Rapid Mix Burner ™ Case Study 105 *Patented TODD Ultra Low Emissions Burner Installation The Situation In the summer of 1996, a new 230,000 lb/hr Nebraska boiler at a paper plant in Staten Island, NY, was supplied with a TODD ® Combustion Dual Rapid Mix Burner (D-RMB) utilizing induced Flue Gas Recirculation (FGR). The D-RMB was selected to meet the specified NOx and CO limits of 0.011 lb/MMBtu (approximately 9 ppm) on natural gas firing. For this unit, TODD provided the burner, windbox and fuel trains for gas and oil The Boiler A natural gas and No. 2 oil fired, 272 MMBtu/hr D-RMB was installed on a Nebraska ‘A’ type package watertube boiler rated for 230,000 lb/hr steam flow and equipped with an economizer. The TODD Combustion Group supplied one dual fuel D-RMB, an insulated windbox with baffles to provide uniform combustion air distribution, main and ignitor gas valve trains, a No. 2 fuel oil valve train, and an atomizing steam valve train. A fully metered, cross-limited control system and PLC- based Burner Management Systems were both provided by others. The TODD Result Fig. 2 illustrates the NOx results over the load range as obtained by a Continuous Emissions Monitoring System (CEMS). The NOx ranged between 7 and 8 ppm across the load range. The excess O 2 varied from about 5% at a minimum load to 3% at full load. FGR rates ranged between 30% and 35%. The CO emissions varied between 0 ppm and 9 ppm. The CO and NOx numbers are corrected to 3% O 2 . Field Test Data Load % O 2 % CO ppm NOx ppm 20 4.8 2 8 50 3.5 3 7 90 3.4 6 7 0 25 50 75 100 9 8 7 6 5 4 3 2 1 0 40.0 35.0 30.0 25.0 20.0 15.0 10.0 5.0 0.0 NOx ppm, O 2 % FGR % Load % NOx O 2 % FGR% Fig. 2: Emissions Data Fig. 1 ®

TODD Ultra Low Emissions Burner Installationgta.gastechnology.org/reflibrary/j_zink_105.pdf · Title: Rapid Mix Burner(TM) Case Study 105: TODD Ultra Low Emissions Burner Installation

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Rapid Mix Burner™ Case Study 105*Patented

TODD Ultra Low EmissionsBurner Installation

The SituationIn the summer of 1996, a new 230,000 lb/hr

Nebraska boiler at a paper plant in Staten Island,NY, was supplied with a TODD® Combustion DualRapid Mix Burner (D-RMB) utilizing induced FlueGas Recirculation (FGR). The D-RMB was selectedto meet the specified NOx and CO limits of 0.011lb/MMBtu (approximately 9 ppm) on natural gas firing. For this unit, TODD provided the burner,windbox and fuel trains for gas and oil

The BoilerA natural gas and No. 2 oil fired, 272 MMBtu/hr

D-RMB was installed on a Nebraska ‘A’ type packagewatertube boiler rated for 230,000 lb/hr steam flowand equipped with an economizer. The TODDCombustion Group supplied one dual fuel D-RMB,an insulated windbox with baffles to provideuniform combustion air distribution, main andignitor gas valve trains, a No. 2 fuel oil valve train,and an atomizing steam valve train. A fullymetered, cross-limited control system and PLC-based Burner Management Systems were bothprovided by others.

The TODD ResultFig. 2 illustrates the NOx results over the load

range as obtained by a Continuous EmissionsMonitoring System (CEMS). The NOx rangedbetween 7 and 8 ppm across the load range. The excess O2 varied from about 5% at a minimum loadto 3% at full load. FGR rates ranged between 30% and

35%. The CO emissions varied between 0 ppm and 9ppm. The CO and NOx numbers are corrected to 3% O2.

Field Test Data

Load % O2 % CO ppm NOx ppm

20 4.8 2 8

50 3.5 3 7

90 3.4 6 7

0 25 50 75 100

9876543210

40.0

35.0

30.0

25.0