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CCM Mega Presentation



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  • Thank plant here.
  • 135 test points9 4th orderequationsPressure andtemperature compensated


  • 1. Combustion Optimization for Decreased Emissions and Improved Efficiency
    J. Estrada, Progress Energy
    St. Petersburg, FL
    D. Earley, Combustion Technologies
    Apex, NC
    B. Kirkenir, Progress Energy
    Raleigh, NC
  • 2. Acknowledgements
    Bob Sisson
    Crystal River Plant Engineer
    Crystal River Power Plant
    Crystal River, FL
  • 3. Ideal Furnace Combustion
    Proper and even burner stoichiometry leads to consistent flames in furnace
    Fuel:Air ratio distribution
    Emissions reduction and improved efficiency
    Low hanging fruit
    Potential alternative to post combustion emission equipment
  • 4. Crystal River Unit 4
    B&W Opposed Fire Pulverized Coal 770 MW
    6 MPS-89 Puvlerizers
    9 Coal Outlets per Mill
    54 B&W DRB-4Z Low NOx Burners
    • 6 Compartmentalized Windboxes
    • 5. 3 x Front, 3 X Rear
    • 6. SCR, Cold Side ESP& Wet FGD
  • Continuous Combustion Management (CCM)
    Equipment Additions:
    Coal Flow Measurement & control valves
    Burner Secondary Air Flow Measurement & auto purge
    Burner Secondary Air Flow Adjustment
    Primary Air Measurement and Auto Purge
    CO measurement
    Equipment Modifications
    Relocation of O2 Probes
    New O2 equipment (probes and cabinets)
  • 7. Coal Balancing
    Problem: Uneven Coal distribution
    Solution: Online coal measurement + adjustment
    Coal Out
    Adjustable Coal Valves
    Pulverizer Discharge
    Coal In
  • 8. Coal Flow Measurement
    Air Monitor Corporation
    Santa Rosa, CA
  • 9. Coal Flow Balancing
  • 10. Coal Flow Balancing
  • 11. Burner Air:Fuel Ratios
  • 12. Secondary Air Balance
    Windbox Air Dampers
    Windbox Air Dampers
    • Problem: Uneven Secondary Air (SA) distribution
    • 13. Solution: Measure SA flow at each burner and adjust SA dampers
    Secondary Air
    Secondary Air
  • 14. Secondary Air Measurement
    Wind Tunnel Testing at Air Monitor HQ
  • 15. Why Automate SA Dampers?
    Dynamic windbox flow profiles
    Fluctuating windbox pressure
    Ash build-up
  • 16. Post-Combustion
    CO and O2 measurement accuracy is critical
    Grid configuration preferred
  • 17. O2 Probe Relocation
    Old location not representative of furnace O2 profile
    • New location proven to be more accurate through testing with B&W
    • 18. Significant distribution improvement realized due to new location
  • O2 Probe Standard Deviation
  • 19. CRN O2 Distribution Comparisons
    CR4 O2 Profiles
    CR5 O2 Profiles
    Note: Unit scales are different
  • 20. CO Probe Augmentation
    CO is better diagnostic tool than O2 alone
    Air leakage impact on O2 probe
  • 21. CCM Tuning
  • 22. Remote Combustion Dashboard
  • 23. New O2 Curve
    LOI benefit
  • 24. NOx Benefit
  • 25. Project Results
    Boiler Efficiency Increase = 0.5%
    Annual fuel savings
    Combustion NOx Reduction
    7% at full load, 15-25% at part load
    Annual Ammonia Reagent Usage Reduction
    SCR Catalyst Life Extension
    Fan Auxiliary Power Savings
  • 26.
  • 27. Additional “Soft” Benefits
    Reduced emissions
    Reduced pulverizer wear
    Reduced wear on Coal Yard equipment.
    Reduced boiler tube & non-pressure part erosion due to lower flue gas velocities.
    Improved ESP performance due to lower flue gas velocities.
    Reduced potential for slagging and fouling events
    Improved Pressure part life due to improved temperature profile
    Reduced ash disposal costs
    Reduced boiler tube failures due to reducing atmospheres
  • 28. Contact
    Joe Estrada –
    David Earley –
    Bill Kirkenir –