煤粉低尘燃烧器热态试验研究

以液排渣旋风燃烧技术为基础的煤粉低尘燃烧器可在燃烧过程实现捕渣,为工业加热提供含尘浓度低的高温火焰,是工业加热过程实现以煤代油的先进燃烧技术。本论文介绍了新型煤粉低尘燃烧器的热态燃烧试验研究结果,该燃烧器采用端面旋流进风,煤粉和一次风在旋转气流外层送入,分级燃烧等技术。热态试验研究表明,采用上述技术的煤粉低尘燃烧器具有燃烧完全,捕渣率高,NOx排放浓度低等特点。     

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.     

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.     

The roles of added chlorine and sulfur on ash deposition mechanisms during solid fuel combustion

The focus of this paper is on effects of chlorine and sulfur on coal ash deposition rates, under practically relevant but systematically controlled combustion conditions. This problem is important, not so much for coal, but to understand and predict deposition rates for biomass combustion where chlorine contents can be high. To this end, ash deposition rates on a controlled temperature surface were measured for controlled amounts of chlorine and sulfur added to a pulverized coal, doped with potassium and burned in a 100 kW rated combustion rig. Previous work with 35 tests on 11 coal, biomass and petroleum coke fuels burned under a range of operating conditions had strongly suggested that the deposition rate of the tightly bound inside deposits was independent of the ash aerosol composition, and depended only on PM₁ in the flue gas. The loosely bound outside deposition rate was dependent primarily on the total alkali content in the flue gas. The new results using chlorine added to the fuel (in the form of ammonium chloride) required these previous conclusions to be drastically revised. They showed that chlorine, not alkali alone, had large effects on the deposition rate of the inside deposits, which now were orders of magnitude higher than without chlorine addition, and did not fit previous (multi-fuel) correlations with PM₁. Sulfur addition, together with chlorine, did not affect deposition rates much, although it did lower the chlorine content of the deposit. These results are interpreted in terms of the ash aerosol size segregated composition, which was also measured, and potential sulfation reactions within the deposit.     

Influence of combustion temperature and coal types on alumina crystal phase formation of high-alumina coal ash

The alumina content (more than 40%) of high-alumina coal ash is comparative to the middle content bauxite ores in China. So far, in order to meet the high demand of alumina and the rise of circular economy industrial chain, extracting alumina from coal ash has become a way to comprehensively utilize high-alumina coal ash. However, this process has high requirements on the crystal phase and stability of alumina. Different from most studies, this paper focuses on how to produce coal ash more beneficial to the later refining of aluminum. Therefore, the effects of combustion temperature and coal types by classifying high-alumina coal into dull coal and bright coal on alumina crystal phase formation were studied. Through proximate analysis, ultimate analysis, calorific value analysis, X-ray fluorescence spectroscopy, X-ray diffraction (XRD) and scanning electron microscope (SEM) and other methods, it is found that γ-Al₂O₃ in high-alumina coal ash translated into more stable θ-Al₂O₃ and finally α-Al₂O₃ when combustion temperature is higher than 1000°C. Thus compared with pulverized coal boilers, circulating fluidized bed (CFB) boilers with lower combustion temperature can produce higher quality coal ash. Moreover, at the same combustion temperature, alumina crystal phase in dull coal ash is relatively less stable than that in bright coal ash, which is more suitable to the later refining and electrolysis of aluminum.     

Modeling of the submicron particles formation and initial layer ash deposition during high temperature oxy-coal combustion

The future use of coal as a fuel for power generation in the US depends on the availability of financially viable technologies for capture and storage of CO₂ emissions from power plants. Key second-generation candidates for CO₂ capture include high temperature and pressurized oxy-firing of coal, which has the potential to increase efficiency, lower capital costs, avoid air ingress and reduce oxygen requirements. However, unquantified challenges, such as flame behavior, heat transfer, ash transformation, ash deposition and char oxidation, still exist for those technologies. This study specifically focuses on the formation of submicron particles and initial layer ash deposition during high temperature oxy-coal combustion. Previous work has shown that the initial layer deposits are mainly formed of submicron size ash aerosols transported by thermophoresis. Unfortunately, the importance of submicron particle deposition has not received much attention, probably due to the insignificant deposit mass and difficulty in prediction of the submicron particles formation. In this work, models including mineral matter vaporization model, scavenging model and deposition model are developed and applied into a three-dimensional CFD framework to predict the submicron particles formation and subsequent initial layer deposits formation. The model results are comparable to experimental data. The merits of this work are that it has led to the development of a novel approach to predict both submicron particle formation and initial layer ash deposition during oxy-coal combustion.     

Prediction of particle sticking efficiency for fly ash deposition at high temperatures

The tendency of ash particles to stick under high temperatures is dictated by the ash chemistry, particle physical properties, deposit surface properties and furnace operation conditions. A model has been developed in order to predict the particle sticking efficiency for fly ash deposition at high temperatures. The model incorporates the particle properties relevant to the ash chemistry, particle kinetic energy and furnace operation conditions and takes into consideration the partial sticking behaviour and the deposit layer. To test the model, the sticking behaviours of synthetic ash in a drop tube furnace are evaluated and the slagging formation from coal combustion in a down-fired furnace is modelled. Compared with the measurements, the proposed model presents reasonable prediction performance on the particle sticking behaviour and the ash deposition formation. Through a sensitivity analysis, furnace operation conditions (velocity and temperature), contact angle and particle size have been found to be the significant factors in controlling the sticking behaviours for the synthetic ash particles. The ash chemistry and furnace temperature dictate the wetting potential of the ash particles and the melting ability of the deposit surface; particle size and density not only control the particle kinetic energy, but also affect the particle temperature. The furnace velocity condition has been identified as being able to influence the selective deposition behaviour, where the maximum deposition efficiency moves to smaller particles when increasing the gas velocity. In addition, the thermophoresis effect on the arrival rate of the particles reduces with increasing the gas velocity. Further, increasing the melting degree of the deposit layer could greatly enhance the predicted deposition formation, in particular for the high furnace velocity condition.     

Measurements and modelling of oxy-fuel coal combustion

Oxy-fuel combustion is one of the most promising technologies to isolate efficiently and economically CO₂ emissions in coal combustion for the ready carbon sequestration. The high proportions of both H₂O and CO₂ in the furnace have complex impacts on flame characteristics (ignition, burnout, and heat transfer), pollutant emissions (NO_x, SO_x, and particulate matter), and operational concerns (ash deposition, fouling/slagging). In contrast to the existing literature, this review focuses on fundamental studies on both diagnostics and modelling aspects of bench- or lab-scale oxy-fuel combustion and, particularly, gives attention to the correlations among combustion characteristics, pollutant formation, and operational ash concerns. First, the influences of temperature and species concentrations (e.g., O₂, H₂O) on coal ignition, volatile combustion and char burning processes, for air- and oxy-firing, are comparatively evaluated and modelled, on the basis of data from optically-accessible set-ups including flat-flame burner, drop-tube furnace, and down-fired furnace. Then, the correlations of combustion-generated particulate/NO_x emissions with changes of combustion characteristics in both air and oxy-fuel firing modes are summarized. Additionally, ash deposition propensity, as well as its relation to the formation of fine particulates (i.e. PM_0.2, PM₁ and PM₁₀), for both modes are overviewed. Finally, future research topics are discussed. Fundamental oxy-fuel combustion research may provide an ideal alternative for validating CFD simulations toward industrial applications.     

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.     

Mössbauer Studies of Thermal Power Plant Coal and Fly Ash

Iron-57 Mössbauer spectroscopic studies were carried out at room temperature on samples of coal, slag (bottom ash) and mechanical ash collected from Bhatinda (India) thermal power plant. Hyperfine parameters such as isomer shift, quadrupole splitting and total internal magnetic field of ⁵⁷Fe nuclei were used to characterize various iron-bearing minerals. The observed parameters indicate the presence of pyrite, siderite and ankerite in coal sample while magnetic fractions of mechanical ash and slag samples show the formation of hematite and Al-substituted magnesio-ferrite. The non-magnetic fraction of slag ash shows the dominance of Fe²⁺ phases while that of mechanical ash demonstrates the formation of both Fe²⁺ and Fe³⁺ phases. These findings are compared with Mössbauer and magnetic susceptibility studies on fly ash samples of Panipat (India) thermal power plant reported earlier.     

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.     

煤粉燃烧过程中灰膜形成比例实验研究

煤焦颗粒燃烧过程中,灰膜形成显著影响其燃烧特性.因此,本文借助高温沉降炉研究了 61～75,75～90和90～125 μm三种粒径黄陵烟煤在1273和1673 K温度下的燃烧特性与灰膜形成比例;借助扫描电镜(SEM)详细观测空心微珠颗粒内部结构,提出灰膜比例计算公式,并分析温度,粒径和碳转化率对灰膜比例的影响.结果表明...     

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.     

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.     

A three mixture fraction flamelet model for multi-stream laminar pulverized coal combustion

A three mixture fraction flamelet model is proposed for multi-stream laminar pulverized coal combustion. The technique of coordinate transformation is utilized to map the flamelet solutions from a unit pyramid space into a unit cubic space to improve the stability of the simulation. The validity of the three mixture fraction flamelet model was assessed on different configurations, including a laminar counterflow pulverized coal/methane flame and a laminar piloted pulverized coal jet flame. The flamelet predictions were compared to the reference results of the detailed chemistry solutions. For the counterflow flame, it was found that the flame temperature and major species mass fractions are correctly predicted by the three mixture fraction flamelet model. However, discrepancies are observed for combustion-mode-sensitive species such as CO and H₂ in the premixed combustion region. The thermo-chemical quantities in the char surface reaction zone cannot be correctly predicted if the mixing between the char off-gas stream and other streams is neglected. For the piloted jet flame, it was shown that the stable thermo-chemical variables can be correctly predicted at the upper and middle stream locations. However, at the downstream location, discrepancies can be observed in certain regions. Overall, the validity of the three mixture fraction flamelet model for multi-stream pulverized coal combustion is confirmed and its performance in turbulent pulverized coal combustion will be tested in future work.     

An intrinsic kinetics model to predict complex ash effects (ash film,dilution, and vaporization) on pulverized coal char burnout in air (O2/N2) and oxy-fuel (O2/CO2) atmospheres

During coal combustion, char chemical reaction is the slowest step, particularly in the last burnout stage, where the char consists of small amounts of carbon in a predominant ash framework. Existing kinetics models tend to deviate from experimental measurements of late char burnout due to the incomplete treatment of ash effects. Ash can improve pore evolution through vaporization, hinder oxygen transport by forming an ash film, and reduce active carbon sites and available surface per unit volume by penetrating into the char matrix. In this work, a sophisticated kinetics model, focusing on these three ash evolution mechanisms (ash vaporization, ash film, and ash dilution) during pulverized coal (PC) char combustion, is developed by integrating them into a thorough mechanistic picture. Further, a detailed comparison of the three distinct ash effects on PC char conversion during air (O₂/N₂) and oxy-fuel (O₂/CO₂) combustion is performed. For the modeled coal, the mass of ash vaporization is approximate 3 orders less than the mass of ash remaining, which participates in ash dilution and ash film formation, both in O₂/N₂ and O₂/CO₂ atmospheres. The influence of these phenomena on burnout time follows the order: ash dilution > ash film > ash vaporization. The influence of ash vaporization on burnout time is minor, but through interactions with the ash dilution and ash film forming processes it can have an impact at high extents of burnout, particularly in O₂/CO₂ atmospheres. In O₂/N₂ atmospheres the residual ash predominately exists as an ash film, whereas it mainly exists as diluted ash in the char matrix in O₂/CO₂ atmospheres. The residual ash particle is encased by a thick film when the ash film forming fraction is high (low ash dilution fraction). These results provide in-depth insights into the conversion of PC char and further utilization of the residual ash.     

煤粉燃烧火焰辐射光谱实验研究

针对煤粉燃烧辐射光谱问题,利用光纤光谱仪对煤粉平面火焰炉实验装置煤粉燃烧火焰辐射光谱进行了测量,详细分析了煤粉辐射光谱特征,并基于普朗克辐射传热定律,通过对光谱仪波长响应特性的标定,得到火焰绝对辐射强度随波长的分布情况,进而利用最小二乘法获得火焰温度与辐射率参数,由此提出基于煤粉燃烧火焰辐射光谱测量的火焰参数测量方法。利用该方法对不同燃烧条件下煤粉燃烧参数进行测量,开展了不同燃烧参数下煤粉火焰辐射光谱实验研究,研究结果表明：煤粉燃烧火焰辐射在200～1 100 nm波段具有较强且连续的光谱特征,基于普朗克辐射定律与最小二乘法可实现煤粉燃烧火焰温度与辐射率的测量;煤粉燃烧火焰辐射光谱在590,766,769和779 nm附近可见明显的Na和K等碱金属痕量元素原子光谱发射谱线,并且这些原子谱线的出现与火焰温度有关;随着煤粉浓度的提高,虽然燃烧温度变化不大,但由于火焰辐射率的增加,造成辐射光谱强度的大幅提升。这对锅炉煤粉燃烧优化具有重要参考价值。     

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.     

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.