Sources of unburned carbon in the fly ash produced from low-NO x pulverized coal combustion

Abstract

The unburned carbon in the fly ash produced from low-NOx pulverized coal combustion is shown to consist of a mixture of soot and coal char. The soot was identified by the presence of chains or aggregates of 10–50-nm-diameter primary particles in electron microscope images of both laboratory samples and a sample of fly ash from a power plant operating low-NOx burners. Laboratory samples showed increasing carbon content with decreasing nitrogen oxide (NOx) concentration. The experiments included a high-NOx base case and four low-NOx cases consisting of (1) staged combustion with short (0.5 s) residence time, (2) staged combustion with long (1.5 s) residence time, (3) a low-NOx burner with slow mixing, and (4) reburning using coal as the reburning fuel. Comparison of the base case that used premixed coal and air with the long-residence-time staged combustion case shows a decrease in the NOx from over 900 ppm to below 200 ppm and an increase in the carbon in the ash from 4% to over 30%. The fly ash from staged combustion was a mixture of large soot aggregates, porous char, and spherical particles of mineral ash, whereas the ash from reburning lacked the large aggregates. For all laboratory conditions, the carbon content in the particle fraction with an aerodynamic diameter over 10 μm was higher than in the 1–2,5-μm-diameter fraction. Both soot aggregates and char contributed to the high carbon in the large particle fraction. The difference in carbon burnout between the two staging conditions was consistent with published soot oxidation rates. Both char burnout and soot formation need to be considered in studies of the carbon content of pulverized coal fly ash.