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.     

The progressive formation of submicron particulate matter in a quasi one-dimensional pulverized coal combustor

In this work, we aim to investigate the formation mechanisms of submicron particulate matter (PM₁) by observing progressive changes of collected samples at different combustion stages. A 25 kW quasi one-dimensional down-fired pulverized coal combustor was used, where PM₁ was collected from the furnace centerline through the desired sampling ports by using a nitrogen-aspirated, water-cooling isokinetic sampling probe followed a 13-stage electric low pressure impactor. First, the mass concentration particle-size-distributions (PSD) of PM₁ sampled at coal flame zone clearly exhibit two distinct modes separated by a fraction of 0.173–0.267 μm, ultrafine mode and intermediate mode. However, the ultrafine peak around 63 nm greatly decreases and becomes flat as coal combustion further progresses along axial length. Then, the contributions of either organically bounded minerals or inherent minerals to these two modes at different stages are analyzed. Finally, the evolution of sulfur-concentration PSD reveals the effects of pyrite decomposition and the sulfation reaction on PM₁ formation in the combustion system.     

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.     

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.     

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.     

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.     

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 H2S formation and evolution in air staged combustion of pulverized coal

High-concentration H₂S formed in the reduction zone of pulverized coal air-staged combustion can result into the high temperature corrosion of water wall tube of boiler, so it is of great importance to accurately predict H₂S concentration for the safe operation of boilers and burners. H₂S formation and evolution depends on two steps: the sulfur release from coal conversion and gas-phase reactions of sulfur species. In this study, the sulfur release characteristics from the pyrolysis of 17 coals, including 5 lignite, 9 bituminous coals and 3 anthracites, are investigated in a drop tube furnace (DTF). Sulfur release model is developed to describe the relationship between sulfur release and coal types. A global gas-phase reaction mechanism of sulfur species composed of ten reactions is used to calculate and predict the formation and evolution of H₂S, COS and SO₂ in the reduction zone of pulverized coal air-staged combustion. A wide range of air-staged combustion experiments of 17 coals are conducted in the DTF at different temperatures and stoichiometric ratios to validate the developed model. The results show that the prediction errors of sulfur species, including SO₂, H₂S and COS, are within ± 30%, which indicates that the developed prediction model of sulfur species is of great assistance for CFD modeling of actual engineering application.     

An improved model of fine particulate matter formation coupling the mechanism of mineral coalescence and char fragmentation during pulverized coal combustion

An improved model of fine particulate matter formation coupling the mechanism of mineral coalescence and char fragmentation under different pulverized coal combustion environments has been constructed. Firstly, based on the theoretical model of char fragmentation and percolation, the included minerals with different types and particle sizes are constructed in the model, and a three-dimensional char particle sub-model is established. And the type, content and particle size distribution of included minerals are introduced as input parameters by using computer controlled scanning electron microscopy (CCSEM) technology. All of the above makes it more in line with the actual distribution of the included minerals. Then a sub-model of char fragmentation is built based on the sub-model of the char particle. And considering the influence of char combustion reaction on the particle formation process and melting characteristics of included minerals, a sub-model of mineral melting coalescence under different combustion environments is established. Finally, based on this improved model, we compared the calculation results with the experimental data and the calculation results of the traditional model. Fully considering the process of mineral coalescence and char fragmentation, which contains the characteristics of different included minerals, the results show that the newly established model has a good fitting effect for the experiment and is closer to the actual process of char particle combustion to generate particles. By the new model, the influence of the factors (mineral content, particle size distribution and porosity) on the formation of particulate matter is preliminarily analyzed.     

Effects of mechanical stresses around single tube on ash shedding in pulverized coal combustor

In this study, the effects of mechanical stresses on the shedding of ash deposits in a coal-fired boiler were evaluated. We have confirmed that the shedding occurred because of the fracture within the initial deposit layer, which was formed by powdered ash residues. Therefore, assuming that the mechanical stress acting on the initial layer influenced the shedding, the distribution of the tensile stress and shear stresses acting on the initial deposit was calculated on the basis of elastic mechanism. Because the ash deposits were brittle in nature, it was assumed that the initial deposit failed on the basis of the maximum principal stress theory (MPST). The stress values were calculated based on the data for deposit shapes, which were obtained through previous ash deposition experiments on two bituminous coals, one subbituminous coal, and two lignite coals. The fracture strength of the deposit increased with a decrease in the ash fusion temperature. This result indicated that the strength of the deposit increased because of ash coalescence. Moreover, as the MPST, the starting point of fracture was estimated from the position where the principal stress became the largest, and the stress value was used to presume whether the fracture depended on tensile stress or shear stress. The deposit with a narrow adherence region failed because of tensile stress, and the signature of peeling due to tensile stress was observed in the cross-sectional scanning electron microscopy (SEM) image of the deposit after ash shedding. In contrast, the deposit with a wide adherence region failed because of shear stress. Therefore, peeling was not observed in the cross-sectional SEM image of the deposit after ash shedding. The results obtained from the analysis on the basis of the MPST well with the actual behavior of ash shedding.     

Char characteristics and particulate matter formation during Chinese bituminous coal combustion

The characteristics of char particles and their effects on the emission of particulate matter (PM) from the combustion of a Chinese bituminous coal were studied in a laboratory-scale drop tube furnace. The raw coal was pulverized and divided into three sizes, <63, 63–100, and 100–200 μm. These coal samples were subjected to pyrolysis in N₂ and combusted in 20 and 50% O₂ at 1373, 1523, and 1673 K, respectively. Char samples were obtained by glass fiber filters with a pore size of 0.3 μm, and combustion-derived PM was size-segregated by a low pressure impactor (LPI) into different sizes ranging from 10.0 to 0.3 μm. The characteristics of char particles, including particle size distribution, surface area, pore size distribution, swelling behavior and morphology property, were studied. The results show that, coal particle size and pyrolysis temperature have significant influence on the char characteristics. The swelling ratios of char samples increase with temperature increasing from 1373 to 1523 K, then decrease when the temperature further increases to 1623 K. At the same temperature, the swelling ratios of the three size fractions are markedly different. The finer the particle size, the higher the swelling ratio. The decrease of swelling ratio at high temperature is mainly attributed to the high heating rate, but char fragmentation at high temperature may also account for the decrease of swelling ratio. The supermicron particles (1–10 μm) are primarily spherical, and most of them have smooth surfaces. Decreasing coal particle size and increasing the oxygen concentration lead to more supermicron-sized PM formation. The influence of combustion temperature on supermicron-sized PM emission greatly depends on the oxygen concentration.     

Prediction and validation of ash sticking probability under fouling conditions in pulverized coal combustion

Under the fouling conditions in stationary coal combustion systems, the sticking/rebound behavior of solid incident particles is a key issue in determining the ash deposition rate. From a dynamic point of view, the bulk fly ash, which dominants the deposited mass, successively interacts with the clean tube, the inner fine deposited layer and the bulk deposited layer during ash deposition. In this paper, we experimentally investigate the time-resolved evolution of ash fouling in a 25 kW coal combustor. The deposited mass flux rapidly reaches a stable state that fluctuates around a mean value of ～3 g/(m²·s) for two kind of probe materials. The rapid initial stage only allows the formation of 1–2 layers of bulk deposited ash, revealing the dominant role of bulk deposit in capturing large incident particles. Inspired by the observation, we apply a 3D adhesive discrete element model (DEM) to fully describe the many-body evolving process subject to the incident events of a 30-µm particle. The simulation agrees well with the experiments when using a higher particle surface energy of 200 mJ/m². The rapidly growing feature of ash sticking probability with increasing the bulk deposit layers can be reproduced in this case, and an empirical formula is proposed. It is also validated that, at the deposit growth stage, the newly-deposited particles stay just where they impact. The effectiveness of the DEM tool shall benefit a fully-validated sticking/rebound model under the fouling condition that is convenient for CFD use.     

Optical diagnostics on coal ignition and gas-phase combustion in co-firing ammonia with pulverized coal on a two-stage flat flame burner

Gradual substitution of coal with green ammonia is a practical approach for the coal power phasedown at a minimal cost of modification, but the ignition and gas-phase reaction during co-firing NH₃ with coal remain largely unclear. In this work, we investigate the co-combustion behaviors of NH₃ and a high-volatile coal on a two-stage flat flame burner. Remarkably, the post-flame oxygen mole fraction X_i,O2 of the inner stage can be manipulated to reproduce a proper reducing-to-oxidizing environment that coal particles experience in the practical combustor. We first reveal that, under certain values of X_i,O2 and NH₃ co-firing energy ratios E_NH3, the reaction intensity (manifested by OH-PLIF signals) in the NH₃-coal flame is stronger than burning either pure coal or NH₃. This synergetic effect originates from an NH₃-combustion-induced enhancement of volatile release. We then propose a characteristic time scale τ_OH from the OH signals for the initiation of overall reactions in the system. In the case of X_i,O2=0, τ_OH monotonically increases with E_NH3, while for X_i,O2=0.2, the trend transitions to a decreasing one. It can be interpreted by comparing τ_OH with the characteristic O₂ diffusion time, coal particle heating time, and the coal pyrolysis time under different X_i,O2. Furthermore, the coal particle ignition in coal-NH₃ flames can no longer be determined by visual images. Instead, we apply CH* chemiluminescence to identify the stages of coal particle ignition and volatile combustion in the NH₃-coal flame. While NH₃ addition has both positive (elevating temperatures & diluting coal particles) and negative (consuming O₂) effects on coal ignition, the combined influence of E_NH3 is marginal on coal ignition delay time. On the other hand, the volatile combustion time decreases linearly with E_NH3, suggesting a pure effect of reduced coal feed rate.     

Evaluation of a flamelet/progress variable approach for pulverized coal combustion in a turbulent mixing layer

A steady flamelet/progress variable (FPV) approach for pulverized coal flames is employed to simulate coal particle burning in a turbulent shear and mixing layer. The configuration consists of a carrier-gas stream of air laden with coal particles that mixes with an oxidizer stream of hot products from lean combustion. Carrier-phase DNS (CP-DNS) are performed, where the turbulent flow field is fully resolved, whereas the coal is represented by Lagrangian point particles. CP-DNS with direct chemistry integration is performed first and provides state-of-the-art validation data for FPV modeling. In a second step the control variables for FPV are extracted from the CP-DNS and used to test if the tabulated manifold can correctly describe the reacting flow (a priorianalysis). Finally a fully coupled a posteriori FPV simulation is performed, where only the FPV control variables are transported, and the chemical state is retrieved from the table and fed back to the flow solver. The a priori results show that the FPV approach is suitable for modeling the complex reacting multiphase flow considered here. The a posteriori data is similarly in good agreement with the reference CP-DNS, although stronger deviations than a priori can be observed. These discrepancies mainly appear in the upper flame (of the present DNS), where premixing and highly unsteady extinction and re-ignition effects play a role, which are difficult to capture by steady non-premixed FPV modeling. However, the present FPV model accurately captures the lower, more stable flame that burns in non-premixed mode.     

Soot formation characteristics in a lab-scale turbulent pulverized coal flame with simultaneous planar measurements of laser induced incandescence of soot and Mie scattering of pulverized coal

Soot formation characteristics of a lab-scale pulverized coal flame were investigated by performing carefully controlled laser diagnostics. The spatial distributions of soot volume fraction and the pulverized coal particles were measured simultaneously by laser induced incandescence (LII) and Mie scattering imaging, respectively. In addition, the radial distributions of the soot volume fraction were compared with the OH radical fluorescence, gas temperature and oxygen concentration obtained in our previous studies [1], [2]. The results indicated that the laser pulse fluence used for LII measurement should be carefully controlled to measure the soot volume fraction in pulverized coal flames. To precisely measure the soot volume fraction in pulverized coal flames using LII, it is necessary to adjust the laser pulse fluence so that it is sufficiently high to heat up all the soot particles to the sublimation temperature but also sufficiently low to avoid including a too large of a change in the morphology of the soot particles and the superposition of the LII signal from the pulverized coal particles on that from the soot particles. It was also found that the radial position of the peak LII signal intensity was located between the positions of the peak Mie scattering signal intensity and peak OH radical signal intensity. The region, in which LII signal, OH radical fluorescence and Mie scattering coexisted, expanded with increasing height above the burner port. It was also found that the soot formation in pulverized coal flames was enhanced at locations where the conditions of high temperature, low oxygen concentration and the existence of pulverized coal particles were satisfied simultaneously.     

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.