a study of a 60 horse-power suction gas producer, using

A Study of a 60 HpiBe-Jtowef Sucjioii

Cas Producer, using ^Anthmdte^^G^^

B. S, ;

1509^^:?;;^^;^^^:-r;^•^^!:-^^'

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UNIVERSITY OF ILLINOISLIBRARY

^'^^ Book Volume

Ja 09-2tM

Digitized by the Internet Archive

in 2013

http://archive.org/details/studyof60horsepo00evan

A STUDY OF A 60 HORSE-POWER SUCTION GAS

PRODUCER, USING ANTHRACITE COAL

BY

MARTIN EDWARD EVANS

PAUL MARTIN JOHANNING

BARTLETT MARTIN KERR

HARVEY McGINNIS

THESIS FOR THE DEGREE OF BACHELOR OF SCIENCE

IN MECHANICAL ENGINEERING

IN THE

COLLEGE OF ENGINEERING

OF THE

UNIVERSITY OF ILLINOIS

Presented June, 1909

Ev I

\

110 1

UNIVERSITY OF ILLINOIS

JUNE 1, 1909

THIS IS TO CERTIFY THAT THE THESIS PREPARED UNDER MY SUPERVISION BY

MARTIN EDWARD EVANSPAUL MARTIN JOHANNINGBARTLETT MARTIN KERR

HARVEY MCGINN IS

ENTITLED A STUDY OP A 60 HORSE-POWER SUCTION GAS PRODUCFR,

USING ANIHHAQITE GOAL..

IS APPROVED BY ME AS FULFILLING THIS PART OF THE REQUIREMENTS FOR THE

DEGREE OF BACHELOR OF SC IENCE.

APPROVED:

Instructor in Charge

HEAD OF DEPARTMENT OF MECHANICAL ENGINEERING

145138

CONTENT^;.

-0-

Page. ITo.

Introduction. 1,

Description of the Producer. 2.

Method of Conducting the Test. 3.

Arrangement of Apparatus. 3.

Operation of Plant. -~~ 3.

Uniformity of Conditions. 5.

Starting and Stopping Test.-r-- —^- 5.

Fuel and Ash. 5.

Gas sampling Apparatus. 6.

Analysis and Calorific value of Gas. 6.

Jacket water. • 6.

Scrubber water. —-— 7.

Moisture Determinations. — 7,

High Temperature Determinations. 7.

Theory of Gas Producer. P.

General Discussion. Pa.

Conclusion. Pa.

Calculations. — •—— 10.

Results of Gas Producer Trials. 20.

Log Sheets. 31.

Drawings of Producer. 55.

1.

ThlST OF A AUCTION GAS PRODUCER .

The constantly increasing use of gas producers in

the last few years has resulted in a popular demand upon the part

of producer manufacturers and power consumers for a fuller

knowledge of the scientific principles underlying the operation,

care, and management of gas producers. Comparative values

of the performances of the various types of producers, or of

any particular type operated under varied conditions are valuable

to all power consumers. The producer manufacturer is equally

as well interested because such data gives him an opportunity

to study his producer with the view of improving it and enables

him to correctly represent his product to prospective purchasers.

In order that relative values of performances may

be established, the adoption of some standard method of testing

producers is essential. Various methods have been followed

in testing but all are more or less incomplete. A complete

rational method which has not as yet been given general publica-

tion has been developed by LIr. C. M. Garland, of the University

of Illinois, in collaboration with A. P. Kratz, a graduate

student of the University of Illinois.

In accordance with this latter method a series

of tests was made upon a small producer in the Mechanical

Engineering Laboratory of the University of Illinois. Their

object was to determine the efficiency of the producer under

various loads. Pour of the series are developed and discussed

in the following pages. A more elaborate treatment of them

is continued in a thesis by Iwr. A. P. Kratz.

Description of the Producer .

The producer u.pon which the tests were made was

of the suction t.,pe for the use of anthracite coal. It was built

by the Otto Qas Engine Company, Philadelphia , Penn. , and has

a rating of 60 H. P. The general appearance and arrangement

of the plant is clearly shown by the accompanying diagram on

page 35^ , from which it is seen that the principal parts are

the generator and economizer, the scrubber, the condenser, and the

dryer. In this type the .generator and economizer are integral,

the latter being in the form of a water jacket surrounding the

incandescent fuel bed. The generator is equipped with a small

hand blov/er for furnishing air blast to start the producer. The

wet scrubber, shovm to the right of the generator, is cylindrical

in form and filled with coke. Water decends over the coke and

collects in the bottom to form a seal, the excess overflowing. To

the right of the scrubber is a jet condenser into which a Schutle-

Koeting steam ejector of 12000 cubic feet capacity per hour dis-

charges the gas and steam drawn from the scrubber. The dryer

consists of two telescopeing sheet iron cylinders within which

is a large quantity of straw. V/ater forms an effective seal

preventing the escape of gas between the two cylinders. A pipe

3.

leads from the upp^r snd of the inner cylinder to the two

Westinghouse gas meters, one of 8000 cubic feet capacity and the

other of 3500 cubic feet connected in paralell. Prom the metersthe gas

pipes disoharge^into the open air.

Method of CondjacJLing the Test .

The purpose of the test determines the method ofseries of

proce dure. Sirxe the object of the^tests is to determine the

efficiency of the producer under various loads, the general

method requires that the energy imput and output together with

the behavior of auxilliary apparatus be observed. Only such

auxilliary observations are essential as tend to shoxv the most

economical way of operating the plant.

iiRRiiNaEI.iSNT OP APPARATUS.

Manometers consisting of U tubes containing water

were placed at the suction orifice of the generator, at the ash

pit, and at the exit of the gas from the producer. Thermometers

were placed so as to determine the temperature of the water

entering and leaving the scrubber and vaporizer, of the gas

leaving the producer and scrubber and on entering the meter.

Samples of gas w^re collected from the same orifice for chemical

analysis and for heat determinations with the Junker's calorimeter

OPERATION OF PLAINT .

The charge of anthracite coal in the hopper grad-

ually decends into the combustion zone over the grate ishere an

incandescent bed of fuel about two feet in depth is maintained.

The intense heat of the fire is kept from affecting the cast iron

shell of the generator by a lining of fire brick. Above the

combustion zone surrounding the magazine is the vaporizer in

which water is evaporated. The air passing from the entrance

orifice travels over the water in the vaporizer and carries a

load of vapor with it as it is drawn under the grate and up through

the incandescent coal. Through the action of ' the : heat upon

the water, air, and coal , chemical action takes place, resulting

in the formation of gas. The gas passes from the generator into

the scrubber where it aseends thru the porous coke over which

water is steadily falling. The poroua nature of the coke allows

a very intimate mingling of the gas and water that is very effectie

in the process of purification. Thus the gas is cleansed of

impurities such as soot and tar. It is then drawn from the

scrubber by a steam ejector and discharged into a jet condenser

from which it passes through a dryer and thence through the meters

and out through the open air. The steam ejector is used to

secure the necessary draft because of the simplicity, convenience

and absolute control of the suction which it gives, and which

were deemed necessary to expedite the con duction of the testt

Under commercial operating conditions the draft f'or starting

is produced by a hand fan blower until the gas becomes of such

a quality as to run the engine, the engine then furnishing the

draft through. the action of the piston.

UNIFOBAITY OF CONDITIONS .

In order to insure a uniform quality of gas the

conditions of operation must remain nearly constant throughout

the test. The condition of the pressures of the steam and air

blast, of the thickness of the fire and bed of ashes, the regul-

arity of firing and quantity of coal fired at each time, frequency

of poking, and intervals between times of cleaning fires all were

kept as nearly uniform as possible.

STARTING AND STOPPING TEST,

The producer was fired and run for a time sufficient

to bring all conditions up to a normal state. Then the tests

proper were begun with a clean grate, full coal magazine, and the

gas of a fair quality. The condition of the producer in all

respects was nearly as possible the same at the close of the

test as at the beginning. The fire was of the same quality, the

ashes cleaned out and the hopper filled with coal.

FUEL AND ASH .

The coal was weighed and a representative sample

of every shovel full taken as fired. Samples were taken as the

magazine was charged at the start and at all other times except

at the finish when the magazine was filled to leave in the state

in which it was when the test began. All ashes were weighed

and a representative sample for analysis taken by the following

method which applies equally as well to the final selection of

6.

the coal taken from the charging sample. Immediately after the

test was over, the ash was broken, spread, mixed, and quartered

by drawing two diagonals of a square, and the two opposite

quarters were rejected. This was continued until a .sample of

two or three pounds remained which was preserved in well closed

bottles for analysis,

GAS SAMPLING APPARATUS.

The method of securing representative gas samples

is a matter seldom receiving due attention. The device used

in these tests consists of three small tubes leading from a small

chamber into the gas line. One pipe terminates just within the

gas line, one at the center of the line and the other • v/i thin a

very short distance of the opposite wall, so that a representative

quality of gas collects in the little chamber from which samples

for the calorimeter and for chemical analysis are with-drawn.

Continuous samples are with drawn for the latter purpose which

insures an accurate representation of the gas produced.

ANALYSIS AND CALORIFIC VALUE OF GAS .

Hempel's method of volumetric determination was

used for analysis from which the heating value was determined.

A second determination of the heating value by Junker's calor-

imeter was used as a check.

JACKET WATER.

The water in the economizer was kept at nearly a

constant height by adjusting the supply so as to maintain a slight

overflow and the net weight of the water was determined by weigh-

ing both supply and overflow. From the weight of the water

evaporated the humidity of the a|r drawn thru the vaporizer and

the moisture contained in the coal, the percentage of moisture

supplied to the fire. was calculated.

SCRUBBER WATSR .

The scrubber water was measured by a n^eter placed

in the supply pipe. The meter read in cubic meters.

MOISTURE DSTERiai

N

ATIONS.

A continuous sample of gas is with drawn fro :m the

generator discharge pipe by means of a small aspirator and passed

thru a small cooler, on thru a meter, and then thru a vessel

containing; Calciiim chloride. In its passage the gas gives up

its moisture to the chloBide. Then from the increase weight of

the chloride due to the moisture obtained from the gas, and the

volume of gas as indicated by the small meter, the total moisture

of the gas may be calculated.

HIGH TEIvlPERATURE DETERIHNATIONS.

The high temperatures of the gas as it left the

generator and of the fuel bed in the various zones were deter-

mined by means of a thermo-couple. A platin um- rhodium-couple

protected by porcelain tube was used in connection with a

galvaanometer reading directly in degrees Centigrade.

8.

THEORY OF CiAS PRODUCTION .

Producer gas is the product of incomplete combustion

of fuel in a generator or producer. In a measure the action

which takes place depends upon the type of producer and upon the

kind of fuel. In the suction typ« of producer using anthracite

coal which contains a large percentage of carbon and but little

volitile matter, the action is as follows:- Water vapor and air

pass thru the . ash zone and enter the combustion zone of- the

generator. Here the incandescent carbon unites with the oxygen

to form G Og* while the water vapor becomes superheated steam

and possibly begins to decompose. In the upper strata of the

combustion zone the C Og takes up more C and becomes C 0, while

the steam is decomposed into H and • These reactions require

high temperatures, not lower than 1800° P. The fuel just above

the fire is heated so that volatile matter is driven off and the

hydro carbons resulting add to the heating value of the gas when

driven off at sufficiently high temperatures.

Steam or water vapor is introduced in order that

the calorific power of the gas may be increased by the presence

of the hydrogen and to eliminate the formation of clinker in thebed

fuel^; Its effect is to absorb the heat on the grate and to car-

ry it to the incandescent fuel bed. Also by moistening the ashes

and keeping tliem soft and porous it allows a imiform passage of

air thru the fire

9.

However, an excessive use of steam rejultG in part of it passing

thru tho fire without being decomposed and then appearing in

the form of water vapor in the gas thus decreasing the fuel

value of the gas.

«

Gftnoral Discussion *

An examination of the average re suite and of the

log sheets sliows that the generally accepted theories of producer

operation readil^'- account for the behavior of the various parts

of the producer during the tests. Some of these general theories

are as follows:

(1.) The effect of allowing too nuch moisture in the air as

it passes thru the fuel bed is to cause an excess of C O2 in the

gas.

(2) Careful operation is necessary in charging and in cleaning

the grates in order that the quality of the gas may not be impared

Air admitted thru the charging hopper and thru leaks so that it

does not pass thru the fire causes a very lean gas to be formed.

(3) The temperature of the gas varies with the rate of gasif-

ication.

CONCLUSION.

A general conclusion is that the producer does not come

up to its rated capacity. The maximum efficiency was obtained

with the largest load. Other than these general statements are

not warranted because of the small number of the tests.

10.

CALCULATIONS

The following will show the method of arriving at

some of the results obtained; the others being self evident.

Item 16 .- The depth of fuel bed was talcen as the dist-

ance between the upper edge of the ash zone and the section where

the gases separate from and leave the fuel.

Item 43. - The weight of dry coal equals the total weight

of coal as fired minus the weight due to moisture in the coal or

Item 43. = Item 41. ( 1 - .

)

Item 46 .- The total weight of combustible consumed is

taken as the total weight of dry coal fired minus weight of ash,

computed from the analysis minus the weight of nitrogen minus

1 1/8 times the weight of oxygen minus the weight of carbon con-

tained in ash and refuse.

m^, T4. yi/- - T* A rr Item 43. X Item 58.Then Item 46.= Item 43. - ^^^^ -

Item 43. X Item 56. 1 l/8 x Item 43. x Item 65 .

io6 io6'

Item 44. x Item 60.100

ii^- = 11141: X 100.

Item 62 . = Item 43.

Hours

Item 46 .

Item 63. =Hours.

11.

Item. 64, Item 62.xtem x^.

Item 65. Item 63.

Item 66.Item 62.Item i/.

Item 67.Item 63.It«»Tn 17.

Item 68.Item 66.

Item 69. —

•

Item 67.j.uem xD

.

Item 71. Item 70. X Item 43.Item 46.tXr WV-/iXj O-W «

X T<ein / ro.

~

ine neating vaxue oy analysis is given

by the formula : 145408

S, H, and represent the percentages of carbon, sulphur, hydroger

and oxygen respectively contained in the fuel. The constants

represents the heating values of the products.

Then Item 72. •j^(ltem 53. x 14540 -|- Item 57. x 4000 f

(Item 54. - l/S x Item 55.) 62000.^

Item 73. Item 72 x Item 43.Item 46.'

Item 76. Item 74. - Item 75.

Item 77. Item 76. + Item 77^ + Item 77^.

Item 77-b The weight of water fed to the producer

in the air equals the percent of moisture in the air times the

total weight of dry air used times l/lOO or

12.

Item 96.Item 77^ = Item 95

Item 77^ - I tem 41. X Item 42.100

Item 78. = Item 77. - item 79.

Item 79. = Item 100 X Item 111.100

Item 80. = Item If^m 7^ Item 100 x Item 111

100

Item 81. = ItemItem I&* X 100.

77,

Item 82. _ ItemItem

78,77,

Item 83._ Item

Item78,TTl,

Item 84.Item

"* Item78 •

48.

Item 85,_ Item

Item78.

46.

Item 86. ItemItem

7896.

Item 87. _ ItemItem

77.

Item 88. _ ItemItem

77.46.

Item 89. _ ItemItem

77.

Item 91._ Item 76.

Hours,

Item 92. _ ItemItem

91.22.

Item 93. = Item 77,Hours,

13.

Item 94 . = I^eSLfO-" Hours,

Item 95 . - The percent moisture in air, percent by

weight of dry air is given by the formula x 100 = ~ where100m m

P = percent saturation or the relative humidity of the air, n =

weight of moisture contained in one cubic foot of saturated air

at the temperature of the fire room or Item 31., m = weight of

one cubic foot of dry air at the observed temperature,^^o"

~

weight of moisture in one cubic foot of air as used. Then

Item 95. = ( See Kent p. 484 for weight of air and moisture.)m

Item 96 . - The total weight of air used was calcul-

ated from the weight of nitrogen appearing in the gas. This

nitrogen comes from the air used and from the nitrogen introduced

with the fuel. Taking analysis by weight of pounds.

The total weight of in the gas = £J!s where W is the2 100^

total weight of the gas.

The weight of No supplied by the fuel = ^1 ^1 where =100

^

weight of dry coal and H^^ = percent by weight of Ng contained

in the fuel.

The total weight W4 of N2 in the air is therefore

WN2 _ Wi Hi100 ;loo

Then the total weight of air supplied = = ^ " ^1^1.77 .77

or Item 96. =r(ltem 111.x «074 x Item 123.) ^ts Item 104.

( Item 43. x Item 56. )1

14.

Item 97 . = ilsmjie.hours.

Item 98 . = f^^2i4|-—• Item 43.

Item 99 . = j}^^' Item 467

T4. inn - Item 77. - Item 78 . .^^Item 100 . = TTT

—

TTi x 100.' Item 14.

Item 104 . - The sum of the products of the con-

stituents of the gas by volume times their respective specific

weights at 62^ F. and 30 inches Kg. x l/lOO gives the specific

weight of the standard gas in pounds per cubic foot.

Then Item 104. =( Item 115. x .1161 + Item 116. x .07262

+ item 117. x .08418 + Item 118. x .00530 f Item 119. x .04278

+ Item 120. X .0737 + Item 121. x .1633 f Item 122. x .08682

+ Item 123. x .0740 )^|^^.

Item 105 . - Taking the specific heat of the gases

for constant pressure.

For 00 2, .19 - .0000977 t,—— (a).

" H2O, .426 - .000176 t,—-.(b).

" H2 , 3.355 - .000678t,—— (c).

" CO , % .24 - .0000484 t,—— (d).

" N2 , cp

.24 - .0000484 t,—— (e).

" GH4 ,.6 "(f).

" O2 , .21 - .0000424 t,—-(g)-

t = temperature of gas leaving producer outlet or

15.

Item 37. The specific heat of the producer gas is equal to

the sum of the products of the constituents of the gas by weight

times the specific heat of the constituent.

Then Item 105. = |(a x-1161 x Item 115 .

^L Item 104.

(c X 'Q0^^^^-USL223.. ) 4 (d X »07262 x.Item 116.

^item lUft. j^^^

ro V « 0'740 x Item 123. \ . f ^ ^ .04278 x Item 119. x ^^® Item 104'. ^ + (f X item 104. ^ +

{ rr ^ .08418 X Item 117. s\ 1^ ^ Item 104. giOO

Item 106 .- The total weight of carbon appearing in

a unit weight of gas = (jL by weight CO2 x i^q^ + ^ by weight

GO X 3/700 t ;2 by weight OK4 x 3/400 + ;2 by weight C2 H4 x rr^gj '

The total weight of H2 appearing in a imit weight of

gas = 1/100 % by weight H2 f ^ by weight CH4 x l/4 f ^ by

weight C2 H4 X 1/7 or Item 106. =

OO2 X + ;2 00 X 7 t ^ GH^ X I f ;g Gg H4 X ^ jp

:; TT ~, where

[% ^2 ^ ^ ^"4 x4t;^C2H4xAj

analysis is given % by weight.

Item 107 .- The volume is calculated from the

analysis of the gas and the analysis of the coal.

The total weight of the carbon appearing in the gas

should equal the total weight of carbon in the coal minus the

weight that is lost thru the grate minus the weight lost in

16.

soot and tar. The latter being very small was neglected.

The weight of the carbon consumed in the producer = Wg =

?L-Z^^2ll, where P and represent the % by weight of carbon100 ^

in dry coal and ash respectively; and W and Wj^ = total weight

of dry coal and ash respectively. The carbon is contained in

the CO2, CO, CIi4, and H4. The total weight of carbon con-

tained in a unit weight of gas = W3 = ( 3/II COg + o/4 CO -

6/7 C2H4) X 1/100, where COg, CH4, GO, and C2H4 represent fo by

weight from gas analysis. The % of carbon contained in gas as

- ^ weight GO2 X 3/11 ^ ^ , . ^ .CO2 = ' ^ . The actual weight of thisW 3

carbon = ^..b wei^ht CO 2 x 3/ll ^ ^ ^^^^^X 100 O

gas = Wg f^^^g^^ ^ X 3 2/3. The standard volumeW3 X 100

of CO2 - by weight COgx Wg^ ^^^^^^ ^ specific weight of

W3 X 100 X Wg

GO 2 at 62° F. and 30 in. Hg.

This volume is (a) % of the total volume of gas delivered

by the producer. Then the total volume of standard gas from

the gas analysis = ^ weight GO ^ x Wg ^^^^ ^^^^ =W3 X Wg X a

(«^161 X Item 115. ^^^^ ^ ^^^^ 53^ ^^^^ ^ j^^j^j g^^^Item 104.

.1161 X Item 115. (|^x % GOg +• | x GH4 f | x .'^ 00 f | x ,^ ^^4)

where analysis if gas is used as % by weight.

T4. tr\a _ Item 107 .

= Hours.

Item 109,

I tern 110.

Item 111.

Item 112.

Item 113.

Item 114.

Item 124.

17.

Item 107Item 43.

Item 107 ,

Item 46.

Item 111.Hours.

Item 43.

Item 46.

The grate efficiency is the ratio of

the total B. T. U. contained in the fuel minus the B. T, U. in

the fuel lost thru thr grate, to the total B. T. U. contained in

the fuel, times 100; or Item 124. =

Item 45. x Item 70. x 100 ~ Item 44. x Item 60. x 14540.. .

Item 43. X Item 70.

Item 125 . The hot gas efficiency is the ratio of

the total heat of combustion of the gas plus the sensible heat

of the gas, to the total heat of combustion of the fuel plus the

sensible heat of the fuel and the sensible heat contained in the

air and moisture times 100. The sensible heat of the fuel,

air and moisture is ordinarily very small and these quantities

are neglected.

Then Item 125. =[ltera 102. x Item 107 + Item 105.x

Item 111. x Item 37. - 62° + Item 79. x 1116 + .6( Item 37. -

212°) J X 100. -2- Item 49. x Item 74.

18.

The specific heat of superheated ateam is taken at .6

Item 126. The cold eras effinienny is •rn+^r^ r^f»

the total heat of combustion of the gases to the total heat of

combustion of the fuel times 100. or Item 126. =

Item 102 XItem 43. x

I ten, 107.Item 70.

-r^__ i^r^ _ Item 127. x Item 41.xzem 1^0. -j^^^^ ^^^^ ^

Item 129. - Item 90. x 1000." Item 107. x 62i5

Heat Balance -A-

Debit:-

1. The total heat supplied per pound of dry coal is

taken as the calorific value by oxygen calorimeter or Item 70.

2. Item 98. x .24( Item 31. - 62^F,)

3.Item 77>> X (H - 1070 )— Item 43."" """ where H - total heat in one

pound of saturated steam at temperature of the fire room.

4.Item 43. x Item 2.

^ ^ Op s

Item 43 x 100 ^^^em 31. - 62 F. )

5. .24 X ( Item 31. - 620F. )

6,Item 77a ( Item 33. - 62°p. )

Item 43.

Credit:-

1. Item 105. X Item 113. x (item 37. - 62°F,

)

2, (Item 100 X Item 113)x|~Item 37. - 212°F. )x 1116x .s)

100.

3. Item 102. X Item 109.

4.Item 44. x Item 60.

Item 43. x 100 ^ ^^^^^

19.

5. This is very small and is neglected.

6.xtem li

* ^ ^ ^tem 34. - Item 33.)

7. The radiation and condition is equal to the sum of

the items on the debit side minus the sura of the items 1^ 2, 3, 4,

5, and 6 of the credit side.

Heat Balance -B-

Debits:-

1. C02 by weight x Item 113. x 3980.

2. CO by weight x Item 113. x 1850.

3. Item 57. x 40.

4. This is the total heat from the items 2, 3, 4, 5, and

6 of the Heat Balance A.

Credits:-

1. Same as item 1. of A.

2. Same as item 2, of A.

•z Item 73. x 6890.3. — item 4'6.

"

4. The heat contained in the ash and refuse as sensible

heat is small and is neglected.

5. Same as item 6. of A.

6. Sum of items on debit side minus sum of items 1, 2,

3, 4, and 5 of the credit side.

20,

RESULTS.P

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No. 5

U OF I. S. S. FO»M 3

a study of a 60 horse-power suction gas producer, using

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