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^CENTENNiq^ r 80-GT-102
m ^. HE AMERICAN SOCIETY OF MECHANICAL ENGINEERS
45 E 47 St., New York, N.Y. 10017
a Society shall not be responsible for statements r;r up i cns advanced in papers or.
y z ^ ! discussion at meetings of the Society or of ,ts D vr.r or :Sections or printed in
.. its publications Discussion is printed or);v l the paper is published in an ASME
iF?V,MEG^P j — Journal or Proceedings Released for gei erdl p,,til eatu;n upI.n. pr'sentation. Full
credit should be given to ASME. ftr : hfm..rl Drvisirun and the .+ ithor(si
NOMENCLATURE plan area and coal feed ports which result from pres-
surizing the fluidized bed combustor.
ha — combustion air enthalpy The power required to compress the fluidizing
combustion air is very large and can be accomplished
hg — combustion gas enthalpy most economically if the high pressure, high tempera-
ture combustion gases are used to drive a gas turbine
0
which, in turn, drives the compressor. Depending on
ma - mass of combustion air per mass coal the pressure and temperature of these combustion
gases, considerable net power may be obtained from
0
the turbine-compressor unit thus giving rise to a
mg - mass of combustion gas per mass coal combined cycle power plant. A representative cycle
configuration for this type of plant is shown in
P - pressure Fig. 1.
Use of the power recovery turbine also permits
q' - heat release in furnace per unit mass coal increased bed depth without a substantial increase in
the pumping losses associated with the combustion air
INTRODUCTION system. Both combustion efficiency and sulfur reten-
tion have been shown to be proportional to the fluid-
The pressurized fluidized bed coal combustor ized bed depth, hence the deeper bed is desirable in
(PFBC) coupled to a combined gas/steam turbine power these aspects as well as the further reduction in
cycle, has emerged as a promising power conversion plan area which accompanies use of a deep bed.
concept with the potentials of both high overall ef- Although reduced furnace capital costs and en-
ficiency and low SO2 emissions. The pressurized hanced sulfur capture are noteworthy advantages, the
combustor is also seen as a potentially lower cost potential for obtaining high plant efficiencies in
furnace than either conventional pulverized coal com- the combined cycle system is certainly a major ob-
bustors (PCC) or atmospheric pressure fluidized bed jective in PFBC development. The cost of electricity
combustors (AFBC). This is due to the reduction in (CUE) for a given power plant is strongly related to
its overall efficiency (which affects capital cost)
whereas large percentage changes in the cost of major
components have less impact.
*Research sponsored by Tennessee Valley Author- The high efficiency of the PFBC is attributable
ity under Interagency Agreement TV-48296A under Union to the extraction of power from the high thermo-
Carbide Corporation contract W-7405-eng-26 with the dynamic availability in the combustion gases via the
U.S. Department of Energy. power recovery turbine. Design studies have consis-
tently predicted overall efficiencies of 40% if a gas
turbine inlet temperature (GTIT) of 870 + ° C (1600 +
'By acceptance of this article, the publisher or recipient acknowledges the U.S. ° F) is utilized. However, operation of a gas turbine
Government's right to retain a nonexclusive, royalty free license in and to any
copyright covering the article. on the erosive and corrosive combustion gases at high
temperatures has proven to be a formidable obstacle
Contributed by the Gas Turbine Division of The American Society of
Mechanical Engineers for presentation at the Gas Turbine Conference & in the path of PFBC development.
Products Show, New Orleans, La., March 10-13, 1980. Manuscript received at A review of past experience with removing par-
ASME Headquarters December 19, 1979. ticulate matter from hot gas streams indicates that
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COMPRESSOR TURBINE IP LP
COMB
;EN
CONDENSER
PUMP
is a particulate removal efficiency of about 95% for required development effort, its effect on the plant
particles on the order of 10 p in size and 60-90% for efficiency should be understood. Characteristics of
5 p particles when using cyclone or multiclone par- the Brayton cycle indicate that the compressor pres-
ticle collectors [1,2] (an exception is the recent sure ratio should also be included in the investiga-
test series at the Exxon miniplant [31). Other re- tion due to its pronounced effect on the efficiency
sults show a general lack of effectiveness for cy- of that cycle.
clones on particles less than lop in size [4].
The turbine manufacturers have reached a ANALYTICAL APPROACH
preliminary conclusion that at high temperature, the
turbine inlet gas should contain no more than about Examination of the problem and desired results
9-45 mg/m 3 (0.004-0.02 gr/SCF) [5], although values revealed that the gas turbine and furnace could be
as low as 0.40 mg/m 3 (0.00017 gr/SCF) have been studied parametrically and separately from the steam
suggested, for particles sized 10 p and larger. From system which was subjected to its own parametric in-
data for the typical particulate effluent from a PFBC vestigation. The appropriate match on parametric
[5] it can be deduced that the collection efficiency operating maps could then be accomplished by an en-
must be about 99.7 to 99.9 for particles 10 p and ergy balance on the economizer in which the flue
larger. This performance is certainly pushing the gases are cooled by heating the feedwater stream (see
capabilities of cyclones and as yet development Fig. 1).
efforts for granular bed filters and ceramic panel
filters have met with limited success. Steam System Description
Experience in the Locomotive Development Commit-
tee coal-fired turbine program and that gained with A slightly simplified conventional steam power
power recovery turbines on catalytic cracker units in system was selected for use in the study. The sim-
petroleum refineries has indicated that if the tur- plifications included limiting the number of feed-
bine inlet temperature is reduced, higher dust load- water heaters to five and eliminating auxiliary
ings can be tolerated. This is probably due to the boiler feed pump turbines with complex extraction
greater hardness of the metal and the allowable use schemes. The fundamental parameters for this typical
of harder metals, since corrosion is also reduced at system are itemized in Table I.
the lower temperatures [6,7,8]. Successful operation Although there are numerous schemes for incor-
with turbine inlet dust loadings on the order of 122 porating the economizer into the feed heating stream,
mg/m 3 (0.054 gr/SCF) has been achieved at length the configuration shown in Fig. 2 was found to yield
when the inlet temperature has been below 677 ° C the highest cycle efficiencies of several simple ap-
(1250 ° F) [6]. proaches which were tested. The final feedwater tem-
Fundamental thermodynamic considerations indi- perature varied from case to case depending on the
cate, of course, that the cycle efficiency for a heat available from the gas stream but was not
plant such as shown in Fig. 1 would suffer from allowed to exceed 277 ° C (530 ° F) in any case. The com-
lowering the peak temperature at which work is ex- plexity in analysis arises from the fact that the
tracted from the combustion gases. However, the com- amount of energy available from the turbine exhaust
bined cycle configuration with rather complex inter- to heat the feedwater influences the amount of steam
action between gas and feedwater streams does not extracted, which effects the net steam flow through
lend itself to a trivial analysis. Since the turbine the turbine and remainder of the feed heating train.
inlet temperature is apparently a major factor in the A computer model of the power plant was utilized to
COMBUSTION GAS
FROM TURBINE EXHAUST
ROM
EAERATOR
TO BOILER
OR
FEEDWATER HEATER
38 •
J 37
J
Pressure loss
o
538°C
(1000°F)
Component
kPa psi 36 O AFBC
aExpanded bed depth is 3.66 m Fig. 3 Effects of gas turbine inlet temperature and
(12 ft). pressure ratio on PFBC overall efficiency
COMPRESSOR TURBINE IP LP
COMBI
IEN
CONDENSER
PUMP
40 REFERENCES
870°C
(1600 ° F)
1 J. P. Meyer and M. S. Edwards, Survey of
650 ° C
Industrial Coal Conversion Equipment Capabilities:
= 39
(1200°F) High-Temperature, High-Pressure Gas Purification,
REHEAT ORNL/TM-6072 (June 1978).
U
1593°CF REHEAT
1100
2 D. F. Ciliberti et al., "Particulate Control
z
W_ 38 for Pressurized Fluidized Bed Combustion Processes,"
0 650°C pp. 642-654 in Proceeding of the Fifth International
593°C (1200°F)
LL
Confer-ence on Fluidized Bed Combustion - Volume II,
(1100 ° F)
I- Mitre Corporation, December 1978.
37
3 R. C. Hoke et al., "Miniplant PFBC Studies,"
J
presented at the Pressurized Fluidized Bed Workshop,
a Secaucus, New Jersey, June 5-6, 1979.
4 W. M. Swift et al., "Plans and Studies on
36 O AFBC
0 Flue Gas Cleaning and Particulate Monitoring in
PFBC," pp. 493-521 in Proceedings of the Fifth Inter-
national Conference on Fluidized Bed Combustion -
35
Volume II, Mitre Corporation, December 1978.
5 CFCC Development Program - Advanced Clean-up
Hardware Performance Guidelines for Commercial Plant
(Task 4.1.2), FE-2357-37, (March 1978).
2 4 6 8 10 12 14
6 M. E. Lackey, Summary of the Research and
FAN OR COMPRESSOR PRESSURE RATIO
Development Effort on Open - Cycle Coal - Fired Gas Tur-
bines, ORNL/TM-6253, (October 1979).
Fig. 6 Effect of combustion gas reheat on PFBC 7 J. P. Balfoort, "Power Recovery Systems and
plant efficiency Hot Gas Expanders," published in the Proceedings of
the Third Turbomachinery Symposium, Gas Turbine Lab-
cycle with peak and reheat temperature of 730 ° C oratories, Texas A&M University, College Station,
(1350 ° F) is practically equivalent to the 870 ° C Texas.
(1600 ° F) PFBC non-reheat system in terms of plant 8 L. M. Stettenberg, "The Power Recovery Gas
efficiency. Expander in the Fluid - Bed Catalytic Cracking Cycle,"
The capability of attaining high efficiency presented at the 47th Annual Fall Meeting of the
while mitigating the problems of gas cleanup and tur- Western Gas Processors and Oil Refiners Association,
bine erosion and corrosion through (1) lower inlet Newport Beach, California, October 5-6, 1972.
temperature and (2) single stage turbines is cer- 9 J. H. Kennan and J. Kaye, Gas Tables, John
tainly an improvement over currently envisioned PFBC Wiley & Sons, Inc., New York, 1950.
systems. The cost of this alternate system has not 10 D. G. Shepherd, Principles of Turbomachin-
as yet been estimated. , MacMillan Company, New York, 1956.
11 D. H. Brown et al., ECAS Phase II Final
CONCLUDING REMARKS Report Volume II Advanced Energy Conversion Systems-
Conceptual Designs, Part 2 Closed Turbine Cycles,
The PFBC system has been shown to be a concept NASA-CR134949 Volume II, Part 2 (1976).
in which continuing improvements in technology will 12 A. Wunsch, "Combined Gas/Steam Turbine Power
produce higher fuel efficiency. Even at modest pres- Plants - The Present State of Progress and Future
sure and temperature some improvement over AFBC sys- Developments," Brown Boveri Rev. 10, 646 (1978).
tems and considerable improvement over pulverized 13 D. J. Amos, et al., ECAS Westinghouse Phase
coal systems with scrubbers can be achieved. I Final Report, Volume Combined Gas-Steam Turbine
The optimum pressure at turbine inlet tempera - Cycles, NASA CR 134941 Vol. V (February 1976).
ture has been characterized and is within the capa- 14 D. J. Amos and J. E. Grube, ECAS Westing-
bilities of a variety of types of turbomachinery cur- house Phase I Final Report Volume IV - Open Recuper-
rently in use. The effect of implementing more rug - ated and Bottomed Gas Tur-bine Cycles, NASA CR134941
ged but possibly less efficient turbines was shown to Vol. IV (February 1976).
be significant for the more advanced PFBC systems. 15 R. W. Wolfe, ECAS Westinghouse Phase I Final
A new concept for the PFBC utilizing a gas re- Report - Volume XI - Advanced Steam Systems, NASA CR
heat has been introduced, offering relatively high 134941 Vol. XI (February 1976).
efficiency ("39%) at a conservative peak cycle tem - 16 Roger L. Schonewald, Ingersoll-Rand Re-
perature of 649 ° C (1200 ° F). The concept also pro- search, Inc., personal communication to R. L. Graves,
vides for simple control and use of turbomachines Oak Ridge National Laboratory, June 1979.