DOE/METC/C-96/7200. CRADA Opportunities in Pressurized Combustion Research. Authors: Daniel J. Maloney Thomas S. Norton Kent H.

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1 DOE/METC/C-96/72 CRADA Opportunities in Pressurized Combustion Research Authors: Daniel J. Maloney Thomas S. Norton Kent H. Casleton Conference Title: Advanced Coal-Fired Power Systems 95 Review Meeting Conference Location: Morgantown, West Virginia Conference Dates: June 27-29, 1995 Conference Sponsor: U.S. Department of Energy Morgantown Energy Technology Center

2 DSCLAMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. This report has been reproduced directly from the best available copy. Available to DOE and DOE contractors from the Office of Scientific and Technical nformation, 175 Oak Ridge Turnpike, Oak Ridge, TN 37831; prices available at (615) Available to the public from the National Technical nformation Service, U.S. Department of Commerce, 5285 Port Royal Road, Springfield, VA 22161; phone orders accepted at (73)

3 PA.4 CRADA Opportunities in Pressurized Combustion Research Daniel J. Maloney Thomas S. Norton Kent H. Casleton Morgantown Energy Technology Center OBJECTVES The Morgantown Energy Technology Center recently began operation of a Low Emissions Combustor Test and Research (LECTR) Facility. This facility was built to support the development of Advanced Gas Turbine Systems (ATS) by providing test facilities and engineering support to METC customers through the ATS University-ndustry Consortium and through CRADA participation with industrial partners. BACKGROUND NFORMATON The ATS program is a major DOE initiative to develop more efficient gas turbine systems for base load utility and industrial electric power generation. The program goals include electric generating efficiency in excess of 6 percent, reductions in NO,, CO, and unburned hydrocarbon (UHC) emissions, and 1 percent lower cost of electricity compared to existing technology. The strategy of the program is to fund teams led by U.S. turbine manufacturers to develop ATS systems while at the same time developing a technology base to address key. technical issues. A university/ industry consortium administered by the South Carolina Energy Research and Development Center was established to provide cross-cutting technical support for the ATS program. The METC combustion facilities will play a key role in this technology base development by providing facilities and resources for concept testing and demonstration. A major thrust of the METC program is in the area of low emissions combustor development. NO, formation and removal will be critical issues for selection of future power generation systems. Commercial vendors offer "ultra-low NO," (< 9 ppmvd) burners for gas turbine combustion systems fired with clean fuel gases (natural gas), but the demand for more efficient and cost effective power systems poses the challenge of increasing operating temperatures and pressures while burning lower quality "dirty" fuel gases. Meeting these demands is particularly important for ntegrated Gasification Combined Cycle (GCC) and Advanced Pressurized Fluidized-Bed Combustion (PFBC) Systems that burn coal-derived fuel gas in turbine combustors. The METC LECTR facility is designed to support the development of coalderived, gas-fired combustors as well as the natural gas-fired combustion systems of primary interest for the ATS program. PROJECT DESCRPTON The LECTR is a versatile test facility with capabilities for evaluating a variety of low emissions combustion concepts at temperatures and pressures representative of gas turbine applications. The LECTR was constructed as a mid-scale test platform to support DOE'S ATS program and utilizes the full range of high -71-

4 pressure (up to 3 atm), high temperature (1 O F air preheat, 33 OF combustor wall), and mass flows (3.5 b/s combustion air) available in METC s Advanced Combustion Facility. Figure 1 illustrates how the LECTR design incorporates a set of flanged sections or modules including an inlet plenum, combustor test sections, a gas sampling section, and an afterburner/ quench section. Combustor test sections can be custom designed to meet a specific application by varying the internal refractory dimensions. This modular design approach offers the flexibility to test multiple concepts with rapid turnaround thus maximizing operating time while reducing the time and cost associated with building new inlet, sampling, and quench systems for each application. These features are illustrated in Figures 2 through 5. The high pressure and mass flow capabilities of the LECTR facility make it well suited for evaluation of advanced combustion concepts at combustion scales up to 3 M W, (1 MM Btu/h). Q Vent Replaceable Test Section Fuel Figure 1. Low Emissions Combustion Test and Research Facility The LECTR facility test modules are configured with multiple access ports for -72- application of both intrusive probe measurements as well as optically based diagnostic systems. METC has the facilities and expertise for performing a range of diagnostic methods including extractive gas sampling and analysis, radiation pyrometry, video and high-speed imaging, and laser-based diagnostics for flow visualization, velocity, and species measurement. To complement these capabilities, METC has state-of-the-art, high-speed data acquisition capabilities to directly support our customer needs. This mix of test facilities, diagnostic capabilities, expertise, and mission enables METC to provide critical test data that otherwise would not be available to the customer. n its current configuration, the LECTR employs an extractive gas sample probe supported by a number of on-line gas analyzers. Analysis capabilities include major combustion exhaust species such as O, CO,, and H,O as well as COYNO, and total NO,, N,O, and UHC. Details regarding specific analyzers, including analysis method and detection sensitivity, are provided in Table 1. Results of emissions measurements from recent combustion tests are illustrated in Figures 6 and 7. The saw tooth profiles observed in these figures are due to fluctuations in the aidfuel ratio (Ah?)during the tests. As one might expect, when the A/F changes, resulting changes in the, and CO, levels in the exhaust gas mirror each other. These figures are included to provide examples of the diagnostic capabilities and to illustrate the response and sensitivity of the analyzer train. A further illustration of the LECTR diagnostic capabilities is shown in Figure 8. This figure demonstrates results of radiation pyrometry measurements, indicating changes in burner surface temperature as a function of changing A/F. These data were taken during execution of a recent CRADA with a small industrial burner manufacturer.

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6 Figure 3. Modular Design Offers Rapid, Cost-Effective Test Configuration Changes applications. This work was conducted as part of a CRADA arrangement with an industrial partner. At present, LECTR test modules are being configured to prepare for collaborative combustion tests with Vanderbilt University. These tests are part of METC s commitment to the ATS University-ndustry Consortium discussed above and are expected to run through December of Discussions are in progress with several other potential partners for subsequent use of the LECTR facility. The facility is available for use by METC customers through CRADAs or other arrangements, and all interested parties should contact one of the authors for more details. -74-

7 Figure 4. Refractory-Lined Test Modules With Multiple Ports for Temperature and Pressure Measurements As Well As Optical Diagnostics -75-

8 Figure 5. AfterburnedQuench Module With Refractory Mold Shown; Refractory Can Be Cast to Meet the Application -76-

9 Table 1. METC Gas Analyzers Analyzer 2 Horiba COP Manufacturer Method Horiba Paramagnetic Ranges -1% -25% NDlR Sensitivity -2% -5 ppm.2% co Horiba NDlR - 15 ppm 5 PPm Total Hydrocarbons Backman FD -4% Continuously adjustable - 1 ppm? NONOX Horiba -25 ppm Chemiluminescence -5 ppm -25 ppm NDlR Mass Spectrometer 2,5, 1, 2,5,1, Protimeter Chilled mirror Dewpoint VGFisons Scanning Magnetic Sector Variable.2 ppm.5 ppm DP f.3 C Variable M95222W E 6 c._ + g Time (Minutes) Time (minutes) M95W2221W M95W222m Figure 6. Product Gas Compositions From Run Figure 7. Emissions Data From LECTR Run

10 et 3-1 -m 2-96 Y a E c 2 r % g - E Time (s) MgMo2224w Figure 8. Burner Surface T and ALE' Ratio Variation DMALON\ :