Search Results (42)

Co-firing large-sized straw biomass in pulverized coal boilers is a potential pathway for carbon emission reduction in China’s thermal power plants. However, experimental data on large-sized straw combustion under pulverized coal boiler combustion conditions are critically lacking. This study selected typical large-sized wheat straw particles. Employing a two-mode experimental setup in a drop tube furnace (DTF) system simulating pulverized coal boiler conditions, we systematically investigated the combustion behavior and alkali metal release characteristics of this large-sized straw biomass, with combustion processes summarized for diverse particle types. The findings reveal asynchronous combustion progression across particle surfaces due to heterogeneous mass transfer and gas diffusion; unique behaviors distinct from denser woody biomass, including bending deformation, fiber branching, and fragmentation, occur; significant and morphology-specific deformations occur during devolatilization; fragmentation universally produces particles of varied shapes (needle-like, flaky, blocky, semi-tubular) during char combustion; and potassium release exceeds 35% after complete devolatilization and surpasses 50% at a burnout degree exceeding 80%. This work provides essential experimental data on the fundamental combustion characteristics and alkali metal release of large-sized wheat straw particles under pulverized coal boiler combustion conditions, offering engineering application guidance for the direct co-firing of large-sized flexible straw biomass in pulverized coal boilers. Full article

To compensate for the instability of renewable energy sources during China’s energy transition, large thermal power plants must provide critical operational flexibility, primarily through deep peaking. To investigate the combustion performance and wear and tear of a 600 MW pulverized coal boiler under deep peaking, the gas–solid flow characteristics and distributions of flue gas temperature, wall heat flux, and wall wear rate in a 600 MW tangentially fired pulverized coal boiler under variable loads (353 MW, 431 MW, 519 MW, and 600 MW) are investigated in this study employing computational fluid dynamics numerical simulation method. Results demonstrate that increasing the boiler load significantly amplifies gas velocity, wall heat flux, and wall wear rate. The maximum gas velocity in the furnace rises from 20.9 m·s⁻¹ (353 MW) to 37.6 m·s⁻¹ (600 MW), with tangential airflow forming a low-velocity central zone and high-velocity peripheral regions. Meanwhile, the tangential circle diameter expands by ~15% as the load increases. The flue gas temperature distribution exhibits a “low-high-low” profile along the furnace height. As the load increases from 353 MW to 600 MW, the primary combustion zone’s peak temperature rises from 1750 K to 1980 K, accompanied by a ~30% expansion in the coverage area of the high-temperature zone. Wall heat flux correlates strongly with temperature distribution, peaking at 2.29 × 10⁵ W·m⁻² (353 MW) and 2.75 × 10⁵ W·m⁻² (600 MW) in the primary combustion zone. Wear analysis highlights severe erosion in the economizer due to elevated flue gas velocities, with wall wear rates escalating from 3.29 × 10⁻⁷ kg·m⁻²·s⁻¹ (353 MW) to 1.23 × 10⁻⁵ kg·m⁻²·s⁻¹ (600 MW), representing a 40-fold increase under full-load conditions. Mitigation strategies, including ash removal optimization, anti-wear covers, and thermal spray coatings, are proposed to enhance operational safety. This work provides critical insights into flow field optimization and wear management for large-scale coal-fired boilers under flexible load operation. Full article

Climate change is a global issue that has gained much attention recently. Co-firing biomass with coal/waste coal reduces the electricity sector’s GHG emissions sustainably. This study uses commercial software to model waste coal and biomass co-firing in 100 MW and 600 MW power plants. The objective is to assess the effects of fluid types (subcritical and supercritical), plant capacities (100 MW and 600 MW), boiler types (pulverized coal and circulating fluidized bed boilers), biomass and waste coal co-firing ratios (0:100, 20:80, 40:60, 60:40, 80:20, and 100:0), and carbon capture and storage efficiencies (0%, 90%, 95%, and 97%) on performance parameters such as net plant efficiency, heat rate, net plant CO₂ and SO₂, and particulate matter emissions. The feedstocks selected for this investigation include anthracite waste coal and loblolly pine biomass. As the biomass fraction increases from 0% to 100%, co-fired power plants net efficiency increases by 3–8%. Supercritical plants had a 6% higher net plant efficiency than the subcritical plants. The study found that the biomass’s high heating value decreased the fuel flow rate and reduced plant CO₂ emissions by 10–16%. With 100% biomass power plant feed and 90% carbon capture and storage efficiency, CO₂ emissions drop by 83% and SO₂ and PM emissions drop to zero. Full article

An alternative combustion technology to replace conventional start-up and flame stabilization using fuel oil or natural gas in pulverized coal-fired boilers has been investigated. In this study, a novel plasma burner design is proposed as a replacement for traditional auxiliary burners, operating by generating plasma through the ionization of air using microwave energy. The burner features an internal combustion system and a multi-stage ignition process to enhance flame stability, improve combustion efficiency, and enable more controlled pulverized coal burning within the plasma. Supported by a magnetron generating microwave energy at 915 MHz with a 75 kW output, the burner directly ignites approximately 22% of the coal–air mixture in the plasma zone, forming a stable flame that ensures complete combustion of the remaining coal. An experimental system was established, and tests were conducted by burning up to 3000 kg/h of pulverized coal in an industrial-scale setup at Unit-1 of the 22 MW_e Soma A Power Plant to optimize burner parameters. The specific microwave energy consumption was calculated as 0.055 kWh/kg of coal, demonstrating high energy efficiency and low operational cost. These results confirm that the microwave-assisted plasma burner is a technically viable, energy-efficient, and environmentally friendly alternative to conventional auxiliary burners. Full article

China established a coal power capacity payment mechanism to allow coal power to play a fundamental supporting and regulating role. It is difficult to generate peak power for long periods. The effects of variation in over-fire air ratio and burner deflection angle were investigated to optimize combustion conditions at half load. This simulation is based on field data from a new 660 MW tangentially fired boiler. The results indicate that when the over-fire air ratio increased from 17.6% to 27.6%, the NO_x concentration decreased by about 45.1% in the burnout zone. The concentration decreased from 284 mg/m³ to 156 mg/m³. However, a large eddy formed in the top zone affected the flow field. The heat transfer at the horizontal flue was affected. The flow field structure can be optimized by moderately adjusting the deflection angle (−5°) of the burner. A further increase in the deflection angles (−10° and −15°) reduced NO_x by about 10%. It affected the adequate combustion of pulverized coal and the flow field at the top zone. Considering the overall combustion conditions, it is recommended that the burner be offset downward at a small angle. Full article

To investigate the safe, stable, and economically viable operation of a boiler under ultra-low-load conditions during the deep peaking process of coal-fired units, a numerical simulation study was conducted on a 660 MW front- and rear-wall hedge cyclone burner boiler. The current research on low load conditions is limited to achieving stable combustion by adjusting the operating parameters, and few effective boiler operating parameter predictions are given for very low-load conditions, i.e., below 20%. Various burner operation modes under ultra-low load conditions were analyzed using computational fluid dynamics (CFDs) methods; this operation was successfully tested with six types of pulverized coal combustion in this paper, and fitting models for outlet flue gas temperature and NO_x emissions were derived based on the combustion characteristics of different types of pulverized coal. The results indicate that under 20% ultra-low-load conditions, the use of lower burners leads to a uniform temperature distribution within the furnace, achieving a minimum NO_x emission of 112 ppm and a flue gas temperature of 743 K. Coal type 3, with the highest carbon content and a calorific value of 22,440 kJ/kg, has the highest average section temperature of 1435.76 K. In contrast, coal type 1 has a higher nitrogen content, with a maximum cross-sectional average NO_x concentration of 865.90 ppm and an exit NO_x emission concentration of 800 ppm. The overall lower NO_x emissions of coal type 3 are primarily attributed to its reduced nitrogen content and increased oxygen content, which enhance pulverized coal combustion and suppress NO_x formation. The fitting models accurately capture the influence of pulverized coal composition on outlet flue gas temperature and NO_x emissions. This control strategy can be extended to the stable combustion of many kinds of coal. For validation, the fitting error bar for the predicted outlet flue gas temperature based on the elemental composition of coal type 6 was 8.09%, whereas the fitting error bar for the outlet NO_x emissions was only 1.45%. Full article

Under the background of achieving carbon dioxide peaking and carbon neutrality, the rapid development of renewable energy power generation poses new challenges to the flexible adjustment capabilities of traditional power plants. To explore the furnace combustion stability and optimal operation modes during deep peak shaving, a simulation of the combustion process under low-load conditions for a 600 MW wall-fired boiler is performed utilizing computational fluid dynamics (CFD) analysis. The impact of burner combination modes on the combustion process within the furnace is explored at 25% and 35% boiler maximum continuous ratings (BMCRs). This study investigates two configurations of burner combinations. One mode operates burners in layers A, B, and C, which include the lower layers of burners on the front and rear walls of the boiler, as well as the middle-layer burners on the rear wall, referred to as OM1. The other mode operates burners in layers A and C, which include the lower layers of burners on the front and rear walls of the boiler, referred to as OM2. The results indicate that OM2 exhibits superior capabilities in orchestrating the distribution of the airflow velocity field and temperature field under the premise of ensuring no more than a 1% decrease in the pulverized coal burnout rate. When OM1 is employed, the airflow ejected from the middle-level burners hinders the upward movement of pulverized coal sprayed from the lower-level burners, causing a larger proportion of pulverized coal to enter the ash hopper for combustion. Consequently, the ash hopper attains a peak mole fraction of CO₂ at 0.163. OM2 delays the blending of pulverized coal with air by enhancing the injection quantity of pulverized coal per burner. As a result, the generation of CO in the ash hopper reaches a notable mole fraction of up to 0.108. The decreased furnace temperature promotes the formation of fuel-based NO_x during low-load operation. Taking the 25% BMCR as an example, the NO_x emissions measured at the furnace outlet are 743 and 1083 ppm for OM1 and OM2, respectively. This study focuses on the impact of combustion combinations on the combustion stability when the boiler is operating at low loads. The findings could enrich previous research on combustion stability and contribute to the optimization of combustion schemes for power plant boilers operating at low loads. Full article

Renewable energy sources are becoming increasingly crucial in the global energy industry and are acknowledged as a significant substitute for fossil fuels. Oil palm fronds are a type of biomass fuel that can be utilized as a substitute for fossil fuels in the combustion process of boilers. Co-firing (HT-FRD) is a beneficial technology for reducing exhaust gas emissions generated by coal-burning power stations. By utilizing computational fluid dynamics (CFD), this study has modeled and evaluated co-firing palm frond residue (HT-FRD) with hydrothermal treatment into a 315 MWe boiler. In the simulation, six different HT-FRD co-firing ratios, 0%, 5%, 15%, 25%, 35%, and 50%, were used to demonstrate the differences in combustion characteristics and emissions in the combustion chamber. The data indicate that HT-FRD co-firing can enhance temperature distribution, velocity, and unburned particles. All in all, co-firing conditions with 5–15% HT-FRD ratios appear to have the most favorable combustion temperature, velocity, and exhaust gas characteristics. Full article

The basic national condition that is dominated by coal will not alter in the foreseeable future. Coal-fired boiler is the main equipment for coal utilization, and cyclone burner is a practical type of burner. There is a cyclone formation, a primary air duct inside the center air duct, and a secondary air duct. Introducing a small stream of pulverized coal gas or oil mist stream or gas directly into the reflux zone in the center duct ignites first a stable combustion and a small fluctuation of ignition pressure. In this paper, the variation of furnace temperature for cyclone pulverized coal burner corresponding to different excess air factors and the composition of gases such as O₂, CO, CO₂, and NO_X produced by combustion were investigated using fluent software. A single cyclone pulverized coal burner from an actual coal-fired boiler is used, and a combustion zone applicable to the study of a single pulverized coal burner is established to study the actual operation of a single pulverized coal burner at different excess air coefficients. The findings indicate that the ignition position of pulverized coal combustion advances with decreasing α (Excess Air Factors); however, the length of the produced high-temperature flame gets shorter. As the value of α decreases, the burnout in the furnace decreases and the CO emission concentration increases, with a maximum CO mole fraction of 0.38% at α = 1.2 and a maximum CO mole fraction of 3.13% at the axial position when α decreases to 0.8. The furnace’s concentration of NO_X, the NO_X emission level decreases significantly with decreasing α. The NO_X mole mass increases gradually with increasing α, and in the bottom portion of the primary combustion zone, more NO_X is produced. The concentration of NO_X in the chamber changes significantly after α exceeds 1.0, and the NO_X at the outlet surges from 417.25 ppm to 801.07 ppm, which is attributed to the increase in the average temperature of the chamber, which promotes the generation of thermophilic NO_X. The distribution pattern of O₂ mole fraction along the furnace height cross-section at different excess air factors is basically the same, with a maximum at the burner inlet and a gradual decrease in the O₂ content as it enters the combustion chamber to react with the pulverized coal in a combustion reaction. The value of α = 0.8 when the air supply is obviously insufficient, the fuel cannot be fully combusted, and only a small amount of CO₂ is produced. Full article

This study is a numerical study to predict the temperature of the heat exchange tubes inside the pulverized coal-fired boiler through the conjugate heat transfer analysis. Due to the aspect ratio and number of tubes inside the pulverized coal-fired boiler, actual tube modeling analysis has rarely been conducted. Most of the research has been conducted through the porous media method, resulting in limited information on the temperature distribution of each tube. However, for the development of a digital twin model for improving the performance of the boiler and reducing maintenance costs, information on the local temperature of the tubes is required. In this study, all the tubes inside the boiler were modeled, and conjugate heat transfer analysis was performed to confirm the local temperature distribution. For this purpose, the analysis was conducted using Fluent 2020 r2, and the analysis model was constructed using more than 300 million structured grids. The calculation was performed considering conjugate heat transfer in the pulverized coal-fired boiler, heat exchange by steam inside the tubes, and conductive heat transfer of the tubes. As a result, it was confirmed that there is a significant deviation in the local temperature for each tube position. Furthermore, the maximum temperature of the PrSH tube ranges widely, between 492 and 532 degrees, depending on the tube’s position. It was observed that the point of the highest temperature inside the tubes also varies for each tube due to the flow of external combustion gas. Based on these results, it is expected that strategic approaches to boiler design and maintenance can be achieved. Furthermore, it is anticipated to contribute to the high efficiency of power facilities by being utilized as basic data for the development of a digital twin model for the boiler. Full article

Hydrogen blending of pulverized coal in boilers is a promising technology. However, there are few studies on hydrogen blending in coal-fired boilers. In order to reduce CO₂ emissions from coal-fired boilers, this study investigates the co-combustion of pulverized coal and hydrogen in a swirl pulverized coal burner by numerical simulation. Itis shown that the burnout rate of fuel is 5.08% higher than that of non-hydrogen blended coal when the percentage of hydrogen blended is 5%. The water vapor generated by hydrogen blending not only leads to the formation of a low-temperature zone near the burner outlet; it also results in a prolonged burnout time of moist pulverized coal and a high-temperature zone near the furnace outlet. The greater the amount of hydrogen for blending, the higher the water produced. When 1–3% hydrogen is blended, the water vapor in the furnace reacts with the carbon to produce a large amount of CO. When the amount of hydrogen added to the furnace is more than 3%, the water content in the furnace rises, resulting in a lower temperature at the burner outlet and a decrease in the amount of CO produced. When 1–3% hydrogen is blended, the CO₂ emission rises. The CO₂ emission decreased by 1.49% for 5% hydrogen blending compared to non-hydrogen blending and by 3.22% compared to 1% hydrogen blending. Full article

This study endeavors to enhance the operational efficiency of extant coal-fired power plants to mitigate the adverse environmental impact intrinsic to the prevalent utilization of coal-fired power generation, which is particularly dominant in China. It focuses on the assessment and optimization of continuous denitrification systems tailored for a 1000 MW ultra-supercritical pulverized coal boiler. The extant denitrification framework encounters challenges during startup phases owing to diminished selective catalytic reduction (SCR) inlet flue gas temperatures. To ameliorate this, three retrofit schemes were scrutinized: direct mixing of high-temperature flue gas, bypass flue gas mixing, and high-temperature flue gas mixing with cold air. Each option underwent meticulous thermodynamic computations and comprehensive cost analyses. The findings elucidated that bypass flue gas mixing, involving the extraction and blending of high-temperature flue gas, emerged as the most financially prudent and practical recourse. This scheme optimizes fuel combustion heat utilization, significantly curtails fuel consumption, and fosters efficient internal heat transfer mechanisms within the boiler. The evaluation process meticulously considered safety parameters and equipment longevity. The insights derived from this investigation offer valuable guidance for implementing continuous denitrification system retrofits in industrial coal-fired power plants. Full article

In this paper, we propose a data classification and analysis method to estimate fire risk using facility data of thermal power plants. To estimate fire risk based on facility data, we divided facilities into three states—Steady, Transient, and Anomaly—categorized by their purposes and operational conditions. This method is designed to satisfy three requirements of fire protection systems for thermal power plants. For example, areas with fire risk must be identified, and fire risks should be classified and integrated into existing systems. We classified thermal power plants into turbine, boiler, and indoor coal shed zones. Each zone was subdivided into small pieces of equipment. The turbine, generator, oil-related equipment, hydrogen (H2), and boiler feed pump (BFP) were selected for the turbine zone, while the pulverizer and ignition oil were chosen for the boiler zone. We selected fire-related tags from Supervisory Control and Data Acquisition (SCADA) data and acquired sample data during a specific period for two thermal power plants based on inspection of fire and explosion scenarios in thermal power plants over many years. We focused on crucial fire cases such as pool fires, 3D fires, and jet fires and organized three fire hazard levels for each zone. Experimental analysis was conducted with these data set by the proposed method for 500 MW and 100 MW thermal power plants. The data classification and analysis methods presented in this paper can provide indirect experience for data analysts who do not have domain knowledge about power plant fires and can also offer good inspiration for data analysts who need to understand power plant facilities. Full article

On a cold single-phase test stand, the effect of central air on the exit flow field of Babcock, Germany, burner was investigated. Industrial measurements were taken for a 700 MW wall-fired pulverized-coal utility boiler with above burners. Gas temperature, gas composition and concentration in the burner area were measured at 444 MW, 522 MW and 645 MW loads, respectively. Only when the central air mass flow was zero did a center reflux zone exist in the burner outlet area. The steady combustion of faulty coal was aided by early mixing of primary and secondary air, which was made possible by the decreased central air mass flow. At all different loads, the pulverized coal in center region took a long distance to ignite. The temperature in center steadily dropped as central air mass flow decreased, while the temperature in secondary air region gradually rose. Within 1.5 m from the primary air duct outlet, the highest CO concentration was 25 ppm and the highest O₂ concentration was close to 21% under all loads. The gas concentration near sidewall was more influenced by load. With all valves opening of burner center air at 30%, the boiler was able to operate safely and stably without oil at a load of 262 MW. The furnace chamber temperature in burner area reached 1056.1 °C. Full article

In order to integrate renewable electricity into the power grid, it is crucial for coal-fired power plant boilers to operate stably across a wide load range. Achieving steady combustion with low nitrogen oxide (NO_x) emissions poses a significant challenge for boilers burning low-volatile coal in coal-fired power plants. This study focuses on developing a decoupling combustion technology for low-volatile coal-fired boilers operating at low loads. A three-dimensional numerical simulation is employed to analyze and optimize the geometrical parameters of a burner applied in a real 300 MW pulverized coal fired boiler. Detailed analysis of the burner’s decoupling combustion characteristics, including stable combustion ability and NO_x reduction principles, is conducted. The results indicate that this burner showed three stages of coal/air separation, and the flame holder facilitates the stepwise spontaneous ignition and combustion of low-volatile coal. By extending the time between coal pyrolysis and carbon combustion, the burner enhances decoupling combustion and achieves low nitrogen oxide emissions. Based on optimization, a flat partition plate without inclination demonstrates excellent performance in terms of velocity vector field distribution, coal air flow rich/lean separation, combustion, and nitrogen oxide generation. Compared with the initial structural design, the average nitrogen oxide concentration at the outlet is reduced by 59%. Full article