Elsevier S & T

Combustion Engineering Issues for Solid Fuel Systems

Miller, Bruce G.; Tillman, David

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Table of contents

Dedication Pagev
Contentsvii
Prefacexix
List of Authorsxxiii
Chapter 1: Introduction1
1.1 Overview1
1.1.1 A Perspective on Solid Fuel Utilization2
1.1.2 Fuels and Combustion Technology Development4
1.2 Solid Fuels Used in Electricity Generation and Process Industry Applications
1.2.1 Characteristics of Solid Fuels
1.2.2 Some Economic Considerations of Solid Fuels
1.3 The Combustion Process for Solid Fuels
1.3.1 Combustion Mechanism Overview
1.3.2 Heating and Drying
1.3.3 Pyrolysis or Devolatilization
1.3.4 Volatile Oxidation Reactions
1.3.5 Char Oxidation Reactions
1.3.6 Formation of Airborne Emissions
1.3.7 Reactions of Inorganic Matter
1.3.8 Combustion and Heat Release
1.4 The Combustion System
1.4.1 Fuel Quality and Fuel Management
1.4.2 Fuel Preparation
1.4.3 Burners and the Combustion Systems
1.4.4 Post-Combustion Controls29
1.5 Organization of This Book30
1.6 References30
Chapter 2: Coal Characteristics33
2.1 Introduction to Coal80
2.1.1 Coal Formation and Coalification80
2.2 Coal Classification80
2.2.1 Coal Rank80
2.2.2 Coal Type80
2.2.3 Coal Grade80
2.2.4 Coal Classification80
2.2.4.1 ASTM Classification System80
2.2.4.2 International Classification System80
2.3 Coal Reserves/Resources80
2.3.1 World Coal Reserves80
2.3.2 United States Coal Resources and Reserves80
2.4 Coal Production80
2.4.1 World Coal Production80
2.4.2 United States Coal Production80
2.5 Traditional Coal Characterization Methods and Their Industrial Application80
2.5.1 Proximate Analysis80
2.5.2 Ultimate Analysis70
2.5.3 Heating Value70
2.5.4 Sulfur Forms71
2.5.5 Chlorine71
2.5.6 Grindability71
2.5.7 Ash Composition71
2.5.8 Trace Element Characterization
2.5.9 Ash Fusion
2.5.10 Free-Swelling Index (FSI)
2.5.11 Petrography/Coal Reflectance
2.6 Nontraditional Characterization Methods and Their Industrial Application
2.6.1 Coal Structure
2.6.2 Coal Reactivity
2.6.3 Volatile Matter Evolution Patterns
2.7 References80
Chapter 3: Characteristics of Alternative Fuels83
3.1 Introduction
3.1.1 Typical Alternative Fuel Applications
3.1.1.1 The Use of Alternative Fuels in Electric Utility Boilers
3.1.1.2 Cofiring Alternative Fuels in Process Industries and Independent Power Producers
3.2 Petroleum Coke
3.2.1 Petroleum Coke Production Processes
3.2.2 Fuel Characteristics of Petroleum Coke
3.2.2.1 Proximate and Ultimate Analysis of Petroleum Coke
3.2.2.2 Ash Characteristics of Petroleum Coke
3.2.3 Petroleum Coke Utilization in Cyclone Boilers
3.2.4 Cofiring Petroleum Coke in Pulverized Coal Boilers
3.2.5 Petroleum Coke Utilization in Fluidized-Bed Boilers
3.3 Woody Biomass
3.3.1 Types of Woody Biomass Fuels
3.3.2 Physical and Chemical Characteristics of Woody Biomass Fuels
3.3.2.1 Proximate and Ultimate Analysis of Woody Biomass
3.3.2.2 Inorganic Matter in Woody Biomass
3.3.2.3 Trace Metal Concentrations
3.3.3 Using Woody Biomass in Dedicated Boilers
3.3.4 Woody Biomass in Pulverized Coal Firing Applications
3.3.5 Cofiring Woody Biomass in Cyclone Boilers
3.3.6 Conclusions Regarding Using Woody Biomass as an Alternative Fuel
3.4 Tire-Derived Fuel (TDF)
3.4.1 General Description of Tire-Derived Fuel
3.4.2 Fuel Characteristics of Tire-Derived Fuel
3.4.2.1 Proximate and Ultimate Analysis of Tire-Derived Fuel
3.4.2.2 Ash Constituents of TDF
3.4.2.3 Trace Element Emissions from TDF
3.4.3 Cofiring Applications with Tire-Derived Fuel
3.4.4 Summary Regarding TDF as an Alternative Fuel
3.5 Herbaceous Crops
3.5.1 Types of Herbaceous Biomass Fuels
3.5.2 Sources and Uses of Herbaceous Materials
3.5.3 Fuel Characteristics of Switchgrass and Related Agricultural Biomass Materials
3.5.3.1 Density of Switchgrass and Related Materials
3.5.3.2 Proximate and Ultimate Analysis of Switchgrass and Related Agricultural Materials
3.5.3.3 Ash Chemistry for Herbaceous Biomass Fuels
3.5.4 Herbaceous Crop Summary
3.6 References
Chapter 4: Characteristics and Behavior of Inorganic Constituents133
4.1 Introduction
4.2 Inorganic Composition of Coal
4.2.1 Distribution of Inorganic Constituents in Coal
4.2.2 Methods of Determining Inorganic Composition
4.2.3 General Coal Characteristics
4.2.3.1 Lignites
4.2.3.2 Subbituminous Coals
4.2.3.3 Bituminous Coals
4.2.3.4 World-Traded Coals
4.3 Ash Formation: Transformation of Coal Inorganic Constituents
4.4 Ash Deposition Formation
4.4.1 Deposition Phenomena in Utility Boilers
4.4.2 Slagging Deposits
4.4.3 Fouling Deposits
4.4.4 High-Temperature Fouling
4.4.5 Low-Temperature Fouling
4.4.6 Ash Impacts on SCR Catalyst
4.4.7 Deposit Thermal Properties
4.5 Deposit Strength Development
4.6 Deposit Characterization
4.7 Predicting Ash Behavior
4.7.1 Advanced Indices
4.7.2 Mechanistic Models
4.8 References
Chapter 5: Fuel Blending for Combustion Management171
5.1 Introduction
5.1.1 Types of Fuel Blending
5.1.2 The Reasons for Fuel Blending
5.1.3 Issues for Fuel Blending
5.2 Equipment and Controls Issues Associated with Fuel Blending
5.2.1 The Blending System at Monroe Power Plant
5.2.2 Alternative Blending Systems
5.3 Fuel and Combustion Effects of Blending
5.3.1 Blending Overview
5.3.2 The Monroe Power Plant Case Study
5.3.2.1 Development of Combustion Models as an Analytical Tool
5.3.2.2 Fuel Effects of Blending at Monroe
5.3.2.3 Volatility and Volatile Release Patterns
5.3.2.4 Char Oxidation
5.3.2.5 Ash Chemistry
5.3.3 Fuel Effects for Other Locations
5.4 Operational Issues with Fuel Blending
5.4.1 Managing Inorganic Constituents
5.4.2 Managing the Fire
5.4.3 Managing Blend Changes
5.5 Conclusions
5.6 References
Chapter 6: Fuel Preparation199
6.1 Know Your Fuel
6.1.1 Fuel Types
6.1.2 Fuel Issues
6.1.3 Coal
6.1.4 Petroleum-Based Products
6.1.5 Biomass
6.2 Fuel Storage Silo
6.2.1 Storage Capacity
6.2.2 Silo/Bunker Design Considerations
6.2.3 Safety Considerations
6.3 Solid Fuel Flow Control
6.4 Fuel Sizing Equipment
6.5 Pulverized Coal System Analysis Guidelines
6.5.1 Mill Sizing and Standard Ratings
6.5.2 Coal Mill Capacity and Capability Analysis
6.5.2.1 Coal Throughput Capability
6.5.2.2 Primary Air Capability
6.5.2.3 Air Heater Leakage
6.5.2.4 Thermal Requirements
6.5.2.5 Analysis Summary
6.5.3 Coal Mill Capability Test Plan
6.6 References
Chapter 7: Conventional Firing Systems241
7.1 Overview
7.2 Types of Traditional Combustion Systems
7.2.1 Stoker Firing Systems
7.2.2 Pulverized Firing Systems
7.2.3 Cyclone Firing Systems
7.2.4 Fluidized-Bed Systems
7.3 Applications and Uses of Conventional Firing Systems
7.3.1 Electricity Generation
7.3.2 Industrial Boilers, Kilns, and Process Heaters
7.4 Basic Issues
7.4.1 Fuel Selection
7.4.2 Operational Considerations
7.4.3 Airborne Emissions
7.4.3.1 Particulates
7.4.3.2 SO2
7.4.3.3 NOx
7.4.3.5 CO2
7.4.3.5 Other Emissions (Hazardous Air Pollutants)
7.5 Firing Systems and Combustion Issues
7.5.1 Stoker Firing
7.5.1.1 Basic Description and Identification of Types
7.5.1.2 Fuel Selection for Stokers
7.5.1.3 Fuel Preparation
7.5.1.4 Design Parameters
7.5.1.5 Functioning of Grates
7.5.2 Pulverized Firing
7.5.2.1 Applications
7.5.2.2 Basic Description and Identification of Types
7.5.2.3 Wall-Fired Pulverized Coal Boilers and Firing Systems
7.5.2.4 Tangentially Fired Pulverized Coal Boilers
7.5.2.5 Vertically Fired (Arch-Fired) Boilers
7.5.2.6 Pulverized Coal Burner Systems
7.5.2.7 Typical and Maximum Conditions
7.5.2.8 Fuel Preparation
7.5.2.9 Effect of Moisture
7.5.2.10 Swirling Flow
7.5.2.11 Overfire Air Systems as Burner-Based Emissions Control
7.5.3 Cyclone Firing
7.5.3.1 Basic Description and Identification of Types
7.5.3.2 Typical and Maximum Conditions
7.5.3.3 NOx Formation and Cyclones
7.5.3.4 Design and Operating Parameters
7.6 Concluding Statements
7.7 References
Chapter 8: Fluidized-Bed Firing Systems275
8.1 Introduction
8.2 Fluidized-Bed Combustion Systems
8.2.1 Bubbling Fluidized-Bed Combustion (BFBC)
8.2.2 Circulating Fluidized-Bed Combustion (CFBC)
8.2.3 Pressurized Fluidized-Bed Combustion (PFBC)
8.3 Heat Transfer
8.4 Combustion Efficiency
8.5 Fuel Flexibility
8.6 Pollutant Formation and Control
8.6.1 Sulfur Dioxide
8.6.1.1 Transformation of Sorbents in the FBC Process
8.6.1.2 Bed Temperature
8.6.1.3 Particle Residence Time
8.6.1.4 Bed Quality
8.6.1.5 Gaseous Environment
8.6.1.6 Combustor Pressure
8.6.1.7 Chemical Composition
8.6.1.8 Porosity
8.6.1.9 Surface Area
8.6.1.10 Particle Size
8.6.2 Nitrogen Oxides
8.6.2.1 NOx Formation
8.6.2.2 Fuel Nitrogen and Volatile Matter Content: Fuel Rank
8.6.2.3 Combustion Temperature
8.6.2.4 Excess Air
8.6.2.5 Gas Velocity/Residence Time
8.6.2.6 Limestone Effects
8.6.2.7 NOx Reduction Techniques
8.6.3 Particulate Matter
8.6.4 Carbon Monoxide/Hydrocarbons
8.6.5 Trace Elements
8.7 Ash Chemistry and Agglomeration Issues
8.7.1 Chemical Fractionation of Biomass
8.7.1.1 Results of the Chemical Fractionation Study
8.7.2 Thermodynamic Modeling to Predict Inorganic Phases
8.7.3 Viscosity of Inorganic Melt Phases
8.7.3.1 Viscosity Results
8.7.4 Conclusions
8.8 FBC Boilers and Their Role in Clean Coal Technology Development
8.8.1 United States
8.8.1.1 Clean Coal Technology Development Program (CCTDP)
8.8.1.2 Clean Coal Power Initiative
8.8.2 Worldwide
8.8.3 Further Developments Needed for Conventional Clean Coal Technologies
8.9 Unique Opportunities for FBCs
8.9.1 Background of Opportunity/Food Industry Issue
8.9.2 Disposal Options328
8.9.3 Cofiring ATB in Coal-Fired Boilers for Carcass Disposal329
8.9.4 Summary of ATB/Coal Cofiring in a Pilot-Scale Fluidized-Bed Combustor329
8.9.4.1 NCBA/Cargill Food Solutions Tests330
8.9.4.2 PEDA/Cargill Food Solutions Tests332
8.9.4.3 DOE Oxygen-Enhanced Combustion Testing332
8.9.5 Closing Statements333
8.10 References
Chapter 9: Post-Combustion Emissions Control341
9.1 Introduction
9.2 Particulate Capture
9.2.1 Introduction
9.2.2 Electrostatic Precipitation
9.2.2.1 Introduction
9.2.2.2 Theory
9.2.2.3 Equipment Arrangement
9.2.2.4 Resistivity
9.2.2.5 Process Control
9.2.2.6 Operating an Electrostatic Precipitator
9.2.2.7 Diagnostics
9.2.2.8 Resistivity Conditioning
9.2.3 Baghouse/Fabric Filters
9.2.3.1 Overview
9.2.3.2 Basic Principles
9.2.3.3 Specific Designs
9.2.3.4 Collection Efficiency
9.2.3.5 Conclusions
9.3 Acid Gas Control
9.3.1 Acid Gases of Importance: SO2, HCl
9.3.2 Array of Technologies Depending on Application
9.3.3 Wet Scrubber Technology
9.3.3.1 Basic Principles
9.3.3.2 Typical Designs/Scale of Operations
9.3.3.3 Efficiencies
9.3.4 Spray Dryer Absorbers
9.3.4.1 Basic Principles
9.3.4.2 Typical Designs/Scale of Operation
9.3.4.3 Efficiencies
9.3.4.4 Waste Streams
9.3.5 Dry Injection Systems
9.3.5.1 Basic Principles
9.3.5.2 Typical Designs/Scale of Operations
9.3.5.3 Efficiencies
9.3.6 Reactions
9.3.6.1 Kinetics and Thermodynamics
9.4 NOx Control
9.4.1 Introduction
9.4.2 Post-Combustion Technologies of Significance
9.4.2.1 Selective Noncatalytic Reduction (SNCR)
9.4.2.2 Selective Catalytic Reduction (SCR)
9.5 Mercury Control380
9.5.1 Mercury Emissions from Existing Control Technologies from Coal-Fired Power Plants380
9.5.2 Mercury Legislation383
9.5.3 Technologies for Mercury Control383
9.5.3.1 Sorbent Injection384
9.5.3.2 Wet Flue Gas Desulfurization
9.6 Carbon Dioxide Capture
9.6.1 Introduction
9.6.2 Approaches for Capturing Carbon Dioxide from Coal-Fired Power Plants
9.6.3 Post-Combustion Carbon Dioxide Scrubbing
9.7 References
Chapter 10: Some Computer Applications for Combustion Engineering with Solid Fuels393
10.1 Introduction
10.1.1 Computer Applications in Combustion Engineering
10.1.1.1 Analytical Modeling
10.1.1.2 Computer Applications for Process Control
10.1.1.3 Computer Applications for Fuel Control
10.2 Background
10.3 Process for Fuels Opportunity Realization
10.3.1 Identify Current Fuels Opportunities
10.3.2 Validate Objectives and Develop Effective Design
10.4 Successfully Applying Computer Technology to Fuels Control
10.5 AccuTrack Situation Challenges and Response
10.6 Modeling the Flow of Coal in Bunkers and Silos
10.6.1 Plug Flow Models
10.6.2 Discrete Element Modeling (DEM)
10.6.3 Void Model
10.6.4 Stochastic Model
10.6.5 Bunker Geometry
10.6.6 Validation of Bunker Modeling
10.7 Conclusions Regarding the AccuTrack Approach to Computer Management of Fuel Properties
10.8 Summary
Chapter 11: Gasification423
11.1 Introduction to Gasification
11.2 Gasification Theory
11.3 Features of Gasification Systems
11.3.1 Bed Type
11.3.2 Flow Direction
11.3.3 Feed Preparation
11.3.4 Operating Temperature
11.3.5 Oxidant
11.3.6 Reactor Containment
11.3.7 Primary Syngas Cooling
11.3.8 Primary Gas Cleaning
11.3.9 Fuel Issues
11.4 Commercial Gasification Systems
11.4.1 GE Energy (formerly Texaco)
11.4.2 Shell
11.4.3 E-Gas (ConocoPhillips)
11.4.4 Siemens (formerly Future Energy GSP)
11.4.5 KBR Transport Gasifier
11.4.6 Lurgi
11.4.7 Raw Gas Analyses
11.5 Trace Components in Gasifier Syngas
11.5.1 Sulfur Compounds
11.5.2 Nitrogen Compounds
11.5.3 Chlorine Compounds
11.5.4 Unsaturated Hydrocarbons
11.5.5 Oxygen
11.5.6 Formic Acid
11.5.7 Carbon
11.5.8 Metal Carbonyls
11.5.9 Mercury
11.5.10 Arsenic
11.6 Gas Treating
11.6.1 Introduction
11.6.2 Desulfurization
11.6.3 Chemical Solvent Processes
11.6.3.1 Amine Processes
11.6.4 Physical Solvent Processes
11.6.4.1 Physical Washes
11.6.4.2 Selexol
11.6.4.3 Rectisol
11.6.4.4 Liquid Redox Processes
11.6.5 Membranes
11.6.6 COS Hydrolysis
11.6.7 CO Shift
11.6.7.1 Clean Gas Shift
11.6.7.2 Raw Gas Shift
11.6.8 Mercury Removal
11.7 Complete Systems
11.7.1 Integrated Gasification-Combined Cycle (IGCC)
11.7.1.2 Gasification Block
11.7.1.3 Gas Treatment and Sulfur Recovery
11.7.1.4 Combined Cycle Power Plant
11.7.2 IGCC with Carbon Capture
11.7.3 Methanol
11.8 Benefits and Limits of Gasification
11.8.1 Efficiency
11.8.2 Environmental Impact
11.8.2.1 Sulfur Emissions
11.8.2.2 NOx Emissions
11.8.2.3 Mercury
11.8.2.4 Other Emissions
11.8.2.5 Start-up Emissions
11.8.3 Availability
11.8.4 Capital Requirements
11.9 References
Chapter 12: Policy Considerations for Combustion Engineering469
12.1 Introduction
12.1.1 Combustion Engineers Do Not Make Policy
12.1.2 Combustion Engineers Respond to Policy
12.2 Environmental Policy and the Engineering Response
12.2.1 A Historical Perspective
12.2.2 Environmental Policy and Legislation Since 1990
12.2.3 Mechanisms of Engineering Response to Environmental Policy
12.3 Energy Policy and Combustion Engineering
12.3.1 Energy Policy and Fuel Selection
12.3.2 Deregulation and Its Precursors
12.3.3 Energy Efficiency and Energy Policy
12.4 Other Federal, State, Local, and Private Policies Impacting Combustion Engineers
12.5 Conclusions
12.6 References
Index485

Book details

Vendor Elsevier S & T
SKU 9780123736116
ISBN-13 9780080558059
Author Miller, Bruce G.; Tillman, David
Category Technology & Engineering
Subject Chemical & Biochemical

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Design, construct and utilize fuel systems using this comprehensive reference work. Combustion Engineering Issues for Solid Fuel Systems combines modeling, policy/regulation and fuel properties with cutting edge breakthroughs in solid fuel combustion for electricity generation and industrial applications. This book moves beyond theory to provide readers with real-life experiences and tips for addressing the various technical, operational and regulatory issues that are associated with the use of fuels. With the latest information on CFD modeling and emission control technologies, Combustion Engineering Issues for Solid Fuel Systems is the book practicing engineers as well as managers and policy makers have been waiting for.

• Provides the latest information on CFD modeling and emission control technologies
• Comprehensive coverage of combustion systems and fuel types
• Addresses policy and regulatory concerns at a technical level
• Tackles various technical and operational issues

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