Firing, NOx 0042005

THIS STANDARD IS: STD NO : 4-2005-00
New INDEX : 21.13

PERFORMANCE STANDARD DATE : 17 FEB 2006
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PAGE : 1 OF 78
SUBJECT :TILTING TANGENTIAL FIRING SYSTEM SELECTION FOR BITUMINOUS AND SUB-
BITUMINOUS COALS
PURPOSE : To define the procedures and guidelines necessary for the selection of tilting tangential
firing systems for all applicable steam generators.
REMARKS: This Standard to be effective immediately.
NOTES: 1. See Page 2 for Versions.

2. This Standard Supercedes and Cancels Standard No. 7-96, Index 21.13.
PROGRAM MANAGER
PREPARED BY: T. MISKELL STANDARDS ENGINEERING - 9390
MANAGER
APPROVED FOR CONTENT: R. KUNKEL PERFORMANCE DESIGN ENGINEERING - 8152
PROGRAM MANAGER
APPROVED FOR PUBLICATION: T. MISKELL STANDARDS ENGINEERING - 9390
THIS DOCUMENT CONTAINS PROPRIETARY DATA AND SHALL NOT BE REPRODUCED

OR DISCLOSED WITHOUT THE PERMISSION OF ALSTOM POWER INC.
SUBJECT: Tilting Tangential Firing System Selection For STD NO : 4-2005-00
Bituminous and Sub-Bituminous Coals INDEX : 21.13
DATE : 17 FEB 2006
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UNITS: ENGLISH; METRIC; BOTH; NONE

PRODUCT LINES: CHECK THE PRODUCT LINES THAT THE STANDARD IS APPLICABLE TO
ALL; A = CONTROLLED CIRC. BOILERS H = HEAT RECOVERY STEAM GENERATORS (HRSG)
B = SUPERCRITICAL BOILERS P = PULVERIZERS – MILLING SYSTEM
C = VU40 AND VU60 BOILERS R = CHEMICAL RECOVERY BOILERS
E = FLUIDIZED BED BOILERS (CFB) S = SERVICES (AFTER MARKET USE)
F = NATURAL CIRC. BOILERS (UTILITY)
Versions
Ver 0 - First Issue.

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TABLE OF CONTENTS
Section Page
LIST OF FIGURES 4
1 PURPOSE AND SCOPE 6
2 DEFINITIONS 6
2.1 Coal
2.2 Furnace
2.3 Firing Process
3 COAL APPRAISAL 12
3.1 Coal Rank
3.2 Slagging and Fouling
3.3 Corrosion Risk Appraisal
4 FURNACE SIZING 22
4.1 Plan Area
4.2 Firing Zone Height
4.3 B-Criterion
4.4 Distance to Hopper Bend Line
4.5 Volumetric Heat Release Rate
4.6 Furnace Outlet Temperature
5 WINDBOX ARRANGEMENTS 36
5.1 Selection Notes
5.2 Data Required
5.3 Selection Procedure
5.4 Coal Nozzle and Nozzle Tip Selection Procedure
6 SOFA SYSTEM 63
6.1 Definitions and Equations
6.2 Location of SOFA Windboxes
6.3 Sample Calculation
7 NOx PREDICTION 67
7.1 Base NOx Emission
7.2 Correction Factors
7.3 Other Parameters
7.4 Calculation Procedure
8 CARBON LOSS PREDICTION 76
9 TURNDOWN PREDICTION 77
10 APPENDICES 78
10.1 Unit Conversion Chart
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LIST OF FIGURES
Figure No. Title Page
2-1 Definitions for Two-Pass Boiler 8
2-2 Definitions for Tower Boiler 8
3-1 Coal Properties (1/2) 13
3-2 Coal Properties (2/2) 14
3-3 Ash Properties 16
3-4 Ash Slagging Potential Appraisal 18
3-5 Ash Fouling Potential Appraisal 20
3-6 Chlorine Corrosion Potential 21
4-1m Cross-Sectional Area Heat Release Rate (metric) 24
4-1e Cross-Sectional Area Heat Release Rate (English) 25
4-2m Burner Belt Heat Release Rate (metric) 26
4-2e Burner Belt Heat Release Rate (English) 27
4-3 B-Criterion 28
4-4 Minimum Residence Time 29
4-5 Residence Time – Tower Unit 30
4-6 Residence Time – Two-Pass Unit 31
4-7m Maximum Distance to Hopper Bend Line (metric) 32
4-7e Maximum Distance to Hopper Bend Line (English) 33
4-8m Volumetric Heat Release Rate (metric) 34
4-8e Volumetric Heat Release Rate (English) 35
5-1 Standard LNTFS Windbox and OFA Compartment Arrangements 40
5-2 Coal Classification for NOx 41
5-3m LNTFS Selection for Group 1 Coals (metric) 42
5-3e LNTFS Selection for Group 1 Coals (English) 43
5-9 LNTFS Design Arrangement Selection Guideline (Coal Firing) 54
5-10 LNTFS Intermediate Auxiliary Air Compartment Arrangements 55
5-11m Secondary Air Velocity Guidelines (metric) 56
5-11e Secondary Air Velocity Guidelines (English) 57
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5-12m Recommended Primary Air Velocity at Nozzle Tip (metric) 58

5-12e Recommended Primary Air Velocity at Nozzle Tip (English) 59
5-13 Standard CoalNozzle Tips 60
5-14 Flame Attachment Coal Nozzle Tips 61
5-15 Wide Range Coal Nozzle Tips 62
6-1 SOFA System Definitions 63
7-1 Base NOx Emissions vs. Fuel Ratio 68
7-2 Air Factor in Firing Zone Correction Factor 69
7-3 Residence Time Correction Factor 70
7-4 Coal Nitrogen Content Correction Factor 71
7-5 Burner Tilt correction Factor 72
7-6 NOx Predictor Utilization with CCOFA (Lower Burner Operation) 74
7-7 NOx Predictor Utilization with CCOFA (Upper Burner Operation) 74
7-8 NOx Predictor Utilization with CCOFA and SOFA 75
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1. PURPOSE AND SCOPE Application of either ASTM standard or DIN

standard leads to similar results even though
there is no correlation between the two series of
The purpose of this standard is to define the
results. Fusible and non-fusible compounds will
performance criteria and calculation procedures
be classified as such whatever is the method
that shall be applied to select tilting tangential
used.
firing systems for bituminous and sub-bituminous
coals (including American-type lignites) for new
The following trends are observed : the ASTM IT,
Alstom Power two-pass and tower boiler
HT and FT temperatures are close to the DIN
performance designs. The scope of the
points T1, T2 and T3.
standard includes detailed coal appraisal and
furnace sizing criteria, which form the basis for
For slagging appraisal, the temperatures
the windbox arrangement selection process.
measured under both oxidizing and reducing
This standard does not address mechanical
atmosphere should be available and generally
design details that complete the firing system
the lowest fusibility temperatures will govern.
selection. These details shall be covered by
existing standards and methods used in Stuttgart,
If possible the sintering temperature –as defined
Velizy and Windsor.
in the DIN Standard 51730- could be considered
in order to address for long term fouling.
2. DEFINITIONS
2.1.3 Fuel Ratio
The following definitions shall apply for the
purposes of this standard.
In addition to the ASTM definitions, the coal fuel
ratio, FR, is introduced as follows :
2.1 Coal
2.1.1 General • Apparent Fuel Ratio
Fixed Carbon FC
The coal characteristics and analyses applicable FRapparent = =
for this standard are those defined in the relevant Volatile Matter VM
ASTM standards.
• Corrected Fuel Ratio
2.1.2 Ash Fusibility Temperatures FRcorrected =
FC
Regarding the ash fusibility temperatures, ASTM
standard D1857 and DIN Standard 51730 can VM − H 2 O crystallization − CO 2-Carbonates
equally be applied.
Unless otherwise stated FR shall mean FRcorrected.
ASTM standard D1857 defines four critical
temperatures : Crystallization water is the water bound to the
• the “initial deformation temperature”, IT, mineral matter (essentially clay) and which
• the “softening temperature”, ST remains after determination of the total moisture.
• the “hemispherical temperature”, HT It is released at high temperature (typically
• the “fluid temperature”, FT. 300°C) with other gaseous compounds, which
makes direct measurement of crystallization
DIN standard 51730 (1984) defines 3 critical water quantity difficult.
temperature points :
• “erweichungspunkt” i.e. softening point, The crystallization water quantity can be
referred to as T1 in this standard estimated assuming that clay in coal is basic clay
i.e. kaolin (Al2O3, 2 SiO2, 2 H2O).
• “halbkugelpunkt” i.e. hemisphere point,
referred to as T2 in this standard
• “fliesspunkt” i.e. fluid point, referred to as
T3 in this standard
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The estimating method is the following: Correction for CO 2-Carbonates
(i) determination of the limiting parameter and CO 2-Carbonates = 0.786x0.103x0.13 = 1.05%(ar)

calculation of Al2O3 + SiO2 mass involved in
kaolin formation Finally,
• Al2O3 is the limiting parameter if FRcorrected = 53 / (27-1.27-1.05) = 2.15
mass(SiO2) ≥ 1.1765 mass(Al2O3),
then the mass of Al2O3 + SiO2 involved in 2.2 Furnace
kaolin formation is
mass(Al2O3+SiO2) = 2.1765 mass(Al2O3) The portion of the boiler enclosure within which
the combustion process takes place and wherein
• SiO2 is the limiting parameter if heat transfer occurs predominantly by radiation.
mass(Al2O3) ≥ 0.85 mass(SiO2),
then the mass of Al2O3 + SiO2 involved in In case of divided furnace, only one basic cell
kaolin formation is shall be considered for the purposes of this
mass(Al2O3+SiO2) = 1.85 mass(SiO2) standard and especially for calculation of furnace
parameters.
(ii) determination of the crystallization water
mass 2.2.1 Geometrical Data
mass(H2Ocrystallization)=0.16mass(Al2O3+SiO2)
For the definitions which follow, refer to Figures
2-1 and 2-2.
CO 2-Carbonates is the carbon dioxide contained in
the calcium carbonates which are part of the Furnace outlet plane n°1 or Horizontal furnace
mineral matter. Correction for CO 2-Carbonates is outlet plane –HFOP– for two pass boilers
used only when the CaO in coal content is
The plane which passes perpendicular to the gas
significant ( more than 1 % weight as received
flow where the furnace gases reach the first
basis except for U.S. sub bituminous coal).
radiation superheater or reheater surface.
Then, the CO 2-Carbonates mass content in coal is
taken equal to 0.786 times the CaO mass content Furnace outlet plane n°2 or vertical furnace outlet
in coal. plane –VFOP– for two pass boilers
Example The plane which passes perpendicular to the gas

flow where the furnace gases reach the first
convection superheater or reheater surface.
Let’s consider a coal with 27 %(ar) VM , 53
%(ar) FC, 13 %(ar) ash , and, in ash, 47% SiO2, The convection heat exchangers have a
28 % Al2O3 & 10.3 % CaO. transversal pitch lower than 450 mm (18 inches).
Then,
FRapparent = 53/27 = 1.96
Correction for crystallization water
per kg of coal,
mass(Al2O3) = 36.4 g
mass(SiO2) = 61.1 g = 1.68 mass(Al2O3)
Al2O3 is the limiting factor
mass(Al2O3+SiO2) = 2.1765 x 36.4 = 79.2 g
mass(H2Ocrystallization) = 0.16 x 79.2 = 12.7 g
and, H2Ocrystallization = 1.27%(ar)
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VFOP Furnace outlet

plan n°2
HFOP
Furnace
Panels and
outlet P
platens
plan n°1
Panels and
platens P
B
DA J
β
W
A
B Firing zone
W with N coal H
nozzle levels
A
Firing zone C
with N coal H
nozzle levels D
α
C E
D
α X
E
Figure 2-1 Figure 2-2
Definitions for Definitions for

Two Pass Boiler Tower Type Boiler
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N – Number of coal nozzle levels installed h – Firing zone height, m (ft)

The firing zone height is defined as the number of
n – Number of coal nozzle levels in service operating coal nozzle levels, multiplied by the
The number of coal nozzle level in service average nozzle spacing.
depends on the firing conditions; it is equal to or h=n×e
smaller than N. In the case of N-1 adjacent coal nozzle levels in
service, the firing zone height is equal to the coal
α – Hopper angle, deg nozzle zone height H.
Angle between hopper wall and horizontal.
J, m (ft)
β – Arch angle, deg For two pass boiler only, distance from arch bend
For two pass boiler only, angle between arch line to arch nose elevation.
slope and horizontal.
P – Platen height, m (ft)
A – Furnace height, m (ft) Distance from bottom to top of the platen and
Distance from hopper bend line to first heat panel heat exchangers.
exchanger bottom.
In the case of a two pass boiler without radiation DA – Furnace depth at nose of the arch, m (ft)
heat exchangers, A is the distance from hopper For two pass boiler only, distance from front wall
bend line to centerline of roof tubes. tubes centerline to centerline of arch nose tubes.
A=C+H+B
Pr – Furnace perimeter, m (ft)
B, m (ft) The furnace perimeter is defined as the furnace
Distance from centerline of top coal nozzle level depth plus the furnace width, multiplied by two.
to bottom of first heat exchanger (or to centerline Pr = 2 × ( D + W )
of roof tubes, in the case of a two pass boiler
without radiation heat exchangers). X – Hopper opening, m (ft)
C, m (ft) W – Furnace width, m (ft)

Distance from hopper bend line to centerline of Distance between centerlines of opposing side
lowest coal nozzle level. wall tubes.
D – Furnace depth, m (ft) EPRS – Effective Projected Radiant Surface, m2

Distance from centerline of front wall tubes to (ft2)
centerline of rear wall tubes. The Effective Projected Radiant Surface is
defined as the projected area of all boundary
E – Hopper height, m (ft) surfaces forming the furnace enclosure, modified
Distance from hopper bend line to hopper by appropriate factors for specific types of
opening. surfaces.
e – Nozzle spacing, m (ft) When calculating EPRS, observe the following:

Average distance between two adjacent coal
nozzle levels. (i) furnace dimensions are measured from tube
centerline to tube centerline of opposite
H – Coal nozzle zone height, m (ft) walls
Distance from centerline of bottom coal nozzle
(ii) cut-off corners are treated as square corners
level to centerline of top coal nozzle level.
(iii) the projected area of the hopper throat is
included as EPRS
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VA - m3 (ft3)
(iv) an effectiveness factor of 1.0 is used for
This is the volume of the furnace zone comprised
• furnace outlet plane n°2 between the hopper and the bottom of the first
• hopper throat heat exchanger (or the boiler roof, in the case of
a two pass boiler without radiation heat
• tangent tube walls
exchangers) and corresponding to the height A.
• web walls
• panels and platens VE – Hopper volume, m3 (ft3)
(v) an effectiveness factor of 0.0 is used for tile- This is volume of the hopper.
covered floors or studded walls covered with W × E × (D + X)
VE =
chrome ore 2
(vi) an effectiveness factor of 0.6 is used for
areas covered with a thin refractory coating VP - m3 (ft3)
(Super-3000). This is the volume of the cavity where the panel
and platen heat exchangers are located.
FZS – Firing Zone Surface, m2 (ft2) (or burner belt
area) V – Furnace volume, m3 (ft3)
This is the peripheral band enclosing that zone of The furnace volume includes the volume of the
the furnace cell, defined by the firing zone height. cavity where the panel and platen heat
FZS = h × Pr exchangers are located and the volume
corresponding to the upper third of the hopper
FZE – Firing Zone Envelope, m2 (ft2) height which is approximately half the hopper
The sum of all surfaces bounding the firing zone. volume.
FZE = FZS + 2 PA Thus V = VA + VP + VE/2
PA – Furnace Plan Area, m2 (ft2) S/V – Surface to volume ratio, m-1 (ft-1)
The furnace Plan Area is the product of furnace This parameter defines the radiant beam length
depth and furnace width at the windbox elevation. in the furnace. When evaluating it, the total
PA = D × W projected surface should be used, rather than the
effective projected radiant surface.
S – Total projected surface of furnace enclosure,
m2 (ft2) W/D – Aspect ratio
Same as EPRS, except effectiveness factor of This is the width to depth ratio.
1.0 is applied to all surfaces.
FZV-Firing Zone Volume, m3 (ft3) 2.2.2 Furnace Thermal Data

This is the volume of the firing zone.
HFOT – Horizontal Furnace Outlet Temperature
FZV = PA × h
for two pass boiler or FOT1 for tower type boiler,
°C (°F)
This is the mean temperature of the flue gas
leaving the furnace measured in the horizontal
furnace outlet plane as defined here above.
VFOT – Vertical Furnace Outlet Temperature for

two pass boiler or FOT2 for tower type boiler, °C
(°F)
This is the mean temperature of the flue gas
leaving the furnace measured in the furnace
vertical outlet plane as defined here above.
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GHR – Gross Heat Release, MW (Btu/hr) Fouling

The Gross Heat Release is the sum of : Ash build up in the heat exchangers
(i) gross fuel heat input based on high heat
value of fuel Gas recirculation ratio
(ii) sensible heat, calculated above 26.7°C
Gas recirculation ratio =
(80°F), contained in :
• fuel Recirculated gas (kg/h )(lb/hr)
• preheated air Furnace gases without recirculation (kg/h )(lb/hr)
• recirculated gas.
NHI – Net Heat Input, MW (Btu/hr)
λFZ – Firing zone stoichiometry
The Net Heat Input is obtained by subtracting the
The firing zone stoichiometry is defined as the
following items from the Gross Heat Release :
ratio between the actual air flow in the firing zone
(i) Latent heat of vaporization of water in the and the stoichiometric air flow required to burn
coal and water formed by combustion of the coal entering the firing zone.
hydrogen, taken as 2395 kJ/kg (1030 Btu/lb)
in accordance with ASTM standard D 121 . OFA – Over Fire Air
(ii) Combustible heat loss. The Over Fire Air system consists in diverting a
portion of the secondary air to a burning zone
NHRR – Net Heat Release Rate, MW/m2 above the main burning zone where pulverized
(Btu/hr.ft2) coal injection takes place.
This is the Net Heat Input divided by the EPRS. The OFA ports can be of two types :
(i) Close Coupled OFA ports which are located
BBHRR – Burner Belt Heat Release Rate,
at the top of the upper windbox
MW/m2 (Btu/hr.ft2)
This is the Net Heat Input divided by the FZS. (ii) Separated ports which are located apart and
above the upper windbox.
CSAHRR – Cross Sectional Area Heat Release
Rate, MW/m2 (Btu/hr.ft2) τ – Residence time, s
This is the Net Heat Input divided by the furnace The residence time is defined as the time
plan area (PA). necessary for a flue gas particle to move upward
in the furnace from one elevation to another.
VHRR – Volumetric Heat Release Rate, MW/m3 For calculation details refer to section 6.
(Btu/hr.ft3)
This is the Net Heat Input divided by the furnace Slagging
volume (V). Ash build-up on the furnace walls.
θ – Tilt, deg
2.3 Firing Process θ is defined as the angle between centerline of
nozzle and horizontal.
CFS – Concentric Firing System
In the classic tangential firing system, all fuel/air
and secondary streams are aimed in unison at
the tangent of an imaginary circle in the center of
the furnace.
In the Concentric Firing System, a part of the
auxiliary secondary air is offset to be aimed at the
tangent of a larger imaginary circle which
encompasses the original inner circle.
The CFS permits to create an air rich atmosphere
close to the walls in the firing zone.
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3. COAL APPRAISAL
• HHV and LHV conversion formula
The purpose of the coal appraisal procedure is to For a reference of 0°C (32°F),
assess : HHV – LHV (kJ/kg) ≅ 223.5 H
• the coal rank and its reactivity, + 25.0 H2O
• the coal slagging and fouling potential,
For a reference of 80°F (26.7°C),
• the coal behavior regarding NOx
HHV – LHV (kJ/kg) ≅ 217.8 H
emission,
+ 24.4 H2O
• the coal behavior regarding corrosion where H and H2O are the weight
risks. percentage of hydrogen and water
(weight percentage and heating values
3.1 Coal Rank are expressed on the same basis)
• The given analysis and heat value are
3.1.1 Understanding Coal Analyses
considered consistent if the difference
between the heat value calculated with
To start with coal appraisal and achieve coal rank
the here above formula and the given
identification, a good understanding of coal
heat value is less than 4%.
analyses (proximate and ultimate) is requested.
This understanding can be reached by following
In this process of understanding coal analyses,
the here after guidelines.
nothing can replace experience and if any
discrepancy or deviation is noted the combustion
Coal analyses (proximate and ultimate) and their
department manager’s advice is requested.
mass balances shall be checked.
Coal analyses should be compared with previous

coal analyses from the same origin (refer to
Alstom Power experience or the literature).
The consistency of the ultimate analysis with the

given heating value shall be checked according
to the following rules :
• Boïe statistical formula for HHV

calculation
HHVBoïe (kJ/kg) = 351.69 C + 1162.65 H -
110.95 O + 104.67 S +
62.80 N
where C, H, O, S and N are the weight
percentage of carbon, hydrogen, oxygen,
sulfur and nitrogen (weight percentage
and the HHVBoïe are expressed on the
same basis),
• Or Dulong statistical formula (with C, H,
O, S same as above)
HHVDulong (kJ/kg) = 339.6 C + 1442.1
⎛ 0⎞
⎜ H - ⎟ + 94.2 S
⎝ 8⎠
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COAL PROPERTIES
VM_daf basis (%)
66.7 62.5 58.8 55.552.6 50 40 33.3 25 20 16.7 14.3 12.5 11.1 10 9.1 4.76
38000
36000
34000
32000
HHV_daf basis (kJ/kg)
30000
28000
26000
24000
22000
20000
18000
0.5 0.55 0.6 0.65 0.7 0.75 0.80.850.9 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 15 20 25
1 10
Fuel Ratio
High Med
Sub Low Volatile
Lignite Vol Vol Anthracite
Bit Bituminous
Bit Bit
Figure 3.1 – Coal Properties (1/2)

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abcd COAL PROPERTIES

COAL PROPERTIES
(2/2)
Energy VM_daf basis (%)
Energy Systems
66.7 62.5 58.8 55.5 52.6 50 50 33.3 25 20 16.7 14.3 12.5 11.1 10 9.1 4.76
35 35
30 30
Oxygen_daf basis (%)
25 25
(C+H)/O
20 20
15 15
10 10
5 5
0 0
0.5 5 0.7 0.8 0.9 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 8 9 10 15 20 25
1
Fuel Ratio
High Med
Sub Low Volatile
Lignite Vol Vol Anthracite
Bit Bituminous
Bit Bit
Figure 3.2 – Coal Properties (2/2)

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3.1.2 Rank Identification

Appraising the slagging/fouling risks requires first
The rank identification will be done according to of all a good understanding of ash analysis and
ASTM standard D 388. then a comparison with previous experience of
ash of similar quality.
In case of insufficient information to apply the
ASTM standard, which often happens for Nothing can replace this comparison with
imported coals, coal rank identification will be previous experience.
achieved by using the diagrams and statistical
curves here enclosed. For these curves, the main To understand the ash analysis, the here after
parameter in abscissa is the ASTM rank ; the FR guidelines should be followed.
has been used only to meter this axis.
• Check the analysis and its mass balance.
If a unique rank cannot be identified by using
these diagrams and statistical curves, or, if the • Check the consistency of the fusibilities with
studied coal notably departs from the statistical the ash components (particularly the %
curves, the combustion department manager’s Fe2O3, as a guide refer to here after curves).
advice is requested. For definition of ash fusibility temperatures
refer to paragraph 2.1.2 .
3.1.3 Coal Reactivity
• Check whether the “atmosphere” for the ash
Coal rank identification is a key parameter to fusibility measurement is specified. If it is
assess coal reactivity. not, ask for it (in general the atmosphere
giving the lowest fusibility temperature
To complete the reactivity assessment, the should be applied).
corrected fuel ratio as defined in paragraph 2.1.3
shall be calculated. • Find a similar ash analysis in previous
Alstom Power experience (or in the
Moreover, for unknown coal (no or very little literature).
Alstom Power experience regarding the
considered coal), the coal reactivity assessment In this process of understanding the ash analysis,
ought to be completed by a Thermo Gravimetric if any discrepancy or deviation is noted the
Analysis, an inflammation point determination, or combustion department manager’s advice is
any other in-house test. requested
The decision to perform these tests shall be
taken with the combustion department manager.
3.2 Slagging and Fouling
Understanding Ash Analysis
Appraisal of the slagging/fouling risks shall be

based on the quality of ash and never on its
quantity. However, it is quite clear that the greater
the amount of ash, the more quickly difficulties
will arise. Ash of slagging/fouling quality, even in
very small amounts, can lead to major problems.
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T1 ,T2 ,T3 relation with %Fe2O3 in ash

1 2 3 4 5 6 7 8 9 10 20 30 40
1600
T3 >=1500°C
1500
* These curves are given for typical ashes with no singularity

Fusibility Temperature (°C)
* For ashes with singularities, lower temperature as below :

1400
Effect of Fe2O3 and Na2O are cumulative
- if Fe2O3 /CaO=0.6 to 1.5 and Fe2O3>7%

T3-100°C T2-70°C
- if Na2O=1.2 to 3.0% => T3-150°C T2-80°C

- if Na2O>3.0% => T3-180°C T3
1300
T2
1200
T1
1100
Fe2O3 vs T1inf
Fe2O3 vs T1mean
Fe2O3 vs T1max
Fe2O3 vs T2
Fe2O3 vs T3
1000
1 2 3 4 5 6 7 8 9 10 20 30 40
%Fe2 O3 content in ash

Figure 3.3 – Ash Properties
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Slagging Appraisal
The table given here after proposes a

classification of the slagging risks according to
the ash characteristics.
Four degrees of slagging are defined :

NS – non slagging
MS – moderately slagging
HS – highly slagging
SS – severely slagging.
Referring to the classification table, make a first

estimation on the basis of the ash fusibility
temperatures.
Then crosscheck this first estimation with the

other criteria listed in the classification table.
Finally, take the highest degree of severity.
Example :
Ash with the following characteristics
T3 ≥ 1380 °C (in reducing atmosphere),
Fe2O3 = 18 %, Na2O = 2.2 %
Although the T3 value is very high (possibly
leading to a NS classification), the other two
components make us classify this fuel as
HS.
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Degree of slagging
NS MS HS SS
Parameters
T3 or FT °C > 1400 1300 +100, -50 1200 ± 50 < 1150
(°F) (> 2550) (2370 +180, -90) (2190 ± 90) (< 2100)
T1 or IT °C < 1200 < 1150 < 1100

(°F) (< 2190) (< 2100) (< 2010)
T3 – T 1 °C < 60 and T3 ≤ 1200

or FT – IT (°F) (100 and T3 < 2190)
CaO (%) < 10 10 to 20 20 to 40 40 and

S>1.9g/MJ HHV
Na2O (%) <1 1 to 3 3 to 5 >5
Fe2O3 (%) <7 7 to 15 15 to 25 25

(look at FeS2)
Fe2O3/CaO Whatever the 0.5 to 0.7 0.7 to 1.4

ratio if Fe2O3 < 7 or and
1.4 to 1.8 Fe2O3 > 10
and
Fe2O3 > 7
B/A ≠ 0.5 ± 0.1 0.5 ± 0.1
Figure 3-4 - Ash slagging potential appraisal

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Observations The criteria for fouling appraisal in that 2nd

For slagging potential appraisal, each zone are given in the here after table.
parameter line shall be considered
independently Four degrees of fouling potential are defined :
The here above criteria have been defined for NF – non fouling
furnace without refractory lining. In case of MF – moderately fouling
refractory lining in the firing area, the slagging HF – highly fouling
degree determined with here above criteria SF – severely fouling.
shall be worsened by one rank.
B/A is the base to acid ratio As regards the precautions to be taken, only two
Fe 2 O 3 + Na 2 O + K 2 O + CaO + MgO(%) categories are considered:
B =
A SiO 2 + Al 2 O 3 + TiO 2 (%) • ash that has a non or moderately fouling
potential (NF and MF degree)
• fouling ash (HF and SF degree).
For high Fe2O3, check by calculation the
maximum possible level of pyrite (FeS2).
Experience has shown that severe slagging can
occur with pyrite content greater than 1.5 % on
dry coal basis ; extremely severe slagging with
boiler derating can occur with 3 % pyrite
Be careful of high CaO levels in ash which may
be hidden by the SO2 capture under laboratory
conditions
If % Na2O > 1 % , determinate and consider
active Na
Other coal ash parameters may influence
slagging and/or fouling potential such as the % in
ash of K2O, As2O3, P2O5
Fouling Appraisal
A distinction should be made between two zones

and two different modes of fouling:
• 1st zone where the flue gas temperature is

higher than T1 : it is possible to have partially
fused ash particles, thus, the fouling criteria
are roughly the same as the slagging ones
(except the criteria on Fe2O3 content which
is no longer valid),
• 2nd zone where the flue gas temperature is
lower than T1 – 50°C (approx); fouling takes
place from particles that are theoretically
“dry” but which, thanks to the possibility of
having a binder in the hottest spots (such as
Na2O which condenses at around 800 °C),
agglomerate together and form a hard and
sticky deposit.
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Degree of risk severity Low fouling ash Fouling ash
Parameters NF MF HF SF
Na2O (%) <1 < 2.5 2.5 to 5 >5
CaO (%) <5 5 to 10 ≥ 10
f = % Na2O x B/A < 0.1 0.1 to 0.5 > 0.5
P2O5 Look at literature if P2O5 > 3 %
Figure 3-5: Ash Fouling Potential Appraisal for fouling of heat exchangers operating with flue gas
temperature below T1 – 40°C
Observations
For fouling potential appraisal, each parameter line shall be considered independently
B/A is the base to acid ratio
Fe 2 O 3 + Na 2 O + K 2 O + CaO + MgO(%)
B =
A SiO 2 + Al 2 O 3 + TiO 2 (%)
Pay attention to Cl content in coal as an indicator of Na presence
For special cases of coals containing high amounts of FeS2, Na2O, CaO refer to specific studies.
3.3 Corrosion Risk Appraisal
The corrosion phenomenon presently considered In case that the chlorine in coal content is higher
is the medium temperature corrosion which can than 0.3 % weight (daf), the possibility for low
affect the waterwall tubes. This medium NOx firing with sub-stoichiometric conditions in
temperature corrosion mechanism essentially the firing zone is limited and appropriate
depends on measures shall be defined with the combustion
• the chlorine and sulfur contents in coal, department manager.
• the existence of a reducing atmosphere or of
an atmosphere alternately reducing and
oxidizing.
The here after graphic gives the lowest

permissible firing zone stoichiometry according to
the chlorine in coal content.
As soon as the chlorine in coal content exceeds

0.1 % weight (daf), secondary off set air (CFS) is
compulsory.
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1,3
1,1 Permissible firing zone stoichiometry
0,9
λ FZ
0,7
Firing Zone Stoichiometry,
Forbidden firing zone stoichiometry
0,5
Minor Medium High

0,3
corrosion risk corrosion risk corrosion risk
0,1
0 0,1 0,2 0,3 0,4 0,5

Chlorine (%w, daf)
Figure 3.6 - Chlorine Corrosion Potential( sulfur about 1% w, ar)

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4. FURNACE SIZING 4.4 Distance to Hopper

Bend Line
Furnace sizing is determined by calculating the
parameters in paragraphs 4.1 – 4.4 below: The distance between the centerline of the lowest
coal nozzle and the hopper bend line, C, is
4.1 Plan Area determined by figures 4-7 m/e.
Select the cross-sectional area heat release rate
4.4.1 The hopper angle α is
(CSAHRR) from figures 4-1 m/e, knowing the NHI
recommended to be 50° for non-slagging coals
and the ash slagging appraisal. Furnace plan
and 53-55° for slagging coals.
area (PA) equals NHI/CSAHRR. The furnace
width to depth (W/D) ratio should be within the
4.4.2 The hopper opening dimension X
range 0.83 to 1.2.
shall be 1.25m (4 ft.) for coals with non-slagging
ash. For moderate to severe slagging ash, the X
4.2 Firing Zone Height dimension shall range from 1.25m (4 ft) to1.5m (5
ft), according to company experience and/or
Select the burner belt heat release rate (BBHRR) customer specifications.
from figures 4-2 m/e as a function of the ash fluid
temperature T3 (DIN STD. 51730(1984)). Firing 4.5 Volumetric Heat Release Rate
zone height, h, equals NHI/(2* BBHRR* (W+D)).
See section 5.1 for more details. Coals with a As a check, calculate the volumetric heat release
high slagging tendency (which means a low fluid rate (VHRR) and verify that it does not exceed
point) need to be combusted in a furnace with low the recommended limit in figures 4-8 m/e.
BBHRR.
4.6 Furnace Outlet Temperature
4.3 B-Criterion As a check determine the furnace outlet

temperature (FOT) and compare with the
The distance between the middle of the top coal recommended maximum (not to exceed)
nozzle and the bottom of the first heating temperatures in the table below.
surfaces (= B) typically ranges from 0,95 to 1,2
times the square-root of the furnace plan area
(PA), depending on the fuel ratio.
The function (B-Criterion) is given in figure 4-3.
In case of severe NOx-requirements, B may

become larger than the above mentioned value.
4.3.1 Residence Time is typically in the

range of 1.2 to 1.5 seconds as a function of fuel
ratio (Fig. 4-4) between the top coal elevation
centerline and the bottom of the heating surfaces
(see figures 4-5 and 4-6) Calculate residence
time (see section 6 for procedure) as a check of
the “B” criterion selection. If the residence time
falls below 1.2 to 1.5 seconds, the NOx and
unburned carbon loss may get worse.
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Recommended Maximum
abbr Definition Furnace Outlet
Temperature / °C
FOT 1 (Tower Furnace outlet temperature at the bottom of the first

T3
type boiler) radiation heating surfaces (Panels & platens)
FOT 2 (Tower Furnace outlet temperature at the bottom of the first

T1
type boiler) convection heating surfaces (not platenized)
Furnace outlet temperature at the bottom of the first

HFOT (Two
(horizontal) radiation heating surfaces (Panels & T3 + 50
pass boiler)
platens)
Furnace outlet temperature at the entrance to the

VFOT (Two
first (vertical) convection heating surfaces (not T1 - 50
pass boiler)
platenized)
with T1: softening point

T3: fluid point from DIN Standard 51730 (1984)
Remark concerning tower type boiler: If the first heating surfaces do not consist of panels and platens, FOT
1 and FOT 2 are identical, so that the FOT becomes T1.
If the FOT is exceeded, the slagging behavior may get worse.

SUBJECT: Tilting Tangential Firing System Selection For Bituminous and Sub-Bituminous Coals STD NO : 4-2005-00
INDEX : 21.13
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Figure 4-1m
Cross-sectional Area Heat Release Rate (CSAHRR)
9.0
non slagging
8.0
7.0
moderately slagging
6.0
CSAHRR, MW/m 2
5.0
highly slagging
4.0
severely slagging
3.0
2.0
1.0
0.0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600
NHI, MW
INDEX : 21.13
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Figure 4-1e
Cross-sectional Area Heat Release Rate (CSAHRR)
3.0
2.5 non slagging

CSAHRR, MM/Btu/hr ft2
2.0 moderately slagging
1.5
highly slagging
1.0 severely slagging
0.5
0.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
NHI , MBtu/hr
INDEX : 21.13
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Figure 4-2m
Burner Belt Heat Release Rate (BBHRR)
3.5
3.0
2.5
BBHRR, MW/m²
2.0
1.5
1.0
severe slagging highly slagging moderately slagging non slagging
0.5
0.0
1050 1100 1150 1200 1250 1300 1350 1400 1450 1500
DIN fluid point T3, °C
INDEX : 21.13
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Figure 4-2e
Burner Belt Heat Release Rate (BBHRR)
1.1
1.0
0.9
0.8
BBHRR, MM/Btu/hr ft2
0.7
0.6
0.5
0.4
0.3
severe slagging highly slagging moderately slagging non slagging
0.2
0.1
0.0
1900 2000 2100 2200 2300 2400 2500 2600 2700
DIN fluid point T3, °F

INDEX : 21.13
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Figure 4-3
B-Criterion
1.30
1.20
1.10
B-Criterion
1.00
0.90
0.80
1 2 3 4 5 6
Fuel Ratio Corrected
INDEX : 21.13
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Figure 4-4
Minimum Residence Time
1.70
1.60
Minimum Residence Time / s
1.50
1.40
1.30
1.20
1.10
1.00
1 2 3 4 5 6
Fuel Ratio Corrected

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Heating
FOT 2 surfaces
Panels & platens
FOT 1
B τ total OFA
Burner
levels
Minimum residence time: t_total = 1,2...1,5 s = f (Fuel ratio)
Furnace outlet temperature: FOT 2 <= T1

FOT 1 <= T3
B-Criterion: B = 0,95...1,2 x SQRT (PA) = f (Fuel ratio)
Figure 4.5 - Residence Time – Tower Unit

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VFOT
Heating
Panels & surfaces
platens
HFOT
B τ total OFA
Burner
levels
Minimum residence time: t_total = 1,2...1,5 s = f (Fuel ratio)
Furnace outlet temperature: VFOT <= T1 - 50 °C

HFOT <= T3 + 50 °C
B-Criterion: B = 0,95...1,2 x SQRT (PA) = f (Fuel ratio)
Figure 4.6 – Residence Time – Two Pass Unit

INDEX : 21.13
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Figure 4-7m
Minimum Distance to Hopper Bend Line
5.5
5.0
Minimum Distance C, m
4.5
4.0
3.5
3.0
2.5
2.0
3 5 7 9 11 13 15 17 19 21
Mean Furnace Cell Dimension (W + D)/2, m

INDEX : 21.13
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Figure 4-7e
Minimum Distance to Hopper Bend Line
20
19
18
Minimum Distance C, ft
17
16
15
14
13
12
11
10
9
8
10 20 30 40 50 60 70
Mean Furnace Cell Dimension (W +D)/2, ft

INDEX : 21.13
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Figure 4-8m
Volumetric Heat Release Rate (VHRR)
0.25
0.24
0.23
0.22
0.21
0.20
VHRR, MW/m 3
0.19
0.18
0.17
0.16
0.15
0.14
0.13
0.12
0.11
0.10
0.09
0.08
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600
NHI, MW
INDEX : 21.13
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Figure 4-8e
Volumetric Heat Release Rate (VHRR)
0.025
0.024
0.023
0.022
0.021
VHRR, MBtu/hr ft3
0.020
0.019
0.018
0.017
0.016
0.015
0.014
0.013
0.012
0.011
0.010
0.009
0.008
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
NHI, MBtu/hr
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5. WINDBOX ARRANGEMENTS Calculate the firing zone height (h) as follows:
The purpose of this section is to define windbox h = NHI/(2*BBHRR*(W+D))

performance selection procedures for tilting
tangential firing systems. Windbox mechanical The target distance between coal nozzle
selection procedures shall be defined by site centerlines (e) shall be calculated by dividing the
(Stuttgart, Velizy, Windsor) specific standards. firing zone height (h) by the number of operating
This section is applicable for the selection of all pulverizers at full load.
tilting tangential coal firing systems in vertical wall
and spiral wall furnaces with/without The maximum heat input per compartment shall
supplementary fuel. All selections shall not exceed 100 MWTH
incorporate some quantity of overfire air (OFA)
for NOx control. The abbreviation LNTFS (Low Secondary air velocity is selected from Figure 5-
NOx Tangential Firing System) is applicable to all 11 (e&m) “Secondary Air Velocity Guidelines”.
system selections. The coals are classified according to Figure 5-2,
and the design velocity is based on the actual
5.1 Selection Notes temperature and elevation.
The firing system arrangement and overfire air The free gas area within the windbox (excluding
quantity are established by the required NOx OFA) is determined by the distribution of
emissions guarantee and coal type. secondary airflow to the fuel and auxiliary air
compartments as shown in Figure 5-9. For
Figure 5-1 shows the three standard firing system compartment heights and free areas, refer to site
arrangements, which are differentiated based on (Stuttgart, Velizy, Windsor) specific windbox
overfire air quantity and the location of the OFA mechanical design standards.
compartments.
The overfire air (OFA) compartments are
• Arrangements 1a and 1b use close coupled considered “open” at the design BMCR condition.
overfire air (CC-OFA) The typical number of compartments are shown
• Arrangements 2a, b, c and d use close in Figure 5-1 and the flow distribution of OFA is
coupled and separated overfire air (SOFA). given on Figure 5-9 .
• Arrangements 3a and 3b use close coupled
and two (2) levels of SOFA. The windbox to lower furnace pressure
differential is determined by the formula
Figure 5-9 contains the “Selection Guidelines” for ∆P = 1.25 ρ V2/2, where ρ is density and V is
each sub-arrangement. Figure 5-10 shows the velocity, both in consistent units. Air density and
standard intermediate auxiliary air compartment velocity are at actual conditions.
arrangements. Supplemental fuels, such as oil
and gas, are located in these auxiliary air The furnace stack effect must be subtracted from
compartments. the above pressure drop to obtain the design
windbox-to-furnace outlet pressure differential
All windbox sizing calculations and selections are reported on the selection sheets. The furnace
based upon the design coal, utilizing the stack effect (from the centerline of the active
minimum number of pulverizers required for firing elevations to the centerline of the furnace
“boiler maximum continuous rating” (BMCR). If outlet) at sea level is 1mm of water per meter of
spare pulverizers are provided, they are furnace height , and 0.012 inches of water per
considered “inactive” along with the associated foot of furnace height.
fuel and air compartments. The airflow through
an “inactive” compartment is assumed to be 10% The recommended primary air/fuel mixture
(minimum) of the full open flow rate. velocity at the coal nozzle tip is shown in Figure
5-12 (e&m).
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The recommended primary air/fuel mixture 5.3 Selection Procedure

velocity at the nozzle choke should be at least
10% greater than at the coal nozzle tip. Coals Determine and list the NOx guarantee
with a Free Swelling Index (FSI) greater than 4 requirements vs. fuels and load. Windbox
should have choke velocities 20-30% greater selections are governed by the most stringent
than the tip discharge velocity (refer to note on fuel(s), loads(s) and guarantee conditions.
page 38). Designs shall be selected with a minimum 10%
NOx performance margin to account for operating
The Separated Overfire Air (SOFA) location conditions, i.e. excess air, furnace temperature,
criteria for low NOx tangential firing systems is tilts and unknown coal performance
determined in Section 6 of this standard. characteristics. Margin must be approved by
manager of department or designated reviewer.
5.2 Data Required
Typical design margins based on coal group are:
Unit Performance
Group 1 25 – 40%
• Heat input at design BMCR Group 2 20 – 30%
• Total air flow required for combustion Group 3 15 – 25%
(includes excess air) Group 4 15 – 25%
• Furnace air in-leakage Group 5 10 – 20%
• Total primary air flow to furnace Group 6 10 – 20%
(includes seal air)
• Secondary air temperature From Figure 5-2 determine the coal “group” for
• Plant elevation the design coal, alternate coals, and range coals
(unspecified coals whose range of properties are
Furnace Dimensions stated). Range coals are classified by selecting a
surrogate coal based on the lowest volatile matter
• Width in the specified range, and compatible with the
moisture, ash, and nitrogen contents in the range.
• Depth
• Vertical distance from top coal nozzle
Calculate a performance NOx for each of the
centerline to furnace outlet centerline
classified coals as follows:
• Number of firing corners (4 or 8)
• Vertical distance between top and Performance NOx = (Guarantee NOx) x
bottom coal nozzles (1-% Margin/100)
Coal Pulverizers There is a different LNTFS selection chart for
each coal “group”. Enter the appropriate
• Mill size selection chart (Figures 5-3 through 5-8) at the
• Total number of mills calculated Performance NOx value and move
• Minimum number of mills operating horizontally until you intersect one of the vertical
at BMCR lines. Read the corresponding LNTFS
• Coal pipe diameter arrangement indicated directly below this line
• Number of coal nozzles/mill (1A, 1B, 2A, 2B, 2C, 2D, 3A or 3B) and also the
firing zone stoichiometry (λFZ) for each coal. See
Proximate & Ultimate Coal Analysis (as Figure 5-9 for “Selection Guidelines” Calculate
received) the overfire air (OFA) quantity for each coal as
follows:
• % Fixed carbon
• % Moisture % OFA = 100[1-(λFZ/(1 + Excess Air %/100))]
• % Ash Note: OFA is expressed as a % of the total
• % Sulfur Combustion Airflow.
• Higher heat value
• % Chlorine
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The windbox design is governed by the highest (Note: A cell is defined as one (1) fuel
LNTFS arrangement type (3>2>1) and greatest compartment plus one-half (1/2) each adjacent
quantity of OFA. auxiliary air compartment, i.e., one (1) fuel plus
one (1) auxiliary air compartment). The active
Use the furnace plan area to select the design number of firing levels (or cells) is obtained by
discharge velocity for secondary and overfire air taking the minimum number of mills required for
based on the coal “group” from Figure 5-11, MCR and adding 0.1 (i.e. 10%) times the number
Recommended Secondary Air Velocity. of “out of service” mills. The distribution of free
area between the coal and auxiliary air
Set the windbox width by adding four (4) inches compartments, shown in Figure 5-9, is based on
(102 mm) minimum to the coal pipe diameter and the selected firing system arrangement.
picking the nearest standard size which is equal
to or greater than this value. Refer to site NOTE: The three (3) compartment arrangement
(Stuttgart, Velizy, Windsor) specific windbox for intermediate auxiliary air is optional for firing
mechanical design criteria for standard windbox system arrangements 1A through 2B and
widths. standard for arrangements 2C through 3B. The
sum of the % free area distribution for the three
Based on the selected arrangement, calculate (3) auxiliary air compartments is equal to the total
total OFA mass and volume flow (at actual auxiliary air % distribution with firing system
conditions of temperature, pressure and arrangements 1A through 2B. For arrangements
elevation). Then from Figure 5-9, determine the 2C through 3B, the sum of the free area
flow distribution to each level (i.e. CC-OFA, distribution (110%) is greater than the auxiliary air
SOFA). Calculate the free area per corner per % distribution (70%), because either the “CFS” or
level using the design discharge velocity. Initially “straight” air compartments are assumed to be
assume two (2) compartments for CC-OFA and partially “closed” during normal operation. This
three (3) for SOFA. design approach provides operations flexibility for
units firing a range of coals, including high
The free area of the “cooling air” gaps at the top chlorine coals (refer to section 3.3). Figure 5-10
of the main windbox and the top/bottom of each shows the allowable single and multiple
Sep-OFA windbox is equal to one (1) inch (25.4 intermediate auxiliary air compartment
mm) times windbox width and should be included arrangements.
as part of the total free area per corner of the
“CC-OFA” and “Sep-OFA” respectively The free air of the “cooling air” gap at the bottom
of each main windbox (1” (25.4 mm) x windbox
NOTE: For compartment heights and free areas, width) should be included as part of the total free
refer to site specific windbox mechanical design area per corner of the End Air compartments.
standards.
Once the coal and auxiliary air compartment free
Secondary air mass flow to the main windboxes areas are calculated, the height of each
is equal to the total combustion air (TCA) minus compartment can be selected. Refer to site
furnace in-leakage (balanced draft units only) (Stuttgart, Velizy, Windsor) specific standards for
minus mill primary air (including seal air on windbox mechanical design (compartment size
pressurized mills) and minus the OFA flow vs. free area) details.
calculated above. The secondary air volume flow
is calculated (at actual conditions) and then
divided by the target discharge velocity, number
of windboxes and number of active firing levels
(or cells) to determine the required free area per
cell.
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Based on the compartment heights selected 5.4 Coal Nozzle and Nozzle Tip Selection
above, the coal nozzle centerline spacing is Procedure
calculated by summing the heights of all
compartments in one (1) cell (i.e. coal and There are three different types of coal nozzle
intermediate auxiliary air) plus 3/8 (9.5 mm) of an tips to choose from for the particular firing system
inch for each partition plate (2, 3 or 4 per cell design: Standard, Flame Attachment, and Wide
depending upon arrangement). This value is Range tips. NOx emissions and/or turndown
then compared to the target value set earlier (see requirements are the primary determinants for
Paragraph 5.2, Furnace Dimensions). If which type for tip is used.
necessary, the height of the coal and/or
intermediate auxiliary air compartments can be Standard coal nozzle tips (non-flame attachment)
increased to obtain the desired centerline (Fig. 5-13) are selected for LNTFS Arrangements
spacing. The height of an individual intermediate 1a and 1b. If the coal can be classified as high
auxiliary air compartment can be increased by 4” risk* for coking / plugging on the tip, then the
(102 mm) over the minimum shown on. AERO-tip style shall be used. This is a modified
Standard nozzle tip design that incorporates a
Calculate the actual OFA and secondary air recessed primary air shroud and tapered edges
discharge velocity based on the selected “active” on the coal-touched plate work. Refer to site
free area. The “active” free area is based on full (Stuttgart, Velizy, Windsor) specific windbox
flow through “in-service” compartments, cooling mechanical design standards for further selection
air gaps and mini-air compartments (if provided), and design details.
and minimum 10% leakage flow through “out-of-
service” compartments. With arrangements 2C Flame Attachment-type coal nozzle tips (Fig. 5-
through 3B, some of the intermediate auxiliary air 14) are selected for Arrangement 2 and 3 LNTFS
compartments are assumed to be partially designs. Refer to site specific (Stuttgart,
“closed” during normal operation, but total Windsor, Velizy) windbox mechanical design
“active” cell auxiliary airflow is 70%. The “active” standards for selection details.
free area of closed or partially closed
compartments is proportional to the assumed Wide Range coal nozzle tips (WRCN) (Fig. 5-15)
flow rate. are generally selected when unit operation below
35% MCR, on coal only, is required for all
Determine the actual combined net pressure loss medium and high volatile U.S. and foreign
between the windbox and upper furnace by bituminous coals. Refer to site (Stuttgart, Velizy,
subtracting the furnace stack effect (0.012 inches Windsor) specific windbox mechanical design
(0.3 mm) of water per foot of height, times the standards for further selection and design details.
distance from centerline of windbox to centerline
of furnace outlet plane) and then multiply by the *NOTE: Certain bituminous coals soften, or
elevation correction factor. The quoted “Design” become plastic, when heated. This property can
windbox to furnace differential pressure (FD fan cause accumulation of coal on hot nozzle tip
sizing) shall not be less than 4.0” w.g. (102 mm plate work, which can lead to coal nozzle/nozzle
wg). This value is increased to the nearest 0.5” tip pluggage and/or fires. Unfortunately, there is
(12.7 mm) greater than the calculated net no direct way to judge the coal plasticity from the
pressure loss. fuel/ash analysis, and only specialized testing or
experience identifies high risk coals. In general,
low, medium, and high volatile A and B
bituminous coals specifically will display some
“caking” or swelling propensity. Sub-bituminous
and lignite coals will not. If available, the free
swelling index (FSI) can be used to assess the
coal caking qualities. A FSI > 4 is sufficient to
classify the coal as high risk for the purposes of
these standards.
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Figure 5-1
STANDARD LNTFS
WINDBOX and OFA COMPARTMENT ARRANGMENTS
H-SOFA
H-SOFA
H-SOFA
M-SOFA
M-SOFA
M-SOFA L-SOFA
L-SOFA L-SOFA
L-SOFA L-SOFA
L-SOFA
CC-OFA CC-OFA CC-OFA CC-OFA

CC-OFA CC-OFA CC-OFA CC-OFA
TEA TEA TEA TEA
COAL COAL COAL COAL
CFS CFS
AUX AUX AUX AUX
AIR AIR AIR AIR
CFS CFS
COAL COAL COAL COAL
CFS CFS
AUX AUX AUX AUX
AIR AIR AIR AIR
CFS CFS
COAL COAL COAL COAL
CFS CFS
AUX AUX AUX AUX
AIR AIR AIR AIR
CFS CFS
COAL COAL COAL COAL
AIR AIR CFS CFS
OIL OIL OIL OIL
GAS GAS GAS GAS
AIR AIR CFS CFS
COAL COAL COAL COAL

BEA BEA BEA BEA
UFA UFA
Arrangemen Arrangement Arrangement Arrangement

t 2A & 2B
1A & 1B 2C & 2D 3A & 3B
- IFM Ignitor - Flame Scanner

DATE : 17 FEB 2006
OWNER : 8152
PAGE : 41 of 78
Figure 5-2
Figure 5-2
Coal Classification
COAL CLASSIFICATIONfor NOx
100
98
92
86
12500
83
Group 1
78
75
Group 2
69 11750
67
64.75
Group 3
58
Group 5 Group 6
54.25
Group 4
50
45
8300 7000
11750
40
16,000 14,000 13,000 11,000 9,500 8,300 7,000
WET (AS RECEIVED), MINERAL-MATTER-FREE HHV, BTU / LB
(HHV - 50 * %S) * 100 / (100 - 1.08 * %Ash - 0.55 * %S)

INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 42 of 78
Figure 5-3m
Figure 5-3m
LNTFS Selections
LNTFS Selections for Group 1 Coals
for "Group 1" Coals
1050
1A
1000
Performance NOx (mg/Nm3 6% O2, dry flue gas)
1B
950
900 2A
850
800
750 2B
700
2C
650
600 2D
550 3A
500
3B
450
400
350
300
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
Firing Zone Stoichiometry
INDEX : 21.13
DATE : 17 FEB 2006
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PAGE : 43 of 78
Figure 5-3e
Figure 5-3e
LNTFS Selections
for "Group 1" Coals
0.90
0.85 1A
Performance NOx (lbs/106 Btu)
0.80 1B
0.75
2A
0.70
0.65
2B
0.60
0.55 2C
0.50 2D
0.45 3A
0.40 3B
0.35
0.30
0.25
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 44 of 78
Figure 5-4m
Figure 5-4m
LNTFS
LNTFSSelections for Group 2 Coals
Selections
for "Group 2" Coals
900 1A
850
1B
800
750
2A
700
650
2B
600
550 2C
500 2D
450 3A
400
3B
350
300
250
200
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 45 of 78
Figure
Figure5-4e
5-4e
LNTFS Selections
LNTFS for Group 2 Coals
Selections
for "Group 2" Coals
0.80
0.75
1A
0.70
1B
0.65
0.60 2A
0.55
2B
0.50
0.45 2C
0.40 2D
3A
0.35
3B
0.30
0.25
0.20
0.15
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 46 of 78
Figure 5-5m
Figure 5-5m
LNTFS Selections
for "Group 3" Coals
800
1A
750
700 1B
650
2A
600
550
2B
500
2C
450
400 2D
3A
350
300 3B
250
200
150
100
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 47 of 78
Figure 5-5e
Figure 5-5e
LNTFS Selections
for "Group 3" Coals
0.70
0.65
1A
0.60
1B
0.55
0.50 2A
0.45
2B
0.40
2C
0.35
2D
0.30 3A
0.25 3B
0.20
0.15
0.10
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 48 of 78
Figure 5-6m
Figure 5-6m
LNTFS Selections
for "Group 4" Coals
800
1A
750
700
650 1B
600
2A
550
500
2B
450
2C
400
2D
350
3A
300
250 3B
200
150
100
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 49 of 78
Figure 5-6e
Figure 5-6e
LNTFS Selections
for "Group 4" Coals
0.70
0.65
1A
0.60
0.55
1B
0.50
2A
0.45
0.40
2B
0.35
2C
0.30 2D
3A
0.25
3B
0.20
0.15
0.10
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 50 of 78
Figure 5-7m
Figure 5-7m
LNTFS
LNTFS Selections
Selections for Group 5 Coals
for "Group 5" Coals
1A
700
650
600
1B
550
500 2A
450
400
350 2B
300 2C
250 2D
3A
3B
200
150
100
50
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 51 of 78
Figure 5-7e
Figure 5-7e
LNTFS Selections
for "Group 5" Coals
0.60
1A
0.55
0.50
1B
0.45
0.40 2A
0.35
0.30 2B
0.25 2C
2D
0.20 3A
3B
0.15
0.10
0.05
0.00
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 52 of 78
FigureFigure
5-8m 5-8m
LNTFS Selections
LNTFS Selectionsfor Group 6 Coals
for "Group 6" Coals

1A
1000
950
900
850
800 1B
750
700
2A
650
600
550
2B
500
450 2C
400
2D
350
300 3A
250 3B
200
150
100
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 53 of 78
Figure 5-8e
Figure 5-8e
LNTFS Selections
for "Group 6" Coals
1A
0.80
0.75
0.70
0.65 1B
0.60
0.55 2A
0.50
0.45
2B
0.40
0.35 2C
0.30 2D
0.25 3A
0.20 3B
0.15
0.10
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
DATE : 17 FEB 2006
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PAGE : 54 of 78
Figure 5-9
LNTFS Design Arrangement SELECTION GUIDELINE (Coal Firing)
I. LNTFS Arrangements
1A 1B 2A 2B 2C 2D 3A 3B
Total OFA % of TCA* 12% 20% 25% 30% 35% 40% 43% 47%
“CC” – OFA % of TCA 12% 20% 7% 7% 10% 10% 7% 7%
“Low” – SOFA % of TCA - - 18% 23% - - 18% 20%
“Mid” – SOFA % of TCA - - - - 25% 30% - -
“High” – SOFA % of TCA - - - - - - 18% 20%
II. LNTFS Arrangements

1A 1B 2A 2B 2C 2D 3A 3B
Total OFA % of StA 14.4% 24% 30% 36% 42% 48% 51.6% 56.4%
“CC” – OFA % of StA 14.4% 24% 8.4% 8.4% 12% 12% 8.4% 8.4%
“Low” – SOFA % of StA 21.6% 27.6% 21.6% 24%
“Mid” – SOFA % of StA 30% 36%
“High” – SOFA % of StA 21.6% 24%
III. Windbox Secondary Air

Free Area Distribution
Coal Fuel Air % of cell 35.0% 35.0% 30.0% 30.0% 30.0% 30.0% 30.0% 30.0%
Total Auxiliary Air % of cell 65.0% 65.0% 70.0% 70.0% 70.0% 70.0% 70.0% 70.0%
IV. Intermediate Auxiliary Air

Compartment Arrangements
“Single” Compartment STD STD STD STD
“Double” Compartment OPT OPT OPT OPT
“Triple” Compartment OPT OPT OPT OPT STD STD STD STD
“CFS” Air Compartment

“Slagging” Coal STD STD STD STD STD STD STD STD
“Non-slagging” Coal NR NR NR NR STD STD STD STD
“Triple” Compartment Aux. Air

Free Area Distribution
“CFS” Comp’ts % (2-comp’ts) of cell 15.0% 15.0% 17.5% 17.5% 27.5% 27.5% 27.5% 27.5%
“Str.” Aux. Air/Fuel Comp’t % of cell 35.0% 35.0% 35.0% 35.0% 55.0% 55.0% 55.0% 55.0%
V. Top/Bottom & Underfire Air

“Top and Bottom” End Air Comp’ts STD STD STD STD STD STD STD STD
“UFA” Compartment OPT OPT OPT OPT STD STD STD STD
Top/Bottom & Underfire Air

“Top and Bottom” End Air % of cells 33% 33% 35% 35% 30% 30% 30% 30%
“Underfire” Air % of cell - - - - 30% 30% 30% 30%
VI. Additional System

Requirements
S-OFA Flow Measurement NA NA OPT OPT OPT OPT STD STD
Dynamic Classifier OPT OPT OPT OPT STD STD STD STD
Notes “STD” - Standard

“OPT” - Optional
“NR” - Not Required
“NA” - Not Applicable
TCA - Total Combustion Airflow
StA - Stoichiometric Airflow
* - TCA equals 120% of StA in these guidelines
DATE : 17 FEB 2006
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PAGE : 55 of 78
Figure 5.10
LNTFS Intermediate Auxiliary Air Compartment Arrangements
I. Single Compartment Arrangement
AIR straight
AUX straight CFS offset OIL air plus
AIR air only CFS air only GAS auxiliary
AIR fuel
II. Double Compartment Arrangement
AUX AIR straight

AIR straight CFS offset GAS air plus
AUX air only CFS air only GAS auxiliary
AIR AIR gas only
III. Triple Compartment Arrangement
CFS offset CFS offset & AIR straight

AUX and OIL straight OIL air plus
AIR straight GAS air plus GAS auxiliary
CFS air only CFS aux. fuel AIR fuel
INDEX : 21.13
DATE : 17 FEB 2006
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PAGE : 56 of 78
Figure 5-11m
Secondary Air Velocity Guidelines*
62
Design Velocity, m/sec
58
Groups 5,6
54
- Groups 1,2,3,4
50
46
42
0.0 100.0 200.0 300.0 400.0 500.0
Furnace Plan Area per Cell, sq. m.
* NOTE: These velocities are applicable for units with secondary air damper control (SADC), for units without SADC, the velocities in
the diagram should be increased 10%.
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 57 of 78
Figure 5-11e
Secondary Air Velocity Guidelines*
200
190
Design Velocity, ft/sec
180 Groups 5,6

170
Groups 1,2,3,4
160
150
140
130
120
0 1000 2000 3000 4000 5000
Furnace Plan Area per Cell, sq. ft.
* NOTE: These velocities are applicable for units with secondary air damper control (SADC), for units without SADC, the velocities
in the diagram should be increased 10%.
INDEX : 21.13
DATE : 17 FEB 2006
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PAGE : 58 of 78
Figure 5-12m
Recommended Primary Air Velocity at Burner Nozzle tip (m/s) vs VM dry basis
32
31
30
29
Primary Air Velocity (m/s)
28
27
26
25
24
23
22
21
20
19
18
17
16
15
10 15 20 25 30 35 40 45 50
VM dry basis %
INDEX : 21.13
DATE : 17 FEB 2006
OWNER : 8152
PAGE : 59 of 78
Figure 5-12e
Recommended Primary Air Velocity at Burner Nozzle Tip
105
100
95
Primary Air Velocity (ft/s)
90
85
80
75
70
65
60
55
50
10 15 20 25 30 35 40 45 50
VM dry basis %
DATE : 17 FEB 2006
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PAGE : 60 of 78
ILLUSTRATIONS OF FIVE COAL NOZZLES AND TIP STYLES
STANDARD TIP
FIGURE 5.13
STANDARD AERO TIP

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AGGRESSIVE FLAME ATTACHMENT TIP
SEMI-AGGRESSIVE FLAME ATTACHMENT TIP FIGURE 5.14

DATE : 17 FEB 2006
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PAGE : 62 of 78
WIDE RANGE TIP
FIGURE 5.15
DATE : 17 FEB 2006
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PAGE : 63 of 78
6. SOFA SYSTEM
The purpose of this section is to specify the %CCOFA CCOFA mass flow as a
vertical furnace location of separated overfire air percentage of MTCA (%)
(SOFA) windboxes, for the optimization of NOx
control and combustion efficiency. Because this %LSOFA Lower SOFA mass flow
location criteria is based upon optimizing mean as a percentage of MTCA
coal residence time at sub-stoichiometric (%)
conditions (tsub), this section also defines this
calculation procedure. %MSOFA Middle SOFA mass flow,
if applicable, as a
6.1 Definitions and Equations percentage of MTCA (%)
This section is applicable for the selection of all %HSOFA High SOFA mass flow, if
tilting tangential coal firing systems utilizing applicable, as a
separated overfire air (SOFA) for the control of percentage of MTCA (%)
NOx emissions. This includes both vertical – and
spiral – walled furnace arrangements, both with HFOT Furnace outlet
and without supplementary fuel. temperature (°F, °C)
Residence Time Calculation Procedure
Required Data
h1 Distance from centerline of

Horizontal
top coal nozzle to centerline Furnace Outlet
of CCOFA compartments Plane
(HFOP)
(ft; m)
h4
h2 Distance from CCOFA
centerline to centerline of
HSOFA
LSOFA or MSOFA Centerline
SEPARATED
OVERFIRE AIR
compartments (ft; m) h3
LSOFA (SOFA)
Centerline WINDBOXES
h2
h3 Distance from LSOFA COFA
h1 Centerline
centerline to HSOFA
centerline, if applicable (ft; Top Coal
Centerline
m)
MAIN
WINDBOX
h4 Distance from HSOFA
centerline to horizontal
furnace outlet plane (feet)
PA Furnace plan area (ft2; m2)

Figure 6.1 - SOFA System Definitions
MTCA Total combustion air mass
flow (lb/hr, kg/hr)
Mcoal Total coal flow (lb/hr, kg/hr)
%ASH Mass percentage of ash

in coal (%)
DATE : 17 FEB 2006
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6.2 Location of SOFA Windboxes 6.3 Calculation
6.2.1 Circumferential Location In order to determine sub-stoichiometric

residence time for a given configuration, it is
SOFA windboxes shall be located at or near the necessary to separately calculate the residence
corners of the unit, as a function of arrangement time for each of the four vertical sections (h1-h4)
limitations and/or cost efficiency. indicated in Figure 6-1 (Note: For configurations
with only one SOFA elevation, section h3 does
6.2.2 Vertical Location of SOFA not apply). For each section, mean residence
Windboxes time is calculated using the following formula,
where the subscript “i” signifies the appropriate
SOFA windboxes shall be sized with free area section, 1 through 4, corresponding to h1 through
consistent with Std. Section 5 of this standard, h4 on Figure 6-1.
with the ability to achieve ± 30 degree vertical tilt
and ± 15 degree horizontal yaw. ρi represents the gas density of the
relevant furnace section, in lb/ft3 or kg/m3. This
The vertical centerline of each SOFA windbox value is determined by first calculating the gas
shall be located a suitable minimum distance (h2, density at the horizontal furnace outlet plane:
h3) above the centerline of the upper coal nozzle
so as to satisfy the following criteria:
ρ HFOP =
39.75
(english ⋅ units )
6.2.3 SOFA Location – Single HFOT + 460
Elevation
For arrangements utilizing one elevation of ρ HFOP =

353
(metric ⋅ units )
HFOT + 273
SOFA, the corner windboxes shall be located
such that each of the following two residence
Density for the individual furnace sections are
time criteria apply:
then given by the following equations,
For LSOFA (per Std. Arrangement 2A or 2B)
ρ HFOP
τsub ≥ 0.6 sec. and 0.4 ≤ τsub/τtotal ≤ 0.5 ρ1 =
1+ C
For MSOFA (per Std. Arrangement 2C or 2D) ρ HFOP

ρ2 =
τsub ≥ 0.8 sec. and 0.5 ≤ τsub/τtotal ≤ 0.6 ⎛ 0.5 × h2 + h3 + h4 ⎞
1 + C × ⎜⎜ ⎟⎟
⎝ h1 + h2 + h3 + h4 ⎠
6.2.4 SOFA Location – Double
ρ HFOP
Elevation ρ3 =
⎛ 0.5 × h3 + h4 ⎞
For arrangements utilizing two SOFA elevations, 1 + C × ⎜⎜ ⎟⎟
the lower elevation (LSOFA) shall be located ⎝ h1 + h2 + h3 + h4 ⎠
ρ HFOP
ρ4 =
(τ1 + τ2) ≥ 0.6 sec. and 0.4 ≤ ((τ1 + τ2)/τtotal) ≤ ⎛ 0.5 × h4 ⎞
0.5 1 + C × ⎜⎜ ⎟⎟
⎝ h1 + h2 + h3 + h4 ⎠
The upper elevation (HSOFA) shall be located
τsub ≥ 1.0 sec. and 0.6 ≤ (τsub/τtotal )≥ 0.7

DATE : 17 FEB 2006
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PAGE : 65 of 78
Where the appropriate correction factor, C, is 6.4 Sample Calculation (English Units)
applied as follows:
Consider design utilizing two (2) elevations of
For configurations with one SOFA elevation: SOFA. The following data is given:
C = 0.14 Top Coal Nozzle Centerline Elevation 169.0’

Centerline of CCOFA Compartments 171.6’
For configurations with two SOFA elevations:
LSOFA Windbox Centerline 183.2’
C = 0.10 HSOFA Windbox Centerline 193.4’
Mi, representing the gas mass flow for the HFOP Elevation (Tip of Nose Arch) 211.9’
relevant furnace section is calculated using the Furnace Width 36.75’
following equations:
Furnace Depth 36.75’
M1 = 0.01 × MTCA × (100 - %CCOFA - %LSOFA - Total Combustion Airflow 1,752,418 lb/h
%HSOFA) + Mcoal (1 - .002 × %ASH) Total Coal Flow 228,700 lb/h
Ash in Coal (% of Mass) 5.0%
M2 = 0.01 × MTCA × (100 - %LSOFA - CCOFA Flow (% of TCA) 8.0%
%HSOFA) + Mcoal (1 - .002 × %ASH) LSOFA Flow (% of TCA) 21.0%
HSOFA Flow (% of TCA) 21.0%
M3 = 0.01 × MTCA × (100 - %HSOFA) Predicted Furnace Outlet Temperature 2500 °F
+ Mcoal (1 - .002 × %ASH)
Calculate Heights
M4 = MTCA + Mcoal (1 - .002 × %ASH)
h1 = Distance from top coal nozzle to CCOFA centerline
Sub-stoichiometric residence time is then equal h1 = 171.6 – 169.0 = 2.6’
to the following:
h2 = Distance from CCOFA to LSOFA centerline
For configurations with one SOFA elevation: h2 = 183.2 – 171.6 = 11.6’
h3 = Distance from LSOFA centerline to HSOFA centerline
For configurations with two SOFA elevations:
h3 = 193.4 – 183.2 = 10.2’
τ sub= τ 1 + τ 2
h4 = Distance from HSOFA centerline to HFOP
τ sub= τ 1 + τ 2 + τ 3 h4 = 211.9 – 193.4 = 18.5’
Total residence time (top coal nozzle to HFOP) is

given by:
τ total = τ 1 + τ 2 + τ 3 + τ 4
Residence time τi = hi x ρ x PA / Mi
i
DATE : 17 FEB 2006
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Calculate Gas Densities Calculate Residence Times
39 . 75 39 . 75 3600 × h1 × ρ1 × PA 3600 × 2.6 × 1351 × .0122

ρ HFOP = = = 0 . 0134 lb / ft 3 τ1 = = = 0.14 s
FOT + 460 2500 + 460 M1 1,102,622
For two (2) elevations of SOFA, C = 0.10 3600 × h2 × ρ 2 × PA 3600 ×11.6 × 1351× .0124
τ2 = = = 0.56s
M2 1,242,815
ρ HFOP
ρ1 = = 0 . 01224 lb / ft 3
1+ C
ρ HFOP 3600 × h3 × ρ 3 × PA 3600 ×10.2 ×1351× .0127
ρ2 = = 0 .0124 lb / ft 3 τ3 = = = 0.39 s
⎛ 0 .5 × h2 + h3 + h4 ⎞ M3 1,610,823
1 + C × ⎜⎜ ⎟⎟
⎝ h1 + h2 + h3 + h4 ⎠ 3600 × h4 × ρ 4 × PA 3600 ×18.5 × 1351× .0131
τ4 = = = 0.60s
M4 1,978,831
ρ HFOP
ρ3 = = 0.0127 lb / ft 3
⎛ 0.5 × h3 + h4 ⎞
1 + C × ⎜⎜ ⎟⎟ Check for Acceptability
⎝ h1 + h2 + h3 + h4 ⎠
LSOFA Location:
ρ HFOP τ1 + τ2 = .14 + 0.56 = .70 s

ρ4 = = 0 .0131 lb / ft 3
⎛ 0 .5 × h4 ⎞ 0.70 > 0.60 … o.k.
1 + C × ⎜⎜ ⎟
⎟
⎝ h1 + h2 + h3 + h4 ⎠ (τ1 + τ2)/ τtotal = .70/1.69 = 0.41
0.41 > 0.40 … o.k.
HSOFA Location:
τsub = τ1 + τ2 + τ3 = 0.14 + 0.56 + 0.39 =

Calculate Gas Mass Flows 1.09s
M1 = 0.01 × MTCA ×(100 - %CCOFA - %LSOFA - τtotal = τsub + τ4 = 1.09 + 0.60 = 1.69s
%HSOFA) + Mcoal (1 - .002 × %ASH) = 0.01
(1,752,418) (100-50) + 228,700[1-.002(5)] τsub = 1.09s 1.09 > 1.0 … o.k.
= 1,102,622 lb/h
τsub/τtotal = 1.09s / 1.69 = 0.64
M2 = 0.01 × MTCA ×(100 - %LSOFA - %HSOFA) 0.64 > 0.60 … o.k.
+ Mcoal (1 - .002 × %ASH) = 0.01
(1,752,418) (100-42) + 228,700[1-.002(5)]
= 1,242,815 lb/h In the event that any of the above residence
times or ratios were not acceptable (below the
M3 = 0.01 × MTCA ×(100 - %HSOFA) + Mcoal (1 - minimum values defined in Section 6.2), the
.002 × %ASH) = 0.01 (1,752,418) (100-21) LSOFA, MSOFA or LSOFA and HSOFA windbox
+ 228,700[1-.002(5)] = 1,610,823 lb/h elevations (and therefore h2 and h3) shall be
increased such that the minimum residence time
M4 = MTCA + Mcoal (1 - .002 × %ASH) = 0.01 values are achieved.
1,752,418 + 228,700[1-.002(5)] =
1,978,831 lb/h
DATE : 17 FEB 2006
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PAGE : 67 of 78
7. NOx PREDICTION
This NOx predictor tool is designed for giving a

rapid and accurate evaluation of NOx emissions
for the coal, the furnace and operating conditions
considered. This NOx predictor supplements the
NOx performance capability charts in Section 5.
The evaluation of NOx is based on four
parameters:
• Coal rank (using the various parameters of
section 3.1.2, metered by fuel ratio)
• Firing zone stoichiometry in the burner zone
( λ FZ )
• Residence time in reducing zone
• Burner Tilting
The accuracy of the prediction is within ± 15 %.

All NOx guarantees must include margin to cover
operational and theoretical uncertainties, see
section 5.
7.1 Base NOx Emissions
0
The base NOx emission ( NO x ) vs. the coal fuel
ratio (corrected Fuel ratio FRcorrected) is given in
Fig. 7-1. This base curve is established for:
• a close couple OFA (i.e. No or insignificant
residence time between last operating burner
level and OFA);
• λ FZ = 1.0 ;
• %Ndaf=1.7 %
DATE : 17 FEB 2006
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NOx0 vs. Fuel ratio λFZ=1

900
800
700
NOx0 mg/m3(n) @ 6%O2 dry flue gas
600
500
400
300
200
100
0.5 0.6 0.7 0.8 0.9 1.0 2 3 4 5 6 7 8 9 10.0
Fuel Ratio (FR)
Figure 7-1: Base NOx Emission vs. Fuel Ratio

DATE : 17 FEB 2006
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PAGE : 69 of 78
NOx emission correction factor vs. air factor in firing zone
2.0
1.9
1.8
1.7
1.6
Firing zone stoechiometry correction factor (-)
1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6
Firing zone stoechiometry air factor (-)

Figure 7-2: Air Factor in Firing Zone Correction Factor
7.2 Correction Factors
The base NOx emissions level is corrected to evaluate the expected NOx emissions by using three
correction factors.
Firing Zone Stoichiometry Correction Factor
The firing zone stoichiometry (taking into account air in burners only) is an important parameter for NOx
emission level. The firing zone stoichiometry correction factor k λFZ is given in Figure 7-2
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Correction factor vs Residence Time &

Excess air factor
1
0.95
0.9
0.85
0.8
Correction Factor (-)
0.75
0.7
0.65 XS air factor <=0,7

XS air factor =0,75
XS air factor=0,8
XS air factor in FZ=0,85
0.6
XS air factor in FZ=0.95
XS air factor in FZ=1.0
0.55 XS air factor in FZ=1,05
XS air factor in FZ>=1.2
0.5
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Residence Time (s)
Figure 7-3: Residence Time Correction Factor

Correction factor for Residence time in reduction zone
The effect of the residence time on the NOx reduction is coupled with the stoichiometry. Here, the “mean
weighted residence time τ OFA ” is considered. This residence time is calculated considering that the burner
tilting is null. This residence time is equal to the sub-stoichiometric residence time as defined in section 6 of
this standard.
The residence time correction factor ( kτ ) is given in Figure 7-3.
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Coal Nitrogen content NOx correction factor
1.10
Correction factor kN
1.00
0.90
0.80
0 0.5 1 1.5 2 2.5 3
%N daf
Figure 7-4: Coal Nitrogen Content Correction Factor
Nitrogen Content Correction Factor
For taking into account the coal nitrogen content, a correction factor ( k N ) is used. This correction factor is
based on %Ndaf. And is taken from Figure 7-4.
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Burners Tilt N O x em ission correction factor
1.25
1.20
1.15
ktilt (-)
1.10
1.05
1.00
0.95
-40 -30 -20 -10 0 10 20 30 40
θ - B urners Tilt (°)

Figure 7-5: Burners Tilt NOx Emission Correction Factor
Burner Tilting Correction Factor
Burners tilt has an impact on NOx emission, a correction factor ( k tilt ) is given in Figure 7-5. The burners tilt
is marked as below:
• 0° corresponds to horizontal inclination;
• negative value corresponds to downward tilting
• positive value corresponds to upward tilting
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7.3 Other Parameters
Some other parameters (not quantified in the

present standard) have an influence on NOx
emissions:
• The boiler load : the decrease of the boiler

load induces a decrease of the fire
concentration favorable for NOx reduction,
but simultaneously with the decrease of the
load there is an increase of the XS air in the
furnace increasing the NOx emissions.
• Furnace and burner sizing : increasing fire
concentration can raise NOx emissions;
• State of fouling of the furnace: clean walls
increase heat exchange in the furnace,
reduce the fireball temperature and decrease
the NOx emissions;
• The flame attachment: the quality of the
flame attachment gives an information of the
quality of the combustion of the volatile
matters near the burner in reducing zone. A
good flame attachment tends to decrease
Volatile-N conversion to NO.
• Quantity and Quality (in volatile matter or in
fixed carbon) of nitrogen content in the coal;
7.4 Calculation Procedure
The NOx emission level can be calculated by :
NO x = NO .k o
x λ FZ .k .k
τ tilt .kN
Examples
Two type of examples are presented here for

estimating NOx emissions :
• two examples with a CCOFA;
• one example with staged OFA
CCOFA ONLY
Two examples are given for estimating NOx

emissions with a CCOFA, for the same coal
FR=2, %Ndaf=1,8 :
• First one, the three lower level are in
operation, the residence time between last
level and CCOFA is about 0.7 s,
• λ FZ = 0.85 , tilt=0°
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• Second one, for the same excess air in the CCOFA WITH THE MORE UPPER BURNER
firing zone, the upper burner level is in LEVEL IN OPERATION
operation, the residence time is about 0.35 s,
tilt=0° A general view of this example is given in Figure
7-7. By using Figures 7-1 through 7-5, the base
CCOFA WITH LOWER BURNER LEVELS IN level and the correction factor are determined.
OPERATION • NO x0 = 670 mg / m 3 (n)
A general view of this example is given in Figure • k λFZ = 0.86
7-6. By using Figures 7-1 through 7-5. the base
level and the correction factor are determined.
• kτ = k RT (0,35 , 0,85) = 1
• NO x0 = 670 mg / m 3 (n) So the expected NOx level is :
• k λFZ = 0.86 NO x = 670 0.86.1.1.015
• kτ = 0.84 = 584 mg / m 3 (n) @ 6%O2 dry
• k N = 1.015 This example compared to previous one shows
So the expected NOx level is : the importance of the residence time in reducing
zone.
NO x = 670 .0.84.0.86.1.015
= 492mg / m 3 (n) @ 6%O2 dry
CC OFA
Last Burner
τ FZ = 0.35 s
level in operation
λFZ = 0.85
CC OFA
τ FZ = 0.7 s
Last Burner
level in operation
λFZ = 0.85
Figure 7-7: NOx Predictor Utilisation with

CCOFA (more upper burner level in operation)
MULTIPLE OFA LEVEL
A general view of this example is given in Figure

Figure 7-6: NOx Predictor Utilisation with 7-8.
CCOFA (lower burner in operation)
By using Figures 7-1 through 7-5 the base level
and the correction factors are determined.
• NO x0 = 670 mg / m 3 (n)
• k λFZ = 0.86
• kτ = k RT (1.1 , 0,85) = 0.72
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PAGE : 75 of 78
So the expected NOx level is :
NO x = 670 0.86.0.72. 1.015

= 422 mg / m 3 (n) @ 6%O2 dry
λtotal =1.2
SOFA
λCCOFA = 1.0 τ COFA = 0.7 s
CC OFA τ OFA = 1.1 s
τ FZ = 0.7 s
Last Burner
level in operation
λFZ = 0.85
Figure 7-8: NOx Predictor Utilisation with

CCOFA and SOFA (low burner level in
operation)
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8. CARBON LOSS PREDICTION
LATER
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9. TURNDOWN PREDICTION
LATER
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10. APPENDICES
Appendix 1 (1/1)
10.1 Unit conversion chart
Multiply by To obtain
°F (5/9)°F –17.8 °C
ft 0.3048 m
ft2 0.0929 m2
ft3 0.02832 m3
lb 0.453592 kg
Btu 1.05506 kJ
Btu/hr 0.293071 W
Btu/lb 2.3260 kJ/kg
2
Btu/hr.ft 3.15459 W/m2
Btu/hr.ft3 10.3497 W/m3
°C (9/5) °C + 32 °F
3.28084 ft
m
10.7639 ft2
m2
35.31467 ft3
m3
2.20462 lb
kg
0.947817 Btu
kJ
3.41280 Btu/hr
W
0.429923 Btu/lb
kJ/kg
0.316998 Btu/hr.ft2
W/m2
0.096621 Btu/hr.ft3
W/m3

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What is the purpose and scope of the standard?

What is the purpose and scope of the standard?

What factors are considered for coal appraisal?

What factors are considered for coal appraisal?

THIS STANDARD IS: STD NO : 4-2005-00

New INDEX : 21.13

REMARKS: This Standard to be effective immediately.

NOTES: 1. See Page 2 for Versions.

THIS DOCUMENT CONTAINS PROPRIETARY DATA AND SHALL NOT BE REPRODUCED

UNITS: ENGLISH; METRIC; BOTH; NONE

Ver 0 - First Issue.

1 PURPOSE AND SCOPE 6

8 CARBON LOSS PREDICTION 76

5-12m Recommended Primary Air Velocity at Nozzle Tip (metric) 58

1. PURPOSE AND SCOPE Application of either ASTM standard or DIN

2.1.1 General • Apparent Fuel Ratio

The estimating method is the following: Correction for CO 2-Carbonates

(i) determination of the limiting parameter and CO 2-Carbonates = 0.786x0.103x0.13 = 1.05%(ar)

Example The plane which passes perpendicular to the gas

VFOP Furnace outlet

Figure 2-1 Figure 2-2

Definitions for Definitions for

N – Number of coal nozzle levels installed h – Firing zone height, m (ft)

C, m (ft) W – Furnace width, m (ft)

D – Furnace depth, m (ft) EPRS – Effective Projected Radiant Surface, m2

e – Nozzle spacing, m (ft) When calculating EPRS, observe the following:

FZV-Firing Zone Volume, m3 (ft3) 2.2.2 Furnace Thermal Data

VFOT – Vertical Furnace Outlet Temperature for

GHR – Gross Heat Release, MW (Btu/hr) Fouling

Coal analyses should be compared with previous

The consistency of the ultimate analysis with the

• Boïe statistical formula for HHV

Figure 3.1 – Coal Properties (1/2)

abcd COAL PROPERTIES

Figure 3.2 – Coal Properties (2/2)

3.1.2 Rank Identification

3.2 Slagging and Fouling

Understanding Ash Analysis

Appraisal of the slagging/fouling risks shall be

T1 ,T2 ,T3 relation with %Fe2O3 in ash

* These curves are given for typical ashes with no singularity

* For ashes with singularities, lower temperature as below :

- if Fe2O3 /CaO=0.6 to 1.5 and Fe2O3>7%

- if Na2O=1.2 to 3.0% => T3-150°C T2-80°C

%Fe2 O3 content in ash

The table given here after proposes a

Four degrees of slagging are defined :

Referring to the classification table, make a first

Then crosscheck this first estimation with the

Finally, take the highest degree of severity.

T1 or IT °C < 1200 < 1150 < 1100

T3 – T 1 °C < 60 and T3 ≤ 1200

CaO (%) < 10 10 to 20 20 to 40 40 and

Na2O (%) <1 1 to 3 3 to 5 >5

Fe2O3 (%) <7 7 to 15 15 to 25 25

Fe2O3/CaO Whatever the 0.5 to 0.7 0.7 to 1.4

B/A ≠ 0.5 ± 0.1 0.5 ± 0.1

Figure 3-4 - Ash slagging potential appraisal

Observations The criteria for fouling appraisal in that 2nd

The purpose of this section is to define windbox h = NHI/(2BBHRR(W+D))