Development of an Acoustic Sensor On-Line Gas Temperature Measurement in Gasifiers

Peter Ariessohn

关键词: ACCURACY;    ACOUSTICS;    ATTENUATION;    COAL;    CONTRACTORS;    DESIGN;    EVALUATION;    GASIFICATION;    PYROMETERS;    RIVERS;    STAINLESS STEELS;    TEMPERATURE MEASUREMENT;    TESTING;   

DOI  :  10.2172/966140
RP-ID  :  None
PID  :  OSTI ID: 966140
Others  :  TRN: US200921%%379

美国|英语

来源: SciTech Connect

【 摘 要 】

This project was awarded under U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL) Program Solicitation DE-PS26-02NT41422 and specifically addresses Technical Topical Area 2 - Gasification Technologies. The project team includes Enertechnix, Inc. as the main contractor and ConocoPhillips Company as a technical partner, who also provides access to the SG Solutions Gasification Facility (formerly Wabash River Energy Limited), host for the field-testing portion of the research. The objective of this project was to adapt acoustic pyrometer technology to make it suitable for measuring gas temperature inside a coal gasifier, to develop a prototype sensor based on this technology, and to demonstrate its performance through testing on a commercial gasifier. The project was organized in three phases, each of approximately one year duration. The first phase consisted of researching a variety of sound generation and coupling approaches suitable for use with a high pressure process, evaluation of the impact of gas composition variability on the acoustic temperature measurement approach, evaluation of the impact of suspended particles and gas properties on sound attenuation, evaluation of slagging issues and development of concepts to deal with this issue, development and testing of key prototype components to allow selection of the best approaches, and development of a conceptual design for a field prototype sensor that could be tested on an operating gasifier. The second phase consisted of designing and fabricating a series of prototype sensors, testing them in the laboratory, and developing a conceptual design for a field prototype sensor. The third phase consisted of designing and fabricating the field prototype, and testing it in the lab and in a commercial gasifier to demonstrate the ability to obtain accurate measurements of gas temperature in an operating gasifier. Following the completion of the initial 3 year project, several continuations were awarded by the Department of Energy to allow Enertechnix to conduct extended testing of the sensor at the Wabash River facility. In February, 2008 the sensor was installed on the gasifier in preparation for a long-term test. During the initial testing of the sensor a stainless steel tube on the sensor failed and allowed syngas to escape. The syngas self-ignited and the ensuing small fire damaged some of the components on the sensor. There was no damage to the gasifier or other equipment and no injuries resulted from this incident. Two meetings were held to identify the root causes of the incident-one at Wabash River and one at Enertechnix. A list of recommended improvements that would have addressed the causes of the incident was created and presented to the Department of Energy on May 2, 2008. However, the DOE decided not to pursue these improvements and terminated the project. This report describes all of the activities conducted during the project and reports the findings of each activity in detail. The investigation of potential sound generation and coupling methods led to the selection of a reflected shock method which has been developed into a functioning prototype device. The principles of operation of this device and its performance characteristics are described in the report. Modeling of the attenuation of sound by suspended particles and by interaction of the sound pulses with the high temperature syngas inside the gasifier was conducted and the predictions of those models were used to determine the required sound pulse intensity to allow the sound pulses to be detected after passage through the gasifier environment. These modeling results are presented in this report. A study of the likely spatial and temporal variability of gas composition inside the gasifier was performed and the results of that study was used to predict the impact of that variability on the accuracy of the acoustic temperature method. These results are reported here. A design for a port rodding mechanism was developed to deal with potential slagging issues and was incorporated into the prototype sensor. This port rodding mechanism operated flawlessly during the field testing, but because these tests were performed in a region of the gasifier that experiences little slagging, the effectiveness of the rodding mechanism in dealing with highly slagging conditions was not fully demonstrated. This report describes the design and operation of the automated Gasifier Acoustic Pyrometer (autoGAP) which was tested at the Wabash River facility. The results of the tests are reported and analyzed in detail. All of the objectives of the initial R&D project were achieved and a field prototype acoustic pyrometer sensor was successfully tested at the Wabash River gasifier plant.