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ENERGY OF HEAT • ENERGY OF LIFE • ENERGY OF SOLUTIONS

LOW-COST TECHNOLOGICAL METHODS TO SIGNIFICANTLY REDUCE NOx FOR COAL-FIRED BOILERS Felix Serant , Evgeny Russkikh SibCOTES Anatoly Smyshlyaev - EC ZIOMAR POWER-GEN EUROPE June 200 7. ENERGY OF HEAT • ENERGY OF LIFE • ENERGY OF SOLUTIONS. 1. CONTENTS.

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ENERGY OF HEAT • ENERGY OF LIFE • ENERGY OF SOLUTIONS

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  1. LOW-COST TECHNOLOGICAL METHODS TO SIGNIFICANTLY REDUCE NOx FOR COAL-FIRED BOILERS Felix Serant, EvgenyRusskikh SibCOTES Anatoly Smyshlyaev - EC ZIOMAR POWER-GEN EUROPEJune 2007 ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 1

  2. CONTENTS Problem of nitrogen oxides formation and the concept of horizontally-and-vertically staged combustion Results of the application of horizontally-and-vertically staged combustion systems Results of the application of horizontally-and-vertically staged combustion systems with OFA(with coal and gas reduction stages) Main conclusions ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 2

  3. NITROGEN OXIDES FORMATION NOx concentration, mg/Nm3 up to FURNACE TECHNOLOGIES SNCR SCR Temperature range for the application of different methods ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 3 Capital costs: 90-140 $/kW Capital costs: 10-30 $/kW Capital costs: 4-10 $/kW

  4. CONCEPT FOR NOx ABATEMENT Lower percentage of primary air Active recirculation of high-temperature furnace gases NOх emission reduction Longer resident time within the reducing zone for coal particles Intensive mixing of burning pulverized coal with secondary air Lower temperature level ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 4

  5. TWO-STAGE COMBUSTION SYSTEM AT TOM-USINSKAYA POWER PLANT, RUSSIA Symbol Bituminous coal Wr, % 11.5 Ar, % 21 Nr, % 2.1 Sr, % 0.3 Q, kJ/kg 20072 Vdaf, % 40.0 ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 5 Sec.pl.s/h Boiler front Sec.conv.s/h Trans.zone ECO Tubular a/h-3 Tubular a/h-2 Tubular a/h-3 MODEL RESEARCH 1 - PC burners 2 – Oil burners 3 – Secondary air ports 4 – OFA ports

  6. RESULTS RECEIVED AT TOM-USINSKAYA POWER PLANT, RUSSIA ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 6 Excess air: On burners b= 0.74-0.80 Downstream superheater s/h= 1.25 Unburned carbon: 0.4-0.7% Content of СО≤ 30-50 mg/Nm3 Stable output of liquid slag MODEL RESEARCH

  7. TWO-STAGE COMBUSTION SYSTEM AT POWER PLANT EKIBASTUZSKAYA GRES-2, KAZAKHSTAN (Unit-2) Bituminous coal Wr, % 7 Ar, % 40-49 Nr, % 1.5 Sr, % 0.4-0.7 Q, kJ/kg 18000-23900 Vdaf, % 27.0 ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 7 Boiler front Boiler front Boiler front Symbol mg/Nm3 NOx = 500-650 mg/Nm3 (O2=6%). MODEL RESEARCH D/D0

  8. TWO-STAGE COMBUSTION SYSTEM AT POWER PLANT EKIBASTUZSKAYA GRES-2, KAZAKHSTAN Bituminous coal Wr, % 7 Ar, % 40-49 Nr, % 1.5 Sr, % 0.4-0.7 Q, kJ/kg 18000-23900 Vdaf, % 27.0 ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 8 Content of NOx ≤ 650mg/Nm3 (planned value) ECO Zone for bank repl.in backpass ECO Sec.conv.s/h-1 Sec.conv.s/h-1 Sec.conv.s/h-2 Conv.s/h Sec.conv.s/h-2 Conv.s/h Header for ammonia water input Header for ammonia water input Platen s/h-2 Platen s/h-2 Platen s/h-1 Platen s/h-1 Expansion joint Expansion joint Symbol MODEL RESEARCH Rail road Motor car road

  9. THREE-STAGE COMBUSTION ON BOILER OP-210 AT SCAWINA POWER PLANT, POLAND Bituminous coal Wr, % 10.2-14.0 Ar, % 16.9-27.7 Nr, % 1.0 Sr, % 0.7 Q, kJ/kg 18000-23900 Vdaf, % 42.0 ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 9 Boiler front Boiler front Conv.s/h-1 Platen s/h ECO-2 Conv. s/h-2,3 3-rd zone (reburning) Boiler front Boiler front ECO-1 2-nd zone (reduction) Tubular a/h 1-st zone (burning) Symbol Tubular a/h Tubular a/h MODEL RESEARCH

  10. COAL HANDLING SYSTEM AND HIGH-DENSITY PRESSURE FEED • Raw coal bunker (2 pcs.) • Raw coal feeder (2 pcs.) • Mill MR-19 (2 pcs.) • Separator (2 pcs.) • Cyclone (2 pcs.) • Pulverizing fan (2 pcs.) • PC bin (1 pcs.) • PC feeder (10 pcs.) • PC pipeline (8 pcs.) • PC pipeline (4 pcs.) • Main burners, 1-st tier (4 pcs.) • Main burners, 2-nd tier, (4 pcs.) • Discharge burners, reducing stage, (4 pcs.) • OFA ports (4 pcs.) • Hot air to main burners • Hot air to OFA ports • Turbo-air-blower • Drying agent recirculation line • Recirculation gases to reducing stage burners • Input of discharge drying agent to reducing stage burners Flue gases for drying from ID fan for recirculation gases Hot air after tubular air pre-heater ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 10 MODEL RESEARCH

  11. RESULTS RECEIVED ON BOILER OP-210 WITH REBURNING ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 11 Excess air downstream superheater s/h= 1.16-1.25 Unburned carbon: 1.0% Content of CO = 20-50 mg/Nm3 Requiredvalues for NOxemissions are provided within the entire operation range: 0.7-1.0Drated The cost of the reconstruction was about $ 10 per 1 kW of the rated power unit capacity

  12. RESULTS OF STAGE COMBUSTION SYSTEMS APPLICATION ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 12 Bituminous coal Lignite MODEL RESEARCH

  13. THREE-STAGE COMBUSTION WITH GAS REBURNING ON BOILER TPE-214 AT NOVOSIBIRSKAYA CHP-5 POWER PLANT, RUSSIA Bituminous coal Wr, % 12 Ar, % 13 Nr, % 2 Sr, % 0.4 Q, kJ/kg 22880 Vdaf, % 40.0 ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 13 Gas-fired burners 1-tier burners OFA level Symbol 1 – 1-tier burners; 2 – 2-tier burners; 3 – gas reburn burners; 4 – OFA ports; 5 - control gate-valves on secondary air input; 6 – Venturi tubes; 7 – natural gas flow-meter; 8 – Venturi tube at recycle gas feeding to ports of reducing stage; 9 – secondary air ports. MODEL RESEARCH

  14. gr h 94 boiler 1 % 93 ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 2 14 92 91 520 560 600 640 680 Dboiler, t/h 1 – two-stage combustion; 2 – three-stage combustion RESULTS RECEIVED ON BOILER TPE-214 WITH REBURNING MODEL RESEARCH

  15. CONCLUSIONS 15 ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS Low-cost technological methods - first, and most efficient way to reduce NOx Developed concept of horizontally-and-vertically staged combustion was applied on many boilers firing a wide range of fuels, and it ensures 30-50% NOx reduction Technology of horizontally-and-vertically staged combustion is a low-cost measure, at the same time, it is highly efficient Vast experience accumulated by Russian power engineers in design and application of furnace and burner arrangements and fuel handling systems can be used worldwide to ensure efficient NOx abatement

  16. THANK YOU FOR YOUR ATTENTION! www.cotes.ru e-mail: cotes@cotes.sib.ru ENERGY OF HEAT• ENERGY OFLIFE • ENERGY OFSOLUTIONS 16

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