ρ g Dvin<br />

Re = 2.68 e+6 5.60 e+5<br />

μ<br />

Stk =<br />

d<br />

ρs p<br />

2<br />

50<br />

Solid<br />

concentration ρ s<br />

g<br />

v<br />

in<br />

g<br />

Dμ<br />

g<br />

3.16 5.45<br />

ρ s<br />

736.8 736.8<br />

Cs<br />

_ in<br />

ρ<br />

104 e-6 104 e-6<br />

7


DIPLEG SCALING PARAMETERS<br />

The collected particles removed from the PFBC <strong>cyclone</strong> <strong>system</strong> flow down a dipleg<br />

and are transported by means of pneumatic conveying thought a suction nozzle in the bottom<br />

of the dipleg. There are no specific models of this flow inside the dipleg, so an approximate<br />

analysis, resorting to reasonable and simple models of the physical situation, is appropriate.<br />

Flow patterns inside the dipleg may be expected to possess the following features:<br />

— Particles slid down on the dipleg wall, following a helical path of variable pitch.<br />

— The gas flow generally follows two paths: near the wall, it moves downwards, with<br />

tangential and axial velocity components, whereas it is reversed at the leg core,<br />

<strong>for</strong>ming an upward flow.<br />

As first approximation dipleg behaviour depends on the following variables<br />

( , ρ , , D , L,<br />

V , V , g,<br />

C )<br />

f ρ μ<br />

(7)<br />

g<br />

s<br />

g<br />

In this case, selecting, L, ρg and Vax as independent variables in order to identify<br />

dimensionless groups and rewriting<br />

dl<br />

ax<br />

t<br />

⎛<br />

2 ⎞<br />

⎜<br />

D<br />

ρ<br />

dl ρs Vax<br />

V L gV<br />

ax ax<br />

f , , C<br />

⎟<br />

⎜<br />

sol , , ,<br />

(8)<br />

⎟<br />

⎝ L ρ g Vt<br />

gL μ<br />

⎠<br />

A 1/5 scaled model has been built <strong>for</strong> the dipleg. This factor has been chosen to simulate the<br />

whole PFBC <strong>cyclone</strong> <strong>system</strong>. First dimensionless group is a ratio between dipleg dimensions<br />

and it is maintained. Particle-solid densities ratio is also conserved since it was also a<br />

dimensionless group in <strong>cyclone</strong> <strong>scaling</strong>. Solid concentration as solid- air flow through dipleg<br />

is maintained with the assumption of <strong>cyclone</strong> efficiency is similar. Velocities ratio<br />

dimensionless number is equal to the tangent of the sliding particle velocity. Particles<br />

tangential velocity is supposed to be proportional to the tangential velocity calculated with<br />

Alexander equation (Alexander, 1949):<br />

sol<br />

V r cte<br />

n<br />

t = (9a)<br />

( ) ⎟ ⎟<br />

0.<br />

3<br />

⎛ ⎞ ⎞<br />

0.<br />

14 T<br />

1−<br />

0.<br />

67D<br />

* ⎜ ⎟<br />

⎛<br />

n = 1−<br />

⎜<br />

⎜<br />

dl<br />

(9b)<br />

⎝<br />

⎝283⎠<br />

⎠<br />

Particle axial velocity is proportional to the gas velocity though the dipleg and could be<br />

estimated as<br />

V<br />

m<br />

= (10)<br />

a _ nozzle<br />

ax ρ g Asn<br />

8


The conservation of the transport air flow makes the sliding angle to be conserved. This takes<br />

into account the effects of vortex extending due to suction. This effect could modify the<br />

dipleg flow patterns, so it is important to maintain it constant:<br />

V<br />

V<br />

ax<br />

t<br />

msn<br />

=<br />

ρ A<br />

g<br />

sn<br />

1 ⎛ Ddl<br />

⎜<br />

V ⎝ D<br />

in<br />

⎞<br />

n<br />

⎟<br />

⎠<br />

m<br />

=<br />

m<br />

sn<br />

air<br />

A<br />

A<br />

in<br />

sn<br />

⎛ D<br />

⎜<br />

⎝ D<br />

The small difference in the values of exponent n in Alexander equation modifies slightly the<br />

sliding angle between PFBC <strong>cyclone</strong> and cold flow model. This difference could be estimated<br />

as a 1.6 % and can not be reduced since n depends on the temperature. Froude number is<br />

calculated as a relation between axial velocity, dipleg length and gravity. Because of the<br />

conservation of transport air, Froude number is maintained. Finally, Reynolds number could<br />

not be conserved due to gas viscosity is fixed by the cold flow model temperature.<br />

Table 3 lists the dipleg geometric and operating variables. They have been used to<br />

calculate the dipleg <strong>scaling</strong> <strong>parameters</strong> and dipleg erection. Table 4 summarised the<br />

dimensionless <strong>parameters</strong> of the dipleg, the values of the <strong>scaling</strong> <strong>parameters</strong> were closely<br />

matched between the cold flow model and the Escatrón PFBC except <strong>for</strong> Reynolds number.<br />

Table 3. Comparison between Escatrón PFBC and laboratory dipleg cold flow model<br />

<strong>parameters</strong><br />

dl<br />

n<br />

⎞<br />

⎟<br />

⎠<br />

REAL DIPLEG LABORATORY COLD<br />

FLOW MODEL DIPLEG<br />

Ddl (mm) 400 80<br />

L (m) 9.15 1.83<br />

T (K) 1030 293<br />

P (bar a) 11.14 3.22<br />

ρg (kg/m 3 ) 3.8 3.8<br />

ρs (kg/m 3 ) 2800 2800<br />

Mair (kg/s) 10.6 0.19<br />

Mnozzle (g/s) 163 2.9<br />

Mash (g/s) 800 14.0<br />

(11)<br />

9


Table 4. Comparison of dipleg Escatrón PFBC and cold flow model dimensionless <strong>scaling</strong><br />

Dipleg dimensions<br />

Density ratio<br />

Solid concentration<br />

Velocities ratio<br />

Froude number<br />

Reynolds number<br />

<strong>parameters</strong><br />

ESCATRON PFBC<br />

REAL DIPLEG<br />

LABORATORY COLD<br />

FLOW MODEL DIPLEG<br />

L<br />

Ddl<br />

22.0 22.0<br />

ρ s<br />

ρ<br />

736.8 736.8<br />

g<br />

C =<br />

M<br />

75 e-3 74 e-3<br />

sol<br />

ash<br />

M air<br />

Vax 0.568 0.559<br />

V<br />

t<br />

2<br />

ax<br />

Fr = V gL<br />

105.3 105.4<br />

Lρ<br />

gVax Re =<br />

μ<br />

CYCLONE AND DIPLEG COLD FLOW MODEL<br />

1.96 e+5 4.08 e+4<br />

Figure 1 shows <strong>cyclone</strong> and dipleg built with the similarity criteria a<strong>for</strong>ementioned<br />

and have linear dimensions which are one-fifth those of the real PFBC dimensions. Figure 2<br />

shows the cold flow model device that is made up of the following components:<br />

- Two air-pressure supplies: main (L1) and a secondary line (L10) <strong>for</strong><br />

fluidisation of the particle-discharging hopper.<br />

- Pressurized solid storage tank (T1) and variable speed rotary valve connected<br />

to a Venturi nozzle (L3).<br />

- Primary <strong>cyclone</strong> inlet (L4), air with a design solid concentration of 290 g/m 3 .<br />

- Experimental primary <strong>cyclone</strong> (T2), equipped with a PMMA dipleg (T4).<br />

- Secondary <strong>cyclone</strong> (T3) with a solids-collecting bin (T7).<br />

- Two sedimentation chambers with fabric filters <strong>for</strong> complete collection of<br />

particles and cleaning of the exhaust air (T5 and T6).<br />

- Control of airflow by flow meters and valves downstream the sedimentation<br />

chambers (I1 and I2)<br />

10


control<br />

pressure valve<br />

hopper<br />

fluidisation<br />

T P<br />

Pin= 2.21 bar(g)<br />

Tin= 20 °C<br />

ash flow= 50 kg/h<br />

air flow= 680 kg/h<br />

a<br />

Figure 1. Scaled <strong>cyclone</strong> dimensions<br />

b<br />

De<br />

D<br />

B<br />

S<br />

h<br />

H<br />

L<br />

Dimensions<br />

a/D 0.460<br />

b/D 0.203<br />

De/D 0.307<br />

S/D 0.891<br />

h/D 1.310<br />

H/D 3.795<br />

B/D 0.399<br />

L/D 9.022<br />

Figure 2. Laboratory cold flow model <strong>cyclone</strong> <strong>separator</strong> <strong>system</strong><br />

ash<br />

hopper<br />

rotary feeder<br />

P ΔP<br />

primary<br />

<strong>cyclone</strong><br />

ΔP<br />

ash extraction<br />

dipleg<br />

suction<br />

nozzle<br />

.<br />

secondary<br />

<strong>cyclone</strong><br />

T P F<br />

filter 1<br />

T P F<br />

filter 2<br />

clean air<br />

clean air<br />

11


CYCLONE AND DIPLEG EXPERIMENTAL COMPARISON<br />

Experimental <strong>scaling</strong> verification is based on a comparison of pressure drop. Cyclone<br />

pressure drop has a strong influence on collection efficiency. The impossibility to take data of<br />

collection efficiency at PFBC power station to compare with cold flow model has made us to<br />

validate the <strong>scaling</strong> <strong>parameters</strong> based on <strong>cyclone</strong> pressure drop. For pneumatic transport as in<br />

dipleg, pressure drop plays an essential role in its analysis. Probes have been placed in several<br />

points though dipleg, and partial and total dipleg pressure drop have been obtained <strong>for</strong><br />

verification.<br />

The data used in the following <strong>scaling</strong> comparisons were taken at operating conditions<br />

after a periodic overhaul of the Escatrón PFBC, with <strong>cyclone</strong>s revised and cleaned of sintered<br />

deposits. The data used in the <strong>scaling</strong> comparison were taken at a single operating condition<br />

and in steady- state operation. The PFBC power plant load was approximately 90% of the full<br />

load with a standard deviation of 1 MW. Cold flow model pressure drop data were taken<br />

using pressure transducers with a range of 0/62 mbar <strong>for</strong> <strong>cyclone</strong> pressure drop and –62/+62, -<br />

37/+37, -37/+37 and –5/5 mbar <strong>for</strong> dipleg. The data from Escatrón PFBC were obtained with<br />

pressure transducer with a range of 0/490 mbar <strong>for</strong> <strong>cyclone</strong> pressure drop, ad –98/+98 mbar<br />

<strong>for</strong> dipleg pressure drop. Data uncertainty is about 0.4% of span.<br />

PFBC <strong>cyclone</strong> pressure drop transducers are installed in five of the nine <strong>cyclone</strong>s.<br />

Data from pressure drop varies from a maximum of 199.2 mbar to a minimum of 141.0 mbar.<br />

Table 5 shows the PFBC data and its comparison with cold flow model data.<br />

PFBC pressure drop data shows discrepancies between real <strong>cyclone</strong>s. Most probably, a<br />

combination of ashes and gases non-homogeneity at <strong>cyclone</strong> inlet could cause these<br />

discrepancies. Another cause to explain this effect is <strong>cyclone</strong> fouling. As it will be proved in a<br />

next paper (Romeo et al., 1999), fouling causes a reduction in <strong>cyclone</strong> pressure drop. A<br />

different fouling between <strong>cyclone</strong>s could be the cause of discrepancies in real data.<br />

In order to compare and validate the cold flow model, it is necessary to scale down the<br />

Escatrón PFBC <strong>cyclone</strong> pressure drop data or scale up the cold flow model data. The<br />

dimensionless variable <strong>for</strong> the pressure drop is<br />

⎛ C ⎞<br />

Δ P ⎜<br />

ρs<br />

s _in<br />

=<br />

⎟<br />

2 f Fr , ,<br />

(12)<br />

1 ρV<br />

⎜ ⎟<br />

2 in ⎝<br />

ρ g ρs<br />

⎠<br />

The right-hand term of the equation (12) is conserved due to the maintenance of<br />

dimensionless numbers that affect <strong>cyclone</strong> behaviour. So, to scale pressure drop data it is<br />

12


necessary take in account the velocity ratio to the power of two, it means to operate by a<br />

factor of five.<br />

The agreement between Escatrón PFBC pressure drop data and cold flow model data<br />

scaled up is excellent, as indicated in table 5. For the PFBC <strong>cyclone</strong>s, the pressure drop has an<br />

average of 168.0 mbar and a standard deviation of 20.3 mbar, the 99% of the data would be in<br />

the range of 127.4/208.6 mbar. In the cold flow model, the average is 148.5 mbar with a<br />

standard deviation of 9.0 mbar, so the 99% of the data would be in the range of 124.0/166.5<br />

mbar. The latter range of data is approximately inside the <strong>for</strong>mer one. This agreement<br />

provides a verification of the <strong>scaling</strong> proposed above.<br />

Table 5. Comparison between PFBC and cold flow model <strong>cyclone</strong> pressure drop data<br />

Cyclone 1<br />

Cyclone 3<br />

Cyclone 5<br />

Cyclone 7<br />

Cyclone 9<br />

Average of five PFBC<br />

Cyclones<br />

Cold flow Model<br />

Cyclone<br />

Cold flow Model<br />

Cyclone Scaled data<br />

Maximum Minimum Average<br />

191.4<br />

199.2<br />

174.9<br />

150.8<br />

145.4<br />

175.7<br />

190.3<br />

167.7<br />

142.9<br />

141.0<br />

182.5<br />

194.7<br />

172.3<br />

147.7<br />

143.1<br />

Standard<br />

deviation<br />

7.00<br />

3.83<br />

2.95<br />

2.89<br />

1.72<br />

194.7 143.1 168.0 20.5<br />

34.43 24.06 29.73 1.79<br />

172.2 120.3 148.5 9.0<br />

Tables 6 and 7 show also a comparison between PFBC and cold flow model dipleg<br />

pressure drop data. Three zones are observed in the dipleg, an upper one where the pressure<br />

drops strongly. An intermediate region where the pressure drop is negative and particles are<br />

going down vertically. Finally, the last zone near the suction nozzle where the pressure drops<br />

due to pneumatic transport. These three zones are observed both, in the PFBC and the cold<br />

flow model, so that qualitatively the behaviour or the diplegs are similar, although a<br />

difference in values is also observed. Table 6 shows the data at real and cold flow model<br />

dipleg.<br />

13


Table 6. Comparison between PFBC and cold flow model dipleg pressure drop data<br />

PFBC dipleg pressure drop 1<br />

PFBC dipleg pressure drop 2<br />

PFBC dipleg pressure drop 3<br />

Cold flow model dipleg pressure drop 1<br />

Cold flow model dipleg pressure drop 2<br />

Cold flow model dipleg pressure drop 3<br />

Maximum Minimum Average<br />

63.2<br />

- 3.44<br />

22.3<br />

60.6<br />

- 4.94<br />

16.3<br />

61.8<br />

- 3.94<br />

18.1<br />

2.50<br />

- 0.18<br />

Standard<br />

deviation<br />

In table 7 the scaled data <strong>for</strong> the cold flow model is compared with real data. Scaling<br />

up has been done in the same manner as <strong>cyclone</strong> <strong>scaling</strong> up, i.e. the velocity ratio to the power<br />

of two. In spite of the similar tendencies in pressure drop, the <strong>scaling</strong> is not as good as the<br />

<strong>cyclone</strong> <strong>scaling</strong>. In this case the effect of varying Reynolds number is affecting the agreement.<br />

Taking into account the Reynolds influence and multiplying by 5 (PFBC and cold flow model<br />

Reynolds relation) the agreement of pressure drop in the two upper zones is excellent.<br />

Possibly, a combination of suction and ash deposition is the responsible of discrepancies in<br />

the lower zone pressure drop data. In addition, the effect of fluidisation air in PFBC dipleg<br />

bottom has not been taken into account in the cold flow model constructed, and it could<br />

modify the measurements or the behaviour in this zone. Further studies are necessary to<br />

explain this discrepancy.<br />

Table 7. Comparison between PFBC and cold flow model dipleg pressure drop data<br />

Pressure drop 1<br />

Pressure drop 2<br />

Pressure drop 3<br />

PFBC data Cold flow model<br />

61.8<br />

- 3.94<br />

18.1<br />

data<br />

2.50<br />

- 0.18<br />

0.04<br />

Scaled data<br />

12.5<br />

- 0.9<br />

0.2<br />

0.04<br />

1.02<br />

0.54<br />

2.31<br />

Scaled data and<br />

Reynolds<br />

influence<br />

62.5<br />

- 4.5<br />

1.0<br />

14


CONCLUSIONS<br />

A 1/5-scale model of the Escatrón PFBC <strong>cyclone</strong> <strong>system</strong> has been constructed based<br />

on <strong>scaling</strong> <strong>parameters</strong>. Comparisons of <strong>cyclone</strong> pressure drop from the cold flow model and<br />

Escatrón PFBC indicates that the <strong>cyclone</strong> behaviour of the two <strong>cyclone</strong>s is similar. Because of<br />

<strong>cyclone</strong> pressure drop is one of the most important <strong>parameters</strong> in collection efficiency, it is<br />

assumed the <strong>cyclone</strong> efficiency would be maintained in both <strong>system</strong>s. This point remains<br />

open due to the impossibility to validate the cold flow model results at the real <strong>system</strong>.<br />

An analysis of the main variables in PFBC <strong>cyclone</strong> dipleg has been done. This study<br />

has not been addressed be<strong>for</strong>e. It has been impossible to maintain all the <strong>scaling</strong> <strong>parameters</strong><br />

that influence dipleg behaviour. Reynolds number has not been maintained due to <strong>cyclone</strong><br />

<strong>scaling</strong> determinate the value of some variables in dipleg behaviour. Reynolds influence has<br />

been taken into account to validate the cold flow model data. Comparison of dipleg pressure<br />

drop from the cold flow model and Escatrón PFBC show a good agreement through the<br />

dipleg. In the suction nozzle some discrepancies has been observed. The reason <strong>for</strong> these<br />

discrepancies could be the different behaviour of the ash conveying lines in Escatrón PFBC<br />

and the sedimentation chamber in the cold flow model. Further studies are needed to fully<br />

understand fluid flow around suction nozzle.<br />

The cold flow model is revealed as an important tool to optimize and understand the<br />

<strong>cyclone</strong> <strong>system</strong> behaviour. It is also useful to know the influence of different operational<br />

variables. At present, these studies are being carried out.<br />

ACKNOWLEDGEMENTS<br />

This research has been fully supported by ENDESA, S.A. Mr Alfonso Ruiz, director<br />

of Escatrón PFBC power station, Dr. Emilio Menéndez, head of the R&D department of<br />

ENDESA, S.A., and Mr. Diego Martínez, head of the R&D department at Escatrón are<br />

gratefully acknowledged <strong>for</strong> making possible the project and <strong>for</strong> all the facilities provided.<br />

Escatrón power plant personnel are also acknowledged <strong>for</strong> their useful assistance.<br />

NOMENCLATURE<br />

Asn<br />

Cs_in<br />

Csol<br />

suction nozzle area (m 2 )<br />

solid concentration at <strong>cyclone</strong> inlet (g/m 3 )<br />

solid concentration at dipleg (g/m 3 )<br />

D <strong>cyclone</strong> diameter (m)<br />

15


Ddl<br />

dp<br />

dp50<br />

dipleg diameter (m)<br />

particle diameter (m)<br />

particle diameter at 50% of the PSD (m)<br />

Fr Froude number<br />

g gravity acceleration (m/s 2 )<br />

L dipleg length (m)<br />

ma_nozzle<br />

Mair<br />

Mash<br />

P pressure (bar)<br />

air flow through the suction nozzle (g/s)<br />

air flow at <strong>cyclone</strong> inlet (kg/s)<br />

ash flow at <strong>cyclone</strong> inlet (kg/s)<br />

Re Reynolds number<br />

Rep<br />

particle Reynolds number<br />

Stk Stokes number<br />

T temperature (K)<br />

Vax<br />

Vin<br />

vr<br />

Vt<br />

Greek Leters<br />

axial velocity at dipleg (m/s)<br />

inlet <strong>cyclone</strong> velocity (m/s)<br />

relative velocity (m/s)<br />

tangential velocity at dipleg (m/s)<br />

η <strong>cyclone</strong> efficiency (%)<br />

ρg<br />

μg<br />

ρs<br />

REFERENCES<br />

gas density (kg/m 3 )<br />

gas viscosity (kg/m s)<br />

solid density (kg/m 3 )<br />

Abrahamson J, Martin CG, Wong KK (1978) The Physical Mechanisms of Dust<br />

Collection in a Cyclone. Transactions of the Institute of Chemical Engineers, Vol. 56, pp.168-<br />

177.<br />

Alexander R (1949) Fundamentals of Cyclone Design and Operation. Procedures of<br />

the Australian Institute Min. Metall, nº 152, pp.203-208.<br />

Chao BT (1982) Scaling and Modelling. Handbook of Multiphase Systems. Edited by<br />

Gad Hetsroni, Hemisphere Publishing Co, pp.(3)44-(3)48<br />

16


Cheremisinoff NP, Cheremisinoff PN (1986) Particulate Capture from Process Gas<br />

Streams in Encyclopedia of Fluid Mechanics, edited by Cheremisinoff NP, Vol. 4, pp. 1217-<br />

1279<br />

Dirgo J, Leith D (1986). Design of Cyclone Separators in Encyclopedia of Fluid<br />

Mechanics, edited by Cheremisinoff NP, Vol. 4, pp.1281-1306<br />

Hoffman AC, Arends H, Sie H (1991) An Experimental Investigation Elucidating the<br />

Nature of the Effect of Solids Loading on Cyclone Per<strong>for</strong>mance. Proceedings of the Filtration<br />

Society, Filtration & Separation, Vol. 2, pp.188-193<br />

Hoffman AC, van Santen A, Allen RWK, Clift R (1992) Effects of Geometry and<br />

Solid Loading on the Per<strong>for</strong>mance of Gas Cyclones. Powder Technology, Num. 70, pp.83-91.<br />

Leith D, Litch W (1972) The Collection Efficiency of Cyclone Type Particle<br />

Collectors. A New Theoretical Approach. Air Pollution and Its Control, AIChE Symposium<br />

Series, Num.26, Vol.68, pp.196-206<br />

Morweiser and Bohnet (1996) Influence of Temperature and pressure on Separation<br />

Efficiency and Pressure Drop of Aero<strong>cyclone</strong>s in High Temperature Gas Cleaning, edited by<br />

E.Schmidt. Institut für Mechanishe Verfahrenstechnik und Mechanik.<br />

Mothes H, Löffler R (1985) Motion and Deposition of Particles in Cyclones. German<br />

Chemical Engineering, Num.8, pp.223-233<br />

Romeo LM, Gil A, Cortés C (1999) Improving Hot Gas Filtration Behaviour in PFBC<br />

Power Plants. Paper accepted to be presented at 15 th International FBC Conferences<br />

Svarovsky L (1981) Solid Gas Separation in Handbook of Powder Technology, edited<br />

by Elsevier ,Vol 3, pp.33-52<br />

Svarovsky L (1986) Solid-Gas Separation in Gas Fluidization Technology, edited by<br />

Geldart D, John Wiley & Sons, pp.197-217<br />

Wheeldon JM, Burnard GK (1987) Per<strong>for</strong>mance of Cyclones in the Off-Gas Path of a<br />

Pressurized Fluidized Bed Combustor. Proceedings of the Filtration Society, Filtration &<br />

Separation, Vol. 3, pp.178-187<br />

17

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