Primary Nox Reduction Technology Development - The Road To Ied Compliance

Primary NOx reduction technology development –
the road to IED compliance
Dr Gerry Riley
VGB Workshop "Flue Gas Cleaning 2016" Highly Confidential – Protected Information
12/03/2016 1
Scope of presentation
• Introduction to RJM International

• NOx
• A total engineering approach
• Case Studies – the path to IED compliance
– Gas: Wall-fired
– Coal: T-fired
– Coal: Wall-fired
– Biomass
12/03/2016 2
NOx trends on RJM installation
in recent years for bituminous coals
Recent RJM installation
12/03/2016 3
Introduction - RJM International
• Formed in 1977 by Richard John Monro
• 60,000 MW of NOx Compliance Experience
• 300+ Utility & Industrial Customers
• Over 7,000MWe references outside USA
• Reducing emissions on >50% of U.K. Coal-fired Power Plants
• European HQ: Winchester, UK (opened in June 2001)
• Formation of RJM International via M.B.O. of international business Feb 2005
(Following closure of USA office in 2004)
• Member of the IFRF and Council Director of
British Flame Research Council
• RJM acquires 60% of SAS, USA
• RJM wins Energy Institute’s 2015 Innovation Award
12/03/2016 4
Recent Global contracts for NOx reduction projects
SUPPLY CONTRACTS, >5000MWe INSTALLED ENGINEERING SERVICES CONTRACTS
• Ostrava 3 boilers (Czech Republic) T-fired, • Vietnam, 2 x 560MW (Current)

Current • 3 x 140MWe Coal and biomass conversion
• UK, 1 x 500MWe Coal Unit (UK) (UK), (Current)
• UK, 1 x 500MWe Coal Unit (T fired) (UK) • Kazakhstan 7 boilers (Current)
• SSE Ferrybridge, 2 x 500MWe Coal Unit (UK) • AES 120MWe and 240MWe Ventanas (Chile),
• Eggborough, 1 x 500MWe Coal Unit (12 (Current)
burners) • Edipower, 2 x 300MW (Italy)
• 2 x 345MWe LIGNITE UNITS (Europe) • Cockenzie, 4 x 300MWe Coal Units
• AES Kilroot, 2 x 260MWe COAL/OIL UNITS, (UK) • Edipower, 2 x 320MWe Oil Units (Italy)
• AES Tisza, 4 x 225MWe OIL/GAS UNITS • EDF 1 x 600MWe Oil Unit (France)
(Hungary) • Eggborough, 4 x 500MWe Coal Units
• Drax, 1 x 660MWe COAL UNIT (UK) • ESB, 3 OIL/GAS UNITS, (Ireland)
• ESSENT, 1 x 640MWe OIL/GAS UNIT • 2 x 500MWe Coal (UK)
(Netherlands) • 3 x 350MWe Tilbury Biomass conversion
• SODA SANAYI, 3 OIL UNITS (Turkey)
• AES 2 x 150MWe Gas (UK)
12/03/2016 5
Primary NOx Measures
The theory is well known Thermal NOx,
Nitrogen partitioning
1. Combustion optimisation Char nitrogen conversion
2. Burner modifications
3. Over and/or under fired air
To be successful requires the correct
application of the theory!
Characteristics of good retrofit is:

• Lower NOx,
• Higher boiler efficiency
• Lower CO.
• Combustion limited to furnace
12/03/2016 6
Total Engineering Approach
This strategy has been well proven on many NOx-reduction projects

worldwide.
1. Site Survey
2. Boiler Baseline Performance Test
3. CFD Modelling (other modelling such as physical modelling may
be required)
4. Detailed engineering design of Burner and Combustion System
5. Supply of total Engineered Solution
“Engineering not hardware makes the difference”
12/03/2016 7
Computation Fluid Dynamics is
central to RJM’s designs
• Engineers use it as a tool unlike a CFD house

• Since RJM began it has developed significantly such that more
powerful computers now allow:
– Highly complex 3D geometries of much greater size and scope
– Highly detailed particulate flows
– Very detailed radiation and combustion modelling
– LES and other transient simulations of coal and gas combustion
• Software development has significantly accelerated all stages
of the process, reducing turnaround times
• Geometry creation, meshing, solving and post-processing can
now be automated, allowing detailed parametric studies to
be performed much more efficiently
12/03/2016 8
Be aware of changing process conditions.
• There is a right way and a wrong way
• The boiler will be designed for a certain

amount of furnace heat release, anything
that changes this balance can lead to
slagging problems.
• Careful design is necessary with ultra-low

NOx retrofit installations.
• Make the flame fit the furnace not the other

way around!
12/03/2016 9
Case studies – learning by doing
References are given at the end if you want more details
12/03/2016 10
Case Study - Gas
• Main issue is Thermal NOx so controlling flame

temperature is key
• Any nitrogen in gas is diatomic nitrogen (inert), not
chemically bound as in other fuels.
• Thermal NOx can be controlled by:
– Fuel/air mixing
– Flue gas recycle
• The risk is unstable combustion
– Combustion rumble
– High CO
– High NOx
12/03/2016 11
Essent Energie’s Clauscentrale, The Netherlands
• Two 640MWe Stork supercritical boilers each firing Bio-oil and

natural gas through 18 opposed fired burners. The original low
NOx burners were supplied by Lentjes; each burner was rated at
110MWth.
• The original NOx was ~270mg/Nm3 on gas.
• The boiler was designed to run with Flue Gas Recirculation but a
number of problems including flame instability and severe
furnace vibrations at high FGR rates.
• The boiler also suffered from excessive temperature excursions
in the Reheater.
12/03/2016 12
Stability Study
Temperature contours
0% FGR
6% FGR
15% FGR
23% FGR
Baseline Upgrade
• For 15% FGR, significant variations in the baseline flame are observed. In this configuration, reliable combustion seems to be
occurring; however, because there is no point where the flame always exists, this type of flame will have large-scale movements, which
were observed in the field as furnace “rumble” or combustion driven vibration and an extended temperature field to the Reheater.
• The RJM the proposed modification maintains a high temperature region near the burner, which will ensure the combustion driven
vibration will not occur and that the flame front will remain firmly fixed at the burner itself.
• For 23% FGR the existing configuration still reliably combusts the fuel and oxygen, but the flame is detached from the burner (large
scale vibration would be anticipated); whereas the proposed modification still has a high temperature region near the burner.
12/03/2016 13
Essent Energie’s Clauscentrale
Gas Burner Performance
• Burner modifications, which

include new flame stabilizers and
atomizers, are shown to produce a
stable gas flame. Burner stability
was demonstrated on gas from 0%
FGR to 23% FGR flow rates.
• NOx emission were 130mg/Nm3
compared to a baseline of
270mg/Nm3. CO was down to 15
ppm from 78ppm.
• Furnace vibration was less than half previous levels and under guarantee.
• Reheater temperatures were back in control and kept within the design constraints.
• Additionally, the boiler was able to operate at lower excess oxygen resulting in a further
benefit of improved boiler efficiency.
12/03/2016 14
“Innovative RJM retrofit achieves IED compliance on
aged gas units, retaining critical grid support”
• “1970s vintage plant is given new life by burner upgrades”.
• The two 180 MWe gas plants were opted out of the LCPD so were destined to close at
the end of 2015. However, new ownership and grid requirements created an
opportunity of continued operation, but on the basis that these circa 40 year old units
could operate under new plant standards in the eyes of the IED.
• The stringent new plant emissions limits of <100mg/Nm3 of NOx and CO and
<5mg/Nm3 of particulates, considering these units were built in the 70’s, represented a
complex engineering challenge.
• Pre-modification performance:
Stack Unit Emissions
NOx mg/Nm3 (ref 3% O2) 300
CO mg/Nm3 (ref 3% O2) 400
Dust mg/Nm3 (ref 3% O2) ~30
O2 % 6.4
12/03/2016 15
Improved computer power
12/03/2016 16
Improved computer power
12/03/2016 17
First Fire, Final NOx <100mg/Nm3 EU Power Station
27th November 2015. Unit 5

performance guarantee tests - the
unit is now IED compliant and
operable in auto mode, from
60MW to 155MW.
All guarantees have been met.
• NOx < 100mg/Nm3,

• CO < 100 100mg/Nm3
• Dust < 5mg/Nm3
The customer is very happy!
12/03/2016 18
Video - NOx <100mg/Nm3 EU Power Station
Flame stability is key to controlling NOx. Without a stable system, it

is impossible to stage the furnace for ultra-low NOx performance.
12/03/2016 19
Coal: Tangentially-Fired Boilers
• Rotating fireball to provide high
coal particle residence time
– Good burnout / high
efficiency
– Furnace combustion
stability
• Design factors:
– Geometric location of
burners
– Relative velocities of
pulverised fuel (PF) and
secondary air (SA)
12/03/2016 20
NOx Reduction Technology
• To achieve reductions in NOx, fuel must be

combusted in a sub-stoichiometric environment
– Suppresses availability of oxygen
– Suppresses flame temperature
– Increases carbon in ash
• To achieve further NOx reductions, the furnace
needs to be staged more aggressively
• Remaining air is added via overfired air (OFA) ports
installed at the top of the furnace
– Needs to target unburnt fuel to control carbon in ash
12/03/2016 21
Maritza East 1
Poor Fireball rotation as found
Level Level
10m above 20m above
Ash Hopper Ash Hopper
Velocity
Contours
coloured by
O2 Mole
Fraction
Counter Rotation in corners - No Fireball rotation

Verified by counter rotational slag profile inside furnace
12/03/2016 22
CFD Coal and OFA Velocity Vectors for upgrades
Coal now Note rotation at every

entrained into level has now been
circulating Fireball established
12/03/2016 23
UK Baseline (As Found) CFD Analysis
Concentrated
CO levels at
furnace exit
Flame visually
apparent on
boiler validates
findings
Serious concern
for further NOx
reduction
12/03/2016 24
Baseline – OFA Analysis
Green 5000 ppm

CO Isosurface
(extends into
convection section)
Red OFA jets do

not penetrate high
CO
Result is high
levels of CO and
CiA
12/03/2016 25
RJM innovation - SUFA Locations
SUFA
Locations
(4 ports)
12/03/2016 26
SUFA Efficiency
SUFA has low O2

concentration
(Blue = 0% O2)
SUFA has high O2

concentration (Red
> 7% O2)
O2 in SUFA is
consumed in
centre of fireball –
fuel is oxidised
12/03/2016 27
CO Improvement
• CO emissions
drastically
reduced from
baseline
• Combustion
complete at
furnace exit
Baseline Upgrade
12/03/2016 28
Oxygen Contours
High O2 remains
present in fireball
centre at higher
levels
High O2 at
bottom of fireball
12/03/2016 29
Innovative solutions
Following a period of
optimisation, the individual use
of SUFA was seen to reduce
carbon in ash to less than 7%,
with a simultaneous NOx
reduction of 20%, i.e. the
difference in/out of service
Detailed engineering tools and analytical techniques make a project

successful, not the application of standard hardware
12/03/2016 30
Wall Fired: Coal
12/03/2016 31
Swirl Stabilised Flame : Coal Particle Trajectories
Under High and Low NOx Operation (Smart, 2010)
12/03/2016 32
CFD Video – importance of particle trajectory
Get the coal into the

right zone of the flame
12/03/2016 33
Ferrybridge “C” 500 MW
• SSE owned
• NOx reduction measures:
– 1st generation low NOx burners in late 1990s
– To remain complaint with LCPD a BOFA
system
• With time two operational problems
became apparent:
– Unexpectedly high CIA in normal
operation
– Expensive tube failures
• Collaborative approach. Investigation gave
SSE enough confidence to get RJM to
install new burners and modify the BOFA
nozzles.
12/03/2016 34
Single Burner Models
CO – 10,000 ppm max
Typical 1st Gen Low

NOx Burner Furnace Wall
(85% Air)
Issue of flame length
New design similar in

CO RJM Burner
(100% Air) – HIGHER STOICHIOMETRY flame length to original
Mole Fraction
turbulent burners
12/03/2016 35
Burner Models
NOx Formation
Existing LNB NOx Burner stoich. <1.0
RJM Ultra Low NOx Burner stoich. <1.0

but with 25% NOx reduction
NO Mass Fraction
12/03/2016 36
Furnace Models
CO – 10,000 ppm max
CO Existing Burners RJM Burners

Mole Fraction
12/03/2016 37
Ferrybridge Unit 3 Complete ULNB Retrofit
Operation at 510MWe Gen

• NOx 251mg/Nm3
• Dust 4mg/Nm3
• CO 92mg/Nm3
12/03/2016 38
Punch through
• For a low NOx burner to provide a stable flame and efficient
combustion, it must produce the optimum PF particle path into the
burner Internal Recirculation Zone (IRZ), where the volatiles are
released under highly reducing conditions.
• This can be achieved by providing a strong IRZ. Below is an example of
a burner design that was unable to achieve the optimum particle path
due to the high primary mass flow.
X Vel. Par. Vel. Mag. (m/s)
(m/s)
20.0
0
-10 0
12/03/2016 39
And finally RJM’s Biomass Burner
The strong IRZ is very good for the large wood particles
Poor burner dynamics Optimised burner dynamics

(not RJM) (RJM)
12/03/2016 40
Robust Hardware Design
• Part of our success is based on hardware that is

designed to survive in a hostile environment
• We now have ULNB with over 6 years operation

without problems.
12/03/2016 41
Upgrade Project Co-Ordinator’s Feedback.
“The performance improvement in terms of

reduced emissions that RJM has delivered on both
units is remarkable. In terms of cost per tonne of
NOx reduction, the RJM solution was by far the
lowest cost option we could have chosen to meet
IED compliance and both upgrades were carried
out on time and within budget. This project’s
overall success greatly benefitted from the close
working relationship between RJM and the Site
Project Team.”
12/03/2016 42
Conclusions
• IED compliance for NOx emissions, when firing Coal, Biomass

or Gas, is now possible using primary measures only.
• Coupled to an efficient secondary NOx solution, 100mg/Nm3
NOx emissions from Coal firing may be possible at a fraction
of the current standard costs (Capex/Opex).
• RJM’s “Total Engineering” approach achieves the most cost-
effective solutions (especially if undertaken collaboratively)
• RJM has demonstrated its ability to solve boiler issues that
the OEMs failed to overcome
• RJM has a track record of providing innovative solution for all
types of plants and fuels.
12/03/2016 43
References
• John Goldring, Steve Cornwell and Steve Billett, (2016a), “Performance
Improvements on a Lignite Fired Boiler”, Kotel a Enegeticka Zarizeni, Brno,
Czech Republic, 14-16 March 2016
• Steve Cornwell, John Goldring and James Dennis, (2016), “NOx Emissions
Reduction on a Corner Fired Boiler”, Boilers & Energy Equipment, Brno,
Czech Republic, 14-16 March 2016
• John P Goldring, Larry Berg and Guy Sharp, (2012), “Results from Study on
Low-NOx Combustion at SSE Ferrybridge Power Plant”, PowerGen Europe,
Cologne June 12th-14th 2012
• John Goldring, Matthew Shields, Steve Billett, Pete Knight, (2016b)
“Pioneering RJM Ultra Low NOx Burner Retrofit Achieves IED NOx
compliance Using Primary Measures only at Rugeley Power Station”
PowerGen Europe, Milan, Italy, 21-23 June 2016
• Larry Berg and John Goldring, “How the experience use of CFD analysis
allows generators to meet strict LCPD NOx (emission) requirements with
proven technology at low cost”, (2006), IPG Conference 06, Leipzig 2006
12/03/2016 44
Acknowledgements
• John Goldring
• Larry Berg
• Steve Cornwell
• Steve Billett
• James Dennis
• Mathew Shields
• Mike Kryjak
12/03/2016 45
Thank You
www.rjm-international.com
griley@rjm-international.com
12/03/2016 46

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Primary Nox Reduction Technology Development - The Road To Ied Compliance

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Primary NOx reduction technology development –

the road to IED compliance

• Introduction to RJM International

Recent RJM installation

SUPPLY CONTRACTS, >5000MWe INSTALLED ENGINEERING SERVICES CONTRACTS

• Ostrava 3 boilers (Czech Republic) T-fired, • Vietnam, 2 x 560MW (Current)

Characteristics of good retrofit is:

This strategy has been well proven on many NOx-reduction projects

“Engineering not hardware makes the difference”

• Engineers use it as a tool unlike a CFD house

• There is a right way and a wrong way

• The boiler will be designed for a certain

• Careful design is necessary with ultra-low

• Make the flame fit the furnace not the other

• Main issue is Thermal NOx so controlling flame

• Two 640MWe Stork supercritical boilers each firing Bio-oil and

• Burner modifications, which

27th November 2015. Unit 5

• NOx < 100mg/Nm3,

The customer is very happy!

Flame stability is key to controlling NOx. Without a stable system, it

• To achieve reductions in NOx, fuel must be

Counter Rotation in corners - No Fireball rotation

Coal now Note rotation at every

Green 5000 ppm

Red OFA jets do

SUFA has low O2

SUFA has high O2

Detailed engineering tools and analytical techniques make a project

Get the coal into the

Typical 1st Gen Low

New design similar in

Existing LNB NOx Burner stoich. <1.0

RJM Ultra Low NOx Burner stoich. <1.0

CO Existing Burners RJM Burners

Operation at 510MWe Gen

Poor burner dynamics Optimised burner dynamics

• Part of our success is based on hardware that is

• We now have ULNB with over 6 years operation

“The performance improvement in terms of

• IED compliance for NOx emissions, when firing Coal, Biomass

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