7/29/2019 Coal Feled Diesel

1/10

DOEflvIC/23174-93/C0175Coal-Fueled Diesel Emissions Control Technology Development

Authors:C. Cook,E. Gal DOE/MC/23174--93/C0175M. MengelW. Van Kleunen D_,93 008874

Contractor: ....... _ iGE Transportation Systems2901 East Lake RoadErie, PA 16531

Contract Number:DE-AC21-88MC23174

Conference Title:Energy-Sources Technology Conference and Exhibition

Conference Location:

Houston, TexasConference Dates:

January 31-February 3, 1993

Conference Sponsor:he American Society of Mechanical Engineers

/I' I_lgTl=llBIt,mON OF THIS DOCUMENT IS UNLIMITED

,, ' ' ' i,i, , , , ,, ,

7/29/2019 Coal Feled Diesel

2/10

dt

DISCLAIMERThis report was prepared as an account of work sponsored by an agency of theUnited States Government. Neither the United States Government nor anyagency thereof, nor any of their employees makes any warranty, express orimplied, or assumes any legal liability or responsibility for the accuracy,completeness or usefulness of any information, apparatus, product, or processdisclosed, or represents Ihat its use would not infringe privately owned rights.Reference herein to any specific commercial product, process, or service by tradename, trademark, manufacturer, or otherwise, does not necessarily constitute orimply its endorsement, recommendation, or favoring by the United StatesGovernment or any agency thereof. The views and opinions of authorsexpressed herein do not necessarily state or reflect those of the United StatesGoverrunent or any agency thereof.This report has been reproduced directly from the best available copy.Available to DOE and DOE contract"rs from the Office of Scientific andTechnical Infomlation, P.O. Box 62, Oak Ridge, TN 37831; prices availablefrom (615)576-8401, FFS 626-8401.Av_dlable to the public from the National Technical Information Service, U.S.Department of Commerce, 5285 Port Royal Rd., Springfield, VA 22161.

7/29/2019 Coal Feled Diesel

3/10

! ..../!L .....

COAL-FUELED DIESEL EMISSIONS CONTROL TECHNOLOGY DEVF2.OPMENT

C. Cook, E. Gal, M. Mengei and W. Van KleunenGeneral Electric Environmental Services, Inc.200 North Seventh Street, Lebanon, PA 17042

ABSTRACTThe objective of this project is to develop an emissions If the emissions control system costs mo_ than 10% of the ov

control system for a GE locomotive powered by a Coal Water cost of the locomotive, the conversion from conventional diesSlurry(CWS) fuel diesel engine. The development effort is fuel to CWS fuel may be unattractive. Further, there is a limdirected toward reducing paniculate matter, SO2 and NOx amount of space available on the locomotive, with width andemissions fromthe engine exhaust gas at 700 - 800F and 1-2 psig. height fixed by right of way con_derations. The third constrThe commercial system should be economically attractive while is the pressure drop across the emissions control system, withsubject to limited space constraints, higher pressure drop resulting in reducedengine efficiency.

After testing various alternatives, a system composed of a The characteristics of the emissions, and the bench scbarrierfilter with sorbent injection upstream was selected for and slip stream systems used to evaluate various concepts ofcontrolling particulates, SO2 andNOx emissions. In bench scale controlling emissions, are described in detail in the previousand500 acfm slip stream tests, removal efficiencies greater than progress reports (Galet ali 1990 & 1991). Beeau._ of the.s90% for SO2 and 85% for NOx were achieved. Particulate size of the particulate matter, it was determined that only a bemissions from the barrier filter are within NSPS limits, filter can meet particulate matter emission requirements.

Furthermore, space constraints requize high _ throughputsvolume of filter, and a high filtration velocity through the filINTRODUCTION media. At high filtration velocities, the fmc pazficlm tend to

very resistive, non-permeable filter cake. To reduce pressurDiesel engines may be powered by CWS containing 50%, drop and to allow effective cleaning of the filter media, it wa

by weight, pulverized, cleaned coal (Gal et al 1990; Flynn and determined that a coarser material should be injected into theHsu 1989; Nydick et al 1987). Depending on the source, the stream, upstreamof the barrierfilter. The coarser material,washed coal contains about 1% ash and 0.5-1% sulfur. When blended with the fine engine exhaust particles, forms a moreburned in a diesel engine, the exhaust gas contains particulate permeable filter cake which is easier to remove from the filtmatterand SO2 in greater quantities than exhaust gas from media when it is cleaned.conventional diesel engines. In order for a CWS fueled engine tobe environmentally acceptable, its emissions must be reduced. In the concept developed, the emissions control syste

designedo be located downstreamf the _er wherTo meet emission levels associated with conventional exhaust gas is at 700-800F and atjust above atmospheric pr

diesel engine operation, the emissions control system must remove Particulate matter will be removed by a high temperature fibat least 95% of the particulates and at least 67 % of the SO2 in the metal filter media. Sorbent, in the form of fine powder (coaexhaust gas. In order to meet NSPS requirements for coal fired than the CWS ash) will be injected upstream of the filter toutility boilers, particulates emission would have to be reduced by capture SO2 and to create a permeable filter cake. Ammoni98% and SO2 and NOx would need to be reduced by 50%. injection can significantly reduce NOx emission when the Ssorbent is a catalyst for NOx reduction.

In addition to emissions, there are several other aspects tobe considered. The system must be economically attractive.

7/29/2019 Coal Feled Diesel

4/10

To accommodate space constraints, a compact barrier filterdesign was developed. The filter housing contains 6 - 8 sq. ft. offiltermedia percubic foot and b designed to ope_te at a filtrationvelocity of up to i0 ft/mim A surface areaof 2,000 sq.fl.contained in a 420 cu.ft, housing is requiredfor filteringapproximately 20,000 aefm of exhaust gas. A conceptual designof CWS fuel diesel locomotive with emission control system is ] |shown in Figure 1.

I :'7.'--7 ....Aoldnowmo olf I jL, ........ ::=._..-,, : ., .. ,sp=ceonstr_ts,wassu_.ssfuuyestedca1etal1991).The I __, ,/, _ _,Y= "!!I-)._._ ,.....,J-_ .1_.._ ...,a .m- ._ ,results of the cold flow testprovided the basis for the design of a _,_,-,-_ '__---_; _-,,.w,:_ liI,_-----/iII LT_:_i ,_tl'"ri_., i _!_Ii -'1It" , ' 10500 acfm hot gas test filter, as well as for the design of the fur II- r__i _i, i __ ii / Iscale20,000acfmsystem. I I i I ! JI II'_,"lli_=L= t,,_,ila=ai = =I : , ig=_ ......!1 .'=1lL_J[)-IIil?_,_ 11EXPERIMF_2NTAL ,,11- / _''_tt"

m t i mtJl_J

Following cold flow modeling, a 500 acfm system treating "ffi--'-=_'_a slip stream from a single cylinder CWS fuel diesel engine wasdesigned, constructed and tested. The system, as installed in theengine test laboratory, is shown in Figure 2. The system consists Figure 2: Test CeU Arrangement for Slip Streamof a 6 in. diameter pipe with a flow control valve which diverts up Envelope Filter Testto 500 acfm of exhaust gas from the single cylinder engineexhaust manifold. A gravity feeder injects sorbent into theexhaust gas stream which flows into the filter. In addition,anhydrous ammonia is injected into the gas stream from apressurized cylinder to control NOx emission. The gas enters thefilter housing from the top. Turning vanes direct the flowdownwardtoward the filter elements. The gas leavesthe filter "L -from the side. A detailed drawing of the filter, a filter element auim"" mland compressed air system for cleaning the filters elements areshown in Figure 3. "_== J

The filter media elements are closely spaced to increase thesurface area-to-cloth ratio and to meet the space constraints. Thefilter media is composed of fiber metal with 3-5 micron fibersexhibiting good filtration eharactea'isties. The fiber metalelements axe relatively light and are constructed of Iconel or 316 =atom

SS, and can operate in the exhaust gas environment. ___ .J_L.

,= _,. _=_g_ .....,_ _, ,i='_Patc=ilLd-_ z'-! 311illlllm,nl".___" " " I ,,=.,!.=..

i iiiiiiilllllll l "--" ,Figure 1: Conceptual Design of CWS Fuel Figure 3: Slip Stream Envelope Filter to Treat 500ACFM of Exhaust Gas from a Single

Diesel Locomotive Cylinder CWS Fuel Diesel Engine

,

7/29/2019 Coal Feled Diesel

5/10

RESULTS and DISCUSSIONHigh removal efficiency of particalate matter and SO2 was

achieved using the barrierfilter. The NOx removal efficiencywas somewhat lower than was achieved in a bench scale test, yetmore than 85 % reduction of NOx level could be achieved. Since 500-a CWS fuel diesel engine produces significantly lower NOxconcentration compared to a conventional engine (400-700 ppm _ --"compared to 1000-1500 ppm), the controlled NOx emissions froma CWS fuel diesel engine is significantly less than the NOx ,.ooemission from a conventional engine.

In Figures 4, 5 and 6, gas flow, pressure drop and NOx "tozoo,a:concentration are shown as a function of test time during a 3 hoursingle cylinder engine test. Typical gas flow rate through the oemission control system is shown in Figure 4. At a flow rate of _- 200445 acfm, the filtration velocity was 8.9 ft/min. The flow was

7/29/2019 Coal Feled Diesel

6/10

;d,' ,,2.1 15 -

otw_ 5 "'

0 0_.0 50 1O0 150 200 _.

TIME, MINUTES .rr"

0 Figure 6: NOx Removal Across Emissions Control a _ 10o 150 200

System with NII3 and CuSO 4 on Alumina "nME,MINLrrEsInjection Upstream of High TemperatureFilter -- Test 005 Figure 7: Pressure Drop Across Emissions ControlSystem, Test 006 -- Filtration Velocity =8.5 FPM, Particulate Loading - 0.7

In Figures 9 and 10, the effect or: NaHCO 3 injection upon Grains/ACFSO2 emission is sho,,_.i for two tests of 3 hours or longer duration.In Figure 9, SOz was reduced from 230-320 ppm at the filterinlet, to 0-50 ppm at the filter outlet. Filter cleaning had verylittle impact on the SO 2 emission, indicating that most of the SO2removal occurred in the gas stream upstream of the filter ratherthan on the filter cake. This fact is illustrated in Figure 10, asoutlet SO:, increased from approximately 50 ppm, to 150 ppm, assoon as NaHCO3 injection was stopped. Ammonia injectionduring NaI-ICO3 injection resulted in a 15-25 % reduction of NOxemission, as shown in Figures 9 and 10.

20The effect of filter cake conditioning on pressure drop is _:raAno,tU_m,._millustrated by Figures 11 and 12. At a constant gas flow of sz _t_ 10.e

approximately 420 acfm (8.4 ft/min filtration velocity) and with 6 i'an alumina powder feed rate corresponding to 3-10 grains/acf, an 3: in _ -Figure 12, when sorbent injection was eliminated 80 minutes after a: Io flhe beginning of the test, pressure drop increased significantly due a:"_ 10 _to the formation of filter cake composed of only engine exhaust ,., / , ,a:particles. That filter cake strongly adhered to the filter media and -_ //1was not effectively removed by high pressure air pulsing, ta

n-

0 0 50 100 150"I'IME, MINUTES

Figure 8: Pressure Drop Across Emissions ControlSystem with NaHCO 3 Particulate Loadin= 0.7-1.0 GrainsdACF Test 007

_

........ Ill ,ip,i ,

7/29/2019 Coal Feled Diesel

7/10

4

'tm,

A full scale20,000 acfmsystemhasbeendesigned. Thefull scalesysmmwill treattheentireexhaustgas flow from a 12cylinder, 3,000 HP, CWS fuel testenginein GETSEngineTesLaboratory and will demonstratethe viability of the emissionscontrol concept. The system, including sorbent silo, sorbentinjection system, ammonia injection system, high temperature

5i t_f _ envelope filter arid spent sorbent hopper, is shown in Figure 13.

=4oo __ ,z, s i13. I I

z70_ 2OO - ., ,, .. _

cq F _' _

0 r-_--J -- _ __

z I008 AI 1 :_._00

4r_ i/,. O0 50 100 150 200 250 _ 200 ............

TIME,INUTES

Figure 9: SO2 and NOx Removal Across Emissions looControl System with NaHCO3 Injection2NaHCO3/SO 2 = 1.9 Test 006

0 ...........0 5O TOO 1TIME, MINUTES

Figure 11: Typical Gas Flow Rate Through TheEmissions Control System Test 009 -- "Filtration Velocity = 8.4 FPM

_ _ ............

. _, L ,: I- N.HCO_CN.mC'nON._UNSnC.Fz ! ....0.7 I Ol zT-_.0 ,ol 1.o"/ ' ', , CONCLUSIONS5400 i i," I ' ' Basedon the slip stream tests described in this progresso ' j report, the following conclusions can be made:I I_ I Iz t _ I sl A barrier filter, with sorbent injection upstream, is a viable

z , t , , concept for controlling particulates, SO2 and NOx emissions200 I ! j' i ' N_ from a CWS fuel diesel engine.q I !

_ __J_L The bah'icr filter with sodoent injection system can + instaJz _ A conditioner, which can also be an SO2sorbent, should be0 .......o 5o _oo _so 2o0 added to the exhaust gas to reduce filter cake pressure dropaTIME.MINUTES tOallow cleaning of the filter media.

Removal efficiencies greater than 90% for SO2 and 85% forFigure 10: SO2 and NOx Removal Across Emissions NOx cart be expected.

Control System with NaI-ICO3 Injection.2NaI-ICO3/SO2 = 1.9 to 2.9 at AverageFilter Inlet SO2 Concentration = 270

PPMV -- Teat 0075

7/29/2019 Coal Feled Diesel

8/10

r

REFERENCESFlynn P.L. and Hsu B.D., (1989), Coal Fueled DieselTechnology Development, Proceeding of the Sixth Annual Coal-

20 .A - Fueled Heat Engines and Gas Stream Cleanup Systems,somtm _,:enoN /V' Morgantown, West Virginia.... _1 _ ii_3GRAINSIACF -_10 I NONE /t Gal E. Flynn P., Samuel E., and Cohen M. (1990), Coal-._ I I _ I15 li ) - Fueled Diesel Technology Development Emissions: A Status

z I I

- i I A/ Report, Proceedings of the Seventh Annual Coal-Fueled Heat, t Engines and Gas Stream Cleanup Systems Contractors Review

,,. , l Meeting, Morgantown, West Virginiae_ AIGal E., Cook C.S., Cohen M. Van Kleunen W. and Hamilton,t}t/}ta R., (199 I), Coal-Fueled Diesel Emissions Control Technologywa. _ Development: A Status Report, Proceedings of the Eighth Annu

_, s --- _/ Coal-Fueled Heat Engines and Gas Stream Cleanup SystemsContractors Review Meeting, Morgantown, West Virginiao -- Nydick S.E., Porchet F. and Steiger H.A., (1987), Continuedo r,o 10o 15o Development of a Coal Water Slurry Fired Slow-Speed Diesel

TIME,MINtfrEs Engine, ETCE, Dallas, Texas

Figure 12: Pressure Drop Across Emissions ControlSystem Test 009 -- Filtration Velocity =8.4 FPM

' ' i lT! ' , i.......-.... +.-i-.+.... ' - I i I.__l I I , _I.....ll |i|||l I II I li 11p i 1111 [111111 [_.J__tn_!i_ :_6

Figure 13: Full Flow Envelope Filter with Inlet Ductand Sorbent Injection System

ACKNOWLEDGMENTWe wish to acknowledge the support of this work by theMorgantown Energy Technology Center (ME'TC) of the U.S.Department of Energy under Contract No. DE-AC21-88MC23174.

6

7/29/2019 Coal Feled Diesel

9/10

7/29/2019 Coal Feled Diesel

10/10