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The effect of air staged, co-combustion of pulverised coal and biomass blends
on NOx emissions and combustion efciency
S. Munir 1, W. Nimmo , B.M. Gibbs
Energy and Resources Research Institute, School of Process, Environmental and Materials Engineering, University of Leeds, Leeds LS2 9JT, UK
a r t i c l e
i n f o
Article history:
Received 5 March 2010
Received in revised form 16 June 2010
Accepted 28 July 2010
Available online 11 August 2010
Keywords:
Co-ring
Air-staged
Un-staged
Biomass
Over-re air
a b s t r a c t
Co-ring of biomass residues with coal is continuously increasing in its application in coal-red boilers
for electricity production. In this study, co-ring experiments were performed using a Russian coal with a
range of biomasses, shea meal (SM), cotton stalk (CS), sugarcane bagasse (SBT), sugarcane bagasse (SBR)
and wood chips (WC) as biomasses in 5%, 10% and 15% thermal fractions to evaluate their potential as
substitute fuel and an agent for NOx control. It was found that the addition of biomass increased NO
reduction under both un-staged and air-staged conditions. However, NO reductions obtained under optimum conditions of primary zone stoichiometry (SR1 = 0.9) and over-re air (OFA) injection port location
3, were found to be signicantly higher than un-staged co-ring for the same biomass thermal share in
the fuel blend. It was found that the addition of biomass has a positive effect on carbon burnout under the
optimum conditions that were determined in the study. A 10% biomass blending ratio (BBR) was found to
be optimum for air-staging conditions. When co-red under optimum air-staged conditions, a 10% BBR of
sugarcane bagasse (SBR), shea meal (SM), wood chips (WC), cotton stalk (CS) and sugarcane bagasse (SBT)
in coal gave NO reduction of 49%, 51%, 53%, 60% and 72%, respectively.
2010 Elsevier Ltd. All rights reserved.
1. Introduction
The role of renewable fuels is continuously increasing due to
climate change and energy security threats. By April 2009, 78
countries had signed the statute of the International Renewable
Energy Agency (IRENA). Members include most countries of the
European Union and many developing countries, from Africa to
Asia-Pacic to Latin America, including Argentina, Chile, Ghana, India, Pakistan, Morocco, Philippines, Senegal, South Korea, and Tunisi. By early 2009, 73 countries have renewable energy policy
targets [1]. EU-25/EU-27 has a binding target of a 20% share of
renewables in the energy consumption by 2020 [2]. Despite the
increasing share of renewables in energy generation schemes,
new technologies are not yet competitive to combat climate
change [3]. In this scenario, co-ring biomass residues with coal
in traditional coal-red boilers for electricity production represents the most cost effective and efcient renewable energy and
climate change technology [46]. During the last 10 years, much
progress has been made in the utilization of biomass in coal-red
power stations. Existing biomass power generation (and cogeneration) capacity is about 52 GW [1]. Currently, over 234 units have
Corresponding author. Tel.: +44 1133432513.
E-mail address: w.nimmo@leeds.ac.uk (W. Nimmo).
On leave from the Institute of Chemical Engineering and Technology, University
of the Punjab, Lahore, Pakistan.
1
0016-2361/$ - see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.fuel.2010.07.052
127
BFB
CFB
CFB,BFB
42
1
13
Grate
1
4
4
1
PF
8
1
1
7
7
10
4
Unknown
6
22
2
6
6
1
48
1
1
7
1
1
2
5
35
5
17
16
29
98
30
Total
8
5
1
7
12
81
27
2
7
6
1
2
15
1
1
18
40
234
2. Experimental
2.1. Experimental set up
The experimental furnace is a 20 kW down red combustor
(shown in Fig. 1). It is additionally equipped with three different
fuel feeders, air and gas supply systems, calibration set-up, gas
measuring analytical equipment, gas cylinder manifolds, water
cooled sample probes, char sample collection quenching system,
thermocouples, data logger and PC. The schematic diagram of the
combustor is given in Fig. 1.
For the biomass and coal co-ring tests, an arrangement of two
feeders could be utilised. While pre-blending coal with biomass,
the main feeder (Rospen) was used in conjunction with a smaller
(Dowson DB1-3/4) which permitted mixing of coal and biomass
on the spreader tray. Feeders were pre-calibrated before each test
run that were performed under un-staged and air-staged conditions. The coal and biomass were transported to the burner by
the primary combustion air ow. A part of the secondary air was
injected at a distance away from the burner to create a fuel lean
zone for the completion of combustion. The overall stoichiometry
was kept at 1.16 during the tests.
Gas samples were drawn through stainless steel probes from
any of the available ports along the length of the furnace. Axial distance measurements of the ports from the burner are given in Table 3. All the gas samples were dried and ltered before entering
individual on-line analysers. Instruments were calibrated before
each run with certicated BOC special gases mixtures. Oxygen
was measured using a Servomex Paramagnetic Analyser 570A;
CO, CO2 by NDIR analysers (Analytical Development Company;
ABB Easyline IR CO2 analyser); NO and NOx by a chemiluminescence analyser (Signal Ltd. series 440). Each gas analyser and Rtype sheathed thermocouples were connected through a data logging interface (Pdaq 56) and recorded directly to an Excel spreadsheet with a data sampling rate of 10 s using daq-view software.
In order that data for NO emission can be obtained at a particular plant condition, stable operation at that condition is achieved.
Stability is deemed to occur when the measured variables (mainly
O2 and NO) do not drift from a constant average level for a period
of up to 10 min. The data is logged every 10 s and post-run analysis
for the period of the test within the run involves extracting data
which has been averaged over 3040 sampled data points. Statistical analysis of example data is presented in Table 2 for the two
Table 2
Example statistics of data analysis method.
O2 mean
Standard deviation
NO mean
Standard deviation
5% SM + RC
15% SM + RC
3.2
0.05
541
4.02
3.3
0.03
479
3.2
Table 3
Axial distance of ports from burner.
Port no.
1
2
3
4
5
6
7
8
9
Flue
56.5
86.5
116.5
146.5
161.5
191.5
221.5
236.5
259.5
299
128
NOred%
NObaseline @ 6% O2 NOBBR @ 6% O2
NObaseline @ 6% O2
100
The base line value of NO was taken at the exit without the
addition of any biomass/staging. This was then corrected at 6%
O2. Similarly, all the NO values for coalbiomass blends (staged
and un-staged) were also corrected at 6% O2 to avoid any dilution
effect.
The proximate and ultimate analyses along with bulk densities
and HHV of the samples are given in Table 3. The caloric values
were determined by using a Parr 6200 oxygen bomb calorimeter.
For the determination of surface area, the char samples were analyzed using surface area and pore size analyzer Model (Quanta
Chrome Nova 2200e). Ash analysis was done using a PANalytical
Axios Advanced XRF spectrometer aided with PANalytical
IQ + Semiquantitative software.
The VM/FC of all the biomass samples was found to be 3.510.5
times higher than VM/FC of coal (Table 5). This is an indication of
signicant difference in volatility between the coal and the biomasses. Cellulose and lignin are generally recognized as main components in agricultural residues. The weight fraction, except for the
cellulose and lignin fraction, corresponds to the fraction of acidsoluble hydrocarbons in the biomass. Fig. 2 shows the differences
in the biomass samples structure. The cellulosic content in the biomasses may enhance the ignition characteristics since cellulose
compounds have the structure of branching chain of polysaccharides and no aromatic compounds, which are easily volatilized
[13].
Fig. 3. (a) Effect of SR1 and the location of OFA nozzle on NO with RC. (b) Effect of
SR1 and the location of OFA nozzle on NO with 10% SM-coal blend.
Fig. 4. (a) Effect of OFA nozzle location and SR1 on the carbon burn out for RC. (b)
Effect of OFA nozzle location and SR1 on the carbon burn out for 10% SM-RC blend.
129
burn out (Fig. 4). This is due to the fact that each step increase in
the primary zone length increases the residence time in the oxygen
decient, fuel rich primary zone (Fig. 5a). This was in agreement
with the ndings of Ribeirete and Costa, 2009 [16].
A strong reducing environment in primary combustion zone restrain coal combustion, and large amount of unburned char enters
burn out zone [14]. If the length of the burn out zone is short and
temperature is not sufciently high, carbon burnout efciency can
drop. Figs. 3 and 4 showed that a decrease in the primary zone stoichiometry (SR1) has a positive effect on NO reduction and negative
effect on carbon burnout. This could be due to the fact that the
lower the fuel rich zone stoichiometry the stronger is the reducing
environment and longer residence time in the fuel rich zone
(Fig. 5b). Increasing the residence time in the fuel rich zone favours
the decomposition of N species (NO, NH3, HCN) resulting a significant reduction in NOx emissions. Decreasing SR1 can lead to an increase of reducing species formed in the primary combustion zone,
which is conducive to NOx destruction [17]. But at the same time
when SR1 is too low, pulverised coal combustion remains incomplete in the primary zone and large amounts of unburnt char enter
the burnout zone which may affect the combustion efciency.
There is a trade off between NO reduction and carbon burnout
while selecting an optimum OFA nozzle location and SR1. Therefore, too low or too high SR1 will result either low NO reduction
with high carbon burn out or high NO reduction with poor carbon
burnout at all OFA nozzle locations. Similarly, too short or too long
a residence time in the primary zone will result in either, higher
carbon burnout with low NO, or high NO reduction with low carbon burnout.
In Fig. 6, NO reduction and carbon burnout have been plotted.
From Fig. 6, an optimal position is estimated where the carbon
burnout begins to level off as SR1 increases. It is also clear from this
comparison that the addition of biomass benets both carbon
burnout and NO reduction at this condition. Keeping in view the
above discussion and results exhibited in Figs. 3, 4 and 6, an OFA
nozzle location at port 3 and SR1 = 0.9 were found to be optimum.
Fig. 5. (a) Effect OFA injection location on residence time. (b) Effect of primary zone stoichiometry on residence time. Air-staged conditions.
130
Fig. 6. Effect of SR1 on carbon burnout of 10% BBR blends and NO reduction showing optimal condition at SR1 = 0.9 (OFA = port 3) (RC + SBT , RC + SM d, RC + CS j,
RC + WC N, RC + SBR ., RC H).
131
Fig. 8. (a) Effect of BBR on volatility under un-staged co-ring conditions. (b) Effect of volatility on NO reduction under un-staged co-ring conditions.
Table 4
Proximate and ultimate analysis and HHV of the fuel samples.
Fuels as received basis
SM
CS
RC
WC
SBT
SBr
a
Ultimate analysis
Proximate analysis
C (%)
H (%)
Oa (%)
N (%)
S (%)
Ash (%)
FC (%)
VM (%)
H2O (%)
41.70
45.2
60.36
42.2
33.6
42.34
5.0
4.40
4.5
4.94
5.3
5.62
32.32
40.5
8.35
35.48
36.27
37.13
2.47
1.0
1.84
0.28
1.5
0.24
0.09
0.0
0.30
0.10
0.0
0.001
4.29
4.9
14
1.70
11.05
9.56
24.58
18
45.48
11.90
13.86
17.11
57
73.1
29.87
71.1
62.81
68.23
14.13
4.0
10.65
15.3
12.28
5.1
Bulk density
(kg/m3)
HHV (MJ/kg)
490
310
620
270
160
180
17.70
17.70
27.29
16.39
11.80
17.37
Calculated by difference.
Table 5
Volatility and particle size of the samples.
Fuels
VM/FC
SM
CS
WC
SBT
SBR
RC
2.32
4.06
5.97
4.53
3.99
0.656
150.29
209.89
586.25
743.11
586
85.292
the biomasses is higher than coal (Tables 4 and 5) and the volatiles
from biomass devolatilization are mainly the combustibles CO,
H2, CxHy [6]. The addition of biomass to replace coal increases
the volatility of the fuel. The dominant volatile-nitrogen compound
in coal combustion is HCN and in biomass combustion is NH3. The
ratio of HCN to NH3 is 0.9 in coal combustion and 0.1 in wood combustion [23]. The formation of NH3 and HCN increases with
increasing fuel volatility [24] and gas-phase combustion becomes
predominant [18]. Furthermore, most of the fuel nitrogen in biomass is initially converted ammonia and subsequently by reaction
to NHi radicals during combustion. The N species reduces NO to
molecular nitrogen (essentially providing an in situ thermal DeNOx
source) [6,19,25,26]. The mechanistic pathways for formation and
reduction of nitrogen oxides during air-staged coal combustion
were described by Beer (2000). Bai (2000) described mechanism
of wood chips combustion. The reactions involved in two staged
biomass combustion has been described by Nussbaumer (2003)
[20,21,27]. In the light of above elucidated referred work, possible
routes for the NO reduction in near burner reducing zone during
two staged biomass coal co-combustion are shown in Fig. 10.
Therefore, the synergistic effect of the addition of biomass to
control NOx under staged conditions becomes apparent. As biomasses contain less carbon and are highly oxygenated compared
to coal (Table 4), the amount of theoretical air required for combustion is less than coal combustion, alone. It is anticipated that
the addition of biomass without increasing SR1 level can cause locally stronger reducing environments within the ame in the primary zone resulting in a negative effect on carbon burnout and
132
Fig. 9. Effect of SR1 and BBR on NO, OFA port 3, air-staged conditions.
Fig. 10. Possible routes for NOx reduction during co-combustion of biomass with coal in the primary zone.
133
Secondary fuel
Reactor type
Un-staged NO
(ppm) for 6%
O2 in the
primary zone
Initial primary
zone
stoichiometric
ratio (SR1)
Primary zone
stoichiometric
ratio range
(SR1)
Primary zone
residence
time (s)
Maximum NO
reduction efciency
at primary zone
stoichiometric
ratio (SR1)
References
Bituminous
Russian coal
90% RC
90% RC
90% RC
90% RC
85% RC
Hard coal
N/A
20 kW pulverised fuel
combustor
-do-do-do-do-do0.5 MW pulverised fuel
combustor
-do-do-do-do-do-do1.5 MW under stoker furnace
100 kW laboratory furnace
854
1.16
0.81.2
1.17
67% (0.80)
This study
811
828
794
673
769
1384
1.16
1.16
1.16
1.16
1.16
12
0.81.2
0.81.2
0.81.2
0.81.2
0.81.2
0.61.2
1.25
1.29
1.20
1.21
1.16
0.9
67% (0.8)
73% (0.8)
54% (0.8)
76% (0.8)
71% (0.8)
38% (0.6)
This
This
This
This
This
[19]
1160
1575
935
1450
1225
1775
631
458
12
12
12
12
12
12
12
1.15
0.771.2
0.551.2
0.65120
0.551.2
0.521.2
0.612
0.412
0.81.15
0.9
2.5
0.9
2.5
2.5
2.5
0.5
0.3
30% (0.88)
77% (0.7)
39% (0.82)
81% (0.70)
76% (0.60)
79% (0.60)
50% (0.70)
80% (0.80)
[19]
[19]
[19]
[19]
[19]
[19]
[21]
[16]
Hard coal
Hard coal
Hard coal
Hard coal
Hard coal
Hard coal
UF chipboard
Bituminous
Russian coal
10%
10%
10%
10%
15%
N/A
SM
CS
WC
SBT
SBR
10%
10%
40%
25%
40%
NA
N/A
N/A
straw
straw
straw
straw
straw
study
study
study
study
study
Fig. 12. Effect of BBR on CO concentration in the primary zone, SR1 = 0.9, air-staged
conditions. (RC1 + WC N, RC1 + SBT , RC1 + SM d, RC1 + CS j, RC1 + SBR
.).
Fig. 11. Effect of BBR on NO, OFA port 3, SR1 = 0.9, air-staged conditions.
etry was found to cause a decrease in both NO emissions and carbon burnout (Figs. 4, 6 and 9). This was in agreement with the
ndings of Ribeirete and Costa (2009), Li et al. (2009) and Spliethoff and Hein (1998) [14,16,19].
4. Slagging and fouling
Inorganic constituents in the fuel are the main contributor to
slagging and fouling [25,34]. The major elements including alkali
metals (K, Na), alkaline earth metals (Ca, Mg), silicon, chlorine
and sulphur are involved in reactions leading to ash slagging and
fouling [34,35]. Biomasses have lower ash content compared to
coal (Table 4). At the same time, biomass ash materials are rich
in alkali and alkaline earth metals [7] and these are effective uxes
for alumina-silicates and lower the ash fusion temperature resulting an increase in slagging and fouling propensity [31]. Despite the
lower ash fraction in biomass, co-ring of biomass with coal can
134
Fig. 14. Temperature proles of coal and coalbiomass blends, SR1 = 0.9, air-staged
conditions.
Fig. 13. (a) Effect of BBR on burnout with SR = 1.16 (un-staged co-combustion). (b)
Effect of BBR on burnout with SR1 = 0.9, OFA port 3, air-staged conditions.
lead to an enhanced slagging and fouling propensity due to its lower fusion temperature depending on chemical and mineralogical
composition of y ash as well as on conditions (temperature and
velocity distribution, reducing or oxidizing atmosphere and many
others) in the furnace [35]. The ash chemical composition (from
air staged co-combustion experiments) for 10% optimum BBR is
shown in Table 7.
Ash chemical composition of the coalbiomass blends with 10%
BBR does not differ signicantly from the pure coal ash (Table 7).
This was in agreement with the ndings of Pronobis (2005) and
Grammelis et al. (2006) [35,36]. Pronobis (2005) concluded that
Table 8
Traditional slagging and fouling indices.a.
Slagging (basic 10
acidic compounds
ratio) Index
Table 7
Air staged (SR1 = 0.9) co-red ash composition for 10% BBR of different blends.
Components
(%)
RC
RC + SM
RC + CS
RC + WC
RC + SBT
RC + SBR
Na2O
MgO
A12O3
SiO2
p2o5
K2O
CaO
TiO2
Fe2O3
SO3
Othersa
0.35
1.386
23.07
63.35
0.444
2.18
1.5
0.995
5.75
0.058
0.32
1.68
21.57
60.98
0.7
2.5
2.69
0.9
6.78
0.223
0.36
1.7
22.77
59.9
0.58
2.83
2.27
0.965
5.6
0.06
0.36
1.36
22.98
63.27
0.49
2.28
1.55
0.998
5.74
0.06
0.44
1.83
22.66
61.73
0.5
2.38
2.25
0.95
5.66
0.079
0.33
1.36
21.1
62.36
0.51
2.86
2.39
0.92
5.9
0.089
Include V2O5, Cr2O3, SrO, ZrO2, BaO, Mn3O4, NiO, CuO, ZnO, PbO, HfO2.
Simplied B/A
Slagging (Babcock)index
Fouling index
Source: [35,37,38].
SBt
SBR
CS
SM
WC
RC
Rb
B/A
B/A(+P)
R(B/A)
RS
Fu
SR
12.56
0.1472
0.153
0.115
0.039
0.415
86.37
12.84
0.1522
0.158
0.116
0.043
0.485
86.60
12.76
0.15.26
0.1595
0.116
0.043
0.487
86.22
13.97
0.1674
0.176
0.135
0.051
0.472
88
11.29
0.1294
0.135
0.1
0.039
0.342
87.97
10.56
0.1202
0.1255
0.0931
0.0409
0.2977
88.74
135
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