Modeling of a Combined Cycle MHD/Steam Power Plant

Transcription

1 University of Tennessee, Knoxville Trae: Tennessee Researh and Creative Exhange Masters Theses Graduate Shool Modeling of a Combined Cyle MHD/Steam Power Plant Edward H. Kiessling III University of Tennessee - Knoxville Reommended Citation Kiessling, Edward H. III, "Modeling of a Combined Cyle MHD/Steam Power Plant. " Master's Thesis, University of Tennessee, This Thesis is brought to you for free and open aess by the Graduate Shool at Trae: Tennessee Researh and Creative Exhange. It has been aepted for inlusion in Masters Theses by an authorized administrator of Trae: Tennessee Researh and Creative Exhange. For more information, please ontat trae@utk.edu.

2 To the Graduate Counil: I am submitting herewith a thesis written by Edward H. Kiessling III entitled "Modeling of a Combined Cyle MHD/Steam Power Plant." I have examined the final eletroni opy of this thesis for form and ontent and reommend that it be aepted in partial fulfillment of the requirements for the degree of Master of Siene, with a major in Mehanial Engineering. We have read this thesis and reommend its aeptane: R.L. Young, James N. Chapman (Original signatures are on file with offiial student reords.) Y.C.L. Wu, Major Professor Aepted for the Counil: Dixie L. Thompson Vie Provost and Dean of the Graduate Shool

3 To The Graduate Counil: I am submitting herewith a thesis written by Edward H. Kiessling III entitled "Modeling of a Combined Cyle MHD/Steam Power Plant. " I have examined the final opy of this thesis for form and ontent and reommend that it be aepted in partial fulfillment of the requirements for the degree of Master of Siene, with a major in Mehanial Engineering../. L. Wu, Ma jor Professor We have read this thesis and Aepted for the Counil: The Graduate Shool

4 MODELING OF A COMBINED CYCLE MHO/ STEAM POWER PLANT A Thesis Presented for the Master of Siene Degree The University of Tennessee, Knoxville Edward H. Kiessling III August 19 84

5 ACKNOWLEDGMENTS The guidane, assistane, and reo mmendations offered by Dr. James N. Chapman are grate fully acknowledged. A speial word of thanks is due Mr. James R. Hollis for the diretion.he pro vided during the early days of this effort. The reommendati ons offered by Dr. Ying-Chu Li n Wu and Dr. Robert L. Yo ung are aknowledged and appreiated. The timely assistane provided by Mr. Cal vin D. Prather is acknowledged and appre iated. The exellent typing and ad ministrati ve support provided by Ms. Madge Gibson is acknowledged and appreiated. The author also wishes to thank his wife, Janet, and his daughter, Jennifer, for their patiene and support during this lengthy and demanding projet. ii

6 ABSTRACT The objetive of this effort was to develop an improved proess mo del of a prototype MHD/ steam ent ral station powe r plant. This model was designed to perform a first law thermodynami analy sis for steady state plant operation. An existing MHD topping y le model was modified to provide predi tions of mass flows and energy requi rements assoiated with topping y le equipment for oal proessing and oxi-.dant preparation. This topping y le is haraterized by full slag arryover to the heat and seed re overy system, and by dire t fired oxidant preheating. New models we re developed for the potass ium formate seed regeneration proess, and for the heat and seed reovery system. PRE STO II, a program for analyzing the performan e of regenerative,. superheated steamrturbine y les, was added to the existing model struture to provide a detailed steam y le model. The resulting model was exe uted for a speified design ondition and the results reported herein. iii

7 TAB LE OF CONTENTS CHAPTER I. INTRODUCTI ON. II. PLANT DESCRIPTI ON III. MODE L STRUCTURE AND CAPABILITIES. IV. MHD TOPPING CYCLE v. SEED REGENERATI ON VI. VII. VIII. BIBLIOGRAPHY APPENDIX VITA HRSR SYSTEM AND STEAM CYC LE MODE L RESULTS CONCLUSI ONS PAGE iv

8 LIST OF TABLES TABLE PAGE 4-1. Proess Mass Flows for MHD Topping Cyle Variables for whih Values are Read by SINGH Energy Quantities for MHD Topping Cyle States for whih SINGH alls NASA SP-27 3 to Calulate Plasma/Flue Gas Properties Seed Regeneration Proess Streams Reyle Streams to Potassium Sulfate Dissolver HRSR System Model Variables Steam Cyle Model Variables (SINGH ) Major Charateristis of Modeled Plant Coal Analyses and HHV SINGH Input Data for Modeled Plant Model Exeution Re sults 97 v

9 LIST OF FIGURES FIGURE PAGE Plant Shemati Diagram. Proess Ma ss Flow Diagram for MHD Topping Cyle Seed Regeneration Proess Diagram HRSR System Diagram Steam.C yle Diagram vi

10 CHAPTER I INTRODUCTION The eletri power indus try is on the ve rge of a risis. The United States of Ameria is an advaned industrial soiety whih requires large amounts of eletri power. This eletri power is produed by generating plants whih use oal, oil, natural gas, nulear fission, and hydro power as their primary energy soures. (Unonventional energy soures suh as solar power, wind power, and geothermal produe a negligible fration of the total eletri power generation and are not onsidered in this analysis). Given the present state of the art of energy onversion tehnology and the onstraints of resoure availability, it appears that the five primary energy soures, either individually or olletively, will be unable to satisfy future eletri power demand in a satisfatory manner. The next ten paragraphs onsider the problems assoiated with eah of the five primary energy soures. Hydro power is probably the most desirable soure for generating eletri power. The environmental impat of dam onstrution is relatively minor and normally inludes only loal alteration of river flow behavior, silt transportation patterns, and biologi al eosys tems. The reservoirs reated by dams are often popular rereation lakes. Sine the ultimate soure of hydro power is rainfall, this soure is ontinually renewed. Hydro power is a very inexpensive soure of eletri power beause there is no ost assoiated with allowing river water to flow through turbines (i.e., no fuel ost). Unfortunately, there are 1

11 2 relatively few sites suitable for onstruting hydro power dams and nearly all these sites have already been developed and put into servie. At present, hydro power furnishes about 15 % of the nation's eletri 1 power output There will be no signifiant hydro power additions to the nation 's eletri power generation apaity. During the 19 60's, nulear fission reators were promoted as a safe, lean, and inexpensive means for generating eletri power. Nulear power advoates predi ted that nulear power plants would eventually generate most of the nation's eletri powe r at very low ost. "Too heap to meter", was the desription of eletriity to be produed by nulear fission plants. In 19 84, years later, the nulear power industry is a troubled industry. Nulear fission plants produe only about 10% of the nation's eletri power. Many plants ordered in the early 19 70's have been anelled. Many of the plants under onstrution are experiening ostly onstrution delays due to modifiations required by the Nulear Regulatory Commds sion (NRC). What went wrong? The nulear power industry has three major problems : publi distrust, disposal of radioative plant wastes, and an assured fuel supply. The environmental onservation movement of the early 19 70's publily raised the issue of nulear power plant safety and painted a frightening piture of the potential disaster assoiated with a nulear power plant malfuntion. In 19 79, the aident at the Three Mile Island Nulear Pl ant seemed to elevate the level of fear and suspiion. In response, the Nulear Regulatory Commission tightened its ontrol on the nulear power industry in an attempt to assuage publi fears and restore redibility and aeptane to the nulear power program. These added

12 3 ontrols extended the time required to liense and ons trut a nulear power plant. They inreased the amount of analysis, reord keeping, and testing assoiated with nulear plant onstrution. Furthermore, the NRC onduted extensive design reviews whih resulted in required modifiations for both operating and under ons trution plants. All of these ations greatly inreased the ost of developing nulear powe r and utilities began to lose. interest. The reession with its derease in eletri power demand and its high interest rates exaerbated the utilities' position. The lak of a well developed program for disposing of radioative nulear plant was te has also hurt the nulear power industry In the limate of environmental quality awareness, whih has been strong for the past deade, there has been muh ative interest in was te disposal for nulear plants. The two maj or aspets of this problem are that nobody wants a storage faility in his bakyard and, seondly, everybody wants a failure-p roof storage system. For the nulear power indus try, this means higher operating osts for the long term and operating ons traints in the near term. The third problem overshadowing the nulear power industry is the unertainty of a long term fuel supply. The quantity of naturally available radioative ompounds is not suffiient to supply a large demand for many years. The fission industry would require development of the breeder reator in order to assure a long term fuel supply. Un fortunately, there has been opposition to the breeder reator researh program and it is showing very little progress or promi se.

13 4 Oil and natural gas are out of the question as fuels for the eletri power indus try. They are nonrenewable natural resoures whih are steadily being depleted. As this happens, their ost inreases and their use is restrited to those ativities for whih they are mos t essential. Finally, there is oal. Coal is the most abundant energy mi neral possessed by the Un ited States. Domesti supplies ould easily furnish eletri power demand for the next entury and beyond. Coal has been the primary energy soure for U.S. eletri power generation for several deades. There are two problems assoiated with oal use. The first, and least serious, onerns reovering the oal. The seond problem is 2 the role played by oal plant emdssions in the prodution of aid rain Coal is reovered for use via surfae or underground mining operations. Surfae mining (s trip mining), unless followed by ostly restoration operations, leaves behind a sarred lands ape, disrupted surfae and subsurfae drainage patterns, and the problem of aid mine drainage whih pollutes loal waterourses. Underground mining disrupts subsurfae drainage patterns, sometime s preipitates land subsidene, and also produes aid mine drainage with its water pollution onsequenes. Al though these are serious problems, their effets are loalized and an be mi tigated. Control of these problems will be ostly, but it will-be a neessary onsequene of oal fired eletri generation. The most damaging aspet of oal fired power plants is their prodution of S0 2 and NOx during the oal ombustion proess. These ompounds are released to the atmosphere via flue gases and mi x with

14 5 atmospheri moisture to form sulfuri aid and ni tri aid. These aids ultimately return to the earth's surfae in rain. This aid rain destroy s lake eosystems and forests. For areas dependent upon forest indus try, the loal eonom, dies with the forests. In No rth Ameria, the aid rain damage has been most extensive in eastern Canada and the northeastern United States. Citizens groups and environmentalists have protested and alled for ation. Commdttees have been formed, studies have been ommissioned, and reports have been rendered. The u.s. Congress seems to be on the verge of taking ation. This ation will most likely take the form of emissions ontrol legislation whih will markedly redue, perhaps by as muh as 50%, the permissible levels of S02 and NOX in oal plant flue gases. Suh legislation would result in subs tantial equipment and operating ost inreases for the eletri utility industry. Furthermore, the flue gas lean-up equipment wou ld redue plant operating effiieny. While it may not be enated this year, this new legislation will almost ertainly be pas sed in the near future and must be ons idered when planning for the future of the eletri power industry. Thus the eletri power industry faes a risis. How will it generate the eletri power neessary to satisfy future demand? Hy dro power soures are nearly fully deve lo ped. Oi l and natural gas are too preious and too ostly for use in entral station power plants. Nulear power is struggling to remain viable, but is severely hampered by publi distrust, high onstrution osts, unaeptable was te disposal alternatives, and unertainty of a suffiient long term fuel supply.

15 6 Coal utilization generates environmental pollution problems at both the mine and smokestak; however, at leas t there is an abundant domesti supply of oal. By the proess of elimination, oal appears to be the best primary soure for future eletri power generation. Coal is seleted beause it is the only andidate whih promises an abundant long term supply. If the emissions problems assoi _ated with oal utilization ould be solved, oal would be onsidered a desirable fuel for entral station eletri power generation. Coal fired magnetohydrodynami (MHD) eletri power generation is a tehnology whih shows substantial promise for utilizing oal, inluding high sulfur oal, while produing very low levels of S0 2 and NOX emissions. When an MHD yle is oupled with a onventional steam yle, the MHD/s team ombination holds the potential for substantial imp rovement in overall generating effiieny for oal fired plants. Although oal fired MHD power generation is presently very muh in a researh and development state, this doument looks into the future to propose and analyze a possible plant onfiguration. This is aomplished-by developing a omputer based mathematial model of the plant proesses. The seond hapter of this doument disusses the general onfiguration and sys tem interfaes of the proposed plant. The next hapter desribes the general struture and apabilities of the model. The following three hapters present the detailed algorithms whih onstitute the model ode for eah of the four maj or plant systems. The basis for these algorithms is also disussed. The next hapter presents

16 7 and explains a sample ase exeution of the omplete model, and the final hapter presents the onlusions drawn from this effort. The model presented in this doument is not a ompletely original work. However, the pre-existing model was substantially altered and.expanded by this effort. Chapters III through VI learly identify the hanges and additions made to the model. In spite of these modifiations, the model, like MHD tehnology itself, is still in a developmental stage. Hopefully, this model will serve as a useful tool for prediting and analyzing the potential performane of future entral station MHD/steam plants and thereby ontribute to the development of design riteria for future plant equipment.

17 CHAPTER II PLANT DESCRIPTION This hapter desribes the general onfiguration and proess sequene of the proposed MHD/steam ombined y le power plant. The plant is divi ded into the following four interrelated systems : 1. MHD topping yle 2. Heat and seed reovery (HRSR) 3. Steam bottoming y le 4. Seed regeneration Figure 2-1 is a shemati portrayal of these systems and their interrelationships. The remaining paragraphs of this hapter address eah of the four systems at greater length. The primary equipment.of the MHD topping y le onsists of a ombustor, nozzle, MHD generator, and diffuser. The MHD generator is omposed of a generating hannel, a superonduting magnet, and inverters (DC to AC). Seondary equipment assoiated with the MHD topping y le inludes the oxidant ompressor, the air separation plant, and the oal preparation equipment. The proess sequen e begins with the preparation of the oal and oxidant streams whih are ultimately fed to the primary ombustor. The air separation unit produes the oxygen whih is mixed with ambient air to ahieve the speified enrihment level. This mixture is then ompressed to the required pressure by the oxidant ompressor. Af ter ompression, the oxidant is preheated by heat 8

18 Make-up Seed Air Water I.- Regenerated Seed Coal Jt 1 Seed Regeneration Plan t I 4111(: Potassium sulfate Heat ' Air Eletri Power MHD Topping Cyle - Flue gas Heat -... Heat and Seed Reovery System Air Flue gas Steam Steam Bottoming Heat - Cyle Heat 1 Eletri Power Fig ure 2-1. Plant Shemati Diagram. \0

19 exhangers in the HRSR equipment and is then ready to enter the primary 10 ombus tor. These heat exhangers transfer heat diretly from the flue gas to the oxidant. Pr evious studies have identified the diret fired tehnique as preferable to the separately fired oxidant heating method from both eonomi and effiieny perspetives. Coal preparation onsists of pulverizing and drying the oal. Eletrially powered pulverizera aomplish the size redution. Dry ing is aomplished by a nitrogen stream from the air separation unit. The nitrogen stream is heated by heat exhangers in the HRSR equipment and is then passed through the pulverized oal to dry it. The dry pulverized oal is then stored in pressurized hoppers until it is required in the primary ombustor. The oal and preheated oxygen enrihed air are mixed and ombusted substoihiometri ally in the primary ombustor in order to ontrol NO X levels. Due to the oxidant enrihment and preheat, the ombustion temperature is suffiiently high to ionize the ombustion gases. While the ombustion is being aomplished, a reyled potassium omp ound is inj eted into the primary ombustor. The potassium ompound, termed seed, is added to inrease the ondutivity of the plasma. In this study, potassium formate is the seed ompound. Th resulting plasma is then aelerated through the nozzle and enters the MHD generating hannel at a high veloity. The superonduting magnet whih surrounds the generating hannel produes a high strength stationary magneti field. As the high veloity plasma passes through the magneti field, a diret urrent is generated transverse to the diretion of the moving plasma and the lines of fore of the magneti field. The diret urrent is passed to the inverters where it is hanged to alternating urrent for

20 11 transmi ssion through the power distribution grid. While the plasma is produing eletrial energy, it is losing thermal energy and eventually ools to the point where it loses its eletrial ondutivity and beomes merely a hot flue gas. One this happens, no more eletrial energy an be reovered via the.generating hannel. Howeve r, the gas is still very hot, in exess of 3500 F, and is still moving at a high veloity. A diffuser reeives the ga s as it exits the generating hannel and slows the gas while simul taneously reovering pressure. Beause the ombustor, nozzle, hannel, and diffuser are exposed to high ga s temperatures, their walls require ooling by water streams. The heat gained by these water streams is utilized by the steam y le equipment as explained la. ter. The heat and seed reovery system (HRSR) performs six ruial funtions. Fi rst, it provides extensive heat transfer surfaes for removing heat from the flue gas and providing that heat for use in power generation yles and proess streams. The seond funtion of the HRSR sys tem is to provide suffiient residene time at elevated tempe ratures to permit deomposition of the nitrogen oxides ontained in the flue gas. It s third funtion is to separate oal slag from the flue gas. The fourth funtion is to provide a seondary ombustor for ompleting ombustion of the substoihiometri flue gas. The fifth task of the HRSR system is to reover the potassium originally ontained in the seed. The final HRSR funtion is sulfur removal. In the flue gas, potassium ombines with sulfur and oxygen to form potas s ium sulfate whih the HRSR reovers from the flue gas.

21 12 The proess sequene for the HRSR system begins with the radiant furnae whih reeives the flue gas flow from the MHD topping y le diffuser. The radiant furnae enloses suffiient volume to provide the required flue gas residene time at high enough temperature to aomplish deomposition of nitrogen oxide s. The walls of the radiant furnae ontain water tubes whih absorb heat from the flue gas and produe steam whih ultimately powers the plant 's steam driven equipment. The radiant furnae also aomplishes removal of most of the oal slag from the flue gas stream. As it exi ts the radiant furnae, the flue gas enters the seondary o bu stor where it is mixed with air and ompletes the ombustion proess. Like the radiant furnae, the walls of the seondary ombustor will onsist of water walls whi h ontribute to steam generation. After exiting the seondary ombustor, the flue gas passes over onvetive heat transfer surfaes whih aomplish steam superheating and reheating as well as preheating of the oxidant for the MHD y le. As the flue gas passes over these surfaes and ools, a large fration of the potas sium sulfate ondenses and is separated from the flue gas. The potassium sulfate is reovered and transported to the seed regeneration plant for proessing As the flue gas exits the onvetive heat transfer setion, it is divided into four streams. One stream passes through a heat exhanger and heats the nitrogen flow stream intended for oal drying. Another stream passes through a seond heat exhanger and heats the seondary ombustion air. The third flue gas stream provides the heat neessary for generating the low pressure steam required by the seed regeneration proess. The remaining flue gas onstitutes the fourth stream whih is passed through eonomizers to

22 13 provide heat for feedwater heating in the steam y le. After exiting their. respetive heat exhangers, the four flue gas streams are reombined and passed through an eletrostati preipitator whih reovers the remaining potassium sulfate and ash from the flue gas. The reovered potassium sulfate is transported to the seed regeneration plant for proessing. Upon exiting the eletrostati preipitator, the flue gas is divided into two streams. One stream is diverted to the seed rege neration plant for the purpose of drying the reproessed potass ium formate seed. The other stream proeeds diretly to the stak where it is rej oined by the diverted stream with its added moisture. The flue gas is then released to the atmosphere as it exits the stak. The steam bottoming y le utilizes thermal energy reovered from the HRSR equipment and the MHD topping y le to produe mehanial shaft power whi h is then used to generate eletri power and to drive the MHD y le oxidant ompressor as well as the oxygen plant ompressor. The equipment whih omprises the steam y le onsists of the steam turbines whih drive the eletriity generator, the MHD oxidant ompressor, and the oxygen plant ompressor; the ondenser whih reeives the low pressure, low temperature steam exhausted from the turbines; the feedwater heaters whih use extration steam from the turbines for heating the feedwater; the steam drum; the ooling water passages in the MHD topping y le equipment whih provide additional feedwater heating and some steam generation; and finally the heat trans fer surfaes ontained in the HRSR equipment whih provide steam generation, superheating and reheating, as well as some feedwater heating. proess steps whih omprise the steam y le. There are four general They are ondense spent

23 14 steam, heat feedwater, generate steam, and expand steam. Low temr perature, low pressure turbine exhaust steam is piped to the ondenser. The ondensate {o r feedwater) produed in the ondenser is then direted to a series of feedwater heaters whih provide inremental inreases in feedwater temperature. The soure of heat for the feedwater heaters is steam extrated from different stages of the eletri power turbine. The feedwater heaters are designated as low pressure if loated upstream of the boiler feed pump, and high pressure if loated downs tream of the boiler feed pump. Additional feedwater heating is aomplished in the waterwalls of the MHD hannel and in the eonomizers loated in the HRSR system. Steam generation is divided into the phases of initial generation, superheating, and reheating. Initial generation takes plae in the ooling passages in the walls of the MHD y le ombustor, nozzle, and diffuser as well as the ooling passages whih form the walls of the radiant furnae and the seondary ombustor whih are loated in the HRSR sys em. The heated feedwater enters these passages and approximately twenty perent of this water turns to steam by the time it reahes the steam drum. In the steam drum, the steam and the water are separated. The water is reirulated through the ooling passages for additional steam generation. The steam is direted to the superheater, loated after the seondary ombustor, for additional heating. From the superheater the steam enters the turbines and begins the expansion stage in whih the pressure and thermal energy of the steam is. onverted into mehanial shaft power. After traversing the high pressure setion of the eletri power turbine, the steam is returned to the HRSR system and enters the reheater where it absorbs additional thermal energy before

24 15 returning to. the eletri power turbine and entering the intermediate pressure setion. After the intermediate pressure setion, the steam enounters the low pressure setion from whih it is disharged to the ondenser and begins the yle again. The ompressor turbines are similar exept that they have only one setion eah, and their steam supplies are not reheated. Po tassium seed regeneration is an absolute neessity for MHD power generation to be ommerially viable. Previous studies have established that seed regeneration is preferable to srubber. tehnology due to eonomi and effiieny onsiderations. The initial ost of potassium ompounds suh as potassium arbonate and potassium formate ditates the need for potassium reyling. For this reason, a seed regeneration system is an integral part of the plant. The formate proess is employed to aomplish regeneration of the potassium seed. Po tassium sulf ate reovered from the flue gas by the HRSR equipment is fed to the seed regeneration plant whih onverts it to potassium formate. There are six maj or steps assoiated with the formate regeneration proess. The first step is to gasify oal in order to produe arbon monoxide for - the formate reation. This is aomplished by feeding oal, preheated ompressed air, and water to a pressurized gasifier whih produes a produt gas whih is fed to the formate reator. The seond step is to dissolve the reovered potassium sulfate in water and mix it with unslaked lime. The resulting slurry is then heated and fed to the formate reator. St ep three is aomplished in the formate reator when the slurry and produt gas reat to produe potas sium formate and gypsum. The fourth proess step is to filter the gy psum from the formate

25 16 produt stream. produt stream. In the fifth step, water is removed from the formate The sixth and final step onsists of reheating the potassium formate stream until the formate beomes molten. This permits filtering out any remaining potassium sulfate beause it remains in the solid state. The potassium formate is then returned to the MHD yle for use as seed. This hapter has provided a brief overview of eah of the four major plant systems. system interfaes. It has also provided a general desription of the The next hapter presents an overview of the plant model. It is followed by hapters whih explain the details of eah system model as well as how to use the omplete model ode.

26 CHAPTER III MODEL STRUCTURE AND CAPABILITIES This hapter desribes the general struture and apabilities of SYSTEMS III as revised in June SYSTEMS III is a speial purpose program for analyzing the proess performane of a p otential ommerial prototype entral station power plant. This plant, as desribed in Chapter II, employs a oal fired, full slag arryover, oxygen enrihed MHD topping yle whih is oupled with a onventional, regenerative, superheated steam bottoming y le. In its present form, SYSTEMS III is a omposite of the following five subordinate programs : 4 Pr ogram COAL COAL DESIGN3 SINGH NASA SP-273* PRE STO II is the first program exeuted during a plant performane analysis by SY STEMS III. COAL is a data transformation program whih prepares an input data file for the NASA SP-273 program and selet input data values for the SINGH program. The program user provides the following data input to COAL. 1. Coal proximate analysis (ASTM D3172). 2. eoal ultimate analysis (ASTM D3176). 3. Coal ash analysis (ASTM D3174). 4. Hi gher heating value of dry oal (ASTM D3286). *NASA SP-273 was modified at UTSI to alulate the eletri transport property per Frost 3, and to provide the means for speifying ombustor heat loss. 17

27 18 5. "As fired" oal moisture ontent. 6. MHD ombustor heat loss. 7. Stoihiometri ratio for MHD primary ombustion. 8. Enrihing oxygen ontent of MHD primary oxidant. 9. Pr eheat temperature of MHD primary oxidant. 10. Pe rent potassium in total plasma flow. Us ing the above information, COAL performs a series of alulations as explained by Woodring 4 As a result of these alulations, COAL is able to output the hemial omposition, relative proportions, and preheat temperatures of the oal, potassium seed, and oxidant whih are fed to the MHD ombustor. The ombus tor heat loss is als o inluded in this output. The format in whih COAL prints this data is preisely that required for the input data file read by the NASA SP-273 program. COAL also prints out values for the following parameters required by SINGH : 1. Hi gher heating value of dried oal. 2. Moisture ontent of "as fired" oal. 3. Pe rent of MHD oxidant that is air. 4. Pe rent of MHD oxidant that is pure oxygen. 5. Fration of fuel input that is potassium seed. 6. MHD ombustor heat loss per unit mass of dried oal flow. 7. Sulfur ontent of dried oal. In its present form, COAL is run independently and the program user must prepare the input files used by NASA SP-273 and SINGH. The use of COAL as a part of SYSTEMS III is one of the additions implemented by the urrent revision of SYSTEMS III.

28 5 DESIGN3 is the seond program exeuted during a plant performane 19 analysis by SYSTEMS III. DESIGN3 is a program whih designs an MHD generating hannel. It provides the user with a wide range of options for speifying hannel onditions, harateristis, and restraints. The following onstitutes a general list of parameters addressed: 1. Channel mass flow. 2. Pl asma thermodynaud and eletri properties. 3. Channel geometry. 4. Magneti field distribution and maximum strength. S. Ele trial loading. 6. El etrial operating restraints. 7. Gas dynami s onsiderations. The detailed use of DESIGN3 has been doumented by wu 5 Normally, the design of a generating hannel using DESIGN3 requires several program exeutions before the user has satisfatorily balaned all the signifiant onsiderations and speified a reasonably effiient hannel. The final hannel design serves as a referene hannel for the SYSTEMS III plant analysis. The following parameters from the DESIGN3 output file are inluded in the input file for SINGH: 1. Pl asma Mah number at hannel entrane. 2. Ratio of hannel exit area to entrane area. 3. Maximum magneti field strength. 4. Channel length. S. Channel entrane area. 6. Pl asma mas s flow rate. 7. Generator hannel effiieny.

29 20 8. Generating hannel enthalpy extrat ion. 9. St at i pressure at hannel exit. As explained in Chapter IV, SINGH uses these referene hannel parameters to extrapolate the performane of similarly designed generator hannels whih mu st ao mmodate different plasma mas s flow rates. In its present form, DESIGN3 is exe uted independently and the program user must prepare the input file required by SINGH. The use of DESIGN3 in the plant performane analysis does not ons titute a new development for SYSTEMS III. The third phase of plant performane analy sis by SYSTEMS III onsists of the sequential exeution of NASA SP-273, SINGH, and PRESTO II. The ma in program of NASA SP begins the sequene by reading and storing the inpu t data ge nerated by COAL. Af ter this is aomp lished, NASA SP-273 relinqu ishes program exe ut ion ontrol to SINGH whih, tehnially, is a subrout ine of NASA SP-273. SINGH first reads values for the variables listed in Ta ble 4-2 (see Chapter IV). SINGH then exeutes it s program ode wh ih models the proess performane of the MHD topp ing y le, the seed regenerat ion plant, and the heat and seed re overy system (HRSR). As it performs alulat ions for the MHO topping yle and the HRSR system, SINGH alls other NASA SP-273 subroutine s whih provide plasma/flue ga s thermodynami propert ies for seve ral state point s. After HRSR model al ulat ions are ompleted, SINGH alls PRESTO II whih models the steam y l e based upon inpu t data provided by SINGH. PRESTO II 7 ' 8 is a omputer ode for analy zing the performane of regenerat ive, superheated steam turbine y les at valves ide-open des ign

30 21 flow. At the onlusion of PRESTO II exe ution, SINGH ompletes the plant performane analy sis by alulating the overall plant effiieny. Before losing this hapter, a few words about energy loss onside rations are in order. This model aounts for major heat and equipment effiieny losses. The MHD topping y le and the steam y le models estimate losses assoiated with fluid flow through heat exhangers and piping. Th e seed regeneration model and the HRSR sy stem mode l do not address energy losses assoiated with fluid flow. The losses whi h are a lulated by the model are desribed in the following three hapters or addressed in the referenes mentioned in those hapters.

31 CHAPTER IV MHD TOPPING CYCLE The MHD topping y le is the first plant system modeled during exeution of the SYSTEMS III program. Fi gure 4-1 is a diagram of the topping y le proess as modeled by SYSTEMS III. The proess steps whih onstitute the topping yle model ons ist of the following : 1. Produe oxygen from ambient air. 2. Blend the oxygen with ambient air to produe an oxygen enrihed MHD oxidant. 3. Compress the MHD oxidant. 4. Preheat the MHD oxidant. 5. Pulverize oal. 6. Dry the pulverized oal. 7 Injet oal, oxidant, and potassium seed into the MHD ornr bus tor. 8. Combust the oal, oxidant, and seed mi xture substoihiometrially to produe a high temperature plasma. 9. Aelerate the plasma into the MHD eletri power generation hannel. 10. Generate D.C. eletri power and invert to A.C. 11. Deelerate the plasma in the diffuser. 12. Cool the walls of the ombus tor, nozzle, MHD power generation hannel, and diffuser. 22

32 Tl l Tl O T3 T9 T7 Oxi dant Comp. T6 o 2 & Air Blendin g Ai r ----.I se paration Plant T4 Tl I' Coal Pu lve r izing & Dryin g Tl3 r j"iirsit-1 I Syste T r - T2 T8 Tl 4 r _l _ Seed I Regen. 1 L P a _J I p _...._ _ L T _ T I MHD Combu stor Tl 5, Steam Cyle --.._ - r-- -- MHD Channel Inve rter Ma gnet Tl , -- - I MHD Diffuser I _, Tl 7 ; System I L l Fi gu re 4.1. Proess Mass Flow Diagra m fo r MHD Toppin g Cyl e. N (...)

33 24 Subroutine SINGH ontains the algorithms whih model these proess steps. This hapter is devoted to a des ription of both the form and the basis of these algorithms. As a proess model, SINGH has four distint objetives: 1. Calulate mass flow rates for proess flow-s treams. 2. Calulate energy transfers, equipment energy requirements, and eletrial energy prodution quantities. 3. Calulate selet thermodynami properties for speified proess flow streams. 4. Calulate selet geometri dimensions for speified y le equipment. The following desription of the topping yle algorithms ontained in SINGH is presented in two segments. The first part addresses alulation of proess mass flows while the seond addresses energy alulations as well as omputation of the thermodynami properties and geomet rial dimensions. This pres entation format parallels the SINGH exeution sequene. Before beginning the topping y le model desription, a word about variables is in order. the MHD topping yle. SINGH uses a large number of variables to model An attemp t to fully explain eah of these variables in the text would be extremely tedious and would likely onfound the reader. The following present at ion explains variables only to the extent neessary to learly desribe the funtioning of the model as it works to ahieve its four previously stated objet ives. Appendix A ontains a listing of subroutine SINGH whih inludes omment statements ontaining definitions of variables. For detailed explanations of

34 those variables whose soure is the original NASA SP-273, the reader is di reted to the manual by Gordon and MBride 6 The MHD topping yle mass flows modeled by SINGH are depi ted in 25 Figu re 4-1 and desribed in Table 4-1. SINGH begins its exeution by reading input values for ertain topping yle va riables. These variables are named and defined in Table 4-2. The first mass flow alulated by SINGH is the flow of dried oal {MCT02, lbm/h r) to the MHD ombustor. To aomplish this, SINGH first uses the desired net elet rial output {P OUT, Watts) and the estimated effiieny {E FF, %) of the ombined MHD and steam yles to ompute the thermal input {THIN, Btu/h r) requi red from oal. The oal referred to here does not inlude that requi red by the seed regene ration plant. The algo rithm has the form: THIN= POUT* / {E FF/1 00. ) The highe r heating value {HCC, Btu/lbm) of dry oal is then used with THIN to alulate the required flow rate of dried oal {MCT02, lbm/h r) to the MHD ombustor. MCTO 2 = TH IN/HCC The mass flow ra te of "as re e ived" oal (M CTOl, lbm/hr) is the next quantity alulated. This alulation requi res speif iat ion of the "as ree ived'" moisture ontent {M OISAR, %) of the oal as well as the "as fired" moisture ontent {M OI SAF, %) of the oal. These two moisture ontents are used to alulate the moisture restoration fator {M OISRF, dimensionless) as follows : MIOSRF = {{M OISAR* {{loo.-m OISAF) /{ M OI SAR) ) OI SAF) )/100.

35 Table 4-1. Proess Ma ss Flows for MHD To pping Cyle. Steam No. Variable Desription Name Al.gori tina Units Tl Coal from stokpile to pulverizers MCTO l MCT02*MOISRF lbm/hr T2 Dr ied oal to MHD ombustor MCT02 THIN/HCC lbm/hr T3 Ambient air to MHD ompressor MAT03 (PCTA/lOO. ) *MOAT08 lbm/hr T4 Ambient air to air se paration plant MAT04 MOTOS/0.232 lbm/hr TS Oxygen from air se paration plant MOTOS (PCTO/lOO. ) *MOAT08 lbm/hr T6 Oxyg en enrihed air to MHD ompressor MOAT06 MOAT08 lbm/hr T7 Oxygen enrihed air to air heater MOAT07 MOAT08 lbm/hr TB Oxygen enrihed air to MHD ombustor MOAT08 OF*MCT02/ (1.-SFLO) lbm/hr T9 Ni trogen and argon from air se paration MNAT09 MAT04 - MOTOS lbm/hr TlO Ni trogen and argon released to atmo sphere MNATlO MNAT09-MNAT11 lbm/hr Tll Ni trogen and argon for oal drying MNATll 1.2S*QWVT13/ (250.0*0.244) lbm/hr T12 Ni trogen and argon for oal drying MNAT12 MNAT ll lbm/hr N 0\

36 Table 4-1 (Continued) Ste am No. Desr1ft1on Vari able Name Al a orithm Units Tl3 Ni tro gen, ar gon, and moi sture from oal MTT13 MNATll + MCTOl - MCT02 lbm/hr Tl4 Po tassium se ed to MHD ombustor MKT14 SFLO*MCT02/ (l.-sflo) lbm/hr TIS Pl asma to MHD h annel MPTlS MCT02 + MKT14 + MOAT08 lbm/hr Tl6 Pl asma to MHD diffuser MPT 16 MPTlS lbm/hr T17 Flue gas to HRSR equipment MFGT17 MPTlS lbm/hr N...

37 Table 4-2. Variables for whih Values are Read by SINGH. Variable Name Desription Units... Soure POUT Desired ne t eletri po wer outpu t from plant WATTS Us er Speified EFF Es tima ted ne t effi eny of plant % User Speified HCC Hi gher heating value of dried oal Btu/l bm Program COAL MOISAR Mois tu re on tent (by weight) of "as reeived" oal % Coa l Proxima te Analysis MOISAF Mois ture ontent (by weight) of "as fired" oa l % Program COAL PCTA Peren t of MHD oxidant flow that is air % Program COAL PCTO Perent of MHD oxidant flow that is pure oxygen % Program COAL SFLO Fration of fue l input that is po tassium se ed Program COAL PRINT MHD ombustor operating pressure ATM User Speified TAlC Tempe ra ture of oxidant enrihed air at ombus tor inlet OK User Speified QLCPUM Heat loss from ombus tor to oo ling wa ter per uni t mass of gas side ombustor mass flow Btu/l bm Program COAL N 00

38 Table 4-2 (Continued) Variable Name Desription Units Soure EMACH A REAR BMAX CEFFI CLEN ENT GDMF GEF HF PSTAT xs XS AR Plasma Mah No. at hannel entrane Rat io of referene hannel exit area to entrane area Maximum magneti field strength Inverter effiieny Length of referene hannel Entrane area of referene hannel Referene generating hannel mass flow Frational generator effiieny of referene hannel Frational enthal py extration of referene hannel Stati pressure at referene hannel exit We ight fration of dried oal that is sulfur Weight fration of "as reeived" oal that is sulfur Program DESIGN3 Program DESIGN 3 Tesla Program DESIGN 3 % Us er Speified Meters Program DESIGN 3 Sq M Program DESIGN 3 lbm/hr Program DESIGN 3 Program DESIGN 3 Program DESIGN 3 ATM Program DESIGN 3 Program COAL Coal Ul timate Analysis I N \0

39 Table 4-2 (Continued) Variable Name Desription Units Soure XAAR We ight fration of "as reei ved" oal that is ash Coal Ult imate Analysis TAH04 Seondary ombustion air temperature at seondary ombustor inlet OR User Speified SR Stoihiometri ratio for MHD ombustor Program COAL HSTEAMA Steam enthalpy at Superheater exit Btu /lbm User Speified HSTEAMR. St eam enthalpy inrease in reheater Bt u/lbm Us er Speified w 0

40 31 The development of the above equation begins by onsidering a mass of 100 pounds of "as fired" or dried oal. Of this 100 pounds, MOISAF pounds is the amount of moisture ontained in the mass and (100. MOISAF) pounds is the amount of other oal material. Similarly, a 100 pound mass of "as reeived" oal ontains MOISAR pounds of moisture and ( 100.-MOISAR) pounds of other oal material. The "a s re eived mass will ontain less oal material than the "as fired "-mass. The oal material ontent of the "as re eived " oal has to be inreased by a fator of (100.-MOIS AF)/100.-MOISAR) to make it equal to the oal material ontent of the "a s fired" oal. Sine moisture ontent and oal material ontent of a given ma ss are proportional, MOISAR must also be inreased by the same fator. MOISAR* ((100.-MOISAF)/(100.-MOISAR) ) The quantity of moisture whi h mus t be removed from the enlarged "as reeived" mass in order to yield a 100 pound mass of "as fired'" oal is expressed as: MOISAR*((lOO. -MOISAF)/(100.-MOISAR) ) OISAF) The total mass of "a s ree ived" oal neessary to yield 100 pounds of as fired oal is then expressed as the sum of the mo isture removed plus 100 pounds. (MOISAR*(100.-MOISAF)/(100.-MOISAR) ) OISAF) +l00. Dividing the above expression by 100 yields the dimensionless value for MOISRF. Us ing MOISRF and MCT02, SINGH alulates the mass flow rate of "as re eived " oal (MCTOl). MCT0 1 = MCT02*MOISRF

41 32 At this point, SINGH alls data and subroutines from the NASA SP program for the purpose of speify ing ombus tion onditions for the MHD primary ombustor. The program exeut ion details an be obtained by reviewing the referene ited for the NASA SP-273 program. The oxidant flow rate (MOAT08, lbm/hr) is the next quantity to be omputed by SINGH. This alulat ion requires the oxidant to fuel ratio (OF) whih was alulated during the preeding all for NASA SP- 273 subroutines. The frat ion of the fuel input onsisting of potassium seed (SFLO) is also required for alulating MOAT0 8. MOAT0 8 = OF*MCT02/ (l.-sflo) SINGH ont inues by alulating the following quant it ies : Amb ient air to the MHD ompressor (MAT0 3, lbm/hr). Oxy ge n for enrihing MHD ombustion air (MOTOS, lbm/hr). Amb ient air to air separation plant (MAT04, lbm/hr). Ni trogen and argon exhausted from air separat ion plant (M NAT0 9, lbm/hr). Mo isture to be removed from stokpiled oal (MWVT1 3, lbm/hr). The algorithms for the above quantities are straightforward and are presented in Table 4-1. At this point, SINGH mus t determine how muh of the air separation plant s nitrogen and argon effluent will be used for oal drying. Formulation of the algorithms nees sary to make this determination requi ed some assump tions and analysis. Fi rst, it was neessary to estimate an init ial temperature of the stokpiled oal and its moisture. The ambient temperature for the plant evaluation was assumed to be 80 F (540 R, 300K). It was also neessary to speify a temp erature for the

42 33 heated moisture. Based on the example of another MHD/ steam plant study 9, 150 F (610 R, 339K) was seleted as the temperature to whih the moisture mu st be heated in order to drive it from the oal. At 80 F the moisture is assume d to be a saturated liquid. At 150 F the mois ture is assumed to be a saturated vapor. These assump tions are onservative and they insure that the alulated heat requirement for oal drying will be suffiient. Us ing the 1967 ASME Steam Tables 10, the heat required to raise the temperature of one pound of moisture from the saturated liquid state at 80 F to the saturated vapor state at 150 F was found to be 1078 Btu. The heat (QWVT13, Btu/hr) required to raise the temperature of the exess moisture ontained in the "as reeived" oal ould then be expressed as: QWVT13 = 1078.*MWFT13. The above alulation is performed by SINGH. The next step in the analysis required speifiation of the temperature to whih the drying gas must be heated. Based upon the results of a previous MHD/ steam plant study 11 onduted at UTSI, flue gas at temperatures less than 700 F (1160 R, 644K) is of negligible va lue to either the steam y le or the primary oxidant heating proess. Flue gas ooler than 700 F is therefore an exellent soure of heat for oal drying. Al lowing a temperature differential of 100 F aross the heat exhanger, the flue gas an heat the drying gas to a temp erature of 600 F (1060 R, 589K). 12 standard referene on oal fired powe r plants A states that some ommerially available pulverizers are apable of reeiving dry ing gases as hot as 650 F (1110 R, 617K). Thus, 600 F was hosen as the ternperature to whi h the drying gas will be heated. The ni trogen and

43 34 argon gas is assumed to ool to 150 F during the oal drying proess. It is also assumed that only 80% of the heat released from ooling the drying gas will atually ontribute to moisture removal. The remaining 20% of the heat is assumed to heat the oal itself. It is further assumed that the oal ools bak to the ambi ent temp erature while stored in a harging hopper. Thus, that fration of the heat released by the drying gas is ultimately lost to the atmosphere. From Re ynolds and Pe rkins 13, approximately 100 Btu are released by eah pound of nitrogen as it ools from 600 F to 150 F. Beause argon onstitutes suh a small fration of the drying gas, the gas was idealized as pure nitrogen when alulating thermodynami properties. Based on the preeding information, the algorithm developed to alulate the required mass flow of nitrogen and argon dr.ying gas (MNATll, lbm/hr) takes the form: MKT14 = SFLO*MCT0 2/ (1.-SFLO) The potassium formate seed is a ombination of reyled seed and make-up seed. The relative amounts of reyle and make-up seed are alulated as desribed in Chapter V. At this point SINGH is able to alulate the ma ss flow rate of plasma to the MHD hannel (MPT15, lbm/hr) whih is simply the sum of dry oal to the ombustor (MCT02), oxidant to the ombus tor (MOAT08), and potas sium formate seed to the ombus tor (MKT1 4). Beause there are no mass losses from the plasma side of the MHD hannel and diffuser during steady state operation, the values for plasma to the diffuser (MPT16, lbm/hr) and flue gas to the HRSR equipment (MFGT17, lbm/hr) are equal to MPT15 and are not separately alulated by SINGH. At this

44 35 point, the determination of topping yle mass flows, as depited in Figure 4-1 (page 23), is omplete. The remainder of this hapter addresses the energy requirements, energy prodution, and energy losses assoiated wi th the MHD topping yle. The presentation inludes desription of the algori thms whih alulate required thermodynami properties and omponent geometry. Eah maj or equipment omponent is onsidered indivi dually and the order of presentation parallels the SINGH exeution sequene. Table 4-3 presents a list of the key energy quantities developed in this setion. The table inludes defini tions, algorithms, units, and variable name s for the subj et quantities. The air separation plant (ASP) model was developed from information 14 provided by Lotepro Corporation The proess model is essentially a blak box whih reeives air at ambient temperature and pressure and disharges an oxygen produt stream as well as an effluent stream omposed of nitrogen and argon. Both the produt stream and the effluent stream are disharged at ambient temperature and pressure. Beause all inoming and outgoing mass flows are at ambient temperature and pressure, there is no net energy transfer among them. The only energy required.by the ASP is that required to power the plant equipment (POWERO, MW). A proess air ompressor and a old box ons titute the major plant equipment and both are powered by a steam driven turbine. Aording to the Lotepro report, the plant energy requirement is kilowatt hours per ton of oxygen produed. This information was used to develop the algorithm for POWERO whih is presented in Ta ble 4-3. this model, POWERO is the power delivered by the turbine shaft. In The

45 Table 4-3. Energy Quantities for MHD To pping yle. Desription Va r_!able Algorithm Units Heat required to remove moisture from oal QWVT *MWVT13 Btu/hr Shaft power required from ASP turbine POWERO *MOT05 Watts Shaft power delivered to oxidant ompressor PCOMP See text pg. 39 Watts Heat gained by oxidant during ompression QOAT0 7 See text pg. 40 Btu/hr Energy lost during ompression proess ELOCT PCOMP *QOAT07 Watts Heat added to oxidant in HRSR heat exhanger QHEOAT See text pg. 41 Btu/hr Energy transported into ombustor by oxidant QOAT08 QOAT07 + QHEOAT Btu/hr Eletri power required by pulverizers and drying fans PPFT 7*MCT0 1 Wat ts Heat gained by N 2 and Ar drying gas in HRSR QNAT12 131*MNAT 11 Btu/hr Dry ing gas heat lost to oal and atmosphere QLCDT T13 Btu/hr Heat retained by oal drying ga s QNAT13 QNAT1 2 - T1 3 - QLCDT Btu/hr Energy required to deompose potassium formate QKT14 4.*MKT14 Btu/hr Heat lost from ombustor to ooling water QLCOMB QLCPUM*MPT15 Btu/hr w 0'\

46 Table 4-3 (Continued ) Desripion Va riable Algorithm Units Ki neti energy and heat transported from ombustor bf plasma EQKTl S (HSUM( l)-hsum( S) ) *1. 8*R*MPT15 Btu/hr Un released hemi al energy transported from ombustor by plasma ECTlS THIN + QOAT08 -QKT14-EQKT15 Btu/hr DC elet ri power developed by the MHD hannel PEXM (HSUM(l)-HSUM( S) )*R *1.8*.293l*HFF*MPT15 Watts AC eletri power to grid from hannel POUTM CEFFI*PEXM Wat ts Plasma energy lost to hannel ooling water as heat QLMHD (PEXM* * (1.-GEFF) )/GEFF Btu/hr Ki neti energy and heat transported from hannel by plasma EQKT16 EQKT15-(PEXM*3.4129) - QLMHD Btu/Hr Total energy transported from hannel by plasma ETT16 EQKT1 6+ECT15 Btu/hr Eletri power required to operate the superonduting magnet PMAG See Text pg. 49 Watts Heat lost from plasma to diffuser ooling water QLDIF See Text pg. 49 Btu/hr Total energy transported from diffuser by flue gas ETT17 ETT16 - QLDIF Btu/hr Ki neti energy and sensible heat transported from diffuser by flue gas EQKT17 ETT17 - ECTlS Btu/hr w ""-

47 38 The steam yle model, presented in Chapter VI, alulates the steam flow required by the turbine. The MHD oxidant ompressor is assume d to be an axial, multistage, turbine driven mahine without interooling. Whether or not interoolers should be used for this partiular appliation is an unresolved question. On one hand, interoolers are expensive and the oxidant will have to be reheated anyway. On the other hand, interooling redues the energy required for oxidant ompre ssion, and low temperature flue gas is available for oxidant preheating. A final resolution of this question requires a seond law thermodynami analysis as well as a detailed ost analysis. Both of these analyses are beyond the sope of this work, and this study assumes interoolers will not be used. The ompressor model alulates shaft power required to drive the ompressor, the temperature of the oxidant as it is disharged from the ompressor, and the heat gained by the oxidant du ring the ompression proess. The oxygen enrihed air enters the ompressor sution side at ambient temp erature and pressure, and is ompressed to a speified disharge pressure (POAT07, psia). During the ompression, the oxidant is assumed to behave as a perfet gas. SINGH alulates POAT07 from the following expression: POAT0 7 = 14. 7*PRINT+15. PRINT is the operating pressure of the MHD ombustor. It is speified in atmospheres and its value is read from the input data file. Th e 15 psi term is added to PRINT to aount for frition losses aumulated from the HRSR heat exhanger and the interonneting piping between the

48 39 ompressor exit and the ombustor entrane. From Hansen 15, the ompressor power requirement an be estimated by the following expression: - 1 ] /n where Power = shaft power delivered to ompressor (horsepower) Pl = P 2 V1 oxidant pressure at ompressor entrane (psia) oxidant pressure at ompressor exit (psia) oxidant flow volume at ompressor entrane (fm) y = ratio of oxidant speifi heats (i.e. C p /C v ) n = ompressor isentropi effiieny A modified form of the above equation is used by SINGH to alulate the shaft power (PCOMP, Watts) whih must be developed by the turbine to drive the oxidant ompressor. P 1 is the ambient pressure and has a value of 14.7 psia. P 2 is the previously defined POAT0 7. VI is represented in SINGH by AFLOV whih is alulated from MOAT08 and the fat that one pound of air oupies ubi feed at 80 F and 1 atmosphere. AFLOV = 13.56*MOAT08/60. The value for y is 1.4 and onsequently, the value for y/(1 - y) is 3.5. The value for (y - 1)/y is A ording to Chapman16, 0.89 is a reasonable estimate for ompressor effiieny. The resulting expression for PCOMP beomes: PCOMP = 3.25*14. 7*AFLOV*3.5 *(((POAT0 7/14.7)**0.286)-1)/0.89

49 The temperature of the oxidant as it exits the ompressor (TOAT0 7, 0R) is alulated from the following expression from Hansen ls : (y - 1) T 2 = T l (P 2 /P l ) y 40 where Tl = T 2 = oxidant temperature at ompressor entrane (0R) oxidant temperature at ompressor exit (0R) for isentropi proess P 1, P 2 and y remain as previously defined For the oxidant ompressor model T 1 is 540 R, P1 is 14.7 psia, T 2 is TOAT0 7, P 2 is POAT0 7, and y is 1.4. T 2 is the outlet temperature alulated for an isentropi proess, but the ompressor is not an isentropi mahine. Therefore, TOAT07 will atually be greater than T 2 To provide a better estimate for the value of TOAT0 7, the preeding expression for T 2 is divided by the ompressor isentropi effiieny. The resulting algorithm for TOAT07, as used in SINGH, beomes: TOAT0 7 = (540.* (POAT0 7/14.7)**0. 286) /0.89 SINGH next alulates the rate at whih heat is transferred to the oxidant (QOAT0 7, Btu/hr) as it undergoes ompression. The following algorithm is based on Van Wylen l7 and the fat that the oxidant is idealized as a perfet gas : QOAT07 = MOAT0 8* (1.1875E-05* ((TOAT07**2)-(540.**2) ) (TOAT )) SINGH alulates the energy lost during the ompression proess (ELOCT, Btu/hr) as the differene of PCOMP minus l*QOAT07. After exiting the ompressor, the oxidant passes through a heat exhanger in the HRSR setion. This heat exhanger transfers heat from

50 41 the flue gas to the oxidant in order to raise the temperature of the oxidant to the value required for entering the ombustor (TAIC,K). SINGH reads the value of TAlC from the input data file. 17 Wylen From Va n, the rate at whih heat is added to the oxidant flow in the heat exhanger (QHEOAT, Btu/hr) an be alulated from the following algorithm: QHEOAT = MOAT08*(1.1875E-05*(((TAIC( 1.8)**2) -.(TOAT07**2) )+. 224* ( (TAIC* 1. 8)-TOAT07) ) After alulating QHEOAT from the above expression, SINGH alulates the total amount of heat entering the ombustor with the oxidant flow (QOAT0 8, Btu/hr). QOAT08 is alulated as the sum of QOAT07 and QHEOAT. The requirements for pulverizing and drying oal inlude pulverizers for reduing oal partile size, a drying gas whih vaporizes and transports the moisture, and fans to move the drying gas through the oal partiles. This model assumes the pulverizers and fans are driven by eletri power. From Babok and Wilox 12, the eletri powe r required to operate pulverizers and fans an be estimated as 14 kilowatt hours per ton of oal input. SINGH alulates the eletri power required to drive the pulverizers and fans (PPFT, watts) as follows : PPFT = 7.*MCT0 1 As previously disussed, the drying gas is a portion of the nitrogen and argon effluent (MNAT11) from the air separation plant. The nitrogen and argon effluent exits the air separation plant at ambient temperature and pressure. It is then passed through an HRSR heat exhanger where it reeives heat from flue gas. During this heat transfer proess the temperature of the drying gas inreases from its

51 initial ambient value of 80 F to a final value of 600 F. 42 From Reynolds 13 and Pe rkins, the heat gained per pound of drying gas will be 131 Btu/ lbm. A ordingly, SINGH alulates the heat transferred to the drying gas {QNAT12, Btu/hr) as : QNAT12 = 131.*MNAT11 When the drying gas mixes with the oal, its heat ontent is divided three ways. Part of the heat is used to vaporize the moisture and bring its temperature to 150 F. This quantity {QWVT13) was previously alulated during the mass flow analysis. The algorithm for QWVT13 is listed in Table 4-3. Some of the heat is lost to immediate oal heating and ult imately to the atmosphere. This quantity (QLCDT, Btu/hr) is alulated as equivalent to 25% of QWVT13. The remaining heat {QNAT13, Btu/hr) is never released from the drying gas and serves to maintain the gas temperature at 150 F as the gas transports the vaporized moisture to the HRSR equipment. The algorithm used by SINGH to alulate QNAT13 is as follows : QNAT13 = QNAT12-QWVT13-QLCDT At this point, SINGH alls upon several NASA SP-273 subroutines 6 to alulate and store hemi al and thermodynami data for four plasma/flue gas states. Eah individual state is identified by a different index value for the NASA SP-273 variable NPT{I). For example, the previously alulated plasma properties in the ombustor are identified by NPT( l). The four states alulated at this point are numbered 2, 5, 6 and 7. They are desribed in Table 4-4 along with the other three states. These alulations are aomplished at this point in the SINGH exeution beause data for NPT( 5) is required for the ombustor analysis. The

52 Table 4-4. States for whih SINGH alls NASA SP-273 to Calulate Pl asma/flue Gas Properties. Identifiation Temperature Number Desription of St ate (K) 1 Plasma at ombustor exit TAlC 2 Flue gas at stak Flue gas at MHD hannel exit TT(3) 4 Flue gas at diffuser exit TT( 4) 5 Referene Flue gas at eonomizer inlet Flue gas at seondary ombustor inlet 1867 Pressure (Atm ) PRINT 1.0 PST AT PD0/ po. w

53 omputational tehniques used by the NASA SP-273 subroutines begin with properties for a given temperature and use onvergene tehniques to 44 alulate values for lower temperatures. Thus it is expeditious to alulate as many points as possible during a onvergene sequene. The MHD ombustor is a waterooled pressure vessel whih aomplishes substoihiometri ombustion at a spei fied pressure (PRINT, atmospheres). For this analysis, the nozzle, whih aelerates the plasma flow into the MHD hannel, is onsidered as part of the ombustor assembly. The ombustor reeives three inj eted mass flows whih onsist of oxygen enri hed air (MOAT08), dried oal (MCT02), and potass ium forma te seed (MKT14). The oxygen enrihed air flow transports energy (QOAT08), in the form of sensible heat, into the ombustor. The dried oal flow transports hemial energy (THIN) into the ombustor. The potassium forma te seed ontributes no energy ; instead, it requires an estimated 4 Btu/lbm to drive the reation whih frees potassium atoms for the work of sulfate formation and sulfur removal. SINGH alulates this energy requirement ( QKT1 4, Btu/hr) using the required mass flow rate of potassium formate seed (MKT14) : QKT14 = 4.*MKT14 There are only two paths for energy transport out of the MHD ombustor. One path is the ooling water flow whih ools the ombustor and nozzle walls. SINGH alulates the amount of heat transferred from the ombustor and nozzle walls to the ooling water (QLCOMB, Btu/hr). To aomplish this, SINGH reads a value for the amount of heat lost to ombustor ooling water (QLCPUM, Btu/lbm) per pound of oal input to the

54 45 ombustor. As part of it s alulat ion sequene, program COAL alulates a value for QLCPUM. The result ing algorithm for QLCOMB beomes : QLCOMB = QLCP MCT0 2 The other path for energy transport out of the ombustor is provided by the plasma flow whih exits the nozzle. There are three energy forms transported by the plasma. First there is the kineti energy of the plasma flow. Next there is the sens ible heat of the plasma. F inally, there is the hemial energy retained by the unombusted fuel ompounds. The kine t i energy and sens ible heat are alulated as one quant ity (EQKT15, Btu/hr) by realling the stagnat ion enthalpy of the plasma (HSUM( l), J/KG) at ombustor ondit ions. HSUM( l) was previously alulated and stored by NASA SP-273. SINGH alulates EQKT15 with the following algor ithm: EQKT15 = (HSUM( l)-hsum( 5) )*R* l.8*mpt15 The unreleased hemial energy (ECT1 5, Btu/hr) transported by the plasma is omputed by differene in SINGH. ECT1 5 = THIN+QOAT0 8-EQKT1 5 SINGH then alulates the total energy transported from the ombustor (ETT1 5, Btu/hr) by the plasma flow as the sum of EQKT15 and ECTlS. The final step in the ombustor analy sis sequene is to alulate selet thermodynami and geometri parameters from plasma flow through the nozzle. The six values alulated are the nozzle ros s setional area at the throat (AT, Sq. Meters) and at the exit (AE, Sq. Meters), the plasma dens ity at the nozzle throat (RHOT, KG/C u. Meters), and at the nozzle exit (RE, KG/C u. Meter), as well as the stat i pressure (PENZ, ATM) and temp erature (TE, Kelvin) of the plasma flow at the

55 nozzle exit. SINGH alulates these quantities through the use of lassial gas dynamis equations for isentropi nozzle analysis in onjuntion with data values previously alulated by NASA SP-273 subroutines. The Mah number for the plasma as it enters the MHD hanne l (EMACH, dimensionless) is required and is read by SINGH. The alulation seq uene is learly identified in SINGH and is not elaborated upon here. The MHD generating hanne l is the next topping yle omponent addressed by SINGH. The hanne l reeives the aelerated plasma flow from the nozzle exit. The energy transported, by the plasma, into the hannel has been previously alulated as ETTl S. As the plasma passes through the hanne l and its assoiated magneti field, the plasma energy ontent is dereased by two mehanisms. First, the MHD effet transforms a portion of the kineti and sensible heat energy (EQKTlS) into eletri power. Seond, a portion of the plasma sensible heat is transferred to the hannel ooling water. The determination of the eletri power produed by the MHD hanne l is a lengthy proess. The first step is design of a referene generating hannel _ by means of independent exeution of the DESIGN3 program 5 The DESIGN3 user sizes the referene generating hanne l in aordane with the expeted plasma flow and omposition for the subsequent SINGH exeution. In addition, the DESIGN3 user must speify numerous other parameters req uired to adequately desribe the operating haraeristis of the referene hanne l. The detai led us e of DESIGN3 is addressed by Wu 5, and is not explained here. Several data values output by DESIGN3 are required by the hanne l mode ling algorithms and are read 46

56 47 by SINGH at the beginning of its exe ution yle. The variable names assoiated with those data outputs are listed below and are defined in Table 4-2. BMAX CEFFI GDMF HF CLEN AREAR ENT PST AT GEF The values read by SINGH are used to alulate the performane and geometry of a gene rating hannel, simi lar to the referene hannel, but proportioned to reeive the exat plasma flow alulated for the urrent SINGH exeution y le. This is aomplished through the use of algorithms whih modify seleted referene hannel parameters using oeffiients expresed in terms of the ratio of plasma flows through the SINGH developed hannel and the referene hannel speified by DESIGN3. The first suh value alulated is the frational enthalpy extration (HFF, dimensionless). SINGH uses the following algorithm from Chapman 16 to alulate HFF. HFF = HF*((l.+( MPT15/GDMF) )*0.5)**0.35 The frational MHD generator effiieny (GEFF, dimens ionless) is the next quantity alulated by SINGH. The algorithm for this parameter is also from Chapman 16 GEFF GEF*((l.+( MPT15/GDMF) )*0.5)**0.5 The hannel entrane area (ENTA, Sq. Me ters) is assumed to be proportiona! to mas s flow through the hannel and is alulated as follows : ENTA = (MPT15/GDMF) *ENTA

57 Us ing AREAR and ENTA, SINGH alulates the ross setional area of the hanne l exit (EXTA, Sq. Meters ). 48 EXTA = AREAR*E NTA The length of the generating hannel (CLEN, meters) is assumed equal to the length of the referene hannel. Us ing HFF and stagnat ion enthalpy data previously alulated by NASA SP-273, SINGH next alulates the diret urrent eletri power deve loped by the MHD generating hannel (PEXM, Watts). PEXM = (HSUM( l)-hsum( 5) )*R*l.8*. 293l*HFF*MPT15 To alulate the elet ri power output to the alternat ing urrent bus (POUTM, Watts), SINGH mu ltiplies PEXM by the inverter effiieny (CEFFI, dimens ionless ). POUTM = CEFFI*P EXM One PEXM AND GEFF have been alulated, it is possible to alulate the amount of plasma sens ible heat trans ferred through the hannel walls to the ooling water (QLMHD, Btu/hr). SINGH alulates QLMHD as follows : QLMHD = (PEXM*3.4129* (1.-GEFF) )/GEFF The energy ontent of the plasma exiting the generating hannel has two omponents. The first omponent is the kineti energy and sensible heat ontent (EQKT16, Btu/hr). SINGH alulates the value of EQKT16 as : EQKT 16 = EQKT15-(PEXM*3.4129) -QLMHD The seond plasma energy omponent is the unreleased hemial energy whih remains unhanged at ECT15. The total plasma energy ontent at the generating hannel exit (ETT1 6, Btu/hr) is alulated thus : ETT16 = EQKT16+ECT15

58 49 The next quantity alulated is the power required to operate the superondut ing magnet and its ooling system (PMAG, Watts). 16 following algorithm from Chapman to alulate PMAG. SINGH uses the PMAG = CLEN* *(13.4*((ENTA**. S) +( (E NTA*AREAR) **.5) )+7.*BMAX*ENTA) As the final step in generating hannel analysis, SINGH alls upon NASA SP-273 subroutines to alulate plasma properties at the hannel exit (NPT = 3). The sequene in whi h SINGH alls the other subroutines is learly evident n the SINGH listing and is not explained here. Interested readers are invited to refer to Gordon and MBride 6 The last topp ing y le omponent addressed by SINGH is the diffuser. The primary funtions of the diffuser are to deelerate the plasma flow and to reover pressure. Fo r this model, the diffuser oeffiient of performane is set at The MHD hannel design proedure requires the hannel exit Mah number to be between 0. 9 and The hannel exit stati pressure (P STAT) is set at a value (normally about 0. 7 ATM) whih permits the stati pressure to reover to 1.0 ATM at the diffuser exit. As the plasma passes through the diffuser, a portion of the plasma sensible heat energy passes through the diffuser walls and is transferred to the ooling water. The quantity of heat lost to the ooling water (QLDIF, Btu/hr) is alulated by SINGH in 16 aordane with a proedure presented by Chapman The algorithm for QLDIF is as follows : QLDIF = * 4.*(TTT (3) -TWALL) * (0.0316*BBB*DLEN * *DLEN*DLEN E- 06*BBB*

59 50 *DLEN*DLEN-( 1.412E- OS* *(DLEN**3) )/3. where TTT( 3) = plasma temperature at diffuser entrane. Calulated by NASA SP-272 ( K) BBB = (ENTA*AREAR) **.S* loo. DLEN = diffuser length (entimeters) = 3.79*BBB Sine QLDIF is the only energy transferred from the plasma during its passage through the diffuser, the energy balane for the diffuser is straightforward. The total energy ontent of the plasma flow entering the diffuser equals that of the plasma flow exiting the generating hannel whih has already been alulated as ETT16. The total energy ontent of the flue gas exiting the diffuser (ETT17, Btu/hr) is then readily alulated as follows : ETT17 = ETT1 6-QLDIF Like ETT16, ETT17 onsists of two separate energy omponents. One omp onent is the omposite of kineti and sens ible heat energy (EQKT17, Btu/hr), and the other omponent is the unreleased hemial energy (ECT17, Btu/hr). Be ause no additional oxidant is added to the plasma flow in the diffuser, the unreleased hemial energy remains unhanged at a value of ECTlS. The kineti and sensible heat energy of the flue gas exiting the diffuser is then alulated as : EQKT17 = ETT17-ECT1 5

60 51 Finally, SINGH alls upon NASA SP-273 subroutines to alulate and store flue gas propert ies at the diffuser exit (NPT = 4). This is 6 aomplished per Gordon and MBride and is not explained here. The desription of the MHD topping y le is now omplete. The algo rithms whi h alulate mas s flows, energy transport and transfer, and power requirements for the oal proessing equipment and the air separation plant are new additions to SINGH. The remaining alulations were generally unhanged.

61 CHAPTER V SEED REGENERATION One of the maj or hanges implemented by this revision of SYSTEMS is the replaement of the Tomlinson/Tampella seed regeneration model by the Formate proess model. is hapter desribes both the proess sequene and the algorithms whih omprise the potassium formate reovery proess. model now ontained in SYSTEMS. Figure 5-l is a proess flow diagram of the formate proess. Table 5-l defines the numbered flow streams presented in Figure 5-l. Both the figure and the table will be useful referenes while reading the remainder of this hapter. The primary referene for developing this model was the Coneptual Design Study of Potential Early Commerial MHD Powerplant 9 by Finn A. Hals. Throughout this hapter, the report will be referened simply as the Hals report or Hals model. The seed regeneration plant reeives potassium sulfate from the HRSR as well as its own gasifier. Through appliation of the formate proess, the seed regeneration plant transforms the potassium sulfate into potassium formate seed whih is routed bak to the MHD ombustor as well as the gasifier used by the seed regeneration plant. The six major proessing steps whih omprise the formate proess are as follows : 1. Gasify oal to supply arbon monoxide to the reator. 2. Dissolve the potassium sulfate. 3. Produe potassium formate produt in reator. 52

62 1-- Servie water R2 -R20 - Mixing K2 S0 Rl5 4 Heat Tank Exhanger Dissolver r--+- B.. Regenerator I HRSR I Rl4 & Srubber, Rl L.:_Y m _J R3 I' R43 R21, Rl6J J R. Rl8 I 7 Rl2 IC Mi x ing Tank R26... RlO Rl9 - Heat... Exhanger R3 1 A R27 Rll R9 Gasif ier - R8 R22 R25 R29 Reator R23 Flash Tank 1 R24 i R6 R7 (_ r ::.....J..J_---. g r -./4 R4 RS Rl3 I R Gypsum Fil ter R30 f R z, 33 Figure 5-l. Seed Regeneration Proess Diagram. VI w

63 R34 R33 Evaporator R KC 0 2 H Spr ay Dryer R3 8 He at Exhanger R40.. K 2 so 4 Fil ter R44.. R22 J R36 j R39 R37 R41 R42 ' ' \ R43 Figure 5-l. (ont inued) V1

64 Table S-1. Seed Regeneration Proess Streams. Steam No. Desriftion Variable Name Al s orithm Units Rl Dry K 2 so 4 from HRSR equipment MKSRO l S. 44*0. 98XS *MCT02 lbm/hr R2 Servie water for K 2 so 4 slurry MSWR02 O. l l*mksro l lbm/hr R3 K 2 so 4 slurry to dissolver MKWR02 MKSROl+MSWR02 lbm/hr R4 Gasifier oal to mixing tank MCR *MKSRO 1/ ( 1-l.BS*XS) lbm/hr R5 Po tassium formate to mixing tank MKRO S ( 78/ 32) *XS *MCR04 lbm/hr R6 Servie water for gasifier oal slurry MSWR06 O.S2*MCR04 lbm/hr R7 Coal and potassium formate slurry to gasifier MCWR07 MCR04+MSWR06 + MKROS lbm/hr R8 Air to gasifier MAROB 4.02*MCR04 lbm/hr R9 Coal slag from gasifier MASR09 XSAR*MCR04 RIO Dry K 2 so 4 from gasifier MKSRlO 544*XSAR* MCR04 lbm/hr VI VI

65 Table 5-l (Continued) Steam Variable No. Desri 2 tion Name Alsorithm Units Rll Produt gas from gasifier MGRO ll MCWR07 + MAR08 - lbm/hr MASR09 - MKSRlO Rl2 Servie water for K2 so 4 slurry MSWR12 O. l l*mksrlo lbm/hr Rl3 K2so 4 slurry to dissolver MKWR1 3 MKSRlO + MSWR12 lbm/hr Rl4 Lime to K 2 so 4 dissolver MCAR * (MKSRO 1 + lbm/hr MKSRlO) Rl5 K and Ca ompound slurry from dissolver MTR1 5 MKSR1 5 + MKFR1 5 + lbm/hr MWR15 + MCHR1 5 Rl6 Steam to heat exhanger B MSR1 6 QTRlS/983.6 lbm/hr Rl7 Condensate from heat exhanger B MWR1 7 MSR16 lbm/hr Rl8 K and Ca ompound slurry to reator MTR18 MTR1 5 lbm/hr Rl9 Produt gas to srubber MGR19 MGRl l lbm/hr R20 o 2 from regenerator to atmosphere MCDR *MGR19 lbm/hr R21 Produt gas to reator MGR2 1 MGR1 9 - MCDR20 lbm/hr R22 Produt gas to heat reovery MGR *MGR2 1 lbm/hr VI 0'

66 Table 5-l (Continued) Steam No. Va riable Desrip_i() Name Algorithm Units R2 3 K and Ca ompound slurry to flash tank MTR2 3 MTR18 + MGR2 1 - MGR2 2 lbm/hr R2 4 K and Ca ompounds from flash tank MTR2 4 MTR2 3 - MSR2 5 lbm/hr R2 5 Steam from flash tank MSR *MTR2 3 lbm/hr R2 6 Servi e water to heat exhanger A MSWR *MGR1 1 lbm/hr R27 Servi e water from heat exhanger A MSWR2 7 MSWR2 6 lbm/hr R2 8 Gypsum and water to disposal MYWR *MTR2 4 lbm/hr R2 9 Re y le K ompound slurry from gypsum filter MTR2 9 MTR3 1 - MSR2 5 1 bm/h r R3 0 K ompound slurry from gypsum filter MTR3 0 MTR2 4 + MSWR2 7 - MYWR2 8 - MTR2 9 lbm/hr R3 1 Reyle K ompound slurry from flash tank and gy psum filter MTR3 1 MKSR3 1 + MKCR3 1 + MWR3 1 lbm/hr R3 2 Reyle K ompound slurry MTR3 2 MKSR3 2 + MKCR3 + MWR3 2 lbm/hr R3 3 K ompound slurry to evaporator MKWR3 3 MTR3 0 - MTR3 2 1 bm/hr VI '-1

67 Ta ble 5-l (Co tinued ) Steam No. Desri :e tion Va riable Name Al s orithm Units R34 Steam vented from K ompound slurry MSR O*MKWR3 3 lbm/hr R35 K ompounds to spray dryer MKWR3 5 MKWR3 3 - MSR3 4 lbm/hr R3 6 Gas from evaporator MGR3 6 MGR2 2 lbm/hr R37 Flue gas to spray dryer MFGR *MKWR3 5 lbm/hr R3 8 K ompounds to heat exhanger C MKR *MKWR35 lbm/hr R3 9 Flue gas and moisture to stak MFGR3 9 MFGR3 7 + MKWR3 5 + MKR3 8 lbm/hr R40 K omp ounds to K 2 so 4 filter MKR4 0 MKR3 8 lbm/hr R41 Steam to heat exhanger C MSR4 1 QKR4 0/983.6 lbm/hr R4 2 Condensate from heat exhanger C MWR4 2 MSR4 1 lbm/hr R4 3 Re yle K 2 so 4 from filter MKSR *(MKS RO l + MKS RI O lbm/hr R4 4 Po tassium Fo rmate to MHD y le MKCR4 4 MKR40 - MKSR43 lbm/hr VI 00

68 Table S-1 (Continued) Stream Va riable No. Desri E tion Name Rl8 He at required from heat exhanger B QTR1 8 R31 K 2 so 4 omponent of reyle stream R3 1 MKSR3 1 R3 1 KC0 2 H omponent of reyle stream R3 1 MKCR3 1 R3 1 Water omponent of reyle stream R31 MWR3 1 R32 K 2 so 4 omponent of reyle stream R3 2 MKSR3 2 R32 KC0 2 H omponent of reyle stream R3 2 MKCR3 2 R32 Water omponent of reyle stream R3 2 MWR3 2 R4 0 He at required from heat exhanger C QKR4 0 Alsorithm 101.7*MTR *MKSR0 1 + MKS R *MKSR *MKSR * (MKSR0 1 + MKS R0 9) 4.8 S*MKSR *MKSR30 MKS38*40 Units Btu/hr lbm/hr lbm/hr lbm/hr lbm/hr lbm/hr _ lbm/hr Btu/hr VI \0

69 60 4. Filter reator effluent to separate potassium formate produt from gypsum by-produt. 5. Dry the potassium formate produt. 6. Reheat formate and filter sulfate. Potassium sulfate reovered in the HRSR is mixed with servie water to form a slurry. The slurry is pumped into a potassium sulfate dissolver. "As reeived" oal is mixed with potassium formate and servi e water to form a slurry whih is fed to the gasifier. In the gasifier, the slurry reats with air to produe produt gas, oal slag, and potassium sulfate. The potassium sulfate is expelled from the gasifier, mixed with servie water and pumped to the potassium sulfate dissolver. The oal slag is removed from the gasifier and moved to a disposal site. The produt gas is ooled after exiting the gasifier. It is then passed through a regenerator whih removes arbon dioxide. From the regenerator, the produt gas is moved to the reator where the majority of its arbon monoxide is utilized in the formation of potassium. formate. The remaining gas is disharged from the reator and is passed through the evaporator where it transfers its exess heat to the potassium ompound flow stream. The gas exits the evaporator at 250 F and is released to the atmosphere through the plant stak. Bak at the potassium sulfate dissolver, lime is added to the potassium sulfate slurry as are reyle streams from the flash tank, gypsum filter, and potassium sulfate filter. The resulting slurried mixture is heated by heat exhanger B and then fed to the reator where the formate reation takes plae. After exiting the reator, the produt stream is passed through a flash tank whih removes a substantial

70 61 amount of water from the produt stream in the form of steam. Next the produt stream passes through a gypsum filter whih removes the alium sulfate formed in the reator. From the gypsum filter, the produt stream moves on through an evaporator and a spray dryer. Both of these omponents remove more water from the produt stream. The evaporator employs heat available from the reator effluent gas while the spray dryer uses flue gas extrated from the HRSR. The produt stream ontinues on through heat exhanger C whih provides suffiient heat for melting the potassium formate and ontained in the produt stream. molten produt stream passes through a potassium sulfate filter whih removes the potassium sulfate for return to the potassium sulfate dissolver. The potassium formate is returned to the stokpile for reyling through the MHD ombustor or the gasifier. The first step in modeling the seed regeneration proess is to determine. how muh potassium sulfate (K2so4) will have to be proessed. The HRSR model.assumes a 100% sulfur removal rate from the gas stream; however, some of the potassium and sulfur ompounds are removed with oal slag and thus are not available for potassium reovery proessing. The preise amount of potassium and sulfur removed with the oal slag is diffiult to estimate beause so li ttle is known about the hemistry of potassium, sulfur, and oal slag interation. This study assumes that 2% of the sulfur is removed with oal slag. The remaining 98% is reovered in the form of potassium sulfate provided that the amount of available potassium is suffiient. The model assumes the flue gas mixes thoroughly and that the /S ratio of 1 will aomplish omplete sulfur removal. Any exess potassium is assumed to form potassium arbonate. The

71 62 SINGH alulates the amount of potassium sulfate reovered from the HRSR (MKSROl, lbm/hr) as follows : MKSRO l = 5.44*MCT0 2*0.98*XS where 5.44 = reiproal of weight fration of S per uni t we ight of potassium sulfate. (dimensionless) MCT02 = previously alulated mass flow rate of dry oal to the MHD ombustor (lbm/hr) 0.98 fration of sulfur ontent reovered (dimensionless) XS = weight fration of sulfur in dried oal (dimensionless) The value of XS is read by SINGH at the beginning of its exeution yle. SINGH next alulates the amount of potassium lost with the ash and slag (KLHRSR, lbm/hr) : KLHRSR = (39/ 84)*MKT14- (78/174) *MKSR01 where 39/84 = weight fration of potassium per unit weight of potassium formate (dimensionless). MKT14 = previously alulated mass flow rate of potassium formate to the MHD ombustor (lbm/hr). 78/ 174 = weight fration of potassium per unit weight of potassium sulfate (dimens ionless). If KLHRSR is less than zero, SINGH prints a warning that insuffiient potassium is present for omp lete sulfur reovery. SINGH then realulates MKRSO l based on the available potassium as shown below. MKSRO l = (1 74/ 78)* (39/84)*MKT14*0.98 One the amount of potassium sulfate reovered from the HRSR equipment has been determined, the amount of servie water (M SWR0 2, lbm/hr)

72 63 neessary to reate the slurry is omputed by proportion from the Hals model: MSWR0 2 = *MKSR0 1 The potassium sulfate slurry (MKWR0 3, lbm/hr) entering the potassium sulfate dissolver is then omputed as the sum of MKSR0 1 and MSWR02. The next quantity alulated by SINGH is the amount of oal (MCR04, lbm/hr) required by the seed regeneration gasifier. In the Hals report, the quantity of potassium sulfate entering the potassium sulfate dissolver inluded a ontribution from the gasifier oal. The Hals model required lbm/hr of gasifier oal for reproessing lbm/hr of potassium sulfate. That quantity of potassium sulfate inluded a ontribution from gasifier oal as well as that reovered from the HRSR equipment. The gasifier oal requirement is lbm of oal per pound of potassium sulfate. Assuming 100% sulfur removal from the gasifier oal, and having previously alulated the amount of potassium sulfate reovered from the HRSR equipment, the algorithm for a ulating the gasifier oal requirement is developed as follows : MCR0 4 = 0. 34* (MKSR0 1+( 544*XS*MCR04) MCR * (XS*MCR04) = 0.34*MKSR0 1 MCR0 4* (1-1.85*XS) = 0. 34*MKSR0 1 MCR0 4 = 0. 34*MKSRO 1/ ( *XS) The last of the four expressions for MCR0 4 is the one whih appears in SINGH. After MCR0 4 has been alulated, SINGH determines the quantity of potasisum formate (MKROS, lbm/hr) required for reovery of the sulfur ontained in the gasifier oal.

73 64 MKR0 5 = (78/ 32) *XSAR*MCR0 4 The gasifier oal and potassium formate are mixed with servie water (MSWR06, lbm/hr) to form a slurry (MCWR0 7, lbm/hr) whih is then fed to the gasifier. MSWR0 6 is alulated as follows : MSWR0 6 = 0.52*MCR04 The value of MCWR0 7 is alulated as the sum of MCR0 4, MCR05, and MCWR0 6. The mass flow of air to the gasifier (MAR08, lbm/hr) is omputed by proportion from the Hals model as follows : MAR0 8 = 4.02*MCR0 4 The oal slag (MASR09, lbm/hr) is alulated by the following algorithm: MASR0 9 = XAAR*MCR04 XAAR is the "as reeived" ash ontent of the gasifier oal. The value of XAAR is read by SINGH. The dry potassium sulfate disharged from the gasifier (MKSRl O, lbm/hr) is alulated as follows : MKSRl O = 5.44*XAAR*MCR04 The produt gas produed in the gasifier (MGRl l, lbm/hr) is then alulated by differene. MGRl l = MCWR07+MAR08 ASR09 KSR10 Most of the remaining mass flow streams are alulated by proportion from fators based on the Hals model. The flow stream desriptions, variable names, and algorithms are presented in Ta ble 5-l. The flow streams whose algorithms require additional explanation are addressed in the following paragraphs. One of the flow streams not readily determined from the Hals report is Rl6 whih is steam supplied to heat exhanger B. The purpose of this steam is to heat proess stream Rl 5 from 200 F to 392 F. From data

74 65 ontained in the Hals report, one an determine that Btu are required for heating eah pound of the potassium sulfate/lime slurry whih passes through heat exhanger B. The Hals report gives no information regarding the required steam flow or steam onditions. This paragraph develops the neessary algorithms for modeling the steam flow to and from heat exhanger B. This analy sis assumes the use of the ounterflow heat exhanger with a minimum temperature differene ( T) of 50 F between flow streams. The slurry entering the heat exhanger has a temperature of 200 F. steam will be 250 F. temp erature of 392 F. Therefore, the mi nimum temperature of the proess The slurry exiting heat exhanger B will have a Aordingly the steam entering heat exhanger B will have a minimum temperature of 442 F. However, a higher temperature differene will permit onstrution of a smaller less expensive heat exhanger. For this reason, the temp erature of the steam entering heat exhanger B will be set at 500 F. To ensure the steam ondenses at 250 F the system will be designed with a pressure of 28 psia at the ondensate outlet from heat exhanger B. 10 From the ASME steam tables, the enthalpy of the entering steam at 500 F is Btu/lbm. The enthalpy of the ondensed water, exiting heat exhanger B, is Btu/lbm. This means that eah pound of steam will yield Btu for heating the slurry. Thus, the required mas s flow rate of proess steam to heat exhanger B (MSRl S) an be determined one the mass flow rate of potassium sulfate/lime slurry from the R2so 4 dissolver (MTR15, lbm/hr) has been a lulated. Determination of the mass flow rate of the potassium sulfate/lime slurry from the potass ium sulfate dissolver is an involved proess beause there are three reyle steams (i.e. R3 1, R32,

75 66 and R4 4) whose preise values have not yet been determined and whih enter the potassium sulfate dissolver. Two of these streams are multiompound streams. Us ing proportional relations from the Hals report it is possible to alulate the mass flows of these reyle streams before alulating the mass flows of all of the streams whih preede them. Four distint ompounds COmPrise flow stream Rl5. The ompounds and their variable names are listed below: Po tassium sulfate Po tassium formate Water Calium Hydroxide MKSR1 5 MKFR1 5 MWR15 MCHR1 5 The units for eah of the above mass flows are pounds per hour. Mass flows for the above ompounds annot be speified until mass flows have been estimated for eah of three reyle streams. Two of the reyle streams are also multi-omp ound flow streams. The three reyle streams, their omponent ompounds, and variable names are shown in Table 5 2. Eah variable is alulated in terms of pounds per hour. The Hals mode l provides the data for determining proportion fators whih serve as the basis for the algorithms used in SINGH to alulate the mass flows. The potass ium sulfate portion of eah of the three reyle flows is alulated in relation to the quantity of potassium sulfate reeived by the potassium sulfate dissolver. The three algorithms are as follows : (442/ 3842 l) *(MKSR0 l+mksr1 0) MK SR3 2 = (323/ 3842l)*(MKSR0 l+mksr1 0) MKSR43 = (7649/3842l)* (MKSR0 l+mksr10)

76 67 Table 5-2. Reyle Streams to Potassium Sulfate Dissolver. Flow Stream Compound Variable Name R31 Potassium Sulfate MKSR31 R31 Potassium Formate MKFR31 R31 Water MWR31 R32 Potassium Sulfate MKSR32 R32 Potassium Formate MKFR32 R32 Water MWR3 2 R43 Potassium Sulfate MKSR43

77 68 The remaining ompound mass flows whih omprise reyle streams R31 and R32 are alulated from the Hals model using proportion fators relating the potassium sulfate mass flow for the partiular reyle stream to the mass flow of. the ompound of interest. The remaining four algorithms are as follows : MKFR31 = (2143/442)*MKSR31 MW]31 = ( /442)*MKSR31 MKFR3 2 = (1 566/323)*MKSR3 2 MWR3 2 = (4076/323)*MKSR3 2 At this point it is possible for SINGH to alulate the quantity of eah ompound ontained in the mass flow exiting the potassium sulfate dissolver. The algorithms are as follows : MKSR15 MKSRO 1-+MKSR13iMKSR31-+MKSR3 2+MKSR4 3 MKFR15 = MKFR31-+MKFR32 MWR15 = MWRO 2-+MWR12iMWR3 1 +MWR3 2 MCHR15 = (1 6335/ ) *MCAR14 MCAR14 is the lime added to the potassium sulfate dissolver in pounds per hour. The algorithm for MCHR15 is based upon the Ha ls report. The total flow from the potassium sulfate dissolver (MTR1 5, lbm/hr) is then alulated as the sum of the onstituent ompound flows. MTR15 = MKSR15-+MKFR1 5+MWR15+MCHR15 One MTR1 5 has been alulated, it is possible to ompute the required steam flow to heat exhanger B (MSR1 6, lbm/hr). Eah pound of MTR15 requires Btu as previously explained. Thus the total heat to be added to MTR15 ( QTR18, Btu/hr) is alulated as follows : QTR18 = 101.7*MTR15

78 69 Re alling that eah pound of steam in MSR1 6 yields Btu, MSR18 is alulated b the following MSR16 = QTR18/ The ondensate flow from heat exhanger B ( 7) equals MSR1 6. The steam flow to heat exhanger C is another quantity whose alulation requires some explanation. Aording to the Ha ls report, eah pound of the potassium formate and potassium sulfate mi xture whih passes through heat exhanger C requires 40 Btu of heat addition. The steam used to.supply this heat will be at the same temperature and pressure as that supplied to heat exhanger B. Thus, eah pound of steam will be able to supply Btu. Us ing this information, the amount of heat required by MK38 (QKR40, Btu/hr) an be alulated as follows : QKR4 0 = MK38*40. The required steam flow to heat exhanger C (MSR41) then beomes : MSR4 1 = QKR40/ The ondensate flow from heat exhanger C (MWR42, lbm/hr) equals MSR42. The potassium formate proessed for reyling (MKFR4 4, lbm/hr) is subtrated from the sum of MKT14 and MKR0 5 to determine the required make-up mass flow of potassium formate (MKMTR, lbm/hr). At this point, SINGH has ompleted its alulations for modeling seed regeneration by the formate proess.

79 CHAPTER VI HRSR SYSTEM AND STEAM CYCLE This hapter presents the models for the heat reovery and seed reovery (HRSR) system and the steam yle. It also ontains a desription of the alulations for overall plant effiieny whih are per- formed at the end of a SINGH exeution yle. The hapter begins with a desription of the objetives and onfiguration of the HRSR system. This is followed by a similar desription for the steam y le. Ne xt, the algorithms whih omprise the models of these two major subsystems are addressed. The final paragraph of this hapter desribes the overall plant effiieny alulations performed by SINGH. Wi th the exeption of plant effiieny and oal slag rejetion alulations, the model relationships presented in this hapter are new additions to SYSTEMS. The proess obj etives of the HRSR are as follows : 1. He at reovery from flue gas for the following purposes : a. steam generation for eletri power prodution. b. primary oxidant heating.. oal drying. d. seondary ombustion air heating. e. steam generation for seed regeneration heat exhangers. 2. Removal of sulfur from flue gas stream. 3. Reovery of potassium seed from flue gas stream. 70

80 71 4. Provide suffiient residene time at elevated temperature 2900 F) for deomposition of flue gas NO ontent. X 5. Removal of oal slag and ash from the flue gas stream. 6. Combustion of remaining flue gas fuel ontent. To aomplish the above obj etives, the HRSR is onfigured as shown in Figure 6-1. Flue gas enters the radiant furnae from the MHD diffuser. In side the radiant furnae, the flue gas first enounters a slag sreen whih is assumed to remove 80 perent of the oal slag ontained in the flue gas. As explained in Chapter V, some potassium and sulfur are also removed from the flue gas stream with the oal slag. After passing the slag sreen the flue gas stream is direted vertially upward into the main hamber of the radiant furnae. The main hamber ontains suffiient volume to provide the neessary residene time for deomposition of the NO ontained in the flue gas. The radiant furnae X shell onsists of water walls whih ons titute boiler surfae for steam generation. As it passes through the radiant furnae, the flue ga s surrenders the heat required for steam generation. Simultaneously, the NO x ontent in the flue gas deomposes to a negligible amount. By the time it exits the radiant furnae, the flue ga s has been ooled to 2900 F (18 67K). Below 2900 F, the NO formation and deomposition X reations ease funtioning. Thus, the flue gas will remain essentially NO X free provided its temp erature is not inreased above 2900 F during the remaining proess steps. Before onsidering the remaining HRSR omp onent s, it is neessary to address two maj or obstales to detailed modeling of the HRSR sy stem.

81 'T opping I Tl7 Cyle t-1 -- l _j [] -=---r- --- _ - :ll--. H3 Radiant Furnae, Hl H2 H4.. L Topping l Cyle I Tll -tt12- - Seond ar y Combu stor HS -r Superheater Reheater Oxidant Htr. I T8 T7 r - L_---1 Topping ---. Cy le I L l rseed - ; 1 I Re gen. 1 Plant I R3 7 '- J I R39 H6 H6 Seond Convetive Hea t Transf er Setion H7... Eletrostati Preip. H9 It Indued Draf t Fan HlO -... HB Steam I, Seed Regen. Plant L _ y l: I L..J I Figure 6-1. HRSR System Diagram.... N

82 73 The first obs tale is the limited informa tion addressing the behavior and interation of oal slag/ash and potassium sulf ate in the HRSR envi ronment. To redue this obstale, this model assumes that 80 perent of the oal slag, 2 perent of the potassium sulfate, and any ' additiona! potassium in the flue gas are removed from the flue gas in the radi ant furnae. The model also assume s that the remaining. oal slag/ash and potassium sulfate i s removed from the flue gas stream by the time it exits the eletros tati preipitator. The final assump tion is that some unspeified mehanism permi ts the reovered potassium sulfate to be onve niently separated from the oal slag/ash. The seond maj or obstale to HRSR modeling onerns heat reovery and NO formation. One approah would ool the flue gas well below X the NO formation temp erature zone in the radiant furnae. Th is would X permi t seondary ombustion to be aomplished without raising the flue gas temperature to the NO formation zone. A ording to an earlier X 11 study, this approah requi res o-l oation of a superheater, reheater, or primary oxidant heater with the radiant furnae. This is neessary to balane the relative requirements for boiler steam, superheat, reheat, and primary oxidant preheat agains t the available flue gas heat at temperatures permitting e onomi al heat trans fer. Unfortunately, material ons traints prohibit plaement of a onvetive heat transfer surfae in the hemi ally reduing environment of the radiant furnae. The alternative is to introdu e the flue gas into the seondary ombustor at the highest possible temperature (i.e F), to aomplish seondary ombustion, and then ool the flue gas below 2900 F as quikly as possible. The basis for this alternative is the fat that the

83 74 NO formation rate is muh slower than the ombustion reations. Thus, X seondary ombus tion and subsequent ooling an be aomplished before any appreiable amount of NO has formed. At present, there is no X presribed me thod for exeuting this proess. This model assumes the seondary ombustor water walls absorb suffiient ombus tion generated heat to maintain the flue gas at 2900 F during its passage through the seondary ombustor. This assumption resolves the seond obstale for modeling purposes, and the desription of the remaining HRSR omponents follows. As it exits the radiant furnae, the flue gas flow is redireted horizontally and enters the seondary ombustor. Like the radiant furnae, the shell of the seondary ombustor is omposed of water walls whih provide boiler surfae area for steam generation. Pr eheated seondary ombustion air is added to the flue gas to omplete ombustion of the remaining fuel ontent of the flue gas. For the reasons previously disussed, the seondary ombustor is sized in suh a manner as to remove suffiient heat to keep the flue gas temperature from rising above 2900 F during the ombustion proess. After exiting the seondary ombustor, the flue gas passes through the onvetive heat transfer surfaes of the superheater, reheater, and primary oxidant heater. As the flue gas ools below 2400 F, the potassium sulfate begins to ondense, form droplets, and fall from the gas stream. The potassium sulfate is reovered from the HRSR and routed to the seed regeneration plant for proessing. As the flue gas exits the primary oxidant heater, its temperature has been redued to 700 F. At this point flue gas flow is split into four parallel streams. One

84 stream provides heat to the nitrogen stream to be used for oal drying. 75 The seond stream heats the seondary ombustion air. The third stream gene rates the low pressure steam required by the seed regeneration plant heat exhangers. the eonomizer. The last stream transfers heat to boiler feedwater via The four streams are. reombined as they enter the elet ros tati preipitator (E SP ) at 250 F. The remaining potass ium sulfate and oal ash is reovered in the ESP. After exiting the ESP, most of the flue gas passes through the indued draft fan and is released through the plant stak at 250 F. The remaining flue gas firs t passes through the spray dryer of the seed regeneration plant and then ont inues through the indued draft fan to the stak where it too is released to the atmosphere at a temperature of approximately 250 F. The proess obj et ive of the steam y le is to onvert thermal energy reovered by the HRSR system and the MHD y le into mehanial shaft power whih is used to ge ne rate eletri powe r and to drive both the MHD y le oxidant ompressor and the oxygen plant ompressor. Figure 6-2 presents the steam y le onfiguration. With two exeptions, this onfiguration is very simi lar to the steam y le arrangement whih is harateristi of onventional oal fired plants. The first exeption is the addi tion of two single stage turbines for this plant. One turbine drives the MHD oxidant ompressor and the other powe rs the oxygen plant ompressor. The seond exeption is the large amount of relatively low temp erature heat available from the HRSR eonomizer and the MHD generator ooling water. In onventional oal fired plants, low temp erature flue ga s heat is used to preheat ombustion air at atmo s pheri pressure. This is not possible in the MHD plant beause the MHD

85 Boiler Superheater Reheater Compressor Fw H 1 B F P Turbine H P Eon 'I 1 Fw H.._.._. 3 Fw H 4 I 1,..- W H 6 MHD Chan & il.. _jfw H.,..._.. L P Eon a. Condensa te Ptunp Figure 6-2. Stearn Cy le Diagram. -...J 0\

86 77 oxidant is ompres ed and reeives a large portion of its preheat during that proess. For the MHD plant, the onsequene of this large amount of eonomizer heat is normally one or two fewer feedwater heaters in the steam y le. The remaining paragraphs of this hapter address the algorithms developed for the HRSR system model, the steam yle model, and for alulating the overall plant effiieny. Table 6-1 presents variable names, desriptions, units, and algorithms for HRSR variables. Table 6-2 ontains like information for steam yle variables. The mas s flow rate of flue ga s entering the radiant furnae has been previ ously alulated as MFGT17. Likewise, the total energy transported into the radiant furnae (ETT17) has also been previously alulated by SINGH. ETT17 onsists of the thermal and kineti energy posses sed by. the flue gas (E QKT17) and the unreleased hemial energy ontained in the flue gas (ECT15). The mass flow rate of oal slag, potassium, and sulfur ejeted through the radiant furnae slag tap (MSKHOl, lbm/hr) is alulated by the following algorithm: MSKHO l = (0.80*MCT02*XAAR*(l00.-MOISAF) /100.-MO ISAR) ) + KLHRSR+(0.02*MCT02*XS) XAAR is the mass fration of ash in the "as reeived" oal. The expression ontaining MOISAF and MO ISAR orret XAAR to a dried oal basis. KLHRSR is the previously alulated mass flow rate of potass ium lost from the flue gas stream. SINGH next alulates the heat lost with the material rejeted at the slag tap (E QHO l, Btu/hr). The model assume s this material is rejeted at a temperature of 2420 F (1600K). The model further assumes the heat ontent of the rejeted material is

87 Table 6-1. HRSR stem MOdel Va riables. Va riable Name Desription Algorithm UNITS MSKH0 1 Mass flow of oal slag, potassium, and sulfur removed at radiant furnae slag tap (0. 8 0*MCT02*XAAR* (100.MOISAF)/100.MOISAR) ) +KL RSR+( 0.02*MCT02*XS ) lbm/hr EQH0 1 He at lost with mass ejeted at radiant furnae slag tap 431. *MSKH0 1 Btu/hr MFGH0 2 Mass flow of flue gas exiting radiant furnae MFGT17-MSKH01 lbm/hr EQH0 2 Flue gas thermal energy exiting radiant furnae MFGH0 2* (HSUM( 7)-HSUM( 5) ) *R*1.8 Btu/hr ETH02 To tal energy transported with flue gas EQH02+ECT15 Btu/hr EQSRF Heat for steam generation transferred in radiant furnae EQKT17-EQH0 1-EQH02 Btu/hr MAH0 4 Mass flow of seondary ombustion air ((1.05-SR) /SR) * (MAT03 +MAT04) ) lbm/hr MFGHO S Flue gas mass flow from seondary ombustor MFGH02-tMAH04 lbm/hr "'-J OJ

88 Table 6-1 (Continued ) Va riable Name Desription Algorithm UNITS EQH04 Heat transported to seondary ombustor by ombustion air (1.1875E-05* (TAH04* * **2)+. 224* (TAH ) )*MAH0 4 Btu/hr QAFG05 Heat gained by seondary air mass in ombustor ( E-05* (3360.**2- TAH0 4**2)+. 224(3360. TAH04) Btu/hr EQSSC Heat for steam generation transferred in seondary ombustor ECT15-QAFGH5 Btu/hr QFRG56 He at removed from flue gas in superheater/ reheater/oxidant heating setion MFGH05* (HSUM( 7) HSUM( 6))*R*l.8 Btu/hr EQSSR He at available for superheating, reheating, and steam generation in first onvetive setion QRFRG56-QHEOAT Btu/hr QRFG67 He at reovered from flue gas in seond onvetive heat transfer setion MFGH05* (HSUM( 6) HSUM( 2) )*R* l.8 tu/hr EQSE He at transferred to eonomizer water QRFG67-QTR1 8-QKR4 0 -QNAT12-EQH04 Btu/hr.. \.0

89 Table 6-1 ( Continued) Va riable Name Desription Algorithm UNITS MSH08 Mass flow of oal ash reovered in ESP 0.20*MCT02*XAAR* (100.-MOISAF)/ (100.-MOISAR) lbm/hr MTH08 Mass flow of oal ash and potassium sulfate reovered in EXP MKSR0 1+MSH08 lbm/hr MFGH09 Flue gas mass flow from ESP to ID fan MFG07-MSH08-MFGR37 lbm/hr MFGH10 Flue gas mass flow to stak MFGH09-+MFGR39 lbm/hr PFAN Eletri power required by ID fan 0. 4*MFGH10 Watts 00 0

90 Table 6-2. Steam Cyle Model Va riables (SINGH). PRESTO II Run No. Variable Name Desription Algorithm Units 1 QT Estimated steam flow to MHD and oxygen plant ompressors *(PCOMP+POWERO)/ (HSTEAMA*. 3 5) lbm/hr 1 WSHAFT Shaft power required by MHD and oxygen plant ompressors (PCOMP+POWER0)/1, 000,000 MW 2 QHPE Heat reovered in high pressure eonomizer 0.55EQSE Btu/hr 2 QLPE Heat reovered in low pressure eonomizer 0.45 EQSE 2 EXTSER( 7) Heat added to feedwater between heaters 6 and 7 QLMHD+QLPE Btu/hr 2 EXTSER( 3) Heat added to feedwater between heaters 2 and 3 QHPE Btu/hr 2 EXTRNL 2 QTB To tal heat available to steam yle Steam flow to MHD and oxygen plant ompressors QLCOMB+QLMHD+QLDIF +EQSRF+QESSC+EQSSR +EQSE -QT (from Run 1) MW lbm/hr 00

91 .. Table 6-2 (Continued) PRESTO II Run No. Variable Name Desription Algorithm Units 2 QT Estimated total steam flow (EXTRNL*3.413 * l.oe +06) / (HSTEAMA + HSTEAMR) lbm/hr 2 WRATE Estimated eletrial output 0.3 5*EXTRNL MW e o N

92 Btu/lb at 2400 F. Thus, SINGH uses the following expression for alulating EQH01: EQH0 1 = 431.*MSKH01. SINGH next alulates the mass flow rate of flue gas exiting the radiant furnae (MFGH02, lbm/hr) as the differene MFGT17 and MSKH0 1. The energy transported from the radiant furnae by the flue gas (ETH02) has two omponents. One omponent is unreleased hemial energy whose value has been previously alulated as ECT15. The other omponent is the thermal energy of the flue gas (EQH02, lbm/hr). To alulate EQH02, SINGH realls data previ ously alulated and stored by NASA SP-273 subroutines EQLBRM and SAVE. During exeution of the MHD topping yle ode, SINGH direted other NASA SP-273 subroutines to ompute and store flue gas thermodynami properties for several states defined by speifi temperatures and pressures. The state speified for the radiant furnae exit required a temperature of 2900 F (1867K) and a pressure of 1 ATM. This state point for this ondition is identified as point 7 in the program ode. Another state, identified as point 5, was speified with a temperature of 80 F (300K) and a pressure of 1 ATM. Point 5 represents the zero enthalpy referene ondition established for the plant analysis. SINGH uses the realled data in the following algorithm for EQH02: EQH02 = MFGH0 2* (HSUM( 7)-HSUM( 5))*R*1.8 where R = Universal gas onstant = J/ ((KG-MOLE) (K) ) HSUM( 7) = h/r at point 7 HSUM( 5) = h/r at point 5 h = enthalpy (Joules/Kg )

93 84 After EQH0 2 has been alulated, SINGH alulates ETH0 2 as the sum of EQH0 2 and ECT15. The next quantity of interest is the amount of heat transferred from the flue gas to the water walls for steam generation (EQSRF, Btu/hr). EQSRF is alulated by the following expression: EQSRF = EQKT17-EQH0 1-EQH0 2 As the flue gas exits the radiant furnae, it simultaneously enters the seondary ombustor where it mixes with seondary ombustion air and spontaneously ompletes ombustion. SINGH alulates the mass flow rate of seondary ombustion air (MAH04, lbm/hr) as follows : MAH0 4 = ((1.05-SR) /SR) * (MATO T0 4) SR is the stoihiometri ratio for primary MHD ombustion. The value of SR is read bf SINGH. The desired mass flow rate of seondary air should be 5 perent in exess of the minimum required for omplete ombustion. This is the signifiane of the 1.05 term in the expression for MAH0 4. The sum MAT0 3 and MAT0 4 represents the oxidant mass flow to the MHD ombustor for the ase of no oxygen enrihment. The mass flow rate of flue gas from the seondary ombustor (MFGH05, lbm/hr) is alulated as the sum of MFGH02 and MAH04. The heat released by seondary ombustion has been previously alulated as ECT1 5. This heat performs two funtions. Beause this model assumes that all flue gas exits the seondary ombustor at 2900 F, some of the heat released during ombustion must be used to heat the mass that entered the seondary ombustor as seondary ombustion air. The remaining heat released during ombustion is alloated to steam generation in the seondary ombustor water walls.

94 The seondary ombustion air enters the seondary ombustor at TAH04 degrees Rankine. user and read by SINGH. The value of TAH04 is speified by the program The heat required to raise the temperature of the seondary air (QAFGH5, Btu/hr) from TAH0 4 to 2900 F (3360 R) is 16 alulated by SINGH aording to Chapman QAFGHS = (1.1875E-05* (3360.**2-TAH04)**2)+. 224*(3360.-TAH04) ) *MAH04 One QAFGHS has been determined, SINGH alulates the heat available for steam generation in the seondary ombustor water walls (EQSSC, Btu/hr) by the following: EQSSC = ECTlS-QAFGHS The amount of thermal energy transported into the seondary ombustor by the seondary ombustion air (EQH04, Btu/hr) is also alulated 16 aording to Chapman : EQH04 = (1.187SE-OS* (TAH0 4**2-540.**2)+. 224*(TAH ))*MAH04 The total energy transported from the seondary ombustor by the flue gas (EQHOS, Btu/hr) is in the form of thermal energy and is alulated by SINGH as the sum of EQH02, EQH04, and QAFGHS. From the seondary ombustor, the flue gas enters a onvetive heat transfer setion onsisting of the superheater, the reheater, and the MHD primary oxidant heater. These heat exhangers redue the temperature of the flue gas from 2900 F (1867K) to 700 F (644K). SINGH alulates the quantity of heat removed from the flue gas (QRFG56, Btu/hr) as follows: QRFGS6 = MFGHOS* (HSUM( 7)-HSUM( 6) )*R1.8 HSUM( 6) is alulated for a temperature of 700 F and a pressure of 1 85

95 86 ATM. The amount of thermal energy transported from this setion by the flue gas (EQH06, Btu/hr) is alulated as the differene of EQHO S and QRFG56. The quantity of heat required for MHD primary oxidant heating has been previously alulated as QHEOAT. Thus, the quantity of heat available for steam superheating and reheating (EQSSR, Btu/hr) is readily alulated by SINGH as the differene of QRFG56 and QHEOAT. At this point it is not possible to divide EQSSR between superheating and reheating requirements. The preise superheat and reheat demands will not be alulated until the PRESTO II program is exeuted. To exeute, the PRESTO II program must be provided with only the gross quantity of heat available for steam generation. PRESTO II then determines the boiler, superheating, and reheating requirements. It is possible that PRESTO II results will not require all of EQSSR for superheat and reheat. In this ase, the exess heat will be alloated for initial steam generation. For this reason, the model is very general in its treatment of EQSSR. The flue gas exits the first onve tive heat transfer setion at 700 F (394K). The seond heat transfer setion uses the reovered flue gas heat to generate steam for the seed regeneration plant, to heat a nitrogen stream for oal drying, to heat seondary ombustion air, and to heat eonomizer water for the steam y le. SINGH alulates the heat reovered from the flue gas by this seond heat transfer setion (QRFG67, Btu/hr) as follows: QRFG6 7 = MFGHOS*(HSUM( 6)-HSUM( 2))*R*l.8 HSUM( 2) is alulated for a temperature of 250 F and a pressure of 1 ATM. With the exeption of eonomizer heat, all of the heat demands for

96 87 this heat exhanger setion have been previously alulated. The seed regeneration plant demand is the sum of QTR1 8 and QKR40. The oal drying demand is QNAT12, and the seondary ombu stion air demand is EQH04. The amount of eonomizer heat available (EQSE, Btu/hr) is then alulated by SINGH as follows : EQSE = QRFG67-QTR18-QKR40-QNAT 12-EQH04 The amount of thermal energy transported by the flue gas from the seond onvetive heat transfer setion (EQH07, Btu/hr) is alulated as the differene of EQH06 and QFRG67. From the exit of the seond onvetive heat transfer setion, the flue gas enters the eletrostati preipitator (ESP) where the model assumes all potassium sulfate and the remaining oal ash are reovered. The author reognizes that this assump tion will be proven inaurate, however, there is no available data to indiate how the potassium sulfate and ash will ultimately be removed. Therefore, this assumption will have to serve for the present. The amount of potassium sulfate olleted has been previously alulated as MKSROl. The mass flow rate of the remaining oal ash (MSH08, lbm/hr) is alulated by SINGH as follows: MSH08 = 0. 20*MCT02*XAAR* (100.-MOISAF) /100.-MOISAR) SINGH then alulates the total po tass ium sulfate and oal ash reovered (MTH08, lbm/hr) as the sum of MKSRO l and MSH08. As it exits the eletrostati preipitator, the flue gas flow is split into two streams. One stream flows to the seed regeneration plant where it removes moisture from the potassium formate flow in the spray dryer. The mass flow rate of this flue gas stream has been previously alulated as

97 88 MFGR37. The other flue gas stream (MFGH09, lbm/hr) proeeds diretly to the indued draft fan after exiting the eletrostati preipitator. SINGH alulates MFGH0 9 by the following algorithm: MFGH09 = MFGH07 SH08-MFGR37 At the indued draft fan, the flue gas stream returning from the seed regeneration plant 's spray dryer rejoins the main flue gas flow. The mass flow rate of the flue gas plus its added moisture has been previously alulated as MFGR3 9. The total flue gas mass flow rate through the stak (MFGHlO, lbm/hr) is alulated as the sum of MFGH0 9 and MFGR3 9. The heat load transported from the plant by the flue gas was previously alulated as EQH07. The power required to drive the indued draft fan (PFAN, Watts) is alulated by the following algorithm from 16 Chapman : PFAN = MFGH10*0.4 This alulation onludes the HRSR system alulation sequene. The steam y le is the last maj or plant system modeled by SYSTEMS III. PRESTO II is the program used to model the steam y le. The origina! version of this program, titled "PRESTO", was developed at the Oak Ridge National Laboratory, Oak Ridge, Tennessee and was doumented by Fuller and Stova11 7 PRESTO was later modified by Choo and Steiger 8 The modified program was named "PRESTO II". For a omplete understanding of how to use PRESTO II, both referene 7 and referene 8 must be onsulted. This hapter does not attemp t to fully explain the program ode whih onstitutes PRESTO II. In stead, it desribes the steam y le onfiguration modeled by PRESTO II and presents a summary of the tehnique by whih PRESTO II is used to model this steam bottoming

98 89 y le. This hapter also desribes the alulations performed by SINGH in preparation for exeuting PRESTO II. PRESTO II is a program for prediting regenerative superheated steam y le performane at the y le design steam flow ondition (i.e. valves wide open). PRESTO II is apable of performing these predi tive alulations for a variety of y le onfigurations. The y le onfiguration modeled for the SYSTEMS III program is diagrammed in Figure 6-2. He at from the MHD topping y le ompo ents and the HRSR system produes superheated steam whih drives the oxidant ompressor turbine, the air separation plant ompressor, and the high pressure stage of the generator turbine. Spent steam from the oxidant and air separation ompressors is routed diretly to the ondenser. Steam exhausted from the high pressure stage is passed through a reheater and then enters the intermediate pressure stage. The steam exhausted from the intermediate pressure stage is split into two streams. One stream drives the boiler feed pump and is then routed to the ondenser as spent stream. The other stream enters the low pressure stage of the generator turbine and is exhausted as spent steam whih is routed to the ondenser. The ondensate leaving the ondenser is passed through a series of feedwater heaters whose heat soure is steam ext rated from the three stages of the generator turbine. After exiting feedwater heater 7 (i.e. the heater immediately downs tream from the ondensate pump), the ondensate is passed through the MHO hannel ooling water passages as well as the low temperature segment of the eonomizer where it reeives the available heat. The ondensate is then returned to feedwater heater 6 and ontinues through the heater series until it exits feedwater heater 3.

99 90 From feedwater heater 3, the ondensate passes through the high temperature side of the eonomizer and then returns to omplete its passage through the remaining feedwater heaters. From feedwater heater 1, the feedwater begins the steam generation phase and the y le repeats itself. To model this steam yle, SINGH alls PRESTO II twie. The first PRESTO II exeution alulates the steam flow required by the oxidant and air separation ompressors. To aomplish this alulation, SINGH must provide an estimate of the steam flow required by the two ompressors (QT, lbm/hr). SINGH alulates QT as follows : QT = 3.413* (PCOMP+POWERO) /HSTEAMA*.35) HSTEAMA is the enthalpy of the steam in its superheated state in Btu/lbm. HSTEAMA is read by SINGH. SINGH must also alulate the required value for the shaft power required by the ompressors (WSHAFT, Megawatts). This is aomplished by the following algorithm: WSHAFT = (PCOMP+POWE R0) /1,000,000. The remaining values required by PRESTO II have already been assigned values within the adapted PRESTO II ode. At this point SINGH alls PRESTO II. After the first PRE STO II exeution is ompleted, SINGH prepares for the seond PRESTO II exeution whih models the entire steam y le. In preparation for this exeution, SINGH alulates values for eight variables. Th ese variables are listed and defined in Table 6-2. Table 6-2 also ontains the algorithms used to alulate the variables and the units in whih the results are expressed. SINGH alls PRESTO II for the seond time and the steam y le is modeled.

100 91 Upon ompletion of the seond PRESTO II exeution, SINGH performs some final alulations with the obj etive of determining overall plant effiieny. First SINGH alulates the eletri power produed by the steam y le (PEXS, Watts) as follows : PEXS = WWGEN*l, OOO,OOO. WWGEN is the PRESTO II variable whih reports elet ri power generated in Megawatts. SINGH next alulates the auxiliary powe r required to operate plant equipment suh as pumps, HVAC equipment, lighting, mot or operated valves, et. Also inluded in the ategory of auxiliary power is the power required by the superonduting magnet, the pulverizers, the drying fans, and the indued draft fan. The auxiliary power (PAUX, Watts) is alulated by the following: PAUX = PMAG+PPFT *(PEXS+POUTM) +PFAN The term * (PEXS+P OUTM) aounts for the plant equipment demand '. 16 as disussed by Chapman The next quantity alulated by SINGH is the total eletri power furnished to the distribution grid by the plant (TPOWR, Watts) : TPOWR = POUTM+PEXS- PAUX SINGH then alulates the plant effiieny negleting the seed regeneration oal requirement (EFFMS) : EFFMS = TPOWR/ (THIN*.2931) SINGH next realulates THIN to inlude seed regeneration oal: THIN = THIN+(MCR0 4*HCC/MOISRF) Finally, SINGH alulates the overall plant effiieny (EFFC) : EFFC = TPOW]/ (THIN*.2931) At this point, exeution of the SYSEMS III model is omplete.

101 CHAPTER VII MODEL RESULTS This hapter. reports the results of a plant analysis performed by the model desribed in the preeding hapters. The maj or harateristis of the modeled plant are presented in Table 7-1. As di sussed in Chapter III, COAL is the first program used in the model exeution. Table 7-2 presents the oal analyses and HHV data required for the COAL input data file. The stoihiometri ratio, oxidant preheat temperature, and oxygen enrihment are also required as input for COAL. Their values have already been speified in Table 7-1. Three remaining input requirements for COAL are the perent potassium in the total plasma flow, the MHD ombustor heat loss, and the "as fired" moisture ontent of the oal. For this analysis, the perent potassium is set at 1.3%, the ombustor heat loss is speified as 1% of oal thermal input, and the as fired"" moisture ontent of the oal is set at 2%. The potassium perent is based upon sulfur removal requirements rather than plasma ondutivity onsiderations. DESIGN3 is the seond program to be exeuted. The design onstraints speified for the MHD generator hannel are as follows : Magneti Field Strength 6. 0 Te sla Eletrial Load Pa rameter 0.7 Channel Inlet Mah Number 0. 9 Maximum Axial Field (E ) X Maximum Tr ansverse Field (E ) y 2500 volts/meter 4100 volts/meter 92

102 93 Table 7-1. Maj or Charateristis of Modeled Pl ant. Approximate Power Output (Net) Coal Type 1000 MW e Il linois 1!6 MHD To pping Cyle Combustor Pr essure Oxidant Pr eheat Temperature Oxygen Enrihment Stoihiometri Ratio MHD Generating Channel 9 ATM!lOOK 20% 0.85 DCW HRSR Seondary Combustion Ai r Preheat Temperature Flue Gas Temperature Steam Cyle Throttle Pr essure Throttle Temperature Reheat Temperature Condenser Pressure Number of Feedwater Heaters 2400 PSIA 1000 F 1000 F 2.00 IN.HG 7

103 94 Table 7-2. Co al Analyses and HHV. (%) Ultimate Analysis, Hydrogen Carbon Ni trogen Oxygen Sulfur Heating Va lue, Wet, Btu/lb Heating Va lue, Dry ' Btu/lb Coal Rank Pr oximate Analysis, Coal, as Reeived (%) Moisture Vo latile Matter Fixed Carbon Ash Ash Analysis Si0 2 Al Fe T P 2 o 5 CaO MgO Na 2 0 K 2 0 so 3 Initial Deformation Temperature F Softening Temperature F Fluid Temperature F BVCB ± 5.4 ± 6.8 ± 6. 8 ± 3.3 ± 1. 3 ± ± ± ± 200

104 95 Maximum Transverse Current (Jj ) Design Mass flow Stagnation Pr essure at Channel In let 1 amp/meter Kg/se 9 A The results of DESIGN3 and COAL exeutions are used to speify some of the values required by the SINGH input data file. The remaining values are user speified. The variables required by SINGH and their values as speified for this analysis are presented in Table 7-3. The reatant data from COAL as well as the SINGH input data file are provided to NASA SP-273 and SINGH whih they exeute. SINGH alls PRESTO II whih models the steam yle. The results of the model exeution are presented in Table 7-4. The model results were ompared to a. 11 simi lar ase analyzed by a previous study, and provided agreement within reasonable limits.

105 96 TABLE 7-3. SINGH Input Da ta for Modeled Pl ant. Va riable POUT HCC EFF MOISAR MOISAF PCTA PCTO SFLO PRINT TAIC QLCPUM EMACH A REAR BMAX CEFFI ENT GDMF GEF HF CLEN PSTAT xs XSAR XAAR TAH04 SR HSTEAMA HSTEAMR Va lue 1, 000,000, o. 97 o o Units Watts Btu/lbm % % % % % Atm OK Btu/lbm Tesla M 2. Kg /se meters Atm OR Btu/ 1bm Btu/1bm

106 97 Table 7-4. Model Exeution Re sults. Mass Fl ows (lbm/hr) MHD Topping Cyle Raw oal to pulverizers Dried oal to MHD ombustor Po tassium formate seed to MHD ombustor Air to air separation plant Oxygen to MHD ompressor Waste stream for oal drying Was te stream to atmosphere Air to MHD ompressor Oxidant to MHD omp ressor Pl asma to hannel and diffuser HRSR System Flue gas from topping yle Slag, seed, and sulfur rej eted at radiant furnae Flue gas to seondary ombustor Seondary ombustion air Flue gas to onvetive heat transfer setions Potassium sulfate and ash reovered Flue gas diret to ID fan Flue gas to seed regeneration then to ID fan Flue gas to stak Seed Regeneration Pl ant Po tassium sulfate from HRSR Servi e water Ga sifier oal Gasifier air Lime Flue gas to spray dryer Carbon dioxide from regenerator Pr odut gas (ombus ted) Gy psum and water for disposal Vented steam Flue gas and moisture to stak Ga sifier slag Potassium formate for reyle

107 98 Table 7-4 (Continued) Mass Fl ows (lbm/hr) Steam Cyle Steam flow to ASU ompresser Steam flow to MHD ompresser Steam flow to HP turbine Steam flow to reheater Steam flow to IP turbine Steam flow to LP turbine Condenser flow Feedwater flow Energy Quantities (MW) MHD To pping Cyle Coal Chemi al Energy Oxidant Thermal Content Seed Deomposition Combustor heat loss Inverter loss MHD eletri power MHD hannel heat loss Superonduting magnet power Di ffuser heat los s Flue gas thermal energy at dif fuser exit Flue gas unreleased hemi al energy at diffuser exit HRSR Sy stem Flue gas thermal energy at radiant furnae entrane Steam generation in radiant furnae Slag, potassium, and sulfur heat loss Seondary air thermal ontent at seondary ombustor entrane Steam generation in seondary ombustor Superheating Reheating Steam generation in first onve tive set ion

108 99 Ta ble 7-4 (Continued) Energy Quantities (MW) He at transferred to seondary ombustion air Heat for oal drying He at for seed regeneration steam Eonomi zer He at lost to stak Seed Regeneration Coal Steam Steam Cyle Generation Ne t Power to Gr id Overall Pl ant Ef fiieny %

109 CHAPTER VIII CONCLUSIONS The obj etive of this effort has been to develop a mo re detailed model for analyzing prototype MHD/ steam entral station power plants. This has been aomp lished. When the author began this work, the existing model was primarily an MHD topping y le model. It did not address the seed regeneration proess. It modeled the HRSR system and the steam y le with one algorithm whih expressed eletri power produed by the turbine gene rator as the produt of an average steam plant effiieny and the availab e heat. The available heat was expressed as the produ t of flue gas ma ss flow and its enthalpy differene between the MHD diffuser exit and the stak, less the heat required for oxidant heating. The plant model proposed in the preeding hapters implements a potassium formate seed regeneration model, an HRSR model, and a steam yle model based upon PRE STO II. streams and alulate mas s flows. These new models define proess They alulate energy transfers and equipment power requirement s. thermodynami property data. For some streams they also alulate The new plant model also implements a modified MHD topping y le model whih ontains additional proess streams and required power alulations assoiated with the air separation plant and the oal drying and pulverizing equipment. At this time in the development history of MHD/ steam power plant tehnology, the model results reported in the preeding hapter are a statement of what ould be as opposed to a statement of what will be. 10 0

110 While many of the model algorithms are well subs tantiated, others are 101 only good estimates, and a very few are just estima tes. As the development program ontinues, empirial data will either validate or alter the estimates. When this happens the validity of the model will inrease. The model will then prove more useful in assessing the plant-wide impat of operating ondition or performane alterations.

111 BIBLIOGRAPHY

112 BIBLIOGRAPHY 1. Masters, G. M., In trodution to Environmental Siene and Tehnology, New Yo rk, New Yo rk : John Wi ley and Sons, In., p. 261, "Study : Aid Rain Linked to Power Pl ant Emissions," The Huntsville Times, Huntsville, Alabama, June 29, 1983, p. D Frost, L. S., "Condut! vi ty of Seeded Atmospheri Pr essure Pl asmas," Jo urnal of Applied Physis, Vo lume 32 (No. 10), Otober Woodring, J., "Computer Pr ogram COAL," System Study Gr oup In ternal Report, Energy Conversion Di vision, The Uni versity of Tennessee Spae Institute, O tobe r Wu, Y. C. L., et al., "Investigation of the DCW Generator," Pr oeedings of the 13th Symposium on the Engineering As pets of MHD, Stanford University, Stanford, California, Marh Gordon, S. and B. J. MBride, "Computer Pr ogram for Calulation of Complex Chemial Equilibrium Compositions, Ro ket Pe rformane, In ident and Refleted Shoks, and Chapman- Jougeut Detona tions," NASA SP-273, Fuller, L. C. and T. K. Stovall, User's Manual for PRESTO, Oak Ridge Na tional Laboratory, Oak Ridge, Tennessee, Chao, Y. K. and P. J. St eiger, "New Features and Appliations of PRESTO," NASA Lewis Researh Center, Cleveland, Oh io, Ha ls, Finn A., "Coneptual Design Study of Po tential Ea rly Commerial MHD Powerplant," AVCO Ev erett Re searh Laboratory, In., NASA Lewis Re searh Center, NASA Contrator Re port NASA CR , Marh Meyer, Charles A., "Thermodynami s and Transport Properties of Steam, " Amerian Soiety of Mehani al Engineers, N w Yo rk, New Yo rk, Hollis, J. R., et al., "Parametri Study of Po tential Early Commerial MHD Power Pl ants," The University of Tennessee Spae Institute, NASA Lewis Re searh Center, NASA Contrator Report CR , April Babok & Wilox Company, Steam/It s Generation and Use, 39th Edition, New Yo rk, New Yo rk,

113 Reynolds, W. C. and H. C. Pe rkins, Engineering Thermodynamis, New York, New York : MGraw-Hi ll Book Company, Lotepro Corporation, prepared for Gi lbert Assoiates, In.,.. Proess Design/Engineering Studies and Co st Es timates for Oxygen Enrihed Air Plants, " Hansen, R. E., "Power Calulations for Nonideal Gases,.. Reprint, Hydroarbon Proessing, Compressor Handbook, Houston, Texas : Gulf Publishing Company, Chapman, J. N., "On the Eonomi Optimization of the Steam Power Plant," PhD dissertation, The University of Tennessee, Knoxville, Tennessee, Va n Wylen, G. J., Thermodynamis, New Yo rk, New Yo rk : John. Wiley and Sons In., Zuker, R. D., Fundamentals of Gas Dynami s, Champaign, Il linois: Matrix Publishers, In., 1977.

114 APPENDIX

115 106 SU8RCIITINE SJNt;H VEHSION: ARCH 26, 1984 fc ATE SEEC RECE E TiiN (P.Y EH ) CCUBLF. PRECISION CEXP CCUP.LE PRECISICN CLOG CCUBLE PRECISICN X G,SU tcuble PRECISICN H UM,SSU,CPR,tLVTF,OLVFT,GAM A CCUBLE PRECISION CCEF L S! EN. E LN HO,DELN CCUBLE PRECISIO ENL, LW,CLNT,AA CCUBLE PRECISICN E8LSLCCP1.CCP2 CCUeLE PRECISION PP8I CCUP.LE PRECISION PPP-LF,PPDtS,PPt, PPXLPI,TTE FTF,OOLPE OCU8LE PRECISION CCHPE,HHS!EMA CCU LE PRECISICN HHSTE R tcuble PREC ISICN tcu8le PRECISICN w RAtE 1 1 PF, EEXTSER,QQTC, C G 1,0Gt8,EEXTRN L W W SHFt, CCE N LCGICAL HP,SP, TP,CONVG,IONS,SIN C,LCCV,ISI C,TC,VCL,SHOC,RJ1E,JI l,calch CCMMGN/COST/TFLO,FEX,FEXS, ENtA AREAR,CL EN,B AX,CFLC TAIC,FCC P 1tTCOMBLPRINTLHFr, GEFf,F AG, AFLCV, POUT,THIN,Cl F. N,8P.e 1 6LDIF, CC, 2 CUT L TPOWR, AUX l EFFC,SFLC,1ACLH, TFG, HCC,OL, a CHH,Q lag, 3GLCO,TAIP TAIP FRKS F C S RF,WSO, ASCEF, LS, 4FF U,SAFLOz!FLC L frast, G F,6FfGA,SR t CfLOH, r LGH,AFLCH, ENGrE S,PECTC2,NO,AFC I,WGXY,POwE A,PC ERC, ECt CC MON/COST!/BCAS, OHPAH, SC U8,0L HD,QC VAl g= 8 8, 5! 6 e PPC13),CLV!FC13),ClVP1 Cli) 1,GA ASC13), PC26) L TC2 ),VC13), PP(13),W (13) 2,SONVEL(13),TTT(1J),VL (13),TCtN(13) 1 a 6 s g i1i : j88 : s 65j o,2> 2,SUJ( 30 ) CCWMON/MISC/ENN SU N,Tt,SC, A TG (3 101),LLMt(15) eoc15),80p(15,2) 1,TMLTLOw T IC,fHIGH,PF,CF UM QF, EORAT, FFCt ' HSUBO,AC(2),AM(2) A : l EC l! f s : l : l 4,RHGP,RMW(1 ),TLN,CR,LXF( 1 5),EN L, ENS ve,e L R l { N LSAV,TRACE {,ENSC15) CC MCN /DOUELE/ GC25 26) X (25) CC MC /INDX/ IrEeOC,CCNV t lf HP f 1 SP,ISV, NPF 1 NS KMAT,I Al,lG1 NCF NL I I NEWR,NSUe, SUP lt,cpcvf CPCVEG 2, fo NC 1 NSERT J S G! JlfC ASE, REAC, IC,JS1,VOl, HCC,IT,NF2,ALCH 3,IQSAvE,uSAVE, f SUF, SUE, f l UM f l CLESLNP,NT,NP1,NL CC MCN/CALVIN/8BLS,CCP 1,CCF2,IICC, IIFPT IIF JCASE, NN XT N, 1NNF 1 NNFH NNHf NN TF NNLF NNCSPE,N N SHAF1 PP IF, f e M,NNFI NNFL J E f 2l; x l i Ri 4 NNCSGN,wWRAtE, NNt(12),11ES!, OOGE CC CN/CAL1 / W W GE,QCTT f : Q a t! aa :68 E i i i : f H CC MCN/ADATeLK/OGEN I ETE CC Q /ADA!A/PCMU L P6Ls,eLS OtC, PDGS, PF,VE S, NHF, IRHP, :t NIP IRIP 1 NLP, IRLt-, NF 1NFI,NFL,ICC, tir GS, NCSPE *!FEAI<, IPLACE CC CN /AEXTHT/ EXTPA (12), EXTSE (12),QFRCSS (2),HFROSS(2), * CEXT(12), EXT(12), CECCNr (13),QFWEXT(12),HF EX1(12), HECCN[ (13), 1.

116 107 * IN/.IICE2 CC MCN /AFEE C/ EFF EF, EF1 CF 1 CP2 CC MC /AFFT /QFPT, AFP11HPFFf,PXF T,HXFP1,IFPT CC O /Af H/HAEI, HAEC, R, * 0Er(J2), HEF C12) QC C{2), GF (12) QE (12),QCR HCR C O,QC I1LP,I CC MnN IAGS / OGS, HEGS, FEGS A BGS SeGS,VBGS iegs,pxgs, AMXGS,SXGS, L VXGS1TXGS H XGS GS,M GS, I GS, C C w M u f-1 / A H t. J 't I Pt. (12), HE ( 1 2 ) CC CN /AIP2/ PBIF CC MON /ALEJK/OL (2 1)tHL (2 1),0SPE,O C ass. SR, FSSR, CF H,CSSR U, * HSSR U,OSSR 1 NCLX (21 J NCHF AT (3), L K,NC L,NCASF. CC CN /ALP/OBLP,PELP,ieLP, JMBt,F,HBLP, SBLP,GXlP, FXLP,TXLF,AWXLP, L L 0 GS! t I XLP UEEPLP PXLPI CC CN /A4ISICMT (18)l 1C,tFP TR,HR,w ATE GC, L,WGL,Q U,OFP, L ltp,wgen, WfwF HTR1 N HTHTG CEFFN,CEPFG,PXCR CF (2 CC MGN /APAR {/HO(l ),HI C{2),0AE,HC, HFP, CHP,ti (12),Tt(12),TCCA (12), Ht1 J (A,FLB NC 12),NCC(J2),XX,NF NSHAFT CC MCN /APJR2/ SH 12),tSH(t2),TC(12, PXHF,FXIP CC MCN/AR 1/ TRH 1 RH2 NRH CC CN /ARH21PXRHf,PIRA1 PFF1,TXRH1,HXRH1,HIRH 1,QRH * FXRH2, PIRH2,HXRH2, HIRA2,C H2, TXRH2,WSHAF 1, EJ{TE N CC HCN /AT/CT PT TE PTE A T HT CC MCN /AADCO /ai e,ext L, E itrn,exthtt,wshft,hcsgn,ncc,nex1pn * NFA A f CN /APRCSS/PPEXT (12) HFEXT C12), QPEXT(12), PE,NFE NPEI FEL L S SHAF2, SHAF1, CCNREJ, CCMMCN/AENTHM/HT 1H8GS MXGS,HBHPM1HXHP HI 1 HXRH{. E F HXFP L HeiP, HXIP HI H HXRH2,HBLP HX PM UE F,H -E f u AEO,HC ( { 2),H f C12),HEM(1 ) HCMC{2),HC, HCHM, ArPM,H.DHP,HBFPf,HXFF1,HSSR, *HSSRMJ-4,HLK,.. (21 S C CMMO N/AEX! IEXTSE ( 12) EXtFAM(12),0EXT (12),HEX1 (12),QECC N ( 13),H *ECCN C13) QF OSM(2) HF S (2 l,oef (12),HEF (12),HTRCUM C12),CCNPEM L EXTERM Qr EX C12), fwex (12) tm CN/lPRESSM/PT,PBGS,P X GSM,FBHPM, PXHPM!Fiq t,pxrhlm,p IF,PXIP * 1P lhh2m,pxrh2, FBLPM, PXLP,PE MC12),PSH (1 ), REAL VARIABLES FCR THE SEEr REGERATION SYStE H C F,P8fFT,PXfF1 t i a:s 2 i gl6: e2t : e2 i S ai: = jr = g jlf ; = = 6 f-: M; ; l = =. 4 YW 2, S R381MFGR391MKR401MS 41 M TR29, MTR30, K R3J, WRJS,MSRJ4,MGRJ6, FG J7, L R42 6 JSRO. KSR1 1MKFRIS, CHH15,MWH17 L KSR43, KCR 44, KLHRSR, K OS, REAL VARIABLES FC R MHC TOPF ING CYCLE REAL CT02 GISAR CIS F C 101 CATOS MAT03 CTnS T04, l NAT09,MWVft3,MN.ilt, NAflO,MT T13,M l{4, P 1{S, tii, TCT, 2"'FG!17 REAL VARIAELES FCR THE HRS SECT ICN REAL MSKH01,MfGH02,MAH04, FGHOS, SH 08,MT OS, wfgh0 9, FGH10 REAL VARIAELES FCR SINGH EAL X,MFR S,MFR C,MFRASt, CISRF PCUT IS DESIRED ELECT ICAL CUTPUT OF PLANT I AttS HCC IS THt:: f-ieat CCNTENT CF COAL IN BTII PE"R LE P INT IS THE AIR PRESSU E!C CO EUSTCR IN AT PRESA IS THE AIR P ESSURE TC CO PRESSOR IN PSIA TAIC IS THE AIR!E PER.TURE tc 1HE CGMBUSTCR I CEG K SFLO IS THE FRACt icn C F SEEC IN THE FUEL PC F1 tcn CF T E INPUT M

117 108 SR IS THE S! OICHIC ET IC AJ RA! IC 8MAX IS THE MAGNE1 IC FIELC STRENGTH. TESLA E C IS THE MACH I AT!HE ENTRA NCE Or THE M D GENERATO E-D (5 1000) POU HCC P INT, TAIC,8 AX SFLr 1,Eff 1GLCPIJ SR TAH04,CEfri,HSTE.AMA,HSTEA R,E"ACH,GD F 1 2,Hf L Ef CLfN A EAR L L ENt,FST 1,FC!A,PC10, 3MGI AR, MOISA, XS,X AR, XAAR. L C. WR ITE (6 1012) PC UT HCC PRINT T IC,B AX S rlc 1,Erf 0LCPU SR TA H04,CEFri, SfEA NA,HSTE MR,E ACH,GC F 2,HF EF,CLEN,A E R F. t,fst T,PC1A,PCtO 3, C SAR, MOISAF,XS, f 1 J. L l A SAR,XAAR ********* * * FO EC K IESSL I NG ' S D ES I GN PLA T **************** THIN IS THER Al J FUT FROM COAL INJECTEC INtC THE PRI ARY HC COMBUS!CR CBTU /HH ) THIN:POUT*3.4129/ CEFf/100. ) C***** SINGH CALCULATES THE ASS FLOw RATES for THE HC!CPPI G CYCLE **** ( SEE f I CURE 3 1 : F REFERENCE 1 ) MCT02 IS THE ASS FLO RATE Of triec COAL!C THE Ht PRI A Y CC 8USTOR (LeM/HR ) C!02:THIN/HCC CISRF IS THE OISTURE RESJCRATICN ractcr CISRF: (( C I S AR* ((loo. CISAf)/(10 0. M01SA )) CISAF)+l 0 0.)/100. MCTOl IS THE MASS FLO RATE OF CRIED COAL FRCM THE STOC PILE CLB /HR) CT01:MCT02*MOISRF *** SINGH CALL DATA.ND SUPRC U1 INES FRO *'* MHO PRIMA Y CO MeUSTOR CCNCITIG S *** HP:.TRUE. PP:PR INT T1 :3000. Cf:OXFC1) CALL NEWOF CALL EOLBRfi' HP:.FALSE. TCO B=TT NAS A SINGH NOW RESU ES ASS FLO RATE CALCUL AT lc NS *'* SF 273 TC CEFJNE OAT08 IS THE MASS FLCW RATE Of 02 ENRICHEt AIR TO THE C CC B (Le /HF ) g j 0,s 0 C - it f L fr IN THE flcw PClA=PCTA A103 IS THE MASS FLO R TE OF A BlENT AIR TC THE Ht OX IC.NT CC PRESSOR (LB /HH ) AT03= CPCTA/100.)* 0AT08 PClC IS THE PERCE NT OF CXYGEN I THE FLC PCTO:PCTO 0105 IS THE MASS flow RATE OF FURE C2 FRO 1HE AIR SERPARATICN FLANT (L8"4/'HR) MC105:(PCTC/100.) AT04 IS THE NASS FLO RATE OF A"'81ENT AIR TC THE AIR SEFA AliON UNIT (LBM/HR) AT 04:MOTOS/ ATC8 NAT09 IS 1HE ASS FLC RA1E CF N2 ANC AR FRC THE AlP SEFA ATIC UNIT (LBN /HR ) NAT09= AT04 MCT05 WVT1 3 IS THE ASS FLC R A TE CF CISTURE RE CVEC FRG THE CC AL (LEM/H l

118 109 VT13=MCT0 1 MCT02 Q VT13 IS THE E T RECUIREr TO E OVE CISTU E FRC THE CCAL (8TUIH ) CwVT13=107S. wvt 13 MNAT11 IS THE ASS FLC R TE OF N2 AND AR EC. FCR COAL CRYING (l8mih ) NAT11=1.25*0 VT NAT10 IS T HE MASS FLG RATE CF N2 AND A RELEASEC TO THE AT CSPHERE (LB IHR) N T10= NAT09 N T1l TT13 IS THE MASS FLO RATE OF 2,AR, ANC CISTURE RELEASEC 10 THE PLANt STACK (LEM/HR) TT13= NAT11+ WVt13 K1 14 IS T E ASS FLO RATE Of FCTASSIU FCR ATE SEED SUPPLIED TO THE HD COMEUSTOR (LB IHR) 14:SFLO CT021C1. SFLC) PT15 IS T E ASS FLO RATE OF FLASMA TC THE Ht CHANNEL CtE IHR) Pt15= CT02+MKT14+ 0ATCB TIT IS T f TOTAL MASS INFtCW TC THE HC TCPFINC CYCLE (LP IHR)!IT: AT03+ AT04i C!01+ T14 )II TCT IS THE TOTAl J'ASS CliTflO 'FROP4 THE' HC 10FPING CYCLE (LP.MIHR) TCT: NAT10+ TT 13i PT15 FGT17 IS THE MASS FLC R TE OF FLUE GAS FRC THE CIFF USFR (l8mihr) )II FGT17:MPT15 K1 ****** MASS FLO SUM ARY.NO CVERALL ASS eal NCE ****** = ii f t T t f! : 6:1 : 6 e r S ti :ttt, 2 NAT10. TT13,MK 14, P Lt5,MT T L M1Ct 5209 FCR AT ('1'fi L T30 '**** MHr TwPFING CYCLE CrEL * **** ',1, 12X 'Ji'CT02: t.10 2X 'fo'cisiijc=',e10.5,2x 'MCISAF= ' 2E10.5,2X, tisrf: f E{O.S,2X,'MCT01=' E16.s 2X,' CAT08= 'r 3E 10.5,2X,'FCTA: ' r E{0.5l2X,1(2XL 'MATOj:,Et6.sf2X,'PCTO:, 4E 10.5,2X,' CT05: E10. l2x, MAt04: ',E10.5, 2X, NAT09:', 5E Xf' VT13=,E10. 2X r'owv11 3: ',E10. 6' NAT { t:,e10.5,2x! 'MNAT{ 0: re10.5t2x, ' 72X,' KT14='tE10.5, X,'fo'PT15 =,E10.,2X, 'MTIT=',E10.5, e : f ; I f 5 5 L i 2X M TT1 = f, E { 0.5, T sii Ai6 MOTC5L NAT09, AT03 L MCA!08,MCTOS 5210 FCRMAT( 31,'MHC TC PING YCLE MASS LC SU M RY ' 1 ll,t20 1MASS INFLCWS ' f, f T70,'MASS GUTFLO S ',I, 2 33 '** ** AIR SEFARAt ON U IT ***** ' II 3tS, ftescrip1ion ',T42,'QUANTlTYCLBM/HR ',{Ox, 4'CESCRIPTIGN ' 5T95 'OUANTI1Y flb"'ihr)', I I 15, 6'AI TO AIR SEPAPAliO UNft T42 7F X 'PURE CXYGEN FROtUft,f95 F12.1,1 /,T64, A f : *!*0M n T 6! R 1 ''''' Ji,Ts, 1'CESCRIPTIC ',T42 2'0UẠNt ity(l2 1HK) f,10x, 'CESCRIPTICN,T95, 3'QUA TITY CLPM/HR)' II 4T5, 'AIR TO CO FRES!oRft142,F12.1,10X, 5'ENRICHED AIR FRC CO RESSCR ', 6t95 F12. 1!/I tt5 f 'PURE C2 TC COMFRESSCR ',142,F12.1,11) RI E(6L5l11J C 01, CT02, AT11, TT FGRMATC"l30, 1'* **** PIILVERIZERS, fans, & 8AGHCUSE *****',II,TS, 2'CESCRIPTIGN ',T42 3'QUANTITY(l8 1HR) r,10x, 'CESCRIP1 ICN',T95, 4'CUANTITYCLe /HH) ',II 5T5,'CCAL F CM STCCK PfLE ' T 42,F12.1 lox, 6'CPIEC COAL tc MHC CO eus C ',T95,F{2.1,11,15, 7'N2 AND AR tryi G GAS ' 8!42,F12.1,10X,' D YING las ' MOISTURE Tr STAC ', 91 95,F12.1,/I) f '

119 110 R!TE (6 5212) CT02, Ptt5, C T08, M T E'CFIMAT ( i 25, 1'* **** MHO CCM BUStC R CH NNEL AND DIFFUSER ***** ', // 2 TS 'DESC IPTION ', T4i, 1 s t 'CUAN TitY(LEM/HH) ',lox, 3 CE CRIPTICN ',T95 4'0UANtiTY CLP"'IHR) f,// TS ' [J;IEC COAL TO p.tht CO,.eUSTCR ', St42,Ft2.1,tox FLUE GAS i AtiANt r U RNACE ' 1 TQS, Ft2.1 t // 6 TS '02 ENRICHED AIR L TC p.th[ COMeUSTGR 1, t42,r12*1,1/,t, 7 f SEtD TO HC COMeUSiCR ' 147 F12.1 // ) WPITE ( )MAT0 3 f 1 MNAT{ O, T04,,.fTt3 MCT01, PT 15 M T14, TI,MTOT 1 l 5213 fgrmat( 31 ' Ht tc PING CYC LE CVERA L A S BALANCE ',! /, 1120 ' ASS f NFLCWS ' T70, ' A OUTFLOWS ', // IS, 2'tESCRIPTICN ',T42 fua Tit (LB / HR) ',lox CtESCR JFTICN ', T95, 3'0UANtiTY (Le /HR)C // ' AIR TC MHC CO FRESSOR ',T42,F12.1,10X, 4'N2 & AR EF FLIIEN'I 10 AT,.. o.:sft' RE ' T95 F12.1,//,TS, 1 S'AIR TO AIR SEFAPAtiON PLAN1 ', T4i F1.1,10X 1, 6'N2 AR ANC MQISTU E t L 'IC S T ACK ' T S f12.1,//,t5,! t. 7 'CGAL FHOM STOCK PILE ' T42, F12.,10, 8 ' f L U E GAS 1 C R AD I A N t F 11 R t A C E ' 9T9S,F12.1,1/,T5 'PCTAS I U FOR A'IE SEEC',T42,F12.1,/,T42, 1 / ' 10 t95 ' -- ' II, 2T5, ' T CTAL INfLo f t4 F12.t, 10X, ' f OTAL CUTF L! W ',T95,F12.1,/) IF(MTOT.GT. TI'I), uc T t 5235 GO TC write(6,*) '*** WARN ING ASS I CREATEC I TOP PING CYCLE *** ' 5236 IF(MTCT LT.(0. 99* TIT)) GO GC TC WRITE (6 *) ' *** L GC to 8113 MHC TOPP ING CYCLE IS NOT A S BAL NCED *** ' 8713 CCNTINUE **** SINGH CALC ULA TES ENERG Y QUANTitiES!. THER CCYNA IC PROPEPTIES, AND GEC ET Y FCR THE MHC TOPPING CYCLE *** * PCWERC IS THE SHAFT PC E FEOUI EC FRO THE ASF TUReiNf ( ATTS) FGwERC=101 75* POAT07 IS ihe PRESSURE REQCIREC FRO THE OXltANT CC PRESSOR CISCHARGE. PCAT07=14. 1$PRIN1+15. AFLOV IS THE OXICANT FLCw VCLUME TO THE CXICANT CC PRESSCR (CfM ) AFLOV: 13.56* 0A 08/60. PCC F IS THE SHAFT PC ER C E LIVEREC TO THE 'C XIDANT CC PRESSCR (WATtS ) PCCMP:3.25*14.7*AfLOV*3 5 *(((PGAT01/14.7)* * 2 6) 1)/0.89 'IOA'I07 IS tlie TEJII PERAIUt<E :( f' THE MHC OXItA T A1 'I HE COMPJ:CESSC R EXIT (RAN KINE) TOAT07: (540.*(POAT01/14.7)** 28 )/.89 CCAT07 IS THE RATE AT WHICH HEAT IS GAINED ey 'IHE CXIOAN1 CURING CC PRESSJON (BTU/HR ) QCAT07:MOAT08* ( E 0 5* ( (TO A10 7**2 ) (54C.**2))+0.224* l(tcat )) ELCCt IS THE ENERGY LCS'I D U I G THE CXIr.AN'I CO PRESSION FRCCESS (WAtTS ) ELCCT=PCOMF *00At07 CHECAT IS THE HEAT ACCEC TC OXItANT IN HRS HEAt EXCHANGER (ETU/H ) QHEOAT=MOAT08*( E O S*( ( ( TAIC *l.8) **2) (1 0 AT07**2)) * CTOAtC7 54u.)) QCAT08 IS THE RATE OF HEAt JDDitiCN TO CCMPUSTCP BY THE CXIDANT FLC (ETU/HR ) GCAT08:QOAT07+0HECAT FFFT IS THE ELECtRIC PC ER ECUIRED to CRIVE t E PULVEPIZE S AND CRYING FANS (WATTS ) PPFT=7.*MC!Ol CNJT12 IS T E HE 'I TRANSFEP EC TC THE NI TCGE ANC ARGON

120 111 C CRYING CAS FRO FLUE GJS (E1U/HRl Q NAT12:t31.* NAT 11 C GLCDT IS THE DRYING HEAT LCST TC CCAL H E A TING ANt THEN TC C THE AT OSPHEPE (ETU/HH ) OLCDT=0.25*CWVT13 C CNAT13 IS THE H E AT RETAINEt ey THE COAL CRYI G GAS CBTU/HP ) Q NAT1 3:QNAT 12 QWVT 1 J CLCCT **** SINGH C A L L S NASA SF 213 TC CALCULATE ANC STCRE FLUE CAS PPCP ERT Y CATA AT FCUq CIFFERENT ST ATFS, THEY ARE STATE P O I N T S FnR SECCNtARY C C M 8UST C R 1NLE1, ECONOMIZER INLET, STAC ANC ReFEREN C E CC CI1ICN **** TP:.TRUE NPT=2 IDtNTIFIES P OPERTIE AT THE EXIT CF THE ST EA PLANT ISV:- NPT N P T:'7 NPT :'7 I DENT I F I ES PROPERT IE AT THE SE CONCARY CC EUSTOR INLET CALL SAVE I S V : t CALL SAVE PP: 1 00 TT :1S66.7 CALL EQLBR" ISV: 7 CALL SAVE A"'IX:EQRAT EQRA'I:.9524 CF: ( EQRAT* V IN C2) VPLS (2))/ (VPLS (l)+eqrat*v IN (l)) CALL NEWOF NFT:6 IDENTIFIES PROPE TIE AT 1HE ECONC IZE INLET NPT:6 TP:.TRUE. 1SV=7 CALL SAVE TTCLC: tt:ttgld PP 1 00 '11:2000. CALL EQL8Rfol I S V = - 6 CALL SAVE CALL OUT2 N P 1 = 6 ISV =6 CALL SAVE T'I =1600. P P:1.00 CALL EQLBR"' ISV=-6 CALL SAVE CALL CUT2 IF CTT.NE.O.O) CO TG 40C1 T'JCLC=TTOLIH 100. N P1=2 GC TC CONTINUE N P1:6 ISV:6 CALL SAVE TT:1200. FP: l.oo CALL EOLBRJol ISV= 6.l

121 112 CALL SAVE CALL O UT2 NP'I:6 ISV:6 CALL SAVE TT:$J001 PP:l.Ou CALL EOLBR ISV= 6 CALL SAVE CALL OUT2 NPt:6 ISV:NPT CALL SAVE TT=644.4 PP=1.00 CALL EOLBRJII ISV= 6 CALL SAVE CALL OUT2 NPt =2 I S V:6 CALL SAVE PP= 1.00 itl 9 0 LBR,_ ISV= 2 CALL SAVE CALL CUT2 C C NP1=5 IDENT IFIES FRCPE tle A T T:2 98 DEG., ANC P:l.O AT. THE C HOSE N EFERENCE CCNCITICN : NP'I:S ISV=2 CALL SAVE i 6o CALL E C LARJII CALL OUT2 lfctt.n.0.0) GO TO 5003 NPT :8 ISV:2 CALL SAVE PPr: l.oo Itt 0 o LBRfo' CALL OUT2 STC!P 5003 EQRAT:A IX CF: ( EORAT*VMIN(2) VPLS (2))/(VFl5 (1)+EORATtV IN(1)) CALL NEwOF' 'IP:.FALSE. **** SINGH RESU ES CALCULAT ION CF E N ERGY Ol ANTITIES L THERHCCYNAMIC PRCFER'IJES, &. Gt:C!o'ETRY FCI< f-!ht twpping CYCLE. **** Q T 14 IS THE ENERGY RECUIREt TC FREE PC'I S IU FROJII FCR TE CElll/HR) C:tr:114=4 *MI<T 14 C:lCCMB is 'IHE HEAT FRC THE CCM USTCR LCST 'IC THE CCOLJNG ATER CBTUIHR) CLCOME:OLCPU * C1 02 EC T15 IS THE KINETIC ENERGY ANC HEAT lranspcp.'iec FRC.M THE

122 113 CC BUSTOR P.Y the PLAS CeTU/HR ) C T15=CH S C 1 E ( ) - H S U M (5))*1 8 * P 1 1 S * R ECl 15 IS THE UNRELEASEt CHt ICAL J ENERGY TR NSPCRTEC FRO THE CC AUSTOR ey the FLAS (81U/H ) ECl 1 5=TH IN+COA1 0e EQKT 1 5 Ql CP B **** SINGH CALCUl ATES NCZZLE GEC ETRY ANC FLAS A!HERMOCYNA IC PROPERT IES **** SONVEL (l) IS THE VELOC ITY CF SOUND T H R OU GH!HE PLASMA AT CC BUS T O R CCNOITICNS (,ETE S/SEC ) SCNVEL (1): (RR*GA AS (l)* TT1 (1)/ (1))** 5 RHCC I THE PLAS DENS ITY IN THE CC BUS!OR (KG/CUB IC ElER) 1 g = i s r tl; 1 8l sity AT TH E NOZZLE THRC T (KG/CUEIC FtER) RHCT:RHOC/ ((1.+(GA ASC1) 1.)12.)**C1. 0 / CGAM AS(1) 1.))) AT IS THE CROSS SECTICNAL JREA Cr THE NCZZtE THRC AT (SQUARE ETER S) AT: (MPT 15*.45359)/(SO VEL ( 1 )*RHC1*36 00.) A N = l. + C G A AS ( 1) 1. ) * C C E A C H * * 2 ) 1 2.) 8N=2.1 (GAM AS (1 ) +1.) CN: l.i (BN *(G A M A S(1) 1.)) AE I S THE CROSS SECTICNAL JREA CF THE NCZZlE EXll (SQ U A R E ETERS ) AE: ( AT/EMACH )*((8N*AN )**CN ) RE IS THE PL ASMA tensity A1 THE NCZZLE EXIl (KG/CUB IC ME1E ) R E : RHOC /( A N ** (1.1 ( G A M A S ( 1 ) 1.))) TE IS THE S T A 1 I C TE=TCCMB/AN FENZ IS THE S T A T I C PRESSURE AT THE NOZZLE EXIT CAT ) PENZ:P RINT/ ( AN** ( GA MAS (1)/ (GAM AS(1) 1.))) 1 E PE ATURE AT!HE NOZZl E E X I 1 (C EGREES KE LVIN) ** * MHO GENERATCR CHANNEL A NALYS I S **** GtMF IS THE G ENE TO R CESIGN MASS FLCW IN L8 /HR HFF IS THE FRACT ICNAL ENTHJLPY E X T R A C TION -EY GENE ATOR CHA NEL H =( f+ Fa ==gf EF FICIE CY =i F ; l == i l:0tal* i EL I (SCUA R E METERS ) ENTA: (MPT 15/GD f)le T AREAR IS THE AREA RATIC Of!HE CHANNEL--EXIt AREA CVER ENTR) CE E XT A IS THE GENERATOR CHANNEL EX I T AREA (SQUARE ETERS) EX'IA:AREAR*ENTA PEXM IS THE D.C. ELECT JC FC WER D E V E LOPE D EY HD CHANNEL ( JTTS ) PEXM: (HSUH (l) HSU (5))*R*1. 8*.293l* HFF* Pt15 CEFFI IS THE INVERTER EFFICIENCY FCUT IS THE A.C. ELECTRIC P O W ER AVAILABLE TC G Rit (WATTS) POUTJ!l:CEFf"I*PEXM QL Ht IS THE PLASMA ENE RGY TRANSfERRED TC C H A NNEL COOL ING water AS HEAT ( BTU/HR ) OL"HC= CPE X *3.4129* Cl. GEFF ))/GEFF EQ T16 IS THE KINET IC ENERGY ANC HEAT T R A NS P C R T E t FROM C H A NN E L ey PLASMA CBTU/H ) EOKT16=EOKT1S CPEX * } QL HC ET116 IS THE TOTAL EN E R G Y 1 ANSFCRTEt FRCM CHANNEL BY PLAS ) ETT16:EOKT 16+ECT15 CLEN I S THE CHANNEL LENGTH I ME1ERS F AG IS THE ELECtRIC PC W E R REQUIRED TO CFE ATE T H E SUPER CCNOUCT ING AGNE'I (WATtS ) FMAG=CLEN* 1000.*Ct3.4* ( (EN1 ** 5)+((ENTA A EAR )** 5) ) h 7.*BMAX *E:NlA) RITE (6,3014) CLEN,E TA,. EAR,HFF,GEFF, FS1At, FREC!HE NEXT StEPS U'I!LIZE SF 273 TC FIND TI!E ;C Tt-IE THER!o4CrYNA IC FRCPERTIES FOR TH E ENTHALPY AflC F R ESSIIRE' A'I 1Hf E X IT OF 'IHE 11HD

123 114 C CUC T **** SINGH CALLS ASA SF 27 3 SUEROUTINES FC R CH NNEL EXIT PROPERTIES (NFT:3) * * ** NPT=3 IOEN!JfiES FROPER'IIES A T T H E CIFFUSEFO 1HE EXIT CF THE DUCT CENTRANCE OF NP1=3 ISV=l CALL SAVE lo! P :. T RUE. FSTAT IS THE STAT IC PRESSUPE A'I GUTPUT CF C U CT PP:PSTAT TT:2400. HSUBO:HSU80 PEX *3.413 /( PT 15*1. 8*R*GEFF ) CALL EQLBR **** DIFFUSER AHALYSIS **** ( C j T :. E ;E * ( G T CCM > tl ( 7t B lll 'IEMPERATUPE n,all:1200. CLDIF IS THE HEAT TRANSFERRED FROM THE PLAS A TC DIFFUSER COCLING WATER (BTU/HR) CLCif:4 1 *(TTT(3) 'I ALL)*C. C316* E8E* DLEN * 0349* DLEN* DL EK E u6* BEB*CLE N *DLE - C E 05*.0349* CLEN **3))/ 3.)* ETT17 IS THE TOTAL ENERGY tfansfcrtec FRCM DIFFUSER PY FLUE GAS CBTU /HR ) ETT 17: ETT16 QLOIF EO T17 IS THE!NETIC ENERG ANt SENSIBLE TRANSFCRTEt ENERGY, FRCM DIFFUSER BY FLUE GAS ( E'l'U/HR) E QKT 1 7=ETT17 ECT1 5 **** SINGH CALLS NASA SP 27 3 SUE ROUTINES TC CETER INE FLUE CAS PRCPERTIES A'I ClFFUSER EXIT (NP T:4 ) **** PtC IS THE STAGNATION PRESSURE AT OUTPUT OF DIFFUSER IN FSIA FD0:( (.2 5*1.E+03* CSONVEL (3} *2))/(VLM (3) 1C1385. )+PSTAT )'14.7 NP1:4 ISV=3 CALL SAVE HP:.TRUE. HSUBO=CHSU (3) 0LC1F)/CR*1. 8*MPT15) ((.4*SCNVEL(3) )**2l/(5. 9 1E OS*R*1.8) ; gg i 4.7 CALL EOLBRM MHC TCPP ING CYCLE ENERGY 8JLANCE w RIT (6 1210)PCWERC I 1210 FORMATC 11,T31, ' HC TCFPING CYCLE ENERGY QUANTitiES ' 1,/, T31, ' ' 1,11,T20, 'ENERGY I ',T7, 'ENERGY CUT',/, ' ' T70 ' -- ',11, 2T 3 3,' **'** AIR SEFA ATifN F LANi ***** ',/, ' ' II, 3t sl 4'Ct.SCRIPTIC ', 5t 95 ' Q U A N TIT Y ( e TU/ H P C ATT S ) ', I /, TS, 6'SHIFt P O E REUUIRED EY ttfbine ',T42, 7F1 2.1,'WATTS ',I/) write(6,1211 )PCO F,OOAT07 ' tescrip1 ICN ', t42, 'GUANT ITY CP-tU/HR or WATts> ',l OX,.

124 FC MAT CT3n1 ' ** P I ARY OXI ANT CC PRESSCR tt ',ll,ts, 1 ' DESCRIPTI N ',T42 1'QUANTITY (PTUIHR) r,jox, 'CESCRIPTICN ',TQ5, 3'QUANTITY (P.1 U IHR) ' II 4TS,'SHAFT PC,.. ER FlE611I Er: P Y TIJRP.INE',T42,F12.1, ' A TTS ', 5X, 5'0XItANT THERMAL ENERGY ' 195 F12.1 II) WRITE ( )PPFT,CLCtt,6NA1 {2,CNAf13 L 1212 fcrmat(130, 1'* ** COAL PULVERIZERS & DRYERS *** ', I I,TS, 2'CESCRIPTICN ',T42 31GUANTITY(8'IUIHR 6R WATTS) 1,10X,'CESCRIPT ICN ',!95, 4'0UANT ITY CE''Ili1HR CR W AT'IS) 1 II 5t5,' ELECTRIC POWER FCR PULV RifERS & FANS ', T42,F12.1, 6' ATTS',SX, ' H EAT LCST lc CCAL ' l95,f12.1,1/ 15, 7'THERMAL ENERGY CF NIT CGEN DRflNG STREA ',f42,f12.1,10x, 8'THERMAL ENERGY IN EXITING AS', 9T95,F12.1,1/l write (6 1213)THIN, QKT 14, QCJT08, CLCO,FOKT15,ECT FCIH4At( f 25, 1 ' * **** MHO CO EUSTCR ***** ' II 2,TS 'DESCRIPTION ',T42, 'QUA fity ( BTUIHR CR ATTS) ',10X, 3'DE CRIPTICN ',T9S 4'QUANTITY (E!U/HR tr WAT'IS) II,TS 'CCAL CHE IC L ENERGY ', f 5T42, X 'SEEC CECC PC ITICN { T95,F12.1,11 6 'I f 5, OXIDANT HER AL ENERGY 1T42, F 2.1, 10X, 7 CCMBUSTOR HEAT LCSS',T95,F1. II,. 8164,'PLASHA THER AL & E' T 95 rf2.1 II, 9T64, ' P LAS A CHE ICAL ENER y,f9s,f1.1,11) write C6 1214)EQKT15,PCUt,CL HD, ECT15,EQ T16,P AG, ECT 15 L FCRMAT(125, 1'***** MHO GENERATCR CHA NE l ***** ' II 2 T5 'DESCRIPTION ', t42, 'GUA tity ( 8TUiHR OR -AlTS) ', t OX, r s L 1 8GA I I ia 5 R watts> t L t ll 1 ts, 4'FLAS A KINFTIC ' lher AL E NERvY 5142 F12.1,10X 'ELECTRIC PC ER TC GRIC ', T95 F12.1 6'WAftS ' II, T6 'HEAT LCST ' T C COCLING WAtER f!95,f12.1, 711,TS, ' LASMA HE ICAL ENE GY ' t42,f12.1,10a, 9'PLASMA THERMAL & E 1,!95,F12. {,11, 9'I5 'MAGNET PO ER ', 142,F12.!,10X,'PLASHA CHE MICAL ENERGY ', 1T9 :,F12.1,11) FliTE (6 1215) EQKl 16,0LCIF, E CT15,EOKT17,ECT FCRMA'I( f 25, 1 ' * **** MHO tiffuser ***** ' II 2 T5 ', T42, 'CUA 1 ITY CBTUIHR CR AtTS)', 1 0X, 3 r CE CRIPTICN ', T9S. 4'QUANTITY CetU/HR CR watts),ii,t5 41FLHE GAS THERMAL & KINETIC ENE GY ', 5T42,F12.1,10X, 'HEAT LCST TC CCCL ING WATF.R ', T95,F12.1,11 6,T5 1FLUE GAS CHE ICAL ENE Gl ',t42,f12.1,1 X, 7'fLuE GAS THER AL & KE ' T95 F1.1 II, 8T64, ' F LUE GAS CHE ICAL ENEPGY ',t9,f12.1,11) 1 'CESCRIFTIOU **** SEED REGENERATICN VIA the FCRMATE PROCESS * *** KSR0 1 IS C Y K2SC4 FRC HS EQUIPMENT LP /HR KSR01=5 44*MCT02*XS*.98 KLHRSR IS THE POTASSIIIJII LCS 'I IN the RADIAN'! FUR1UCE (Le,.IHR) LHRSR: (3q./84.)t Kl14 ( ) IF( KLHRSR.GE.O) GC TO 9898 WRITE (6, *) ' INSUFFICIENt PCTJSSIUM FCR SULFU R RECCVERY ' -. 1 ' * KSR01 l

125 LHRSR:O.O KSR01:( )*( }*MKt14 CCNTINUE S R02 IS SERVICE ATE FC K2SC4 SLURRY LB /HR S R02:0.11* KSR0 1 wr03 IS K2SC4 SLURRY TG t lssolver LBM/HR K R03: KSR01+ S R02 CR04 IS CCAL TO GASIFIER le /Hr CR04:0. 34* KSR01/(1 1.85*XS) K"05 IS THE MASS FLO RATE OF FCTASSIU FC R AlE TO lxing TA K CLB IHR ) KR05:(78./32.)*XS*MCRC4 SwR06 IS SERVICE ATER FC GASIFIER COAL SLURRY LBM/HR SwR06:0.52*MCR04 C R07 IS CCAL SL URRY tc G SIFIER L8M/HR CwR07:MCH04+MSWR06 + MK 05 AR08 IS AIR TO GASifiER L E /H A 08:4 02* CR04. ASR09 fs!he COAL SLAG FRC TriE GASIFIE (LPM/HR) ASR09:XAAR*MCR04 KSR10 IS CRY K2SC 4 FRC G SIFIER LeM/HR KSR 10=5.44 *XS* CR04 GR11 IS PRODUCT GAS FRC GASIFIER LeM/HR MGR11=MCWR07+MAR08 MASR09 SR 10 MSwR12 IS SEPVICE watef FCR K2SC4 SLURRY LE M/HR SwR 12= 0.11* KSR10 MK R13 IS K2S04 SLURRY 1C t issclvep LeM/ R K R1 3=MKS" 10+MSwR 12 CAR14 IS l ime TC K2SC4 CISSOLVER LeM/HR CAR14:0.32* C KSR01+M S 10) SR43 IS RECYCLE 2SC4 FRC FillER L8 /HR SR43=0.2C*C KSR0 1+ KSP10) KSR31 IS K2S04 CQ PONENT C F RECYCLE STREA R29 L8 /HR KSR3l:O.Ol* CMKS"Ol+ M S 10} CR31 IS KC02H CC PONENt C F RECYCLE ST REA R29 L8 /HR CR31: 4.35*MKSR3 1 WR 31 IS W TER CC PONEKT CF RECYCLE STREA R29 LEM/HR MWR31:324 01*HKSR31 TR 31 IS AECYCLE K CO FCUNC SLURRY F ROM FLASH TANK AND GYFSUM FILTER LB /HR tr3 1:MKSR31+ KCR31+M R31 KSR32 IS K2SG4 CO PONENT CF RECYCLE STREA R30 LB /HR KSR32=0.08* C SR01+ KSR 10) CR32 IS KC02H CCMPONENT Cf RECYCLE STREA R30 Le /HR KCR32=4. 95*MKSR32 32 IS!ER CC FONEN! C F RECY CLE STREAM R30 LE /HR WR 32=12.62tMKSR32 TR 32 IS RECYCLE K C C PCUNt SLURRY L8M/HR T 32= KSR32+MKCR32+M R 32 KSR15=MKSRC1+ KSR13+ SR3t+MKSR 32+ SR43 KFR15= KFP31+ KF 32 wp15 =M R02+MWR 12+MwR31+ R 32 CHR 15:( )* CAR 14 IR15 IS K NC CA CO PCUNC SL!IRRY FROM CISSCLVER LE /HR TR15:MKSR15+ KF 15+ WR 15+ CHR IS HEAT RECUIREC FRC HEA1 EXCHANGER 8 PTU/HR CTR 18=101.7t TR 15 SR16 IS SIE AM TC HEA1 EXCr. NGER 8 LEM/HR SR16:QTR19/9 3.6 w R17 IS CCNCENSAtE FRC HE T EXCHANGER E te /HR R17:MSR16. TR18 IS K NC CA COMFCU C SLURRY TC REACTCR LE /MR M T 18= TR15 GR21 IS P CDUCT GAS TC SC UBP.E LBM/HR MGR21= GR11

126 117 CtR20 IS CC2 FRC REGENERJTOR TC ATMOSFHE E LEM/HR C H20=0.085*MG 21 GR21 IS PRCDUCT GAS tc RFJCTCR LeM/HR G 2l=MGR21- CCR2 0 GR22 IS PRCDUCT GAS TC HE! RECCVERY LB /HR G 22=0 93* GR21 tp23 I K AND CA COMPCUNC S LliR Y TC FLASH T N lb /HR M1R23 :MTR1 + GR21- G R22 SR25 IS StEA FRC FLASH 1 NK LE /HR 5 25=0 12* TR23 tr24 I K AND CA COMFCUNt FRO FLlSH T U te / R MtR24:MTR23 SR25 S R26 IS SERVICE ATE TC HEAt EXCHA GER A LE /HR MS H26=1.80lMG 11 S R27 IS SERV ICE w TE FRC HEAT EXCHANGE A LEM/HR S R27:MSWR26 Y R28 IS GYPSU ANC ftjter TO CISPOSAL LBM/HR YwR28=0.24 TR24 TR29 IS RECYCLE K CO FCUNr SLURRY FRO GYFSU FILTER LB /P.R MT 29:MtR31 MS 2S TF30 IS K CO POUNC SLURRY FRQ GYPSUM FIL!ER LB /HR MtR30:MTR24+MSwQ27 MYwP28-!P29 K R33 IS CC PCUND SLURRY TO EVAPCRATCR le /HR KwR33:MTR3C MTR32 MSR34 IS STEAM VE NTEC FRO K CO POUNC SLUR Y Le /HP S 34=0.SO* K R 33 R35 IS CO PCUNDS TC SF AY CRYER Le /H KwR35:MKWP 33 MS 34 GR36 IS CAS FRO EVAPC TC F LB /HR MGR 36:MGR22 FGR 37 IS FlUE CAS TC SPRAY DRYER LB /HR FGR37=14. 12*MKW 35 M R38 IS K COMPOUNCS tc HEJ1 EXCHANGER C LE M/HR KR 38:0.636tMKWR35 FGR39 IS FLUE G ANt CIS1URE TC STACK LEM/HR MFGR39= FGR37+ K R35- KR3 KR40 IS COMPOUNCS TC K2SC4 FILTER LB /HR K 40:M R38 CKR40 IS THE HEAt RfQU IREt FROM HEAT EXCHA GER C (PTU/HR) CK"40:MKR3B*40. SR41 IS STEAM TC HEA1 EXCH NGER C LB /HR MS"4 1=0 R40/983 6 R42 IS CCNCEN JTE FRCM H E T EXCHANGER C le /HR 42=MSR41 CR44 IS PCTASSJU FCR ATE TO MHC CYCLE LEM/HR KCR4 4=MKR40 MKSR43 SG FR IS MASS FLC RATE rf STAC GASES (LB /HR) SG FR:CFLO +SFLOH+JFLCn+SAFLO 1-SRRF- FGR37+MFCR 39+MGR IS SUM OF SWR02+ S R06+ SWR26 S020524= SftR02+MS R06+ SwR26 TC!Ali IS SUM OF ALL AeCVE INPUT FLOw StREA S TOTALI=MKSR01+S CP04+MAR08+MCAR1 4+MFG 37 TQT ALO IS SU CF ALL AECVE. CIITPUT FLCW STRE A S TC1ALC=MCOR20+MGR 22+ YwR28+ 5R34+ FGR39+ KCR44+MASR09 w ITE (6 719)XS MCI0 2,MKSR01tMS "02, R0 3 1 L KSR1n, SWR12,MK R13, JR14, CR04, SwR06, 1 C R07, AR08,M Rll, 2 KSR31 MKCR31tMWR31, MT 31, SR32, MKCR32, W 32, T 32, 3MtR 15 YTRlR MSR16 R FG Af ( ' l ',i 20, '******* FC ATE SEEC REGENE A11C CCEL ****** ', 1/,2X 'XS= ' E10.5 2X L t 1 ' CT02 ', ElC. 5,2X ' KS 01 =' E1.S 2X, 2 ' E10.,2X, 3' S R06:',E10.S,2X, 'MC R07 ', E10. 5,2X, 'MARCS:',EIO. S,2X, L 1 M SW 02:',t10. S, X, MKwROJ ', E1C. S,/, X, 'MCR04: 1 C 1

127 118 4' GR 11 ' E10.S / 12X ' SR1 : ' E10.5,2X,' S R12 : ',E10. 5,2X, r r L 5'MKWR1 :,E10., X, MCAR14 ', 10. S,/t2XJ. 6' SR3 : ' E X 'MKCR31 ' E10 r l 5,2 t ' R31:', E10 5,2X1 7' 1 R31 ', 10., X, KS 32: i l ,2A, ' KCR32: ',E O.S,tX, 8'M R32 ', EtC.S,2X1 'MTR 32: ', t10.s,lx1 1MT 15: ', F.10.5,2X, 9 ' Q1R18 ' E1C.51/ L lx, ' T R15:',E10. 5) RITE ( 12l)MT 1, R21 M([RtO GRtl GR22 t T 2J SPlS MTR24 swr2! s R2,MYw 9,MTR 9,w1R30 2 K R3, SR3,MK R 3 /. MS 34 GR36, FGR37, 3 KR40 MS 41 MwR42 SR43, KCR fcrmaf C2X, ' TR 18:f,E1C.5 2 X, 1 M G 21= ', E10.5 2X, * ' MCDR20: ' E10.512X ' G 2{: r l E10.512X r 'MGR2 : ' L E1C.5 1 /,2X, t ' TR2 3= ' lo.s r l lxt MSR25:', t1j.s,tx, MTR24: ', 10 S,tX, 2' Sw 26:,E10.,2A1 'MSk 17: ' E10.51/12 X r 'MYw 28: 32X, ' E10. tx, K R33: ',t10.5, 6 tx, ' 52X, 'MGR 36= ' r E10.5l2, ' fgr 37= ', E 0.5,2X, 'MKR38:',E 0.,1, 62X, ' FGR39:,E10. 12X ' KR 4C= ', E10. 5,2X1 'MSR 41:',E10. S, 72X r 1 'MWR42:',E10. 5,JX, KSR43=',E10.S,/,JX, ' KCR44: ', 8E1u. S,//////). L L t l tx L L ' SR16: '1F.10.5 L H 38,MfGR3, t L E10.5, M TR29:',E10.5,tX1 ' TRJC: L 42X,' SR34:',E10.S,I/. M K P3J: ' E1.S,2X, ' SR34: ' E10.S, { { RITE C ) 722 FCR t Cf31, ' HD /S TEAM CC P.J NED CYCLE POWER PlANT',/, 1 131, ' ',11, 2 T29, 1FOR ATE SEEC RFGENE ATICN P CCESS U PY ', /, , ' ', 11, 4 T34, 1 0 VERALL SYS!E ASS EALANCE ', I, 5 T34, ' ', 1, 6 T2 '(ALL ASS FLOk ARE IN U ITS OF FOUNCS/HOUR ) ',/1/ ) f = g f = a!,:g =i 8 ff,ttalc 1= f( A 4: = f= l 729 FO A (T20, FLCW S REA S ',T70, 'flcw TREA S CUT', I,T20, ' * ' T 7 0 ' ' * //,15 'POT AASIU SULFA1F F O HSR EQUJP ENT ' T42,F12.l 10X, 'C02 FRO REGE RATOR ' l/,15l 'SEP.VICE AtER ' t T42 ff2.1 t, T95 F12.t A 10X f :; :.r o u Ej e t 9iar6 s t 1 i : 2 r 5 :T ;e ' * AIR TO GASIFI R ' 142 F12.t,10X 'VENTEC STEA T9 F1t.,1/,T, * 'LIME TO DISSOLVE ' T 2 F 12 1 t6x 'FLUE GAS ANf ofsture TC STACK ', * T9S! Ft2.1 L /I,T5 L 'FL6E Gls 1 AP Ai CRYER ', 142 L F FCH ATE rcr RE YCLE ',T95 F F 12.1,1/ /,1S, 'T01 AL ', 142,r12.1, 9S,F12.1 8,1/ ) ************ H RS S Y STEM MCC EL * **** ******** L f tox, 'PC1Assru //,!64, 'SLAG trc GASIFIER ', T95, SKHOl IS THE SLAG, PCT SS JUM 1 C SULFUR E CVEt FROM FLUE GAS AT RADIA T FU PNACE TAP CL M/HR) SKH01:(0.60+MCTC2* XAA"*(1CC. MC ISAF )/(100. CISAR)) 1+KLHRSR+(0.02 * MC102*X5 ) EOH01 IS THE OUA TlTY CF H E AT LCST WITH SKH01 Ce1U/HR) EQH0 1=431.* SKH01 FGH02 IS THE MASS FLC RAT E CF FLUE GAS EX IliNG THE RADIANT FU NACE AHC ENTERING T E SECONDARY CCMBUSTCR (18 /HR) fgh02=mfgt 17 MS H01 EOH02 IS THE THEP AL ENERGY TRA SPCRTED FRC T E RACIANT FURNACE BY THE FLUE GAS Ce1U/H ) EOH02= FGH02* CHSU (, ) SU ( 5))* R* 1.8 ETH02 IS THE TCTAL ENE GY T ANSFCRTfC FRC 1HE RADIANT FUR CE BY THE FLUE GAS (PTU /H R) ETH02:EQH02 ECT 15 ECSRF IS T HE HEA1 lransferec FRCM T E FLUE GAS IN THE ACIA T FU NACE FOR STEA GENERAllC EQSRF=EOKT 17 EOH0 1 EQ C2 (81U/HR) t

128 119 AH04 IS THE MASS F'LO\rt R 'IE OF SECONC ARY CC EIJSTICN AIR C LE P'/HR) MAH04:((1.05 S )/SF )*( Ai03+MAt04} FGHOS IS THE ASS FLC RATE OF FLUE GAS F C 'IHE SECONC R CC BUSTOR ( L AP'/HR ) FGHOS:MFG 02+ A 04 CAFGHS IS the HE T REOUIRfr TO AISE SECCNCA Y AIR TE PERAT U E FJ;C TAH04 TO 2900 r.eg F (p111/hr ) O FGH5: (1 1P75E C5* (3360.* 4 tahc4**2 )+.224*(336C. TAH04 ))* AH04 f EOSSC IS HE HEA1 AVAILAP.LE FCR STEA GENE A'IICN IN THE SECCNDARY CC BUSTION ATE ALLS CeTU/HR ) EOSSC=ECT15 GAFG S ECH04 IS THE HEAT T R ANSPORTED INTC SECGNCA Y CC EUSTCR B SECONCARY CCMBUS'I IC AlP CETU/H ) EGH 04: (1.187SE O * CTAHC4 **2 540.**2)+.224*CTAH ))* AH04 ECHOS IS ENERGY 1RANSPCRTEt FRO THE SfCCNCARY CC fustop y THE FLIIE GAS C2'IU/HR ) EOHOS=EOH02+EOH04+C FGH 5 ORFG56 IS THE A CUNT CF HEAT RE CVEC FRC THE FLUE G AS EY THE SUPEPHE TER Q FG56:MFGH CS* CHSU ( 7} Su (6) )*. EGH06 IS THE OOA tity CF H E T t ANSPCRTEC FRC T E SUPER EATFR, REHEAtER, & OXID NT HEATE ey THE flue GAS (8TU/HR) ECH 06:EQH05 0RFG5 6 EQSSR IS THE QUANTITY CF HEAT AVA ILABLE FO SUi:!EFIHEATING ANC REHEATI G StEA (PTU/HR ) ECSSR:QRFG56 0H CA1 CRFG67 IS THE OUA NTtTY CF H E AT RE OVEn FRO THE FLUE GAS IN THE SECOND HEAT transfef SECTIC (BTU/HR ) QRFG67:114FGI-ICS*CHSU1o1 (6) HS\Ifo1 (2) }*R*1.8 EOSE IS THE HEAT AVAILAeLE FOR the ECONCfoll2 ER (81U/HR) EOSE:QRFG67 0 TR 1 A OKR 4 ECH O? IS THE HEAt thanspor!ed F CM THE S ECC NC HEAt TRANSFER SECTION BY 1HE FL UE GAS (P.TU/HR) EGH07=EOH06 QRFG6 7 SH08. IS THE QUANTITY CF CCAL ASH E OVEC ln THE ESP C LEP'/H ) MSH08:0.20 C CT02 XAAR*C10C. MC ISAF)/ ( CISAR ) ) TH08 IS THE TOTAL K2S04 A t COAL ASH RE OVEt BY ESP CLe /HR ) th08=mksr0 1+MSHC 8 FGH09 IS THE ASS FLC R ATE OF FLUE GAS F Cfol THE ESP TO THE Itl D I l C E C 0 R A F 1 F A l ( L A Ji I H ro FGH09:MFGH05- TH08 - FGR37 MFGH10 IS the total FLUE GAS MASS FLOW RATE 10 the ST ACK FGH 1 0= FGH09+MFGR39 FF N IS THE ELECT RIC PC ER REQUIRED SY I.D. FAN <WATtS) FFAN: MFGH 10*0.4!. REH EA'IE!. ' OXICANT HEA1E Ce!U/H ) R *1.8 0 C AT12 ECH0 4 OUT PUT HRSR VARIAeLES R ITE C6 7209) SK 01,ECHC1, FGH02,EOH02,ETHC2,ECSFF, AH04 1 FGH05 6AFGH5 EQSSClEC 04 1 E CHOS 0RfG56,EQH06,EOSSR,CRFG6, 1 1 2EQSE EuH07, SH03, TnOR, F C9 MrG FCP ltc ' l ',I,T30, ' ****4 H R SYSTE ODEL,,, 12X, ' SKH01= ' E1.5,2X,'EOHOl=',E10.5,2X, ' FGH02= 2E lu. 5,2X, 'ECH02=',E10.5,2X,'ETH02= ' E10.5,2X 'EGSKF: t 3E 10.5,2X, ' AH04: ',E10.5,2X, / 2X 'MF H05:',E1.5 2X 'QArGH5: ', L 1 t 4E10.5,2X, EQSSC=7 ' E10.5 2X, '!foh 4= ' E10.5 2X, ' E!.OH0':>=', L SE10.512X, O FGSo: E1C.':> 61EQSSK= E1 0.5,2X, ORFG67: 1, E10.5,2X 'EQSE: ' E1.5 72X, 'EOH0 : Et4.7 2X, ' E10.5 2Xt ' TH OS: ', E10. 5, 82X ' FGH09: ElO.J /,2X ' FGH O= ', E 0.':) //) RRfTE(6,7210 lmrg 1 1i MSKH0 1, FGHC2, MFGHO, FGH05 AH04 L / FCRMATC'1', 1 3 1, 'HRSH SYSTE MGDEL ASS FLC S0 ARY ' 1,/, T 3 1, ' ' 1,11,T20, 1MA.SS BIFLCwS ', 't'70, 'loiass GIITFLOwS ', I, 1 T 2 0 ' ', T70, ' ', 11, 21 33, ' **'** RACIAN1 FUP NACE * * *** ', /, 1 : 1 0 f, 6, l r L 2X, EOH 06:,E10.':),/,2X, fo' SHO@: ' { { 1 ' t

129 ', 11, 3TS t CCESCRIFTION 1,T42, 'CUANT ITY (L8M/ H P) 1, 1 0X, 41tt.SC'RIPTICN ' 5195 'OUANTITY flb /HR) ',/1 T5, 6'FL6E GAS F OH RAC I ANt FIJ N CE ' T42 7 Fl2.1,10X, 'SLAG SEEC & SULFUR,T9,F12.1, /1 t64, R'FLliF GAS TC SE 1... CC11'..-USTC!' ',T9,Fl2.1 ///,T3 6, 9'***** SECCNCARY CC BUSTOR ***** ', 1/,T, 1'DESCR IPT ICN ', T42 2'0UANTITY (LE /HK) C,lOX, 1CESCRIF1 ICN 1, T95, CLe /HR)' II 4t 5, 1FLUE GAS FRO ACfANT FCRNACE 1, t42,f12.1,10x, S'FLUE GAS FROM SE C. CC EUSTCR ' 195,F12.1,/I, 6T5 'SECONDA Y CG USTICN AJF 1,f421F12.1,//) R f TE ( ) FGHO S,MTH08, FGH09, FGR FCJ:iMA'I( 3 0, 1 1 * **** ELECTROSTAT IC PRECIF ITATCR ***** ', 11,15, 2'CESCRIPT ICN 1, T4 3'0UANTITY (lem/hr) f, t ox, ' CESCRIP1 ICN 1, T95, 41GUANTITY(LE /hr )' // 515.t, 1FLliE GAS F'RO tonhctive SFCTI0t11,T42,F12.1,10X, 61Pl.:TASS IUM SIJLFAT E & ASH 1 T S5 F12.1,1/,t64, 7'FLUE GAS TC IC FAN ',T95 12.,II 8T64, 1 F LUE GAS TO SEED RE E ', 91 95, F 12.1, II ) WRIT (6 7212) FGH09,MFGH 1 0, F'GR FCRMAT ( f 25, 1'***** INOUCEn DRAFT FAN * **** ',II 2 TS 1CESCR I FTICN ',142, 'CUAN1 ITY ( LBM/HR) ',1CX, 3 r CE CRIPTION ',T9 4 I au AN 1 1 r y L e 'Jj\ 1 H R > r. 1 1 trs t FLuE G As FRoM E sf I, 5142 F12.1 lox 'FLilt. G.I'S C STACt< ' T95,F12.1 II 6,ts : FLUE 1GAS 1FRC SEEt PEGENERATfON 1,T42,Fi2.1,1/) Q18P40:QTR 18+0 KR40 RITE (6,8210)EQK! 17 EOSRF CH 0 1, J.E FCPMA!( '1',131, 1HRS ": SYStt. MOtEL - ENERGY SUP.l,. Afl Y1 1, /, T 3 1, ' ' l,/i,t20, 'ENE RGY ln 1,T70, 1E E RGY CUT',/, 1 T 2 0 ' ' T ', 11, 2133, ' **'** RADIAN fu N CE ***** ', 1, 2 T 3 3 ' ', 11, 3T 5 1 CDESCRIPT ION ', T 42, 1CUANT ITY CETU/HR )',10X, 4'Dt.SCRIPTICN 1 ST95 iquantity ETU/H ),// 15, 6'FL6 GAS THER Al ' KE FRl DifFUSER ' 142, 7F 12.1,10X 'STE M GENERATICN ' t93,f14.{,11 164, 8 ' S LAG, POTASSil! 1 SUlFUR t 95 F12.1,// f 64, ( { E r : IL : E H 2 gi't L E Gls<'tl 2' 2F12.1,10X, 1FLU S CHE IC A L ENERGY 1, f9s,ft2.1,///). -RITE (6 821 t )EQH02,EQ OS,EC1 15,EOSSC,EOH04 H 8211 FC MA1Cf 301 1***** SECC t ARY CC EUSTCR **** ', 1/,TS, 1 1 CESCPIPTiuN ',142 21QUANT ITY! etu/hr) I, l OX, ' tescrifticn 1, T 95, 3'QU NTITY 1 f L 3'C UANTITY ETU/ HR ) 1,// { 1 5 ' l. 1, 4T5 1FLUE AS THEP AL ERGY 1 V f L 5Gj E t i 5 t G "' { l E GH02,EC! 15tECT15 T42,f12.1,10X, 1 { 42 t F12.1,10X, 715 f EAM GE FKATIG 1 T95 F12. 1,// T 8 1 S E COrWARY COJ.!JS'I f CN lir 1 'I 42 l12.1,ii) RITE(6, 212 )EOH0 5,EQ H06,C fca f,ecssr,

130 FORMAT (t3n, 1'*** SUPERHEATE 1 REHEATE & GXICANT HEATE * * *',11,15, 2'tESC IPTICN ',T4t 3'0UANt ity(e1u/hr) f,lox,'cescp IF1IG ', T95, 41GUANTITY(R!U/HR) 1,//, 515 'FLUE GAS THER AL ' 1 42 F 12.1,10X, 6'FlUE GAS TH R Al ' T9 i t F1.1,//,t64,. 7'CXItANT HEATING ' q5 r12.1 // 8T64,'SUPERHEAT, R f HEAi ' erfle ', 9T95,F12.1,/ /) write (6 f 8213)EOHC6,EQH07,EC O,CNAT12,01R P40,EG SE,EG H FCRMAT( 25,. 1'***** 2ND CONVECTIVE HEAT TRA SFER SECTJO *** * *',// 2 T5 1 'CESCRIPTICN',T42, 'CUAN1ITY (etu/hr)1,1cx, 3 CE CRIPTICN ',T95 4'CUANTITYCETU/HR) 1 f i/ A T5 'FlUE GAS t THEq AL ', ; 4 l f 6Ag r g e8s ro f j ;i g f i!i t 2: l l G i ; i9 F1 f: 11, 9164,' ECONO IZER ',T95,F12.1,///, 1T64, 1ENERGY LOST THROUGH ST PCK :',T95,F12.1,//) ************ STEA PLANT C A LCtll T IONS (PRESTC ) *********** DO 540 1=1,12 PE(l):O.O PPE (l):oble(pe(l)) EX1SER (IJ=O.O EEXTSERC I):CBLE (EXTSER (I)) 540 CCNTINUE CT IS THE STEA FLC RATE 1C THE AIR CO FRESSOR TURfJNE ANt C XYGEN PLANT. UNITS A E LP./ STEA. CT:3.413* (PCO P+FC ERC)/(HS1EA.35) QOl=D8LE (QT) CTC:QT QOtO:CBLE(CTC) PT: PPT=CBLE CPT) wshft:( PCU F +POwERC)*l.OE C6 WwSHFT=DBLf (WSHF1 ) arate:.97*wshft WWRATE=DBLf (whate) WRITE 6,*l 'FROM SINGH ' f f O) WRITE )00T 1 0C T C, wwshft, WHATE 3939 FORMA (ix L 'QOT:, t e.j,lx, CO!C= ',D8.3,1X, 'wwshft= ',q.3, 11X,'WwRAT = 1,C8.j,////) ITEST:O TitEST=O CALL PRESTC C CISR IS FRACTICN L CC L CISTURE, AS RECE IVEr = I = i 8 ACTICN L CCAl CISTURE, S FIRE C C CISF:. 002 THE FCLLOWING CALCULATJCN E STI les THE ther Al INPUT TC THE NITRCGEN USED FC PULVERIZING ANC C YlNG EASTERN CCAL BY CALC!ILATI G T E ATER TC EE EVAFCR TE C C SSIGNJNG AN EFFICIENCY (60 ) TC ACCCUNT FCR LCSSES ANn

131 122 ENtHALPY EX H AUST t frc THf COAL/GAS SEP RJtCR. QLCD I S THE ENTHALPY Rf OVfC FRC THE FLUE CASE! FC COAL t YING CLCD: (CMOISR CMOJSF ) *CF LCHt GLFE IS THE EN'IHALPY ACCEC 10 THE FEEDWATE IN THE LO PRESSIIF<E ECOttC IZER S EC'IICN. CHFE IS T ENtHALFY ACCEC TO THE FEEDWATE IN THE HIGH PRESSURF ECCNCMIZEP. THE FCLLOWI G CALCULA'I ICN SSUMES A AR8ITFOUA Y tivision 8E'IWEEN HIGH AND LCW PRESSU RE ECONOMIZER OF SSt TC HPE (JNC ) CHFE=0. 55*EGSE QGHPE:DBLE(GHPE ) CLPE=.45*ECSE OCLPE=DBLE(QLPE) EX'ISER (7l:OL HD+CLFE EEXTSER(7)=C BLE CEXTSE (7) ) EXTSEIH)):QHPE EEXTSER (3)=C LE C EX'ISER C3)) -RITE ( 6, ) HS u,.. ( 1 ), H s u fl ( 7 ), 1 r: L 0 I. H tj,. ( 8 ), H s u"' ( 6 ) Is A F L I 1 PEXM OLSR OHPAH CLCC,.. e,ol CLFE IOHFE,CLCt ihsum (2) 4023 F 6 RMATf i1,7 1 'HSU (1): ',Et2.5 1X 'HStJ,. (7): ' E 8.1 1X 'TFLC: ', t 1, { r L 1E8.311,2X1 'H U (8): '1EB.1,1X, HSuM(6): ' EB. 1lX1 SArLO= A 1X,'K= 1 1 E9.31/ 6 x t 'PEXM= ' EB.3 lx 6 CLSR: ',E8.3,1X, :s ix6, E; t ;2,j ;x: l;'!ei;. 2x ' u f : s 6 'i> EXTRNL:( LCCMB UL IF EC Pt+EOSSC+ EQSSR+CLMH C+ GSE ) *.2931 * 1.0E 6 EEXTRNL:DBLE CEXTRNL ) DO 541 I=1.12 NO (I):O NNt (I ):N D(I) 541 CONTINUE GTB= QT OOTA:DBLE(QT8) NRH:J NNRH:NRH PEC1): PPE(l): OBLECP E(l)) FE C2l=883.5 PPE(2):DBLE (PEC2)) F (3):494.5 PPE (3):DBLF (PE (3)) F (4):355.3 PPE (4) :0BLE (PE(4)) FE C5):167.2 PPE CS):DBLE CPECS)) FE C6):105.6 PPE (6) :DBLE C PE(6)) PE( 7):6.57 PPE(7):0BLE(PEC7)) S42 I=8,12 PE (I):O.O PFE (I):CBLE(PE(l)) 542 CONTINUE NSHAFT=3 NNSHAFT:NSHAFT NF:7 NNF:NF' NFH=3 NNFH: NFH NFI=2 NNFI:NFI FL:2 NNFL:NFL

132 NIP= l NN IP:NIP NRH:l N N R H : N R H NDSGN= l NNCSGN:NDSGt\ F8IP=459. PPE! IP=D8LECF2IP) QTz ( XTRNL*3.413*1.0E+06 )/(hstea /I+tiSTEA R ). QQ'I :DBLE (Ot) CTt:QT. OO'ID:CBLE (Ctrl ) THE FOLLO ING ES'I I ATES THF ELECTR IC L PCWER OUTPUT, WRATf. ( EASEC ON ASSU I G 35, CC NVF SION EFfiCIENCY. CADCEC BY J C J RATE:. 35*EX'IRNL wwra'ie=dble (WRATE ) writec6 rormatc X, EXTRNL:,EB.3, tx, 10'IP.: ', E12.5,1X, 'Q1: ', E8.3,1) 29? 9)EXTPNL 1 0t 8,CT WSHF'I:O. wwshrt:oble (WSHF'I ) OGEN=O. OOG EN:OBLE CGGEN ) IITEST:1 ITEST:1 CALL PRESTC OQTT:SNGL (Ct ) WWGEN:SNGL CwWGEN) RITE(6,4197 )EXT Nl, WwGEN rormat (/,2X, 'EXTRNL:',1E12.5,2X, ' WWGEN= ',le12.5,1) HPz.TRUE EORAT:.9 24 OF: C EQRAT*V IN (2) VPLS C2))/(VPLS (l)+ EORAT*V IN (l)) CALCH:.TRUE. CALL NEWOF NPT:8 ISV:7 CALL SAVE CALL EOLB M H P:. r A LSE. FEXS:WWGE t.oe+06 PAUX IS T O T A L RECUIREt UXJLIARY PO ER ( ATTS) FAUX=P AG+P FFT+0.026* CFEXS+ F0Ut ) +PFAN TPCWR:POUTf'+PFXS PAIIX EFF S IS THE TCPF ING ANC e'itq ING CYCLE EF FICIENCY NEGLECTING SEED R EGE NER T I C K COA L EFF MS:TPOWR /(THIN* ) THIN IS THE THER AL INFUT THlN:THIN+C CR04*HCC/ C lsrf ) IS THE CALCULATEC SY EM EF FICIENCY EFFC=TPOWRI ( THIN.2931 ) WR ITE (6, 30 13) EFFC,THI,FFF S HHFF:lOO. *HFF GG EFF:100 GEFF T NEt=POUf PCO F write (6,1002 ) HHFF, GGEFF, FOUt, PEXS, 'IPCw,t NE'I 1000 FC AT C 2E1S.6 L 4F8.3,/,4F8. 3,1,4FB.3,E15.6, 1/ L 8F9.3,/ L 5F9.l J), 1012 F R T (/,LX L E1S. 6,4F 8. 3,/,4F8. 3,1, 4F8. 3,E15. 6, 1/ 8F9. 3, /, S 9. 3)... t=8 L 1101 ; I f 1>