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Combustion Technology

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Combustion Technologies Description

ETEC has applied our extensive combustion technology to optimize the combustion fired equipment performance and operation for numerous clients, including electric utilities, refineries, chemical plants, paper mills, and industrial furnaces. The ETEC combustion optimization protocol is comprised of four parts, described as follows:

1. Pre-Outaqe Testing

Testing is conducted prior to the scheduled maintenance outage for the purpose of documenting existing performance and identifying deficiencies which need to be addressed and incorporated into the maintenance punch list. The Pre and Post-Outage performance calculations are based on the American Society of Mechanical Engineers (ASME) Codes, e.g., PTC 4-1998 "Fired Steam Generators, Performance Test Codes" for boiler efficiency and combustion calculations. Testing would document existing performance:

  • Combustion Performance
  • Air heater Leakage
  • Boiler Efficiency
  • Unit Heat Rate

2. Boiler Inspection

During the outage a detailed boiler inspection is conducted to identify the cause of any existing or potential combustion related problems known or identified during the pre-outage testing. The inspection includes the following items:

  • Identify burner and fuel system items which require maintenance.
  • Air registers calibrations.
  • Evaluation of furnace and convective passes; gas side deposits, air heater, and stack condition.

3. Post-Outage Boiler Performance Optimization

This phase consists of the following tasks:

  • Baseline testing to establish baseline efficiencies and potential for performance improvement over the firing range.
  • Combustion and operational modifications made to improve boiler performance (using our Step-by-Step boiler adjustment procedure for low excess O2 operation). This procedure establishes the unit's characteristic O2 /CO curves, as illustrated in Figure 1. These curves serve as a basis for future reference. We have found that some boilers require operation with excessively high excess O2 levels to control CO emissions. Such cases have been due to burner design, flame impingement, and/or burner system condition. Once the cause is identified, then corrective measures are recommended.

    Figure 1. Determining Optimum (Target) O2 Level
    Combustion Technology
  • Post modification checkout to document final performance and establish the minimum excess oxygen levels by which the operators will fire by over the load range.

4. Test Report

A detailed test report is prepared to assemble and analyze all data collected during the testing and tuning. To ensure completeness and to standardize the report, the following format is used as a guide:

Executive Summary

  • Section 1. Introduction
  • Section 2. Test Program and Equipment Description
  • Section 3. Test Results
  • Section 4. Combustion Control System Adjustments
  • Section 5. Discussion of Results
  • Section 6. Conclusions and Recommendations