COAL UTILIZATION CENTER PILOT-SCALE FACILITIES

Pilot-Scale Apparatuses

The WFGD test facility is connected to a 400,000 Btu/hr down-fired combustor that is capable of firing natural gas and solid and liquid fuels. SO₂ can be injected at various locations within the combustor to simulate flue gas having an elevated SO₂ concentration. The combustor has several sampling ports from which particulate and gas samples can be taken. Diagnostics include:

Continous emissions monitoring of CO, CO₂, O₂, SO₂ and NO_x

Temperature profiles

Down-Fired Combustor Specifications and Photograph

Scrubber Features

Design	Scrubber Dimensions:10' high, 16" diameter Material of Construction:316 and 304 Stainless Steel Nozzle Type:BETE Spiral
Scrubbing Capacity	4,500 scfh flue gas
Gas Velocity	1.1 ft/s @ 400,000 Btu/hr
Inlet Gas Temperature	250-280^oF
Outlet Gas Temperature	140^oF
Gas Liquid Contact Time	1-7 seconds
Liquid/Gas Ratio	60-120
Reaction Tank Conditions	pH: 4.5-7.5 Residence Time: 15 minutes Temperature: 140^oF
Typical Slurry Characteristics	% Solids: 2 Particle Size Distribution: 92-98% -325 mesh (44 microns)
Diagnostics	Continuous monitioring of pH, temperature, flue gas composition (inlet and outlet), slurry flow rate and slurry density. Particle Size Solids Loading Chemical Analysis Liquid Anions: SO₃^-2, SO₄^-2, Cl^-, NO₂^-2, NO₃^-, PO₄^-2 Cations:Ca⁺², Mg⁺² Solid S, Mg, Ca, CO₃

Stoker Simulator

Photograph of Stoker Simulator

Schematic of Stoker Simulator

The stoker apparatus simulates the combustion environment typically found in stoker-fired boilers. The facility simulates a moving bed in that the air flow rates are varied with time. The ignition plane can be traced as a function of time and operating conditions.

Features

Design	Fabricated from 14" steel pipe; 1.25" concentric castable refractory and 3.5" of insulation. Four sampling ports (3/8" diameter) at 90^o angles to each other at 1" intervals (axially) from the grate Electric coil is used to provide the ignition energy to the top of the bed
Fuel Fired	Coal, Coal-Biomass Mixture, Coal-Tire Mixture
Fuel Charge	1.7 lb corresponding to a bed thickness of 4.5" giving a midrange area firing density typical of utility-scale stoker boilers (8-50 lbs per sq ft)
Combustion Air	Supplied via distributor plate to the bottom of the chamber
Diagnostics	Continous emission monitoring:CO, CO₂, O₂, SO₂ and NO_x within the bed Gateway 2000 computer interface with apparatus to collect temperatures, gas composition data and pressure drop across the bed using Viewdac data collection software

Coal Preparation Equipment

Coal Cleaning

The CUC has the capability to conduct custom cleaning tests in a froth flotation circuit. The circuit can be run as a single stage or rougher-cleaner configuration. The circuit has the capability to handle coals having a wide range of sulfur and ash content. A variety of additives can also be tested for relative performance. The cake is then dried or slurried depending upon the product use. Complete characterization of the feed fuel and cleaned product is conducted on site. Washability (float-sink) determinations are also conducted in conjunction with the Mineral Processing Program at Penn State.

Froth Flotation Circuit Features

Design	Rougher and cleaner circuits consisting of 4 and 2 Wemco flotation cells, respectively
Capacity	0.3-0.5 toh/h
Typical Additives	MIBS (frothing agent), dodecane (collector)
Size of Feed to Rougher Cells	-100 mesh
Dewatering	Denver disk filter (2 - 24" disks)

Froth Flotation Circuit- Rougher Cells

Froth Flotation Circuit - Cleaner Cells

For more information on the Coal Utilization Center contact
Bruce G. Miller,
Associate Director, Coal Utilization Center

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Scrubber

Schematic of Scrubber