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

Abstract

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. Since 1989 the U.S. Department of Energy has supported development of advanced coal gasification technology. The Wabash River and TECO IGCC demonstration projects supported by the DOE have demonstrated the ability of these plants to achieve high levels of energy efficiency and extremely low emissions of hazardous pollutants. However, a continuing challenge for this technology is the tradeoff between high carbon conversion which requires operation with high internal gas temperatures, and limited refractory life which is exacerbated by those high operating temperatures. Attempts to control internal gas temperature so as to operate these gasifiers at the optimum temperature have been hampered by the lack of a reliable technology for measuring internal gas temperatures. Thermocouples have serious survival problems and provide useful temperature information for only a few days or weeks after startup before burning out. For this reason, the Department of Energy has funded several research projects to develop more robust and reliable temperature measurement approaches for use in coal gasifiers. Enertechnix has developed a line of acoustic gas temperature sensors for use in coal-fired electric utility boilers, kraft recovery boilers, cement kilns and petrochemical process heaters. Acoustic pyrometry provides several significant advantages for gas temperature measurement in hostile process environments. First, it is non-intrusive so survival of the measurement components is not a serious problem. Second, it provides a line-of-sight average temperature rather than a point measurement, so the measured temperature is more representative of the process conditions than those provided by thermocouples. Unlike radiation pyrometers, the measured temperature is a linear average over the full path rather than a complicated function of gas temperature and the exponential Beer's law. For this reason, acoustic pyrometry is well suited to tomography allowing detailed temperature maps to be created through the use of multiple path measurements in a plane. Therefore, acoustic pyrometry is an attractive choice for measuring gas temperature inside a coal gasifier. The objective of this project is 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 is organized in three phases, each of approximately one year duration. The first phase consists 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 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 can be tested on an operating gasifier. The second phase consists of designing and fabricating a series of prototype sensors, testing them in the lab and at a gasifier facility, and developing a conceptual design for an engineering prototype sensor. The third phase consists of designing and fabricating the engineering prototype, testing it in the lab and in a commercial gasifier, and conducting extended field trials to demonstrate sensor performance and investigate the ability to improve gasifier performance through the use of the sensor.