In order to reach the highest possible efficiencies in a coal-fired turbine-based power system, the turbine should be directly fired with the products of coal conversion. Two main types of systems employ these turbines: those based on pressurized fluidized-bed combustors and those based on integrated gasification combined cycles. In both systems, suspended particulates must be cleaned from the gas stream before it enters the turbine so as to prevent fouling and erosion of the turbine blades. To produce the cleanest gas, barrier filters are being developed and are in use in several facilities. Barrier filters are composed of porous, high-temperature materials that allow the hot gas to pass but collect the particulates on the surface. The three main configurations of the barrier filters are candle, cross-flow, and tube filters. Both candle and tube filters have been tested extensively. They are composed of coarsely porous ceramic that serves as a structural support, overlain with a thin, microporous ceramic layer on the dirty gas side that serves as the primary filter surface. They are highly efficient at removing particulate matter from the gas stream and, because of their ceramic construction, are resistant to gas and ash corrosion. However, ceramics are brittle and individual elements can fail, allowing particulates to pass through the hole left by the filter element and erode the turbine. Preventing all failure of individual ceramic filter elements is not possible at the present state of development of the technology. Therefore, safeguard devices (SGDs) must be employed to prevent the particulates streaming through occasional broken filters from reaching the turbine. However, the SGD must allow for the free passage of gas when it is not activated. Upon breaking of a filter, the SGD must either mechanically close or quickly plug with filter dust to prevent additional dust from reaching the turbine. Production of a dependable rapidly closing autonomous mechanical device at high temperatures in a dusty gas stream is difficult because of problems with materials corrosion, dust leakage, and detection of filter failure. Therefore, the Energy & Environmental Research Center is using its knowledge of the factors that make filter dust sticky at gas filtration temperatures to make a simple and inexpensive SGD that employs an adhesive yet thermodynamically stable coating on a highly porous ceramic substrate. The SGDs are placed on top of individual candle filters at the filtered gas exit. Upon failure of the filter, the dirty gas flows through the SGD where the adhesive surface rapidly and permanently traps dust particles, causing the device to plug and prevent the dust from reaching the turbine.
