This document summarizes the Continuous Combustion Management (CCM) project implemented at the Crystal River Unit 4 power plant. The project involved adding equipment to measure and control coal and air flows to improve combustion and reduce emissions. Key results included a 0.5% increase in boiler efficiency, 7-15% reduction in NOx, and annual fuel and reagent savings. The project demonstrates how automated balancing of coal and air flows can optimize combustion and improve plant performance.

1. 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
3 x Front, 3 X Rear
SCR, Cold Side ESP & Wet
FGD

5. 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)

6. Coal Balancing
Problem: Uneven Coal distribution
Solution: Online coal measurement +
adjustment
Coal Out
Adjustable Coal
Valves
Pulverizer
Coal In Discharge

7. Coal Flow Measurement
Air Monitor Corporation
Santa Rosa, CA

8. Coal Flow Balancing

9. Coal Flow Balancing

10. Burner Air:Fuel Ratios

11. Secondary Air Balance
Windbox Air Windbox Air
Dampers Dampers
•Problem: Uneven Secondary Air
(SA) distribution
•Solution: Measure SA flow at Secondary
Secondary
each burner and adjust SA Air
Air
dampers

12. Secondary Air Measurement
Wind Tunnel Testing at Air Monitor HQ

13. Why Automate SA Dampers?
Dynamic windbox flow profiles
Fluctuating windbox pressure
Ash build-up
Burner Burner Burner
1 2 3

14. Post-Combustion
CO and O2 measurement accuracy is critical
Grid configuration preferred
Combustion Parameters
Optimum Zone Boiler Efficiency
CO
Comfort
Zone
Slagging
NOx
Fireside Corrosion
Tube Leaks
O2
LOI
Air Flow

15. O2 Probe Relocation
Old location not representative of furnace O2
profile
40'
New location Economizer
CASCADE ROOM
proven to be more
OLD O2
accurate through LOCATION
testing with B&W
NEW O2
FLUE GAS
15'
LOCATION
Significant
distribution
improvement ECONOMIZER ASH
HOPPER
realized due to new
location

16. O2 Probe Standard Deviation
CR4 O2 Probe Standard Deviation
8
7
6
5
(Probes 2 & 7 Omitted)
Stanard Deviation
4 Pre-Outage
Pre-Tuning
Post Tuning
3
2
1
0
0 100 200 300 400 500 600 700 800 900
Gross Load (MW)

17. CRN O2 Distribution Comparisons
CR4 O2 Profiles
CR5 O2 Profiles
Note: Unit scales are different

18. CO Probe Augmentation
CO is better diagnostic tool than O2 alone
Air leakage impact on O2 probe

19. CCM Tuning

20. Remote Combustion Dashboard

21. New O2 Curve
LOI benefit
Unit 4 O2 Curve
10.0%
9.0%
8.0%
7.0%
6.0%
Excess O2 (%)
5.0% Old Curve
Manual Curve
4.0%
New Curve
3.0%
2.0%
1.0%
0.0%
0 1000 2000 3000 4000 5000 6000
Steam Flow (kpph)

22. NOx Benefit

23. 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

24. Pre vs. Post CCM Boiler Efficiency Comparisons
Base -- Original OEM Predicted Post CCM test w/ 2.5 lb Sulfur Coal &
Operational Description Efficiency Pre CCM Test w/ 2.5 lb Sulfur Coal Post CCM Test w/ 2.5 lb Sulfur Coal optimized O2 Curve
This test was run @ full load on 6/24/10 This test was run @ full load on 8/16/10
Original predicted performance This test was run @ full load on 5/30/10 after initial balancing of the coal burner w/ stable O2 & CO parameters. The
assumes 0.013 lbs moisture / lb of air prior to placing the CCM project in lines and placing the secondary air O2 curve had been adjusted down to
Comments (80˚F & 60% Humidity). service. registers in automatic. optimize overall boiler efficiency.
Adjustments / Variables
Excess Air 20.0 16.0 15.0 11.0
Humidity 60% 80% 80% 80%
Average Air Heater Exit Gas Temperature ˚F 262 317 319 315
Annual Capacity Factor 85% 71% 71% 71%
% Dry Carbon in Refuse --- 4.00 2.70 3.20
Boiler Efficiency Parameter
Dry Gas Loss % 4.43 5.36 5.28 4.99
Water from Fuel Loss % 5.91 5.15 5.13 5.12
Moisture in Air Loss % 0.11 0.21 0.20 0.19
Unburned Combustible Loss % 0.30 0.51 0.34 0.41
Radiation Loss % 0.15 0.15 0.15 0.15
Unaccounted for Manuf Margin % 1.50 1.50 1.50 1.50
Total Losses % 12.40 12.88 12.61 12.36
Overall Boiler Efficiency % 87.60 87.12 87.39 87.64
Input in Fuel (MKB/HR) 6581.00 6717.48 6690.00 6662.11
Input in Fuel (MLB/HR) 639.80 584.13 581.74 579.31
Wet Gas Wt (MLB/HR) 6579.00 6892.86 6821.53 6570.70
Tot air to Burn Equip (MLB/HR) 5891.00 6324.39 6254.89 6008.25

25. Additional “Soft” Benefits
1. Reduced emissions
2. Reduced pulverizer wear
3. Reduced wear on Coal Yard equipment.
4. Reduced boiler tube & non-pressure part erosion due
to lower flue gas velocities.
5. Improved ESP performance due to lower flue gas
velocities.
6. Reduced potential for slagging and fouling events
7. Improved Pressure part life due to improved
temperature profile
8. Reduced ash disposal costs
9. Reduced boiler tube failures due to reducing
atmospheres

26. Contact
Joe Estrada – jose.estrada@pgnmail.com
David Earley – dearley@combustiontc.com
Bill Kirkenir – bill.kirkenir@pgnmail.com