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

5. 3 x Front, 3 X Rear

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

13. Solution: Measure SA flow at each burner and adjust SA dampersSecondary 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 Burner 3 Burner 2 Burner 1

16. Post-Combustion CO and O2 measurement accuracy is critical Grid configuration preferred

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

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 – jose.estrada@pgnmail.com David Earley – dearley@combustiontc.com Bill Kirkenir – bill.kirkenir@pgnmail.com