-------
ACKNOWLEDGMENTS
The results of this phase of the contract are due to the efforts of
others at the Alliance Research Center. In particular, W. L. Sage was
responsible for administrative help; E. D. Scott and F. M. Holsopple were
responsible for furnace operation; and E. IV. Stoffer, J. M. Kibler, and F. M.
Holsopple were responsible for instrumentation.
IV
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TABLE OF CONTENTS
Page
SYMBOLS AND ABBREVIATIONS - ix
I. INTRODUCTION 1
A. Objectives 1
B. Phase I - - 1
C. Background and Description of Work 2
D. Significant Results 2
II. APPARATUS 5
A. Description of the Basic Combustion Test Unit 5
B. Instrumentation and Sampling -- -- -- 11
C. Furnace and Burner Detail -- 16
III. PROCEDURES 19
IV. MEASUREMENTS AND CALCULATIONS 21
A. Variables Studied 21
B. Range of Variables 21
C. Measurements Taken 22
V. RESULTS - 23
VI. ANALYSIS OF DATA AND RESULTS 25
VII. DISCUSSION 51
A. Results - 51
B. Data and Testing Effects 61
C. Final Presentation 66
D. Interrelated Variables 66
VIII. CONCLUSIONS - 69
IX. FUTURE WORK 71
X. REMARKS 73
APPENDIX A, FUELS DATA, ANALYSES, AND CALCULATIONS A-l
APPENDIX B, OPERATING CONDITIONS, MEASUREMENTS, AND CALCULATIONS B-l
APPENDIX C, PRELIMINARY TEST DATA C-l
APPENDIX D, PRELIMINARY DATA PLOTS --- D-l
APPENDIX E, MATHEMATICAL DERIVATIONS AND CALCULATIONS E-l
APPENDIX F, PRELIMINARY ECONOMICS ON FIELD UNIT MODIFICATION
OR CONTROL - F-l
APPENDIX G, PHASE II - WORK PLAN G-l
-------
List of Tables
Table
6.1 Initial Tests (Series I for Coal) 26
6.2 Flue Gas Recirculation Tests (Series II for Coal) 27
6.3 Two Stage Combustion Tests (Series III for Coal) 28
6.4 Natural Gas Tests (Series IV A) 29
6.5 Oil Tests (Series IV B) - 30
6.6 Swirl Tests (Series V) - -- 31
6.7 Quench Tests (Series VI) --- 31
6.8 Summary of Series II, Part 1 — 32
6.9 Summary of Series II, Part 2 --- --- 32
6.10 Summary of Series III, Part 1 33
6.11 Summary of Series III, Part 2 34
6.12 Summary of Series IV A, Part 1 - - - 35
6.13 Summary of Series IV A, Part 2 35
6.14 Summary of Series IV B, Part 1 - 36
6.15 Summary of Series IV B, Part 2 - 36
6.16 Summary of Swirl Tests, Series V, Part 1 -- - - 39
6.17 Summary of Swirl Tests, Series V, Part 2 39
6.18 Summary of Quench Tests, Series VI, Part 1 -- 40
6.19 Summary of Quench Tests, Series VI, Part 2 40
6.20 Carbon Loss and Burner Efficiency - 41
7.1 Relative Effects on NO in Flue Gas 67
A.I Coal Analysis Data A-2
A.2 Natural Gas Analysis A-2
A.3 Bunker C Oil Analysis (#6 Residual) -- A-3
C.I to C.4 Series I, Preliminary Data C-3,C-4
C.5 to C.8 Series II, Preliminary Data C-5,C-6
C.9 to C.12 Series III, Preliminary Data -- C-7,C-8
C.13 to C.16 Series IV A, Preliminary Data C-9,C-10
C.17 to C.20 Series IV B, Preliminary Data - - C-11,C-12
C.21 to C.24 Series V, Preliminary Data C-13
C.25 to C.28 Series VI, Preliminary Data C-14
VI
-------
List of Figures
Figure Page
2.1 Basic Combustion Unit (Single Burner) 6
2.2 Coal Burner 6
2.3 Gas Burner 6
2.4 Oil Burner 6
2.5 Oil Atomizer 7
2.6 Burner with Fixed Vanes 9
2.7 Burner with Adjustable Vanes 10
2.8 Front Slot Positions - 12
2.9 Side Slot Positions 12
2.10 View of Burner and Slots --- 13
2.11 Sample System --- 14
2.12 Instrumentation 14
2.13 Furnace Cross Section 17
2.14 Burner Cross Section - 17
6.1 Excess Air 43
6.2 Load 43
6.3 Preheat 43
6.4 Preheat, High Excess Air 43
6.5 Air Input with Coal 44
6.6 Primary Flue Gas Recirculation 45
6.7 Secondary Flue Gas Recirt.ulation - 45
6.8 Staged Combustion Options 46
6.9 Coal, Variable Port 46
6.10 Coal, Staged Combustion 46
6.11 Gas, Staged Combustion 47
6.12 Oil, Staged Combustion 47
6.13 Burner Efficiency vs. Stoichiometry 47
6.14 Burner Efficiency vs. Load — 47
6.15 Burner Efficiency vs. Stoichiometry x Load 48
6.16 Burner Efficiency vs. Load/Stoichiometry — 48
6.17 NO Reduction for Swirl Tests 49
6.18 NO Reduction for Quench Tests 49
VI1
-------
List of Figures (Continued)
Figure Page
D.I to D.24 Preliminary Data, Coal D-5 to D-10
D.25 to D.48 Preliminary Data, Gas D-ll to D-16
D.49 to D.72 Preliminary Data, Oil D-17 to D-22
D.73 to D.77 Flue Gas Recirculation D-23, D-24
D.78 to D.84 Two Stage Combustion D-24, D-25
G.I Tijne Schedule for Phase II G-2
Vlll
-------
SYMBOLS AND ABBREVIATIONS
This list of symbols and abbreviations includes all items from the text
from which confusion may result. All air weights and measurements are calculated
dry unless otherwise noted.
Symbol, Abbreviation
A
Aver
BTU
BTUa
BTU£
BTUG
BTUm
D2
e
E
f
FB
FC02
FGR
FH20
Definition
Pre-exponential rate constant
The average of two measurements
Fuel enthalpy release, BTU/hr
Air enthalpy, BTU/lb
Flue gas enthalpy, BTU/lb
Total enthalpy release in furnace, BTU/hr
Humidity (in air) enthalpy, BTU/lb of air
Differential
Diameter of orifice, inches
Diameter of pipe, inches
Natural constant
Activation energy
Subscript indicating forward
Fraction of total air at burner
Fraction of CO^ in flue gas
Flue gas recirculation, %
Fraction of HJD in flue gas
IX
-------
SYMBOLS AND ABBREVIATIONS (Continued)
Symbol, Abbreviation Definition
k Kinetic rate constant
L, Measured value #1, base point
L.] Standard deviation on base point
measurement
L2 Measured value #2, reduced point
LI Standard deviation on reduced point
measurement
L., Calculated reduction
L, Standard deviation of calculated
reduction
MA Moles of stoichiometric air/lb fuel
MAI Moles of stoichiometric igniter air/lb
igniter fuel
M'VR Moles of stoichiometric test air/lb
test fuel
MC Moles of C02 in flue gas/lb fuel
MCI Moles of CC>2 in igniter flue gas/lb
igniter fuel
MCR Moles of CO, in test flue gas/lb test
fuel i
MF Moles of flue gas/lb fuel
MFI Moles of igniter flue gas/lb igniter fuel
MFR Moles of test flue gas/lb test fuel
Mvi Moles of moisture in flue gas/lb fuel
MMF Moles of moisture from the fuel
MMH Moles of moisture from the air humidity
MMI Moles of moisture in igniter flue gas/lb
igniter fuel
-------
SYMBOLS AND ABBREVIATIONS (Continued)
Symbol, Abbreviation Definition
NMR Moles of moisture in test flue gas/lb
test fuel
n Temperature exponential in kinetic rate
expression
NDIR NO measurement from the NDIR instrument, ppm
Also used for Beckman "Non dispersive
Infrared"
NF Fraction of full meter flow for natural
gas igniter
NO Nitric oxide*
NO- Nitrogen dioxide
N0v A mixture of NO and N00
x &
N_ Nitrogen*
02 Oxygen*
PB Barometric pressure, atm
PBA Percent of stoichiometric air at burner
PH Q Partial pressure of H-O in atmosphere, atm
P Total pressure on orifice, atm
POP Percent oxygen measured in flue gas,
corrected for combustibles
PS Pnet - PH20> atm
PT PB - PH Q, atm
it
PTA Percent stoichiometric (theoretical) air
r Subscript indicating reverse
* This symbol in brackets; i.e., [NO], indicates the concentration of that gas.
XI
-------
SYMBOLS AND ABBREVIATIONS (Continued)
Symbol, Abbreviation
R
R-N
STDV
t
T
TA
TAG
TECo
TFG
TM
Total
W
Wa
W
W,
N
W,
NI
Gas constant
Specifies an organic fuel bound
nitrogen molecule*
Standard deviation of Aver
Time
Temperature of orifice, °F; also used
as kinetic temperature for any reaction
Ambient temperature, °F
Air preheat temperature, °F
NO measurement from TECo instrument, ppm;
also used for "Thermo Electron Corp."
chemiluminescence
Flue gas temperature, °F
Total moles/lb fuel
Subscript designating sum of all partial
concentrations
Weight of gas flow, Ib/hr
Weight of air input to furnace, Ib/hr
Weight of fuel input to furnace, Ib/hr
Weight of flue gas from furnace, Ib/hr
Weight of recycled flue gas, Ib/hr
Weight of natural gas flow, Ib/hr
Weight of natural gas flow in igniter,
Ib/hr
* This symbol in brackets; i.e., [NO], indicates the concentration of that gas.
XII
-------
SYMBOLS AND ABBREVIATIONS (Continued)
Symbol, Abbreviation Definition
W- Weight of air through second stage, Ib/hr
x Subscript of variable type indicating any
combination; i.e., r, 1, etc.
AH Differential pressure across orifice,
inches HLO
1,2,3... Subscript indicating reaction number for
partial value
xi 11
-------
I. INTRODUCTION
A. Objectives
The primary objective of this contract is to investigate on experimental
coal fired furnaces, a variety of combustion techniques which could be
applicable for control of NO and related combustible emissions such as CO,
x
carbon, and hydrocarbons. In addition, we are to provide detailed correla-
tions and to define the critical conditions for application of the most
promising combustion control techniques to a single burner furnace. And
finally we are to optimize the most successful techniques for pollution con-
trol in the burning of coal and to identify potential problems in boiler
operational and thermal performance. The work for the contract is divided
into three phases:
Phase I: Identification of the most promising control techniques
using a single burner, pulverized coal fired furnace.
Phase II: Correlation and definition of the conditions for the
most promising techniques as applied to the single burner
unit used in Phase I.
Phase III; Optimization of the most successful techniques from Phase
II as applied to a multiburner, pulverized coal fired
furnace.
The criteria applied to the testing will include the degree to which nitrogen
oxides are reduced, effects on thermal and operational performance, and applica-
bility and cost of modification to existing or new boilers.
B. Phase I
The primary objective of this phase is to identify the major variables
which influence the formation of NO and the related combustible emissions in
-A.
an experimental single burner, coal fired furnace. In addition, it is necessary
-1-
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to compare the effectiveness of the various combustion control techniques for
gas and oil and to determine the general applicability of control techniques
to all utility boiler types and fuels.
C. Background and Description of Work
The contract work for Phase I was started October, 1972, and was planned
to continue for about 30 weeks. The criteria utilized for Phase I were the
degree to which combustion techniques will control or inhibit NO formation,
A
the effects of these techniques on thermal and operational performance of the
unit, and the general applicability and cost fo->- application of these techniques
to existing units or new units under design.
The design and operational variables studied were fuel type, ratio of
air to fuel, heat liberation rate, air preheat, flue gas recirculation, staged
combustion and port position, quench, and swirl. Most of the testing was done
using one coal, although natural gas and a heavy residual fuel oil were inves-
tigated on a limited basis for comparison. For all operational and design
variables except port position, quench, and swirl, the variable was changed
over a wide range to include both normal operating conditions and extreme
operating conditions which are not ordinarily practical.
D. Significant Results
It has been found that fuel type is of extreme importance and
that a change in the type of fuel produces entirely different effects for the
major variables studied. In particular, gas and coal are significantly dif-
ferent in most responses to operational variables and although thev behave
similarly for the design variables, thev show far different reduction effects.
Oil has NO emission levels similar to gas but its responses to variables are
Jx
similar to coal.
In the coal firing tests, the major changes were due to excess air
and load at moderate or high excess air. Flue gas recirculation was only
-2-
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effective at high levels of recirculation. Staged combustion was the most
promising but only moderately effective and flue gas recirculation in combina-
tion with staged combustion showed no further reduction over staging alone.
Preheat of air showed only very small effects. The quench rate (heat removal
rate) showed some effect on NO emission levels.
A.
The NO levels for natural gas were greatly affected by air preheat,
J\.
flue gas recirculation, staged combustion, and flue gas recirculation in
combination with staging. Minor effects on NO emission are found from changes
.X
in excess air and load. A change in swirl also produced a minor change in NO
A
emissions. Impeller position was an important variable also.
Although the magnitude of the NO emissions for oil are similar to gas
.A.
under most conditions, many of the responses to variables are the same as for
coal. The major variable effecting NO emission for oil was found to be staged
J\.
combustion. A small effect is noted for flue gas recirculation. Little or no
effect on NO. emissions is noticed for preheat, load, or excess air except at
.A.
low excess air.
-3-
-------
-4-
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II. APPARATUS
The single burner coal furnace used at the Alliance Research Center is
called "The Basic Combustion Test Unit." Next to the furnace is a laboratory
area where the instrumentation for stack gas measurements is operated.
A. Description of the Basic Combustion Test Unit
A schematic of the furnace is shown in Figure 2.1. It is of cylin-
drical construction with a water-cooled jacket and partially lined with a
1-inch thick refractory brick. The fuel and air input at the burner is split
into the primary (fuel) and secondary (air) flows. Depending upon fuel type,
the following input is a normal loading of 5,000,000 BTU per hour:
1) Coal - primary air - ^ 15% total combustion air
- coal in prijnary air - ^ 500 Ib per hour
- secondary air - balance of burner combustion air
2) Gas - primary fuel feed of about 250 Ib gas per hour
- secondary air - burner combustion air
3) Oil - primary fuel feed of about 300 Ib per hour
- primary atomization with steam (^ 10 Ib per hour)
- secondary air - burner combustion air
Figure 2.2 is an illustration of the burner used for coal firing. The spinning
vanes are fixed and therefore only one swirl can be applied to the secondary
air. The coal spreader at the end of the primary pipe is set at a 45° angle
of divergence from the centerline to disperse the coal into the secondary air
stream. Figures 2.3 and 2.4 show the burner used for gas and oil. There are
16 movable vanes (not illustrated, but in the same relative position as shown
in Figure 2.2) which are symmetrically placed around the burner. The vane
angle can be varied from 0°, or no swirl, to a maximum of 30°, or the maximum
swirl used during this test period. Figure 2.5 illustrates a typical oil
sprayer plate; the atomization is accomplished by use of steam. The gas/oil
-5-
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FIGURE 2.1
FIGURE 2.2
BASIC COMBUSTION UNIT (SINGLE BURNER)
COAL BURNER
STACK
NATURAL GAS
LIGHTER
FUEL
FIGURE 2.3
FIGURE 2.4
GAS BURNER
OIL BURNER
/ i
•
•*
'• \
.
-6-
-------
FIGURE 2.5
OIL ATOMIZER
J$^
s^/y^/^^/^y^y^y^y/y/j
OIL
-7-
-------
burner was only used for coal when unsuccessful attempts were made to determine
the effect of swirl on coal firing. Figures 2.6 and 2.7 are photographs of the
coal and gas/oil secondary burner hardware respectively (no fuel supply is
shown) as they look before placement in the windbox. In summary, the following
configurations have been used for firing:
1) Coal - coal burner (6 vaned) for all tests except swirl at
immovable vane setting - coal feed pipe carries primary air
(> 15% total combustion air) for coal transport and has a
divergent 45° spreader outlet.
2) Swirl (coal) - gas/oil burner - gas spuds and oil impeller
were removed and replaced with coal feed as used in No. 1.
Vanes always set at 30° (fire unstable at lower angles,
with loss of ignition at 0°).
3) Gas - all tests used eight spuds with ring feed and impeller
in place. Variable setting of impeller used only for
specific tests, Vanes always set at 30° (maximum angle)
except for swirl tests.
4) Oil - all tests used oil feed in center pipe with impeller
in place. Impeller setting was varied only for specific
tests. Gas spuds removed. Gas feed ring left in place.
Vanes always set at 30° (maximum angle) for all tests.
5) Igniter - supplied up to 1% by weight fuel and up to 21 BTU
release rate in furnace. Uses about 3 Ib natural gas per
hour at 20% flow. Only used during tests for coal to main-
tain stable firing at low air and high load. Used for all
coal tests for consistency at 3 Ib per hour except when
required for one test at 7 Ib per hour. For all gas and
oil tests, used only for initial flame ignition and then
shut off.
-8-
-------
FIGURE 2.6
BURNER WITH FIXED VANES
inches
I
I I I I I I I I |
ONE FOOT
-9-
-------
FIGURE 2.7
BURNER WITH ADJUSTABLE VANES
o
o
. o
o
c
-10-
-------
The positions of the staging ports are illustrated in Figures 2.8 and
2.9. Figure 2.10 is a photograph of the ports as placed inside the furnace.
The front slots are set up to admit second stage air from 12-in. by 1-in.
inlets parallel to the burner fuel/air feed. The side slots are set up to
allow air into the furnace from 2-in. by 6-in. slots perpendicular to the
central axis but offset circumferentially and arranged so that the mixing
swirl around the center axis is opposite to the secondary swirl. Only one
set of second stage ports is operated at one time; never both sets simulta-
neously.
The refractory lining of the furnace is 1-in. brick. The refractory
lining extends from the burner down to the mid section of the furnace for a
length of 4 ft. During the tests using a higher quench rate, the refractory
was removed from the last 2 ft and covered only the area from the burner down
one-quarter length of the furnace.
B. Instrumentation and Sampling
There are two probes in the stack from which gases and ash are
regularly taken for measurement. Figure 2.11 shows the relative probe
positions on the stack and the relative position of the gas sampling probe
inside the stack. The first probe is used exclusively for pulling ash samples
into a bag filter to determine the ash loading in the gas stream and to provide
an ash sample for further analysis. The second probe is used exclusively for
gas samples and subsequent measurements. A third probe position is available
1 ft above and slightly offset from the gas sample probe for availability of
an EPA train and for traverses of the stack.
The instrumentation probe branches into two gas sample lines. The
first line carries the gas sample into a pair of Bailey Meter hot-wire
analyzers used for measuring CL and total gaseous combustibles. The output
from these two meters is continually monitored and recorded. The second line
carries the gas sample into a 50°F ice bath (see Figure 2.12) before being
-11-
-------
FIGURE 2.8
FRONT SLOT POSITIONS
FIGURE 2.9
SIDE SLOT POSITIONS
-12-
-------
FIGURE 2.10
VIBY OF BURNER AND SLOTS
-13-
-------
FIGURE 2.11
SAMPLE SYSTEM
FIGURE 2.12
INSTRUMENTATION
TO EPA
TRAM
TO BALEY
METERS
TO NO, SCj, f
CO, 0-INSTRUMENTS
GAS*
SAMPLE
PROBE
P2;
ASH
SAMPLE
., PROBE
'-:>;
~T
BAG A )
FITER (J
FLUE GAS .
SAMPLE
COLD FINGER
50 F ICE BATH
MALLCOSORB COLUMN
\
WHITTAKER
S02
carried into the instruments. This removes most of the water in the sampled
flue gas. The temperature is maintained as closely as possible to 50°F. The
gas sample then flows separately into each of the following instruments:
1) A Thermo Electron Corporation (TECo) chemiluminescence
NO-NO- monitor
2) A Whittaker NO chemical cell instrument with a Mallcosorb
column to remove SO-, CO-, and H-0 before NO measurement
3) A Beckman nondispersive infrared (Nl)IR) NO analyzer with
a pretreatment chamber to remove 1LO which interferes in
the NO measurement
4) A Whittaker chemical cell SO- analyzer
5) An MSA infrared analyzer (LIRA) for CO
-14-
-------
6) An MSA paramagnetic 0- analyzer
All instrumental outputs except for the CO and 0- analyzers are continuously re-
corded. The outputs of the CO and 0_ instruments are manually recorded for each
test however.
Large discrepancies were found between the NDIR and TECo in our early
tests. These discrepancies could not be attributed to water interference be-
cause the TECo usually had a higher reading than the NDIR; a water interference
would have been indicated only if the TECo read lower than the NDIR. The
following pretreatments were tried before the NDIR gas measurement cell, but
after the 50°F water bath:*
1) No pretreatment
o
2) A 3 A mole sieve with small amounts of silica gel as an
indicator
o
3) A 3 A mole sieve with no silica gel
4) Silica gel
5) A dry ice bath
6) A dual dry ice bath (two baths in tandem)
7) Anhydrous CaCl2
8) CaCl2-2H20 (dihydrate)
9) A 34°F water bath
The 50°F water bath was sufficient for the TECo and the reading of the
TECo was unaffected by minor changes of temperature in this bath.
-15-
-------
The results of each unsatisfactory method are summarized below by method
number:
1) Small variations in the temperature of the 50°F water bath led
to changes in the H-0 content of the gas sample and large
variations in the NDIR reading.
2-4) Loss of NO from flue gas when SO- and 09 were present.
Z t*
5-6) When compared, treatment 6 gave lower NO readings than
treatment 5 suggesting both treatment methods were unreliable.
7-8) Same results as methods 2-4.
Thus it was found that treatment No. 9, the 34°F water bath, was the only
successful treatment for flue gas measurement of NO in the presence of SO-
and 0~. The temperature of the sample gas in the cold finger was maintained
during testing at 34 +_ 0.5°F by addition of ice to the water in the bath
periodically. The water interference due to the humidity of 34°F saturated
flue gas was determined experimentally by bubbling warm air at 70-80°F through
water of the same temperature, passing it through the 50°F water bath, and
then through the 34°F ice bath noting condensation of water in the cold finger.
The measured interference used to correct all future flue gas measurements
was 55 +_ 5 ppm NO (the instrument cannot be read to better than H^ 5 to 10 ppm
NO). No further problems were experienced either with loss of NO or increased
water interference in NDIR readings.
C. Furnace and Burner Detail
Figures 2.13 and 2.14 illustrate the details of the furnace and burner
cross sections. The impeller positional extremes are shown for the oil and gas
burner. The coal nozzle exit position is just at the beginning of the throat
flair of 27° (to the burner axis).
-16-
-------
FIGURE 2.13
FURNACE CROSS SECTION
FIGURE 2.14
BURNER CROSS SECTION
-17-
-------
-18-
-------
III. PROCEDURES
The day's testing always commenced with the furnace warmup period and
instrument calibration. The test series to be carried out in the day's testing
started with one or two base line tests at normal operating conditions to
verify that everything was operating properly. Only when the furnace, its related
systems, and the instrumentation were working properly did testing begin.
The sequence for a test run would be to set furnace conditions and check
the operation of all instruments. When all equipment and all temperatures were
equilibrated to a constant state of firing, the data would be taken; first data
were read from non-recording instruments, and then data were read off the strip
charts for recording instruments on the basis of the time the test was made.
If there were to be comparison tests run in pairs to determine the
relative decrease in emissions, both tests were always run together on the
same day in order to minimize day-to-day variations.
-19-
-------
-20-
-------
IV. MEASUREMENTS AND CALCULATIONS
A. Variables Studied
There are two types of control that can be used for reduction of NO,.
.A.
Operational control techniques are more easily applied to existing units; the
physical change on the unit is minijnized and the final cost of the change on
the unit will be lower. Design methods would be applied to new units yet to
be constructed and, therefore, in this manner a minimum of redesign and re-
construction costs would be entailed. In addition, it is important to realize
that modification of existing units might be physically impractical or economi-
cally unattractive.
The design variables, which suggest physical and mechanical changes which
would be made in the unit, include flue gas recirculation, staged combustion,
quench rate, and basic fuel type. On the other hand, the operational variables
used to modify control on existing units include excess air, fuel firing rate,
air preheat, and swirl. These groups of variables are not meant to be mutually
exclusive.
An attempt was jnade to hold all conditions constant and to change the
one variable under study over a wide range. However, many of these are inter-
related and thus as load, excess air, preheat, and the other variables were
changed, the air velocities changed leading to a variation in mix rate, turbu-
lence, and combustion intensity. No attempt has been made to relate all of
these variables, but an attempt to do so is projected as part of Phases II and
III.
B. Range of Variables
As each variable was in turn studied, the other variables were held
constant. Generally the two extremes and the middle of the range of a variable
were tested.
-21-
-------
The range of each variable was selected so that the entire practical
range of field unit operation could be studied. The extremes of the range
were usually outside the practical limits for normal operation of boilers.
The exceptions have occurred where our basic combustion unit would have shown
unstable combustion tendencies and no meaningful test data could be attained.
Each variable will be specifically described under the results.
C. Measurements Taken
For each of the test run measurement sequences, the time was noted; all
recording instruments were read at the equivalent of that time after all non-
recording instruments were read. There were always two people to take measure-
ments; one for the flue gas analysis instrumentation and one for the furnace
conditions.
The raw flue gas analysis data* taken was: barometric pressure; temper-
ature of the instrument area; oxygen from the MSA; carbon monoxide from the MSA;
S02 from the Whittaker; and NO from the TECo, Whittaker (no C02, S02, or H20 in
measured sample), and the NDIR (34°F saturated). In addition, spot checks were
made by ORSAT of oxygen, carbon monoxide, and carbon dioxide; for substoichio-
metric firing, only ORSAT could be used for carbon monoxide. Ash samples were
also taken .during some tests and the measurements required were: time duration
of test; change in weight of ash filter bag; and the orifice temperature,
differential pressure, and absolute pressure. An ash sample was removed from
the filter bag for further analysis; always for unburned carbon and sometimes
for nitrogen.
The furnace data accumulated was: the temperature, differential, and
absolute pressures across a flow meter on an orifice for each of primary air,
secondary air, the flue gas for all recirculation methods individually including
primary, secondary, and second stage; the natural gas burner, and the natural
gas igniter. The oil supply and return pressures and the coal feeder rate were
also recorded, but were only used as checks for the stoichiometric calculations.
Finally, the Bailey oxygen and combustibles meter was also recorded.
* Unless otherwise specified, all instrumental flue gas measurements were made
at the equivalent of 50°F saturated.
-22-
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V. RESULTS
There -were six series of tests run for this phase of the contract.
A total of about 200 test points are available. The data are presented
completely in tables in Appendix C, in figures in Appendix D, and the mathe-
matical equations and derivations are in Appendix E. Some preliminary work
with the data was necessary for the data to reach a readily usable form,
therefore, the "raw, as recorded" data are not included in the report.
-23-
-------
-24-
-------
VI. ANALYSIS OF DATA AND RESULTS
The data in final form are presented in Tables 6.1 to 6.7. These
data were used to prepare all of the final data graphs for this section.
The headings for the tabular columns are:
1) Original Series and Run Numbers - Self explanatory.
2) Total Air, % - This is the total air added as the percentage
of 1001 theoretical (stoichiometric) air. The excess air is
simply 100% less than this number.
3) Heat, kBTU/ft /hr - This is the overall net heat release rate
in the furnace in thousands of BTU per unit volume.
4) Gas Preheat, °F - Self explanatory.
5) Flue Gas Input, I - This is the weight percentage of flue
gas recycled back through the air input.
6) Air in Burner, % - This is the total air at the burner as
percent of 100% theoretical (stoichiometric) air. The
balance of the air between columns 2 and 6 is the air which
enters through the second stage ports.
7) NO , ppm - This is the NO content of the flue gas corrected to 3%
_/\.
oxygen, dry conditions.
8) CO, ppm - This is the as measured, uncorrected concentration of
CO (and H~ equivalent as CO) in the flue gas.
9) 0~, % - This is the as measured, uncorrected (except for combusti-
bles) concentration of 0- in the flue gas.
In addition, Tables 6.8 to 6.15 inclusive are the final calculations based on
Tables 6.1 to 6.7 for use in evaluation of NO reduction for flue gas
-25-
-------
TABLE 6.1
INITIAL TESTS (SERIES I FOR COALI
FINAL DATA EVALUATION
•JW 1C, I ML
SfiRU S
ANU
«UN «-i
I - 1
I - ?
I - 3
I - 4
I - 5
1 - fc
1 - 7
I - rt
I - <;
I - lu
1-11
I - i?
1-13
I - 14
I - 1 c
1 - ll:
1-17
I - !!•
I - 1 =
! - 20
> - 21
1 - 22
I - ?j
I - ?4
1 - 20
I - ?(.
1 - '7
I - ?«
! - 2r-
1 - 3u
I - -H
I - 32
1 - 33
I - 34
I - 35
I - 36
\ - 37
I - 18
I - 3S
I - 40
I - 41
I - 42
I - ".3
ICTAL
AIR,
•f
116.3
142. u
1 Cl.S
1 12.4
135.1
1C1.9
1 1* . 0
137.0
I'M.?
113.3
t C 1 . 7
1 3h.O
111.3
114. 2
1 12.9
1C1 .A
14C.O
135.1
1 1 1.8
104.4
1 \S.O
14C.O
112.1
99.1
11C. 3
103. 3
135.1
11 '< . L,
11C. 7
111.'
103.3
115. b
1 4 1 . 0
103.2
116.3
141. p
l
51.5(i
31.91
49. 2H
29.71
51.17
50.ft9
47.63
62.3?
31.09
r>2.50
62.01
48.96
47.47
4 3.46
59.02
S7.22
CAS
PKF-
hEAT
OFG F
tee
c2<;
587
'rll
622
592
620
t47
tC5
S7C
?~<4
505
565
638
384
371
393
3H9
ie*
366
3t1
643
t3S
547
507
503
534
505
4 1C
279
263
52«
54f
515
553
527
5t>3
550
f 13
376
154
373
3t3
FILE
GAS
INPU1
lit
C.C
0.0
0.0
O.C
C.O
0.0
0.0
0.0
0.0
o.o
C.C
0.0
C.O
C.O
C.O
0.0
C.C
0.0
c.c
0.0
C.C
0.0
C.C
0.0
0.0
C.O
C.O
0.0
C.O
0.0
C.C
0.0
C.O
C.C
O.C
0.0
0.0
0.0
O.C
0.0
O.t)
o.o
0 .C
AIR
IN
BURNER
(Tl
116. 3
142.0
101.9
112. 4
135.1
101.9
113.0
137.0
101.2
113.3
101. 7
136.0
111.3
114.2
112.9
101.4
140.0
135.1
111.8
104.4
139.0
140.0
112.1
99. 1
110.3
103. 3
135.1
113.0
110. 7
111.3
103.3
US. 5
141.0
103.2
116.3
141.8
140.0
115. P
105.2
119.9
104. c
1 1 7.6
101.7
NOX
PPM
725
913
431
714
94R
431
746
998
54IS
534
292
795
546
8C«
683
420
834
821
460
321
6P1
9S5
791
282
746
538
956
676
428
6C1
312
731
958
466
789
749
922
834
558
739
449
764
5C'<
CO
PPM
205
RO
800C
180
90
8000
260
115
15000
115
90PC
85
240
360
5CO
8000
7C
65
24C
3200
60
90
165
20000
400
4000
140
100
800
400
18000
375
50
450C
26C
400
5C
750
3000
90
3200
360
700C
02
X
.
3.2
6.2
0.8
2.6
5.5
0.8
2.7
5.7
1.0
2.8
C.8
5.6
2.4
2.9
2.7
0.7
6.0
5.5
2.5
1. 1
"i.0
6.0
2.5
o.a
2.2
r.9
5.5
2.7
2.3
2.4
1 .6
3.1
6.1
0.9
3.2
6.2
6.0
3.1
1.3
3.7
1.2
3.4
C. 7
-26-
-------
TABLE 6.2
FLUE GAS RECIRCULAT ION TESTS (SERIFS II f CB CCALI
FINAL DATA
JP IG1NAL
SERIES
ANH
RUN »-S
1 4 - 1
I A - 2
14 - 3
I A - 4
IA - •,
IA - 6
1 A - 7
IA - 8
IA - 9
II A - 10
I I A - 11
I IA - 12
t r A - i .?
I IA - 14
II A - 15
MA - 16
IIA- 17
I A - IP
[[A - 19
II A - 2C
1 A - 21
IA - 22
IA - 23
Irt - 2-4
IA - 2?
IA - 2t-.
IA - 27
14 - 2fl
I A - 29
I I A - 3C
I IA - 31
IIA - 12
II A - 33
tlA - 34
HA - 35
IIA - 36
IIA- 37
MS - 1
1 Id - 2
[ I » - 3
MB - 4
1 IB - 5
116 - 6
ne - 7
i IB - a
ne - 9
118 - 10
IIB - 11
I IB - 12
IIB - 13
IIB - 14
IIB - 15
IIB - 16
118 - 17
IIB - 18
IIB - 19
116 - 2C
IIB - 21
IIB - 22
IIB - 23
IIB - 24
IIB - 25
IIB - 26
HE - 27
TC1AL
A tH,
t
114.3
112.7
m.c
132.2
132.3
1C2.H
1R2.6
113.3
113.3
1 37.0
!><;.s
11*. C
1 14. C
1 C 3 . 9
1C2.9
113.-:
1 1 3 . <;
135.1
131.4
1C3.S
1C3.2
114.0
lll.t
1 36. C
135.1
1C1.4
1C1.9
1 12. 7
111.8
111.7
1 1 7 . 0
112.4
111.0
13C.5
13f. 5
134. 1
133.2
116.7
115.0
1 1S.I
US. 2
142.0
139.9
1CH. 1
1C6.7
114.6
143. C
103. 3
142. C
117. C
117.7
13S.O
140.0
104.3
104.4
117.0
117.4
141.0
142.0
104.4
IC5.1
13S.6
133.2
1C?. 6
HEAT,
K6TU/
H»*3
/ HR.
52.34
51.87
5C.69
55.57
54. 7C
5C.1H
4R.65
40.89
62.95
65. C8
6?. 74
63.50
6B.C2
09.65
5 rf . S 5
32. ??
31.44
32.15
33.72
28.53
27.35
61.30,
60.99
6C.9I
6-". 19
56,f>2
54. P6
40.65
50.54
3 1.67
30.34
49. C4
48. 57
52.42
5C.'6
62.64
61.93
63. 1 1
65. C»
3U.26
30.81
31.52
40.63
27.98
29.00
52.27
53.44
28.84
58.95
51.48
53.13
56.98
55.25
49. 75
5C.22
31.20.
31.52
31. 3t
32.62
28.69
28.45
6C.91
63.27
56.27
CAS
PRE-
*EAT
DEC F
63C
645
t49
648
653
6CS
424
f31
66C
662
675
64q
66C
fc33
fr4S
551
577
600
57fi
515
54 7
521
52<:
541
527
5C5
520
516
506
459
4t:4
394
4C4
4CC
4C9
4C1
403
630
62S
560
565
579
596
538
54C
626
636
524
420
623
623
644
(42
601
595
573
557
566
593
53C
523
656
646
612
FILE
GAS
INPUT
1%}
c.c
1.8
3.2
C.O
1.3
C.O
?.o
0.0
1.4
0.0
1.2
0.0
u?
0.0
1.9
0.0
3.C
2.8
C.C
0.0
4. 3
0.0
1.6
1.2
0.0
o.c
1.8
1.9
O.C
0.0
2.4
0.0
1.9
C.O
1.5
C.C
1.4
0.0
1?. 1
o.o
21.0
17.5
C.O
C.O
21.4
0.0
0.0
0.0
0.0
0.0
3C.9
C.O
18.4
0.0
31.5
0.0
24.0
C.O
22. 8
0.0
41.1
0.0
20.4
0.0
AIR
IN
BURNER
i ii
-~ —
114.3
112. 7
113. C
133.?
132.3
102. fl
102. f
113.3
113.3
137. C
1 39. S
114.0
114.0
103.9
102.9
113.5
113.9
135.1
131.4
103.8
103.2
1 14.0
111.6
136.0
135.1
101.4
101.9
112.7
1 11. »
111.7
11 7. C
112.4
111.0
130.5
130.5
1 34. 1
133.2
116.7
115.0
119.1
119.2
142.0
139.9
10R. 1
106. 7
114.6
143.0
103.3
142.0
117.0
117.7
139.0
140.0
104.3
104.4
117.0
117.4
143.0
142.0
104.4
105.1
135.6
133.2
102.6
NUX
3PM
774
694
659
ess
89fl
449
472
329
740
98C
969
762
704
571
5S2
4 70
494
699
65"
246
251
654
635
R68
913
444
387
630
667
452
5CI
613
622
706
734
910
791
P21
7CH
459
416
532
722
333
258
832
1080
289
1014
833
54B
1048
797
552
372
576
392
810
596
320
242
1013
«14
538
CU
PPM
90
80
90
100
9C
4000
320C
90
90
140
140
100
85
150C
26CC
6bO
240
90
90
4000
450C
90
125
1 15
1C5
4000
40CC
240
1 80
350
200
165
260
90
90
1 15
1 \f
I 15
1 15
165
115
100
100
2600
1500
eo
70
400C
90
f)0
70
80
80
2000
1400
100
90
80
80
3500
450
70
90
5000
02
t
2.9
2.6
2.7
5.3
5.2
0.8
C.7
2.8
2.fl
5.7
6.0
2.8
2.8
C.9
C.8
2.8
2.8
5.5
5.1
1.0
0.9
2.8
2.4
5.6
5.5
0.5
0.6
2.6
2.5
2.5
3.3
2.6
2.3
5.0
5.0
5.4
5.3
3.3
3.0
3.6
3.6
6.2
6.0
1 .8
1.5
2.9
6.3
0.9
6.2
3.3
3.4
5.9
6.0
1.0
1.0
3.3
3.3
6.3
6.2
1.1
1.1
5.5
5.3
0.8
-27-
-------
TABLE 6.3
TV.C STAGE CCNBUSIION TESTS (SERIES III FCR CO«LI
FINAL DtJt
l)R IlilNiL
StR It S
AM;
HUN «-s
i
1 A- 1
1 1 A- 2
1 I A- 3
1 1 A- 4
1 1 A- 5
I 1 A- t
1 1 A- 7
I 1 A- 8
II A- <;
II A- 10
II A- 11
11 A-12
II A-13
II A- 14
II A-15
II A-16
II A- 1 7
II A-1P
I! 1 A- 14
III A-20
III A- 2 I
III U- 1
III fl- 2
111 M- ?
Ill R- <•
III B- 5
1
1
1
I
1
I
I
I
I
1
I
I
I
1
I
I
1
1
I
1
1
1
1
I
I fl- 6
1 H- 7
I B- S
I «- 9
J B-IC
1 B-ll
I B-12
I B-13
I B - 1 4
I 0-15
I *-16
I f)-l 7
1 B-18
1 8-19
1 H-,-i>
1 ft-21
1 H-27
1 K-2?
1 R-<".
1 B-2*
1 W-2o
IB-,;?
1 P.-28
I R-2«
III H-(0
III 8-11
1 1 H-!2
1 I 0 1
1 I C- I
1 I C- 3
I I C- 4
I I C- 5
1 1 C- 0
i i n- i
III D- 2
TCTAL
AIR,
J
1 l<;.0
13*. 1
IC3.S
111.8
140.9
1 14.<;
136.0
113.7
I 15.5
116. C
1 15.6
103.1
1C3.S
1 1 '. . 7
1C3.0
1 3 7 . C
113.6
136.0
117.7
136.0
iri2.6
16.3
16.3
2C.(
17.7
16.3
14.8
116.1
116.0
116.0
116.3
117.0
m.i
114.3
115.6
102.8
103.5
1C3.6
116.0
11S.3
117.2
1C3.2
1C4.0
ICft. I
137. C
137. S
1U.9
134. 1
136.9
113. 4
112. C
1J7.9
139. <,
115.6
116. <5
1 15.0
116. 1
102.1
116. C
S7.2
HFAT,
KBTU/
FT*»3
/ MR.
51.56
53.99
66.65
6*. 84
66.57
30.26
31.83
51.56
51.72
51. 2<.
51.64
50.22
50. !<•
65. 3S
63.90
51.17
52. T.
65.55
31. ««
3A.66
28. t9
«9.0'.
*7.55
«.5.19
48.18
4P.O?
47.63
46.6°
47.86
48.26
48.65
47.24
45.90
49.67
48.57
47.16
46.06
48.2ft
61.85
61.30
61. 7C
62.17
59.57
60, 26
48.18
47.63
50.38
62.56
61.70
31.26
31.36
32.46
31. S9
47.00
48.96
49.04
48.49
47.47
62.17
48.10
1
8K.9 | 51.7?
CAS
PRE-
HEAT
(HC F
615
t35
613
<25
65C
553
560
610
«C7
612
M4
5E6
5S7
62fi
tit
632
621
645
568
5E6
529
606
604
624
614
639
644
629
623
tl
-------
TABLE 6.4
NAILHAL GAS TESTS (SERIES IV 4)
FINAL DATA EVALUATION
ORIGIMAL
SEK1ES
AND
RUN «-S
IV A- 1
IV A- 2
IV A- •>
IV A- 4
IV A- 5
IV A- 6
IV A- 7
IV A- P
IV A- 9
IV A- 1C
IV A- 11
IV A- 12
IV A- 13
IV A- 14
IV ft- 1*
IV A- If-
IV A- 17
IV A- 18
IV A- 19
IV A- 2C
IV A- 21
IV A- 22
IV A- 23
IV A- 24
IV A- 25
IV A- 26
IV A- 27
IV A- 2R
IV A- 2<5
IV A- 30
IV A- 31
IV A- 32
IV A- 33
IV A- 34
IV A- 35
IV A- 36
IV A- 37
IV A- 38
IV A- 39
IV A- 4C
IV A- 41
IV A- 42
IV A- 43
IV A- 44
IV A- 4!)
IV A- 46
IV A- 47
IV A- 48
IV A- 49
TCTAL
AIR,
T
U4.3
131.1
1C2.S
115.0
138. C
103.1
113.7
138. C
102.7
113.7
135.3
1C3. 1
113.7
135.3
1C3.1
113.7
1C4.C
135.3
115.7
115.6
137.1
1C3.7
103.3
114.3
1C2.7
115.7
115.0
113.1
114.4
116.3
117.0
114.4
115. C
115.0
103.6
104.2
137.1
135.3
137.1
115.7
S9.4
84.9
76.4
113.1
111.9
1C3. 1
1C3.7
137. 1
\1k.2
HEAT,
KBTU/
FT»»3
/ MR.
55,41
56. 9R
55. PC
67.91
67.67
68. C6
37.10
37. C2
37.18
51.72
52.19
52.58
64.45
64,29
65. 39
33.32
32.77
35. 13
57.37
56.75
56.08
57.37
57.14
71.91
36.55
56.27
54.23
56.90
53.92
52.58
51.72
54.47
55.65
53.60
37.80
51.24
69.79
66.88
65.76
56.27
63.27
73.01
68.77
55.88
56.43
55.88
55. PC
56.43
56.75
GAS
PRE-
HEAT
DEC F
t<55
tS8
ess
7C3
7C9
7CC
664
t73
t£5
351
35E
345
345
346
344
36C
H3
326
684
686
691
679
676
686
644
691
fc62
660
649
698
663
*85
660
664
712
661
696
711
6R8
688
688
688
6f"i
tti
tS5
6S9
ePUT
IT)
C.C
0.0
0.0
0.0
0.0
c.o
0.0
0.0
0.0
0.0
0.0
0.0
c.o
0.0
0.0
c.o
C.C
0.0
27.1
14.5
24.7
33.1
26.4
27.4
30.5
0.0
0.0
27.4
26.1
0.0
23.1
0.0
26. C
26.6
0.0
23.2
0.0
0.0
18. 1
0.0
0.0
0.0
0.0
C.O
C.O
0.0
C.O
0.0
c.o
AIR
IN
BURNER
It)
114.3
137.1
102.8
115.0
138.0
103.1
113.7
138.0
102.7
113.7
135.3
103.1
113.7
135.3
103.1
113.7
104.0
135.3
115.7
115.6
137.1
103.7
103.3
114.3
102.7
115.7
87.0
85.7
86. 1
61.4
60.4
85.0
86.5
87.1
52.6
66.4
137.1
87.2
87.6
115.7
99.4
84.9
76.4
111.1
111.9
103.1
103.7
137.1
136.2
1
1 NQX
PPM
322
380
267
3ca
310
249
303
311
245
14H
135
123
144
127
124
156
109
139
44
74
47
60
33
54
24
346
256
23
178
90
53
310
28
220
120
70
330
269
198
365
251
128
53
332
235
194
278
314
283
CO
PPH
150
103
113
70
53
810
40
40
690
40
4C
107C
35
50
1020
<>3
960
15
7
22
22
200
133
22
480
0
0
3
7
40
8
0
0
C
760
323
0
0
C
0
10500
64038
151622
22
15
t75
460
15
15
02
t
.
2.9
5.8
0.6
3.0
5.9
0.7
2.8
5.S
0.6
2.8
5.6
0.7
2.8
5.6
0.7
2.8
0.9
5.6
3.1
3.1
5.8
C.8
0.7
2.9
0.6
3.1
3.0
2.7
2.9
3.2
3.3
2.9
3.0
3.0
O.P
0.9
5.8
5.6
5.8
3.1
0.4
Q.O
0.0
2.7
2.5
C.7
0.8
5.8
5.7
-29-
-------
TABLE 6.5
CIL TESTS (SERIES IV B)
FINAL CAT* EVALUATION
CRIGINAL
SFRH S
ANO
^UN K-S
1
IV h- I
IV S- 2
I v e- 3
l v f>- 4
IV "- 5
I V B- 6
IV l>- 7
iv - 21
IV B- 22
IV P. - 23
IV P- 24
IV P- 25
IV B- 26
IV B- 27
IV B- 2R
IV B- 29
IV B- 30
IV B- 31
IV B- 32
IV B- 33
IV B- 34
IV »- 35
IV B- 36
IV B- 37
IV B- 38
IV B- 39
IV fa- 40
IV B- 41
IV h- 42
IV B- 43
IV B- 44
IV B- 45
IV B- 46
IV B- 47
IV P- 48
IV B- 49
IV B- 5C
TCTAL
AIR,
%
113.1
115.0
115.0
1C3.2
1C3.B
131. fl
131.8
115.0
13C.B
103.6
115.0
126. "3
102.8
113.7
12S.8
103.7
115.6
126. S
1C4. 1
113.7
13C.8
113.1
1C3.3
127. 5
115.6
116.3
1 17.0
12S.8
1C4.2
1C4.2
115. C
115.0
114.3
1C4.7
115. h
116.3
114.3
115.6
115.0
116.3
114.3
113.7
113.7
113.7
115.6
103.7
1C3.6
127.fi
127. P
127.8
HEAT.
KRTL/
FT»»3
/ I-R.
53.37
52.50
52.50
52.34
52.11
54.54
54.54
51.79
54.54
51.24
64.37
68.69
63.50
13.32
35.84
32.15
47.86.
51.01
47.94
30.73
3C.97
56.79
58.32
61.38
51.40
52.74
51.64
55.88
51 .56
52.19
65.31
64.05
33.40
32.62
51 .32
48.89
50. C6
50.46
48.34
48.41
51.79
49.99
49.04
50.22
48.26
50.69
47.94
67.36
62.72
62.25
CAS
PRE-
HEAT
DEC F
693
6S7
6S1
688
tfb
696
7C1
691
696
688
699
704
696
668
674
«75
366
384
333
312
3C6
296
301
299
6<58
660
686
693
679
67G
695
701
669
644
692
691
6TC
659
700
681
7CC
675
651
669
666
69C
6SC
7C3
710
688
FLLE
G*S
INPUT
(*l
0.0
0.0
0.0
0.0
0.0
0.0
0.0
c.c
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
c.c
c.o
c.c
c.o
0.0
0.0
0.0
0.0
25. 9
14.6
23.8
14.5
26.5
14.4
o.c
0.0
20.2
C.C
0.0
14.7
31.3
0.0
14.2
C.O
O.O
1-..5
14.1
13.7
0.0
0.0
0.0
c.c
14. P
AIR
IN
BURNER
(I)
113.1
115.0
115.0
103.2
103.8
131.8
131.8
115.0
130.8
103.6
115.0
126.9
10?. 8
113.7
129.8
103.7
115.6
128.8
104.1
113.7
130.8
1 1 3.1
103.3
127.9
115.6
116.3
117.0
129.8
104.2
104.2
115.0
115.0
114.3
104.7
115.6
86.0
84.4
85.4
70.3
71.0
114.3
85.3
84.0
85.1
86.5
103.7
65.9
127.8
77.0
76.8
NOK
PPM
257
27*
3CO
238
210
289
343
253
284
200
279
319
222
212
245 •
173
219
253
174
181
218
220
182
263
260
244
235
256
193
174
252
282
214
152
255
224
203
205
175
172
262
241
213
213
19R
204
145
327
235
215
CO
PPM
25
22
15
260
SO
15
10
60
40
600
60
60
320
60
40
543
50
55
500
70
60
70
178
ao
50
45
45
45
90
14C
60
50
50
140
50
50
45
55
55
60
80
60
210
80
80
335
66C
115
125
127
02
I
2.7
3.0
3.0
0.7
0.8
5.8
5.8
3.0
5.7
0.8
3.0
5.3
C.6
2.8
5.6
0.8
3.1
5.5
0.9
2.8
5.7
2.7
0.7
5.4
3.1
3.2
3.3
5.6
0.9
0.9
3.0
3.0
2.9
1.0
3.1
3.2
2.9
3.1
3.0
3.2
2.9
2.8
2.8
2.8
3.1
0.8
C.8
5.4
5.4
5.4
-30-
-------
TABLE 6.6
SxIRL TESTS (SERHS V - A IS FCR NATURAL GAS AND 8 IS FOR COAt >
FINAL CATA EVALLATION
ORIGINAL 1
S E R 1 e S 1
AND
RUN »-S
V A - 1
V A - 2
V A - 3
V A - 4
V A - 5
V A - 6
V A - 7
V A - 8
v A - q
V A - 10
V A - 11
V A - 1?
V 8 - 13
V B - 14
V B - 15
V B - 16
V B - 17
V B - 18
V P. - 19
V 8 - 2C
TCTAL
AIR,
*
113.7
11*. 3
113. 1
113.7
103.2
135.2
113.7
1C2.6
136.2
1 13.7
102.8
135.2
115.5
115.6
115.5
116. 1
13*. 1
115.3
133.1
103.6
HEAT,
KBTU/
FT*«3
/ HR.
55.17
67.91
35.21
34.97
34.50
36.00
54.47
41.97
55.65
67.83
6>a.l4
68.46
60.52
60.60
03.74
62.72
63.74
5C.93
54.94
51 .40
CAS
PRE-
HEAT
OtC F
d)
7C1
675
i7C
663
68C
tS3
685
fSS
7C4
tsg
705
632
628
64C
632
645
613
629
6C7
FLUE
GAS
INPUT
m
0.0
0.0
0.0
0.0
0.0
c.o
0.0
0.0
c.o
0.0
0.0
c.o
c.c
c.o
11.2
c.c
0.0
c.c
o.c
0.0
AIR
IN
BURNER
m
113.7
114. 3
113.1
113.7
103.2
135.2
113.7
102.6
136.2.
113.7
102.8
135.2
90.4
90.7
115.5
116. 1
134.1
115.3
133.1
103.6
NOX
PPM
330
329
283
261
212
275
269
230
265
270
239
245
658
649
717
791
971
750
934
556
CO
PPM
60
80
75
70
335
70
6
81C
70
75
36C
90
530
75
2500
850
2CO
1050
2P5
270C
C2 1
t
2.8
2.9
2.7
2.8
C.7
5.6
2.8
0.6
5.7
2.8
0.6
5.6
3.1
3.1
3.2
3.2
5.4
3.1
5.3
0.9
TABLE 6.7
QUENCH TESTS FCR CCAL (SERIES VII
fINAL CAT* EVALUATION
UK IGISAL
•a-ui s
ANC
tUN «-S
VI - 1
VI - 2
VI - 3
VI - 4
VI - 5
VI - 6
VI - 7
VI - 8
TCTAL
AH,
>
1
1 14.9
115.4
110.4
1 lfc.9
1 30.4
1C6. 1
1 17.5
1 12.0
HEAT,
KBTU/
FT»«3
/ HK.
51.24
4S.3t
49.51
51. C9
5(-.27
4H.10
62.25
62.80
Gas
PRf -
HFAT
OEC F
623
6C9
tr?
616
t3<;
607
(•34
(-.5^
FLV.E
CAS
INPLT
1 »
C.O
c.o
0.0
<;.3
c.o
c.o
c.o
c.o
AIR
IN
BURNER
(t)
114.9
89. 7
88.7
116. 9
130.4
106.1
117.5
132.0
NOX
PPM
707
555
571
603
829
545
766
899
CO
PPM
285
810
6tC
500
42C
2225
750
72C
02
T
+
3.0
3.1
3.1
3.3
5.0
(.4
3.4
5.2
-31-
-------
TABLE 6.8
O11 SfRltS II --- F. G. R. FOR COAL
FINAL RECUCTIONS (PART 1)
1 VICINAL
TEST
NUS.
I
A I/ 2
A I/ 3
A 4/ 5
A ft/ 7
A 10/ 11
A 12/ 19
A 14/ 15
A 1ft/ 17
A IB/ 19
A 20/ 21
A 22/ .'3
A 2-/ 25
A 26/ 27
A ?»/ 29
A < 0 / 'il
A >?. 1 33
A 34/ 35
A t6/ 17
(' 3/ 4
t> 5/ ft
R ?/ M
P IV !<.
H IS/ 16
n 17/ l»
ft !«)/ 20
^ 2 1 / .' 2
K ?3/ ?4
!' 25/ 26
AVERAGES FUR TESTS
LCAC,
J
117.8
1 16.3
121.6
113.4
140. 1
142.0
114.9
73.1
71.8
65.1
141.1
14C.2
13C.5
114.9
!2.5
1 16.0
12C.7
146.0
143.5
'•S.I
7S.9
(.5.5
1 I 5.9
121. e
112.7
7C.4
7C.O
t5.t
1 15.0
EXCt SS
AIR, T
J
13.5
13.6
12. 7
2.7
38.4
M.O
3.4
13.7
33.2
1.5
12. R
15.5
1.6
12.2
14. 3
11.7
10. 5
13.6
15. P
19.1
40.9
7.4
17. 3
39. 5
4. 3
17.2
42.5
4. 7
14.4
TE«P.
lltG F
1
637
639
t5C
616
66P
654
641
564
589
531
525
534
512
512
471
399
404
402
1
629
56?
5P7
539
623
643
598
565
589
526
651
RURNER
AIR
113.5
113.6
132.7
102.7
138.4
J14.0
103.4
111.7
133.2
103.5
112.8
135.5
101.6
112.2
114.3
111.7
130.5
133.6
...
115.8
119.1
140.9
107.4
117.3
139.5
104.3
117.2
142.5
104.7
134.4
SIDE
Oft
FRONT
SLOTS
— — — —
— - — -
FU/'
GAS
RFCYf.
X
J
1.8
3.2
1.3
2.0
1.?
1.5
1 .Q
3.0
2.H
4.3
1.6
1 .2
1 .P
1 .0
2.4
1.9
1.5
1.4
12. 1
21.0
17.5
21.4
30.9
1H.4
31.5
14. il
22. A
41.1
20.4
PURNEK
OR
PORTS
JJ
PR I .
PRI.
PRI.
PR! .
PRI.
PRI .
PBI.
PRI.
PHI.
PHI.
PRI .
PR!.
PR!.
PRI.
PR I.
PRI.
PRI.
PPI.
SbC.
SFC.
StC.
SEC.
SFC.
SEC.
SEC.
SEC.
qFC.
SFC.
SEC.
TABLE 6.9
CF StUIfS II F. G. R. FOR COAL
F I.SAL RECUCT ICNS IPAPT 21
I'RICINAL
TE-S T
NUS.
1J
A I/ 2
A I/ 3
A 4/ 5
A &/ 7
A 1U/ 11
A 12/ 13
/ I4/ IS
A It/ 17
A IS/ 19
A 20/ 21
A 22/ 23
A ?4/ 25
A 21, f 27
A 28/ 29
A 30/ 31
A 32/ 33
A 34/ 35
A 36/ 37
1
01/2
R 3/ 4
05/6
P 7/ 8
H 13/ 14
R 15Y 16
B 17/ IP
R 19/ 20
H 21/ 22
l< ?3/ 24
1) 25/ 26
HASt
VALUE
i— __ -
774 » H
774 * 11
HSfl ± 70
443 * 2
9fiO • 5
762 + 25
*71 ± 11
470 « 34
•)5fl * 11
240 * ?4
(-.54 * 49
913 t 91
4*4 * f)
667 » 69
452 » 10
613 » 129
7Cft » 245
910 * 120
828 » 80
4S9 i 2<)
722 ± 46
333 « 25
833 + IS
1048 » 13
552 ± 4
576 ± 10
810 » 30
320 ± 2
£013 ± 13
Mr cppfi
VilTH
CHANGES
i_
604 + 4
659 + 0
8<58 * 53
472 ± 30
96S » 12
794 t 107
552 » 20
494 * 10
699 * 6
2S1 * 20
635 » 41
868 4 96
3B7 T 49
630 « 52
501 » 35
622 * 55
734 » 172
791 » 57
_|
708 ± 68
416 * 13
532 i 59
25fl * 18
548 t 12
797 t 16
372 * 2
312 » 6
596 » 20
242 * 1
814 » q
REOUCTITK
RO t 12
115 i 11
0 * 88
-23 t 30
I 1 » 13
-32 * 1 10
!•> * 24
-24 » 45
-41 * 13
-5 * 31
19 » 64
45 «• 132
57 t 50
37 i R6
-49 * 46
-9 ± 140
-28 » 299
111 ± 133
120 » 105
S3 * 31
190 + 75
75 i 31
285 ± 22
251 ± 21
180 i 4
184 t 12
214 ± 36
78 * 2
199 + 16
REDUCTION ||
IN | |
NO. t ||
1 1
| |
II
10.3 ± 1.511
14.9 * 1.4||
0.0 « 9.B | |
-5.11 6.7 | |
1.11 1.3||
-4.2 ± 14.4 ||
3.3 » 4.211
-5.1 » 9.7||
-6.2 i 1.9||
-2.0 ± 12.7 ||
1 1
2.1 » S.8 1 1
4.9 t 14.5 ||
12. fl » 11.2 II
5.5 ± 13.0 1 1
-10. R + 10.2 ||
-1.5 » 22.9 I I
-4.0 ± 42.4 | |
13.1 t 14.7 II
JJ
II
14.5 » 12. R II
16.6 J» 6.311
26.3 1 10.5 | |
22.5 ^ 9.4 ||
34.2 ± 2.711
24.0 i 2.0 I 1
32.6 * 0.8 1 1
31.9 ± 2. 1 1 1
26.4 ± 4.6 1 1
24.4 ± 0.7 | |
1 1
19.6 « t.6 f |
1 1
-32-
-------
TABLE 6.10
SLVARY CF SF.PIf< III STAGED COMBUSTION
FINAL PFCUCTICNS (PART 1)
(JPIG1NH 1
T C C T 1
1 C i 1 J
NOS.
1_
A 8/ B 1
A a/ e 2
A S/ H 3
A (»/ B *
A «/ B 5
A 8/ B 6
A 9/ R 7
A 9/ B 8
A 9/ B 9
A10/ BIO
Aid/ Bll
A10/ 612
All/ B13
All/ f\l*
A12/ R15
A12/ B16
/U3/ 617
All/ B18
Al*/ B19
M*/ R20
A15/ 1)21
M5/ P2?
A15/ fl23
A16/ «;>*
A16/ H25
A17/ f>76
A18/ 827
A1B/ B2S
All/ B29
A19/ H30
»20/ B31
A20/ H32
J_
A 8/ C 1
A 9/ C 2
A I/ C 3
All/ C *
A12/ C 5
Al*/ c 6
J
A17/ D 1
A17/ C 2
/VERAGtS FOM TESTS
LC*C,
T
11^.7
115.9
114.0
11^. A
116.1
116.9
11*. "»
117.*
116.8
114.8
H«.8
11*. 2
llf. 4
lie. 5
113.8
113.9
115.1
146.1
1*7.1
1*5.5
1*6.3
1*5. A
1**.0
112.9
112.2
116.8
1**.2
1*3.0
7?. 2
73.6
77.0
76.*
115. S
1 1 1 . 6
116.2
117.7
11*. 5
1*6. 1
11?.*
12C.2
EXCESS
AIR. X
15.0
15.0
17.1
15.7
15.0
1*.2
15.8
15.8
15. P
16. 1
16.5
17.5
1*.9
15.6
2.9
3.3
3.7
15.3
15.0
15.9
3. 5
3.9
5.0
37.0
37.*
1*.2
35.0
36.*
15.5
1*.8
16. S
37. q
1_
1*.6
16.2
15.3
15. P
2.6
15.3
5.*
1.3
1EHP.
DEC f
608
607
617
612
62*
627
618
615
613
tC7
61S
625
615
t29
5S6
600
58*
622
A37
632
<-2C
627
61*
630
628
612
6*6
6*5
577
65S
58<5
sat
601
595
612
603
"82
625
60*
598
BURNER
A T U
a i K t
X
91.3
68.2
5*. 8
93.0
68.0
52.*
65.9
5*. 2
67.8
90.9
67.2
5*. 3
66.7
*6.3
79.1
56.7
80.5
90.7
69.1
91.3
80.4
57.3
82. 7
92.1
93.1
<;o.*
95.8
"8.0
77.*
77.*
93.3
9*. 8
1
66.7
68.0
66.7
67.0
79.7
97.0
105.*
101.2
SICE
rtQ
UK
FRUST
SLOTS
SIDE
SIDE
SIDE
FRONT
FRONT
FRONT
SIDE
SIDE
SIDE
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
FRONT
SIDE
FRONT
FRONT
SIDE
FRONT
FRONT
SICE
FRONT
SIDE
FRONT
FRONT
SIDE
FRONT
SIDE
FRONT
SIDE
U 1.
FRONT
SIDE
FRONT
SIDE
FRONT
FRONT
J.
1 FLUF
1 r AS
1 l» **->
RECYC.
X
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0. 0
J
11. B
21.2
22.2
11.1
7. 1
9.9
0.0
0.0
BURNER
OR
PCRTS
_l
---_
1
PORTS
BURNER
BURNER
POSTS
PORTS
PORTS
1.
-33-
-------
TABLE 6.11
SUHMARY OF SERIES II! STAGED COMRLSTIGN
FINAL KECUCTICSS (PART 2)
1
ORIGINAL
TL--C T
' C J 1
NOS.
_ .
A 8/ E 1
A 8/ B 2
A 8/ 8 3
A B/ B 4
A 8/ B 5
A 8/ E 6
A 9/ B 7
A 9/ 6 8
A 9/ 6 9
A10/ 810
A10/ 611
AID/ B12
All/ 613
All/ B14
A12/ H15
A12/ B16
A13/ 817
A14/ 61R
A14/ BIS
A14/ B20
A15/ B21
A15/ B22
A15/ 823
A16/ 824
A16/ B25
A17/ 626
A18/ 827
A18/ B28
A19/ 629
A19/ 630
A20/ B31
A20/ 832
J.
A 8/ C 1
A 9/ C 2
A 9/ C 3
All/ C 4
A12/ C 5
A14/ C 6
_i
A17/ C 1
A17/ 0 2
EASE
VALUE
1
830 4 10
830 4 10
830 4 10
830 .4 10
830 4 10
830 ± 10
7S7 4 18
7S7 4 18
797 4 18
869 4 1A
869 4 IA
669 ± IA
765 4 7
765 4 7
534 4 6
534 4 6
641 4 22
885 ± 15
885 4 15
885 4 15
591 4 A
591 4 A
591 ± A
942 4 0
S42 i Q
739 4 3
1001 ± 17
1001 4 17
605 4 3
605 4 3
770 4 i
770 4 1
J
S30 4 10
797 4 Ifl
797 4 1R
765 4 7
534 4 6
885 4 15
.
739 i 3
739 4 3
NC (PPH)
WITH
CHANGES
-
677 4 8
488 4 9
505 4 9
711 4 o
343 4 11
295 4 9
467 ± 6
359 4 2
432 4 0
733 ± IA
385 4 2
350 4 2
374 4 9
389 4 2
399 4 18
283 4 8
371 4 11
693 4 18
4C9 ± 11
656 4 1
524 4 10
334 4 5
469 ± 6
689 4 28
685 4 24
674 4 7
807 4 It
844 4 12
282 4 9
362 4 9
410 4 2
524 4 2
320 ± n
465 4 2
366 4 23
411 4 16
323 4 2
655 ± 15
L
377 4 7
203 4 10
"EDUCI iON
— J
153 4 13
342 4 13
325 4 13
119 4 1C
487 4 15
535 4 13
330 4 IS
438 4 IP
365 ± 18
136 i 20
AR4 4 it,
519 4 14
391 4 11
376 4 7
135 4 19
251 4 10
270 i 25
192 4 23
476 ± 19
229 4 15
67 4 11
257 4 6
122 4 7
253 i 2P
257 4 ?4
65 i R
194 4 23
157 4 21
323 4 9
243 i s
360 4 2
246 4 2
J
510 i U
332 4 18
431 4 29
354 4 17
2114 6
230 i ?\
J
362 i f
536 4 10
RECUCT ION
T W
1 "(
NCI , *
1
18.4 ± l.A
41.2 ± 1.7
39.2 i 1.7
14.3 ± 1.2
5R.7 1 1.9
64.5 ± 1.8
41.4 ± 2.6
55.0 4 ?.6
45.8 ± 2.5
15.7 ± 2.3
55.7 4 1.9
59. 7 ± l.q
51.1 4 1.6
49.2 ± 1.1
25.3 i 3.6
47.0 4 1.9
42.1 i 4.1
21.7 4 2.7
53. ft i 2.3
25.9 ± 1.8
11.3 4 1.8
A3. 5 .4 1.1
20.6 .4 1.2
26.9 i 3.0
27.? 4 2.5
P." ± J.o
19.4 4 ?.<.
15.7 i 2.1
53.4 4 1.6
40.? i 1.6
46. R jt 0.3
31.9 4 0.3
i
61.4 i ?.l
41.7 i 2.5
54. 1 ± 3.0
46.3 i 2.3
39.5 4 1.3
26. C i 2.4
L il
49.0 4 1.0
72.5 4 1.4
-34-
-------
TABLE 6.12
SUMMARY Of- SFRIFS IV* NATURAL GAS
FINAL RFCLCTIONS (PART 1)
ORIGINAL
T C 0 T
I C. o I
NOS.
1
IVA 1/19
IVA 1/20
IVA 2/21
IVA 3/22
IVA 3/2}
IVA 4/24
IVA 9/25
i
IVA26/27
IVA26/28
IVA26/29
1VA26/30
I VA26/31
IVA26/32
IVA26/33
I VA26/34
iva 9/35
IVA 3/36
IVA37/3P
1VA37/39
AVERAGES FOR TESTS
.. _ i
LTAO,
»
_J
124.9
125.0
124.5
12h.S
127.1
154. S
83.2
_J
126.6
127. B
127.1
126. 4
126.3
126.9
126. 5
126.5
PR. J
125.5
1*4.3
153. R
EXCESS
AIR, 1
_
15.0
14.9
37.1
3.2
3.0
14.6
?.7
15.3
14.4
15.0
16.0
16.3
15.0
15.3
15.3
3.1
3.5
36.2
37.1
TEVP.
OFG F
L_ _ i
689
69C
694
6B4
682
694
654
i
676
675
67C
694
677
6R8
675
677
688
675
703
61?
BURNER 1 SIDE
AIR
1
115.0
114.9
137.1
103.2
103.0
114.6
102.7
87.0
85.7
86.1
61.4
60.4
85.0
86.5
87.1
52. A
66.4
87.2
87.6
np
UK
FRONT
SLOTS
_ i
-_-.-
_ 1
FRONT
FRONT
FRONT
FRONT
FRONT
SIDE
SIDE
SIDE
FRONT
FRONT
FRONT
FRONT
FLUE
f AC
\3 f*3
RECYC.
x
J_
27.1
14.5
24.7
33.1
26.4
27.4
30.5
0.0
27.4
26.1
0.0
23.1
0.0
26.0
26.6
0.0
23.2
0.0
18.1
BURNER
no
u**
PPRTS
BURNER
BURNER
BURNER
BURNER
BURNFR
BURNER
BURNER
.
BURNER
PORTS
____
PORTS
BURNER
PORTS
PORTS
PORTS
TABLE 6.13
SUMMARY CF SERIES IVA NATURAL GAS
FINAL REDUCTIONS (PART 21
ORIGINAL
T f S T
M:<,.
1
IVA 1/1<5
IVA 1/20
IVA 2/21
IVA 3/22
IVA 3/23
IVA 4/24
IVA 9/25
i i
IVA26/27
I VA26/28
IVA26/29
IVA26/30
1 VA26/31
I VA26/32
I VA26/33
I VA26/34
IVA 9/35
IVA 3/36
I VA37/38
IVA37/39
RASE
VALUE
1
322 * 5
322 * 5
J2U + 4
267 t 3
?67 * 3
3Cn i o
245 t C
1 _ _l
^46 + 6
346 i *
346 + ft
346 t 6
346 * 6
346 * t,
346 + 6
346 t 6
245 * 0
267 + 3
330 i 7
330 i 7
NC I PP^ )
WITH
CHANCES
L _ .
44 2
74 7
47 7
60 '
33 4
54 16
?4 4
L _J
256 ± 5
23 + 2
178 •» 3
90 i 0
53 + 0
310 + 0
28 •» 1
220 + 7
120 * 10
70 + 3
269 i 2
198 + 1
~
REDUCTION
J
278 » 5
248 i 9
273 i 8
207 + 6
234 » 5
254 ± 16
221 +
-------
TABLE 6.14
SUMMARY OF SERIES IV8 »4 RESIC. FUEL OIL
FINAL RECICTICNS (PART 1)
ORIGINAL 1
T l_ C T 1
' t O I I
NOS.
a __
IVB25/26
IVH?5/27
IV3 6/2B
IVB 5/29
IVR 5/30
IVP1 1/31
IVB16/34
L_ _ i
IVB35/36
IVl>35/37
IVR35/38
IVB35/39
IVB35/40
1VB41/42
IV841/43
IVP41/44
IVB41/45
I VB46/47
IVB48/49
IVB48/50
AVERAGES FOR TgStS
LCAOt •
X
114.3
113.8
11S.O
116.2
116.1
143.1
72.8
-
L13.6
114.3
113.6
114.1
113.4
115.9
1 15.6
115.2
1 14. J
I 14.0
147.?
147.4
EXCESS
AIR, T
1 . J
15.9
16.3
30.8
4.0
4.0
15.0
4.2
L_ J
15.9
14.9
15.6
15.3
15.9
14.0
14.0
14.0
14.9
3.6
27.8
27.8
TEMP.
DEO f
i
689
692
694
682
682
697
65S
„
691
681
675
696
686
687
675
684
6P3
690
706
695
1 RURNEK
AIR,
t
*
115. 9
116.3
130.8
104.0
104.0
1 15.0
104.2
1-
86.0
84.4
85.4
70.3
71.0
85.3
84.0
85. 1
86.5
65.9
77.0
76.8
SIDE 1
«n I
OR 1
FRONT 1
SLOTS
1
J
|
t
— --
_L
FRONT
FRONT
FRONT
FRONT
FRONT
SIDE
SIDE
SIDE
FRONT
FRONT
FRONT
FRONT
FLUE
C A C
u A D
RECYC.
j
25.8
14.6
23.8
14.5
26.5
14.4
20.2
J _J
0.0
14.7
31.3
0.0
14.2
0.0
14.5
14.1
13.7
0.0
0.0
14.8
BURNER
OR
PORTS
BURNER
BURNER
BURNER
BURNER
BURNER
BURNER
BURNER
BURNER
BURNER
BURNER
PORTS
BURNER
PORTS
PORTS '
11
TABLE 6.15
OF SERIES IVB --- «6 RFSID. FUEL OIL
FINAL KEOLCTIONS IPAKT 2)
CRIGINAL
T t C T
1 t i 1
NOS.
1VH25/J6
IVB25/27
IVil 6/28
IVI1 5/25
IVH 5/30
I V I! 1 1 / 3 1
IVB16/34
1VB35/36
1VP35/37
I VB35/36
IVR35/39
IVR35/40
IVB41/42
IV641/43
I VB41/44
I V841 /45
IVP46/47
IVB48/4S
IV048/50
BASE
VALUf
_! J
260 * 2
260 ± 2
2P9 t 1
210 * 2
210 » 2
?79 » ?
1 73 * 2
_[ _]
255 + 0
255 ± 0
255 ± 0
?55 ± 0
255 ± 0
262 » 3
262 » 3
262 + 3
262 * 3
?04 ± 2
327 » 2
327 * 2
\C (PPK)
hITH
CHANGES
244 4
235 4
256 6
193 2
174 2
252 + 0
152 + 1
J
224 ± 1
203 » 3
204 » 5
175 + 3
172 » 4
241 + 5
213 » 5
213 » 5
198 » 3
145 * 3
23f » 1
215 « 6
«tDUCTION
16 » 4
25 * 4
33 + 6
17 ± 3
36 t 3
27 ± 2
21 * 2
. J
31 * 1
52 » 3
51 * 5
SO + 3
83 » 4
21 * 6
49 + 6
49 * 6
64 + 4
59 t 4
92 i 2
112 * 6
RECUCT ION
I N
Nil, t
6.2 • 1.7
9.6 » 1.7
11.4 i 2. 1
n. 1 ± 1.3
17.1 Jt 1.4
9. 7 i 0. 7
12.11 1.3
_il
12.2 i 0.4
20.4 i 1.2
20.0 ± 2.0
31.4 ± 1.2
32.5 ± I. ft
8.0 i 2.2
18.7 jt 2.2
18.7 i 2.2
24.4 i 1.6
28.9 ± 1.8
28.1 ± 0.7
34.3 Jt 1.9
-36-
-------
recirculation and/or staged combustion. The series are each described by two
tables; part 1 and part 2. The tabular headings are described as:
Part 1 1) Original Test Numbers: When coupled with the Series
number in the table title, this is self-explanatory.
2) Averages for Tests: These values are the average
values for the two tests for:
a) Load, %: The percentage of fuel BTU input
based on 5,000,000 BTU/hr.
b) Excess Air, %: The percent of air based on
stoichiometric air added over and above the
1001 theoretical air level.
c) Temperature, °F: The total preheat for the
fuel/air input.
3) Burner Air, I: This is the percentage of 100%
theoretical Cstoichiometric) air coming through
the burner as first stage air.
4) Side or Front Slots: This is the slot position
used for second stage air if the tests involve staged
combustion.
5) Flue Gas Recycled, %: This is the percentage of
flue gas recycled back from the stack into the
combustion air.
6) Burner or Ports: This is the position for addition
of the flue gas. For coal, all flue gas additions
of burners are secondary air additions; the only
-37-
-------
exception is in Series II, flue gas recirculation,
where primary and secondary are differentiated,
but are both burner additions.
Part 2 7) NO (ppm): The NO measurements in the flue gas corrected
to dry, 3% oxygen conditions for the following tests:
a) Base Value: The test before any NO correction
methods were tried.
b) With Changes: The test made with NO correction
method(s) applied.
c) Reduction: The difference between columns a
and b.
8) Reduction in NO, $: This is the percentage reduction
from columns 7a and 7b based on the initial value in
7a.
In addition, similar tables, Tables 6.16 to 6.19, have been prepared for the
swirl and quench tests.
Table 6.20 is the table showing burner efficiency calculated from
combustibles (mostly solid carbon found in ash samples) from a wide sampling
of coal tests. The burner efficiency for gas and oil is 100%. The tabular
headings are:
1) Test and Series Number - Self explanatory.
2) Firing Data - This is the fuel/air input data:
-38-
-------
TABLE 6.16
SUMMARY OF SWtCL TESTS SERIFS V (GAS)
FINAL REDLCT IUNS (P4RT 1)
DKIGINAL
TEST
NOS.
VA 3/ 4
IVA 9/ 5
IVA 8/ h
VA I/ 7
IVA 9/ 8
IVA 21 9
VA 2/10
IVA 6/tl
IVA 5/12
AVERAGES Fan TESTS
LCAC,
t
_J
7S.3
82.0
80.5
123.3
SO. 3
123.5
152.1
154.6
149.1
EXCESS
AIRt *
._ J
13. 4
2.9
36.6
13.7
2.6
36.6
14.0
2.9
36.6
TEHP.
DEC F
_...
672
664
676
693
675
696
702
69S
707
BURNER
AIR,
X
J
113.4
102.9
136.6
113.7
102.6
136.6
114.0
10?. 9
136.6
SIDE 1
OR 1
FRONT
SLOTS
1 FLUE
GAS
RECYC.
s
.
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
1
BURNER
OR
POSTS
TABLE 6.17
OF SWIRL TESTS SERIES V
-------
TABLE 6.18
Sl"MARY OF QUENCH TESTS — SERIES VI - COAL
FINAL 3ECUCTIONS (PART 1)
TEST
NOS.
i _
IA 1/1
IB 1/2
IB10/3
P 2/4
IA 2/5
IA13/6
IA14/7
IA18/8
AVERAGES FOP TESTS
LCAC,
j.
116.1
114.8
129.3
121.8
112.5
143.fi
141.0
EXCESS
AIR, X
L_
14.9
15.fi
15.8
15.9
32.7
5.0
16.1
34.0
TEMP.
DEC f
L 1
619
607
604
622
637
602
631
65C
BURNER
AIR,
%
114.9
90.5
89.fi
115.9
132.7
105.0
116.1
134.0
SIDE
OR
FRONT
SLOTS
FLUE
GAS
RECYC.
X
0.0
0.0
0.0
10.7
0.0
0.0
0.0
1 0.0
1
BURNER
OR
PTRTS
L 1
TABLE 6.19
SIHHAP.Y OF QUENCH TESTS SERIES VI - COAL
FINAL REDACTIONS (PART 2)
CP IGINAL
T r c 7
1 r :> 1
NCS.
1
I
1
14 1/1
IB 1/2
1FUC/3
H 2/4
IA 2/5
IA13/6
IA14/7
1A16/8
NO (PPM)
BASE
VALUf
J _l
flP2
677
733
7Cft
icei
641
885
1CC1
15
8
14
68
13
22
15
17
WITH
CHANGES
—1
707
555
571
603
f>29
545
766
899
25
13
I
8
4
17
22
33
ptnuci ICN
J
175
122
162
105
222
96
119
102
29
15
14
6P
14
28
27
37
REOUCT ION
I N
Nil , T
1.
19.8 ± 3. 3
18.0 « ?.3
22.1 i 2.0
14.8 ± 9.B
21 .1 ± 1.3
1*.0 i 4.4
13.4 i 3.C
10.2 • 3.7
-40-
-------
TABLE 6,20
CARflON LCSS AND RUBNF-K EFFICIENCY
SCR Its
A N P
TEST
MIMH FR
1 - 6
I -20
1 -26
1 -41
i I A- fc
11 A-l'.
1 I A-?6
II B- 2
II B- -i
II H-l "
I I I A- 1
III A- 2
III A- 5
III A - 6
III A- 1
III n- 5
III H- 6-
III H- H
II 1 B-15
III B-16
111 B-lB
1 1 I ii-20
III 5-21
HI 13-22
I I I H-25
1 I 1 S - 2 S
III 11 - 2 -r7
?75
Wf. IGMS, L
FUEL
(OPY)
i,hQ ***,«
272
572
4 19
464
54<=
516
5Pi (K )
263 ( a )
447 I a )
468
47S
SI".
27.S
471
4 r. 4 (SI
470 ( S>
47,' ( S >
450 IS)
4 i 1 IS)
5 S ? ( S )
577 (S)
r- "5 C ( S )
5 R 2 ( S I
4 4 H (SI
571 (S)
29? ( S )
301 (S)
463 < S-* )
475 (S-K)
5 ». 2 1 S - R )
447 (Sim)
4P6 (SU-«)
3./HR .
FLUf
GAS
5284
31 IS
648?
47RO
522/1
62«5
6118
7?62
30l>2
51 11
5925
7046
HS.)1?
.3556
5P»0
5P5-.
5=64
590"
5007
5027
7203
7735
6570
65R9
6577
^C9^
') 777
45-?!
5P03
5907
72 (0
4766
4 779
ASH
T M
1 N
F .r,.
i
O.HO
0.35
1 .55
O.hR
0.61
0 • R 3
0. 7«
i . n
0. >2
0.9"i
O. 56
U. •-!<
1 .71
U. 74
1.01
0.63
O.OK
1 . 0'.
J.o«
1 .24
1 . *1
1.21
.' . 4 2
c. U
1.15
1.13
0.53
1.11
1.02
O.a-i
1 .39
1 .04
??
r.
i j..
1 N
4SH,
54.6
51 .3
57.3
52.3
55. H
S<;. "i
C.D.6
64. 1
52. 2
r-6. 1
34 .',
4 •• . 3
3c.O
24.4
*<• . I
''T. 7
60.*-
3C . '
iJ. 7
3'- .0
3 '. 1
31 .1
<. ^ , t'
4 « . '
2'<. c
11 .^
36.2
1 c- .>*
4".°
24.--.
i5.5
M • 7
64.7
t p c r r
r ^ f" 1 (. •
IN *
BY WT .
94. i
97.9
H9.0
95.0
Qf>. 2
"4.3
94.6
°0 . 3
'• R . 0
93.9
°6.2
O.6
''5 .4
96. 7
95.2
°3.5
95.3
«7. 7
^7. 1
95.6
94.6
07.',
•">«, . 4
9'.h
97. !
9 3.1
94. '.
1
c«««» - (<;) = SIAGFl: CIMI-USTICN TfST
1 = ) = KLUE C-AS "i-c IKCUI AT ICN TFST
,S-' ) = STA{;r;i C ."M'UI<; I ICN TfST JITH
IC«!"TH 1C
(JAS •> L f I o CU L A T 1CN
-41-
-------
a) Air, % - The percent of 100% theoretical air.
b) Flue Heat - Net heat release rate in the furnace in kBTU/ft3/hr.
c) Deg F - The total air preheat in °F.
3) Weights, Ib/hr - For dry fuel (coal only) and total flue gas weight.
4) Ash in F.G., % - This is the total weight percent of solid ash in
the flue gas.
5) C in Ash, % - This is the total weight percent of carb»n in the
solid ash.
6) Burner Efficiency in Percent by Weight - This is the amount of coal
burned to total flue gas after correction due to unburned solid (and
gaseous for all except substoichiometric tests) combustibles.
Figures 6.1 to 6.4 illustrate the typical major effects observed for coal,
oil, and gas. The variables observed are excess air, firing intensity, and
preheat. The constant conditions observed in these figures are:
Excess air level - about 151
Preheat level - about 600'F
Firing rate - about 40,000 BTU/ft3/hr
(High excess air - about 35%)
Figure 6.5 shows the air addition to the furnace for coal. Between 15%
to 201 of the total air added to the furnace is used for coal transport and
is primary air. Flue gas recirculation does not change the weight of gas in
the primary since an equal weight of air is removed from the primary and
added to the secondary. The weight of the secondary always changes with flue
-42-
-------
C\J
-H
Q Q- ~1
LUCE .
OIO o
ZD_J z son-
CD
cent
CRS
CC
CE
cn
CO
rriu
RRTE OF HEflT RELEflSE. KBTU/FT«x3/HR
LLJH
QCO
"^»— 1
LDZ:
CL
iLJ
n
UJ
cc
Q_
soo
PREHERT, °F
COf- £
CE Q-
LULU .
ecu o
IDLU z S00-
LDQC
CORL
EXCESS flIR, X
500
PREHERT. °F
100
-------
RGURE 6.5
AIR INPUT WITH COAL
fPreheof up to 800°F
SECONDARY <
L2000-5000 Ib/hr
PRWARY
No preheat
400-600 Ib/hr
gas recirculation for single stage firing. Figure 6.6 is the result of primary
flue gas recirculation for coal. Figure 6.7 is the overall result of flue gas
recirculation for all fuels studied.
Second stage combustion air can be added to our furnace in two ways (see
Figure 6.8). The front slots produce a "progressive mixing" and involve addi-
tion of the air in the burner area. The side slots, on the other hand, produce
a defined second stage addition downstream of the burner area. Figures 6.9 to
6.12 show the result of the staged combustion tests. When flue gas recircula-
tion was used in the ports, it was added to the port air.
Figures 6.13 and 6.14 illustrate the effect of load and stoichiometry on
the burner efficiency and carbon loss. Figures 6.15 and 6.16 illustrate the
interdependence of load and stoichiometry on carbon loss and burner efficiency.
The final two figures, 6.17 and 6.18, illustrate the effects of swirl for
gas and quench for coal.
-44-
-------
CJ
cc
*— — t
LJ
LU
COCC
•CO
CD
LJ
GCLU
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iiii|iin
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FLUE GflS RECYCLED, 7.
LO
FLUE GflS RECYCLED, 7.
-------
FIGURE 6.8
STAGED COMBUSTION OPTIONS
_
(SifrfioTto Bide slots)
#' <*-
,-.*•••• Similar to
/ front stots)
FIGURE 6. 9
CGflL, VRRIRBLE PORT
REDUCTION IN NO, X
FIGURE 6.10
CGRL, 5TRGED COMBUSTION
REDUCTION IN NO, V.
-46-
-------
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- LOW 100"- 1075
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STOICHIOMETRY RT BURNERS. 7. LOAO,%
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STOICHIOMETRY RT BURNERS, X
STOICHIOMETRY, %
-------
100-
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11(1
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oo
100
STOICHOMETRYxLCAD, %
200
50
100
LOAD^-STOICHIOMETRY, %
150
-------
FIGURE 6.17
NO REDUCTION FOR SWIRL TESTS £AS)
WO REDUCTION, %
LOW LOAD
MID LOAD
HIGH LOAD
LOW MiO HIGH
AIR AIR AIR
10
(14, 6)
4
8
19
18
12
17
21
FIGURE 6.18
NO REDUCTION FOR QUENCH TESTS (COAL)
NO REDUCTION, %
LOW LOAD
MID LOAD
HIGH LOAD
LOW MK) HIGH
AIR AJR AIR
15
20
18- STAG.
22-STAG.
15-F.G.R
13
21
10
-49-
-------
-50-
-------
VII. DISCUSSION
The discussion section has been divided into four sections. These
sections will deal with the data results, special effects which were observed
in the testing, final data discussion, and possible correlated interrelation-
ships. The discussion will present the data as measured and a proposal for
possible future considerations. The future work scheduled for Phase II will
be discussed in a later section.
A. Results
The effects of each variable studied are usually significantly
different for each of the three fuels studied when surveying a single variable;
the simplest curve was drawn through the available data. These data
were usually taken at the extremes and middle of the range for each variable;
but in a few cases, only at the extremes of the range. In most cases, if a
straight line did not fit the data, a slightly curving line did. It must be
emphasized that in many cases the extremes of a single variable are beyond the
range of what is currently considered acceptable operating practice. In addi-
tion, these results apply only to a small single burner test unit. Even so,
it is believed that the trends will probably hold for large multiburner units,
although the magnitude of these changes may be appreciably different. Finally,
some of these variable changes may not be acceptable on large units.
In reviewing these results, it should be borne in mind that iN'O
emissions are due to a combination of thermal and fuel bound nitrogen sources.
During combustion of natural gas, only thermal fixation of atmospheric nitrogen
is possible since there is no fuel bound nitrogen:
N + 0. > 2 NO
*
A
'',.*.
-51-
-------
(Only the overall formation is discussed here, not the mechanism of formation.)
In contrast, coal contains fuel bound nitrogen and an additional source of
nitric oxide is oxidation of this fuel bound nitrogen to NO:
2 NO
and
'L\
2 R-N + 02 —> 2 NO
(2)
where R is the fuel portion of the molecule.
The kinetic form of these equations is given by a general form:
from (1):
>1 [N2] [02] - kp ^ [N0]:
(3a)
from (2):
>2 [R-N]2[02J - k^ [NO]2
(3b)
where k,- -, , kr 9, k ,, and k 7 are of the form:
1,1 ij^ ij-1- * »^
n 'Ex/RT
n
(3c)
(Note: by definition: k , = k 9)
ri i z
-52-
-------
It should be noted that the reverse reactions of (1) and (2) are identical
and therefore it is not valid to say:
if reactions (1) and (2) are considered separately. If this happens to be
true for a given case, it is simply coincidental.
The initial thought for oil is that the NO concentrations observed
j\.
should be higher than for gas due to the fuel bound nitrogen. In our unit,
however, oil burns with a more luminous flame than gas and has a larger
visible flame envelope. Hence, lower NO levels from oil combustion are
attributed to better radiating properties and therefore a lower bulk gas
temperature.
Excess Air
The results of the excess air tests show:
Effect
Mean Emission
(under standard
conditions)
Peak Position
(percent excess
air)
Variation from
Maximum to
Minimum Emission
Percent Variation
Coal
Major
700 ppm
1000 ppm
(35%)
±300 ppm
400-1000 ppm
«v40%
Gas
Strong
300 ppm
350 ppm
(20%)
±65 ppm
220-350 ppm
^25%
Oil
Strong
250 ppm
300 ppm
(401)
±50 ppm
200-300 ppm
^20%
to Mean
-53-
-------
There are significant differences between gas and coal which are at least
partially attributable to fuel bound nitrogen. Although there are differences
between the two fuels in flame temperature, combustion rate, physical state of
the fuel, and even gas velocities, these differences would be expected to
produce less change in NO than the fuel bound nitrogen. In particular, the
JC
difference in the shape of the curve is expected to be a change due to fuel
bound nitrogen.
The NO emission from gas, the thermal fixation of atmospheric
nitrogen, depends upon temperature and excess air level. At low excess air
levels, the effect of increasing oxygen level more than offsets the decreasing
flame temperature, thus the curve initially rises. In addition, the flame
can be more luminous at lower excess air level; this can lead to more rapid
quench rates. At high excess air levels, the decreasing temperature becomes
the overriding effect and the curve drops after passing through a maximum.
In contrast, the coal, which contains fuel bound nitrogen as a
second source of NO, shows a different position of peak maximum, shifted to
higher excess air, and an increase in formation of NO at low excess air.
These differences are, at least qualitatively, due to the fuel bound nitrogen.
The trend thus shown indicates a positive correlation between increased fuel
bound nitrogen conversion to NO and increased excess air. It is not felt
that the fuel bound nitrogen can yet be quantitatively evaluated. (An
additional factor which must be pointed out is the apparent greater luminosity
(and therefore greater rate of radiation) of the coal flame as compared to
the gas flame at low excess air: in addition, the coal flame luminosity
appears to .be insensitive to excess air level whereas the gas flame luminosity
is very greatly dependent upon excess air.)
Oil tends to behave in shape and peak of curve as though there is a
fuel bound portion. The actual levels of NO are low, and as stated previ-
ously, are probably due to its high luminosity when compared to gas. The
relative positions of the curves with coal highest, gas intermediate, and
-54-
-------
oil slightly below gas agree in general with field test data. The gas and oil NO
emission levels fall in the low range and this could be due to the fairly con-
servative furnace heat liberation rate for these fuels in our test unit.
Load
The result of load change shows :
Coal - Very strong effect; varies from 400-800 ppm
under normal conditions.
Gas - No dependence; 300 ppm under normal conditions.
Oil - Intermediate between gas and coal; 175-275 ppm
under normal conditions.
Again it should be pointed out that with the burner arrangement used
for these tests , the air velocity through the burner and the turbulence change
with load. However, there is no indication of a peak level being reached under
increasing load conditions. In addition, due to the refractory shielding in the
front half of the furnace , probably there is less response of NO to load than
would be obtained with different quench rates.
Preheat
The dependence of NO emission level on air preheat is very interest-
ing. Normal conditions (15% excess air, normal 100% load) result in:
NO Range , ppm
Fuel Dependence (Deviation of Mean)
Coal None 725
Gas Strong 100-300 (+^50 S)
Oil Moderate 200-250 (+
-------
and for high excess air and normal load:
Coal Moderate 750-1000 C
Gas Strong 100-300 (+
Oil Moderate 225-300 (+_M.5%)
The indication is that thermal production of NO is increasing at a rate of
about 50 ppm per 100°F preheat increase. This is determined from the slope
of the curve for gas. The slope for gas is unaffected by excess air. Since
the same type of increase of thermal emission of NO should, but doesn't,
occur for coal, and since it should be affected by excess air in the same
manner as gas, then the fuel bound nitrogen conversion must be the reason for
the differences in slope between gas and coal. Therefore, the results indicate
that conversion of fuel bound nitrogen increases with decreasing air preheat.
The increased slope of the two coal curves (from horizontal at normal air to
15% at high excess air) simply means that the total NO of the preheat curve is
higher at higher excess air, not that the percent conversion of fuel bound
nitrogen has changed with increased excess air.
Oil shows the tendency again to have a fuel bound nitrogen component
like coal, but to be predominantly a thermal NO emitter. The oil curves are
therefore consistent with the gas and coal.
Flue Gas Recirculation
The following results were obtained for flue gas recirculation:
Reduction of NO, I
Fuel Effect (at 30% FOR)
Coal, primary Little <5S (at 5?o FGR)
Coal, secondary Moderate 30
Gas Very Strong 85
Oil Slight 10
-56-
-------
Since the primary transport air for coal represents about 15% of the total
combustion air, a high level of primary flue gas recirculation is not
possible, even when high levels of primary flue gas substitution are used.
Blending the flue gas with the primary air affects the primary ignition zone
and burner performance, further limiting the maximum levels of primary flue gas
recirculation attainable. Also, as a result of the effect on burner stability,
data for primary flue gas recirculation tests showed considerable scatter. It is
felt, however, that this trend is realistic and that any reduction of NO by use
of this approach is relatively insignificant.
The overall effect of flue gas recirculation (secondary flue gas
recirculation for coal) appears to be reduction of thermal NO emissions as
evidenced by the natural gas data. The effect of flue gas recirculation on
conversion of fuel bound nitrogen is unknown, but the reduction of this
component is probably minimal. In fact, reduction of thermal NO could be the
cause of the lower overall reduction of NO in the coal tests. It is possible
that with lower temperatures in the flue gas, the amount of NO from conversion
of fuel bound nitrogen may actually increase, partially offsetting the de-
crease in thermal NO. Overall for coal then, the effect is moderate, but
not overwhelming. For coal, the addition of 10 to 151 flue gas recirculation
resulted in a reduction in NO emission levels of 10 to 151.
For oil, the reduction of NO emissions by use of flue gas recircu-
lation is small. The reason for this is probably that the base line data for
oil are already so low, that little or no change is seen for basic reduction
methods when applied to oil combustion.
Staged Combustion
The results of the staged combustion data are as follows:
-57-
-------
REDUCTION IN NO, I
Staging Test
Coal
Gas
Oil
Normal:
Effect on NO
Maximum Reduction
Burner Air at Max.
Red., I Stoich.
Strong
60
Very Strong
90
Moderate
35
•v-SS
Substoichiometric:
Maximum Reduction
Burner Air at Max.
Red., % Stoich.
100
100
With Port FGR
No Effect
95 No Effect
at %50I Stoich.
With Burner FGR
No Effect
100
at -v80% Stoich.
No Effect
Variable Port Position
Some Effect
(Max. Red.:
Side Ports 50
Front Ports 60)
No Effect
No Effect
The difference in the second stage port position is important for
the coal firing tests. Although the reduction in NO is not significantly
different numerically at low burner to total air ratios* for the two slot
positions, the visible flame pattern .indicates a low second stage combustion
efficiency for the side slots. In particular, a large cylindrical, highly
turbulent flame envelope surrounds a blacker carbon containing core. Carbon
becomes visible in the smoke from the stack. Although the transparency of
* The burner to (total) air ratio is defined as the weight of air through
the burner divided by the total weight of air into the furnace.
-58-
-------
the flame is much greater than this for gas and oil, incomplete burning and
poor mixing is assumed to occur in the second stage for these fuels also.
Therefore, only the front slot, or "progressive combustion" data are used for
discussion of further results.
It should be noted that these staged combustion data were obtained
with fixed burner and slot openings. Thus, as the burner to total air ratio
decreases and staging increases, the air velocity through the burner decreases
and the air velocity through the ports increases. It is for this reason
that the performance and the effect on two stage combustion is unsatisfactory
at lower burner to air ratios when using the side slots.
The greatest effect of staging is found with gas. Almost all of
the NO is eliminated by staging the gas combustion. The addition of flue
gas recirculation can remove most of the rest of the NO emission. The
important item is that burner flue gas recirculation is more important than
port flue gas recirculation. This indicates that precursors (free radicals,
atoms, etc.) which later form thermal NO are formed in the first stage, even
under highly substoichiometric conditions: if this were not the case, burner
flue gas recirculation would show the same or less effect on NO than port flue
gas recirculation. Therefore, the addition of flue gas recirculation effects
more than just a lowering of the flame temperature in the combustion. The
position of any maximum reduction of NO is uncertain, but is to be expected
at about 50% burner air.
Again, in the case of oil, the reductions of NO for staged combus-
tion are small due to the already low base values of NO emissions from oil.
Coal tests show reduction of up to 601 of the NO emission levels
for staged combustion. An apparent maximum reduction of the NO is reached
at about 50% burner air to total air ratio. This minimum is not unexpected
because it represents the diminishing return on the reduction of the thermal
-59-
-------
NO precursors and conversion of the fuel bound nitrogen in the first stage
as contrasted to increasing thermal NO formation in the second stage due to
increasing enthalpy release in the second stage combustion.
The substoichiometric tests for gas and coal, when superimposed,
indicate the same shape of curve and intercept for 100% reduction of NO.
These results seem to mean that both thermal NO formation and fuel bound
nitrogen conversion to NO under substoichiometric combustion conditions have
the same final precursors in atomic or free radical form such as NH, N, etc.
In other words, the reactions directly leading to NO are independent of the
source which provides these free radicals. In addition, it would appear that
there is a lower level of burner air below which NO formation in the first
stage drops to zero and it is of no further use to decrease the burner to
air ratio. Obviously, this is a function of second stage geometry, spacing,
gas temperature, etc.
It is expected that flue gas recirculation would further reduce
the staged reduction of NO for coal. It does not; therefore, the assumption
is that staging has reduced all or most of the thermally produced NO, but
only a portion of the fuel bound nitrogen conversion. This may indicate
that the residence tijne in the first stage is too short and a greater
physical separation is required between stages. If so, the burner area is
not the place to add second stage air. An alternative might be to increase
swirl and mixing in the first stage, but increased temperature and combustion
intensity will result.
Swirl
A minor effect from swirl was noted for natural gas tests. In
general, a greater reduction was noted for greater percentage of total air
and/or for higher load. Both effects, separately or in combination, were
important and lead to higher velocities and probably more rapid mixing.
-60-
-------
The only exception is for increasing load at low air. In this case, increased
mixing may not be important since the lower oxygen concentration may limit
kinetics and thus the combustion reactions are not diffusion limited but
kinetic limited.
Quench
Coal showed a quench dependence which indicates a trend for greater
reductions in NO for either decreasing load or increasing air. There is in-
sufficient data to indicate whether a combination of factors also produces
the same effect. This could result from higher residence time and/or more
rapid combustion and therefore higher temperatures in a shorter length
(smaller volume) of furnace: this would then utilize to maximum efficiency
the cooling surface of the furnace and the quench rate and thus reduce the
overall tme for formation of thermal NO. Therefore, all that is probably
being observed is a quench of the thermal formation of NO and its subsequent
reduction due to decreased temperature and decreased time at temperature.
B. Data and Testing Effects
NDIR/TECo
The NDIR and TECo instruments are very easy to use and only require
minimum maintenance. Both instruments or one instrument and another method
of NO measurement should be used at the same time. Either instrument may
slowly drift away from the true NO measurement and require recalibration if
this problem occurs. An indication of problems is seen almost immediately
when the instruments do not agree on the NO measurement. The most common
problems encountered for the NDIR were:
1) Dirty cell, inability to calibrate with wide range,
insensitivity to changes in reading.
-61-
-------
2) Method of water removal (before systematic use of 34°F
water/ice bath), loss of NO.
3) Increase of temperature in final ice bath, increase of
NO reading.
The most common problems encountered for the TECo were:
1) Leaks from a broken capillary (the yellow capillary chipped
at both ends if the instrument was moved due to faulty
alignment of the tube ends).
2) Clogging of capillaries over long periods of time by a
"greasy" substance lowering sample flow.
3) Loss of total chamber pressure due to viscosity changes
in pump oil by using commercial pump oil.
Any of these problems for either instrument is easily correctable if it is
recognized. In our early testing, many of these problems occurred at once
and it was difficult to track them all down. Now preventative maintenance
has eliminated almost all differences between the instruments. Whenever
measurements are currently made, the instruments must agree within ± 10 ppm
or ± 5% (whichever is larger) or a problem is suspected and the situation
corrected. Calibration checks are made several times a day and no signifi-
cant drift for either instrument over a single day is noticed.
The only gaseous interferent observed for either instrument is
HJD which absorbs infrared like NO when measured by the NDIR. The
presence of CO with NO does not reduce the NO measurement, even when
passed through the heated stainless steel coil used for the NO^ conversion
in the TECo.
-62-
-------
Whittaker (NOX)
The Whittaker chemical cell NO monitor shows unreconcilable
differences when compared to readings from the NDIR and TECo during most coal
testing. It does not respond to the true NO levels in the flue gas. Although
it may read correctly at times, it does not do so consistently. When the
reading is in error (greater than ± 10% deviation), it always reads a value
higher than the NDIR and TECo. This higher reading cannot be reconciled and
it does not seem to involve the following:
1) Calibration - This has been checked even before and
after bad measurements.
2) S0? - Fresh Malcosorb and calibration steps rule
this out because of the very rapid response.
3) C0/C02 - Test gases with these, even when saturated
with water have no effect except at very high con-
centrations of CO (>1% CO).
4) PNA (polynuclear aromatics) - No hydrocarbons can
be found by gas chromatograph in even substoichiometric
flue gas.
For gas and oil firing tests, the Whittaker agrees very well with
the TECo and NDIR in most tests. In some tests (besides substoichiometric
tests), an inconsistent and unexplainable deviation occurs; this deviation
is always high. The Whittaker never adjusts as well as either the TECo or
the NDIR and usually shows greater differences from the "true" NO measure-
ment than either the TECo or NDIR.
-63-
-------
Impeller Position
The oil impeller position was found to be important during some
gas fired tests. Since this was not listed as a variable to be studied and
since there is no inpeller in position during coal tests, this variable is
only of minor interest and therefore is only mentioned in passing. The results
obtained showed:
NO Emission, ppm (all normal load)
Impeller Withdrawn Impeller Impinging
from Flame Front on Flame Front
High Air 314 (10% reduction) 283
Mid Air 332 (29% reduction) 235
Low Air 278 (30% reduction) 194
The effect appears to be predominantly a mixing/turbulence effect which allows
more rapid mixing, higher local oxygen concentration, and therefore more rapid
combustion. More rapid mixing would indicate higher peak temperatures but may
also yield a more rapid quenching of the flame by entrainment of recirculating
cooler flue gas. Since thermal NO formation is somewhat delayed in time from
peak temperature achievement, the result is a predominance of the lower quench
and therefore a lower NO emission level. In the case of high excess air, this
may no longer be dominantly diffusion limited but more kinetics limited and
the mixing effect is less.
Scatter in Coal Data
From day to day, changes in the NO emission levels for duplicate
tests occur. The causes of these changes are unknown. The following sugges-
tions have been made, but it is not known if they even contribute to the
problem:
-64-
-------
1) Air temperature (no air preheat in primary)
2) Humidity in air
3) Moisture in coal
4) Slight changes in fraction of total air used for primary
coal transport (changes primary air to coal weight by
much larger amount)
5) Barometric pressure fluctuations (could change velocities
in furnace somewhat)
The magnitude of these changes is usually less than the error
of measurement (± 5$) but can sometimes become ± 10%. It is not considered
a major problem however and has usually been ignored.
Carbon Loss
The carbon loss (opposite of burner efficiency) from the coal
fired tests on our unit (there is no observable solid carbon loss during oil
or gas fired tests on our unit) is dependent upon both load and air as seen
below:
Burner efficiency with increasing excess air
High Load Strongly Increases
Mid Load No Dependence
Low Load Slightly Decreases
(Net effect is decreasing burner efficiency with increasing
load for all air.)
-65-
-------
When the burner efficiency is plotted against the product of load and percent
of stoichiometric air, more scatter is evident. If the variable is load
divided by percent of stoichiometric air, there is a greater correlation
between this compound variable and burner efficiency.
The net effect is that carbon loss increases with increasing load
and decreasing residence time; the oxygen effect is therefore not unexpected
since although that also further decreases residence time, more combustion
occurs in that time due to increased 0~ concentration and faster kinetics.
C. Final Presentation
Table 7.1 shows the final results for the Phase I studies. This
table is used to indicate the effect of each variable on NO emission levels.
The number of pluses or minuses is only meant to be a relative indication of
NO reduction.
D. Interrelated Variables
Some of the variables are interrelated and should only be considered
in combination, (For example, see preheat and excess air effect upon preheat
as shown in Table 7.1.) In addition, many of the variables studied could be
defined by a new set of variables such as enthalpy content, temperature,
velocity, etc. It is possible that during Phase II, this will be tried during
the mathematical correlation.
-66-
-------
TABLE 7.1
RELATIVE EFFECTS ON NO IN FLUE GAS
Under Normal Conditions
Increasing Level of
Variable Coal Gas Oil
Excess Air ++++* ++/-- ++
Load ++++ 0 ++
Preheat (normal air) 0
(high air) +++
Flue Gas Recirculation --
Staged Combustion / — --/
(with FGR added-further effect 0 ---/ 0)
Quench -- no data no data
Swirl no data ++ no data
* + indicates increasing; number of +'s indicates magnitude.
- indicates decreasing; number of -'s indicates magnitude.
/ indicates maximum or minimum is reached.
-67-
-------
-68-
-------
VIII. CONCLUSIONS
The following conclusions have been derived from the work done in
Phase I for coal firing on the single burner test unit:
1) There is a distinct difference in NO emissions from coal
and gas attributable to fuel bound nitrogen.
2) The conversion of fuel bound nitrogen is directly pro-
portional to the level of excess air.
3) The conversion of fuel bound nitrogen is inversely
proportional to the level of air preheat.
4) Primary flue gas recirculation is insignificant in
reduction of.NO emissions.
5) A moderate reduction of NO from secondary flue gas
recirculation has been shown, although only thermally
formed NO is apparently reduced.
6) A minimum of 601 burner air (total burner to 1001
theoretical air) is indicated for staged combustion.
No further first stage reduction of NO would seem
reasonable at lower percentages of burner air.
7) A definite physical separation is required for addition
of the second stage air for reduction of NO. Progres-
sive mixing may be good enough. Even so, a separately
spaced second stage probably is required.
8) The same free radicals are responsible for conversion
of fuel bound nitrogen and thermal NO in the final
steps of NO production under substoichiometric conditions.
-69-
-------
The final conclusions to be drawn from the Phase I work shows for
coal testing on our basic combustion unit and applicable for single burner
units (no consideration of burner design is attempted):
1) Thermal/fuel bound nitrogen conversion NO emission
effects which are different. Conditions to change one
are not the same to change the other.
2) Flue gas recirculation is not the method which shows
most promise for new units for NO reduction.
3) For existing units, excess air level shows the most
promising means of controlling flue emissions of NO.
4) For new units, staged combustion and total air control
show the most effective means of reducing NO emissions.
5) The second stage air probably should not be added with the
burner air for greatest effect, but farther away in
separate NO ports.
-70-
-------
IX. FUTURE VK)RK
Appendix G includes the specific work plans for Phase II. The general
steps in Phase II will be:
1) Further testing
2) Data correlation
3) Construction of a new multiburner test unit for use in
Phase III
Phase III will be the testing phase for the new multiburner unit. Data
correlation will continue into Phase III also.
-71-
-------
-72-
-------
X. REMARKS (Recommendations)
The indications from the Phase I single burner, coal fired data show
several currently accepted philosophies will have to be modified if the EPA
emission standards for NO become lower for coal fired utility boilers.*
J\.
The obvious satisfactory NO reduction method for existing units without
construction or costly modification is control of excess air. This requires
lowered excess air, probably below 10% excess air. Another method for new
units is staged combustion. Again the requirement appears to be a separate
first stage with reducing conditions prevalent. Since these concepts require
a change in overall utility/manufacturing philosophy, there will be a long
period of salesmanship and education required to convert people to these
ideas. Much of the problem will be fears of increased corrosion (which may
or may not be substantiated in the future), increased carbon loss, decrease
in burner stability (which may or may not exist), slagging, etc. A general
discussion of the economics can be found in Appendix F.
* Most new coal units are being designed to meet current EPA limits. Many
existing coal units also currently meet EPA limits, but may be on the
borderline of acceptance.
-73-
-------
APPENDIX A
FUELS DATA, ANALYSES, AND CALCULATIONS
-------
A. Fuel Data
The coal used in all of our coal fired tests is an Ohio #5 and #6 seam
coal. The time lag for analysis is at least 30 days from the time of sub-
mission of samples from the tests. Therefore all calculations pertaining
to stoichiometry and load were carried out based on three prior, but recent
coal analyses. These three analyses, the average used in calculations, and
a later analysis are shown in Table A.I. Although the coal analysis in
January, 1973, showed some change in the coal analysis, the calculations
were not corrected since any error was considered smaller than the experi-
mental measurement techniques.
The natural gas analysis used is shown in Table A.2. The analyses first
used were averaged and all calculations based on these numbers. Later, a new
analysis was found and although the molecular constituents were about the
same, the density and BTU value were different and the new analysis was used
in all final calculations. The oil analysis is shown in Table A.3. Again,
the earlier analysis was used for preliminary calculations and the final
analysis was used for all final calculations.
In addition to those analyses listed, coal fuel bound nitrogen analyses
were also frequently run. Below follows the listing of these:
Coal
Date of Sample
Nitrogen, \ dry
Moisture
Carbon
10/25/72
1.05
--
--
11/21/72*
1.31
3.5
74.1
12/1/72
1.15
4.16
--
1/30/73
1.02
6.8
--
Coal was dumped from hopper and not used in coal firing tests.
A-l
-------
TABLE A.I
COAL ANALYSIS BVTA
MW Ub.
Serial No.
Date of Sample
\ Volatile
Fixed Carbon
Ash
t Total Moisture
BTU/lb, Dry
Ultimate. Dry \
C
H
N (determined)
S
Ash
0 (difference)
C-13688
V20/72
38.6
49.4
12.0
5.7
12290
69.1
4.8
1.1
2.8
12.0
10.2
C- 13689
S/9/72
58.1
48.7
13.2
6.4
12020
67.9
4.6
1.0
2.7
15.2
10.6
C-13692
5/15/72
59.6
49.2
11.2
6.3
12410
69.7
4.9
1.1
2.8
11.2
10.3
Average
used in
Calculations
--
--
--
--
6.13
12240
68.9
4.77
1.07
2.77
12.1
10.4
C-13762
(not used
in average)
1/18/73
--
--
--
5.4
--
72.8
5.0
1.1
--
7.6
--
TABLE A. 2
NATURAL GAS ANALYSIS
Type
Date
Mole i"
N,
c62
™4
C21'6
C3H8
C4H10
C6H14+
f>
(calc.)
ETU (calc.)
Columbia Gas Transmission Corp.
Pittsburgh Group, Steubenville
12/20/71
0.47
0.72
95.01
3.19
0.41
0.15
0.05
--
0.5864
1038.7
6/21/71
0.40
0.97
95.57
2.63
0.30
0.10
0.03
--
0.5835
1029.0
1/23/71
0.49
0.77
95.08
2.93
0.49
0.19
0.05
--
0.5872
1038.1
Average of
three groups
--
0.45
0.82
95.22
2.92
0.40
0.15
0.04
--
O.S8S7
1035.3
New Analysis
later used
12/18/72
0.40
0.78
95.84
2.54
0.30
0.11
0.03
--
0.5814
1030.5
*Sulfur bearing materials were small and therefore not entered into the calculations.
A-2
-------
TABLE A. 3
BUNKER C OIL ANALYSIS (16 RESIDUAL)
KW sample * F-680 (analysis used in final calculation)
I F-367 (analysis used in preliminary data)
Date of sample
Moisture
C
H
S
N (determined)
0 (by difference)
Ash
BTU/lb.
F-367
7/2/71
--
87.9
10.8
0.7
0.24
0.34
0.02
18S80
F-680
3/2/73
--
87.2
11.1
1.2
0.22, 0.23, 0.24, average
0.26
0.02
18620
0.23*
•These analyses for fuel bound nitrogen were run on samples taken at least
once a week.
A-3
-------
B. Fuels Analyses
No fuels analyses are done at B§W ARC for natural gas. All values are
reported to B§W by the Columbia Gas Company at regular intervals.
All of the important fuels analyses are shown below by method:
Moisture ASTM; heating and weight difference
in samples
BTU ASTM; bomb calorimetry
Total - carbon ASTM; collection of CCL in ultimate train
- hydrogen ASTM; collection of H-0 in ultimate train
- nitrogen Kjeldahl distillation and titration
- sulfur ASTM; bomb calorimetry washings as BaSO,
- ash ASTM; complete combustion and residual
weight
- oxygen By difference
C. Fuels Calculations
In the chemical description of the coal for mathematical purposes, all
•weight percent contents including moisture are converted to atom percentages.
The ash is considered to be SiO_. An ash analysis indicates large amounts of
A190X and Fe0CL and so the Si09 is a good average in molecular weight between
Lt O 2t «J £
A10, r and FeO, p. The fuel values on conversion show the following atomic
J. • 0 x • D
ratios:
A-4
-------
Coal - C = 54.049 Stoichiometric Air - N = 469.33
(wet) H = 50.973 (dry) 0 = 125.90
N = 0.718
S = 0.813
Si = 1.902
0 = 13.117
Oil - C = 7.2593 Stoichiometric Air - N = 74.929
H = 11.011 (diy) 0 = 20.100
S = 0.0374
N = 0.0164
0 = 0.0169
Si = 0.0003
Gas - N = 0.90 Stoichiometric Air - N = 1520.7
0 = 1.64 (dry) 0 = 407.91
H = 403.58
C = 103.88
The theoretical air requirement as used above can then yield a curve of
excess air versus oxygen concentration in the flue gas after combustion has
taken place. Suitable curves were chosen* rather than calculating each case
separately. The curves chosen are:
* Useful Tables for Engineers and Steam Users, llth Ed., 1969, The Babcock
Wilcox Company.
A-5
-------
Coal: If 0.0 <_ % 02 <_ 2.5102
(% theoretical air = PTA and % oxygen as
measured in the flue gas = POP)
Then PTA = 100 + 4.7279 (POP)
If % 02 > 2.5102
Then PTA = 100 + ^ (POP) + | (TOP)2
Oil: If 0.0 1 % 02 <_ 4.8522
Then PTA = 100 + 4.7279 (POP)
If % 02 > 4.8522
Then PTA = 100 + i (POP) + (POP)2
Gas: If 0.0 <_ % QZ <_ 2.4588
Then PTA = 100 + 4.7279 (TOP)
If I 02 > 2.4588
Then PTA = 100 + I (POP) + i (POP)2
A-6
-------
APPENDIX B
OPERATING CONDITIONS, MEASUREMENTS, AND CALCULATIONS
-------
A. Operating Conditions
Before any data runs for a day's testing commenced, the furnace was
warmed up and all instruments were calibrated. The furnace warmup period
was at least one half to one hour. During this time, all instruments were
zeroed and calibrated with at least one standard gas.
The NO instrumentation was always checked with at least three or four
JC
Matheson gas standards of ^200, ^500, "o800, and ^1300 ppm NO in nitrogen.
As standard tanks of gas near the point of being empty, new standards of the
same concentration are ordered with a certified analysis. These new standards
are checked against the old ones to verify the analysis before use as calibra-
tion gases.
The standard operating conditions selected for our basic combustion
tunnel are 115% theoretical air, 600°F preheat for the secondary air, and a
5,000,000 BTU (5 MBTU)/hour load or heat release rate. During all coal tests,
the natural gas igniter was operated at three Ib/hr and a heat release rate
of about 70,000 BTU (70 kBTU)/hr. The igniter was not used during natural
gas and fuel oil firing tests.
B . Calculations
The calculations used are based on the ASTM Fluid Meter Report, 1940.
The important equations are:
W = 358.9 (Dp KEY p AH
where: KEY = 0.935 (0.7 - D^)
273'16
and p_ - 0.0741
true »•«'-"• 0.55556 (T + 459.67)
B-l
-------
The air calculations for the furnace firing reduce for all inlets to:
459.6
Where:
Dry air inlet description
Normal primary air
Compressed primary air
(with primary flue gas
recirculation)
Primary air plus primary
flue gas
Normal secondary air
Secondary flue gas
Second stage air, normal
Second stage flue gas
Natural gas (for ptrue
replace 0.0741 with 0.0434)
2.25
0.75
1.625
D2
4.00
1.50
2.50
K, a constant
7028.
2808.
3911.
7.0
5.0
4.5
3.0
1.0
12.0
12.0
8.0
8.0
1.5
68689.
33601.
28110.
11785.
1127.
The addition of humidity in the air is easily accomplished:
WH20 = Wair
= W - ,/ 0.62133
clli
PSH20
Where:
WH 0 is the weight of water in Ib/hr
and W - is the weight of air in Ib/hr (previously calculated above)
3.1JT
B-2
-------
The ash sampling probe also reduces to the same type of equation whereby D,
is 0.625, D- is 1.5, and K is 525.3. For the natural gas igniter, the
orifice equation is:
10t0(0.61278 + log(NF)) . 21.3480(0.0072527 • AH *
(T + 459.7)
Although the form is awkward, it shows the flow meter/orifice constants.
B-3
-------
APPENDIX C
PRELIMINARY TEST DATA
-------
The preliminary data is presented in the tables on following pages. Sbc
series of tests were rim. Each series of tests is described by four tables.
The series of data are:
I. Base line coal tests
II. A. Primary flue gas recirculation - coal
B. Secondary flue gas recirculation - coal
III. A. More base line tests for coal
B. Staged combustion with coal
C. Staged combustion and flue gas recirculation with coal
D. Substoichiometric firing with coal
IV. A. All natural gas tests
B. All fuel oil (#6 residual) tests
V. A. Swirl tests with natural gas
B. Swirl tests with coal
VI. Quench tests with coal
The table headings are discussed below also:
Table 1 - Furnace input data in pounds per hour for the natural gas
igniter, fuel, primary air (used as transport air for coal
only), secondary air, second stage air, and flue gas re-
cycled. (The two numbeis for 1-1, fuel are 471/502 and
are respectively the fuel weight dry and the fuel weight
with normal moisture.)
Table 2 - Total amount of air, in percent of stoichiometric; the
heat release rate in 10 BTU per cubic foot per hour;
the total, averaged gas preheat for all air and any
C-l
-------
recirculated flue gas; the weight percent of flue gas
recycled; and the percent of stoichiometric air which
enters through the burner (primary and secondary summed
together).
Table 3 - The three NO instrument readings in ppm NO reduced to
.A.
3$ oxygen and dry for the Beckman NDIR, TECo chemi-
luminescence, and the Whittaker chemical cell; the
average of the NDIR and TECo expressed as ppm NO ±
the standard deviation of the average; and the con-
version of the ppm NO to pounds of NO (not N02) per
million BTU input as fuel BTU only.
Table 4 - The humidity and barometric pressure in mm Hg; the un-
corrected ("raw, as recorded") concentration of oxygen,
carbon monoxide, sulfur dioxide, and carbon dioxide;
and the ash loadings as weight percent of ash in the
flue gas (pounds of ash per hundred pounds of flue gas)
and weight percents of carbon and nitrogen as found in
the ash (pounds of total carbon and total nitrogen,
forms undeterminable, per hundred pounds of ash).
C-2
-------
TABLE C.I
TABLE C.2
IMIUl UStS ISfOliS I fOP COAL»
FiRMCE cat* (INPUT}
'•< li.lNM II
<1"IIS II II-.MIID
.if Jt'A 1 1 K.AM
- 1 II 1.2
£ II **2
- 3 II l.J
- 4 || i.l
- 5 II >.2
- 6 II «.<•
- 7 II ).2
• •' II ill
- lr II l.l
II
- ll II >.'
- 1? II 1.2
-11 II 1.2
- 11 II 3^2
- U II 3.2
- 17 II 3.2
- ID II 3.2
- 11 II J.I
- 20 It l.l
II
- 21 II 3.2
- 22 II 3.2
- '3 M 3-2
- 24 II 3.1
- 25 1 1 3.2
- 26 II 3.1
- 21 II 3.1
-If II l.l
- 21 II 3.1
- 1C II 3.1
II
- 1 II 3.1
- 2 II 1.2
- 3 II 1.2
- 4 II 3.2
- 5 l\ 3.2
- f II 1.2
- 37 II ).'
- IP II ).'
- 11 II 1.2
- *r 1! ).'
1 1
- 41 II (.2
- -2 II 3.2
- 41 II 3.2
LB.
tun.
48»/5?0
512/031
550/5. H6
274/212
301 /320
297/11 7
S5»/514
413/52!
2<7/')16
272/210
377/401
467/417
•1P/JI7
2flh/305
C12/6 2
511 /6 0
4R1/5 1
21B/3 7
4R4/5 *
212/J11
473/504
457/487
446/47t
574/612
2BR/306
471/502
573/61 0
45C /47S
451/411
4(1/447
466/602
Alb
666/717
678/7)2
•4 I/5C2
541/413
",!/'«4
oCe/641
<6W7C<
5ie/!i«
518/552
52C/556
605/643
163/714
517/556
683/721
676/725
(Cl/646
516/55?
6C1/647
514/556
65C/616
(22/661
614/655
654/7CI
'.4C/502
606/647
612/724
tCI/648
C2I/66C
C3C/60
696/1)1
il»
5517/514C
6468/4822
2051/22lf
3266/3531
2,5*2/2741
5210/5560
55U/5102
541V586C
2574/2751
2133/227)
4340/46K
54*6/5806
5522/5121
2125/22H5
5550/5125
6701/718C
4431/476C
2555/2771
4390/4716
2214/24(1
4411/4722
5352/56CC
3654/3916
5517/5101
3266/3516
541)1/5864
54*3/5772
3775/4017
*412/46fl6
34*1/3662
5451/5776
«M
O/ C
O/ 0
or c
O/ 0
O/ 0
O/ 0
O/ 0
o/ c
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
o/ c
O/ 0
o/ r
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
o/ n
O/ 0
o/ c
O/ 0
I/ 0
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
O/ 0
1 1
CAS II
1 I 1
C 1 1
C II
0 II
0 1 1
C 1 1
C 1 1
C 1 1
C 1 1
c 1 1
II
C 1 1
0 II
C | |
o II
0 1 1
0 1 1
0 II
1 II
c II
II
c II
0 1 1
0 II
c II
0 II
0 1 1
0 II
0 II
C 1 1
II
c 1 1
0 II
C 1 1
0 II
0 II
0 II
0 II
0 II
0 1 1
C 1 1
II
0 II
0 II
C 1 1
II
II
II
II
II
II
II
II
II
II
II
II
II
1 1
II
II
1 1
1 1
II
II
II
II
II
II
II
1 1
II
1 1
1 1
II
1 1
II
1 1
II
1 1
II
1 1
II
1 1
1 1
II
1 1
II
II
II
1 1
II
II
1 1
II
<.!5.1
1 1 1.0
IK. 7
111.1
IC3.3
US. 5
141.0
1C).?
116.3
1»!.K
14C.C-
Mi. e
K5.2
1 11.1
IC4.1
117.0
1C1.7
/ H«.
51 .15
52. 5f
50. 1C
53.ec
54.62
50. «1
64. CO
66.41
31.65
31. ««
21.6!
i.ti
2.46
».6«
«.C1
7.31
50. 3C
52* 11
31.20
it. 11
11. «
52.11
65. 7»
70* fl
65. >1
60. 7$
t».6<
51.56
11 .It
41. J8
J1. 71
S1.17
50. 61
47.6)
6?. )!
11.91
'2.50
62. Cl
4H.96
47.47
.).*«
5<.02
51. J2
tic. f
6C*
1.21
587
611
HI
412
62C
647
6C5
57C
514
515
96«
6l«
114
371
31)
)9S
3 4
1 «
1 7
6 1
6 1
547
407
501
5)4
505
470
274
263
32S
5««
515
5!3
527
563
54C
611
)7(
154
373
361
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
| |
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
| |
II
1 1
II
II
II
II
III
0.0
0.0
0.0
0.0
0.0
0.0
3.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0*0
0.0
0.0
C. 0
0.0
0.0
0.0
0.0
0.0
n.o
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
o.c
0.0
0.0
0.0
n.o
0. C
U.O
0.0
0.0
It)
116. 1
14.'. 0
101. 1
112.4
114.1
101.1
II'. o
1 17.0
101.'
II). 1
101. '
136. C
III. 1
114.2
112.1
111.4
1 40.0
KS.l
111.1
1C4.4
1 W.O
140. n
II'. 1
">.l
110. 1
103.1
11 .1
11 .0
11 .7
11.1
1-3.1
1 .*!
1 1 ."
1 «.2
1 ' . I
1 1.1
1 ,>.0
1IS.P
l\->.t
ll">. 1
10*>*1
HI. 6
1CI.7
II
1 1
II
II
II
II
II
II
II
II
j j
II
II
II
1 1
II
II
II
1 1
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
II
C-3
-------
TABLE C.3
TABLE C.4
INITIAL USTS ISfMFS I FTP COAL)
hOX "f Ireful MS
IMI1*L TESIS
II tin IIS -
II -IIS 1-^
I 1
II
II
1 1
II
1 1
1 1
II
II
1 1
II
1 1
n
1 1
u
1 1
u
i
i
i
j
i
|
| |
I |
| |
| |
II
II
I I
| |
| |
| |
II
I |
| |
II
1
- 2
- >
<.
- 5
- e.
j
t
<;
- lu
- 1 1
- t 2
- 13
- 1 *
- I \
- It
- 1 7
- I P
- 1*1
- ;c
- 2 1
- 22
- 2 3
- 24
- ? ;
- ?t
- .' 7
- ?fl
- tf>
- 1C
- 3 I
- H
- ) S
- "
- 17
- if
- 1
P42
Hi
SC6
:<•?
537
775
6<3
4:2
I1H
I5C
<.24
7K
)23
77C
<4C
t>8«
442
5PO
> ? I
734
714
747
«7i
847
570
149
464
777
Se 3
ItCU
738
ISC
430
761*
1C54
12>
lO'll
IS!
*54
842
673
343
f 70
fit
I04(.
AC
74
72
11
66
41
A2
i*"
7.'9
7B4
7M
118
»22
546
*28
431)
751
4H
Khlt
79C
10?>
5»1
8L1
I1CI
•IT4
1 <2I
506
C13
116
731
547
127
1*4
1C94
495
4 SO
7>75
1112
157
4H»
717
524
>2I
fi
ac
9t
Rfl
<2
717
«1
M4
570
|[
II
II
II
II
II
II
II
II
II
1 1
II
II
II
II
n
1 1
n
n
1 1
u
1 1
ii
1 1
n
n
n
u
!!
1 1
1 1
u
n
1 1
n
n
ii
1 1
pov.
FlUt
725
113
431
114
14 a
746
5S*
212
540
j<. •
f * •
420
814
321
185
111
7«2
746
<*6
676
4211
601
112
711
7«1
749
522
834
55f
731
449
764
509
31 P2
CIS
1 1*
i •>
•
1 '
t f>
• 10
1 11
1 C
•- I."
• »7
.' l«
1 «5
£ 51
t «
t *
• I
J -i
I »
£ »
i 1«
t 70
1 1C
t '
t
t 1
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-------
TABLE C.5
TABLE C.6
HIK r.AS CICIICUIAIIO. ItSU ISEPIfS II fC« CUAll
notice CAM dhBuii
lilt CAS 3K l««Jl»t U> USIS littltS II K« C01LI
HJRNACI CAIA IflMll
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n n
HIM- 1 II 1.1
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1 1 1 11 - 7 1 1.0
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1 1 1 1 i - 1C 1 l.C
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1 1 1 U - 11 II l.f.
1 1 II A - 12 II ). 1
1 1 IIA - 1 1 II 1.1
1 1 111 - !<• II <.!
1 1 1 1 A - 1' II I.I
1 1 1 1 A - 1 1 II 1.1
1 1 III - l» II I.I
1 1 1 1 A - 1 -. II 1.1
1 1 111 - 2C II 1.1
II II
II 111-21 II *.l
1 1 IU - il II 1.1
1 1 111 - i\ II 1.1
11111-24 || 1.1
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1 1 1 U - 27 || 1.1
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1 1 tin - 1 II l.l
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1 1 ll.l - •> |l ). 1
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1 1 1 1 - S II 1.2
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1 1 II -11 II ).2
1 1 II -21 II 1.2
M II
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1 1 1 Ih - 27 II 1.2
fuu
476/507
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445/4 74
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471/502
257/1K
464/SOO
406/576
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475/612
571/611
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4e 7/497
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415/50*
45E/488
447/4.77
214/3C;
277/3-M
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547/581
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t01/63t
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17I/4C7
60 t/654
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C05/6S7
6?6//>77
37S/414
601/650
37I/4C7
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472/721
5II./S76
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525/568
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12 fl/Sft6
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607/6%6
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606/t4*]
60A/644
«14/(57
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524/Sif
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675/117
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4414/472P.
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4068/434C
6670/7|)a
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546S/604I;
427S/47M
247C/274K
427A/47)!
5162/5004
5)62/54CO
67)0/ 72 17
6802/7)111
5512/5POI
5519/5017
25)5/2727
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420B/45C7
2040/2J4)
2041/224)
4450/4674
2042/21 't
4452/4MP
Sell/6250
5551/59)2
J8I4/40K)
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-------
TABLE C.7
TABLE C.8
ftl-i r,t-, ifCIBCul»rICK 11SIS lifslfi II FCO COil I
KCI »i»Sl,»£«!MS
U»
J
A
q
n
n
12
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740
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-------
TABLE C.9
TABLE C.10
CLfPUST ICN Tt^T«, IStftHS 111 I-CR U.M I
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- - II 137.1
- 1 II IC2.*
- - II 11). 0
s 1 1 i itf.C
• ' H 103,1
- T || in.'
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9 II IC2. J
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I |
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- i> M in,:
- 14 l| | JS.l
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- l« 1 1 II).?
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•in ll M). ;
- !•» 1 1 11). 7
- .'l> II 115.6
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- ?4 1 t I 14, 3
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II
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- - 1 11 76.4
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67 .9 |
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pai- it XECVCU?
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0(&. F M III
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tf «: i 1 J.o
loi ii r.G
1C1 II 0.0
ICO II O.C
6b« II 0,0
671 II 0.0
C6S II O.C
m ii 3.0
1 1
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1.) II 0.0
!>c II 0.0
)4« tl 0.0
)tC II C.O
n i ll o.o
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frfl* II ? 7 . 1
O8b 11 I •*. ^
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6T< II M.I
676 II .'6.*.
b6o 11 ^ '.*
64« II 30,%
6SI II U.O
662 II 0.0
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6X II ?6.l
6.0
664 | | M.6
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66t |l 2 ' . ^
i. «J 6 |l 0,0
711 || 0.0
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6Ffl 11 1.0
I i
f>fP H 0.0
608 II .'.0
OS J II 0.0
t«* II O.C
64« t 1 O.C
f S 1 II 0 . C*
:•':•, II 0.0
'CO II 0.?
Mfi t' ;
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it) <
1
1
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1 ' . 7 1
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C-9
-------
TABLE C.I5
TABLE C.16
NJTUDAl CAS ItStS ISIRIES IV Al
IOII.XL ..AS 76
- 2 1 1 !»
- 1 II >to
- -II 3C8
- 5 II )IO
- 0 II 2!0
- Ill ICO
- Ill 3C7
- Ill 245
- 10 II 1-0
U
- 11 II I3S
- > II I?'
- 3 II 145
- 4 II I 30
- s || i;s
- 611 140
- '11 III
- » II 1*2
- 9 tl '3
- la 1 1 >o
II
-/ill si
- 11 1 1 (3
- 21 II !6
- M 1 1 0
- 2s II n
- it II J42
- !' II 2'.;
-
-
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-
-
-
-
-
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411 1 76
ell <;o
II
111 '.)
2 II MO
311 It
4 II 225
s II 112
6ii 72
'II >J5
d 1 1 248
1 II IS'
en ;<6
II
1 II I'.tl
2 II 12*
311 S3
* 1 1 !32
•> II 2ifl
• II I")
' II 2r3
It il 1/0
•I 1 1 >I.S
31
11
26
30
30
1*
30
31
MS
146
131
no
1*3
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15)
lilt)
136
AS
70
*,!
56
30
43
21
'•0
260
25
teo
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31
7
21
1?
6
33
?7
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<«3
252
1?"
SI
332
2)3
181
212
icr
2«1
n
350 II 322 1 S
349 II 320 • 4
29-. II 267 1 1
34S || 30» 1 0
152 || 310 • 1
2»« 1 1 249 • 2
331 II 303 • S
143 II 311 • 6
212 1 1 245 1 0
1*1 II I4B • 3
tl
l/'K | | 131 1 6
12' 1 1 Ul 1 6
149 II 1*4 • I
139 II 12' 1 «
I2t II 12« ; I
U7 II 156 1 S
in ii io« i 3
ISO II 131 1 «
SI II «* 1 2
art 1 I 7*» '
1 1
"311 «7 1 '
Mil 60 • S
«6 II 33 1 «
5" II S» 1 16
3111 2t • «
)S6 II 346 1 6
251 1 1 256 • S
2111 23 t 2
1>? II 178 t 3
fl<> 1 1 40 1 0
II
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3C1 II 110 1 0
3111 2« 1 1
2^0 1 1 220 1 7
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1 1 1 1 70 1 >
122 II 310 • )
.>£•> II 269 • i
IHII 19B i 1
3S« II 365 i I
II
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211 1 1 114 • 1
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I0»6 HIU 1 I
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II
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0.21 1 .0 II
0.27 : .0 II
0.33 • .0 II
0.20 • .0 II
C.27 1 .0 II
0.33 £ .01 II
0.20 • .0 II
0.11 1 .0 II
II
0.14 . .01 II
0.10 • .0 II
0.13 1 .0 II
0.13 i .0 II
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0.01 t .0 II
0.141.0 II
0.04 1 .0 II
O.C7 J .01 II
| |
0.04 1.01 II
0.05 • .0 II
0.03 1.0 II
0.05 i .01 II
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O.)0 1 .0 II
0.22 1.0 II
0.02 1 .0 II
C.IS 1 .0 II
O.OS i .0 II
II
0.05 1.0 II
0.27 1 .0 II
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0.19 1.01 II
0.09 1 .01 II
0.06 1 .0 M
0.34 i .01 II
0.27 1 .0 II
0.20 * .0 II
0.32 1 .0 II
II
0.19 1 .0 11
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0.30 • .0 II
0.21 i .0 II
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0.23 • .01 II
0.13 1 .01 II
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C-10
-------
TABLE C.I7
TABLE C.18
usi< tstHJFS u a»
tHNJCt CAT* CISPt'T)
Cll TESTS (SERIES IV al
t-ijOMCt CAT* IFIKAO
I I C.H I ill Nil
-r. / h£i toT.»
; RU.S . fl'.r, 1 1
l I'f KoKS | 1 I(,A$) 1
i 1 1
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1 i v rt- i 11 U.O
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1 V r - <• II C.C
1 v "- *. II C.O
i v e - o it c.c
1 v P - ? II 0.0
1 V H- H II G.O
I vi'- « 11 O.C
1 V * - 1 U II 0.0
1 1 1
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1 V H- U II C.C
1 v 'l - 1 1 11 C.C
I C rt - U 11 O.C
I V •»- I S || C.C
1 v f' ' 1 ' 1 1 O.C
1 V 1' - 1 7 || O.C
1 v t*- 1 P 11 0.0
1 v (• - H II C.C
1 V K- 20 II 0.0
1 1 1
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1 v n- 2t- II c.c
1 V H- ^ 7 || 0,0
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1 1 1
1 V Ii- i 1 II U.C
II V o - 3 .' 11 C.O
II v K- 3 1 II C.C
|| v P- !*• M C.O
J I v h- U |l C.O
II v B- U II G.O
II v tt- l° 11 0.0
11 V M- lr< II O.C
|| V B- 40 11 0.0
II II
11 V l- *.-' II C.O
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1
1
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31 4/31 <•
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310/3K
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311/311
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37e>*/4 IOC
2761/1016
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3122/1AOE
3606/ 392f>
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870/^30C
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6*?/frl57
390/*?96
385/vTee
60n/6S73
6020/6S6*'
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3* 78/1911.
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79||
1)911
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II
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v a- a II
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1 1
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f 1 AL I
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PHI- II OfCTCF-iC
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II
t» II 0.0
666 II 0.0
6^6 II 0.0
>C! II 0.0
691 II 0.0
6^6 1 1 0.9
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1 1
6CS 1 1 0.0
H> II 0.0
xor. II 0.0
ot« II 0.0
674 II 0.0
if: II 0.0
3»« II 0.0
lit II 0.0
it; ii o.o
II
H< II 0.0
111, II 0.0
Kl II 0.0
?SS || C.O
6<98 II 0.0
6PC II ^4. II
et.o II
F4.I II
flo.4 11
103. 7 ||
64.9 1 1
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77.0 1 1
76. R 1 |
C-ll
-------
TABLE C.19
TABLE C.20
Cll TiSIS I'tnlES IV 81
II c
II S
II I
"fulfill II PPF NfJX )| 02, QHV 11 »f»N HOt I*
»• '-S II >.[!« | IICO
II II
11
II
II
II
II
II
1 1
II
II
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1 1
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II
II
II
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II
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II
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1 1
1 1
1 1
II
II
II
II
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1 1
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1 1
II
1 1
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rt- ^11 2*9
0- > H 2SC
It- 4 II 2)7
a- s | 1 211
8- A II 24C
1-- 7 II ]4)
0- « II 2^5
e- 1 II It'.
»- 10 II 1C!
II
»- 1 II 1H>
b- < II 111
»- 1 II III
»• 4 II 1
221
217
176
2»8
218
241
232
211
194
I7S
2*2
211
212
HI
244
223
2CI
201
171
U9
259
2)8
209
209
146
203
143
128
234
211
khlt || FLUt GAS
II
251 II 257 j »
271 II 274 £ 7
1IC II 300 1 14
244 II 23« t 1
222 II 210 t 2
297 II 2*9 1 I
1)1 II 54} 1 0
267 II 2*3 1 2
24? II 284 J C
216 II 200 1 2
II
297 II 279 . 2
114 II 319 1 2
244 H 222 1
221 II 212 i
246 1 1 24* £
IM || 173 1
225 II Z19 i
2»4 II 253 1
178 II 174 t
117 II 111 t
11
21? II 218 1
23C II 220 1
194 Ii 182 t
24S II 263 1
27} II 260 1
248 II 244 1
248 II 239 1
266 11 2*6 i
197 I) 193 1
114 II 174 1
1 1
267 || 252 1
1C) II 282 1
222 1 1 214 1
1«7 H 152 3.
273 II 255 1
237 II 224 1
214 II 203 1
216 II 205 ± 5
IM II 115 1 3
171 1 1 172 i 4
11
269 1 1 262 1 >
238 II 241 1 *
214 || 211 i 4
214 II 21) t 4
149 II 198 1 1
2C4 1 1 204 i 2
148 II 144 • 1
ill II 127 1 2
245 II 215 1 1
210 1 1 21) J 6
L>. KOI / II
I0««6 »TU 1 1
INPUT ||
II
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0*2? j "" *'
0,29 |
0.21 J
0.19 J
0.12 J
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0.24 j
0.31 1
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0.34 i
0.19 1
0.20 ;
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0.16 i
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0.21 j
0.21 1
0.17 |
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0.14 1
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0.2*
0.2)
0.21
0.21
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0.19
0.36
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.01 II
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.0 II
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II
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C-12
-------
TABLE C.21
TABLE C.22
ItSIS l 1 1 C.O
' 1 1 0.0
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1 1
III O.C
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TABLE C.23
TABLE C.24
ASO 0 IS f LH COAI I
11 SI
1 1 »(.
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617
625
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TABLE C.25
TABLE C.26
tlthCM ItSIS *CR CCAL (SERIES Vll
fURNACE CAT* IIKPljT)
CG*l (SF8HS vll
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TABLE C.27
TABLE C.28
if us f ID (C*i tscmts
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C-14
-------
APPENDIX D
PRELIMINARY DATA PLOTS
-------
The data plots are split up inter two groups. First, the original data
points are plotted arid the appropriate data line(s) drawn to describe the
points. Secondly, a blank graph is presented with the "normal", mid air,
mid load data line drawn on it. The data plots require the grouping of data
into variable ranges which are defined below:
Variable Range
Low Mid High
Excess Air, I <7.5 7.5-25. > 25.
Load, % <100. 100. -125.* >125.*
(kBTU/ft3/hr < 40. 40. - 50.* > 50.*;
Preheat, °F <450. 450. -550. >550.
These data groupings, although arbitrary, recognize the fact that data were
gathered at the extremes and center of the variable ranges studied. The
representation of these ranges is:
Variable
Excess Air, %
Load, %
Preheat, °F
Low
^ 3
^ 75
^350
Range
Mid
^ 15
-x-115
-^500
High
*> 35
^140
•^650
The lines which are drawn through the data points are "eyeball" fits
and are simply used to describe the apparent trend of the data. These lines
are done from visual fitting and no mathematical correlation has been used.
* For natural gas only, the value is 130% instead of 125% (or 52. kBTU/i't /hi
instead of 50. kBTU/ft3/hr).
D-l
-------
The simplest form of line has been drawn through the data points - straight
where possible.
The graphical descriptions follow:
Graph #'s Comments
1-3 Solid line - high preheat - curved line required
Dotted line - low and mid preheat - curved line
required
4-6 All data on graph described by one line
7-12 Normal mid air or mid load and high preheat line
13-18 Solid line - low range of air or load
Dotted line - mid range
Dash/dot line - high range
19-24 Normal mid air/mid load line
25-30 For excess air, a curve was used for data
Solid line - low preheat
Dotted line - high preheat
31-36 For all graphs except #31, one line was used to
describe all data even though slight, differ-
ential, consistent trends do seem to exist.
The line drawn follows the trend of mid air
or load since this condition is "normal."
In graph #31, the solid line is low excess
air and the dotted line is mid/high air.
37-48 Normal trends for mid air, mid load, and high
preheat ranges.
D-2
-------
Graph #'s Coinments
49-51 Solid line - low preheat
Dotted line - high preheat
52-54 Line follows trend of normal higher preheat -
second line not drawn to avoid confusion
55-60 Line drawn follows trend of mid air/load range.
Other lines not drawn to avoid confusion
although separate trends are observed.
61-72 Normal trends for mid air, mid load, and high
preheat ranges
73 Dotted line sets off an area of possible NO
•reduction bounded by "zero" line and dotted
line. Scatter in data makes true reduction
unknown.
74-76 Single line seems to describe all data equally
well
77 Composite curves - solid - coal
dotted - gas
dash/dot - oil
78 No single line would suffice for all data
79 Solid line - describes front slot staging
Dotted line - side slot staging
Hatched line - substoichiometric
80 No single line describes all data
D-3
-------
Graph #'s Comments
81 Solid line - staging (front slots)
Dotted line - staging with burner flue gas
recirculation
Dash/dot line - staging with port flue gas
recirculation
Hatched line - substoichiometric
82 No single line drawn through all data
83 All front slot data represented by one line
84 Solid - coal
Dotted - gas
Dash/dot - oil
D-4
-------
.
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5TOICHIOMETRY flT BURNERS, 7.
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APPENDIX E
MATHEMATICAL DERIVATIONS AND CALCULATIONS
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Initial calculations are done by- computer and yield the weight of fuel,
air, and natural gas from the igniter including any moisture if present (see
Appendices A and B). In addition, the percentage of theoretical air is calcu-
lated. For large amounts of combustibles (>3%) in the flue gas during sub-
stoichiometric tests, a gas chromatographic sample is analyzed for CO and H~
Li
(and CFL) for coal fired tests to determine equivalent combustibles as 00; and
for natural gas tests, the equivalent CO is hand calculated since both fuel
and air are metered. (The equivalent CO for combustibles assumes all
combustible is present as CO for ease of excess air calculations - H~ and CO
both require 1/2 02 and no other combustibles are found in the flue gas
except solid carbon in coal tests. Since the unburned carbon in all coal
tests is relatively constant, it is ignored in these excess air calculations.)
The flue gas recirculation is calculated by taking the ratio of flue gas
recycled to the total weight of fuel and air in the combustion:
FGR = 100.0 x
W'
fg
The criterion for staging is the stoichiometry at the burner which is given
by:
x FB
100.0
where FB = W,/Wa
6 a
In addition, corrections are applied to the NO instrument readings
X
for C09 and H70. The following series of constants are used:
E-l
-------
Constant Used
Coal
Gas*
Oil
Wt of fuel
Wt of moisture/
O . JOO
6.13
J.O.HO
0.0
LJ. /I
0.0
100 Ib fuel
MF .
1
MA .
1
MM .
MC -
f MFI
MFR
t,
\ mi
MAR
.
' MMI
MMR
{ MCI
MCR
0.6298
0.3154
0.5694
0.2976
0.1192
0.02549
0.06135
0.05405
0.6315
0.6315
0.5709
0.5709
0.1197
0.1197
0.06138
0.06138
0.6298
0.5028
0.5694
0.4752
0.1192
0.05506
0.06135
0.07259
The equations are thus given as:
1M = MF
where MF = MFI x W + MFR x W
MA = MAI x
WNI +
MAR x Wr
= MA x
H2°
* Gas analysis used for coal and oil igniter firing is slightly different from
latest used for gas firing. Difference in final calculations using old gas
analysis for igniter is insignificant.
E-2
-------
WMF = 0.0613 Ib H20/lb coal (only for coal)
FC02 =
TM
MCI x WXTT + MCR x
_ NI
TM
mi x WMT + MIR x Wr MMH + MMF
Corrections applied to the NO instrumentation are:
Jx.
Whittaker: Multiply by (1.0 - FH20 - FC02)
TECo: Multiply by (1.0 - FH20 + 0.012117V (1.0 - FH20))
NDIR: Miltiply by (1.0 - FH20 + 0.0065342*7(1.0 - FH20))
after subtraction of 50 ppm correction due to water
absorption.
(The NDIR correction due to water absorption at 34°F saturation was determined
experimentally.)
For all: correction to dry, 31 02 in flue gas, multiply by:
18.0 1
FT x (21.0 - POF) X (1.0 - FH20)
The average of the NDIR and TECo, Aver, was calculated by:
Aver = ^rnr
and the standard deviation, STDV, by:
* Saturation factor at temperature of measurement.
Infrared absorption correction for actual water content of sampled flue gas.
E-3
-------
STDV
= J (NDIR - Aver)2 + (TECo - Aver)2 = ^ 2.0 x |TECo - Aver)
The BTU value from the fuel enthalpy release is given hy three equations,
one for each fuel:
Coal : BTU = 23855 x WNJ + 11533 x W£
Gas : BTU = 23920 x (WNI + W£)
Oil: BTU = 23855 x WNI + 18620 x W£
The air and recycled flue gas preheat adds enthalpy to the flue gas during
combustion also. This addition is given by (no primary preheat):
BTUG = BTU + W x BTU + QM x W f x 18.016 +
3. 3. -T
(MNfl + MvtF) x 18.016) x BTUm + W' x BTUf
where BTUa = (TAG - TA) x (0.240 + 10"5 x TAG)
BTU^ = (TAG - TA) x (0.444 + 2 x 10"5 x TAG)
and BTUf = (TFG - TA) x (0.252 + 10"5 x TFG)
For correction of ppm NO at 3% CL, dry flue gas conditions to Ib NO, (as NO)
-X £ A
per million BTU (fuel BTU only) input, the NO value is multiplied by:
(No conversion constant is necessary since BTU and ppm must both be divided
by 106.)
In conversion of load percentages to thousands of BTU per ft per hour,
the factors to be remembered are:
E-4
-------
1) furnace volume - vL27 ft (8 ft long, 4.5 ft diameter)
2) 100% load E 5,000,000 BTU per hr
and therefore if million BTU load is divided by 0.1272, the result is in
kBIU/ft3/hr.
For calculation of the fractional reduction, L,, of the measured values
L, (base point) and L,, (reduced value with reduction modification in firing
test):
and since the values were
Li±Li
and
L2±L2
then
2 + L'2]2 ffL -L!
4 j + |L1 L2]
Li
The calculations as used in data tables and graphs do not yet include
conversion to the Si/metric system. It is intended that these conversions will
be made during the later contract work when required by EPA.
E-5
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APPENDIX F
PRELIMINARY ECONOMICS ON FIELD UNIT MODIFICATION OR CONTROL
-------
Reduction of NO by Field Unit Modification or Control utilizing the data
Jx
from this report would have to be discussed on a preliminary basis only.
Although the trends from the single burner test unit are useful, the magnitude
of these trends might not hold on large field units with many burners. The
limit of control used on the basic combustion unit may also be outside the
practical range of large field units. Preliminary economical analyses are
included for the best methods of proposed NO control:
Jt
1) Control of excess air - Pulverized coal fired units normally
operate in the range of 15% to 30% excess air for control reasons.
Operation at low excess air may present difficulties. Problems
which need to be solved are, for example, the slagging from
Eastern coals or excessive carbon loss.
2) Load/Rating - There is this capability in existing units. The
cost of adding lower efficient units must be considered as
the cost for making up for the loss of electricity from reduc-
tion of load on the operating units.
3) Preheat - This must be balanced against the combustion effi-
ciency since carbon and stack losses in the field increase as
preheat decreases. In addition, burner stability for safe
operation may limit the amount of preheat reduction which is
permissible.
4) Flue gas recirculation - The greatest problem appears to be
the needed capacity for moving this flue gas around. Increased
capital costs and operating costs are unavoidable. In addition,
erosion may be accelerated.
5) Staged combustion - Two problems immediately evident are slagging
and potential corrosion in the reducing/oxidizing boundary zone.
The progressive mixing concept might hold greater promise as a
compromise means of staging so that reducing gas would be kept
off of the metal surfaces.
F-l
-------
APPENDIX G
PHASE II - WORK PLAN
-------
Future Work Plan for Phase II
I. Task I Data Correlation/Further Firing Tests
A. Data Correlations (NO and combustibles)
1) Computer analysis of data - preliminary
2) Firing tests to fill data gaps
3) Correlation to find quantitative trends
4) Further testing where uncertainty exists or for further
information such as substoichiometric firing, etc.
B. Further Testing
1) Optimize most important trends from A - Detailed data correlation
2) Test two additional coals with different fuel bound nitrogen
3) Further quantifying tests as time permits, e.g., fuel bound
nitrogen conversion, etc.
4) Prepare a preliminary operator's guide manual for application
of technology to existing units
C. Reporting, Monthly, and Final
II. Task II Construction of New Multiburner Unit
A. Justification Report
B. Design
C. Purchase of Materials
D. Construction and Site Preparation
E. Preliminary Testing
F. Reporting, Monthly, and Final
G-l
-------
PLJ
H
CO
<
— c\Jro
-------
BIBLIOGRAPHIC D/»TA 1. f\: port No. 2.
SHEET EPA-650/2-74-002a
3.NEJecip:enc's Accession No.
4. lii'n,- ,mJ Submit "y. Report Date
Effects of Design and Operating Variables on NOx from January 1974
Coal-Fired Furnaces -- Phase I
7. Author(s)
W. Joseph Armento
9. Performing Organization Name and Address
Research and Development Division
Babcock &Wilcox Company
Alliance, Ohio 44601
12. Sponsoring Organization Name and Address
EPA, Office of Research and Development
NERC-RTP, Control Systems Laboratory
Research Triangle Park, NC 27711
6.
8- Performing Organization Kept.
No.
10. Project/Task/Work Unit No.
ROAP 21ADG-41
11. Contract 'Grant No.
68-02-0634
13. Type of Report & Period
Covered
Phase I, Final
14.
15. Supplementary Notes
16. Abstracts rj.^ report gives results of Phase I of an ii
modification techniques for controlling NOx emissior
utility boilers. The techniques --studied on a 5-milli<
unit—included: excess air; air preheat; rating; flue g
ustion; quench; and swirl. The study showed that NO:
possible either using staged combustion or by loweri
zero %. Flue gas recirculation yielded only moderate
nitrogen conversion increased with increasing excess
erature. At substoichiometric conditions, the final p
either fuel-bound nitrogen or thermal atmospheric fi
existing units , control of excess air promises to be i
however, for new units , staging (with physical separ
17. Key Words and Document Analysis. 17a. Descriptors tO 1
ATT T^nlliifinn ....
Nitrogen Oxides
Combustion Control
Coal
Combustion Chambers
Flue Gases
17b. Identifiers/Open-Ended Terms
Air Pollution Control Excess Air
Stationary Sources Quench
NOx Reduction Swirl
Staged Combustion Fuel Nitrogen
Flue Gas Recirculation
Air Preheat
17c. COSATI Field/Group j^g ^ 20M, 21B
18. Availability Statement
Unlimited
ivestigation of combustion
is from pulverized- coal-fired
Dn Btu/hr single-burner pilot
•as recirculation; staged comb-
's reductions of up to 50% are
ng excess air levels from 30 to
3 NOx reductions. Fuel-bound
5 air level and decreasing temp-
recurs ors for NO formation from
xation appeared identical. For
:he best method for NOx reduction;
ation of the two stages) appears
DC the most promising.
19. Security Class (This 21. No. of Pages
Report) •,(••,
UNCLASSIFIED ±V5
20. Security Class (This 22. Price
Page
UNCLASSIFIED
FORM NTIS-35 IREV. 3-721
THIS FORM MAY BE REPRODUCED
H-l
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