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ABSTRACT
In June 2001 the Lower Colorado River Authority (LCRA) entered into a competitively bid
contract with ALSTOM Power Inc. (ALSTOM) to design, supply and install low NOx
equipment for Fayette Power Project Units 1 and 2. Low NOx firing systems were installed on
Unit 1 in the fall of 2002 and on Unit 2 in the spring of 2004. ALSTOM tuned the modified
firing systems during the contracted time period, achieving emissions that were lower than the
contractual guarantees. After the Low NOx Concentric Firing Systems (LNCFS) were
commissioned, LCRA continued to tune each boiler and further reduced NOx emissions. The
capabilities of both the modified firing systems and the existing control system have been
utilized to minimize emissions, even while plant load varied. NOx emissions that resulted in a
yearly average of 0.103 lb/mmBtu and monthly averages of less than 0.10 lb/mmBtu have been
achieved. This paper will present an update on long-term Unit 1 results, as well as the most
recent results for Unit 2.
INTRODUCTION
The Texas Commission on Environmental Quality requires all coal-fired power generation units
in the eastern half of the state to limit yearly average NOx emissions to no more than 0.165
lb/mmBtu, starting in May 2005. Based on industry experience with similarly sized tangentially
fired power boilers fueled by Powder River Basin coal, LCRA staff recommended that boiler
combustion system modifications be utilized to achieve this requirement. A Request for
Proposal was issued in January 2001 to several potential vendors to engineer, supply and install
1
these modifications for the Fayette Power Project (FPP) Unit 1 and 2 boilers. ALSTOM was
selected as the vendor to provide these modifications. Equipment for FPP Unit 1 was installed
during a planned unit outage in October November 2002. Unit 2 modifications were executed
during a March April 2004 outage.
After starting up each unit, ALSTOM personnel tuned each boilers combustion system during a
six-week period. During the Unit 1 acceptance tests, NOx emissions generally averaged 0.14
lb/mmBtu. After the acceptance tests, FPP personnel further tuned the unit to even lower
averages. For most of 2004, monthly NOx emissions averaged below 0.10 lb/mmBtu.
The Unit 2 retrofit benefited from the previous Unit 1 experience. NOx emissions during the
acceptance tests were 0.107 lb/mmBtu. Lowest NOx achieved was 0.096 lb/mmBtu for the
month of October 2004.
This paper describes the installed boiler combustion modifications, the initial tuning efforts by
ALSTOM personnel, and the tuning work performed by FPP personnel for each unit.
Figure 1
DESCRIPTION OF PROJECT
Combustion System Modifications
As stated earlier, LCRA entered into a
contract with ALSTOM for the supply of an
LNCFS Level 3 system for FPP Units 1 and
2. A typical Level 3 system is shown in
Figure 2. For units that fire PRB coal, three
major components are integrated into the
LNCFS Level 3 system to lower NOx
emissions with minimal effects on boiler
performance. These three components are 1)
precise furnace stoichiometry control, 2)
initial combustion process control, and 3)
concentric firing via the CFS air nozzle tips.
Figure 2
Precise furnace stoichiometry control is achieved by
the use of multiple levels of overfire air (OFA). It is
one of the most common and accepted methods of
reducing NOx emissions from a tangentially fired
boiler. Overfire air is used to stage the combustion
process by introducing a portion of the secondary air
above the main firing zone in order to reduce the
amount of oxygen initially available to the fuel. The
LNCFS Level 3 system utilizes a combination of
CCOFA and separated overfire air (SOFA) to achieve
the precise furnace stoichiometry control necessary to
reduce NOx, while at the same time minimizing any
increases in carbon monoxide (CO) and/or unburned
carbon (UBC) in the fly ash. To further minimize
increases in CO, the OFA compartments have manual
yaw adjustment. This allows each OFA compartment
3
to be directed to maximize mixing during the burnout process. These manual adjustments are
set during the tuning phase and remain in place once the optimum settings are defined. For both
FPP units, the new SOFA elevations each consist of four (4) overfire air registers located in each
corner above the main windbox. The registers each consist of four (4) compartments containing
nozzle tips and individual air damper control.
Initial combustion process control is established through the use of Aerotip coal nozzle tips.
A special design feature of these coal nozzle tips allows enhanced flame front position control
under tilted conditions. This ability allows the flame front to be established near the exit of the
coal nozzle tip, which allows for early devolatilization of the coal to support further reductions
in NOx. Establishing early coal ignition improves flame stability and minimizes increases in
unburned carbon.
Figure 3
As illustrated in Figure 3,
horizontally adjustable CFS
air nozzle tips direct a portion of
the secondary air in the main
windbox away from the fuel
stream in a circle concentric with
the main firing circle. The
CFS offset air provides an
oxidizing boundary layer along
the furnace waterwall and also
reduces the lower furnace
waterwall slagging. For both
FPP units, the existing auxiliary
air nozzle tips were replaced with adjustable yaw CFS tips.
Based upon the results of the tests conducted on Unit 1 in January of 2003, new control curves
were developed for the SOFA dampers; and modifications were made to the existing CCOFA
and fuel air damper, excess air, and windbox-to-furnace differential pressure control curves.
Final yaw settings for the SOFA, CCOFA, and CFS secondary air nozzle tips were also
established.
With the ability to achieve full load with five (5) of the six (6) mills in service, full load can be
achieved with six different mill combinations. The OFA curves were verified and/or modified
as required, depending on the combination of mills in service. Different OFA damper control
curves were used for the majority of the SOFA and CCOFA elevations, depending on which
mill was out of service.
Upon completion of the tuning efforts, the boiler was operated for approximately six weeks with
the final operating curves in place before the guarantee testing was conducted.
T-35 / 23456
T-34 / 12356
T-33 / 12345
T-29 / 12456
T-28 / 13456
T-27 / 12346
T-26 / 12346
T-25 / 12346
0
T-24 / 12346
60
0.05
T-23 / 12346
0.08
T-21 / 23456
120
T-19 / 23456
0.10
T-18 / 12345
180
T-17 / 12345
240
0.13
T-16 / 12345
0.15
T-15 / 12345
300
T-14 / 12345
0.18
T-13 / 12345
360
T-11 / 12345
0.20
T-10 / 12345
420
T-9 / 12345
480
0.23
T-8 / 12345
0.25
T-7 / 12345
540
T-6 / 12345
0.28
T-5 / 12345
600
T-4 / 12345
0.30
T-3 / 12345
CO
A third-party testing company was contracted to conduct two (2) guarantee tests. One (1) test
was conducted with the bottom five (5) mills in service and the second test with the top five (5)
mills in service. Data obtained indicated that ALSTOMs LNCFS Level 3 system met all
contractual obligations. Post-modification guarantee test results are listed in Table 1. Also
illustrated in Table 1 are the pre-modification operating and emissions data for comparison.
Load Gross MW
Steam Flow, klb/hr
NOx, lb/mmBtu (avg. from CEMS)
CO, ppm (corrected to 3.0% O2)
UBC in Fly Ash, %
Exit O2, %
Mills in Service
Table 1
Pre-Modification
605
595
3,921
4,072
0.305
0.345
NA
NA
NA
NA
3.72
3.22
12345
23456
Post-Modification
636 *
636 *
3,971
3,986
0.136 **
0.145 **
148 **
164 **
<0.1 **
<0.1 **
3.34
3.37
12345
23456
NA Not Available
* It should be noted that the modifications to the firing system did not cause this load increase.
** Post-modification NOx, CO, and UBC data reported by third party testing firm.
Programs were developed and implemented in the DCS to optimize air distribution and to
control excess O2 and furnace temperatures.
The following sections describe, in greater detail, the operational changes made to the boiler.
Although described in this paper as discrete activities, it should be noted that some portions of
each activity were implemented concurrently.
As stated earlier, there are six burner elevations of which only five are required for design steam
load. Therefore, there are six combinations of burners (and mills) available to achieve full load
operation. As part of their tuning process, ALSTOM technicians developed individual CCOFA
and SOFA damper curves for each mill combination. Each combination, however, produced
different NOx emission levels. (It should be noted that, for each combination, NOx levels
remained comfortably below the 0.165 lb/mmBtu limit.) With a change in mill combination,
CCOFA and SOFA dampers would adjust to a different position relative to load.
FPP technicians considered whether developing one set of curves could level out these
fluctuations in NOx emissions. After the optimization of the first mill combination, work was
started in developing standardized curves. After many trials, standardized curves were
developed for the SOFA and CCOFA dampers for all mill configurations that would produce
low NOx emissions at fairly uniform levels when optimum conditions occurred.
BOILER
MASTER
FUEL
LOAD vs EXCESS O2
SETPOINT
AIR
O2 Controller
To measure excess O2 levels, a total of eight (8) excess O2 analyzers, located in the boiler
ductwork between the economizer section and the air preheater, are used. These analyzers are
located after a bifurcation in the flue gas ductwork; therefore, each of the two ducts has a group
7
of four analyzers. The measurements from the group of four analyzers per duct are averaged;
and, of the two averages, the lower value is used for control.
The utility industry has known for many years that operating boilers with lowered excess O2
levels, while improving heat rate, also results in lower NOx emission levels. However,
operating at too low an excess O2 level was detrimental because of wet slag build-up on
furnace walls. This wet slag is difficult to clean using conventional wallblowers1. CO
emissions also increase when excess O2 levels are reduced. Therefore, for good control of NOx,
CO, and slagging, optimal excess O2 control is essential.
Historically, there were two issues that made operating at optimal excess O2 levels difficult for
this unit:
Unequal distribution of excess O2 at the locations where the O2 analyzers were located,
and
Changes in the distribution of excess O2 when mill configuration and burner tilt angles
changed.
Before the combustion system modifications were made, significant differences in excess O2
levels between analyzers and average excess O2 values between ducts occurred frequently. This
phenomenon was the result of stratification of excess O2 in the flue gas, which prevented true
measurements of excess O2 levels. Average excess O2 differences as high as 2-2.5% between
ducts sometimes were observed. Certain mill combinations and burner tilt positions exacerbated
the differences. With these erroneous measurements, along with the original control scheme,
high CO excursions would occur with certain mill combinations. With other mill combinations,
excess O2 levels could be biased down to reduce NOx emissions without incurring CO spikes.
Now that the goal was to operate the unit with even lower NOx levels, this problem with excess
O2 imbalance had to be resolved. Two operational changes were adopted that mitigated the
effects of these issues.
First, a modification to the excess O2 control scheme was developed. Instead of using excess O2
levels as the primary trim control; a three-tier control scheme was developed, as illustrated in
Figure 6. Like the original control scheme, a load - excess O2 function was used for trimming
airflow. However, a boiler stoichiometry limit and CO limit were added. A boiler stoichiometry
limit, based on trial and error empirical data, was set using a ratio of measured combustion air
flow and fuel flow that produced good combustion characteristics. A multiplier was used to set
the ratio, so that the optimum ratio equaled one. The controls would allow this ratio to operate
above one, but operating below this ratio would cause an increase in airflow. A CO limit was
also set up, so that CO was maintained below 100 ppm. An increase in CO above this value
would also cause an increase in airflow. Depending on mill configuration, excess oxygen at full
load can now vary from 2.5 to 3.2%. This change in the primary control parameter significantly
reduced the fluctuation in NOx emissions.
Horizontally adjustable CFS air nozzle tips were added to FPP Unit 1 to also reduce
instances of wet slag on waterwalls.
8
Figure 6
LOAD vs EXCESS O2
SETPOINT
(Air) 1
Fuel
BOILER
MASTER
CO 100 ppm
FUEL
AIR
O2 Controller
Secondly, a novel change in burner tilt control was implemented. As stated previously, there are
two ducts with four analyzers each. Before the combustion system modifications were made, a
significant difference in average excess O2 values between ducts occurred frequently. It was
determined that tilt position relative to each windbox had a first order effect upon O2 imbalance.
Whereas, before the burner tilts operated at the same relative angle, the burner tilts at each
corner of the boiler are now operated at different tilt angles above and below the horizontal
position. At 0 all burner tilts are at horizontal. Since implementing this change, excess O2
splits have stayed less than 1% in most cases.
T-27 / 23456
T-26 / 13456
T-25 / 12456
T-24 / 12345
T-23 / 12346
T-22 / 13456
0
T-14 / 23456
60
0.05
T-13 / 12456
0.08
T-12 / 12345
120
T-11 / 12356
180
0.10
T-8R / 23456
240
0.13
T-10 / 23456
300
0.15
T-9 / 23456
360
0.18
T-8 / 23456
420
0.20
T-7 / 23456
480
0.23
T-6 / 12346
540
0.25
T-5 / 23456
600
0.28
T-4 / 23456
0.30
T-3 / 23456
CO - CEMs
The same third-party testing company was, once again, contracted to conduct two (2) guarantee
tests for Unit 2. The two tests were also conducted with the top and bottom five (5) mills in
service, respectively. The gathered data indicated that ALSTOMs LNCFS Level 3 system
10
met all contractual obligations for Unit 2. Guarantee test results are presented in Table 2. It
should be noted that Unit 1 pre-modification data was used as the baseline for Unit 2, since both
units are identical in configuration.
MW
Steam Flow, klb/hr
NOx, lb/106Btu
CO, ppm (corrected to 3.0% O2)
UBC in Fly Ash, %
Exit O2, %
Mills in Service
Table 2
Pre-Modification *
605
595
3,921
4,072
0.305
0.345
NA
NA
NA
NA
3.72
3.22
12345
23456
Post-Modification
625 **
633 **
4,164
4,143
0.107 ***
0.107 ***
197 ***
107 ***
<0.1 ***
<0.1 ***
3.57
3.44
12345
23456
FPP Unit 2
FPP Unit 2 returned to service in May 2004. Tuning was accomplished during May and June,
with performance testing being conducted in July 2004. With all performance guarantees
having been met, FFP personnel have been continuing with fine tuning Unit 2 across the load
range. From July 2004 through December 2004 NOx emissions averaged 0.102 lb/mmBtu.
Figure 9 shows that NOx emissions in December 2004 increased as compared to previous
11
months, which was determined to be due to an inoperable fuel air damper. This clearly
illustrates the need for maintaining proper air distribution and periodic inspection of key
components. Similar to Unit 1, the lowest monthly average NOx emission from FPP Unit 2
averaged 0.096 lb/mmBtu in October 2004.
Figure 8
0.18
0.16
0.14
0.12
0.1
0.08
Nov-04
Sep-04
Jul-04
May-04
Mar-04
Jan-04
Nov-03
Sep-03
Jul-03
May-03
Mar-03
Jan-03
0.06
Month, Year
Figure 9
FPP UNIT 2 -AVERAGE MONTHLY NOx EMISSIONS
Dec-04
Nov-04
Oct-04
Sep-04
Aug-04
Jul-04
Jun-04
May-04
Apr-04
Mar-04
Feb-04
0.38
0.34
0.3
0.26
0.22
0.18
0.14
0.1
0.06
Jan-04
0.2
Month, Year
12
CONCLUSIONS
Consistent low NOx emissions of less than 0.10 lb/mmBtu can be achieved in a tangentially
fired boiler firing PRB coal. ALSTOMs LNCFS Level 3 system was installed on FPP Units
1 and 2, which reduced baseline NOx emissions by over 50 percent. FPP personnel further
reduced NOx emissions by focusing on optimization of furnace air distribution and excess O2
control, and by placing more emphasis on maintaining the wallblower system in order to operate
with cleaner furnace walls. An overall reduction in NOx emissions of almost 69 percent has
been attained for each unit. FPPs future efforts will be to optimize NOx emissions at reduced
loads as well as continue fine tuning emissions at full load.
REFERENCES
1.
Hart, D., LaFlesh, R., Marti, D., Nava Paz, J. C., Plumley, A.L. Bailey, W., Phase 1
Tangentially- Fired Unit Low NOx Operating Experience, ABB C-E Services, Inc., TIS
8648, 1998.
2.
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