New Method of Post Flame Combustion Diagnostics Based on Continuous Monitoring of Unburned Carbon and Combustibles

MK Engineering Inc. recently developed a new method of combustion diagnostics based on analysis of flue gas turbulence to provide continuous on-line monitoring of combustion parameters in the post-flame zone. Based on this new approach, the new MPV combustion diagnostic systems have been developed and tested on large utility boilers. One system - MPV - 1 Combustion Diagnostic System -receives signals from optical sensors mounted in the furnace exit zone and provides continuous monitoring of LOI and flue gas temperatures. It was installed and tested on three coal-fired units at Homer City Generating Station (Units 1 and 2 - 620 MW each with Foster-Wheeler boilers, Unit 3 - 650 MW with a Babcock-Wilcox boiler). In another system - MPV-Plus - signals from individual burners are added to enhance system capabilities. Using available boiler adjustments, such as OFA dampers, SA dampers and individual burner registers, the operator can now balance the boiler and adjust individual burners to enhance combustion performance and reduce NOx. During the first several months of using the new systems, Homer City reported significant NOx reduction on all 3 units. All MPV systems are PC-based, generate output signals characterizing combustion characteristics across the furnace and monitor the distribution of combustion parameters across the furnace to identify and correct combustion imbalances and to achieve the optimum compromise between NOx and products of incomplete combustion (LOI and CO). These systems require no power supply, no cooling air, no extraction and are virtually maintenance-free, reliable and inexpensive. The MPV systems are universal and applicable to almost any type of combustion systems. These new MPV Combustion Diagnostic Systems offer an effective new tool to enhance boiler performance.