Retrofit of a 600 MW Down-Fired Pulverized-Coal Furnace for Low NOx Emission

Aiming at solving the problem of high NOx emissions of a down-fired boiler, a new combustion system has been proposed by means of the numerical simulation using Ansys Fluent. The coal-lean stream (tertiary air), which was originally mixed with a separated overfired air (SOFA) stream on the front and rear walls of the upper furnace, was relocated to the lower zone of the furnace after retrofit. The secondary-air slots were transformed into a new annular port type, which was injected into the furnace with a down-tilt angle to increase the residence time of the coal stream. Furthermore, the effect of secondary air distribution and velocity of coal stream on performance was studied. After retrofitting the combustion system, the NO emissions were effectively controlled, decreasing from 906 mg Nm-3 to 576 mg Nm-3, but the carbon content of fly ash increased from 2.46% to 5.78%. Aiming at decreasing the carbon content of fly ash, the effect of coal/primary air velocity on the arch was studied. Less carbon content in fly ash can be observed for the lower arch airflow velocity. The results showed that the NO emissions can be controlled below 595 mg Nm-3, and the carbon content of fly ash was reduced to 3.39% when the velocity was decreased to 18 m s-1.