Chapter7 Pulverized coal-fired boiler and

combustion equipment

 Furnace and burner of pulverized coal-fired boiler

 Turbulent burner and its layout
 Direct - burner and its layout
Stable combustion of pulverized coal flame
Combustion with W-type flame
Fouling, slagging and safe operation of water
wall
Prof&Dr Zhongzhu Qiu 1
Furnace and burner of pulverized coal-
Furnace：
fired boiler
Functions: ensure complete combustion, appropriately arrange heat
transfer in furnace, appropriate heating surface to fulfill the
requirement for boiler capacity.
 Appropriately arrange burner for fast ignition and good
aerodynamic field to make sure uniform heat load on the surface;
good fullness, no dead and vortex zone to avoid flame flashing
wall and slagging;
 Enough volume and height of furnace to ensure complete
combustion;
 Appropriate heating surface arrangement to fulfill the
requirement for capacity; Meantime, assure proper furnace outlet
temperature and guarantee no slaggling and safe operation on
convection heating surface;
 Radiation surface must have reliable hydrodynamic
characteristics to assure safety;
 Compact furnace, low metal and
Prof&Dr other
Zhongzhu Qiumaterials consumption；
2
easy for manufacture, installation, maintenance and operation;
1. Furnace volume heat release rate：
BQar,net
qv  , kW / m 3

V1
2. Furnace cross-section heat release rate：

BQar,net
qa  , kW / m 3

Prof&Dr Zhongzhu Qiu 3

3. Thermal load on furnace wall in the area of
burner
BQar,net
qr 
uH r
4. Thermal load on furnace wall

B jQ
qf 
F
Prof&Dr Zhongzhu Qiu 4
Burner:
Primary air: air entrains pulverized coal into burner;
Secondary air: air sent into furnace after ignition;
Tertiary air: when bin storage type pulverizing system uses hot air
transportation, the exhaust gas which dries coal in mill contains
10%-15% pulverized coal；
Basic requirements for burner：
• Stable ignition for coal flow;
• After ignition, primary and secondary air should be timely and
appropriately mixed for high combustion efficient;
• Flame has good fullness in chamber and can not flash furnace
wall and avoid agglomeration;
• Good fuel adaptability and wide load adjustment range;
• Low resistance；
• Low NOx formation, contaminant
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Prof&Dr Zhongzhu Qiu 6
Prof&Dr Zhongzhu Qiu 7
 Turbulent burner and its layout
Features of swirling jet：
1.Swirling jet has not only axial speed, but also tangential
speed. Strong initial turbulence, fast decay, short range;
2. Axial speed is negative near burner outlet, having
recirculating zone, ignition starts both from inside and
outside;
3.Larger growth angle
Turbulent intensity and influences：
Turbulent intensity
8M
n
DK
M: Rotational moment of momentum
K: Axial momentum
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① n is small, there is weak or no swirling air, small or no
recirculation zone, which is called closed air flow; when n
increases, the recirculation zone enlarges. The air flow is
closed when the main stream has low speed because of
recirculation zone extend, which is called open air flow; with
the increase of n, the growth angle grows and then causes
pressure difference between outside of air flow and
recirculation zone, which forms dispersion jet. The air flow
moves along furnace wall after leaving burner, which called 飞
边.
② With the increase of n, recirculation zone increase firstly and
then shorten. But short recirculation zone can not entrain high
temperature flue gas. So it is important to select correct n to
make sure that the jet is open jet and there is enough high
temperature flue gas going back to the root of flame to
accelerate ignition and combustion;
③ The growth angle increases with swirling intensity increase,
which is beneficial for ignition;
④ The range of swirling jet decreases with the increase of
swirling intensity, so the flame
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Zhongzhu Qiu should be appropriate. 9
 Typical turbulent burner

 Single spiral case with expanding cone turbulent burner;

 Double spiral case turbulent burner;

 Axial blade turbulent burner;

 Tangential blade turbulent burner.

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Single spiral case with expanding cone turbulent burner

1. flame stabilizer

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 Double spiral case turbulent burner

1 central duct; 2 primary spiral case; 3 secondary spiral case, 4

primary air duct; 5 duct for oil

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Primary air
Axial blades turbulent burner

Secondary
air

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Tangential blades turbulent burner

Secondary
air

Primary
air
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Flame stabilizer

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The arrangement of turbulent burner

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 Direct - burner and its layout

Basic features of direct flow

Notions:

• turbulence jet；Re>106
• free isothermal jets；
• Jet range：When the axial speed of one cross section wm
decreases to the value>0 , the distance between cross
section and vent.
• Growth angle：determine the boundary and configuration
of the jet.

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Initial zone full developed zone

2-dimensional free jet

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Formulations:

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Prof&Dr Zhongzhu Qiu 20
Corner Firing Tangential Circle with direct -
burner and its layout

The arrangement of direct-burner outlet

 Uniform air distribution: for bituminous coal, lignite，

CE corporation, when Vdaf≧13%, use this method；

 Staged air: for anthracite, lean coal, low-grade

bituminous coal also use stage air

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Prof&Dr Zhongzhu Qiu 22
 Uniform
arrangement staged
arrangement

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1 burner; 2 dilute O2 zone; 3 Primary air jet, 4
Second air jet; 5 O2 excessed zone; 6 water wall

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Swirl removal secondary air
Tertiary air
Oil secondary air
Upper primary air
Swirl startup secondary air
Middle primary air
Lower primary air
Swirl startup secondary air
Oil secondary air

Burner
Prof&Drarrangement
Zhongzhu Qiu 25
a.Peripheral secondary air, b. sandwich, c. cross

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 Surrounding air: entrain high temperature flue gas and
protect primary air nozzle; thin wind strata, 15-25mm, high
speed 30－45 m/s, low flow rate, ~10％of secondary air.

 Sandwich wind: supply the air after ignition timely;

increase the rigidity of primary air; enhance turbulence
pulse for good mixture; decrease growth angle of jet and
protect wall from agglomeration;

 Cross wind: complementary oxygen

Prof&Dr Zhongzhu Qiu 30
Thermal parameters of firing tangential circle with
direct -burner :
 Layers of primary air nozzle
 Thermal load per nozzle
 Primary air rate, secondary air rate are determined by Vdaf,
ignition, mill system and conditions for ignition
 Primary air speed, secondary air speed and tertiary air speed

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Arrangement of firing tangential circle with direct -
burner

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 Flow deflection of firing tangential circle
with direct -burner
Reasons：
1. Monument of primary and secondary air;
2. Diameter of assuming circle; (table 7－7)
3. Section configuration of furnace;
4. Air replenishment from double sides of burner;
5. Structure features of direct flow burner: configuration of
nozzle（ h/b）influences rigidity;

Measures for correcting flow deflection：
1. Proper diameter of assuming circle and flame fullness
2. Proper monument of primary and secondary air, overload
secondary air monument will form lateral thrust on
adjacent angle; entrainment of primary air
3. Proper burner structure and nozzle arrangement
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4. Reasonable section of furnace (rectangle)
Stable combustion technology for pulverized coal flame

1. Measures for stable combustion

2. WR burner(direct flow, wide adjustment
ratio, sway)
3. Flame stabilization boat direct -burner
(Tsinghua)
4. Bluff-body burner (HUST)
5. Coal pre-combustion chamber(Tsinghua
etc.)
Turbulent
Coaxial jet with high speed difference
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 Stabilization measures

 Typical measures
① Laying combustion area;
② Blowing pulverized coal with hot air;
③ Comparative low primary air speed and rate;
④ Decreasing fineness of particles;
⑤ Controlling minimum operation load and using good
performance burner.
 “Three-high” theory
high temperature, high concentration of pulverized coal
and high oxygen supply.

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WR burner (CE)

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 Boat Flame Stabilizer Direct Flow
Burner(Tsinghua University)

Primary air

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Bluff-body flame stibilizer burner (HUST)

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Coal pre-combustion chamber(Tsinghua etc.)
for stabilization, Turbulent burner

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Coaxial jet with high speed difference

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 W-type flame

Features of W-type flame

W-type flame burner

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 Features
1. Aims
anthracite, lean coal ignition zone should maintain high
temperature and accelerate ignition and have enough
combustion range Mechanism of W-type flame
2. 3 stages of W-type flame combustion mode
 1st ignition, pulverized coal ignited and initially combusted
in weak turbulence. Air is supplied with low speed and flow
rate in case too much air affects ignition.
 2nd combustion, the ignited coal flow is strongly mixed with
secondary and tertiary air to boost the combustion .
 3rd radiation and burn out, the flue gas goes up to radiation
chamber. Flue gas radiate heat to heating surface as well as
burn out in weak turbulence .

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 Back

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3. Features:
① Main combustion zone is near nozzle, the radiation of the arc
and combustion area both facilitate the coal with low volatile
to ignite and combust；
② Stage combustion can not only facilitate ignition and
combustion but also decrease excess air coefficient and NOx
generation;
③ Long flame range increases residence time of coal, which is
beneficial for burning out;
④ When the flame turns around with 180°at the bottom of
combustion chamber, some ash is separated , which
decreases the fly ash content in flue gas;
⑤ Direct flow burner or swirling burner or high coal
concentration burner is easy for organize good ignition and
combustion;
⑥ When load fluctuates, the temperature of flame does not
change much. So it has good load adaptability. When
operating in low load mode,
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Zhongzhu requirement for oil is low45
 W-type flame
1. High concentration pulverized coal burner with
cyclone separator

2. Split burner

3. High concentration pulverized coal burner with

modified Dense/ Sparse Pulverized Coal Separator

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High concentration pulverized coal burner with cyclone
separator

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Split burner

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High concentration pulverized coal burner with modified
Dense/ Sparse Pulverized Coal Separator

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 High temperature fouling, slagging and corrosion
on waterwall
Fouling: the ash temperature is below ash fusion point and
deposits on the surface of water wall
Slagging: the fusion ash sticks on the surface of water wall.

Reasons:
1. Fusion point: DT ST FT
2. The aerodynamic in furnace is not good and flame spreads along the wall ; flue gas near the furnace
wall is reducing atmosphere and ash fusionProf&Dr
point isZhongzhu
low. Qiu 50
 High temperature corrosion

High temperature corrosion is the corrosion phenomenon on high

temperature tube surface, which is caused by the corrosive ash, slagging
or gas generated during the combustion of sulfur.
• Internal Reason: the sulfur content in the fuel
• External Reason: the water wall is located in high temperature flue gas
and the wall temperature is high. When the flame is close to the wall,
the atmosphere adjacent to the metal surface is reducing, which
decreases fusion temperature and aggravates the fouling or slagging.
Finally, the high temperature corrosion happens on tube surface.
• The most severe corrosion commonly happens in combustion area or
superheated area.
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 High temperature corrosion

High temperature corrosion on water wall can be generally

classified as 3 types:

• Sulfate(K2SO4, Na2SO4)-high temperature corrosion;

K2SO4 and Na2SO4 react with Fe2O3, which is a protection
layer of a metal pipe

• Sulfide(FeS2)-high temperature corrosion;

FeS2 -> [S],[S]+Fe -> FeS,FeS+O2 -> Fe3O4

• SO3, H2S, HCl caused high temperature corrosion

Fe2O3 + SO3-> Fe(SO4)3

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 Measures for avoiding high temperature corrosion

1. Corrosion resistance coating, or using corrosion resistance

material.
2. Lean oxygen combustion. Decreasing excess air would
reduce the amount of free O. Furthermore, less SO2 is
converted to SO3. So low concentration of SO3 would
dramatically decrease the opportunity for high temperature
corrosion.
3. Proper air supply and air turbulence enhancement can avoid
reducing atmosphere in some area, which can reduce H2S
and sulfide corrosion.
4. Adjusting primary air and make sure identical coal flow rate
in all burners, even coal concentration
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5. Decrease the water wall temperature
6. Flue gas recirculation can decrease flame temperature and
SO3 concentration in flue gas, which can reduce high
temperature corrosion.
7. Forming a thin air protection layer in oxidation atmosphere,
which can also avoid high temperature corrosion.
8. Additives in fuel can change slagging characteristics.

Prof&Dr Zhongzhu Qiu 54