THIS STANDARD IS: Updated PERFORMANCE STANDARD

STD NO INDEX DATE OWNER PAGE

: : : : :

292-76-03 21.13 22 MAY 2003 8152 1 OF 7

SUBJECT PURPOSE REMARKS: NOTES:

: SEPARATED OVERFIRE AIR (SOFA) LOCATION CRITERIA FOR LOW NOX TANGENTIAL FIRING SYSTEMS : To provide a specification of location of SOFA compartments based on standardized sub-stoichiometric residence time calculation procedure. This Standard to be effective immediately. 1. See Page 2 for Versions.

PREPARED BY: S. GARCIA APPROVED FOR CONTENT: R. KUNKEL APPROVED FOR PUBLICATION: T. MISKELL

SR. ENGINEERING TECHNICIAN STANDARDS ENGINEERING - 9809 MANAGER PERFORMANCE DESIGN ENGINEERING - 8152 PROGRAM MANAGER STANDARDS ENGINEERING - 9809

This document contains proprietary data and shall not be reproduced or disclosed without the permission of ALSTOM Power Inc.

SUBJECT:

STD NO. : 292-76-03 INDEX : 21.13 DATE : 22 MAY 2003 OWNER : 8152 PAGE : 2 of 7 ______________________________________________________________________________________________________ UNITS: n ENGLISH; o METRIC; o BOTH; o NONE PRODUCT LINE: CHECK THE PRODUCT LINE THE STANDARD IS APPLICABLE TO o ALL; n A = CONTROLLED CIRC. BOILERS n B = SUPERCRITICAL BOILERS n C = VU40 AND VU60 BOILERS o E = FLUIDIZED BED BOILERS (CFB) n F = NATURAL CIRC. BOILERS (UTILITY) o H = HEAT RECOVERY STEAM GENERATORS (HRSG) o P = MILLING SYSTEMS (PULVERIZERS) o R = CHEMICAL RECOVERY BOILERS o S = SERVICES (AFTER MARKET USE)

Separated Overfire Air (SOFA) Location Criteria for Low NOx Tangential Firing Systems

Versions Ver. 1- Standard completely revised; updated Standard format. Ver. 2 - Revised Paragraphs 3.1, Figure 1, 3.2, 4.0, 4.1, 5.0, 5.1, 5.3 and 5.4. Ver. 3 - Updated standard format; name change to ALSTOM Power Inc.

SUBJECT:

STD NO. : 292-76-03 INDEX : 21.13 DATE : 22 MAY 2003 OWNER : 8152 PAGE : 3 of 7 ______________________________________________________________________________________________________

Separated Overfire Air (SOFA) Location Criteria for Low NOx Tangential Firing Systems

1.0

Purpose

MTCA Mcoal %ASH

Total combustion air mass flow (lb/hr) Total coal flow (lb/hr) Mass percentage of ash in coal (%) CCOFA mass flow as a percentage of MTCA (%) Lower SOFA mass flow as a percentage of MTCA (%)

The purpose of this standard is to specify the vertical furnace location of separated overfire air (SOFA) windboxes, for the optimization of NOX control and combustion efficiency. Because this location criteria is based upon optimizing mean coal residence time at sub-stoichiometric conditions (tsub), this Standard also serves to define this calculation procedure. 2.0 Scope

%CCOFA %LSOFA

This standard is applicable for the selection of all ALSTOM Power tangential coal firing systems utilizing separated overfire air (SOFA) for the control of NOX emissions. This includes both vertical - and spiral - walled furnace arrangements, both with and without supplementary fuel. For procedures defining the sizing and arrangement of overfire air compartments, refer to Standard No. 7-96, Index 21.13. For overfire air location guidelines for process boiler application and/or alternate fuels, consult with Performance Design Engineering. 3.0 Residence Time Calculation Procedure 3.1 Required Data

%MSOFA Middle SOFA mass flow, if applicable, as a percentage of MTCA (%) %HSOFA High SOFA mass flow, if applicable, as a percentage of MTCA (%)

FOT

Furnace outlet temperature (o F)

h1 Distance from centerline of top coal nozzle to centerline of CCOFA compartments (ft) h2 Distance from CCOFA centerline to centerline of LSOFA or MSOFA compartments (ft) h3 Distance from LSOFA centerline to HSOFA centerline, if applicable (ft) h4 Distance from HSOFA centerline to horizontal furnace outlet plane (ft) A Furnace plan area (sq ft)

SUBJECT:

STD NO. : 292-76-03 INDEX : 21.13 DATE : 22 MAY 2003 OWNER : 8152 PAGE : 4 of 7 ______________________________________________________________________________________________________

Separated Overfire Air (SOFA) Location Criteria for Low NOx Tangential Firing Systems

Figure 1

3.2

Calculation

Horozontal Furnace Outet Plane (HFOP)

h4
HSOFA Centerline

In order to determine substoichiometric residence time for a given configuration, it is necessary to separately calculate the residence time for each of the four vertical sections (h1 - h4) indicated in Figure 1. (Note: For configurations with only one SOFA elevation, section h3 does not apply.) For each section, mean residence time is calculated using the following formula, where the subscript i signifies the appropriate section, 1 through 4, corresponding to h1 through h4 on Figure 1.
Separated Overfire Air (SOFA) Windboxes

i =

h3
LSOFA Centerline

3600 * hi * i * A Mi

h2
COFA Centerline

h1

i represents the gas density of the relevant furnace section, in lb/ft3. This value is determined by first calculating the gas density at the horizontal furnace outlet plane:
HFOP = 39.75 FOT + 460

Top Coal Centerline

Main Windbox

Density for the individual furnace sections are then given by the following equations,
1 = HFOP 1+ C
2 = HFOP

1+ C *

0.5 *h2 +h3 + h4 h1 + h2 + h3 + h4

3 =

1 + C*

0.5 * h3 + h4 h1 + h2 + h3 + h4

HFOP

HFOP 1 + C*
0.5 * h4 h1 + h2 + h3 + h4

SUBJECT:

STD NO. : 292-76-03 INDEX : 21.13 DATE : 22 MAY 2003 OWNER : 8152 PAGE : 5 of 7 ______________________________________________________________________________________________________

Separated Overfire Air (SOFA) Location Criteria for Low NOx Tangential Firing Systems

Where the appropriate correction factor, C, is applied as follows: For configurations with one SOFA elevation: C = 0.14 For configurations with two SOFA elevations: C = 0.10 Mi, representing the gas mass flow for the relevant furnace section (in lb/h), is calculated using the following equations: M1 = 0.01 * MTCA * (100 - %CCOFA - %LSOFA -%HSOFA) + Mcoal (1 - 0.002 * %ASH) M2 = 0.01 * MTCA * (100 - %LSOFA - %HSOFA) + Mcoal (1 -0 .002 * %ASH) M3 = 0.01 * MTCA * (100 %HSOFA) + Mcoal (1 - 0.002 * %ASH) M4 = MTCA + Mcoal (1 - 0.002 * %ASH) Sub-stoichiometric residence time is then equal to the following: For configurations with one SOFA elevation: sub = 1 + 2 For configurations with two SOFA elevations: sub = 1 + 2 + 3 Total residence time (top coal nozzle to HFOP), is given by: total = 1 + 2+ 3 + 4

4.0

Vertical Location of SOFA Windboxes

SOFA windboxes shall be sized with free area consistent with Standard No. 7-96, Index 21.13, with the ability to achieve 300 vertical tilt and 150 horizontal yaw. The vertical centerline of each SOFA windbox shall be located a suitable minimum distance (h2, h3) above the centerline of the upper coal nozzle so as to satisfy the following criteria: 4.1 SOFA Location - Single Elevation

For arrangements utilizing one elevation of SOFA, the corner windboxes shall be located such that each of the following two residence time criteria apply: For LSOFA (per Std. Arrangement 2A or 2B) sub

0.6 sec. and sub / total 0.4

For MSOFA (per Standard Arrangement 2C or 2D) sub

0.8 sec. and sub / total 0.53

SOFA Location - Double Elevation

4.2

For arrangements utilizing two SOFA elevations, the lower elevation (LSOFA) shall be located such that each of the following two residence time criteria apply: (1 + 2 ) 0.6 sec. and (1 + 2 ) / total 0.4 The upper elevation (HSOFA) shall be located such that each of the following two residence time criteria apply: sub

1.0 sec. and sub / total 0.60

SUBJECT:

STD NO. : 292-76-03 INDEX : 21.13 DATE : 22 MAY 2003 OWNER : 8152 PAGE : 6 of 7 ______________________________________________________________________________________________________

Separated Overfire Air (SOFA) Location Criteria for Low NOx Tangential Firing Systems

5.0

Sample Calculation

Consider design utilizing two elevations of SOFA. The following data is given: Top Coal Nozzle Centerline Elevation Centerline of CCOFA Compartments LSOFA Windbox Centerline HSOFA Windbox Centerline HFOP Elevation (Tip of Nose Arch) Furnace Width Furnace Depth 169.0 171.6' 183.2 193.4 211.9 36.75 36.75

HFOP = 0.0127 lb / ft3 0.5 * h3 + h 4 1+ C * h1 + h2 + h3 + h4 HFOP = 0.0131 lb / ft3 0.5 * h4 1+ C * h1 + h2 + h3 + h4

5.3

Calculate Gas Mass Flows

Total Combustion Airflow 1,752,418 lbs/h Total Coal Flow 228,700 lbs/h Ash in Coal (% by Mass) 5.0 % CCOFA Flow (% of TCA) 8.0 % LSOFA Flow (% of TCA) 21.0 % HSOFA Flow (% of TCA) 21.0 % Predicted Furnace Outlet Temp. 2500 F 5.1 Calculate Heights

M1 = 0.01 * MTCA *(100 - %CCOFA - %LSOFA -%HSOFA) + Mcoal (1 - 0.002 * %ASH) = 0.01 (1,752,418) (100-50) + 228,700 [1-.002(5)] = 1,102,622 lb/h M2 = 0.01 * MTCA *(100 - %LSOFA - %HSOFA) + Mcoal (1 - 0.002 * %ASH) = 0.01 (1,752,418) (100-42)+228,700[1- 0.002(5)] =1,242,815 lb/h M3 = 0.01 * MTCA *(100 - %HSOFA) + Mcoal (1 - 0.002 * %ASH) = 0.01 (1,752,418) (100-21) + 228,700 [1- 0.002(5)] = 1,610,823 lb/h M4 = MTCA + Mcoal (1 - 0.002 * %ASH) = 1,752,418 + 228,700[10.002(5)] = 1,978,831 lb/h

h1 = distance from top coal nozzle to CCOFA c.l. h1 = 171.6 - 169.0 = 2.6 h2 = distance from CCOFA to LSOFA c.l. h2 = 183.2 - 171.6 = 11.6 h3 = distance from LSOFA c.l. to HSOFA c.l. h3 = 193.4 - 183.2 = 10.2 h4 = distance from HSOFA c.l. to HFOP h4 = 211.9 - 193.4 = 18.5 5.2
HFOP =

Calculate Gas Densities

39.75 39.75 = = 0.0134 lb / ft3 FOT + 460 2500 + 460

For 2 elevations of SOFA, C = 0.10

1 = HFOP = 0.0122 lb / ft3 1+ C

2 HFOP 0.5 * h 2 + h3 + h 4 1+ C * h1 + h 2 + h3 + h 4 = 0.0124 lb / ft 3

SUBJECT:

STD NO. : 292-76-03 INDEX : 21.13 DATE : 22 MAY 2003 OWNER : 8152 PAGE : 7 of 7 ______________________________________________________________________________________________________

Separated Overfire Air (SOFA) Location Criteria for Low NOx Tangential Firing Systems

5.4

Calculate Residence Times

3600 * h1 * 1 * A 3600 * 2.6 * 1351* .0122 = = 0.14 s M1 1102,622 , . 3600 * h2 * 2 * A 3600 * 116 * 1351* .0124 = = 0.56s M2 1242,815 , 3600 * h3 * 3 * A 3600 * 10.2 * 1351* .0127 = = 0.39s M3 1610,823 , 3600 * h4 * * A 3600 * 18.5 * 1351* .0131 4 = = 0.60s M4 1978,831 ,

5.5

Check for Acceptability

LSOFA Location:

1+ 2 = .14 + 0.56 = .70s 0.70 > 0.60 ... o.k.

(1+ 2)/total = .70/1.69 = 0.41 0.41 > 0.40 ... o.k. HSOFA Location:

sub = 1 + 2 + 3 = 0.14 + 0.56 + 0.39 = 1.09s total = sub + 4 = 1.09 + 0.60 = 1.69s sub = 1.09s 1.09 > 1.0 ... o.k. sub / total = 1.09 / 1.69 = 0.64 0.64 > 0.60 ... o.k.
In the event that any of the above residence times or ratios were not acceptable (below the minimum values defined in Paragraphs 4.0 4.2), the LSOFA, MSOFA or LSOFA and HSOFA windbox elevations (and therefore h2 and h3) shall be increased such that the minimum residence time values are achieved.