RESEARCH

PROCESS DESIGN

Burner Flow Reactor(BFR) Process Flow Diagram(PFD)

The Burner Flow Reactor (BFR) process was designed to simulate conditions in coal power plants, enabling the study of ash deposition and particle burnout. With the goal of converting coal power plants into 100% biomass combustors, this research is critical for improving combustion efficiency and reducing environmental impact in utility boilers. I contributed to the design and implementation of the BFR process, including the development of the Process Flow Diagram (PFD) using Microsoft Visio.

The BFR features an aerodynamically stabilized diffusion burner, designed to replicate the temperature profile and residence time of a coal utility boiler. Multiple observation and sampling windows were incorporated to monitor flame stability, collect ash samples and assess particle burnout.

An ash deposition probe was strategically inserted through one of the windows to collect deposits for strength analysis and further characterization. Preliminary findings from the ash deposition studies revealed key insights into deposit formation mechanisms, which could inform strategies for reducing fouling in industrial boilers.

This project was a collaborative effort with a team of undergraduate students, where I focused on process design, wiring of instruments, process controls and testing, whilst my colleagues helped with instrument installation, calibration, and testing. Working on the BFR process has depened my understanding of combustion dynamics and ash deposition, while also improving my skills in process design, process operations and data analysis.

Burner Flow Reactor(BFR) Process & Instrumentation Diagram(P&ID)

I designed a comprehensive Piping and Instrumentation Diagram (P&ID) for the entire process using Microsoft Visio. This diagram played a critical role in ensuring operational safety and efficiency, as it was utilized during a Hazard and Operability (HAZOP) review to identify potential risks and optimize process design. Additionally, the P&ID served as a detailed reference map for the installation and calibration of instruments, ensuring accurate implementation across the system.

PROCESS CONTROL | INSTRUMENTATION WIRING| INSTRUMENTATION INSTALLATIONS

PLC Electrical Box Layout

Using Microsoft Visio, I created a scaled layout for two electrical boxes; one on the left and one on the right. The left-side box houses the Groove EPIC system, power supply components, signal wires, and terminal blocks, while the right-side box contains a Honeywell Burner Control System. This detailed layout ensured accurate placement and integration of components, enabling reliable operation and control of the BFR process.

Installation of Electrical Box Components

Electrical Box Mounted

Following the layout design, I led the installation of all electrical components, ensuring precise placement and alignment as specified in the diagram. This step was critical for ensuring system intergrity and optimal performance.

COMBUSTION MODELLING

FactSage

FactSage 8.3 is a tool I use for thermodynamic modeling. The software features a fully integrated database for computing chemical thermodynamics, enabling calculations of equilibrium compositions, phase diagrams, and other critical parameters. I utilized FactSage to model and understand the ash fusion temperatures of biomass under varying additive concentrations, providing valuable insights of the reactions taking place at the temperatures of interest.

BIOMASS MILLING

To optimize combustion efficiency and prevent system clogging, we milled the biomass to achieve a specific particle size distribution that promotes higher burnout and effective fluidization with air. In addition to our in-house milling efforts, we collaborated with external partners since they have industrial size equipment. Idaho National Laboratory processed our corn stover, while Green Gold Development in Idaho milled our switchgrass and miscanthus to our desired particle size distribution.

Chopped and Pelleted Miscanthus

Milled Corn stover

Switchgrass Bales

Mikro Pulverizer Hammer Mill

At Brigham Young University, we utilized this mill to process chopped miscanthus and switchgrass, achieving the desired particle size distribution. This step was critical for ensuring consistent feedstock quality and optimal combustion performance in our experiments.

Raymond Bowl Mill

At the Utah San Rafael Energy Lab (USREL), we conducted milling trials on miscanthus pellets using he bowl mill. These efforts were part of our ongoing work to optimize feedstock preparation for combustion studies.

RUNNING A COMBUSTION FURNACE

OPTO 22

I utilize the Groove EPIC system from Opto 22 to operate the reactor, monitor combustion processes and log experimental data. This system provides precise control and real-time data acquisition, ensuring reliable results throughout the tests.

GAS ANALYZERS

Carlifornia Analytical Instruments (CAI) Gas Analyzer

We integrated the CAI gas analyzer with the Opto 22 system to acquire real-time data on flue gas composition. The analyzer measured key gases, including oxygen (vol%), carbon monoxide (vol%), carbon dioxide(vol%), sulfur dioxide(ppm), and nitrogen oxides (ppm), providing critical insights into combustion efficiency and emissions.

COMBUSTION VIDEOS

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