Abstract Booklet 2006 - Swanson School of Engineering - University ...

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syngas filter, a gas cleanup process, and related systems. Built at a sufficient scale to test advanced power systems and components in an integrated fashion, the PSDF provides data necessary for commercial scale-up of these technologies. To guide future tests and commercialization of the technologies at the PSDF, a series of conceptual commercial plant designs has been completed in partnership with the DOE and the Electric Power Research Institute (EPRI). Six TrIG combined cycle cases ha been developed to investigate the relative costs and benefits of oxygen-blown or air-blown gasification, of stack gas or syngas cleanup, and of carbon dioxide capture. These cases are all based on a 2x1 GE7FA+e combined cycle fueled by syngas from two Transport Gasifiers using Powder River Basin (PRB) sub-bituminous coal. Detailed performance modeling and cost estimation have shown that the optimal configuration for power production without carbon dioxide capture includes air-blown gasification and cold syngas cleanup. Airblown gasification was also shown to be preferable when carbon dioxide is captured in a TrIG combined cycle system. SESSION 14 SYNTHESIS OF LIQUID FUELS, CHEMICALS, MATERIALS AND OTHER NON-FUEL USES OF COAL: COKE AND OTHERS 14-1 Hydrothermal Extraction of Brown Coals for Their Effective Utilization Kouichi Miura, Hiroyuki Nakagawa, Masato Morimoto, Ryuichi Ashida, Kyoto University, JAPAN A novel coal conversion process was proposed: the method combines "a hydrothermal extraction of brown coal (HT-Extraction, extraction of brown coal by inherent water under hydrothermal condition)" and "a catalytic hydrothermal gasification of the extract (CHT-Gasification)" both of which are performed under the exactly same conditions of less than 350°C and less than 20 MPa. The HT-extraction intends to increase the amount of organic compounds in the aqueous phase and the CHT- Gasification gasifies the organic compounds in the aqueous phase using a novel Nisupported carbon catalyst developed by the authors, producing combustible gas rich in CH 4 and H 2 . Then the proposed process is expected to be not only a dewatering/ upgrading process of brown coal but also an effective brown coal gasification process. To elucidate the behaviors on the HT-Extraction, several brown coals were treated in flowing water or different concentrations of phenol aqueous solutions at temperatures of 350°C. Experiments combining the extraction and the catalytic reaction process were also performed using an Australian brown coal to examine the validity of the proposed concept. 14-2 The Characterization of Cokes from Co-coking of Decant Oil and Coal Parvana Gafarova Aksoy, Caroline Burgess Clifford, Leslie Rudnick, Harold H. Schobert, The Pennsylvania State University, USA Researchers at The Pennsylvania State University have been involved for the last fifteen years in the development of thermally stable jet fuel. The focus of production of this fuel is to incorporate coal or coal derived materials into existing oil refinery operations. Penn State’s researchers have clearly shown that the kinds of chemicals in the fuel that make it stable at 900°F (hydroaromatics and naphthenes) can be derived in abundant amounts from coal. The overall objectives of refinery integration project are: 1) Investigate and develop an understanding of the most promising refinery integration of all process streams resulting from the production of a coal-based jet fuel. 2) Demonstrate the quality of each of the process streams in terms of refinery requirements to maintain a stable, profitable refinery operation. 3) Demonstrate the performance of key process streams in practical testing used for application of these streams. Therefore, the project focus is to examine the characteristics and quality of the streams, such as gasoline, diesel fuel, fuel oil, and coke and to determine the effects of those materials on other unit operations in the refinery. The work presented will focus on the blending of coal with decant oil as delayed coker feed. The objective of this work is to evaluate coke from co-coking of decant oil and coal. The affect of coal to coking of decant oil will be examined. The unique pilot-scale coking unit was used for performing coking and co-coking experiments. This work mainly focused on characterization of uncalcined and calcined coke samples. Densities and ash contents were determined for calcined and uncalcined coke samples. X-ray diffraction technique was used for evaluation the degree of structural anisotropy in coke samples. 14-3 Co-pyrolysis of Hydrothermally Upgraded Brown Coal and Wax Formed From Waste Plastics Susan Roces, De La Salle University, USA Ryuichi Ashida, Masato Morimoto, Kouichi Miura, Monthicha Pattarapanusak, Kyoto University, USA The authors have recently presented a new method that not only removes water from brown coal but also separates the coal into upgraded coal and extract of low molecular mass compounds. Brown coals were hydrothermally treated using flowing liquid water at around 350°C. The treatment of an Australian brown coal, Loy Yang, resulted in 12 obtaining 46% upgraded coal and 46% extract. It was found that the upgraded coal contained much less oxygen than the raw coal and its elemental composition was close to higher rank coals. However, the upgraded coal was still not like bituminous coals and it will need some technique to be utilized more effectively. In this study copyrolysis of the upgraded coals and waxes formed from waste plastics was investigated as one of the methods of their effective utilization. Waxes were prepared through pyrolysis of high density polyethylene, polypropylene, and polyethylene terephtalate. Upgraded coals were then impregnated with the waxes by treatment in an autoclave at 200°C under pressure. The mixtures of coal and wax were rapidly heated up to 1040°C at about 3000°C/s using a Curie point pyrolyzer in an inert atmosphere. It was found that char yield was greatly enhanced by a factor of 1.1 to 1.3 compared to the char yield of the upgraded coals and waxes when pyrolyzed independently. Even at a slower heating rate (0.17°C/s) the char yields increased by a factor of 1.2 for all waxes. Since no such effect was found when using raw brown coal instead of the upgraded coal, it was suggested that the improvement of the structure of brown coal by our method could enhance interactions between the coal and the wax when co-pyrolyzed. 14-4 Structural Characterization of Alternative Binder Pitches for Carbon Anodes Uthaiporn Suriyapraphadilok, David J. Clifford, Caroline E. Clifford, Harold H. Schobert, The Pennsylvania State University, USA John M. Andresen, University of Nottingham, UNITED KINGDOM The demand for coal tar binder pitch in the aluminium industry accounts for about 75% of the pitch market. Since the production of coal tars is rapidly decreasing in the United States as well as throughout the world, the development of alternative binders should be considered. The objective of the present work was to understand the chemistry of alternative pitches from different origins and processes and compare with the well-developed coal tar binder pitch. The pitch samples studied included a coal tar pitch, coal-extracted pitch, gasification pitch, and laboratory-generated co-coking pitch. Coal tar binder pitches are traditionally obtained from coal tars that are the by-product of bituminous coal coking process used to make coke for blast furnaces in iron production. Gasification pitches are distilled by-product tars produced from the coal gasification process. A production of coalextracted pitches involves a pre-hydrogenation of coal followed by extraction using a dipolar solvent. The co-coking pitch is a unique material derived from co-carbonization of coal and decant oil under the conditions simulating a delayed-coker in our laboratory. All samples were characterized by nuclear magnetic resonance (NMR) spectroscopy and laser desorption mass spectrometry (LDMS). A comparison of average structure and molecular mass of these pitch samples will be presented. 14-5 Supercritical Fluid Extraction of Diterpenes from Slovak Brown Coal Udmila Turcani, Slovak Academy of Science, SLOVAK REPUBLIC Franciszek Czechowski, Institute of Organic Chemistry, POLAND Helena Sovava, Institute of Chemical Process Fundamentals AS CR, CZECH REPUBLIC Franti ek Verbich, Upper Nitra Mines, SLOVAKIA Anton Zubrik, Silvia Uvanova, Institute of Geotechnics, SLOVAKIA The finely powdered Handlova brown coal was extracted under supercritical conditions at temperature of 323K with CO 2 and at temperatures 573 and 613K with cyclohexane isopropanol mixture (9:1 v/v). Particles size of the powdered coal used to extraction (Ad = 7.7%, Cd = 54 %) averaged around 6.5m (planetary mill Molinex). The coal granularity under 10 m, according to literature, assured highest extract yield. The extracted material amounted 0.42, 13.95 and 7.99% of raw coal mass at the above mentioned temperatures, respectively. The supercritical fluid extracts were preliminarily separated to three fractions by semipreparative HPLC (HP 1090, Hewlett-Packard, Germany) equipped with UV detector (HP 1090, Series II) using chromatographic column Lichrosphere 100 RP 18 (mobile phase: acetonitrile-water). The fraction selected on the base of elution time within narrow range found for elution time of kaurenoic acid (14.647 minutes, UV wavelength 210 nm) was further analyzed by GC/MS (Agilent Technologies 6890N - Folsom, USA). This fraction constituted high abundance of diterpenoic compounds: 16 H kaurane - C 20 H 34 , kaurenoic acid - C 20 H 30 O 2 , abietatriene C 20 H 30 , ferruginol C 20 H 30 O and others. The data on fungicidal activity of the terpenoic compounds separated from coal will be presented. SESSION 15 COMBUSTION TECHNOLOGIES – 3: OXY-FUEL COMBUSTION 15-1 Expanding the Clean Coal Portfolio: Oxyfiring to Enhance CO 2 Capture Glen Jukkola, Nsakala Nsakala, Greg Liljedahl, Frank Kluger, Alstom Power, USA A portfolio of Clean Coal power generation technologies are on path to commercialization in response to the need for near-zero emissions and CO 2 capture for storage/sequestration. Technology providers are responding to generators needs with innovations ranging from higher efficiency to post-combustion capture to alternative plant designs. Among the
promising Clean Coal technologies under development to address CO 2 emissions is oxygen combustion. By firing with nearly pure oxygen, atmospheric nitrogen is not introduced into the products of combustion and a concentrated CO 2 flue gas stream is produced. This CO 2 stream can be dried and compressed for sequestration, or further processed into a high purity CO 2 product for varied uses including enhanced oil recover (EOR) or enhanced gas recovery. Oxyfiring is an attractive option for coal combustion for a number of reasons, including: 1. It uses proven, reliable, commercially available Pulverized Coal (PC) and Circulating Fluidized Bed (CFB) technology 2. Oxygen can be readily produced by commercial cryogenic air separation 3. CO 2 cleanup, compression, and liquefaction is proven technology It is anticipated that initial deployment of oxyfiring would be for commercial EOR application, with co-production of electricity, use of CO 2 for oil field stimulation, and use of by-product nitrogen (from oxygen production) for oil field pressurization. Oxyfiring is also a stepping stone to additional advanced Clean Coal processes, including chemical looping. ALSTOM is actively participating with the US-DOE as well as European partners, Utilities, and academia to design and demonstrate oxyfiring utilizing PC and CFB technologies. This paper will address the key aspects of the design of oxyfired boilers and the timeline for commercialization. Recent studies have developed important knowledge on heat transfer, combustion efficiency, and emissions. This data will form the design basis for scale-up for oxyfired demonstration plants. The next step is to demonstrate oxyfiring at a scale of 10 to 100 MWe. The goal is to provide coal-based power generation options that are clean, cost competitive, and reliable. 15-2 Comparisons among Different Implementation Options for Coal-Fired Oxyfuel Power Plants Xinxin Li, Columbia University, USA Climate change concerns over carbon dioxide emissions from fossil fuel combustion have led to the development of carbon dioxide capture technologies for coal fired power plants. One particularly promising approach known as oxyfuel-combustion replaces air in the combustion chamber with a mixture of pure oxygen and carbon dioxide rich recycled flue gas. The resulting concentrated stream of CO 2 can be pressurized and transported from the plant to a storage site where it is disposed off safely and permanently. Oxyfuel-combustion based power plants are shown to be a very competitive option for CO 2 capture. This study evaluates three major strategies for introducing oxyfuel power plants: (1) construction of new oxyfuel plants; (2) retrofit of existing power plants to oxyfuel plants; (3) construction of new conventional plants that are designed for a cost-efficient future retrofit. The paper considers the engineering aspects in the three cases and develops an economic analysis to compare the three options with each other and with a conventional coal fired power plant that provides the baseline case. The net present values of the different plants are calculated and compared; a sensitivity analysis is performed and the implications of different sensitivities of the key parameters are discussed in the context of long-term investment decisions. The study suggests that under a wide range of assumptions building new oxyfuel power plant is the most attractive options for power plant investors. Retrofit options are not competitive unless the plant has a remaining lifetime of more than twenty years. This is rarely the case for today s power plant fleet in the United States. The situation changes, however, if the upgrade can significantly increase the remaining lifetime of the plant. The sensitivity analysis indicates that the electricity price and CO 2 credit price heavily influence the choice of plant options. An increase in the price of CO 2 credit makes new oxyfuel plant even more attractive, the decrease in the price of CO 2 credit makes the base plant more attractive, the minimum CO 2 credit for oxyfuel power plants to be competitive with the base plant is $25.30/ton. An increase in the price of electricity also makes the base plant more attractive; at electricity prices greater than 7.15 c/kWh, new oxyfuel power plant is not attractive as the loss in additional electricity outweighs the gain from carbon credits. Under those conditions, the best investment is a conventional coal-fired power plant. 15-3 An Optimized Supercritical Oxygen-Fired Pulverized Coal Power Plant for CO 2 Capture Andrew Seltzer, Zhen Fan, Foster Wheeler North America Corp., USA Timothy Fout, DOE/NETL, USA The Department of Energy and Foster Wheeler have jointly developed a conceptual supercritical pulverized coal (PC) boiler plant design that will allow practical carbon dioxide (CO 2 ) capture for future CO 2 sequestration efforts. CO 2 is a major greenhouse gas, which has been linked to global climatic change. A novel process for CO 2 sequestration is proposed utilizing a supercritical oxygen-fired PC boiler, which, as part of a Rankine steam cycle, forms a high efficiency, zero emission, stackless power station. Coal is combusted in the furnace where the oxidizer consists of a mixture of O 2 and recycled flue gas, which contains primarily CO 2 gas. Recycling of the flue gas is utilized to control flame temperature in the boiler furnace to maintain acceptable waterwall temperatures. NO x formation is minimized by combustion staging via low NO x burners and over-fire gas ports. Virtually all of the flue gas sensible and latent heat energy is recovered in the heat recovery area of the boiler where steam superheaters, steam reheaters, gas recuperators, and water economizers are located. The effluent of the plant is virtually pure CO 2 , which is condensed, pressurized, and piped from the plant to the sequestration site. Overall power plant system and component designs are presented for a 475 MW (gross) supercritical coal-fired plant. The power plant system cycle was optimized to minimize the overall power plant heat rate and facilitate CO 2 sequestration. Vent gas power recovery and vent gas recycle for O 2 recovery are incorporated to minimize the CO 2 removal auxiliary power. The furnace and heat recovery area components were designed to optimize the location and design of the furnace, burners, over-fire gas ports, and internal radiant surfaces producing a more compact and efficient design than air-fired furnaces. A detailed thermal/hydraulic design and analysis of the waterwall geometry was conducted to avoid high metal temperatures due to dryout or departure from nucleate boiling and to avoid flow instabilities. An investigation of the improvement in cycle efficiency and the reduction in CO 2 removal penalty due to the integration of advanced oxygen separation techniques is also presented. 15-4 Numerical Modeling of the Effect of Aerodynamics on NO x Emissions and Char Burnout for Combustion of Coal in O 2 /CO 2 Sarma V. Pisupati, Prabhat Naredi, The Pennsylvania State University, USA Combustion of coal in O 2 and Recycled Flue Gas (RFG) medium is one of the approaches to obtain pure CO 2 stream from an existing power plant that can be sequestered to reduce the greenhouse gas emissions into the atmosphere. Other advantages of this approach are an increase in char burnout and reduction in NO x emissions. However, in order to retrofit the existing boiler, approximately 30% O 2 and 70% CO 2 blend is required in the oxidizer stream. This leads to a decrease in the volume of combustion gases which subsequently changes the mixing pattern of oxidizer and coal particles inside the boiler. If coal particles and oxygen are not well mixed, NO x emissions will be altered due to local fuel rich pockets. In the present paper, an, axi-symmetric, 2-D computational model was developed using Fluent CFD code, for a 1,000 lb steam/hr “A-frame”, water-tube research boiler to identify and optimize the key variables that influence the NO x emissions. Model predictions were compared with the experimental measurements of gas temperature, particle speed and gaseous emissions for Upper Freeport (Bituminous) coal fired in air medium. The effects on gaseous emissions such as NO x , and CO 2 due to change in combustion gas loading and presence of increased CO 2 are predicted under similar operating conditions. The effect of swirl number was analyzed to minimize the NO x emissions from the boiler in enriched O 2 /CO 2 medium. 15-5 Experimental and Modeling Study on Particle Size Distribution Effects Due to Oxy-Combustion of Coal Achariya Suriyawong, Scott Skeen, Richard Axelbaum, Pratim Biswas, Washington University in St. Louis, USA O 2 -CO 2 coal combustion is a promising technology for mitigating the increase of CO 2 in the atmosphere. Advantages include the potential for CO 2 capture, reduction of NO x emissions, and improvement in combustion efficiency. This paper presents an experimental study developed to examine the effects of O 2 -CO 2 combustion on fine particle formation and flame stability from both a laminar flow drop-tube furnace and a piloted coal flame reactor. The results were compared with those obtained under conventional combustion conditions (air) and differences are highlighted. SESSION 16 ENVIRONMENTAL CONTROL TECHNOLOGIES: SO x , NO x , PARTICULATE AND MERCURY – 1 16-1 A Multi-Pollutant Wet Scrubber for Capture of SO 2 , NO x and Hg Nick Hutson, Ravi Srivastava, Brian Attwood, US EPA, USA; Carl Singer, Arcadis, USA An enhanced wet scrubber that removes SO 2 , NO x and Hg (both Hg 2+ and Hg 0 ) from coal combustion flue gas has been developed and tested at the EPA/RTP laboratories. In this multi-pollutant system, a traditional limestone (or other alkali) scrubber solution is enhanced with an additive that promotes the capture of NO x and Hg species. In the optimized system, SO 2 (1800 ppm), NO x (200 ppm) and Hg 0 (30 ppb) were all captured at near 100% efficiency. Results from this testing will be provided and discussed in the presentation. 16-2 Study on NO Reduction by Coal and Chars in an Entrained Flow Reactor Ping Lu, Shengrong Xu, Xiuming Zhu, Nanjing Normal University, P.R. CHINA Rapid pyrolysis and NO reduction efficiency of five Chinese pulverized coals and their chars produced at the different conditions under coal reburning were systematically carried out in an entrained flow reactor (EFR). The results indicate that the release of carbon and nitrogen is almost the same as the coal mass loss, however, hydrogen release fraction is significantly larger than the coal mass loss and the release fraction of carbon, nitrogen. The NO reduction efficiency decreases with increasing primary-zone or reburning-zone air: fuel stoichiometry ratio. The char contributions to total NO reduction efficiency increase with increasing proximate volatile matters. The relative contribution of char to total NO reduction at the 13
Page 1 and 2: TABLE OF CONTENTS Oral Sessions Pag
Page 3 and 4: 1-1 SESSION 1 GASIFICATION TECHNOLO
Page 5 and 6: The U.S. pioneered development of s
Page 7 and 8: 5-5 Enhanced Hydrogen Production wi
Page 9 and 10: derived synthesis gases employing i
Page 11 and 12: Several physical adsorbents, partic
Page 13: 13-1 SESSION 13 GASIFICATION TECHNO
Page 17 and 18: high selectivity (theoretically pro
Page 19 and 20: 19-3 Development of Highly Efficien
Page 21 and 22: The Aim of the project is the impro
Page 23 and 24: 24-3 Development of Fluidizable Lit
Page 25 and 26: the classical Lurgi-gasifcation pro
Page 27 and 28: 28-5 A Kinetic Approach to Catalyti
Page 29 and 30: turbine cycles. The models provide
Page 31 and 32: up to 290 psia and temperatures up
Page 33 and 34: 35-2 Development of Iron-Based Pero
Page 35 and 36: features of the BGL 1000 technology
Page 37 and 38: Heat-exchangers, particle filters,
Page 39 and 40: 41-4 Using Fly Ash-Based Foundry Co
Page 41 and 42: ocks using elemental ratios. Data f
Page 43 and 44: 600-900°C. Changes in the amount o
Page 45 and 46: ATL process has three stages, namel
Page 47 and 48: commercial-scale gasifier was shutd
Page 49 and 50: 52-5 Pilot-Scale Demonstration of U
Page 51 and 52: POSTER SESSION 1 COMBUSTION TECHNOL
Page 53 and 54: experimental data available in lite
Page 55 and 56: activation. It was concluded that C

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