TOTAL

EFFICIENCY

CONCEPT:

USERS

GROUP 2014

a technical solution to

meet every need…

Combustion Efficiency

Process Efficiency

Environmental Efficiency

Maintenance Efficiency

Safety Efficiency

TOTAL EFFICIENCY CONCEPT

• Maximize the overall performance of your Combustion Process.

• Measure and control various parameters in important areas of the

process

• Balance the requirements as dictated by their importance

Oxygen Trim System

CO as surrogate for Non-Dioxin Organic HAPS

NOx Control Technology

Combustion Efficiency

vs

Emissions Efficiency

CONSIDERATION MUST BE GIVEN TO HOW COMBUSTION

EFFICIENCY AFFECTS EMISSIONS

EPA & DOE HAVE FOR A LONG TIME IDENTIFIED MONITORING

PARAMETERS SUCH AS CO &O2 AS CRITICAL TO MAINTAINING

GOOD COMBUSTION EFFICIENCY WHILE MINIMIZING EMISSIONS

EPA ruling 40 CFR Part 63

National Emission Standards for Hazardous Air Pollutants for

Industrial, Commercial, and Institutional Boilers.

Hazardous Air Pollutant Emissions Monitoring can be a significant

cost depending on how the source is required to comply.

Major HAPS such as Hg, HCl & PM are the most costly to

implement

while CO & O2 Trim are the most common and easiest to install &

maintain

INDUSTRIAL BOILER MACT-40 CFR 63

UTILITY BOILERS: Coal, NG, Oil,

Biofuel

COMBUSTION TURBINES: NG. Oil,

Biofuel.

COMBUSTION ENGINES: NG. Oil

COMBUSTION & PROCESS VARIABLES

These considerations will vary depending on the combustion system and the

fuel.

However standard optimization considerations apply in all cases

Finding a balance between Minimum Emissions and Maximizing combustion

efficiency

Fuel Subcategory Boiler Subcategory

Particulate

Matter

(pounds/MMBtu)

Hydrogen

Chloride

(pounds/MMBtu)

Mercury

(pounds/TBtu)

Carbon Monoxide

(ppmvd @ 3% O2)

Dioxins/Furans (Total

TEQ) (ng/dscm @ 7%

O2)

Coal

Stoker

0.02 (0.0001) 0.02 3.0

50 (7) 0.003

Fluidized bed 30 0.002

Pulverized coal 90 0.004

Biomass

Stoker

0.02 (0.001) 0.006 0.9

560 0.004

CFB 250 40) 0.02

Suspension burner/

Dutch oven 1010 0.03

Fuel cell 270 0.02

Liquid NA 0.004 (0.002) 0.0009 4.0 1 0.002

Process Gases NA 0.05 (0.003) 0.000003 0.2 1 0.009

Existing Limits for Boilers & Process Heaters

(lbs/MBTU))

Emissions limits

Red levels indicate new

limits

COMBUSTION & PROCESS VARIABLES

Pre-Combustion:

• Fuel composition (Coal Blending) (Gas mix – biofuel)

• Measure Fuel & Air Flow (overall & Individual Burners)

• Coal Mill Air Flow

Post – Combustion:

• Furnace Wall Temperature

• Furnace Exit Gas Temperature

• By-Products of Combustion CO, NOx, CO2, O2, LOI.

COMBUSTION OPTIMIZATION

COMBUSTION MEASUREMENTS

INCREASE EFFICIENCY & REDUCE EMISSIONS

MEASUREMENTS: LOCATIONS:

•FUEL COMPOSITION Fuel Stock,

•AIR FLOW, FUEL FLOW Burner Feeders,

•FEGT, CO, O2 Furnace Exit,

• O2, CO, NOx Economizer Inlet,

EXCESS AIR vs EXCESS FUEL

Combustion Air Flow Monitoring

Furnace Temperature Control

INFRARED THERMOMETER

FURNACE CAMERA

IN-SITU PROBE SAMPLES A SINGLE POINT

FAST RESPONSE TIME

MEASUREMENT: CHEMI ,UV, NIDR, GFC, TDL, ,ZiO2 ,

EASY TO CALIBRATE

POOR SENSITIVITY AT LOW CONCENTRATIONS

CAN BE SUBJECT TO CROSS-SENSITIVITY

MEASUREMENT TECHNIQUES

Zirconia Oxygen Analyzer

MEASUREMENT TECHNIQUES

August 14, 2009

Detector probe modular design – the flow

tube way

Diffuser flow tube (in the flue)

This stays in place and is not removed for maintenance

Different lengths, materials

Blow down fitting option (not shown)

ensures tube is clear.

Tube diameter and short length will

Avoid any extractive effects

Detector

- Mounts to the flow tube outside flue

- Detector may be removed quickly while

flow tube is not removed

- Easily change filters (finger tight screw)

- Easily swap cell/heater

Filter

cap

Cal gas

Cap to

access

Terminal

screws or

To change

cell

Flow diffuses though

The tube

Low NOx Burner Control

Primary Air / Fuel Secondary Air Tertiary Air

Good Burner Management with Combustion Air Control & Fuel Flow

to individual burners along with good flame monitoring can improve

combustion and avert problems with:

• burner fires, burner tip problems

• incomplete combustion, burner blowout and explosions

• slagging in coal fired boilers,

• milling problems

• Reduce NOx

PERFORMANCE OPTIMIZATION

CO versus NOx

The use of a CO monitor can ensure emission levels are not

too high and maximize the efficiency of the burner operation.

There is a fundamental thermodynamic application for

combustion that is consistent with all methods of burning fuel.

If the operating unit can minimize the excess O2 and

maintain the CO between 50 to 300ppm, the efficiency of

the burner will be optimized.

By optimizing the efficiency, the owner/operator reduces

operating costs through fuel savings

CO MONITORING

CO OPTIMIZATION

NOx Contributing Factors

Areas for Reduction of Excess Air

Overfire

Air

Flow

Fuel/Air Carbon

Monoxide

CO

Carbon

in Ash

Excess

Oxygen

Boiler

Load

Burner

Levels

In-Service

Steam

Temperature

RH/SH

Wall

Sootblowing

Furnace

Wall

Cleanliness

Steam

Temperature

RH/SH

Wall

Sootblowing

Burner

Tilt

Position

Bulk

Flame

Temperature

NOx

Emission

Level

ENVIRONMENTAL EFFICIENCY

CT PERFORMANCE OPTIMIZATION

HRSG INLET

CT OUTLET

Todays regulations are placing demands on all types of CT

sets for tighter control of their emissions.

No one solution can solve all application demands but there

are several alternate measurements that can help improve

their chances without costly upgrades.

While CT manufacturers are striving to find the ultimate

solution for the next generation turbines, they are still reliant

on a combination of combustion technology & post combustion

technology to achieve the lowest possible emissions.

Tighter NOx & CO control, through combustion improvements

and better catalyst efficiency is a target for many.

Regulatory Constraints.

Since the flame temperature of a lean-premixed combustor is

designed to be near the lean flammability limit, lean-premixed

combustor performance is characterized by a CO/NOx tradeoff. At

the combustor design point, both CO and NOx are below target

levels; however, deviations from the design point flame temperature

cause emissions to increase. A reduction in temperature tends to

increase CO emissions due to incomplete combustion; an increase in

temperature will increase NOx. This tradeoff must be addressed

during part-load turbine operation when the combustor is required to

run at an even leaner condition.

NOx / CO Tradeoff

NOx / CO Tradeoff

Whether the best performance is achieved through:

DLN combustors

Water – Steam Injection

Catalytic Combustors

Any combination of above.

Addition of post combustion reduction systems

Being able to achieve this during transient conditions:

Deviations from design flame temperature cause emissions

increase.

Load Swings

Startup and Shutdown

Emissions Control

g

NOx / CO Tradeoff

Tunable Diode Laser Gas Analyzer

Typical TDL applications

• The Unisearch O2 Monitor is in a

bistatic configuration

• The DBR laser is fiber coupled

similarily as the DFB lasers

• This enables the use of

conventional Unisearch single

pass optics as well as employing

optical multiplexurs enabling

multi-location sampling with a

single instrument

• This system is constructed

specifically to monitor the R-

branch of the oxygen A-band at

760 nm, minimizing interference

and optimizing detection using a

high resolution GaAs detector

that is passive and highly

sensitive at this wavelength

• The fiber coupled system (shown

with audit cell) has detection

limits better than 0.1% oxygen

per meter of optical path

measured

Single Pass In-situ O2 Monitors

IN-SITU ACROSS STACK CROSS-STACK (SINGLE OR DOUBLE PASS)

SAMPLES ACROSS ENTIRE STACK or DUCT

MEASUREMENT: NDUV/NDIR/GFC/TDL/DOAS

APPLICATION DEPENDENT ON PERFORMANCE IN WET

OR DUSTY LOCATIONS

LOW CONCENTRATION MEASUREMENTS GAS

DEPENDENT

MEASUREMENT TECHNIQUES

NDIR PROBE & INSITU MEASUREMENT

Gas mesurement for CO, NOx,

IR OPTICAL/GFC

MEASUREMENT TECHNIQUES

Dilution CEMS in Shelter With Redundant Dilution Air Cleanup

EX-SITU CLOSE COUPLED EXTRACTIVE

FAST RESPONSE TIME

ELECTRO-CHEMICAL/CATALYTIC

NDIR/GFC/DOAS/FTIR

CAN HAVE POOR PERFORMANCE AT LOW

CONCENTRATIONS DEPENDING ON METHOD

USEFUL IN UNUSUAL SAMPLING CONDITIONS

REASONABLY EASY TO CALIBRATE

MEASUREMENT TECHNIQUES

CEMTEK Instruments

Model 8000 Analyzer

EXSITU CHEMILUMINESCENCE & ZIRCONIA

MEASUREMENT

•High Temperature Operation

•Minimal Zero Drift

•Fast Response for Feed Forward Control

•Low Maintenance (Low Flow Sample System)

•High Accuracy at Low Detection Levels

•Ammonia Scrubber for Post SCR Applications

NOx- O2 Monitor

Close Coupled – Hot / Wet Basis SAMPLE DELIVERED TO ANALYZER ABOVE DEW-POINT

USEFUL FOR BIOMASS BOILERS, MSW & HOSPITAL

INCINERATORS WHERE ACID GASES ARE PRESENT HCL,

HF, H2SO4.

MEASUREMENT TYPE: GFC, DIFERENTIAL ABSORPTION

USEFUL FOR THC, NMHC, AND VOC MEASUREMENTS

MEASUREMENT: FID, GC-FID

MINIMAL PREFORMANCE AT LOW CONCENTRATIONS

RELATIVELY EASY TO CALIBRATE

SAMPLE POINT TIME-SHARE CAPABLE

MEASUREMENT TECHNIQUES

Close Coupled Sampling Systems

Analyzer bench for selected gas

mounted in temperature controlled enclosure

Available as :

Direct Extractive

Hot Wet Extractive

Low Flow Low Dilution sampling system.

QUESTIONS?

Cemtek Environmental Inc.

3041 S. Orange Ave.

Santa Ana, CA 92707

800-400-0200

www.cemteks.com

a technical solution to

meet every need…