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Mechanisms and Mitigation of Agglomeration During Fluidized Bed Combustion of Biomass

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Mechanisms and Mitigation of Agglomeration During Fluidized Bed Combustion of Biomass Mechanisms and Mitigation of Agglomeration During Fluidized Bed Combustion of Biomass Jonathan Morris A thesis submitted in partial fulfilment of the requirements for the degree of Doctor of Engineering (EngD) February 2021 Department of Mechanical Engineering Faculty of Engineering The University of Sheffield Redaction Notice Content has been redacted in the online version of this thesis for commercial confidentiality reasons. The redacted content includes the entirety of Chapter 7 and related supplementary Appendices E-K. Where content has been redacted, it has been made clearly apparent with a notice. The overall pagination of this redacted version of the thesis remains identical to the unredacted copy. This page is intentionally left blank in the unredacted version of the thesis, and therefore remains intentionally unnumbered in this redacted version of the thesis. Abstract Fluidized bed combustion technology is increasingly used for biomass fuels, due to the high variability of their energy density and composition. However, this technology is still susceptible to ash-related issues. Agglomeration is caused by ash melting onto or reacting with bed material to form alkali silicate melts, allowing bed particles to adhere together. Accumulation of agglomerates causes bed defluidization, and consequently unscheduled downtime. This thesis investigates agglomeration mechanisms and mitigation measures at the pilot-scale, focusing on agricultural fuels that have received less attention in literature and may be of interest for boiler operators. When burning wheat straw, the magnesium-iron silicate bed material olivine lengthened defluidization times versus silica sand, though this was not sufficient to make the fuel viable. The additives kaolin and dolomite prevented bed defluidization entirely when burning miscanthus, but had no effect with wheat straw, despite chemically reacting with both fuel ashes. In combination with thermochemical modelling, it was proposed that the poor breakdown of wheat straw pellet sand release of ash to their surface allows the pellet to act as a seed for agglomerate formation, hence additives proving ineffective. Agglomeration mechanisms were studied with different fuels, bed materials and additives. This included a novel analysis of agglomerates from different bed locations, and a spatially defined study of agglomerates from tests with additives, both of which revealed mechanisms in greater detail than previously reported. A novel thermochemical modelling approach using FactSage was applied to agglomerate compositional data, together with an appraisal of the software for agglomeration studies. Through collaboration with project sponsor Sembcorp Energy UK on their “Wilton 10” bubbling fluidized bed boiler, a 5-year fuel data set was studied to determine fuel quality improvement potential. Several analytical methods were applied, including a machine learning algorithm. Recommendations were made regarding fuel quality and sampling. i Declaration of Authorship The candidate confirms that they are aware of the University of Sheffield guidance on the use of unfair means (www.sheffield.ac.uk/ssid/unfair-means). This work has not previously been presented for an award at this, or any other, university. The candidate confirms that the work submitted is their own, except where work that has formed part of jointly authored publications has been included. The contribution of the candidate and the other authors to this work has been explicitly indicated below. The candidate confirms that appropriate credit has been given within the thesis where reference has been made to the work of others. Paper I: Mechanisms and mitigation of agglomeration during fluidized bed combustion of biomass: A review. Morris, J.D., Daood, S.S., Chilton, S., Nimmo, W. 2018. Fuel, Vol. 230, pp. 452-473. This paper forms part of Chapter 2. J.D. Morris was lead author, responsible for carrying out the literature review and writing the manuscript. S.S. Daood as second supervisor provided feedback on the manuscript and project guidance. As an industrial contributor, S. Chilton supplied some further sections of the manuscript, which have been removed in this thesis, and provided feedback on the manuscript. W. Nimmo as first supervisor provided feedback on the manuscript and project guidance. Paper II: Agglomeration and the effect of process conditions on fluidized bed combustion of biomasses with olivine and silica sand as bed materials: Pilot-scale investigation. Morris, J.D., Daood, S.S., Nimmo, W. 2020. Biomass and Bioenergy, Vol. 142, Article No. 105806. This paper forms part of Chapter 4. J.D. Morris was lead author, responsible for performing testing and sample analysis, analysing data, and writing the manuscript. S.S. Daood as second supervisor assisted with pilot-scale combustion tests and provided feedback on the manuscript and project guidance. W. Nimmo as first supervisor provided feedback on the manuscript and project guidance. Paper III: The effect of using kaolin and dolomite additives to mitigate agglomeration with challenging agricultural biomass fuels. Morris, J.D., Daood, S.S., Nimmo, W. Unpublished manuscript under submission. ii This paper forms parts of Chapter 5 and Chapter 6. J.D. Morris was lead author, responsible for performing testing and sample analysis, analysing data, and writing the manuscript. S.S. Daood as second supervisor assisted with pilot-scale combustion tests and provided feedback on the manuscript and project guidance. W. Nimmo as first supervisor provided feedback on the manuscript and project guidance. For a list of all other dissemination activities in relation to this project see Appendix A. © 2021 The University of Sheffield and Jonathan Morris. The right of Jonathan Morris to be identified as author of this work has been asserted by him in accordance with the Copyright, Designs and Patents Act 1988. This copy has been supplied on the understanding that it is copyright material and that quotation from the thesis may not be published without proper prior acknowledgment or through proper citation. iii Acknowledgements I would first like to thank my supervisors, Prof. Bill Nimmo and Dr. Sheraz Daood. Bill and Sheraz provided expert guidance and supervision to develop me into a researcher over the last four years. They both enabled my success throughout the process: providing ideas and encouragement, ensuring experimental and modelling work was fruitful, securing additional resources when needed, and providing opportunities to publish and present findings. For their continued support I am incredibly grateful. Experimental work made up a large part of the research and would not have been possible without the training and support of various technical staff. At the Low Carbon Combustion Centre (LCCC), I think everyone helped at some point to run (or frequently, fix) the pilot-scale fluidized bed. Special thanks in alphabetical order to Sam Chapman, Dave Dunstan, Andy Hemstock, and Ashley Thornton, all of whom spent many hours providing dedicated technical support. For the analysis work, particularly SEM/EDX, thanks are due for Tes Monaghan, Dr. Cheryl Shaw, and Stuart Micklethwaite (Leeds University). A major benefit of the EngD is the training programme and cohort structure. I would like to thank all staff and students, past and present, at the Centre for Doctoral Training in Carbon Capture, Storage & Cleaner Fossil Energy for making the journey enjoyable, for the development opportunities, and of course for the funding. On a similar note, I would also like to thank the entire Energy 2050 group at Sheffield, as well as the wider academic and industrial community, for the many useful discussions over the years. A significant chunk of my time was spent with project sponsors Sembcorp Energy UK in Middlesbrough. A big thanks goes to the performance engineering team, past and present, during my time at Sembcorp: Howard Sutton, Nick Tann, Graeme Lewis, Jonathan Scroggie, Nicholas Chen, and Dr. Stephen Chilton. The team welcomed me, gave me interesting projects, valued my inputs, took me on many in-depth tours of the site, and contributed significantly to my development as an engineer. Many others at Sembcorp contributed to various projects over the years, and all have my gratitude. I also of course must thank my family for their support and encouragement. They are probably relieved that they will never have to hear about fluidized beds, biomass, and/or agglomeration again (or will they?). iv …And finally, one of the fun(?) things about writing a thesis is that it will sit around in a dusty corner of the library internet for a very long time. Allow me then to share a couple of anecdotes from the research process with future readers: • In March 2018, during the UCU strikes, students barricaded themselves inside the Arts Tower in Sheffield. Samples that I needed to analyse for my first conference (overseas, six weeks later) were inside my office cupboard. In the Arts Tower. Luckily, after a few stressful days rebooking carefully planned analysis, the students ended their occupation. • Towards the end of 2019, I had a few remaining pilot-scale tests planned and plenty of samples stored at the LCCC facility in Beighton. I had a test planned for the 8th of November. In the early hours of the 8th of November, the River Rother flooded the labs, destroying all my equipment and washing away most of my samples. Fortunately, I had enough results to write up, some modelling work to finish, and some samples in the
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