Lignite Properties and Boiler Performance

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1 Lignite Properties and Boiler Performance Energy Generation Conference: Reducing CO 2 Intensity in Power Plants Steve Benson Presented at the Energy Generation Conference Bismarck, ND January 28,

2 Contact Information Microbeam Technologies, Inc. North Dakota Office: 4200 James Ray Drive, Ste. 193 Grand Forks, ND Tel.: (701) Fax: (701) Minnesota Office: Hwy 7, Ste. 202 Minnetonka, MN Tel.: (701) Fax: (763) Steve s Cell: (701)

3 Background of Microbeam Technologies, Inc. Mission: To provide advanced analysis and interpretations of the impacts of fuel properties on plant fireside performance. Founded: 1991 and began performing analysis of samples using advanced electron microscopy methods in 1992 Growth: Expanded laboratory in 2004 to include high-temperature small scale test equipment slag/ash behavior in combustion/gasification systems; New office in Minneapolis in 2014 Clients: Equipment developers, gasification (syngas, methane, fertilizers), electric utilities, state and federal government, coal companies, consultants, universities, law firms, research organizations, and others Work: Conducted >1450 projects worldwide, >7000 samples analyzed Staff: experience with fossil/renewable fuels conversion and environmental control systems research/development commercialization education problem solving focus 3

4 Overview Lignite Properties Managing to improve performance Lignite Preparation Energy Conversion Combustion/Boilers Fate of Lignite Impurities Ash formation Slag Ash deposits wall slagging and convective pass fouling Fine particulate Boiler Design for Lignitic Coals Predictive Tools use to improve performance and reduce CO 2 intensity Summary 4

5 Lignite Properties High Moisture High oxygen content organically associated impurities Form and abundance of impurities ashforming materials, sulfur High reactivity Non-caking 5

6 Coal Impurities No ash in coal! ash-forming components or impurities Particles minerals and other materials Electron microscopy size, composition, abundance (3000 particles) Inorganic elements associated with coal matrix elements (alkali and alkaline earth elements) Chemical fractionation abundance of organically associated elements 6

7 Sources of Impurities in Lignite During Formation From original plant material Influx of sand clays by wind and water Ground water flow Mineralization During Mining Overburden, partings, underclay incorporated into lignite 7

8 Association of Impurities in Lignite 8

9 Lignite Preparation 9

10 Crushers and Pulverizers Cyclone Fired Boilers -3/8 in Fluidized bed -1/4 in Pulverized Coal 80% -200 mesh (74 µm) 10

11 Impurities in Coal Higher mineral content Quartz and clays Ca organically associated Clay mainly included 5 6 Figure Point/Area Description Na Mg Al Si S K Ca Ti Fe Zr O 5 1 Excluded mineral Included mineral Included mineral Excluded mineral Excluded mineral Included mineral Included mineral Coal matrix Included mineral Included mineral Included mineral Included mineral Included mineral Excluded mineral Excluded mineral Included mineral Included mineral Excluded mineral Excluded Average Included Average

12 Mineral Types in Coal 12

13 Conventional Analyses on Coals Oxides Antelope Rawhide Caballo ND Lignite Ash Composition, Wt % Equivalent Oxide Proximate, Wt % Ultimate, Wt % Heating Value, BTU/lb SiO Al2O Fe2O TiO P2O CaO MgO Na2O K2O SO Moisture Vol. Matter Fixed Carbon Ash Hydrogen Carbon Nitrogen Sulfur Oxygen Ash Btu

14 Advanced Versus Conventional ASTM Analysis 14

15 Energy Conversion Systems Combustion - Boilers 15

16 Overall Ash Formation and Deposition Processes Benson, S.A., Jones, M.L. and Harb, J.N. Ash Formation and Deposition--Chapter 4. In: Fundamentals of Coal Combustion for Clean and Efficient Use, edited by Smoot, L.D. Amsterdam, London, New York, Tokyo: Elsevier, 1993, p

17 Rocket Science?

18 Combustion Pulverized Coal Flame Test Burner 18

19 Pulverized Coal Combustion Systems Tangential-fired (A) Wall-fired (B, C) (A) (B) (C) Primary Air and Coal Primary Air and Coal Secondary Air Primary Air and Coal Secondary Air Secondary Air 19

20 Cyclone-Fired Coal Combustion Systems Secondary superheater Reheat superheater Secondary Air Platers (suspended surface) Slag Centrifugal Action Primary superheater Economizer Coal Air Air Slag tap 20

21 Fate of Lignite Impurities 21

22 Ash Formation in a Coal Flame Vapors Na, K, SO 2 NOx, Hg etc. Molten Ash Droplets Solid Particles 3-22

23 Pulverized Coal Fired Ash Formation Processes 23

24 Transformations of Impurities in Boiler Size of ash particles Composition of ash particles Physical properties of ash particles Deposits formation and collection of ash particles 24

25 Ash Formation Partitioning 25

26 Ash Particle Size and Composition Distribution Na and Ca rich 26

27 How do deposits form in boilers? Transport of particles and vapor phase material to the surface Sticking to the surface sticky material formation 27

28 Ash Transport to Heat Transfer Surfaces The transport of intermediate ash species (inorganic vapors, liquids, and solids) is function of: State and size of the ash species System design burner type, heat transfer surface configuration System conditions, such as gas flow patterns, gas velocity, and temperature 28

29 Ash Transport Mechanisms eddy 29

30 Sticking and Bonding Phases 30

31 Silicate Viscosity: Slag Flow, Particle Sticking, Deposit Strength 31

32 Wall Slagging Wall Slagging (hightemperature bonding phases) Indicates propensity of deposits to accumulate on the radiant walls of a boiler Temperatures from 2000 to 3000 F (1093 to 1649 C). Slagging Convective pass fouling High temperature Low temperature Burners 32

33 Deposit Thickness T-fired boiler Ma, Inman, Lu, Sears, Kong, Rokanuzzaman, McCollor, Benson, Fuel Processing Technology 88 (2007)

34 Convective Pass Fouling Silicate (high temperature) Occurs in high-temperature convective pass Temperatures between 1600 and 2400 F Silicate-based deposits Convective pass fouling High temperature Low temperature Sulfate (low temperature) Low-temperature convective pass Temperatures between 1000 and 1700 F Sulfate-based deposits Slagging Burners 34

35 Deposit thickness (mm) on super heater division panel Ma, Inman, Lu, Sears, Kong, Rokanuzzaman, McCollor, Benson, Fuel Processing Technology 88 (2007)

36 Convective pass deposits 36

37 Deposit Sampling and Analysis 37

38 Boiler Design for Lignite 38

39 Effects of Rank and Coal Type on Boiler Sizing 39

40 Important Design Criteria for the Furnace Net heat input per furnace plan area (Btu/hr-ft 2 ) Vertical distance from top fuel nozzle to furnace arch Distance is function of furnace width and depth Furnace dimensions must provide residence time to: Properly burn fuel Cool the combustion products Function of body of the boiler (radiative heat transfer)

41 Important Factors in Convective Pass Fouling Erosion can be diminished by minimizing gas velocities. Fouling can be reduced by: Sootblowing - Air for low-fouling situations - Steam for high-fouling situations - Pulsed detonation - Acoustic horns Lower heat release rates (large furnace volume) Greater number of wall blowers to minimize wall slagging Higher excess air levels Greater number of retractable sootblowers in the convective pass Increased tube spacing Additives

42 Convective Pass Design

43 Design Evolution for Boilers Firing North Dakota Lignite Coals 43

44 Predictive Tools 44

45 Ash Behavior Indices Example 45

46 Example: Predicted High-Temperature Fouling for Lignite Blends at four temperatures Day 2 Lignite blend fired under 4 conditions Day 3 Lignite blend fired under 5 conditions Day 4 Lignite blend fired Under 4 conditions Day 1 Baseline Lignite Blend 46

47 Comparison of observed with predicted fouling behavior 47

48 Summary - Lignite Property Impacts Moisture lowers heating value, increases volume of gas in combustor, changes where heat is absorbed Volatile matter lower volatile matter decreases ability to stage and reduce NOx Ash increase lowers heating value Higher basic ash (Na, Mg, Ca, K, Fe) (low ash contents) fine particle formation, reflective ash in boiler, higher furnace exit gas temperatures, increased convective pass fouling, higher opacity Higher acidic ash (Si, Al, Ti) (higher ash contents) larger ash particle formation, wall slagging, high-temperature convective-pass fouling, lower low-temperature convective-pass fouling, lower opacity Blending significant opportunity to improve the efficiency/reliability and decrease CO 2 intensity 48

49 Contact Information Microbeam Technologies, Inc. North Dakota Office: 4200 James Ray Drive, Ste. 193 Grand Forks, ND Tel.: (701) Fax: (701) Minnesota Office: Hwy 7, Ste. 202 Minnetonka, MN Tel.: (701) Fax: (763) Steve s Cell: (701)

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