| LIST OF FIGURES |
xix |
| LIST OF TABLES |
xxxii |
| |
|
1.0 |
INTRODUCTION
(449kb) |
1-1 |
| |
1.1 |
DOD Project Objectives |
1-1 |
|
1.2 |
Summary of Phase I Activities |
1-2 |
| |
1.2.1 |
Coal Beneficiation and Preparation Studies |
1-2 |
|
1.2.2 |
MCMWM and DMC Combustion Performance Evaluation |
1-2 |
|
1.2.3 |
Engineering Design |
1-3 |
|
1.2.4 |
Cost/Economic Analysis |
1-3 |
|
1.3 |
Summary of Phase II Activities |
1-4 |
|
|
1.3.1 |
Emissions Reduction |
1-4 |
|
1.3.2 |
Coal Preparation/Utilization |
1-5 |
|
1.3.3 |
Engineering Design and Cost; and Economic Analysis |
1-6 |
|
1.4 |
Phase III Project Outline |
1-6 |
|
1.5 |
References |
1-7 |
| |
|
2.0 |
COAL
PREPARATION/UTILIZATION (3.41MB) |
2-1 |
| |
2.1 |
Particle Size Control |
2-1 |
|
|
2.1.1 |
Conventional Ball Milling |
2-1 |
|
2.1.2 |
Stirred-Media Milling |
2-9 |
|
2.1.3 |
Attrition Milling |
2-13 |
|
2.1.4 |
Grinding Circuit Simulation |
2-20 |
|
2.1.5 |
Integrated Grinding/Cleaning Circuit |
2-25 |
|
2.2 |
Physical Separations |
2-27 |
| |
2.2.1 |
Fine Coal Classification |
2-28 |
|
2.2.2 |
Dense-Medium Separation |
2-39 |
|
2.2.3 |
Magnetic Fluid Separation |
2-44 |
|
2.2.4 |
Centrifugal/Flotation Separations |
2-56 |
|
2.3 |
Surface Based Separation Processes |
2-59 |
| |
2.3.1 |
Continuous Froth Flotation |
2-59 |
| |
2.3.1.1 |
Results and Discussion |
2-63 |
|
2.3.1.2 |
Conclusions |
2-76 |
|
2.3.2 |
Column Flotation |
2-76 |
| |
2.3.2.1 |
Effect of Hydrostatic Pressure Setting |
2-82 |
|
2.3.2.2 |
Effect of Recovery Zone Height |
2-83 |
|
2.3.2.3 |
Effect of Feed Solids Concentration |
2-84 |
|
2.3.2.4 |
Effect of Air Flow Rate |
2-86 |
|
2.3.2.5 |
Evaluation of Vortactor Turbulent Contactor |
2-86 |
|
2.3.2.6 |
Correlation for Column Carrying Capacity and Yield |
2-89 |
|
2.3.3 |
Overall Evaluation |
2-91 |
|
2.3.4 |
Conclusion |
2-92 |
|
2.4 |
Dry Processing |
2-94 |
| |
2.4.1 |
Continuous TriboElectrostatic Separation |
2-95 |
|
2.4.2 |
Charging/Deagglomeration Testing |
2-99 |
|
2.4.3 |
Integrated Grinding/Seperation |
2-103 |
|
2.5 |
References |
2-105 |
| |
|
3.0 |
EMISSIONS REDUCTION |
3-1 |
| |
3.1 |
NOx Reduction /
SO2 Removal (2.79MB) |
3-1 |
| |
3.1.1 |
Low-Temperature Selective Catalytic Reduction |
3-2 |
| |
3.1.1.1 |
System Modifications and Shakedown |
3-3 |
|
3.1.1.2 |
Preliminary Testing and Results |
3-16 |
|
3.1.1.3 |
Low-Temperature SCR Testing and Results |
3-19 |
|
3.1.2 |
BioLimeTM Injection |
3-31 |
|
|
3.1.2.1 |
Experimental |
3-34 |
|
3.1.2.2 |
Down-Fired Combustor (DFC) |
3-36 |
|
3.1.2.3 |
Results and Discussion |
3-37 |
|
3.1.2.4 |
Conclusions |
3-50 |
|
3.1.3 |
Reburning |
3-51 |
| |
3.1.3.1 |
Objectives |
3-51 |
|
3.1.3.2 |
Background |
3-51 |
|
3.1.3.3 |
NOx Control Technologies |
3-54 |
|
3.1.3.4 |
Test Program |
3-58 |
|
3.1.3.5 |
Conclusions |
3-70 |
|
3.2 |
Polycyclic
Aromatic Hydrocarbons (846kb) |
3-71 |
| |
3.2.1 |
Introduction |
3-71 |
|
3.2.2 |
Objectives |
3-71 |
|
3.2.3 |
Description of Equipment and Experimental Matrix |
3-72 |
| |
3.2.3.1 |
Drop-Tube Reactor |
3-72 |
|
3.2.3.2 |
Demonstration Boiler |
3-72 |
|
3.2.3.3 |
Fuel Analysis |
3-75 |
|
3.2.4 |
Analytical Methodology |
3-75 |
|
3.2.5 |
Operation of the MM5 Sampling Train |
3-77 |
|
3.2.6 |
Sample Recovery and Preparation for Analysis |
3-78 |
|
3.2.7 |
GC Analysis |
3-79 |
|
3.2.8 |
GC/MS System, Calibration and Operation |
3-79 |
|
3.2.9 |
Results |
3-81 |
| |
3.2.9.1 |
Drop-Tube Reactor Results |
3-81 |
|
3.2.9.2 |
Demonstration Boiler Results |
3-83 |
|
3.2.10 |
Discussion |
3-84 |
| |
3.2.10.1 |
Discussion of Drop-Tube Reactor Results |
3-84 |
|
3.2.10.2 |
Discussion of Demonstration Boiler Results |
3-86 |
|
3.2.11 |
Conclusions |
3-87 |
|
3.3 |
Trace Elements
(3.92MB) |
3-88 |
| |
3.3.1 |
Fine Particulate Matter/Mercury |
3-89 |
| |
3.3.1.1 |
Ceramic Filter Testing |
3-89 |
|
3.3.1.2 |
Effect of Particle Control Device on Trace Elements Emissions |
3-113 |
|
3.3.2 |
Effect of Coal Cleaning on Trace Element Emissions |
3-120 |
| |
3.3.2.1 |
Background |
3-121 |
|
3.3.2.2 |
Analysis of AMAX Fuels |
3-123 |
|
3.3.2.3 |
AMAX Combustion Tests and Results |
3-125 |
|
3.3.2.4 |
Combustion Tests and Results of the CQ, Inc. Coals |
3-131 |
|
3.3.2.5 |
Effect of Atomization Quality on Trace Element Emissions |
3-136 |
|
3.3.2.6 |
Conclusions |
3-137 |
|
3.3.3 |
Methodology Development |
3-139 |
| |
3.3.3.1 |
Introduction |
3-139 |
|
3.3.3.2 |
Early Development of the PSU Method |
3-141 |
|
3.3.3.3 |
Preliminary Test Results - Multielements |
3-144 |
|
3.3.3.4 |
Preliminary Test Results - Total Mercury |
3-149 |
|
3.3.3.5 |
Further Test Results |
3-151 |
|
3.3.3.6 |
Comparison of PSU Method to ATS Unified Method |
3-163 |
|
3.3.3.7 |
Conclusions |
3-165 |
|
3.4 |
CO2 Removal
(1.85MB) |
3-166 |
| |
3.4.1 |
Experimental |
3-168 |
| |
3.4.1.1 |
Preparation of the Adsorbents |
3-168 |
|
3.4.1.2 |
Characterization of the Adsorbents |
3-170 |
|
3.4.1.3 |
Measurement of the CO2 Adsorption / Desorption
Performance |
3-170 |
|
3.4.1.4 |
Adsoprtion Separation of Simulated Flue Gas Mixture |
3-171 |
|
3.4.1.5 |
Adsorption Separation of a Boiler Flue Gas Mixture |
3-171 |
|
3.4.2 |
Results and Discussion |
3-173 |
| |
3.4.2.1 |
Preparation of the CO2 "Molecular Basket" Adsorbent
Preparation and Characterization of the CO2 "Molecular
Basket" Adsorbent |
3-173 |
|
3.4.2.2 |
Adsorption Separation of CO2 from Simulated Flue Gas
|
3-192 |
|
3.4.2.3 |
Adsorption Separation of Boiler Flue Gas |
3-208 |
|
3.4.3 |
Conclusions |
3-212 |
|
3.5 |
References
(647kb) |
3-213 |
|
|
|
4.0 |
ECONOMIC EVALUATION
(Part 1 - 3.7MB)
(Part 2 - 3.5MB) |
4-1 |
| |
4.1 |
Cost and Market Penetration of Coal-Based Fuel
Technologies |
4-1 |
| |
4.1.1 |
Introduction |
4-1 |
|
4.1.2 |
Market Penetration Model Approach and Structure |
4-2 |
| |
4.1.2.1 |
Optimization Model |
4-3 |
|
4.1.2.2 |
Market Penetration Model Formulation |
4-5 |
|
4.1.2.3 |
Fuel Supply Costs |
4-7 |
|
4.1.2.4 |
Transportation Costs |
4-9 |
|
4.1.2.5 |
Retrofit Technology Costs |
4-9 |
|
4.1.2.6 |
Potential MCWM Supply Sites |
4-11 |
|
4.1.2.7 |
Boiler Inventory |
4-11 |
|
4.1.2.8 |
Pennsylvania Inventory of Active Boilers |
4-13 |
|
4.1.2.9 |
Focus on Cambria and Indiana Counties |
4-14 |
|
4.1.3 |
Results and Conclusions |
4-18 |
| |
4.1.3.1 |
Market Penetration Model Results |
4-18 |
|
4.1.3.2 |
Sensitivity Analysis |
4-22 |
|
4.1.4 |
Conclusions |
4-26 |
|
4.2 |
Selection of Incentives for Commercialization of the
Coal-Using Technology |
4-28 |
| |
4.2.1 |
Motivation and Aim of the Study |
4-28 |
|
4.2.2 |
Data |
4-28 |
|
4.2.3 |
Methodology |
4-33 |
|
4.2.4 |
Empirical Results |
4-42 |
|
4.2.5 |
Conclusion |
4-51 |
|
4.3 |
Community Sensitivity to Coal Fuel Usage: Economic
Valuation of Risk Perceptions: Measuring Public Perceptions and
Welfare Impacts of Electric Power Facilities |
4-54 |
| |
4.3.1 |
Introduction |
4-54 |
|
4.3.2 |
Background and Previous Research |
4-56 |
| |
4.3.2.1 |
Risk Perceptions |
4-56 |
|
4.3.2.2 |
Valuation and Perceived Risks |
4-58 |
|
4.3.3 |
Theory |
4-60 |
|
4.3.4 |
Survey Design |
4-63 |
|
4.3.5 |
Estimation and Results |
4-67 |
|
4.3.6 |
Conclusions |
4-74 |
|
4.4 |
Regional / National Economic Impacts of New Coal
Utilization Technologies |
4-75 |
| |
4.4.1 |
Introduction |
4-75 |
|
4.4.2 |
Basic Features of the Conservation Strategy |
4-76 |
|
4.4.3 |
The U.S. CGE Model |
4-80 |
|
4.4.4 |
Simulation Results |
4-81 |
| |
4.4.4.1 |
Basic Results |
4-82 |
|
4.4.4.2 |
Sensitivity Analysis |
4-88 |
|
4.4.5 |
Conclusions |
4-92 |
|
4.5 |
Economic Analysis of the Defense Department's Fuel
Mix |
4-93 |
| |
4.5.1 |
Introduction |
4-93 |
|
4.5.2 |
Power Generation Technologies that could Lead to
Changes in Fuel Consumption Patterns in the Military |
4-95 |
| |
4.5.2.1 |
Energy Management Initiatives |
4-95 |
|
4.5.2.2 |
Flue Gas Desulfurization : "e-scrub technology" |
4-96 |
|
4.5.2.3 |
Dry Micronized Coal and Coal/Water Mixture Technology - New
Boiler and Handling Technologies |
4-96 |
|
4.5.2.4 |
Fuel Cell Technology |
4-97 |
|
4.5.2.5 |
Combined Cycle Gas Turbine |
4-100 |
|
4.5.2.6 |
Other Clean Coal Technology Programs |
4-100 |
|
4.5.3 |
Transport: Technology that could Lead to Changes in
Fuel Consumption Patterns in the Military |
4-101 |
| |
4.5.3.1 |
Alternative Fuels |
4-101 |
|
4.5.3.2 |
State and Federal Government Initiatives and Legislative Aspects |
4-102 |
|
4.5.4 |
Conclusions |
4-103 |
|
4.6 |
Constructing a National Energy Portfolio which
Minimizes Energy Price Shock Effects |
4-104 |
| |
4.6.1 |
Introduction |
4-104 |
|
4.6.2 |
Methodology |
4-107 |
|
4.6.3 |
Estimation and Results |
4-110 |
|
4.6.4 |
Policy Recommendations |
4-116 |
|
4.6.5 |
Conclusions |
4-118 |
|
4.7 |
Proposed Research on the Coal Markets and their
Impact on Coal-Based Fuel Technologies |
4-119 |
| |
4.7.1 |
Historical and Prospective Changes in Electric Power
Coal Use 1947-1993 |
4-119 |
| |
4.7.1.1 |
Air Quality Legislation |
4-120 |
|
4.7.1.2 |
Influence of Regulations on Fuel Use |
4-121 |
|
4.7.1.3 |
Slower Generation Growth |
4-122 |
|
4.7.2 |
Fuel Use in the Electric Utility Industry 1947 to
1993 |
4-122 |
| |
4.7.2.1 |
Regional Electricity Fuel Use |
4-123 |
|
4.7.3 |
Coal Consumption in Electric Utilities 1947 to 1993 |
4-127 |
|
4.7.4 |
Trends in Coal Consuming Electric Utilities |
4-128 |
|
4.7.5 |
Historical patterns in Electric Utility Power Plant
Additions, Developments 1947 to 1993 |
4-128 |
| |
4.7.5.1 |
Coal Capacity Additions |
4-131 |
|
4.7.5.2 |
Oil Capacity Additions |
4-131 |
|
4.7.5.3 |
Natural Gas Capacity Additions |
4-132 |
|
4.7.6 |
Market Structure and Reorganization of the U.S.
Electric Utility Industry |
4-132 |
| |
4.7.6.1 |
Status Quo of the Electric Utility Industry |
4-133 |
|
4.7.6.2 |
Existing Proposals for Restructuring Total Deregulation |
4-136 |
|
4.7.6.3 |
Factors to be Considered for Restructuring |
4-142 |
|
4.7.6.4 |
A New Proposal |
4-142 |
|
4.7.6.5 |
Conclusion |
4-150 |
|
4.8 |
References |
4-151 |
| |
|
5.0 |
EVALUATION OF
DEEPLY-CLEANED COAL AS BOILER FUELS (2.44MB) |
5-1 |
| |
5.1 |
Modification of the MCWM Preparation Circuit |
5-1 |
|
5.2 |
Fuels Characterization |
5-3 |
| |
5.2.1 |
AMAX Filter Cakes |
5-3 |
|
5.2.2 |
MCWM Preparation - Shakedown |
5-4 |
|
5.2.3 |
MCWM Formulation |
5-5 |
|
5.2.4 |
MCWM Full-Scale Production |
5-11 |
|
5.2.5 |
MCWM Atomization Performance |
5-12 |
|
5.2.6 |
Fine Coal Handleability |
5-17 |
|
|
5.2.6.1 |
Background |
5-17 |
|
5.2.6.2 |
Experimental |
5-25 |
|
5.2.6.3 |
Shear Cell Test Results |
5-32 |
|
5.2.6.4 |
Design Criteria |
5-40 |
|
5.2.6.5 |
Bin Testing |
5-42 |
|
5.2.6.6 |
Conclusions |
5-46 |
|
5.3 |
Pilot-Scale Combustion Tests |
5-48 |
|
5.4 |
Demonstration-Scale Combustion Tests |
5-48 |
| |
5.4.1 |
Demonstration Boiler System |
5-48 |
|
5.4.2 |
Combustion performance |
5-51 |
| |
5.4.2.1 |
AMAX Filter Cake MCWMs |
5-53 |
|
5.4.2.2 |
Comparison of the AMAX Filter Cake MCWMs with other MWMs Tested
at Penn State |
5-55 |
|
5.4.3 |
Concluding Remarks |
5-56 |
|
5.5 |
References |
5-57 |
| |
|
6.0 |
ACKNOWLEDGEMENTS
(53.4kb) |
6-1 |
| |
|
APPENDICES (2.44MB) |
|
APPENDIX 3A |
Summary Sheets for Phase III MCWM and DMC Testing |
3A-1 |
|
APPENDIX 3B |
Ceramic Filter Chamber Pressure Drop as a Function
of Time Firing Coal |
3B-1 |
|
APPENDIX 4A |
Market Penetration Model Source Code Listing |
4A-1 |
|
APPENDIX 4B |
MCWM Supply Cost Model |
4B-1 |
|
APPENDIX 4C |
MCWM Retrofit Technology Cost Model |
4C-1 |
|
APPENDIX 4D |
Electric Power In Your Community |
4D-1 |
|
APPENDIX 4E |
Sector Definition |
4E-1 |
