Ash formation and deposition during combustion of pulverized torrefied wood and coal in a 100 kW downflow combustor

Torrefied wood originating from beetle-killed trees is an abundant biomass fuel that can be co-fired with coal for power generation. In this work, pulverized torrefied wood, a bituminous coal (Sufco coal) and their blended fuel with a mixing ratio of 50/50 wt.%, are burned in a 100-kW rated laboratory combustor under similar conditions. Ash aerosols in the flue gas and ash deposits on a temperature-controlled surface are sampled during combustion of the three fuels. Results show that ash formation and deposition for wood combustion are notably different from those for coal combustion, revealing different mechanisms. Compared to the coal, the low-ash torrefied wood produces low concentrations of fly ash in the flue gas but significantly increased yields (per input ash) of ash that has been vaporized. All the mineral elements including the semi- or non-volatile metals in the wood are found to be more readily partitioned into the PM₁₀ ash than those in the coal. The inside layer deposits sticking to the surface and the loosely bound outside deposits exposed to the gas both show a linear growth in weight during torrefied wood test. Unlike coal combustion, in which the concentration of (vaporized) ash PM₁ controls the inside deposition rate, wood combustion shows that the formation of porous bulky deposits by the condensed residual ash dominates the inside deposition process. Co-firing removes these differences between the wood and coal, making the blended fuel to have more similar fly ash characteristics and ash deposition behavior to those of the bituminous coal. In addition, results also show some beneficial effects of co-firing coal with torrefied wood, including reduction of the total deposition rate and the minimization of corrosive alkali species produced by wood.     

Online deposition measurement and slag bubble behavior in the reduction zone of pulverized coal staged combustion

An online thermogravimetric measurement method of ash deposition was developed. Ash deposition and slag bubble in the reductive zone of pulverized coal staged combustion were investigated. Firstly, a steady pulverized coal staged combustion was achieved in an electrically heated down-fired furnace. Additionally, gas species, coal conversion, and particle size distribution were quantitatively measured. Secondly, real-time ash deposition rates at different temperatures (1100–1400 °C) were measured, and deposition samples were carefully collected with an N₂ protection method. The morphologies of collected samples were investigated through a scanning electron microscope. It was found that the deposited ash transformed from a porous layer composed of loosely bound particles to a solid layer formed by molten slag. Different behaviors of the slag bubble were observed, and bubble sizes were significantly affected by the deposition temperature. A deposition and bubble formation mechanism was proposed and used for modeling. Results showed that the proposed model well predicted the observed ash deposition and bubble formation process.     

Characteristics of the sub-micron ash aerosol generated during oxy-coal combustion at atmospheric and elevated pressures

This paper is concerned with the effect of pressure on the particle size distribution and the size-segregated composition of the sub-micron ash aerosol created during oxy-coal combustion under near practical self-sustaining combustion conditions. The problem is important because pressurized oxy-coal combustion has been proposed as one promising technology to minimize CO₂ emissions. Sub-micron ash plays a major role in ash deposition mechanisms, which, in turn, can control boiler performance. In this work, the same bituminous coal was burned at pressures of 1, 8 and 15 bar in O₂/CO₂ environments. Tests employed a 100 kW (rated) oxy-fuel combustor (OFC) operated at atmospheric pressure (1 bar) and a 300 kW (rated) entrained-flow pressurized reactor (EFPR) at elevated pressures (8 and 15 bar). Although these tests were conducted under near practical combustion conditions, confounding effects of peak flame temperature variations were minimized for the 1 bar and 15 bar tests, allowing the role of elevated pressure to be isolated. For the EFPR tests, a specially designed sampling system was used to sample sub-micron ash aerosols from the pressurized combustor and is described in detail. Results showed that at the same peak temperature but higher pressure, the fractions of ash aerosol partitioned into the PM_0.6 and PM₁ size fractions were greatly diminished. Moreover, elevated pressures caused significant changes in the composition of the (size-segregated) sub-micron aerosol, especially in its alkali content, which increased significantly. Examination of fractions of each element that ended up in the sub-micron fume suggested that, at constant temperature, the effect of pressure on vaporization of semi-volatile metals was very different from that on the release into the gas phase of non-volatile metals and could not be explained by equilibrium.     

Oxy-coal combustion in a 30 kWth pressurized fluidized bed: Effect of combustion pressure on combustion performance,pollutant emissions and desulfurization

Oxy-coal combustion with pressurized fluidized beds has recently emerged as a promising carbon capture and storage (CCS) technology for coal-fired power plants. Although a large number of energy efficiency analyses have shown that an increase in combustion pressure can further increase the net plant efficiency, there are few experimental studies of pressurized oxy-coal combustion conducted on fluidized bed combustors/boilers with continuous coal feeding. In this study, oxy-coal combustion experiments with lignite and anthracite were conducted with a 30 kW_th pressurized fluidized bed combustor within the pressure range of 0.1 MPa to 0.4 MPa. The investigation focused on the elucidation of the impacts of combustion pressure on the combustion performance, pollutant emissions and desulfurization of oxy-coal combustion in fluidized beds. The results showed that an increase in pressure increased the combustion efficiency and combustion rate of coal particles, and the promoting effect of pressure increase was more significant for the high rank coal with smaller particle size and the high O₂ concentration atmosphere. For both coals, NO_x emissions decreased with pressure but N₂O emissions increased with pressure and accounted for a considerable part of the nitrogen oxide pollutants under high pressure oxy-coal combustion conditions. The pressure had insignificant impact on the SO₂ emissions of oxy-coal combustion but an increase in pressure enhanced the direct desulfurization of limestone.     

Prediction of particle sticking efficiency for fly ash deposition at high temperatures

The tendency of ash particles to stick under high temperatures is dictated by the ash chemistry, particle physical properties, deposit surface properties and furnace operation conditions. A model has been developed in order to predict the particle sticking efficiency for fly ash deposition at high temperatures. The model incorporates the particle properties relevant to the ash chemistry, particle kinetic energy and furnace operation conditions and takes into consideration the partial sticking behaviour and the deposit layer. To test the model, the sticking behaviours of synthetic ash in a drop tube furnace are evaluated and the slagging formation from coal combustion in a down-fired furnace is modelled. Compared with the measurements, the proposed model presents reasonable prediction performance on the particle sticking behaviour and the ash deposition formation. Through a sensitivity analysis, furnace operation conditions (velocity and temperature), contact angle and particle size have been found to be the significant factors in controlling the sticking behaviours for the synthetic ash particles. The ash chemistry and furnace temperature dictate the wetting potential of the ash particles and the melting ability of the deposit surface; particle size and density not only control the particle kinetic energy, but also affect the particle temperature. The furnace velocity condition has been identified as being able to influence the selective deposition behaviour, where the maximum deposition efficiency moves to smaller particles when increasing the gas velocity. In addition, the thermophoresis effect on the arrival rate of the particles reduces with increasing the gas velocity. Further, increasing the melting degree of the deposit layer could greatly enhance the predicted deposition formation, in particular for the high furnace velocity condition.     

Measurements and modelling of oxy-fuel coal combustion

Oxy-fuel combustion is one of the most promising technologies to isolate efficiently and economically CO₂ emissions in coal combustion for the ready carbon sequestration. The high proportions of both H₂O and CO₂ in the furnace have complex impacts on flame characteristics (ignition, burnout, and heat transfer), pollutant emissions (NO_x, SO_x, and particulate matter), and operational concerns (ash deposition, fouling/slagging). In contrast to the existing literature, this review focuses on fundamental studies on both diagnostics and modelling aspects of bench- or lab-scale oxy-fuel combustion and, particularly, gives attention to the correlations among combustion characteristics, pollutant formation, and operational ash concerns. First, the influences of temperature and species concentrations (e.g., O₂, H₂O) on coal ignition, volatile combustion and char burning processes, for air- and oxy-firing, are comparatively evaluated and modelled, on the basis of data from optically-accessible set-ups including flat-flame burner, drop-tube furnace, and down-fired furnace. Then, the correlations of combustion-generated particulate/NO_x emissions with changes of combustion characteristics in both air and oxy-fuel firing modes are summarized. Additionally, ash deposition propensity, as well as its relation to the formation of fine particulates (i.e. PM_0.2, PM₁ and PM₁₀), for both modes are overviewed. Finally, future research topics are discussed. Fundamental oxy-fuel combustion research may provide an ideal alternative for validating CFD simulations toward industrial applications.     

The roles of added chlorine and sulfur on ash deposition mechanisms during solid fuel combustion

The focus of this paper is on effects of chlorine and sulfur on coal ash deposition rates, under practically relevant but systematically controlled combustion conditions. This problem is important, not so much for coal, but to understand and predict deposition rates for biomass combustion where chlorine contents can be high. To this end, ash deposition rates on a controlled temperature surface were measured for controlled amounts of chlorine and sulfur added to a pulverized coal, doped with potassium and burned in a 100 kW rated combustion rig. Previous work with 35 tests on 11 coal, biomass and petroleum coke fuels burned under a range of operating conditions had strongly suggested that the deposition rate of the tightly bound inside deposits was independent of the ash aerosol composition, and depended only on PM₁ in the flue gas. The loosely bound outside deposition rate was dependent primarily on the total alkali content in the flue gas. The new results using chlorine added to the fuel (in the form of ammonium chloride) required these previous conclusions to be drastically revised. They showed that chlorine, not alkali alone, had large effects on the deposition rate of the inside deposits, which now were orders of magnitude higher than without chlorine addition, and did not fit previous (multi-fuel) correlations with PM₁. Sulfur addition, together with chlorine, did not affect deposition rates much, although it did lower the chlorine content of the deposit. These results are interpreted in terms of the ash aerosol size segregated composition, which was also measured, and potential sulfation reactions within the deposit.     

煤粉低尘燃烧器热态试验研究

以液排渣旋风燃烧技术为基础的煤粉低尘燃烧器可在燃烧过程实现捕渣,为工业加热提供含尘浓度低的高温火焰,是工业加热过程实现以煤代油的先进燃烧技术。本论文介绍了新型煤粉低尘燃烧器的热态燃烧试验研究结果,该燃烧器采用端面旋流进风,煤粉和一次风在旋转气流外层送入,分级燃烧等技术。热态试验研究表明,采用上述技术的煤粉低尘燃烧器具有燃烧完全,捕渣率高,NOx排放浓度低等特点。     

Prediction and validation of ash sticking probability under fouling conditions in pulverized coal combustion

Under the fouling conditions in stationary coal combustion systems, the sticking/rebound behavior of solid incident particles is a key issue in determining the ash deposition rate. From a dynamic point of view, the bulk fly ash, which dominants the deposited mass, successively interacts with the clean tube, the inner fine deposited layer and the bulk deposited layer during ash deposition. In this paper, we experimentally investigate the time-resolved evolution of ash fouling in a 25 kW coal combustor. The deposited mass flux rapidly reaches a stable state that fluctuates around a mean value of ～3 g/(m²·s) for two kind of probe materials. The rapid initial stage only allows the formation of 1–2 layers of bulk deposited ash, revealing the dominant role of bulk deposit in capturing large incident particles. Inspired by the observation, we apply a 3D adhesive discrete element model (DEM) to fully describe the many-body evolving process subject to the incident events of a 30-µm particle. The simulation agrees well with the experiments when using a higher particle surface energy of 200 mJ/m². The rapidly growing feature of ash sticking probability with increasing the bulk deposit layers can be reproduced in this case, and an empirical formula is proposed. It is also validated that, at the deposit growth stage, the newly-deposited particles stay just where they impact. The effectiveness of the DEM tool shall benefit a fully-validated sticking/rebound model under the fouling condition that is convenient for CFD use.     

CFD在燃煤细粒子凝聚过程中的应用

燃煤产生的细粒子富集了大量的有毒痕量元素,对大气环境和人类健康造成严重危害。本文针对燃煤细粒子的形成过程,在计算流体力学(CFD)的基础上,结合气溶胶动力学理论,模拟了烟气中细粒子在圆柱形流场中由于碰撞而凝聚的过程,并通过计算结果分析细粒子颗粒特征参量(速度、质量、直径和颗粒数目)随流场的变化趋势,为深入研究燃煤细粒子的形成演化机理提供理论基础。     

An intrinsic kinetics model to predict complex ash effects (ash film,dilution, and vaporization) on pulverized coal char burnout in air (O2/N2) and oxy-fuel (O2/CO2) atmospheres

During coal combustion, char chemical reaction is the slowest step, particularly in the last burnout stage, where the char consists of small amounts of carbon in a predominant ash framework. Existing kinetics models tend to deviate from experimental measurements of late char burnout due to the incomplete treatment of ash effects. Ash can improve pore evolution through vaporization, hinder oxygen transport by forming an ash film, and reduce active carbon sites and available surface per unit volume by penetrating into the char matrix. In this work, a sophisticated kinetics model, focusing on these three ash evolution mechanisms (ash vaporization, ash film, and ash dilution) during pulverized coal (PC) char combustion, is developed by integrating them into a thorough mechanistic picture. Further, a detailed comparison of the three distinct ash effects on PC char conversion during air (O₂/N₂) and oxy-fuel (O₂/CO₂) combustion is performed. For the modeled coal, the mass of ash vaporization is approximate 3 orders less than the mass of ash remaining, which participates in ash dilution and ash film formation, both in O₂/N₂ and O₂/CO₂ atmospheres. The influence of these phenomena on burnout time follows the order: ash dilution > ash film > ash vaporization. The influence of ash vaporization on burnout time is minor, but through interactions with the ash dilution and ash film forming processes it can have an impact at high extents of burnout, particularly in O₂/CO₂ atmospheres. In O₂/N₂ atmospheres the residual ash predominately exists as an ash film, whereas it mainly exists as diluted ash in the char matrix in O₂/CO₂ atmospheres. The residual ash particle is encased by a thick film when the ash film forming fraction is high (low ash dilution fraction). These results provide in-depth insights into the conversion of PC char and further utilization of the residual ash.     

Mercury speciation in air-coal and oxy-coal combustion: A modelling approach

In this study, a mechanism for mercury chlorination in flue gases resulting from the combustion of pulverised coal has been presented. Arrhenius parameters of the gas-phase elementary reactions in the Hg–Cl sub-mechanism have been updated and are mainly based on recent experimental and quantum mechanical rate determinations. The mechanism is validated by comparison to accurate experimental data that is unbiased by Hg oxidation in the impinger solutions of aqueous chemistry methods. Solid-phase retention of Hg⁰ has been studied in parallel to char combustion; the heterogeneous model describes condensation of mercury on fly ash particles. The combined homogeneous–heterogeneous model predictions show comparable trends to those of power plant data. This approach aims to provide an improved prediction of mercury speciation from coal-fired power plants and to shed light on the chemical kinetic changes encountered during oxy-coal operation.     

煤中钠元素赋存形态对亚微米颗粒物形成的影响研究

将原煤通过三步化学提取实验(水洗,NH_3OAc洗,HCl洗),然后通过浸溶实验(Impregnation Experiment),将煤中羧基(-COOH)中的H离子置换成Na离子.并将原煤、提取实验后煤和浸溶实验后的三种煤样在沉降炉中热解和燃烧,研究煤中钠的有机/无机赋存形态对其气化特征和亚微米颗粒物形成的影响.实验结果发现:提取实验后的煤样,Na元素大部分以硅酸盐形式存在,两种煤在沉降炉中的热解结果表明以硅酸盐形式存在于煤中的钠元素很难气化.浸溶实验后的煤样中,Na元素大部分以羧酸(COO-Na)的形式存在,两种煤在沉降炉中的热解实验结果表明以有机结合态存在于煤中的钠元素非常易气化.Na元素赋存形态对其燃烧过程中气化有重要影响,最终表现在亚微米颗粒物中的含量上.     

PM10 formation during the combustion of N2-char and CO2-char of Chinese coals

The formation of PM₁₀ (particles less than or equal to 10 μm in aerodynamic diameter) during char combustion in both air-firing and oxy-firing was investigated. Three Chinese coals of different ranks (i.e., DT bituminous coal, CF lignite, and YQ anthracite) were devolatilized at 1300 °C in N₂ and CO₂ atmosphere, respectively, in a drop tube furnace (DTF). The resulting N₂-chars and CO₂-chars were burned at 1300 °C in both air-firing (O₂/N₂ = 21/79) and oxy-firing (O₂/CO₂ = 21/79). The effects of char properties and combustion conditions on PM₁₀ formation during char combustion were studied. It was found that the formation modes and particle size distribution of PM₁₀ from char combustion whether in air-firing or in oxy-firing were similar to those from pulverized coal combustion. The significant amounts of PM_0.5 (particles less than or equal to 0.5 μm in aerodynamic diameter) generated from combustion of various chars suggested that the mineral matter left in the chars after coal devolatilization still had great contributions to the formation of ultrafine particles even during the char combustion stage. The concentration of PM₁₀ from char combustion in oxy-firing was generally less than that in air-firing. The properties of the CO₂-chars were different from those of the N₂-chars, which was likely due to gasification reactions coal particles experienced during devolatilization in CO₂ atmosphere. Regardless of the combustion modes, PM₁₀ formation in combustion of N₂-char and CO₂-char from the same coal was found to be significantly dependent on char properties. The difference in the PM₁₀ formation behavior between the N₂-char and CO₂-char was coal-type dependent.     

Combustion processes for carbon capture

A review of the technologies for coal-based power generation closest to commercial application involving carbon capture is presented. Carbon capture and storage (CCS) developments are primarily adaptations of conventional combustion systems, with additional unit operations such as bulk oxygen supply, CO₂ capture by sorbents, CO₂ compression, and storage. They use pulverized coal combustion in entrained flow—the dominant current technology for coal-based power, or gasification in entrained flow, although similar concepts apply to other solid-gas contacting systems such as fluidized beds. Currently, the technologies have similar generation efficiencies and are associated with efficiency penalties and electricity cost increases due to operations required for carbon capture. The R&D challenges identified for the combustion scientist and engineer, with current understanding being detailed, are those of design, optimisation and operational aspects of new combustion and gasification plant, controlling the gas quality required by CCS related units and associated emission compliance, and gas separations. Fundamental research needs include fuel reactions at pressure, and in O₂/CO₂ atmospheres, as few studies have been made in this area. Laboratory results interpreted and then included in CFD models of combustion operations are necessary. Also identified, but not detailed, are combustion issues in gas turbines for IGCC and IGCC-CCS. Fundamental studies should be a component of pilot-plant and demonstrations at practical scale being planned. Concepts for new designs of combustion equipment are also necessary for the next generation of technologies. The challenges involved with the design and operation of these integrated systems, while supplying electricity on demand, are considerable.     

Particle imaging of ignition and devolatilization of pulverized coal during oxy-fuel combustion

Oxy-fuel combustion of coal is a promising technology for cost-effective power production with carbon capture and sequestration that has ancillary benefits of emission reductions and lower flue gas cleanup costs. To fully understand the results of pilot-scale tests of oxy-fuel combustion and to accurately predict scale-up performance through CFD modeling, fundamental data are needed concerning coal and coal char combustion properties under these unconventional conditions. In the work reported here, the ignition and devolatilization characteristics of both a high-volatile bituminous coal and a Powder River Basin subbituminous coal were analyzed in detail through single-particle imaging at a gas temperature of 1700 K over a range of 12–36 vol % O₂ in both N₂ and CO₂ diluent gases. The bituminous coal images show large, hot soot cloud radiation whose size and shape vary with oxygen concentration and, to a lesser extent, with the use of N₂ versus CO₂ diluent gas. Subbituminous coal images show cooler, smaller emission signals during devolatilization that have the same characteristic size as the coal particles introduced into the flow (nominally 100 μm). The measurements also demonstrate that the use of CO₂ diluent retards the onset of ignition and increases the duration of devolatilization, once initiated. For a given diluent gas, a higher oxygen concentration yields shorter ignition delay and devolatilization times. The effect of CO₂ on coal particle ignition is explained by its higher molar specific heat and its tendency to reduce the local radical pool. The effect of O₂ on coal particle ignition results from its effect on the local mixture reactivity. CO₂ decreases the rate of devolatilization because of the lower mass diffusivity of volatiles in CO₂ mixtures, whereas higher O₂ concentrations increase the mass flux of oxygen to the volatiles flame and thereby increase the rate of devolatilization.     

Influence of combustion temperature and coal types on alumina crystal phase formation of high-alumina coal ash

The alumina content (more than 40%) of high-alumina coal ash is comparative to the middle content bauxite ores in China. So far, in order to meet the high demand of alumina and the rise of circular economy industrial chain, extracting alumina from coal ash has become a way to comprehensively utilize high-alumina coal ash. However, this process has high requirements on the crystal phase and stability of alumina. Different from most studies, this paper focuses on how to produce coal ash more beneficial to the later refining of aluminum. Therefore, the effects of combustion temperature and coal types by classifying high-alumina coal into dull coal and bright coal on alumina crystal phase formation were studied. Through proximate analysis, ultimate analysis, calorific value analysis, X-ray fluorescence spectroscopy, X-ray diffraction (XRD) and scanning electron microscope (SEM) and other methods, it is found that γ-Al₂O₃ in high-alumina coal ash translated into more stable θ-Al₂O₃ and finally α-Al₂O₃ when combustion temperature is higher than 1000°C. Thus compared with pulverized coal boilers, circulating fluidized bed (CFB) boilers with lower combustion temperature can produce higher quality coal ash. Moreover, at the same combustion temperature, alumina crystal phase in dull coal ash is relatively less stable than that in bright coal ash, which is more suitable to the later refining and electrolysis of aluminum.     

锯屑与煤混烧过程积灰实验研究

积灰降低锅炉效率,危及安全运行,是生物质燃烧技术发展的主要障碍.本文基于高温一维下行炉,选用锯屑和兖矿原煤作为燃料,通过自动控温采样枪收集积灰,分析积灰的采集效率、撞击效率和捕集效率等宏观效果参数.结果显示,锯屑与兖矿混烧时积灰倾向性显着增加.扫描电镜/能谱微观分析发现:碱金属和碱土金属的存在是积灰倾向增加的原因,两条主要途径是:碱性物质在飞灰表面冷凝增加了飞灰的表面黏性;碱性物质与硅铝酸盐结合形成低熔点的化合物.     

Biomass fly ash deposition in an entrained flow reactor

Fly ash deposition on boiler surfaces is a major operational problem encountered in biomass-fired boilers. Understanding deposit formation, and developing modelling tools, will allow improvements in boiler efficiency and availability. In this study, deposit formation of a model biomass ash species (K₂Si₄O₉) on steel tubes, was investigated in a lab-scale Entrained Flow Reactor. K₂Si₄O₉ was injected into the reactor, to form deposits on an air-cooled probe, simulating deposit formation on superheater tubes in boilers. The influence of flue gas temperature (589 – 968°C), probe surface temperature (300 – 550°C), flue gas velocity (0.7 – 3.5?m/s), fly ash flux (10,000 – 40,000?g/m²h), and probe residence time (up to 60?min) was investigated. The results revealed that increasing flue gas temperature and probe surface temperature increased the sticking probability of the fly ash particles, thereby increasing the rate of deposit formation. However, increasing flue gas velocity resulted in a decrease in the deposit formation rate, due to increased particle rebound. Furthermore, the deposit formation rate increased with probe residence time and fly ash flux. Inertial impaction was the primary mechanism of deposit formation, forming deposits only on the upstream side of the steel tube. A mechanistic model was developed for predicting deposit formation in the reactor. Deposit formation by thermophoresis and inertial impaction was incorporated into the model, and the sticking probability of the ash particles was estimated by accounting for energy dissipation due to particle deformation. The model reasonably predicted the influence of flue gas temperature and fly ash flux on the deposit formation rate.     

燃煤含铁矿物的迁移转化特性研究

采用场发射扫描电镜结合X射线能谱分析仪(FSEM-EDX)系统研究了燃煤电站静电除尘器下各电场飞灰中磁珠的显微结构和化学组成,并利用热力学软件FACT计算预测了煤中含铁矿物的迁移转化过程．结果表明,外在含铁矿物在燃煤过程中易直接氧化形成结晶程度较好的铁氧化物相;内在含铁矿物与其他矿物在高温下熔合形成含Fe、Al、 Si的复杂的玻璃相,煤中含铁矿物的赋存特征、反应温度和气氛是影响含铁矿物迁移转化的主要因素。燃煤过程中Fe2 中间产物的形成以及Fe-O-S共熔体在炉内的长时间停留是结渣形成的重要原因。