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• 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]

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]

• 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]

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]

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]