REDUCTION OF ATMOSPHERIC POLLUTION
FINAL REPORT ON RESEARCH ON
REDUCING EMISSION OF SULPHUR OXIDES,
NITROGEN OXIDES.AND PARTICULATES
BY USING FLUIDISED COMBUSTION OF COAL
Appendices: (Vol. 2 of 3)
1 -- Experiments with 36-in. combustor
2 -- Experiments with 48x24-in.
pressurized combustor
3 -- Experiments with 27-in. combustor
Environmental Protection Agency,
Office of Air Programs,
Research Triangle Park,
North Carolina 27711
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NATIONAL COAL BOARD
FINAL REPORT
JUNE 1970 - JUNE 1971
REDUCTION OF ATMOSPHERIC POLLUTION
APPENDIX 1. EXPERIMENTS WITH THE 36 IN COMBUSTOR. (TASK I)
PREPARED FOR
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
411 WEST CHAPEL HILL STREET
DURHAM, NORTH CAROLINA 27701
FLUIDISED COMBUSTION
REFERENCE NO. DHB 060971 CONTROL GROUP
SEPTEMBER 1971 NATIONAL COAL BOARD
LONDON, ENGLAND
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REDUCTION OF ATMOSPHERIC POLLUTION
Research on reducing emission of sulphur oxides,
nitrogen oxides and particulates by using
fluidised bed combustion of coal
Appendix 1. Experiments with the 36 in combustor. (Task I)
Main objective
To compare the performance of the 36 in combustor
with that of the 6 in combustors at the N.C.B's
Coal Research Establishment and at the Argonne
National Laboratory, and to extend the range of
operating conditions for which experimental data
is available.
Report prepared by: D.G. Cox and J. Highley
Report approved by: A.D. Dainton and H.R. Hoy
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FOREWORD
This Appendix describes experimental work carried out using
the 36 in combustor at CRE., between June 1970 and June 1971, as
Task I of the joint N.C.B./O.A.P. research programme. The
objective of Task I was to compare the performance of the 36 in
combustor with that of the 6 in combustors at CRE and Argonne,
and to extend the range of operating conditions for which
experimental data is available. Attention is drawn to the main
results obtained, but the results are not discussed here. A
summary of the work is presented in the main report and the
results are discussed there, together with results from other
pilot plants.
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Table of Contents
Page No.
Foreword
1. Description of Plant Al. 1
1.1 The combustor Al. 1
1.2 The fluidising air supply Al. 2
1.3 The cyclones and fines recycle system Al. 3
1.4 Coal and acceptor preparation Al. 3
1.4.1 The Fluostatic plant Al. 3
1.4.2 The Atritor plant Al. 3
1.5 The coal and acceptor feeding systems Al. 4
1.6 The cooling system Al. 4
1.7 Instrumentation Al. 5
2. General Operating Procedures Al. 6
2.1 Plant start-up Al. 6
2.2 Establishment of equilibrium for a test Al. 7
2.3 Plant shut-down Al. 7
2.4 Mass balance procedure Al. 7
2.5 Data processing Al. 9
3. Results A1.13
3.1 Test Series 1 A1.13
3.1.1 Description of Test Series 1 A1.13
3.1.2 Results of Test Series 1 A1.15
3.2 Test Series 2 A1.17
3.2.1 Description of Test Series 2 A1.17
3.2.2 Results of Test Series 2 A1.18
3.3 Test Series 3 A1.20
3.3.1 Description of Test Series 3 A1.20
3.3.2 Results of Test Series 3 A1.21
3.4 Test Series 4 A1.23
3.4.1 Description of Test Series 4 A1.23
3.4.2 Results of Test Series 4 A1.24
3.5 Test Series 5 A1.26
3.5.1 Description of Test Series 5 A1.26
3.5.2 Results of Test Series 5 A1.27
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Page No.
3.6 Test Series 6 A1.29
3.6.1 Description of Test Series 6 A1.29
3.6.2 Results of Test Series 6 A1.30
4. Acknowledgement A1.32
Tables A.1.1.1 to A.1.1.21 Results of Test Series 1
Tables A.1.2.1 to A.1.2.16 Results of Test Series 2
Tables A.1.3.1 to A.1.3.19 Results of Test Series 3
Tables A.1.4.1 to A.1.4.18 Results of Test Series 4
Tables A.1.5.1 to A..1.5.18 Results of Test Series 5
Tables A.1.6.1 to A.1.6.18 Results of Test Series 6
Figures A.1.1 to A.1.8 Details of plant design
Figures A.1.1.1 to A.1.1.16 Results of Test Series 1
Figures A.1.2.1 to A.1.2.7 Results of Test Series 2
Figures A.1.3.1 to A.1.3.10 Results of Test Series 3
Figures A.1.4.1 to A.1.4.9 Results of Test Series 4
Figures A.1.5.1 to A.1.5.8 Results of Test Series 5
Figures A.1.6.1 to A.1.6.9 Results of Test Series 6
(Note that when referring to Tables and Figures in the text the
prefix A.I is omitted).
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1. DESCRIPTION OF PLANT
A general flow diagram of the 36 in combustor plant is given
in Fig. 1.
1.1 The combustor
The design and dimensions of the combustor are shown in
Fig. 2. The combustor comprised a mild steel shell, 4 ft 6 in
square cross-section, fabricated in five sections. The combustor
was supported at the centre section in order to permit the upper
or lower sections to be removed for maintenance or modification.
The upper four sections were refractory lined to give an internal
cross-section of 36 in by 18 in. (The cross-section was originally
36 in square, but was reduced to allow operation at higher
velocities with the existing air supply and cooling system).
The first section contained a stainless steel plenum chamber,
36 in square cross-section, 33 in high, to which the air distributor
was bolted, Fig. 2. The plenum chamber was surrounded by loose
fill insulation. A 3 in diameter bed ash offtake pipe passed down
through the centre of the plenum chamber and terminated in a rotary
valve.
The air distributor comprised a mild steel plate with 72 stand
pipes on a 3 in square pitch in the central 36 in by 18 in area.
The stand pipes were $ in outside diameter stainless steel, 3$ in.
long, and having four 0.147 in diameter holes drilled horizontally
3 in above the base plate. The distributor was designed to give a
pressure drop of 10 in water gauge at a fluidising velocity of
4 ft/s, i.e. about 50% of the pressure drop of a 2 ft deep bed.
The second section, the boiler, contained the fluidised bed,
the coal and additive feed lines, the fines recycle line and the
cooling tubes. The coal and additive were fed through adjacent
1 in inside diameter pipes extending 7 in into the bed such that
the feed could be considered as at the centre. The height from
the air jets to the feed lines was 5 in. Preliminary tests in
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the 12 in corrosion rig, Task IV had demonstrated that coking
of Pittsburgh coal could occur in the bed section of the coal
feed line if this was uncooled. In order to prevent this
occurring, a water jacketed coal feed-line was used. The
primary fines were recycled via a. 3 in diameter line which
entered the. boiler section opposite the feed lines and extended
3/4 in into the bed. The boiler section, usually contained a
.bed ash sampling..probe, 6 thermocouples and. 3 pressure probes
arranged as in Fig. 3.
There were 14 cooling tubes installed in the boiler section,
arranged on a k{ in triangular pitch as shown in Fig. 2. The
tubes were 2 in inside diameter, 2| in outside diameter stainless
steel and were sealed at one end, with an inner 1 in inside
diameter tube. This design allowed all the associated pipework
to be on one face of the combustor. The tubes were connected in
series.
The two sections above the support section contained gas
sampling points, thermocouples, pressure probes and steam
injection lines, as shown in Fig. 3. The gas offtake was a 12 in
diameter pipe from the top of the reactor.. There were also two
bursting discs for explosion relief in the top section. Fresh bed
material was fed pneumatically to a point in the fourth section.
The total height from the distributor air jets to the gas
offtake was 15 ft.
1.2 The fluidising air supply
The arrangement of the air supply is shown in Fig. 1.
2
Air was taken from the 100 Ib/in gmains supply and the pressure
2
reduced to 45 lb/ingfor flow measurement. In normal operation,
without the hot gas generator, the total flow rate of air to the
combustor was measured and then the coal and additive transport
air were diverted from the fluidising air. For start-up there was
an additional primary air line to the hot gas generator and part
of the main air supply was fed to the generator as secondary air.
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1.3 The cyclones and fines recycle system
The off-gas from the combustor passed through lagged 12 in
diameter ducts to the primary and secondary cyclones and then to
the stack. The primary cyclone was manufactured from stainless
steel and was 24 in in diameter and 8 ft 10 in high. The gas
inlet velocity was 37-75 ft/s at 4-8 ft/s fluidising velocity
and the collection efficiency is shown in Fig. 4. The
secondary cyclone, also of stainless steel was 171 in in
diameter and 6 ft 7 in high and had a gas inlet velocity of
75-150 ft/s. The collection efficiency is also shown in
Fig. 4. The primary cyclone fines passed down a vertical line
to either the fines recycle injector or to a collecting drum.
An incremental sampler was installed in the line immediately
above the collection drum. The secondary cyclone fines were
discharged directly into a sealed sample pot.
1.4 Coal and acceptor preparation
1.4.1 The Fluostatic drier/sample house crusher system
The coal for Task 1 was prepared using the Fluostatic/sample
house system shown in schematic form in Fig. 5. The coal, as
supplied, was fed through a roll crusher which produced a top size
of 3/8 in. This was fed, by a screw feeder, into a Fluostatic
fluidised bed drier operating at a fluidising velocity of 12 ft/s.
The elutriated fines were collected in a cyclone and pneumatically
conveyed together with bed overflow material, to an intermediate
hopper. From there the coal was fed to a vibrating screen of the
appropriate size, £ in or 10 B.S. mesh (1680 ym). The oversize
was fed to a hammer mill and then recycled to the screen. Coal
transport in this section of the plant was by screw feeders. The
prepared coal from the screen was conveyed pneumatically either to
the 36 in combustor coal hopper or to a storage hopper. The
throughput of the plant was 2 tons per hour.
1.4.2 The Atritor plant
The limestones and dolomite for Task 1 were prepared using
the Atritor plant, shown in schematic form in Fig. 6. The stone,
A1.3
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as supplied, was loaded into the feed hopper by an elevator. It
was then metered by a rotary table into a disperse phase drier
and carried by the hot gas to the Atritor mill, which was a disk
attrition mill. The gas also passed through the mill and
transported the stone to a cyclone where it was separated. The
stone passed to a vibrating screen of the appropriate size, J in
or 10 B.S. mesh (1680 ym), and the oversize, about 10%, was
recycled to the feed hopper. The prepared stone was collected
in drums. The throughput of the plant was $ ton per hour.
1.5 The coal and acceptor feeding systems
The arrangement of the coal and acceptor feeding systems is
shown in Fig. 1. The basic design of the three systems was
identical. The solids flowed by gravity into the rotary valve
which metered the supply into an air stream. The feed rate was
determined by the size and the number of pockets in the rotary
valve and the speed of rotation. A pressure balancing line
connected the coal transport line to the hopper top in order to
prevent backflow of air through the rotary valve. Both the coal
and acceptor feed lines incorporated a diverter valve and sample
vessel. The sampling systems were designed to allow an
uninterrupted flow of transport air. The capacities of the
hoppers and the range of feed rates available were:-
Capacity Feed rates
Coal hopper 10 ton 40 - 400 Ib/h
Large acceptor hopper 5000 Ib 20 - 200 Ib/h
Small acceptor hopper 1000 Ib 10 - 70 Ib/h
1.6 The cooling system
The cooling system is shown in Fig. 1. The steam leaving
the tubes in the bed was desuperheated by a water spray, condensed,
and recycled to the bed tubes and desuperheater spray. The water
used in the cooling system was de-ionised and de-oxygenated.
A1.4
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1,7 Ins trumentation
The plant was well automated and was operated by a pneumatic
system from a central control room.
The air and gas flow rates were measured by orifice plate
units. The solids feed rates were determined from the rotary
valve speed of rotation, using the results of calibration tests.
The;output 'solids were collected and weighed. The fines recycle
rate was calculated from (the temperature drop in the fines due to
a cooling coil on the recycle line. Pressures were measured by
open-ended" 3/16 in diameter probes maintained clear by a nitrogen
bleed. Temperatures were measured- by 'Pyrotenax' sheathed chromel/
alumel thermocouples * The flow rates, pressures and 'temperatures
were--recorded on' a punched tape data logger in addition to being
recorded1 or indicated on the control panel-J
1 The bed height was calculated from the ratio of the total
bed pressure-drop to pressure--drpp across 8 in of the bed. The
height was normally controlled automatically by a pressure ratio
controller operating the ashjofftake rotary valve.
The water flow rate to the cooling tubes could be controlled
either manually or by an automatic controller which adjusted the
flow to maintain a set bed temperature.
A continuous gas sample was extracted 5 ft after the
secondary cyclone for SCL determination by an infra-red analyser
(IRA) , The SO £ concentration was indicated and recorded on the
control panel. Gas samples were taken at a probe 4 ft after the
cyclone for S0_ determination by other methods, and for measurement
of other constituents, as described in Section 2.4. The SO
concentrations indicated by the infra-red analyser were found to
be consistently about 12% below the mean values obtained by the
iodinej method, Fig. 8»
A1.5
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2. GENERAL OPERATING PROCEDURES
2.1 Plant start-up
Before start-up, the plant services were checked and the
solids rotary feed valves were calibrated for the particular coal
and acceptor to be used. The combustor was heated by passing
hot gas through the fluidising air system; the hot gas was
produced by burning natural gas and then moderating the tempera-
ture to 1300°F by additional air. The starting bed material was
fed to the combustor when the exit gas temperature was about 300°F
and the coal was fed when the bed temperature had risen to 850 F.
As the temperature increased, the fluidising air flow was reduced
manually in order to prevent the fluidising velocity exceeding
that for the first test condition. A low water flow was maintained
through the cooling tubes once the coal feed was started, in order
to purge nitrogen from the cooling system. As the bed temperature
approached that required for the first test, the water flow was
changed to automatic control to maintain the set temperature. The
air and coal feed rates were then adjusted to the required values
for the first test and acceptor feed was started, if required.
This start-up procedure was normally completed in about 8 hours.
2.2 Establishment of equilibrium for a test
Once an operating condition was established, the plant was
operated under automatic control until equilibrium was reached.
For the purposes of the present work this was defined as being
a condition at which three successive S02 determinations by the
iodine method, taken at intervals of i h, were in agreement.
If a mass balance was not to be carried out, for example when
determining the datum SO- concentration at the start of each
test series, the plant data sheets were then completed and
temperatures, pressures and flow rates were recorded on the
data logger.
For Test Series 2 to 6, the specified operating condition
was that the concentration of oxygen in the off gas should be
A1.6
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2.5 to 3.5%o Because of this it was necessary to correct any
variation in oxygen concentration during the stabilising period
by adjusting the coal feed rate, which of course, also
necessitated adjusting the additive feed rate. The time required
to reach equilibrium conditions was about 6 hours.
2.3 Plant shut-down
The normal manual shut-down procedure was used throughout the
A.P.C.O. programme; there were no emergency shut-downs due to
power failures, etc. The coal feed rate was stopped and the bed
temperatures reduced to 750 F over a period of 2 hours in order
to avoid thermal shock to the bed tubes. The air flow rate was
increased in order to maintain the fluidising velocity as the bed
temperature fell. Coal and acceptor transport air were continued
to prevent blockage of the lines. The bed material was then
discharged into drums and the fines collection pots were emptied.
When the cooling system temperature fell below 212 F the
circulating pump was stopped and nitrogen was admitted to relieve
the vacuum. The fluidising air was stopped and the services were
shut off. Finally all the collecting pots and rodding-points
were emptied to avoid contamination of the next run.
2.4 Mass balance procedure
The equilibrium conditions were maintained for a minimum
of A hours and during this time sufficient samples were taken to
carry out a balance. The only exception was during the latter
tests of Series 3 when shortage of time necessitated a reduction
to 3 hour periods.
At the start of each balance a sample of bed ash of approx.
1 Ib was taken to determine the chemical and size analysis of the
initial bed. The apparatus used is shown in Fig. 7. A second
bed ash sample was taken upon completion of each balance to give
the final bed conditions. When possible an offtake ash sample
was also taken to give supporting information regarding the bed,
but this sample was only a spot sample of about 10 Ib and was
A1.7
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obviously only possible when there was an overflow of ash.
The primary fines were sampled throughout the balance using
an incremental sampler designed to take a full cross-sectional
sample of the entire fines flow. Twenty increments were taken
each hour of the balance and the hourly samples bulked to give
one sample of about 40 Ib. This quantity was then reduced by
rotary divider to give a representative sample of about 1 Ib.
The entire output of secondary fines was collected during each
balance and was likewise reduced by rotary dividing to give a
1 Ib sample. Samples of exhaust dust were obtained from a probe
4 ft after the secondary cyclone by extracting isokinetically
a known volume of exhaust gas and passing it through a weighed
filter. Four such dust samples were taken over the balance
period and these were combined to give one sample for analysis.
Coal and additive were sampled directly from the input lines
immediately before each balance. In Test Series 1 the samples
were bulked to give an incremental sample for the week, but in
all other series samples were retained for each test.
Gas samples were taken at two probes in the vertical
line from the secondary cyclone, 4 and 5 ft above the cyclone
respectively. The upper probe was used only for the infra-red
SO- analyser, and a continuous record was obtained. The lower
probe was used for all other gas analyses, as follows:
(a) Samples were taken in evacuated vessels for analysis
of 0_, CO,,, CO and CH, by chromatograph. A minimum of
two such samples were taken during the mass balance.
The minimum level of detection of CO and CH, was 0.02%,
(200 p.p.m.)
(b) By means of a vacuum pump, gas was bubbled through a
solution of iodine for SO,, determination. The volume
of gas required to decolourise a solution of known
concentration was recorded. A determination of SO
by this method was carried out every half hour.
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(c) Samples were taken for determination of NO by Saltzman's
X
method by bubbling gas through distilled water, to remove
SO-, and then passing through a sample bottle. The sample
was taken after allowing sufficient gas to purge air from
the system. Two samples were taken for NO during tests
X
in Test Series 4, 5 and 6.
(d) By means of a vacuum pump, gas was bubbled through a
solution of hydrogen peroxide except when carrying out
(a), (b) and (c) above. The solution was analysed for
S02, Cl and NH3<
Throughout the balance, at hourly intervals, all solid
products were weighed and plant data sheets completed, In
addition the feed rates of coal, acceptor and air, the plant
temperatures and pressures were recorded hourly on the data
logger,
2.5 Data processing
The data logger tape from each test was processed by
computer to calculate the mean feed rates, plant temperatures
and pressures for the mass balance period. The feed rates,
measured solids output rates and chemical analyses of the input
and output streams were then used to calculate by computer the
mass balances.
The major factor in the mass balance which was not measured
was the flow-rate of flue gas, which it was necessary to estimate.
Since the gas analysis was carried out on a dry volume basis, the
dry volume was estimated rather than mass flow-rate of flue gas.
The estimate was obtained by correcting the feed air flow-rate
for the volume changes which occurred due to the following
reactions:-
(i) 4H (coal) +
(ii) 20 (coal)
(iii) 2C + 0
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(iv) Mg C03 K MgO + C02
(v) CaC03 >- CaO + C02
(vi) CaO
The volume changes due to (i) and (ii) were calculated
assuming that all the hydrogen and oxygen in the coal were
released. The increase due to (iii) was calculated from the
measured concentration of CO in the flue gas. With limestone
the net effect of (v) and (vi) was small and this was usually
neglected. Thus for tests without acceptor and most tests with
limestone the flue gas flow-rate was calculated as:
_, ,, Air + 379 x Coal Feed Rate x (0 Content/32- H Content/4)OOT,T1
Flue gas flow-rate (1 - 0.5 x CO in Flue Gas) SCF*
For tests with dolomite, and also for Test 5.4 with limestone, the
volume changes due to (iv), (v) and (vi) were also taken into account.
The following mass balances were carried out:-
(i) Total In this, mass flow-rate of dry flue gas was calculated
from its composition and a hydrogen balance was
assumed. For Test Series 4 and 6 with dolomite and
Test 5.4 at a Ca/S ratio of 6, the CO- from
calcination was added to the flue gas rate as calcu-
lated above.
(ii) 'Ash' This is a balance for the inorganic solids, i.e. ash
and acceptor. No allowance was made for the weight
changes due to calcination of CaCO, (except in Test 5.4)
and formation of sulphate. Where dolomite was used,
Test Series 4 and 6, it was assumed that the MgCO_ was
completely calcined and the equivalent calcined product
rate was used in the balance.
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'Car-an
(iv)
(v)
Nitrogen
'Oxygen*
(vi) Sulphur
(vii) Calcium
(viii) Magnesium
Thi.s I* a valasce £o£ Eha dfgaSie carbon in
coal and is directly relevant to the combustion
process. Allowance was made for the CO. in the
flue gas arising from calcination only in the
tests with dolomite and in Test 5.4.
This balance serves as a check on the accuracy
of the flue gas analysis.
This is a balance for the oxygen in the air and
the organic oxygen in the coal. It is directly
relevant to the combustion process. Allowance was
made for the oxygen as CO- from calcination only
in tests with dolomite and Test 5.4.
This is a balance for the total sulphur content of
the coal, using the mean SO- concentration
measured by the iodine method.
This is a balance for the total calcium in the coal
and acceptor.
This is a balance for the magnesium in the acceptor
and was carried out only for tests with dolomite.
The following parameters were calculated from the flow rates in
the mass balance:-
(i) Excess air level, defined as:
Excess air = Feed *ir." Stoichip-metric air for coal feed rate
Stoichiometnc air for coal feed rate
(ii) Carbon loss, defined as:
Unburnt carbon output rate
Carbon loss
Total carbon output rate
x 100%
The carbon loss is based on the total measured carbon output
rate since this is considered to be a more accurate estimate of the
carbon input rate than that based on the coal feed rate and chemical
composition.
(iii) Sulphur retention, defined as:
Sulphur retention = Jl - hur in f lu
^ C
..
Total sulphur input)
x 100%
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(iv) Ca/S mol ratio, defined as:
Mols of Ca in additive feed
Ca/S mol ratio
Mols of S in coal feed
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3. RESULTS
3.1 Test Series 1
The objective of the test series was to obtain data on the effects
of bed temperature and Ca/S mol ratio on sulphur dioxide emission with
Pittsburgh coal and American limestone. The intended nominal operating
conditions were:
Coal Pittsburgh, prepared to - 10 BS mesh
Acceptor Limestone 18, prepared to - 10 BS mesh
Ca/S mol ratio 0,1,2 and 3
Fluidising velocity 3 and 4 ft/s
Bed temperature 1380, 1470 and 1560°F
Bed depth . 2ft
Excess air 10 to 20%
Fines recycle System not in operation
3.1.1 Description of Test Series 1
The tests series was sub-divided into three sections, each comprising
one week of plant operation, as follows:
3.1.1.1 Test Series 1.1
The objective for Test Series 1.1 was to carry out an extended test,
without limestone addition, at a fluidising velocity of 4ft/s and a bed
temperature of 1470 F.
The test series was carried out from 19 to 21 November, 1970. The
plant was started up using an initial bed of Newdigate shale prepared
to have a top size of 1/16 in. The required operating conditions were
maintained for 26 hrs and a four hour mass balance designated Test 1.1
was carried out towards the end of this period.
The water cooled coal feed inlet for the coking coal, which was
in use for the first time, functioned satisfactorily.
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During the test series gas samples were withdrawn for S0£ analysis
by the iodine method both after the cyclones and at three positions in
the freeboard cross-section at 22 in above-the bed surface (shown in
Fig. 3). Some difficulty was experienced with air leaks into the
sampling system and following this test series, the sampling probes were
modified and the air leaks eliminated in subsequent test series.
3.1.1.2 Test Series 1.2
The objective for Test Series 1.2 was to determine the optimum
bed temperature for subsequent experimental work.
The test series was carried out from 17 to 19 December, 1970. The
plant was started up using ash from Test Series 1.1 together with about
10% of fresh Newdigate shale. A test was carried out without limestone
addition at 4 ft/s and 1470°F, Test 1.2, which was followed by three
tests, Tests 1.3, 1.4 and 1.5 with limestone addition at a Ca/S mol
ratio of 2 and bed temperatures of 1470, 1380 and 1560°F respectively.
In the period between Tests 1.2 and 1.3, there was a coal feed blockage
and it was necessary to slump the bed for a period of two hours in order
to clear the line. On re-starting it was necessary to add 70 Ib of
shale to re-establish a 2 ft bed.
The limestone feeding system was used for the first time in this
test series and no difficulties were encountered apart from a blockage
of short duration prior to Test 1.5. The continuous infra-red SO?
analyser was also commissioned during the test series. The initial
results from this did not agree with those obtained by titration with
iodine solution and were obviously low. Between Tests 1.3 and 1.4 a
heater was fitted between the sample point and the instrument. This
modification immediately gave rise to higher S02 reading, but even so
in this, and all subsequent tests, the infra-red analyser gave values
about 12% below the mean result obtained by the iodine method. Fig. 8
compares the S02 concentrations using the two methods from this test
and all subsequent test series.
A1.14
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3.1.1.3 Test Series 1.3
The objectives for Test Series 1.3 were to obtain data on the
effect of the Ca/S mol ratio on sulphur dioxide emission at a fluidising
velocity of 4 ft/s with a bed temperature of 1560°F and to operate at
3 ft/s with a bed at 1470°F in order to allow direct comparison with data
from the 6 in combustor, Task V.
The test series was carried out from 11 to 15 January, 1971. The
plant was started up without limestone addition using an initial bed of
Newdigate shale prepared to have a top size of 1/16 in. When steady
operating conditions were achieved at 4 ft/s, 1560°F, the datum S02
concentration without additive was recorded. Limestone addition was
then started and Tests 1.6, 1.7 and 1.8 were carried out at
stoichiometric ratios of 1, 2 and 3, respectively. The limestone feed
rate was reduced back to a ratio of 1 and a further test, Test 1.9,
was carried out.
The bed was removed and a new bed of shale was established. The
plant was re-started at 3 ft/s, 1470 F without limestone addition and
the SOo concentration was recorded. Tests 1.10 and 1.11 were then
carried out with limestone addition to give stoichiometric ratios of
1 and 2, respectively.
Inspection of the combustor interior after the test series revealed
a split, about 1 in long, in one of the bed temperature control tubes.
There was no means of determining when this damage had occurred.
3.1.2 Results of Test Series 1;
The experimental operating conditions through Test Series 1 are
summarised in Table 1.1. The input and output size distributions and
chemical analyses are detailed, in Tables 1.2 to 1.8. The flue gas
analyses are given in Table 1.9, with the variation in the S02
concentration with time plotted in Figures 1.1 to 1.14. Mass balances
and calculated operating parameters are given in Tables 1.10 to 1.20.
The pressure drops and temperature distributions through the plant are
in Tables 1.21 and 1.22 respectively. The positions of the thermo-
couples in the combustor during the test series are given in Fig. 1.15.
A1.15
-------
The carbon loss data, Tables 1.10 to 1.20, indicate that without
fines recycle the combustion efficiency at 4 ft/s was about 92%,
independent of bed temperature in the range 1380 to 1560°F. Because of
this, the oxygen concentration in the off-gas at 10% excess air was
about 3.5%. The off-gas temperature, shown in Table 1.22, was
unaffected by bed temperature, indicating that more combustion was
occurring in the freeboard at the lower temperatures. Between 5 and
10% of the total heat release occurred in the freeboard. (The lower
off-gas temperature in Test 1.2 is probably due to the refractory of
the freeboard not being at an equilibrium temperature). The combustion
efficiency at 3 ft/s was not significantly different from that at
4 ft/s, but the off-gas temperature was lower, indicating that a higher
proportion of the combustion was occurring within the bed.
The bed temperature was uniform to within about - 10°F, but there
was a .tendency for the maximum temperature to be recorded at the
thermocouple 8~in above the coal feed point, Table 1.22.
The results from datum tests 1.2, and those prior to tests 1.6 and
1.10 (Tables 1.9a to 1.9d) show that over the range 3-4 ft/s fluidising
velocity did not affect sulphur release. The low value for Test 1.1
was due to the feed coal having a lower sulphur content than in
subsequent tests.
The reductions in SO- emission with addition of limestone 18 are
given in Table 1.23 and the results are plotted against the added Ca/S
mol ratio in Fig. 1.16. The curves show that increasing the Ca/S ratio
reduces the emission of SO-. The additive is somewhat more effective
at 3 ft/s than at 4 ft/s but corisiderably less effective at 1380°F than
at 1470 and 1560°F
The gas samples taken 2 ft above the bed surface showed a marked
radial S0£ concentration gradient, Fig. 1.1.
Centre 2800 p.p.m.
6 in radius 1750 p.p.m.
12 in radius 14000 p.p.m.
In comparison, the concentration at the stack was 1750 p.p.m.
A1.16
-------
3.2 Test Series 2
The objective of the test series was to obtain data on sulphur
dioxide emission with Pittsburgh coal at a fluidising velocity of
8 ft/s, using coarser coal and limestone size distributions and at
4 ft/s, using fine limestone with recycle of-the elutriated fines.
The intended nominal operating conditions were:-
Coal Pittsburgh, prepared to - ^ in.
Acceptor Limestone 18 prepared to - 4 in and
- 120 B.S. mesh.
Ca/S mol ratio 0, 1, 2 and 3.
Fluidising velocity 4 and 8 ft/s.
Bed temperature 1560°F.
Bed depth 2 ft.
Flue gas oxygen 2.5 to 3.5%.
Fines recycle System in operation for a single
test with - 120 mesh limestone.
3.2.1 Description of Test Series 2
The test series was carried out from 26th to 29th January, 1971.
The plant was started up without limestone addition using an initial
bed of Newdigate shale prepared to have a top size of £ in. When the
operating conditions were steady at a fluidising velocity of 8 ft/s, .
the datum S02 concentration without additive was recorded. Tests 2.1,
2.2 and 2.3 were then carried out with addition of the - 4 in limestone
to give stoiehiometric ratios of 1, 2 and 3 respectively. The bed was
replaced by fresh - £ in shale and the plant restarted at a fluidising
velocity of 4 ft/s. After 12 hours operation the S02 concentration
was constant and was recorded as the datum. The -120 B.S. mesh lime-
stone was then fed to give a stoiehiometric ratio of unity for Test 2.4.
During the following 15 hours it was necessary to adjust the coal feed
rate occasionally in order to maintain the required oxygen concentration
of 25% to 36% above the bed. These adjustments delayed the start of
the mass balance which was eventually carried out 27 to 31 hours after
the restart.
A1.17
-------
The limestone feed rate was then increased to give a
stoichiometric ratio of 2, but continuous difficulty was experienced
in feeding the limestone and despite changes in operating procedure,
the feed rate was variable to the point of complete stoppage. After
14 hours it was decided to discontinue the programme and to attempt
a short test at a fluidising velocity of 3 ft/s and a stoichiometric
ratio of 1, in order to allow direct comparison with Task V. This
condition was successfully maintained for about 2 hours and is
designated Test 2.5, although no mass balance was carried out.
On removal of the fine limestone rotary valve after shut-down,
it was found that there was a partial blockage caused by damp
limestone. This accounted for the erratic feed rate obtained. The
source of the water was thought to be the nitrogen bleeds around the
hopper outlet.
NOy determinations were carried out during the datum test and
Tests 2.1 and 2.2 by staff from BCURA using Saltzmanb method.
3.2.2 Results of Test Series 2
The experimental operating conditions through Test Series 2 are
detailed in Table 2.1. The input and output size distributions and
chemical analyses are detailed in Tables 2.2 to 2.8 and the flue gas
analyses in Table 2.9, with the variation in the 862 concentration
with time plotted in Figures 2.1 to 2.5. Mass balances and
calculated operating parameters are given in Tables 2.10 to 2.13.
The pressure drops and temperature distributions through the plant
are shown in Tables 2.14 and 2.15 respectively. The positions of the
thermocouples in the combustor during the test series are given in
Fig. 2.6.
The combustion efficiency without fines recycle in the tests at
1560 F, at a fluidising velocity of 8 ft/s was about 87% for the mean
excess air level of 3% which is lower than the efficiency of 92%
obtained at 4 ft/s with 10% excess air in Test 2,4 and in Test Series 1.
The lower excess air level at 8 ft/s was necessary in order to achieve
the specified oxygen concentrations. The steam injection rate to the
freeboard necessary to limit the off-gas temperature indicates that a
A1.18
-------
higher proportion of the combustion was occurring in the freeboard
during tests at 8 ft/s, Table 2.15.
At 8 ft/s there was a hot spot in the bed-above the coal feed
point, 60°F above the mean bed temperature at a point 8 in above the
feed, thermocouple N4, Table 2.15. The maximum temperature difference
between this point and the coolest point in the bed was 100 F.
The reductions in S02 emission achieved with the limestone 18
are given in Table 2.16 and plotted against the Ca/S mol ratio in
Fig. 2.7. Comparison with Fig. 1.16 shows that there is about 20%
less reduction in emission at 8 ft/s than at 4 ft/s. The reduction
with 120 B.S. mesh (-125 ym) stone at 3 and 4 ft/s is close to that
obtained with 10 B.S. mesh (-1680 ym) stone in Test Series 1, i.e.
grinding the limestone more finely had no significant effect.
The mean NOx emission without limestone was 424 p.p.m.,
Table 2.9. The NOx emission increased to 470 p.p.m. with limestone
addition at.-a Ca/S of 1.1, and increased further to 515 p.p.m. at a
Ca/S of 2.3.
A1.19
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3.3 Test Series 3
The objective of the test series was to obtain data on sulphur
dioxide emission with U.K. Welbeck coal and U.K. limestone. The
intended nominal operating conditions were:
Coal U.K. Welbeck prepared to -£ in.
Acceptor . U.K. limestone prepared to -$ in.
Ca/S mol ratio 0, 2 and 3.
Fluidising velocity 4 and 8 ft/s.
Bed Temperature 1560°F
Bed Depth . 2 and 4 ft.
Flue-gas oxygen 2.5 to 3.5%
Fines recycle System in operation for a single test
at 4 ft/s.
3.3.1 Description of Test Series 3
The test series was carried out from 15 to 19th February, 1971.
The plant was started up without limestone addition using an initial
bed of Newdigate shale prepared to have a top size of £ in. Since
a new coal was being used a complete mass balance was carried out
without limestone addition, Test 3.1. This was carried out at 8 ft/s
with a 2 ft deep bed. The bed temperature control during the test
was poor, varying within -25° of the set value, and this was thought
to be due to an erratic coal feed rate. Consequently, before continuing
with the program the plant was shut down to allow the coal feed system
to be dismantled and checked. The plant was restarted after a delay of
12 hours and subsequently the temperature .control was better. Test
3.2 was carried out with limestone addition at a stoichiometric ratio
of two, but the limestone feed rate in this test was erratic.
Subsequently, the limestone feed valve rotor was replaced and a
further test was carried out at the same nominal operating conditions,
Test 3.3. The limestone addition rate was then increased to a
stoichiometric ratio of three for Test 3.4.
After this test was completed an additional experiment, not
in the original programme was carried out. It had been noticed,
during the period when the bed temperature was varying, that the
S02 concentration indicated by the infra-red analyser was also
A1.20
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varying in phase. The apparent rapid response to temperature was
investigated by increasing the bed temperature to 1630°F decreasing
to 1470° and increasing back to 1560 during a period of 1 hour.
Fresh shale was added to the bed to give a bed height of 4 ft
for Test 3.5. In this and the subsequent test, the mass balance period
was reduced to 3 hours because of the low stock of prepared coal
remaining. For the final test, Test, 3.6, the bed height was reduced
to 2 ft and the fluidising velocity was 4 ft/s. There was insufficient
of the prepared coal available to carry out the scheduled test with
fines recycle.
3.3.2 Results of Test Series 3
The experimental operating conditions through Test Series 3 are
summarised in Table 3.1. The input and output size distribution
and chemical analyses are detailed in Tables 3.2 to 3.8 and the flue
gas analyses in Tables 3.9, with the variation in the SOn concentration
with time plotted in Figures 3.1 to 3.7. Mass balances and calculated
operating parameters are given in Tables 3.10 to 3.15. The pressure
drops and temperature distributions through the plant are in Tables
3.16 and 3.17 respectively. The positions of the thermocouples in
the combustor during the test series are given in Fig. 3.8.
The mean combustion efficiency in these tests with Welbeck coal
at 8 ft/s was 89%, a slight improvement over the 87% obtained in Series 2
for Pittsburgh coal. Thus a lower coal feed rate could be used to attain
the specified oxygen concentrations, giving a mean excess air level of
7% in comparison with 3% in Series 2.
The bed .temperatures were more uniform than with Pittsburgh coal
and there was no 'hot spot' above the coal feed. Even so there were
differences of about 40°F between maximum and minimum temperatures
within the bed.
The reductions in S0« emission are given in Table 3.18 and
are plotted against the Ca/S mol ratio in Fig. 3.9. The result of
Test 3.2 has been neglected in drawing the curve in Fig. 3.9 because
it appears to be in error. The reduction at 8 ft/s is about 5% less
than that obtained with Pittsburgh coal and U.S. limestone in
A1.21
-------
Test Series 2. The single result at 4 ft/s is low in comparison with
those in Series 1. The SC>2 emission was not affected when the bed
height was increased from 2 ft to 3.8 ft.
The variation of S02 concentration during the bed temperature
survey is shown in Fig. 3.5. The SC^ concentration responded almost
immediately to a change in bed temperature. The SC^ reductions during
the survey are given in Table 3.19 and plotted in Fig. 3.10. The
datum SC>2 concentration measured by the IRA was surprisingly high, and
was not used. Instead, a datum value was calculated as 12% below the
concentration obtained by the iodine and 1^02 methods, i.e. allowing
for the usual instrument off-set. There appears to be an optimum
temperature for S02 reduction of about 1450°F and the reduction falls
rapidly as the temperature is increased.
A1.22
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3.4 Test Series 4
The objective of the test series was to determine the effects of
bed temperature, Ca/S mol ratio and fluidising velocity on sulphur
dioxide emission when using dolomite as additive. Also, tests were to
be carried out under conditions closely resembling those used in Task II,
in order to make a direct comparison between pressurised and unpressurised
operation. The intended nominal operating conditions were:
Coal Pittsburgh prepared to - 10 B.S. mesh.
Acceptor Dolomite 1337 prepared to - 10 B.S. mesh.
Ca/S mol ratio 0, 1 and 2.
Fluidising velocity 2 and 4 ft/s.
Bed Temperature 1380, 1470 and 1560°F.
Bed depth 2 and 4 ft.
Flue-gas oxygen 2.5 to 3.5%.
Fines recycle System in operation for a single test at 2 ft/s
3.4.1 Description of Test Series 4
The test series was carried out from 2 to 5 March, 1971. The plant
was started up without limestone addition using an initial bed of Newdigate
shale prepared to have a top size of 1/16 in. When the operating conditions
were steady at a fluidising velocity of 4 ft/s and a temperature of 1470°F,
the datum S02 concentration without additive was recorded. Tests 4.1,
4.2 and 4.3 were then carried out with dolomite addition at a
stoichiometric ratio of 2 and temperatures of 1470, 1380 and 1560 F
respectively.
The bed temperature was then changed to 1470°F and the alternative
dolomite feed system was brought into operation for tests at a nominal
stoichiometric ratio of 1. Test 4.4 was carried out at a fluidising
velocity of 4 ft/s. Shale was then added to increase the bed height to
4 ft and the fluidising velocity was decreased to 2 ft/s for the first
of the tests at the pressurized combustor operating conditions, Test 4.5.
The S02 levels in Tests 4.4 and 4.5 were considerably lower than had
been expected and it was suspected that the dolomite feed rate was in
error. Consequently, the dolomite feed was diverted from the bed, in
order to measure its rate and it va.s found to be alir.ost double that intended.
A1.23
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The reason for this higher rate through the rotary valve than in the
pre-test calibration is not known. After several re-calibration checks
over a range of rotary valve rotation rates it was confirmed that the
feed rates were consistently higher than before.
The limestone feed line was re-connected'to the bed and a final
Test 4.6, was carried out at 2 ft/s with the fines recycle system in
operation. About 400 Ib of fines had to be added to the bed in order
to establish the recycle flow.
Test Series 4 was the first in which NOjj determinations were
made by CRE staff. Samples were taken after the cyclones and Saltzman's
method was used.
3.4.2 Results of Test Series 4
The experimental operating conditions throughout the series are
detailed in Table 4.1. The input and output size distributions and
chemical analyses are given in Tables 4.2 to 4.8 and the flue gas
analyses in Table 4.9, with the variation in the S02 concentration
with time plotted in Figures 4.1 to 4.7. Mass balances and calculated
operating parameters are given in Tables 4.10 to 4.15. The pressure
drops and temperature distributions through the plant are given in
Tables 4.16 and 4.17 respectively. The positions of the thermocouples
in the combustor during the test series are given in Fig. 4.8.
The combustion efficiency without fines recycle at 4 ft/s was
about 91% and was independent of bed temperature; this is in good
agreement with the result in Test Series 1. There was no significant
improvement on decreasing the velocity to 2 ft/s and increasing the
bed height to 4 ft. However total primary fines recycle, at a rate of
about five times the coal feed rate, increased the combustion efficiency
to 99.3%. The temperature distributions through the combustor confirmed
the findings of Series 1.
The reductions in S0_ emission with dolomite 1337 are given in
Table 4.18 and plotted against the Ca/S mol ratio in Fig. 4.9. At
4 ft/s there was about 10% less reduction with dolomite than with
limestone 18, (Test Series 1, Fig. 1.16). Unlike limestone, the
A1.24
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reduction in emission did not become less when the bed temperature was
reduced to 1380°F. The SC>2 reduction at 2 ft/s with dolomite was close
to that with limestone at 3 ft/s, again indicating a lower effectiveness.
With fines recycle at 2 ft/s, the SC^ concentration was reduced to 20
p.p.m., a reduction of 99%.
The NOV emission at 4 ft/s with a 2 ft bed was about 240 p.p.m.
A
for both 1470 and 1560°F. The NO^ emission increased to about 390 p.p.m.
at 2 ft/s with a 4 ft bed. The single result with fines recycle indicates
that recycle, with the associated low S02 concentration, did not effect
the NOV emission:this is in contrast to Test Series 2 without fines
A
recycle, where reduction of SOo emission did increase NO^ emission.
A1.25
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3.5 Test Series 5
The objectives of the test series were to determine the effects
of bed height and fluidising velocity on sulphur dioxide emission with
limestone addition, and also to test the effectiveness of a very high
Ca/S mol ratio. The intended nominal operating conditions were:
Coal Pittsburgh, prepared to -J in.
Acceptor Limestone 18, prepared to -| in.
Ca/S mol ratio 0, 2 and 6.
Fluidising velocity 4 and 8 ft/s.
Bed temperature 1560°F.
Bed depth 2 and 4 ft.
Flue-gas oxygen 2.5 to 3.5%.
Fines recycle System not in operation.
3.5.1 Description of Test Series 5
The test series was carried out from 17 to 22 March 1971. The
plant was started up without limestone addition using an initial bed
of Newdigate shale prepared to have a top size of | in. When operating
conditions were steady at a fluidising velocity of 4 ft/s and bed depth
of 2 ft the datum S0_ concentration without additive was recorded.
Tests 5.1 and 5.2 were then carried out with limestone addition to
give a stoichiometric ratio of 2 at fluidising velocities of 4 and
8 ft/s respectively. During these tests the SO^ concentration was
determined in the freeboard using a movable probe 24 in. above the bed
Fresh shale was added to increase the bed height to 4 ft for Test 5.3
at 8 ft/s with stoichiometric ratio of 2. The limestone feed rate
was increased to give a stoichiometric ratio of 6 for Test 5.4. On
completion of the mass balance of this test it had been intended to
continue operating the plant for a further 24 hours at the same
operating conditions. However immediately after the mass balance there
was a coal feed failure and it was necessary to shut down the plant to
allow the coal feed system to be examined. The plant was re-started
after a period of 12 hours and operated under steady conditions for a
period of 20 hours, designated Test 5.5, but no mass balance was
carried out.
A1.26
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3.5.2 Results of Test Series 5
The experimental operating conditions through Test Series 5 are
detailed in Table 5.1. The input and output size distributions and
chemical analyses are detailed in Tables 5.2 to 5.8 and the flue gas
analyses in Table 5.9, with the variation in the SC^ concentration with
time plotted in Figures 5.1 to 5.6. Mass balances and calculated
operating parameters are given in Tables 5.10 to 5.13. The pressure
drops and temperature distributions through the plant are in Tables
5.14 and 5.15 respectively. The positions of the thermocouples in
the combustor during the test series are given in Fig. 5.7.
The combustion efficiencies of 85 and 81% in Tests 5.3 and 5.4
at 8 ft/s without fines recycle are lower than in Test 5.2 and in Test
Series 2 (87%) because of the lower excess air level in Tests 5.3 and 5.4.
The hot spot, above the coal feed was considerably less marked than in
Series 2, being only about 30°F above the mean bed temperature in
Test 5.2, and almost non-existent in the deeper beds of Tests 5.3 and
5.4. It should be noted that there were tubes in only the bottom 2 ft
of the bed.
The reductions in SC^ emission are given in Table 5.16 and plotted
against the Ca/S mol ratio in Fig. 5.8. The single datum SC>2 concentration
value taken at the stack is surprisingly low, and has not been used. The
value used, 2400 p.p.m., was calculated by correcting the value during
Test Series 2 for the higher sulphur content of the coal in this series.
The value is also justified by the IRA datum of 2060 p.p.m., which
value is usually about. 12% below that, of .the iodine method, Fig. 1.8,
indicating an iodine value of about 2320 p.p.m. The S02 reductions in
Tests 5.1, 5.2 and 5.3 are in reasonable agreement with Test Series 1
and 2, Figs. 1.16 and 2.7. Tests 5.4 and 5.5 demonstrate that almost
complete reduction of S02 can be achieved by using a high Ca/S mol ratio.
The gas samples taken 2 ft above the bed surface show a marked
radial SO. concentration gradient, Fig. 5.1 and Table 5.17 as in
Test Series 1. It is not possible to determine whether or not reaction
of S02 is occurring in the freeboard, from these results.
A1.27
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The NOx concentration in the datum test at 4 ft/s was about
300 p.p.m., in reasonable agreement with Test Series 4. At 8 ft/s
with limestone addition at a Ca/S mol ratio of 1.6 the NO^ increased
to 450 p.p.m. and there was a further increase to 550 p.p.m. on
raising the .limestone feed rate to give Ca/S of 6. However in the
later stages of Test 5.5, NO^ concentrations of 320 p.p.m. were
measured. If these final values were neglected, it could be concluded
that the NO^ concentration increases as S02 is reduced by limestone
addition, in agreement with Test Series 2; (except in the case of fines
recycle) but this would be difficult to justify.
A1.28
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3.6 Test Series 6
The objective of the test series-was to obtain data .on sulphur
dioxide emission when using coarse dolomite additive at a fluidising
velocity of 8 ft/s with deep beds. The intended nominal operating
conditions were:
Coal Pittsburgh, prepared to -^ in.
Acceptor Dolomite 1337, as received (-£ in. + 30 B.S.S.)
Ca/S mol ratio 0, 2 and 4.
Fluidising velocity 8 ft/s.
Bed temperature 1560°F and a survey over the range 1420
to 1620°F.
Bed depth 2, 4 and 9.5 ft.
Flue-gas oxygen 2.5 to 3.5%.
Fines recycle System not in operation.
3.6,1 Description of Test Series 6
The test series was carried out from 29th March to 2 April, 1971.
Prior to the test series the bed pressure drop probes were modified and
the steam inlet line was raised to allow operation with the deep bed
envisaged. The plant was started up without dolomite addition using a
2 ft. deep bed of Newdigate shale prepared to have a top size of £ in.
When the operating conditions were steady, the datum SO- concentration
without additive was recorded. Additive feeding was commenced at a
stoichiometric ratio of 2 for Test 6.1. On completing this test the
dolomite feed was increased to a ratio of 4 for Test 6.2. However there
was a dolomite feed failure part way through the mass balance and it was
necessary to slump the bed for a period of 1 hour while repairs were made.
On re-starting the conditions were again stabilised and a complete mass
balance for Test 6.2 was carried out. The bed depth was then increased
to 4 ft by adding ash from previous tests. Test 6.3 was carried out,
maintaining the stoichiometric ratio at 4. After this test, the bed
temperature was increased to 1620°, decreased to 1420° and returned to
1560 F over a period of one hour. During this period the air, coal and
dolomite feed rates were maintained constant.
A1.29
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The bed was then slumped in order to allow the coal and dolomite
hoppers to be re-filled. On re-start the fluidising velocity was
maintained at 4 ft/s while shale and ash were added to give a bed
depth of about 7 ft. The fluidising velocity was then increased to
8 ft/s to give an expanded bed depth of 9 ft. However this bed depth
could not be maintained because of excessive elutriation, despite
feeding the coarse dolomite at a stoichiometric ratio of 4, and the
depth decreased to 6 ft over a period of about 12 hours. During this
period the operating conditions were otherwise steady, and a four hour
mass balance was carried out with a bed depth of about 7 ft, Test 6.4.
A further mass balance was carried out at a steady bed depth of 6 ft,
Test 6.5.
3.6.2 Results of Test Series 6
The experimental operating conditions through Test Series 6
are detailed in Table 6.1. The input and output size distributions
and chemical analyses are detailed in Tables 6.2 to 6.8 and the flue
gas analyses in Table 6*9, with the variation in the SO- concentration
with time plotted in Figures 6.1 to 6.6. Mass balances and calculated
operating parameters are given in Tables 6.10 to 6.14. The pressure
drops and temperature distributions through the plant are in Tables
6.15 and 6.16 respectively. The positions of the thermocouples in the
combustor during the test series are given in Fig. 6.7.
The combustion efficiency without fines recycle at 8 ft/s was in
the range of 84 to 87%, in good agreement with Test Series 2 and 5.
In Tests 6.3, 6.4 and 6.5, with deep beds, only a small quantity of steam
was required to limit the off-gas temperature, indicating that a higher
proportion of .the combustion was occurring within the bed. As in Test
Series 5, there was no hot spot above the coal feed point, Table 6.16.
The reductions in S02 emission are given in Table 6.17 and are
plotted against the Ca/S mol ratio in Fig. 6.8. Comparison with Test.
Series 4, Fig. 4.9, indicate that there is about 15% less reduction at
8 ft/s than at 4 ft/s. The evidence on the effect of bed height at
8 ft/s is conflicting. Tests 6.2, 6.3 and 6.5 suggest that there is no
effect, whereas Test 6.4 indicates an increase in efficiency of reduction
with increasing height.
A1.30
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The variation of S0» concentration during the bed temperature survey
is shown in Fig. 6.4. As in Test Series 3, the SCL concentration
responded almost immediately to a change in bed temperature. The S0_
reductions during the survey, based on an estimated IRA datum, are given
in Table 6.18 and plotted in Fig. 6.9. There appears to be an optimum
temperature for SCL reduction of about 1400 F and the reduction falls by
20% when the temperature is increased to 1650 F. The magnitude of this
effect is perhaps surprising in view of the high Ca/S mol ratio of 5.3.
The NOX concentration averaged 400 p.p.m. during the Test Series
and there was no significant variation between the individual Tests.
A1.31
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4. ACKNOWLEDGEMENT
The authors acknowledge the contributions of their colleagues at
CRE in carrying out the work described in this report. The work was
administered by Dr. A.D. Dainton and Mr. J. McLaren; the overall
experimental programme was devised by Mr. D.C. Davidson and Dr. D.F. Williams;
Mr. A.A. Randell was responsible for the operation of the plant the shift
team leaders were Mr. R. Dryburgh, Mr. J.C. Holder, Mr. M. Powell and
Mr. L.C. Stephensf the chemical analyses were carried out under the
supervision of Dr. H.A. Standing by Mr. G.J. Corney, Mr. H.W. Harris and
Mr. L. Stanley; the .NO^ measurements were carried out by Mr. W.N. Adams
and Mr. J.T. Shaw (from BCURA); maintenance of the plant-was carried out
by the CRE engineering and instrumentation sections.
The contribution made by Mr. E.L. Carls, the O.A.P. representative
in the U.K. is also acknowledged.
A1.32
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Table A.1.1.1. Operating conditions during Test Series 1
Coal Pittsburg coal
Coal size (upper limit) 1680 um
Acceptor Limestone 18
Acceptor size (upper limit) 1680 jam
Fines Recycle System not in operation
Test Series
Test No.
Time
from start
of Test
Series
(hrs)
S
t
a
r
t
E
3
Ca/S mol ratio
Coal Rate
Ib/h dry
Fluidising Velocity
ft/s
Bed Temperature
OF
Bed Height
1.1
1.1
18
22
0
123
4.0
1470
2.3
1.2 '
1.2
8
12
0
124
4.0
1,3
33
37
2.2
116
4.0
1
1470 | 1470
2,2 | 2,2
!
1.4
46
50
2.2
124
4,0
1380
2o2
1.5
56
60
2.2
112
4.0
1560
2.2
Test Series
Test No,
Time
from start
of Test
Series
(hrs)
S
a
I
Ca/s mol ratio
Coal Rate
Ib/h dry
Fluidising Velocity
ft/s
Bed Temperature
Bed Height
1.3
Datum
0
1
0
116
4.0
1560
2.2
1.6
15
19
1.3
116
4.0
1560
2.2
1.7
27
31
2.2
121
4-0
1560
2.1
1.8
38
42
3,3
124
4.0
1560
2.2
1.9
51
55
1.2
124
4,0
1560
2,1
Datum
62
64
0
97
3.0
1470
2.3
1,10
70
74
2,,2
97
3.0
1470
2.3
1.11
84
88
3.3
94
3,1
1470
2.1
AL33
-------
Table A.1.1.2 - Chemical Analyses of coal
Test Series
Test Number
Proximate Analysis
Total moisture
Ash
Volatile matter
Ultimate analyses
Carbon
Hydrogen
Nitrogen
Sulphur
Oxygen + errors
Chlorine
Carbon dioxide
Ash analysis
CaO
MgO
Na20
K20
A1203
Fe203
Si02
Calorific value (gross)
Swelling No.
Gray King coke type
Forms of sulphur
Organic
Pyritic
Sulphate
% a.r.
% a.r.
% d.a.f.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b .
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
Btu/lb
d.a.f.
% a.r.
% a.r.
% a.r.
1.1
1.1
2.8
16.8
39.7
67.5
4.2
1.45
2.15
5.2
0.14
0.95
7.3
1.6
0.76
1.7
20.6
12.3
46.8
14,550
-
-
-
-
1.2
1.2-1.5
1.3
14.4
41.2
71.5
4.5
1.4
2.7
4.3
0.09
0.52
8.0
1.3
0.67
1.6
18.8
14.4
45.2
15,490
8
G9
1.2
1.45
0.07
1.3
1.6-1.11
1.6
13.5
41.1
71.7
4.5
1.4
2.5
4.4
0.1
0.61
-
-
-
-
-
-
-
-
-
-
-
-
-
Al. 34
-------
Table A.1.1.3 Size distribution of coal
Test Series
Test No.
Particle Size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median dia. (ym)
Packed bulk
density lb/ft3
% in grade by weight
1.1
1.1
0
3.8
16.7
30.0
20.2
11.9
7.8
3.6
5.9
508
62.8
1.2
1.2-1.5
0
0.2
11.9
34.4
21.2
12.9
8.8
3.1
. 7.5
456
60.7
1.3
1.6-1.11
0
0.5
11.3
27.1
18.8
13.2
12.4
6.8
9.9
337
61.0
]
Al. 35
-------
Table A.1.1.4 Chemical and size analyses of acceptor
Test Series
Test No.
Chemical Analysis
CaO a.r.
MgO a.r.
C02 a.r.
Si02 a.r.
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (pm)
Packed bulk
density Ib/ft
1.2 & 1.3
1.2-1.11
45.9
0.94
34.7
14.7
% in grade by weight
0
0.1
5.9
15.1
22.0
22.5
12.2
5.0
17.2
20.7
71.5
Al. 36
-------
Table A.1.1.5. Chemical and size analyses of primary cyclone fines
Test Series
Test No.
Chemical Analysis
Carbon % a.r.
Sulphur % a.r.
Carbon dioxide
% a.r.
CaO % a.r.
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+45-66
45
Median diam. (ym)
Packed bulk
density Ib/ft
1.1
1.1
34.3
1.25
0.25
4.05
1.2
1.2
40.1
1.3
0.47
3.08
1.3
20.5
2.8
4.1
23.0
1.4
21.4
2.45
7.74
21.6
1.5
16.8
3.0
5.3
28.6
1.3
1.6
23.7
2.8
2.48
20.7
1.7
19.7
2.95
4.34
15.4
1.8
17.0
2.85
5.1
32.4
1.9
22.8
2.85
3.01
23.2
1.10
22.7
2.7
5.63
25.4
1.11
17.3
2.45
7.34
32.2
% in grade by weight
0
0
0
0.2
9.7
18.0
24.5
12.1
35.5
71
39.9
0
0
0
0.1
7.0
19.0
27.4
12.4
34.1
72
40.6
0
0
0
0
8.4
31.2
21.3
9.6
29.5
95
49.7
0
0
0
0
7.1
28.5
21.2
10.4
32.8
82
51.3
0
0
0
0
7.2
31.4
20.9
9.2
31.3
90
56.9
0
0
0
0
7.9
27.9
25.4
8.5
30.3
93
48.6
0
0
0
0
6.7
30.8
22.5
8.9
31.1
91
41.8
0
0
0
0
7.4
30.3
20.9
8.7
32.7
89
56.9
0
0
0
0
6.9
24.5
25.8
8.7
34.1
83
51.0
0
0
0
0.1
2.2
28.2
27.4
10.6
31.5
82
55.7
0
0
0
0.1
3.2
30.8
27.0
8.2
30.7
92
57.1
Al 37
-------
Table A.1.1.6 Chemical analyses of secondary cyclone fines
Test Series
Test No.
Analysis
Carbon % a.r.
Sulphur "
co2
CaO
1.1
1.1
2.5
1.5
0.06
3.78
1.2
1.2
8.0
1.3
0.16
3.04
1.3
2.1
6.55
2.57
17.9
1.4
3.2
6.2
4.01
19.7
1.5
3.9
6.1
3.8
22.4
1.3
1.6
4.0
4.9
1.62
25.7
1.7
6.5
5.0
3.93
23.4
1.8
0.8
6.2
6.41
29.0
1.9
6.3
5.4
2.47
19.2
1.10
7.2
5.0
3.83
17.2
1.11
0.7
5.25
9.46
29.4
Table A.1.1.7 Chemical analyses of exhust dust
Test Series
Test No.
Analysis
Carbon % a.r.
Sulphur "
co2
CaO
1.1
1.1
0.4
2.6
0.22
2.94
1.2
1.2
2.9
4.7
0.12
2.8
1.3
2.1
5.9
0.94
11.3
1.4
2.9
5.6
0.62
13.7
1.5
3.2
5.9
0.94
15.7
1.3
1.6
1.6
6.7
1.4
7.3
1.7
3.9
6.75
1.4
18.8
1.8
3.2
7.5
1.4
22.8
1.9
4.3
5.1
1.4
16.2
1.10
5.5
5.55
1.4
15.7
1.11
3.7
6.45
1.4
23.8
A1.38
-------
Table A.l.l.Sa Chemical and size analyses of bed material
fc
CO
Test Series
Test No.
Sample
Chemical Analysis
Sulphur % a.r.
C02 % a.r.
CaO % a.r.
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+45-66
- 45
Median dian. (ym)
Packed bulk _
density Ib/ft
1.1
1.1
Initial
0.65
0.11
33.6
Final
0.65
0.11
33.6
Offtake
-
-
-
1.2
1.2
Initial
0.7
0.12
29.4
Final
0.75
0.13
30.8
1.3
Initial
3.7
0.3
16.5
Final
4.7
0.38
20.3
1.4
Initial
4.95
8.11
25.9
Final
4.7
10.94
27.1
Offtake
6.15
0.91
32.3
% in grade by weight
0.3
1.3
19.5
56.6
22.0
0.2
0.1
764
82.9
0.4
1.6
22.7
53.5
21.4
0.3
0.1
0
0
729
80.6
0.3
1.3
22.5
55.8
19.3
0.5
0.2
0.1
0
732
85.6
0.3
1.1
18.7
57.6
22.3
0
0
0
0
760
94.9
0.2
1.3
23.6
53.6
21.3
0
0
0
0
733
82.5
0.2
1.2
24.1
50.6
23.6
0.3
0
0
0
725
92.1
0.3
1.0
22.6
52.3
23.4
0.4
0
0
0
716
83.3
0
0.7
23.6
45.9
28.9
0.6
0.1
0.1
0.1
700
97.1
0.2
1.8
24.4
45.4
27.6
0.5
0.1
0
0
723
90.9
0
0.4
13.1
48.5
36.9
1.0
0.1
0
0
597
57.5
-------
Table A.l.l.Sb Chemical and size analyses of bed material
Test Series
Test No.
Sample
Chemical Analysis
Sulphur % a.r.
C02
CaO
Size Analysis
Particle size (pm)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (vim)
Packed bulk
density lb/ft3
1.2
1.5
Initial
5.6
0.62
31.8
Final
6.2
0.64
33.4
Offtake
5.3
9.6
29.3
1.3
1.6
Initial
2.15
0.17
10.2
Final
2.6
0.18
12.5
1.7
Initial
3.65
0.22
18.0
Final
4.05
0.24
22,3
Offtake
3.5
0.15
17.2
1.8
Initial
4.55
0.16
23.2
Final
5.15
0.17
26.6
Offtake
4.8
0.18
24.4
% in grade by weight
0.1
1.3
20.8
49.9
27.4
0.5
0
0
0
714
87.0
0
0.7
24.2
44.3
30.0
0.6
0.1
0.1
0
689
87.6
0
0.4
14.7
49.2
34.7
0.9
0.1
0
0
621
89.6
0
1.2
25.4
46.3
26.5
0.5
0.1
0
0
736
86.5
0
1.1
24.9
44.1
29.5
0.4
0
0
0
701
83.9
0
0.8
21.8
45.7
31.1
0.5
0.1
0
0
673
84.6
0
1.2
24.0
42.6
31.2
0.7
0.1
0.1
0.1
674
88.1
0
1.1
20.0
45.0
33.1
0.7
0.1
0
6
647
91.6
0
0.7
20.5
43.2
34.9
0.7
0
0
0
628
87.7
0.1
1.0
22.5
41.4
34.0
0.7
0.1
0.1
0.1
639
85.2
0
0.9
20.4
37.4
40.4
0.9
0
0
0
570
86.5
-------
lapie A.i.i.ac unemicai and size analyses ui: bed material
Test Series
Test No.
Sample
Chemical Analysis
Sulphur % a.r,
CO % a.r.
CaO % a.r.
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+45-66
- 45
Median diam, (uro)
1.3
1.9
Initial
5.9
0.21
26.0
Final
5.8
0,22
26.0
Offtake
6.85
0.18
28.8
1.10
Initial
1,75
0.32
9,65
Final
2,6
0.34
13.9
Offtake
2oO
0.22
9,8
1.11
Initial
4.25
0.36
22.3
Final
4.6
0.39
23.8
Offtak
mif
-
% in grade by weight
0
0.9
20.0
44.4
34.2
0.5
0
0
0
637
Packed bulk ,
density lb/ftJ j 8 '&
0
0.7
20.2
42.0
36.3
0.6
0.1
0
0.1
612
84.7
0
0.7
15.4
39.3
43.8
0.8
0
0
i °
539
85.1
0
0.7
21.9
44.9
30.0
2.5
0
0
0
670
84.9
0
0.7
21.1
44.8
30.4
3.0
0
0
0
660
83,7
0
0.6
19.7
43.6
33 = 1
3.0
0
0
0
627
83.9
0
0.6
17.3
42.9
34.7
4.5
0
0
0
594
87.4
0
0.6
19.5
40.5
34.1
5.2
0.1
0
0
596
87.9
0
0.4
14.9
39.4
39.3
5.9
0.1
0
0
537
88.0
A1.41
-------
Table A.1.1.9a Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature F
Bed Height ft
Gas Analysis
Vol % dry gas
co2
" °2
CO
" CH4
p. p.m. SO-
so2
so2
Cl
II J^TT
Method
Chroma-
tograph
ti
"
ii
Iodine
I.R.A.
H2°2
ii
ii
1.1
1
14.1
4.0
0
0
1.75
14.0
4.0
0
0
3
13.6
4.2
0
0
Mean
0
4.0
1470
2.3
14.6
4.1
0
0
1750
-
-
-
"
1.2
0
15.1
3.3
0.02
0
1.5
14.9
3.4
0.02
0
3
14.8
3.3
0.02
0
Mean
0
4.0
1470
2.2
14.9
3.3
0.02
0
2050
-
1980
72
3
1.3
1
14.4
4.1
0
0
3
14.4
4.5
0
0
Mean
2.2
4.0
1470
2.2
13.9
4.3
0
0
400
-
-
-
^
A1.42
-------
Table A.1.1.9b Flue gas analyses
est No.
"ime from start (h)
Operating Conditions
a/S mol ratio
xluidising Velocity ft/s
ned Temperature F
ed Height ft
Gas Analysis
vol % dry gas CO
°2
CO
II ptl
.p.m. S0_
so2
so2
Cl
II JJTT
Method
Chroma-
tograph
"
n
...
Iodine
I.R.A.
H2°2
n
ii
1.4
0
14.5
3.8
0
0
1.5
14.2
4.3
0
0
2.5
15.1
3.3
0
0
Mean
2.2
4.0
1380
2.2
14.6
3.8
0
0
1020
-
-
-
"*
1.5
3.5
15.3
3.4
0
0
Mean
2.2
4.0
1560
2.2
15.3
3.4
0
0
360
360
-
-
~
Datum
0
4.0
1560
2.2
14.2
4.0
0
0
2100
-
-
-
~
1.6
0
14.2
4.5
0
0
2
14.2
4.4
0
0
3.75
14.3
3.9
0
0
Mean
1.3
4.0
1560
2.2
14.4
4.2
0
0
880
780
710
61
0
A1.43
-------
Table A.1.1.9c Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature °F
Bed Height ft.
Gas Analysis
Vol % dry gas C02
°2
CO
II prr
p. p.m. SOo
so2
so2
Cl
NH3
Method
Chromatograph
n
ti
"
Iodine
I.R.A.
H202
"
n
1.7
2
15.4
2.9
0
0
3.5
15.0
3.3
0
0
Mean
2.2
4.0
1560
2.1
15.2
3.1
0
0
510
380
500
86
6
1.8
1.5
15.0
3.3
0
0
3
15.2
3.3
0
0
Mean
3.3
4.0
1560
2.2
15.1
3.3
0
0
180
90
160
24
4
1.9
2
14.5
•2.8
0
0
3.75
14.5
2.5
0
0
Mean
1.2
4.0
1560
2.1
14.6
2.6
0
0
840
790
550
21
0
Al. 44
-------
Table A.1.1.9d Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature F
Bed Height ft
Gas Analysis
Vol % dry gas CO-
°2
CO
II ,-lrt
p .p .m. ^9
so2
so2
Cl
II JJTT
Method
Chroma-
tograph
ii
ii.
ii
Iodine
I.R.A.
H2°2
ii
M
Datum
0
3.0
1470
2.3
15.0
2.6
0
0
2020
-
-
-
-
1.10
0.5
15.1
2.8
0
0
1.5
15.4
2.8
0
0
2.5
15.8
2.8
0
0
3
15.4
3.2
0
0
Mean
2.2
3.0
1470
2.3
15.4
3.0
0
0
330
315
340
49
2
1.11
0
13.5
2.6
0
0
1.5
13.2
3.3
0
0
Mean
3.3
3.0
1470
2.1
13.5
2.9
0
0 .
42
25
73
32
2
A1.45
-------
Table A.1.1.10 Mass balance for Test 1.1
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Ouput
Loss (In-Out)
Loss Percent
Total
123.4
0
1300.4
1423.8
0
3.0
18.9
1.3
1.5
1393.7
1418.4
5.4
0.4
•A i»
Ash
20.7
0
0
20.7
0
3.0
12.4
1.3
1.5
0
18.1
2.6
12.6
'Carbon'
83.3
0
0
83.3
0
0
6.48
0.03
0.01
76.7
83.2
0.1
0.1
Nitrogen
0
0
999
999
0
0
0
0
0
1003
1003
- 4
-0.4
'Oxygen'
6.4
0
301.4
307.8
0
0
0
0
0
306.0
306.0
1.8
0.6
Sulphur
2.65
0
0
2.65
0
0.02
0.24
0.02
0.04
2.42
2.74
-0.09
-3.4
Calcium
1.1
0
0
1.1
0
0.07
0.55
0.04
0.03
0
0.69
0.41
37.3
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
15.4%
7.8% (Unburnt)
9%
0
A1.46
-------
Table A.1.1.11 Mass balance for Test 1.2
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
124.4
0
1300.4
1424.8
0
0
19.3
0.9
1.8
1395.6
1417.6
7.2
0.5
'Ash'
17.9
0
0
17.9
0
0
11.5
0.8
1.8
0
14.1
3.8
21.2
'Carbon'
89.2
0
0
89.2
0
0
7.72
0.07
0.05
78.1
85.9
3.3
3.7
Nitrogen
0
0
999
999
0
0
0
0
0
1006
1006
-7
-0.7
'Oxygen*
5.3
0
301.5
306.8
0
0
0
0
0
302.4
302.4
4.4
1.4
Sulphur
3.41
0
0
3.41
0.05
0
0.25
0.01
0.09
2.81
3.21
0.20
5.9
Calcium
1.09
0
0
1.09
0.10
0
0.42
0.02
0.04
0
0.58
0.51
47.3
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
9.2%
9.2% (Unburnt)
18%
0
A1.47
-------
Table A.1.1.12 Mass balance for Test 1.3
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Ouput
Loss (In - Out)
Loss Percent
Total
116.5
27.0
1316.0
1459.5
0
14.0
28.4
1.8
2.3
1408.6
1455.1
4.4
0.3
'Ash'
16.8
27.0
0
43.8
0
14.0
22.6
1.8
2.2
0
40.6
3.2
7.3
' Carbon
83.5
0
0
83.5
0
0
5.82
0.04
0.05
76.4
82.3
1.2
1.4
Nitrogen
0
0
1011
1011
0
0
0
0
0
1014
1014
- 3
- 0.3
'Oxygen1
5.0
0
305.0
310
0
0
0
0
0
309.8
309.8
0.2
0.1
Sulphur
3.19
0
0
3.19
0.79
0.59
0.80
0.12
0.13
0.56
2.98
0.21
6.5
Calcium
1.02
8.86
0
9.88
2.14
1.84
4.66
0.23
0.18
0
9.05
0.83
8.4
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
17.4%
7.2%
83%
2.2
(Unburnt)
A1.48
-------
Table A.1.1.13 Mass balance for Test 1.4
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
124.4
28.3
1377.2
1529.9
0
12.2
31.5
2.0
1.6
1475.8
1523.1
6.8
0.4
'Ash'
17.9
28.3
0
46.2
0
12.2
24.8
1.9
1.6
0
40.5
5.7
12.3
'Carbon'
89.2
0
0
89.2
0
0
6.74
0.06
0.05
81.1
87.9
1.3
1.4
Nitrogen
0
0
1058
1058
0
0
0
0
0
1065
1065
-1
0.7
'Oxygen'
5.3
0
319.2
324.5
0.
0
0
0
0
320.6
320.6
3.9
1.2
Sulphur
3.41
0
0
3.41
-0.26
0.59
0.77
0.12
0,09
1.48
2.80
0.61
17.9
Calcium .'
1.09
9.29
0
10.38
0.95
2.32
4.85
0.28
0.16
0
8.56
1.82
17.5
Excess air
Carbon loss
Sulphur retention
Ca/s mol ratio
13.7%
7.8% (Unburnt)
56%
2.2
A1.49
-------
Table A.1.1.14 Mass balance for Test 1.5
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
111.5
25.8
1239.2
1376.5
0
12.0
29.5
2.2
0.8
1332.0
1376.5
0
0
'Ash'
16.1
25.8
0
41.9
0
12.0
24.5
2.1
0.8
0
39.4
2.5
6.0
'Carbon'
80.0
0
0
80.0
0
0
4.96
0.09
0.03
76.4
81.5
-1.5
-1.9
Nitrogen
0
0
952
952
0
0
0
0
0
955
955
- 3
-0.3
'Oxygen'
4.8
0
287.2
292
0
0
0
0
0
292.4
292.4
- 0.4
- 0.1
Sulphur
3.06
0
0
3.06
0.57
0.71
0.89
0.13
0.05
0.47
2.82
0.24
7.8
Calcium
0.98
8.46
0
9.44
1.15
2.80
6.02
0.35
0.09
0
10.40
-0.96
-10.1
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
12.4%
6.2% (Unburnt)
85%
2.2
Al. 50
-------
uaxauce lUi. i £3 L J. • O
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
116.1
14.1
1254.8
1385.0
4.0
11.0
.25.0
1.4
0.5
1343.3
1385.2
-0.2
0
'Ash'
15.9
14.1
0
30.0
4.0
11.0
19.1
1.3
0.5
0
35.9
-5.9
-19.7
'Carbon'
83.6
0
0
83.6
0
0
5.92
0.06
0.01
72.8
78.8
4.8
5.8
Nitrogen
0
0
964
964
0
0
•
0
0
0
967
967
- 3
-0.3
'Oxygen'
5.1
0
290.8
295.9
• o
0
0
0
0
295.5
295.5
0.4
0.1
Sulphur
2.95
0
0
2.95
0.55
0.26
0.70
0,07
0,04
1,16
2.78
0.17
5.9
Calcium
1,02
4.63 i
0
5.65
J
i
•
1,93
0-89
3.70
0 29
"
0,03
0
6.83
-1,18
-20.9
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
16,3%
7.6% (Unburnt)
61%
1.3
Al. 51
-------
Table A.1.1.16 Mass balance for Test 1.7
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
121.0
26.3
1243.1
1390.4
0
12.0
32.1
2.0
0.6
1335.2
1381.9
8.5
0.6
'Ash'
16.6
26.3
0
42.9
0
12.0
25.8
1.9
0.5
0
40.2
2.7
6.3
'Carbon'
87.1
0
0
87.1
0
0
6.32
0.13
0.02
Nitrogen
'o
0
955
955
0
0
0
0
76.0 ; 960
82.5 ; 960
4.6 -5
5.3 -0.5
'Oxygen'
5.3
0
288.1
293.4
0
0
0
0
0
290.7
290.7
2.7
0.9
Sulphur
3.07
0
0
3.07
0.45
0.46
0.95
0.10
0.04
0.67
2.66
0.41
13.4
Calcium
1.07
8.63
0
9.69
3.37
1.73
3.53
0.33
0.07
0
9.04
0.65
6.8
Excess air
Carbon loss
Sulphur retention
Ca/s mol ratio
9.2%
7.9% (Unburnt)
78%
2.2
Al. 52
-------
Table A.1.1.17 Mass balance for Test 1.8
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
1
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (in - Out)
Loss Percent
Total
124.0
39.0
1254.8
1417.8
0
16.0
38.0
1.5
0.7
1348.2
1404.4
13.4
0.9
'Ash'
17.0
39.0
0
56.0
0
16.0
31.5
1.5
0.7
49.7
6.3
11.2
'Carbon'
89.3
0
0
89.3
0
0
6.46
0.01
0.02
76.2
82.7
6.6
7.4
Nitrogen
0
0
964
964
0
0
0
0
0
968
968
- 4
-0.4
' Oxygen '
5.5
0
290.8
296.2
0
0
0
0
0
295.4
295.4
0.8
0.3
Sulphur
3.15
0
0
3.15
0.61
0.78
1.08
0.09
0.06
0.22
2.84
0.31
9.7
Calcium
1.09
12.79
0
13.88
2.45
2.85
8.78
0.31
0.12
0
14.50
-0.62
-4.5
Excess air 10.3%
Carbon loss 7.9%
Sulphur retention 93%
Ca/S mol ratio 3.3
(Unburnt)
Al. 53
-------
Table A.1.1.18 Mass balance for Test 1.9
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
124.0
14.1
1244.3
1382.4
0
9.0
29.0
2.2
1.5
1334.4
1376.1
6.3
0.5
'Ash1
17.0
14.1
0
31.1
0
9.0
22.4
2.1
1.4
0
34.9
-3.8
-12.2
'Carbon'
89.3
0
0
89.3
0
0
6.61
0.14
0.06
73.0
79.8
9.5
10.6
Nitrogen
0
0
956
956
0
0
0
0
0
957
957
-1
-0.1
'Oxygen1
5.5
0
288.3
293.8
0.
0
0
0
0
295.9
295.9
-2.1
-0.7
Sulphur
3.15
0
0
3.15
-0.11
0.53
0.83
0.12
0.08
1.10
2.55
0.60
19.0
Calcium
1.09
4.62
0
5.72
0
1.67
4.81
0.30
0.17
0
6.95
-1.23
-21.5
Excess air 13.8%
Carbon loss 8.5%
Sulphur retention 65%
Ca/S mol ratio 1.2
(Unburnt)
Al. 54
-------
Table A.1.1.19 Mass balance for Test 1.10
Rate: Ib/h
: Coal Feed
• Acceptor Feed
Total Air
!
i
1
Total Input
|
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
1
Total
96.9
20.6
972.2
1089 . 7
0
15.0
23.0
1.6
1.0
1045.2
1085.8
3.9
0.4
'Ash1
13.3
20.6
0
33.9
0
15.0
17.8
1.5
1.0
0
35.3
-1.4
-4.1
'Carbon'
69.8
0
0
69.8
0
0
5.22
0.12
0.06
60.2
65.6
4.2
6.0
1
Nitrogen
0
0
747
747
0
0
0
0
0
749
749
- 2
-0.3
I
' Oxygen '
4.3
0
225.2
229.5
0
0
0
0
0
229.1
229.1
0.4
0.2
Sulphur
Calcium
2.46 i 0.85
0 i 6.76
i
0
2.46
0.99
0.33
0.62
0.08
0.06
0.34
2.42
0.04
1.6
o
7.61
3.49
1.26
4.16
0.20
0.11
0
9.22
-1.61
-21.2
Excess air 8.1%
Carbon loss 8.2%
Sulphur retention 86%
Ca/S mol ratio 2.2
(Unburnt)
Al. 55
-------
Table A.1.1.20 Mass balance for Test 1.11
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
94.5
30.5
1010.0
1135.0
0
17.0
25.8
2.0
1.4
1085.1
1131.3
3.7
0.3
'Ash1
12.9
30.5
0
43.4
0
17.0
21.3
2.0
1.4
0
41.7
1.7
3.9
'Carbon1
68.0
0
0
68.0
0
0
4.46
0.01
0.05
62,6
67.2
0.8
1.2
Nitrogen
0
0
776
776
0
0
0
0
0
781
781
-5
-6
'Oxygen1
4.2
0
234.0
238.2
0
0
0
0
0
234.9
234.9
3.3
1.4
Sulphur
2.4
0
0
2.4
0.37
0.75
0.63
0.11
0.09
0.08
2.03
0.37
15.4
Calcium
0.83
10.0
0
10.83
1.15
2.8
5.93
0.42
0.24
0
10.54
0.29
2.7
Excess air 9.2%
Carbon loss 6.7% (Unburnt)
Sulphur retention 97%
Ca/S mol ratio 3.3
Al. 56
-------
Table A.1.1.21 Pressure drops through the combustor
Test Series
Test No.
Fluidising Velocity
ft/s
Bed Height ft
Baseplate
Bed
Density
(over 8 in)
1 Cyclone
2 Cyclone
1.1
1.1
4.0
2.3
1.2
1.2
4.0
2.2
1.3
4.0
2.2
1.4
4.0
2.2
1.5
4.0
2.2
Pressure drop, inches w.g.
12.5
18.5
5.4
0.5
3
12
19
5.8
0.5
3
12
19
5.8
0.5
3
13
19.8
6
0
3.5
11
17.7
5.4
0.5
3.5
Test Series
Test No.
Fluidising Velocity
ft/s
Bed Height ft
Baseplate
Bed
Density
(over 8 in)
1 Cyclone
2° Cyclone
1.3
1.6
4.0
2.2
1.7
4.0
2.1
1.8
4.0
2.2
1.9
4.0
2.1
1.10
3.0
2.3
1.11
3.1
2.1
Pressure drop, inches w.g.
\>
10
20
6.1
0.5
3
10
19
6
0.5
3
10.5
19.5
5.9
1.0
3.5
10.5
19
6
1.0
3
7
20.5
5.9
0.5
1.5
7
20
6.3
0.5
2
Al. 57
-------
Table A.1.1.22a Temperature distribution through the combustor
Test Series
Test No.
Fluidising Velocity
Bed Height
Excess Air %
Probe
Number
N 2
N14
N 3
N 4
N15
N 5
N20
N 9
N23
N10
N25
Nil
N26
N27 .
Height above
bubble caps
(ins)
4
4
12
12
12
20
50
94
94
130
130
154
154
154
Projection into
combus tor
(ins)
3
9
3
9
3
9
9
9
9
9
9
9
9
9
1° Cyclone
2° Cyclone
Steam to freeboard at N22 ib/h
1.1
1.1
4.0
2.3
15.4
1.2
1.2
4.0
2.2
9.2
1.3
4.0
2.2
17.4
1.4
4.0
2.2
13.7
1.5
4.0
2,2
12.4
Temperature °F
1481
1456
1492
1503
1481
1490
1528
1584
1593
1564
1553
1542
1549
1524
1395
1393
0
1477
1485
1492
1499
1474
1485
1517
1562
1560
1508
1510
1477
1477
1461
1333
1333
0
1476
1485
1490
1501
1483
1486
1526
1591
1587
1560
1573
1546
1549
1535
1391
1400
0
1386
1393
1398
1409
1384
1391
1468
1560
1558
1555
1567
1551
1553
1537
1393
1418
0
1564
1573
1576
1594
1562
1571
1602
1625
1638
1558
1593
1553
1553
1546
1389
1396
100
Al. 58
-------
leiuperauure gj.scrjLDuuJ.on ttii/ougn une comoustor
Test Series
Test No.
Fluidising Velocity ft/s
Bed Height ft
Excess Air %
Probe
Number
N2
N14
N3
N4
N15
N5
N20
N9
N23
N10
N25
Nil
N26
N27
Height above
bubble caps
(ins)
4
4
12
12
12
20
50
94
94
130
130
154
154
154
Projection into
combus tor
(ins)
3
9
3
9
3
9
9
9
9
9
9
9
9
9
,o _
1 Cyclone
2 Cyclone
Steam to freeboard at N22 Ib/h
1.3
1.6
4.0
2.2
16.3
1.7
4.0
2.1
9.2
1.8
4.0
2.2
10.3
1.9
4.0
2.1
13.8
1.10
3.0
2.3
8.1
1.11
3.1
2.1
9.2
o
Temperature F •
1558
1567
1573
1600
1562
1564
1593
1636
1634
1594
1602
-
1569
1549
1404
1409
0
1557
1571
1576
1600
1562
1566
1607
1629
1648
1571
1603
-
1562
1553
1400
1409
<100
1558
1571
1575
1593
1562
1567
1609
1623
1652
1575
1600
-
1564
1555
1398
1418
<100
1562
1569
1575
1598
1560
1567
1614
1623
1657
1580
1609
-
1573
1562
1400
1409
<100
1474
1479
1486
1490
1476
1479
1524
1582
1582
1549
1564
-
1531
1513
1355
1342
0
1470
1476
1481
1483
1474
1476
1521
1582
1582
1555
1569
-
1539
1521
1360
1362
0
Al. 59
-------
Table A.1.1.23 SOo concentrations and % reductions
Test No.
Fluidising Velocity, ft/s
Bed Temperature, °F
Ca/S mol ratio
S(>2 concentration, p. p.m.
S02 reduction, %
1.1
4
1470
0
1750
0
1.2
4
1470
0
2050
0
1.3
4
1470
2.2
400
81
1.4
4
1380
2.2
1020
50
1.5
4
1560
2.2
360
83
Datum
4
1560
0
2100
0
1.6
4
1560
1.3
880
58
Test No.
Fluidising Velocity, ft/s
Bed Temperature, °F
Ca/S mol ratio
SO 2 concentration, p. p.m.
S02 reduction, %
1.7
4
1560
2.2
510
76
1.8
4
1560
3.3
180
91
1.9
4
1560
1.2
840
60
Datum
3
1470
0
2020
0
1.10
3
1470
2.2
330
84
1.11
3
1470
3.3
42
98
« reductions are based on a datum level of 2050 p.p.m.
Al. 60
-------
A. 1.2.1 Operating Conditions during Test Series 2
Coal
Pittsburg coal
Coal size -3175 ym
Acceptor Limestone 18
Bed Temperature 1560°F
Recycle
No
Test No.
Time
from start
of Test
Series
(hrs)
Ca/S mol ratio
S
t
a
E
n
d
Coal Rate
Ib/h dry
Fluidising Velocity
ft/s
Acceptor Size
urn
Bed Height
Datum
0
5
0
258
8.1
2.1
2.1
18
22
1.1
258
8.1
-3175
2.1
2.2
28
32
2.3
258
8.1
-3175
2.1
2.3
38
42
2.9
258
8.0
-3175
2.1
Datum
62
64
0
128
4.0
_
2.1
2.4
77
81
1.0
128
4.0
-125
2.1
2.5
97
99
1.0
96
3.0
-125
2.0
A1.61
-------
Table A.1.2.2 Chemical analyses of coal
Test Number
Proximate analysis
Total moisture
Ash
Volatile matter
Ultimate analysis
Carbon
Hydrogen
Nitrogen
Sulphur
Oxygen + errors
Chlorine
Carbon Dioxide
Calorific value (gross)
Swelling No.
Gray King coke type
% a.r.
% a.r.
% d.a.f.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
Btu/lb d.a.f.
2.2
1.4
11.6
41.5
73.5
4.6
1.5
2.4
5.0
0.06
0.5
-
8
G9
2.4
1.5
11.7
-
73.6
4.7
1.6
2.3
4.7
0.08
0.5
-
8J
G9
Additional samples of coal analysed for sulphur only
Test No.
Sulphur % d.b.
2.1
2.15
2.2
2.4
2.3
2.45
2.4
2.3
A1.62
-------
Table A.1.2.3 Size distribution of coal
Test No.
Particle Size (ym)
+ 3175
4 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 125
+ 45-66
- 45
Median diam.(pm)
Packed bulk
density Ib/ft
% in grade by weight
2.1
0.6
12.9
14.4
23.7
17.6
11.4
8.8
4.6
6.0
526
60.6
2.2
0
2.1
8.1
20.9
25.9
16.8
13.7
6.6
5.9
309
61.9
2.3
0
2.1
9.6
24.6
23.1
15.9
12.8
7.3
4.6
337
61.5
2.4
0.3
19.9
19.4
23.9
13.0
8.1
6.5
2.2
6.7
763
62.1
-------
Table A.1.2.4 Chemical and size analyses of acceptor
Test No.
Chemical Analysis
CaO a . r .
MgO "
co2 "
Si02 "
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (urn)
Packed bulk
density lb/ft3
2.1-2.3
44.8
0.86
36.9
—
2.4
45.6
0.86
37.1
—
% in grade by weight
0
11.1
14.7
20.9
20.0
15.6
7.1
2.6
8.0
453
119.6
-
-
-
-
-
-
-
-
-
A1.64
-------
Table A.1.2.5 Chemical and size analyses of primary cyclone fines
Test No.
Chemical Analysis
Carbon % a.r.
Sulphur % a.r.
/*• r\ 7 & T-
V»V/ n /O Ct • J. •
CaO % a.r.
Forms of Sulphur
Organic % a.r.
Pyritic % a.r.
Sulphate % a.r.
Size Analysis
Particle size (ym)
+ 3175
2.1
36.7
2.25
2.1
17.5
0.40
0.03
1.70
2.2
24.3
2.65
4.36
28.2
0.30
2.3
22.3
2.7
4.25
32.8
0.25
0.05 ; 0.02
2.15 !; 2.35
i
2.4
25.2
2.5
4.37
28.6
0.30
0.02
2.15
% in grade by weight
0
+ 1680 - 3175 ! 0
+ 1003 - 1680 0.1
+ 500 - 1003
3.3
+ 250 - 500 ! 12.6
+ 125 - 250 ' 19.8
+ 66 125 i 23.6
+ 45 - 66 8.1
0
0
0 0
0
2.2
12.3
17.8
20.7
7 •»
' • '
'
- 45 32.5 39.3
Median diam. (ym) i 90 74
Packed bulk '
density Ib/ft i ^
;
54.4
0
1.9
11.9
17.7
19.4
7.8
41.3
69
55.3
0
0
0
0.1
4.2
11.9
26.4
9.9
47.5
49
44.8
Al. 65
-------
Table A.1.2.6 Chemical analyses of secondary cyclone fines
Test No.
Analysis
Carbon % a.r.
Sulphur % a.r.
C02 % a.r.
CaO % a.r.
2.1
6.8
3.7
1.17
14.3
2.2
2.2
7.15
4.68
31.6
2.3
2.5
5.75
2.85
28.4
2.4
2.5
6.1
3.31
34.7
Table A.1.2.7 Chemical analyses of exhaust dust
Test No.
Analysis
Carbon % a.r.
Sulphur % a.r.
C02 % a.r.
CaO % a.r.
2.1
4.0
4.75
1.05
11.2
2.2
4.1
6.8
1.05
24.4
2.3
2.8
7.95
1.05
26.2
2.4
2.8
9.15
1.05
27.4
A1.66
-------
Table A.1.2.8 Chemical and size analyses of bed material
Test No.
Sample
Chemical Analysis
Sulphur % a.r.
C02 % a.r.
CaO % a.r.
Size Analysis
Particle size (pm)
+ 3175
+ 1680 - 3175
+1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+45-66
- 45
Median diam. (pm)
Packed bulk .
density Ib/ft
2.1
Initial
1.75
0.44
10.6
Final
2.4*
0.45*
14.9*
Offtake
1.25
0.21
7.8
2.2
Initial
2.8
0.27
16.6
Final
3.4
0.27
20.2
Offtake
2.0
0.27
12.2
2.3
Initial
3.55
0.25
21.5
Final
4.1*
0.25*
22.9*
Offtake
3.9
0.25
21.7
2.4
Initial
0.8
0.12
7.0
Final
0.9
0.16
7.0
% in grade by weight
1.8
42.1
27.1
26.1
2.2
0.4
0.1
0.1
0.1
1516
94.4
-
3.1
43.6
28.3
23.3
1.6
0.1
0
0
0
1594
90.3
1.1
32.8
28.8
35.6
1.5
0.1
0.1
0
0
1243
82.6
0.9
29.6
31.6
36.0
1.1
0.1
0.1
0.1
0.1
1217
90.7
2.1
42.9
30.1
23.4
1.1
0.2
0.1
0
0.1
1556
86.9
0.6
33.2
27.7
36.7
1.6
0.1
0
0
0.1
1218
86.5
-
2.3
32.8
29.3
33.3
2.1
0.1
0.1
0
0
1286
87.0
0.7
26.8
24.5
36.4
11.6
0
0
0
0
1039
93.9
1.0
27.3
34.2
37.5
0
0
0
0
0
1211
85.7
*Estimates
-------
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature °F
Bed Height ft.
Gas Analysis
Vol % dry gas C02
°2
CO
CH4
p. p.m. NO"
so2
S02
so2
Cl
NH3
Method
Chroma-
tograph
ii
ii
M
Saltzman's
Iodine
I.R.A.
H202
M
ti
Datum
0
8.1
1560
2.1
15.5
2.2
0
0
(443
(404
1830
-
2.1
2
15.2
2.9
0
0
(467
(471
Mean
1.1
8.1
1560
2.1
15.2
2.9
0
0
470
1200
900
1240
23
4
2.2
0.5
14.9
2.9
0
0
533
3
14.5
2.9
0
0
497
Mean
2.3
8.1
1560
2.1
14.7
2.9
0
0
515
900
650
860
30
4
2.3
0.5
16.1
2.5
0
0
3.75
16.2
2.5
0
0
Mean
2.9
8.0
1560
2.1
16.1
2.5
0
0
-
650
475
680
40
0
A1.68
-------
Table A.1.2.9b Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
' Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature °F
Bed Height
Gas Analysis
Vol % dry gas C02
" n
°2
CO
CH.
4
p. p.m. NOX
S02
so2
so2
Cl
NH3
Method
Chromatograph
it
n
n
Saltzman's
Iodine
I.R.A.
H202
n
n
Datum
0
4.0
1560
2.1
15.2
3.0
-
-
-
2100
1850
-
_
^*
2.4
1.5
15.1
3.1
0
0
2.5.
15.2
3.0
0
0
3
15.6
2.7
0
0
Mean
1.0
4.0
1560
2.1
15.0
3.2
0
0
-
1050
990
890
20
0
2.5 :
16.6
2.5
0
0
16.3
2.8
0
0
Mean ,
1 :
1.0
3.0
1560
2
16.4
2.6
0
0
-
1050
-
-
_
"~
A1.69
-------
Table A.1.2.10 Mass balance for Test 2.1
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
258.3
24.1
2525.1
2807.5
0
9.0
64.5
4.0
2.1
2713.9
2793.5
14.0
0.5
'Ash'
30.0
24.1
0
54.1
0
9.0
40.8
3.7
2.0
0
55.5
-1.4
-2.6
'Carbon'
190.4
0
0
190.4
0
0
23.67
0.27
0.08
154.1
178.1
12.3
6.5
Nitrogen
0
0
1940
1940
0
0
0
0
0
1952
1952
-12
-6.2
'Oxygen'
12.9
0
585.1
598.0
0
0
0
0
0
590.2
590.2
7.8
1.3
Sulphur
5.68
0
0
5.68
0.56
0.19
1.45
0.15
0.10
3.19
5.64
0.04
0.7
Calcium
2.27
7.86
0
10.13
2.56
0.82
8.06
0.41
0.17
0
12.02
-1.89
-18.7
Excess air 2.5%
Carbon loss 13.5% (Unburnt)
Sulphur retention 44%
Ca/S mol ratio 1.1
A1.70
-------
Table A.1.2.11 Mass balance for Test 2.2
Rate: Ib/h
Coal Feed
| Acceptor Feed
Total Air
i
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
258.3
54.0
2517.3
2829.6
0
11.4
86.0
3.4
2.8
2699.5
2803.1
26.5
0.9
'Ash'
30.0
54.0
0
84.0
0
11.4
65.1
3.3
2.7
0
82.5
1.5
1.7
'Carbon'
190.4
0
0
190.4
o
0
20.9
0.07
0.12
148.6
169.7
20.7
10.9
Nitrogen
0
0
1934
1934
0
0
0
0
0
1957
1957
-23
-1.2
'Oxygen'
12.9
0
583.3
596.2
0
0
0
0
0
575.7
575.7
20.5
3.4
Sulphur
6.2
0
0
6.2
0.45
0.35
2.28
0.24
0.19
2.38
5.89
0.31
4.9
Calcium
2.27
17.60
0
19.88
1.86
1.50
17.37
0.77
0.49
0
21.99
-2.11
-10.6
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
4.1%
12.4% (Unburnt)
62%
2.3
A1.71
-------
Table A.1.2.12 Mass balance for Test 2.3
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Ouput
Loss (In - Out)
Loss Percent
Total
258.3
72.0
2509.6
2839.9
0
14.0
100.0
4.0
2.1
2710.0
2830.1
9.8
0.3
'Ash'
30.0
72.0
0
102.0
0
14.0
77.7
3.9
2.0
0
97.6
4.4
4.2
' Carbon '
190.4
0
0
190.4
0
0
22.30
0.10
0.06
162.2
184.7
5.7
3.0
Nitrogen
0
0
1928
1928
0
0
0
0
0
1928
1928
0
0
'Oxygen'
12.9
0
581.6
594.5
0
0
0
0
0
601.4
601.4
- 6.9
- 1.2
Sulphur
6.46
0
0
6.46
0.42
0.54
2.70
0.23
0.17
1.71
5.77
0.69
10.7
Calcium
2.27
23.47
0
25.74
0.76
2.23
23.50
0.81
0.39
0
27.69
-1.95
-7.6
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
1.3%
12.2%
73%
2.9
(Unburnt)
Al. 72
-------
Table A.1.2.13 Mass balance for Test 2.4
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Total
128.2
12.0
1262.6
1402.8
0
4.0
27.1
3.4
1.3
1
Flue Gas I 1356.3
1
Total Output
1392.1
1
Loss (In - Out)
Loss Percent
10.7
0.8
i
'Ash'
14.9
12.0
0
26.9
0
4.0
20.3
3.3
1.3
0
28.9
-2.0
-7.4
'Carbon'
94.5
0
0
94.5
0
0
6.83
0.09
0.04
76.1
83.0
11.5
12.1
Nitrogen
0
0
970
970
0
0
0
0
0
975
975
-5
-0.5
'Oxygen'
6.4
0
292.6
299.0
0
0
0
0
0
296.3
296.3
2.7
0.9
Sulphur
3.01
0
0
3.01
0.10
0.03
0.68
0.21
0.12
1.39
2.53
0.48
15.9
Calcium
1.13
3.84
0
4.97
0
0.20
5.53
0.84
0.26
0
6.83
i
-1.86
-37.4
j
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
9.3%
8.4% (Unburnt)
54%
1.0
A1.73
-------
Table A.1.2.14 Pressure drops through the combustor
Teat No.
Fluidiaing Velocity
ft/8
Bed Height ft.
Baseplate
Bed
Density
(over 8 in.)
1° Cyclone
2° Cyclone
2.1
8.1
2.1
2.2
8.1
2.1
2.3
8.0
2.1
i
2.4
4.0
2.1
Pressure drop, inches w.g.
40
14.5
4.6
2.5
17
40
14
4.4
2.5
17
40
13.5
4.3
2.5
17.5
12
18.5
5.9
0.5
4
A1.74
-------
Table A.1.2.15 Temperature distribution through the combustor
Test No.
Fluidising Velocity ft/s
Bed Height ft
Excess Air %
„ , ! Height above
Probe , , fn
„ , bubble caps
Number , . N
| (ins)
N2
N14
N3
N4
N15
N5
N20
N9
N23
N10
N25
4
4
12
12
12
20
Projection into
combustor
(ins)
3
2.1
8.1
2.1
2.5
2.2
8.1
2.1
4.1
2.3
8.0
2.1
1.3
2.4
4.0
2.1
9.3
Temperature F
1551
9 1578
3 1589
9
1638
3 1564
9 I 1584
1551
1585
1589
1627
1527
1580
50 , 9 1634 1638
94
94
9 1391 1411
9 j 1605 1634
130 9 ! 1596 1616
130 9 | 1544 j 1567
Nil I 154 9 1596
N26 154 9 ' 1580
N27 154 9
1 j
1 Cyclone
1537
1429
1603
1607
1558
1447
2° Cyclone 1465 ' 1481
Steam to freeboard at N22. Ib/h ! 440 420
1548
1580
1584
1630
1564
1558
1634
1427
1632
1629
1580
1611
1618
1567
1449
1485
440
1567
1578
1591
1589
1562
1573
1659
1522
1688
1594
1600
1602
1596
1566
1391
1420
200-100
Al. 75
-------
Table A.1.2.16 S09 concentrations and % reductions
Test No.
Fluidising Velocity, ft/s
Bed Temperature, °F
Acceptor size, ym
Ca/S mol ratio
SOo concentration, p. p.m.
S02 reduction, %
Datum
8
1560
-
0
1830
0
2.1
8
1560
-3175
1.1
1200
34
2.2
8
1560
-3175
2.3
900
56
2.3
8
1560
-3175
2.9
650
68
Datum.
4
1560
-
0
2100
0
2.4
4
1560
-125
1.0
1050
49
2.5
3
1560
-125
1.0
1050
49
The low datum concentration before Test 2.1 was due to the low
sulphur content of the coal, Table A. 1.2.2. This was used only
for Test 2.1. The datum for the other tests was taken as
2050 p.p.m.
A1.76
-------
Table A.1.3.1 Operating Conditions during Test Series 3
1
Coal
Coal size
Acceptor
Welbeck coal
(upper limit) 3175 ym
U.K. Limestone
Acceptor size (upper limit) 3175 ym
Fines Recycle System not in operation
Test No.
Time
from start
of Test
Series
(hrs)
i
Ca/s mol ratio
S
t
a
r
t
E
Coal Rate
Ib/hr. dry
Fluidising
Velocity
ft/s
Bed height
ft
Bed Temperature
F
3.1
22
26
0
303
7.9
2.1
1560
3.2
55
59
1.8
293
8.0
2.1
1560
3.3
76
80
2.1
301
8.0
2.1
1560
3.4
86
90
2.8
301
7.9
2.2
1560
Temperature
Survey
90
91
2.8
301
8.3-7.7
2.2
1630-1470
3.5
96
99
2.8
312
8.0
3.7-3.9
1560
I
3.6
104
107
3.0
152
4.1
2.2-2.4
1560
Al. 77
-------
Table A.1.3.2 Chemical analyses of coal
Test Number
Proximate analysis
Total moisture
Ash
Volatile matter
Ultimate analysis
Carbon
Hydrogen
Nitrogen
Sulphur
Oxygen + errors
Chlorine
Carbon Dioxide
Ash analysis
CaO
MgO
Na20
K20
A1203
Fe203
Si02
Calorific value (gross)
Swelling No.
Gray King coke type
Forms of Sulphur
Organic
Pyritic
Sulphate
% a.r.
% a.r.
% d.a.f.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
Btu/lb d.a.f.
% a.r.
% a.r.
% a.r.
3.1
3.3
24.5
38.0
61.7
3.6
1.3
1.45
4.4
0.62
1.21
4.9
1.96
1.8
3.1
19.3
8.2
54.2
14,100
1
C
0.73
0.65
0.03
3.5
3.5
25.9
-
60.0
3.4
1.4
1.4
4.0
0.57
1.03
3.2
2.0
1.76
3.2
19.4
8.3
56.2
-
-
-
0.67
0.65
0.02
Additional samples of coal analysed for sulphur only
Test No.
Sulphur % d.b.
3.1
1.45
3.2
1.4
3.5
1.4
3.6
1.4
A1.78
-------
Table A.1.3.3. Size distribution of coal
Test No.
Particle Size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diara. (ym)
Packed bulk _
density Ib/ft
% in grade by weight
3.1
0.1
12.6
17.2
24.2
16.2
9.5
7.0
2.6
10.6
571
60
3.2
0.1
15.3
18.1
20.0
14.7
9.2
7.3
3.4
11.9
569
63.1
3.3
0
25.9
20.2
18.2
9.7
6.3
5.9
2.7
11.1
889
58
3.5
0.1
24.7
22.6
18.7
10.3
6.4
5.4
2.5
9.9
929
56.8
3.6
0.3
24.8
22.6
22.2
8.9
4.8
4.6
2.0
9.8
946
65.9
Al. 79
-------
Table A.1.3.4 Chemical and size analyses of acceptor
Test No.
Chemical Analysis
CaO a.r. :
MgO "
C02 "
Si02 "
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (ym)
3.4
55.5 ;
0.28
43.8
—
3.5
55.4
0.28
43.7
—
% in grade by weight
0
11.1
13.9
16.3
22.7
14.2
8.2
2.9
10.7
391
0
6.8
12.4
20.4
27.8
14.3
18.3
2.3
7.7
316
Al. 80
-------
Table A.1.3.5 Chemical and size analyses of primary cyclone fines
i
Test No.
Chemical Analysis
Carbon % a.r.
Sulphur % a.r.
CO % a.r.
CaO % a.r.
Forms of Sulphur
Organic % a.r.
Pyritic % a.r.
Sulphate % a.r.
Size Analysis
Particle size (um)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam, (um)
Packed bulk
density Ib/ft
3.1
23.6
0.4
0.4
3.08
.
-
-
3.2
18.9
1.1
2.59
14.3
_
-
-
3.3
16.3
1.2
12.3
17,2
_
-
-
3.4
18.3
1.25
3.9
17.5
0,15
0.06
1.10
3.5
18.5
1.6
4.29
18.8
0.15
0.07
1.35
3.6
15.5
1.95
4.5
20.0
.
-
-
% in grade by weight
0
0
0.1
8.7
24.7
17.3
15.4
5.8
28.0
129
45.3
0
0
0
6.1
20.9
18.2
18.1
6.4
30.3
107
53.9
0
0
0
5.2
19-7
17.9
17.9
6.7
32.6
99
52.5
0
0
0
6.6
17.3
15.9
18.4
7.7
34.1
90
49.7
0
0
0.2
8.4
20.2
13.0
17.8
6.3
29.1
113
51.6
0
0
0
0.4
13.7
25.5
19.9
6.9
33.6
94
46.3
Al. 81
-------
Table A.1.3.6 Chemical analyses of secondary cyclone fines
Test No.
Analysis
Carbon % a.r.
Sulphur "
C02
CaO
3.1
13.8
0.35
0.08
2.7
3.2
6.9
2.3
0.23
9.9
3.3
7.6
2.35
0.25
11.8
3.4
7.8
2.25
0.46
10.5
3.5
8.6
2.6
0.34
11.6
3.6
7.9
2.45
0.45
10.8
Table A. 1.3.7 Chemical analyses of exhaust dust
Test No.
Analysis
Carbon % a.r.
Sulphur "
C02
CaO
3.1
1.25
0.5
0.2
14.9
3.2
4.3
2.3
0.23
10.7
3.3
6.7
2.35
0.25
11.4
3.4
6.7
2.25
0.46
10.5
3.5
6.7
2.6
0.34
3.2
3.6
6.7
2.45
0.45
3.2
A1.82
-------
Table A.1.3.8a Chemical and size analyses of bed material
oo
CO
Test No.
Sample
Chemical Analysis
Sulphur % a.r.
r*o 7 a v
VsW *•) /o d • 1. •
CaO % a.r.
Size Analysis
Particle size (pm)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (pm)
Packed bulk ,
density Ib/ft
3.1
Initial
0.3
0.18
3.5
Final
0.55
0.18
4.6
3.2
Initial
1.0
0.18
8.4
0.1
16.9
28.5
48.2
6.0
0.1
0.1
0.1
0
944
78.3
0.2
13.9
29.4
49.3
7.1
0.1
0
0
0
920
79.0
0.4
17.7
24.4
51.9
5.6
0
0
0
0
909
83.7
Final
1.15
0.22
9.9
Offtake
1.2
0.2
10.3
3.3
Initial
1.25
0.02
10.2
Final
1.7
0.16
13.0
Offtake
2.0
0.22
15.1
3.4
Initial
1.7
0.28
12.9
Final
2.15
0.22
16.1
Offtake
-
-
-
% in grade by weight
0.1
13.4
28.7
52.4
5.3
0.1
0
0
0
909
77.2
0
26.9
29.8
39.7
3.3
0.2
0.1
0
0
1113
77.7
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
0
21.5
27.7
47.7
2.7
0.2
0.1
0
0.1
992
79.7
0
15.5
28.7
52.8
2.9
0.1
0
0
0
932
73.9
0
12.9
27.6
55.8
3.1
0.3
0.1
0.1
0.1
894
78.1
0.3
22.3
28.8
44.5
3.7
0.2
0.1
0.1
0
1024
79.6
-------
Table A.I.3.8b Chemical and size analysis of bed material
Test No.
Sample
Chemical Analysis
Sulphur % a.r.
C02
CaO
MgO
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
45
Median diam. (pm)
Packed bulk
density lb/ft
3.5
Initial
1.7
0.19
12.5
-
Final
2.1
0.25
15.2
-
Offtake
2.15
0.25
15.2
-
3.6
Initial
: 2.1
0.17
;12.7
-
Final
2.2
0.11
13.2
-
Offtake
2.15
0.19
12.7
-
Newdigate
Shale
_
-
0.91
1.12
% in grade by weight
0
22.0
30.8
45.3
1.7
O.I
0.1
0
0
1043
74.6
0.1
- 18.8
31.0
48.1
1.6
0.1
0.1
0,1
0.1
1002
80.4
0.2
23.8
30.9
41.4
3.4
0.2
0.1
0
0
1079
78.9
0
16.3
28.5
46.6
8.1
0.2
0.1
0.1
0.1
933
78.0
0.1
14.2
25.9
47.6
11.8
0.1
0.1
0.1
0.1
875
61.1
0.2
22.4
28.1
43.6
5.4
0.2
0.1
0
0
1013
79.1
Al. 84
-------
Table A.1.3.9a Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity, ft/s
Bed Temperature °F
Bed Height, ft
Gas Analysis
Vol % dry gas C02
" °2
CO
CH4
so2
S02
S02
M
Cl"
NH3
Method
Chromato-
graph
M
ti
ii
Iodine
I.R.A.
H2°2
ii
ii
3.1
1
15.2
2.7
0
0
3
15.2
3.0
0
0
Mean
0
7.9
1560
2.1
15.2
2.9
0
0
1480
1430
1475
430
11
3.2
1.5
15.6
2.8
0
0
3
15.4
3.1
0
0
Mean
1.8
8.0
1560
2.1
15.5
3.0
0
0
910
850
980
565
8.5
3.3
1
14.1
4.4
0
0
1.5
15.1
3.5
0
0
3.5
15.0
3.3
0
0
Mean
2.1
8.0
1560
2.2
15.0
3.4
0
0
740
590
630
455
8
Al. 85
-------
Table A.1.3.9b Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature °F
Bed Height ft.
Gas Analysis
Vol % dry gas C02
II n
°2
CO
II pit
p. p.m. S02
so2
so2
Cl
" NH3
Method
Chromatograph
"
n
n
Iodine
I.R.A.
H2°2
n
"
3.4
2
14.9
3.4
0
0
2.5
15.2
3.2
0
0
3.5
14.9
3.4
0
0
Mean
2.8
7.9
1560
2.2
15.0
3.4
0
0
540
420
465
380
11.5
3.5
2
15.2
3.3
0
0
Mean
2.8
8.0
1560
3.8
15.2
3.3
0
0
540
420
580
455
13
3.6
0.5
16.0
3.6
0
0
2.5
16.1
3.0
0
0
Mean
3.0
4.1
1560
2.3
16.0
3.1
0
0
420
280
390
410
10
A1.86
-------
Table A. 1.3.10 Mass balance for Test 3.1
Rate: Ib/h
| Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
r
Total
303.0
0
2463.9
2766.9
0
27.5
76.5
2.5
2.1
2644.9
2753.5
13.4
0.5
'Ash'
73.9
0
0
73.9
0
27.5
58.4
2.2
2.0
0
90.1
-16.2
-21.9
'Carbon'
187.0
0
0
187.0
0
0
18.05
0.35
0.03
150.8
169.2
17.8
9.5
Nitrogen
0
0
1893
1893
0
0
0
0
0
1909
1909
-16
-0.9
'Oxygen'
13.3
0
570.9
584.2
0
0
0
0
0
570.2
570.2
14.0
2.4
Sulphur
4.39
0
0
4.39
0.12
0.12
0.31
0.01
0
3.76
4.32
0.07
1.7
Calcium
2.79
0
0
2.79
0.39
0.80
1.68
0.05
0.22
0
3.14
-0.35
-12.6
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
5.2%
10.9% (Unburnt)
14%
0
Al. 87
-------
Table A.1.3.11 Mass balance for Test 3.2
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
293.4
23.8
2501.8
2819.0
0
33.5
86.5
3.0
2.1
2688.1
2813.2
5.8
0.2
'Ash'
71.6
23.8
0
95.4
0
33.5
70.2
2.8
2.0
0
108.5
-13.1
-13.7
'Carbon'
181.0
0
0
181.0
0
0
16.35
0.21
0.09
155.3
172.0
9.0
5.0
Nitrogen
0
0
1922
1922
0
0
0
0
0
1932
1932
- 10
-0.5
'Oxygen'
12.9
0
579.8
592.7
0
0
0
0
0
586.1
586.1
6.6
1.1
Sulphur
4.25
0
0
4.25
0.09
0.36
0.95
0.07
0.05
2.32
3.84
0.41
9.6
Calcium
2.70
9.45
0
12.15
0.69
2.19
8.82
0.21
0.16
0
12.07
0.08
0.7
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
7.3%
9.7%
45%
1.8
(Unburnt)
Al. 88
-------
Table A.1.3.12 Mass balance for Test 3.3
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
301.1
26.4
2497.9
2825.4
0
21.0
91.0
3.5
2.1
2680.5
2798.1
27.3
1.0
'Ash'
73.5
26.4
0
99.9
0
21.0
76.2
3.2
2.0
0
102.4
-2.5
-2.5
'Carbon'
185.8
0
0
185.8
0
0
14.83
0.27
0.14
150.9
166.2
19.6
10.5
Nitrogen
0
0
1919
1919
0
0
0
0
0
1930
1930
-11
-0.5
'Oxygen'
13.2
0
578.9
592.1
0
0
0
0
0
584.6
584.6
7.5
1.3
Sulphur
4.06
0
0
4.06
0.23
0.31
1.09
0.08
0.05
1.90
3.66
0.40
9.9
Calcium
2.77
10.48
0
13.25
1.04
1.74
11.19
0.29
0.17
0
14.43
-1.18
-9.0
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
9.7%
9.2% (Unburnt)
53%
2.1
Al. 89
-------
Table A.1.3.13 Mass balance for Test 3.4
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
301.1
36.4
2471.7
2809.2
0
21.0
108.0
4.0
2.1
2651.5
2786.6
22.6
0.8
'Ash'
73.5
36.4
0
109.9
0
21.0
88.2
3.7
1.9
0
114.8
- 4.9
- 4.4
'Carbon'
185.8
0
0
185.8
0
0
19.76
0.31
0.14
149.3
169.5
16.3
8.8
Nitrogen
0
0
1899
1899
0
0
0
0
0
1908
1908
-9
-0.5
'Oxygen'
13.2
0
572.7
585.9
0
0
0
0
0
579.2
579.2
6.7
1.2
Sulphur
4..06
0
0
4.06
0.47
0.40
1.35
0.09
0.05
1.42
3.78
0.28
6.9
Calcium
2.77
14.45
0
17.22
2.41
2.17
13.50
0.30
0.16
0
18.54
-1.32
-7.6
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
6.9%
11.9% (Unburnt)
65%
2.8
A1.90
-------
Table A.1.3.14 Mass balance for Test 3.5
Rate: Ib/h
Coal Feed
j Acceptor Feed
Total Air
i
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
311.7
39.0
2486.3
2837.0
5.0
19.5
112.5
5.1
2.1
2669.9
2814.1
22.9
0.8
'Ash'
83.5
39.0
0
122.5
5.0
19.5
91.7
4.7
2.0
0
122.9
-0.4
-0.3
'Carbon'
187.0
0
0
187.0
0
0
20.81
0.44
0.14
152.3
173.7
13.3
7.1
Nitrogen
0
0
1910
1910
0
0
0
0
0
1919
1919
-9
-0.5
'Oxygen'
12.5
0
576.3
588.8
0
0
0
0
0
583.4
583.4
5.4
0.9
Sulphur
4.36
0
0
4.36
0.79
0.37
1.80
0.13
0.05
1.42
4.56
-0.2
-4.5
Calcium
2.87
15.48
0
18.35
3.96
1.93
15.07
0.42
0.05
0
21.43
-3.08
-16.8
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
5.8%
12.3% (Unburnt)
2.8
A1.91
-------
Table A.1.3.15 Mass balance for Test 3.6
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
151.5
20.0
1278.1
1449.6
0
20.0
33.0
3.0
1.1
1375.6
'1432.7
16.9
1.1
'Ash1
40.6
20.0
0
60.6
0
20.0
27.9
2.8
1.0
0
51.7
8.9
14.8
'Carbon'
90.9
0
0
90.9
0
0
5.11
0.24
0.07
82.5
87.9
3.0
3.3
Nitrogen
0
0
982
982
0
0
0
0
0
980
980
2
0.2
'Oxygen'
6.1
0
296.1
302.2
0
0
0
0
0
305.9
305.9
- 3.7
- 1.2
Sulphur
2.12
0
0
2.12
0.24
0.43
0.64
0.07
0.03
0.57
1.98
0.14
6.9
Calcium
1.39
7.94
0
9.22
0.84
1.85
4.72
0.23
0.02
0
7.66
1.67
17.9
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
10.4%
6.2%
73%
3.0
(Unburnt)
A1.92
-------
Table A.1.3.16 Pressure drops through the combustor
Test No.
Fluidising Velocity
ft/s
Bed Height ft
Base plate
Bed
Density
(over 8 in)
1 Cyclone
2 Cyclone
3.1
7.9
2.1
3.2
8.0
2.1
3.3
8.0
2.1
3.4
7.9
2.2
3.5
8.0
3.75-3.9
3.6
4.1
2.2-2.4
Pressure drop, inches w.g.
38
12
3.8
2.5
13.5
36.5
12
3.8
2.5
14
36
12
3.8
3
15
35
12.5
3.8
3
15
35
24
4.3-4.1
2.5
13
12.5
19
5.8-5.3
1
3
A1.93
-------
Table A.1.3.17 Temperature distribution through the combustor
APCO Test No.
Fluidising Velocity
Bed Height
Excess Air %
Probe
Number
N 2
N14
N 3
N 4
N15
N 5
N20
N 9
N23
N10
N25
Nil
N26
N27
Height above
bubble caps
(ins)
4
4
12
12
12
20
50
94
94
130
130
154
154
154
Projection into
combustion
(ins)
3
9
3
9
3
9
9
9
9
9
9
9
9
9
1° Cyclone
2° Cyclone
Steam to freeboard at N£2 lb/h
3.1
7.9
2.1
5.2
3.2
8.0
2.1
7.3
3.3
8.0
2.1
9.7
3.4
7.9
2.2
6.9
3.5
8.0
3.7 - 3.4
5.8
3.6
4.1
2.2 - 2.4
10.4
Temperature F
1567
1584
1585
1585
1567
1593
1634
1441
1650
1639
1582
1629
1625
1571
1454
1494
300
1557
1575
1584
1557
1571
1587
1636
1429
1636
1614
1555
1598
1598
1539
1425
1474
350-420
1539
1558
1562
1537
1557
1582
1648
1539
1648
1611
1562
1614
1609
1555
1425
1479
~530
1540
1564
1573
1544
1566
1591
1647
1350
1458
1566
1483
1524
1528
1501
1353
1407
560-600
1540
1558
1575
1540
1571
1584
1611
1494
1578
1522
1479
1504
1494
1459
1328
1400
600
1557
1562
1573
1548
1555
1578
1632
1589
1656
1571
1573
1566
1544
1539
1337
1386
200
A1.94
-------
Table A.1.3.18 S00 concentrations and % reductions
Test No.
Fluidising Velocity, ft/s
Bed Temperature, F
Bed Height, ft
Ca/S mol ratio
S0~ concentration, p. p.m.
S02 reduction, %
3.1
8
1560
2.1
0
1480
0
3.2
8
1560
2.1
1.8
910
38
3.3
8
1560
2.1
2.1
740
50
3.4
8
1560
2.2
2.8
540
64
3.5
8
1560
3.8
2.8
540
64
3.6
4
1560
2.3
3.0
420
72
Table A.1.3.19 S0? concentrations and 7, reduction during temperature survey
Time, mins .
0
10
18
20
25
35
40
45
50
60
68
72
80
88
92
120
Bed Temperature
1571
1580
1614
1598
1625
1492
1544
1499
1544
1468
1578
1517
1634
1526
1632
1562
SO- concentrations
p .p >m .
420
500
640
560
700
360
460
380
500
380
580
500
820
400
640
500
S09 reduction
%
68
62
51
57
46
72
64
71
62
71
55
62
37
69
51
61
The datum S0_ concentration for the infra-red analyser was taken
as 1300 p.p.m.
Al. 95
-------
Table A.I.A.I Operating conditions during Test Series 4
Coal Pittsburg coal
Coal size - 1680 pm
Acceptor Dolomite 1337
Acceptor size - 1680 pm
Test No.
Time
from start
of Test
Series
(hrs)
S
t
a
r
t
E
3
Ca/S mol ratio
Coal Rate
Ib/h dry
Fluidising Velocity
ft/s
Bed Temperature
Bed Height
ft
Recycle
Datum
0
7
0
123
4.0
1470
2.1
No
4.1
16
20
3.1
123
4.0
1470
2.1
No
4.2
27
31
2.6
133
4.1
1380
2.1
No
4.3
38
42
2.7
119
3.8
1560
2.1
No
4.4
47
51
2.7
121
4.0
1470
2.1
No
4.5
61
65
2.2
73
2.1
1470
3.7
No
4.6
82
86
1.6
60
2.2
1470
3.8
Yes
Al. 96
-------
Table A.1.4.2 Chemical analyses of coal
Test Number
Proximate analysis
Total moisture
Ash
Volatile matter
Ultimate analysis
Carbon
Hydrogen
Nitrogen
Sulphur
Oxygen + errors
Chlorine
Carbon Dioxide
% a.r.
% a.r.
% d.a.f.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
4.1
1.6
14. 8
-
70.5
4.3
1.4
2.65
4.3
0.1
0.7
4.6
1.5
13.5
-
71.6
4.5
1.45
2.7
4.4
0.08
0.65
Additional samples of coal analysed for sulphur only
Test No.
Sulphur % d.b.
4.1
2.65
4.2
2.6
4.3
2.7
4.4
2.6
4.5
2.75
4.6
2.7
Al. 97
-------
Table A.1.4.3 Size distribution of coal
Test No.
Particle Size (pm)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. dtnn)
Packed bulk .
density Ib/ft
% in grade by weight
4.1
0.1
1.0
13.7
33.0
22.7
12.2
8.0
3.2
6.1
474
58.9
4.2
0
0.3
14.0
31.8
22.5
12.7
8.4
5.7
4.6
453
56.9
4.3
0
0.6
19.1
32.2
20.5
11.2
7.4
2.6
6.4
525
57.3
4.4
0
0.5
20.2
33.7
20.2
10.8
6.8
4.6
3.1
560
57.4
4.5
0.1
0.4
16.2
32.3
21.6
11.6
8.2
4.4
5.3
486
58.0
4.6
0
0.4
20.5
32.6
20.1
11.1
7.3
4.3
3.6
549
57.7
A1.98
-------
Table A.1.4.4. Chemical and size analyses of acceptor
Test No.
Chemical Analysis
CaO a.r.
MgO a.r.
C02 a.r.
SO. a.r.
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
45
Median diam. (ym)
Packed bulk
density Ib/ft
4.1
29.7
21.8
47.0
-
4.4
29.8
22.1
47.1
-
4.6
29.8
22.1
47.5
-
% in grade by weight
0
0.4
4.5
6.9
10.2
19.3
31.7
11.2
15.8
106
108
0
0.9
7.1
12.6
9.3
19.0
27.6
10.3
13.2
122
112.4
0
1.4
7.4
12.2
9.9
20.3
27.7
9.6
11.5
128
105.5
Al. 99
-------
Table A.1.4.5 Chemical and size analyses of primary cyclone fines
1
Test No.
Chemical Analysis
Carbon % a.r.
Sulphur "
co2
CaO "
MgO
Size Analysis
Particle size (pm)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
45
Median diam. (ym)
Packed bulk
density lb/ft3
4.1
12.6
3
11.34
31.6
21.5
4.2
12.9
2.1
20.9
27.0
18.7
4.3
14.1
3.2
12.1
29.2
19.8
4.4
15.0
3.4
9.2
27.9
19.7
4.5
13.0
3.05
12.3
25.8
18.5
4.6*
1.9
6.95
2.9
25.6
18.7
% in grade by weight
0
0
0
0.1
2.8
12.1
37.4
15.9
31.7
69
56.7
i
0
0
0
0
4.2
18.5
35.7
13.5
28.1
79
58.4
0
0
0
0
2.8
10.6
32.4
16.8
37.4
60
58.3
0
0
0.2
0.3
3.9
15.2
35.4
14.8
30.2
73
53.3
0
0
0.1
0.2
1.8
14.1
37.7
15.9
30.2
71
56.4
0
0
0
0.1
0.1
7.8
41.1
17.4
33.5
65
80.3
* Note that this analysis refers to a sample of the recycling fines
Al. 100
-------
A.1.4.6 Chemical analyses of secondary cyclone fines
Test No.
Analysis
Carbon % a.r.
4.1
7.0
Sulphur % a.r. | 4.3
CO- % a.r.
5.34
CaO % a.r. ' 16.5
MgO • % a.r. 10.1
4.2
9.5
4.4
4.7
14.4
8.7
4.3
9.3
4.1
4.5
15.4
9.7
4.4
8.8
4.35
3.42
13.5
8.2
4.5
13.0
3.8
3.9
12.6
8.0
4.6
6.2
4.05
3.76
15.1
9.5
Table A.1.4.7 Chemical analyses of exhaust dust
Test No.
Analysis
Carbon % a.r.
Sulphur % a.r.
v>u _ /o 3. • r •
CaO % a.r.
MgO % a.r.
4.1
3.8
4.7
0.14
7.7
3.8
4.2 ! 4.3
4.9 ; 3.8
4.7 5.35
0.94 0.14
9.4 9.8
5.0 4.8
4.4
3.8
3.65
0.14
9.7
5.3
4.5
9.0
3.35
0.14
8.5
4.7
4.6
7.4
3.1
0.14
11.0
5.0
Al. 101
-------
Table A.1.4.8a Chemical and size analyses of bed material
Test No.
Sample
Chemical Analysis
Sulphur % a.r.
co2
CaO "
MgO
Size Analysis
Particle size (vim)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam (ym)
Packed bulk
density lb/ft3
4.1
Initial
2.1
1.57
11.1
3.3
0
1.9
15.1
40.7
26.1
12.7
2.6
0.4
0.5
582
83.1
Final
3.0
0.26
12.3
5.2
4.2
Initial
3.85
3.46
12.7
7.3
0
2.0
19.0
52.1
26.5
0.3
0.1
0
0
721
84.0
0
2.5
22.0
49.9
25.0
0.4
0.2
0
0
745
84.1
Final
4.3
3.82
14.1
8.5
Offtake
3.55
2.49
10.9
6.3
4.3
Initial
5.3
0.21
14.7
8.3
Final
5.1
0.25
14.1
8.0
Offtake
5.6
0.36
15.4
8.8
4.4
Initial
5.55
0.24
14.6
8.6
Final
5.6
0.26
14.6
8.3
% in grade by weight
0
2.1
21.8
44.7
29.3
1.4
0.5
0.1
0.1
684
85.2
0
1.6
17.2
51.4
29.4
0.4
0
0
0
686
87.9
0
1.9
21.5
50.7
25.6
0.2
0.1
0
0
738
86.7
0
1.8
21.2
50.1
26.7
0.2
0
0
0
726
85. e
0
1.9
18.0
48,2
31.2
0.4
0.1
0
0.1
666
84.3
0
1.9
23.5
50.5
23.9
0.2
0
0
0
723
88
0
1.7
21.5
51.6
25.0
0.2
0
0
0
744
81.2
-------
A.1.4.8b Chemical and size analyses of bed material
Test No.
Sample
Chemical Analysis
Sulphur % a.r.
CO 2 % a.r.
CaO % a.r.
MgO % a.r.
Size Analysis
Particle size (pm)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45-66
- 45
Median diam. (urn)
Packed bulk
density Ib/ft
4.5
Initial
4.15
0.2
10.6
6.3
Final
4.5
0.25
11.5
7.0
Offtake
4.65
0.2
11.6
6.8
4.6
' Initial
4.7
0 .25
12.3
7.2
Final
4. 65*
0.22
12.6
7.3
Offtake
5.4
0.2
14.0
8.2
% in grade by weight
0.2
1.1
16.4
47.0
30.0
5.1
0.1
0
0.1
638
86.2
0
1.6
17.9
46.0
29.1
5.3
0.1
0
0
650
86.3
0
1.2
15.4
48.6
30.0
4.7
0.1
0
0
641
84.5
0
1.1
16.2
42.9
28.3
9.8
1.4
0.2
0.1
602
84.4
0
0.9
14.3
41.1
29.7
11.3
2.3
0.2
0.2
561
87.8
0
1.3
15.6
39.0
28.5
12.1
3.3
0.1
0.1
560
91.3
Al. 103
-------
Table A.1.4.9a Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature °F
Bed Height ft
Recycle
Gas Analysis
Vol % dry gas CO-
°2
CO
CH4
p. p.m. NO
X
so2
so2
so2
Cl
NH3
Method
Chroma-
tograph
"
"
it
Saltz-
man's
Iodine
I.R.A.
H2°2
"
Datum
0
4.0
1470
2.1
No
15.3
2.5
0
0
2240
2000
4.1
1
16.9
2.6
0
0
2
16.0
3.3
0
0
4
16.7
3.1
0
0
Mean
3.0
4.0
1470
2.1
No
16.5
3.0
0
0
234
380
290
350
46
34
4.2
1
15.2
3.9
0
0
2
15.7
3.7
0
0
Mean
2.6
4.0
1380
2.1
No
15.7
3.7
0
0
620
510
570
44
6
4.3
1
15.9
2.6
0
0
3
15.6
3.1
0
0
(245
C244
Meat
2.'
3.8
156<
2.1
No
15.;
2.9
0
0
24.
600
4 K
630
5
6
Al. 104
-------
Table Af1.4.9b Flue gas analyses
Test No.
Time from start (h)
)perating Conditions
Ca/s mol ratio
?luidising Velocity ft/s
Bed Temperature F
Bed Height ft
Recycle
2as Analysis
Vol % dry gas O>2
°2
CO
II .-ITT
p.p.m» NO
X
so2
so2
so.
2
Cl
NH3
Method
Chroma-
tograph
ii
ii
ii
Saltz-
man's
Iodine
I,R,A.
H->°9
2 2
"
"
4.4
0
15.3
3.8
0
0
1
15.0
3.8
0
0
Mean
2.7
4.0
1470
2.1
No
15.2
3.8
0
0
-
580
460
570
42
6
4.5
1.5
16.7
2.8
0
0
2.5
16.7
2.7
0
0
3
360
Mean
2.2
2.1
1470
3.7
No
16.7
2.8
0
0
360
380
380
380
29
7
4.6
-2
(398
{386
0
15.7
3.2
0
0
3.5
16.7
3.1
0
0
Meani
1.6'
2.2
1470
3.8
Yes
16.3
3.1
0
0
392
20
20
22
38
8
Al. 105
-------
Table A.1.4.10 Mass balance for Test 4.1
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
123.0
61.0
1285.9
1469.9
0
7.0
63.0
2.0
0.5
1397.7
1470.2
- 0.3
0
'Ash'
17.8
46.2
0
64.0
0
7.0
55.1
1.9
0.5
0
64.5
-0.5
-0.8
'Carbon'
87.3
0
0
87.3
0
0
7.94
0.14
0.02
80.8
88.9
-1.6
-1.7
Nitrogen
0
0
988
988
0
0
0
0
0
990
990
- 2
-0.2
1
'Oxygen'
5.3
0
297.9
303.2
0
0
0
0
0
303.4
303.4
- 0.2
- 0.1
Sulphur
3.32
0
0
3.32
1.04
0.18
1.89
0.09
0.02
0.49
3.71
-0.39
-11.7
Calcium
1.08
12.93
0
14.01
1.04
0.58
14.17
0.24
0.03
0
16.06
-2.05
-14.5
Magnesium d
0
8.1
0
8.1
1.30
0.18
8.13
0.12
0.01
0
9.74
-1.64
-20.3
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
7.1%
9.1% (Unburnt)
85%
3.1
Al. 106
-------
Table A.1.4.11 Mass balance for Test 4,2
Race: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
132,8
53.6
1384,9
1571.3
0
14.0
55.0
2.0
0.6
1500.5
1572.1
-0.8
-0.1
'Ash'
19.3
40.7
0
60.0
0
14.0
47.9
1.8
0.6
0
64.3
-4.3
-7.2
'Carbon'
. 94.3
0
0
94,3
0
0
7.09
0.19
0.03
84.2
91.5
2.8
3.0
Nitrogen
0
0
1064
1064
0
0
0
0
0
1064
'Oxygen'
5.7
0
320,9
326o6
0
0
0
0
0
329.9
1064 | 329.9
0
0
-3.3
-1.0
Sulphur
3.45
0
0
3.45
0.52
0.57
1.15
0.09
0.03
0.87
3.23
0.22
6.4
Calcium
1.17
11.36
0
12.53
1.16
1.34
10.61
0.21
0.04
0
13,36
-0.83
-6.6
Magnesium
0
7.13
0
7.13
0.81
0.66
6.15
0.10
0.02
0
7.74
-0.61
-8.6
i
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
12.3%
8.0% (Unburnt)
75%
2.6
Al. 107
-------
Table A.1.4.12 Mass balance for Test 4.3
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
119.1
52.0
1181.9
1353.0
0
8.0
57.0
2.8
0.7
1280.3
1348.8
4.2
0.3
'Ash'
17.3
39.6
0
56.9
0
8.0
49.0
2.5
0.6
0
60.1
-3.2
-5.6
'Carbon'
84.5
0
0
84.5
0
0
8.04
0.26
0.03
70.8
79.1
5.4
6.4
Nitrogen
0
0
908
908
0
0
0
0
0
918
918
-10
-1.1
'Oxygen'
5.1
0
273.9
279.0
0
0
0
0
0
270.8
270.8
8.2
2.9
Sulphur
3.21
0
0
3.21
-0.24
0.42
1.82
0.11
0.04
0.77
2.92
0.29
9.2
Calcium
1.05
11.02
0
12.07
-0.48
0.82
11.91
0.31
0.05
0
12.61
-0.54
-4.4
Magnesium
0
6.90
0
6.90
-0.24
0.40
6.77
0.16
0.02
0
7.11
-0.21
-3.0
I
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
5.8%
10.5% (Unburnt)
76%
2.7
Al. 108
-------
Table A.1.4.13 Mass balance for Test 4.4
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
121.0
49.0
1285.9
1455.9
0
6.0
48.0
1.8
0.5
1388.2
1444.5
11.4
0.7
'Ash'
17.5
37.3
0
54.8
0
6.0
40.8
1.6
0.5
0
48.9
5.9
10.8
'Carbon'
85.9
0
0
85.9
0
0
7.20
0.16
0.02
74.6
82.0
3.9
4.6
Nitrogen
0
0
988
988
0
0
0
0
0
996
996
-8
-0.8
'Oxygen'
5.2
0
297.9
303.1
0
0
0
0
0
297.2
297,2
5.9
1.9
Sulphur
3.15
0
0
3.15
0.06
0.33
1.63
0.08
0.02
0.78
2.90
0.25
7.8
Calcium
1.07
10.44
0
11.51
0
0.62
9.55
0.17
0.04
0
10.38
1.13
9.8
Magnesium
0
6.51
0
6.51
-0.23
0.32
5.66
0.09
0.02
0
5.86
0.65
10.0
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
12.7%
9.0% (Unburnt)
75%
2.7
Al. 109
-------
Table A.1.4.14 Mass balance for Test 4.5
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
72.8
26.0
700.2
799.0
0
3.0
28.0
1.2
1.0
762.0
795.2
4.8
0.6
'Ash'
10.6
19.8
0
30.4
0
3,0
24.3
1.0
0.9
0
29.2
1.2
3.9
'Carbon'
51.7
0
0
51.7
0
0
3.67
0.16
0.09
45.0
48.9
2.8
5.4
Nitrogen
0
0
538
538
0
0
0
0
0
537
537
1
0.2
'Oxygen'
3.1
0
162.2
165.3
0
0
0
0
0
168.6
168.6
-3.3
-2.0
Sulphur
2.00
0
0
2 .00
0.81
0.13
0.85
0.05
0.03
0.28
2.15
-0.15
-7.5
Calcium
0.64
5.54
0
6.18
1.39
0.24
5.15
0.11
0.06
0
6.95
-0.77
-12.4
Magnesium
0
3.46
0
3.46
0.93
0.12
3.10 .•
0.06 >
0.03 .
o ;
4.24 )
a; ?r4
-22.5 |
J. .•:•[ I
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
6.8%
8.0% (Unburnt)
85%
2.2
Al. 110
-------
Table A.1.4.15 Mass balance for Test 4.6
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
60.0
15.2
726.4
801.6
6.5
2.5
0
3.0
1.6
783.8
797.4
4.2
0.5
'Ash1
8.7
11.6
0
20.3
6.5
2.5
0
2.8
1.5
. .0
13.3
7.0
34.5*
'Carbon'
42.6
0
0
42.6
0
0
0
0.19
0.12
45.8
46.1
-3.5
-8.3
Nitrogen
0
0
558
558
0
0
0
0
0
561
561
- 3
-0.5
'Oxygen'
2.6
0
168.4
171.0
0
0
0
0
0
169.3
169.3
1.7
1.0
Sulphur
1.62
0
0
1.62
0.18
0.11
0
0.12
0.05
0.02
0.48
1.14
70.3*
Calcium
0.53
3.24
0
3.77
0.89
0.22
0
0.32
0.13
0
1.56
2.21
58.6*
Magnesium
0
2.02
0
2.02
0.45
0.11
0
0.18
0.05
0
0.79
1.23
60.9*
i
i
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
Fines recycle rate
16.4%
0.7% (Unburnt)
99%
1.6
320 Ib/h
* These poor balances are probably the result of the weight
of fines in the recycle system increasing during the balance.
Al. Ill
-------
Table A.1.4.16 Pressure drops through the combustor
Test No.
Fluidising Velocity
ft/s
Bed Height ft
Baseplate
Bed
Density (over 8 in)
1 Cyclone
2 Cyclone
4.1
4.0
2.1
4.2
4.1
2.1
4.3
3.8
2.1
4.4
4.0
2.1
4.5
2.1
3.7
4.6
2.2
3.8
Pressure drop, inches w.g.
11
20
6.3
1
3
12.5
20
6.3
1
3
9
21
6.7
1
3
10.5
20
6.3
1
3
4.5
41
7.2
0.5
1
5.5
39
6.8
0.5
1
Al. 112
-------
Table A.1.4.17 Temperature distribution through the combustor
APCO Test No.
Fluidising Velocity ft/s
Bed Height ft
Excess air
I
i Probe
[ Number
N2
N14
N3
N4
N15
N5
N20
N9
N23
N10
Height above
bubble caps
(ins)
4
4
12
12
12
20
50
94
94
130
N25 130
Nil | 154
N26 j 154
N27 154
Projection into
combustor
(ins)
3
9
3
9
3
9
9
9
9
9
9
9
9
9
1 Cyclone
2° Cyclone
Steam to freeboard at N22. Ib/h
4.1
4.0
2.1
6.8
4.2
4.1
4.3
3.8
2.1 | 2.1
11.9 5.6
4.4
4.0
2.1
12.1
4.5
2.1
3.7
4.6 |
2.2
3.8
6.6 15.8
Temperature F i
1477 ' 1384 1 1566 1474 1486
1481
1486
1479
1387
1389
1393
1476 1382
1485
1387
1566
1571
1567
1562
1564
1530 1458 1600
1591 1530 1485
1589 : 1528
1576
1524
.
1584 1531
1576 1530
1564 1519
1551 1506
1355: 1317
1404 , 1387
0 0
1560
1477 1476
1483
1479
1474
1474
1530
1591
1483
1468
1474
1468
1497
1508
i
1594 1510
1494 1585 1472
1470 1594 1483
1477 1587 1456
1468 1576 1445
1440
1567 1432
1270 1353 1216
1328 1411 1225
200 | 0 0
1477
1470
1477
1459
1468 i
1456
1490
1517 .
1517
1512
1522
1515
1504 '
1490 i
i
1247 ;
1321 ;
o i
Al. 113
-------
Table A.1.4.18 S07 concentrations and % reductions
Test No.
Fluidising Velocity, ft/s
Bed Temperature, °F
Bed Height, ft
Fines Recycle
Ca/S mol ratio
SO- concentration, p. p.m.
SOj reduction, %
Datum
4.0
1470
2.1
No
0
2240
0
4.1
4.0
1470
2.1
No
3.1
380
83
4.2
4.1
1380
2.1
No
2.6
620
72
4.3
3.8
1560
2.1
No
2.7
600
73
4.4
4.0
1470
2.1
No
2.7
580
74
4.5
2.1
1470
3.7
No
2.2
380
83
4.6
2.2
1470
5.8
Yes
1.6
20
99
Al. 114
-------
Table A.1.5.1 Operating Conditions during Test Series 5
Coal Pittsburg coal
Coal size -3175 ym
Acceptor Limestone 18
Acceptor size -3175 pm
Bed Temperature 1560°F
Recycle System not in operation
Test No.
Time
from start
of Test
Series
(hrs)
S
t
a
j-
E
n
d
Ca/S mol ratio
i
Coal Rate
Ib/h dry
Fluidising Velocity
ft/s
Bed Height
ft.
Datum
6
14
0
122.
4.0
2.1
5.1
24
28
1.7
122
4.0
2.1
5.2
37
41
1.6
247
8.0
2.2
5.3
51
55
1.9 •
253
7.8
3.5
J.H
65
69
.5.7
253
8.0
3.6
5.5
85
105
6
245
8.0
3.6
Al. 115
-------
Table A.1.5.2 Chemical analyses of coal
Test Number
Proximate analysis
Total moisture
Ash
Volatile matter
Ultimate analysis
Carbon
Hydrogen
Nitrogen
Sulphur
Oxygen + errors
Chlorine
Carbon Dioxide
% a.r.
% a.r.
% d.a.f.
% d.b. '
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
5.4
1.5
15.5
-
69.5
4.3
1.4
2.8
4.5
0.1
0.7
Additional samples.of-coal-analysed for, sulphur only
Test No.
Sulphur % d.b.
5.1
2.85
5.2
2.8
5.3
2.75
5.4
2.8
Al. 116
-------
Table A.1.5.3 Size distribution of coal
I
i
Test No.
1 Particle Size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
% in grade by weight
5.1
0.3
17.7
17.1
22.6
15.0
9.5
7.7
3.5
6.6
i
Median diam. (pm)
.
Packed bulk
density lb/ft3
648
60.1
5.2
0.4
24.7
17.7
19.8
14.8
8.8
6.0
2.6
5.2
803
57.4
5.3
[
0.6
25.8
19.7
19.5
11.6
7.4
6.0
3.2
6.2
893
58.0
5.4
0.4
19.3
18.1
21.7
16.9
11.0
6.6
3.7
2.3
677
59.6
Al. 117
-------
Table A.1.5.4 Chemical and size analyses of acceptor
Test No.
Chemical Analysis
CaO a.r..
MgO a.r.
CO - a.r.
S 02 a.r.
Size Analysis
Particle size (ym)
+ 3175
+1680 - 3175
+1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (ym)
Packed bulk
density Ib/ft
5.1
44.5
-
36.8
^
5.2
-
-
-
^
5.4
43.7
-
36,2
^
%. in grade by weight
0
9
12.4
17.0
23.2
16.7
8.9
3.5
9.3
362
122.4
0
8.9
12.0
16.0
23.5
17.1
10.1
3.9
8.5
343
-
0
17.6
15.1
17.0
18.1
12.4
8.4
2.1
9.3
495
114.4
Al. 118
-------
Table A.1.5.5 Chemical and size analyses of primary cyclone fines
Test No.
Chemical Analysis
Carbon % a.r.
Sulphur "
co2
CaO
Size Analysis
Particle (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
5.1
20.8
3.3
3.5
25.6
5.2
25.1
2.9
3.4
24.5
5.3
25.1
2.9
4.64
25.2
5.4
!
19.4
2.5
4.37
36.2
% in grade by weight
0
0
0
0.1
8.4
32.5
24.5
+45-66 ! 7.5
- 45
Median diam. (ym)
27.0
102
0
0
0.1
2.5
14.5
19.1
21.7
8.1
34.0
0
0.1
0.1
4.6
13.2
"18.9.
23.5
7.7
31.9
87 93
'; j
Packed bulk _- 0 ,-Q
density Ib/ft3 j 51'2 58'9
i
48.5
0
0.1
0.1
2.8
9.9
15.7
20.7
9.8
40.9
i
j
64
48.9
Al. 119
-------
acceptor
Table A.1.5.6 Chemical analyses of secondary cyclone fines
Test No.
Analysis
Carbon % a.r.
Sulphur % a.r.
CO. % a.r.
CaO % a.r.
5.1
7.7
4.6
3.8
19.6
5.2
4.5
5.4
2.6
21.0
5.3
8.7
5.6
3.5
24.1
5.4
2.5
6.45
9.1
44.4
Table A.1.5.7 Chemical analyses of exhaust dust
Test No.
Analysis
Carbon % a.r.
Sulphur % a.r.
CO % a.r.
'
CaO % a.r.
'
5.1
4.5
5.0
1.0
12.5
5.2
5.4
5.1
1.0
17.5
5.3
5.7
6.4
1.0
18.9
5.4
1.7
9.1
4.7
36.8
Al. 120
-------
Table A.1.5.8a Chemical and size analyses of bed material
(Test No.
Sample
Chemical Analysis
Sulphur % a.r.
co2
CaO
Size Analysis
Particle size (pm)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (urn)
Packed bulk
density Ib/ft^
5.1
Initial
1.55
0.33
9.1
Final
2.7
0.21
14.1
l Off take
1.5
0.18
9.1
5.2
Initial
3.85
0.2
19.5
Final
3.3
0.24
15.6
Offtake
3.4
0.17
16.5
5.3
Initial
3.55
0.26
15.7
Final
3.65
0.23
15.7
5.4
Initial
3.8
1.65
21.7
Final
3.8
0.85
21.2
Offtake
3.2
0.29
17.8
% in grade by weight
0.8
18.3
14.8
23.3
31.0
10.0
1.2
0.3
0.3
580
88.1
0.5
27.7
21.1
27.0
22.7
0.8
0.2
0
0
987
81.4
0.6
29.3
24.3
30.7
14.9
Q.2
0
0
0
1090
87.9
0.6
20.7
27.3
45.1
6.0
0.2
0.1
0
0
983
86.4
0.5
25.1
30.0
40.0
4.2
0.1
0.1
0
0
1094
81.7
0.8
35.5
)
,27.9
32.0
3.7
0.1
0
0
780
92.2
1.0
29.8
32.8
34.8
1.5
0.1
0
0
0
1245
87.7
1.0
31.0
)
,30.7
35.5
1.6
oa
0
0.1
750
86.5
0.2
27.3
30.2
40.4
1.8
0.1
0
0
0
1129
84.2
0.5
26.9
31.9
38.8
1.7
0.2
0
0
0
1157
1.5
41.2
28.8
26.3
1.8
0.3
0.1
0
0
1491
i
!
82.0 \ C2 .'?
; 1
-------
Table A.1.5.8b Chemical and size analyses of bed material
, ,|T',|yftes oi i^-.'ontlarcycione lines
Test No.
Time from start (hi
Chemical Analysis
Sulphur % a.r.
CO. % a.r.
CaO % a.r.
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (ym)
Packed bulk .
density Ib/ft
5.5
2
3.75
0.38
20.6
5
3.9
0.49
22.7
8
3.55
0.52
24.6
11.5
4/25
0.55
26.5
16.5
3.75
0.6
26.4
Z in grade by weight
0.4
28.2
29.9
37.5
3.7
0.2
0.1
0
0
1150
82.7
0.3
28.8
27.7
39.3
3.5
0.2
0.1
0
0
1119
87.0
0.3
23,4
29.9
42.8
3.5
0.1
0
0
0
1058
83.1
0.5
24.3
29.8
41.7
3.3
0.2
0.2
0
0
1075
83.5
0.2
21.3
27.4
47.2
3.8
. 0.1
0
0
0
986
83.1
Al. 122
-------
Table A.1.5.9a Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature F
Bed Height ft
Gas Analysis
Vol % dry gas C02
°2
CO
II X,TT
p. p.m. NO
v v x
. so2
so2
so.
2
Cl
NH3
Method
Chroma-
tograph
"
ii
"
Saltz-
man ' s
Iodine
I.R.A.
H,09
2 2
11
Datum
0
4.0
1560
2.1
(280
(330
1850
2060
_
-
"
5.1
'0
15.2
3.1.
0
0
3
15.2
3.2
0
0
Mean
1.7
4.0
1560
2.1
15.2
3.2
0
0
850
650
780
60
2
5.2
2
15.7
2.8
0
0
(450
(440
3.75,
14.6
3.8
0
0
Mean
1.6
8.0
1560
2.2
15.3
3.2
, 0
0
445
1180
"950
1180
65
4
i
5.3
0 .
16.2
2.3
0
0
2
16.2
2.4
0
0
Mean
1.9
7.8
1560
3.5
16.2
2.4
0
0
-
1040
1000
1050
65
2
Al. 123
-------
Table A.1.5.9b Flue gas analyses
i coctrial
Test No.
Time from s
Operating C
Ca/S mol ra
Fluidising
Bed Tempera
Bed Height
:art (h)
mditions
:i=f
Velocity ft/s
ture °F
ft;
Gas Analysis
Vol % dry g
"
"
"
p. p.m.
"
n
"
n
11
i
, |
as C02
°2
CO
CH4;
NOX
so2
so2'
so2
• Cl
1 NH3
i
1
<
i
i
Method
Chroma tograph
n
"
! "
!
Saltzman's
j
Iodine 'J
4
I.R.A. ;
H202
" i
!•/ if" i
1
. ,
5.4
1
is.o
h
2.5
i
>'
17j.2
1 2.2
e
° •[
I1 ° '
560
1 ''
\
,
i >f~*
'
1
j
0
0
1
Mean
j
5.7).
8.6'
s
1560
H
\
16.2
(-2.
i
0
0
I 56
8
0
5
1 3
i
8
)
)
4
0
3
"* 5.
3.
- !
»
f, \
16.8
3.3
!3 !
i
550
i-^ 3
— .
.0..0
>•
:
17.0
3.0
4'''
^ «'
,.1
•>
iliL
5
16
i
j
16.9
2.9
0
0
(307
(341
i
Mean
6
8.0
1560
3.6
16.9
3.0
0
0
-
11
0
-
-
-
A1.124
-------
Table A.1.5.10 Mass balance for Test 5.1
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
122.1
23.0
1262.6
1407.7
0
16.0
33.0
2.1
0.8
1356.9
1408.8
-1.1
-0.08
i
'Ash'
19.2
23.0
0
42.2
0
16.0
26.1
1.9
0.8
0
44.8
-2.6
-6.2
'Carbon'
84.9
0
0
84.9
0
0
6.86
0.16
0.04
77.3
84.3 .
0.6
0.7
Nitrogen
0
0
970
970
0
0
0
0
0
976
976
-6
-0.6
'Oxygen1
5.5
0
292.6
298.1
0
0
0
0
0
295.1
295.1
3.0
1.0
Sulphur
3.42
0
0
3.42 '
1.25
0.34
1.0-9
0..10
0;04
1.13
3.95
-0.53
-15.5 |
Calcium
1.07
. 7.31
0
8.38
3.92
1.33
6.04
0.29
0.07
0
11.65
-3.27
-38.9
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
9.3%
8.4% (Unburnt)
67%
1.7
Al. 125
-------
Table A.1.5.11 Mass balance for Test 5.2
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
i
! Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
247.2
43.5
2494.0
2784.7
0
12.0
78.1
1.9
1.7
2682.6
2776.3
8.4
0.3
'Ash'
38.8
43.5
0
82.3
0
12.0
58.5
1.8
1.7
0
74.0
8.3
10.1
'Carbon'
171.8
0
0
171.8
0
0
19.60
0.09
0.09
153.7
173.5
-1.7
-1.0
Nitrogen
0
0
1916
1916
0
0
0
0
0
1924
1924
-8
-0.4
'Oxygen'
11.1
0
578.0
589.1
0
0
0
0
0
587.5
587.5
1.6
0.3 _
, Sulphur
6.92
0 -
- o
... 6.91~
-0.44 K
0.43
2,26 -
0.10 .-
0.09 -
3.10
3-. 34
1.38 _
. : ««
19.9
Calcium
2.18
13.83
0
16.01
- -2.24
- 1.50
- 13-. 67
0.29
0.22
0
13.44
2.57
16.1
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
6.1%
11.4% (Unburnt)
55%
1.6
••*«»•/
A1.126
-------
Table A.1.5.12 Mass balance for Test 5.3
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
253.1
54.0
2432.8
2739.9
0
6.0
108.0
4.1
2.1
2627.8
2748.0
-8.1
-0.3
'Ash'
39.7
54.0
0
93.7
0
6.0
80.9
3.7
2.0
0
92.6
1.1
1.2
'Carbon'
175.9
0
0
175.9
0
0
27.11
0.36
0.12
158.5
186.1
-10.2
-5.8
Nitrogen
0
0
1869
1869
0
0
0
0
0
1872
1872
-3
-0.1
'Oxygen
11.4
0
363.8
575.2
0
. 0
0
0
0
579.5
579.5
Sulphur
7.09
. 0
0
7.09
0.15
0.22
3.13
0.23
0.14
2.66
6.53
i
-4.3 j 0.56
-0.7
7.9
Calcium
2.23
16.85
0
19.08
0
0.67
19.44
0.71
0.28
0
21.10
-2.02
-10.6
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
-1.9%
14.8% (Unburnt)
62%
1.9
Al. 127
-------
Table A.1.5.13 Mass balance for Test 5.4
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
253.1
163.0
2494.0
2910.1
0
16.5
190.0
6.0
4.5
2744.8
2961.8
-51.7
-1.8
'Ash1
39.7
113.8
0
153.5
0
16.5
153.1
5.8
4.5
0
179.9
-26.4
-17.2
'Carbon'
175.9
0
0
175.9
0
0
36.86
0.15
0.08
162.6
199.7
-23.8
-13.5
Nitrogen
0
0
1916
1916
0
0
0
0
0
1911
1911
5
0.3
'Oxygen-1
11.4
0
578.0
589.4
0
0
0
0
0
602.8
602.8
-13.4
-2.3
i — -
HSulphur
7.09
0
0
7.09
0
0.63
4.75
0.39
0.41
0.21
6.38
0.71
10.0
! Calcium
2.23
50.86
0
53.09
-0.47
2.52
49.02
1.90
1.19
0
54.17
-1.08
-2.1
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
-3.9%
18.61 (Unburnt)
97*
5.7
Al. 128
-------
Table A.1.5.14 Pressure-drops through the combustor
Test No.
Fluidising Velocity ft/s
Bed Height ft.
Baseplate
Bed
Density
(over 8 ins.)
1 Cyclone
2° Cyclone
5.1
4.0
2.1
5.2
8.0
2.2
5.3
7.8
3.5
5.4
8.0
3.6
Pressure-drop, inches w.g.
11 ! 36
j
22
6.8
0.5
3.5
17
4.8
2.5
15
33
29
5.6
2
.
14.5
33
28
5.2.
2
15
Al. 129
-------
Table A.1.5.15 Temperature distribution through the combustor
APCO Test No.
Fluidising Velocity ft/s
Bed Height ft.
Excess Air %
Probe
Number
N 2
N14
N 3
N 4
N15
N 5
N20
N 9
N23
N10
N25
Nil
N26
N27
Height above
bubble caps
(ins)
4
4
12
12
12
20
50
94
94
130
130
154
154
154
Projection into
combustor
(ins)
3
9
3
9
3
9
9
9
9
9
9
9
9
9
1° Cyclone
2° Cyclone
Steam to freeboard at N22 Ib/h
5.1
4.0
2.1
9.3
5.2
8.0
2.2
6.1
5.3
7.8
3.5
-1.9
5.4
8.0
3.6
-3.9
Temperature °F
1567
1573
1578
1576
1566
1540
1585
1605
1627
1548
1560
1548
1530
1517
1335
1371
150
1546
1584
1584
1602
1564
1562
1603
1420
1600
1576
1513
1557
1549
1497
1375
1432
400
1535
1564
1569
1580
1566
1548
1600
1404
1548
1504
1459
1479
1470
1434
1308
1375
400
1531
1562
1575
1564
1566
1544
1596
1519
1594
1546
1506
1533
1526
1483
1353
1429
300
A1.130
-------
TableA. 1.5.16 S0? concentrations and % reductions
Test No.
Fluidising Velocity, ft/s
Bed Temperature F
Bed Height, ft
Ca/S mol ratio
S0_ concentration, p. p.m.
SCL reduction, %
Datum
4
1560
2
0
1850
0
5.1
4
1560
2
1.7
850
65
5.2
8
1560
2
1.6
1180
51
5.3
8
1560
3.5
1.9
1040
57
5.4
8
1560
3.6
5.7
80
97
5.5
8
1560
. 3.6
•'"' ' .6
11
100
The datum SO. concentration for these tests was taken as 2400 p.p.m.
This value was calculated by multiplying the datum of Series 2,
2050 p.p.m., by the ratio of the sulphur contents of the coal, 2.8/2.4
Table A. 1.5.17 Variation in SO,, concentration 2 ft above bed
Test No.
Datum
5.1
5.2
S0_ concentration, p. p.m. '
Above feed
;2350
\:,w
2150
3 in from feed
1950
.-
-
6 in from feed
1250
400
1400
Stack
2400*
850
1180 "
Values taken from Fig. 5.1
* Value based on infra-red analyser re.idfng.
Al. 131
-------
Table A.1.6.1 Operating Conditions during Test Series 6
Coal Pittsburg coal
Coal size -3175 nm
Acceptor Dolomite 1337
Acceptor size -3175 + 500 pm
Recycle System not in operation
Test No.
S
Time *•
QL
from start r
of Test t
Series g
(hrs) n
d
Ca/S mol ratio
Coal Rate
Ibs/hr dry
Bed Height ft.
Fluidising Velocity
ft/s
Bed Temperature °F
Datum
0
1
0
247
2.7
8.0
1560
6.1
6
10
2.5
247
2.7
8.0
1560
6.2
24
28
5.4
244
2.7
8.0
1560
6.3
34
38
5.3
253
4.0
8.1
1560
Temperature
Survey
40
41
5.3
253
4.0
8.2-7.5
1620-1420
6.4
68
72
5.2
256
7.3-6.4
8.0
1560
6.5
84
88
5.0
253
5.5
8.0
1560
Al. 132
-------
Table A.1.6.2 Chemical analyses of coal
Test Number
Proximate analysis
Total moisture
Ash
Volatile Matter
Ultimate analysis
Carbon
Hydrogen
Nitrogen
Sulphur
Oxygen + errors
Chlorine
Carbon Dioxide
% a.r.
% a.r.
% d.a.f.
% d.b.
% d.b.
% d.b.
% d.b.
% d.b.
7. d.b.
% d.b.
6.3
1.7
14.0
-
70.8
4.5
1.5
2.6
4.4
0.08
0.95
Additional coal samples analysed for sulphur only
Test No.
Sulphur % d.b.
6.1
2.7
6.2
2.6
6.3
2.6
6,5
2.7
Al. 133
-------
Table A.1.6.3 Size distribution of coal
Test No;
Particle Size (vim)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (pm)
Packed bulk
density lb/ft3
% in grade, by weight
6.1
0.7
15.9
17.5
23.1
16.9
9.3
7.1
3.1
6.4
627
60.6
6.2
0.7
20.3
18.6
23.3
16.3
8.9
9.9
1.8
0.2
757
62.3
6.3
0.4
19.3
19.5
20.8
15.5
9.1
7.0
3.6
4.8
.702
62.5
6.5
0.2
13.7
17.3
22.7
18.2
10.0
7.9
5.2
4.8
564
63.4
Al. 134
-------
Table A.1.6.4 Chemical and size analyses of acceptor
Test No.
Chemical Analysis
CaO a.r.
MgO a.r.
CO a.r.
S^ a.r.
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (ym)
Packed bulk „
density Ib/ft
6.1
29.5
21.8
47.0
6.5
29.7
22.0
47.0
"
% in grade by weight
0
14.9
28.1
30.3
8.9
4.2
5.7
2.3
5.6
874
111.1
0
20.9
30.0
25.2
9.0
4.1
5.3
2.1
3.4
1022
104.1
A1.135
-------
Table A.1.6.5 Chemical and Size analyses of primary cyclone fines
Test No.
Chemical Analysis
Carbon % a.r.
Sulphur "
C02
CaO "
MgO
Size Analysis
Particle size (ym)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250 - 500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (ym)
Packed bulk
density Ib/ft^
6.1
19.2
3.05
5.52
27.3
18.5
6.2
13.3
2.95
3.88
34.4
24.3
6.3
14.8
2.8
3.49
36.4
23.2
6.4
13.2
2.5
2.51
27.7
19.5
6.5
14.5
2.65
3.76
32.8
22.3
% in grade by weight
0
0
0
1.4
5.3
9.1
31.3
17.4
35.5
62
57.5
0
0
0
1.1
4.4
9.3
34.1
17.6
33.5
65
49.4
0
0
0.2
2.0
4.5
10.8
36.2
18.4
27.9
71
56.3
0.1
2.5
5.1
15.1
5.0
8.5
24.8
13.8
25.1
87
57.7
0
0.6
1.7
4.9
4.7
10.0
29.4
15.6
33.1
68
51.9
A1.136
-------
Table A.1.6.6 Chemical analyses of secondary cyclone fines
Test No.
Analysis
Carbon % a.r.
Sulphur % a.r.
CO- % a.r.
CaO % a.r.
MgO % a.r.
6.1
4.1
4.9
2.8
17.0
10.5.
6.2
2.4
5.35
4.5
23.4
14.9
6.3
3.7
5.95
5.45
24.9
15.4
6.4
2.3
7.7
3.62
27.2
19.2
6.5
3.1
7.7
5.74
28.0
18.7
Table A.1.6.7 Chemical analyses of exhaust dust
Test No.
Analysis
Carbon % a.r.
Sulphur % a.r.
C02 % a.r.
CaO % a.r.
MgO % a.r.
6.1
3.6
6.8
0.75
17.6
8.2
6.2
1.8
8.3
0.75
19.0
12.3
6.3
1.7
8.9
0.75
19.0
11.3
6.4
1.1
10.6
0.75
24.0
15.3
6.5
1.1*
10.6*
0.75*
24.0*
15.3*
* Estimates
A1.137
-------
Table A.1.6.8 Chemical and size analyses of bed material
Test No.
Sample
Chemical Analysis
Sulphur 1 a.r.
CO. 1 a.r.
CaO % a.r.
MgO * a.r.
Size Analysis
Particle size (vim)
+ 3175
+ 1680 - 3175
+ 1003 - 1680
+ 500 - 1003
+ 250-500
+ 125 - 250
+ 66 - 125
+ 45 - 66
- 45
Median diam. (ym)
Packed bulk
density Ib/ft
6.1
Initial
•1.2
0.13
5.7
-
Final
1.9
0.21
7.8
-
6.2
Initial
3.1
0.27
11.9
-
Final
3.65
0.26
14.3
-
6.3
Initial
3.15
0.27
11.2
-
Final
3.25
0.15
11.9
-•
6.4
Initial
1.45
0.16
5.2
-
Final
1.5
0.18
6.0
-
6.5
Initial
1.55
0.2
6.4
-
Final
1.6
0.13
6.9
-
% in grade by weight
0.2
27.3
36.2
32.8
3.0
0.1
0.2
0.1
0.1
1240
87.0
0.3
25.4
37.9
33.4
2.6
0.1
0.1
0.1
0.1
1230
86.4
0.2
25.0
36.9
35.0
2.5
0.1
0.1
0.1
0.1
1203
81.7
0.2
23.5
39.2
34.4
2.3
0.1
0.1
0.1
0.1
1211
81.9
0.4
25.3
37.6
34.7
1.9
0.1
0
0
0
1222
84.3
0.1
24.2
37.5
36.5
1.7
0
0
0
0
1192
84.5
0.2
25.0
42.4
30.4
1.5
0.1
0.2
0.1
0.1
1287
81.4
0.7
29.2
41.7
27.2
0.6
0.2
0.2
0.1
0.1
1321
80.0
0.2
35.3
42.6
21.5
0.2
0.1
0.1
O
0
1421
84.7
0.3
33.4
43.6
22.0
0.3
0.1
0.1
0.1
0.1
1396
83.1
CO
00
-------
Table A.1.6.9a Flue gas analyses
Test No.
Time from start (h)
Operating Conditions
Ca/S mol ratio
Fluidising Velocity ft/s
Bed Temperature °F
Bed Height ft.
Gas Analysis
Vol % dry gas C02
02
" CO
II £TT
p . p . m . NO Y
so2
so2
so2
Cl
" NH3
•
Method
Chroma-
tograph
n
n
Saltz-
man's
Iodine
I.R.A.
H202
11
n
Datum
0
8.0
1560
2.7
15.2
2.9
0
0
(355
(420
2190
6.1
0
16.4
2.7
0
0
1.5
16.4
2.9
0
0
3.5
15.9
3.1
0
0
Mean
2.5
8.0
1560.
2.7
16.2
30.0
0
0
-
840
730
840
62
4
6.2
0
16.7
3.4
0
0
(420
!365
2.5
16.3
3.5
0
0
3.5
16.5
3.2
0
0
Mean
5.4
8.0
1560
2.7
16.5
3.3
0
0
390
280
240
275
59
9
Al. 139
-------
Table A.1.6.9b Flue gas analyses
Test No.
Time from start (h)
Operating Condition
Ca/S mol ratio
Fluidising Velocity
Bed Temperature °F
Bed Height
Gas Analysis
Vol % dry gas C02
02
CO
CH4
p. p.m. NOy
so2
so2
so2
Cl
NH3
s
ft/sec
Method
Chroma tograph
"
"
it
Saltzman's
Iodine
I.R.A.
H2°2
tt
11
0
16.4
3.5
0
0
£305
(415
6.3
3
16.9
3.3
0
0
Mean
5.3
8.1
1560
4.0
16.7
3.4
0
0
360
260
190
260
59
15
0
16.7
2.7
0
0
bss
6.4
3
16.3
2.7
0
0
1
Mean
5.2
8.0
1560
7
16.5
2.7
0
0
400
155
115
175
55
7
0.5
16.9
2.8
0
0
(405
(450
6.5
3
16.3
3.3
0
0
Mean
5
8.0
1560
5.5
16.6
3.0
0
0
425
280
160
295
60
12
Al. 140
-------
Table A.1.6.10 Mass balance for Test 6.1
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (in - Out)
Loss Percent
Total
246.7
100.0
2505.7
2852.4
0
14.0
118.0
4.4
2.0
2729.3
2867.7
- 15.3
-0.5
'Ash'
35.3
64.7
0
100.0
0
14.0
95.3
4.2
1.9
0
115.4
-15.4
-15.4
'Carbon'
174.7
0
0
174.7
0
0
22.66
0.18
0.07
154.2
177.1
- 2.4
- 1.4
Nitrogen
0
0
1925
1925
0
0
0
0
0
1932
1932
-7
-0.4
1
'Oxygen'
10.9
0
580.7
591.5
0
0
0
0
0
589.9
589.9
1.6
0.3
Sulphur
6.66
0
0
6.66
0.71
0.22
3.60
0.22
0.13
2.22
7.10
- 44
-6.4
Calcium
2.17
21.10
0
23.27
1.52
0.68
23.01
0.53
0.25
0
25.99
-2.72
-11.7
Magnes ium
0
13.10
0
13.10
0.71
0.32
13.10
0.26
0.12
0
14.51
-1.41
-10.8
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
4.0%
12.9% (Unburnt)
67%
2.5
Al. 141
-------
Table A.1.6.11 Mass balance for Test 6.2
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
243.8
202.0
2501.8
2947.6
0
15.5
165.0
6.0
2.9
2758.7
2948.1
-0.5
0
'Ash1
34.9
126.7
0
161.6
0
15.5
143.1
5.9
2.8
0
167.3
'Carbon'
172.6
0
0
172.6
0
0
21.95
0.14
0.05
149.0
171.1
-5.7 ' 1.5
-3.5 • 0.9
I '
Nitrogen
0
0
1922
1922
0
0
0
0
0
1937
1937
-15
-0.8
'Oxygen'
10.7
0
579.8
590.5
0
0
0
0
0
579.9
579.9
10.6
1.8
Sulphur
6.34
0
0
6.34
0.54
0.52
4.87
0.32
0.24
0.74
7.23
-0.89
-14.1
Calcium
2.15
42.62
0
44.77
1.68
1.45
40.59
1.00
0.39
0
45111
-0.34
-0.8
Magnesium
0
26.46
0
26.46
0.79
0.68
24.10
0.53
0.21
0'
26.31
0.15
0.6
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
5.5%
12.9% (Unburnt)
88%
5.4
Al. 142
-------
Table A.1.6.12 Mass balance'for Test 6.3
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
! Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
.
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
252.6
205.0
2513.5
2971.1
0
0
177.0
7.0
4.8
2778.5
2967.3
3.8
0.1
'Ash'
36.1
124.2
0
160.3
0
0
150.8
6.7
4.7
0
162.2
- 1.9
- 1.2
'Carbon'
178.9
0
0
178.9
0
0
26.20
0.26
0.08
150.5
177.0
1.9
1.1
Nitrogen
0
0
1931
1931
0
0
0
0
0
1939
1939
-8
-0.4
' Oxygen '
11.1
0
582.5
593.6
0
0
0
0
0
590.5
590.5
3.1
0.5
Sulphur
6.57
0
0
6.57
0.16
0
4.96 ,
0.42
0.43
0.69
6.66
-0.09
-1.3
Calcium
2.22
43.25
0
45.47
0.78
0
46.02
1.25
0.65
0
48.70
-3.23
-7.1
Magnesium
0
26.9
0
26.9
0.31
0
24.60
0.64
0.36
0
25.91
0.99
3.7
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
3.7%
15.0% (Unburnt)
90%
5.3
Al. 143
-------
Table A.1.6.13 Mass balance for Test 6.4
Rate: Ib/h
Coal Feed
Acceptor Feed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out )
Loss Percent
Total
255.6
203.0
2509.6
2968.2
-34.9
0
210
9.0
7.2
2772.2
2963.5
4.7
0.2
'Ash' '
36.5
122.2
0
158.7
-34.9
0
182.3
8.8
7.1
0
163.3
-4.6
-2.9
'Carbon'
181.0
0
0
181.0
0
0
27.72
0.21
0.08
149.2
177.2
3.8
2.1
Nitrogen
0
0
1928
1928
0
0
0
0
0
1955
1955
- 27
-1.4
'Oxygen'
11.2
0
581.6
592.8
0
0
0
0
0
569.2
569.2
23.6
4.0
Sulphur
6.65
0
0
6.65
-0.38
0
5.25
0.69
0.75
0.41
6.73
-0.08
-1.2
Calcium
2.25
42.83
0
45.08
0.23
0
41.58
1.75
1.22
0
44.78
0.3
0.7
Magnesium
0
26.60
0
26.60
-0.52
0
24.57
1.04
0.66
0
25.75
0.85
3.2
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
0%
15.5% (Unburnt)
94%
5.2
Al. 144
-------
Table A.1.6.14 Mass balance for Test 6.5
Rate: Ib/h
Coal Feed
Acceptor Peed
Total Air
Total Input
Accumulated in bed
Offtake Ash
Primary Fines
Secondary Fines
Exhaust Dust
Flue Gas
Total Output
Loss (In - Out)
Loss Percent
Total
252.6
203.0
2501.8
2957.4
0
0
186.5
9.9
7.0
2764.7
2968.1
-10.7
-0.4
'Ash'
36.1
122.2
0
158.3
0
0
159.5
9.6
6.9
0
176.0
-17.7
-11.2
'Carbon1
178.9
0
0
178.9
0
0
27.04
0.31
0.08
148.8
176.2
2.7
1.5
Nitrogen
0
0
1922
1922
0
0
0
0
0
1942
1942
-20
-1.0
'Oxygen1
11.1
0
579.8
590.9
0
0
0
0
0
575.0
575.0
15.9
2
Sulphur
6.82
0
0
6.82
0.14
0
4.94
0.76
0.74
0.74
7.32
-0.50
-7.4
Calcium
2.22
42.83
0
45.05
0.86
0
44.2
1.98
1.20
0
48.24
-3.19
-7.1
Magnesium
0
26.60
0
26.60
0
0
24.99
1.11
0.64
0
26.74
-0.14
-0.5
Excess air
Carbon loss
Sulphur retention
Ca/S mol ratio
1.3%
15.6% (Unburnt)
89%
5.0
Al. 145
-------
Table A.1.6.15 Pressure drops through the combustor
Test No.
Fluidising Velocity ft/s
Bed Height ft.
Baseplate
Bed
Density (over 8 ins)
1° Cyclone
2° Cyclone
6.1
8.0
2.7
6.2
8.0
2.7
6.3
8.1
4.0
6.4
8.0
7.3-6.4
6.5
8.0
5.5
Pressure drop, inches w.g.
34
21
5.2
2.5
14
34
19
4.8
2.5
14
33
30
5.0
2
13
32
67-59
6.1
4
11
32
50
6.1
2
13
Al. 146
-------
Table A.1.6.16 Temperature distribution through the combustor
Test
Fluidising Velocity ft/s
Bed Height ft
Excess Air %
Probe
Number
N2
N14
N3
N4
N15
N5
N6
N16
N7
N19
N20
N21
N9
N23
N10
N24
N25
Nil
N27
Height, above
.bubble caps
(ins)
4
4
12
12
12
20
27
27
39
39
50
50
94
94
130
130
130
154
154
Projection into
combustor
(ins)
3
9
3
9
3
9
3
9
9
9
9
9
9
9
9
3
9
9
9
1 Cyclone
2 Cyclone
Steam to Freeboard Ib/hr
6.1
8.0
2.7
4.0
6.2
8.0
2.7
5.5
6.3
8.1
4.0
3.7
Temperature
1546
1578
1589
1582
1558
1540
1575
1567
1593
1593
1593.
1602
1481
1648
1585
1616
1560
1580
1531
1391
1452
300
1539
1561
1589
1575
1558
1551
1576
1564
1593
1589
1591
1605
1490
1638
1605
1627
1575
1593
1540
1573
1459
250
1539
1567
1584
1569
1566
1558
1587
1580
1589
1580
1598
1589
1500
1629
1557
1593
1596
1584
1567
1400
1454
0
6.4
8.0
6.9
0
6.5
8.0
5.5
1.3
.°F
1522
1562
1571
1569
1558
1569
1589
-
-
1593
-
-
1602
1620
1582
1580
1602
1589
1584
1405
1449
50
1526
1569
1584
1578
1562
1578
1526
.-
1594
1607
1488
-
1571
1636
1580
1591
1611
1594
1585
1409
1454
50
Al. 147
-------
Table A.1.6.17
SO,, concentrations and % reductions
Test No.
Fluidising Velocity, ft/a
Bed Temperature, °F
Bed Height, ft
Ca/S mol ratio
SOo concentration, p. p.m.
S02 reduction, %
Datum
8
1560
2.7
0
2190
0
6.1
8
1560
2.7
2.5
840
62
6.2
8
1560
2.7
5.4
280
87
6.3
8
1560
4.0
5.3
260
88
6.4
8
1560
7.3-6.4
5.2
155
93
6.5
8
1560
5.5
5.0
280
87
Al. 148
-------
Table A.1.6.18 SO,., concentrations and % reductions during temperature survey
Time, mins
0
10
20
28
33
40
50
60
80
90
100 :
110
120
Bed Temperature, F
1550
1560
1637
1595
1627
1505
1477
1450
1420
1460
1525
1560
1560
S0? concentrations
p .p .m.
240
240
510
290
360
175
150
125
125
90
125
200
.
175
1
SO- reduction
%
88
88
74
85
81
91
92.3
93.5
93.5
93.5
93.5
90
91
The datum S02 concentration for the infra-red analyser was taken as 1950 p.p.m.
A1.149
-------
Condenser
Primary
Cyclone
To Cooling
Tower
Ul
o
Air
Hot Gas Generator
Gas
Incremental fa Incremental
Feed Samples p-Ash Samples-
Ash
Offtake
Ash
'Sample
Stack
4—To IRA
f-*-Gas and Dust Samples
Fig. A.1.1. General Flow Diagram. 36" Combustor Plant.
-------
Explosion Relief
To Cyclones
Bed Ash
Filling Point
36Y18" Cross-Section
Throughout
Temperature Control
Tubes, 2'/e in O.D.,9n
in Triangular-Pitch.
Fines Recycle
Air Distributor
Ash Offtake
Fig.A1.2. The 36in. Combustor
Al. 151
-------
NU
Coal
8s
N2 F Nl
12'up
N15
Tc
Tc
Tc
N4 N3
20"up
Tc
N5
27up
N16 N17
No Probe
N6
39"up
N18 N19
No Probe
N7
50 up
N20 N21
T
i
c 6s Gs!
i
N8
94*up
N22 N23
e
a
m
: Tc
'
E P
Tc
N
&
a
m
131
24
1
Dup
N2
re
5
Tc
N26 N27
Tc Tc Tc
N9
N10
N11
Key
Thermocouple
Bed Ash Sampler
Gas Sampler
Pressure probe
TC
BS
GS
P
Fig. A.I.3 Cross-sections of 36in combustor at varying heights above
air jets showing typical positions of probes etc.
A1.152
-------
CO
100
90
80
70
60
u
0)
UJ
30
20
10
0
Secondary cyclone
Primary cyclone
10
20
Particle size
Fig. A.
Efficiencies of the primary and secondary cyclones
-------
Hot Gas
Generator
Ruidised Bed
Drier
36" Combustor
Coal Hopper
Fig. A 1.5. The Fluostatic Drier/Sample House Crusher System
Used For Coal Preparation.
Al. 154
-------
Feed Hopper
Rotary Table
Feeder
Disperse Phase
Drier
Hot Gas
Generator
To Stack
Fig. A 1.6. The Atritor Plant Used For Limestone And
Dolomite Preparation.
Al. 155
-------
Nz Supply ^ =
Cyclone.
Sampler Open
Solids In
01
OS
Actuating Air
Sealing
Gland^
\
=L
:Mt
N, Vent
Solids Separating
Cyclone and
Collecting Vessel
U-
Solids Separating
Cyclone and
Collecting Vessel.
Sampler Closed
Fig.A.1.7. Apparatus for sampling the solids in the fluidised bed.
-------
2500
0
1000 1500 2000
S02 ppnn (v/v) iodine method
2500
Fig.AI. 8. Comparison of S02 results from two methods of analysis
Al. 157
-------
2900
2500
•o2000
o
0)
c
e
Q.
(s.1500
o
w
1000
500
0
v V0°°
0
a
D
D
Test Series 1.1
Operating Conditions
Ruidising Vel.-.ft/s
Acceptor
Bed Temp.:°F
Bed Depth : ft
A
none
U70
2-3
1
O O
00 Q
O D
> O
D
D
I
Probe
N8
N21
Stack
Projection
into
Combustor
Tin
9in
Sin
• —
Symbol
I
D
O
1
I
10 15 20 25
Hours from start of test series
30
Fig. At. 1.1. Variation in S02 concentration (iodine method) with time and
sampling position in Test Series 1.1
Al. 158
-------
2400
2000
1500
E
Q.
O.
1000
500
14
O
O
O
Operating Conditions
Fluidising Vet. ft./s
Acceptor
Bed Temp. °F
Bed Depth, ft.
4
None
K70
2-3
O
O
Analysis
Iodine |Q
Mass Balance.
i
16 18 20
Hours from start of test series.
O
22
FIG. A. 1.1.2. So2 concentrations in Test 1-1
A1.159
-------
2400
2000
1500
E
O.
0.
o"
1000
500
O
0
O
O
Operating Conditions
Fluidising Vet. ft./s
Acceptor
Bed Temp ° F
Bed Depth, ft.
I*
None
U70
2-2
0
©
H
Analysis
Iodine
£
H
-0
.Mass Balance.
6 8 10
Hours from start of test series.
12
Fig. A. 1.1.3. So* concentrations in Test 1*2
Al. 160
-------
2400
2000
1500
E
Q.
Q.
o01
1000
500
'Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. • F
Bed Depth, ft
4
2-2
U70
2-2
Analysis
Iodine
o
o
0
O 0 O
0
0
O O
Mass Balance
29
31 33
Hours from start of test series
35
37
Fig. A 1.1.4. So2 concentrations in Test 1/3
Al. 161
-------
2400 r
2000
1500
E
Q.
Q.
1000
500
0
42
Operating Conditions
Ruidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. °F
Bed Depth, ft
4
2-2
1380
2-2
^V
o
Analysis
Iodine
I R A
O
o
O
O
o
o
•Mass Balance
44 46
Hours from start of test series
50
Fig. A 1.1.5. So2 concentrations in Test 1*4
Al. 162
-------
2400
2000
1500
E
Q.
Q.
(M
O
(f)
1000
500
Operating Conditions
Fluidising Vel.
Acceptor Ca/
ft/s
S mol ratio
Bed Temp. °F
Bed Depth ft.
4-0
2-2
1560
2-2
o
Analysis
Iodine
IRA
O
-
O O
O
Mass Balance
52
54 56 58
Hours from start of test series
60
Fig. A 1.1.6. Soj concentrations in Test 1- 5
Al. 163
-------
2400
2000
1500
E
o.
Q.
1000
500
O
Operating Conditions
Fluidising Vel ft/s
Acceptor
Bed Temp °F
Bed Depth ft.
4- 0
None
1560
2-2
Analysis
Iodine
1 RA
0
-
-Datum —
I
0 1
i
2
i
3
i
4
i
Hours from start of test series
Fig. A.I.1.7. Datum So2 concentration for Tests 1-6 to 1-9
A1.164
-------
2400
2000
1500
£
Q.
Q.
(M
o
U)
o
1000
500
0
Operating Conditions
Fluidising Vel. ft /s
Acceptor Ca /S mol ratio
Bed Temp. °F
Bed Depth ft.
4-0
1 - 3
1560
2-2
Analysis
Iodine
H202
IRA
O
H
-
O
o o
o
o
Mass Balance
11
13 15
Hours from start of test series
17
19
Fig. A 1.1.8. So2concentrations in Test 1-6
Al. 165
-------
2400
2000
1500
E
Q.
0.
01
o
1000
500
Operating Conditions
Fluidising Vel ft/s
Acceptor Ca/Smol ratio
Bed Temp. °F
Bed Depth ft.
4-0
22
1560
2- 1
Analysis
Iodine
H2 02
1 RA
O
H
—
Mass Balance
_L
23
25 27 29
Hours from start of test series
31
Fig. A 1.1.9. So2 concentrations in Test 1 • 7
Al. 166
-------
2400
2000
1500
£
Q.
Q.
1000
500
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca /S mol ratio
Bed Temp. °F
Bed Depth ft.
4-0
3-3
1560
2- 2
Analysis
Iodine
H202
1 RA
O
H
—
Mass Balance
O
O
O
O
_L
36 38 40
Hours from start of test series
Fig. A 1.1.10. So2 concentrations in Test 1-8
Al. 167
-------
2400
2000
1500
E
Q.
Q.
1000
500
Operating Conditions
Ruidising Vel.
ft/s
Acceptor Ca/S mol ratio
Bed Temp °F
Bed Depth ft
4-0
1 -2
1560
2-1
Analysis
Iodine
H202
IRA
O
H
—
QO
O
H
•Mass Balance
49 51
Hours from start of test series
53
55
Rg. A 1.1.11. 802 concentration in Test 1-9
M A1.168
-------
2400
2000 -
1500
E
Q.
Q.
01
1000
500
Operating Conditions
Fluidising Vel ft./s
Acceptor
Bed Temp0 F
Bed Depth, ft.
3
None
U70
2-3
Datum
60
62
66
Hours from start of test series
Fig. A.1.1.12. Datum So2 concentration for tests 1-10 and 1-11
Al. 169
-------
2400
2000
1500
E
a
a.
N
a
1000
500
Operating
Conditions
Fluidising Vel. ft/s
Acceptor Ca/S
mol ratio
Bed Temp. -F
Bed Depth, ft
3
2-2
1470
23
o
Analysis
Iodine
H202
1 RA
0
H
—
•Mass Balance
66
68 70 72
Hours from start of test series
Fig. A 1.1.13. 802 concentrations in Test 1-10
Al. 170
-------
2400
2000
1500
E
Q.
Q.
1000
500
Operating Conditions
Ruidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. ° F
Bed Depth, ft
3
3-3
R70
2-1
Analysis
Iodine
H202
I R A
0
H
—
•Mass Balance
Q
H
-e-
80
82 8A
Hours from start of test series
86
88
Fig. A1.1.K. So2 concentrations in Test 1-11
Al. 171
-------
4 "up
NU
N2 F N1
12 up
N15
Tc
Bs
Coal
Feed
Tc
Tc
Tc
Tc
KK N3
~f.n
20 up
Tc
N5
27 up
N16 N17
No Probe
N6
39"up
N18 N19
No Probe
N7
50 up
N20 N21
Tc |Gs fes
N8
N
S
t
e
a
m
94
22
up
N
Tc
23
Tc
N
S
e
a
m
13C
24
)up
N2
Tc
5
Tc
N
154
26
Tc
up
N
Tc
27
Tc
N9
N10
N11
Key
Thermocouple
Bed Ash Sampler
Gas Sampler
TC
BS
GS
Fig. A.1.1.15 Cross-sections of 36in combustor at varying heights above
air jets showing typical positions of thermocouples in Test
Series 1
Al. 172
-------
100
90
80
70
60
c
o
~50
3
T3
CU
040
CO
30
20
10
Test Series 1
Pittsburgh Coal
Limestone 18
—
Fluidising Vel.: ft/s
3
4
4
A
Bed Temp. :°F
U70
1380
U70
1560
Symbol
f
®
•
0
1 1 -1
Ca/S mol ratio
Fig. A1.1.16. S02 reduction in Test Series 1
A1.173
-------
2400
2000
1500
E
Q.
Q.
1000
500
O O
O
Operating Conditions
Fluidising Vel ft./s
Acceptor
Bed Temp • F
Bed Depth, ft.
8-1
None
1560
2-1
•Datum
O
O
Analysis
Iodine
0
RA
Hours from start of test series
Fig. A.1.2.1. Datum So2 concentration for tests 2-1 to 2-3
-------
2400
2000
1500
E
Q.
Q.
o01
CO
1000
500
Operating Conditions
Ruidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. ° F
Bed Depth, ft
8-1
1-1
1560
2-1
Analysis
Iodine
H202
I RA
0
H
—
O
o
o
o
Q
H° O
0 O
Mass Balance
16 18
Hours from start of test series
20
22
Fig.A 1.2.2. So2 concentrations in Test 2-1
Al. 175
-------
2400
2000
1500
E
Q.
Q.
rg
O
U)
1000
500
Operating Conditions
Fluidising Vei ft /s
Acceptor Ca/S mol ratio
Bed Temp. °F
Bed Depth ft.
8-1
2-3
1560 .
2-1
Analysis
Iodine
H202
IRA
0
H
—
O
O
Mass Balance
26
28
30
32
Hours from start of test series
Fig. A.1.2.3. So2 concentrations in Test 2-2
A1.176-
-------
2400
2000
1500
E
Q.
O.
Ol
O
1000
500
0
Operating Conditions
Fluidising Vel ft Is
Acceptor Ca /S mol ratio
Bed Temp. °F
Bed Depth ft.
8-0
2 -9
1560
2- 1
Analysis
Iodine
H2 02
1 RA
0
H
—
O
O
O
O
O
H
O O O
Mass Balance
34
36 38 40
Hours from start of test series
42
Fig. A 1.2.4. So2 concentrations in Test 2-3
Al. 177
-------
2400
2000
1500
E
Q.
Q.
3
1000
500
Operating Conditions
Fluidising Vel. ft /s
Acceptor Ca/S mol ratio
Bed Temp. ° F
Bed Depth, ft
4
1-0
1560
2-1
Analysis
Iodine
H202
I R A
0
H
-
o
o
o
o
Mass Balance
73 75 77 79
Hours from start of test series
Fig. A 1.2.5. So2 concentrations in Test 2-4 Al. 178
81
-------
NU
12" up
N15
20" up
Tc
Coal
Feed
Tc
BS
Tc
Tc
Tc
Tc
N2 F Nl
N3
N5
27"up
N16
N17
1 •
No Probe
1
39"up
N18 N19
No Probe
50" up
N20 N21
Tc
•
N6
N7
N8
94" up
N22 N23
s
t
a
m
:
:
Tc
Tc
130"up
N24 N25
f
a
m
Tc
Tc
N26 N27
Tc Tc Tc
N9
N10
N11
Key
Thermocouple
Bed Ash Sampler
T C
BS
Fig. A.1.2.6. Cross-sections of 36 in combustor at varying heights above
air jets showing positions of thermocouples in Test Series 2
Al. 179
-------
100
90
80
70
c
o
3
TJ
0)
50
8*°
30
20
I'D
Test Series 2
Pittsburgh Coal
Limestone 18
Temp.:°F
1560
1560
Acceptor Size.-jim
-3175
-125
Ruidising Vel.:ft/s
8
3&4
Symbol
D
X
0
Ca/S mol ratio
Fig. At. 2.7. S02 reduction in Test Series 2
Al. 180
-------
2AOO
2000
1500
£
o.
CL
(M
1000
500
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/Smol ratio
Bed Temp. ° F
Bed Depth ft.
7- 9
None
1560
2 • 1
O
18
Analysis
Iodine
H2 02
IRA
O
H
—
Mass Balance
20 22 24
Hours from start of test series
26
Fig. A 1.3.1. So2 concentrations in Test 3-1
Al. 181
-------
2000
1500
E
a
a.
rv
O
1000
500
Operating Conditions
Fluidising Vel ft/s
Acceptor Ca/S mol ratio
Bed Temp. °F
Bed Depth ft.
7- 9
2-8
1560
2- 2
O
O
O
O
Analysis
Iodine
H,02
IRA
O
H
-
O
O
Mass Balance
82
84 86 I
Hours from start of test series
90
Fig. A.I.3.k. So2 concentrations in Test 3-4
Al. 182
-------
1700
1600
LL
o
oi 1500
Q.UOO
£
0)
1300
1000
£
Q.
••, 500
o
CO
i r
H 1 1 1 1-
I I
0 10 20 30 40 50 60 70 80 90 100 110 120
Elapsed time: mi'nutes
Fig.A1. 3.5. S02 concentrations during the bed temperature
survey (Ca/Smol ratio 2-8 : 8ft/s : 2-2 ft bed )
Al. 183
-------
2400
2000
1500
E
CL
o.
1000
500
Operating Conditions
Fluidising Vel ft/s
Acceptor Ca / S mol ratio
Bed Temp. °F
Bed Depth ft.
8- 0
2-8
1560
3-8
O O
Analysis
Iodine
H202
IRA
O
H
-
o
o
o
I
•Mass Balance-
L
92
94 96 98
Hours from start of test series
100
Fig. A 1.3.6. So2 concentrations in Test 3-5
Al. 184
-------
2400
2000
1500
£
Q.
0.
o01
1000
500
Operating Conditions
Fluidising Vel. ft /s
Acceptor Ca / S mol ratio
Bed Temp. °F
Bed Depth ft
A-1
3- 0
1560
2 • 3
Analysis
Iodine
H202
IRA
O
H
—
O
Mass Balance
i
100
102 104 106
Hours from start of test series
108
Fig. A. 1.3.7. So2 concentrations in Test 3-6
Al. 185
-------
Tup
NU
Tc
Coal
Reed
Tc
BS
N2 F N1
12 "up
N15
Tc
Tc
KK N3
20 "up
Tc
N5
27"up
N16 N17
No Probe
N6
39"up
N18 N19
No Probe
N7
50 "up
N20 N21
Tc
N8
N22 N23
Tc
Tc
N9
130"up
N2t N25
Tc
Tc
N10
IBCup
N26 N27
Tc Tc Tc
N11
Key
Thermocouple
Bed Ash Sampler
TC
BS
Fig. A.I. 3.8. Cross-sect ions of 36 in combustor at varying heights above
air jets showing positions of thermocouples in Test Series 3
Al. 186
-------
100
90
80
70
60
I 50
u
30
20
10
Test Series 3
Welbeck Coal
U.K. Limestone
Fluidising Vel.:ft/s
U
8
8
Bed Depth:ft
2
2
2&4
Symbol
O
D
k]
Ca/S mol ratio
Fig. A1.3.9. S02 reduction in Test Series 3
Al. 187
-------
70
O
O
60
O O O\O
TJ
0)
50
O O
UOO
1500
Bed temperature *F
1600
Fig A.1.3.10. So2 reduction during the bed temperature survey
Al. 188
-------
2400
2000
1500
E
Q.
Q.
1000
500
oo
Operating Conditions
Fluidising Vel ft./s
Acceptor
Bed Temp0 F
Bed Depth, ft.
4
None
1470
2-1
O
Analysis
Iodine
IRA
23456
Hours from start of test series
8
Fig A. 1.4.1. Datum So2 concentration for test series 4
Al. 189
-------
2400
2000
1500
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. ° F
Bed Depth, ft
4
3
U70
2-1
E
a.
a.
1000 -
500
Analysis
Iodine
Ha02
I RA
0
H
—
12
H
O
o
>Hass Balance
14 16
Hours from start of test series
18
20
Fig A1.4.2. So2 concentrations in Test 4-1
Al. 190
-------
2400
2000
1500
:E
Q.
Q.
01
O
1900
Operating Conditions
Ruidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp ° F
Bed Depth, ft
U
2-6
1380
2-1
500
O
Analysis
Iodine
H2 02
1 R A
0
H
—
23 25 27
Hours from start of test series
Fig. A 1.4.3. 802 concentrations in Test 4-2
Al. 191
29
31
-------
2400
2000
1500
E
a
a.
-------
2400
2000
1500
E
Q.
Q.
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. °F
Bed Depth, ft
4
2-7
U70
2-1
Analysis
Iodine
H202
1 FVA
O
H
—
1000
500
•Mass Balance
43 45 47
Hours from start of test series
Fig. A 1.4.5. So2 concentrations in Test 4-4
A1.193
49
51
-------
2000
1500
E
a
a.
01
o
U)
1000
500
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. ° F
Bed Depth, ft
2-1
22
U70
3-7
Analysis
Iodine
H202
IRA
0
H
—
•Mass Balance
57 59 61 63
Hours from start of test series
Fig. A 1.4.6 So2 concentrations in Test 4- 5
65
Al. 194
-------
2400
2000
1500
Q.
Q.
1000
500
Operating Conditions
Fluidising Vcl.'ft/s
Acceptor Ca/S mol ratio
Bed Temp °F
Bed Depth, ft
2-2
1-6
1470
3-8
Analysis
Iodine
H202
1 RA
O
H
—
-Mass Balance
O
"FT
-Q-
78 80 82
Hours from start of test series
Fig. A 1.4.7. So2 concentrations in Test 4-6.Fines Recycle
Al. 195
86
-------
NU
Tc
Coal
N2 F N1
12" up
N15
Tc
Tc
NU N3
20" up
Tc
N5
27"up
N16 N17
No Probe
N6
39"up
N18 N19
No Probe
N7
50 "up
N20 N21
Tc
N8
9Cup
N22 N23
f
a
m
i
Tc
Tc
N9
130"up
N24 N25
Tc Tc
N10
154" up
N26 N27
Tc Tc Tc
N11
Key
Thermocouple
Bed Ash Sampler
TC
BS
Fig. A.I. 4.ft Cross-sections of 36 in combustor at varying heights above
air jets showing positions of thermocouples in Test Series I*
Al. 196
-------
100
90
80
70
c
o
'•S 50
D
TJ
0)
i_
CJ
8*0
30
20
10
Test Series 4
Pittsburgh Coal
Dolomite 1337
—
RuidisingVel.:ft/s
2
2
4
4
A
Bed Temp.:°F
U70
U70
1380
K70
1560
Symbol
R
A
®
•
0
R with fines recycle
I 1
I
Ca/S mol ratio
Fig.A1.4.9. S02 reduction in Test Series
Al. 197
-------
2400
2000
llSOO
a
c
o
I
o
o
0*1000
500
A
A
D
Datum —
Projection into
combustor at N8
3 in
7
Sin
D
9 in
A
Stack
O
O
• Test 5.1.
-Test 5.2—
j_
10
15 20 25 30
Hours from start of test series
35
Fig. At. 5.1. Variation in S02 concentration with sampling position in
Test SeriesS (Ca/Smol ratios of 0,1-7* 1-6: 4,U8ft/s :1560*F: 2-1ftbed)
Al. 198
-------
2400
2000
1500
E
Q.
Q.
-------
2400
2000
1500
E
Q.
CL
1000
500
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp.°F
Bed Depth, ft
8
1-6
1560
2-2
0
33
Analysis
Iodine
HjOa
IRA
0
H
—
O
0
o OH ©
0
-Mass Balance
35 37
Hours from start of test series
39
Fig. A.I.5.3 So2 concentrations in Test 5-2
A1.200
-------
2400
2000
1500
E
Q.
Q.
r«
O
c/)
1000
500
0
Operating Conditions
Fluidising Vel
ft/s
Acceptor Ca/S mol ratio
Bed Temp ° F
Bed Depth ft
7-8
1-9
1560
3-5
OO
\ Analysis
Iodine
H2 02
1 RA
0
H
—
O
H
O
O
O
Mass Balance
47
49 51
Hours from start of test series
53
55
Fig. A 1.5.4. So2 concentrations in Test 5-3
Al. 201
-------
2400
2000
1500
E
a
a.
1000
500
Operating Conditions
Ruidising Vel. ft/s
Acceptor Ca /S mot ratio
Bed Temp °F
Bed Depth ft.
8-0
5-7
1560
3-6
Analysis
Iodine
H202
IRA
0
H
—
Rg. A 1.5.5.
•Mass Balance-
O 0 Q
0
0
H
i
000
65
Hours from start of test series
67
69
concentration in
Al. 202
-------
2400
2000
1500
E
Q.
Q.
«M
O
in
1000
500
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. • F
Bed Depth, ft
8
6
1560
3-6
Analysis
Iodine
NOx
IRA
0
+
—
85
90
35
100
105
Hours from start of test series
Fig. A 1.5.6. So2 and NOX concentrations in test 5-5
Al. 203
-------
4"up
Nil
Tc
Coal
Feed
Tc
BS
N2 F N1
12"up
NTS
f
Tc
Tc
N4 N3
20'up
Tc
N5
27"up
N16 N17
No Probe
N6
39 "up
N18 N19
No Probe
N7
50 "up
N20 N21
Tc ,Gs
I
1
1
N8
94 "up
N22 N23
S
t
e
a
m
Tc
Tc
130"up
N2£ N25
S
t
§
m
•
Tc
Tc
N26 N27
Tc Tc Tc
N9
N10
N11
Key
Thermocouple
Bed Ash Sampler
Gas Sampler
TC
BS
OS
Fig. A.I. 5.7. Cross-sect ions of 36 in combustor at varying heights above
air jets showing positions of thermocouples in Test Series 5
Al. 204
-------
100
90
80
70
60
c
o
50
40
30
20
10
Test Series 5
Pittsburgh Coal
Limestone 18
—
Temp. :°F
1560
1560
1560
Flu id is ing Vel: ft/s
4
8
8
Bed Depth .-ft
2
2
3-5
Symbol
0
D
H
I I I I 1 1
I
0
3 A 5
Ca/S mol ratio
Fig. A1. 5. 8. S02 reduction in Test Series 5
Al. 205
-------
2400
2000
1500
E
a
a.
1000
500
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. • F
Bed Depth, ft
- 8
2-5
1560
2-7
O 0
0
Analysis
Iodine
H202
1 RA
0
H
—
0
•Mass Balance
4 6
Hours from start of test series
8
10
Fig. A 1.6.1. So2 concentrations in Test 6-1
Al. 206
-------
2400
2000
1500
E
Q.
Q.
1000
500
Operating Conditions
Fluidising Vel. ft/s
Acceptor Ca/S mol ratio
Bed Temp. °F
Bed Depth, ft
8
5-4
1560
2-7
Analysis
Iodine
H202
1 RA
0
H
—
• Mass Balance
o
Q Q Q QH
20
22
24
26
28
Hours from start of test series
Fig. A 1.6.2. So, concentrations in Test 6-2
Al. 207
-------
2400
2000
1500
E
o.
0.
$
1000
500
Operating Conditions
Fluid ising Vel ft/s
Acceptor Ca /S mol ratio
Bed Temp. °F
Bed Depth ft.
8-1
5-3
1560
A-0
Analysis
Iodine
H2 Ot
IRA
0
H
-
Mass Balance
30
32 34 36
Hour from start of test series
38
Rg. A 1.6.3. So2 concentrations in Test 6- 3
Al. 208
-------
1700
.u-1600
21500
0»
Q.
0)
*-<
-01400
0)
m
1300
500
400
E
Q.
Q.
§300
§ 200
c
o
u
CM
100-
I
I
20 40 60 80 100
Elapsed time: minutes
120
140
Fig. A1. 6. 4- 862 concentrations and bed temperatures during bed
temperature survey (Ca/Smol ratio of 5-3:8ft/s; 4ft bed)
Al. 209
-------
2400
2000
1500
E
o.
O.
1000
500
Operating Conditions
Fluidising Vel ft/s
Acceptor Ca / S mol ratio
Bed Temp °F
Bed Depth ft
8-0
5-2
1560
7'0
Analysis
Iodine
H2 02
IRA
0
H
—
Mass Balance
I
66 68 70
Hours from start of test series
72
Fig. A 1.6.5. Soj concentrations in Test 6
A1.210
-------
2400
2000
1500
E
Q.
Q.
o01
1000
500
Operating Conditions
Fluidising Vel.
ft/s
Acceptor Ca/S mol ratio
Bed Temp. ° F
Bed Depth, ft
8
5-0
1560
5-5
G
O
Analysis
Iodine'
H202
1 RA
0
H
—
•Mass Balance
Ho o o
80
82 84
Hours from start of test series
86
Fig. A 1.6.6. So2 concentrations in Test 6*5
Al. 211
-------
NU
12"up
N15
20'up
Coal
Feed
Tc
BS
Tc
Tc
Tc
Tc
N2 F N1
N3
N5
27"up
N16 N17
Tc
N6
39 "up
N18 N19
Tc
Tc
N7
50"up
N20 N21
Tc
Tc
N8
N22 N23
Tc
Tc
N9
130"up
N24 N25
Tc
Tc
N10
N26 N27
Tc
Tc j
•
?
Tc
e
n
Nil
Key
Thermocouple
Bed Ash Sampler
T C
BS
Fig. A.I. 6.7. Cross-sect ions of 36in combustor at varying heights above
air jets showing positions of thermocouples in Test Series 6
Al. 212
-------
too
90
80
70
60
c
o
-------
100
90
c
o
tJ
0)
o
CO
80
70
60
O
O
O
UOO
1500
Bed temperature °F
1600
Fig. A 1.6.9. So2reduction during bed temperature survey
Al. 214
-------
NATIONAL COAL BOARD
FINAL REPORT
JUNE 1970 - JUNE 1971
REDUCTION OF ATMOSPHERIC POLLUTION
APPENDIX 2. EXPERIMENTS WITH THE 48 IN x 24 IN PRESSURISED COMBUSTOR. (TASK II)
PREPARED FOR
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
411 WEST CHAPEL HILL STREET
DURHAM, NORTH CAROLINA 27701
FLUIDISED COMBUSTION
REFERENCE NO. DHB 060971 CONTROL GROUP
SEPTEMBER 1971 NATIONAL COAL BOARD
LONDON, ENGLAND
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REDUCTION OF ATMOSPHERIC POLLUTION
Research on reducing emission of sulphur oxides,
nitrogen oxides and particulates by using
fluidised bed combustion of coal
Appendix 2. Experiments with the 48 in x 24 in pressurised combustor. (Task II)
Main objective
To obtain, for operation under pressure, data
on (i) the emission of sulphur and nitrogen
oxides and (ii) corrosion/deposition of boiler
metal and turbine blade specimens.
Report prepared by: A.G. Roberts
J.E. Stantan
D.M. Wilkins
Report approved by: A.D. Dainton and
H.R. Hoy
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FOREWORD
This Appendix describes experimental work carried out using the
48 in x 24 in pressurised combustor at BCURA, between June 1970 and
June 1971, as Task II of the joint N.C.B./O.A.P. research programme.
The objective of Task II was to obtain, for,operation under pressure,
data on (i) the emission of sulphur and nitrogen oxides and (ii)
corrosion/deposition of boiler metal and turbine blade specimens. A
summary of the work is presented in the main report and the results
are discussed there, together with results from other pilot plants.
A2.v
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Table of Contents
Page No.
Foreword
1. Description of Plant A2. 1
1.1 General A2. 1
1.2 Air supplies A2. 3
1.3 Nitrogen A2. 4
1.4 Steam A2. 4
1.5 Coal and acceptor preparation A2. 5
1.6 Coal feeding A2. 6
1.7 Cooling and quench water A2. 6
1.8 Effluent disposal A2. 7
1.9 Gas A2. 8
1.10 Dust Removal and Sampling A2. 8
1.11 Bed Removal A2. 9
1.12 Temperature measurement A2.10
1=13 Pressure measurement A2.10
1.14 Gas sampling and measurement A2.ll
1.15 Bed level measurement A2.12
2. General Operating Procedures A2.15
2,1 Preparation A2.15
2.2 Warming up A2.15
2.3 Start up A2.15
2.4 Increasing Pressure A2.16
2.5 At steady conditions A2.16
2.6 Shut down A2.19
2.7 Emergency shut-down A2.20
2.8 Mass Balances A2.21
2o8,l Weights and Flow Rates A2.21
2,8.2 Components of Materials A2.22
3, Results A2.24
3.0 Summary A2.24
3.0.1 S02 emission A2.24
3,0.2 NO emission A2.25
X
3=0,3 Particulate emission A2.25
3,0,4 Combustion efficiency A2.25
A2. vii
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Table of Contents (Cont'd)
Page No.
3.0.5 Temperature distribution A2.26
3.0.6 Blade cascade and target rods A2.26
3.1 Test Series A2.27
3.1.1 Objectives of Test Series A2.27
3.1.2 General description of Test Series A2.27
3.2. Test Series 2 A2.32
3.2.1 Objective of Test Series .. A2.32
3.2.2 General description of Test Series A2.32
3,3.. ..Test Series 3 A2.38
3.3.1 Objective of Test Series A2.38
3.3.2 General description of Test Series A2.38
3.4 . Test Series 4 A2.40
3.4.1 Objectives of Test Series A2.40
3.4.2 General description of Test Series A2.40
3.5 Test Series 5 A2.43
3.5.1 Objective of Test Series A2.43
3.5.2 General description of Test Series A2.43
4. References A2.47
5. .Acknowledgements A2.48
Tables A2.2.1 - A2.2.2
A2.3.1 - A2.3.114
Figures A2.2.1 - A2.2.10 Design of combustor plant
A2.3.1 - A2.3.12 Results
(Note that when referring to Tables and Figures in the text the
prefix A*2 is omitted).
A2. viii
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.1. DESCRIPTION OF PLANT
1.1 General
A flow diagram of the pressurized combustion rig and its ancillary
equipment is shewn in Fig, 2.1; details of the construction of the
combustcr are given in Fig. 2,2. The combustion vessel was a refractory-
lined shaft of approx. 48 in x 24 in cross-section, 10ft high, housed in
a cylindrical steel shell, 22 ft long x 6 ft diameter having domed ends
and capable of withstanding an internal pressure of up to 100 p.s.i.g.
The walls of the shaft, which were lined with a 3 in thick lightweight
insulation refractory,acted mainly as a temperature barrier and were
intended to withstand a pressure differential of about - 5 p.s.i.
The base of the combustor was closed by an air distributor plate of
i in En58b steel, fitted with 465 bubble caps on a l£ in square pitch.
Each bubble cap had four horizontal jets, 1 in above the distributor plate,
with an aggregate area of 1.3% of the shaft cross-section.
The bed normally contained about 1800 Ib coal ash, and with a fluidising
velocity of 1.8 to 2.0 ft/s had an expanded depth of about 45 in. Immersed
in the bed were 65 hairpin loops of 1 in o.d= x 16 s.w.g. En58b steel tubing
cantilevered .from the 4 ft side walls. The hairpins formed a staggered
pattern of 17 rows of 7 or 8 tubes per row, with horizontal and vertical
pitches of approximately 6 in and 1| in respectively (Fig. 2.3). Six
2
of the hairpins, with a surface area of 6-3 ft , were used for air preheating
2
and six air-cooled corrosion specimen assemblies (6,2 ft total surface)
formed part of a further six hairpins: the hot air from these assemblies
was fed with the preheated air to the plenum chamber. The remaining 53
2
hairpins of total.external surface of 56 ft were bed cooling circuits;
bed temperatures were controlled by selecting water circuits giving the
total cooling surface required,.
Air preheated in the tubes in the bed to between 300° and 500°F,
according to operating pressure, was fed to a plenum chamber below the
distributor plate-. Gas burners having a rating of 5 therms/h were
positioned in the chamber to heat the fluidising air and hence the
fuel-bed during start-up.
A.2 .1
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Coal, premixed with acceptor, was fed pneumatically in either air
or nitrogen from a pressurised lock hopper system through four i in B.S,
pipe-lines terminating at nozzles, fitted with water-cooled shrouds,
projecting 5$ in into the bed through the 4 ft side walls of the
combustion vessel. The nozzles were located 1 ft from each of the two
*/ft sides, at a height of about 4 in above the distributor plate.
A bank of 4 rows of uncooled horizontal 1 in o.d. En5Sb tubes on
a nominal 3. in triangular pitch was .located immediately above the upper
surface of the bed.(at 46 in to 54 in above the distributor plate) and
parallel to the 2 ft sides of the combustor. The tube bank acted as a
baffle system to minimise "splashing".
Three water-cooling circuits, having a total surface area of 16.6
o
ft , were provided in the gas space above the uncooled tube bank to cont
the gas temperature if excessive combustion occurred in the freeboard.
The dust-laden gas leaving the shaft passed through a 10 in diameter
recirculation cyclone, suspended from the top closure plate, and the fines
were returned to the bed via a dipleg terminating approximately 3 in from
the distributor plate. The lower end of the dipleg was fitted with an
"air slide" through which a small flow of nitrogen was passed to facilitate
the.downwards flow of solids. The amount of material being recycled back
to the bed was unknown, but available evidence suggests that it was small
and the combustor probably behaved as a non-recycle system. The partially-
cleaned combustion products were passed successively through two further
10 in diameter cyclones from which collected fines were continuously
removed by positive blow-down systems. Physical dimensions of the three
cyclones are given in Table 2.1 and Fig. 2.4.
Combustion products leaving the second stage of dust cleaning were
passed through an egg-box type flow straightener before being accelerated
through the gas turbine blade cascade (Fig. 2.5). The blades were obtained
from a stator segment of a Rolls Royce marine Proteus engine and were made
in X40 alloy having a high cobalt content. Two 3/32 in diameter Nimonic
75 target rods were fitted in the gas stream immediately downstream of the
cascade, at a point where the Mach number was about 0.6, to simulate leading
edges of a turbine rotor blade.
A2.2
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Downstream of the cascade assembly there were sampling probes for
(a) alkalis, S02, S03 and HC1,
(b) NOX
(c) exhaust dust, and
(d) gas analysis.
The gases were then quenched, by spraying water into the duct, passed
through a venturi scrubber to wet the particles of dust before passing
through a hydrocione which removed the wetted particles and water droplets
from the gases. The cleaned gases finally passed through the pressure
let-down valve before being exhausted to atmosphere via a chimney stack.
1.2 Air supplies
Air from three compressors of total nominal output of 2.3 Ib/s at
7.8 atm pressure, was passed through filters and active carbon beds to
remove water droplets and traces of hydrocarbons before flowing through
air receivers to the main air orifice and main air control valve* The main
air control valve was controlled from the control room by a Swartwout flow
controller which received a signal from a pressure transmitter sensing the
main air differential pressure. The air stream then split into two to supply
(a) the air preheat tubes and (b) the corrosion tube assemblies. The supply
to the air preheat tubes sub-divided into six flow streams, each having an
orifice section, flow control valve and an isolating valve external to the
pressure shell. All these flow control valves were controlled from the
control room in a similar manner to the main air valve: The air supply
to the corrosion tube assemblies divided into four streams which were also
equipped with orifice metering sections, flow control valves and isolating
valves. Flow through the corrosion tubes was governed by Foster indicator/
controllers which sensed a metal temperature in the corrosion tube specimen
assembly (see Fig. 2.6) and compared this with a preset temperature to give
a "reduce flow" or an "increase flow" signal to its control valve. To avoid
continual hunting, the metal temperatures were sensed for 7 s in a 100 s
cycle, the control valve remaining at constant opening for the remainder of
the cycle. Two further corrosion tube assemblies were not supplied with air
and the metal specimens involved were thus maintained at bed temperature
throughout the test series. Air from the outlets of the air preheat tubes
and the corrosion tube assemblies was piped to the plenum chamber beneath
the distributor plate,.
A2..3
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Air from the main air receivers was supplied to the top and bottom of
the pressure shell via an orifice meter and remotely controlled valve to
maintain the required static pressure in the shell. A pneumatically-
controlled valve in a 4 in B.S.P. vent from the upper dome of the pressure
shell was operated by a pilot valve, Swartwout differential pressure
controller and differential pressure transducer to control the differential
pressure between the plenum chamber and the space around the combustion
vessel. The vent discharged into the hydroclone entry, i.e. upstream of
the pressure let down valve.
Air from the receivers was supplied via a silica gel dryer of 20
ft^/min capacity to two instrument air receivers, a low pressure receiver
operating at 3.4 atm and a high pressure receiver operated at line pressure.
The instrument air was used for operating the numerous remotely-controlled
valves on the plant.
A further supply of dry air of approximately 0.4 Ib/s at 7 atm
pressure was available for use in the coal transfer and coal feeding
sections of the plant.
1.3 Nitrogen
o
Nitrogen.from a 53,000 ft evaporator was available at pressures up
to 10 atm for:
a. purging the plant,
b. use when required in the coal feeding and pressurising system,
c. as an inert atmosphere in the coal storage bunkers,
d. supply to the dip-leg "air slide", and
e. purging pressure tappings.
1.4 Steam
Approximately 2750 Ib/h of steam at 8 atm pressure was supplied by a
Stone-Vapour package boiler to three of the bed cooling tubes to heat the
bed to about 300 F during the initial stages of start-up. After passing
through throttling valves, external to the pressure shell, the waste steam
from the circuits was condensed in a vertical pipe fitted with a water spray;
the condensate was then run to waste.
A2o4
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1,5 Coal and accepter preparation
Coal and acceptor were mixed before feeding to the combustor. The.
flow sheet, for the preparation process is shown in Fig. 2,7. The raw coal
was discharged from the base of the main coal storage, bunker cnto a
vibratory gyrating screen having two screen decks of 1/16 in and 72 B.S, mesh
respectively. The 72 B.S, mesh screen was deliberately run in a flooded
condition so that the intermediate product contained some -72 mesh material.
The nominal 1/16 in x 72 mesh output was blended with dolomite and stored in
Storage Bunker 1. The undersize material from the 72 mesh screen was
rejected, and the oversize (+1/16 in) material was dried and milled. The
mill incorporated a crude classifier which recycled most of the +1/16 in
material. The mill product: was discharged onto a vibratory gyrating screen
having two screen decks of 1/16 in and 72 mesh. Oversize and undersize
material were rejected and the main output was blended with dolomite and
stored in Storage Bunker II,. The discharges from Storage Bunkers I and II
were mixed and conveyed to the coal feeding system. At this stage the
product, was 100% less than 1/16 in and about 15% less than 75 urn. This is
typical of the size distribution which would be produced in a commercial
plant.
The complex coal handling system was adopted for two main reasons:
(a) initial separation cf +1/16 in and -1/16 in was carried out to minimise
the production of fines in the milling system; (b) subsequent blending of
screened and milled coal was carried out because the ash characteristics
(particularly ash content and ash degradabiiity index) of each stream were
different.
The raw dolomite was dried in a gas oven at 220 F before being
screened on the vibratory gyrating screen fitted with 1/16 in and 72 B.S-
mesh (operated.in the "flooded" state) sieves. Oversize and undersize
material was rejected.
The coal and dolomite were blended by sprinkling the prepared
dolomite into the stream of sized coal as it left the vibration screen.
The quantity of dolomite added was in accordance with the Ca/S mol
ratio required. The rate of production, of the blend was monitored
continuously from the weight in the storage bunker.
A..2 ,5
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1.6 Coal feeding
A flow diagram of the coal feeding system is given in Fig. 2.8, and
a section through the Petrocarb feed vessel revealing the six internal
feed cones.is shown in Fig. 2.9. The storage and feed vessels were mounted
on load cells and had capacities of 8500 and 6500 Ib respectively. To
ensure consistent output rates, the contents of the feed vessel were
normally not allowed to fall below 3250 Ib. Four of the coal outlets
were connected by \ in B.S. piping, each approximately 100 ft long, to
the four coal nozzles: the remaining two outlets were each arranged as
spare feed lines to two of the coal nozzles. Remotely-controlled valves
in the coal feed pipes at the pressure shell could be operated from the
coal feed station, and these allowed instantaneous selection of normal or
spare feed pipes. In addition, the spare lines could be used as nitrogen
or air supplies to "back-blow" the normal lines, after isolation from
the combustor, for clearance of coal blockages.
Control over coal feed rate was obtained by adjusting the pressure
differential between the coal feeder and the combustor. Minor changes
to equalize flow in individual lines could be made by adjusting the
quantity of conveying air (or nitrogen) admitted via Rotameters to the
lines at the feeder end.
Two of the feed lines were equipped.with a sampling device "teed"
into them via an isolating,cock. The samplers consisted of a small
pressure;vessel containing a cylindrical screen to support a disposable
paper sample bag (from a domestic vacuum cleaner), together with an air
vent.
1.7 Cooling and quench water
Cooling water for the tubes in the bed and freeboard was obtained
2
from the mains water supply and boosted to 120 Ib/in gauge by a
centrifugal pump of 7,000 gal/h capacity, driven by a 35 hp electric
motor. The outlets of the cooling circuits discharged through manually-
operated control valves sited at the inlets of Rotameters so that these
operated substantially at atmospheric pressure: the Rotameters
discharged into a tank which overflowed to the drains. The pump also
supplied liner cooling coils fitted to the inside surface of the pressure
shell and three sets of sprays for cooling the combustion products, viz:
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a. 4 sprays at the entry to the.quench section, 100 gal/h approx.,
b. 4 sprays at the discharge end of the quench section, 150 gal/h
approx., and
c. 4 sprays in the throat of the venturi scrubber, 900 gal/h approx.
Provision was made to supply the following auxiliary circuits, as required,
from the booster pump or directly from the mains water supply:-
a. the cooled shrouds surrounding the four coal nozzles,
b. the. 2 U V flame failure detectors for the flame from the gas
burner in the plenum chamber,
c. two sets of cooling tubes attached to the beam within the
pressure shell from which the combustion vessel was suspended,
d. two heat, transfer loops in the combustor at the surface of the
bed, and
e. the cooling loops for the. radioactive source, and two Geiger
tubes used for detection of bed level.
r\
In the event of pump failure, water at 60 Ib/in gauge was available
directly from the mains supply via a non-return valve. Although water,
at this pressure would have been reasonably satisfactory for the cooling
circuits, flow through the quench sprays would have been barely adequate.
1,. 8 E f f 1 yent d i s pu s a 1
Water containing finely-divided solids, removed from the combustion
products by the hydroclone, flowed under the action of gravity into the
sludge vessel, a horizontal pressure vessel approximately 7 ft long by
4 ft diameter. The level of liquid in this vessel was detected by a
float switch, which under high level conditions supplied a signal to a
pneumatically-operated discharge valve in the base of the sludge vessel.
When t.he level in the vessel fell 1J in to the low-level condition, the
discharge valve, closed. The operating pressure within the vessel was
adequate to force the liquid effluent along a 2 in diameter pipe into a
separating tank sited outside the building. Liquid from this tank over-
flowed into a header tank supplying a "dirty water" pump which transferred
the effluent to a 50,000 gal reservoir where the solids settled out.
Clear water from the reservoir was later discharged to the local sewers.
A.2,7
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products, at the entry to the quench section adjacent to the water
sprays, to increase the pH of the liquid effluents to 7. Liquid
ammonia was obtained from cylinders and supplied via a variable area
meter, non-return valve, control and isolating valves. The ammonia
flashed off to a gas as it passed the final constriction in the piping
and then rapidly dissolved in the water droplets in the quench section.
In practice the flow of ammonia was manually controlled according to the
colour developed by wide-range pH indicator paper which had been dipped
into a sample of water discharged from the sludge vessel.
1.9 Gas
Gas for the plenum chamber burners was obtained from the mains,
o
compressed to 4.7 atm approx. by a piston-type compressure of 1000 ft /h
capacity before being delivered to the metering system for the burners.
The burner assembly consisted of a line of five identical burners, of
which the centre burner was a pilot. Operation of the system was
controlled by a Honeywell flame-failure instrument in the following
manner. When the ignition button was pressed, gas was allowed to pass
through the pilot and an ignition coil was energised to provide a spark
adjacent to the pilot. The flame from the pilot burner was sensed by a
U V detector which then completed the electrical circuit to a solenoid
valve in the gas supply to the four main burners. The detector and
spark ignition units were duplicated so that an alternative could be
selected in the event of non-ignition due to faults in the units or
their wiring, and to obviate the necessity for gaining access to the
inside of the pressure shell to cure the fault.
1.10 Dust Removal and Sampling
Dust from the primary cyclone blowdown was piped through the lower
closure plate of the combustor pressure shell into a venturi scrubber where
the particles were wetted with water from sprays. The dust/water mixture
was passed to a disposal container through a § in bore boron carbide nozzle
(see Fig. 2.10) to control the rate of blowdown. The amount of water used
on the venturi scrubber sprays also had some influence on blowdown rate.
For 3 minutes in every hour, the gases were diverted from the scrubber
into a sample pot, 13 in long by 6 in diameter capable of withstanding
A208
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the combustor test pressure. A filter in the outlet end of the pot
retained the solids, whilst the cleaned gases were discharged through a
silencer and steel orifice to atmosphere. The bore of this orifice was
selected so as to be able to maintain the same mass flow of gases through
the sampling system as through the venturi scrubber. Provision was made
to bypass the scrubber and sample pot in the event of blockage in the
scrubber. All valves used in the system were water-cooled plug or ball
cocks.
Dust from the secondary cyclone blowdown was piped through two
sample pots, 21 in long by 4 in diameter, fitted with filter elements
in their discharge flanges. After one sample pot had been in service
for an hour, the stream was diverted to the second pot for the following
hour. A steel orifice at the outlets of the pots controlled the rate
of blowdown from the cyclone: the cleaned gases were vented to
atmosphere via a silencer. As in the primary blowdown system, a bypass
was available for emergency use and all the cocks were water-cooled.
A half-area flow-mixer baffle was.fitted (see Fig. 2.2) in the
flange immediately downstream of the cascade blading. Exhaust gas
sampling for dust content was achieved via a probe inserted on the axis
of the quench chamber and terminating in a sharp-edged nozzle positioned
upstream of the water sprays. The combustion products were sampled
isokinetically, by the standard BCURA method', to collect gas-borne solids.
Sampling was carried out over ten minute periods at approximately hourly
intervals.
1.11 Bed Removal
Excess bed material was removed at intervals via a 2 in o.d. x
16 SWG Nimonic 75 tubular overflow pipe inserted at 40 to the vertical
through one of the 4 ft wide side walls of the combustor, terminating
34 in above the distributor and 3| in from the inside face of the
combustor wall. External to the combustor, the overflow pipe was
run vertically downwards through the lower closure plate of the pressure
shell. Bed material was conveyed in combustion products down the
overflow pipe, passed into a horizontal stainless steel side arm, I in
bore, 6 ft long, fitted with water-cooled isolating cocks, and finally
discharged at atmospheric pressure into an open container placed on platform
scales.
A2.9
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An extension which was originally fitted to the overflow pipe
inside the combustor, became dislodged during Test Series 2 and was
not re-fitted for subsequent test series. This extension had a $ in
high x 1| in wide rectangular slot, positioned at 43 in above the
distributor plate,
1.12 Temperature measurement
The location of the 101 thermocouples in the pressure shell is
given in Table 2.2 and more detailed information on the position of the
thermocouples in the bed and freeboard is available in Table 2.3. One
of the two thermocouples at the cascade inlet was a suction thermocouple
which was operated at spasmodic intervals throughout the test series to
obtain the true total temperature of the combustion products. All the
remaining static thermocouples were formed from Chromel/Alumel wires
sealed into closed Pyrotenax-sheaths; those in the corrosion tube
assembly specimens were 0.041 in diameter, whilst the remainder were
0.125 in diameter.
.1.13 -Pressure measurement
Static and differential pressures throughout:the plant were
displayed on Bourdon tube type gauges.and on:mercury manometers
respectively; they .were also sensed by pressure transducers for output
to the data logger and for control purposes.
Because the gases in the plenum chamber.were essentially free
from solid.particles, the pressure points in the plenum chamber were
regarded as the main pressure tappings and all differential pressures
were referred to.them. The other limbs of the differential pressure
gauges were connected to pressure tappings in the freeboard, at the
entries to the primary cyclone, the secondary cyclone, cascade and,
venturi scrubber: these tappings were typically 4 inch diameter
square-edged holes which were continuously purged with approximately
10 S.C.F.H. of nitrogen. Mercury catchpots, isolating cocks and bypass
cocks were provided at the manometers used for measuring differential
pressure.
A2dO
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1.14 Gas sampling and measurement
For normal monitoring of the combusti.cn process, gaseous products
were sampled simultaneously from three locations in the plant, viz:
a, top closure plate of combustion vessel;
bn at inlet to quench section; and
c. from the space at. the top of the pressure shell.
All three sampling systems operated under positive pressure anid consisted
of a glass wool filter immediately external to the pressure shell, a self-
draining stainless steel line to a cooler and catch-pot, a secondary
cooler, calcium chloride and silica gel dryers and finally a blow-off
bubbler. The gas supplies to the various gas analysis instruments were
teed off immediately after the dryers. A valved vent to atmosphere from
the outlet: of the first cooler in the line allowed gas flow through the
bubbler to be controlled.
The response times (the time to reach 95% of a new level
following a step change) for the lines varied between 15 and 35 seconds
according to combustor operating pressure and blow-off rate from the
coolers. The various analysers (paramagnetic for oxygen, and
infra-red absorption for carbcn dioxide and carbon mcnexide) had similar
response times, viz: 15 to 25 seconds.,
Except ;n a few rare occasions, the inlet quench section sampling
point was used continuously throughout the tests as the main source of
gas for the oxygen, carbon dioxide and carbcn monoxide analysers. The
output from these analysers was displayed in the main control room and
at the fuel feeding position in addition to being recorded by the
data logger for subsequent calculations. At this sampling point mixing
could be considered complete.
Gases from the top plate probe were also.simultaneously analysed
for oxygen, carbon dioxide and carbon monoxide; the readings were
displayed on charts. Gas composition at this point fluctuated more
rapidly than the gases from the inlet quench section because mixing
was not. complete.. Never the! ess, the reduced response time obtained
with this line, particularly during start-up, made it an asset
especially when ^empoxarily operating -jnder reducing conditions,.
A2-.ll
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It was desirable that the pressure differential across the
combustor walls was sufficiently high to prevent out-leakage of
combustion products. The space above the combustor was therefore
continuously monitored for traces of carbon dioxide by a sensitive
infra-red analyser capable of indicating changes as small as 0.01%.
The Hartmann Braun infra-red S02 analyser was not available
until Test Series 3, when it was installed in the gas sampling bay and
supplied with combustion products from the inlet quench section probe.
Thirty five hours after the start of Test Series 4 it was moved to
the combustor platform and was supplied with gases from the alkali
sampling probe immediately downstream of the cascade assembly. This
arrangement enabled an extremely short line to be used which eliminated
any possibility of condensation occurring in the pipe to the instrument.
During Test Series 1 gases for determination of nitrogen oxides
content were sampled through a plain i in diameter probe in the
measuring section mid-way between the cascade and quench sections.
Analysis was made in two places, (a) adjacent to the pressure shell and
(b) approximately 20 ft from the pressure shell. In both locations,
gases were blown off to the atmosphere to sweep the line, and a small
bleed of gas,.was passed.to the analyser. During the remainder of
the test series the plain probe was replaced by a water-washed probe,
the spray head passing 20 to 50 gal/h of water. A new self-draining
sampling line, 40 ft long x | in o.d. stainless steel pipe, was
installed for Test.Series 2, and terminated in a catch pot vented to
atmosphere via a constant area flowmeter.
1.15 Bed-level measurement
Three methods of estimating depth of bed in the combustor were
available. These were:-
(a) by pressure differential;
(b) by heat transfer measurement, and
(c) by absorption of gamma radiation.
A2ol2
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(a) Pressure tappings were provided on one of the 2 ft wide side walls
of the combustor at 9; in 21\ -in and 98 in above the distributor plate.
All three tappings were continuously purged by nitrogen; the two lower
tappings were in the bed and the highest tapping was in the freeboard.
Assuming that the bulk density of the solids comprising the bed did not
vary with bed height and that the pressure differential in the freeboard
between the surface of the bed and the upper pressure tapping was
constant, the differential pressures afford an estimate of bed depth and
bed bulk density, viz:
if differential pressure between 9? in and 27? in tappings = P-i
differential pressure between 9j in and 98 in tappings = ?2
and Pi and ?2 are measured in inches of mercury.
bed depth = 18 P2 + 9| in
Pl
bed bulk density = 47?i lb/ft3.
(b) For estimating bed height by heat transfer measurement, two
horizontal hair-pin tubes, each fabricated from 3 ft lengths of | in
2
o.d. En 58b tubing and having surface areas of 42 in were fitted
through one of the 2 ft wide sides of the combustor at 36 in and 45 in
above the distributor plate. A cooling water flow was passed first
through the lower loop and then through the. upper loop, its
temperature rise being obtained from thermocouples installed at
the inlet, of the lower hair pin and the inlet and outlet, of the upper
hairpin* A higher temperature differential was obtained when a
loop was immersed in the bed than when the loop was in the freeboard.
(c) The third method of estimating bed height utilised a 400 mC
Caesium source held in a water-cooled casing fixed on the outside of
a 4 ft side of the combustor at 44 in above distributor plate level.
The outputs from two Geiger tubes, mounted on the outside of the opposite
combustor wall at 37 in and 46 in height above the distributor plate, were
displayed by ratemeter indicators in the control room. A fall in bed
level below the plane of the source unit and Geiger tube resulted in
an increased count being obtained.
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All three methods were used in the test series, but method
(a) was found to be most informative in that a rate of change of bed
depth could be obtained. This method was used to indicate when it was
necessary to remove bed material to maintain a desired bed level.
The electrical outputs from much of the instrumentation e.g.
thermocouples, static and differential pressure transmitters, load
cells, and gas.analysers, was recorded on punched tape at ten minute
intervals by a data logger having 197 channels, in addition to being
displayed at the various control positions.
A2.14
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2. GENERAL OPERATING PROCEDURES
2,1 Preparation
Before the start-up operation commenced, approximately 1800 Ib
of Newdigate shale was loaded into the combustor to form the initial
bed. The coal feeding unit, the combustor and effluent disposal units
were pressure tested to 7.5 atm prior to elimination of minor leaks at
6.5.atm pressure.
2.2 Warming up
Steam at 8 atm pressure was then passed through three of the bed
cooling coils and the bed fluidised at about 1.5 ft/s with cold air.
This air flow pressurised the combustor to 1.5 atm abs approx. After
about one hour, when the warm air from the bed had heated the internal
surfaces of the cyclones and their blowdown legs to above the water
dewpoint, the gas burner in the plenum chamber was lit. In earlier
combustor tests, when the bed was not preheated prior to lighting the
gas burner, condensation occurred in the dust extraction system so that
fines elutriated from the bed choked the cyclone blowdown legs. The
gas input was regulated to obtain a maximum air temperature below the
distributor of 1400 F. As the bed warmed up the mass flow of air was
decreased to maintain fluidising velocity in the range 1.5 to 1.8 ft/s.
The quench section and venturi scrubber water sprays were established
when the inlet cascade temperature reached 180 F.
2.3 Start up
When the temperature throughout the bed reached 930°F conveying
air was admitted via the four coal nozzles, the combustor pressure was
set to 2 atm and a small flow of coal was fed to'the bed. Providing
the carbon monoxide content of the combustion products did not peak
to more than 1.5%, coal.input rate was gradually increased and air
flow adjusted to obtain a progressive rise in bed temperature with
fluidising velocity in the range 1.8 to 2.0 ft/s. The coal flow
was either reduced or stopped altogether if the carbon monoxide
content became excessive. Water flow was set to one of the freeboard
gas cooling coils if the freeboard gas temperature exceeded bed
temperature. Gas flow to the plenum chamber burner was reduced to
A2,15
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1 therm/h when the bed temperature reached 1200 F and shut off at a
bed temperature of 1380 - 1430 F. Once the bed temperature exceeded
1300 F, the carbon monoxide content of the combustion products
usually dropped slowly to the normal operating level of 0.1% or less.
2.4 Increasing Pressure
When bed temperature reached 1470 F, bed cooling circuits were
commissioned as necessary whilst air flow and operating pressure were
increased until the set running conditions were obtained. During the
short periods when a bed cooling circuit was brought into (or out of)
service, very rapid changes in metal temperature occurred. A water-air
emulsion was supplied to several of the circuits during this period
to prolong.-the life of the tubes. Until the combustor operating
pressure exceeded 2.7 atm, the liquid effluent from the hydroclone was
allowed to drain to the sewers. At higher pressures, the effluent was
diverted to the dirty water treatment system.
As operating pressure was increased, flow through the primary
and secondary ash blow-down systems was reduced by shutting off the
emergency bypasses and duplicate orifice assemblies which had been in
circuit during start-up. Flow through the two systems was then
controlled by the resistance of a single orifice at the discharge
points. Water flow was established as soon as possible to the horizontal
venturi scrubber in the primary cyclone blowdown piping. An increase
in the-amount of spray water resulted in a decrease in gas flow; water
flow was adjusted to obtain a metal temperature of 550° to 750°F up-stream
of the .venturi scrubber where the piping passed through the closure plate.
The corresponding metal temperature for the secondary cyclone blowdown
system was 300 to 350 F. If this was not obtained during steady operation
with the normal discharge orifice, the possibility of blockage of the filter
in the outlet of the sample pot was investigated.
2.5 At steady conditions
.As soon as the set conditions for the test had been attained
(normally lj.. to 3 hours from coal on), the data logger was switched on to
operate on a ten minute cycle.
A2»16
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No chart records were available for the thermocouples during
the logging period as their electrical outputs were automatically
switched to the data logger input a few seconds before the
commencement of the period. The speed of reading the data was
limited by the speed of the paper punch to about 2 channels per
second.
Approximately 1 Ib/h of liquid ammonia was bled in the inlet
to the quench section to neutralise the acids formed by absorption
from the combustion products. Samples of the liquid effluent were
taken every hour and checked with pH indicator paper. The ammonia
flow was then regulated as necessary to obtain an effluent having
a pH of 7.
Primary cyclone fines were sampled every hour by the two
following procedures. First, the wetted fines discharged from the
venturi scrubber were diverted to a 40 gallon drum for ten minutes.
Each drum accumulated three hourly samples before being changed.
After the test series, when the fines had settled to the bottom of
the drum, the sludge was dried in a gas oven and weighed to give
an estimate of mass flow of fines during the period. Second, the
blowdown was diverted, from a point upstream.of the venturi scrubber,
into a sample pot for a three minute period. These samples were
batched as necessary and submitted for chemical and physical analysis:
their weights provided a check on the estimates of mass flow obtained
from the wet sampling system.
Secondary cyclone fines were sampled continuously by passing the
blowdown through a sample pot; the sample pot was changed every hour.
These samples were weighed to obtain the hourly estimates of mass
flow and after batching as required were submitted for chemical and
physical analysis.
Estimates of dust loading in the combustion products were made
at approximately hourly intervals and with a sampling period of ten
minutes. There were periods during some of the tests when the
intervals between dust, samples was longer than this due to the
operators being involved with less frequent sampling routines or
with servicing the probe and sampling equipment.
A2ol7
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Combustion products were sampled for ten minute periods every
1 to 1^ hours from the-probe fitted..to the duct immediately downstream
of the cascade section, and analysed for sulphur dioxide and sulphur
trioxide by the modified Shell chemical method. During periods when it
was known that the level of these components would be changing rapidly,
the frequency of sampling was increased to one determination every
twenty minutes.
Alkali determinations were made relatively infrequently, i.e. once
per twelve hour shift. Gases were sampled over a twenty minute period,
from the probe immediately downstream of the cascade and alkali content
2
estimated using Ounsted's electrostatic precipitator method and
subsequent determination of sodium and potassium with a flame photometer.
A 2 Ib sample of the coal plus acceptor fed to the combustor was
taken every three hours. The coal sampler.was teed into the supply
line to one of the coal nozzles at a point directly beneath one of
the coal feeder.discharge cones. In order to sample the whole stream
of solids, the following procedure was adopted. The cock in the coal
supply line to the nozzle was shut and after the line had been blown
clear by the conveying air, the coal flow was supplied to the combustor
via the spare line. The arrangement of cocks allowed the conveying
line to be isolated and the sampler to be connected directly to the
coal feeder outlet so that coal fell vertically downwards into the
sampler aided both by gravity and by the flow of air from the feeder.
After closing the cock at the inlet to the sampler, feeding via the
spare line was discontinued and the conveying line cock on the normal
feed line was opened to re-establish coal supply to the coal nozzle.
The sampler was then dismantled, the solids emptied into a screwed-cap
jar which was sealed and stored for batching, as required, with other
samples.
The frequency of removing bed material from the combustor
was dependant.upon the nature of the ash in the coal and the size grading
and proportion of acceptor fired with the coal. Typically, 150 Ib of
material representing 4 inches of bed was removed on each occasion:
the minimum time between extractions was of the order of two hours.
The removal procedure consisted solely of opening the cock in the weir
A2018
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blowdown pipe external to the pressure shell and tapping the piping
at the change in direction beneath the combustor. This allowed the
settled solids remaining in the pipe from the previous extraction to
be swept out in the stream of solids plus combustion products. The
solids flowed out of the open end of the weir blowdown piping into a
tared container; no control over flow rate was provided. When
sufficient material had been removed from the bed, the cock in the
blowdown piping was closed.
On the rare occasions during the tests when the bed continuously
lost height, it was necessary to add additional inert material. The
procedure used to do this was to discontinue the normal flow of coal
to one of the four nozzles and to feed instead a mixture of 80% w/w
inert material + 20% w/w coal from a small fluidised feeder of 800 Ib
capacity, operated at a positive differential pressure with respect
to the combustor. The inert material used was either shale or bed
material recovered from earlier non-acceptor test runs. Feed rate
was matched to maintain bed temperature at 1470 F and thus represented
a higher coal input than normal since it was necessary to supply
additional heat to raise the cold inert solids to the bed temperature.
2.6 Shut down
The shut-down procedure was straightforward comprising the
following main actions:-
(a) turning off coal by closing the discharge cocks beneath the.
feeder. A flow of conveying air was maintained through the coal
nozzles to purge the lines.
2
(b) as the bed cooled, reducing combustor pressure in 5 Ib/in steps
to maintain 2 ft/s fluidising velocity.
(c) shutting off the water supply to the bed and freeboard cooling
circuits.
(d) diverting the liquid effluent to the sewers.
(e) when bed temperature fell to 750 F, shutting off the water supply
to the venturi scrubber and opening the bypass systems in the
primary and secondary cyclone blow-down systems.
A2ol9
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(f) when bed temperature fell to 550 F, shutting off the combustor
fluidising air supply and the water flow to the coal nozzle cooling
jackets.
(g) immediately after stage (f), shutting off the water supplies to
the quench section sprays and the venturi scrubber.
2.7 Emergency shut-down in event of failure of public electricity supply:
Failure of the mains electricity supply would result in failure of
the majority of the automatic controllers, two out of the three air
compressors, and all temperature indicating/recording instruments, gas
analysers and the inter-comm system. Although the main air valve would
fail safe in the closed position a limit stop was provided to enable a
small flow of air to be fed to the combustor for purging purposes: the
air supply to the space between the pressure shell and the combustor
would however cease, causing an imbalance of the two pressures. The
pump supplying high pressure water to the quench section sprays and
to the cooling circuits would stop, but the circuits would immediately
by supplied with water from the normal mains, albeit at a greatly
reduced pressure.
The following procedure was successfully adopted to avoid damage
to the plant when the mains electricity supplies failed:-
(a) The building was evacuated except for two control room staff.
(b) Coal flows to the combustor were shut off at the feeder isolating
cocks and also by use of a control room lock out switch.
(c) The control valve in the pressure balance piping, linking the
combustor outlet piping with the space between the combustor
and pressure shell, was fully opened, (although this valve was
pneumatically controlled, its maximum opening under auto conditions
was much less than its maximum possible opening).
(d) Corrosion tube air supplies were shut off when the combustor pressure
fell to 1.7 atm.
(e) The ammonia supply to the quench system was stopped and water to
the venturi scrubber in the primary cyclone blowdown system was
turned off.
A2.20
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(f) The quench section water sprays were then shut off and immediately
after this had been done, the manual cocks in the air supplies to
the air preheat tubes were closed.
(g) Finally the emergency bypasses in the primary and secondary cyclone
blowdowns were opened.
2.8 Mass Balances
Mass balances were computed for each of the Tests, using the
following general procedures:-
2.8.1 Weights and Flow Rates
The weight of the bed was calculated from the static pressure-drop
across the bed, and the rate of material "gained by bed" was the gain in
bed weight during the test divided by the duration of the test.
Coal and Acceptor: The individual feed rates of coal and acceptor were
obtained from the flow rate of mixture and from the value of d, the
weight fraction of acceptor in the mixture, calculated from the equation:
d = (x - cy)/(C(l + c) - c)
where x and y are respectively the weight fractions of COo and "ash"
in the mixture, c is the CCL/ash ratio in the raw coal, assumed to be
constant, and C is the C02 content of the raw acceptor. These
assumptions eliminate the need to assume a constant composition for
the raw coal.
Air and Nitrogen: These gases were measured as described elsewhere
in this Appendix. The coal conveying air was the total air used for
fluidising the feed vessel and for conveying, less the vent flow from
the feed vessel.
Weir Solids: The flow rate of weir solids was the actual weight of
material extracted over the weir during the test, divided by the
duration of the test. The rate of material gained by bed should be
added to the flow rate of weir solids to obtain the flow rate obtainable
under steady-state conditions.
Cyclone Solids: The primary cyclone solids flow rates were those
assessed by the wet sampling method.
A2.21
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Exhaust Dust: The flow rate of dust escaping with flue gas exhausted
from the secondary cyclone was assessed from the weight of dust present
in a known weight (usually approx. 40 Ib/h) of flue gas sampled for
10 minutes.
Flue Gas: The flow rate of flue gas was calculated assuming a total
materials balance, and the water vapour content of the flue gas was
calculated assuming a hydrogen balance.
2.8.2 Components of Materials
Ash: The "ash" contents of coal-acceptor mixtures were obtained by
the usual method for determining the ash content of coal. Analysis
of the "ash" from these mixtures invariably showed a high sulphate
content, due to capture of sulphur by the calcined acceptor present,
and the "ash" contents have therefore been corrected to the
sulphate-free basis. "Ash" contents of acceptor, bed materials and
output solids were not determined, and in all cases were assumed to
be equal to:
(100 - % H20 - % S03 - % C02 - Elemental carbon) %
Carbon: It was assumed that air contains 0.03 mol % of C02«
Hydrogen: Hydrogen inputs in coal and acceptor include hydrogen
present as moisture. The moisture content of the main combustion
air was assumed to be that corresponding with saturation under the
conditions at which the flow was measured. The coal conveying air was
dried by silica gel, and the nitrogen input was assumed to be dry.
Hydrogen detected occasionally in output solids was assumed to be
present as moisture absorbed after weighing. In no instance was
hydrogen or methane detected in the flue gas, and the total hydrogen
input was therefore assumed to be converted to water vapour in the
flue gas.
Nitrogen: For the purposes of the mass balances, nitrogen oxides
in the flue gas were assumed to be present as nitric oxide. The
elemental nitrogen content of the flue gas was obtained by difference,
and therefore includes analytical errors; it was assumed to have a
molecular weight of 28.17, as for "nitrogen" in air.
A2.22
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Oxygen: The oxygen content of coal-acceptor mixture was, as usual,
obtained by difference (after correcting the "ash" content for sulphate)
and therefore includes analytical errors. The oxygen contents of
acceptor, bed material and output solids comprised oxygen present as
CO- and SO-. The oxygen content of flue gas was the sum of oxygen
present as CO-, 0-, CO, NO, SO- and SO-.
Sulphur: Sulphur in acceptor, bed materials and output solids was
assumed to be present as sulphate.
Calcium, Magnesium, Sodium and Potassium: These elements were
determined in input and output solids as their oxides, but the oxygen
combined with them is not included in the oxygen inputs and outputs.
Alkalis present in the flue gas were determined in the form of
condensed aerosols, but were assumed to be present in the gas as
vapours of the oxides.
Chlorine: Chlorine was assumed to be absent from acceptor. Chlorine
in the flue gas was probably mainly in the form of HC1, but no
allowance was made for the hydrogen associated with chlorine in gas
when computing the vapour content.
A2.23
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3. RESULTS
3.0 Summary
The detailed results of each Test Series are presented in
Section 3.1 to 3.5. The main variables investigated were Ca/S
ratio, type of additive, size of additive and coal. Other operating
variables such as fluidising velocity, bed depth and bed temperature
were substantially constant at 1.9 ft/s, 3.75 ft and 1A70°F,
respectively. Operating pressure was either 3.5 ttf 5 atm absolute.
3.0.1 S02 emission;
All the data on the reduction in S02 emission are plotted
in Fig. 3.12. The main conclusions, as far as Task II is concerned,
are:
(1) Reduction was not affected by pressure in the range
31/2 to 5 atm.
(2) Altering the median size of the additive (in this
case dolomite 1337) from 1100 to 400 micron did not
affect the reduction in S02 emission. The change
in size was produced by widening the size distribution,
i.e., by increasing the proportion of fines.
(3) Reduction with Welbeck/U.K. dolomite appeared to be
slightly higher than with Pittsburg/Dolomite 1337,
although the range of Ca/S ratios investigated did
not overlap sufficiently for a firm conclusion to be
drawn.
(4) Reductions obtained with limestone 18, although
considerably lower than with dolomite (on a Ca/S basis),
were surprisingly high in view of the fact that
limestone does not calcine at these conditions.
The time taken to reach an equilibrium S02 emission was substantial
when dolomite was the additive - about 20 to 50 hours when the initial
bed contained no dolomite. The accumulation of unconverted CaO in the
bed also reached a maximum in a similar time as illustrated in Fig. 3.5.
With limestone 18, equilibrium was reached much more rapidly.
A2.24
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S02 emission appeared to fluctuate in sympathy with the coal
feed rate. Figure 3.9 shows typical extracts from the recorded
outputs of the C>2 and SCL gas analysers. The variations in Q£ content
were due to fluctuations in coal feed rate.
3.0.2 NOy emission The NOX content of the exhaust gases was generally
in the range 80 to 190 p. p.m. (v/v) . None of the variables investigated
appeared to have any effect on NOx emission.
3.0.3 Particulate emission The dust burden of the gases passing over
the cascade was about 150 Ib dust/10 Ib gas (about 0.1 grains/sft ) when
burning Pittsburgh coal. This was about twice the dust loading obtained
when burning Welbeck coal. The inert input (dolomite or limestone) was
considerably higher with Pittsburgh coal, partly because of its higher
S content, and partly because it was decided to use higher Ca/S ratios
with the Pittsburgh coal.
The dust was sized by Coulter Counter and found generally to have a
median size. of 6 to 8 micron with about 90% less than 30 micron. As with
all determinations of size distribution in this range, however, the value
of the data, is open to question. Earlier tests with Welbeck coal had
shown that most of the larger dust particles were in the shape of
'platelets' which would not be regarded as erosive.
3.0.4 Combustion efficiency In the later tests with Pittsburgh coal the
combustion efficiency was greater than 99%. In the early tests, when the
acceptor was Dolomite 1337 with the high median size, the efficiency was
about 97^%. This lower efficiency was probably due to the poorer
mixing in the coarser bed produced by using the coarser dolomite.
With Welbeck coal, under fluidising conditions similar to the later
tests with Pittsburgh coal, the combustion efficiency was about
Combustion in the freeboard, based on heat balance between the
top of the bed and the top of the freeboard, amounted to 2 to 3% of
the coal heat input.
The major loss of combustion efficiency in all cases was in the
carbon of size less than 50 micron elutriated from the bed.
A2,25
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3.0.5 Temperature distribution The temperature of the bed showed
a small, but consistent, rise of 30 to 40 F between a level near the
bottom of the bed and one near the top. At any particular level the
variation in temperature was about - 20 F, although no measurements
near a coal feed point were made.
3.0.6 Blade cascade and target rods The blades were not cleaned
between tests and the appearance did not vary greatly from test to test.
Typical appearances after Tests 2 and 3 are shown in Fig. 3.11. Usually
there was a light accumulation of dust on the leading edge with flecks
of dust adhering to the concave faces and negligible deposition on the
convex faces. There were no signs of sintered deposits or of erosion.
The target rods usually had a small knife-edge of deposit on their
leading face, and had developed a considerable 'tail'. Cross-sectioning
and examination under a microscope revealed no evidence of corrosion or
erosion.
A2.26
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3.1 Test Series 1
3.1.1 Objectives of Test Series
To measure the emission of SC>2 and NO^ from the combustor when
burning Welbeck coal and U.K. dolomite at nominal Ca/S ratios of 0,
1 and 2.
3.1.2 General description of Test Series
3.1.2.1 Outline of Test Series
The test was carried out between 1st and 5th June 1970 and lasted
for 100 hours. The test was carried out in three main sections: an
initial period of 8 hours with no dolomite addition, followed by two
periods of 47£ and 44$ hours each at a different level of dolomite
addition. The test was limited intentionally to one operating
pressure so that accurate information could be obtained on the time
required to reach equilibrium.
Based on the measurements made, five Test periods were selected
for carrying out heat and mass balance computations. Coal, primary and
secondary dusts were bulked according to each test period. Operating
conditions are given in Table 3.1 and analyses of coal, dolomite, cyclone,
exhaust dust and bed samples are given in Tables 3.2 to 3.10.
Average.gas composition measurements for each of the Test periods are
given in Table 3.11. Combustion conditions were substantially constant
throughout the test, as shown in Table 3.12, where the variations of bed
temperature and gas composition are illustrated.
After the test, two of the water circuits were found to be leaking
slightly.
3.1.2.2 Coal and dolomite preparation
For this test the coal was not screened before milling (i.e. all the
raw coal was milled). The dust caused during the coal/dolomite blending
process was controlled by means of vacuum cleaners. After the test it
was found that they had preferentially extracted dolomite dust from the
blend. In consequence, the actual Ca/S ratios of the blends were lower
than intended. For subsequent Test Series the extraction system was
modified to avoid this problem.
A2o27
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3.1.2.3 Sulphur emission
Measurements of the S(>2 and SO^ content of the flue gas were
made at approximately hourly intervals (more frequently when the rate
*
of dolomite injection.was nominally increased) using the "Shell"
2 U
condensation method for 863 and the BCURA iodine absorption method for
the SO- content.
The results are given in Table 3.13 and in Fig. 3.1. Also shown
in Fig. 3.1 are the variations in the approximate Ca/S stoichiometric
ratio in the feed, calculated from the C0£ contents of the coal/acceptor
samples and an assumed average value for the sulphur and ash contents
of the coal. The tabulated data under the various Test periods in
Fig. 3.1 refer to the mean operating conditions for these periods and
give the actual Ca/S mol ratios based on the Ca and S contents of the
bulked coal/acceptor samples collected during that period.
Table 3.14 shows the percentage of sulphur retained in each of
the test periods.
3.1.2.4 NOy emissions
Determinations of oxides of nitrogen were made at irregular
intervals throughout the test. Results are summarised in Table 3.15.
When the two methods used (Saltzman and Hersch) were operated
concurrently, reasonable agreement between the two estimates was
obtained.
3.1.2.5 Retention of alkalis and.chlorine
Determinations of sodium, potassium and chlorine in the flue gas
are summarised in Table 3.ISA. Table 3.14 also shows the percentages
of H&20, K£0 and chlorine retained. Both these and the sulphur
retention figures are expressed as 100 (weight of component input -
weight in gas)/weight of component input. To avoid negative results,
chlorine retentions are based on weights of chlorine in the output
solids.
Alkali retention was virtually complete at all Ca/S mol ratios.
A2,28
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3.1.2.6 Mass balances
The mass balances computed for each of the test, periods of Test
Series 1 are presented in Tables 3.16 to 3.19A. The computations were
based on the assumptions already described in Section 2.8, together
with the additional assumptions listed underneath the tables.
With some exceptions, the balances are.satisfactory. An obvious
exception was the chlorine balance: in Tests 1.1 to 1.4 inclusive,
the chlorine content of the flue gas exceeded the chlorine input in
coal fed. This may have been due to errors of determining the chlorine
content of the gas. The periods selected for the tests of the series
corresponded with times when the sulphur emission appeared to have
become constant following a change in the rate of acceptor input.
However, it can be seen from the rates "gained by bed", and from
analyses of bed materials at the start and end of each test, that the
bed composition did not become consLant during the Test Series.
Comparison of coal ash and acceptor analyses suggests that until bed
composition became constant, there would be gains in the sulphur,
calcium and magnesium contents, and falls in ash and potassium contents
during a test, and this behaviour was shown in each of the four tests
following the start of acceptor feeding. It is likely that an
appreciable error was associated with the method of determining bed
weight. The rates "gained by bed" are based on differences between
estimates of two large bed weights (approx. 1800 Ib) and two analyses.
They are therefore likely to be more in error than many of the other
input and output rates and may account for most of the differences
between inputs and outputs. Analytical errors associated with analyses
of "ash" in the coal-acceptor mixture and of acceptor can lead to
errors in the rates of individual components of coal and of acceptor;
this is revealed by the negative magnesium content of coal in Test 1.5.
However, the sum of the inputs in coal and acceptor equals that computed
from the analysis of the mixture.
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3.1.2.7 Heat Balances
The heat balances are presented in Table 3.20. The heat balances
are poor, since only 83 to 88% of the total heat input is accounted for.
This could be due to the leakage of water into the combustor and the
results are consistent with a leakage rate of 250-300 Ib/h.
The. data are expressed in million Btu/h, rounded off to the
nearest 0. .01 million Btu/h, and the calculations were based on the
assumptions given below.
All heat quantities refer to a datum . temperature of 32 F. The
heat input in coal-acceptor mixture, which includes sensible heat
of solids (approx. 0.002 million Btu/h), is predominantly the
potential heat of the coal fed, based on its gross calorific value.
Potential heats of output solids are calculated from their elemental
carbon contents, assuming a heat of combustion of 14,544 Btu/lb carbon.
The total heat of weir solids (sensible plus potential heats) includes
the heat content of material gained by the bed. Sensible heats of
outlet gases are based on the appropriate temperatures, i.e., bed
temperature for weir gas blowdown, the relevant cyclone temperature
for the cyclone gas blowdowns, and the secondary cyclone exhaust
temperature for the exhaust flue gas. Potential heats of gas outputs
are the heat of combustion of the CO in the gas, and the latent heats
refer to the water vapour content. The heats of acceptor reactions:
CaC03 + S02 + J02 = CaS04 + C02 + 77.1 kcal/mole
MgC03 = MgO + C02 - 24.2 kcal/mole
were calculated from heats of formation of reactants and products
«
given by 0. Kubaschewski and E.LI. Evans ("Metallurgical Thermochemistry".
London: Pergamon Press, 1958).
The main loss of potential heat (i.e. combustion efficiency) was
in the carbon carried over into the primary cyclone. The bulk of this
loss occurred in the finer fractions (less than 53 micron) as shown
in Table 3.21.
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3.1.2.8 Corrosion of metal specimens in the bed
The specimens were examined visually for deposits and corrosion
or erosion damage. A few randomly-selected specimens were then
sectioned, mounted and polished for metallographic examination, but
the majority.were descaled in a sodium hydride bath and the weight
change for the run determined.
The high temperature tubes 1 and 6 (1450°F) had a matt red
coloured film on the underside thinning to clean metal surfaces at
the top of the tubes. This deposit was thin (.001") and had lifted
in some places to expose clean metal beneath. Tube 2 (1320-1380°F)
was similar but more patchy. Tubes 3 and 4 (1020-1160 F and
930-1020°F) were completely covered by a dark red to black film with
a polished appearance. There was no indication of it breaking away
from the surface. The 1% Cr |% Mo and 2^% Cr 1% Mo specimens in
these tubes had a blistered appearance. Tube 5 (660-1020°F) had
a dark brown polished film on the top surface similar to tubes 3 and 4.
The underside, however, had a striated appearance because of the
leakage of cooling air around the edges of the specimens, the leaks
being caused by sagging of the tube assembly during the run.
The rates of weight loss of the specimens after descaling are
given in Table 3.22 and are summarised in Table 3.23. The
metallographic examination confirmed the weight loss results; no
intergranular penetration was found in any of the specimens
(see Table.3.24). The higher weight losses of the 2|% Cr 1% Mo,
1% Cr i% Mo ferritic specimens were associated with a general surface
roughening.
3.1.2.9 Blade cascade and target rods
See Section 3.5.2.9 at end of Test Series 5.
A2o31
-------
3.2 Test Series 2
3.2.1 Objective of Test Series
To measure the emission of S0_ and NOV from the combustor when
2. A
burning Pittsburgh coal with dolomite 1337 addition at a nominal Ca/S
ratio of 2.
3.2.2 General description of Test Series
3.2.2.1 Outline of Test Series
The Test was carried out between 19th and 23rd October 1970 and
lasted for 81\ hours. During the first 8 hours of the test considerable
loss of bed material occured, and about 750 Ib of make-up shale was
added in this period. This coincided with a period when coal prepared
from the -1/16 in fraction was being used. The ash from this fraction
had an extremely low bulk density, and it is possible that all the
input ash was being elutriated. Alternatively, material may have been
carried up the dip-leg of the recirculation cyclone because the "airslide"
settings at the base of the dip-leg were too high for the Pittsburgh coal/
dolomite mixtures. After 8 hours operation the "airslide" flows were
reduced, coincident with using a well-mixed blend of coal prepared from the
+1/16 in and -1/16 in fractions. No further difficulties were experienced
in maintaining bed level and bed material was removed at regular intervals.
. After 73 hours operation the plant had to be shut down rapidly when
the combustor pressure suddenly increased from 60 p.s.i.g. (5 atm) to 73
p.s.i.g. due to a failure of the pressure control system. The test was
resumed after a delay of six hours for plant inspection.
After 81\ hours operation the Test was terminated when it became
apparent from the temperature records that the bottom 6 inches of the bed
had cooled down and defluidised. Subsequent examination of the combustor
showed that sintered ash agglomerates had formed around and above the
coal nozzles; the nozzles had also overheated. At the time it was assumed
that the sinter was a result of the low ash-fusion temperature of the
Pittsburgh.coal and the immediate solution appeared to be to provide
additional cooling at the coal nozzles so as to reduce the temperature
in their immediate vicinity. Accordingly water-cooled jackets for the
coal nozzles were fabricated and installed.
A2-32
-------
The test was restarted using the same bed material (after screening
out the +1/16 .in sintered lumps). It was noted during the warm-up period
that the bed was more difficult to fluidise (requiring about twice the
normal.fluidising velocity at low bed temperatures) than usual, and after
4 hours operation on coal the lower part of the bed again defluidised.
The plant was shut down immediately (on the previous occasion the bed was
operated for the final 3 hours with the bed partially defluidised) and,
on inspection, no evidence of sintering could be found. At this point
it was decided to terminate Test Series 2.
Analysis of the bed material after the test showed that there had
been a major change in size distribution since the beginning of Test .
Series 2, the median size of the particles increasing from about 400
micron at the beginning to about 900 micron at the end. This was due
partly to the friable nature of the ash, but mainly to the lack of fine
particles in the dolomite 1337. The dolomite was fed in the essentially
"as received" state (after the small amount of +1/16 in material had
been screened out) and had a median particle size of about 1000 micron
(see Fig. 3.2.).
It.is now believed that the difficulties experienced at the end of
Test 2 were not caused by sintering, but were due to the alteration in
the particle size of the bed. Fig. 3.3 shows the fluidising characteristics
of the material before-and-after Test 2, as determined in a 12 in diameter
vessel using cold air. Although the after-test material was more difficult
to fluidise,.it is not immediately obvious that the bed would defluidise
under test conditions until it is remembered that if the temperature of
the gases falls, the gas velocity will also fall correspondingly. An
increase in the particle size of the bed material would reduce the
circulation of heat .to the bottom of the bed and it is likely that in
a combustion system there is a threshold limit of gas velocity which is
necessary to maintain the temperature of the bed. Below this limit the
temperature, and therefore gas velocity, will fall and the bed will
defluidise.
Four Test periods of steady operation and a fifth which included
the defluidising period were selected for computation of combustion
efficiency, heat and mass balances. Samples of coal, primary and
A2o33
-------
secondary cyclone fines, exhaust dust and bed extract were bulked
before analysis to conform with these.selected periods. Operating
conditions are given in Table 3.25 and the analysis of the coal,
dolomite, cyclone, exhaust dust.and bed.samples are given in
Tables 3.26 to 3.35. Average gas composition measurements for each
of the Test periods are given in Table 3.36, variations in bed
temperature and gas composition are given in Tables 2.37 and 3.38.
3.2.2.2 Sulphur emission
Measurements of SCL and SO- were made at approximately hourly
intervals using the "Shell" condensation and BCURA iodine absorption
methods. **
Results are tabulated in Table 3.39 and Fig. 3.4. Also shown
in Fig. 3.4 are the variations in the approximate Ca/S stoichiometric
ratio in the feed, calculated from the CO. contents of the coal/acceptor
samples and an assumed average value for the sulphur and ash contents of
the coal. The tabulated data under the various test.periods in Fig. 3.4
refer to.mean operating conditions for these periods and give the actual
Ca/S mol ratios based on the Ca and S .contents of bulked coal/acceptor
samples collected during that period.
Equilibrium as regards S02 emission appeared to be reached in 15
to 20 hours. This is considerably shorter than the 50 to 60 hours
required in Test 1, presumably because in Test Series 2 the initial bed
material contained some "free" calcium, tha dolomite input rate was
higher, and the dolomite size was such that more was likely to be
retained in the .bed. Support for this explanation is provided by
Fig. 3.5 which shows the variation of weights of total and of
unconverted calcium (expressed as Ib of equivalent CaO) in the bed, and
the concentration of S02 in the flue gas. The diagram has been simplified
by linearly interpolating between weights of CaO at the times of with-
drawal of bed material. During most of the test the average weight of
unconverted CaO in the bed was approximately 300 Ib, and this weight
was reached .after approximately 20 hours. Some of the variation in
sulphur content of the gas was probably due to variation in the rate of
sulphur input; for example, during Test 2.4 (4081 and 4352 min from
A2o34
-------
start of test) the average rate of sulphur input was 20% higher than
in Test 2.3.(2304 to 4031 min), but for the first 4000 min of the
test the sulphur content of the gas reflects the free calcium inventory
reasonably well. During the last 500 min of Test 2, the SO- levels
started to increase as a consequence of the poor fluidisation and
eventual sintering experienced in this test. The percentage of sulphur
retained in each of the test periods is shown in Table 3.40.
3.2.2.3. NOx emissions
Determinations of oxides of nitrogen in the exhaust gases were
made throughout the test, mainly using the Hersch6method. Results
are summarised in Table 3.41. For this and subsequent tests, a water-
washed probe was used.
3.2.2.4 Retention of alkalis and chlorine
Determinations of contents of sodium and potassium oxides and
chlorine in the flue gas were made during Test Series 2 and are
summarised in Table 3.42. The percentage retentions of alkalis and
chlorine are shown in Table 3.40. As in Test 1 the retention of
alkali was virtually complete. It is thought that the figures for the
retention of chlorine obtained in Test Series 2 are more reliable than
those for Test: Series 1; the percentage retentions are higher but this
may be due to the lower chlorine content of the coal.
3.2.2.5 Mass Balances
The mass balances computed f'cr each of the tests of Test Series
2 are.presented .in Tables 3.43 to 3.47. The computations were based
on the assumptions already fully described in Section 2.8, but for
Test 2.1 it was assumed that the rate of input of shale-coal mixture,
which was fed intermittently during Test 2.1 was the total weight fed
(weighed directly) divided by the duration of the test. The coal
content of the mixture was deduced from the carbon content and from
the analysis.of the raw coal, and the.coal ash, moisture, hydrogen
and oxygen contents were also deduced from the analysis of the raw
coal. The shale content, of the mixture was assumed to be 100% ash,
and the sulphate content of the total ash was assumed to be nil.
-------
Until constant bed composition was achieved, it would be expected
that the sulphur, calcium and magnesium contents of the bed would rise,
and the ash, sodium and potassium contents would fall. Such behaviour
was shown during Tests 2.1 and 2.2, although the sulphur emission had
become stable during Test 2,,1. In Tests 2.3 to 2.5, the variations
in bed composition were small and random, probably reflecting to some
extent analytical errors, e.g. the large loss of sodium from the bed
in Test 2.5 resulting in a negative total sodium output.
3.2.2.6 Heat Balances
The heat balances are presented in Table 3.48. Good accountability
of the heat input was obtained in Tests 2.2 to 2.5, but not in Test 2.1
during which a shale-coal mixture was fed intermittently to compensate
for excessive loss of solids from the system via the primary cyclone. It
is possible that this introduced errors in the measurements used in the
calculations.
The main loss of potential heat (i.e. combustion efficiency) as
in Test Series 1 was in the carbon carried over into the primary
cyclone. The bulk of this loss ocurred in the finer fractions (less
than 53 micron) as shown in Table 3.49.
3.2.2.7 Corrosion of metal specimens in the bed
The specimens were treated as for Test Series 1. The appearance
of the tube assemblies after the test is described below:
Tubes 1 and 6 (1470 F metal temperature). There was a reddish
film, matt on the PE16 and mottled on the SF316 and RF36.
There was a black film on the Esshete.
Tube 2 (1290-1380°F)o A brick red to cream film, flaking in places.
Tube 3 (1110-1170°F). Smooth, dark film on the high chrome alloys.
The 1% and 2|% Chrome alloys showed some blistering on the
surface.
Tube 4 (840-1110°F). Similar to Tube 3. Smooth dull red/dark green
film with slight blistering on the 1% and 2{% Chrome alloys.
Tube 5 (630-930°F). Similar to Tubes 3 and 4.
A.2.,36
-------
The rates of weight loss measurements are given in Table 3.50
and the results are summarised in Table 3.51. The results of the
metallographic examination of some of the specimens are given in
Table 3.52. It is apparent from the results that corrosion was
greater than in Test Series 1. The most likely explanation lies in
the poor fluidisation experienced in Test Series 2, which could have
caused high local bed temperatures.
It is also apparent that in this test, and in the other tests,
the Tube 4 had consistently higher weight losses than would be
expected from other tubes operating at similar temperatures. Tube 4
was not near a coal nozzle, but it must be concluded that it operated
in a more corrosive environment: than the other tubes.
3.2.2.8 Blade cascade and target rods
See Section 3.5.2.9 at end of Test Series 5.
A2,37
-------
3.3 Test Series 3
3.3.1 Objective of Test Series
To measure the emission of SC^ and NO^ from the combustor when burning
coal at 5 atm absolute pressure with dolomite 1337 addition at a nominal
Ca/S ratio of 2. This was to be a completion of.the Test Series 2 programme
at a higher operating pressure.
3.3.2 General description of Test Series
3.3.2.1 Outline of Test Series
The test was carried out between 9th and llth December 1970. The
feed material was identical with that used in Test Series 2, but in
order to obviate or delay the onset of the partial defluidisation which
occurred in that test:- (a) the initial bed was a mixture of 60% shale
and 40% of material from Test Series 1 with a median particle size of
about 400 micron, and (b) the test was limited to a period of 45 hours.
Interruptions occurred after 7 and 23$ hours operation due to
national power grid failures. After each interruption it required a
progressively higher velocity to initiate fluidisation, signifying a
gradual change in bed size. The test was completed satisfactorily with
91% of the operating time at 5 atm abs. pressure, but it is likely that
defluidisation would have occurred eventually as in Test 2.
Two periods of steady operation were selected for computation of
combustion efficiency, heat and mass balances. Samples of coal,
primary and secondary cyclone fines, exhaust dust and bed extract were bulked
before analysis to conform with these periods. Operating conditions are
given in Table 3.53 and analyses of coal, dolomite, cyclone, exhaust dust
and bed samples are given in Tables 3.54 to 3.59, Average gas composition
measurements for each of the Test periods are given in Table 3.60.
3.3.2.2 Sulphur emission
Measurements of SO- and SO- were made at approximately hourly
intervals using the "Shell" condensation and BCURA iodine absorption
methods.
AT..38
-------
Results of measurements are tabulated in Table 3.61.and Fig. 3.6.
Also shown in Fig, 3.6 are the variations in the approximate Ca/S
stoichiometric ratio in the feed and the average operating conditions
for each test period. The percentage of sulphur retained in each of
the test periods is shown in Table 3.62.
3.3.2.3 . NOy.emissions
Determinations of oxides of nitrogen in the exhaust gases were
made in the early part of the test, using mainly the Saltzman method.
Results are tabulated.in Table 3.63.
3.3.2.4 Retention of alkalis and chlorine
See Table 3.62 and 3.63A.
3.3.2.5 Mass Balances
The mass balances are shown in Tables 3.64 and 3.65, based on
the assumptions already fully described in Section 2.8, unless
otherwise stated in the footnotes to the tables. Constant bed
composition was probably achieved early in Test period 3.1. Error in
determining the sodium content of the bed at the end of Test 3.2
probably accounts for the large loss of sodium, resulting in negative
output.
3.3.2.6 Heat Balances
The heat balances for Tests 3.1 and 3.2 are presented in
Table 3.66.
3.3.2.7 Corrosion of metal specimens in the bed
The metal specimens were not examined after Test Series 3 and
were left undisturbed until the end of Test Series 4.
A2..39
-------
3.4 Test Series 4
3.4.1 Objectives of Test Series
To measure the emission of SO. and NO from the combustor when
^ A
burning Pittsburgh coal blended with finer dolomite 1337 than used
hitherto.
3.4.2 General Description.of Test Series
3.4.2.1 Outline of Test Series
The test was carried out between llth and 15th January 1971 and
lasted for 100 hours. The initial bed was a mixture of shale and bed
material from earlier ("no dolomite") tests. For 96% of the time the
operating pressure was 5 atm absolute, and the test was carried out
at two levels of dolomite addition.
No difficulties were experienced in maintaining satisfactory
fluidisation and there were no sintered agglomerations of any
significant size in the bed at the end of the test. One interruption
of 17 minutes occurred after 43 hours due to a failure in the air
supply to the coal feeding plant, but no difficulties were experienced
in restarting.
The rate of removal of bed material.necessary to maintain a
constant bed level .was. lower .than in Test-3 (see..Fig. 3.7).
Two periods of steady operation were selected for computation
of combustion efficiency, heat and mass balances. Samples of coal,
primary and secondary cyclone fines, exhaust dust and bed extract
were bulked before analysis to conform with these selected periods.
Operating conditions are given in Table 3.67 and analyses of coal,
dolomite etc. samples are given in Tables 3.68 to 3.75. Average gas
composition and measurements for each of the Test periods are given
in Table 3.76 and the variations in bed temperature and gas
composition in Tables 3.77 and 3.78.
3.4.2.2 Preparation of coal and dolomite
The raw dolomite was crushed, after drying and before screening,
in a jaw crusher to produce a wider size distribution than was used in
-------
i'esLs 2 and 3. Tins had Lhe objective of achieving a lower mean
bed particle size than in Test 2 when difficulties were experienced
in maintaining fluidisation.
3.4.2.3 Sulphur emission
Measurements of SO were made at approximately 90 minute
K
intervals using the BCURA iodine absorption method. No measurements
of SO were made.
Results are tabulated in Table 3.79 and Fig. 3.8. Also shown
in Fig. 3.8. are the variations in the approximate Ca/S stoichiometric
ratio in the feed and the average operating conditions for each test
period The percentages of sulphur retained in both test periods are
shown in Table 3.80.
During this test the Hartmann Braun SO. infra-red analyser was
commissioned. The output was recorded continuously. Once certain
commissioning problems had been overcome, excellent agreement was
obtained between the infra-red analyser and the chemical method
(Table 3.81). The recorded trace from the infra-red analyser showed
that the S0~ content of the gases was extremely sensitive to
operating conditions. Fluctuations in coal feed rate which produced
changes in 0_ concentration also produced immediate changes in SO
concentration (see Fig. 3.9). In fact, with the gas sampling
systems being used, a change in coal feed rate was first apparent from
the S0? analyser rather than the 0. analyser.
3.4.2.4 NOy emissions
Determinations of oxides of nitrogen were made throughout the
test, using.both the Saltzman and Hersch methods. Results are
summarised in Table 3.82.
3.4.2.5 Retention of alkalis and chlorine
Determinations of sodium and potassium oxides and chlorine are
summarised in Table 3.83, and the retention of alkalis an3 chlorine
are shown in Table 3.80.
A2.nl
-------
3.4.2.6 Mass Balances
The mass balances are shown in Tables 3.84 and 3.85, based on
the assumptions already fully described in Section 2.2 unless other-
wise stated in the footnotes to the tables. Constant .bed composition
was attained in Test 4.2.
3.4.2.7 Heat Balances
Heat balances for the test periods are presented in Table 3.86.
3.4.2.8 Corrosion of metal specimens in the bed
The specimens were treated as for the earlier tests. The
appearance of the tube assemblies after the test was similar to that
after Test Series 2.
The rates of weight loss measurements are given in Table 3.87
and the results are summarised in Table 3.88. Results of the
metallographic examination of some of the specimens are given in
Table 3.89.
3.4.2.9 Blade cascade and target rods
See Section 3.5.2.9 at end of Test Series 5.
A2.42
-------
3.5 Test Series 5
3.5.1 Objective of Test Series
To measure the emission of S0_ and NO from the combustor when
£. A
burning Pittsburgh coal blended with (a) limestone 18 at nominal
Ca/S ratios of 2 and 3, and (b)-fine dolomite 1337 at a nominal Ca/S
ratio of 1.
3.5.2 General Description of Test Series
3.5.2.1 Outline of Test Series
The test was carried out between 22nd and 26th February 1971
and lasted for 100 hours. The initial bed was shale. For 98i hours
the operating pressure was 5 atm absolute. No difficulties were
experienced in maintaining satisfactory fluidisation and there were
no clinkered agglomerations in the bed at the end of the test. The
first 40 hours of the test were with limestone 18 at a Ca/S mol ratio
of about 2, the next 25 hours with limestone 18 at a Ca/S ratio of
about 2.5; and the final 35 hours with dolomite 1337 at a Ca/S ratio
of about 1.
The rate of removal of bed material necessary to maintain a
constant bed level is shown in Fig. 3.^. Towards the end of the test
the rate of accumulation of bed material was zero. This coincided
with a gradual increase in the SO concentration in the exhaust gases
and a lower value of the Ca/S ratio in the feed. This lower ratio
was probably due to segregation in the bunkers in the preparation
plant sincethe Ca/S ratio was higher than intended in the first part
of the period using dolomite.
Three periods of steady operation, corresponding to the three
nominal operating conditions, were selected for computation of
combustion efficiency, heat and mass balances. .Samples of coal,
primary and secondary cyclone fines, exhaust dust and bed extract were
bulked before analysis to conform with these selected periods. Operating
conditions are given in Table 3.90 and analyses of coal, dolomite cyclone
etc. samples are given in Tables 3.91 to 3.98.
A2,43
-------
Average gas composition measurements for each of the test
periods are given in Table 3.99 and variations.in bed temperature
and gas composition are given in Tables 3.100 and 3.101.
3.5.2.2 Preparation of coal and limestone
The raw limestone was dried and crushed by an external supplier
before screening on site.
3.5.2.3 Sulphur emission
The main measurements of the SO- concentration in the exhaust
gases were made using the Hartmann-Braun infra-red analyser. The
recorded trace from the ananlyser was averaged (by eye) every 30
minutes. Results are given in Table 3.102 and Fig. 3.10.
Measurements of SO- by the iodine absorption method were made
every 2 to 3 hours. Comparison of these results with the infra-red
values is shown in Table 3.103. Agreement was generally good.
Equilibrium SO- emissions were reached quickly when using
limestone as the acceptor, but were as-usual approached slowly
(c. 15 to 20 hours) when dolomite was used.
The percentages of sulphur retained in the test periods are shown
in Table 3.104.
3.5.2.4 .. NOy emissions
A limited number of determinations of oxides of nitrogen were
made throughout the test. Results are tabulated in Table 3.105.
3.5.2.5 Retentions of alkalis and chlorine
Determinations of sodium and potassium oxides and chlorine in
the exhaust gases are summarised in Table 3.106 and the retention of
alkalis and chlorine are shown in Table 3.104.
3.5.2.6 Mass Balances
The mass balances are shown in Tables 3.107 to 3.109, based
on the assumptions already described in Section 2.£ unless otherwise
stated in the footnotes to the tables. Changes in bed composition
during Tests 5.1 and 5.2 would be expected to include gains in
sulphur and calcium contents, and falls in ash and potassium contents;
-------
these changes were observed, indicating that bed composition had not
become constant although constant sulphur emission had been achieved.
Similarly, in Test 5.3 following a change from limestone to dolomite
changes in bed composition might be expected giving rises in sulphur,
magnesium and potassium, and falls in ash and calcium. Since these
changes were not observed it is concluded that constant bed composition
had been achieved in Test 5.3.
3.5.2.7 Heat Balances
Heat balances for the test periods.are.summarised in Table 3.110.
3.5.2,.8 Corrosion of metal specimens in the bed
The specimens were treated as for the earlier Test Series. The
appearance of the tube assemblies after the test is described below:
Tube 1 and 6 (1450 F metal temperature). There was a reddish/
brown film on the specimens, only lightly adhesive, having
spalled on many specimens.
Tube 2 (1040-1200°F). A black polished film toward both ends
with a red/brown coating on the middle sections which had
spalled in places.
Tube 3 (750-840°F). A polished light-brown film overlaid with
a rough black scale which had spalled.
Tube 4 (880-950°F) .. Similar to Tube 3.
Tube 5 (660-910°F). Similar to Tube 3.
The rates of weight loss measurement are given in.Table 3.111
and the results are summarised in Table 3.112. Results of the metallo-
graphic examination are given in Table 3.113.
The operating temperatures of the different tubes were altered
slightly for this test. More low-chrome ferritic specimens were ussed in
this test, and Tube 3 was operated at a correspondingly lower temperature.
It will be seen from Table 3.112 that weight losses on Tube 3 were
lower than those on Tube 5, although the operating temperatures were
similar. Prior to this Tube 3 had been operated at higher temperatures
mainly with better quality materials. It will be seen from Fig. 2.3
-------
that Tube 5 is in the vicinity of a coal nozzle and therefore might be
expected to produce higher corrosion rates. This would appear to be
confined to the low chrome metals, however, since in earlier tests there
was no evidence that losses for better materials were higher on Tube 5
than would be expected.
3.5.2.9 Blade cascade and target rods
At the beginning of the programme the Proteus nozzle segment had
been used for 400 hours. The blades were examined after each Test
Series. Mechanical cleaning (by brushing) was carried out on one blade
after Test Series 1, the other blade was not cleaned, except by "soft-
blasting" as described below, and at the end of the.programme had remained
uncleaned for 740 hours.
The-appearance of the blades did not vary greatly from test to test
and typical appearances after Tests Series 1, 2 and 3 are shown in Fig.3.11.
Usually there was a light accumulation of dust on the leading edge with
flecks of dust adhering to the concave faces and negligible deposition on
the convex faces. There were no signs of sintered deposits or of erosion.
There was not sufficient material adhering to the blades for analysis, but
there was sufficient dust on the side walls of the cascade holder after
Test Series 2 to show that it had a similar composition to the exhaust
dust passing over the cascade (see Table 3.114).
Slightly heavier accumulations of dust on the blades occurred
after Test.Series 1. Between Test Series 1 and 2 a short (10 hour
duation) test was carried out, outside the APCO remit. Towards the
end of this test, 2 Ib of crushed fruit stone was injected upstream
of the cascade over a period of 1 minute. This successfully removed
the accumulations of dust.
At the beginning of the programme the target rods had been in use
for 300 hours. They were inspected after each Test Series, but were not
cleaned except by "soft-blasting" as described in the previous paragraph.
The rods usually had a small knife-edge of deposit on their leading
face and had.developed a considerable "tail". Weighing, sectioning and
examination under a microscope of one of the rods revealed no signs of
erosion or corrosion.
-------
4. REFERENCES
1. B.S. 3405, Measurement of grit and dust emissions from chimneys,
Appendix A, British Standard Institute, London, 1961.
2. Goksifyr, H and Ross, K., J. Inst. Fuel, (1962), 36_, 177-179.
3. Ounsted, D., J. Inst. Fuel, (1958), Jtt, 474-479.
4. Bulletin MC/316, Boilers Availability Committee, (1961),
Section 5, 39-51.
5. Saltzman, B.E., Anal. Chem., (1954), .26, 1949-1955.
6. Hersch, P., Paper to llth Anachem conf., Detroit, 1963.
See also Shaw, J.T., Brit. J. Anaesth, (1968), 40, 299-303
and Appendix 9 of present report.
7. Kobaschewski, 0 and Evans, E.L., "Metallurgical Thermochemistry"
London, Pergamon Press, 1958.
A2.47
-------
5. ACKNOWLEDGEMENTS
The Project Leader for Task II was D.M. Wilkins.
The programme was supervised by A.G. Roberts and was carried out in
the Process Development Group (Director - H.R. Hoy) of BCURA Industrial
Laboratories Ltd.
Members of staff of BCURA who took part in the experimental work
included:
S. Badzioch
C. Chanter
E.S. Dingoor
M. Fisher
W.A. Gearing
F.W. Hood
J. Kobak
A.W. Lindsay
R.S.E. Leslie
A.G. Roberts
J.A.C. Samms
J.E. Stantan
D.G. Warrilow
D.M. Wilkins
M.A. Wright
J.M. Wyrill
Design work was carried out by R.L. Johnson.
A2.48
-------
Table A.2.2.1 Details of cyclones
Duty
Material: body
flanges
dimensions (inches)*
Gas inlet: height, h
: width, w
Gas outlet: diameter, De
: length, Le
Barrel: dimeter, D
: length, L
Cone: length, 1*2
Dust exit: diameter, D^
Performance characteristics**
o
Normal gas flow, ft /s
Inlet velocity, ft^/s
Outlet velocity, ft-Vs
2
Typical pressure drop, Ib/in ***
Recirculation
A. I. S.I. 321
A. I. S.I. 321
7i
41
71
8!
10
12|
20$
4
15.5
65
50
0.6
Primary cyclone
(1st stage gas
cleaning)
Incoloy DS
En 58 b
6i
3£
5
8
10
13i
20
3
15.5
115
115
1.3
Secondary cyclone
(2nd stage gas
cleaning)
Incoloy DS
En 58 b
6i *
2i
5
8
10
13|
20
3
15.5
140
115
3.8
*
**
***
See Fig. A.2.2.4.
based on cross section area of combustor of 7.75 ft , a fluidising
velocity of 2 ft/s and operation at circa 5 atm pressure and 1470 F.
the pressure drops also include ducting losses and pressure changes
due to acceleration of gases.
A2.49
-------
Table A.2=2.2 Location of thermocouples within the pressure shell
Location and duty
Plenum chamber
Air preheat tubes: outlets
Corrosion tubes: metal temperatures,
a. top upstream
b. bottom upstream
c. top downstream
d, bottom downstream
Corrosion tubes: air outlets
Bed
Bed cooling circuits: inlet
: outlets
Freeboard
Freeboard cooling circuits: outlets
Coal nozzle cooling shrouds: outlets
Heat transfer loops
Bed ash blowdown leg
Dipleg and recirculation cyclone
, Dust cleaning cyclones and blowdowns
i Cascade inlet
Cascade outlet
Quench section bellows
Combustor surface
Space beneath combustor
Space above combustor
Suspension beam
Radio-active source
Total
Number of
thermocouples
2
6
6
6
6
6
4
16
1
13
9
3
4
3
1
2
5
2
2
1
2
1
1
4
1
107
A2. 50
-------
Table A.2.2.3 Details of location of thermocouples in the bed and freeboard
Thermocouple
reference
(Data logger
channel)
In bed
101
102
106
107
108
109
110
112
117
113
115
118
119
120
121
122
In freeboard
125
126
127
128
129
130
131
132
82
Height above
distributor
plate
in
U
24
21
2*
31
31
3i
Insertion
in
11
3
3
3
2
2
2
4| 2
12| | 1
12|
12|
1
1
15| 1
35? | 3
35J 3
351 3
351 i 3
77 3
77 3
77 : 3
77 3
106J : 131
106| 131
106| i 131
From*
dist .plate
wall AB
wall BC
wall AD
wall CD
wall CD
wall AB
wall AB
wall CD
wall CD
wall AB
wall CD
wall AB
wall AB
wall CD
wall CD
wall AB
wall AB
wall CD
wall CD
cover plate
n u
Location*
Below nozzle D
adjacent nozzle A
centre
centre
2j in. from wall AD
31 in. from wall BC
centre
4 in. from wall BC
centre nozzle C
adjacent nozzle C
centre
adjacent nozzle D
above nozzle B
above nozzle A
above nozzle D
above nozzle C
above nozzle A, 11 in. from wall AD
above nozzle B, 11 in. from wall BC
above nozzle C, 11 in. from wall BC
above nozzle D, 11 in. from wall AD
see right hand diagram below
u u
u u it u
106| i 131 i
106J : 131
I
it u
u ii i u u
j
* see left hand diagram below, nozzle denotes coal nozzle.
2 ft
wall
BC
nozz]
4 ft wall CD
e C nozzl
e D
nozzle B nozzle A
4 ft wall AB
2 ft
wall
AD
X
82 S V 132
130 / ^ gas
X V129 I / outlet
\ /
X
131
Plan view of combustor,
looking downwards
Plan view looking down on
cover plate
A2.51
-------
Table A.2.3.1 Operating.conditions during Test Series 1
Coal
Welbeck
Coal size (upper limit) 1587 ym
Acceptor
size (upper limit) 1587 ym
Coal rate 370-390 Ib/h
Fluidising velocity 1.95 ft/s
Bed temperature 1455 °F
Combustor pressure 3.5 atm abs
Bed height 3.75 ft
Test No.
Elapsed time
from start of
test series
Acceptor
Stoichiometric
start, h
end, h
ratio
1.1
4.45
8.95
None
0
1.2
10.95
22.62
U.K.
Dolomite
0.77
1.3
23.12
50.62
U.K.
Dolomite
0.73
1.4
58.62
73.28
U.K.
Dolomite
0.91
1.5
73.62
99.95
U.K.
Dolomite
0.92
A2.52
-------
Table A.2.3.2 Analysis of spot (coal + dolomite) samples
Test Series 1
to
en
CO
Sample
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Sample
time
min
82
267
447
607
777
952
1147
1317
1507
1682
1867
2007
2187
2397
2575
2624
2758
2952
3127
3292
3352
3437
3663
3842
4012
4199
4387
4567
4747
4967
5102
5285
5463
5641
5822
5989
Moisture
%
5.6
5.7
5.7
5.6
4.9
5.2
4.6
4.4
5.1
5.2
5.0
4.8
4.8
4.6
5.0
4.8
4.6
4.9
4.9
5.3
5.0
5.0
5.0
4.9
4.9
4.7
4.6
4.3
4.5
4.9
4.7
5.1
4.6
4.8
4.7
5.1
"Ash"
%
21.1
13.6
13.8
17.1
21.7
20.1
26.6
23.2
20.2
19.3
20.8
20.0
19.5
22.0
18.6
21.8
20.2
17.5
16.2
16.2
18.8
19.2
19.4
19.4
17.7
18.7
17.9
17.8
18.9
17.0
16.8
15.7
15.5
17.6
15.9
3.3
CO 2
7.
0.5
0.3
0.2
1.9
2.6
2.0
3.7
2.9
2.8
2.5
2.7
2.8
2.8
3.3
2.1
2.6
2.2
2.2
7.. 8
1.7
3.3
3.4
3.1
4.1
3.3
3.6
2.1
3.9
4.2
2.9
2.9
2.6
3.6
3.7
3.1
12.7
Size grading: % within stated size grade
-1588
+ 794 pm
9.8
9.2
8.3
9.9
8.4
8.8
9.4
12.1
15.1
13.1
14.6
15.0
14.8
16.8
13.5
12.2
16.8
20.0
18.9
17.4
18.8
12.7
11.4
14.5
11.6
11.4
10.3
13.7
14.4
13.1
14.9
14.3
13.0
12.9
13.1
21.8
-794
+500 ym
22.4
20.2
18.8
23.5
18.7
21.4
21.2
24.7
31.2
22.6
24.5
26.4
29.1
27.6
25.1
23.7
25.6
40.1
27.1
27.2
26.0
23.2
21.4
24.4
22.8
22.8
21.9
22.6
21.7
25.1
23.0
24.2
21.9
21.7
22.2
36.5
-500
+211 pm
42.7
39.1
43.3
40.7
47.4
42.5
50.4
42.7
39.9
42.2
40.0
41.5
39.6
41.4
41.5
46.1
38.3
33.4
32.3
35.5
38.9
37.5
44.9
38.4
43.4
39.6
41.0
38.7
41.7
38.2
42.6
37.2
41.1
44.7
35.7
36.5
-211
+152 pm
7.7
8.1
6.9
6.9
5.9
7.4
5.6
6.3
5.8
5.4
5.3
4.5
5.2
3.9
5.9
4.5
5.4
3.9
4.5
4.9
3.5
6.3
5.2
5.9
5.0
6.6
7.4
6.3
4.8
5.8
4.9
5.7
5.3
6.6
6.4
6.4
-152
+ 75 pm
7.7
8.9
8.3
7.5
6.6
5.6
5.5
5.9
5.5
6.3
5.4
4.7
4.4
3.9
5.3
4.5
5.0
4.3
4.9
5.0
4.1
6.7
5.9
6.2
5.8
7.2
7.9
9.0
5.9
6.2
5.6
6.3
5.8
7.4
7.1
7.6
- 75pm
9.7
14.5
14.4
11.5
13.0
14.3
7.8
8.3
7.5
10.4
10.2
7.9
6.9
6.4
8.7
9.0
8.9
8.3
12.3
10.0
8.9
13.6
11.2
10.7
12.4
12.4
11.5
11.7
11.5
11.6
12.0
12.3
12.9
14.7
15.5
15.0
Median
diameter
£m
7 400
400
400
400
400
370
400
430
450
400
440
460
470
470
450
420
460
500
470
470
460
400
410
430
400
380
380
400
410
400
410
390
390
320
390
370
Analyses are given as weight Z on an "as fired" basis.
-------
Table A.2.3.3 Analysis of bulked samples of (coal.plus dolomite)
Test Series 1
Test
Sample Ref
Sample period
min
Moisture
"Ash"
Sulphur
Carbon dioxide
CaO
MgO
Na20
K20
1.1
36609
267
to
447
5.9
13.9
1.2
0.2
2.3
1.6
-
-
1.2
36627
777
to
1317
4.8
22.9
1.3
2.8
9.1
5.6
1.6
2.8
1.3
36628
1507
to
1867
5.1
20.1
1.3
2.7
9.4
6.0
1.2
2.5
36629
2007
to
2397
4.7
20.5
1.2
3.0
10.0
6.4
1.4
2.7
36630
2575
to
2952
4.8
18.6
1.2
2.2
8.4
5.3
1.5
2.5
1.4
36631
3663
to
4387
4.8
18.6
1-2
3.2
12.0
7.6
1.4
2.4
1.5
36632
4567
to
5285
4.6
17.6
1.2
3.5
12.8
8.2
1.7
2.4
36633
5463
to
5988
4.8
16.0
1.1
3.3
14.2
9.2
1.9
2.4
Moisture, "Ash", S and C02 are given as weight percent on an "as fired basis"
and refer to (coal + dolomite) mixture fed to the combustor.
CaO, MgO, Na20 and K_0 are given as weight percent of the "Ash".
A2.54
-------
analysis ot bulked samples of (coal plus dolomite)
Test Series 1
Test
Sample Ref
Proximate analysis
Moisture
Volatile Matter
Fixed Carbon
Ash
Carbon dioxide
Ultimate Analysis
Ash
Carbon
Hydrogen
Nitrogen
Sulphur
Oxygen + errors
Chlorine
Forms of Sulphur
Pyritic
Sulphatic
Organic
Total
Calorific Value
Swelling Number
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Btu/lb
1.1
36609
5.9
36.9
50.6
13.9
0.2
14.8
70.3
4.5
1.5
1.3
7.0
0.61
0.32
0.02
0.86
1.2
14813
1
1.2 & 1.3
36634
5.1
39.3
45.4
20.1
2.4
21.2
63.2
4.1
1.5
1.4
7.7
0.55
0.40
0.02
0.88
1.3
n.d.
1
1.4 & 1.5
36635
5.1
39.3
47.4
16.8
3.3
17.7
66.1
4.2
1.4
1.3
8.8
0.56
0.30
0.02
0.88
1.2
n.d.
1
The ultimate analysis is stated on a dry basis, volatile matter
content and calorific value are stated on a d.a.f. basis. The
remaining analyses are given on an 'as fired' basis.
For ash analyses, see Table 3.5.
n.d. = not determined.
A2.55
-------
Table A.2.3.5 Ash analysis of bulked samples of (coal plus dolomite)
Test Series 1
Test
Sample Ref.
Ash Analysis
Si02
A12°3
Fe203
CaO
MgO
Na20
K20
Ti02
Mn304
P2°5
so3
Total
Ash Fusion
Initial deformation F
Hemisphere F
Flow °F
1.1
36609
57.8
23.2
6.8
2.3
1.6
2.2
3.0
1.0
0.2
1.8
99.9
2120
2440
2730
1.2 & 1.3
36634
47.8
19.1
5.9
8.4
6.1
1.6
2.6
0.8
0.1
0.2
6.2
98.8
2170
2210
2550
1.4 & 1.5
36635
41.0
17.3
5.2
12.2
8.6
1.8
2.4
0.8
0.1
0.2
9.5
99.2
2160
2190
2320
Ash analyses given on a weight percent basis, and refer to the
(coal + dolomite) analyses given in Table A.2,3.4.
Ash fusion determined in H?/CO?.
A2. 56
-------
Table A.2.3.6 Analysis of raw dolomite
Test Series 1
Test
Sample Ref
Analysis
CaO %
MgO %
Na20 %
K20 I
so3 %
co2 %
1.2 & 1.3
36602
29.2
21.5
1.3
0.6
0.1
46.7
1.4 & 1.5
36603
29.4
21.4
0.5
0.1
0.1
45.8
Analysis given on weight percent basis
20 incremental samples were taken from the dolomite
added to the coal stream during Tests 1.2 & 1.3 to make up Sample 36602
37 incremental samples were taken from the dolomite
added to the coal stream during Tests 1.4 & 1.5, to make up Sample 36603
A2.57
-------
Table A.2.3.7 Analysis of primary cyclone fines
collected by dry sampling system
Test Series 1
Test
Sample Ref
Sample period
min
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO " %
MgO %
Na20 %
K20 %
Size Grading Wt
-1588 + 794 ym
- 794 + 500 ym
- 500 + 251 ym
- 251 + 152 ym
- 152 + 75 ym
- 75 + 53 ym
-53+0 ym
Median dia. ym
1.1
1520
273
to
493
13.4
0.0
0.7
0.1
0.05
2.0
1.4
1.4
2.6
% wi
1
7
19
9
13
6
45
70
1.2
1521
604
to
970
11.5
0.1
1.5
0.2
-
3.5
2.5
1.3
2.6
:hin s
1
6
18
10
14
8
44
70
1522
1037
to
1326
8.4
0.1
2.2
0.2
-
4.9
3.4
1.3
2.6
tated
1
7
18
11
17
7
37
90
1.3
1523
1387
to
1868
7.6
0.1
2.6
0.2
-
6.0
4.3
1.3
2.6
size g
1
7
19
12
16
8
36
90
1524
1926
to
2405
6.0
0.1
2.9
0.2
-
7.0
4.9
1.3
2.6
rade
2
8
18
15
18
7
33
115
1525
2523
to
2951
6.2
0.1
2.8
0.2
-
6.7
4.7
1.3
2.6
2
8
20
15
15
8
32
120
1.4
1526
3009
to
3311,
8.5
0.1
2.7
0.2
0.17
6.5
4.8
1.3
2.5
2
8
17
12
16
6
40
90
1527
3543
to
4209
5.8
0.1
3.4
0.6
-.
10.0
6.6
1.3
2.4
2
8
18
12
16
8
36
100
1528
4270
to
4391
6.7
0.1
3.6
0.4
-
9.7
6.5
1.3
2.3
3
9
19
14
18
6
31
120
1.5
1529
4446
to
5407
5.5
0.1
3.7
0.4
-
10.2
7.2
1.4
2.3
2
7
, 16
12
16
8
39
85
1530
5464
5o
5997
5.3
0.1
4.2
0.7
0.46
12.6
8.6
1.7
2.2
1
6
14
12
17 .
6
43
75
Analyses are given as weight percent on an "as received" basis.
% Carbon does not include carbon present as carbon dioxide.
Samples were taken approximately hourly and, except for chlorine, were bulked
over the periods indicated. % chlorine determined on a single sample taken
within the period indicated.
A2.58
-------
Table A.2.3.8 Analysis of Secondary Cyclone fines
Test Series 1
Test
Sample Ref
Sample period
mm
Carbon %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
1.1
1534
259
to
559
9.2
1.2
-
0.37
3.5
1.5
2.3
2.5
1.2
1535
679
to
1042
6.4
2.2
-
-
5.5
3.0
1.9
2.0
1536
1047
to
1369
8.1
2.8
0.2
-
7.0
4.6
1.6
1.8
1.3
1537
1369
to
1818
6.4
3.2
-
-
7.8
6.1
1.8
2.0
1538
1955
to
2375
5.0
3.8
-
-
9.5
7.3
1.9
2.0
Size Grading Wt. % within stated size grade
- 75 + 60 ym
-60+50 ym
-50+40 ym
-40+30 ym
-30+20 ym
-20+15 ym
-15+10 ym
-10+5 ym
-5+0 ym
Median dia. ym
Mean dia. ym
DP
0
0
0
0
2
7
19
56
16
8
6
2
4
1
3
8
9
14
47
12
9
7
0
0
2
2
3
11
20
42
21
7
6
0
0
1
2
6
8
16
49
17
8
6
1
1
1
2
2
5
14
47
27
7
6
1539
2554
to
2974
5.7
3.2
0.2
-
8.1
7.0
1.8
2.1
1
1
1
1
2
6
20
45
21
7.4
6.4
1.4
1540
2974
to
3283
5.0
3.2
0.1
0.65
7.7
6.9
2.1
2.3
0
0
1
6
5
6
15
19
20
7
6
1541
3517
to
4245
5.9
3.9
-
-
14.6
8.9
2.8
1.6
0
0
4
2
5
7
14
49
17
8
6
1542
4245
to
4422
6.8
3.6
0.7
-
11.5
4.0
1.7
1.9
0
0
1
2
7
9
18
47
16
8
7
1.5
1543
4422
to
5443
3.9
3.9
-
-
11.7
10.4
2.5
2.4
1
2
5
5
4
14
14
34
23
8
7
1544
5443
to
5997
2.3
4.2
0.5
0.92
15.2
12.2
2.9
2.4
0
2
0
7
5
5
11
49
22
7
6
Analyses are given as weight percent, on an "as received" basis.
Carbon does not include carbon present as C02«
Samples were taken approximately hourly and, except for chlorine, were bulked over
the periods indicated. % Chlorine determined on a single sample taken within the
period indicated.
Size gradings were obtained by a Coulter Count on the material passing through a
75 micron sieve. Except for Sample 1536, the +75 micron content was less than 2%.
For Sample 1536, 4.8% was +75 micron.
Dp is given by — =
where Xj_j is the weight
fraction between particle size limits d£ and d-
A2.59
-------
i. Analysis of Exhaust Dust
Test
Sample Ref
Carbon %
Sulphur %
Chlorine %
CaO Z
MgO %
Na20 %
K20 %
Size Grading
-75 +60 ym
-60 +50 ym
-50 +40 ym
-40 +30 ym
-30 +20 ym
-20 +15 ym
-15 +10 ym
-10 + 5 ym
- 5 + 0 ym
Median diameter ym
Mean diameter,
Dpym
1.1
1548
9.0
2.1
1.1
4.1
1.9
2.4
2.3
1.2
1549
7.5
2,9
-
4.8
5.1
1.7
1.8
1.3
1550
6.7
3.6
1.2
6.4
9.1
2.3
2.2
1.4
1551
11.7
3.1
-
7.6
15.2
1.3
1.6
1.5
1552
5.5
3.0
1.1
9.4
17.1
2.8
2.4
% within stated size grade
5
3
2
7
7
7
12
42
15
9
8
3
9
5
3
3
11
8
38
20
9
7
4
1
9
6
0
6
13
39
22
8
7
6
2
3
3
2
6
10
42
26
7
6
12
! 1
3
6
4
3
13
34
24
8
7
Analyses are given as weight per cent on an 'as received1 basis.
% carbon does not include carbon present as carbon dioxide.
Size gradings were obtained by a Coulter Count on material
passing a 75yVsieve. Sample 1548 contained 4.3% by weight of
+75 yVrparticles; the remaining samples had zero +75 yfecontent.
D as defined in Table A.2.3.8.
P
A2. 60
-------
Table A.2.3.10 Analysis of Bed Material
Test Series 1
Test
Sample time min
Sample Ref
Carbon %
Sulphur %
Carbon «_
dioxide
Chlorine %
CaO %
MgO %
Na20 %
K20 Z
Size Grading
-1588+794vim
- 794+500ym
- 500+ 251pm
- 251+152ym
- 152+ 75ym
- 75+ 53ym
- 53+ Oum
Median dia. ym
1.1
715
to
B65
1556
0.1
1.1
-
-
3.0
2.3
1.6
3.3
1.2
1225
1557
<0.1
2.3
-
-
6.3
8.1
1.6
3.0
1.3
1860
1558
0.3
2.5
-
-
6.5
4.3
2.0
2.9
2260
1559
0.2
1.4
-
-
3.7
2.8
1.8
3.3
2865
1560
0.3
2.8
-
-
7.2
4.8
1.6
2.9
3175
1561
0.2
2.7
-
0.10
6.9
4.4
2.0
3.2
1.4
3825
1562
0.2
2.5
-
-
7.5
4.8
1.6
2.9
4370
1563
0.1
3.6
0.7
-
10.6
6.8
2.4
3.1
1.5
4890
1564
0.2
3.6
-
-
10.7
7.3
2.2
3.0
5475
1565
0.2
4.0
-
-
10.2
5.3
1.3
2.6
5790
1566
<0.1
4.4
0.8
0.24
11.5
7.7
2.4
2.9
5915
1567
0.3
4.7
-
-
13.1
8.2
3.0
3.1
1568
<0.1
4.3
0.6
0.28
11.7
8.6
1.6
2.5
Z within stated size range
10
34
45
7
1
2
1
470
3
11
27
18
20
8
13
190
5
20
43
16
7
5
4
340
14
32
35
10
6
1
2
460
6
20
39
15
6
9
5
350
13
30
35
11
7
2
2
450
10
27
37
13
8
3
2
400
8
21
31
16
14
4
6
310
6
19
34
17
10
8
6
310
10
24
32
16
12
3
3
370
9
22
35
16
8
6
4
360
8
20
31
18
14
3
6
300
15
29
44
11
1
-
-
450
Analyses are given as weight percent on an 'as received* basis. Z Carbon does not include carbon present
as carbon dioxide.
1568 sample refers to.material remaining in bed after the test series.
Sample 1556 to 1567 refer to material removed via the weir during the test series.
-------
Table A.2.3.11 Gas composition measurements
Test Series 1
Test
Elapsed time
from start of
test series
Operating
Conditions
Gas composition
% by volume
(dry gas)
Gas composition
p. p.m. by volume
(dry gas)
Start, h
End, h
Ca/S
mol ratio
Variable
parameters
co2
CO
°2
SO,
so3
NO
X
Cl
Na20
K20
1.1
4.45
8.95
0
No
Acceptor
15.1
0.10
3.8
1020
9
40
490
1.5
0.4
1.2
10.95
22.62
0.77
Acceptor
U.K.
Dolomite
14.9
.05
4.2
620
14
-
590
1.2
0.3
1.3
23.12
50.62
0.73
Acceptor
U.K.
Dolomite
15.1
.03
4.6
430
14
80
640
0.9
0.2
1.4
58.62
73.28
0.91
Acceptor
U.K.
Dolomite
15.1
.03
5.1
100
8
120
460
0.5
0.2
1.5
73.62
99.95
0.92
Acceptor
U.K.
Dolomite
15.2
.02
4.8
150
5
130
330
0.5
0.2
A2.62
-------
Table A.2.3.12 Variation of gas composition and bed temperature during test
Test Series 1
Numbers in columns are % of time in stated range
Gas Analysis
Test 1.2 & 1.3
Test 1.4 & 1.5
<2% 02
4
2
2 to 4% 02
37
23
4 to 6% 02
44
68
>6% 02
15
6
Gas Analysis
Test 1.2 & 1.3
Test 1.4 & 1.5
0 to 0.025% CO
33
75
0.025 to 0.05% CO
51
24
> 0.05% CO
16
1
Bed Temperature
U" to 5" above Test 1.2 & 1.3
distributor _ •,/.,-
Test 1.4 & 1.5
' 13" to 16" above Test 1.2 & 1.3
distributor _ , . . , r
Test 1.4 & 1.5
i
36" above Test 1.2 & 1.3
' distributor Tegt 1>4 & 1>5
<1400°F
4
3
1
2
0
0
1400 to
1436°F
34
38
25
30
13
8
1436 to
1472°F
48
53
57
58
60
66
1472 to
1508°F
13
6
17
10
27
26
> 1508°F
1
0
0
0
0
0
A2.63
-------
Table A.2.3.13 Test Series 1
Measurements of S00 and SO. in exhaust gases
Time from start
mins
65
85
105
124
142
161
260
300
328
349
382
402
434
454
493
507
530
548
575
604
622
647
674
752
826
885
948
1015
1068
1087
1205
1248
1336
1397
1488
1589
1667
1722
1866
1922
1972
2039
2109
2162
2236
2285
2349
2404
2522
2577
2639
2712
2801
so2
p. p.m. (v/v)
772
1682
930
1176
909
738
854
1008
941
-
1067
1026
1101
1037
1035
993
989
918
732
729
780
669
599
810
596
677
657
476
554
516
626
755
522
598
542
451
527
466
582
386
362
288
315
279
340
262
268
270
504
524
568
587
522
so3
p. p.m. (v/v)
15.3
30
21.6
12.4
9.9
4.8
10.8
9.6
1.9
12.5
1.5
12.3
5.4
26.7
6.1
13.0
37
14.6
3.9
9.2
2.4
16.4
4.9
6.6
3.9
-
2.2
32.7
-
20.7
14.2
24.6
19.1
-
-
10.6
9.0
9.8
17.5
13.4
21.7
16.5
5.2
16.4
4.1
19.7
5.5
10.4
9.8
16.6
17.5
15.4
29.3
Time from start
mins
2857
2919
2974
3026
3111
3162
3223
3282
3332
3378
3402
3421
3443
3467
3543
3602
3665
3721
3784
3840
3911
.3968
4100
4155
4244
4300
4357
4412
4461
4544
4592
4658
4708
4764
4825
4887
4955
5016
5089
5159
5222
5279
5339
5395
5452
5533
5582
5670
5733
5789
5845
5904
5972
so2
p. p.m. (v/v)
434
412
510
634
447
477
537
491
514
255
207
191
133
186
117
113
115
79
93
97
95
123
120
123
112
166
210
293
111
212
200
138
88
86
98
195
156
234
181
143
201
178
233
205
132
99
81
105
105
92
92
108
89
so3
p. p.m. (v/v)
22.5
9.9
5.4
7.5
ti
-
17
20
16
4
2.3
it
5
6
4.8
0
0
0
9.5
28.7
8.6
23
5.1
1.6
14
4.6
1.0
4.4
6.2
3.5
4.0
9
2.5
4
7.4
3.9
12
9.1
4
3.3
9.5
6.8
3.8
2.9
5.5
2.7
3.6
4
3
3.6
2.6
10.8
2
A2.64
-------
Table A.2.3.14 Percentage Retention of Sulphur, Alkalis and Chlorine
Test Series 1
Test No.
Stoichiometric Ratio
Total Ca/S Mol Ratio
Retention %
Sulphur
Sodium
Potassium
Chlorine
Reduction %
Sulphur Emission
1.1
0.00
0.15
8.9
99.0
99.8
1.7
Nil
1.2
0.77
0.92
51.8
99.3
99.9
3.5
38.8
1.3
0.73
0.88
62.3
99.4
99.9
4.1
56.7
1.4
0.91
1.06
90.4
99.6
99.9
12.9
89.2
1.5
0.92
1.07
85.5
99.6
99.8
20.6
85.1
% Retention of sulphur, sodium and potassium
= 100 (Total Input-Output in Gas)/Total Input
% Retention of chlorine
= 100 (Total Output-Output in Gas)/Total Output
% Reduction of sulphur emission
= 100 (Emission without acceptor-Emission observed)/(Emission without
acceptor)
Emission without acceptor (Test 1.1) assumed to be 1031 p.p.m. v/v in dry gas
Stoichiometric Ratio assumed = (Total Ca/S Mol Ratio - 0.15)
A2.65
-------
Table A.2.3.15 Concentration of NOX in combustion gases
Test Series 1
Time from Start
min.
117 - 247
1497 - 1527
2937 - 2997
4267 - 4392
4392 - 4437
4425 - 4437
4452 - 4722
5817 - 5847
NOX concentration
p. p.m. (v/v)
Av. Range
37
66
93
120
98
95
115
209
18- 62
48- 82
66-125
115-125
85-112
80-110
85-150
165-241
No. of
determinations
4
4
3
Continuous
4
Continuous
ti
3
Method
Saltzman
ii
ti
Hersch
Saltzman
Hersch
ii
Saltzman
Table A.2.3.ISA Determinations of Alkalis and Chlorine in Flue Gas
Test Series 1
Time, hours
from Start
4.42
12.57
25.75
41.55
53.97
63.80
73.70
88.72
97.93
Concentration,
yg/1 dry gas
Cl
782
926
1259
779
588
586
867
594
441
Na20
4.1
3.4
3.2
1.6
1.8
1.0
1.5
1.2
1.8
K20
1.5
1.3
1.0
0.6
1.2
0.7
0.9
0.4
1.1
Concentration,
p. p.m. by volume, dry gas
Cl
494
585
796
492
372
370
548
375
279
Na20
1.5
1.2
1.2
0.6
0.7
0.4
0.5
0.4
0.7
K20
0.4
0.3
0.2
0.1
0.3
0.2
0.2
0.1
0.3
Note: The quantities of Cl, Na and K measured are assumed
to exist in vapour form.
A2.66
-------
a..*..J.J.Q nass caiances lor lest JL.l
Test Series 1
Flow Rates in Ib /h
Inputs
Coal
No Acceptor
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
No Acceptor
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
369
3275
315
17
3976
55
2
0
3918
3976
Sulphur
4.428
4.428
0.388
0.018
0.009
4.034
4.450
Ash
50.37
50.37
47.02
1.32
0.37
48.71
Calcium
0.8431
0.8431
0.7933
0.0378
0.0127
0.8438
!
Carbon
244.3
0.4
0.0
244.7
7.4
0.1
0.0
222.6
230.2
Magnesium
0.4950
0.4950
0.4687
0.0137
0.0050
0.4873
Hydrogen
17.93
0.87
18.80
18.80
18.80
Sodium
0.837
0.837
0.576
0.026
0.008
0.008
0.618
Nitrogen
5
2508
242
17
2772
2780
2780
Potassium
1.28
1.28
1.20
0.03
0.01
0.00
1.24
Oxygen
44.8
765.6
73.2
883.6
0.6
0.0
0.0
890.9
891.6
Chlorine
1.99
1.99
0.03
0.01
0.00
2.14
2.18
Bed Composition assumed not to have changed during the test.
Chlorine content of Bed assumed.
A2.67
-------
Table A.2.3.17 Mass Balances for Test 1.2
Test Series 1
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
365
21
3238
274
15
3913
-5
28
64
1
0
3825
3913
Sulphur
5.010
0.008
5.018
1.913
0.557
1.191
0.028
0.013
2.419
6.120
Ash
71.78
11.14
82.91
-9.33
26.43
54.24
0.95
0.36
72.65
Calcium
1.381
4.368
5.749
3.463
1.105
1.932
0.050
0.015
6.565
Carbon
220.4
2.7
0.4
0.0
223.5
-0.2
0.0
6.4
0.1
0.0
215.2
221.6
Magnesium
0.271
2.714
2.986
1.484
0.487
1.145
0.025
0.013
3.156
Hydrogen
16.36
0.68
17.03
17.03
17.03
Sodium
0.85
0.20
1.05
0.06
0.33
0.62
0.01
0.01
0.01
1.03
Nitrogen
5
2481
210
16
2712
2715
2715
Potassium
1.95
0.10
2.05
-0.63
0.69
1.39
0.02
0.01
0.00
1.48
Oxygen
44.6
7.1
756.0
63.6
871.3
2.9
0.8
1.9
0.0
0.0
872.7
878.3
Chlorine
1.89
1.89
-0.00
0.03
0.06
0.00
0.00
2.48
2.57
Chlorine contents of Bed, Weir Solids and elutriated materials assumed.
Other components of Bed, and Magnesia content of Weir Solids,
interpolated from smoothed plots versus time.
Hydrogen content of primary cyclone solids assumed to be due to moisture
absorbed after weighing, and the analysis has been corrected to the dry
basis.
A2.68
-------
Table A.2.3.18 Mass Balances for Test 1.3
Test Series 1
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total
360
19
3242
292
16
3929
-0
12
72
1
0
3844
Total Output 3929
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outp_uts
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Sulphur
4.540
0.008
-
-"
4.548
0.226
0.317
2.031
0.037
0.010
1.713
4.333
Ash
59.79
10.25
-
-
70.03
-1.00
11.30
61.77
0.92
0.24
-
73.23
Calcium
0.944
4.019
-
-
4.963
0.345
0.592
3.422
0.066
0.013
-
4.438
Carbon
226.8
2.5
0.4
0.0
229.7
0.2
0.0
4.9
0.1
0.0
217.1
222.2
Magnesium
0.160
2.497
-
:
2.657
0.233
0.331
2.013
0.044
0.016
—
2.637
Hydrogen
16.86
-
0.99
-
17.85
-
-
17.85
17.85
Sodium
0.590
0.186
-
-
0.775
0.048
0.163
0.700
0.014
0.005
0.005
0.934
Nitrogen
5
-
2482
224
16
2728
-
-
2705
2705
Potassium
1.52
0.10
-
:
1.61
0.05
0.30
1.57
0.02
0.01
0.00
1.95
Oxygen
44.4
6.6
758.9
67.9
<•»
877.7
0.6
0.5
3.1
0.1
0.0
899.7
904,0
Chlorine
1.97
-
-
-
1.97
-0.00
0,01
0.09
0.01
0.00
2.71
2.83
Carbon Dioxide contents of Bed and Weir Solids assumed.
Chlorine contents of Bed, Weir Solids and Primary and Secondary
Cyclone Solids assumed.
Other components of Bed interpolated from smoothed plots versus time.
Hydrogen content of Primary Cyclone Solids assumed to be due to Moisture
absorbed after weighing, and the analysis has been corrected to the dry
basis.
A2.69
-------
Table A.2.3.19 Mass Balances for Test 1.4
Test Series 1
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Out£uts
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
346
24
3251,
289
16
3926
-15
22
77
1
0
3841
3926
Sulphur
4.430
0.010
-
-
4.440
0.720
0.661
2.726
0.026
0.006
0.426
4.566
Ash
49.13
13.15
• -
• -
62.28
-16.79
19.84
64.92
0.57
0.15
-
68.69
Calcium
0.795
5.107
-
-
5.902
2.364
1.402
5.484
0.064
0.010
-
9.325
Carbon
224.5
3.0
0.4
0.0
228.0 .
0.1
0.1
5.0
0.0
0.0
217.4
222.6
Magnesium
0.017
3.138
-
-
3.155
1.360
0.759
3.078
0.027
0.017
-
5.240
Hydrogen
16.42
-
0.72
17.14
-
17.14
17.14
Sodium
0.62
0.09
-
-
0.71
0.29
0.32
0.75
0.01
0.00
0.00
1.38
Nitrogen
5
-
2491
222
16
2733
-
-
2693
2693
Potassium
1.35
0.02
-
-
1.37
-0.33
0.54
1.52
0.01
0.00
0.00
1.74
Oxygen
44.5
8.1
759.2
67.2
878.9
1.0
1.1
4.4
0.0
0.0
911.0
917.5
Chlorine
1.92
-
-
-
1.92
0.05
0.03
0.20
0.01
0.00
1.95
2.24
Chlorine contents of Bed, Weir Solids and elutriated materials assumed.
Other components of Bed interpolated from smoothed plots versus time.
Hydrogen content of Primary Cyclone Solids assumed to be due to Moisture
absorbed after weighing, and the analysis has been corrected to the dry
basis.
A2.70
-------
Table A.2.3.19a Mass Balances for Test 1.5
Test Series 1
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
319
24
3286
283
15
3928
-14
26
56
1
0
3858
3928
Sulphur
4.106
0.010
-
-
—
4.116
-0.150
1.079
2.382
0.028
0.008
0.596
3.943
Ash
39.04
13.11
-
-
—
52.15
-12.99
22.74
46.62
0.59
0.24
—
57.20
Calcium
0.467
5.093
-
-
—
5.560
-0.735
2.094
4.620
0.066
0.019
-
6.064
Carbon
213.1
3.0
0.4
0.0
—
216.5
-0.1
0.1
3.1
0.0
0.0
221.0
224.2
Magnesium
-0.105
3.128
-
-
—
3.024
-0.033
1.101
2.702
0.047
0.029
-•
3.846
Hydrogen
15.52
-
0.87
-
—
16.39
-
-
-
-
-
16.39
16.39
Sodium
0.680
0.090
-
-
—
0.769
-0.526
0.419
0.652
0.014
0.006
0.003
0.568
Nitrogen
4
-
2516
218
16
2754
-
-
-
-
-
2715
2715
Potassium
1.13
0.02
-
-
—
1.15
-0.59
0.62
1.06
0.01
0.01
0.02
1.13
Oxygen
40.8
8.1
768.2
65.8
— •
882.9
- 0.3
1.8
3.8
0.0
0.0
903.7
908.9
Chlorine
1.75
-
-
-
—
1.75
0.03
0.06
0.26
0.01
0.00
1.40
1.76 1
Hydrogen content of Primary: Cyclone Solids assumed to be due to Moisture
absorbed after weighing, and the analysis has been corrected to the dry
basis.
Bed compositions interpolated from smoothed plots versus time.
A2.71
-------
Table A.2.3.20 Heat balances, million Btu/h
Test Series 1
Test No.
Heat Inputs
In Coal-dolomite mixture, total
In Air and nitrogen, total
Heat of Sulphation of CaCO.
Total Heat Input
Heat Outputs
Weir solids, total
Elutriated solids, sensible
potential
Cyclone and weir blowdowns, total
Exhaust flue gas, sensible
potential
latent
To water cooling in bed
in freeboard
shell cooling
To shell pressurising air
Estimated radiation losses
Heat of calcination of MgCO»
Total heat output
Unaccounted (input-output)
Unaccounted, % of input
1.1
4.34
0.05
0.00
4.39
-
0.02
0.12
0.05
1.23
0.02
0.18
1.81.
0.20
0.13
0.02
0.01
-
3.79
+0.60
+13.7
1.2
3.95
0.04
0.01
.4.00
0.01
0.02
0.09
0.05
1.17
0.01
0.16
1.66
0.20
0.12
0.02
0.01
0.00
3.52
+0.48
12.0
1.3
4.04
0.05
0.01
4.10
0.00
0.03
0.08
0.05
1.24
0.00
0.16
1.56
0.19
0.12
0.01
0.01
0.00
3.45
0.65
15.9
1.4
3.98
0.04
0.02
4.04
0.00
0.03
0.07
0.05
1.19
0.00
0.16
1.44
0.26
0.12
0.02
0.01
0.01
3.36
+0.68
+ 16.8
1.5
3.79
0.05
0.02
3.86
0.00
0.02
0.05
0.05
1.19
0.00
0.15
1.50
0.13
0.12
0.02
0.01
0.01
3.25
+0.61
+ 15.8
Total heats are the sums of sensible heat and of potential and/or latents heats.
Sensible heats refer to 32 F datum; the sensible heat of coal-acceptor mixture
approx. 0.002 million Btu/h.
Potential heat of coal-acceptor mixture equals that of the coal fed.
Latent heat of water vapour in input gas approx. 0.02 millions Btu/h.
Total heat of weir solids includes that due to gain in weight of bed.
Reaction heats calculated assuming the following reaction equations:
CaC03 + S02 +
+ C02 + 77.1 kcal/mole
MgC03 - MgO + C02 - 24.2 kcal/mole
A2.72
-------
Table A.2.3.21 Distribution of carbon loss in primary fines fractions
Test Series 1
Sample ref
Sample time
1574
4446 to 5407 mins
Grading
+ 1588pm
-1588 + 794 ym
- 794 + 500 ym
- 500 + 251 ym
- 251 + 152 ym
- 152 + 75 ym
- 75 + 53 ym
- 53 ym
Total
Wt %
Nil
1.8
7.6
16.4
12.7
16.3
7.4
37.8
100.0
% C in
stated grade
0.5
0.4
0.4
0.3
1.4
6.0
14.2
Ib C/100 Ib
sample
0.01
0.03
0.07
0.04
0.23
0.44
5.37
6.19
% of total C
in stated
grade
0.2
0.5
1.1
0.6
3.7
7.1
86.8
100.0
A2.73
-------
Table A.2.3.22 Weight Losses of Corrosion Specimens
Test Series 1
yg/cnrh
N
-i
Tube
No.
1
2
3
4
5
6
Location of
Ring
Alloy
Weight Loss
Temperature (°F)
Alloy
Height Loss
o
Temperature ( F)
Alloy
Height Loss
Temperature (°F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Height Loss
Temperature (°F)
Alloy
Height Loss
Temperature (°F)
a
N
5
H
3
H
1
E
9
H
2.7
N
7
b
**
1450
**
1330
**
1020
**
93C
**
660
**
1450
c
R
44
N
4
Fl
***
Fl
359
Fl
24
R
13
d
S
30
W
***
F2
***
P2
433
F2
35
S
***
e
N
7
E
18
W
3
W
***
R
4
N
8
f
R
11
N
5
R
3
N
5
W
1
R
13
g
E
51
S
10
N
3
R
12
N
2
E
49
h
S
36
R
7
S
3
S
10
S
1
S
13
i
N
6
S
7
E
3
H
6
R
3
N
9
*
R
9
N
4
H
5
R
12
W
2
R
10
k
S
8
H
5
N
***
N
6
S
4
S
12
1
N
6
S
9
S
4
W
7
E
6
N
9
m
R
10
N
4
R
3
S
11
N
3
R
***
n
E
30
H
6
Fl
357
Fl
388
W
1
E
68
o
**
1450
**
1380
**
1160
**
u/s
**
1020
**
1450
P
S
10
R
12
F2
308
F2
458
R
4
S
15
q
N
6
E
39
N
3
R
13
S
5
N
13
r
R
30
N
6
S
5
S
11
N
4
R
13
8
S
7
R
7
E
7
N
6
S
5
S
12
t
N
***
S
4
R
5
R
17
H
2
N
11
**
***
Specimen used for measuring metal temperature
Specimen not descaled, retained for further
examination.
F. Ferritic II Cr JZMo steel S Austenitic Type 316
F. Ferritic 2{ZCr steel R Austenitic Type 347
\r Ferritic 12ZCr steel E Austenitic Type Esshete 1250
H Nimonic PE 16
-------
Table A.2.3.23 Summary of weight losses of corrosion specimens
Test Series 1
Material
Av. loss
11 Cr Max/Mfin
No. of
Specimens
Av. loss
2iZ Cr Ma*/11"1
Z** Cr No. of
Specimens
Av. loss
12Z Cr M3*/*1"1
12Z Cr No. of
Specimens
Av. loss
_ -.., Max/Min
SF316 No. of
Specimens
Av. loss
, Max/Min
**36 No. of
Specimens
„ . Av. loss
Esshete ' .....
. Max/Mm
"^ No. of
Specimens
Av. loss
>*" r^in
Specimens
Tube 1
1450°F 1A50°F
-
-
-
33 8
36/30 10/7
2 3
27 15
44/11 29/9
2 3
51 30
1 1
6 6
6/6 7/5
2 2
Tube 6
1450°F 1450°F
-
-
-
13 13
15/12
1 3
13 12
13/13 13/10
2 2
49 68
1 1
8 10
8/7 13/9
2 4
Tube 2
1330°F 1330°F
-
-
6 3
6/5
2 1
7 10
9/4
3 1
9 7
12/7
2 1
39 18
1 1
5 5
6/4 5/4
3 2
Tube 3
1160°F 1020 F
357
1
307
1
5 3
4/1
1 2
5 3
3/4
2 1
-------
Table A.2.3.24 Test Series 1 Metallographic examination of
corrosion specimens
Temp.
°F
1110
1350
1470
Material
Fl
F2
W
S
R
E
N
Surface
Texture
v. rough
v. rough
smooth
smooth
smooth
rough
smooth
Deposit
Scale
heavy
heavy
slight
slight
slight
slight
slight
Penetration ym
Pits
0
0
0
0
0
10
0
Sulphur
0
0
0
0
0
0
0
CLASSIFICATION OF SURFACE TEXTURE AS USED IN TABLES 3.24, 3.52. 3.85 & 3.113
The surface texture of the specimens after test, when examined
•- metallographically, have been placed into one of three cate-
gories -
1. Smooth : surface irregularities of up to 4 ym
2. Rough : surface irregularities of up to 12 ym
3... Very rough : surface irregularities of greater
than 12 ym
Irregularities of greater magnitude than the average texture
have been reported as pits of specified depth.
A2.76
-------
Table A.2.3.25 Operating conditions during Test Series 2
Coal
Coal size (upper limit)
Pittsburgh.
1587
Acceptor Dolomite 1337
Acceptor size (upper limit) 1587 ym
Fluidising velocity 1.9 ft/s
Bed temperature 1465 °F
Bed height 3.75 ft
Test No.
Elapsed time Start, h
test series End, h
Stoichiometric ratio
Coal rate Ib/h
Combustor pressure atm.abs.
2.1
1.73
15.2
1.41
420
3.5
2.2
16.2
37.2
1.88
420
3.5
2.3
2.4
i
38.4
67.1
1.93
420
3.5
68.0
72.5
1.88
500
5
2.5
74.5
80.5
1.55
420
3.5
A2.77
-------
Table A.2.3.26 Analysis of spot samples of (coal + dolomite)
Test Series 2
Sample
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
• Sample
time
min
0
134
313
544
752
859
993
1216
1380
1564
1736
1919
2106
2326
2510
2683
2878
3102
3282
3475
3676
3832
4002
4182
4363
4596
4732
4806
4890
Moisture
%
2.7
- '
-
-
-
-
-
-
-
-
-
-
1.4
1.0
1.1
0.9
1.0
-
-
-
-
-
-
-
-
—
-
—
—
"Ash"
%
22.6
-
-
-
—
-
-
-
-
-
-
-
22.9
25.2
20.5
20.9
24.0
-
-
-
-
-
•—
—
_
-
—
-
—
u,2
4.1
6.7
11.5
10.4
10.6
11.0
7.1
13.8
11.5
16.9
9.2
10.1
10.2
12.2
8.3
10.0
10.3
9.4
16.8
10.5
10.3
12.9
11.1
8.9
14.7
10.0
7.1
10.1
7.7
Size grading: % within stated size
-1588
+794 pm
19
14
24
21
17
27
16
33
25
33
12
18
0
27
18
20
23
20
34
19
21
24
26
38
22
30
20
27
21
-794
+500 vim
21
13
19
17
13
20
15
19
16
17
13
14
34
16
14
14
15
16
18
13
14
16
17
19
17
18
15
18
17
-500
+251 pm
32
22
22
22
22
22
24
19
22
20
21
21
21
19
19
19
20
23
18
21
19
18
20
19
20
18
20
17
21
-251
+152 pm
11
15
11
13
15
11
14
9
12
11
14
14
13
12
13
12
13
13
10
14
12
11
11
9
12
9
12
10
12
-152
+75 vim
7
16
10
12
15
9
13
9
11
10
14
15
14
12
15
14
13
11
9
13
15
12
11
7
12
9
13
10
11
-75 pm
10
20
14
15
18
11
18
11
14
9
20
18
18
14
21
21
16
17
11
20
19
19
15
8
17
16
20
18
18
Median
diameter
pm
430
250
410
360
270
460
290
530
400
500
270
280
300
400
260
280
340
330
520
280
290
350
450
640
400
500
310
510
460
to
•
-q
00
Analyses are given as weight percent on an 'as fired' basis.
-------
Table A'.2.3.27 Analysis of bulked samples of (coal + dolomite)
Test Series 2
Test
Sample Ref
Total moisture %
Carbon dioxide %
Ash %
Carbon %
Hydrogen %
Nitrogen %
Sulphur %
Oxygen + errors %
Chlorine %
Ash analysis
CaO %
MgO %
Na20 %
K2° %
Ash fusion (in air)
Initial deformation, F
Hemisphere F
Flow °F
2.1
1599
1.7
9.6
22.2
61.6
3.9
0.6
2.6
9.1
0.05
32.7
18.9
0.3
0.7
-
2.2
1600
1.2
11.3
24.3
57.1
3.4
0.6
2.3
12.2
0.08
34.2
20.7
0.5
0.8
2480
2535
2.3
1601
1.2
11.3
23.5
58.6
3.5
0.9
2.2
11.2
0.07
34.7
22.6
0.5
0.7
2515
2535
2.4
1602
1.3
11.6
22.6
59.1
3.6
1.0
2.2
11.4
0.07
35.2
23.4
0.4
0.6
2480
2535
2.5
1603
1.4
9.3
19.7
63.6
4.0
0.6
2.2
9.8
0.09
34.0
21.8
0.5
0.7
2515
2535
Analyses are given on a weight percent basis.
Total moisture and carbon dioxide are given
on an 'as received* basis.
Ultimate analysis is given on a dry basis.
A2.79
-------
Table A.2^3.28 Analysis of (coal + dolomite); overall sample
Test Series 2
Sample Ref.
Proximate analysis
Moisture %
Ash %
Volatile matter %
Fixed carbon %
Swelling number
Gray King coke type
Forms of sulphur
Pyritic %
Sulphatic %
Organic %
Total . %
Ash analysis
Si02 %
Fe203 %
CaO %
MgO %
Na20 %
Ti02 %
Mn30A %
P2°5 *
so3 %
Total %
1604
1.3
23.1
49.5
38.1
6
G7
1.38
0.06
0.82
2.26
20.8
9.2
7.0
33.5
21.0
0.5
0.8
0.4
0.1
0.2
4.6
98.1
Except for volatile matter, the analyses
are given on an 'as received* basis;
volatile matter is given on a d.a.f.
basis.
A2.80
-------
Table A.2.3,29 Analysis of Dolomite
Test Series 2
Material
Sample ref
Moisture %
Loss on ignition at %
800°C
sio2 %
Fe203 %
CaO %
MgO %
Na20 %
K20 %
S %
rn 7
co2 %
Size grading
-2411 +1588 um
\ -1588 + 794 ym
- 794 + 500 ym
- 500 + 0 ym
Median diameter ym
Mean diameter, D , ym
P
Raw
Dolomite*
1591
-
-
-
-
-
-
-
-
-
—
Sieved
Dolomite **
1647
0.1
44.3
0.7
0,2
31.0
21.4
0.1
0.1
<0.05
47.6
% within stated size
22
71
6
1
1390
1060
0
75 :
18
7
1100
700
Analyses are on a weight per cent basis
* Before sieving
** As blended with coal fed to the combustor
D as defined in Table A.2.3.8.
P
A2.81
-------
Table A.2.3.30 Chemical analysis and size grading of shale
+ coal mixture
Test Series 2
Test Series
Sample Ref,
Carbon
Sulphur
Chlorine
CaO
MgO
Na20
K20
Size grading
% within stated size
grade
-1588 +794 Mm
-794 +500 vim
-500 +251 vim
-251 +152 ym
-152 + 75 ym
-75+0 ym
Median diameter U^m
Mean diameter, D tt/m
P i
2
1620
10.0
0.3
0.06
3.3
2.9
0.5
3.2
24
47
23
2
1
3
650
370
Analyses are given as weight per
cent on an 'as received* basis.
Dp as defined in Table A.2.3.8.
A2.82
-------
Test Series 2
Test
Sample Ref
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Size Grading
-1588+794 ym .
- 794+500 ym
- 500+251 ym
- 251-152 ym
- 152+ 75 ym
- 75+ 0 ym
Median diameter ym
Mean diameter D ym
P
2.1
1605
4.5
0.1
3.5
5.0
0.16
13.7
4.9
0.6
1.7
2.2
1606
9.2
0.1
3.9
8.3
0.05
17.7
8.4
0.4
0.9
2.3
1607
11.1
0.1
4.3
8.6
0.07
18.9
5.6
0.3
0.6
2.4
1608
10.0
0.1
4.4
5.5
0.08
16.4
7.4
0.4
0.8
2.5
1609
22.0
0.2
2.8
5.4
0.06
13.5
7.2
0.4
0.7
% within stated size grade
16
21
24
9
7
23
360
120
7
11
11
7
12
52
70
65
6
7
7
4
11
65
45
55
3
4
3
2
5
83
25
45
-
1
2
2
6
89
35
40
Analyses are given as weight percent on an 'as received' basis.
% carbon does not include carbon present as carbon dioxide.
A2.83
-------
Test Series 2
Test
Sample Ref
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na00 %
*•
iX^U /B
^
Size Grading
- 75 + 60 M m
- 60 + 50 urn
-50 + 40 tm
-40+30 Am
-30 + 20 Lira
-20+10 j^m
- 10 + 5 ^m
-5+0 A»m
Median diameter km
Mean diameter. D urn
P>
2.1
1610
3.7
0.1
3,4
1.7
0.11
9.7
6.4
0.8
1.8
%
1
8
11
11
11
19
23
16
30
12
2.2
1611
3,3
0,1
2.7
2.3
1612
3.9
0.1
2.9
•
0.5 0.7
0.09
0.08
8.6 9.2
5.6 5.0
0.7 :' 0.7
1.6 1.6
.
within stated
2
5
1 6
2 1
5 5
21 16
51 36
20 29
7
6
7
6
2.4
1613
1.9
0.1
3.2
2.5
1614
2.4
0.1
2.5
i
0.4 i 0.6
i
0.08 0.09
9.2 8.7
5.2 5.3
1
0.7 0.6
1.6 1.5
size grade
1
2
5
4
9
27
1
3
3
1
9
23
27 39
24 21
10
7
8
7
Analyses are given as weight percent on an 'as received* basis.
7, Carbon does not include carbon present as carbon dioxide.
Size gradings were obtained by a Coulter Count on the material
passing through a 75 micron sieve. For sample ref: 1610, 26%
was + 75 micron. The remaining samples were 100% less than
75 micron.
A2.84
-------
Table A.2.3.33 Analysis of Exhaust Dust
Test Series 2
Test
Sample Ref
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na_0 %
2.1
1615
3,1
0.2
3.3
0.2
0.2
7.7
7.6
1.0
^
K20 % 1 . 9
Size Grading %
-75 +60 Pm 8
i
-60 +50 Pm ; 3
•
-50 +40 pm 5
-40 +30 pm ; 6
-30 +20 pm ; 6
-20 +10 pm 12
-10 + 5 pm '.23
- 5 + 0 pm 36
Median diameter, pm 7
Mean diameter, D urn ' 6
P
2.2
2,3
i
1616
2.7
0,2
4.1
0.5
0.2
9.0
6.5
0.8
1.6
1617
3.9
0.1
3,3
0.5
0.1
10.5
5.4
2.4
1618
2.2
0.2
4.4
0.4
0.3
2.5
1619
j
7.0
,
0.2
3.2
0.5
i
0.3
10.4 10.0
5.2 4.5
i
0.7 0.8 0.8
•
1.7 : 1.8 1.8 .
• i
within stated size range
2
1
2
6
8
16
26
39
1 ' ~ '; 1
1 - 2
0 4:0
i
1 3 } 7
!
7 8
8
14 25 ; 15
!
33 31 1 30
43 29 ! 37
6 6 8(6
5 5 , 6 . 5
i
Chemical analyses are given as weight percent, on an 'as received'
basis.
% Carbon does not include carbon present as carbon dioxide.
A2.85
-------
Table A.2.3.34 Analysis of bulked samples of bed material
Test Series 2
Test
Sample ref
Carbon %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Sulphite sulphur %
Sulphide sulphur %
Size grading
-1588 + 794 ym
- 794 + 500 ym
- 500 + 251 ym
- 251 + 152 ym
- 152 +0 ym
Median diameter ym
Mean diameter, Dp> ym
Before
2.1
1589
0.1
2.6
0.4
0.14
7.3
5.5
1.4
2.6
-
-
2.1
1622
0.1
4.1
6.4
0.05
16.8
11.9
0.7
1.7
0.03
<0.01
2.2
1621
0.2
8.3
10.4
0.06
32.8
21.9
0.4
0.6
0.02
<0.01
2.3
1643
0.2
7.9
11.7
0.05
31.2
21.4
0.3
0.4
-
-
2.4
1644
0.1
8.1
11.3
0.05
32.2
22.7
0.9
0.7
-
-
2.5
1645
0.1
8.8
10.3
0.04
33.2
21.8
0.7
0.6
-
-
After
2.5
1642
-
9.2
-
-
31.5
21.2
-
—
-
-
% within stated size grade
15
30
44
10
1
475
400
29
27
36
8
0
550
470
51
25
18
6
0
810
590
63
23
11
3
0
950
710
59
24
14
3
0
910
670
56
24
16
4
0
880
650
52
25
19
4
0
420
350
Analyses are given as weight percent on an 'as received1 basis
% Carbon does not include carbon present as carbon dioxide
Sulphur not present as sulphite or sulphide is assumed to be present as sulphate
Samples 1621, 1622, 1643-1645 refer to bed material extracted during the test
via the weir.
D as defined in Table A.2.3.8.
P
A2.86
-------
Table A.2.3.35 Analysis of additional samples of bed material extracted via the weir
Test Series 2
Sample Ref
Sample time,
mm
CaO
MgO
Sulphur
Size Grading
- 1588 + 794 pm
- 794 + 500 pm
- 500 + 251 pm
- 251 + 152 pm
- 152 + 75 pm
Median size pm
Mean dia. Dp,pm
Sample Ref
Sample time,
mm
CaO
MgO
Sulphur
Size Grading
- 1588 + 794 pm
- 794 + 500 pm
- 500 + 251 pm
- 250 + 152 pm
- 152 + 75 pm
Median size pm
Mean dia. Dp, urn
1622
909
to
924
16.8
11.9
4.1
1623
1493
to
1589
33.1
23.5
8.7
1624
1763
to
1810
32.5
20.2
7.8
1625
2235
28.4
18.3
7.0
1626
2617
to
2665
30.5
21.5
7.5
1627
2793
to
3807
30.2
21.0.
7.7
1628
2916
to
2930
29-7
20.6
7.6
1629
3040
to
3048
30.2
20.6
7.7
1630
3152
to
3163
31.0
21.1
7.9
1631
3261
to
3270
30.5
20.9
8.0
% within stated size grade
29
27
36
8
0
560
470
1632
3391
to
3406
31.4
21.6
8.0
58
29
10
3
0
900
670
1633
3521
to
3536
30.7
20.9
8.1
58
23
15
4
0
890
650
1634
3641
to
3656
34.1
22.7
8.1
45
27
21
7
0
740
550
1635
3750
to
3765
32.6
22.8
8.1
60
14
13
3
0
920
680
1636
3891
to
3906
33.1
23.0
7.7
50
26
18
5
1
800
590
1637
3992
to
4000
32.1
22.0
8.1
58
25
14
3
0
890
670
1638
4111
to
4120
32.2
22.7
8.1
57
24
15
4
0
890
650
1639
4355
to
4363
32.8
23.2
8.3
52
25
18
5
0
820
600
1640
4541
to
4556
33.5
21.7
8.7
53
26
16
5
0
840
610
1641
4687
to
4702
32.8
21.9
8.9
1642 .
4890
31.5
21.2
9.2
% within stated size grade
65
22
11
2
0
990
740
62
22
13
3
0'
940
690
71
21
7
1
0
1040
810
63
24
11
2
0
960
730
57
24
15
4
0
890
660
65
23
10
2
0
980
730
60
24
13
3
0
920
670
60
24
13
3
0
910
670
57
24
16
3
0
880
650
60
24
13
3
0
930
700
52
25
19
2
0
820
1 610
Analyses are given as weight percent on an 'as received' basis.
D as defined in Table A.2.3.8.
P
A2.87
-------
Table A.2.3.36 Gas composition measurements
Test Series 2
Test No. "-TV*
Elapsed time
from start of
Test Series
Operating
conditions
Gas composition
X by volume
(dry gas)
Gas composition
p. p.m. by volume
(dry gas)
Start, h
End, h
Ca/S
mol ratio
Variable
parameter
co2
CO
°2
so2
so3
N0x
Cl
K20
2.1. .
1.73
15.2
1.41
Pressure
3j atm
15.4
0.03
3.0
210
1
80
80
0.9
0.3
2.2
16.2
37.2
1.88
Pressure
3j atm
14.8
0.03
4.5
90
0
130
70
0.5
0.2
2.3
38.4
67.1
1.93
Pressure
3J atm
14o8
0.04
4.9
70
1
90
50
0.3
0.1
2.5
68.0
72.5
1.88
Pressure
5 atm
13.8
0.02
6.3
110
100
-
2.5
74.5
80.5
1.55
Pressure
3$ atm
15 .4
0.06
3i'8
220
0
70
-
A2.88
-------
Table A.2.3.37 Variation in gas composition
Test Series 2
Oxygen in combustion products (volume basis)
Test
2.1
2.2
2.3
2.4
2.5
% of test time in stated range
< 1%
8
5
1
0
3
i
1-2%
26
5
4
0
17
2-4%
45
36
24
12
39
I
1
4-6%
17
33
48
29
33
> 6%
4
21
23
59
8
mean
oxygen
%
2.98
4.51
4.94
6.34
3.81
Carbon monoxide in combustion products (volume basis)
j
1
Test
2.1
I
% of test time in stated range
0 to
0.025%
92
2.2 i 94
2.3
2.4
2.5
94
59
57
0.025 to
0.05%
> 0.05%
0 ! 8
2
3
41
26
4
3
0
17
mean
CO %
0.030
0.029
0.037
0.023
0.064
A2.89
-------
Table A.2.3.38 Variation of temperature in bed and freeboard
Test Series 2
Height above
distributor*
Bed
1 in to 5 in
13 in to 16 in
Bed
36 in
Freeboard
*7 T •
/ / in
Freeboard
107
Test
2.1
2.2
2.3
2.4
2.5
2.1
2.2
2.3
2.4
2.5
2.1
2.2
2.3
2.4
2.5
2.1
2.2
2.3
2.4
2.5
2.1
2.2
2.3
2.4
2.5
% of test time in stated temperature ranges
<1400°F
6
6
3
7
4
4
2
1
0
1
0
0
0
2
0
1
8
16
0
0
8
19
0
48
61
1400° to
1436°
35
35
30
34
33
24
23
12
18
16
7
3
0
0
2
7
11
23
6
0
49
54
21
28
21
1436° to
1472°F
39
45
52
48
49
43
46
45
42
39
36
35
17
19
12
34
32
35
18
6
27
26
38
21
14
1472° to
1508°F
18
13
14
10
13
26
25
37
34
39
47
50
65
46
68
47
16
15
27
26
15
1
36
3
3
>1508°F
2
1
1
1
1
3
4
5
6
5
10
12
18
33
18
11
33
11
49
68
1
0
1
0
1
Mean
temp. °F
1445
1443
1449
1443
1443
1454
1456
1467
1463
1463
1474
1481
1490
1488
1490
1477
1479
1449
1506
1517
1434
1418
1427
1409
1393
A2.90
-------
Table A.2.3.39 Measurements of S00 andSO, in exhaust gases
^^•"^™^™""™^ ^ _^^^^— i ^^.WWMW^W^H^ ««.^_^_^_^_«^ _«_»«
Test Series 2
Time from
start, min
186
242
303
434
527
635
759
892
1001
1070
1126
1268
1348
1398
1488
1573
1663
1733
1793
1833
1894
1948
2084
2214
2335
so2
p. p.m. (v/v)
297
241
285
346
223
135
88
100
92
167
81
83
68
84
77
35
55
43
54
37
44
88
102
65
43
so3
p. p.m. (v/v)
0
2.3
0
0
0
0.7
0
1.8
1.4
0
0
0.5
1.0
0.6
0.5
0
0.5
0
0,3
0
0.3
0
0
2.0
1.0
Time from
start, min
2382
2463
2530
2673
2751
2983
3050
3210
3318
3426
3626
3720
3917
3968
4127
4187
4281
4360
4485
4572
4675
4760
4810
4860
so2
p. p.m. (v/v)
75
68
65
70
73
65
84
76
124
101
54
72
53
56
93
96
133
252
107
262
221
270
220
401
so3
p. p.m. (v/v)
1.0
0
0.7
1.3 *
0.7
0
0.3
0
0
0
0.9
0.5
0
0
0
0
0
-
0.5
0.5
0
0
0.2
0
A2.91
-------
Table A.2.3.40 Percentage Retention of SulphurfAlkalis and Chlorine
Test Series 2
Test No.
Stoichiometric ratio
Total Ca/S Mole ratio
Per cent retention
Sulphur
Sodium
Potassium
Chlorine
Per cent reduction
Sulphur emission
2.1
1.41
1.57
92.3
98.8
99.8
32,6
89,4
2.2
1.88
2.04
96.4
99.3
99.7
20.5
95.6
2.3
1.93
2.09
96.8
99.5
99.8
28.2
96.4
2.4
1.88
2o04
94.5
99.2
99.7
22.0
94,7
2.5
1.55
1.71
90.6
99.4
99.8
24.7
89.4
% Retention of sulphur, sodium and potassium
= 100 (Total input-output in gas)/Total input
% Retention of chlorine
= 100 (Total output-output in gas)/Total output
% Reduction of sulphur emission
= 100 (Emission without acceptor - Emission observed)/(Emission
without acceptor)
Emission without acceptor assumed to be 2032 ppm v/v in dry gas
Stoichiometric ratio assumed = (Total Ca/S mole ratio - 0.16)
For Test 2,1, the Stoichiometric ratio and total Ca/S mole ratio
do not take into account calcium and sulphur inputs in the shale-
coal mixture. If these are taken into account, Stoichiometric
ratio = 1.29 and total Ca/S mole ratio = 1.64.
A2.92
-------
Table A.2.3.41 Concentration of N0y in combustion gases
Test Series 2
Time from
start, min
286 to 290
293
294
295 to 297
301
303 to 310
884
988
1098
1108
1338 to 1348
1348 to 1358
1358 to 1368
1368 to 1378
1378 to 1386
1630 to 1640
1640 to 1650
1650 to 1660
1660 to 1670
j 1670 to 1680
I 2029 to 2046
2061 to 2064
2069 to 2089
2384 to 2393
2397 to 2401
2404 to 2412
2418 to 2426
2428 to 2437
2067 to 3079
3447
3478
3479
NOX
p. p.m. (v/v)
77 to 79
92
103
68 to 73
122
71 to 88
93
150
99
73
93 to 113
104 to 120
106 to 129
115 to 131
113 to 127
115 to 134
110 to 134
122 to 136
124 to 134
124 to 139
81 to 111
93 to 97
93 to 120
62 to 82
93 to 111
88 to 102
88 to 111
88 to 120
69 to 93
77
66
68
Method
Hersch
Saltzman
ii
Hersch
Saltzman
Hersch
ii
ii
ii
ii
ii
ii
ii
ii
ii
ii
ii
ii
ii
n
n
ii
n
n
n
n
n
n
ii
ii
n
n
Time from
start, min
3484
3485
3486
3487
3772
3773
3775
3776
3777
3778
3779
3780
3781
3782
3946
3947
3948
3949
3950
3951
3952
3954
3955
3956
3957
3958
3959
3960
3961
4720 to 4722
4727 to 4734
NOX
p. p.m. (v/v)
84
77
82
82
84
86
88
97
84
79
93
89
79
84
120
115
95
88
84
88
93
97
111
97
93
95
95
95
93
63 to 79
63 to 82
Method
Hersch
n
n
n
n
n
n
n
n
n
n
n
n
ii
n
n
n
n
M
n
n
n
n
n
n
n
ii
"
n
n
n
A2.93
-------
jTable A.2.3.42 Determinations of Alkalis and Chlorine
in Flue Gas
Test Series 2
Time, from
start, h
5.33
23.42
27.48
50.53
Concentration,
ug/l dry gas
Cl
123
110
110
79
Na2°
2.6
1.3
1.3
0.9
K20
1.3
0.9
0.9
0.4
Concentration,
ppm by volume, dry gas
Cl
78
70
70
50
Na2°
1.0
0.5
0.5
0.3
K20
0.3
0.2
0.2
0.1
A2.94
-------
Table A.2.3.43 Mass Balances for Test 2.1
Test Series 2
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Shale + Coal
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Shale + Coal
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
331
79
56
3204
307
31
4009
15
146
3
1
3844
4009
Sulphur
10.64
0.02
0.17
-
-
10.83
2.45
5.16
0.10
0.02
0.83
8.55
Ash
44.2
41.1
49.1
-
-
134.4
0.8
119.0
2.5
0.6
~
122.8
Calcium
3.46
17.43
1.33
-
-
22.22
9.90
14.42
0.20
0.04
—
24.56
Carbon
237.8
10.2
5.6
0.4
0.0
254.1
2.3
8.5
0.1
0.0
222.2
233.1
Magnesium
0.04
10.15
0.98
-
-
11.17
5.71
4.35
0.11
0.03
-
10.21
Hydrogen
16.35
0.01
0.40
0.85
-
17.61
-
17.61
17.61
Sodium
0.141
0.058
0.219
-
-
0.417
-0.479
0.656
0.017
0.005
0.005
0.204
Nitrogen
2
-
0
2454
236
31
2724
-
2756
2756
Potassium
0.45
0.07
1.47
-
-
1.99
-0.62
2.08
0.04
0.01
0.00
1.52
Oxygen
19.7
27.3
0.5
748.8
71.4
867.7
9.8
13.1
0.2
0.0
846.5
869.6
Chlorine
0.205
-
0.034
-
-
0.239
-0.080
0.236
0.003
0,001
0.331
0.491
Sulphate content of "Ash" of Coal-Dolomite mixture assumed constant throughout
Test Series 2.
Bed compositions interpolated from smoothed plots versus time.
Hydrogen contents of elutriated solids assumed to be due to moisture absorbed
after weighing, and the analyses have been corrected to the dry basis.
A2.95
-------
A.2.J.44 Mass Balances for Test 2.2
Test Series 2
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Out£UtS
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
321
95
3239
267
. 17
3939
13
33
73
1
1
3818
3939
Sulphur
9.55
0.02
-
-
9.57
4.27
2.71
2.87
0.04
0.05
0.34
10.28
Ash
45.83
49.42
-
-
95.25
-2.31
22.44
52.87
1.29
0.94
-
75.22
Calcium
3.45
20.95
-
-
24.40
11.46
7.66
9.32
0.09
0.07
—
28.60
Carbon
221.9
12.3
0.4
0.0
234.6
1.4
1.0
8.5
0.0
0.0
213.5
224.4
Magnesium
0.26
12.21
-
-
12.47
6.16
4.32
3.73
0.05
0.04
—
14.30
Hydrogen
15.11
0.01
0.68
-
15.80
-
-
15.80
15.80
Sodium
0.300
0.070
-
-
0.370
-0.148
0.097
0.219
0.008
0.007
0.003
0.184
Nitrogen
2
-
2482
205
17
2706
'
-
2721
2721
Potassium
0.585
0.079
-
-
0.663
-0.687
0.163
0.550
0.019
0.015
0.002
0.062
Oxygen
26.2
32.8
755.9
62.0
876.9
9.8
6.5
8.7
0.1
0.1
867.0
892.2
Chlorine
0.333
-
-
-
0.333
0.016
0.020
0.037
0.001
0.002
0.295
0.371
Sulphate content of "Ash" of Coal-Dolomite mixture assumed constant throughout
Test Series 2.
Bed compositions interpolated from smoothed plots versus time.
Hydrogen contents of elutriated solids assumed to be due to moisture absorbed
after weighing, and the analyses have been corrected to the dry basis.
A2.96
-------
Table A.2.3.45 Mass Balances for Test 2.3
Test Series 2
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
323
95
3454
276
17
4165
1
65
82
2
1
4014
4165
Sulphur
9.177
0.019
-
-
—
9.196
-0.053
5.119
3.558
0.047
0.028
0.293
8.991
Ash
42.7
49.8
-
-
—
92.5
0.6
44.3
56.8
1.4
0.7
-
103.8
Calcium
2.93
21.12
-
-
—
24.05
0.13
14.45
11.18
0.11
0.06
—
25.92
Carbon
229.2
12.4
0.4
0.0
~
242.1
0.3
2.2
11.1
0.1
0.0
224.3
237.9
Magnesium
0.91
12.31
-
-
—
13.22
-
0.50
8.36
2.79
0.05
0.03
—
11.73
Hydrogen
15.18
0.01
0.72
-
—
15.91
-
-
-
-
-
15.91
15.91
Sodium
0.289
0.071
-
-
—
0.360
0.194
0.144
0.184
0.008
0.004
0.002
0.537
Nitrogen
4
-
2647
212
17
2879
-
-
-
-
-
2851
2851
Potassium
0.484
0.079
-
-
—
0.564
0.054
0.215
0.412
0.021
0.012
0.001
0.715
Oxygen
22.3
33.1
806.0
64.1
™
925.6
0.6
13.2
10.5
0.1
0.0
922.9
947.3
Chlorine
0.293
-
-
-
—
0.293
-0.005
0.032
0.058
0.001
0.001
0.223
0.311
Sulphate content of "Ash" of Coal-Dolomite mixture assumed constant throughout
Test Series 2.
Bed compositions interpolated from smoothed plots versus time.
Hydrogen contents of elutriated solids assumed to be due to moisture absorbed
after weighing, and the analyses have been corrected to the dry basis.
A2.97
-------
Table A.2.3.46 Mass Balances for Test 2.4
Test Series 2
Flow Rates in Ib/h
Inp_uts
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
383
118
4797
402
28
5728
12
33
78
1
1
5603
5728
Sulphur
11.00
0.02
-
-
11.02
1.94
2.69
3.46
0.03
0.03
0.61
8.77
Ash
44.9
61.7
-
-
106.6
5.9
22.7
57.1
0.9
0.6
—
87.2
Calcium
1.96
26.14
-
-
28.11
4.45
7.64
9.22
0.07
0.05
—
21.43
Carbon
276.8
15.3
8.2
0.0
300.3
0.4
1.1
9.1
0.0
0.0
293.9
304.4
Magnesium
0.54
15.23
-
-
15.77
0.97
4.55
3.51
0.03
0.02
—
9.09
Hydrogen
18.75
0.01
-
-
18.76
-
.
18.76
18.76
Sodium
0.244
0.088
-
-
0.332
0.077
0.222
0.234
0.005
0.004
0.003
0.544
Nitrogen
5
-
3670
309
28
4011
-
-
3997
3997
Potassium
0.459
0.098
-
-
0.556
0.227
0.193
0.523
0.013
0.011
0.001
0.968
Oxygen
26
41
1120
93
1280
4
7
8
0
0
1293
1312
Chlorine
0.351
-
-
-
0.351
0.006
0.017
0.063
0.001
0.002
0.315
0.403
Sulphate content of "Ash" of Coal-Dolomite mixture assumed constant throughout
Test Series 2.
Bed compositions interpolated from smoothed plots versus time.
Hydrogen contents of elutriated solids assumed to be due to moisture absorbed
after weighing, and the analyses have been corrected to the dry basis.
A2.98
-------
Table A.2.3.47 Mass Balances for Test 2.5
Test Series 2
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
341
79
3429
279
10
4139
-27
54
95
2
1
4015
4139
Sulphur
9.224
0.016
-
-
9.240
-0.586
4.796
2.708
0.039
0.025
Ash
36.60
41.13
-
-
77.73
-19.89
36.84
61.75
1.29
0.64
-
80,63
Calcium
2.36
17.44
-
-
19.80
-8.29
12.93
9.33
0.10
0.06
0.868 !
7.850 14.13
Carbon
253.1
10.2
0.4
0.0
263.8
-1.7
1.6
22.6
0.1
0.1
233,1
255.8
Magnesium
Oo55
10.16
-
-
10.71
-5.23
7.17
4.20
0.05
0.02
-
6.21
Hydrogen
17,03
OoOl
0.91
-
17.95
-
-
17.95
17.95
Sodium
0.244
0.058
-
-
0.302
-0.592
0.283
0.287
0.007
0.005
0.002
-0.008
Nitrogen
3
-
2627
215
10
2854
-
-
2846
2846
Potassium
0.408
0.065
-
-
0.473
-0.508
0.271
0.562
0.019
0.012
0.001
0.357
Oxygen
22.4
27.3
801.4
64.9
916.0
-5.1
11.3
7.9
0.1
0.0
915.9
930.0
Chlorine
0.378
-
-
-
0.378
-0.011
0.022
0.058
0.001
0.002
0.222
0.294
Sulphate content of "Ash" of Coal Dolomite mixture assumed constant throughout
Test Series 2.
Bed compositions interpolated from smoothed plots versus time.
Hydrogen contents of elutriated solids assumed to be due to moisture absorbed
after weighing, and the analyses have been corrected to the dry basis.
A2.99
-------
Table A.2.3.48 Heat balances, million Btu/h
Test Series 2
Test No
Heat Inputs
In coal-dolomite mixture, total
In shale-coal mixture, total
In air and nitrogen, total
Heat of Sulphation of CaCO-
Total Heat Input
Heat Outputs
Weir solids, total
Elutriated solids, sensible
potential
Cyclone and weir blowdowns, total
Exhaust flue gas, sensible
potential
latent
To water cooling, in bed
in freeboard
shell cooling
To she^l pressurising air
Estimated radiation losses
Heat of calcination of MgC03
Total Heat Output
Unaccounted (Input-Output)
Unaccounted, % of Input
2.1
4.29
0.10
0.04
0.04
4.47
0.01
0.05
0.10
0.05
1.31
0.00
0.17
2.01
0.09
0.12
0.01
0.01
0.02
3.95
+0.52
+11.6
2.2
4.01
-
0.04
0.04
4.09
0.02
0.03
0.10
0.05
1.32
0.00
0.15
1.88
0.14
0.13
0.01
0.01
0.02
3.86
+0.23
+5.6
2.3
4.08
-
0.04
0.04
4.16
0.03
0.03
0.13
0.05
1.40
0.01
0.15
1.93
0.16
0.12
0.01
0.01
0.02
4.05
+0.11
+2.6
2.4
4.92
-
0.06
0.04
5.03
0.02
0.03
0.11
0.05
1.96
0.00
0.19
2.56
0.19
0.12
0.02
0.01
0.03
5.29
-0.27
-5.4
2.5
4.45
-
0.05
0.04
4.54
0.01
0.03
0.31
0.05
1.40
0.01
0.17
2.14
0.21
0.12
0.02
0.01
0.02
4.50
+0.04
+0.9
Total heats are the gums of sensible heat and of potential and/or latent heats.
Sensible heats refer to 32°F datum; the sensible heat of coal-acceptor mixture
approx. 0.002 million Btu/h
Potential heat of coal-acceptor mixture equals that of the coal fed.
Latent heat of water vapour in input gas approx. 0.02 million Btu/h.
Total heat of weir solids includes that due to gain in weight of bed.
Reaction heats calculated assuming the following reaction equations:
CaC03 + S02 + ^2 = CaSO^ + C02 +77.1 kcal/mole
MgC03 * MgO + C02 - 24.2 kcal/mole
A2.100
-------
Table A.2.3.49 Distribution of carbon loss in primary
cyclone fines fraction
Sample ref. 1607
Sample time 2304 to 4031.min from start of Test
Series 2
Grading,
microns
+ 1588
- 1588 + 794
- 794 + 500
- 500 + 251
- 251 + 152
- 152 + 75
- 75
Total
Wt»
%
Nil
6.7
8.2
7.0
4.5
11.6
62,0
100.0
% C in
stated
grade
-
3.6
2.7
1.9
3.1
8.4
18.4
Ib C/100 Ib
sample
-
0.24
0.22
0.13
0.14
0.97
11.41
13.11
% of total
C in stated
grade
-
1.8
1.7
1.0
1.1
7.4
87=0
100.0
A2.101
-------
Table A.2.3.50 Weight Losses of Corrosion Specimens
Test Series 2
yig/cm h
>
to
j_,
o
Tube
No.
1
2
3
4
5
6
Location of
Ring
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature (°F)
a
N
16
W
18
W
17
E
***
W
19
N
60
b
**
1450
**
1290
**
1110
**
840
**
630
**
1470
c
R
***
N
21
Fl
***
Fl
202
Pl
99
R
171
d
S
78
W
18
F2
***
F2
277
F2
99
S
285
e
N
62
E
208
W
14
W
24
R
7
N
103
f
R
81
N
54
R
23
N
***
W
17
R
201
g
E
***
S
70
N
9
R
27
N
8
E
***
h
S
92
R
55
S
13
S
30
S
8
S
***
i
N
45
S
45
E
40
W
30
R
***
N
38
J
R
55
N
39
W
14
R
31
W
***
R
136
k
S
71
W
***
N
14
N
17
S
51
S
127
1
N
27
S
47
S
16
W
32
E
15
N
39
m
R
58
N
***
R
30
S
32
N
9
R
94
n
E
207
W
***
Fl
***
Fl
305
W
18
E
223
0
**
1450
**
1380
**
1170
**
1110
**
930
**
1470
P
S
90
R
***
F2
***
F2
361
R
10
S
139
q
N
***
E
212
N
17
R
29
S
12
N
45
r
R
58
N
31
S
40
S
37
N
7
R
122
s
S
71
R
41
E
56
N
18
S
16
S
112
t
N
20
S
***
R
31
R
29
W
16
N
16
** Specimen used for measuring metal temperature
*** Specimen not descaled, retained for further
examination.
W
Ferritic l%Cr JZMo steel
Ferritic 2|%Cr steel
Ferritic 12%Cr steel
S Austenitic Type 316
R Austenitic Type 347
E Austenitic Type Esshete 125O
N Nimonic PE 16
-------
Table A.2.3.51 Summary of weight losses of corrosion specimens
Test Series 2
Material
Av. Loss
1% Cr Max/Min
No. of
Specimens
Av. Loss
2*% Cr !f
-------
Table A.2.3.52 Metallographic examination of corrosion
specimens
Test Series 2
Temp.
°F
1110
1290
1470
Material
Fl
F2
W
R
N
S
R
E
N
Surface
Texture
v. rough
v . rough
smooth
smooth
smooth
rough
smooth
rough
smooth
Deposit/
Scale
heavy
fissured
it
slight
slight
-
slight
slight
heavy
heavy
Penetration ym
Pits
0
0
0
0
0
0
0
0
0
Sulphur
0
0
0
v. slight
0
40
15
25
5
A2.104
-------
Table A.2.3.54 Analysis of Spot Samples of (Coal + Dolomite)
Test Series 3
to
H-1
o
CJ1
Sample
Ref
1658
1659
1660
1661
1662
1663
1664
1665
1666
1667
1668
1669
1670
1671
1672
1673
1674
1675
1676
Sample
time
min
183
368
501
683
884
1036
1214
1409
1550
1677
1797
1912
2090
2207
2326
2400
2450
2568
2700
Moisture
%
1.4
1.1
1.0
1.1
1.0
1.0
1.1
0.8
1.1
1.1
1.2
1.1
0.9
0.8
0.9
0.8
0.8
0.9
0.8
"Ash"
%
17.5
23.5
25.7
22.0
24.6
22.5
24.4
24.1
19.0
17.6
22.2
28.5
22.5
25.4
22.7
21.3
21.5
20.3
21.5
co2
%
7.8
12.5
14.7
11.4
13.9
12.2
12.8
16.5
6.6
7.3
9.8
14.0
10.9
12.7
11.3
10.5
10.1
9.3
10.8
Size Grading: % within stated size grade
-1588
+794 vim
18
27
32
27
35
30
32
38
16
20
25
29
29
33
19
33
33
29
31
-794
+500 pm
17
18
20
17
20
17
19
19
15
15
16
19
18
21
28
19
17
17
15
-500
+251 vim
21
19
19
18
18
19
18
18
21
20
19
20
19
18
18
17
18
18
17
-251
+152 pm
13
11
10
12
9
12
10
10
14
14
13
11
11
9
11
9
10
11
12
-152
+ 75 vim
12
9
8
10
8
9
8
7
14
12
11
9
9
8
9
8
8
10
10
-75
+ 0 pm
19
16
11
16
10
13
13
8
20
19
16
12
14
11
15
14
14
15
15
Median
diameter
Vim
310
410
520
400
570
450
520
600
270
300
360
480
460
550
440
530
500
430
420
Analyses are given as weight percent on an "as fired" basis.
-------
Table Ao2o3o53 Operating conditions during Test Series
Test Series 3
Coal
Coal size (upper limit)
Acceptor
Dolomite size (upper limit)
Coal rate
Fluidising velocity
Bed temperature
Combustor pressure
Bed height
Pittsburgh
1587
Dolomite 1337
1587
550
1«95
1480
5
3.75
pm
Ib/h
ft/a
°F
atm abs
ft
Test No.
3.1
3.2
Elapsed time
from start of
test series
Start, h
End,
25.7
36,8
36.8
45.0
Stoichiometric ratio
1.65
1.80
A2.106
-------
Table A.2.3.55 Analysis of bulked samples of (Coal + dolomite)
Test Series 3
Test No.
Total moisture %
Carbon dioxide %
Volatile matter %
Ash %
Carbon %
Hydrogen %
Nitrogen %
Sulphur %
Oxygen + errors %
Chlorine %
Ash analysis
Si02 . %
A1203 %
Fe203 %
CaO %
MgO %
Na20 %
K20 %
Ti02 %
wn»» w / /o
3 't
P 0 7
^2U5 ''
so3 %
Total %
Ash Fusion (in Air)
Initial deformation F
Hemisphere F
Flow °F
3.1
1.1
11.3
49.0
22.0
58.4
3.5
0.9
2.2
12.9
0.07
20.0
8.6
6.7
31.8
22.1
0.6
0.7
0.4
0.1
0.6
7.1
98.7
2515
2515
2570
3.2
0.9
11.7
49.6
22.2
58.9
3.6
0.8
2.1
12.3
0.07
19.5
9.6
6.0
32.7
22.6
0.5
0.6
0.4
<0.1
0.4
6.9
99.2
2495
2555
2570
!
Analyses are stated on a weight percent basis.
Total moisture and carbon dioxide are given on an
'as received' basis.
Volatile matter is given on a d.a.f. basis, and
Ultimate analysis is given on a dry basis.
A2.107
-------
Table A.2.3.56 Analysis of primary cyclone fines
collected by dry sampling system
Test Series 3
Test No=
Sample ref
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO Z
Na20 %
K2° %
Size Grading
-1588 + 794 ym
- 794 + 500 ym
- 500 + 251 ym
- 251 + 152 ym
- 152 + 75 ym
- 75 + 0 ym
Median diameter ym
Mean diameter, D , ym
P
3,1
1679
9.5
0.1
3,5
6.2
0.04
14 oO
8.8
0.4
0.8
3.2
1680
8.1
0.1
4.4
6.5
0,04
15.3
11.8
0.3
0.7
% within stated size grade
1
3
5
5
10
76
150
45
4
5
7
5
10
69
140
50
I
Analyses are given as weight percent, on an "as received"basis.
% Carbon does not include carbon present as Carbon dioxide.
Hydrogen assumed to be present as water.
Samples were taken approximately hourly and were then bulked.
D defined in Table A»2.3.8,
P
A2.108
-------
Table A.2.3.57 Analysis of Secondary Cyclone fines
Test Series 3
Test No.
Sample ref
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Size Grading
-50 +40 ym
-40 +30 ym
-30 +20 ym
-20 +10 ym
-10 + 5 ym
- 5 + 0 ym
Median diameter, ym
Mean diameter D ym
P
3.1
1682
2.5
0.1
3.0
0.4
0.04
8.8
4.3
0.8
1.7
3.2
1683
2.3
0.1
2.8
0.3
0.02
8.8
4.4
0.7
1.7
% within stated size range
2
4
5
20
45
24
7
5
2
1
8
16
40
33
6
5
Size gradings were obtained by a Coulter Count.
D as defined in Table A.2.3.8.
P
A2.109
-------
Table A.2.3.58 Analysis of exhaust dust
Test Series 3
Test No.
Sample Ref
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Size grading
-60 +50 ym
-50 +40 ym
-40 +30 ym
-30 +20 ym
-20 +10 ym
-10 + 5 ym
- 5 + 0 ym
Median diameter, ym
Mean diameter, Dp ym
3.1
1685
8.3
0.1
3.6
0.4
1.4
9.4
4.8
0.7
1.4-
3.2
1686
6.2
0.2
3.4
0.4
1.3
9.4
4.3
1.3
1.6
% within stated
size range
1
2
11
9
15
38
24
7
6
2
4
4
12
20
33
25
8
6
Analyses are given as weight percent on an 'as received1 basis.
% Carbon does not include carbon present as carbon dioxide.
Size gradings were obtained by a Coulter Count.
Dp as defined in Table A.2.3.8.
A2.110
-------
Table A.2.3.59 Analysis of bulked samples of bed' material
Test Series 3
Test No.
Sample
. , mins
period
Sample Ref
Carbon %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Sulphite sulphur
Sulphide sulphur
Size analysis
-1588 +794 urn
- 794 +500 pm
- 500 +251 urn
- 251 +152 ym
- 152 + 0 urn
Median diameter, um
Mean diameter, D , ym
Before
3.1
0
1698
0.2
1.3
0.4
0.03
4.4
2.2
1.0
2.5
<0.01
nil
3.1
1682
to
2158
1699
0.1
7.4
11.5
0.04
30.4
22.8
0.3
0.4
-
-
3.2
2287
to
2549
1700
0.1
8.3
10.4
0.04
30.4
21.2
0.4
0.5
<0.01
nil
After
3.2
2700
1701
0.1
8.2
9.5
0.05
29.6
20.6
0.3
0.1
-
-
% within stated size grade
12
23
45
19
1
420
350
52
28
16
3
1
830
620
53
27
17
3
0
830
640
50
29
18
2
1
800
600
Analyses are given as weight percent on an 'as received' basis.
T, carbon does not include carbon present as carbon dioxide.
Sulphur not present as sulphite or sulphide is assumed to
be present as sulphate.
D as defined in Table A.2.3.8.
A2.111
-------
Table A,2.3.60 Gas composition measurements
Test Series 3
Test No.
Elapsed time from
Test Series
Operating
conditions
Gas composition
% by volume
(dry gas)
Gas composition
p. p.m. by volume
(dry gas)
Start i h
End, h
Ca/S
mol ratio
co2
CO
°2
so2
NO
X
Cl
Na20
K20
3d
25.7
36.8
1.65
14.6
0.02
5.3
100
3.2
36.8
45.0
1.80
14.1
0.07
5.1
100
160 up to 22.0 hours
60 )
1.5 ^ at 5.1 hours
0.3 )
A2.112
-------
Table A.2.3.61 Measurement of SO,, and SCL in exhaust gases
Test Series 3
Time from
start, min
238
276
312
357
397
519
600
889
968
1024
1105
1189
1239
1254
1268
1358
S02 p. p.m. (v/v)
465
308
325
212
292
157
159
145
77
119
178
112
121
136
113
95
S03 p. p.m. (v/v)
0
0
0
0
0
-
-
-
_
-
-
-
-
-
-
Time from
start, min
1569
1647
1793
1918
1985
2121
2270
2300
2345
2372
2392
2465
2480
2510
2540
2600
2630
2660
S02 p. p.m. (v/v)
91
79
76
126
106
107
154* (85)
200* (110)
184*(102)
170* ( 94)
174*( 97)
182*(100)
186*(103)
182*(100)
187*(103)
169*( 94)
164*( 91)
168*( 94)
SO. p. p.m. (v/v)
-
-
-
-
-
-
-
-
-
-
-
_
-
-
-
-
Note: At the end of Test 3 it was noticed that a blow-off valve in the analyser system was
leaking. As this valve was positioned after the analysis section but before the gas
meter, a leak would have the effect of making the actual sample flow rate higher than
was measured, and the true S02 levels would be lower than indicated. Although the
time at which the valve started leaking is not known it seems probable that it was
after 2270 minutes when there was a sudden unexplained jump in the SO2 values (i.e.
all those values marked * in the above Table). The sampling system was recalibrated
after the Test, with the leaky valve, so that a corrected flow rate could be used.
The corresponding corrected S02 values are given in brackets.
A2.113
-------
Table A.2.3.62 Percentage Retention of Sulphur, Alkalis and Chlorine
Test Series 3
Test No.
Stoichiometric Ratio
Total Ca/S Mol Ratio
Percent Retention
Sulphur
Sodium
Potassium
Chlorine
Percent Reduction
Sulphur Emission
3.1
1.65
1.81
95.4
97.7
99.4
15.5
95.2
3.2
1.80
1.96
94.7
97.0
99.2
16.5
95.2
1 Retention of sulphur, sodium and potassium
- 100 (Total Input-Output in Gas)/Total Input
Z Retention of Chlorine
- 100 (Total Output-Output in Gas)/Total Output
Z Reduction of Sulphur Emission
• 100.(Emission without acceptor - Emission observed)/(Emission without
acceptor)
Bad»»ion without acceptor assumed to be 2032 p.p.m. v/v in dry gas
Itoichionetric Ratio assumed - (Total Ca/S mol ratio - 0.16)
A2.114
-------
Table A.2.3.63 Concentration of NOX in combustion gases
Test Series 3
Time from start,,
min
328
331
1217
1230
1240
1247
1260
NOX
p. p.m. (v/v)
149
152
168
203
153
194
108
Method
Saltzman
ii
ii
ii
Modified Saltzman
Saltzman
n
A2.115
-------
Table A.2.3.63A Determinations of Alkalis and Chlorine in Flue Gas
Test Series 3
Time from start
h
5.12
Concentration,
Ug/1 dry gas
Cl
90
Na20
4.2
K20
1.3
Concentration,
p. p.m. by volume, dry gas
Cl
57
Na2°
1.5
K20
0.3
A2.116
-------
Table A.2.3.64 Mass Balances for Test 3.1
Test Series 3
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
431
127
4875
425
14
5872
-7
94
56
4
1
5724
5872
Sulphur
12.25
0.03
-
-
12.28
1.67
6.98
1.97
0.11
0.02
0.56
11.31
Ash
46.6
66.4
-
-
113.0
-8.7
65.9
42.4
3.2
0.4
-
103.3
Calcium
-0.50
28.15
-
-
27.65
0.66
20.48
5.62
0.23
0.04
-
27.03
Carbon
306.0
16.5
0.6
0.1
323.2
-1.0
3.0
6.3
0.1
0.0
317.5
325.9
Magnesium
-0.18
16.40
-
-
16.22
-0.43
12.96
2.98
0.09
0.02
—
15.63
Hydrogen
20.20
0.01
0.81
-
21.03
-
-
21.03
21,03
Sodium
0.447
0.094
-
-
0.541
-0.017
0.245
0.167
0.021
0.003
0.013
0.431
Nitrogen
5
-
3736
326
14
4082
-
-
4062
4062
Potassium
0.601
0.105
-
-
0.707
-0.025
0.391
0.373
0.051
0.006
0.004
0.801
Oxygen
40
44
1137
99
1320
1
18
5
0
0
1321
1347
Chlorine
0.391
-
-
•
0.391
-0.003
0.038
0.022
0.001
0.008
0.365
0.431
Dolomite analysis assumed to be as in Test Series 2.
Bed compositions interpolated from smoothed plots versus time.
A2.117
-------
Table A.2.3.65 Mass Balances for Test 3.2
Test Series 3
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
391
121
4865
426
20
5823.
21
40
52
2
0
5707
5823
Sulphur
10.73
0.02
-
-
—
10.75
2.13
3.35
2.31
0.06
0.01
0.57
"8.42
Ash
41.7
63.2
-
-
—
104.9
16.7
27.7
38.3
1.8
0.3
-
84.9
Calcium
-0.48
26.80
-
-
—
26.32
3.48
8.76
5.73
0.13
0.03
—
18.13
Carbon
282.8
15.7
0.6
0.1
—
299.2
-0.1
1.2
5.9
0.1
0.0
307.5
314.5
Magnes ium
-0.26
15.62
-
-
•
15.35
1.32
5.16
3.73
0.05
0.01
-
10.27
Hydrogen
18.99
0.01
0.81
-
—
19.82
-
-
-
-
-
19.82
19.82
Sodium
0.328
0.090
--
-
—
0.418
-0.021
0.120
0.117
0.011
0.004
0.013
0.242
Nitrogen
4
-
3729
327
20
4080
-
-
-
-
-
4108
4108
Potassium
0.461
0.100
-
-
"
0.561
-0.601
0.167
0.304
0.029
0.005
0.004
-0.091
Oxygen
32
42
1135
99
—
1308
3
8
6
0
0
1270
1287
Chlorine
0.358
-
-
-
—
0.358
0.029
0.016
0.021
0.000
0.005
0.365
0.437
Dolomite analysis assumed to be as in Test Series 2.
Bed compositions interpolated from smoothed plots versus time.
Flow Rate of Primary Cyclone Solids assessed by dry sampling method.
A2.118
-------
Table A.2,3,66 Heat Balances, million Btu/h
Test Series 3
Test No,
Heat Inputs
In coal-dolomite mixture, total
In air and nitrogen, total
Heat of sulphation of CaCCK
Total Heat Input
Heat Outputs
Weir solids, total
Elutriated solids, sensible
potential
Cyclone and weir blowdowns, total
Exhaust flue gas, sensible
potential
latent
To water cooling, in bed
in freeboard
shell cooling
To shell pressurising air
Estimated radiation losses
Heat of calcination of MgCO-
Total Heat Output
Unaccounted (Input-Output)
Unaccounted, % of Input
3.1
5.58
0,05
Oo05
5,68
0,03
OoOl
0.06
0,05
2.06
OoOO
0,20
2.74
0,19
0,11
0,02
0,01
0,03
5,51
+0,17
+ 300
3,2
5.09
0,05
0.04
5,18
0,02
0,02
0,06
0.05
2.03
0,02
0.19
2.66
0.18
0.11
0,02
0.01
0.03
5,36
-0.18
-3.5
Total heats are the sums of sensible heat and of potential and/or latent heats.
Sensible heats refer to 32 F datum; the sensible heat of coal-acceptor mixture
approx. 0.002 million Btu/h »
Potential heat of coal-acceptor mixture equals that of the coal fed.
Latent heat of water vapour in input gas approx, 0,02 million Btu/h.
Total heat of weir solids includes that due to gain in weight of bed.
Reaction heats calculated assuming the following reaction equations:
CaC0
77,1 keal/mole
MgC03 = MgO + C02 - 24,2 keal/mole
A2.119
-------
Table A.2.3.67 Operating conditions during Test Series
Test Series 4
Coal Pittsbur;
Coal size (upper limit) 1587
Acceptor Dolomite
Acceptor size (upper limit) 1587
Coal rate 560
Fluidising velocity 1.95
Bed temperature 1465
Combustor pressure 4.9
Bed height 3.75
Vim
1337
pm
Ib/h
ft/8
°F
atm abs
ft.
Test No.
4.1
4.2
Elapsed time
from start of
test series
Stoichiometric ratio
Start, h
21.4
End, h
46.9
1.54
68.8
100
2.02
A2.120
-------
Table A/2.3.68 Analysis of spot samples of (Coal + Dolomite)
Test Series 4
to
Sample
Ref
1720
1721
1722
1723
1724
1725
1726
1727
1728
1729
1730
1731
1732
1733
1734
1735
1736
1737
1738
1739
1740
1741
1742'
1743
1744
1745
1746
1747
1748
1749
1750
1751
1752
Sample
time
min
125
295
485
652
853
1011
1197
1387
1555
1735
1914
2095
2270
2503
2700
2875
3079
3274
3481
3616
3832
3970
4164
4344
4525
4732
4877
5058
5239
5421
5610
5786
5960
Moisture
Z
0.7
0.7
0.9
1.3
0.6
1.0
1.0
1.2
0.8
0.8
1.2
1.2
1.1
1.1
1.2
1.1
0.9
0.8
0.7
0.9
0.8
0.8
0.9
1.0
0.9
1.1
1.0
1.0
0.9
0.9
0.8
0.9
1.0
"Ash"
Z
21.0
23.1
21.9
20.0
23.5
19.9
20.0
19.8
21.1
21.6
18.6
19.6
23.0
21.5
17.9
16.9
20.9
22.9
21.1
21.5
21.7
24.2
23.3
19.7
22.2
18.9
20.3
20.7
22.3
24.3
21.8
23.9
23.5
co2
%
9.6
10.6
10.3
8.7
10.5
8.5
9.2
9.2
9.6
9.6
8.2
9.0
11.1
9.5
6.4
6.6
10.3
11.1
10.2
9.6
10.8
12.2
12.4
9.3
11.0
8.8
10.4
10.0
10.6
13.5
11.1
12.4
11.8
Size Grading: Z within stated size grade
-1588
+ 794 ym
19
21
19
14
21
24
23
20
16
17
20
18
18
23
16
17
20
19
17
21
18
19
16
20
27
15
23
19
20
24
13
14
9
-794
+500 ym
13
17
14
15
15
18
16
16
15
16
16
16
15
19
14
16
17
18
16
19
17
18
15
20
19
16
17
17
17
20
13
13
10
-500
+251 vim
19
20
19
20
20
19
19
19
23
22
21
22
24
22
20
21
22
23
23
22
22
23
23
22
20
21
20
21
21
20
20
21
17
-251
+152 Mm
14
12
14
13
13
10
12
12
15
13
14
13
15
11
14
13
14
13
15
12
15
14
16
10
11
13
12
11
13
10
16
15
17
-152
+ 75 ym
14
12
13
14
12
9
11
12
13
13
12
12
13
10
13
13
12
11
13
11
12
12
14
9
8
13
11
11
11
8
15
16
21
-75
+ 0 ym
23
17
20
24
19
20
19
21
17
18
17
19
16
15
22
20
16
16
17
15
16
15
16
19
17
22
18
23
18
18
23
21
27
Median
diameter
ym
240
340
280
250
310
390
350
310
290
300
320
310
300
400
250
300
330
350
300
380
320
340
280
380
420
280
360
310
330
420
220
240
170
Analyses are given as weight Z on an "as received" basis
-------
Table A.2,3.69 Analysis .of Bulked Samples of (coal
Test Series 4
dolomite)
Test
Sample Ref
Proximate analysis
Moisture %
Volatile matter %
'Ash' 7.
Carbon dioxide %
Ultimate analysis
'Ash1 %
Carbon %
Hydrogen 7,
Nitrogen %
Sulphur %
Oxygen + errors 7,
Chlorine %
Ash analysis
Si02 %
A1203 %
Fe2°3 7°
CaO %
MgO %
Na20 %
K20 %
Mn304 7,
P2°5 %
Ti02 %
-------
Table A.2.3.70 Analysis of Raw Coal
Test Series 4
Sample Ref
Proximate
Moisture %
Volatile matter %
'Ash' %
Fixed Carbon %
Carbon dioxide %
Ultimate
'Ash1 %
Carbon %
Hydrogen %
Nitrogen %
Sulphur %
Oxygen + errors %
Calorific value Btu/lb
Ash Analysis
CaO %
MgO %
Na20 %
K20 %
Ash Fusion (H?/C02)
Initial deformation F
Hemisphere °F
Flow °F
1579
1.5
42.3
13.8
49.7
0.6
13.8
2.9
2050
2140
2370
1643
6.5
1.5
0.7
1.6.
1648
1.5
41.3
12.8
50.3
0.5
12.8
73.3
4.9
1.0
3.0
4.8
15088
Analyses are given on a weight percent basis.
Volatile matter and calorific value are given on a d.a,f. basis,,
Moisture, 'ash', fixed carbon and C0_ are given on air dry basis.
Remainder of ultimate analysis are given on dry basis.
A2.123
-------
Table A.2.3.71 Analysis of Shale and dolomite
Test Series 4
Material
Sample Ref
Moisture %
Loss on ignition at 800 C %
Si02 %
A1203 %
Fe203 Z
CaO %
MgO %
Na20 %
K20 ' %
S %
co2 %
Size grading
-1588 +794 ym
- 794 +500 ym
- 500 +251 ym
- 251 +152 ym
- 152 + 75 ym
- 75 + 0 ym
Median size, ym
Mean diameter, D , ym
Shale
1769
-
-
54.3
22.9
4.6
1.8
1.1
0.6
3.3
0.6
-
Dolomite
1719
1:0.05
46.4
1.1
Nil
0.1
31.0
20.8
0.4
0.6
<0.05
47.7
% within stated size
range
23
24
25
9
5
14
28
18
13
9
13
20
400
125
Analyses are on weight percent basis
Dp as defined in Table A.2.3.8.
A2.124
-------
Table A.2.3.72 Chemical Analysis of Primary Cyclone Fines:
collected by dry sampling system
Test Series 4
Test
Sample ref
Carbon %
Hydrogen %
Sulphur 7,
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
-1588 + 794 ym
- 794 + 500 ym
- 500 + 251 ym
- 251 + 152 ym
- 152 + 75 ym
- 75 + 0 ym
Median diameter ym
Mean diameter, D , ym
4.1
1755
4.3
0.05
5.4
8.8
0.04
22.0
14.6
0.9
0.9
9
10
14
7
11
49
80
65
4.2
1756
3.6
0.1
4.1
12.5
0.05
25.7
18.2
0.3
0.4
12
13 -
16
11
23
25
170
95
Analyses are given as weight percent, on an
'as received' basis.
Carbon does not include carbon present as
carbon dioxide.
D as defined in Table A.2.3.8.
P
A2.125
-------
Table A.2.3.73 Analysis of Secondary Cyclone Fines
collected by dry sampling system
Test Series 4
Test
Sample Ref
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Size grading
-75 +60 ym
-60 +50 ym
-50 +40 ym
-40 +30 ym
~30 +20 ym
-20 +10 ym
-10 + 5 ym
-5+0 ym
Median diameter, ym
Mean diameter, Dp, ym
4.1
1759
4.3
0.1
4.0
0.8
0.02
10.4
6.1
0.7
1.3
4.2
1760
4.3
0.1
4.1
1.3
0.05
12.2
6.8
0.7
1.2
% within stated size
range
0
0
1
5
13
30
27
25
10
8
0
0
0
5
11
31
31
23
9
8
Analyses are given as weight percent, on an 'as received' basis.
% carbon does not include carbon present as carbon dioxide.
Size gradings refer to Coulter count of the material passing a 75 ym sieve.
D as defined in Table A.2.3.8.
A2.126
-------
Table A.2.3.74 Analysis of Exhaust Dust
Test Series 4
Test
Sample Ref
Carbon %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Size grading
-75 +60 ym
-60 +50 ym
-50 +40 ym
-40 +30 ym
-30 +20 ym
-20 +10 ym
-10 + 5 ym
- 5 + 0 ym
Median diameter ym
Mean diameter. D , ym
P
4.1
1763
2.9
5.9
0.6
1.40
12.2
15.0
0.6
1.1
4.2
1764
2.9
6.3
0.5
1.08
5.3
6.5
1.4
1.3
% within stated size
range
5
1
2
7
14
31
32
6
14
9
4
2
I
2
28
19
34
9
13
8
Analyses are given as weight percent on an
'as received' basis.
Carbon does not include carbon present as
carbon dioxide.
Size gradings refer to Coulter count of the
material passing a 75 ym sieve.
D as defined in Table A.2.3.8.
P
A2.127
-------
Table A.2.3.75 Analysis of bed material
Test Series 4
Test No.
Sample Ref
Sample time
rains
Chemical analysis
Carbon %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Size grading
-1588 + 794 ym
- 794 + 500 ym
- 500 + 251 ym
- 251 + 152 ym
- 152 + 75 ym
-75+0 ym
Median diameter, ym
Mean diameter, Dp, ym
Before
1773
0
0.1
1.0
0.4
0.01
2.8
1.9
0.8
2.3
Start of
4.1
1774
965
to
1510
0.1
6.4
5.6
0.02
20.6
13.8
0.5
1.0
4.1
1775
1510
to
2800
<0.1
8.0
6.6
0.02
24.0
16.1
0.5
0.8
End of
4.1
1776
2800
0.1
9.4
7.2
0.03
28.0
18.0
0.4
0.4
Start of
4.2
1777
4125
0.1
9.0
9.9
0.04
31.1
18.9
0.6
0.4
4.2
1778
4125
to
5882
0.1
8.7
10.1
0.04
31.0
20.6
0.4
0.6
After
4.2
1779
6000
0.1
8.8
10.5
0.05
32.0
20.4
0.4
0.4
% within stated size range
16
26
42
13
2
1
458
360
37
24
28
10
1
1
625
450
44
24
23
7
1
1
720
500
55
25
17
2
0
0
858
660
54
24
15
5
2
2
846
490
53
27
17
3
0
0
828
640
51
30
15
1
1
3
811
430
Analyses are given as weight percent, on an "as received" basis.
% Carbon does not include carbon present as carbon dioxide.
D as defined in Table A.2.3.8.
A2.128
-------
iaoie A./.J./O oas composition measurements
Test Series 4
Test No.
Elapsed time
Test Series
Operating
conditions
Gas composition
% by volume
(dry gas)
Gas composition
p. p.m. by volume
(dry gas)
Start, h
End, h
Ca/S
mol ratio
co2
CO
°2
so2
NO
X
Cl
Na20
K20
4.1
21.4
46.9
1.54
14.4
.02
5.8
130
140
40
1.5
0.4
4.2
68.8
100
2.02
14.7
.02
5.3
50
190
40
1.5
0.5
A2.129
-------
Table A.2.3.77 Variation in gas composition
Test Series 4
Oxygen in combustion products
Test No.
4.1
4.2
% of test time in stated range
<1%
<1
0
1 - 2%
2
2
2-4%
7
12
4-6%
52
62
>6%
38
14
Mean
Oxygen
5.8
5.3
Carbon monoxide in combustion products
Test No.
4.1
4.2
% of test time in stated range
0 to
0.01%
36
14
0.01 to
0.02%
60
60
>0.02%
4
26
Mean
CO
%
.02
.02
A2.13 0
-------
Table A.2.3.78 Variation of temperature in bed and freeboard
Test Series 4
Height above
distributor
Bed
li in to 5 in
Bed
13 in to 16 in
Bed
36 in
Freeboard
77 in
Freeboard
107 in
Test
No.
4.1
4.2
4.1
4.2
4.1
4.2
4.1
4.2
4.1
4.2
% of test time in stated temperature ranges
<1400°F
1
0
i
0
0
0
-
29
9
22
1400° to
1436°F
18
10
10
7
0
0
-
29
30
34
1436°F to
1472°F
53
59
47
39
23
7
-
36
43
41
1472° to
1508°F
25
29
36
50
59
64
-
7
18
3
>1508°F
3
2
6
4
18
29
-
0
0
0
Mean
temp . °F
1455
1470
1465
1475
1475
1500
1415
1425
1440
1420
A2.131
-------
Table A.2.3.79 Measurements of SO? in Exhaust Gases
Test Series 4
Time from start
Min
129
206
292
375
421
543
565
663
814
868
1003
1057
1115
1246
1346
1626
1743
1861
1910
2060
2235
2386
2502
2571
2801
2911
S02
p. p.m. (v/v)
187
190
154
107
143
70
114
113
157
188
138
155
169
116
129
111
145
105
102
127
132
122
119
147
146
188
Time from start
Min
3020
3104
3213
3297
3419
3486
3547
3641
3731
3787
3863
4084
4171
4330
4468
4571
4702
4819
4917
5055
5242
5278
5527
5627
5765
5861
5954
S02
p. p.m. (v/v)
165
129
86
99
81
67
63
72
80
80
71
49
58
32
54
43
31
69
62
52
64
59
39
25
44
34
65
Note:
No measurements of SO- were made in this test.
A2.132
-------
rercencage tcecencion ot Sulphur, Alkalis and Chlorine
Test Series 4
Test No.
Stoichiometric ratio
Total Ca/S mol ratio
Percent Retention
Sulphur
Sodium
Potassium
Chlorine
Percent Reduction
Sulphur Emission
4.1
1.54
1.70
94.1
98.3
98.8
15.4
93.8
4.2
2.02
2.18
97.5
98.5
98.3
22.8
97.6
% Retention of sulphur, sodium and potassium
= 100 (Total input-output in gas)/Total input
% Retention of Chlorine
= 100 (Total Output-Output in Gas)/Total output
7, Reduction of Sulphur Emission
= 100 (Emission without acceptor - emission observed)/(Emission without
acceptor)
Emission without acceptor assumed to be 2032 p.p.m. v/v in dry gas
Stoichiometric ratio assumed = (Total Ca/S mole ratio - 0.16)
A2.133
-------
Table A.2.3.81 Comparison of measurements of S02 by infra-red and chemical method
Test Series 4
Sample No.
57
56
55
53
52
51
50
49
48
47
46
45
44
43
42
40
37
34
33
32
31
28
Chemical method
SO 2 p. p.m.
65
34
44
39
59
64
52
62
69
31
43
54
32
54
49
80
63
99
86
129
165
147
Av. from I.R.
S0£ p. p.m.
60
70
70
35
60
65
50
50
50
25
40
45
30
45
45
70
30
100
75
135
160
120
Max/min from I.R.
SOo p. p.m.
35/80
55/85
55/90
(I.R. suspect)
25/55
20/115
35/110
30/95
,30/75
30/105
15/30
30/65
30/85
25/45
35/80
25/75
35/140
20/50
50/175
40/100
90/170
55/230
80/165
Notes; (i) Chemical method was based on approx. 10 minute sample periods
(ii) The infra red sample was sampled continuously from a Tee in
the sample line. The figures quoted above are taken from the
recorder chart over the same period as the "chemical"
samples.
A2.134
-------
i>t;cenuj.nai:ions or AiKans and Chlorine in Flue Gas
Test Series 4
Time from
start, h
42.22
86.63
Concentration,
yg/1 dry gas
Cl
67
69
Na£0
4.3
4.3
K20
1.6
2.2
Concentration,
p. p.m. by volume, dry gas
Cl
43
44
Na20
1.5
1.5
K20
0.4
0.5
A2.135
-------
A.2.3.82 Concentration of NO in combustion gases
Test Series 4
Time from start
min
655-668
689-706
707-724
724-751
848-878
2095-2105
2105-2110
2290-2296
2297-2306
2357-2369
2413-2415
3455-3465
3465-3475
3477-3490
3494-3513
3520-3536
4939-4947
4950-4959
4964-4970
4974-4986
NO concentration
xp.p.m. (v/v)
128
129
127
117
117
136
130
132
156
155
149
195
194
190
194
200
187
185
226
174
Method
Modified Saltgman
Saltzman
ii
ii
it
ii
Modified Saltzman
Hersch
Saltzman
Hersch
ii
Saltzman
it
ii
Hersch
ii
Saltzman
n
Modified Saltzman
Saltzman
A2.136
-------
Table A.2.3.84 Mass Balances for Test 4.1
Test Series 4
Flow Rates in Ib/h
.Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
447
104
4871
362
19
5803
-
23
64
2
1
5713
5803
Sulphur
12.10
0.02
-
-
—
12.12
1.99
1.85
3.48
0.07
0.04
0.72
8.16
Ash
51.0
54.4
-
-
—
105,4
-6.1
17.0
47.0
1.6
0.6
—
60 oO
Calcium
2.43
23.08
-
-
—
25.51
3.35
3.97
10.14
0.14
0.06
—
17.66
Carbon
318.7
13.6
0.6
0.0
—
332,9
0.4
0.4
4.3
0.1
0.0
310.7
315.9
Magnesium
1.31
13.07
-
-
—
14.38
1.63
2.25
5.68
0.07
0.07
-
9.69
Hydrogen
21.74
0.00
0.98
-
•"
22.72
-
-
-
—
—
22,72
22.72
Sodium
0.445
0.309
-
-
—
0.754
-0.053
0.086
0.431
0.010
0.003
0.013
0.489
Nitrogen
6
-
3732
278
19
4035
-
-
-
—
-
4038
4038
Potassium
-0.050
0.519
-
-
—
0.469
-0.324
0.154
0.482
0.020
0.007
0.005
0.344
Oxygen
37
36
1137
84
"•
1294
4
4
9
0
0
1340
1358
Chlorine
0.441
-
-
-
—
0.441
0.007
0.005
0.026
0.000
0.010 f
0.271 ,
0.319
J
Test was in two parts separated by 1,67 hours of operation at a reduced rating.
Bed compositions interpolated from smoothed plots versus time.
Hydrogen contents of primary and secondary cyclone solids assumed to be due to
moisture absorbed after weighing, and the analyses have been corrected to the
dry basis.
A2.137
-------
Table A.2.3.85 Mass Balances for Test 4.2
Test Series 4
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
441
130
4874
382
18
5845
-2
41
103
2
1
5700
5845
Sulphur
11.39
0.03
-
-
—
11.42
-0.32
3.55
4.24
0.09
0.05
0.28
7.90
Ash
48.5
67.8
-
-
~
116.3
-1.1
27.7
75.2
1.9
0.7
—
104.3
Calcium
2.38
28.78
-
-
—
31.15
-0.03
9.03
19.02
0.19
0.03
—
28.24
Carbon
309.7
16.9
0.6
0.0
"~
327.3
0.1
1.2
7.4
0.1
0.0
316.1
324.9
Magnesium
1.66
16.29
-
-
-
17.96
0.29
5.06
11.36
0.09
0.03
—
16.85
Hydrogen
21.32
0.00
0.92
-
~
22 = 24
-
-
-
-
-
22.24
22.24
Sodium
0.453
0.385
-
-
-
0.839
-0.088
0.121
0.230
0.012
0.009
0.013
0.297
Nitrogen
6
-
3735
293
18
4053
-
-
-
-
4037
4037
Potassium
-0.230
0.647
-
-
-
0.417
-0.006
0.203
0.344
0.022
0.009
0.007
0.579
Oxygen
44
45
1137
89
™
1314
-0
8
16
0
0
1323
1347
Chlorine
0.400
-
-
-
-
0.400
0.005
0.016
0.052
0.001
0.009
0.277
0.360
Bed compositions interpolated from.smoothed plots versus time.
Hydrogen contents of primary and secondary cyclone solids assumed to be due to
moisture absorbed after weighing, and thr analyses have been corrected to the
dry basis.
A2.138
-------
Table A,2.3.86 Heat Balances, million Btu/h
Test Series 4
Test No.
Heat Inputs
In coal-dolomite mixture, total
In air and nitrogen, total
Heat of sulphation of CaCO,
Total Heat Input
Heat Outputs
Weir solids, total
Elutriated solids, sensible
potential
Cyclone and weir blowdowns, total
Exhaust flue gas, sensible
potential
latent
To water cooling, in bed
in freeboard
shell cooling
To shell pressurising air
Estimated radiation losses
Heat of calcination of MgCO.,
Total Heat Output
Unaccounted (Input-Output)
Unaccounted, % of Input
4,1
5.74
0.05
0.05
5.84
0.01
0.02
0.04
0.05
2.04
0.00
0.21
2.79
0,21
0.07
0.02
0.01
0.02
5.49
+0.35
+6.0
4.2
5.68
0.05
0.05
5.78
0,01
0.04
0.06
0.05
2.02
0.00
0.21
2.84
0.24
0.08
0.03
0.01
• 0.03
5.62
+0.16
+2.8
Total heats are the sums of sensible heat and of potential and/or latent heats.
Sensible heats refer to 32 F datum; the sensible heat of coal-acceptor mixture
approx. 0.002 million Btu/h.
Potential heat of coal-acceptor mixture equals that of the coal fed.
Latent heat of water vapour in input gas approx. 0.02 million Btu/h.
Total heat of weir solids includes that due to gain in weight of bed.
Reaction heats calculated assuming the following reaction equations:
CaC03 + S02
+ CO,, + 77.1 kcal/mole
MgC03 = MgO + C02 - 24.2 kcal/mole
A2.139
-------
Table A.2.3.87 Weight Losses of Corrosion Specimens - yg/cm h
Test Series 4
Tube
No.
1
2
3
4
5
6
Location of
Ring
Alloy
Weight Loss
Temperature ( F)
Alloy
Weight Loss
Temperature ( F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature ( F)
a
N
36
W
12
W
8
E
***
W
5
N
35
b
**
1450
**
1290
**
1040
**
970
**
750
**
1490
c
R
***
N
12
Fl
256
Fl
1066
Fl
24
R
26
d
S
7
W
10
F2
289
F2
***
F2
31
S
72
e
N
47
E
99
W
10
W
10
R
6
N
9
f
R
25
N
***
R
9
N
***
W
3
R
47
g
E
47
S
37
N
11
R
12
N
3
E
***
h
R
14
R
16
S
24
S
14
S
3
S
***
i
N
11
E
86
E
***
W
8
R
***
N
26
J
R
13
N
32
W
10
R
21
W
***
R
18
k
S
17
W
15
N
15
N
11
R
5
S
65
1
N
40
S
45
E
32
W
10
E
8
N
11
m
R
23
N
26
R
8
E
30
N
3
R
45
n
E
144
R
30
Fl
***
Fl
1518
R
5
S
82
o
**
1450
**
1400
**
1180
**
1000
**
1020
**
1490
P
S
18
W
9
F2
***
F2
***
W
5
E
114
q
N
***
E
72
N
7
R
24
E
7
N
13
r
R
14
N
22
S
42
S
21
N
3
R
25
s
E
85
R
18
E
50
N
13
S
7
S
87
t
N
• 38
S
***
R
11
R
14
W
7
N
39
to
** Specimen used for measuring metal temperature
*** Specimen not descaled, retained for further
examination.
FI Ferritic IZCr J%Mo steel S Austenitic Type 316
F2 Ferritic 2{ZCr steel R Austenitic Type 347
W Ferritic 12ZCr steel E Austenitic Type Esshete 1250
N Nimonic FE 16
-------
Table A.2.3.88 Summary of weight losses of corrosion specimens
Test Series 4
Material
Av. loss
1T Max/Min
1Z Cr No. of
Specimens
Av. loss
2*Z Cr Max/Min
2t* Cr No. of
Specimens
Av. loss
12Z Cr Max/Mi^
12Z Cr No. of
Specimens
Av. loss
c ,.,, Max/Min
SF316 No. of
Specimens
Av. loss
Max/Min
RF36 No. of
Specimens
_ . Av. loss
Esshete «„,/«•
1250 Max/Mm
1230 No. of
Specimens
Av. loss
0_ ., Max/Min
rJS lo .. -
No. of
Specimens
Tube 6
1490°F 1490°F
: :
: :
-
78 72
87/65
3 1
30 35
45/18 47/26
3 2
114
1
22 22
39/11 35/9
4 2
Tube 1
1450°F 1450°F
-
: :
-
18 7
18/17
2 1
17 20
23/13 25/14
3 2
110 47
144/85
2 1
39 41
40/38 47/36
2 2
Tube 2
1400°F 1290°F
-
.: :
12 11
15/9 412/10
2 2
45 37
1 1
24 16
30/18
2 1
79 99
86/79
2 1
27 12
32/22
3 1
Tube 3
1180°F 1040 °F
: :
: :
10 9
10/8
1 2
42 24
1 1
10 9
11/8
2 1
41
50/32
2
11 11
15/7
2 1
Tube 4
1000°F 970°F
1513 1066
1 1
-
9 10
10/8
2 1
21 14
1 1
17 12
21/14
3 1
-
12
13/11
2
Tube 5
1020°F 750°F
24
1
31
1
7 4
8/5 5/3
3 2
7 3
1 1
5 6
5/5
2 1
7
1
3 3
3/3
2 1
Notes:- (1)
(2)
Under each Tube heading are given the measured
metal temperatures at the outlet and inlet of
each tube respectively.
The "av. loss" and "max/min" are the weight
losses in
-------
Table A.2.3.89 Metallographic examination of corrosion specimens
Test Series 4
Temp.
°C
800
1000
1110
1290
1470
Material
Fl
F2
W
S
R
E
N
Fl
F2
W
S
R
E
N
Fl
F2
W
S
R
E
N
W
S
R
E
N
S
R
E
N
Surface
Texture
rough
rough
smooth
smooth
smooth
smooth
smooth
very rough
very rough
smooth
smooth
smooth
smooth
smooth
very rough
very rough
smooth
smooth
smooth
smooth
smooth
smooth
smooth
smooth
rough
smooth
smooth
smooth
rough
smooth
Deposit/
Scale
_
-
-
-
-
-
—
heavy scale
heavy scale
-
-
-
-
—
loose grain
loose grain
-
_
-
-
—
-
-
-
scale
—
—
-
-
—
Penetration ym
Pits
0
0
0
. 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Sulphur
0
0
0
0
0
0
0
0
0
0
5
9
5
0
0
0
0
5
0
5 .
0
0
8
14
10
1
30
15
15
5
A2.142
-------
Test Series 5
Coal
Pittsburgh
Coal size (upper limit) 1587 ym
Acceptor size (upper limit) 1587 ym
Coal rate
550 Ib/h
Fluidising velocity 2,0 ft/s
Bed temperature
Combustor pressure
Bed height
1465 °F
4.9 atm abs
3.75 ft
Test No.
Elapsed time
from start of ;
test series ;
Acceptor
Start, h
End, h
Stoichiometric
ratio
5.1
16.2
39.2
Limestone
18
1.87
5c2
4801
64.1
Limestone
18
2,38
5.3
78
86.2
Dolomite
1337
1.08
A2.143
-------
Table A.2.3.91 Analysis of spot sample (coal + acceptor)
Test Series 5
Sample
Ref
1780/1-2
1780/3-4
1780/5-6
1780/7-8
1780/9-10
1781/11-12
1781/13-14
1781/15-16
1781/17-18
1781/19-20
1781/21-22
1782/23-24
1782/25-26
1782/27-28
1782/29-30
1782/31-32
1782/33-34
1782/35-36
1782/37-38
1782/39-40
1782/41-42
1782/45'
1782/46
1782/47
1782/48
1782/49
1782/50
Sample
time
min
113-236
360-477
594-716
834-961
1073-1190
1310-1434
1554-1677
1794-1914
2035-2152
2269-2392
2512-2633
2750-2875
3054-3173
3282-3396
3473-3593
3660-3834
3955-4074
4194-4314
4433-4554
4673-4793
4913-5031
5395
5515
5636
5776
5882
6000
Moisture
%
1.1
1.1
0.8
1.0
0.9
1.1
1.0
1.3
1.2
1.2
1.5
0.9
1.0
0.7
0.9
0.9
0.9
1.1
1.1
1.0
1.0
1.1
1.1
1.0
1.0
1.0
1.0
"Ash"
.%
22.8
20.6
22.4
23.1
6.8
21.1
19.8
20.0
21.7
22.5
22.7
26.3
25.3
21.6
24.3
23.4
20.6
20.0
22.2
21.1
18.2
14.7
15.1
14.6
15.4
14.8
16.8
co2
%
6.4
5.7
6.2
21.4
5.8
5.9
5.3
5.3
5.9
6.5
7.4
8.3
8.3
7.3
7.5
7.1
7.5
7.6
8.2
8.4
6.4
4.4
4.7
4.2
4.9
4.4
5.7
Size grading: % in stated size grade
+ 794
-1588 ym
10
11
12
13
11
12
15
14
11
13
17
13
13
16
13
15
16
18
19
19
17
21
23
18
17
14
18
+500
-794 ym
12
14
14
16
14
15
16
15
16
14
17
15
14
17 .
14
16
17
19
20
18
19
17
19
16
17
16
18
+251
-500 ym
14
15
15
17
14
15
15
14
17
15
18
17
15
17
14
16
16
17
19
23
22
21
26
22
23
23
23
+152
-251 ym
27
23
28
25
28
28
24
26
26
28
22
27
26
24
29
23
28
25
23
14
12
14
6
14
13
16
13
+ 75
-152 ym
16
14
15
13
16
15
14
15
14
14
11
14
14
12
14
13
12
11
11
11
11
11
14
12
17
14
16
-75 ym
22
25
17
15
17
16
16
17
16
16
15
14
16
15
16
18
12
10
9
16
19
16
13
19
13
19
12
Median
diameter
ym
220
240
260
300
250
130
290
260
280
270
330
280
270
320
130
280
320
360
380
340
340
350
390
300
320
270
330
to
Analyses are given in weight percent on an "as received" basis.
-------
Test Series 5
Test No.
Sample ref0
Proximate analysis
Moisture %
Volatile matter %
'Ash' %
Carbon dioxide %
Ash %
Carbon %
Hydrogen %
Nitrogen %
Sulphur %
Oxygen + errors %
Chlorine %
Ash analysis
sio2 %
A1203 %
Fe2°3 %
CaO %
MgO %
Na20 %
K20 %
Ti02 %
Mn304 %
P2°5 %
S03 %
Ash fusion (in air)
Initial deformation F
Hemisphere °F
Flow °F
5.1
1783
1.0
45.0
21.9
5,9
21.9
63.0
4,0
1.3
2.2
7.2
0.07
31.6
12.4
806
35 o 7
1.6
1.0
0.8
0.6
0.1
0.4
7.2
2170
2230
2280
5.2
1784
1.1
53.6
24.6
7.6
24.6
59,4
3.7
1.2
2.2
8,6
0.07
32.1
10.3
7.0
39o7
1.8
0.9
0.9
0.5
0.1
0.4
6.3
2230
2260
2300
5,3
1785
1.1
49.5
20.1
7.7
20.1
63.1
4.0
1.0
2.3
9.1
0.08
34.2
10.9
7.7
24.8
15.6
0.8
0.8
0.5
0.1
0.4
14.3
2410
2430
2480
Analyses are.given on a weight per cent basis,,
Total moisture and carbon dioxide are given on an 'as received' basis
Volatile matter is given on a d.a.f. basis, and -
Ultimate analysis is given on a dry basis.
A2.145
-------
Table A.2.3.93 Analysis of Shale^ Limestone and Dolomite
Test Series 5
Material
Sample Ref
Total moisture %
Si02 %
Fe2°3 %
CaO 7,
MgO I
Na20 %
K20 %
Sulphur %
Carbon %
Carbon dioxide %
Total %
Loss on ignition in
air at 800°C %
Size grading
-1588 +794 ym
- 794 +500 ym
- 500 +251 ym
- 251 +152 ym
- 152 + 75 ym
- 75 + 0 ym
Median diameter, ym
Mean diameter, D , ym
Shale*
1807
-
52o6
23.7
5.0
0.9
1.5
0.7
2.3
-
0.7
-
87.4
-
% withi
31
30
25
8
2
4
610
330
Limestone
1828
0.1
11.9
0.4
0.5
46.0
0.9
0.4
0.1
0
-
36.8
97.1
35.0
n stated si
16
15
21
18
10
20
270
120
Dolomite
1719
< 0.05
1.1
Nil
0.1
31.0
20.8
0.4
0.6
< 0.05
-
47.7
46.4
ze range
28
17
14
8
13
20
400
130
Analyses are given as weight per cent on an 'as received'
basis.
D as defined in Table A.2,,3.8,,
P
* Used for start-up.
A2.146
-------
Table A.203o94 Analysis of .primary cyclone fines: collected
by dry sampling system
Test Series 5
Test No,
Sample ref.
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 I
K20 Z
Size grading
-1588 +794 ym
-794 +500 ym
-500 +251 pm
-251 +152 ym
-152 + 75 pm
- 75 + 0 ym
Median diameter ym
Mean diameter, D , ym
P
5.1
1786
3,8
Ool
4,3
8.2
0.02
23.8
0.9
0.6
1,0
% with
6
9
14
14
12
45
100
70
5.2
1787
1.5
0.1
4.9
11.5
0.02
28,5
1.3
0.6
0.7
in stated
range
4
7
13
12
21
43
90
70
5.3
1788
3.1
0.1
5.8
8.4
0.02
22.8
9.0
0.5
0.7
size
5
8
13
11
9
54
50
60
Analyses are given as weight per cent on an 'as
received' basis.
% carbon does not include carbon present as carbon
dioxide.
D as defined in Table A,2.3f8.
P
A2.147
-------
Table A.2.3.95 Analysis of secondary cyclone fines
Test Series 5
Test No.
Sample ref
Carbon %
Hydrogen 7,
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na 0 %
K20 %
Size grading
-40 +30 ym
-30 +20 ym
-20 +10 ym
-10 + 5 ym
- 5 + 0 ym
Median diameter, ym
Mean diameter, D , ym
5,1
1793
2.2
0.1
4.6
0.6
0.02
11.1
1.2
0.7
1.6
5.2
1794
1.3
0.1
5.3
1.0
0.02
13.5
1.3
1.0
1.6
5.3
1795
2.1
0.05
3.5
0.4
0.02
8.6
4.1
0.9
1.6
% within stated size
range
3
5
17
60
15
7
6
3
2
14
64
17
6
5
2
5
16
62
15
7
6
Analyses are given as weight per cent, on an 'as
received1 basis.
% carbon does not include carbon present as carbon
dioxide.
D as defined in Table A.2.3.8.
P
A2.148
-------
Table A.2.3.96 Analysis of exhaust dust
Test Series 5
Test No.
Sample ref
Carbon %
Hydrogen %
Sulphur %
Carbon dioxide %
Chlorine %
Size grading
-50 +40 U m
-40 +30 u m
-30 +20ru m
-20 +10um
-10 + 5 bm
-5 + 0 4|»m
Median diameter, ^m
Mean diameter, D , ym
5cl
1800
2o8
0.2
6.1
0.3
0.19
5.2
1801
2,3
0,4
7 = 6
0,2
0027
5.3
1802 *
-
-
-.
-
-
% within stated size
1
0
11
16
47
15
8
6
range
3
6
15
22
40
14
9
7
0
2
11
12
54
21
6
5
Analyses are given as weight per cent, on an 'as
received1 basis.
Insufficient sample available for determination of
CaO.MgO, Na20 and.K20.
% carbon does not include carbon present as carbon
dioxide.
* Insufficient sample for chemical analysis.
Size gradings were obtained by a Coulter Count on
material passing a 75 micron sieve.
D as defined in Table A. 2. 3. 8.
P
A2.149
-------
Table A.2.3.97 Analysis of bulked samples of bed material
Test Series 5
Period
Time, min
Sample Ref
Carbon %
Sulphur %
Carbon dioxide %
Chlorine %
CaO %
MgO %
Na20 %
K20 %
Sulphite sulphur %
Sulphide sulphur %
Sulphate sulphur %
Size grading
-1588 +794 ym
- 794 +500 ym
- 500 +251 ym
- 251 +152 ym
- 152 + 75 ym
- 75.. + 0 ym
Median diameter, ym
Mean diameter, D , ym
Start
of Test
5.1
942
1820
0.1
2.9
9.0
0.02
19.6
1.6
0.5
2.0
-
-
-
Test
5.1
1203
to
2229
1821
0
4.3
11.9
0.02
25.9
1.8
0.4
1.3
<0.01
0.1
4.2
End of
Test
5.1
2229
1822
0.1
5.0
12.8
0.02
29.0
1.4
0.4
1.1
-
-
-
Start
of Test
5.2
2921
1823
0,1
5,1
15.7
0.02
32.1
1.7
0,4
0.7
-
-
-
Test
5.2
2921
to
3789
1824
0.1
5,5
15.6
0.02
33.2
2.7
0.3
0.6
<0.01
0.05
5.45
End of
Test
5.2
3789
1825
0.6
5.5
16.2
0.02
35.6
1.8
0.3
0.6
-
-
-
Start
of Test
5.3
4716
1826
0.4
8.0
11.6
0.04
32.2
9.5
0.4
0.4
-
-
-
End of
Test
5.3
5042
1827
0.2
8.4
10.6
0.02
32.7
9.9
0.5
0.4
<0.01
0.1
8.3
% within stated size range
29
25
28
14
2
2
550
360
28
28
31
12
1
0
560
430
35
23
29
12
1
0
580
450
29
25
33
• 12
1
-
540
430
29
23
31
16
1
0
520
410
33
26
30
10
1
0
600
460
37
26
27
10
0
0
640
490
42
30
23
5
0
-
720
570
Analyses are given as weight percent on an 'as received' basis.
% carbon does not include carbon present as carbon dioxide.
Dp as defined in Table 3.8.
A 2 150
-------
Table A.2.3.98 Analysis of bed material (other than bulked samples)
Test Series 5
Sample time, min
Sample ref
CaO
MgO
Sulphur
Size grading
-794 +500 ym
-500 +251 ym
-251 +152 ym
-152 + 0 ym
Median diameter ym
Mean diameter D ym
P
694
1808
15.5
1.5
5.9
2424
1809
29.9
1.0
13.3
~ 2556
1810
30.2
1.4
13.2
2689
1811
31.6
1.1
13.4
2802
1812
32.2
1.4
13.8
3980
1813
34.6
2.3
14.7
4174
1814
34.1
4.0
16.3
4400
1815
32.4
5.6
16.8
4551
1816
31.7
6.7
17.9
4653
1817
32.0
8.0
19.0
5866
1818
31.0
12.4
24.2
6000
1819
30.0
13.7
25.8
% within stated size range
26
27
12
3
590
450
27
31
11
1
570
500
24
31
14
1
550
490
26
32
12
1
550
490
23
30
15
1
540
480
35
32
11
1
550
470
24
31
13
0
570
510
27
29
8
0
630
590
25
27
9
0
660
600
29
26
6
0
680
650
28
24
6
0
710
690
30
23
3
0
740
780
CO
I—'
en
Analyses are given as weight percent on an 'as received* basis.
D ao defined in Table A.2.3.8.
P
-------
Table A.2.3.99 Gas composition measurements
Test Series 5
Test No.
Elapsed time
^ _ *_ _ _. *- f^f
Test Series
Operating
conditions
Gas composition
% by volume
(dry gas)
Gas composition
p. p.m. by volume
(dry gas)
Start, h
End, h
Ca/S
mol ratio
Variable
parameters
co_
2
CO
°2
so2
NOX
Cl
Na20
K20
5.1
16.2
39.2
1.87
Limestone
18
15.0
0.015
3.6
690
90
30
2.1
1.0
5.2
48.1
64.1
2.38
Limestone
18
14.6
0.01
3.8
470
90
50
3.7
1.3
5.3
78
86.2
1.08
Dolomite
1337
14.2
0.015
5.3
310
140
50
0.9
0.3
A2.152
-------
Test Series 5
Oxygen in combustion products:
Test No.
5.1
5.2
5.3
% of test in stated range
< 1%
1
0
0
1-2%
2
5
0
2-4%
58
53
10
4-6%
25
39
73
> 6%
4
3
17
Mean Oxygen
%
3.6
3.8
5.3
Carbon monoxide in combustion products:
Test
No. '
5.1
5.2
5.3
% of test in stated range
0 to
0.01%
31
65
37
OcOl to
0,02%
62
32
27
>0.02%
7
3
36
Mean CO
%
.015
.01
.015
A2.153
-------
lapie
Variation of temperature in bed and freeboard
Test Series 5
Height above
distributor
Bed
li in to 5 in
13 in to 16 in
Bed
36 in
Freeboard
77 in
Freeboard
107 in
Test
No.
5.1
5.2
5.3
5.1
5.2
5.3
5.1
5.2
5.3
5.1
5.2
5.3
5.1
5.2
5.3
% of time in stated temperature range
<1400°F
2
1
0
1
1
0
1
0
0
1
0
2
12
0
22
1400 to
U36°F
12
8
12
8
5
6
2
1
0
8
0
32
47
33
49
1436 to
1472°F
55
66
62
52
62
52
18
18
8
11
1
52
31
44
29
1472 to
1508°F
30
25
26
37
31
50
62
74
74
42
34
14
9
22
0
>1508°F
1
0
0
2
1
2
17
7
18
38
65
0
1
1
0
Mean
temperature
°F
1460
1460
1460
1465
1465
1470
1485
1485
1495
1490
1515
1450
1430
1450
1420
A2.154
-------
Table A.2.3.102 Measurement of S02 in exhaust gases (Cont'd)
Test Series 5
Time from
start, min
4190-4210
4210-4240
4240-4270
4270-4300
4300-4330
4330-4360
4360-4390
4420-4450
4450-4480
4480-4510
4540-4570
4570-4600
4600-4630
4630-4660
4660-4690
4690-4720
4720-4750
4750-4780
4780-4870
4870-4840
4840-4870
4870-4900
4900-4930
4930-4960
4960-4990
4990-5020
5020-5050
so2
p. p.m. (v/v)
430
410
390
420
480
440
430
380
400
375
360
370
380
400
290
310
320
290
310
310
330
330
310
320
310
310
310
Time from
start, min
5080-5110
5110-5140
5140-5170
5170-5200
5200-5230
5230-5260
5260-5290
5290-5320
5320-5350
5380-5410
5410-5440
5440-5470
5470-5500
5500-5530
5530-5560
5560-5590
5590-5620
5620-5650
5650-5680
5680-5710
5710-5740
5740-5770
5770-5800
5800-5830
5860-5890
5890-5920
5950-5980
so2
p. p.m. (v/v)
310
300
310
320
350
370
360
360
370
330
350
360
390
380
390
400
400
420
440
410
500
440
470
470
480
530
470
Note; The SO- values quoted are the averaged values
from the Hartmann-Braun infra red analyser
output for the time intervals stated.
A2.155
-------
laoie
Measurement or S00 in exhaust gases
Test Series 5
Time from
start ,min
320-350
350-380
380-410
410-440
440-470
470-500
500-530
530-560
560-590
590-620
620-650
650-680
680-710
710-740
740-770
770-800
800-830
980-950
950-980
980-1010
1010-1040
1040-1070
1070-1100
1100-1130
1130-1160
1160-1190
1190-1220
1220-1250
1250-1280
1280-1310
1310-1340
1340-1370
1370-1400
1400-1430
1430-1460
1460-1490
1490-1520
1820-1850
1850-1880
1910-1940
194'0-1970
1970-2000
2000-2030
2030-2060
2060-2090
2090-2120
2180-2210
2210-2240
2240-2270
2270-2300
2300-2330
2360-2390
so2
p. p.m. (v/v)
650
700
700
700
650
600
600
670
600
650
600
625
660
620
620
600
580
520
700
640
690
700
710
730
750
790
770
760
680
640
610
490
600
570
610
630
620
700
650
750
730
750
720
700
720
710
680
710
760
720
800
570
Time from
start ,min
2420-2450
2450-2480
2480-2510
2510-2540
2540-2570
2570-2600
2600-2630
2630-2660
2660-2690
2690-2720
2720-2750
2750-2780
2780-2810
2810-2840
2960-2990
2990-3020
3020-3050
3050-3080
3080-3110
3110-3140
3140-3170
3170-3200
3200-3230
3230-3260
3260-3290
3290-3320
3320-3350
3350-3380
3380-3410
3410-3440
3440-3470
3470-3500
3500-3530
3530-3560
3560-3590
3590-3620
3620-3650
3650-3680
3710-3740
3740-3770
3770-3800
3800-3830
3830-3860
3920-3950
3950-3980
3980-4010
4010-4040
4040-4070
4070-4100
4100-4130
4130-4160
4160-4190
S02
p. p.m. (v/v)
590
560
500
510
490
490
500
480
550
600
570
600
560
560
490
440
440
440
420
440
480
530
640
530
470
490
460
490
420
440
470
520
520
460
450
390
450
460
430
440
460
460
470
510 .
530
510
520
500
500
410
420
410
A2.156
-------
Table A.2,,3.103 Comparison of measurements of SO by
infra-red and chemical method
Test Series 5
Sample No.
5
6
7
8
9
10
11
15
16
17
18
19
21
22
23
24
25
26
27
28
29
30
31
33
34
35
36
37
38
39
40
Chemical Method
SO- p^poffl.
600
600
695
690
710
600
595
600
645
670
470
440
710
385
410
410
465
470
430
430
380
335
365
260
330
320
340
380
354
385
400
Av. from IR
SO- p.p.m
650
580
730
680
780
620
570
720
780
740
530
500
610
450
500
470
420
515
495
460
430
405
405
280
315
335
370
455
440
460
465
Max/min on IR
chart
S02 p0p,m
555/770
480/815
420/920
600/760
675/910
420/780
550/590
620/850
540/845
610/825
440/665
395/740
450/900
350/550
470/535
425/530
305/590
435/650
440/520
310/600
363/545
340/470
370/480
205/330
215/450
260/535
330/410
405/510
330/510
375/540
450/495
A2.157
-------
Table A.2,3.104 Percentage retention of sulphur, alkalis
and chlorine
Test Series 5
Test No.
Stoichiometric ratio
Total Ca/S mole ratio
Per cent retention
Sulphur
Sodium
Potassium
Chlorine
Per cent reduction
Sulphur emission
5:i
1.87
2.03
67.2
98.1
98.3
12.5
66.1
5.2
2.38
2.54
78.9
96.8
98.3
12.6
76.8
5.3
1.08
1.24
84,7
98.8
99.4
20.7
84.6
% Retention of sulphur, sodium and potassium
= 100 (total input-output in gas)/total input
% Retention of chlorine
= 100 (total output-output in gas)/total output
% Reduction of sulphur emission
= 100 (emission without acceptor - emission observed)/
(emission without acceptor)
Emission without acceptor assumed to be 2032 p.p.m. v/v in
dry gas
Stoichiometric ratio assumed = (total Ca/S mole ratio - 0.16)
For Test 5.3, % retention of chlorine calculated as for %
retention of sulphur and alkalis
A2.158
-------
Table A.2.3.105 Concentration of NO j.n combustion gases
^^™~"— — - ™»™«*^ _.-!-_ _-.^^M> -j - J£ I l — WBMI I •! I _ .^-^—vM.M—wMn
Test Series 5
c
f Time from start
« min
, 1530
i 1555
3010
3020
4470-4490
4490-4510
5860-5880
j 5880-5900
j NO concentration
[ xp.p.m. (v/v)
i 88
89
85
94
130
137
101
96
:
Method i
1
Modified Saltzman
ii
Saltzman
ii
ii
it
ii
ti
l
A2.159
-------
Table A.2.30106 Determinations of alkalis and chlorine in
flue gas
Test Series 5
Time from
start, h
30.13
35.74
61.20
83.42
88.85
100.00
Concentration,
pg/1 dry gas
Cl
19
82
72
78
83
—
Na2°
3.1
8.4
10.2
2.8
2.3
2o5
K20
1.4
6.7
5.4
0.9
1.4
1.7
Concentration,
p. p.m. by volume, dry gas
Cl
12
52
45
49
53
—
Na20
1.1
3.0
3.7
1.0
0.8
0.9
' K2°
0.3
1.6
1.3
0.2
0.3
0.4
A2.160
-------
Table A.2.3.107 Mass Balances for Test 5.1
Test Series 5
Flow Rates in Ib/h
Inputs
Coal
Limestone
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Outputs
Inputs
Coal
Limestone
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total output
Total
467
80
4813
431
19
5811
9
20
100
2
1
5679
5811
Sulphur
12.03
-
-
-
12.03
2.03
0.86
4.33
0.07
0.08
3,94
Ash
60.8
50.3
-
-
111.2
0.2
15.5
76.8
1.3
1.1
-
95.0
Calcium
4.34
26.22
-
-
30.56
6.79
3.71
17.11
0.12
0.11
—
11.31 | 27.84
!
Carbon
333.3
8.0
0.6
0.1
342.0
1.0
0.6
6.0
0.0
0.0
320.6
328.3
Magnesium
0.723
0.433
-
-
1.156
-0.150
0.218
0.546
0.011
0.010
—
0.635
Hydrogen
22.48
0.01
1.04
-
23.53
-
-
23.53
23.53
Sodium
0.652
0.237
-
-
0.889
-0.025
0.059
0.448
0.008
0.007
0.017
0.515
Nitrogen
7
-
3688
331
19
4045
-
-
4083
4083
Potassium
0.729
0.066
-
Oxygen
31
21
1124
100
1277
6
3
12
0
0
1247
1269
Chlorine
0.383
-
-
i
i
0.796 ; 0.383
-0.440
0.216
0.835
0.021
0.018
0.014
0.002
0.004
0.020
0.000
0.003
0.202
0.664 - 0,230 ,
Bed compositions interpolated from smoothed plots versus time.
Flow rate of primary cyclone solids assessed by dry sampling method.
Hydrogen contents of primary and secondary cyclone solids assumed to be due to
moisture absorbed after weighing, and the analyses have been corrected to the
dry basiso
Alkali and Alkali earth contents of exhaust dust assumed to be equal to those
of secondary cyclone solids.
A2.161
-------
Table A.2.3.108_ Mass Balances for Test 5.2
Test Series 5
Flow rates in Ib/h
Inputs
Coal
Limestone
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Limestone
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by Bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
477
113
4895
435
19
5939
61
98
2
4
5775
5940
Sulphur
12.98
-
-
-
12o98
0.23
3,33
4.84
0.09
0.28
2,74
11.50
Ash
64.4
71.6
-
-
136oO
-1.7
42.7
72.9
1.4
2.7
—
118,0
Calcium
3.90
37 = 28
-
:
41,18
2.62
14,37
20.10
0.16
0.35
—
37»60
Carbon
334.4
11,4
0.6
0.1
346,5
0.7
2.7
4.5
0.0
0.1
317,9
325.9
Magnesium
0,960
0.616
-
:
1.576
0.207
0.986
0.774
0.013
0.029
—
2.009
Hydrogen
22.54
0.01
1.30
. -
23,85
-
-
23.85
23.85
Sodium
0.633
0.337
-
-
0.970
-0.085
0.135
0.439
0.013
0.027
0.031
0.560
Nitrogen
7
-
3749
334
19
4109
-
-
4171
4171
Potassium
0.99
0.09
-
^
1,08
-0.10
0.30
0.57
0.02
0.05
0.02
0.86
Oxygen
35
30
1144
101
1310
1
12
15
0
0
1260
1288
Chlorine
0.413
-
-
^
0.413
0.012
0.020
0.000
0.010
0.293
0.335
Bed compositions interpolated from smoothed plots versus time.
Flow rate of primary cyclone solids assessed by dry sampling method.
Hydrogen contents of primary and secondary cyclone solids assumed to be due to
moisture absorbed after weighing, and the analyses have been corrected to the
dry basis.
Alkali and alkali earth contents of exhaust dust assumed to be equal to those
of seconadry cyclone solids.
A2.162
-------
Table A.2.3.109 Mass Balances for Test 5.3
Test Series 5
Flow Rates in Ib/h
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Inputs
Coal
Dolomite
Main Air
Conveying Air
Dipleg Nitrogen
Total Input
Outputs
Gained by bed
Weir Solids
Primary Cyclone
Secondary Cyclone
Exhaust Dust
Flue Gas
Total Output
Total
451
81
5029
453
19
6033
2
18
82
1
1
5929
6033
Sulphur
12.22
0.02
-
-
—
12.24
1.90
1.43
4.80
0.05
0.03
1.87
10.08
,
Ash
49.49
42.16
-
-
—
91.64
0.01
11.90
60.48
1.31
0.70
-
74.41
Calcium
1.07
17.88
-
-
—
18.95
0.98
4.05
13.48
0.09
0.05
—
18.66
Carbon
321.5
10.5
0.6
0.1
—
332.7
-1.1
0.6
4.5
0.0
0.0
319.5
323.6
Magnesium
-0.06
10.13
-
-
—
10.06
2.47
1.02
4.49
0.04
0.02
—
8.05
Hydrogen
21.93
0.00
1.23
-
— •
23.16
-
-
-
-
-
23.16
23.16
Sodium
0.395
0.240
M
0.635
0.263
0.052
0.307
0.010
0.005
0.008
0.645
Nitrogen
1
5
-
3852
j 348
19
4224
-
-
-
-
-
4231
4231
Potassium
0.308
0.402
-
-
—
0.710
0.007
0.058
0.481
0.020
0.011
0.004
0.580
Oxygen
40
28
1175
105
—
1349
1
4
12
0
0
1353
1370
Chlorine
0.426
-
-
-
—
0.426
-0.045
0.005
0.017
0.000 |
0.000
0.337
0.314 '
Bed compositions interpolated from smoothed plots versus time.
Hydrogen contents of Primary and Secondary cyclone solids assumed to be due to
Moisture absorbed after weighing, and the analyses have been corrected to the
dry basis.
Composition of Exhaust Dust assumed to be equal to that of the Secondary
Cyclone solids.
A2.163
-------
Table A.2.3.110 Heat Balances, million Btu/h
Test Series 5
Test No.
Heat Inputs
In coal-acceptor mixture, total
In air and nitrogen, total
Heat of sulphation of CaCO^
Total Heat Input
Heat Outputs
Weir solids, total
Elutriated solids, sensible
potential
Cyclone and weir blowdowns, total
Exhaust flue gas, sensible
potential
latent
To water cooling, in bed
in freeboard
shell cooling
To shell pressurising air
Estimated radiation losses
Heat of calcination of MgCOo
Total Heat Output
Unaccounted, (Input-Output)
Unaccounted, % of Input
5.1
5.92
0.05
0.04
6.01
0.01
0.04
0.06
0.05
2.05
0.00
0.22
3.25
0.23
0.09
0.02
0.01
0.00
6.03
-0.02
-0.3
-
5.2
5.99
0.06
0.04
6.09
0.03
0.04
0.02
0.05
2.10
0.00
5.3
5.75
0.06
0.04
5.85
0.01
0.03
0.04
0.05
2.12
0.00
0.23 | 0.22
3.26 | 3.01
0.20
0.09
0.02
0.26
0.09
0.02
0.01 0.01
0.00 0.02
6.05 5.88
+0.04 -0.03
+0.7 -0.5
Total heats are the sums of sensible heat and of potential and/or latent heats.
Sensible heats refer to 32°F datum; the sensible heat of coal-acceptor mixture
approx. 0.002 million Btu/h.
Potential heat of coal-acceptor mixture equals that of the coal fed.
Latent heat of water vapour in input gas approx. 0.02 million Btu/h.
Total heat of weir solids includes that due to gain in weight of bed.
Reaction heats calculated assuming the following reaction equations:
CaC0
77.1 kcal/mole
MgC03 • MgO + C02 - 24.2 kcal/mole
A2.164
-------
Table A. 2.3.111 Weight Losses of Corrosion Specimens - yig/anh
Test Series 5
Tube
No.
1
2
3
4
5
6
Location of
Ring
Alloy
Weight Loss
Temperature ( F)
Alloy
Weight Loss
Temperature ( F)
Alloy
Weight Loss
Temperature ( F)
Alloy
Weight Loss
Temperature (°F)
Alloy
Weight Loss
Temperature ( F)
Alloy
Weight Loss
Temperature ( F)
a
N
56
W
3
F2
8
E
***
F2
24
N
24
b
**
1450
**
1040
**
750
**
880
**
660
**
1450
c
R
***
N
4
Fl
19
Fl
82
Fl
44
R
31
d
S
42
W
5
F2
21
F2
86
F2
56
S
19
e
N
92
E
14
F2
13
Fl
117
Fl
65
N
52
f
R
118
N
7
F2
18
N
***
F2
71
R
46
g
E
74
S
8
F2
17
F2
89
Fl
83
E
***
h
S
46
R
20
F2
16
Fl
119
F2
72
S
***
i
N
70
S
4
Fl
28
F2
115
R
***
N
12
J
R
35
N
12
F2
19
Fl
189
W
***
R
23
k
S
21
W
3
F2
23
F2
140
Fl
84
S
11
1
N
33
S
3
F2
32
Fl
165
F2
133
N
14
m
R
49
N
8
F2
20
F2
134
Fl
96
R
30
n
E
54
R
12
Fl
***
Fl
130
F2
76
S
13
o
**
1450
**
1200
**
840
**
950
**
880
**
1450
P
S
10
W
4
F2
***
F2
187
Fl
77
E
49
q
N
***
E
76
F2
17
Fl
250
F2
84
N
73
r
R
24
N
24
F2
29
F2
243
Fl
93
R
408
a
S
10
R
13
F2
20
Fl
277
F2
79
S
60
t
N
16
S
***
F2
39
F2
211
Fl
71
N
50
** Specimen used for measuring metal temperature
*** Specimen not descaled, retained for further
examination
F. Ferritic IZCr $Mo steel
F, Ferritic 2|%Cr steel
\T Ferritic 12%Cr steel
S Austenitic Type 316
R Austenitic Type 347
E Austenitic Type Esshete 1250
N Nimonic PE 16
-------
Table A.2.3.112 Summary of weight losses of corrosion specimens
Test Series 5
Material
Av. loss
1% Cr I*****?
No. of
Specimens
Av. loss
,,. _ Max/Min
Z*Z Cr No. of
Specimens
Av. loss
12Z Cr M^/M111
12* Cr No. of
Specimens
Av. loss
_ .-, Max/Min
SF316 No. of
Specimens
Av. loss
Max/Min
**** No. of
Specimens
Av. loss
Essbete Max/Min
1250 No. of
Specimens
Av . loss
, Max/Min
PE 16 No. of
Specimens
Tube 1
1450°F 1450°F
-
-
44 14
46/42 21/10
2 3
118 36
49/24
1 3
74 54
1 1
74 40
92/56 70/16
2 3
Tube 6
1450°F 1450°?
-
-
-
19 12
13/11
1 2
38 26
46/31 30/23
2 2
49
1
38 37
52/24 50/12
2 4
Tube 2
1200°F 1040°F
-
•
4 4
4/3 5/3
2 2
4 8
4/3
2 1
13 20
13/12
2 1
76 14
1 1
14 6
24/8 7/4
3 2
Tube 4
950°F 880°F
200 106
277/130 119/82
5 3
170 88
242/115 89/86
6 2
-
-
: ;
: \
^ ^
Tube 3
840°F 750°F
28 18
1 I
25 15
39/17 21/8
8 6
-
; .:
-
: i
mm —
Tube 5
880°F 660°F
84 64
93/71 82/64
5 3
93 55
133/76 72/24
4 4
-
; :
-
-
-
OS
O5
Notes:- (1) Under each.Tube heading are given the measured metal
temperatures at the outlet and inlet of each tube
respectively.
(2) The "av. loss" and "max/min" are the weight losses
in iig/cm*h.
-------
Table A.2»3.113- Me_tallograp_hic examination .of corrosion specimens
Test Series 5
Tempo
F
800
930
1110
1470
Material
Fl
F2
Fl
F2
S
R
N
S
R
N
Surface
Texture
smooth
smooth
smooth
smooth
smooth
smooth
smooth
rough
rough
rough
Deposit/
Scale
0
0
0
0
0
0
0
0
0
0
Penetration, ym
Pits
0
0
0
0
0
0
0
0
0
0
Sulphur
0
0
0
0
v. slight
0
0
v0 slight
0
v. slight
Table A.2.3.114 Comparison of dust from walls of cascade holder with
airborne dust passing over cascade
Test Series 2
% CaO
% MgO
% Na 0
% K.O
Dust deposited
on walls
11.2
5.6
008
1.5
Exhaust
dust
7,7 - 10.5
4.5 - 7.6
0.7 - 1.0
1,6 - 1.9
A2.167
-------
(THIS PAGE INTENTIONALLY BLANK)
A2.168
-------
Disposal
stack
Pressure
Primary
cyclone
dary
cyclone
Hydroclone
Cooling
water
Soft-blast
NOX» dust and
alkali samples
Combustor
Startjap only_ ™ "
Start-up only
Cooling
water
disposal
Dirty
water
disposal
Collection
collection
Fig.A2.2.1. TaskH. Flow diagram of Pressurized Fluid-bed Combustor
-------
Notes on diagram of 48 in x 24 in pressurised combustor
1. Water supply to water-cooled circuits
2. First-stage dust-collecting cyclone
3. Internal recirculation cyclone
4. Balance air supply
5. Gas burners for start-up
6. Bed removal pipe
7. Pressure shell
8. Cooled liner
9. Combustor casing
10. Second-stage dust-collecting cyclone
11o Air supplies to air preheating tubes and corrosion assemblies
12. Cascade housing
13. Sampling point for alkali content of gases
v
14. Mixing baffle
15. Sampling point for NO gases
X
16o Spray nozzles
17. Deposition probe (Not used in the APCO programme).
18. Dust sampling and 0_, CO^, CO, probe
19. Exhaust to pressure let-down valve
20. Dip-leg from recirculation cyclone
A2.170
-------
DCTAJL SHOWINO CASCADC OP TURBINE
•LADES FOR STUDYING EROSION,
CORROSION AND DEPOSITION
Coal
Fig.A2,22Taskn. 48x24 pressurised fluid-bed combustion rig
A2.171
-------
o o o o o
oooooooo
oooooooo
O O O O O O DM
OC6O A A O O O!|O
DimiD O O O O O'J O
O O O O O O O !! O
O OC3 O O O O D
o o nri "in o o o o
A AOC1OOOO O
O O OIII-ID A A O O
O O D O O O O
O O O ijO O O A A
O O Oil O O O O O
O O O !| O O O O O
A A rKD A A O O
o o o o o o DirrriDC2
Distributor jjlate
Ut
O Water-cooled circuit or dummy tube
•0 Corrosion probes C1 to C6
A Air-preheating tube
• Coal nozzle
Fig.A2.2.3.Task n. Arrangement of tubes in the bed
A2.172
-------
Fig.A2.2.4. Task!. Key to dimensions of cyclones
(see Table A2.2.1)
A2.173
-------
Blade cascade
Fig.A2.2.5.
Arrangement of blade cascade
and target rods
A2.174
-------
1 in o.d. nom.
Ul
^
v
i
2ft
3?(
Cooling air
N
\
sm
$
shell ^^
^f^^*•
i,\jt .
refractory
lining — —
\
^
5
Vj-j'.vo/
VvV-'V.*-"*
• * '-~:',.",* •'.
' * f - *r* . r ^
\
Plain 1in o.d.
* Dummy specim
temperature t
••{
Decimens
.*'•'*.•* • • '
»"• " * ****.*'*•
• *•," • *•.%""-•
*".••""% "* ' *."'*x
-
s^
s///////
/
Tierod
p
fturn tube
is carrying 2 metal
rmocouples each
&v£-
•V-^::-j.'-:-
/ ~» ' '•'. »\: •;
"• '-« .*»'""."..'
:••'< "">,!;•.
^
\
^
^S
Compression
spring
Hot air to
plenum chamber
Fig.A2.2.6.Task H. Corrosion tube assembly
-------
Dolomite
Raw coal
Dolomite
coarse fines
reject reject
Key
t
__ _ _.
1
H
72mesh
-®-
-^-
Gyratory
screen
Wt
material, b
1000
Analysis
in Table
opposite
fines coarse
reject reject
To coal feeder
Fig.A2.2.7.Task n. Coal and dolomite preparation
* A2.176
-------
Analysis of Coal and Dolomite for Test Series 2
Sample reference in
Fig. A. 2. 2. 7
Composition, %
Moisture
Volatile Matter
Fixed Carbon
Ash
Sulphur
Size Grading
(% less than stated size)
|" (6350 Mm)
i" (3175 urn)
7 BS mesh (2411 Mm)
1/16" (1588 pm)
16 BS mesh (1003 Mm)
1/32" (794 Mm)
30 BS mesh (500 ym)
60 BS mesh (251 Mm)
100 BS mesh (152 Mm)
200 BS mesh (75 Mm) '
A
2.8
-
-
-
-
95
73
63
51
39
-
25
16
11
7
B
1.4
34.7
48.1
15.8
2.8
91
46
25
0
C
1.6
35.4
51.3
11.7
2.9
100
77
-
49
31
21
13
D
2.9
34.2
49.1
13.8
3.3
-
-
-
— '
-
-
99.9
84
44
E
1.2
33.7
46.0
19.1
2.6
99.9
89
-
19
_
-
F
1.4
36.9
48.4
13.3
3.2
-
-
-
-
-
-
-
-
89
56
F
100
-
25
7
4
3
2
A2.177
-------
From main silos
Vent
From main silos
8
w
*•
W
Combustor
To dump tanks
/ i i
&"~i £•"•»
i
•**
I—
;
I
C
•Spare
Spare
0—J
K From feed
vessel
Gas to
cone
Conveying
gas
Fig.A2.2.8.TaskH. Coal feeding system
A2.178
-------
x Coal from storage vessel /
\
10ft
Inside diameter 6ft
Coal outlet
Vent
Air inlets
Fiq.A2.2.9. Task I. Arrangement of Petrocarb coal feed vessel
^ - fi •- rrn
-------
3*
(tin
did
»
5%in.
•™ ™ —
^ayym
^ztfm.
_ — _ —
c
— __.
—— — -- H
* >
U
. 2" C
1
i >
4 n 4 ir\r
72in B.S.R barrel nipple
Boron carbide nozzle
'/sin dia
Station No 3 r
Station 0 at start of
parallel section
Station 1at 2-5mm from 0
„ 2,, 5-Omm „ 0
n 3 „ 7-5mm ., 0
/. 4,,10-Omm „ 0
Section through nozzle
o
C.
o
o3
T3
§
4)
en
a
o Datum zero hours service
x Datum 100 hours service
10.000 20.000 30.000 40.000
Dust through nozzle: Ib
Fig.A2.2.10.Task n. Wear rate of boron carbide nozzle
in primarv cyclone blowdown
-------
CO
•g \f\l\J
u c
JoSsOO
a o£ 6OO
^_ ^J
if) ^p
CM «) ^J
o 'E
c E 200
•o
O
-
-
°2 O
01-6
"tL . .
x. stoJchiomet
o o o -»-•-•
* a> cb 6 to *
80-2
£ O
-
<—
I
1-1
0-15
M65>
O
C
*5atm
1-99
Appr
•ox
(
f o
0 0
0 « ®_
00 0 0 o
0 00
1
1OOO
Test 1-2
Ca/S mo I ratio: O-92
1455*F
3-5 atm
Ruidislng vetocity=1«2ftA
. stoichiometric ratio in
O
o
I °
1
1000
1 '
® -J.{J
o° e e
-•bV ^
i i
2OOO 3OC
Coal :m
Operat
Test 1-3
O-88
1445*F
3-5atm
1-9lft/s
coal-dolomite feed to c
O
Q O O
e 0 0
i i
Q
>0
inutes
ing cond
ombustor
0 <
O Q
1 II '
SO2 content of exhaust gases from combustor
0 00 0<
1
4OOO
tions
Test 1-4
1-06
144O'F
3-5atm
1-92 tt/s
, estimated from C
o
i o o
O
c
1
-
°OOO ° Oo 00 00(
5OOO 6O
Test 1-5
1-07
1445'F .
3-5atm
1-9lft/s
i
O2 and ash contents of feed
o
e o o
o o
0 (
~
,
>
00
>
2OOO 3OOO 4OOO 5OOO 6OOO
Coal: minutes
Fig A2.3.1. Task I. Test Series 1. Ca/S ratio and retention of SO, versus time
-------
00
to
1OOO
c
o
o
"E
•»
0)
N
JMOO
o
o
Q.
I T T
i J I
0-1
1-O
"As received
•9
"As fired"(i.e. after screening out * /is
material)
I I I I I I
J I
1O
5O 9O 95
% undersize by weight
99 99-9
Fig.A2.3.2. Task E. Size distribution of dolomite used in Test Series
-------
25
D)
.E20
• •
a
o
•o 15
L-
Before Test Series 2
After Test Series 2
0 0-2 0-4 0-6 0-8 1-0 1-2 1-4
Velocity:ft/s
Fluidised in a 12in did vessel using cold air at
atmospheric pressure
Bed height (static) c.18in
Expansion c.12%>
Rg.A2.33.TaskH.Fluidising characteristics of
bed material before and after Test Series 2
A2.183
-------
00
OVAJ
SCO
cUdO
Q.
8300
200
1OO
O
o 4-O
5 2-8
£2-4
02-0
o 1-6
O 1-2
*j ' *•
-
-
-
™
l°'t
O
0 0
o
o
o
0 C
1 1
4OO 8OO
Test 2-1
Co/Smol ratiozl-6
1456° F
3-47atm
Fluidisinq ve).1-85ftfc
Approx. stoichlom
0 0 C
0
3
, ,
si
o
O O o
1 1 1
12OO 16OO 2OOO
Operatin
Test 2-2
Ca/S mol ratio = 2-O
1456°F
3 -49 atm
Fluidisinq velocity = 1-85ft/s
ric ratio in coal-dolomite feed t
O
O
O
o
i I i
p
o
ii II
SO; content of exhaust gases from combustor
°o
oo oo o ° o ° o o Q0
1 1 1 1 1
o
Oo
I
I
0 0
0 C
3
1
o
24OO 28OO 32OO 36OO 4OOO 44OO 48OO
Coal minutes
conditions
Test 2-3
Ca/S mol ratio = 2-1
1465°F
3-48 atm
Fluidising velocity = 1-95ft/s
Test 2-4
2-O
1458
4-93
1-9O
combustor, estimated from CO2 and 'ash* contents
O
0 °
o ° ° o
o
0 °
I 1 1 1
•>
O
Test 2-5
Ca/S = 1-7
1458°F
3-62 atm
1-85ft/s
of feed
>
!
o c
o
,
I
o
O 4OO 8OO 12OO 1GOO 20OO 24OO 28OO 32OO 36OO 4OOO 440O 48OO
Coal minutes
FigA2.3.4.Taskn. Test series 2. Ca/S ratio and retention of SOa versus time
-------
>
CO
00
en
800
-o 600
o 400
200
300
200
I 100
Total CaO Inventory
Inventory of Unconverted
CaO
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Time from start of test,min
FigA2.3.5.TaskII. Test Series 2. Variation of calcium content (total and unconverted) in bed
-------
500i
400
£300
Q.
a
£200
10
100
0 ' '
SO2 content
o
i i i
4 — Test 3.t — »
i i
u«- Test 3.2-*
i
of exhaust gases
from combustor
0 0 0 ° °
i |
—
—
OCQO COgQQ
1
400 800 1200 1600
Coal minutes
2000
2400
Test
Ca/S mol ratio
Bed temperature
Pressure
Fluidising velocity
3-1
1-8
1482°F
4-97atm
1-95ft/s
3-2
2-0
1474°F
4-91 atm
1-97ft/s
° 4-0
u
'tl
•S 3-2
| 2-4
y
§ 1-6
X
80-8
a
h-
i i i 1 i
Test 3.1 -+p- Test 3.2+-
il i
Approx. stoichiometric ratio in coal-dolomite feed to combustor,
- estimated from CO2 and 'ash' contents
o
o
o
o
o o °
-
~ 0
1 1 1
D
1
of feed
0
„
_
0
o
o
1
o
o0 :
o
—
-
1
0 400 800 1200 1600 2000 2400
Coal minutes
Fig.A23.6.Task n. Test series 3. Ca/S ratio and retention of
SO2 versus time
A2.186
-------
3000
•a
o
c
'o
•H
C
a
E 5
2 -52000
3
U
in
o ^1000
0)
c.
0)
Operating conditions:
pressure- 5atm abs.
velocity - 2ft/s
Bed temperature - 1470°F
j_
1000 2000 3000 4000 5000 600O
Time: minutes
©
€>
(2)
®
(5)
Test series
3
4
/i
5
//
ii
Acceptor
"Coarse" dolomite
"Fine" dolomite
ii
Li mestone
ii
"Fine" dolomite
Ca/S ratio
1-8-2-0
1-7
2-2
2-0
2-5
1-2
Fig.A2.3.7
Task n. Test Series 3,4,5; rate of removal of material from bed
A2.187
-------
*
tJ|4OO
lls
^£§300
0.0 £
o.*i u
SOS
(in combuj
determined by
o 8 §
Oo
o
O O
o o •
o
1000
fe
•
H- '
00
00
o
£3
3
1°
Appro*, stoichiometric re
0 o °
0 o o o
|
9 O00oo0oo°(
2000
Operating con
Test 4-1
Ca/Smol ratio =1-70
1465*F
4-9 atm
Ruidising velocity = 1-96 ft Is
itio in coal /dolomite feed to co
6
0 ° ° 0 °
o
o
SOg content of exhaust gases from combustor
°o
o
°°0oooOOo o
1 1
3OOO 4OOG
Coal minutes
KJ it ions
mbustor, estimated from O
0
o ° o o o
0
1 1
°o ° o0 °°10 <*> % o0
5OOO €
Test 4-2
Ca/S mo! ratio = 2-18
1465*F
4-9 atm
Fluidising velocity = l-95ft/s
D* and 'ash' contents of feed
o
° 0 ° '
. ° . • o • «
1000 20OO 3OOO 4OOO . 50OO 6<
Coal minutes
Fig.A2.3.8. Task n. Test Series 4. Ca/S
of SOt versus time
-------
0100 hours
- 2lOOhturs
10
L.
0
0100 hours
- 2(>00hours
O:
100
S02 '• ppm
200
Fig. A2.3.9. TaskH. Typical variation of SO2 and O2 in
exhaust gases during Test Series 4
A2.189
-------
Veoo
c
£ TOO
^
^-s C
> |6OO
> K
_ " 8 200
-
000 1
o
00 0 °
000
— oo o o o
0
o
O 8
0 ^ 00 °
0 0 0- -
J « ° °
o o
> o °
o
o
«
o
1
to i 0 XXX) 2OOO
CD
O
,O
•«-» ,
0
^
I
O
•c 2
o
x 1
£
1
O
0 °°
° o ** o o
°°°0
SO2 content of exhaust gases from combustor
0 °° 00
0 - 00
°0 O^JB 00°
0000 00 ^"» 0
O o °
1
3OOO
Coal minutes
Operating conditions
Test 5-1
Ca/S mol ratio = 2-03
1465*F
4-9atm
Ruidising velocity = 1-96 ft /s
Test 5-2
Ca/S mol ratlo= 2-54
M65T
4'9ulfi
Ruidising vel. = 1-99ftA
o o°_
0 °
o °o
°»> ° e g
°«eo0
<
1
40OO
.
•o°oo o°M»eu
». o
1
5OOO
Test 5-3
Ca/S = 1-24
147CTF
4-9atn
2-O4f
^
o
00 °
0 0
eo °
•**/*
>°
60
i
t/s
1
- Approx. stoichiometric ratio in coal/dolomite feed to combustor, estimated from COa and 'ash* c<
0 0 °
0
-
o o o
o o
i
o
o
0
o ° o
i
00°
1
intents ol
o
0
I
feed
t>
o o o o o
_
10OO
2000
30OO
Coal minutes
4OOO
5000
GO
Fig.A2.3.1O. Task n. Test Series 5. Ca/S ratio and retention of SOa versus time
-------
CO
I—1
CD
View looking towards leading
edge
View looking towards trailing edge
Before Test 2
After Test 2
After Test 3
Fig.A2.3.11.Task H. Test Series 2 and 3. Appearance of blade cascade before and after tests
-------
100
!. 90-
c
O
a
E
0)
80
.c
a
« 70
c
o
u
TJ
C?
60
50
'•
1 / 1 1 1
1-0 2-0
Ca/S mol ratio
3-0
Ruidising velocity : c 2ft/s
Bed depth : 3-75 ft
Bed temperature : c1470°F
Coal
Welbsck
Pi'ttsburg
Pittsburg
Pittsburg
Acceptor
Typ»
U.K.Oolomfte
Dolomite 1337
Dolomite1337
Limestone 18
Median size:
micron
750
1100
COO
270
Pressure : aim. abs.
31/!
O
A
5
A
X
m
Fig.A2.3.12.Task H. Reduction in sulphur emission
A2.192
-------
NATIONAL COAL BOARD
FINAL REPORT
JUNE 1970 - JUNE 1971
REDUCTION OF ATMOSPHERIC POLLUTION
APPENDIX 3. EXPERIMENTS WITH THE 27 IN COMBUSTOR. (TASK III)
PREPARED FOR
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR PROGRAMS
411 WEST CHAPEL HILL STREET
, DURHAM, NORTH CAROLINA 27701
FLUIDISED COMBUSTION
REFERENCE NO. DHB 060971 CONTROL GROUP
SEPTEMBER 1971 NATIONAL COAL BOARD
LONDON, ENGLAND
-------
REDUCTION OF ATMOSPHERIC POLLUTION
Research on reducing emission of sulphur oxides,
nitrogen oxides and particulates by using
fluidised bed combustion of coal
Appendix 3. Experiments with the 27 in combustor. (Task III)
Main objective
To carry out long-term tests to assess the
effect of limestone addition on corrosion
of evaporator, superheater and reheater
metals immersed in the fluid bed.
Report prepared by: D.M. Wilkins
Report approved by: A.D. Dainton and
H.R. Hoy
A3. iii
-------
Foreword
This Appendix describes experimental work carried out using
the 27 in combustor at BCURA between June 1970 and June 1971, as
Task III of the joint N.C.B./O.A.P. research programme. The
objective of Task III was to carry out long-term tests to assess
the effect of limestone addition on the corrosion of evaporator,
superheater and reheater metals. The contract programme provided
for only a narrow range of operating conditions, but it was
subsequently agreed that a rather wider range of operating
conditions should be explored- A summary of the work is
presented in the main report and the results are discussed there,
together with results from other pilot plants„
A3.v
-------
Table of Contents
Page No.
Foreword
!„ Description of the 27 in Combustor Plant . A3. 1
lol The Combustor A3. 1
1<,2 Coal and Acceptor preparation and feeding A3. 2
Io3 Instrumentation A3. 3
Io4 Corrosion Probes A3. 4
1»5 Data processing A3. 5
2o Operating Procesdures A3. 7
2.1 Start-up A3. 7
2.2 Establishment of Equilibrium A3. 7
2o3 Sampling Procedures A3. 8
2<,4 Shut-down Procedure A3. 9
2.5 Emergency Procedures A3. 9
3. Results A3. 9
3ol Test Series 1 A3. 9
3,1«1 Objectives of the Test Series 'A3. 9
3do2 Description of Test Series 1 . A3.10
3,lo3 Sulphur Emission A3.10
3.-lo4 Corrosion of Metal Specimens A3.10
3,2 Test Series 2 A3.11
3,2,1 Objectives of the Test Series A3.11
3o2o2 Description of Test Series 2 A3.11
3=2.3 Sulphur emission A3.12
3=2.4 Nitrogen oxide emission A3.13
3,2o5 Corrosion of Metal Specimens A3.14
3,2,6 Mass Balances A3.14
3»3 Test Series 3 A3.15
3.3,1 Objectives of the Test Series A3.15
3c3=2 Description of Test Series 3 A3.15
3o3 = 3 Sulphur emission A3.16
3o3»4 Nitrogen oxide emission A3.18
3o3o5 Corrosion of metal specimens A3.18
3o3c6 Mass Balances A3.18
AS.vii
-------
Table of Contents (Cont'd)
Page No,
3,4 Test Series 4 A3,18
3,4 ?! Objectives of the Test Series A3.18
3-4.-2 Description of Test Series 4 A3.18
3o4o3 Sulphur emission A3=19
3c-4,4 Nitrogen oxide emission A3.20
Acknowledgements A3»20
Tables A3.1 - A3o44
Figures A3d - A3»ll
(Note that when referring to Tables and Figures in the text
the prefix A3 is omitted),
A3. viii
-------
DESCRIPTION OF THE 27 in COMBUSTOR PLANT
lol
A flow diagram of the 27 in combustor plant is shown in Fig. 1.
and a section through the combustor in Fig» 2* The cylindrical
section containing the fluid-bed was 27 in diameter and the shaft
above this section diverged to 46 in diameter for the lower 2 ft
of the freeboard before returning to a cylindrical section 24 in
diameter o The height of the bed zone was 2 ft and the total height
of the freeboard was 11 fto The walls of the bed zone and freeboard
consisted of twenty water-cooled jackets , Combustion products
leaving the freeboard passed into a vertical water-cooled heat
exchanger before entering the external dust cleaning cyclone,,
The bed was supported on a bubble cap distributor plate, air
for combustion being supplied via a plenum chamber located directly
below the distributor plate * Crushed coal and acceptor were metered
into a hopper, transported pneumatically to the combustor and
injected into the fluid-bed via a horizontal 'Y1 feeder „ The two
1 in diameter arms of the "Yf formed injection points which were
radially equidistant from the axis of the combustor at a distance
apart of Or 3 ft approximately „
A 'mushroom' gasburner fitted in the centre of the distributor
plate supplied towns gas for start up= During normal operation it
was used to distribute externally recycled fines,
A low efficiency cyclone positioned in the freeboard recycled
+.50 micron particles to the bed via a dip-leg and lock-hopper system,
whilst a high efficiency cyclone external to the combustor removed
solids greater than 10 micron from the combustion products o A
controlled portion of the fines collected by the external cyclone
could be recycled pneumatically to the bed via the "mushroom"
burner and the remainder was discharged to collection drums o
Access ports for corrosion tube assemblies and other probes
were provided in the walls of the bed section«
The 2 in diameter corrosion tube assemblies were arranged at
5 in centres horizontally and 6$ in centres vertically: the dipleg
from the internal cyclone prevented the use of intermediate tubes
to form a triangular pattern,.
A3.1
-------
A section through a corrosion probe is shown in Figo 3. During
the present series of experiments the probes were cooled with either
steam or air.
1.2 Coal and Acceptor preparation.and feeding
Metered quantities of coal and acceptor were mixed before being
fed pneumatically to the combustor via a single injection nozzle.
The coal preparation system consisted of a storage hopper,
loaded with coal from the shipping cartons and fitted with a
variable speed rotary valve which discharged coal via an inclined
screw conveyor to a gyratory separator fitted with a 3175 micron
mesh screen. Oversize coal from the screen was fed to a hammer
mill, the crushed product being returned to the separator. Under-
size coal from the screen was transported by a bucket elevator and
a conveyor belt to an 8 ton prepared coal storage hopper (Figo !)„
Prepared coal was metered from the storage hopper by a pneumatically
operated weighing conveyor and discharged into a small transfer
hoppero
Acceptor material, sized according to the particular test
requirements, was dried on a steam-heated drying floor before use.
The dried acceptor was loaded into the feed hopper by a skip
capable of holding up to one hour's supply at the highest feed
rater. A 4 in diameter screw at the base of the feed hopper was
driven by a variable speed motor and metered the acceptor into
the stream of coal falling from the weighing conveyor into the
transfer hopper (Figo 1).
The coal-acceptor mixture was transferred by a constant speed
rotary valve fitted to the base of the transfer hopper into a li in
nob. pipe and conveyed pneumatically to the combustoro
Prior to test series in which coarse (-3175 micron) limestone
was to be used, a sufficient amount of limestone from the shipping
cartons was crushed in the same system as used during the tests to
prepare coal to -| in, and stock-piled until required° Fine
(-150 micron) limestone was prepared by an external contractor by
drying and crushing the raw granular limestone. Dolomite from the
shipping cartons was broken in a jaw crusher, screened on a
gyratory separator fitted with a -1587 micron mesh screen and the
undersize fraction stockpiled until required for testing.
A3o2
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103 Instrumentat ion
Combustion air and air supplies for coal and grit transport
were metered by orifice assemblies fitted-with differential pressure
transducers for remote flow indication
Static pressures in the plenum chamber below the distributor
plate, in the freeboard and at the combustor exit were indicated
on panel-type gauges., The differential pressure between the plenum
chamber and the freeboard was used to compute the weight of material
in the bedo
Bed temperatures were measured at 3, 9, 15 and 21 inches above
the distributor plate level and a suction thermocouple was used to
measure exit gas temperature.,
A small flow of gas was continually drawn from the top of the
combustor through a stainless steel gas sampling probe by a small
diaphragm pump, The gases were passed through a glass wool filter,
a water trap and three silica gel dryers in series, before being
supplied to a paramagnetic oxygen analyzer and infra-red CO^ and CO
analyzerso Cylinders of known composition were periodically used
to calibrate the analyzers„ Sample gas for the determination of SO.,
by the iodine and Hartman-Braun infra-red methods, and also for the
determination of NO by the Saltzman method was obtained from a
X
similar system which sampled gases from the 12 inch diameter duct
between cyclone exit and the I.-.D., fano
Estimates of the concentration of dust in the 12 in diameter
duct between the external cyclone and the IoD, fan were made by iso-
kinetic sampling of the gas stream through a probe of accurately known
bore and collecting the dust over a 10 minute period in the standard
BCURA high efficiency dust sampling cyclones.
The instrumentation included warning bells for low steam
pressure and low air pressure in the pneumatic transport and
corrosion probe cooling systems.
The weights of material removed from the bed and of fines
removed from the external cyclone were obtained by direct weighingc
A3»3
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104 - Corrosion Probes
The general assembly of the corrosion probes is illustrated in
Figo 3o The section of the probes exposed to the combustor bed
comprised 26 metal rings all lapped and spigotted together to form
a continuous tube,, These rings were machined from medium carbon,
ferritic and austenitic steel bars or tubes to the shape shown in
Fig. 4. Twenty three of the rings were test specimens for assessing
corrosion rates whilst the remaining three rings each held three
1/16 in Oodo chrome1-alumel thermocouples for measuring metal
temperatures, The arrangement of the thermocouples is shown in Fig. 4:
they entered the probe through glands in the inlet manifold, passed
along the annulus between the bore of the rings and the centre tube
and terminated in a tight push fit in drilled holes in the ring.
Access to these locating holes was provided by machining grooves in
the preceding specimen ringo In order to maintain the metal tempera-
tures at the required level, one thermocouple from each probe was
connected to a Honeywell proportional controller operating a motor-
ised valve in the steam (or air) supply to the probe. The remaining
eight thermocouples in each probe were used for record purposes.
In Test Series 1 and 2 (500 hours and 1000 hours), the corrosion
specimens were cooled with steam at approximately 30 psig, flow being
controlled by the Honeywell motorised valves.
The two lower probe assemblies were controlled at 750°F and
930°F, and the upper assemblies to 1110°F and 1230°Fo During Test
Series 1, waste steam from the probes was piped to an external
cooler and then to waste, whilst during the remaining tests the
steam was vented to atmosphere,,
In Test Series 3 only two corrosion probes were installed in
the bed, these being nominally at 750 F and 930 F. They were
cooled by compressed air as the steam in Test Series 1 and 2 was
found to corrode the inside of some of the less resistant steels.
Steam lines were still connected into the system however, so that in
an emergency the corrosion probes could be supplied with steam. Bed
cooling tubes were installed in place of the nominal 1110 F and 1290°F
corrosion probes and supplied with steam. The motorised valves were
operated by Honeywell proportioning controllers, to adjust the steam
-------
flow to match changes In the bed temperature, measured 9 in above the
distributor,,
»
In Test Series 4, corrosion probes were excluded altogether,
as it was agreed that 100 hours operation was too short a period
for obtaining reliable data on the corrosion of low alloy steels;
consequently only the two steam-cooled bed tubes were retained.
1.5 Data processing
(i) Weights and flow rates
Coal and Acceptor; The individual flow rates were obtained from the
operational settings and calibrations of the two feeders.
Air; Total air supplied for combustion was the sum of the air flow
through the distributor, plus the coal and grit recycle con-
veying air flowSo
Bed extract; The flow-rate of bed extract was the actual weight of
bed material removed during a control period divided by the
duration of the control period in hours»
Cyclone fines; The flow-rate of cyclone fines was the actual weight
of solids removed from the external cyclone during a control
period divided by the duration of the control period in hours.
Exhaust dust; The flow-rate of dust escaping from the external cyclone
was assessed by multiplying the flow-rate of dust collected by
the sample probe under isorrkinetic conditions, by the ratio of
cross-sectional area of duct to the cross-sectional area of the
probe»
Flue Gas; The flow-rate of dry flue gas was calculated knowing the
solids and air inputs to the plant, the gas composition of the
combustion products and assuming a nitrogen balance. The water
vapour content of the combustion products was calculated
assuming a hydrogen balancec
A3 o.5
-------
(ii) Operating parameters
The following parameters were calculated for each test:
„ • t i •• Feed air - Stoichiometric air for coal feed .nnv
Excess air level = —: „••• -, T.——r— •—z r~£—1 * 100%
Stoichiometric air for coal feed
Unburnt Carbon
Carbon in bed extract, cyclone fines and dust
Carbon input
x 100%
Ca/S mol ratio
mols of Ca in additive
moIs of S in coal
Sulphur retention = 1 - Su^uf in.flue fas x 100%
r Sulphur in coal
S02 reduction
(so2)d - (so2)a
(so2)d
x 100%
where (S0_) , is the emission in a datum test without additive
and (S09) is the emission with additive
Z, a.
(iii) Mass balances
Mass balances were carried out for the following materials in
a few typical tests.
Ash; Ash content of coal was determined by the normal analytical method.
Ash content of acceptor was assumed to be (100-%C09)%0 "Ash"
content of output solids was assumed to be(100-%SO„-% combustible)%.
Combustible; The combustible in bed extract and exhaust dust was
assumed to be carbon,. The combustible in cyclone fines was
assumed to be carbon and sulphur from the coalo The sulphur was
assumed present as sulphide and the sulphur/carbon ratio was
assumed to be half of that in the coalo
Hydrogen; No hydrogen or methane was detected in the combustion products,
hence the total hydrogen input was assumed to be converted to water
vapour,,
A3o6
-------
Nitrogen; For the purposes of the mass balances, nitrogen oxides
(NO ) in the combustion products were assumed present as
X
nitric oxide. The elemental nitrogen in the combustion
products was obtained by difference and thus includes anal-
ytical errors„
Oxygen; The oxygen content of the coal was obtained by difference and
therefore includes analytical errors. The oxygen contents of
bed extract, cyclone fines and exhaust dust were assumed to be
present in sulphate. Oxygen from carbon dioxide content of
input and output solids has not been included in the oxygen
balance.
Sulphur; Half of the sulphur in the coal was assumed present as
sulphate and the remainder as sulphide. Sulphur in bed extract
and exhaust dust was assumed to be present as sulphate. Sulphur
in cyclone fines other than that associated with the combustible
(see above) is assumed present as sulphateo
Calcium and Magnesium; These elements were determined in the input
and output solids as oxides. The oxygen combined with them was
not included in the oxygen balance,
2, OPERATING PROCEDURES
2.1 Start-up
The bed was preheated by burning a mixture of 70 Ib/h towns gas
and 130 Ib/h air at the gas burner, at the base of the bed whilst
fluidising the bed with combustion air. When the temperature of the
bed reached 650 F, 40 Ib/h coal was introduced into the bed via the
coal nozzle. This resulted in a rapid increase in bed temperature.
Coal feed and combustion air rates were progressively increased until
the required test conditions were attained. At a bed temperature of
1470 F, the towns gas supply was discontinued and recycle of grit
from the external cyclone commenced,
2,2 Establishment of Equilibrium
Test Series 1 was run at constant operating conditions throughout,
whereas Test Series 2 and 3 consisted of a number of shorter term tests,
A3,7
-------
conditions being changed approximately every 60 hours. The final
16 hours at each set condition comprised the actual test period
during which samples were taken and rates of removing bed material
and cyclone fines from the plant were measured accurately. Thus a
period of approximately 44 hours was. allowed-in, which equilibrium
could be established.
During these tests it was found that providing no change in the
composition of acceptor material was made, equilibrium values of S0?
were attained in 4 to 6 hours after changing operating conditions.
When acceptor composition was changed, a longer-period,-about 10 hours,
was needed.before the S0? concentration in the exit gases became
steady. In Test Series 4, which was run solely to extend the data
on effect of operating conditions on S02 emission, 9 short tests were
carried out. In general, a six hour, period was allowed for conditions
to attain equilibrium prior to a control test of 4 hours duration. The
exceptions were the 22 hour period between start-up and commencement of
the first test and the 10 hour settling period allowed between the end
of test 4.1 and start of test 4.2 because acceptor was changed from
limestone to dolomite.
2.3 Sampling Procedures
During each of the test series, coal was sampled from a point
between the main storage hopper and the coal weigher once every eight
hours, and the accumulated bulk sample obtained after each hundred hour
period was analysed. At the end of each test series a bulk sample
containing part of each of the 100 h samples was sent for a more
complete analysis.
During the control tests of Test Series 2, 3 and 4, bed extract
and cyclone fines were sampled as the appropriate dumping bins
required changing, a bulk sample of each material being accumulated
over the perrod of the control testo These products were then
analysed for size distribution, carbon, CaO, MgO and SO, content.
Dust carried over in the flue gases was sampled at a point in
the exit duct after it has passed through the external cyclone. Two
samples were taken during each control test and mixed to give one bulk
sample. The samples were then analysed for carbon, CaO, MgO, and SO.
content and size distribution by-Coulter counter.
A3.8
-------
A continuous sample or riue gases was drawn from the exit of the
combustor using a simple probe and diaphragm pump and analysed for CO-
and CO by infra-red analysers, A paramagnetic type analyser was used
to measure 02 concentration,, Spot samples were also taken during
control tests via a simple probe situated in the exit duct and
analysed by conventional chemical methods for SO„ and NO . The S09
£* X «
was determined by the standard iodine/thiosulphate titration and the
NO using Saltzman's reagent. In addition, gas from this probe was
X
fed continuously to an infra-red SO^ analyser.
2=4 Shut-down Procedure
The coal weigher, limestone feeder and the grit valve were
switched off simultaneously, leaving the coal valve, coal feed air
and grit feed air supplies open to clear the respective feed lines
completely. The coal valve was then shut-off. When the bed tempera-
ture fell below the controlling temperature of the steam-cooled
corrosion probes, the steam supply was shut off. As the bed tempera-
ture dropped to 400 F the cooling water supply to jackets and probes
was turned off to prevent condensation inside the combustor. When
the bed temperature dropped to below 212 F the I.D. and then the F.D.
fans were switched offo
2.5 Emergency Procedures
The normal supply pressure of the combustion air was 80 p.s.i.g.
A warning bell operated if the supply pressure fell below 75 p.s.i.g.;
this gave adequate time for a stand-by compressor to be started up.
For Test Series 2, compressed air was available to replace the
steam supply for cooling the corrosion probes in the event of failure
of the boiler. For.Test Series 3, in which the corrosion probes were
air-cooled, steam was available as the stand-by coolant in the everit of a
failure of the air compressor„
3. RESULTS
3.1 Test Series 1
3o1o1 Objectives of the Test Series
(i) To measure the corrosion rate of specimens of boiler
steels immersed in the fluid-bed for 500 hours without
addition of limestone.
A3»9
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(ii) To measure the rate of sulphur emission from the plant
when burning Pittburgh coalo
3«l.o2.. Dcrnfst Series 1
The first attempt to carry out .. this test series, designated
Test la, had to be abandoned when the steam supply to the corrosion
specimens failed after 147 hours of operation The 500 hour run
designated Test Ib was successfully carried out from 16th November
to 7th December, 1970 „
Operating conditions are given in Table 1 and analyses of coal,
bed extract, cyclone fines and exhaust dust samples collected during
test series Ib are given in Tables 2 to 6= Average gas composition
data for sequential 100 hour periods together with temperatures in
the bed at four heights above the distributor plate are given in
Table 7o An overall summary of the rates of bed extraction, cyclone
fines and dust in the stack gases is given in Table 80
3olo3 Sulphur Emission
Between two and four measurements of sulphur dioxide content of
the combustion products were made every third day of the test series
using the iodine absorption method „ In all, six determinations were
made during ii'est Aeries la and 23 determinations during _est Series Ib:
the 29 values are reported in Table. 9, The means and variances of the
two sets of measurements were not significantly different; based on a
952 level of probability the mean value of all the determinations was
20.53 - 36 ppm S0» v/vc The 952 confidence limits on a single deter-
mination were + 190 ppm S02° This l»v«l of sulphur dioxide emission
corresponds to a sulphur retention in the bed of 212 and is in accord
with the calcium in the ash having reacted completely with sulphur from
the coal,
3ol»4 Corrosion of Metai_Spej-imeng
There were four corrosion probes at nominal temperatures of
750°F, 930°F, 1110°F, 1290°F; all were cooled with steam from the
central heating boiler „ Some difficulty in controlling probe tempera-
tures was initially experienced due. to water condensing in the steam
lines. This was minimised by lagging the pipes „ Figure 5 shows the
close control over outlet temperature that was achieved after
'eliminating the condensation effects*
A3.10
-------
The specimens from test series Ib were examined visually for
deposits and corrosion or erosion damage» The majority of the test
specimens were then descaled by Immersion for five minutes in a bath
of molten sodium hydroxide containing 27, sodium hydride maintained at
680° to 715°F, The weights of the descaled specimens were then
subtracted from their weights before exposure in the fluid-bed
combustor during the test series. The resulting estimates of rate
of corrosion during test series Ib are given in Table 10, The low
chromium and mild steel specimens were found to have suffered some
internal corrosion, probably as a result of condensate being carried
forward into the probes and to the use of steam obtained from un-
treated water. The internal profiles of these specimens were
accurately identified using a Talysurf profilometer and the necessary
corrections were applied to the weight losses of the specimens before
computing the corrosion rates of these steels0
3o2 Test Series 2
3.2.1 Objectives of the Test Series
(i) the rate of corrosion of boiler steels in a fluid-bed
in the presence of limestoneo
(ii) the sulphur retention at different levels of Ca/S mol
ratio when burning Pittsburgh coal in the presence of
Limestone 18.
(iii) the effect of limestone particle size on sulphur
retention,
and (iv) the effect of bed height on sulphur retention (with
zero recycle of cyclone fines)„
3,2.2 Description of Test Series 2
Test Series 2 was run continuously for a 1000 hour period from
19th January to 2nd March 1971, Fluidising velocity, coal input rate
and bed temperature were maintained nominally constant throughout the
test series at 8 ft/s, 230 Ib/h and 1550 F, respectively. Eighteen tests
were carried out using two sizes of limestone over a range of feed rates
and with and without fines recycle,, Details of the operating conditions
in each test are given in Fig» 6 and Table lie
A3»ll
-------
The first three tests, 2ol, 2o2 and 2-3, were carried out with
coarse (-3175um) limestone with fines recycle from the external cyclone
in addition to internal recycle? The next five tests, 2o4 to 2o8 were
with fine(-150ym) limestone, again with, external fines recycle. The
following two tests, 2o9»l and 2.»9c2 were carried out to assess the
effect of bed height with fine limestone, but without external recycle.
It was necessary to compensate for the lower combustion efficiency
without recycle by increasing the coal feed rate slightlyo
After carrying out a datum test with fines recycle but without
additive (Test 2,10) a further series of tests was carried out with
coarse limestone and recycle, (Tests 2oil to 2»15)o Finally two
tests, 2°16.1 and 2.16o2, were carried out with coarse limestone but
without recycle for comparison with tests 2,9»1 and 209.2o
The 1000 hours operation was completed at 1400 hours on 2nd
March 1971,
The four corrosion probes immersed in the fluid bed were
cooled by steam to nominal metal temperatures of 750 , 930°, 1110°,
and 1290°F.
Chemical analyses and size gradings of coal, limestone, bed
extract, cyclone fines and exhaust dust for each of the tests
comprising Test Series 2 are given in Tables 12 to 16« A more
detailed coal analysis is given in Table 3 for the bulk sample
collected for the test series„
Average gas composition data, together with temperatures in the
fluid bed at four heights above the distributor plate are tabulated in
Table 17o Table 18 summarises the mass flow-rates of air, coal and
acceptor fed to the combustor and the flow-rates of bed material,
cyclone fines and exhaust dust removed from the planto
3o2o3 Sulphur emission
*
Two methods of assessing the sulphur dioxide content of the exit
gases were used during Test Series 2, viz, the Hartmann Braun infra-red
\
gas analyser and the chemical method used in Test Series !„ Good
agreement between the methods was obtained; the values used for
calculation purposes were obtained by the chemical methodo
-------
Mean sulphur dioxide concentrations in the exit gases are reported
in Table 19, together with salient operating details and sulphur
retention by the bed material. This data has been plotted in Fig. 7 to
show the effect of Ca/S mol ratio and limestone particle size on
sulphur retention and S0? reduction= The value .obtained from Test
Series 1, at zero limestone input, has been included in the plot. At a
bed temperature of about 1550 F and a fluidising velocity of 8 ft/s
coarse limestone (-3175 micron) was more effective in 'fixing1 sulphur
than the fine (-150 micron) limestone, Presumably the increase in
available surface offered by the fine limestone does not offset its
shorter residence time in the fluid-bed0 For both size grades,
utilisation of the calcium oxide from the limestone decreases with
increasing limestone addition,,
As shown in Table,19A, Test Series 2 affords:
(i) 4 replicate estimates of S0» reduction.
(ii) 2 comparisons of the effect of weight of solids in the
fluid-bed on S0_ reduction without external recycle.
(iii) 1 comparison of the effect of bed temperature on S0»
reduction when coarse limestone was added to the bed.
In this table, (19A), sulphur dioxide concentrations in the combustion
products, and hence S02 reduction, have been corrected to zero excess air
conditions,
It is concluded that when the coarse or fine grades of limestone
were added to the bed, increasing bed weight by about 30% did not result
in an increase in,the S0_ reduction„
, .- , 3r.2o4 Nitrogen oxide emission
The nitrogen oxides concentration in the combustion products was
determined by the Saltzman method (see Appendix 9). Individual results
are tabulated in Table 20 and mean values for some of the tests are
given in table 17c
Operating conditions in Tests 2o5 and 2.7 were essentially identical,
as were those in Tests 2=6 and 2=8= The mean NO concentrations in these
X
duplicate tests, in which fine limestone was added, were not significantly
A3,13
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different, suggesting that increasing the Ca/S mol ratio from 1018 to
3o55 has no effect on NO emission° These mean concentrations were
X
also not significantly different from the mean value for Test 2.1 in
which coarse limestone was added to the bed to give a Ca/S mol ratio
of 2.25o Pooling all these results leads to a mean value of 434 f 107 ppm
NO based on 7 degrees of freedom at the 5% level of significance, This
A
mean, however, differs significantly from the level of 297 ppm NO
obtained during the period between Tests 2° 3 and 2.4 when zero limestone
was added to the bed° The gas analyses for these sections indicate
that the combustion efficiency was substantially constant regardless
of the changes in operating conditions„
3o2»5 Corrosion of Metal Specimens
The four corrosion tube assemblies were maintained at nominal
temperatures of 750°, 930°, 1110° and 1290°F throughout Test Series 2
by cooling with steam from the central heating boiler« The procedures
used to examine and assess the metal specimens were identical with those
given earlier for Test Series Ib, and lead to the estimates of rate of
corrosion tabulated in Table 21o
The results of a microscopic examination of a number of selected
specimens are given in Table 22.
The surfaces of the high chromium steels were mainly smooth while
the low alloy steels had rougher surfaces particularly when the weight
losses were highc
Intergranular penetration was confined to specimens exposed at
temperatures of 1110 F and above and was generally accompanied by
sulphidation- In some samples, sulphide globules could be seen as a
band in advance of the broadened grain boundarieso The penetration was
also generally associated with some oxide formation..
3=2,6 Mass Balances
Balances have been computed for ash, carbon, oxygen, nitrogen,
sulphur, calcium and magnesium for tests 2o6, 2»7, and 2=9.2, These
are presented in Tables 40, 41 and 42 respectively,,
A3ol4
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3.3 Test Series 3
3o3ol Objectives of the Test Series
(i) To measure the rate of corrosion of boiler steels.
(ii) To assess the effect on sulphur retention in the bed of:
(a) Variation in fluidising velocity at constant Ca/S
mol ratio for different size gradings of limestone
and dolomite, and
(b) Operating at a higher bed temperature.,
3.3.2 Description of Test Series 3
Test Series 3 was run continuously for the 500 hour period from
16th March to 6th April 1971. It comprised seven tests ranging in
duration from 48 h to 72 h with the terminal 16 hours in each test
providing the actual test section.
Details of operating conditions are given in Fig. 8 and Table 23.
Four tests, Tests 3.1 to 3.4 were carried out at fluidising velocities
of 6 and 11 ft/s, with and without external recycle of fines, whilst
adding limestone 18 of 3175 micron maximum particle size to the bed.
In a further test, Test 3,5, -3175 micron limestone was added to the
bed whilst it was fluidised at 8 ft/s and maintained at a higher
temperature than usual (viz» 1660°F instead of 1560°F)o The limestone
feed for Test 3.6 was prepared to -150 micronc, The fluidising velocity
was approximately 6 ft/s and the bed temperature was maintained at the
normal level of 1560 F» Hence, apart from acceptor size, Test 3»6 was
a repeat of Test 3.1» The operating conditions for Test 3,7 were
similar to those of Test 3.5 except Dolomite 1337 having a top size
of 1587 micron was used as the acceptors
It had been hoped that tests could have been carried out at a
fluidising velocity of 4 ft/s, but fluidisation was unsatisfactory at
this velocityD
In order to be able to attain higher bed temperatures during this
test series, the upper two corrosion probes were removed and replaced
by steam-cooled bed tubesc Steam flow through these tubes was con-
trolled by a motorised valve operated by a Honeywell controller which
sensed the bed temperature at 9 inches above the distributor plate.
A3,15
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Because of the need to accumulate more data on the corrosion of low
alloy steels, the two remaining corrosion probes were operated at
750°F and 930°F0
Chemical analysis and size gradings of coal, bed extract,
cyclone fines and exhaust dust for each of the above tests are
tabulated in Tables 24 to 27. A more detailed coal analysis is
given in Table 3 for the bulk sample collected during the test series.
The chemical compositions and typical size gradings of the -3175 micron
Limestone and -1587 micron Dolomite are given in Table 13<,
Average gas composition data, together with temperatures in the
fluid bed at four heights above the distributor plate are given in
Table 28. Mass flow rate data for air, coal and acceptor fed to the
combustor, and the flow rates for bed material, cyclone fines and
exhaust dust removed from the plant are summarised in Table 29,
3°3.3 Sulphur emission
Two estimates of the sulphur dioxide concentration in the combustion
products were made by the chemical method during each of the seven tests
in Test Series 3° The mean values of the two estimates for each test are
reported in Table 28; these have been used for calculating SO. reduction
and sulphur retention by solid materials (Table 30)» In calculating SO.
reduction, the datum SO. emission without additive was assumed to be
2050 ppm SO- as found for Test Series 1=
Data from Table 30 have been used to plot the curves drawn in
Fig. 9, to show the dependence of sulphur retention and S0_ reduction
on fluidising velocity for the -3175 micron limestone,, Sulphur
retention declines slightly with increasing fluidising velocity,,
External recycle of cyclone fines increased retention at the lower
velocity of 6*4 ft/s, but not at 11 ft/s..
An estimate of the effect of fluidising velocity on sulphur
retention during operation at 1560 F with fine (-150 micron) lime-
stone can be obtained by comparing the data for Test 306 with the
interpolated values from Fig» 7 at 207 Ca/S mol ratio»
A3ol6
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Test 3,6
Fig. 7
Fluidising velocity
ft/s
6,4
8.1
SO,, reduction
%
83
70
Sulphur
retention
%
88
80
Hence it is concluded that with both fine and coarse limestone,
operation at a lower fluidising velocity decreased sulphur emission.
An estimate of the effect of bed temperature on sulphur retention
at 8 ft/s with -3175 ym limestone at a Ca/G mol ratio of 2.7 can be
obtained by comparing the results from Test 3.5 with interpolated
values from Fig,- 7<,
Test 3,5
Fig, 7
Bed Temperature
1660°F
1550°F
S02 reduction, %
58
79
Sulphur retention, %
66
86
Hence it is concluded that operation at 1660 F gave less
efficient sulphur retention than at 1550 F.
At a fluidising velocity of 6c4 ft/s and a Ca/S mol ratio of
2o7, reducing the particle size of the limestone increased the SO,,
emission slightly, as shown
Test
x
3.1
3,6
Acceptor particle
size (upper limit)
micron
3175
150
S0» reduction
%
85
83
Sulphur retention
%
90
88
A3,17
-------
3° 3«4 Nitrogen oxide emission
Values for the concentration of nitrogen oxides in the combustion
products obtained, by the Saltzman method are reported in Table 28.
3o3o5 Corrosion of metal specimens
The procedures used to examine and assess the metal specimens
after the conclusion of the Test Series were identical with those used.
in Test Series 2, Estimates of the rates of corrosion are given in
Table 31: the results of the microscopic examination of a few
selected medium carbon steel and ferritic steel specimens are reported
in Table 22.
3o3«6 Mass Balances
Balances have been computed for ash, carbon, oxygen, nitrogen,
sulphur, calcium and magnesium for tests 3°6 and 3o7° These are
presented in Tables 43 and 44 respectively„
3.4 Test Series 4
3.4ol Objectives of the Test Series
To assess the effect of bed temperatures, and Ca/S mol ratio on
sulphur retention when dolomite was fed to the fluid-bed„
3o402 Description of Test Series 4
Test Series 4 was run for a total of 100 h from 19th April to
23rd April 1971, The plant shut down for 1$ hours on the second day
due to the tripping of a thermal overload in the main switch to the
coal weigher. The cause of this was an unusually high ambient
temperature. Thereafter the switch was cooled with compressed air.
Nine tests were carried out, the first seven having a duration
of four hours each with a sixw hour interval between tests to allow
conditions to stabilize,, The last test period continued for five
hours and was divided into two separate tests„ The operating conditions
set during the test series are shown diagrammatically in Fig» 10 and
tabulated in Table 32„
A constant fluidising velocity of 8,2 ft/s and a coal rat£. of
about 240 Ib/h were used throughout the test series„ Limestone 18,
sized -3175 micron was fed to the bed during Test 3ol° Thereafter,
A3ol8
-------
the S0_ acceptor was Dolomite 1337, sized -1587 micron.
Because of the short duration of .the test.series, corrosion
probes were, not installed in the fluid-bed.
The size grading of the coal used during the test series is
given in Table 33 and the chemical composition in Table 3-. Chemical
analysis and size of the bed extract samples and the cyclone fines
are tabulated in Table 34 and 35 respectively» Gas composition data,
together with bed temperatures in the bed at four heights above the
distributor plate, are given in Table 36^ Mass flow rate data for the
input and output air and solids are summarised in Table 37,
3o4o3 Sulphur emission
The concentration of sulphur dioxide in the combustion products
was determined during each of the 9 tests in Test Series 4 by the
chemical methodo These values are tabulated in Table 36 and have
been used to calculate the values of SCL reduction and sulphur
retention which are given in Table 38„ In calculating S0» reduction
the level of sulphur dioxide in combustion products, found during
Test Series 1 (viz0 2050 ppm SO. v/v) when no acceptor was fed to the
fluid bed, has been used as the sulphur dioxide concentration at zero
reduction0
Comparisons are made in Table 39 of the effect of bed tempera-
ture and Ca/S mol ratio on sulphur retention and S02 reduction when
dolomite was added to the fluid-bedo At Oo65 Ca/S mol ratio,
increasing bed temperature from 1425 to 1680 F resulted in an almost
linear decrease in SO- reduction, Figo 11, However, at a Ca/S mol
ratio of 1.8, the relation between bed temperature and SO. reduction
was curved having a maximum at about 1500 F and declining rapidly at
temperatures in excess of 1575 F.
Other comparisons which can be drawn from Test Series 4 are
reported in Table 39 and include the effect of acceptor type, bed
weight and external recycle of fines on sulphur reduction. At 1425 F,
the calcium oxide obtained from the -1587 micron dolomite was a more
effective acceptor of sulpMr dioxide than the calcium oxide obtained
from -3175 micron limestoneo As in previous tests with limestone,
increasing bed height by about 30% during operation with dolomite
addition .did not have a noticeable effect, on.sulphur reduction or
retention. External fines recycle during operation.with -1587 micron
A3ol9
-------
dolomite at 1540 F had a pronounced effect on the amount of acceptor
needed to achieve a SCK reduction of 80%o
3->4>4 Nitrogen oxide emission
The values reported in Table 36 for concentration of nitrogen
oxides in the combustion products were determined by the Saltzman
method -
4. ACKNOWLEDGEMENTS
The Project Leader for Task III was DoJo Loveridge0
The programme was carried out in the Process Development Group
(Director - H»R<, Hoy) of BCURA Industrial Laboratories Ltd,
Members of staff of BCURA who took part in the experimental
work included:
N=HoC, Abbott
MoH, Barker
H R~ Bowling
Pr.D, Brown
C,WS Evans
AoW, Lindsay
DaJo Loveridge
P»R, Morris
P.-Jr. Robinson
R,R, Slaney, and
FoP, Whitehead
Determinations of NO were carried out by JoTo Shaw and
X
M,P, Mendoza-
Chemical analyses were carried out in the BCURA Analytical
Section under the direction of RrG, Jameso
A3o20
-------
Table A3.1c Operating conditions during
Test Series 1
Coal Pittsburgh
Coal size (upper limit) 3175 pm
Coal rate 229 Ib/h
Acceptor Nil
Fluidising velocity 8.0 ft/s
Bed temperature 1512°F
A3. 21
-------
Table_A3JL_2U Tegt Series Ib C500h). Chemical
analysis and size grading of coal
Test period, h.
Total moisture
AC Do Bu moisture
Ash
Volatile matter
Calorific value
Size Grading
-6.350 •* 3175 JJm
-3175 + 1588 urn
-1588 + 794 urn
- 794 + 500 urn
- 500 4. 211 urn
- 211 + 152 pm
- 152 + 75 urn
- 75 + 0 ;um
% aur.
% air dried
7, air dried
% daf
Btu/lb doa.f.
% within
stated size
grade
0-
100
1,9
1,5
12.4
41.5
15090
0
33
25
11
14
3
5
9
100-
200
2.7
1.3
14,5
4104
15050
0
31
27
12
14
3
5
8
200-
300
1.9
1.4
13U5
41,1
15030
0
32
28
12
13
3
5
7
300-
400
1.9
1.5
13.5
41U0
15080
0
30
26
12
15
4
5
8
400-
500
-
1.5
14.2
4K6
15090
0
31
26
13
14
3
5
8
A3. 22
-------
Table A3»30 Chemical analysis of bulk samples
of coal
[
Test Series
Moisture
Ash
Volatile matter
Carbon dioxide
Ash
Carbon
Hydrogen
Nitrogen
Sulphur
Oxygen + errors
Chlorine
Ash analysis
CaO
MgO
Ash fusion (in air)
Initial
deformation
Hemisphere
Flow
Calorific value
Swelling nou
Gray King Coke
% air dried
% air dried
% daf
% air dried
% db
% db
% db
% db
% db
1 db
% db
%
%
°F
°F
°F
Btu/lb daf
-
—
Ib
1.5
13o8
41.0
0.7
14.0
72.1
4.7
1.2
3.0
5.0
—
.
-
2265
2335
2445
-
8
G9
2
1.7
13.1
41.7
0.7
13.3
72oO
4.9
1.1
3.1
5.5
0.07
.
-
2210
2315
2445
15100
64
G9
3
1.5
13o6
41.2
0.6
13.8
72.2
4.9
1.1
2.9
5.1
—
7.1
1.7
2255
2310
2390
15050
8
G9
4
1.5
11.0
40.8
0.4
11.2
74.6
5.1
1.4
2.5
5.2
—
7.5
1.9
2200
2310
2420
15070
8
G9
A 3,.23
-------
and size
analysis of bed extract
Test period, h.
Chemical analysis
Combustible, % a.r.
Size grading
-6350 + 3175 um
-3175 + 1587 um
-1587 + 794 urn
- 794 + 500 um
- 500 + 211 um
- 211 + 152 um
- 152 + 75 um
- 75 + 0 um
0-
100
2.9
0
27
38
21
10
1
2
1
100-
. 200
1.8
% withi
0
30
39
20
8
1
1
1
200-
300
1.3
n stated s
0
29
38
21
8
1
2
1
300-
400
1.3
ize grade
1
29
37
21
8
1
2
1
400-
500
1.2
0
30
37
21
9
1
1
1
A3.24
-------
Table A3.5, Test Series Ib C500h) . Chemical and size
analysis of cyclone fines
Test period, h
Chemical analysis
Combustible, % a.r.
Size grading
-6350 + 3175 ym
-3175 + 1587 pm
-1587 + 794 gm
- 794 + 500 ym
- 500 + 211 ym
- 211 + 152 ym
- 152 + 75 ym
- 75 + 0 ym
0-
100
51,5
0
0
0
2
13
6
24
55
100-
200
53.5
% with.ii
0
0
1
3
11
7
25
54
200-
300
54^3
i stated
0
0
0
2
10
6
25
57
300-
400
58ol
size grade
0
0
0
1
12
9
26
52
400-
500
58,0
0
0
0
1
13
9
26
51
A3. 25
-------
xabie A3.bo Test Series Ib (500h). Chemical and size
analysis of exhaust dust
Test period, h
Chemical analysis
Combustible, % aur0
Size grading
-75 + 60 urn
-60 + 50 pm
-50 + 40 urn
-40 + 30 pm
-30 + 20 urn
-20 + 10 pm
-10 + 5 ym
- 5 + 0 urn
Median diameter pm
Mean diameter D , ym
p
0-100
CD
20.6
% V
0
0
0
3
6
25
51
15
8
8
(2)
20.0
rithin £
0
0
0
1
5
19
52
23
7
7
100-
200
20.9
tated si
0
0
0
1
5
22
51
21
7
7
200-
300
20.4
ze grade
6
0
1
3
9
22
41
18
9
8
300-
400
20.4
0
0
0
4
8
33
36
19
9
8
400-
500
23.1
0
0
0
4
11
31
35
19
9
8
D is given by 1/D
>0.5
, where x.. is the weight
- *. •« «/ — j
fraction between particle size limits d. and d. micron
A3. 26
-------
Table A3(
Test Series Ib (500 h.). Performance data
Test period., h
Gas composition
0?
CO;.
CO
SO 2
NO
X
Bed temperature
Height, above
distributor plate
3 in
9 in
35 in
21 in
.M-s.ar temperature
% vjv
(dry gas)
% v/v
(dry gas)
°F
°F
°F
°F
°F
0-
100
3.1
14.3
Oo77
2045
480
1508
1509
1512
1514
1511
100-
200
3.5
14,6
Oo75
2110
340
1506
1505
1508
1515
1508
200-
300
3,2
14,9
Oo78
2045
—
1505
1508
1510
1521
1511
300-
400
2.9
14.6
0.71
2105
610
1509
1512
1514
1523
1515
400-
500
3o3
14.7
0U58
1960
670
1503
1512
1513
1525
1513
Unburnt carbon
Excess air
2,2%
A3. 27
-------
Table A3. 8. Test Series Ib (500h). Mass flows and
potential heat losses in solids
Air
Through, distributor plate
Coal conveying
Recycle of fines from external cyclone
Total
Coal
Input rate
Approx. calorific value
Bed extract
Rate
Combustible
Approx. heat loss
Cyclone fines rejected
Rate
Combustible
Approx. heat loss
Dust in cyclone exit
Rate
Combustible
Approx. heat loss
Ib/h
Ib/h
Ib/h
Ib/h
Ib/h
Btu/lb
Ib/h
%
%
Ib/h
%
%
Ib/h
7,
%
1980
218
71
2270
229
12750
6.2
1.7
0.05
44.7
55o7
12.4
9.6
20.8
1.0
A3. 28
-------
Table A3.9. Test Series lt Sulphur dioxide content
of combustion products
1
Test
Series
la
IK
J.D
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Date
12th and
13th Nov.
1970
17.11.70
20.11.70
23.11.70
26.11.70
1.12.70
4.12.70
7.12.70
S0£ ppm
2070
2090
2060
2000
2020
2110
2020
2250
1970
1910
1960
2170
2190
211.0
2050
2100
1970
2050
2050
2110
2080
2130
2110
2100
2120
2090
1850
1840
(
1970
A3. 29
-------
Table A3.10. Test Series Ib (jOOh.) • Weight losses for corrosion specimens
Weight loss -is given in pgj'cm2h
Tube
No.
1
2
3
4
Location
of ring
Alloy
Weight
loss
Alloy
Weight
loss
Temp . °F
Alloy
Weight
loss
Temp . °F
Alloy
Weight
loss
Temp.°F.
a
R
13.1
R
5.9
R
6.6
R
7.2
b
R
3.5
S
2.7
T
439
T
53.1
c
W
4.5
R
1.1
W
7.8
W
4.1
d
S
13.3
S
4.3
T
449
T
111
e
R
2.9
R
5.0
R
2.8
R
3.6
f
S
7.6
E
7.3
S
3.8
S
1.5
g
W
6.0
T
603
R
2.3
R
7.6
h
E
18.5
E
8.4
E
6.8
E
4.2
i
S
5.7
T
380
T
254
T
300
j
'E
12.2
W
2.1
<
C
435
< i . .
C
55.1
,
k
R
12.3
_i oon—
s
2.1
1110
T
606
- 930
T
96.0
- 750
1
S
9.9
S
4.1
»'• i • a i
E
11.0
• i^*nmi-»™
E .
>.7
m
E
10.8
S
3.1
_»•
S
3.5
-*
S
1.5
->•
n
w:
3.3
W
3.3
E
3.0
E
0.7
o
S
13.5
E
6.7
S
5.9
S
4.3
P
R
8.3
E
5.7
C
301
C
40.6
q
W
3.7
W
2.1
W
6.1
W
2.9
r
E
21.3
R
1.9
C
464
C
*
s
.S
8.4
R
6.2
E
6.1
E
1.4
t
W
4.3
W
2.3
W
6 ..4
W
4.3
u
R
14.7
T
707
E
7.1
E
5.1
V
E
11.8
T
632
R
9.2
R
0.4
w
W
3.5
W
4.6
W
8.8
W
4.4
X
E
21.5
E
9.1
C
413
C
800
CO
CO
o
* 614 ug/cm2h, obviously a spurious reading
R Austenitic type 347
S Austenitic type 316
E Austenitic type Esshete 1250
W Ferritic 12% Cr steel
T Ferritic 2|% Cr 1% Mo steel
c Ferritic Medium C steel
-------
Table A3. 11. Test Series 2 (1000 ti) Operating conditions during test series
Constant Parameters
Coal
Coal size (upper limit)
Acceptor
Coal rate
Fluidising velocity
Bed temperature
a • • -
3 Variable
parameters
Test
No.
Time elapsed from C Start
start of test C
series (h) C End
Acceptor size - micron
(upper limit)
Ca/S mol ratio
Recycle of cyclone fines
Bed weight - Ib
Pittsburgh
3175 pjn for Tests 2,1 to 2,3> and 2.11 to 2,16: 150 urn for Tests 2.4 to 2.9.
U. So limestone 18
234 Ib/h
8.1 ftys
1548°F
2,1
39
55
3175
1,58
Yes
250
2.2
113
139
3175
0.44
Yes
270
2.3
170
184
3175
3.09
Yes
220
2.4
231
256
150
i.86
Yes
210
2.5
300
316
150
).88
Yes
210
2.6
360
376
150
2.46
Yes
220
2.7
399
435
150
0.74
Yes
230
2.8
484
493
150
2.47
Yes
240
2.9.1
517
523
150
1.63
No
310
2.9.2
541
547
150
1.45
No
250
2.10
603
619
-
0
Yes
270
2.11
671
687
3175
1.09
Yes
260
2.12
731
747
3175
2.37
Yes
220
2.13
805
813
3175
3.89
Yes
210
2.14
851
867
3175
0.62
Yes
270
2.15
911
927
3175
2.45
Yes
210
2.16,1
951
959
3175
1.93
No
280
2,16.2
975
983
3175
2.47
No
210
\
-------
Table A3.12, Test Series 2 (LOOP h} Chemical analysis of coal
>
CO
co
CO
Test period^ h.
Proximate analysis
Moisture
Ash
Volatile matter
Calorific value
Size grading
-6350 + 3175 urn
-3175 + 1587 um
-1587 * 794 jim
- 794 + 500 pm
- 500 + 211 vim
- 211 + 152 urn
- 152 + 75 pm
- 75 + 0 ym
% air dried
% air dried
% daf
Btu/lb d.a.f-
1.00 h
2,1
.1.8
13,2
40.8
15050
1
25
17
12
16
14
6
9
200 h
2.2->2.3
1.8
13.7
40.6
-
%
1
22
26
14
19
3
6
9
300 h
2 = 4
1.7
12,7
41.2
15080
within i
2
25
28
12
15
4
5
9
400 h
2,5-2.6
1.9
13.4
41.1
15170
500 h
2,7-2.8
1.9
13,4
41.5
15120
stated size grade
1
23
27
14
16
4
6
9
1
27
28
11
15
4
6
8
600 h."
2.9.1-2.9.2
1.6
11.0
41.4
15110
-
-
-
^p*.
-
-
—
700h
2.10~2.11
1.3
12,7
41,5
14980
1
39
26
9
12
3
4
6
800 h
2.12
1.9
15.4
41.2
15070
1
30
26
11
15
3
6
8
900 h
2.13-2,14
1.7
15.0
41.7
15090
3
26
24
13
15
4
8
7
1000 h
2.15-2.16
1 = 8
10.4
41.2
15080
2
44
25
8
9
3
3
6
No size grading is available for sample for period 500—600 h.
-------
Table A3,13. Chemical analysis and size grading of additives
Additive
Chemical composition
Si02
A1203
Fe203
CaO
MgO
Na20
K20
C02
Total
Size grading
-6130 + 3175 ym
-3175 + 1587 ym
-1587 + 794 ym
- 794 + 500 ym
- 500 + 211 ym
- 211 + 152 ym
- 152 + 75 ym
- 75 + 0 ym
%
%
%
%
%
%
%
%
%
Limestone 18
13.6
0.5
0.3
45.7
1.4
0.2
0.1
36.6
98.4
-4 in
1
46
21
9
11
3
4
5
-100 BS mesh
A.
'%' 100
J
Dolomite 1337
-
-
-
29.4
21.4
0.5
0.1
45.8
97.2
1 .
- TT ln
~
0
74
16
3
1
2
4
A3. 33
-------
Table A3,14. Test Series 2. Chemical and size analysis of bed extract
co
CO
Test No.
Combustible
Sulphur
CaO
MgO
Particle dize
analysis
-6350 * 3175pm
-3175 + 1587pm
-1587 + 794pm
-794 + 500pm
-500 + 211pm
-211 + 152pm
-152 * 75pm
- 75 + Opm
2,0
2.4
-
-
—
1
17
38
26
15
1
1
1
2.1
3.8
7.5
38.9
0.6
1
29
36
18
11
2
2
1
2.2
0.9
8,1
31 = 4
0.9
2
31
37
19
9
1
1
0
2,3
3.4
8.1
47.3
0.8
1
25
37
22
11
2
1
1
2.4
2.8
~
-
—
1
27
39
18 ;
6
1
4
4
2.5
4.9
-
-
—
2.6
2.4
2.8
14.6
1=9
2.7
4.2
2.7
15.0
2.8
2.8
3.0
2.4
16.5
1.9
2.9.1
0.7
2.3
12.4
2.1
2.9.2
0.7
2.3
12.4
2.1
2.10
1.8
2.4
11.8
2.0
2.11
1.5
8.3
34.7
1.5
2.12
3.6
3.8
40.1
1.4
2.13
2.2
3.5
44.4
1.3
% within stated size grade
2
19
30
17
12
4
10
6
1
17
35
22
13
2
7
3
1
16
27
21
16
4
10
5
1
26
33
18
10
1
7
4
1
40
33
14
1
0
0
0
1
40
33
14
1
0
0
0
2
30
33
18
12
2
2
1
1
22
34
21
16
4
2
0
0
0
19
27
31
12
9
2
0
14
26
26
22
8
3
1
2.14
4.2
7.0
29.0
2.2
1
21
29
17
19
5
7
1
2.15
3.0
6.5
38.1
2.0
0
5
15
19
32
15
13
1
2.16.1
1.4
9.1
43.0
2 = 0
1
23
41
27
6
1
1
0
2.16.2
2.3
9.0
44.4
1.3
0
12
40
37
9
1
1
0
Analyses are stated as weight percent on an "as received" basis
-------
Table A3. 15. Test Series 2 Q-OOO
Chemical and size analyses of cyclone fines
Test No.
Combustible
Sulphur
CaO
MgO
Size grading
-3175 + 1587pm
-1587 * 794pm
- 794 * 500pm
- 500 + 211pm
-211 * 152pm
- 152 * 75pm
- 75 + Opm
2,0
45,2
•^v
-
^*
0
1
1
13
8
25
52
2.1
41.9
-
~
^
0
1
1
20
10
25
43
2o2
50.7
-
-
-
0
1
13
9
27
50
2.3
29,7
-
-
„
0
1
19
13
23
44
2.4
30=2
^
-
-
0
1
6
4
20
69
2.5
28.4
^*
-
-
0
1
5
4
21
69
2.6.
23.3
3ol
31o4
1.2
2.7
25o2
2,8
21,1
0.6
2.8
22.8
3oO
31.4
1.2
2.9.1
37.6
1=7
22.6
0.8
2o9o2
37o6
1.7
22o6
0.8
2.10
43.2
1 = 0
5.9
0.8
2.11
40.6
2.7
14.0
0.9
2.12
X
29.0
3.8
27.4
1 = 1
2.13.
•v N
22.6
5,8
33.7
1.4
2.14
38.1
2.6
12.7
1.1
2.15
26.7
2 = 6
29.0
Oo9
2.16.1
40.7
-
-
-
2.16=2
36.6
4.1
22.6
1.1
7, within stated size grade
0
1
4
5
22
68
0
1
7
4
19
69
0
1
5
4
22
68
0
1
2
10
7
25
55
0
1
2
10
7
25
55
0
1
6
7
18
68
0
1
13
9
24
53
0
12
10
22
56
0
17 ;
14 ;
23 :
46 :
0
12
8
21 :
59
0
1
11
9
30
49
0
2
19
12
25
42
0
1
3
25
14
29
28
Analyses are stated as weight percent on an "as received" basis
-------
Table A3.16. Test Series 2 (1000 h). Analysis of exhaust dust
Test No.
Combustible
Sulphur
CaO
MgO
Size grading
- 78 + 62pra
- 62 + 49p-n
- 49 + 42 urn
- 42 + 33pra
- 33 + 26pm
- 26 + 21um
- 21 + 17pm
- 17 •*• 13pm
- 13 + llpm
- 11 + 9pm
- 9 •*• 7pm
- 7 + Opm
Mean diameter,
pm
Median diameter,
Dp, pm
2.1
20.2
3.3
12.7
0.9,
0
2
3
7
6
10
13
13
46
8
8
2.2
19.8
1.7
5.0
0.9
0
2
6
3
8
9
11
11
50
7
7
2.3
17.5
4.2
24.2
1.0
1
1
0
3
4
5
8
11
11
13
43
8
8
2.4
13.4
5.8
28.9
1.0
2
0
3
7
8
10
12
12
10
36
9
9
2.5
16.3
4.3
21.9
1.0
2
8
7
11
14
13
45
8
8
2.6
13.1
6.4
36.0
1.1
% with
1
2
1
2
4
4
7
lo
11
13
45
8
8
2.7
16.1
4.3
21.6
1.0
in stat
1
1
0
1
3
4
7
7
13
11
12
39
9
9
2.9.1
7.2
8.4
37.5
1.1
ed size
2
1
2
2
4
6
8
11
12
52
8
7
2.9.2
8.1
8.5
35.1
1.0
grade
1
1
2
2
5
9
17
12
13
7
6
25
11
13
2.10
28.3
1.2
4.3
0.7
2
3
6
11
15
17
14
32
9
9
2.11
18.4
-
10.0
-
1
1
1
3
5
4
7
8
11
11
48
8
8
2.12
20.1
-
19.1
-
1
1
2
3
5
6
11
11
15
45
8
8
2.13
16.2
-
27.3
-
1
0
2
4
5
6
10
12
13
47
8
8
2.15
20.0
-
18.1
—
1
. 0
1
2
3
4
7
11
15
13
43
8
8
CO
CO
Analyses are given as weight percent on an "as received" basis
No samples of exhaust dust were taken during Tests 2.8, 2.14 and 2.16
D is given by 1/D : £ x../(d.d.)0'5
between particle size limits d. and d. micron.
where x.. is the fraction by weight
-------
Table A3,17. Test Series 2 QOOO h.) . Performance data
Test No,
Elapsed time frc'in
start of Lest
series ; h
Start
End
Operating . ondi tlcns
Ca/S mol ratio
Acceptor size
(upper limit) ym
Recycle
Bed weight^ Ifa.
Unburnt carbon %
Excess air %
Gas composition
C02 % v/v
CO % v./v
02 % v/V
SO 2 ppm v/v
NO ppm v/v
Bed temperature, F
Height above
distributor plate
3 in
9 in
15 in
21 in
Mean temperature
4
2ol
39
55
1.58
3175
Yes
250
14
-1.8
14.3
0.66
3,7
930
430
1495
149:;
1506
1508
1501
2,2
113
139
0.44
3175
Yes
270
16
-1.2
14.1
0,68
3.5
1760
-
1499
1499
1513
1513
1507
2.3
170
184
3o09
3175
Yes
220
16
-4.4
14=3
0069
2.8
290
-
1531
1531
1539
1529
1533
2.4
231
256
1.86
150
Yes
210
14
2,7
14.6
0.66
3.9
1370
-
1555
1571
1576
1542
1561
2.5
300
316
0.88
150
Yes
210
9
4,2
14.8
0.65
3.5
1520
380
1573
1573
1587
1555
1572
2,6
360
376
2.4;
150
Yes
220
11
4,4
14.1
0.72
3.8
830
490
1546
1553
1569
1535
1551
i
2.7
399
435
0.74
150
Yes
230
8
6.6
14.7
0.69
3.9
1610
500
1555
1555
1567
1539
1554
2.8
484
493
2.47
150
Yes
240
>7
3.8
13.9
0.71
3.8
790
390
1566
1573
1584
1560
1571
2=9.1
517
523
1.63
150
No
310
>20
-1.2
14.3
0.54
4.2
1110
-
1549
1566
1573
1569
1564
2,9 = 2
541
547
1.45
150
No
250
>7
29.1
11.9
0.57
7.6
940
-
1542
1567
1580
1492
1545
2,10
603
619
0
=
Yes
270
>6
5.5
14.9
0.7
3.5
1680
_,
1557
1569
1582
1575
1571
2.11
671
687
1.09
3175
Yes
260
13
-4.1
16.2
0.68
3.4
1220
-
1553
1557
1566
1557
1558
2.12
731
747
2.37
3175
Yes
220
12
1,4
15,2
0.71
3.6
500
490
1553
1553
1567
1546
1554
2,13
805
813
3.89
3175
Yes
210
11
0.5
16.9
0,67
3.6
310
200
1558
1564
1573
1551
1561
2.14
851
867
0,62
3175
Yes
270
^
>9
-0.7
14.8
0.75
3.6
1550
500
1531
1539
1555
1560
1546
2.15
911
927
2.45
3175
Yes
2.10
11
-8.0
15,4
0.71
3.8
530
-
1560
1562
1580
1575
1564
2.16.. i
95 i
959.
1.93
3175
No
280
>16
-11.2
13.7
0.64
4.0
910
-
1535
1535
1544
1544
1500
2,16.2
975
983
2.47
3175
No
210
M6
15.7
10.7
0.48
7.6
680
-
1519
1524
1546
1501
1523
i
-------
Table A3.18, Test Series 2 (1000 h) Mass Flovs Clb/h)
CO
co
CO
Test No=
Aii input
Through
distributor
plate
Coal conveying
External fines
recycle
Total
Coal input ;
Limes tone
input
Bed extract
Cyclone fines
rejected
Exhaust dust
•J.I
1980
214
77
2270
239
44
26
53
9
2.2
1980
213
71
2260
238
12
13
52
8
2,3
1980
217
75
2270
247
88
36
84
11
2.4
1980
212
73
2270
227
50
9
66
18
2 5
1980
209
71
2260
225
23
5
34
22
2.6
1980
212
73
2270
227
65
5
61
33
2.7
1960
214
75
2250
229
20
5
39
20
2.8.
1980
216
73
2270
227
65
6
47
12
2,9 = 1 :
1980
216
75
2270
231
45
4
91
-
?,9,2
1980
205
75
2260
176
33
3
40
6
? \c>
1980
216
75
2270
220
Nil
2
23
—
.2.11
1990
216
75
2280
243
31
17
51
11
2.12
1980
220
73
2270
238
64
36
51
19
2.13
1980
223
86
2290
243
108
44
63
19
2,14
1980
220
86
2290
240
17
16
38
—
2.15
1980
212
82
2270
247
73
45
60
14
2.16,1
1980
216
88
2280
256
60
17
73
—
2=16=2
1960
216
88
2260
196
58
7
66
—
-------
Table A3.19o Test Series 2 (1000 h.)._ Effect of operating
conditions on sulphur retention and SO^ reduction
Test.
2.1
2,2
2.3
2.4
2,5
2.6
2.7
2.o8
2o9.1
2.9.2
2.10
2.1.1
2.12
2.13
2.14
2.15
2,16.1
2,,16o2
Ib
Limestone
Coarse
Fine
Nil.
Coarse
Nil
Bed wt.
Ib
250
270
220
210
210
220
230
240
310
250
270
260
220
210
270
210
280
210
220
Bed Temp
°F
1501
1507
1533
1561
1572
1551
1554
1571
1564
1545
1571
1558
1554
1561
1546
1564
1500
1523
1512
Ca/S mol
ratio
1,58
0.44
3.09
1,86
0.88
2.47
0.74
2,47
1.63
1.45
0
1.09
2o37
3o89
0.62
2.45
1.93
2.47
0
SO 2 in exit
gas ppm v/v
925
1760
290
. 1375
.1520
835
1615
790
1110
940
1680
1220
500
305
1550
530
910
680
2050
Sulphur
retention
I
69
42
91
52
46
71
44
72
62
57
40
59
83
90
48
83
72
72
21
SO 2
Reduction
%
55
14
86
32
26
59
21
61
46
54
18
40
76
85
24
74
56
67
0
Coarse limestone was sized -3175 micron
Fine limestone was sized - 150 micron
A3. 39
-------
Table A3.19A. Test Series 2. Comparative assessments of
Test No.
Limestone
Bed Temp
SO? reduction
Bed weight
ib
Ca/S mol
ratio
. ppm . v/v
Excess
air 7,
Corrected
SOo ppm
\SM
Replicate Tests
2,3
2.13
2.5
2.7
2,8
2.12
2.15
Coarse
Fine
Fine
Coarse
1533
1561
1572
1554
1551
1571
1554
1564
Effect of bed weight
2o9,l
2,9,,2
2.16.1
2.16.2
Fine
Coarse
1564
1545
1500
1523
220
210
210
230
220
240
220
210
310
250
280
210
Effect of bed temperature
2.2
2.14
Coarse
1507
1546
270
270
3.09
3.89
0.88
0.74
2.47
2.47
2.37
2.45
290
310
1520
1610
830
790
500
530
-4.4
0.5
4.2
6.6
4o4
3.8
1.4
-8.0
280
310
1585
1715
865
820
510
490
1.063
1,45
1.93
2.47
1110
940
910
680
-1.2
29.1
-11.2
15.7
1100
1210
810
790
0.44
0.62
1760
1550
-1.2
-0.7
1740
1540
86
85
23
16
58
60
75
76
46
41
60
61
15
25
Coarse limestone was sized -3175 micron
Fine limestone was sized -150 micron
* Calculated from correct S02 and assuming 2050 ppm S02 v/v
in combustion products when zero acceptor is fed to the bed
A3. 40
-------
Table A3 .JO. Test Series 2 Q.OOO 'h3._' Nitrogen oxides emission
in exit gag
Test
2.1
Be tween
2,,3 and
2.4
2.5
2.6
2.7
2.8
Date
21,lo71
21.1.71
22,1.71
22.1.71
28/1,71
1.2.71
4.2.71
5u2o71
9.2071
Time
h
15»40
15.50
11.30
11.50
12.00
12.10
15.00
15.30
11..40
12.00
11.15
11.30
10.00
1.0.30
NO
X
ppm
v/v
418
456
419
420
296
297
329
427
424
553
494
499
382
390
Mean
No
X
ppm
v/v
428
297
378
488
497
386
Limestone addition
mean size
micron
3175
^
150
150
150
150
Ca/S
mol ratio
1.58
0
0.88
2.47
0.74
2.47
-------
Table A3, 21. Test Series 2 CLOOO
Weight Less is given in pg/cm^h
Weight loss for corrosion specimens
Tube
No.
1
2
3
4
Location
of ring
Alloy
Weight
loss
Temp °F
Alloy
Weight
loss
Temp °F
Alloy
Weight
loss
Temp °F
Alloy
Weight
loss
Temp °F
a
S
5.5
b
E
10,8
c
E
8,4
S
5=5
S
0.7
S
0=3
E
3-6
R
1 = 0
R
0=5
S
2=3
d
R
5.1
R
2,7
S
1.3
S
1=0
R
1 = 4
e
R
3,7
f
W
*
g
W
2,9
h.
W
3.9
i
S
12.2
j
R
3=1
k
R
5.7
1
E
14,5
, 1290
W
1.4
W
2=0
R
1.4
W
0 = 3
R
1.6
T
27.4
W
5 = 3
C
41.6
T
8 = 3
C
11 = 3
E
3.3
W
3=5
W
2,7
E
2,1
<-,
R
1=5
<:
R
0,5
T
255
E
4 = 4
— 1110
S
0 = 9
— • i
S
0.3
E
1.2
>30 •
E
1 = 5
R
1,1
T
18=4
m
S
9.3
n
S
7.6
o
W
2,7
P
W
11,7
q
E
10.4
r
R
8,1
s
R
3,0
t
W
3=1
u
S
12:8
V
S
7.7
w
E
14,6
S
2=7
R
1.3
T
184 .
E
1.0
•,.
T
5.5
E
0=8
W
2 = 0
W
1.7
S
1.0
S
0 = 5
W
.1.7
T
340
S
2=3
R
2,1
S
3=7
W
1 = 2
W
3=7
W
2,5
T
54 = 0
T
11, -4
c-_— «« 750 „___,-..
C
22 = 9
C
"7=7
R
0.8
R
1,0
E
1=4
E
1,2
E
loO
E
0.7
T
298
W
2,1
T
43.6
T
9=8
C
44,6
C
12,5
CO
10
* Spurious reading
R Austenitic type 347
S Austenitic type 316
E Austenitic type Esshete 1250
W Ferritic 12% Cr steel
T Ferritic 2{% Mo steel
C Ferritic medium C steel
-------
Table
Microscopic examination of metal corrosion
specimens
Test
series
2
2
2
2
3
3
Temp
750
930
110
1290
750
930
Material
C '
T.
W
S
R
E
C
.T
W
S
R
E
T
W
S
R
E
W
S
R
E
C
T
W
Surface
texture
smooth.
smooth.
smooth.
smooth.
smooth .
smooth.
rough
rough
smooth
smooth
smooth
smooth
rough
smooth
rough
smooth
smooth
smooth
rough
smooth
rough
smooth
smooth
rough
smoo th
Penetration jjm
Pits
-
-
-
-
—
v. slight
v. slight
•«
-
—
some
-
-
-
—
_
•*
—
-
—
Sulphur
-
-
-
-
—
_
-
^
—
v. slight
70
-
30
5
15
v. slight
45
5
25
-
"-•
Code to materials
C
T
W
= Ferritic medium C steel
<= Ferritic 2i% Cr 1% Mo steel
= Ferritic 12% Cr steel
S = Austenitic type 316
R = Austenitic type 347
E » Austenitic type Esshete 1250
Surface Texture
Smooth » surface irregularities of up to 4 \aa
Rough = surface irregularities of up to 12 ym
A3.43
-------
Table A3.23. Test Series 3 (500 h) Operating conditions
during Test Series
Constant Parameters
Coal
Coal size (upper
limit)
Variable Test No.
Parameters
Time elapsed
from start of
Test Series (h)*
Fluidising
velocity
Start
End
ft/s
Coal input rate Ib/h
Acceptor
Acceptor size (upper
limit) micron
Acceptor input rate
Ib/h
Ca/S mol ratio
Recycle
Bed weight
Bed temperature
Ib
°F
Pittsburgh
3175 pm
3,1
67
83
6.4
190
3175
57
2.68
Yes
220
1550
3.2
138
154
10.8
278
3175
83
2.69
Yes
210
1550
3,3
186
202
6.6
183
Lim
3175
55
2.80
No
220
1547
3.4
234
250
10.9
287
sstone 18
3175
86
2.63
No
260
1553
3.5
306
322
8.2
222
3175
67
2.67
Yes
200
1659
3.6
378
394
6.4
185
150
56
2.66
Yes
260
1563
3.7
475
490
8.2
229
Dolomite
1337
1587
77
1.74
Yes
250
1549
A3. 44
-------
Table A3.24. Test Series 3 (500 h). Chemical analysis
and size grading of coal
Test, period,, h
P ; .: x i ,-i'rt : c n n a 1 y s is
Moisture
Ash
Volatile matter
Calorific value
Size grading
-6350 + 3175 pm
-3175 + 1587 pm
-1587 + 794 pm
- 794 + 500 urn
~ 500 + 21.1 pm
- 21.1 + 75 >;m
- 75 + 0 pm
% air dried
% air dried
% daf
Btu/lb daf
% i
0 -
100
1.5
11.6
41,2
15180
within
1
31
29
11
13
5
7
100-
200
1.6
12.1
41.2
15120
stated
0
29
27
11
15
5
9
200-
300
1.4
13.4
40.8
15120
size grad
1
23
26
13
16
6
10
300-
400
1.5
11.5
41.4
15060
e
1
24
26
12
15
6
9
400-
500
1.5
12.3
41.0
14960
1
29
28
11
14
5
8
-------
Table A3. 25. Test^ Series 3 (500 h) -
___
analysis of bed extract
Test No0
Chemical analysis
Combustible
CaO
MgO
Sulphur
Size grading
-6350 + 3175 ym
-3175 + 1587 pm
-1587 + 794 urn
~ 794 + 500 ym
- 500 •*• 211 urn
- 211 + 152 pm
- 152 + 75 pm
- 75 + Opm
3.1
2.3
44.5
1,4
7.3
0
6
18
22
31
17
5
1
3.2
2.4
46.5
3.0
7.8
%
0
25
39
9
15
7
4
1
3.3
1.7
42.4
2.1
7.1
within
0
17
28
19
26
6
3
1
3.4
. 1.2
45.4
1.7
5.9
3.5
2.4
38.1
1.8
4.2
stated size grad
0
34
52
12
1
1
0
0
0
10
23
16
28
13
8
2
3.6
2.5
17.1
1.7
3.3
&
1
26
35
21
12
1
3
1
3.7
4.5
27.1
15.0
6.8
1
21
47
14
7
2
5
3
Analyses are stated as weight per cent on an
''as received" basis
A3. 46
-------
Table A3.26,, Test_Series 3 (500 h). Chemical aid size analysis
of cyclone fines
Test No.
Chemical analysis
Combustible
Sulphur
CaO
MgO
Size grading
-794 + 500 um
-500 + 211 urn
-211 + 152 ym
-152 + 75 vm
- 75 + 0 wn
3.1
27.0
-
-
—
3,2
23.2
-
-
-
3.3
30.4
3.1
26.2
1.3
3.4
29.4
3.2
26.7
0,9
3.5
19.4
3.6
34.1
2.7
3.6
24.6
2o4
33.0
0.7
3o7
28«1
3.9
26.0
17.1
% within stated size grade
0
9
11
21
59
1
13
13
20
53
1
13
13
21
47
4
20
12
19
45
1
11
10
18
60
1
7
5
26
61
1
8
6
26
59
Analyses are stated as weight per cent on an "as received"
basis
A3. 47
-------
Table_A3.i27, Test Series 3 (500 h). Chemical and size analysis
of exhaust dust
Test Ncc
Chemical analysis
Combustible
Sulphur
CaO
MgO
Size grading
-69 •*• 49 I'm
-49 f 42 pm
-42 * 33 JOT
-33 •*- 26 pm
-26 + 21 um
-21 + 17 ;un
-17 + 1.3 pm
-1.3 •»• 11 ?.ira
-11 > 9 wn
- 9 •*• 7 >im
- 7 ' •»• 0 pm
Median diameter
urn
Mean diameter
D ,, um
P'
3.1
18.8
_
1.8.1
-
2
1
5
5
8
9
11
12
12
35
9
9
3,2
20.1
-
36 ., 4
«.
%
2
0
0
4
2
4
6
8
11
63
7
7
3.3
10.7
-
20 o 1
-
within s
1
1
2
2
2
4
17
71
6
6
3.4
1302
-
18.4
-
tated siz
1
1
1
2
4
5
7
9
10
10
50
7
8
3,5
12.5
-
48,6
-
e grade
2
3
3
5
7
14
9
8
49
7
8
3,6
12.3
6.5
47.8
3o4
-
-
_
-
-
-
-
-
-
-
-
3.7
17.4
2,5
10.4
5»5
-
-
-
-
-
-
-
-
-
-
-
Analyses are given as weight, percent on an "as received" basis„
D is given by IjD •= >'. x, . yf.d.d,,) " f where x.. is the weight
P P •^•J^'J rj
fraction between particle size limits d,, and d,, micron.
i J
A3. 48
-------
Table A3.28. Test Series 3 (500 h). Performance data
Test No.
Elapsed time from Start
start of Test
Series h End
Operating conditions
Ca/S mol ratio
Acceptor size (upper
limi t) pm
Recycle
Bed weight^ Ib
Unburnt carbon %
Excess air %
Gas composition
C02 % vjv
CO % v/v
02 % v/v
SOj ppro v/v
NO ppm v/v
X.
Bed temperature,, F
Height above distributor
plate
3 in
9 in
15 in
21 in
Mean
3.1
67
83
2.68
3175
Yes
220
10
-5.2
13.2
0.69
3.7
300
—
1528
1528
1533
1513
1525
3.2
138
154
2.69
3175
Yes
210
8
8.8
14.9
0.65
5.2
480
330
1560
1569
1585
1573
1572
3,3
186
202
2.80
3175
No
220
12
-2.4
14.9
0.63
5.1
380
470
1555
1558
1560
1515
1547
3.4
234
250
2.63
3175
No
260
15
7.4
13.5
0.57
6.1
480
410
1539
1553
1558
1564
1553
3.5
306
322
2.67
3175
Yes
200
6
2.8
14,0
0.64
4.4
860
500
1679
1681
1681
1593
1659
3.6
378
394
2.66
150
Yes
260
14
-3.8
14.5
0.72
3.6
340
470
1562
1569
1575
1548
1563
3.7
475
490
1.74
1587
Yes
250
15
0.6
14.3
0.63
4,4
640
530
1549
1557
1562
1528
1549
* n *r\
-------
Table A3.29. Test Series 3 (500 h). Mass Flows (Ib/h)
Test. No.
Air Injmt
Through
distributor plate
Coal conveying
External, fines
recycle
Total.
CoaJ input
Acceptor input:
Bed extract
Cyclones fines
rejected
Exhaust dust
3.1
1500
214
84
1800
190
57
37
44
10
3»2
2730
212
82
3020
278
83
14
50
23
3*3
1470
216
84
1770
183
57
34
52
4
3.4
2730
216
84
3030
287
83
28
108
3,5
3.5
1980
216
84
2280
222
67
24
41
14
3o6
1480
214
86
1780
185
56
2.4
65
21
3o7
1980
2.16
82
2280
229
69
13
82
13
A3. 50
-------
Table A3,30. Test Series 3- Effect of operating conditions
on sulphur retention and SO? reduction
Test No.
Fluidising velocity, ft/s
Acceptor
Acceptor size (upper
limit) micron
Ca/S mol ratio
Recycle
Bed weight Ibs
Bed temperature F
Sulphur retention %
S(>2 reduction %
3.1
6.4
3.2
10.8
3.3
6.6
3.4
10.9
3.5
8.2
3.6
6.4
•< . — Limestone >
3175
2.68
Yes
220
1550
90
85
3175
2.69
Yes
210
1550
80
77
3175
2.80
No
220
1547
85
82
3175
2.63
No
260
1553
81
77
3175
2.67
Yes
200
1659
66
58
150
2.66
Yes
260
1563
88
83
3.7
8.2
Dolomite
1337
1587
1.74
Yes
250
1549
76
69
-------
Table A3.31. Test Series 3 (500 h) . Weight loss for corrosion specimens
Weight loss is given in jag/cm2h
Tube
No =
1
2
Location
of rig
Alloy
Weight
loss
Temp F
Alloy
Weight
loss
Temp °F
a
T
7.8
R
0.7
b
E
lol
C
1,3
c
S
1.1
S
0.7
d
R
0.7
S
0.9
e
W
3.1
W
2.5
f
R
0.9
T
2.7
g
W
2.2
C
19. 1
h
S
0.8
<
W
1.9
<
i
E
•1.1
C
8.6
j
T
36.7
930
S
1.0
750
k
E
1.4
• . •
E
1.0
1
R
1.1
_*~_>
T
8.4
>
m
S
1.2
E
1.3
n
R
1.0
W
2.7
0
T
27.1
S
1.2
P
W
2.1
W
2.3
q
s
1.3
T
18.4
r
S
1.0
R
1.3
s
R
1.3
R
1.0
t
E
1.4
E
1.0
u
W
2.1
E
1.4
V
T
49.8
T
16.6
w
W
2.2
R
0.8
CO
Ol
NJ
R Austenitic type 346 W Ferritic 12% Cr steel
S Austenitic type 316 T Ferritic 2J% Cr 1% Mo steel
E Austenitic type Esshete 1250 C Ferritic medium C steel
-------
Table A3.32. Test Series 4. Operating conditions.
CO
•
Wl
CO
Constant Parameters
Coal
Coal size (upper limit)
Fluidising velocity
Variable
Parameters
Time elapsed
Test No.
Start
from start of
Test Series
(h) End
Coal input rate Ib/h
Acceptor*
i
S
Acceptor size* <•
(upper limit)
, urn £
Acceptor input
rate, Ib/h
Ca/S mol ratio
Recycle
Bed weight,
Bed temp. F
lb.
Pittsburgh
3175 micron
8.2 ft/s
4.1
22
26
238
L
66
2.94
Yes
350
1428
4.2
36
40
238
D
66
1.89
Yes
310
1418
4.3
46
50
240
D
66
1.88
Yes
210
1535
4.4
56
60
243
D
22
0.62
Yes
230
1564
4.5
66
70
247
D
22
0.61
Yes
200
1678
4.6
76
80
251
D
66
1.79
Yes
180
1680
4.7
86
90
227
D
22
0.66
Yes
250
L426
4.8
96
99
251
D
176
4.78
No
200
1645
4.9
99
101
216
D
176
5.56
No
210
1549
* L « Limestone 18, sized -3175 micron
D « Dolomite 1337, sized -1587 micron
-------
Table A3.33=
Test Series 4 (100 h).
of coal
Size grading
Particle size
-6350 + 3175 jim
-3175 + 1587 Jim
-1587 + 794 um
- 794 + 500 jim
- 500 + 211 jim
- 211 + 152 urn
- 152 + 75 w
- 75 + 0 jam
% within stated
size range
2
31
27
11
14
3
5
7
A3. 54
-------
Table A3.34. Test Series 4 (100 h). Chemical and size
analysis of bed extract
Test No.
Chemical analysis
Combustible
Sulphur
CaO
MgO
Size grading
- 6350 + 3175 pm
- 3175 + 1587 ym
- 1587 + 794 ym
- 794 + 500 ym
- 500 + 211 ym
- 211 + 152 ym
- 152 + 75 ym
75 + 0 ym
4.1
19.2
4.8
44.2
1.6
4.2
22.5
5.6
32.0
18.2
4.3
5.4
8.4 .
29.8
17.5
4.4
3.8
8.8
25.6
13.7
% within stated size grade
1
51
30
8
8
1
1
0
0
23
57
15
4
1
0
0
0
10
35
23
15
4
8
5
0
14
36
23
13
3
7
4
4.7
5.2
3.6
17.1
7.2
0
14
35
23
15
3
6
4
Analyses are stated as weight percent on an "as received" basis.
No bed material was removed during Tests 4.5, 4.6, 4.8 and 4.9
A3. 55
-------
Table A3.35.
Test Series 4 (100 h). Chemical analysis and
size grading of cyclone fines
Test No.
Chemical analysis
Combustible
Sulphur
CaO
MgO
Size grading
-3175 + 1587 ym
-1587 + 794 ym
- 794 + 500 ym
- 500 + 211 ym
- 211 + 152 ym
- 152 + 75 ym
- 75 + 0 ym
4.1
41.7
2.4
17.9
1.0
4.2
52.2
1.9
10.5
5.9
4.3
21.0
3.4
28.6
18.6
4.4
32.3
4.4
19.2
11.7
4.5
32.4
3.1
17.4
11.5
4.6
21.3
3.4
29.0
20.0
4.7
36.1
3.9
18.9
12.2
4.8
16.6
2.6
36.6
6.6
4.9
16.6
2.6
36.6
6.6
% within stated size range
0
13
10
20
57
0
8
7
23
62
0
1
1
6
4
24
64
0
1
7
5
22
65
0
1
9
6
22
62
•
0
1
5
u
23
67
0
7
5
23
65
0
2
5
5
28
60
0
2
5
5
28
60
Analyses are stated as weight percent on an "as received" basis
A3. 56
-------
Table A3.36. Test Series 4 (100 h]. Performance data
Test No.
Elapsed time
from start
of test, h
Start
End
Operating conditions
Ca/S mol ratio
Acceptor
Acceptor size
(upper limit) pm
Recycle
Bed weight, Ib
Unburnt carbon
Excess air
.%
%
Gas composition
C02 % v/v
CO % v/v
02 % v/v
SO j ppm v/v
NO ppm v/v
Bed Temp. °F
Height above distributor
plate
3 in
9 in
15 in
21 in
Mean
4.1
22
26
2.94
L
Yes
350
>24
-5.7
12.3
0.64
4.0
550
410
1427
1427
1422
1436
1428
4.2
36
40
1.89
D
Yes
310
>8
-5.7
14.5
0.60
4.5
530
—
1411
1411
1413
1436
1418
4.3
46
50
1.88
D
Yes
210
>5
-6.7
13.7
0.72
4.3
450
480
1544
1544
1546
1504
1535
4.4
56
60
0.62
D
Yes
230
>0.4
-8.9
12.3
0.74
3.8
1160
—
1562
1566
1573
1553
1564
4.5
66
70
0.61
D
Yes
200
>5
-9.3
12.9
0.75
4.1
1730
—
1693
1693
1693
1634
1678
4.6
76
80
1.79
D
Yes
180
*5
-12.0
14.1
0.69
3.8
1060
-
1697
1697
1695
1680
1680
4.7
86
90
0.66
D
Yes
250
>5
-0.9
13.1
0.63
4.4
650
-
1416
1420
1431
1438
1426
4.8
96
99
4.78
D
No
200
>7
-11.0
17.5
0.75
3.7
750
480
1663
1663
1663
1593
1645
4.9
99
101
5.56
D
No
210
>29
4.4
14.8
0.64
5.6
370
-
1562
1566
1566
1503
1549
L denotes -3175 Jim Limestone 18.
0 denotes -1587 pa Dolomite 1337.
R*
-------
Table A3.37.
Test Series 4 (100 h)
Mass Flows (lb/h)
Test No.
Air Input
Through distributor
plate
Coal conveying
External fines
recycle
Total
Coal Input
Acceptor Input
Bed extract
Cyclone fines
rejected
4.1
1980
220
97
2300
238
66
75
69
4.2
1980
220
95
2300
238
66
19
19
4.3
1980
220
97
2300
240
66
5
44
4.4
1970
220
99
2280
243
22
1
2.5
4.5
1990
220
99
2310
247
22
Nil
28
4.6
1970
220
99
2290
251
66
Nil
41
4.7
1980
220
97
2300
227
22
5
22
4.8
1980
225
99
2310
251
176
Nil
78
4.9
1980
225
99
2310
216
176
Nil
280
Exhaust dust flow rates were not assessed.
A3. 58
-------
Table A3.38,
Test Series 4 (100 h)
Effect of Operating Conditions on Sulphur Retention
Test No.
Accep tor
Ca/S racl ratio
Recycle
Bed weight, Ib
Bed Temp,. CF
Sulphur Retention 7,
SO Reduction %
4.1
L
2o94
Yes
350
1428
78
73
4.2
D
1.-89
Yes
310
1418
78
74
4.3
D
Io88
Yes
210
1535
82
78
4.4
D
0.62
Yes
230
1564
54
44
4.5
D
0.61
Yes
200
1678
31
16
4.6
D
1.79
Yes
180
1680
58
48
4.7
D
0,66
Yes
250
1426
72
69
4.8
D
4o78
No
200
1645
69
64
4.9
D
5.56
No
210
1549
82
82
I denotes Limestone 18, sized -3175 micron,
D denotes Dolomite 1337, sized -1587 micron.
A3. 59
-------
Effey-1 _£f various parame ters on^ sul phur re ten, t ion
Variable.
Parameters i.e.
Effect; of
Change, in
temperature
1488° to 1535°F
and change in
bed weight
310 to 210 Ib.
Change in
temperature
from 1426° to
1.564° to 1678°F
Operation with
•!-3175ym Lime-
stone at 2 .9
Cs./a mo'! i-afio.
OR
Operation with
-15 8 ./SB Dolomite
at 1.9 mol ratio
Operation, at.
l.o 6 Cay'S mol.
ratio with
recycle and
Operation at
5.6 CayS mc-1
ratio without
recycle
Constant Parameters
at
1 ,9 Ca/S mol
ratio
0.6 Cays mol
ratio
•» £.\J £
-
1540°F
with.. . . . . .'..'.
-1587 pm Dolomite
80 2 fty's and
Recycle
«1587 'pm Dolomite
80 2 ft/s
Recycle and Bed
wt, 2.10-250 Ibo
Recycle.;,
Bed weight
310-350 Ib
-~1587;am Dolomite
8»2 ft/s
Bed weight
210 Ib
Sulphur
Retention
change from
78 to 82
change from
72 to 54 to
31
Constant at
" 78
Constant at
82
SO
Reduction
change from
74 to 78
change from
69 to 44 to
16
Constant at.
74
Constant at
80
A3. 60
-------
Table A3.,40.
Mass Balance, Test 2.6
Operating conditions:
Accepter: -150 micron Limestone 18
Cay'S mol ratio: 3*55
Bed temperature: 1551 7
With external recycle of cyclone fines
Fluidising velocity: 8.1 ft/s
Data given in lb/h
Component
INPUT
Coal
Acceptor
Air
Total input
OUTPUT
dry exit gas
water vapour
bed extract
cyclone fines
exhaust dust.
Total output
Input-Output
Difference %
Total
227
65
2270
2562
2205
102
5
61
33
2406
154
6
Ash
30,4
4.U2
0
72
0
0
4o5
42.1
22. 4
69
3
4
C
159 o 7
6.5
0
166
138.1
0
0.1
13,7
4.3
156
10
6
0
12.2
17o3
527
567
457
87.0
0.2
2.8
3.2
550
17
3
N
2.5
0
1743
1746
1768
0
-
-
-
1768
-22
-1
S
6088
-
0
6.9
2o04
0
0,14
1,89
2.11
6.2
0.7
10
Ca
1.54
21.33
0
22.8
0
0
Oo52
13.69
8.49
22.7
0.1
0
Mg
0.30
0.55
0
0.85
0
0
Oo06
0,44
0,22
0.72
0.13
15
A3. 61
-------
Table A3.41. Mass Balance,, Test 2.7
Opera ting ccndi tIons:
Acceptor: -150 micron Limestone 18
Ca/S mol ratio: 1.17
Bed temperature: 1554 F
With, external recycle of cyclone fines
Fluidising velocity: 8.1 ft/s
Data given in Ibjh
Component
INPUT
Coal
Acceptor
Air
Total input
OUTPUT
dry exit gas
water vapour
bed extract
cyclone fines
exhaust dust
Total output
Input-output
Difference %
Total
229
20
2250
2499
2218
103
5
39
20
2385
114
5
Ash
30o7
12.7
0
43
0
0
4.5
27.0
14o6
46
-3
"•"•7
C
161.0
2.3
0
163
141.1
0
0«2
9.3
3.2
154
9
6
0
12.3
5.3
522.0
540
468.3
87.8
0.2
1.6
2.5
560
-20
-4
N
2.5
0
L730
L733
1723
0
—
-
-
1723
10
1
S
6.94
0
0
6.9
3.96
0
0.14
1.09
0.86
6.1
0.8
12
Ca
1.56
6.53
0
8.1
0
0
0.54
5.89
3.09
9.5
-1.4
-17
Mg
0.31
0.17
0
0.5
0
0
0.09
0.14
0.12
0,35
Ool5
30
A3. 62
-------
Table A3.42U Mass Balance, Test 2.9.2
Operating conditions:
Acceptor: -150 micron Limestone 18
Ca/S mol ratio: 1,45
Bed temperature: 1545 P
Without external recycle of cyclone fines
Fluidising velocity: 8.1 ft/s
Data given in Ib/h.
Component
INPUT
Coal
Acceptor
Air
Total input
OUTPUT
dry exit, gas
water vapour
bed extract
cyclone lines
exhaust dust
Total output
Input/Output
Difference %
Total
176
33
2260
2469
2226
80
3
40
6
2355
114
5
Ash
19 o 4
20.9
0
40
0
0
2.8
24
4
31
9
23
C
127.7
3.3
0
131
116.0
0
0.02
14.5
0.5
131
0
0
0
9.8
8.8
524.3
543
492.5
69.0
0.1
0.4
0.8
563
~20
-4
N
2.0
0
1736
1738
1731
0
-
-
-
1731
7
0
S
5.5
0
0
5.5
2.34
0
0.07
0,68
0.51
3.6
1,9
35
Ca
0.99
10.76
0
11.7
0
0
0.27
6.46
1.51
8.2
3.5
30
Mg
0.19
0.30
0
0.5
0
0
0.04
0.19
0.04
0.3
0,2
40
A3. 63
-------
Table A30 4.3 „ Mass Balance, Test 3U6
Operating conditions:
Acceptor: -150 micron Limestone 18
Ca/S mol ratio: 2,,66
Bed temperature: 1563°F
With external recycle of cyclone fines
Fluidising velocity: 604 ft/s
Data given in Ib/h
Component
INPUT
Coal
Acceptor
Air
Total input
OUTPUT
dry exit gas
water vapour
bed extract
cyclone fines
exhaust dust.
Tot..al output
Input-output
Difference %
Total
185
56
1780
2021
1733
85
2.4
65
21
1.906
11,5
6
Ash
2.1. „ 3
.35.5
0
57
0
0
2.1
45.6
1.5.2
63
-^o
-11
c
134 . 8
5.6
0
140
111.5
0
0.06
15.5
2,6
130
10
7
0
9«5
14,9
41.3.0
437
361o6
73.3
0.1
0.6
1.8
437
0
0
N
2.1
0
1367
1369
1386.3
0
-
• ~
-
1386
-17
-1
S
5.4
0
0
5.4
0.65
0
0.08
1.56
1.37
3.7
1.7
31
Ca
1.08
18029
0
19.4
-
0
0.29
15.33
7.17
22.8
-3.4
-18
Mg
0.21
0.47
0
0.68
-
0
0.05
0.27
0.43
0075
-0.07
-10
A3. 64
-------
Table A3.440 Mass Balance, Test 3»7
Operating eondi tions:
Accepter: -\1.587 micron Dolomite 1337
Ca/S mol ratio: 1.74
Bed temperature: 1549°:F
Fluidising velocity: 8.2 ft/s
With external recycle of cyclone fines
Data given in Ibjh.
Component
INPUT
Coal
Ac eep tor
Air
Total input
OUTPUT
dry exit gas
water vapour
bed extract
cyclone fines
exhaust dust
Total output
Input—output
Difference %
Total
229
69
2280
2578
2241
104
13
82
13
2453
125
5
Ash.
28.2
37.4
0
66
0
0
10.2
52.0
10.2
72
-6
-9
C
165.3
806
0
174
139 o 3
0
0.6
22.3
2o3
165
9
5
0
11.7
23oO
529.0
564
475
89.8
1.3
3.7
0.5
570
-6
-1
N
2.5
0
1721
1724
1753.2
0
• ~
-
-
1753
-29
-2
S
6.64
0
0
6.6
1.59
0
0.88
3020
0.33
6.0
0.6
10
Ca
1.43
14.50
0
15.9
0
0
2.52
15.24
0.97
18o7
-2.8
-18
Mg
0.28
8.91
0
9.2
0
0
0.05
80 45
0.43
8.9
0.3
3
A3. 65
-------
To stack
A
to
o>
as
Air
inlet
Cooling
water
circuits
Heat
exchanger
-Internal
cyclone
-Freeboard
rnal
Corrosion
probe cooling
Air distributor
FD.fan
Lock
hopper
Dip leg
• Bed
* material
to wa ste
rr
^r"v\. w w ^s.^^.
Weighing
/conveyor
5 Limestone
-Transfer
hopper
Conveying
air
y I Cyclone fines
M * to waste
Conveying air
Fig.A3.1. Flow diagram of 27in combustor
-------
X
o
t-
a
a
o
I
x
o
a
a.
o
\D
Dip leg lock
hopper actuator
Suction pyrometer
access point
Water-cooled
sections
Dip leg
lock hopper
Bed cooling tube
and corrosion probe
access points
Bubble cap
distributor plate
Exhaust duct
Heat exchanger
Internal cyclone
Bed loading
chute
Sight glass
Fluid bed
Bed temperature
access points
Coal feed
Air box
Fig A3.2. The 27in combustor
A3. 67
-------
Inlet manifold
Steam/air
inlet
Tapped holes
forT/C slands
3 5 approx.
Corrosion specimens
Existing rig tube
Fig A3. 3. General arrangement-corrosion probe
-------
Outside surface ground
to finish of 10uj'n or better
d
TJ
CM
J
d
•Q
*0>
00
<-
I
V
'
"
11, "
64*
7
Y//////7/
Y/////A
3/;
7/g" n
-tel
1
d'
T)
^
9
1
* .— .
n
1 d
•o
*m
5
1
%
CO
"1 1
" i
Stamp code
this face
All corners to have 0-005 rod.
Section through corrosion specimen
Direction of
flow of steam
or cooling air
Groove to allow
thermocouple entry
DriM1/16dia.
\ . -
Three '16dia.
thermocouples
X
Thermocouple
holder
Section A A
Corrosion
specimen
Arrangement of thermocouples in corrosion specimen
Fig. A3. 4. Details of corrosion specimens
A3. 69
-------
co
-q
O
35O
3OO
^
o
8200
Q.
(J
..
<4-»
i> 100
r i — i \ u— -czu .--,-1 . i
.
— -,
.
• —
i
. . i
1 i i
j 1 ' 1 1
_'" — pr=^---^~~ r J' ' ' * ' • —
-i
_
_ | r~~~
! j [ Nominal metal temperature 129O°F
i -
i
i j
i i i i i i i i i i i i i i i i i i i
6OO
500
400
3OO ^
. .
-»-»
200 £
0 300
-
C 4»
8200
D
O.
a) 15O
4)
2 100
^f^T
Nominal metal temperature 111O F _
i i i i i i i i i i i i i i i i i i i
O
500
400
300
2OO
i 35°
1^,300
jjJ°~20O
150
,.250
o2OO
c_
~~1
i
i__ _,
L. J
1 1
_ ,
1 ^
1
i i
r-i r^— --^
nn _j— -• r- - -1 r -^
i i i i i i i i i
b=r— ' r- -T~>===^=-
1 1 1 1 1 1 1 1 1
Nominal
i i i
Nominal
i i i
metal temperature 93O°F -
^ u — •^••K' J i
i i i i i i i
metal temperature 75O°F -
i i i i i i i
6OO
5OO
400
300
500
4OO
-»nn
O
c_
0)
Q.
V
to
17 18 19 20 21 22 23 24 25 26 27 28 29 3O 1 2 3 4 56 7
Nov. Dec.
Fig. A3.5. Test Series 1b.(50Oh). Variation in steam temperature at outlets of corrosion probes
-------
>
-a
Test No.
Acceptor size
(upper lim ft), micron
O
'•H»
E °
2 "7Q.9 A-
C iTSf. £r-
.C
B
•• 59*4 3'
•»-»
D
Q.
^C
-------
100
1 2 3
Ca/S mol ratio
1 2 3
Ca/S mol ratio
3175am Pittsburgh coal
Limestone 18
Bed temperature 1500-1575°F Fluidising velocity 8ft/s
O With external recycle
® No external recycle
100
80
~ 60
u
D
$40
CM
o
LO
20
i i i
-3175pm Limestone
i i i
-150fdm Limestone
/
O
/
I
1 2 3
Ca/S mol ratio
1 2 3
Ca/S mol ratio
Fig. A3.7 Test Series 2. Effect of Ca/S mol ratio on
sulphur retention and SO2 reduction
A3. 72
-------
CO
-4
CO
Test No.
Acceptor
Acceptor size
(upper limit)*micron
1O
en
+j
«»-
- 8
>*
-•-»
o
o
§> 6
O)
c
m
'•S4
•3
07
2
3.1
Limestone
3175
—
3.2
Limestone
3175
Fluid ising
velocity
ft/s
Coal input
rate
Ib/h
Acceptor
input rate
Ib/h
3.3
L' stone
3175
L__J
3.4
L' stone
3175
r —~\
' 1
3.5 3.6 3.7
Limestone Limestone Dolomite
3175 15O 1588
—
T ,
f 1 ••!
1 1
3OO E
O
2OO -
15O a
10O
20O 3OO
Hours operation
4OO
1OO
5O
5OO
u
Q.
Fig.AS. 8. Test Series 3. Test schedule
-------
1UU
in
'"580
c
§60
c
•£40
L.
0.20
in
o
^ 0
/
' ?•' '
3.2
- —
— —
— —
\ \ \
\ 6 8 10 1
1UU
80
c
0
u 60
T3
C
40
CM
O
C/)
o
^20
2 °-
I I I
- 3^7-£-
— —
- —
— —
II I
4 6 8 10 U
Fluidising velocity:ft/s Fluidising velocity: ft/s
Acceptor: -3175fim Limestone 18
Ca/S mol ratio: 2-7
Bed temperature : 1550°F
Test
No.
3.1
3.2
3.3
3.4
Bed weight;
Ib
220
210
220
260
Recycle
Yes
Yes
No
No
Njrnbers adjacent points are test no*.
O With recycle
X No recycle
Fig. A3. 9. Test Series 3. Effect of fluidising velocity
on sulphur retention and SO2 reduction
A3. 74
-------
Test No.
Acceptor
Temperature : °F
E
o
£176
B
1
Limestone
1420
2
Dolomite
142O
3
Dol.
156O
4
Dol.
156O
5
Dol.
170O
6
Dol.
17OO
7
Dol.
142O
-
8
Dol.
17OO
— 9
— Dol.
-156O
CO
-q
01
a.
c
66
O
O
o
0)
o
-t->
4)
E
22
1O 20 3O 4O 50 6O
Time: hours
7O
8O
90
1OO
Fig. A3.10. Test Series 4. Test schedule
-------
1UU
o 80
c
O
60
2!
L. 40
3
JC
a.
$ 20
4.50
Ca/S mol ratio
= 0-61 to 0-66
I I
80
C
O
^60
•a
t_
O
to
20
Ca/S mol ratio
=0-61 to 0-66
I
I
1400 1500 1600 1700
Bed temperature :°F
0
1400 1500 1600 1700
Bed temperature:°F
100
80
C
O
60-
40-
JC
a
I 1
4-2 Q4*
or"
\
^
N
4-6
Ca/S mol ratio
= 1-79 to 1-88
I i
IUU
0
S* bO
c
O
"§60
T>
0)
t_
O
10
20
O
1 1
o4'3
Q * \
*'* \
\
\
Q
4-6
Ca/S mol ratio
= 1-79 to 1-88
i i
20-
1400 1500 1600 1700
Bed temperature:°F
1400 1500 1600 1700
Bed temperature:°F
Numbers adjacent points are Test numbers
Acceptor: -1587u,m Dolomite
Fluidising velocity: 8ft/s
Operation with recycle
Fig.A3.11. Test Series 4. Effect of bed temperature on
sulphur retention and SO2 reduction
A3. 76
------- |