Development of a High Pressure Dry Coal Feed System for a 100 kWt Oxy-Coal Reactor

Abstract

A design concept to feed dry coal from a hopper to a 100 kWt pressurized oxy-coal (POC) reactor using CO2 at 2 MPa was developed using transient computational fluid dynamics (CFD) simulations and bench-scale measurements. The feed system was required to maintain a steady flow of gas and solids at a coal flowrate of approximately 3.8 g/s and a CO2-to-coal mass ratio in the range 1–2. A 5.08-cm diameter vertical coal hopper feeding into a 0.635-cm diameter horizontal pipe was used to represent key elements of the feed system. A fluidized bed concept was found capable of providing the desired coal flowrate and CO2-to-coal flow ratio. Use of separate fluidization and dilution flows allowed the coal flowrate and CO2-to-coal flow ratio to be controlled independently. The amount of coal transported from the hopper was dependent on the net CO2 flow in the hopper but independent of the CO2 dilution flow. Pipe exit coal flowrates were found to fluctuate at levels acceptable for steady burner operation. Tests from a bench-scale apparatus using Pittsburgh 8 coal with a median particle diameter of 50 µm and moisture content of 6% confirmed the feasibility of the fluidization design. However, for a given CO2 fluidization flowrate, experimental coal flowrates were lower than predicted coal flow, in part due to simplifying assumptions of dry, spherical coal particles and smooth piping in the simulations.