Abstract: A combined, integral steam generator coal gasifier includes a vertically elongated, all welded, gas tight enclosure with a burner zone having a double pitch sloping furnace floor and a slag tap extending therethrough. Successive zones located above the burner zone are provided with appropriate tube materials for conveying synthesis gas produced by the coal gasification process. A multi-pass convection pass zone having upflow and downflow passes is located at an upper portion of the enclosure and contains a plurality of superheater (primary and secondary) as well as economizer heating surfaces which extract heat from the synthesis gas to produce steam. An ash remover is connected to the outlet of the convection pass zone to remove ash from the synthesis gas exiting from the convection pass zone. The slag tap located at the bottom of the burner zone communicates with a slag tank or a drag chain deasher for receiving and removing slag from the burner zone.

Abstract: A method and system for removing SO3 and SO2 from a flue gas produced by the burning of a fossil fuel. Particulates are removed from the flue gas to produce partially cleaned flue gas. A sufficient amount of calcium-based, sodium based or magnesium-based dry sorbent, preferably having a particle size larger than 1.0-2.0 microns, is injected into the flue gas to react with and remove substantially all of the SO3 from the partially cleaned flue gas to produce a substantially SO3-free flue gas containing reacted and unreacted dry sorbent. The substantially SO3-free flue gas is conveyed to wet scrubber means for removing SO2 to produce cleaned flue gas. In a first embodiment, sufficient dry sorbent is provided to remove desired amounts of SO3 and SO2.

Abstract: A spacing arrangement for tubes of a reheater or superheater tube section uses a spacer bar that is sufficiently long to span a space across a plurality of tubes in the tube section. The spacer bar has a plurality of holes therein which are spaced apart by a selected spacing corresponding to a desired spacing between the plurality of tubes in the section. A plurality of sleeves is provided with one sleeve on adjacent tubes in the section. A tab is fixed to each sleeve and extends outwardly from the sleeve to which it is fixed so that the tabs of all the sleeves extend outwardly from a common plane containing all the adjacent tubes in the section. The tabs extend into respective holes in the spacer bar and fillet welds fix the tabs to the spacer bar adjacent the holes and at a location spaced from the sleeves.

Abstract: A system for eliminating mist from a flue gas while providing air toxic control includes a wet scrubber housing having an inlet at one of the housing for the entry of the flue gas and an outlet at an opposite end of the housing for the exit of the flue gas. Sprayers are located in the housing for spraying the flue gas with a cleaning liquid in order to remove contaminants from the flue gas. At least one heat exchanger is located in the housing above the sprayers in order to remove entrained contaminants from the flue gas by cooling the flue gas. The flue gas is channeled from the inlet past the collection trays, sprayers and heat exchanger prior to exiting the housing through the outlet. A mist eliminator is also provided for eliminating mist from the flue gas.

Abstract: A variable resistance device for use in a duct of a high pressure air supply system employs a rotatable butterfly damper locatable in the air supply system having a closed and an open position for variably restricting airflow through the air supply system. The butterfly damper is provided with apertures which permit air to flow through the butterfly damper even when it is in a closed position. The apertures are sized to provide a maximum resistance value at a minimum air flow rate in a closed position, a minimum resistance value at a maximum air flow rate in a 70% open position, and a nearly linear relationship between an angular rotation position of the butterfly damper and resistance.

Abstract: An improved main shaft for a coal pulverizer having a selected portion of the main shaft provided with an intervening material such as a thermally sprayed ceramic coating.

Abstract: A CFB furnace or reactor unit is provided having enhanced circulation of the reagents finest particles. The improved circulation is achieved by recycling gas having entrained fine particles from a solids collection hopper connected to the solids separator back into the reactor. A system of one or more conduits connects the upper portion of the solids collection hopper with the reactor. The conduit system is equipped with means for recycling gas from the hopper to the reactor. The invention is an inexpensive system which permits recycling of the finest particles that would otherwise be carried over with the gas flow exiting the separator.

Abstract: A low pressure drop inlet arrangement for an absorber having straight walls has a perforated tray positioned above the gas inlet opening between the walls of the absorber. A ring around the outer edge of the tray lacks perforations, or the perforations are covered. A drip ledge may be positioned on the bottom of the tray around the inner edge of the non-perforated ring. Baffles are positioned over the tray as well. The baffles may extend between the walls of the absorber, or they may only occupy the space over the perforations in the tray and the size of the tray perforations may be varied to control the overall pressure drop. An absorber made in accordance with the invention experiences a low pressure drop at the gas inlet opening.

Abstract: A method and apparatus for ultra-high particulate collection of sub-micron aerosols in a fuel gas conveys the fuel gas to a first venturi scrubber for removing a relatively large amount of particulates and leaving a smaller particulate load which is not removable in the first venturi scrubber. The fuel gas with the smaller particulate load is then conveyed to an electrostatic agglomerator for agglomerating the remaining smaller particles in the smaller particle load into larger particles. The fuel gas with the agglomerated larger particles is then conveyed to a second venturi scrubber for removing the agglomerated larger particles.

Abstract: An apparatus for modifying a gear casing used in coal pulverizer mills prevents lubricating oil leaks through worn O-rings by redirecting the oil in a different path which does not come into contact with the O-ring seals. An internal hose connection provides oil directly to a bearing top chamber through a passage in the bearing cartridge. A special connector is used to connect the internal hose to the passage. Several connector embodiments are disclosed.

Abstract: An improved floor for a recovery boiler furnace having a flat floor has a number of tubes in the floor immediately adjacent each of the sidewalls of the furnace oriented at an oblique angle to horizontal. A method of replacing the floor is provided as well.

Abstract: A diaphragm weld assembly for preventing fluid leakage from a flange. The diaphragm weld assembly has a flange having a platform, the platform having an opening and an annular weld pocket concentric with the opening, a diaphragm resting on the platform and having a ring extending from the bottom face of the diaphragm, the ring engaging with the opening, a weld bead formed in the annular weld pocket and welding the diaphragm to the flange, and a flange cover fastened to the flange. A method of creating the diaphragm weld assembly is also provided.

Abstract: A compound spin vane (CSV) for use in an air passage of a fossil fuel-fired burner. In one embodiment, the CSV is a multi-piece construction of platelike outer and inner vane elements connected to an intermediate platelike rail element. In another embodiment, the CSV includes at least two and possibly three vane portions, rigidly interconnected in spaced lateral relationship with respect to each other. If desired, the vane portions may be simple, curved planar surfaces, and may be arranged with trailing edges arranged at angles with respect to each other. The invention may be employed as a replacement for flat spin vanes found in secondary air passages of known single and dual register burners. When used in such manner in a single register burner, the invention changes secondary air flow characteristics so as to mimic those commonly found in a dual register burner.

Abstract: A method and system for removing SO.sub.3 and SO.sub.2 a flue gas produced by the burning of a fossil fuel. Particulates are removed from the flue gas to produce partially cleaned flue gas. A sufficient amount of calcium-based, sodium based or magnesium-based dry sorbent, preferably having a particle size larger than 1.0-2.0 microns, is injected into the flue gas to react with and remove substantially all of the SO.sub.3 from the partially cleaned flue gas to produce a substantially SO.sub.3 -free flue gas containing reacted and unreacted dry sorbent. The substantially SO.sub.3 -free flue gas is conveyed to wet scrubber means for removing SO.sub.2 to produce cleaned flue gas. In a first embodiment, sufficient dry sorbent is provided to remove desired amounts of SO.sub.3 and SO.sub.2. In a second embodiment, a make-up reagent provided to the wet scrubber means wets the dry sorbent, removes both the reacted and unreacted dry sorbent from the substantially SO.sub.

Abstract: A package boiler having water cooled surfaces positioned relatively close to the combustion burner to improve the radiant heat transfer. Extended surfaces are added to the water cooled tube fireside surface to increase absorption rates to the limits established by water side conditions to avoid departure from nucleate boiling (DNB). The heat release rates of multiple firing rate zone burners are matched to the absorption rates of the water cooled surfaces by adjusting the size and extent of the various firing rate zones. The burner is extended or the physical shape is altered to expose a larger surface to greater areas of water cooled furnace surface. The burner is matched to cooling surface to lower combustion zone temperatures and thus thermal NO.sub.X formations. Further, recirculated flue gas, excess air, water vapor or a combination of these may be used to add mass to the fluid stream flowing through the burner. Finally, either the gas fuel or combustion air may be staged.

Abstract: A method for non-destructively testing closely-spaced objects, such as header tube stubs for a furnace or boiler using electromagnetic acoustic transducers (EMATs) having meander coil sensors. The small size of the sensor combined with the need to move the sensor only a small fraction of the circumference of a tube to scan the entire circumference of the tube under test permits easy and accurate testing of an entire tube, even when the tube is one of a closely-spaced bundle.

Abstract: Methods and additive compounds for retarding the dispersion in water of bitumen-in-water emulsions, and in particular ORIMULSION, are disclosed. Methods include applied mixing at high speed and changing the pH of the emulsion. Additives include salts and flocculants.

Abstract: An improved floor for a recovery boiler furnace having a flat floor has a number of tubes in the floor immediately adjacent each of the sidewalls of the furnace oriented at an oblique angle to horizontal. A method of replacing the floor is provided as well.

Abstract: A circulating fluidized bed (CFB) reactor or combustor having an internal impact type primary particle separator which provides for internal return of all primary collected solids to a bottom portion of the reactor or combustor for subsequent recirculation without external and internal recycle conduits. The CFB reactor enclosure or furnace is provided with plural furnace outlets. This construction permits increased furnace depths and reduced furnace widths, resulting in a compact design.

Abstract: An integrally cast, non-welded coal spreader for a furnace or boiler burner has integrally cast swirl vanes. A shaft of the spreader extends into the hollow interior of a cap of the spreader and the vanes extend outwardly of the cap and are cast as one piece with the cap.