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• An understanding of the radial air staging method for PC utilization is improved and the key parameter (OFA distribution) is optimized. • Compared to the traditional axial air staging method, for the radial air staging method, the OFA distribution has a greater effect on the heat release from PC particles. • The increased R IO is not conducive to the rapid devolatilization from PC particles, resulting in poorer combustion stability of the boiler. • The increased R IO promotes the oxidation reaction of N released from PC particles, which is detrimental to boiler NO x emission reduction. • The advanced mixture of the OFA with the main airflow facilitates the burnout of the PC particles as the R IO increases. Radial air staging is an innovative method for reducing NO x emissions from coal-fired boilers compared to conventional axial air staging. However, an important issue in using this method is to set the over-fired air (OFA) distribution rationally to achieve good boiler performance. This paper aims to optimize the OFA distribution by evaluating important gas-particle (GP) parameters that influence the pulverized coal (PC) combustion performance. The GP flow experiment is conducted in a laboratory furnace model of a coal-fired boiler with different OFA distributions. The experimental results show that as R IO (Two-level OFA distribution ratio) changes from 0:1 to 1:0, the mixture of the OFA jet and airflow in the main combustion zone is advanced, which is conducive to PC burnout. Meanwhile, the size of the central recirculation zone decreases, resulting in poor PC ignition. It is worth noting that at R IO of 1:0, the central recirculation zone disappears at section y/d = 2.5, indicating that there is no high-temperature flue gas downstream to heat the fresh PC particles, which is extremely unfavorable for the stable combustion of the PC. In addition, at R IO of 0:1, compared to other cases, there are more particles in the central recirculation zone, which promotes the reduction reaction of N element released from PC particles, thus reducing NO x emission. According to the comprehensive evaluation, it is recommended that the R IO of the two-level OFA be set to 1:1 when using radial air staging in a coal-fired boiler. The results provide new insights into the application of the air staging method for efficient and clean PC utilization. [ABSTRACT FROM AUTHOR]

• A novel low-NO x technology is proposed for a down-fired boiler with swirl burners. • Gas/particle flow characteristics are studied under two combustion technologies. • Downward depth of gas/particle flows improves for the improved boiler. • Primary air is effectively ejected by burner secondary air for the novel technology. • Turbulent intensity in the recirculation region increases for the improved boiler. To confirm the validity and progressiveness of the eccentric-swirl-secondary-air combustion technology (ESSACT) in improving the economic and environmental performance of the down-fired boiler (DFB) with swirl burners, the gas/particle (GP) cold-modelling experiments are conducted by using a particle dynamic analyzer (PDA) measurement system in a 1:10 scale model of 300-MW e DFB applying original Babcock & Wilcox combustion technology (BWCT) and novel ESSACT, respectively. The distributions of average velocity, fluctuation velocity and particle size are compared and analyzed under the two combustion technologies in this study, in addition to the decay of particle volume flux and the jet trajectory of downward GP flows. In comparison with the BWCT, the rotation intensity of the burner secondary air is greatly weakened, and the vertical velocities of downward GP flows decay more slowly under the ESSACT. Although the recirculation regions are both formed below the arches under the two combustion technologies, the horizontal velocities and the horizontal fluctuation velocities of GP flows in the recirculation regions are both larger for the ESSACT, which benefits pulverized coal ignition. The particle size distributions under the two combustion technologies reveal that the mixing between the primary air and burner secondary air is obviously delayed and the burner secondary air effectively ejecting the primary air downward is realized by the ESSACT, which is advantageous to improve pulverized coal burnout and inhibit NO x formation. In addition, the maximum particle volume flux in the lower part of the lower furnace under the ESSACT is obviously higher than that under the BWCT, and the downward depth of GP flows and the space utilization ratio in the lower furnace increase for the original BW DFB retrofitted by the ESSACT. [ABSTRACT FROM AUTHOR]

The eccentric-swirl-secondary-air combustion technology has been confirmed to comprehensively solve high NO x emission and poor coal burnout for down-fired boilers with swirl burners. The influence of vent-air inclination angle (β v), a critical factor that affects coal burnout, on gas/particle flow characteristics is investigated to further decrease unburned combustible in fly ash. Gas/particle two-phase flow experiments under different β v (i.e., 10°, 20°, 28°, 40° and 50°) are performed by using a particle dynamic analyser in a 1:10-scale model of the full-scale improved boiler. With increasing β v , the under-arch recirculation zone and the recirculation velocities of gas/particle flows continuously increase. In the staged air region, the vertical velocities of gas/particle flows near water-cooled wall for β v of 40° and 50° are still as high as 2–4 m/s, however, the vertical velocities of gas/particle flows basically decay to negative values for smaller β v of 10° and 20°. At furnace section Y/Y 0 from 0.220 to 0.369, the vertical fluctuation velocities of gas/particle flows near water-cooled wall for β v of 40° and 50° are significantly higher than those with β v of 10°, 20° and 28°, and the particle volume flux at the same horizontal position X/X 0 constantly increases with increasing β v. Furthermore, the downward ejection ability of vent air to gas/particle flows from burners continuously improves, and the downward depth of gas/particle flows and the space utilization ratio of lower furnace both increase with increasing β v. The appropriate inclination angle of vent air for the improved boiler varies from 40° to 50°. Image 1 • A novel high-efficiency low-NO x technology is applied to a down-fired boiler with swirl burners. • Gas/particle flow characteristics at different vent-air inclination angles are investigated. • With increasing angle, recirculation zone and downward depth of gas/particle flows increase. • Primary air is more effectively ejected by under-arch air with increasing inclination angle. • The appropriate inclination angle of vent air for the improved boiler varies from 40° to 50°. [ABSTRACT FROM AUTHOR]

To achieve low-NO x emission in the coal-fired industrial boiler, the radial air staging method is proposed. The location of the over-fired air (OFA) is an essential parameter as it affects the combustion stability, NO x generation, burnout, and slagging trend. These are related to the gas-particle flow such as the recirculation region, gas mixture, and gas-particle mixture. Therefore, in this paper, taking a coal-fired industrial boiler with radial air staging method as an object, in a cold-modeling furnace, the gas-particle flow characteristics under various OFA locations (L D of 1.29, 1.43, 1.72, and 2.00) are studied. When OFA is radially arranged, the OFA jet diffuses towards the furnace center. As the L D increases, the size of the central recirculation region increases, thereby improving combustion stability. When the L D is 2.00, the mixing of the OFA jet and PCC jet obviously is delayed. Moreover, an increase in L D leads to more returned particles in the furnace center, promoting the reduction reaction of NO x. In addition, as the L D increases from 1.29 to 1.72, the gas-particle mixing uniformity is enhanced, which is beneficial to the uniform temperature distribution. Comprehensively, the L D of 1.43–1.72 is recommended when radial air staging is adopted in coal-fired industrial boilers. • The radial air staging method accelerates the mixing of OFA and the main airflow while reducing the mixing intensity. • With the increase of L D , the obstructing effect by radial OFA on the diffusion of the swirling main airflow is weakened. • The increased L D facilitates gas recirculation in the main combustion zone, which is conducive to stable combustion. • The mixing uniformity of GPF increases with L D in general, promoting the uniformity of temperature distribution. [ABSTRACT FROM AUTHOR]

The eccentric-swirl-secondary-air combustion technology (ESSACT) is an innovative technology to comprehensively solve high NO x emission and unburned carbon content in fly ash of the down-fired boiler with swirl burners. In this study, a breakthrough idea (i.e. decreasing burner injection angle (θ b)) is proposed to further greatly improve coal burnout of the improved boiler. Using a laser particle dynamic analyzer, the distributions of average and fluctuation velocities of gas/solid (GS) flows, distribution and decay of particle volume flux and jet trajectory of burner primary air in a 1:10 scale model of full-scale furnace at different θ b of 0°, 8°, 15° and 25° are acquired. The effects of θ b on GS flow characteristics (i.e. downward depth of GS flows, recirculation zones below arches and air flow fullness in the lower furnace) in the furnace are intensively studied. As the θ b decreases, the maximum vertical velocity of GS flows increases in the whole lower furnace, and the vertical fluctuation velocity of GS flows and the turbulent intensity and diffusion also increase. With decreasing θ b , maximum recirculation velocity and dimension of recirculation zone below arches both increase continuously, which is conducive to improving ignition and burnout of pulverized coal. Especially, the maximum recirculation velocity with θ b decreasing from 25° to 15° and the dimension of recirculation zone below arches with θ b decreasing from 15° to 8° increase more obviously. With decreasing θ b , the ejection effects of vent air and staged air on GS flows from arches are more effective. In the region below staged air, the maximum particle volume flux for the θ b of 0° and 8° is more than twice that for the θ b of 15° and 25°. As a result, the downward depth of GS flows and air flow fullness in the lower furnace both increase with decreasing θ b. To improve coal burnout of the down-fired boiler applying ESSACT, the θ b is recommended to be set below 8°. Image 1 • A novel low-NO x technology is proposed for a down-fired boiler with swirl burners. • Gas/particle flow characteristics are studied at various burner injection angles. • Recirculation zone and downward depth of flows both increase with decreasing angle. • Particles are more effectively ejected by vent and staged air with decreasing angle. • The burner injection angle is recommended to be set below 8° for the boiler. [ABSTRACT FROM AUTHOR]

A 300-MW e anthracite and down-fired boiler equipped with swirl burners, which was retrofitted with the previously proposed deep-air-staging combustion technology to reduce particularly high NO x emissions, still suffered from high carbon content in fly ash (despite this content being slightly lower than that before retrofit) on basis of significant NO x reduction. To comprehensively produce a high-burnout and low-NO x setting, a novel combustion technology was proposed in which relative to the axis of the primary air duct, the axes of the inner and outer secondary air ducts of the swirl burner shift away from the furnace center, and this technology is called an eccentric-swirl-secondary-air combustion technology. The coaxial symmetrical arrangements of primary and secondary air ducts for traditional swirl burners are broken. Full-scale industrial measurements under original, deep-air-staging and eccentric-swirl-secondary-air combustion technologies with respect to different loads (i.e., 180, 250, and 300 MW e ) were carried out to compare and analyze the validity of and improvement offered by the eccentric-swirl-secondary-air combustion technology. Under different boiler loads, especially at low and middle loads, compared with original and deep-air-staging combustion technologies, eccentric-swirl-secondary-air combustion technology markedly extends the penetration depth of coal/air flow and recirculation regions below arches. The thermal resistance between primary coal/air flow and high-temperature flue gas at the furnace center is reduced further, and the ignition of pulverized coal is timelier. The heating gradient in the burner outlet zone is maintained throughout, and the flame fullness in the primary combustion zone increases. The above three aspects contribute to pulverized coal burnout. Similar to deep-air-staging combustion technology, a low-oxygen and strong reducing atmosphere was formed in the primary combustion zone to reduce NO x formation due to the introduction of overfire air. Compared with deep-air-staging combustion technology, for the eccentric-swirl-secondary-air combustion technology, the air staged combustion in the furnace is improved further, and pulverized coal combustion in the primary combustion zone is more well distributed, which is beneficial to further reducing NO x emissions. The results of low-NO x and high-efficiency performance show that compared with the original boiler, NO x emissions and carbon content in fly ash for the boiler with the eccentric-swirl-secondary-air combustion technology are significantly reduced by above 42% and 32.5 to 20.7% at loads of 180, 250 and 300 MW e , respectively. [ABSTRACT FROM AUTHOR]

Prior to commercial operation of the first-ever 350-MWe supercritical down-fired boiler incorporating multiple injection and multiple staging combustion technology, cold modeling experiments varying the inner-to-outer-secondary air (ISA/OSA) ratio (applying ratios of 0:10, 2:8, 5:5, 6:4 and 10:0) were performed within a 1:13 scale model of the boiler furnace. The aim of these trials was to establish an optimal inner and outer secondary air distribution model for the burner in the full-scale furnace. At ratios of 0:10 and 2:8, the fuel-rich flow apparently diffused toward the furnace center zone after leaving the corresponding nozzle outlet, resulting in the formation of relatively small recirculation zones below the arches and independent fuel-rich and fuel-lean flow streamlines. In contrast, at ISA/OSA ratios greater than or equal to 5:5, the strengthened carrying effect of the inner secondary air significantly reduced the diffusion of the fuel-rich flow. Consequently, the fuel-rich and fuel-lean flow streamlines combined in the middle region of the lower furnace and the recirculation zones under the arches enlarged. As the ISA/OSA ratio was increased from 0:10 to 10:0, the line fitting slopes for the downward airflow decay curves increased from 1.8 to 3.0, meaning that the downward airflow decayed more rapidly, such that the penetration depth was reduced. Finally, at ISA/OSA ratios of 0:10 and 2:8, the initial flow-field deflection was observed to gradually adopt a symmetrical pattern. [ABSTRACT FROM AUTHOR]

A new combustion system has been applied to a 300 MW e down-fired boiler with swirl burners to reduce NO x emissions. The unit provided the introduction of overfire air (OFA) and a decrease in the flow area of the inner and outer secondary air ducts of the swirl burners. Industrial experiments on the retrofitted boiler were performed at different loads. Full-scale measurements of the flue gas temperature distribution in the burner outlet region, the furnace temperature distributions measured by a pyrometer and the local mean gas species concentrations in the region near the sidewall were made at loads of 180, 250, and 300 MW e . The results show that the ignition distance increased with decreasing load, especially as the load decreased from 250 MW e to 180 MW e . At three different loads, the retrofitted coal/air flow could be all ignited in time at a distance in the range of 0.6–1.4 m from the burner outlet. Compared with the original combustion system, the ignition distance of the coal/air flow was significantly reduced at a load of 300 MW e . In addition, at a load of 300 MW e , the temperature of the boiler hopper was much higher than that at loads of 180 MW e and 250 MW e . Compared with the original combustion system, the upper furnace temperature decreased slowly with increasing measurement height at a load of 300 MW e after the retrofit. Measurements of the O 2 and CO concentrations in the region near the sidewall indicate that the fullness degree of the coal flame in the furnace at different loads was different. After the retrofit, the reheat steam temperatures reached the design temperature of 541 °C at loads of 180 MW e and 250 MW e , and the average reheat steam temperatures increased by approximately 13 °C. Compared with the original combustion system, a significant NO x reduction (more than 40%) at different loads was achieved without increasing the levels of unburnt carbon in the fly ash. [ABSTRACT FROM AUTHOR]

Industrial pulverized coal boiler (IPCB) usually employ a pre-combustion chamber (PCC) to ensure stable combustion. However, there are potential slagging problems in the PCC, which threaten the safe operation of the boiler. Air-staged combustion technology is an effective method to reduce NO x emission, and different excess air coefficients affect slagging. CFD simulation is an important method for studying slagging in the furnace. In this paper, Using CFD simulation with slagging model embedded by user-defined function, the slagging trends in the PCC are studied under different excess air coefficients. The particles' collision rate (CR), deposition rate (DR), and sticking rate (SR) on the PCC walls are obtained by CFD simulation. As the excess air coefficient in the PCC (α PCC) increases from 0.3 to 1.1, the CR of particles on all walls of PCC (CR PCC) increases exponentially, indicating the abrasion degree on the PCC walls is growing rapidly. In addition, due to the sizeable annular recirculation zone when α PCC = 0.3, the DR of particles on all walls of PCC (DR PCC) and the SR of particles on all walls of PCC (SR PCC) are much larger than those under other conditions, the slagging trend is the worse. As the α PCC increases from 0.3 to 1.1, the slagging trends in the PCC first decrease and then increase. To improve the safety of boiler operation, it is recommended that the α PCC be adjusted between 0.5 and 0.9. • The effect of excess air coefficients (α PCC) on the slagging trends of PCC walls is studied by CFD simulation. • The relationship between the air-staged levels and CR PCC is established. • The entrainment effect of the secondary air on the particles is a crucial factor affecting slagging. • The annular recirculation zone distribution is the main reason for the maximum value of SR PCC at α PCC = 0.3. • The slagging trends first decrease and increase as the α PCC increases from 0.3 to 1.1. [ABSTRACT FROM AUTHOR]

To ensure good combustion stability, industrial pulverized coal-fired boilers normally employ a swirl burner with pre-combustion chamber (PCC). Owing to the high cross-sectional heat load of the PCC, there is potential for slagging, which can affect the safe and stable operation of the boiler, but can be avoided or reduced through the selection of suitable operating parameter values. Here, the effects on the slagging characteristics of PCC of varying the ratio of the inner to the outer secondary air mass flow rates in a swirl burner, R SA , from 0.00 to 0.83 were investigated using a computational fluid dynamics (CFD) simulation approach. The rates of collision, deposition, and sticking were analyzed. The results showed that as the R SA increases, the total collision rate of the pulverized coal particles in the PCC increases, and when R SA = 0.83, the total collision rate in the PCC is about 7 times of that when R SA = 0.00. Further, slagging tends to appear on the wall near the outlet of the PCC, and the degree of slagging in the PCC first decreases and then increases with increasing R SA. The optimum R SA range was found to be 0.22–0.38, which is conducive to the safe and stable operation of industrial pulverized coal-fired boilers. [Display omitted] • The slagging characteristics in the pre-combustion chamber were studied. • The rates of collision, deposition, and sticking were analyzed. • Slagging tends to appear near the exit area of the pre-combustion chamber. • The degree of slagging first decreases and then increases as R SA increases. [ABSTRACT FROM AUTHOR]

Radial air staging is a new air staging method for industrial pulverized coal boilers. In this paper, its impact on the gas-particle flow characteristics of industrial pulverized coal boilers was studied experimentally. The gas-particle flow experiments were carried out on a 1:6 scale boiler platform by a particle dynamics anemometer. The three-dimensional velocities of the gas-particle, average particle size and particle volume flux under different air stoichiometries in the furnace were measured. When the air stoichiometry was 0.2, the burner outlet could not form a stable reflux zone to establish a good combustion process. When the air stoichiometry is greater than 0.8, the maximum particle volume flow is also located near the water wall, increasing the slagging tendency on the wall. The appropriate air stoichiometry range for the new burner was 0.4–0.8. [Display omitted] • Radial air staging was a new air staging method. • Laboratory test and industrial application on the radial air staging were performed. • The appropriate range of air stoichiometry is recommended to be 0.4–0.8. • Anti-slagging and low NO x combustion are realized on industrial boilers. [ABSTRACT FROM AUTHOR]

Abstract: An OFA (over-fire air) program and matched measures supporting efficient-combustion are proposed for the FW (Foster Wheeler)-type down-fired boiler, where the OFA is supplied from the arches of the boiler. A gas/solid cold test was conducted at a scale of 1:15, using a two-dimensional laser phase Doppler analyzer to measure parameters in the model furnace, such as the two-phase gas/solid flow velocity, fluctuation velocity, particle size, particle volume flux and particle number concentration. The effects of the OFA ratio on the gas/solid flow characteristics in the furnace were investigated. With an increase in the OFA ratio, the jet depth of the fuel-rich flow decreased. For an OFA ratio of 25%, the jet depth of the fuel-rich flow was much less than that for other OFA ratios, and the residence time of the gas/solid flow in the lower furnace was shorter. An increase in the OFA ratio can increase the penetration depth and allow fuller mixing with the upward airflow, while an OFA ratio that is too great will hinder the upward flow back to the burner nozzle region. An OFA ratio of 20% is considered appropriate for the proposed OFA technical scheme. [Copyright &y& Elsevier]

In this study, a novel swirl burner for industrial pulverized coal boiler was studied by laboratory experiments and industrial application tests. First, a cold flow experiment was carried out on a 1:3 scale model experimental platform. The cold air velocities of burner outlet were measured in detail. Moreover, the influence of the mass flow ratio of the inner and outer secondary air on the shape of the central reflux zone and the reflux rate at the burner outlet was analyzed. It was found that a stable central reflux zone can be formed at the burner outlet. In addition, an industry application test was carried out in a 29 MW hot water boiler. The flue gas temperature at the burner outlet and the composition of exhaust gas were obtained under different operating parameters. The influence of inner and outer secondary air damper opening on burner performance (ignition performance, NO x emission characteristics, stable combustion performance, and anti-slagging performance) was analyzed. The influence of inner secondary air damper opening on burner performance was found to be greater than that of outer secondary air damper opening. The maximum concentration of NO x emission at furnace outlet was 364.9 mg/m3, and low-NO x combustion was achieved for industrial pulverized coal boilers. The minimum load without natural gas support was 3 MW. The load regulation rate was close to 10:1, and low load combustion stability was achieved. During three heating seasons, the normal operation of the boiler was not affected by slagging. • Laboratory experiments and industrial application tests are performed. • Influence of different inner and outer secondary air mass-flow ratio are investigated. • Low NO x combustion is achieved for industrial pulverized coal boilers. • Low load combustion stability is achieved for industrial pulverized coal boilers. [ABSTRACT FROM AUTHOR]

Abstract: Due to the limits of reserves and price for the high rank coal, the low rank coal has been employed as fuel for power generation in China and will be eventually employed in the world. To burn low rank coal, centrally fuel-rich swirl coal combustion burner has been studied in Harbin Institute of Technology. This paper reviews and analyzes the major research results. The work has included both experiments and numerical simulation. The experiments were conducted using small-scale single-phase experimental equipment, a gas/particle two-phase test facility and 200- and 300-MWe wall-fired utility boilers. For the burner, the primary air and glass beads partially penetrate the central recirculation zone and are then deflected radially. At the center of the central recirculation zone, there is high particle volume flux and large particle size. For the burners the local mean CO concentrations, gas temperatures and temperature gradient are higher, and the mean concentrations of O2 and NO x in the jet flow direction in the burner region are lower. Moreover, the mean O2 concentration is higher and the gas temperature and mean CO concentration are lower in the side wall region. Centrally fuel-rich burners have been successfully used in 200- and 300-MWe wall-fired pulverized coal utility boilers. [Copyright &y& Elsevier]

• Industrial experiments of down-fired boiler with bituminous coal under various loads are taken. • The ignition heat of coal/air flow under different coal varieties and loads is given. • Burning bituminous coal has a large furnace flame fullness under the low-load. • Strong combustion stability is determined by the low ignition heat and high furnace temperature under the low-load. • The combustion performances of bituminous coal and anthracite under the low-load are analyzed and compared. The new energy generating capacity is increasing year by year in the electric industry structure, but it is greatly influenced by the natural conditions. Coal-fired power generation unit boilers connected to the grid have the ability of flexible peak-load regulation and long-term low-load operation is required. However, the combustion stability is weak under the low-load when the coal-fired boiler burning anthracite. Down-fired boiler fueled with bituminous coal gradually attract the attention. Ignition and combustion stability, burnout, and NO x emissions are experimentally studied under the various loads on a 300 MW down-fired boiler fueled with bituminous coal, and the results compared with anthracite under the low-load. The ignition distance of the coal/air flow burning bituminous coal is gradually advanced with the reduction of load. And under the corresponding load, the ignition heat of the coal/air flow when burning bituminous coal is more than 37% lower than that burning anthracite. With the reduction of load, the decreasing rate of the overall furnace temperature and the cross-sectional heat load in the primary combustion zone decreases, and the furnace temperature in the primary combustion zone is high under the low-load when bituminous coal is burned. Short ignition distance, low ignition heat and high furnace temperature ensures the strong combustion stability of burning bituminous coal under the low-load. Moreover, under three various loads with burning bituminous coal, the carbon in the fly ash are all less than 1.1%, and the NO x emissions at the furnace exit are 410, 397 and 288 mg/m3 @ 6% O 2 , respectively. [ABSTRACT FROM AUTHOR]

Deep peak shaving requires extremely high requirements for low-load combustion stability of boilers. In this study, a novel swirl burner (NSB) with an eccentric secondary air arrangement was proposed, and the validity and the progressiveness of the NSB in achieving ultra-low-load combustion stability for down-fired boilers (DFBs) were confirmed from laboratory experiments to industrial applications. Firstly, the cold-modelling experiments of gas/particle (GP) two-phase flow characteristics involving two combustion systems (i.e., the DFB with traditional swirl burners (TSBs) and the DFB with NSBs) were performed at an ultra-low load of 90 MW e. Compared with the original boiler with TSBs, the maximum horizontal recirculation velocity and the area of recirculation zone below arches significantly increase for the improved DFB with NSBs. The particle number concentration near furnace center for the improved DFB with NSBs is much higher than that for the original DFB with TSBs. The above two aspects will effectively guarantee timely ignition of anthracite. The downward depth of GP flows and the space utilization ratio of the lower furnace increase, which will be beneficial to promoting volume heat load and heat flux density in primary combustion zone. In addition, full-scale industrial-sized measurements aiming at a 300-MW e DFB improved by NSBs were carried out at ultra-low loads of 100 and 90 MW e. For the original DFB after improved by NSBs, the minimum load for stable combustion without oil support is reduced from 150 to 90 MW e , and the ultra-low-load combustion stability is achieved. For the improved DFB with NSBs, pulverized coal ignition distances for operating burners are about 2 and 2.6 m, respectively, and the signal strength of flame detectors for all operating burners is above 95% at 100 and 90 MW e. The flame fullness and combustion stability are good at the initial combustion stage. At ultra-low loads, furnace negative pressure, superheat steam pressure and oxygen concentration at furnace outlet fluctuate slightly. The temperature at air preheater inlet meets the needs of normal operation of denitrification system, and there is no problem of low temperature corrosion on the surface at flue gas side of air preheater. The unburned carbon in fly ash is about 4%. The maximum concentrations of NO x emission at furnace outlet are 714 and 687 mg/m3 (O 2 = 6%) at 100 and 90 MW e , respectively, and ultra-low emission of NO x after denitrification system is achieved. • A novel swirl burner with an eccentric secondary air arrangement was proposed. • Laboratory and industrial experiments were performed. • Performances of flow, mixture, ignition and combustion are all improved. • Ultra-low-load combustion stability is achieved for the improved down-fired boiler. [ABSTRACT FROM AUTHOR]

• Proposed effective low NO x combustion technology with arch-supplied secondary air. • The flow characteristics of the two-phase flows in the furnace were investigated. • Arch-supplied secondary air increases the downward impulse of the two-phase flow. • Increasing arch-supplied secondary air rate can improved the combustion performance. This study proposes a low NO x combustion method for Foster Wheeler type down-fired boilers. The effectiveness of this technique was validated through laboratory-scale gas-particle two-phase experiments and industrial trials. The flow field characteristics within FW-type boiler furnaces equipped with arch-supplied secondary air injection nozzles were investigated. Furthermore, the application of this technique to a 660 MW subcritical FW-type boiler was examined, focusing on NO x emissions and combustion characteristics. Results demonstrate that optimizing the damper openings for F-layer and arch-supplied secondary air can significantly reduce NO x emissions by over 33 %. Additionally, increasing the mass flow rate of arch-supplied secondary air aids in reducing unburned carbon in fly ash and inducing a downward shift in the flame center within the furnace. [ABSTRACT FROM AUTHOR]

A new overfire air (OFA) technology was proposed by the authors for a Foster Wheeler down-fired boiler, and a small-scale cold experimental system for a 660-MWe unit was established. The velocity field distribution was measured in the furnace to study the characteristics of single-phase flow in the furnace at different OFA nozzle angles. The furnace temperature and distributions of the O2 concentration and NO concentration at different OFA nozzle angles were simulated using Fluent 6.3.26, and the average temperature of the furnace outlet, the O2 and NO x concentrations and carbon content in the fly ash were calculated. As the OFA nozzle angle increased, the vertical penetration depth of OFA increased and the horizontal penetration depth of OFA gradually decreased. The carbon content in the fly ash and NO x concentration initially rose and then fell at the furnace outlet, and they were lowest when the OFA angle was set at 20°. Thus, according to the findings of this article, an optimized OFA angle of 20° was chosen. [ABSTRACT FROM AUTHOR]

Abstract: Industrial experiments were performed for a retrofitted 660-MWe full-scale arch-fired boiler. The ignition position of the primary air/fuel mixture flow, furnace temperature and flue gas component after the air heater were measured with different anthracite ratios at loads of 660- and 380-MWe. As the ratio of anthracite increased, the gas temperature decreased in the fuel-burning zones of the C4 and C6 burners, indicating a farther ignition position of the primary fuel/air flow under the arches, the gas temperature of the lower furnace decreased while that of the upper furnace increased, NO x emissions decreased while both the exhaust gas temperature and carbon content in fly ash increased, and the boiler efficiency decreased. At the rated load, an anthracite ratio of 35% was optimal for economical efficiency. At low load, the negative gas pressure fluctuated remarkably, which led to unstable combustion in the furnace. To ensure safe and stable operation of the boiler, a mass ratio of anthracite of 25% is advisable. [Copyright &y& Elsevier]

Abstract: Industrial experiments were performed with a 300-MWe full-scale down-fired boiler. New data is reported for (i) gas temperature distributions within the primary air and coal mixture flows, (ii) gas compositions, such as O2, CO, CO2 and NO x , and (iii) gas temperatures within the near-wall region. The data complements previously-obtained data from the same utility boiler before being modified by declination of the F-tier secondary air. By directing secondary air under the arches, the region where the primary air and pulverized coal mixture is ignited is brought forward within the boiler. Gas temperatures rose in the fuel-burning zone and fell in the fuel-burnout zone. As a result the quantity of unburned carbon in fly ash and the gas temperature at the furnace outlet were both lowered. [Copyright &y& Elsevier]

Through a gas-particle cold-modeling experiment, the particle dynamic analyzer (PDA) is used to investigate the effects of fuel-lean coal/airflow angle and ratio of oil secondary air to F-layer secondary air on the gas/particle flows characteristics in the furnace of a Foster Wheeler (FW) down-fired boiler with enhanced stable combustion technology. As the fuel-lean coal/airflow angle increases from 10° to 45°, the peak value of the vertical dimensionless velocity of the gas/particle flows gradually increases, and the peak position gradually moves to the near wall region. As the ratio of oil secondary air to F-layer secondary air (the secondary air ratio for short) increased, the peak value of the vertical dimensionless velocity of the gas/particle flows gradually increased and the peak value position of the dimensionless velocity gradually moved towards the near-wall region. In actual operation, for the perspective of performance and safety, the recommended fuel-lean coal/airflow angle and secondary air ratio is 30°and 1:2 respectively. The enhanced stable combustion technology had been applied to two 600 MW FW down-fired boilers, and these boilers can achieve stable operation when burning a wide range of coal quality under the load section from 200 MW to 600 MW. • A Foster Wheeler down-fired boiler retrofitted with novel low-load stable combustion technology is studied by PDA. • Effects of fuel-lean coal/airflow angle and secondary air ratio on the gas/particle flows characteristics were investigated. • The fuel-lean coal/airflow angle of 30° and the secondary air ratio of 1:2 is recommended. • This novel low-load stable down-fired boiler combustion technology is suitable for a wide range of coal quality combustion. [ABSTRACT FROM AUTHOR]

In this paper, based on the MIMSC (multi-injection and multi-stage combustion) technology, new burner arrangement and air distribution parameter settings were proposed for a 300-MW subcritical down-fired boiler originally using MBEL (Mitsui Babcock Energy Limited) combustion technology. Numerical simulations were conducted to study the influences of the secondary-tertiary air proportion on the airflow mixing effect in the furnace, the ignition and pulverized coal combustion characteristics. The airflow mixing effect in the furnace is characterized by the size of the dimensionless vertical velocity decay area (V da) and the fluctuation of the maximum vertical velocity decay curve (V dc). During the research, the sum of the secondary and tertiary air rate remained constant, and the secondary air rate was set to 30.54%, 33.54%, 36.54%, 39.54%, and 42.54%. It was found that under the condition of using new type burner, with the secondary air rate increased from 30.54% to 42.54%, the ignition distance of pulverized coal decreased from 1.30m to 0.84m, the dimensionless penetration depth decreased from 1.46 to 1.27, and the NO x emission and carbon in the fly ash decreased first and then increased. The variation of V dc showed the following regulation. At the secondary air rate of 30.54% to 33.54%, increasing the secondary air rate decreased the fluctuation amplitude. While at the secondary air rate of 39.54% to 42.54%, increasing the secondary air rate increased the fluctuation amplitude. Only at the secondary air rate of 36.54%, V dc in the tertiary air mixing area was smooth. When V dc was smooth, V da was small at 0.043, the carbon in fly ash at the furnace outlet was the lowest at 4.19%, and the NO x emission was low at 675.9 mg/m3 at 6% O 2. An optimal secondary air rate of 36.54% is recommended. For the subsequent design of burner structure and parameters, it is suggested that V dc in the tertiary air mixing area should be smooth. [ABSTRACT FROM AUTHOR]

Fuel rich/lean combustion is an important means of reducing NO x in coal-fired boilers. The mass ratio of pulverized-coal in fuel-rich flow to that in fuel-lean flow (MRL) is a key parameter in fuel rich/lean combustion that affects the gas/particle flow characteristics and in turn the coal ignition and NO x formation. In this work, using a 1:40 scale model furnace and a particle dynamics anemometer measurement system, the effects of various MRLs (6:4, 7:3, 8:2 and 9:1) on the gas/particle flow characteristics in a 600 MWe down-fired boiler incorporating multiple-injection and multiple-staging were studied. The results demonstrate that airflows injected from the front-arch burners flow downwards along the front wall and then turn upward in the furnace center zone, forming a U-shaped flow pattern. Increasing the MRL significantly raises the maximum particle volume flux under the fuel-rich flow nozzle, which favors advanced pulverized-coal ignition and improves the fuel rich/lean combustion in the boiler. The velocity decay of the downward gas/particle flow is also accelerated. The particle volume flux in the hopper zone is gradually reduced while the location of the maximum particle volume flux gradually moves away from the hopper declined wall. This scenario avoids the downward flame flushing the furnace hopper and prevents both hopper wall overheating and tube bursts in the actual down-fired boiler. Based on these results, an MRL of 9:1 is recommended as optimal. [ABSTRACT FROM AUTHOR]

• A novel low-load stable combustion technology is applied on a 600MWe FW down-fired boiler. • 33% rated load stable combustion without oil support is achieved. • Full-scale industrial measurements are carried out at 200, 240 and 540MWe. • Combustion and NOx formation characteristics at high and low load are contrastively studied. The randomness and intermittence of solar and wind power generation require coal-fired thermal power boilers that have a low-load stable combustion capacity. This study proposed a novel low-load stable combustion technology in which the oil secondary air flow is arranged parallel to the fuel-rich coal/air flow and participates in pulverised coal combustion during boiler operation. The method was applied to a 600 MWe down-fired boiler manufactured with the technology of Foster Wheeler Corp. Full-scale industrial measurements of furnace flue gas temperature, fuel-rich coal/air flow ignition distance, and distribution characteristics of NOx, O 2 , and CO in the furnace at loads of 200, 240, and 540 MWe were performed. The results showed that the boiler can stably operate without oil support at 240 MWe (40% rated load) and 200 MWe (33% rated load) respectively burning a blended coal of anthracite and lean coal, and blending bituminous coal. At loads of 200, 240, and 540 MWe, the fuel-rich coal/air flow ignition distances were, respectively, approximately 1.4, 1.7, and 1.3 m. NOx emissions at the furnace exit were 406, 407, and 730 mg/Nm3 (O 2 = 6%), and the boiler thermal efficiencies were 92.42%, 92.45%, and 90.58%, respectively. This novel technology presents the characteristics of high efficiency and low NOx emission while realizing low-load stable combustion of down-fired boilers. [ABSTRACT FROM AUTHOR]

[Display omitted] • Laboratory experiments and industrial trials are conducted for a down-fired boiler. • Effects of air-staging degree (ASD) in furnace of the boiler at low load are studied. • On increasing ASD, the trend of particle diffusion to furnace center area increased. • Maximum value and deviation of water-wall temperature is large at low ASD settings. • Optimum coal consumption and NO x emission are as low as 337.36 g·(kW·h)−1 and 654 mg/m3. Low load operation of down-fired boilers has become the norm such that the comprehensive performances of such boilers at low loads need to be investigated to increase the energy conversion efficiency and reduce carbon and NO x emissions. In this work, cold-model air/particle flow experiments and industrial-scale trials were performed to study the effects of the air-staging degree (ASD) on the air/particle flow, combustion, water wall temperature, energy conversion and NO x emission characteristics of a 350 MW supercritical down-fired boiler at low loads. The experimental conditions are four different combinations of damper openings associated with the secondary-air, tertiary-air and OFA (i.e. 60%/40%/15%, 50%/50%/15%, 35%/70%/15% and 30%/55%/55%), and are referred to as ASD = I, II, III and IV, respectively. The results showed that, as the ASD was increased from I to IV, the injection effect of the secondary-air on the fuel-rich flow was weakened. In addition, the downward diffusion of the air/particle flow toward the furnace center increased, while the particle concentration near water wall decreased and the velocity decay was accelerated. Decreasing the ASD shortened the ignition distance of the fuel-rich flow, reduced the carbon in fly ash and slag and improved the boiler efficiency. At an ASD setting of I, a higher thermal load and increased temperature near the water wall were obtained in the lower furnace. These conditions gave the highest superheated and reheated steam temperatures of 568.1 and 570.7 °C, respectively. As the ASD was increased from II to III, the cooling effect of the tertiary-air reduced the maximum water wall temperature. The reduction, in turn, increased the regulating margin of superheating degree, which raised the steam temperature. Increasing the ASD from I to IV increased the specific coal consumption from 337.36 to 348.12 g·(kW·h)−1, indicating that the energy conversion efficiency of the unit was decreased. Additionally, the NO x emissions at the furnace exit were reduced from 770 to 528 mg/m3 at 6% O 2. On the basis of the present results, an ASD setting of II is recommended to ensure the safe and economical operation of such units while minimizing environmental impact. [ABSTRACT FROM AUTHOR]

To alleviate the over-temperature of water-wall and increase the energy conversion efficiency of supercritical down-fired boilers, cold-model air/particle flow experiments and in-situ trials were performed to investigate the effects of the secondary-air distribution wall-side deflection coefficient (w s) on air/particle flow and combustion characteristics. As w s increased from 0 to 0.33, the amount of air/particle flow diffused toward water-wall and the corresponding particle concentration both decreased, while the velocity decay was accelerated. At a w s of 0.16, due to prior ignition of fuel-rich flow and a longer flame stroke in lower furnace, the carbon in fly ash and slag were lowest. As w s increased, the thermal load was gradually focused at the furnace center, and the maximum value and deviation of water-wall temperature in lower furnace decreased. Consequently, the temperatures of superheated and reheated steam respectively increased from 542.7 °C to 543.9 °C–560.2 °C and 560.1 °C, respectively. Furthermore, increasing w s from 0 to 0.28 decreased the specific coal consumption from 346.29 to 341.09 g (kW h)−1, indicating the energy conversion efficiency was improved. However, adjusting w s had only a minimal effect on NO x emissions. A w s of 0.28 is recommended to optimize the water-wall temperature, pulverized-coal burnout, and economic performance. [Display omitted] • Laboratory and industrial experiments are combined performed for a down-fired boiler. • The wall-side deflection coefficient of secondary-air distribution (w s) is proposed. • On increasing w s , maximum value and deviation of water-wall temperature is lowered. • Specific coal consumption is reduced and energy conversion efficiency is improved. • The optimum carbon in fly ash and NO x emissions are as low as 4.92% and 654 mg/m3. [ABSTRACT FROM AUTHOR]

Abstract: A new over-fire air (OFA) program, which called arch-supplied OFA, is proposed for Foster Wheeler (FW) type down-fired boiler in this paper. The OFA nozzles are setting on arches near the furnace center and emitting OFA flow into the furnace at an inclined angle. Cold airflow experiments were conducted to determine the effect of the OFA ratio on the aerodynamic field in a small-scale furnace modeled for a 660-MWe down-fired boiler. As the OFA ratio increases, the penetration depth of the OFA flow increases in the level direction and the turning point from downward to upward of the OFA flow moves to the furnace center. At the same time, the velocity of the F-tier airflow decreases and its ability to bring the arch-injected airflow to deeper positions weakens and the turning point from downward to upward of the F-tier airflow moves to the wall. When the OFA ratio is 20%, the OFA flow could penetrate to the furnace center in the level direction and mix with the upflowing gas completely, while the arch-injected airflow have sufficient travel distance and enough residence time in the lower furnace. Thus, considering the penetration depth of arch-injected flow in the vertical direction and the OFA flow in the level direction, an OFA ratio of 20% is recommended for the new OFA arrangement according to the present work. [Copyright &y& Elsevier]

Abstract: Using an IFA300 constant temperature anemometer system, cold air experiments on a scale-model of a down-fired pulverized-coal 300MWe utility boiler with swirl burners were performed to investigate the influence of the staged-air flow ratio on flow characteristics in the furnace. This ratio was increased in incremental steps over the range of 7%–20%. The flame reach of the downward airflow was decreased with the ratio increased. A shallower reach is accompanied by a weaker mixing of vent and staged-air. At lower ratios, mixing is good and thus favors coal combustion but weak mixing at intermediate ratios produces a delay in the mixing point. This is compensated by an increasing recirculation zone under the arch that benefits ignition and the appearance of an upward airflow below the mixing point due to an increasing influence of vent air. At higher ratios still, this upward flowing disturbance is centered higher up in the furnace generated primarily by mixing with staged-air as vent-air mixing weakens. [Copyright &y& Elsevier]

Abstract: Cold airflow experiments on a small-scale burner model, as well as in situ experiments on a centrally fuel-rich swirl coal combustion burner were conducted. Measurements were taken from within a 300 MWe wall-fired pulverized-coal utility boiler installed with eight of centrally fuel-rich swirl coal combustion burners in the bottom row of the furnace during experiments. Various primary air ratios, flow characteristics, gas temperature and gas species concentrations in the burner region were measured. The results of these analyses show that with decreasing primary air ratio, the swirl intensity of air, divergence angles and maximum length and diameter of the central recirculation zone all increased, and the turbulence intensity of the jet flow peaked but decayed quickly. In the burner nozzle region, gas temperature, temperature gradient and CO concentration increased with decreasing primary air ratio, while O2 and NOx concentration decreased. Different primary air ratios, the gas temperatures and gas species concentrations in the side-wall region varied slightly. [Copyright &y& Elsevier]

Abstract: A start-up ignition burner has been proposed to reduce oil fuel consumption during the firing-up process and partial-load operation. To investigate the influence of different excess air ratios on bituminous coal combustion in the start-up ignition burner, full-scale reacting-flow experiments were performed for an experiment setup. The ignition burner was identical to that normally used in an 800 MWe utility boiler. Gas temperature distributions in the burner were obtained for excess air ratios of 0.56, 0.75, 0.98 and 1.14 (corresponding to primary air velocities of 17, 23, 30 and 35 m/s). Coal burnout and the release of C and H were observed at the exit of the burner nozzle. Gases such as O2 and CO were measured at the center of the burner. A change in resistance was obtained within the burner. [ABSTRACT FROM AUTHOR]

Abstract: We measured various operational parameters of a 200-MWe, wall-fired, lignite utility boiler under different loads. The parameters measured were gas temperature, gas species concentration, char burnout, component release rates (C, H and N), furnace temperature, heat flux, and boiler efficiency. Cold air experiments of a single burner were conducted in the laboratory. A double swirl flow pulverized-coal burner has two ring recirculation zones that start in the secondary air region of the burner. With increasing secondary air flow, the air flow axial velocity increases, the maximum values for the radial velocity, tangential velocity, and turbulence intensity all increase, and there are slight increases in the air flow swirl intensity and the recirculation zone size. With increasing load gas, the temperature and CO concentration in the central region of burner decrease, while O2 concentration, NO x concentration, char burnout, and component release rates of C, H, and N increase. Pulverized-coal ignites farther into the burner, in the secondary air region. Gas temperature, O2 concentration, NO x concentration, char burnout and component release rates of C, H, and N all increase. Furthermore, CO concentration varies slightly and pulverized-coal ignites closer. In the side wall region, gas temperature, O2 concentration, and NO x concentration all increase, but CO concentration varies only slightly. In the bottom row burner region the furnace temperature and heat flux increase appreciably, but the increase become more obvious in the middle and top row burner regions and in the burnout region. Compared with a 120-MWe load, the mean NO x emission at the air preheater exits for 190-MWe load increases from 589.5mg/m3 (O2 =6%) to 794.6mg/m3 (O2 =6%), and the boiler efficiency increases from 90.73% to 92.45%. [Copyright &y& Elsevier]

Abstract: Industrial experiments have been performed on a down-fired pulverized-coal 300MWe utility boiler with vent air valve opening of 100% and 40%. The gas temperature distribution along the primary air and coal mixture flow, gas temperature distribution in the furnace, and gas components such as O2, CO, CO2 and NO x in the near-wall region were measured for the first time. The influence of vent air valve opening on coal combustion in the furnace was determined. The results indicate that ignition of the primary air and pulverized-coal mixture is delayed. The position of the gas temperature peak is above the arches. Emission of NO x is up to 2101mg/m3 (at 6% O2 dry) with vent valve opening of 40%. [Copyright &y& Elsevier]

[Display omitted] • Effect of fuel-lean flow damper opening (FLD) in a down-fired boiler is investigated. • Relation of water-wall and steam temperature in a supercritical boiler is discussed. • On decreasing the FLD, heating of the fuel-rich coal/air flows gradually accelerates. • Specific coal consumption is lowered and energy conversion efficiency is improved. • The optimum NO x emissions and carbon in fly ash are as low as 672 mg/m3 and 4.51%. In-situ trials were carried out to investigate the effects of the fuel-lean coal/air flow damper opening (FLD) on the pulverized-coal combustion and energy conversion efficiency in a 350-MW supercritical down-fired boiler. This boiler was operated with inferior coal, having a high ash content and low calorific value. The influence of combustion in furnace on steam temperature and coal consumption of a supercritical down-fired boiler were discussed innovatively. The experimental results indicate that, as the FLD was decreased from 100% to 25%, heating of the fuel-rich coal/air flow accelerated such that the overall furnace temperature increased and the thermal load gradually focused at the furnace center area. As a result, the maximum temperature of the water-wall in the lower furnace was reduced and the superheating degree rose significantly. Thus the superheated and reheated steam temperatures increased from 550.4 and 545.8 °C to 558.2 and 555.0 °C. Reducing the FLD also lowered the carbon in the fly ash and slag from 8.17% and 7.70% to 4.51% and 3.43%, respectively. Furthermore, the increase of boiler efficiency and the decrease of specific heat consumption both contributed to the reduction of the specific coal consumption, from 354.45 to 340.43 g·(kW·h)−1, thus the energy conversion efficiency of the unit was improved. However, adjustment of the FLD had only a minimal effect on NO x emissions, which remained in the range of 654–672 mg/m3 at 6% O 2. Based on optimizing coal combustion characteristic and economic performance of the unit, an optimal FLD of 25% was recommended. [ABSTRACT FROM AUTHOR]