Kinetics of Coal Drying in Bubbling Fluidized Beds

1
KINETICS OF COAL DRYING IN BUBBLING FLUIDIZED BEDS

Edward K. Levy, Hugo S. Caram, Zheng Yao, Zhang Wei and Nenad Sarunac

Energy Research Center
Lehigh University
117 ATLSS Drive
Bethlehem, Pennsylvania 18015, USA

ABSTRACT

Some coals used in U.S. coal fired power plants have unusually high moisture levels.
High fuel moisture leads to low power plant thermal efficiency, increased stack emissions of
pollutants and maintenance and operational problems. One solution is to dry the coal before
burning it, and if this is done using power plant waste heat, it can result in significant efficiency
improvements.
This paper describes laboratory experiments, to determine the kinetics of coal drying in a
bubbling fluidized bed, and a simple theoretical model of coal drying. The experiments were
performed with coal which had been crushed to minus 6 mm and fluidized with air with
temperatures ranging up to 66C and with velocities of 0.9 to 1.7 m/s. In-bed electrical heaters,
used to simulate an in-bed tube bundle, provided additional thermal energy for drying. The
experiments determined the effects of superficial air velocity, drying temperature and inlet air
humidity level on rate of drying.
A theoretical model of the drying process was developed in which the air and coal
particles are assumed to be at the same temperature and the airwater vapor mixture leaving the
bed at the free surface is in equilibrium with the local values of particle moisture. This model is
in good agreement with laboratory data, showing that for this application, the drying rates do not
depend on fluidized bed bubble behavior or on particle- gas contact, but are controlled by in-bed
heat transfer, flow rate, moisture content and temperature of the feed air, and the equilibrium
moisture content of the coal.

KEYWORDS: Particle Drying, Bubbling Fluidization

____________________
Proceedings Fifth World Congress on Particle Technology, Orlando, Florida, April 2006.

2
I. BACKGROUND

Low rank fuels such as subbituminous coals and lignites contain relatively large amounts
of moisture compared to higher rank coals. When these fuels are used in coal- fired power plants,
the high fuel moisture affects the operation of the power plant, resulting in fuel handling
problems, decreased power plant efficiency, and increased stack gas emissions and station
service power. Recently completed theoretical analyses and coal test burns performed at a U.S.
lignite- fired power plant showed that by reducing the fuel moisture, it is possible to improve
boiler performance and generation efficiency and reduce stack emissions and water consumption
by evaporative cooling towers (Reference 1). The economic viability of the approach and the
actual impact of the drying system on efficiency, stack emissions and water consumption will
depend critically on the design and operating conditions of the drying system. This paper
describes laboratory drying studies performed by the authors to gather data and develop models
on the drying kinetics of high moisture coals.

II. LABORATORY DRYING STUDIES

The drying experiments were performed in a 152 mm diameter, 1372 mm high fluidized
bed column with a sintered powder- metal distributor plate. The compressed air used in the
experiments flowed though a rotameter and air heater before entering the plenum. A submerged
horizontal bundle of 13 mm diameter electric heating elements, instrument ed with thermocouples
to indicate heater surface temperature, provided in-bed heating. Thermocouples inserted through
the bed wall were used to measure vertical distribution of bed temperature. Small samples of
coal were removed from the bed and coal moisture was measured at various time intervals during
the batch bed drying tests.
The experiments were carried out with two coals, a North Dakota lignite and a
subbituminous coal from the Powder River Basin (PRB). The as-received moisture content of
the lignite varied slightly from sample-to-sample, usually ranging from 54 to 58 percent
(expressed as mass of moisture/mass dry fuel) and the PRB coal had a moisture content of
approximately 37 percent. During the first minute or two of each test, fines were elutriated from
the bed. The drying rate presented here is based on the dry coal which remained in the bed after
elutriation had occurred and after coal samples had been removed for analysis.
The drying tests were performed with coal having a wide size distribution, in most cases
with the top size in the 2 to 4 mm range and mean particle sizes from 300 to 400 microns. The
tests were performed with inlet air and heater surface temperatures up to 66C, with superficial
air velocities ranging from 0.9 to 1.7 m/s and with settled bed depths of 0.39 m. The drying
curves for two of the tests are given in Figure 1, where the numerical values for drying rate were
obtained by fitting straight lines to the drying data over the first portions of the tests. Drying rate
results for lignite are summarized in Figure 2, which shows the drying rate as a function of
velocity, for four different particle sizes. The results show that the drying rate increased with air
velocity, but that, within the accuracy of the data, the data for all four particle size distributions
are on the same curve. Thus, the larger drying rates associated with the larger particles, are due
to higher air velocities and not to any inherently higher rates of drying due to particle size. This
suggests that, in this particle size range, drying rate is controlled by the internal pore structure of
the coal, but not by particle size.

3
DRYING RATE VERSUS VELOCITY
0.004
0.005
0.006
0.007
0.008
0.009
0.01
0.011
0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Velocity (m/s)
D
r
y
i
n
g

R
a
t
e

(
d
G
/
d
t
)

(
k
g

w
t
r

/

k
g

d
r
y

c
o
a
l
*
m
i
n
)
2.82 mm top size
2 mm top size
9.53 mm top size
6.35 mm top size
DRYING RATE VERSUS TEMPERATURE
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0.016
0.018
30 35 40 45 50 55 60 65 70
Temperature (C)
D
r
y
i
n
g

R
a
t
e

(
k
g
/
(
k
g

d
r
y

c
o
a
l
*
m
i
n
)
)
Lignite
PRB Coal
U0 = 1.55m/s
Tlog(F) VERSUS G
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
-450 -400 -350 -300 -250 -200 -150 -100 -50 0
Tlog(F)
G
MOISTURE CONTENT VERSUS TIME
0
0.1
0.2
0.3
0.4
0.5
0.6
0 1 0 20 30 40 50 60 70 80 90 100
Time (min)
M
o
i
s
t
u
r
e

C
o
n
t
e
n
t

(
k
g

m
a
s
s
/

k
g

d
r
y

m
a
s
s
)
Tests 39 and 63
U0 = 1.58m/s
Tair,in = 66C
ho = 0.39m
Tube bundle: 2D spacing
6.35 mm top size
Lignite
PRB
As to be expected, drying rate is also a strong function of temperature. Figure 3
compares drying rates for bed and inlet air temperatures ranging from 43 to 66C.

III. FIRST PRINCIPLE DRYING MODEL

The relative humidity of air in equilibrium with coal can be expressed as a function of the
coal moisture content, . Treybal (Ref. 2) presented adsorption data which are correlated well
by

where T is absolute bed temperature and is relative humidity. As is seen in Figure 4, this gives
a good fit of the data, with a relatively small scatter band.

Fig. 1: Comparison of Drying Curves for Lignite
and PRB Coals for a 66C Drying Temperature
Fig. 2: Drying Rate as a Function of
Superficial Air Velocity and Particle Size

Fig. 3: Comparison of Drying Rates for Lignite Fig. 4: Equilibrium Relative Humidity of
and PRB. Effect of Bed and Inlet Air Temperature Air Versus Moisture Content of Lignite

) ( f log T

4
Air
Air
2
1
The equilibrium moisture content-relative humidity relationship, described in Figure 4
was used, along with the equations of conservation of mass and energy, to develop a first
principle model of the drying process. The model assumes at any instant of time, the particles
and air in the bed are at the same temperature and the gas and particle properties do not vary with
vertical distance in the bed. Thus for the batch bed drying process illustrated in Figure 5,
conservation of mass and energy can be written:
( )
i 2
DC
a
m
m
dt
d

&
Eq. 1
( ) ( )
( ) [ ]
1 1 2 2 1 2 pa a
1 2
DC
a
L
2
L C DC LOSS TUBES
hg hg T T C m
m
m
u
dt
dT
C C m Q Q

+ +
1
]
1
,
_
+ +
&
&
& &

Eq. 2
Specific humidity, , can be related to relative humidity and air temperature T, by
( )
( ) T P P
T P 622 . 0
sat
sat

Eq. 3
while the relative humidity is an empirical function of coal moisture (Figure 4).
In addition, the tube bundle heat transfer rate is
( )
BED TUBE TUBE
T T UA Q
&
Eq. 4
and the parameters P
sat
and hg are functions of air temperature.

Fig. 5: Sketch of Dryer Model

Equations 1 to 4 form a system of ordinary differential equations for coal moisture and
bed temperature T
2
as functions of t. This was treated as an initial value problem and solved by a
Runge Kutta numerical integration scheme.
Figures 6-9 show a comparison of the model with one set of drying data. The degree of
agreement shown here is typical of the agreement obtained for the experiments with other bed
operating conditions. The model is an equilibrium model and does not utilize information on bed

5
TEST #36 - COAL MOISTURE CONTENT
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0.55
0.60
0 10 20 30 40 50 60 70
Time (min)
C
o
a
l

M
o
i
s
t
u
r
e

C
o
n
t
e
n
t
Test L36
Uo = 1.15m/s
Tair,in = 150F
ho = 0.39m
2D spacing
TEST #36 - EXIT AIR SPECIFIC HUMIDITY
0.002
0.006
0.010
0.014
0.018
0.022
0.026
0.030
0 10 20 30 40 50 60 70
Time (min)
E
x
i
t

A
i
r

S
p
e
c
i
f
i
c

H
u
m
i
d
i
t
y
Test L36
Uo= 1.15m/s
Tair,in = 150F
ho = 0.39m
2D spacing
TEST #36 - EXIT AIR TEMPERATURE
70
80
90
100
110
120
130
140
150
160
0 10 20 30 40 50 60 70
Time (min)
E
x
i
t

A
i
r

T
e
m
p
e
r
a
t
u
r
e

(
F
)
Test L36
Uo = 1.15m/s
T
air,in
= 150F
Uo = 0.39m
2D spacing
TEST #36 - EXIT AIR RELATIVE HUMIDITY
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0 10 20 30 40 50 60 70
Time (min)
E
x
i
t

A
i
r

R
e
l
a
t
i
v
e

H
u
m
i
d
i
t
y
Test L36
Uo = 1.15m/s
Tair,in = 150F
ho = 0.39m
2D spacing
bubbling behavior, particle- gas contacting nor mass transfer within the particle pores. For the
range of fluidization conditions encountered in this process, a simple equilibrium model works
very nicely.

Fig. 6: Lignite Drying Curve for Test 36 Fig. 7: Exit Air Temperature for Test 36
Comparison Between Theory and Experiment Comparison Between Theory and Experiment

Fig. 8: Exit Air Specific Humidity for Fig. 9: Exit Air Relative Humidity for Test 36
Test 36 Comparison Between Theory and Comparison Between Theory and Experiment
Experiment

IV. CONCLUSIONS

Laboratory experiments were performed on crushed high moisture coal to determine the
effects of fluidization velocity, particle size, bed temperature and coal rank on rate of drying.
The data show that drying rates do not depend on fluidized bed bubble behavior or on particle-
gas contact, but instead are controlled by in-bed heat transfer, flow rate, moisture content and
temperature of the feed air, and the equilibrium moisture content of the coal. The theoretical
model of the drying process described in this paper is in excellent agreement with the laboratory

6
data. The model assumes the bed is well- mixed, with the air and coal particles being at the same
temperature. The model also assumes the air-water vapor mixture leaving the free surface of the
bed is in equilibrium with the local values of particle moisture.

V. ACKNOWLEDGEMENTS

This conference paper was prepared with the support of the U.S. Department of Energy,
under Award No. DE-FC26-03NT41729. However, any opinions, findings, conclusions, or
recommendations expressed herein are those of the author(s) and do not necessarily reflect the
views of the DOE. The authors are also grateful to Great River Energy for providing partial
funding for the project.

VI. NOMENCLATURE

C
c
Specific Heat of Coal
C
L
Specific Heat of Coal Moisture
C
pair
Specific Heat of Air
d
p
Particle Size
hg Enthalpy of Saturated H
2
O Vapor
a
m
&
Flow Rate of Dry Air
P Absolute Pressure
P
sat
Vapor Pressure of H
2
O
LOSS
Q
&

Rate of Heat Loss to Surroundings
TUBES
Q
&

Rate of Heat Transfer in Tube Bundle

T
1
Air Inlet Temperature
T
2
Bed Temperature
u
L
Internal Energy of Coal Moisture
U
o
Superficial Air Velocity
Relative Humidity

Coal Moisture
,
_
coal dry kg
O H kg
2

&

Drying Rate =
dt
d

Specific Humidity of Air

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KINETICS OF COAL DRYING IN BUBBLING FLUIDIZED BEDS

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