Experimental study on co-firing characteristics of ammonia with pulverized coal in a staged combustion drop tube furnace

Utilizing ammonia as a co-firing fuel to replace amounts of fossil fuel seems a feasible solution to reduce carbon emissions in existing pulverized coal-fired power plants. However, there are some problems needed to be considered when treating ammonia as a fuel, such as low flame stability, low combustion efficiency, and high NO_x emission. In this study, the co-firing characteristics of ammonia with pulverized coal are studied in a drop tube furnace with staged combustion strategy. Results showed that staged combustion would play a key role in reducing NO_x emissions by reducing the production of char-NO_x and fuel(NH₃)-NO_x simultaneously. Furthermore, the effects of different ammonia co-firing methods on the flue gas properties and unburned carbon contents were compared to achieve both efficient combustion and low NO_x emission. It was found that when ammonia was injected into 300 mm downstream under the condition of 20% co-firing, lower NO_x emission and unburnt carbon content than those of pure coal combustion can be achieved. This is probably caused by a combined effect of a high local equivalence ratio of NH₃/air and the prominent denitration effect of NH₃ in the vicinity of the NH₃ downstream injection location. In addition, NO_x emissions can be kept at approximately the same level as coal combustion when the co-firing ratio is below 30%. And the influence of reaction temperature on NO_x emissions is closely associated with the denitration efficiency of the NH₃. Almost no ammonia slip has been detected for any injection methods and co-firing ratio in the studied conditions. Thus, it can be confirmed that ammonia can be used as an alternative fuel to realize CO₂ reduction without extensive retrofitting works. And the NO_x emission can be reduced by producing a locally NH₃ flame zone with a high equivalence ratio as well as ensuring adequate residence time.     

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

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

Mechanisms of the central mode particle formation during pulverized coal combustion

Ash particles produced from pulverized coal combustion are considered to be tri-modally distributed. These include the well-known ultrafine and coarse modes, and a central mode that is less reported but attracts increasing attention. This work presents a preliminary study on the formation mechanisms of the central mode particles during pulverized coal combustion. Experiments of four sized and density-separated coal samples were carried out in a laboratory drop-tube furnace under various controlled conditions. Experimental data show that the ash particle size distributions have an evident central mode at 4 μm for all coal samples. Increasing combustion temperature leads to an increase in the central mode particle formation, which is thought to be due to enhanced char fragmentation. The small-size coal sample produces a larger amount of the central mode particles, reasonably due to abundant fine particles in the parent coal sample. Under similar combustion conditions, both the Heavy (>2.0 g/cm³) and Light (<1.4 g/cm³) coal fractions produce a central mode, indicating that not only the included minerals but also the excluded minerals contribute to the formation of the central mode particles.     

Dynamic evolution of impaction and sticking behaviors of fly ash particle in pulverized coal combustion

This paper aims to reveal the mechanisms governing the impaction and sticking dynamics of fly ash particles in pulverized coal combustion. The modeling work is of relevance to experiments in a 25?kW self-sustained down-fired furnace, which provides a sequence of real deposit shapes as varied boundary conditions for CFD simulations. Although the formed ash deposit has a comparable length scale with the probe, it has little effect on the global impaction efficiency of newly-coming particles. However, as the deposit builds up, incident particles impact the deposit and probe at generally larger impact angles and smaller normal velocities despite the almost invariant global impaction efficiency. It results in an enhanced local sticking probability in the center region of the probe, but a decreased one in the lateral regions. The incident kinetic energy of newly sticking particles to the deposit exhibits a converse correlation with their impact angle. The relationship of the averaged local sticking probability as a function of the azimuthal angle of probe is illustrated. Finally, the effect of Reynolds number on global particle impaction efficiency is examined. A universal formula is proposed, which is of importance to bridge lab-scale experiments and practical applications.     

Detailed analysis of early-stage NOx formation in turbulent pulverized coal combustion with fuel-bound nitrogen

A carrier-phase direct numerical simulation (CP-DNS) of pulverized coal combustion in a mixing layer is performed, considering three NO_x formation mechanisms (fuel-NO_x, thermal-NO_x and prompt-NO_x). Detailed analyses, including reaction path analysis, chemical timescale analysis, and a priori and budget analyses are conducted to investigate the NO_x production mechanisms and the performance of the flamelet model. Considering the high computational cost of CP-DNS, this work focuses on the early phase governed by devolatilization, where char reactions are less important. The reaction path analyses show that the principal thermal-NO reaction contributes to the net consumption of NO in fuel-bound nitrogen pulverized coal flames, which is essentially different from fuel-nitrogen-free flames. The chemical timescale analyses show that the production rates of NO_x species are faster than those of major species, which confirms the suitability of the flamelet tables. The a priori analyses show that the gas temperature and major/intermediate species can be predicted well by the flamelet model, while the NO_x species show significant discrepancies in certain regions. Finally, the budget analyses explain why the flamelet model performs differently for major/intermediate and NO_x species.     

Investigating particle and volatile evolution during pulverized coal combustion using high-speed digital in-line holography

Devolatilization is an important process in pulverized coal combustion because it affects the ignition, volatile combustion, and subsequent char burning and ash formation. In this study, high-speed digital in-line holography is employed to visualize and quantify the particle and volatile evolution during pulverized coal combustion. China Shanxi bituminous coal particles sieved in the range of 105–154 µm are entrained into a flat flame burner through a central tube for the study. Time-resolved observations show the volatile ejection, accumulation, and detachment in the early stage of coal combustion. Three-dimensional imaging and automatic particle extraction algorithm allow for the size and velocity statistics of the particle and stringy volatile tail. The results demonstrate the smaller particle generation and coal particle swelling in the devolatilization. It is found that the coal particles and volatiles accelerate due to the thermal buoyancy and the volatiles move faster than the coal particles. On average, smaller particles move faster than the larger ones while some can move much slower possibly because of the fragmentation.     

Experimental and modeling study of water time histories during H2S-N2O combustion in a shock tube

With the interest in directly burning sour gas in gas turbines, and the fact that even small amounts of H₂S or its combustion products can alter combustion characteristics, many research studies have been performed to better understand the combustion chemistry of H₂S. In the present study, the water formation was followed by laser absorption with N₂O as an oxidant, instead of O₂. Nitrous Oxide being essentially consumed via N₂O (+M) ⇌ N₂ + O (+M), the water formation via the H₂S + O route can then be probed to further validate the models. Three H₂S/N₂O mixtures diluted in 98% Ar were studied to cover the following range of equivalence ratios: 0.5, 1.0, and 2.0, over a wide range of temperatures (1580–1940 K) around atmospheric pressure. A chemical kinetic model was then developed first by validating the base N₂O kinetics mechanism, then by investigating the experimental results presented herein. The N₂O kinetics mechanism was updated with recent work on the low- and high-pressure limits for N₂O decomposition (N₂O (+M) ⇌ N₂ + O (+M)) as well as a review of rate coefficients for N₂O + H ⇌ N₂ + OH from the literature. Good agreement is shown for H₂/N₂O mixtures. Updates were then made to the H₂S kinetics mechanism, specifically, an update from the literature on SO₂ + H (+M) ⇌ SO + OH (+M) and an adjustment to SO + SH ⇌ S₂ + OH. Additionally, reactions between SH and N₂O were determined using W1BD data and transition state theory which required the addition of an NNS sub-mechanism. With these updates, the mechanism provides good agreement with the H₂S/N₂O experiments.     

Mechanism on the contribution of coal/char fragmentation to fly ash formation during pulverized coal combustion

In this paper, the correlations between coal/char fragmentation and fly ash formation during pulverized coal combustion are investigated. We observed an explosion-like fragmentation of Zhundong coal in the early devolatilization stage by means of high-speed photography in the Hencken flat-flame burner. While high ash-fusion (HAF) bituminous and coal-derived char samples only undergo gentle perimeter fragmentation in the char burning stage. Simultaneously, combustion experiments of two kinds of coals were conducted in a 25?kW down-fired combustor. The particle size distributions (PSDs) of both fine particulates (PM_1-10) and bulk fly ash (PM₁₀₊) were measured by Electrical Low Pressure Impactor (ELPI) and Malvern Mastersizer 2000, respectively. The results show that the mass PSD of residual fly ash (PM₁₊) from Zhundong coal exhibits a bi-modal shape with two peaks located at 14?µm and 102?µm, whereas that from HAF coal only possesses a single peak at 74?µm. A hybrid model accounting for multiple-route ash formation processes is developed to predict the PSD of fly ash during coal combustion. By incorporating coal/char fragmentation sub-models, the simulation can quantitatively reproduce the measured PM₁₊ PSDs for different kinds of coals. The sensitivity analysis further reveals that the bi-modal mass distribution of PM₁₊ intrinsically results from the coal fragmentation during devolatilization.     

Fundamental investigation of NOx formation during oxy-fuel combustion of pulverized coal

NO_x formation was measured during combustion of pulverized coals and pulverized coal char in N₂ and CO₂ environments under isothermal and nearly constant oxygen conditions (i.e. using dilute coal loading). Three different oxygen concentrations (12% O₂, 24% O₂, and 36% O₂) and two representative US coals were investigated, at a gas temperature of 1050 °C. To investigate the importance of NO reburn reactions, experiments were also performed with an elevated concentration (550 ppm) of NO in the gases into which the coal was introduced. For low levels of background NO, the fractional fuel-nitrogen conversion to NO_x increases dramatically with increasing bath gas oxygen content, for both N₂ and CO₂ environments, though the fuel conversion is generally lower in CO₂ environments. Char N conversion is lower than volatile N conversion, especially for elevated O₂ concentrations. These results highlight the importance of the volatile flame and char combustion temperatures on NO_x formation. For the high background NO_x condition, net NO_x production is only observed in the 36% O₂ environment. Under these dilute loading conditions, NO reburn is found to be between 20% and 40%, depending on the type of coal, the use of N₂ or CO₂ diluent, the bulk O₂ concentration, and whether or not one considers reburn of volatile-NO_x. This dataset provides a unique opportunity to understand and differentiate the different sources and sinks of NO_x under oxy-fuel combustion conditions.     

Quantifying the effect of CO2 gasification on pulverized coal char oxy-fuel combustion

Previous research has provided strong evidence that CO₂ and H₂O gasification reactions can provide non-negligible contributions to the consumption rates of pulverized coal (pc) char during combustion, particularly in oxy-fuel environments. Fully quantifying the contribution of these gasification reactions has proven to be difficult, due to the dearth of knowledge of gasification rates at the elevated particle temperatures associated with typical pc char combustion processes, as well as the complex interaction of oxidation and gasification reactions. Gasification reactions tend to become more important at higher char particle temperatures (because of their high activation energy) and they tend to reduce pc oxidation due to their endothermicity (i.e. cooling effect). The work reported here attempts to quantify the influence of the gasification reaction of CO₂ in a rigorous manner by combining experimental measurements of the particle temperatures and consumption rates of size-classified pc char particles in tailored oxy-fuel environments with simulations from a detailed reacting porous particle model. The results demonstrate that a specific gasification reaction rate relative to the oxidation rate (within an accuracy of approximately +/- 20% of the pre-exponential value), is consistent with the experimentally measured char particle temperatures and burnout rates in oxy-fuel combustion environments. Conversely, the results also show, in agreement with past calculations, that it is extremely difficult to construct a set of kinetics that does not substantially overpredict particle temperature increase in strongly oxygen-enriched N₂ environments. This latter result is believed to result from deficiencies in standard oxidation mechanisms that fail to account for falloff in char oxidation rates at high temperatures.     

Flamelet LES of a swirl-stabilized multi-stream pulverized coal burner in air and oxy-fuel atmospheres with pollutant formation

A large-eddy simulation of a swirl-stabilized multi-stream laboratory-scale pulverized coal burner designed specifically for oxy-fuel investigation is conducted using a three-mixture-fraction flamelet model, in which both NO_x and SO_x emissions are considered. The simulation results are compared to those in an air atmosphere and the available experimental data. The flame structures and pollutant formation mechanisms are analyzed in detail. The results show that the oxy-coal flame is narrower in the radial direction compared to the air-coal flame. Further, the particle clustering phenomenon can be observed in the oxy-fuel atmosphere. The distributions of the thermo-chemical quantities in different conditions are significantly different. For pollutant formation, the results show that NO is mainly formed around the quarl zone in an oxy-fuel atmosphere, while a large amount of NO is formed in the far downstream region in an air atmosphere. Although the instantaneous distributions of SO_x are qualitatively similar in different conditions, they are quantitatively different due to the different oxygen partial pressure in the air and oxy-fuel atmospheres.     

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

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

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

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

Ignition and devolatilization of pulverized bituminous coal particles during oxygen/carbon dioxide coal combustion

Oxygen/carbon dioxide recycle coal combustion is actively being investigated because of its potential to facilitate CO₂ sequestration and to achieve emission reductions. In the work reported here, the effect of enhanced oxygen levels and CO₂ bath gas is independently analyzed for their influence on single-particle pulverized coal ignition of a U.S. eastern bituminous coal. The experiments show that the presence of CO₂ and a lower O₂ concentration increase the ignition delay time but have no measurable effect on the time required to complete volatile combustion, once initiated. For the ignition process observed in the experiments, the CO₂ results are explained by its higher molar specific heat and the O₂ results are explained by the effect of O₂ concentration on the local mixture reactivity. Particle ignition and devolatilization properties in a mixture of 30% O₂ in CO₂ are very similar to those in air.     

Numerical investigation of pulverized coal particle group combustion using tabulated chemistry

The ignition and combustion of coal particle groups are investigated numerically in a laminar flow reactor. The Flamelet Generated Manifold method is extended to account for the complex mixture of gases being released during devolatilization, which is calculated with a competing two-step model. A second mixture fraction is introduced to include the mixing with the second methane fuel stream. The interactions of the gas phase with particles are modeled within a fully coupled Euler-Lagrange framework. To investigate the influence of particle groups on ignition and combustion, successively increasing densities of particle streams have been analyzed. The ignition delay time is increased significantly by higher particle densities. This delay is validated successfully with the available measurements. Moreover, the shape of the volatile flame was found to be strongly influenced by the particle number density inside the flame. A transition from spherical flames around single particles to a conical flame around the particle cloud could be found in numerical results as well as in experiments. As the primary mechanism for the substantial ignition delay and the formation of the flame, the increased heat transfer from the gas-phase to the particle group, resulting in lower gas-phase temperatures, was identified.     

Multiplex CARS measurements in supersonic H2/air combustion

2 and O₂ multiplex coherent anti-stokes Raman spectroscopy (CARS) employing a single dye laser has been explored to simultaneously determine the temperature and concentrations of H₂ and O₂ in a hydrogen-fueled supersonic combustor. Systematic calibrations were performed through a well-characterized H₂/air premixed flat-flame burner. In particular, temperature measurement was accomplished using the intensity ratio of the H₂ S(5) and S(6) rotational lines, whereas extraction of the H₂ and O₂ concentrations was obtained from the H₂ S(6) and O₂ Q-branch, respectively. Details of the calibration procedure and data reduction are discussed. Quantification of the supersonic mixing and combustion characteristics applying the present technique has been demonstrated to be feasible. The associated detection limits as well as possible improvements are also identified. Received: 1 July 1997/Revised version: 29 September 1998