PERFORMANCE TEST OF A MOBILE HYDRONEAL GAS GENERATING PLANT

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03639A001200130001-7
• Release Decision: RIFPUB
• Original Classification: K
• Document Page Count: 21
• Document Creation Date: December 27, 2016
• Document Release Date: October 25, 2012
• Sequence Number: 1
• Publication Date: June 1, 1958
• Content Type: REPORT

II
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41/470 #/b? f
DEPARTMENT OF THE ARMY
CORPS OF ENGINEERS
II
II
II
WAN
Performance Test
of a
Mobile Hydroneal Gas Generating Plant
Report Number: T-58-47
Date: June 1958
DEVELop4
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II
II
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atoriei
FORT BEL VOIR, VIRGINIA
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United States Army
Engineer Research and Development Laboratories
Ft. Belvoir, Virginia
Performance Test
Mobile Hydroneal Gak Generating Plant
Date: June 1958
..................memommimme?MIKI....11,0~INV
'SUbMitted by
Evaluation Engineering Branch
Laboratory Swett=
Prepared by:
S. S.
Senior Engineer
Gas Lab Unit
/U114 R. DONAGHY
Test Engineer
d by:
40,r/ ir
. PETERSEN
Ch., Laboratory
Section
A. J. RUMERFr},RD
Ch., Evalu.ation
Engineering Branch
sec / R '-`? EV DATE it!,.3,:t BY L'
gg JUN A 6 V.61r0 1
onEG COMP _7,?.Z_ CPI ,--, 6 TYPE
OW CLASS Al PAGES 477,-.7 REV CUSS _X---. -
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TABLE OF CONTENTS
Section Title Page
INTRODUCTION 1
1. Subject 1
2. Background 1
3. Personnel 1
II INVESTIGATION 1
4. Description 1
5. Test Procedure 2
6. Test Results 2
III DISCUSSION 1.
7. Analysis of Results 4
IV CONCLUSIONS 5
V APPENDICES
A. Authority
B. Figures 1 - 12
A-1
B-1 - B-10
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SEIMMARY
This report covers the evaluation testing of a Mobile Hydroneal Gas
Generating Plant for the Office of Naval Research, Department of the Navy.
Extensive changes were made to the piping system and flow controls
prior to the performance test. Operational performance was run continuously
for 165 hours at which time the test was stopped due to failure of the re-
torts under high temperature conditions. Major cause of failure was cracking
In the torus rings at the bottom of the retorts. Successive modification and
cyclic testing proved that this source of trouble was eliminated by increasing
the radii and reducing the wall thickness of the rinds, and lowering the oper-
ating temperature of the retorts from 2150?F to 1800
The evaluation results indicate that the Hydroneal Gas Generating Plant
is capable of making a product gas of specification purity at the lover oper-
ating temperature with., no equipment failure. Consideration should be given
to the relocation of the retorts and ammonia reservoir in the future redesign
of the unit.
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LABORATORY SECTION
EVALUATION ENGIN:KRIM BRANCH
Report Number: T-58-47 Date: June 1958
Project Number: FB-79-b
PERFORMANCE TEST
07k
MOBILE HYDROMEAL GAS GENERATING PLANT
I. INTRODUCTION
1. Subject. This report comers the performance testing of a mobile
Hydroneal Gas Generating Plant submitted for test by the Department of the Navy.
2. Background. This testing was requested by Mr. S. Haven, Project Engineer,
Office of Naval Research. Previous to this evaluation request the operation of
the plant was erratic and insufficient for its design purpose. The purpose of
this test was to give the plant a thorough study, cheek out and possible modifi-
cation prior to shipment for field operation.
3. Personnel. Testing was conducted by laboratory personnel under the
supervision-51-07-13. S. Sherriff, Senior Engineer, Gas Generating Unit, Laboratory
Section, Evaluation Engineering Branch.
II. INVESTIGATION
4. Description. The Hydroneal Gas Generating Plant was designed and built
byBaker and Co., Inc., llelork, N. J. The plant is mounted inside a 1953 Inter-
national Harvester i tan (Metro) panel truck, Model P4152, Serial Number 1393,
Engine Number 240607.
The gas production process consists of endothermally splitting of aqueous
ammonia into a gas mixture of three (3) parts hydrogen to one (1) part nitrogen
by using an Englehard catalyst. The ammonia content of the efficient gas stream
is held below 5% by volume.
The process equipment consists of an ammonia storage tank, with electric
vaporizing heaters and heat excnanger, first and second stage preheaters, three
(3) oil fired retorts, external superheaters, and a product gas delivery outlet.
The plant is a self-supporting unit containing its own power supply,
ammonia pump, air compressor for pneumatic controllers, ventilating equipment
and neeeasary controls.
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5. Test Procedure. The testa were conducted at the Gas Generating Equipment
Laboratory, U. S. Army Engineer Research and Development Laboratories, Ft. Belvoir,
Virginia, during the period 9 August 1957 to 9 May 1958. The unit was started
and run in conformance with the operating instructions of the manufacturer.
Duration of the test was to be 24 hour operation, five (5) days per week, for a
period of two (2) weeks.
6. Test Results.
a. As a result of
modifications were made:
(1) The cover
side of the ammonia storage
fram heat radiated from the
initial inspection and check tests the following
of the electrical switch box mounted on the front
tank was lined with asbestos to protect the equipment
retorts.
(2) A small blower was installed on the control cabinet for venti-
lation purposes (See figure 1). The blower was connected to the main electrical
circuit to insure continuous operation while the plant was running.
(3) It was fmmut that the 3 KW Hamelite electric generator was not
of large enough capacity-to fill the operating requirements of the plant. Two
(2) immersion heaters in the ammonia storage tank were disconnected to relieve
the overload but the tank pressure dropped fram 130 psig to 58 psig within two
(2) hours while maintaining the same flaw. A 5 KW engine generator set was
installed and provided enough power to operate all the units of the plant at
maximum capacity.
(4) A mercoid switchvms installed to actuate the immersion heaters
between the limits of 80 psig and 100 psig tank pressure. Anmaual cut-out switch
was connected to the nercoid switch.
(5) The product outlet line was relocated to the left-hand center
door due to the proxiMiti of the valve to hot piping in the original position.
(6) The original insulation around the furnaces was supplemented
by adding a layer of castable high-temperature refractory on the interior of
the fireboxes.
(7) A sheet of asbestos board was placed between the oil-burner
and the furnaces to protectitWxmtars fram radiated heat.
b. A trial run of six (6) hours duration was made with a blind installed
in the product line to the preheaters. This arrangement allowed maximum heat
exchange in the ammonia storage tank in order to increase vaporization. No
beat was gained by the incoming ammonia vapor in the preheaters using this
flaw system (See figure 2).
With burner temperatures between 2000?F and 2150?F and 4000 SCFS product
gas flowing, the pressure in the storage tank increased from 90 psig to 210 psig.
2
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It was the opinion of the representatives of the manufacturer and Office of Naval
Research that the pressure would continue to rise until the safety valve was
overcome, so the test was terminated.
c. TO balance the heat supplied to the storage tank, the following
changes were propmmabythe test personnel, approved by the manufacturer and
put into effect (See figure 2).
(1) Remove the pressure regulating valve in the product gas line
upstream from the second stage preheater and install it in place of the regu-
lating valve existing in the second stage preheater by-pass line.
(2) Install the valve removed from the preheater by-pass line in
place of the cold weather blind in the split gas by-pass line (See figure 3).
(3) Install blinds 'where pressure regulator was removed fram
preheater system (See figure 4).
d. A two-week performance test was started and after approximately
165 hours of satisfactory operation No. 1 retort burned out and was removed
for inspection. Results of the inspection shoved that failure occurred as
extensive cracking along the veld at the bottom of the retort (See figure 5).
The other two retorts were removed and a decision was made to replace all three
torus rings. These rings were fabricated of cold-drawn Inc oloy metal.
The new torus rings were cast of Incoloy by the National Bureau
of Standards. The retorts were then installed in the plant and operation
resumed. After approximately 20 hours operation No. 1 retort again failed.
Failure this time occurred as a hole in the side of the torus at the bottom
of the retort (See figures 6 and 7). No. 1 retort was removed from the system
and No. 2 retort moved to its place.
e. Thermocouples were placed at several locations around the torus
of No. 2 and No. 3 retorts, three (3) an the interior mad three on the exterior,
to check the heat distribution at the bottom of the retorts. Thermocouples
were also placed in the furnace stacks, product line, and incoming gas line
to compare heat loads in the respective furnaces. Chromel-Alamel thermo-
couples and a Minneapolis-Honeywell recorder were used to measure and record
the temperatures. A layer of refractory brick and also installed in the base
of No. 2 furnace to diffuse the burner flame and reduce heat concentration.
f. Operation was restarted and No. 2 retort failed approximately 15
hours afterward. Failure was again due to cracking at the base of the retort
(See figure 8).
g. In an effort to reduce the amount of heat delivered to the retorts
and to improve warm-up time, several different size nozzles were tried in the
oil burner of No. 3 retort. Investigation yielded an optimum nozzle which gave
1.35 GPM at 100 psig fuel pressure. The original nozzle size yielded 1.50 GPM.
3
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b- After consultation with the Navy project engineer and representatives
of Battelle Memorial Institute, Columbus, Ohio, thermocouples were again placed
at numerous locations on the interior and exterior of No. 3 retort and series of
cycling tests, consisting of bringing the retort up to operating temperature
and then shutting off the burner and allowing the retort to cool, were made.
Temperatures were taken continuously during both the sem-up and cooling periods.
The temperature records-obtained were forvarded to Battelle Memorial Institute
for analysis.
i. A new torus of increased radius and reduced wall thickness and
fabricated of cold-drawn Incoloy, was welded to each retort in the USARRDL
Machine Shop and the three retorts installed in the plant. A test of three
(3) weeks duration was then conducted at a reduced operating temperature of
1800?F. The test was a cyclic operation consisting of bringing the plant up
to operating temperature, allowing temperatures to stabilize, and then shutting
off the burners and allowing the unit to cool to ambient temperature. Two (2)
cycles per day were Obtained. After the test was completed the retorts were
removed for inspection. No cracks or defects were found.
j. A road test was conducted to study, vibration effects on the
castable firebox lining. No damage was observed.
III. DISCUSSION
7. Analysis of Results.
a. The plant, as received fram the manufacturer, was capable of
asking a gas product of the required purity, but operation was erratic and re-
quired excessive operator attention.
b. The modifications to the flow system made by personnel
elielnated the problem of storage tank pressuremigalftion. This arrangement
removes one preheater from the system completely, and the operation of the
pressure regulators by-passes the other preheater when pressure in the storage
tank drops below 80 psig. In this way maximum heat transfer can be attained to
increase vaporization. The changes were made in such a way as to allow a change
to the original flow system under high ambient conditions.
c. Failure of the retorts was due to defective welding and operating
temperatures above the safe working temperature of the metal.
d. The original insulation around the firebox was inadequate and the
high temperatures caused burning and warpage of the metal container. The lining
of casiable refractory proved satisfactory in reducing the beat transmitted to
an acceptable level and resistant to damage from road shocks. The refractory
diffuser in No. 2 retort Shoved no advantages.
4
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IV. CONCLUSIONS
Operation at the lover temperature (1800?F) and with the new torus rings
was satisfactory. Product gas purity well below the specification was attained
(See figure 12) and no damage to the equipment was observed.
Based on the results of the tests reported herein, it is concluded that
consideration should be given to a complete review of the design and operating
characteristics of this plant, with special attention to the following items:
(1) Establishing maximum operating temperature at 1800?P.
(2) Incorporation of the new torus rings on all retorts.
(3) Improved insulation around the fireboxes.
(4) Rearrangement of the flow system and controls in accordance with
changes made during these tests.
(5) Provide a larger capacity electric generator set.
(6) Relocation of the furnaces to the rear of the truck, near the
exhaust fan, to reduce the high ambient temperatures around the storage tank
and electrical control equipment.
(7) Increasing the number of rotameters to one per retort. Spare
rotameter Wiles Should also be carried as replacements.
5
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V APPENDICES
A. AUTHORITY
B. FIGURES
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AUTRORITY
Work Order Request from the
Military Engineering Department
to the Evaluation Engineering
Branch, Mechanical Engineering
Department
Project Number: FB-79-b-1
Job Order Number: T-58-47
A-1
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Figure 1. Ventilating fan installed on control
cabinet. (E4548)
B-1
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NI IR MA I- 0 PEPAT forg
all-OPEN$
3'-CLOSESJ
PRODuCT
GAS OuT
AmRiEk1T PERAT
ro
REToRT
FIG. 2. PI PIA/ G R2ARRAAIG471ENT
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Figure 3. Front view of furnaces and relocated pressure
control valve. (18539)
, fMIlleffIrrS
VAMON11,0,
r , 3c,
t AltA,4 ?
Jk
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I ? 441
Figure
-
Figure 4. Piping rearrangements. (E4549)
B-3
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Figure 5. Cracking and distortion of No. 1 retort after
165 hours operation.
(18536-7)
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Figure 6. Failure of No. I retort.
B-5
(E4546:7)
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. .11MMMO
^:111 It 7t II tt
Figure 7. Fused metal removed from No. I retort. (18538)
Figure 8. No. 2 retort after removal. (E4545)
B-6
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B-7
-
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B-8
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B-9
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Interior view of torus from No. 3 reto
5%
2%
i_l_i_ 1.1 , III.] II I:I:
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II