Polttoainekoostumuksen vaikutus lentotuhkan laatuun ja hyötykäyttömahdollisuuksiin UPM-Kymmene Oyj:n Kaukaan tehtailla

Tavoitteena tässä diplomityössä oli selvittää UPM-Kymmene Oyj:n Kaukaan tehtaiden lentotuhkan hyötykäyttömahdollisuuksia. Tarkastelussa olivat mukana metsälannoite-, maarakennus- sekä sementtiteollisuuskäytöt. Ensin työssä tarkasteltiin näitä vaihtoehtoja kirjallisuuden perusteella. Tämän jälkeen pohdittiin Kaukaan lentotuhkasta tehtyjen analyysien perusteella, mihin käyttökohteisiin lentotuhka soveltuu tällä hetkellä, sekä tulevaisuudessa uuden biopolttoainekattilan myötä. Lentotuhkan hyötykäyttöä lannoitteena ja maarakentamisessa säätelee lainsäädäntö. Lannoitteille on asetuksessa säädetty tietyille haitta-aineille enimmäispitoisuudet, jotka tuhkan tulee alittaa, jotta sitä voitaisiin hyödyntää. Maarakennuskäytölle on asetuksessa määritelty raja-arvot, jotka alitettaessa voidaan tuhkaa hyödyntää rakenteissa ilmoitusmenettelyllä. Tämä menettely helpottaa rakennusprojekteja huomattavan paljon, sillä tällöin ympäristölupaa ei tarvitse hakea jokaiselle projektille erikseen. Maarakennuskäyttö on mahdollista, vaikkei raja-arvoja alitettaisikaan, mutta tällöin ympäristöluvan hakeminen hankaloittaa projektien etenemistä ja aiheuttaa kustannuksia. Tuhkan on lisäksi oltava ominaisuuksiltaan riittävän hyvää, jotta hyötykäyttö olisi mahdollista. Kaukaan tuhkasta tehtyjen analyysien perusteella huomattiin, että se sopii hyvin metsälannoitteeksi ja todennäköisesti myös sementtiteollisuuskäyttöön. Maarakennuskäytön osalta tulokset osoittivat tuhkan olevan juuri rajoilla ilmoitusmenettelyn hyödyntämisen suhteen. Maarakennuskäytöstä tarvitaankin vielä lisäselvityksiä jatkossa. Uudessa polttolaitoksessa poltetaan myös turvetta puuperäisen lisäksi. Kirjallisuuden perusteella voitiin tehdä arvio, mihin suuntaan turve tulee tuhkaa todennäköisesti muuttamaan. Todettiin, että turpeen poltto parantaa todennäköisesti tuhkan laatua sementtiteollisuudessa käytön kannalta. Tuhkan lannoitekäyttöön turpeen poltolla todettiin taas olevan negatiivisia vaikutuksia. Maarakennuskäytön kannalta turpeella saattaa myös olla negatiivisia vaikutuksia. Tuhkaa kannattaisikin käyttää sementtiteollisuudessa silloin kun turvetta on polttoaineessa paljon ja muuhun käyttöön silloin kun turvetta on vähän.

Biomass Utilization in PFC Co-firing System with the Slagging and Fouling Analysis

Master’s thesis Biomass Utilization in PFC Co-firing System with the Slagging and Fouling Analysis is the study of the modern technologies of different coal-firing systems: PFC system, FB system and GF system. The biomass co-fired with coal is represented by the research of the company Alstom Power Plant. Based on the back ground of the air pollution, greenhouse effect problems and the national fuel security today, the bioenergy utilization is more and more popular. However, the biomass is promoted to burn to decrease the emission amount of carbon dioxide and other air pollutions, new problems form like slagging and fouling, hot corrosion in the firing systems. Thesis represent the brief overview of different coal-firing systems utilized in the world, and focus on the biomass-coal co-firing in the PFC system. The biomass supply and how the PFC system is running are represented in the thesis. Additionally, the new problems of hot corrosion, slagging and fouling are mentioned. The slagging and fouling problem is simulated by using the software HSC Chemistry 6.1, and the emissions comparison between coal-firing and co-firing are simulated as well.

Prerequisites for commercialization of tube granulator for fly ash

A large amount of fly ash is produced in power plants and a big fraction of it ends up as waste to landfills. Disposal of fly ash to landfills is expensive for power plants due to for example waste taxation. However fly ash can utilized in different applications. Possibility of utilizing fly ash can be increased by granulation which also removes the dustiness problems of ash. This Thesis deals with the prerequisites for commercialization of a new granulation technique, tube granulation. Tube granulation technique utilizes water, calcium oxide in fly ash plus carbon dioxide and heat from flue gas. This Thesis determines the necessary auxiliary equipment for tube granulation, approaches for process dimensioning and implementation of the granulation process into a continuous power plant process. In addition, the economic benefits of tube granulation are examined from the user’s perspective. A continuous tube granulation process requires the following auxiliary systems to function: ash system, water feed system and flue gas system. Implementation of tube granulation system into a power plant process depends on the specific power plant but a general principle is that fly ash should be obtained to the granulator as fresh as possible and flue gas should be taken from the pressure side of a flue gas fan. Dimensioning of the process can be examined for example in terms of degree of filling and residence time in the granulator or in terms of granule drying. Determining the optimal dimensioning parameters requires pilot tests with the granulator.

Ecological efficiency in thermoelectric power plants

This work evaluates the environmental impact resulting from the natural gas and diesel combustion in thermoelectric power plants that utilize the combined cycle technology (CC), as regarding to Brazilian conditions according to Thermopower Priority Plan JPP). In the regions where there are not natural gas the option has been the utilization of diesel and consequentily there are more emission of pollutants. The ecological efficiency concept, which evaluates by and large the environmental impact, caused by CO2, SO2, NOx and particulate matter (PM) emissions. The combustion gases of the thermoelectric power plants working with natural gas (less pollutant) and diesel (more pollutant) cause problems to the environment, for their components harm the human being life, animals and directly the plants. The resulting pollution from natural gas and diesel combustion is analyzed, considering separately the CO2, SO2, NO2 and particulate matter gas emission and comparing them with the in use international standards regarding the air quality. It can be concluded that it is possible to calculate thermoelectric power plant quantitative and qualitative environment factor, and on the ecological standpoint, for plant with total power of 41441 kW, being 27 170 kW for the gas turbine and 14271 kW for the steam turbine. The natural gas used as fuel is better than the diesel, presenting ecological efficiency of 0.944 versus 0.914 for the latter, considering a thermal efficiency of 54% for the combined cycle. (c) 2006 Elsevier Ltd. All rights reserved.

DEVELOPMENT AND APPLICATION OF SHORT-TERM MUTAGENICITY AND CYTOTOXICITY BIOASSAYS FOR INTEGRATED HEALTH ASSESSMENT STUDIES OF COAL FLY ASH EMISSIONS

Two respirable coal fly ash samples ((LESSTHEQ) 3(mu)m), one from a pressurized fluidized-bed combustion miniplant and one from a conventional combustion power plant, were investigated for physical properties, chemical composition and biological activity. Electron microscopy illustrated irregularity in fluidized-bed combustion fly ash and sphericity in conventional combustion fly ash. Elemental analysis of these samples showed differences in trace elements. Both fly ash samples were toxic in rabbit alveolar macrophage and Chinese hamster ovary cell systems in vitro. The macrophages were more sensitive to toxicity of fly ash than the ovary cells. For measuring the cytotoxicity of fly ash, the most sensitive parameters were adenosine triphosphate in the alveolar macrophage system and viability index in the hamster ovary system. Intact fluidized-bed combustion fly-ash particles showed mutagenicity only in strains TA98 and TA1538 without metabolic activation in the Ames Salmonella assay. No mutagenicity was detected in bioassay of conventional combustion fly ash particles. Solvent extraction yielded more mass from fluidized-bed combustion fly ash than from conventional combustion fly ash. The extracts of fluidized-bed combustion fly ash showed higher mutagenic activity than conventional combustion fly ash. These samples contained direct-acting, frameshift mutagens.^ Fly ash samples collected from the same fluidized-bed source by cyclones, a fabric filter, and a electrostatic precipitator at various temperatures were compared for particle size, toxicity, and mutagenicity. Results demonstrated that the biological activity of coal fly ash were affected by the collection site, device, and temperature.^ Coal fly ash vapor-coated with 1-nitropyrene was developed as a model system to study the bioavailability and recovery of nitroaromatic compounds in fly ash. The effects of vapor deposition on toxicity and mutagenicity of fly ash were examined. The nitropyrene coating did not significantly alter the ash's cytotoxicity. Nitropyrene was bioavailable in the biological media, and a significant percentage was not recovered after the coated fly ash was cultured with alveolar macrophages. 1-Nitropyrene loss increased as the number of macrophages was increased, suggesting that the macrophages are capable of metabolizing or binding 1-nitropyrene present in coal fly ash. ^

Radiological and material characterization of high volume fly ash concrete

The main goal of research presented in this paper was the material and radiological characterization of high volume fly ash concrete (HVFAC) in terms of determination of natural radionuclide content and radon emanation and exhalation coefficients. All concrete samples were made with a fly ash content between 50% and 70% of the total amount of cementitious materials from one coal burning power plant in Serbia. Physical (fresh and hardened concrete density) and mechanical properties (compressive strength, splitting tensile strength and modulus of elasticity) of concrete were tested. The radionuclide content (226Ra, 232Th and 40K) and radon massic exhalation of HVFAC samples were determined using gamma spectrometry. Determination of massic exhalation rates of HVFAC and its components using radon accumulation chamber techniques combined with a radon monitor was performed. The results show a beneficial effect of pozzolanic activity since the increase in fly ash content resulted in an increase in compressive strength of HVFAC by approximately 20% for the same mass of cement used in the mixtures. On the basis of the obtained radionuclide content of concrete components the I -indices of different HVFAC samples were calculated and compared with measured values (0.27e0.32), which were significantly below the recommended 1.0 index value. The prediction was relatively close to the measured values as the ratio between the calculated and measured I-index ranged between 0.89 and 1.14. Collected results of mechanical and radiological properties and performed calculations clearly prove that all 10 designed concretes with a certain type of fly ash are suitable for structural and non-structural applications both from a material and radiological point of view.

Development of a Rational Characterization Method for Iowa Fly Ash, HR-286, Annual Progress Report 2, 1987

The following report summarizes research activities on the project for the period December 1, 1986 to November 30, 1987. Research efforts for the second year deviated slightly from those described in the project proposal. By the end of the second year of testing, it was possible to begin evaluating how power plant operating conditions influenced the chemical and physical properties of fly ash obtained from one of the monitored power plants (Ottumwa Generating Station, OGS). Hence, several of the tasks initially assigned to the third year of the project (specifically tasks D, E, and F) were initiated during the second year of the project. Manpower constraints were balanced by delaying full scale implementation of the quantitative X-ray diffraction and differential thermal analysis tasks until the beginning of the third year of the project. Such changes should have little bearing on the outcome of the overall project.

Biomass Refinery as a Renewable Complement to the Petroleum Refinery

Biomass Refinery is a sequential of eleven thermochemical processes and one biological process with two initial basic treatments: prehydrolysis for lignocellulosics and low temperature conversion for biomass with medium-to-high content of lipids and proteins. The other ten processes are: effluent treatment plant, furfural plant, biodiesel plant, cellulignin dryer, calcination, fluidized bed boiler, authotermal reforming of cellulignin for syngas production, combined cycle of two-stroke low-speed engine or syngas turbine with fluidized bed boiler heat recovery, GTL technologies and ethanol from cellulose, prehydrolysate and syngas. Any kind of biomass such as wood, agricultural residues, municipal solid waste, seeds, cakes, sludges, excrements and used tires can be processed at the Biomass Refinery. Twelve basic products are generated such as cellulignin, animal feed, electric energy, fuels (ethanol, crude oil, biodiesel, char), petrochemical substitutes, some materials (ash, gypsum, fertilizers, silica, carbon black) and hydrogen. The technology is clean with recovery of energy and reuse of water, acid and effluents. Based on a holistic integration of various disciplines Biomass Refinery maximizes the simultaneous production of food, electric energy, liquid fuels and chemical products and some materials, achieving a competitive position with conventional and fossil fuel technologies, as well as payment capacity for biomass production. Biomass Refinery has a technical economical capability to complement the depletion of the conventional petroleum sources and to capture its GHGs resulting a biomass + petroleum ""green"" combination.

Availability analysis of heat recovery steam generators used in thermal power plants

The combined-cycle gas and steam turbine power plant presents three main pieces of equipment: gas turbines, steam turbines and heat recovery steam generator (HRSG). In case of HRSG failure the steam cycle is shut down, reducing the power plant output. Considering that the technology for design, construction and operation of high capacity HRSGs is quite recent its availability should be carefully evaluated in order to foresee the performance of the power plant. This study presents a method for reliability and availability evaluation of HRSGs installed in combined-cycle power plant. The method`s first step consists in the elaboration of the steam generator functional tree and development of failure mode and effects analysis. The next step involves a reliability and availability analysis based on the time to failure and time to repair data recorded during the steam generator operation. The third step, aiming at availability improvement, recommends the fault-tree analysis development to identify components the failure (or combination of failures) of which can cause the HRSG shutdown. Those components maintenance policy can be improved through the use of reliability centered maintenance (RCM) concepts. The method is applied on the analysis of two HRSGs installed in a 500 MW combined-cycle power plant. (C) 2010 Elsevier Ltd. All rights reserved.

Bending fatigue of stainless steel shear pins belonging to a hydroelectric plant

Coaracy Nunes was the first hydroelectric power plant in the Amazon region, being located in Araguari River, Amapa State, Brazil. The plant operates since 1976, presenting now a nominal capacity of 78 MW. The shear pins, which are installed in the turbine hydraulic arms to control the wicket gate and regulate the water flow into the turbine blades, suffered several breakdowns since 2004. These shear pins are made of an ASTM 410 stainless steel and were designed to break by a shear overload of 120 kN. Fractographic investigation of the pins, however, revealed two types of fracture topographies: a region of stable crack propagation area, with non-pronounced striation and secondary cracks; and a region of unstable propagation, featuring elongated dimples. These results indicated that the stable crack propagation occurred by fatigue (bidirectional bending), which was nucleated at machining marks under high nominal load. Finite element analysis was carried out using two loading conditions (pure shear and a combination of shear and bending) and the results indicated that the presence of a bending stress strongly increased the stress concentration factor (85% rise in the shear stress and 130% rise in the Von Mises stress). Misalignment during shear pins assembly associated with vibration might have promoted the premature failure of the shear by bending fatigue. (C) 2008 Elsevier Ltd. All rights reserved.

Renewable Power Sources

Of all of the sources of renewable energies available one can argue that the most abundant and accessible are solar power, radiation, and the energy of the tides (70 % of the earth surface is covered by water). The tidal wave energy hasn’t seen a widespread distribution yet, mainly due to the lack of interest of the governments, most of the coastal areas of the world are exclusive responsibility of the governments, thus not easily open for private venture. Considering solar power, there exist two main fields of application, land based systems and space based systems. The former systems are still in a very embryonic phase, with Japan being the lead researcher in the field, with an experimental satellite-power station to be launched before 2010. Land based systems, on the other hand, are well studied, with major research and application programs in all known forms of solar power production. Given a minimum value of incident radiation, and applying the appropriate system, (i.e. power plant type), for any given area the solar power becomes an income-producing industry.

Impact of a price-maker pumped storage hydro unit on the integration of wind energy in power systems

The increasing integration of larger amounts of wind energy into power systems raises important operational issues, such as the balance between power generation and demand. The pumped storage hydro (PSH) units are one possible solution to mitigate this problem, once they can store the excess of energy in the periods of higher generation and lower demand. However, the behaviour of a PSH unit may differ considerably from the expected in terms of wind power integration when it operates in a liberalized electricity market under a price-maker context. In this regard, this paper models and computes the optimal PSH weekly scheduling in a price-taker and price-maker scenarios, either when the PSH unit operates in standalone and integrated in a portfolio of other generation assets. Results show that the price-maker standalone PSH will integrate less wind power in comparison with the price-taker situation. Moreover, when the PSH unit is integrated in a portfolio with a base load power plant, the role of the price elasticity of demand may completely change the operational profile of the PSH unit. (C) 2014 Elsevier Ltd. All rights reserved.

Assessment of direct radiological risk and indirect associated toxic risks originated by Coal-Fired Power Plants

Over the past few decades there has been some discussion concerning the increase of the natural background radiation originated by coal-fired power plants, due to the uranium and thorium content present in combustion ashes. The radioactive decay products of uranium and thorium, such as radium, radon, polonium, bismuth and lead, are also released in addition to a significant amount of 40K. Since the measurement of radioactive elements released by the gaseous emissions of coal power plants is not compulsory, there is a gap of information concerning this situation. Consequently, the prediction of dispersion and mobility of these elements in the environment, after their release, is based on limited data and the radiological impact from the exposure to these radioactive elements is unknown. This paper describes the methodology that is being developed to assess the radiological impact due to the raise in the natural background radiation level originated by the release and dispersion of the emitted radionuclides. The current investigation is part of a research project that is undergoing in the vicinity of Sines coal-fired power plant (south of Portugal) until 2013. Data from preliminary stages are already available and possible of interpretation.

Radiological impact associated to Technologically Enhanced Naturally Occurring Radioactive Materials (TENORM) from coal-fired power plants emissions

Certain materials used and produced in a wide range of non-nuclear industries contain enhanced activity concentrations of natural radionuclides. In particular, electricity production from coal is one of the major sources of increased human exposure to naturally occurring radioactive materials. A methodology was developed to assess the radiological impact due to natural radiation background. The developed research was applied to a specific case study, the Sines coal-fired power plant, located in the southwest coastline of Portugal. Gamma radiation measurements were carried out with two different instruments: a sodium iodide scintillation detector counter (SPP2 NF, Saphymo) and a gamma ray spectrometer with energy discrimination (Falcon 5000, Canberra). Two circular survey areas were defined within 20 km of the power plant. Forty relevant measurements points were established within the sampling area: 15 urban and 25 suburban locations. Additionally, ten more measurements points were defined, mostly at the 20-km area. The registered gamma radiation varies from 20 to 98.33 counts per seconds (c.p.s.) corresponding to an external gamma exposure rate variable between 87.70 and 431.19 nGy/h. The highest values were measured at locations near the power plant and those located in an area within the 6 and 20 km from the stacks. In situ gamma radiation measurements with energy discrimination identified natural emitting nuclides as well as their decay products (Pb-212, Pb-2142, Ra-226, Th-232, Ac-228, Th-234, Pa-234, U- 235, etc.). According to the results, an influence from the stacks emissions has been identified both qualitatively and quantitatively. The developed methodology accomplished the lack of data in what concerns to radiation rate in the vicinity of Sines coal-fired power plant and consequently the resulting exposure to the nearby population.

Dispersion Modelling of Natural Radionuclides 238U, 232Th and 40K Released from Coal-fired Power Plants Operations

The aim of this work was to simulate the radionuclides dispersion in the surrounding area of a coal-fired power plant, operational during the last 25 years. The dispersion of natural radionuclides (236Ra, 232Th and 40K) was simulated by a Gaussian plume dispersion model with three different stability classes estimating the radionuclides concentration at ground level. Measurements of the environmen-tal activity concentrations were carried out by γ-spectrometry and compared with results from the air dispersion and deposition model which showed that the stabil-ity class D causes the dispersion to longer distances up to 20 km from the stacks.