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EMS Energy Institute Photo

< Chunshan Song, Director
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Biosketch
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Biosketch

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(814) 865-4802

< Sharon Falcone Miller, Office of Student Development
(814) 863-8893

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(814) 863-5984

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 Industrial Scale Facilities

Industrial-Scale Demonstration Boiler

Industrial-Scale Demonstration Boiler

Features

Type

Tampella Power Corporation DS-15 Type D Watertube Boiler
Photograph - Front View of Boiler

Rated Capacity

15,000 lb/h saturated steam at 300 psig (420oF)

Design Fuel

Micronized coal
No. 6 fuel oil
Coal-water slurry fuel

Thermal Input

15 to 19 million Btu/hr

Boiler Auxiliaries

Forced draft and induced draft fans
15,000 gallon storage tank and 2,000 gallon day-tank
Q-Pipe Air Preheater
Double pipe heat exchanger - CWSF Preheater
Fabric Filter Dust Collector
Ceramic Filter

Diagnostic Tools

Automated data acquisition system with Viewdac software to log temperatures, pressures, fuel and steam flow rates and flue gas composition
On-line CEM (continuous emissions monitoring) of O2, CO2, CO, NOx and SO2
Sampling ports located in the boiler radiant section and convective pass and before and after the baghouse and ceramic filter
In Situ Sampling/Testing Options

  • Particulate
    • In-situ particle counter-sizer-velocimeter (PCSV) for real time, non-intrusive particle concentration and size distribution measurement
    • PM10 (EPA Method 210)
    • Dust loading via EPA Methods 1 through 5
  • Gas
    • Trace Metals in accordance with EPA Method 29 (Method 5 sampling train)
  • Others
    • On-line probe to measure erosion and deposition in the convective section
    • On-line corrosion probe in the convective section

Coal Storage and Handling Equipment
Coal Micronization System

The industrial-scale preparation facility houses a dry coal micronization circuit to produce the fuel necessary to conduct testing in the Demonstration Boiler. The central coal feed system receives a 2"x0" coal and is composed on a 25 ton coal bin, cage mill, Redler conveyer, 5 tom surge bin and a weight-belt feeder. This central coal feed system delivers minus 0.25" material to the micronized coal circuit shown below.

central coal feed system schematic

Features

Rated Capacity

Nominal 1.0 t/h dry coal

Design

26 inch TCS mill which transfers micronized coal directly to the Demonstration Boiler
Photo of TCS Mill

Coal-Water Slurry Fuel Preparation Facility

The industrial-scale preparation facility houses a coal-water slurry circuit to produce the fuel necessary to conduct testing in the Demonstration Boiler. The central coal feed system receives a 2"x0 coal and is composed on a 25 ton coal bin, cage mill, Redler conveyer, 5 ton surge bin and a weight-belt feeder. This central coal feed system delivers minus 0.25" material to the coal-water slurry circuit shown below.

coal-water slurry circuit schematic

Features

Rated Capacity

Nominal 0.7 to1.0 t/h slurry

Design

Single/double stage wet grinding circuit equipped with 4x8 ft wet overflow ball mill, Midwestern 36" screen, Moorehouse Sand Mill, Rotary Drum Vacuum Filter and several slurry mixing tanks with mixer.

Slurry Storage/ Processing Capacity

Nominal 3,500 gallons

Quality Assurance Instrumentation
  • CEM Microwave Moisture Analyzer
  • Malvern Particle and Droplet Size Analyzer
  • Bohlin Rotational Viscometer
  • Penetrometer
  • Orion pH Meter

Coal-water slurry fuel can also be formulated from filter cake produced during coal cleaning. The circuit is modified as shown below.

coal cleaning circuit

Features

Design
  • 1,000 gallon process tank, surge tank, blend tank and flush tank
  • 40 cubic foot horizontal ribbon mixer
  • 2x2" rotary drum vacuum filter for dewatering
  • In-line dispersant and stabilizer addition

Slurry Storage/ Processing Capacity

Nominal 3,500 gallons

Ceramic Filter Chamber and Conventional Fabric Filter Baghouse

The ducting from the boiler to the particulate filtration devices and from the devices to the induced draft fan contains 6" ports for access to measure particulate loadings and particle size and to obtain samples for air toxics measurements.

Photograph of Ceramic Filter Chamber and Conventional Fabric Filter Baghouse.

Ceramic Filter Chamber Features

Size

8,100 ACFM@400oF

Design

80 filters, 15" long by 7" in diameter, manufactured by CeraMem Separations, Inc.

Filter Area

2,000 sq. ft.

Face Velocity

4.0

Operating Pressure

7 to 10" W.C.

Automatic Pulse-Jet Cleaning

Compressed air

Fabric Filter Dust Collector Features

Size

8,100 ACFM@350oF

Design

196 bags, 10' long by 4.5" in diameter, aromatic polyimide fiber of needled felt construction

Filter Area

2,400 sq. ft.

Face Velocity

3.5

Operating Pressure

6 to 7" W.C.

Automatic Pulse-Jet Cleaning

Compressed air

Additional Features

Field insulated and lagged carbon steel casing with a hinged modular access/hatch cover, OSHA approved platforms and ladders, automatic controls and an indicator panel

Sorbent Duct Injection System

The Demonstration Boiler is equipped with a duct injection system for SO2 reduction. The sorbent is injected into the ducting upstream of the particulate removal devices.

Features

Design
  • Sorbent currently used is sodium bicarbonate
  • Contains a bulk bag unloading station, electric hoist system, dust sealed receiving hopper with vibrator, loss-in-weight controlled feeder, and a pneumatic transfer system
  • 0.8 to 2.5 lb sodium bicarbonate/minute injection rate