Development Of An Acoustice Sensor For On-Line Gas Temperature Measurement In Gasifiers

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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, ... continued below

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Ariessohn, Peter & Hornung, Hans October 1, 2006.

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Description

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. 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 project have been achieved. A field prototype acoustic pyrometer sensor has been successfully tested at the Wabash River gasifier plant. Acoustic signals were propagated through the gases inside the gasifier and were detected by the receiver unit, the times of flight of these sound pulses were measured and these propagation times were converted into temperatures which agreed very well with thermocouple measurements made in the same location as the acoustic measurements. The acoustic pyrometer system was operated under computer control and was shown to be capable of making measurements every 10 minutes (or more frequently) for an extended period. Some minor mechanical issues remain. During testing on the gasifier, one of the pressure seals failed after two days of operation, but this can easily be corrected by the use of a different seal design. Also, the testing performed so far was conducted in a region of the gasifier where conditions are somewhat less harsh than in other parts of the gasifier where thermocouples will not survive. Therefore, additional testing should be performed in those harsher locations to demonstrate the ability of this new measurement technology to provide temperature measurements that cannot be obtained by any other means.

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  • Report No.: None
  • Grant Number: FC26-03NT41617
  • DOI: 10.2172/924343 | External Link
  • Office of Scientific & Technical Information Report Number: 924343
  • Archival Resource Key: ark:/67531/metadc896092

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  • October 1, 2006

Added to The UNT Digital Library

  • Sept. 27, 2016, 1:39 a.m.

Description Last Updated

  • Nov. 23, 2016, 3:32 p.m.

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Ariessohn, Peter & Hornung, Hans. Development Of An Acoustice Sensor For On-Line Gas Temperature Measurement In Gasifiers, report, October 1, 2006; United States. (digital.library.unt.edu/ark:/67531/metadc896092/: accessed December 14, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.