|
LIST OF FIGURES |
v |
|
LIST OF TABLES |
x |
|
GLOSSARY OF TERMS AND DEFINITIONS |
xi |
|
EXECUTIVE SUMMARY |
xiv |
|
1.0 |
INTRODUCTION (11.9kb) |
1 |
|
2.0 |
EXPERIMENTAL A
PROACH
(1.3MB) |
2 |
| |
2.1 |
Scope of Work |
2 |
| |
2.1.1 |
Task 1 - Evaluation of Heat Exchanger Performance in
the SFS |
2 |
|
2.1.2 |
Task 2 - Bench-Scale Testing of Methods to Reduce
Slag Corrosion |
4 |
|
2.2 |
Description of Pilot-Scale SFS |
5 |
| |
2.2.1 |
Fuel Feed System |
8 |
|
2.2.2 |
Slagging Furnace |
10 |
|
2.2.3 |
Radiant Air Heater Panels |
14 |
|
2.2.4 |
Slag Screen |
15 |
|
2.2.5 |
Dilution/Quench Zone |
17 |
|
2.2.6 |
Convective Air Heater |
17 |
|
2.2.7 |
Process Air Preheaters |
18 |
|
2.2.8 |
Slagging Furnace System Heat Exchangers |
19 |
|
2.2.9 |
System Fans |
20 |
|
2.2.10 |
Emission Control |
20 |
|
2.2.11 |
Instrumentation and Data Acquisition |
22 |
|
2.3 |
Dynamic Slag Application Furnace |
22 |
|
3.0 |
RESULTS AND DISCUSSION
(Part 1 - 2.24MB)
(Part 2 - 5.89MB) |
23 |
| |
3.1 |
Pilot-Scale Testing |
23 |
| |
3.1.1 |
Pilot-Scale SFS Performance |
23 |
|
3.1.2 |
CAH Tube Bank Performance |
57 |
|
3.1.3 |
RAH Panel Performance |
71 |
|
3.2 |
Laboratory and Bench-Scale Activities |
89 |
| |
3.2.1 |
Dynamic Slag Corrosion Testing |
89 |
|
3.2.2 |
Effect of Additives on Slag Viscosity |
95 |
|
3.2.3 |
Heated-Stage XRD Analysis of Slags |
98 |
|
4.0 |
CONCLUSIONS AND
OBSERVATIONS (103 kb) |
101 |
| |
4.1 |
Fuel Characteristics |
101 |
|
4.2 |
SFS Performance |
102 |
|
4.3 |
CAH Performance |
103 |
|
4.4 |
RAH Performance |
104 |
|
4.5 |
Bench and Laboratory Corrosion Testing |
105 |
|
5.0 |
RECOMMENDATIONS FOR
FUTURE WORK (14.7kb) |
106 |
| |
|
LIST OF FIGURES |
|
2-1 |
Photograph of the pilot-scale slagging furnace
system |
6 |
|
2-2 |
Combustion 2000 slagging furnace and support systems |
7 |
|
2-3 |
Illustration of the uncooled tubes in the CAH tube
bank |
18 |
|
2-4 |
Schematic of the DSAF |
22 |
|
3-1 |
Coal feed rate versus run time for the January 1999
test, SFS-RH6-0199 |
24 |
|
3-2 |
Coal feed rate versus run time for the February 1999
test, SFS-RH7-0299 |
25 |
|
3-3 |
Coal feed rate versus run time for the April 1999
test, SFS-RH8-0399 |
25 |
|
3-4 |
Furnace and slag screen temperatures versus run time
for the January 1999 test, SFS-RH6-0199 |
30 |
|
3-5 |
Slagging furnace firing rate versus run time for the
January 1999 test, SFS-RH6-0199 |
31 |
|
3-6 |
Furnace and slag screen temperatures versus run time
for the February 1999 test, SFS-RH7-0299 |
33 |
|
3-7 |
Slagging furnace firing rate versus run time for the
February 1999 test, SFS-RH7-0299 |
34 |
|
3-8 |
Furnace and slag screen temperatures versus run time
for the April 1999 test, SFS-RH8-0399 |
35 |
|
3-9 |
Slagging furnace firing rate versus run time for the
April 1999 test, SFS-RH8-0399 |
36 |
|
3-10 |
Photograph of slag screen tubes following the
January test |
38 |
|
3-11 |
Photograph of slag screen tubes following the
February test |
39 |
|
3-12 |
Slag screen differential pressure versus run time
for the April 1999 test, SFS-RH8-0399 |
43 |
|
3-13 |
Photograph of slag screen tubes following the April
test |
45 |
|
3-14 |
Process air preheater temperatures versus run time
for the January test, SFS-RH6-0199 |
46 |
|
3-15 |
Process air preheater temperatures versus run time
for the February test, SFS-RH7-0299 |
47 |
|
3-16 |
Process air preheater temperatures versus run time
for the April test, SFS-RH8-0399 |
47 |
|
3-17 |
Respirable mass emission data for the January (top)
and February (bottom) tests |
52 |
|
3-18 |
Respirable mass emission data for the April test |
53 |
|
3-19 |
Baghouse hopper ash particle-size data |
53 |
|
3-20 |
Multicyclone data resulting from baghouse inlet
sampling |
54 |
|
3-21 |
Baghouse differential pressure versus run time for
the April test |
55 |
|
3-22 |
CAH tube surface and flue gas temperatures versus
run time for the January test, SFS-RH6-0199 |
57 |
|
3-23 |
CAH process air temperatures versus run time for the
January test, SFS-RH6-0199 |
58 |
|
3-24 |
CAH process air, RAH process air, quench gas, and
flue gas flow rates versus run time for the January test,
SFS-RH6-0199 |
58 |
|
3-25 |
Thermocouple locations in the CAH tube bank |
59 |
|
3-26 |
CAH heat recovery versus run time for the January
test, SFS-RH6-0199 |
61 |
|
3-27 |
Photograph of ash deposits on the CAH tubes
following the January test firing Illinois No. 6 bituminous coal |
62 |
|
3-28 |
CAH tube surface and flue gas temperatures versus
run time for the February test, SFS-RH7-0299 |
63 |
|
3-29 |
CAH process air temperatures versus run time for the
February test, SFS-RH7-0299 |
63 |
|
3-30 |
CAH process air, RAH process air, quench gas, and
flue gas flow rates versus run time for the February test,
SFS-RH7-0299 |
64 |
|
3-31 |
CAH heat recovery versus run time for the February
test, SFS-RH7-0299 |
64 |
|
3-32 |
Photograph of ash deposits on the CAH tubes
following the February test firing eastern Kentucky bituminous coal |
66 |
|
3-33 |
CAH tube surface and flue gas temperatures versus
run time for the April test, SFS-RH8-0399 |
67 |
|
3-34 |
CAH process air temperatures versus run time for the
April test, SFS-RH8-0399 |
68 |
|
3-35 |
CAH process air, RAH process air, quench gas, and
flue gas flow rates versus run time for the April test, SFS-RH8-0399 |
68 |
|
3-36 |
CAH heat recovery versus run time for the April
test, SFS-RH8-0399 |
69 |
|
3-37 |
Photograph of ash deposits on the CAH tubes
following the April test firing eastern Kentucky and Illinois No. 6
bituminous coal |
70 |
|
3-38 |
Photograph of new ceramic tiles installed on the RAH
panel inside of the slagging furnace in January 1999 |
72 |
|
3-39 |
Photographs of the RAH panel inside of the slagging
furnace following the January (top) and February (bottom) tests
|
73 |
|
3-40 |
Photograph of the RAH panel inside of the slagging
furnace following the April test |
74 |
|
3-41 |
Illustrations of cracks found in the ceramic
tiles/bricks of the RAH panel after testing in January (left) and
February (right) 1999 |
74 |
|
3-42 |
Illustration of cracks found in the ceramic
tiles/bricks of the RAH panel after testing in April 1999 |
75 |
|
3-43 |
Photograph of the RAH lower support brick, small
lower tile, and the lower edge of the large lower tile following the
February test |
76 |
|
3-44 |
Photograph of the RAH panel from inside of the
furnace following the April test |
77 |
|
3-45 |
RAH ceramic tile temperatures versus run time for
the January test, SFS-RH6-0199 |
77 |
|
3-46 |
RAH tube surface temperatures versus run time for
the January test, SFS-RH6-0199 |
78 |
|
3-47 |
RAH process air temperatures versus run time for the
January test, SFS-RH6-0199 |
78 |
|
3-48 |
Thermocouple locations in the RAH panel |
79 |
|
3-49 |
RAH heat recovery versus run time for the January
test, SFS-RH6-0199 |
81 |
|
3-50 |
RAH ceramic tile temperatures versus run time for
the February test, SFS-RH7-0299 |
82 |
|
3-51 |
RAH tube surface temperatures versus run time for
the February test, SFS-RH7-0299 |
83 |
|
3-52 |
RAH process air temperatures versus run time for the
February tst, SFS-RH7-0299 |
84 |
|
3-53 |
RAH heat recovery versus run time for the February
test, SFS-RH7-0299 |
84 |
|
3-54 |
RAH ceramic tile temperatures versus run time for
the April test, SFS-RH8-0399 |
85 |
|
3-55 |
RAH tube surface temperatures versus run time for
the April test, SFS-RH8-0399 |
86 |
|
3-56 |
RAH process air temperatures versus run time for the
April test, SFS-RH8-0399 |
86 |
|
3-57 |
RAH heat recovery versus run time for the April
test, SFS-Rh8-0399 |
87 |
|
3-58 |
RAH heat recovery for bituminous coal-fired tests
completed in 1998 and 1999 |
88 |
|
3-59 |
Graph of recession with time for the sintered chrome
- alumina refractory and the alumina-based fusion-cast Monofrax L
and M, tested with Illinois No. 6 slag at 2732°F
(1500°C) |
90 |
|
3-60 |
Photograph of the chrome-alumina block from UTRC
after 103 hours of slag feed at 2732EF (1500EC) using Illinois No. 6
slag |
91 |
|
3-61 |
Photograph of the Monofrax after 100 hours of slag
feed at 2732°F
(1500°C)
using Illinois No. 6 slag |
92 |
|
3-62 |
Photograph of the coated Plicast 98 material that
was prefired to 2957°F
(1625°C)
and tested at 2732°F
(1500°C)
for 103 hours using Illinois No. 6 |
93 |
|
3-63 |
Photograph of uncoated Plicast 98 material that was
prefired and tested at 2732°F
(1500°C)
for 54 hours using Illinois No. 6 slag |
94 |
|
3-64 |
Plot of recession versus time for Plicast 98
castable material with and without corrosion-resistant coatings |
95 |
|
3-65 |
Viscosity-versus-temperature curves for two repeat
measurements of the Rochelle slag |
97 |
|
3-66 |
Viscosity-versus-temperature curves for the original
and modified Rochelle slags |
98 |
|
3-67 |
Viscosity-versus-temperature curves for the
originial and modified CCS lignite slag and modified slags |
99 |
|
3-68 |
X-ray diffractograms for the eastern Kentucky slag
tap sample measured while heating to the melting point |
100 |
|
3-69 |
X-ray diffractograms for the eastern Kentucky slag
tap sample measured while cooling from the melting point |
101 |
| |
|
LIST OF TABLES |
|
2-1 |
Theoretical Flow and Heat-Transfer Data for the
Slagging Furnace System |
11 |
|
2-2 |
Refractory Properties |
13 |
|
2-3 |
Pressure, Temperature, and Flow Specifications for
the SFS Fans |
20 |
|
3-1 |
Results of Coal and Coal Ash Analysis for Coal-Fired
Slagging Furnace Tests |
26 |
|
3-2 |
Results of Lignite and Lignite Ashy Analysis for
Lignite-Fired Slagging Furnace Tests |
27 |
|
3-3 |
February Kentucky Coal Ash, Slag Pot, and Slag Tap
Samples |
40 |
|
3-4 |
February Kentucky Coal Ash and Slag Screen Samples |
40 |
|
3-5 |
April Kentucky Coal Ash and Slag Tap Samples |
44 |
|
3-6 |
Flue Gas Emissions for Illinois No. 6 and Kentucky
Coal-Fired Slagging Furnace Tests |
56 |
|
3-7 |
Description of CAH Thermocouple Locations |
60 |
|
3-8 |
CAH Deposit Samples from the February Test |
66 |
|
3-9 |
Description of RAH Panel Thermocouple Locations |
80 |
|
3-10 |
Illinois No. 6 Slag and Slag Reactant Product
Compositions as Determined by WDXRF |
93 |
