The Proceedingsof the

27th International

Technical Conference

on

Coal Utilization

&

Fuel Systems

Volume I of II

March 4-7, 2002

Sheraton Sand Key

Clearwater, Florida, USA

UB/TIB Hannover

121 604 489

89

TABLE OF CONTENTS

VOLUME I (Pages 1-618)

Economic & Financial PerspectivesChairman: Donald P. Daley, Lurgi Lentjes, NA

Evaluating the Merits of Coal Projects in a Competitive Electric Market

Patricia A. Rawls, U.S. Department ofEnergy, National EnergyTechnology Laboratory; Richard E. Weinstein, P.E., Albert A.

Herman, Jr., and James J. Lowe, Parsons Infrastructure &

Technology Group Inc., USA 1

Gasification: Opening Coal to New Markets

David Gray and Glen Tomlinson, Mitretek Systems, USA... 13

Economic Assessment of Life Cycle Analysis of Coal Production and

Use Process

Jayanta Bhattacharya, PhD, Associate Professor, Department of

Mining Engineering, Indian Institute of Technology,INDIA 17

The Vision 21 Program I, II & III

Chairmen: Dr. Lawrence A. Ruth, National Energy Technology Laboratory,U.S. Department ofEnergy andFred Glaser, U.S. Department ofEnergy

Vision 21 Partial Gasification Module Pilot Plant Tests

A. Robertson, Foster Wheeler Development Corporation,USA 31

Vision 21 - Systems Integration MethodologyDr. A.D. Rao and Dr. G.S. Samuelsen, Advanced Power and

Energy Programs, University of California; Dr. F.L. Robson,

kraftWork Systems, Inc.; and Dr. W. H. Day, Pratt & Whitney

Power Systems, USA 41

Hi

Novel Composite Membranes for Hydrogen Separation in Gasification

Processes in Vision 21 Plants

Michael Schwartz, ITN Energy Systems, Inc., USA 49

Near-Term Potential for Power Generation from Coal with Zero

Atmospheric Emissions

Roger E. Anderson, Harry Brandt, Keith L. Pronske and Fermin

(Vic) Viteri, Clean Energy Systems, Inc., USA 51

A Computational Workbench Environment for Virtual Power Plant

Simulation

Mike Bockelie, Martin Denison, Dave Swensen, Zumao Chen,Connie Senior and Adel Sarofim, Reaction EngineeringInternational, USA 63

Advanced-Gasification Combustion: Bench-Scale System Design and

Experimental Results

George Rizeq, Janice West, Raul Subia, Arnaldo Frydman, and

Vladimir Zamansky, GE Energy and Environmental Research

Corporation; and Kamalendu Das, U.S. Department of Energy,National Energy Technology Laboratory, USA 75

Progress in Development of Direct FuelCell®/Turbine SystemsHossein Ghezel-Ayagh and Joe Daly FuelCell Energy, Inc.,USA 85

Software Integrations for Power Plant Simulations

David G. Sloan and Woodrow A. Fiveland, ALSTOM Power

Inc.; Stephen E. Zitney, Aspen Technology, Inc.; and Madhava

Syamlal, Fluent Inc., USA 87

Oxygen Transport Membranes for Application to Zero Emission Power

Plants Using Solid Oxide Fuel Cells

G. Maxwell Christie, Ph.D. and Troy M. Raybold, Ph.D.,Praxair, Inc.; and Larry A. Shockling, Ph.D., Keqin Huang,Ph.D., and Thomas E. Gilboy ,

Siemens Westinghouse Power

Corporation, Stationary Fuel Cells, USA 99

zv

Hydrogen Separation Membranes for Vision 21 Energy Plants

Shane E. Roark, Richard A. Mackay, and Anthony F.

Sammells. Eltron Research, Inc., USA 101

Mercury Control I & II

Chairman: Stanley J Vecci, McDermott Technology, Inc.

Study on Measuring Method of Mercury in Flue Gas and Its

Application for Coal-fired Test Plant

Hirofumi Kikkawa and Takanori Nakamoto, Babcock-Hitachi

Kure Research Laboratory, JAPAN 113

Where Did the Mercury Go? An Examination of the ICR with Respectto the Role of Surface Area

T. Thomas, The Ohio State University, USA 125

Full-scale Testing of Mercury Control for Wet FGD SystemsDennis K. McDonald, Michael G. Milobowski, and Paul S.

Nolan, Babcock & Wilcox; and Gerald T. Amrhein, Greg A.

Kudlac, and Deborah Madden Yurchison, McDermott

Technology, Inc, USA 135

Utilization of Combustion Modifications to Control Mercury Emissions

Vitali Lissianski, Vladimir Zamansky, Peter Maly, and RandySeeker, GE Energy and Environmental Research Corporation,USA 137

Impact of Coal Chlorine and Flue Gas Temperature on MercurySpeciation

R.M. Statnick, J.A. Withum, and A.M. Schwalb, CONSOL

Energy Inc.; and K. Ho, and R.L. Oda, Illinois Clean Coal

Institute, USA 145

Pre-Combustion Removal ofMercury from Coal

F.D. Guffey, A.E. Bland, and T.H. Brown, Western Research

Institute, USA 147

v

Pilot-Scale Research at NETL on Mercury Measurement and Control

William J. O'Dowd, Richard A. Hargis, and Henry W.

Pennline, National Energy Technology Laboratory, U.S.

Department ofEnergy, USA 159

Biomass Interest Group I & II

Chairman: Evan Hughes, Electric Power Research Institute

Firing Sawdust and Tire-Derived Fuel with Coal at Willow Island

Generating Station

David Tillman, Foster Wheeler Energy Corporation; Kathleen

Payette, Tim Banfield and Glenn Holt, Allegheny Energy

Supply Co., USA 165

Emissions Management at Albright Generating Station throughBiomass Cofiring

Kathleen Payette, Tim Banfield and Tom Nutter, AlleghenyEnergy Supply Co.; and David Tillman, Foster Wheeler Energy

Corporation, USA 177

Biomass Cofiring: Results of Technology Progress from the Cooperative

Agreement between EPRI and USDOE

David Tillman, Foster Wheeler Energy Corporation; Sean

Plasynski, National Energy Technology Laboratory, U.S.

Department of Energy; and Evan Hughes, Electric Power

Research Institute, USA 187

Modeling Combustion and Pyrolysis of Wood ChipsMatthew Hagge, M.S. and Kenneth M. Bryden, Ph.D., Iowa

State University, Department of Mechanical Engineering,USA 203

The Environmental Benefits of Cofiring Biomass and Coal

Margaret K. Mann and Pamela L. Spath, National Renewable

Energy Laboratory, USA 205

VI*

Biomass Combustion and Cofirng Issues Overview: Alkali Deposits,Flyash, NOx/SCR Impacts

Larry Baxter, Dale Tree, Fernando Fonseca and Warren Lucas,

Brignam Young University, USA 217

Cofiring Mixtures of Urban Wood and Coal to Stoker Boilers

James T. Cobb, William W. Elder and Hongming Li, Chemical

and Petroleum Engineering Department, University of

Pittsburgh, USA 227

Biomass Cofiring, Other Biomass Energy Topics, and Results From the

EPRI Biomass Interest GroupEvan Hughes, Electric Power Research Institute, USA 233

Advanced Materials

Chairman: Fred Glaser, U.S. Department ofEnergy

A Rugged, Reliable Check Valve for Extremely Harsh Environments

ToddR. Snyder, Southern Research Institute, USA 235

Gas Separations Based on Electrical Swing AdsorptionRoddie R. Judkins and Timothy D. Burchell, Oak RidgeNational Laboratory, USA 247

Materials for Ultrasupercritical Coal-Fired Power Plants

R. Viswanathan, Strategic Science and Technology, Electric

Power Research Institute; R. W. Swindeman, and I. G. Wright,Oak Ridge National Laboratory; and R. Purgert, EnergyIndustries of Ohio, USA 257

vii

Recent Experiences with Utility SCR'sChairman: Michael J. Rini, Alstom Power

Economic and Environmental Analysis ofIGCC Power Generation with

SCR Technology for Further NOx Reduction

David Gray and Glen Tomlinson, Mitretek Systems; Massood

Ramezan, Science Applications International Corporation; and

Gary Stiegel, U.S. Department of Energy, National Energy

Technology Laboratory, USA 273

Second Generation SCR's

Edward V. Bowes, Dominion; and Michael J. Rini, Alstom

Power, USA 277

Leveraging Physical Flow Modelling and CFD to Optimize SCR DesignsDavid Anderson, Alstom Power Plant Labs, USA 279

Fluidized Bed Combustion

Chairman: DonaldBonk, National Energy Technology Laboratory

Prediction of Deposit Formation in Biomass (Co-) Fired FBC Using an

Advanced Characterisation Method

Maria Zevenhoven, Patrik Yrjas, Rainer Backman, Bengt-JohanSkrifVars, and Mikko Hupa, Abo Akademi University, Process

Chemistry Group, FINLAND 281

Aspects of Co-Firing Natural Gas in Fluidized Bed Combustion

Dennis Y. Lu, and Edward J. Anthony, CANMET EnergyTechnology Centre, Natural Resources Canada,CANADA 293

via

Co-combustion of Lignite and Municipal Solid Waste in a Fluidized

Bed: Emission of Nitrogenous SpeciesK. Suksankraisorn, S. Patumsawad, P. Vallikul, and B.

Fungtammasan, Waste Incineration Research Center (WIRC),Department of Mechanical Engineering, King Mongkut'sInstitute of Technology North Bangkok, THAILAND; and A.

Accary, Laboratoire Gestion Des Risques et Environnement

(GRE), Universite de Haute Alsace, FRANCE 313

Effect of Mineral Matter on Coal Combustion ReactivityAndres F. Rojas and Juan M. Barraza, School of Chemical

Engineering; and Magdalena Urhan, and Arlex Chavez, Escuela

de Recursos Naturales y Medio Embiente, University of Valle,

COLOMBIA 325

Gasification TechnologiesChairman: Al Moussa, Blazetech Corporation

Opportunities for ORIMULSION® Gasification via IGCC TechnologyFranzo Marruffo, PhD, Wladimir Sarmiento, Alejandro Alcala,Quality and Technology Department, PDVSA-BITOR,VENEZUELA 333

The Impact of ITM Oxygen on Economics for Coal-Based IGCC

VanEric E. Stein, Air Products and Chemicals, Inc.; Edhi

Juwono, Texaco Power and Gasification; and Elia P. Demetri,

Concepts NREC, USA 345

Thermal Destruction of Plastic Materials in Solid Wastes

Daisuke Jinno, Ashwani K. Gupta, The Combustion

Laboratory, Department ofMechanical Engineering, Universityof Maryland, USA; and Kunio Yoshikawa, Department of

Environmental Science and Technology, InterdisciplinaryGraduate School ofScience and Engineering, Tokyo Institute of

Technology, JAPAN 357

ix

Low NOx Combustion I & II

Chairman: Alan Paschedag, Burns & Roe Enterprises

NOx Reduction of a 165 MW Wall-Fired Boiler Utilizing Air and Fuel

Flow Measurement and Control

Marion Cherry, Santee Cooper, Dave Earley, Air Monitor

Corporation/Combustion Technologies Corporation, David

Silzle, Air Monitor Corporation, USA 365

Optimization and NOx Reduction Using On-Line Pulverized Coal and

Airflow Measurement and Control

J. J. Letcavits, AEP-Pro Serv, Inc., USA 383

Development of an Ultra-Low NOx Integrated System for Pulverized

Coal Fired Power Plants

Galen H. Richards, John L.Marion, and Charles Q. Maney, US

Power Plant Laboratories; and Robert Lewis and Doug Hart,

Performance Projects, ALSTOM Power, Inc., USA 395

Summary of Recent N0X Achievements with Low NOx Firing Systemsand Highly Reactive PRB and Lignite Coal: as low as 0.11 Lb

NOx/mmBtuRobert Lewis, Gary Camody, and Patrick Jennings, ALSTOM

Power, Performance Projects, USA 397

Operational and Performance Update on New Ultra Low NOx

Combustion Systems with Fuel/Air Monitoring and Control TechnologyJohn Grusha, Stefan Laux and Scott Slingerland, Foster

Wheeler Power Group, USA 399

Development of an Effective 1:N Splitter For use in Multi-Phase

Transport SystemsJoel Vatsky, Advanced Burner Technologies Corporation,USA 411

x

Ability of Models to Predict NOx Formation in Coal Fired Boilers

Anthony Williams, PhD Student, University of Queensland;

John H. Pohl, Consultant Combustion and Pollution Control,

Ultra-Systems Technology Pty Ltd.; and Steve Visona,Deceased, AUSTRALIA 423

Low N0X Results: Large & Small

Joel Vatsky, Tarkel Larson, and Charles Onaitis, Advanced

Burner Technologies Corporation, USA 425

Update on Combustion Modification NOx Control for Coal-Fired UtilityBoilers

Doug Gauld, Chris Latham, Todd Melick, Roy Payne and Todd

Sommer, GE Energy and Environmental Research Corporation,USA 439

Opportunity Fuels I & II

Chairmen: David Tillman, Foster Wheeler Corporation, and

Dr. Ashwani Gupta, University ofMaryland

Utility Perspectives on Opportunity Fuels

Kirby Letheby, Aliant Energy, USA 441

Low Solids Coal Water Slurry Cofiring for NOx Trim

Joseph J. Battista, Cofiring Alternatives (EPRI/UCIG),USA 453

The Propensity of Liquid Phases Forming During Coal-OpportunityFuel (Biomass) Cofiring as a Function of Ash Chemistry and

TemperatureSharon Falcone Miller and Bruce G. Miller, The EnergyInstitute, The Pennsylvania State University, Coal Utilization

Lab; and David Tillman, Foster Wheeler Corporation,USA 465

Co-Firing Tire-Derived Fuel with Coal

N. Stanley Harding, N.S. Harding & Associates, USA 477

xi

Petroleum Coke as a Supplementary Fuel for Cyclone Boilers:

Characteristics and Test Results

David Tillman, Foster Wheeler Corporation, USA 489

Ashes to Energy: The Coleman Station ProjectJack Groppo and Tom Robl, University of Kentucky, Center for

Applied Energy Research, USA 503

Cofiring Wood Residue and Sunflower Hulls with Coal

Bruce C. Folkedahl and Christopher J. Zygarlicke, Energy &Environmental Research Center, University of North Dakota,USA 515

Effect of Wood Fuel on S02 Emissions in Co-firing with Peat and Coal

in Fluidized Bed Boiler

Markku M. Orjala, Veli-Pekka Heiskanen, Riikka M. Ingalsuoand Jouni P. HamaJainen, VTT Energy, FINLAND 527

Computer Simulations

Chairman: Dr. Kenneth M. Bryden, Iowa State University

Computational Model for Efficient Filter DesignF. Hrdlicka, O. Kubelka, and P. Slavik, Czech Technical

University, Dept. of Fluid Dynamics and Power Engineeringand Department of Computer Science and Engineering,CZECH REPUBLIC 539

Modeling ofMercury States in Coal-Fired Utility BoilersZ. Chen, C. L. Senior, and A. F. Sarofim, Reaction EngineeringInternational, USA 549

Evaluation of Biomass Co-firing Injection Strategies Using CFD

Simulations: Pilot- and Full-scale Results

Kevin Davis, Hong-Shig Shim, David Lignell, and Martin

Denison, Reaction Engineering International; and Larry Felix,Southern Research Institute, USA 561

xii

A Generic Simulation Method for the Lower and Upper Furnace of

Coal-Fired Utility Boilers Using both Air Firing and Oxy-FuelCombustion with C02 Recirculation

Ligang Zheng, Bruce Clements and Allan Runstedtler,CANMET Energy Technology Center, Natural Resources

Canada, CANADA 571

VR-XPR: A Toolkit for Rapid Development of Virtual Energy SystemsKenneth M. Bryden, Ph.D., Gengxun Huang, M.S., Peter

Johnson, M.S., Department of Mechanical Engineering, Iowa

State University; and Edmundo Vasquez, Ph.D., Research and

Development, Alliant Energy Corporation, USA 581

Coal Compatible Fuel Cells I & II

Chairman: Hans J. Ziock, Los Alamos National Laboratory

Coal Compatible Fuel Cells; A User's Wish List

Klaus. S. Lackner, Department of Earth & Environmental

Engineering, Columbia University, USA 583

Adapting Solid Oxide Fuel Cells for Coal Derived Fuels

Robert J. Remick, Associate Director, High Temperature Fuel

Cell Technology, Gas Technology Institute, USA 585

A Coal Fuelled Solid Oxide Fuel Cell SystemVik Arild, Lygre Asle, Ce M., J. Byrknes and P. Bratland,Prototech AS, NORWAY 595

Anode Materials For Coal Gas Fuel Cells

Fernando Garzon, Eric Brosha and R. Mukundan, Los Alamos

National Laboratory, USA 607

xiii

Solid Oxide Fuel Cells

S. C. Singhal, Battelle Fellow and Director, Fuel Cells, Pacific

Northwest National Laboratory, USA 609

The Opportunity for Coal-based Solid Oxide Fuel Cell PowerplantsCraig P. Jacobson, Steven J. Visco, and Lutgard C. De Jonghe,Materials Sciences Division, Lawrence Berkeley National

Laboratory, USA 611

Using Advanced Solid Oxide Fuel Cells in Zero Emission Coal SystemsRomesh Kumar and Michael Krumpelt, Electrochemical

Technology Program, Chemical Technology Division, ArgonneNational Laboratory, USA 613

VOLUME II (Pages 619 -1,187)

Coal Preparation I & II

Chair: Lisa Corathers, National Mining Association

Integrated Carbon Recovery Systems for Fine Coal Processing WasteY.P. Chugh, A. Patwardhan and D.P. Patil, Southern Illinois

University; R Q. Honaker, B. K. Parekh, D. Tao and Z. Chen,University of Kentucky; and L. Khan, Illinois State GeologicalSurvey, USA 619

The Significance of Illinois Coal and the Illinois State Geological Survey(ISGS) Washer

Latif Khan and William R. Roy, Illinois State GeologicalSurvey; and Ken K. Ho, Illinois Clean Coal Institute,USA 631

Coal Drying Improves Performance and Reduces Emissions

Charles Bullinger and Mark Ness, Great River Energy; and

Nenad Sarunac and Edward K. Levy, Energy Research Center,Lehigh University, USA 639

xiv