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Industrial Boilers 1/ 63
Copyright Training 4 Today 2001 Published by EnviroWin Software LLC
INSTRUCTOR
Insert Instructor Name Here
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OBJECTIVES
Define Industrial Boiler Size. Discuss How Nitrogen Oxide (NOx) is Formed. Discuss Factors Affecting NOx.
GOALS
Be Familiar With Records to Maintain.
BACKGROUND
In 1999, there were 5,489,423 tons of Nitrogen Oxide (NOx) emitted into the atmosphere by industrial boilers. NOx is instrumental in smog and acid rain formation On November 3, 1999, the Justice Department filed seven lawsuits against electric utilities in the Midwest and South charging them with violations of their NOx boiler emissions 43% of all boilers are subject to Nitrogen Oxide (NOx) emission limits
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LEARNERS
Supervisors
Facility Engineers
Maintenance Personnel Department Managers
Building Occupants
Process Specialists Environmental and Safety Committees
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OVERVIEW
The goal of this course is to provide supervisors with the tools needed to properly manage industrial boilers. It recommends practical, actions that can be carried out by facility management, maintenance personnel and building occupants. The course will help you to integrate good industrial boiler management activities into your existing organization and identify which of your staff have the necessary skills to carry out those activities.
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APPLICABLE REGULATIONS
40 CFR 63 National Emission Standards For Hazardous Air Pollutants For Source Categories
40 CFR266-- Subpart H--Hazardous Waste Burned in Boilers and Industrial Furnaces 40 CFR 76 Acid Rain Nitrogen Oxides Emission Reduction Program
INDUSTRIAL BOILERS
Industrial boilers have been identified as a category that emits more than 25 tons of oxides of nitrogen (NOx) per year Boilers include steam and hot water generators with heat input capacities from 0.4 to 1,500 MMBtu/hr (0.11 to 440 MWt). Primary fuels include coal, oil, and natural gas Other fuels include a variety of industrial, municipal, and agricultural waste fuels
BOILER SIZES
Industrial boilers generally have heat input capacities ranging from 10 to 250 MMBtu/hr (2.9 to 73 MWt). The leading user industries of industrial boilers, ranked by aggregate steaming capacity, are the paper products, chemical, food, and the petroleum industries Those industrial boilers with heat input greater than 250 MMBtu/hr (73 MWt) are generally similar to utility boilers Boilers with heat input capacities less than 10 MMBtu/hr (2.9 MWt) are generally classified as commercial/institutional units
Low NOx Burners, Natural Gas Reburning, and Low NOx Burners with Staged Combustion Air are effective in controlling NOx in these units
FUEL CHARACTERISTICS
Boiler baseline NOx emissions are highly influenced by the properties of the fuels burned Among each of fuel types, emissions will depend on highly variable factors such as fuel grade and fuel source In particular, studies have shown that fuel nitrogen content and for coal the oxygen content and the ratio of fixed carbon to volatile matter are key factors influencing NOx formation
FUEL CHARACTERISTICS
Nitrogen Content of Fuels
The following table gives ranges of nitrogen content for different fuels: Fuel Coal Residual Oil Distillate Oil Natural Gas % by Weight .8 3.5 .36 <0.01 0 12.9
FUEL CHARACTERISTICS
Sulfur Sulfur can combine with oxygen and water to form Sulfuric Acid, H2SO4 Fuel % of Sulfur Coal 1-4 Residual Oil 1.3 Distillate Oil .72 Natural Gas <0.001
Although lower sulfur content generally means lower nitrogen, there is no apparent direct relationship between these two fuel oil parameters
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FUEL CHARACTERISTICS
Fuel Ratio Fuel ratio is defined as the ratio of a coal's fixed carbon to volatile matter Under unstaged combustion conditions, lower fuel ratios (i.e. higher volatile content of the coal) correlate to higher levels of NOx, because with higher volatile content coals, greater amounts of volatile nitrogen are released in the high temperature zone of the flame where sufficient oxygen is present to form NOx Firing coal with high volatile content and lower fixed carbon generally results in less solid carbon to be burned out in the post-flame gases, meaning that the coal can be fired at lower excess air before combustible losses became a problem
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FUEL CHARACTERISTICS
Moisture Moisture content plays an important role in the formation of uncombustible emissions in Municipal Solid Waste boilers Non-combustible content of Municipal Solid Waste can range from 5 to 30 percent Moisture content of Municipal Solid Waste can range from 5 to 50 percent Nitrogen contents of Municipal Solid Waste can range between 0.2 and 1.0 percent
CONTROLS
Retrofitting existing generating units with lowNOx burners is the most frequently chosen compliance control because it is an economical way to limit the formation of NOx Low-NOx burners control fuel and air mixing to create larger and more branched flames, reduce peak flame temperatures and lower the amount NOx formed The improved flame structure also improves burner efficiency by reducing the amount of oxygen available in the hottest part of the flame
CONTROLS
In principle, there are three stages in a conventional lowNOx burner: 1. Combustion - combustion occurs in a fuel-rich, oxygendeficient zone where the NOx is formed 2. Reduction - where hydrocarbons are formed and react with the already formed NOx 3. Burnout - internal air staging completes the combustion. Additional NOx formation occurs in the third stage, but it can be minimized by an air-lean environment
Low-NOx burners can also be combined with overfire air technologies to reduce NOx further
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CONTROLS
Natural Gas Reburning Another combustion modification technique involves the staging of fuel, rather than combustion air By injecting a portion of the total fuel input downstream of the main combustion zone, hydrocarbon radicals created by the reburning fuel will reduce NOx emission emitted by the primary fuel This reburning technique is best accomplished when the reburning fuel is natural gas Application of these techniques on boilers has been limited to some municipal solid waste (MSW) and coalfired stokers
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CONTROLS
Staged Combustion Air (SCA) A technique that reduces flame temperature and oxygen availability by staging the amount of combustion air that is introduced in the burner zone SCA can be accomplished by several means. For multiple burner boiler, the most practical approach is to take certain burners out of service (BOOS) or biasing the fuel flow to selected burners to obtain a similar air staging effect Generally, SCA is not considered viable for retrofit to packaged boiler units due to installation difficulties.
CONTROLS
Flue Gas Recirculation (FGR) Involves recycling a portion of the combustion gases from the stack to the boiler windbox These low oxygen combustion products, when mixed with combustion air, lower the overall excess oxygen concentration and act as a heat sink to lower the peak flame temperature and the residence time at peak flame temperature These effects result in reduced thermal NOx formation. It has little effect on fuel NOx emissions FGR is currently being used on a number of watertube and firetube boilers firing natural gas
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SOLID WASTE
NOx reduction techniques that have a potential impact on the disposal of solid waste are combustion controls for Pulverized Coalfired boilers and flue gas treatment systems for all applicable boilers Combustion controls for Pulverized Coalfired boilers are principally Low NOx Burners. These controls can result in an increase in the carbon content of flyash that can preclude its use in cement manufacturing.
HAZARDOUS WASTE
Catalysts used in the Selective Catalytic Reduction process can be hazardous Examples are vanadia and titania catalysts Many catalyst vendors recycle this material thus avoiding any disposal problem for the user Some of the catalysts, especially those that use rare earth material such as zeolites, are not hazardous and their disposal does not present an adverse impact
ASBESTOS
Asbestos was used in fire brick and gunnite used for internal insulation of boilers and other vessels Asbestos is dangerous when it becomes friable Asbestos materials are health hazards because: Inhaled asbestos fibers can be trapped in the lungs Inhaled asbestos fibers have been linked to cancerous cell growth in the lungs If asbestos is in your older boiler, have workman alerted to its presence. Any friable asbestos should be removed by qualified workers.
MONITORING REQUIREMENTS
EPAs Acid Rain Program has established special monitoring and reporting requirements for all units over 25 megawatts and new units under 25 megawatts that use fuel with a sulfur content greater than .05 percent by weight The new units under 25 megawatts using clean fuels are required to certify their eligibility for an exemption every five years All existing coal-fired units serving a generator greater than 25 megawatts and all new coal units must use CEM for SO2, NOx, flow, and opacity. Units burning natural gas may determine SO2 mass emissions by three ways
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MONITORING REQUIREMENTS
Units burning oil may monitor SO2 mass emissions by one of the following methods: 1. daily manual oil sampling and analysis plus oil flow meter (to continuously monitor oil usage) 2. sampling and analysis of diesel fuel oil as-delivered plus oil flow meter 3. automatic continuous oil sampling plus oil flow meter 4. SO2 and flow CEMs.
MONITORING REQUIREMENTS
Gas-fired and oil-fired base-loaded units must use NOx CEMs. Gas-fired peaking units and oil-fired peaking units may either estimate NOx emissions by using sitespecific emission correlations and periodic stack testing to verify continued representativeness of the correlations, or use NOx CEMS All gas-fired units using natural gas for at least 90 percent of their annual heat input and units burning diesel fuel oil are exempt from opacity monitoring For CO2 all units can use either (1) a mass balance estimation, or (2) CO2 CEMs, or (3) O2 CEMs in order to estimate CO2 emissions
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MONITORING REQUIREMENTS
CEM systems include: An SO2 pollutant concentration monitor A NOx pollutant concentration monitor A volumetric flow monitor An opacity monitor A diluent gas (O2 or CO2) monitor A computer-based data acquisition and handling system (DAHS) for recording and performing calculations with the data CEM systems must be in continuous operation and be able to sample, analyze, and record data at least every 15 minutes and reduce flow data to 1-hour averages.
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RECORDKEEPING
The CEM rule includes requirements for notification, recordkeeping, and reporting for the Acid Rain Program, such as: Submission of monitoring plans Written notifications of monitor certification tests Report of certification test results in a "certification application Recording and maintaining of hourly emissions data, flow data, and other information Quarterly reports of emissions, flow, unit operation, and monitoring performance data.
RECORDKEEPING
The owner or operator also must report the data in a standard electronic format available through the Acid Rain Hotline Unless otherwise specified by your regulators or permit conditions, it is recommended to keep these records for a minimum of 3 years unless the boiler destroys hazardous waste, then the records must be kept through closure of the boiler