ASIA-PACIFIC JOURNAL OF CHEMICAL ENGINEERING

Asia-Pac. J. Chem. Eng. 2010; 5: 447–453

Published online 25 May 2009 in Wiley InterScience
(www.interscience.wiley.com) DOI:10.1002/apj.256

Special Theme Research Article

NOx emissions of an opposed wall-fired pulverized coal
utility boiler
Xiaotao Gao1,2 * and Mingyao Zhang1
1
School of Energy and Environment, Southeast University, Nanjing 210096, P. R. China
2
Jiangsu Electric Power Test and Research Institute Co., Ltd, Nanjing 210036, P. R. China

Received 21 August 2008; Revised 28 November 2008; Accepted 30 November 2008

ABSTRACT: The present paper was addressed to the effects of operational variables and coal properties on NOx
emission level of a 600-MW opposed wall-fired pulverized coal utility boiler. The in situ experiments were performed
to study the effects of operational variables on boiler performance by changing individual variables while the other
variables were held nearly constant on the basis of the nominal load operation. It was found that the oxygen level
was a significant parameter to affect the NOx emission. The impacts of coal properties on NOx emission indicated
that NOx emission level decreased with the increase of the ratio of the nitrogen content to low heating value because
the volatile matter content in coal significantly influenced the in-flame NOx formation. Coal volatile content was the
dominant parameter to affect fuel NOx formation through affecting the reducing condition in the inner near-burner
zone when the low NOx burners were applied in the boiler.  2009 Curtin University of Technology and John Wiley
& Sons, Ltd.
KEYWORDS: pulverized coal combustion; NOx emission; operational variables; coal properties

INTRODUCTION for new power plants burning high-volatile coals was

In China, electricity generation industry is significantly
dependent on coal, which makes a contribution of
about three-fourths of the national electricity produc-
tion. Recent years, the installed capacity of coal-fired
power plants has increased greatly from 237 GW in
2000 to 554 GW in 2007 to fuel the fast growth of
national economy. Most newly built coal power plants
are large-scale pulverized coal-fired units.[1] However,
with the significant increase of coal utilization for elec-
tricity generation, pollutant emissions, including par-
ticulate matter, SO2 and NOx, from coal-fired power
plants also increase, which is becoming a great threat
to the national sustainable development.
Power plants are under the pressure of tightened
pollution regulations to cut the emissions. For NOx
emissions, the limit of current national standard (GB
13 223-2003)[2] is 450 mg/m3 (expressed as NO2 at
6% O2 ) for new generators burning coals with volatile
content higher than 20% (on dry ash free basis) and
650 mg/m3 for those firing coals with volatile content
less than 20%, respectively. Compared with the old
version standard (GB13223-1996),[3] the emission limit
*Correspondence to: Xiaotao Gao, School of Energy and Environ-
ment, Southeast University, Nanjing 210096, P. R. China.
E-mail: gaoxiaotao049040@sina.com
 2009 Curtin University of Technology and John Wiley & Sons, Ltd.
decreased significantly from 650 to 450 mg/m3 . More-
over, in order to control the total amount of NOx emis-
sions, Jiangsu provincial government set a pollution
charge of 1.2 RMB (ca US$0.18) per equivalent unit of
NOx (ca 0.92 kg NO2 ) emission for coal-fired power
plants, which took action on July 1, 2007. Whereas
particulate matter emissions are well controlled with
high-efficiency electrostatic precipitators and SO2 emis-
sions with the state-of-the-art flue gas desulfurization
systems in large-scale power plants, NOx emissions
are mainly controlled by using low NOx combustion
technologies such as low NOx burners and air staging.
As a result, controlling and reducing NOx emissions in
pulverized coal-fired power plants have to rely on the
boiler operation and combustion optimization, which is
becoming one of the major concerns of daily operation
for lowering the cost of electricity generation.
It is recognized that NOx generation is a very com-
plex process involving complex mechanisms of in-
furnace formation and destruction, as reviewed in van
der Lans et al .[4] During pulverized coal combustion,
NOx arise from one of two main processes: either by
thermal fixation of atmospheric nitrogen, termed ther-
mal NOx, or by transformation of fuel nitrogen, called
fuel NOx. Thermal NOx is favored by high temperature,
high O2 level, and long residence time in high tem-
perature. Fuel NOx formation is mainly dependent on
448 X. GAO AND M. ZHANG
reaction stoichiometry or oxygen availability. It can also
be suppressed if the release of the fuel nitrogen occurs
under reducing conditions. However, NOx formed in
flame can be destructed and reduced to N2 in reducing
environment. Therefore, the NOx emission from a pul-
verized coal-fired furnace is dependent on many factors
including local temperatures, stoichiometry, and chem-
ical reactions principally in the near-burner region.[4]
There are many plant variables affecting the level of
NOx emission from a pulverized coal-fired boiler. In
general, these variables can be catalogued into three
groups[5] :
• boiler design variables, including capacity, combus-
tion type, burner type, number and capacity of burn-
ers, burner zone heat release, resident time, presence
of over-fire air ports;
• boiler operation variables, such as load, in-service
mill/burner groups, excess air level, burner tilt, burner
settings;
• coal properties, for example, nitrogen content, volatile
content, fixed carbon-to-volatile ratio, heating value.
For a certain unit boiler, the design variables have
been specified although some variables may change
with the operation conditions such as unit load and
heat input. On the contrary, the operation variables
are often adjusted to meet the load requirement and to
optimize the boiler performance during daily operation,
which certainly influences the level of NOx emissions.
Coal properties also vary very often in Chinese power
plants. Power plants have to face frequent variations of
coal types and coal quality because of the uncertainty
of coal market supply. However, the factors affecting
NOx emission are generally coupled with each other
during the boiler operation. It is not easy to obtain the
Figure 1. The layout of the burners and the over-fire air ports. The arrows indicate the direct
of the swirl flow. This figure is available in colour online at www.apjChemEng.com.
 2009 Curtin University of Technology and John Wiley & Sons, Ltd.
Asia-Pacific Journal of Chemical Engineering
data on the effect of the change in single variable on
NOx emission although efforts had been made on this
aspect.[4 – 7]
In the present work, full-scale experiments were
performed on a 600-MW wall-fired pulverized coal
utility boiler to optimize boiler operation, in which
individual operational variables were regulated during
the full-load operation while the others were held
nearly constant. The objective is to study the impacts
of operational variables and coal properties on NOx
emissions so as to provide a systematic data for
optimizing the boiler operation performance.
EXPERIMENTAL
The experiments were performed on a 600-MW super-
critical unit boiler, manufactured by Harbin Boiler
Company, Ltd under the technical support of Mitsui
Babcock Energy, Ltd (MBEL). The boiler’s key design
parameters include a design boiler maximum continu-
ous rate of 1913 t steam/h with a steam temperature
of 571 ◦ C and a steam pressure of 25.4 MPa, design
heat release rates of 81.3 kW/m3 furnace volume,
4.3 MW/m2 furnace cross-section area, and 1.5 MW/m2
burner zone wall area. The boiler was opposed wall-
fired and equipped with 30 low NOx axial swirl burn-
ers (LNASB) of MBEL technology. The burners were
mounted at three elevations on front and rear walls of
the furnace. Each elevation had five burners on each
wall. Above the burners, 10 over-fired air (OFA) ports
(five on front wall and five on rear wall) were equipped
to achieve air staging combustion for further lowering
NOx emission. The layout of the burners and the OFA
ports on the walls is schematically shown in Fig. 1.
Asia-Pac. J. Chem. Eng. 2010; 5: 447–453
DOI: 10.1002/apj
Asia-Pacific Journal of Chemical Engineering
The LNASB burner is schematically shown in Fig. 2.
Within the LNASB, combustion air was divided into
three streams, primary, secondary, and tertiary. Primary
air (PA) is provided to carry the pulverized coal (PC).
The PC/PA mixture was fed to the burner through
a banjo body, subsequently being delivered into the
furnace via the PC/PA tube. Collector castings located
at the end of the PC/PA tube concentrated the PC into
four streams before the PC/PA admission to the furnace
to achieve a stable ignition and a reducing area for NOx
formation suppression. The secondary and tertiary airs
admitted air to the furnace at different stages, which
were gradually mixed into pulverized coal flame to
control the flame temperature. Through monitoring the
flow rates and swirl numbers of the secondary and
tertiary airs, the air staging combustion in the near-
burner region was fulfilled to ensure a stable flame close
to the burner throat and, most importantly, to ensure the
lower overall NOx formation and the complete burnout
of the fuel. In addition to these three air streams, each
burner was provided with core air. The core air was
required to supply sufficient air for a stable oil flame.
While no oil combustion, a small amount of core air
was supplied for cooling the core air tube. The flow
rate of the core air could also be adjusted to affect the
stoichiometric ratio in the inner NOx reduction zone of
the flame.
The boiler was designed to burn a high-volatile bitu-
minous coal. During the experiments, two bituminous
coals were actually used. The two coals were blended to
meet the requirements of the design specifications and
Figure 2. Schematic of the burner. This figure is available
in colour online at www.apjChemEng.com.
Table 1. The properties of the designing coal and the coals utilized for blending in the experiments.
Mar (%) Aar (%) Var (%) Car (%)
Design coal 15.00 8.50 27.88 61.45
Coal A 17.30 6.85 25.88 61.64
Coal B 11.80 18.49 26.80 55.82
ar, as-received basis.
 2009 Curtin University of Technology and John Wiley & Sons, Ltd.
NOX EMISSIONS OF PULVERIZED COAL UTILITY BOILER 449
also to change the coal properties through varying the
blending ratio to investigate the impact of coal proper-
ties on boiler operation performance. The properties of
the design coal and the used coals are summarized in
Table 1.
The in situ experiments were performed on the boiler
to study the effects of individual operational variables
and coal properties on the boiler performance including
NOx emission level and boiler efficiency. During the
experiments, the boiler load was held nearly at the
full load, that is, the best economic continuous rate.
In each testing case, a single variable such as oxygen
level in flue gas was adjusted while the other variables
were kept nearly constant. The investigated operational
variables included oxygen level in flue gas, primary
air speed, core air, distribution of secondary, tertiary,
and over-fired airs, swirl number of secondary air flow,
mill group in service, and so on. The measurements
during the experiments followed the standard procedure
(GB 10 184-88) for pulverized coal-fired utility boiler
testing.[8] In each case of the experiments, the flue gas
was sampled at the exit of the economizer section of
the boiler. NOx (including NO and NO2 , but expressed
as the concentration of NO2 according to Chinese
Standard[3] ) as well as O2 , CO, and CO2 was measured
by a Rosemount MLT gas analyzer with a relative error
of less than 1%. For reporting purpose, the on-site
recorded data were converted to the concentrations of
the gas species in dry flue gas under standard conditions
(0 ◦ C and 101 325 Pa). Totally, 21 testing cases were
carried out. Only a part of the results were summarized
and reported in the present paper with the focus on the
effects of main operation variables and coal properties
on NOx emission.
RESULTS AND DISCUSSION
Effects of boiler operational variables
The effects of O2 level in flue gas on NOx emission
as well as boiler efficiency and unburned carbon in ash
are shown in Fig. 3. During the operation, changing
the oxygen level for the combustion was carried out
by regulating the forced draft fans. In Fig. 3, the dots
represent the operation cases of varying the oxygen
level but with the other operational variables held,
Har (%) Oar (%) Nar (%) Sar (%) LHVar (MJ/kg)
3.95 9.95 0.70 0.45 23.50
3.83 9.06 0.63 0.69 23.08
4.18 8.00 0.73 1.00 21.09
Asia-Pac. J. Chem. Eng. 2010; 5: 447–453
DOI: 10.1002/apj
450 X. GAO AND M. ZHANG Asia-Pacific Journal of Chemical Engineering

(a) (b)
700 95

NOx emission, mg/m3 at 6%O2

600

Boiler efficiency, %
500 94.5

400
94
300 Specified cases
200 Others
Specified cases 93.5
100 All cases
0 93
3 3.5 4 4.5 5 5.5 3 3.5 4 4.5 5 5.5
O2 in exhausted flue gas, % O2 in exhausted flue gas, %

(c)
1.6

1.2
UBC, %

0.8

0.4

0
3 3.5 4 4.5 5 5.5
O2 in exhausted flue gas, %

Figure 3. Influences of O2 level on the boiler performance (a) NOx emission, (b) boiler efficiency,
(c) unburned carbon (UBC) in ash.

whereas the solid lines show the trends. The first point low stoichoimetric ratio was designed for the combus-
at the left side represents the case of nominal operation, tion zone. In this case, increasing the oxygen level may
which was based on ABCEF mill group in service. lead to not only higher oxygen concentration but also
Actually, the O2 level of the plant habitual operation higher temperature in the combustion zone and both
before the experiments was generally high, between the benefited the formation of thermal NOx. Therefore, the
first two points at the left side, to avoid furnace slagging enhanced formation of both thermal NOx and fuel NOx
for firing coals with low-ash-melting temperatures. The with increasing O2 level certainly led to the increase of
value of the nominal case was nearly the lowest used NOx emission. Increasing O2 level slightly enhanced
by the operators. Therefore, this case was chosen as the the burnout of coal particles (see Fig. 3(c)). Neverthe-
base case to study the effects of individual variables on less, increase in O2 concentration implies the increase
boiler performance and as the base case for optimizing of the combustion air, resulted in higher energy loss
the operation. through exhausted flue gas and consequently resulted
It can be seen that, for the nominal case, the NOx in the decrease of the boiler efficiency.
emission level is 480 mg/m3 at 6%O2 , higher than The influences of the other operational variables on
450 mg/m3 , implying the difficulty for the operators to NOx emission were also tested. Figure 4 shows the
meet the regulation limit. Figure 3 shows that increasing impacts of changing burner settings and mill groups in
the O2 level led to a linear increase of NOx emis- service on NOx emissions. It can be seen that changing
sion (Fig. 3(a)) and meanwhile a linear decrease in these variables did not significantly affect the boiler
the boiler efficiency (Fig. 3(b)). These impacts on the efficiency but did affect NOx emission.
boiler performance were expected. High O2 concen- In the experiments, changing burner setting was con-
tration obviously enhanced the formation of fuel NOx ducted through modulating the secondary air dampers of
during pulverized coal combustion. For thermal NOx, the LNASB burners. Because the secondary and tertiary
increasing O2 level favors its formation because of the airs originated from the same wind box, changing the
improved oxygen availability. Besides, increasing O2 amount of the secondary air resulted in the variation of
level also means more air added, generally resulting in the ratio of secondary air to tertiary air, modifying the
lower gas temperature and thus less thermal NOx for- flame profiles near the burners. Figure 4(a) shows that
mation. However, in the boiler studied, air staging was decreasing secondary air (Dec-SA case) from the nom-
applied through the application of OFA. It implies that inal case (N-case) led to only a slight decrease in NOx
 2009 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2010; 5: 447–453
DOI: 10.1002/apj
Asia-Pacific Journal of Chemical Engineering NOX EMISSIONS OF PULVERIZED COAL UTILITY BOILER 451

(a) (b)
600 95 600 95

NOx emission, mg/m3

NOx emission, mg/m3

Boiler efficiency, %
Boiler efficiency, %
500 94.6 500 94.6
400 400
94.2 94.2
300 300
93.8 93.8
200 200
100 93.4 100 93.4

0 93 0 93
N-case Dec-SA Inc-SA ACDEF ABCEF BCDEF

Figure 4. Variations of NOx emission and boiler efficiency with operational variables
(a) burner setting, (b) mill groups in service. The open and filled bars denote NOx emission
and boiler efficiency, respectively.

emission, whereas increasing secondary air (Inc-SA) change the trends of the variations of NOx emission
resulted in a significant increase in NOx emission. The and boiler efficiency with the oxygen level (denoted
reason is that the amount of secondary air in LNASB by the dashed lines in Fig. 3) although the data points
was commonly controlled at very low level (about 10% were very scattering. As for the unburned carbon in ash
of the combustion air was delivered through the burner (Fig. 3(c)), its variation did not seem to correlate with
as secondary air whereas 60% as tertiary air) to achieve O2 level or was masked by more significant variation
a reducing inner zone of near-burner region in order to in operations.
suppress NOx formation. Further decreasing secondary It can be found in Fig. 3(a) that, for many cases,
air had a little effect on lowering NOx formation. On the NOx emissions were higher than the regulation
the contrary, increasing the secondary air resulted in limit and the boiler efficiency was also lower than the
the increase of the O2 concentration in the inner zone base case. It implies that the oxygen level as well
and also in the increase of the combustion temperature, as the other operational variables need be optimized
which means more fuel and thermal NOx formed. during the operation to meet the NOx emission limit
Variation of mill groups in service was expected to and to maintain high boiler efficiency. Figure 3 also
have impact on NOx emission (Fig. 4(b)) because it indicates that changing the operation variables based
changed the in-furnace temperature and oxygen distri- on the nominal case did achieve lower NOx emissions
butions along the furnace height direction. According as well as higher boiler efficiency.
to the boiler design specifications, operating five mills
or five row burners could achieve the maximum contin-
uous output. In Fig. 4(b), the case with ABCEF mill Impacts of coal properties
groups in service was actually the nominal case, in
which the top row of the burners on the front wall (i.e. The measured NOx emissions of all experimental cases
row D, see Fig. 1) was out of service. When the oper- were correlated to the properties of the coal burned
ated mill groups change to BCDEF, the NOx emission in each case, shown in Fig. 5. It is well known that
was almost the same as that of the base case. It was coal nitrogen content is an important parameter to NOx
expected because, in both cases, one of the top rows emission level.[7] Figure 5(a) shows the correlation
of the burners was out of service, and the in-furnace between NOx emission and nitrogen content in coals on
distributions of temperature and oxygen concentration as-received basis. It can be seen that there is a general
were similar. For the case with ACDEF mill groups trend of NOx emission decreasing with the increase
in service, the NOx emission increased significantly as of coal nitrogen content. It should be noted that the
compared with the base case. The reason is the fact that nitrogen content of coal only represents the nitrogen
stopping a bottom row of the burners (i.e. row B) instead amount in unit mass of coal, while the total amount
of a top row narrowed the distance between the combus- of nitrogen that enters the furnace with the coal also
tion flame zone and the over-fired air, which decreased depends on the amount of coal fired, which depends on
the efficiency for OFA to reduce NOx emission. coal heating value. In the experiments, the boiler steam
In Fig. 3, the open symbols denote the experimental thermal output was kept nearly constant. Because of
results of varying operational variables except O2 level only a slight variation of boiler efficiency, the thermal
on the basis of the nominal operation case. It can input of the boiler was almost constant, which was
be seen that the variations of the individual operation actually the product of the amount and the heat value
variables had considerable impacts on both the NOx of the coals burned. Therefore, the nitrogen content of
emission level and the boiler efficiency. With all the coal was normalized with coal heating value to form a
experimental cases considered, it did not significantly new parameter, that is, the ratio of N/LHV (LHV is the
 2009 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2010; 5: 447–453
DOI: 10.1002/apj
452 X. GAO AND M. ZHANG Asia-Pacific Journal of Chemical Engineering

(a) (b)
700 700

NOx emission, mg/m3 at 6%O2

NOx emission, mg/m3 at 6%O2

600 600

500 500

400 400

300 300

200 200

100 100
0.66 0.67 0.68 0.69 0.7 0.71 0.72 0.73 0.028 0.029 0.03 0.031 0.032 0.033 0.034
N, wt% on as-received basis N/LHV, kg/MJ
(c) (d)
700 0.034
NOx emission, mg/m3 at 6%O2

600 0.033

N/LHV, kg/MJ
500 0.032

400 0.031

300 0.03

200 0.029

100 0.028
34 35 36 37 38 34 35 36 37 38
Volatile matter, wt% Volatile matter, wt%

Figure 5. NOx emissions are correlated with coal properties (a) NOx emission with coal nitrogen content,
(b) NOx emission with N/LHV ratio, (c) NOx emission with coal volatile matter content on dry ash free
basis, (d) N/LHV with volatile matter content. The lines in the figures show the trends.

lower heating value of the coal) on as-received basis, observations in both pilot scale furnace[12] and utility
which basically represents the amount of nitrogen input boilers.[10,11] Figure 5(d) indicates that the N/LHV ratio
into the furnace with unit energy consumed. The ratio increases linearly with the volatile matter content of the
was also correlated to the NOx emissions, shown in coal blends used in the experiments. It means that the
Fig. 5(b). It can be seen that there is still a trend that coal with a high N/LHV ratio also had a high content
the NOx emission level decreases with the increase of of volatile matter. As described above, LNASB applied
N/LHV ratio. air staging and high-pulverized coal concentration to
Although the data were scattering, Fig. 5(a) showed form a reducing zone near the outlet of the burner for
a systematic trend that NOx emission decreased with reducing the NOx formation. In this case, coal with
the increase of nitrogen content of coal. Even the a high-volatile content can consume more oxygen in
nitrogen content was normalized with coal heat value, this zone to enhance the reducing atmosphere, which
that is, considering N/LHV ratio, it did not change the benefits the reduction of fuel NOx formation. It implies
trend. This observation is contrary to the commonsense that, for this type of the burner, the volatile content,
that the high nitrogen in coal generally leads to more volatile release, and combustion in the inner near-burner
NOx release.[9 – 11] It should be noted that the previous zone are more dominant factors in fuel NOx formation
results were mostly based on the NOx emission data and destruction than the nitrogen content of the coal.
collected from various power plants. However, in the
present work, the observation was just on one boiler, in
which air staging was particularly applied to suppress
the formation of NOx. As mentioned in the section CONCLUSIONS
on Introduction, among coal properties, the nitrogen
content is not the only parameter affecting the NOx The present work was performed to investigate the
emission. The volatile matter content of coal is also effects of operational variables and coal properties on
one of the key factors of fuel properties.[6] In general, NOx emissions based on extensive in situ experiments
NOx emission decreases with the increase of volatile on a 600-MW opposed wall-fired pulverized coal utility
matter content. Such trend was observed in this work, boiler. The following conclusions were drawn from the
as shown in Fig. 5(c), which is consistent with the study:
 2009 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2010; 5: 447–453
DOI: 10.1002/apj
Asia-Pacific Journal of Chemical Engineering
(1) Oxygen level in flue gas was an important vari-
able to affect NOx emission and boiler efficiency.
The other operation variables also had influence
on the NOx emission level. The optimization of
operational conditions was critical for applying the
burners to meet the emission limit.
(2) The NOx emission level was found to decrease
with the increase of the coal nitrogen input into the
furnace. The reason was that coal volatile content
was the dominant parameter to affect fuel NOx
formation through affecting the reducing condition
in the inner near-burner zone when the low NOx
burners were applied in the boiler.
Acknowledgement
The authors appreciate Professor C. D. Sheng of our
School for the help on the improvement of English
writing.
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