SBIR-STTR Award

A feasibility study and field testing of a new proprietary method capable of in-Line, real-time monitoring of flow of solid and liquid particles in gas streams is planned for this Phase I project. The experimental technique in which commercially available instrumentation is used has already been tested in the laboratory and in one field application. The laboratory tests demonstrated that flow of solid and Liquid particles weighing less than 0.00001 g can be detected and that their kinetic energy, mass, energy and mass distribution, and other characteristics can be measured. One industrial application of the method has been field tested, that is, detection of exfoliated oxides in steam lines of utility boiler/turbine cycles. The test was successful in determining operating modes during which solid particle erosion damage of steam turbine occurs. Based on the previous experience and work performed, we are proposing to apply the particle detection method to <1) flue gas monitoring (to prevent fan and filter damage and malfunction and to monitor combustion and pollution), (2) turbine steam monitoring for exfoliated oxides (to prevent solid particle erosion), and {3) turbine steam monitoring for water droplets (to prevent water induction). Our preliminary work gives us confidence that there is a high probability of success and that the proposed can be achieved at low R&D cost and within a short time.Anticipated Results/Potential Commercial Applications as described by the awardee:The project will determine feasibility of the proposed method for monitoring solid and Liquid particulates in gas streams associated with combustion and steam generation. Potential commercial applications include in-Line monitoring of particulates in flue gases (to prevent fan and filter damage, pollution, and to control combustion), monitoring of exfoliated oxides in steam lines (to prevent solid particle erosion of turbines), and monitoring of water induction. The project relates to utility and industrial steam generation. The applications may be expanded to chemical and mining industries.

In Phase I, feasibility of a new instrumental method was demonstrated for in-fine, continuous, real-time monitoring of solid and liquid particles in steam lines and flue gases. Quantitative monitoring of the number of particles and water droplets and a semiquantitative determination of their mass and mass flow has been tested in the laboratory and in three utility power stations. While rugged and capable of monitoring in the 1100'F/3600 psi steam environment, the method is very sensitive, capable of detecting particles weighing 10-9 g. In Phase 11, laboratory evaluation of effects of particle properties such as size, specific density, and modulus of elasticity will be completed, and a parametric equation relating these properties to the probe and instrument response will be developed, making the method almost quantitative. Early in Phase II, available electronic instrumentation will be reviewed, and the best suited instrumentation will be selected for incorporation into a prototype and a power station monitoring system. One prototype will be produced and field tested in long-time monitoring (at least one month each) of exfoliated oxides, water induction, and flue gases. These tests will be run jointly by the contractor and selected U.S. utility companies. Several companies have already expressed interest in these tests. Product specification and a business plan will be developed as the final tasks. Three types of businesses related to particulates in gases will be pursued: production and marketing of process instrumentation, troubleshooting and evaluation of effects of cycle design and operation, and monitoring and consulting for research and development.Anticapated Results Potential Commercial Applications as described by the awardee:It is anticipated that process control instrumentation for monitoring of exfoliation of oxides in boilers and steam lines and water droplets in steam lines, as well as a monitor for particulates in flue gases, will be developed. The development and use of this instrumentation could lead to significant reductions in operating and maintenance costs and forced outage rate, as well as to better pollution control, by the U.S. utility industry.