Effect of the coal-spreading air on airflow and low-NOx combustion within a 75 t/h coal-fired grate furnace

Abstract

Coal-fired grate furnaces equipped with coal throwers, which conventionally own a low-NOx combustion framework consisting of (i) the partitioned primary air for the horizontal air staging on the grate and (ii) the coal-spreading air and secondary air for the vertical air staging in the freeboard, actually suffer from poor burnout and apparently high NOx emissions at habitual operations. While comprehensive investigations on the in-furnace airflow, coal combustion, and NOx formation, which are devoted to first explaining and then improving these problems, are absent up to now. In order to unveil the airflow, combustion, and NOx emission characteristics within a 75 t/h coal-fired reverse grate furnace, evaluate its coal-spreading air impact on the low-NOx combustion performance, and determine an appropriate coal-spreading air ratio for improving the furnace performance, both industrial-scale tests and numerical simulations were performed at the coal-spreading air ratios of 2 %, 4 %, 6 %, and 8 %, respectively. The flow-field deflection and asymmetric combustion appeared in the upper furnace, with the upward gas deflecting towards the rear-wall side and the front-half furnace part dominated by a weak recirculation zone without effective combustion. With increasing the coal-spreading air, problems of the flow-field deflection and asymmetric combustion aggravated. The combustion intensity weakened in the layer combustion zone while displayed an increase-to-decrease trend in the suspension combustion zone. In terms of indexes related to the furnace performance, burnout rate decreased continuously, and NOx emissions initially raised but then decreased. A comprehensive consideration of the coal-spreading requirement via air, flow-field symmetry, low-NOx combustion, and burnout suggests that a 2 % coal-spreading air ratio should be preferred, where NOx emissions and burnout loss were gained at 249 mg/m3 (6 % O2) and 5.75 %, respectively. It reduced NOx emissions by 49 % while raised slightly burnout loss, as compared with the corresponding levels of 486 mg/m3 and 5.4 % at the habitual case. These results not only negate the air-staging function of the coal-spreading air but also highlight the novelty of this work.