Environmental Policy and Technology Project

Contract No. CCN-0003-Q-OO-3165

TECHNICAL REPORT Boiler House Equipment Evaluation Test Report

Novokuznetsk, Russia

by Bob Erickson - July 1997 Delivery Order 10, Task 5

Prepared for: u.s. Agency for International Development Office of Environment and Health, Moscow

Prepared by' RegIOnal FIeld Office, Moscow, Russia

EnVIronmental Policy and Technology Project A USAID Project ConsortlUm Led by CH2M HILL

I(

l

__ Environmental Policy and Technology "; Project Regional Field Office / Moscow

USAID{Managed by CH2M HILL)

ThIS report was done as part of Novokuznetsk Task 5 of DelIvery Order 10.

ThI~ report has been revIewed for content and approved for dlstnbutlOn

--) ( - )(

EPT Regional Director Date

Executive Summary

The goal of the USAID funded EnvIronmental PolIcy and Technology Project under DO 10 Task 5 was to demonstrate Improvements m aIr qualIty by reducing partIculate emISSIOns from coal burnmg facIlItIes To accomplIsh thIS goal there needed to be defImtIve approaches to reduce emiSSIOns and sufficIent incentives that would provide JustIfIcatIOn for makmg changes In how coal was burned. EconomIc incentIves resulting from savmgs on penaltIes related to reductIOn of emISSIOns was not suffICIent to provide the returns on mvestment for eqUIpment necessary to make functIOnal changes that would result m emISSIOn reductIOns It was belIeved that Improvements in the effectiveness of coal combustIOn would prOVIde the necessary economIC mcentives to make required mvestment as a result of the associated energy savmgs. The overall results of energy audIts, eqUIpment installatIOn, eqUIpment performance evaluations, and clean coal testing are summanzed here.

A three-way approach was developed that would address opportunitIes to Improve coal combustIOn and thereby reduce partIculate emISSIOns These approaches included:

I Energy audIts and boIler tune-ups 2 InstallatIOn of fIxed eqUIpment to mamtam effectIve combustion 3 ProvIdmg cleaner coal (reported separately)

Results of energy audIts mcluded the tune-up of bOIlers to Improve energy effIciency. These bOIler tune-ups focused on reducmg flue gas excess aIr and reducing CO. These audIts also IdentIfied opportumtIes for reducmg energy losses m the end-use of energy such as better control of temperatures at the apartment houses at the Poultry Plant and better process control of cement productIOn, Improvmg product qualIty and thereby reducmg product loss, related energy loss, and assocIated emIssions. Energy savmgs as a result of bOIler tune-ups were found to result m an approximately 6-10 percent savings in energy and have a very short return on the cost of the tune-up However, It is not pOSSIble to mamtam the total effectIveness of the tune-up WIthout improvements in momtonng and control, and a frequent tuning of bOIlers would be necessary to mamtam results On an annual baSIS It IS expected that bOIler tune-ups will result m a 3% energy savmgs.

Energy audIts were conducted at SIX faCIlItIes withm Novokuznetsk to identify opportumtIes for mstallatIOn of Improved controls and heat utIlizatIon systems. RecommendatIOns from these audIts were used as the baSIS for the purchase and mstallauon of approXImately $500,000 of eqUIpment to be granted to the facIlities audIted to Implement recommendations from the audits In addItion, portable equipment brought to Novokuznetsk for the audIts was left III Novokuznetsk as the basis for seed equipment for provIding contmued audIt serVIces

As a result of the energy audIts, recommendatIOns were made for the installation of fixed eqUIpment to better control the bOIlers or proVIde better data to boIler operators with WhICh to run the bOIlers Tests of boIler energy effICIency and p.articulate emIssions were conducted before and after InstallatIOn of eqUIpment to venfy the followmg results.

• DIgItal controls for boIler operatIOn proVIded the boIler operators WIth the ability

to set operatIng regImes more precIsely to optImIze boIler performance and to eaSIly repeat operatIOnal settIngs.

• Test results from control systems demonstratIOns show the potentIal for reaucl11g flue gas combustIOn losses by up to 12 percent.

• ProvIdmg better control of the boIler combustIOn aIr by controlIng aIr flow rate and dIstnbution demonstrated the potentIal for redUCIng partIculate loadmgs to the gas cleanmg eqUIpment by up to 25 percent on average at the Abashevskdya Communal BOller House.

• At Abashevskaya Communal BOller House there was an average 8 percent Improvement m overall bOIler effIcIency wIth the mstallatron of controls With a coal cost of $27 per ton, the annual savmgs are estImated at $52,000, whIch 'v III repay the cost of eqUIpment and Installation In approxImately 16 months

The proper combustIOn of coal also reqUIres qualIty control over the coal proVIded to [he bOIlers Local coal avaIlable In Novokuznetsk tends to have a large percentage of ''fInes.'' that IS. partIcles of coal of a Size less than 6mm. Therefore, a senes of tests were conducted to determIne the effectIveness of sorted coal to reduce particulate emISSIOns and Improve energy effIcIency. Clean coal test results are are reported separately

It was recogmzed from the begInnIng of thIS project that In order to have a sIgmfICJnr effect on the enVIronment of Novokuznetsk It would be necessary to replIcate audns and eqUIpment mstallatIOns m a sIgmficant number of bOIlers m the city ThIS would be accomplIshed only If there were a local capabIlIty to sustam the work Ill1tlated under thIS project Work on DO 10 Task 5, m conjunctIon WIth the Busmess Center, has pro\Ided the ablhty to replIcate the results of thIS project at other boIler houses by provldmg reports on the work that has been done, developIng an experIenced local testIng and bOIler performance assessment capabIlIty, and helpmg to establIsh local representatIOn ror eqUIpment supply The necessary mformatIOn and personnel WIth experIence are avaIlable m Novokuznetsk to support the evaluatIOn of eqUIpment reqUIrements, aSSIst In the selectIOn of control eqUIpment, proVIde support m purchasmg eqUIpment, and make known optIOns for fInancmg eqUIpment

The work completed at the five bOIler houses and at the cement factory demon~trates :hat ~Igmficant Improvements m aIr qualIty are possIble and even cost effectIve. It should be expected that the results of the work completed here WIll serve as an mcentIve for addItIOnal cost-effectIve projects to be unplemented locally, WhICh m the long term '\ III contnbute to cleaner air for Novokuznetsk The fmal results of the energy effiCIency work dre presented m thIS report The results of the clean-coal testmg are aVaIlable In d 'leparate report on that subject

Section 1

Introduction

The mdustnal sector m Novokuznetsk IS very well developed, with many large and heavy mdustnes. There are 160 boIler houses located at medIUm-sized mdustrial sItes and dIstnct heatIng systems that consume a large percentage of the regIOn's energy use and WhICh are major contnbutors to partIculate emISSIOns withm the residentIal dIStricts of the CIty. The facIlItles chosen for the EPT Industnal Audit project are representative of many compames and other faCIlItIes wIthIn the CIty, makIng them Ideal targets for mdustrial energy audit work because of the great potentIal for replIcatIOn. Many of these medium­SIzed plants are VIable, but have not yet Implemented energy conservation activities. Changes WIthIn the system (mcreased energy pnces, pnvatization, etc.) wIll create a new emphaSIS on mcreasmg energy effICIency and reducmg the energy Intensity of production. Parallel emISSIOn reductIOns can be expected WIth Increases in energy effiCIency.

There IS an ImmedIate need for rapId Improvement In industnal energy effICIency because of the wastage that results from poor energy UtIlIzatIOn practIces and lack of proper maIntenance of energy systems Related to the low energy effICIency of faCIlItIes IS a hIgher emISSIOn of partIculates to the atmosphere from the coal-fired bOIlers. Higher­than-deSIgn coal burnmg rates subsequently overload the flue gas clean-up eqUIpment, whIch worsens the emISSIOns problem. EmISSIOns penaltIes do not alone proVIde suffIcient economIC mcentIve to proceed WIth projects to reduce emIssions. Energy effICIency Improvements are cost-effeCtlve WIthin the current energy economy and can prOVIde economIC IncentIves that support the concern to clean up the environment. These energy effICIency improvements WIll also result m an Improvement in arr quality by reducmg emIssions at the source •

Increases m energy pnces to eqUIvalent world pnces have put addItional pressures on Industnal fIrms to conserve energy Changes withm the economIC system (energy pnces, pnvatIzatIOn, etc) WIll create a new emphaSIS on the necessity to Increase energy effic­Iency and reduce energy mtenSIty of productIOn Along wIth the industrIal audIt program to demonstrate the effectIveness of energy effICIency Improvements, the overall EPT program prOVIded trammg on energy effICIency audit practIces, the use of energy performance measurement eqUIpment, and the evaluatIOn of energy conservation opportumties.

The Industnal AudIt Project was comprised of four distmct tasks:

1 IndustrIal plant screenmg :2 IndustrIal plant energy audItmg 3 Purchasmg, shIppmg, and receIvmg eqUIpment to Implement audIt recommendations -+ ImplementatIOn and momtorIng

The screenmg process mcluded an evaluatIOn of multIple boIler houses in order to IdentIfy and select faCllltIes that were representatIve of the vanety of boiler houses used 10 NVK and the larger regIOn We were also lookmg for faCIlIties that were VIable, that I'>. lIkely to remam 10 operatIOn for the foreseeable future, m order to benefit from the audIt and serve as a demonstratIOn The plants selected for the audIt phase were:

Abashevskaya Communal BOller I Zlryanovskaya Communal 3 ZapSIb Combmed Heat and Power Plant BOller -+ The Novokuznetsk RefngeratIOn Plant 5 The Novokuznetsk Poultry Processmg Plant 6 The Novokuznetsk Cement Plant

Fl ve of these facIlItIes are boIler houses, representmg a cross sectIOn of the boIler:, used 111 ;..JVK The cement plant was audIted smce It IS a maJor energy consumer ,md ,1

'>lgl11ilcant source of partIculate aIr emISSIOns, WIth theIr resultmg Impact on the local environment of Novokuznetsk

An energy audIt report dated September 1995 was prepared for each of the SIX tacllltIeS audIted and a seventh report that summanzed the results of the stack partIculate ::,ampl1l1g that was performed at each of the fIve faCIlItIes other than the cement plant The se"en reports represent the complete reportmg of the energy/envIronmental audIt actlvltIe<; conducted m Novokuznetsk. RUSSIa dunng the penod of 25 Apnl-26 May 1995

EqUIpment specIfIed 111 the energy audn was procured, cleared through customs. and delIvered to the audned sItes 111 Novokuznetsk Techmcal support for 1I1stallatIOn \va.', provIded by the RUSSIan team members work1l1g on these audIts Followmg completIon of the mstallatIOn, an assessment of the effectIveness of the energy conservatIon dpplrcatIOn and the effect on emISSIOns reductIOn was carned out ThIS report present) the result.', of that evaluatIOn

Section 2

Results

SectIOn 2 presents the results of tests and evaluatIOns that were performed on the eqUIpment at the sItes to Improve the energy effIcIency of the facility. The overall approach mcluded evaluatIOn of the controls system and monitoring equipment's impact on energy consumptIon and partIculate emISSIOns.

2.1 Thermal Performance Testing

At each facIlIty the appropnate control settmgs for forced aIr fan damper, air distribution damper, coal feed rate, and heat output settmgs were manually adjusted for a gIven set pomt and coal qualIty. These adjustments were made manually to opomize the ' combustIOn effIcIency along wIth provIdmg stable boIler operatIOn. Once these settings were defmed, the controller mamtamed thIS operatmg condition and test data were obtamed. BOIler operatmg condItions were recorded from the data presented on the control panel Energy data related to the flue gas condItIOns were recorded from the oxygen data shown on the control panel and the data from the Bacharach combustion analyzer.

2.2 Particulate Measurement Techniques

Apex Instrument devIces were used to sample particulates and measure their size dIstnbutIon. Necessary calculatIOns were made by means of an MS Excel based software to establIsh cntena for the tests. Due to the lack of a computer program to process partIculate SIze dlstnbutIOn data, they was calculated usmg a technique contamed in the Mark 3 Source Testmg Cascade Impactor Manual.

Samples of partIculates were taken m accordance wIth EPA Methods 1-5 However, CIrcumstances prevented testers from fully complymg wIth the Methods, mostly due to theIr mabIlIty to observe the reqUIrement to have a straIght duct with four different dIameters after the aIr flow IS dIsrupted

After each test had been completed, the samplmg tram was leak checked and moved to the faCIlIty where samples were recovered. Probes and cyclones were washed with acetone and cleaned WIth a nylon bnstle brush. The acetone wash was later placed in a sample contamer Techmcians then put the fIlters mto Petn dishes and sealed them with adheSIve tape The samples were transported to the analytIcal laboratory for gravimetric analYSIS - .

2.3 Coal, Bottom Ash, and Cyclone Dust Sampling Techniques

Coal was sampled manually In the outlet of each mechamcal coal feeder (both left and nght) Each sample Included eIght 2 5 kg lots of coal fuel, I e., 20 kIlograms total. In the course of each one-hour expenment, coal was sampled four times every 15 minutes Total weight of the sample collected dunng one test, therefore, was 80 kg.

Samples were processed In accordance WIth GOST 10742-71 The samples were

1

recovered m accordance With standards set for each partIcular analysIs

Bottom ash samples were taken from prearranged locatIOns pnor to theIr bemg ~upplIed to the bottom and fly ash dIsposal passage. The samples were then quenched WIth water and qUdrtered to reduce weIght to 10 kg

PartIculates samples (1 kg) were taken m the outlet of the cyclone every 15 mmutes dunng each test

2.3 Abashevskaya Communal Boiler House

2.3.1 Plant Description

Abashevskaya Communal Heatmg Plant IS located at the Abashevskaya Mme on the outskirts of Novokuznetsk, RUSSIa It provIdes heatmg and domestIC hot water for approxImately 30,000 reSIdents m some 6,000 dwellmg umts The boIler plant con~I~ts of three 20 gIgacalone/h (gcal/h) nommal output capaCIty coal fIred boIlers WIth reclprocatmg grate stokers and gate feeders The boIlers prOVIde hot water at from 65°C to l2SoC for heatmg to the dlstnct heatmg pomt (approxImately 2 kIlometers from the boIler plant) where flat plate heat exchangers are used to Isolate the bOIler water from the dIstnct heatmg water and to heat domestIc hot water

Boiler Description. The three boIlers at the Abashevskaya communal boiler house are RUSSIan model KT-20 water wall bOIlers WIth a nommal capaCIty of 20 gigacalonesihour (gcallh) Ongmally they were flre~ by cham grate stokers WIth rotary overthrow coal dlstnbutors Due to the hIgh proportIOn of fmes m the avaIlable coal (up to 70 percent less than 6mm) the cham grate stokers had conSIderable problem WIth coal dIstributIOn on the fIre beds Fmes were eIther entramed m the overflre aIr and frequently earned through unburned mto the fly ash or would fall short on the grate and were dumped off the near end of the grate mto the ash pit before they were fully burned

Modified Coal Firing System. The three bOIlers at the Abashevskaya communal boIler house were modIfIed m 1994 by a Chinese contractor usmg reClprocatmg grate stokers whIch are more tolerant of fmes m the coal than the origmal cham grate deSIgn ThIS modIfIcatIOn reversed the flow of coal onto the grate and used a manually adjusted. vertIcally nsmg spreader gate to regulate the flow of coal onto the grate. The gate regulates the depth of the coal bed from 90 mm at 10 gcallh to 125mm at 20 gcaVHr Varymg the length and frequency of stroke of the hydrauhcaUy dnven grate proVIdes fmer control of the fmng rate The regIme card also speCIfIes the settmgs of vanou~ combustIOn aIr controls At the same tIme as the grate modIfIcatIOn, the RUSSIans Jlso added curtam walls to Isolate vanous burnmg areas and provide addmonal furnace re~ldence tIme for suspended fmes ThIS modIfIcatIOn eillmnated the recirculdtlon of t1y d"ih from the convectIOn pass back to the boIler and the use of overflre aIr. dlthough the latter \Vas clpparently a matter of runnmg out of funds

2.3.2 COlllrols Evaluation Testing

B uIlcl perfolmance testll1g wa!> conducted on BOller #2 before clnd after mstallatlOn of the controls !>ystems that were m!>talled to Improve the effectIvene!>s of burnmg coal Jnd

reduce emISSIOns ModIfIcatIOn of the momtonng and control system mcluded the addItIOns of m-SItu oxygen analyzer, automated control of the forced drafted fan, based on fmng rate and flue gas oxygen content, control of the aIr dIstrIbutIOn in three zones under the grate, and control of the coal feed rate. Data were obtained on coal quality but no attempt was made to try to control the qualIty of coal Pre-Illstallation testing was accomplIshed to provIde a reference pomt for evaluatmg the effectiveness of the controls to be mstalled. Dunng these tests the operators followed their normal procedures for bOIler operatIon FollowIllg the mstallatIOn of the combustIOn momtonng and controls, post-mstallatIOn tests were conducted for companson wIth pre-mstallatIOn results. The momtonng and controls system allowed the operators to adjust the combustion process to maXImIze combustIon effICIency whIle mamtammg stable bOIler operations. Data obtamed from the pre-mstallatIOn testmg are presented m Appendix A and carry the "A" deSIgnator m the table number Data from the post-mstallatIOn testing are presented m AppendIX B and carry the "B" deSIgnator III the table number. I

Boiler Efficiency Testing. BOller #2 at the Abashevskaya Communal Boiler House was evaluated WIth and wIthout the mstallatIon of the system controls. CombustIon air was regulated to adjust the fuel/air ratIO to allow reductIOns III excess air and enable the operators, and later the control system, to maXImIze combustIOn efficiency. Pre­mstallatIOn testmg was conducted on 14 and 16 December as shown in Table IA. Post­mstallatIOn testmg was conducted on 29 and 30 Apnl as noted in Table lB. Although the post-mstallatIOn testmg was conducted after the close of the heatmg season, comparable test condItIOns were obtamed as the bOIler house contmued to supply serVIce hot water to the dIstnct

Test tImes, type of coal used, and ci'efimtIOn of the test run coding are defined in Tables 1 AlB The codmg used to Identlfy test runs IS used m all of the following tables. Data for each of the test SItes are contamed m each table to faCIlItate locatmg and companng test condItIOns and results

Unsorted G-mark coal was used for all tests. Coal SIze dIstributIOn and fuel characteristIc m the form of an ultImate analYSIS are presented m Tables 2AJB and 3AJB respectively. The results of the ultImate analYSIS for the Bottom Ash (slag) and Cyclone Dust (fly ash) are presented m Tables 4AJB and 5AIB respectIvely. During pre-installatIOn testing, partIcle SIze testmg was conducted for those partIcles m the flue gas stream entenng the cyclone separators The SIze dIstnbutIOn results are presented m Table 6A. No particle SIze testmg was conducted dunng the post-mstallatIOn testmg BOller operating conditIOns for the tests are presented m Tables 7 AlB These tables III general demonstrate that comparable test condItIOns and fuel charactenstics were obtamed for the pre/post-mstallatIOn testmg •

2.3.3 Summary of Test Results

Coal WIth a hIgh fmes content rangmg from 35 6-40 1 percent of partIcles SIzed less then 6 mm, WhICh IS charactenstIc of thIS boIler type, was tested m the course of the expenment. However, the 13 9-14.5 percent ash III coal IS not typIcal, as the average hgure would be 16-20 percent Overall, there was stable combustIOn of the coal on the grate

7

Combustion Efficiency. CombustIOn test results are presented In Tables 9AIB All data In these tables were obtaIned from the Bacharach combustIOn analyzer, except tor the oxygen data In Table 9B For the post-installatIon testIng, the In-SItu oxygen analyzer-was In place and data from It were used to momtor oxygen level In the flue gas Data from Table SAlE were used to calculate the overall bOIler heat balance data that are presented In Table lOAIE Measured arr flow rate data, temperature data, partIculate emISSIOn rate, and coal, fly ash and bottom ash charactenstlc were used to calculate the heat losses from the flue gasses and carbon losses On the average there IS an eIgnr (8)

percent Improvement In effIcIency between post and pre-mstallatIOn testmg ThI:, Improvement m effICIency occurs both In reductIon of flue gas oxygen levels and reductIOn of mechamcal (unburned partIculates) heat losses Contnbutmg to the overall loss IS a somewhat hIgh temperature of flue gases in the outlet of the boIler Temperature vaned from 213 to 345°C, whIle It was not supposed to exceed 220 0c. ThIS SItuatIOn lead to addItIOnal heat losses with flue gases especIally dunng the pre-InstallatIOn tesrmg

CO content fluctuated from 44 to 776 ppm, WhICh can be attnbuted to the lack of automated combustIon process control or abIlIty to optImIze the control of the aIr dlstnbutIOn through the three burnIng zones. Given tIme to work WIth the system. the operator Will be able to OptImIze the aIr dIstributIon control algOrIthms to proVide Improved control of CO Values less than 200 ppm are conSIdered acceptable

Particuiate Emission Results. The ObjectIve of the overall project was to demomtrate reduced emISSIOns (at the very least as a result of the fact that less coal would be burned to produce the same amount of heat through Improvements made to the overall combustIon effICIency of the bOIlers) Data for flue gas temperature, flue gas flow rate, and total captured weIght of partIculates from the Abashevskaya BOller #2 partIculate testmg are presented In Tables SAlE Some of the calculated results, mcludmg pdrtlculate emISSIOn rates, are also presented. PartIculate emISSIOn data from Tables SAlE and the bOIler fmng rate were used to produce the data In Tables llAIE The data of mterest are the speCIfIC emISSIOns rate of kilograms per gIgacalone As can be seen m companng Tables IIA and llB, there IS an average 27 percent reductIOn In the rate of emISSIOns before the collector wIth the mstallatIOn of the controls system Tables 12AIB summanzed the combIned boIler effIciency and particulate samplIng data

The "pecific emISSIon rate after the collector dId not change sIgmfIcantly assummg that the large change In collector effICIency In the pre-mstallatIOn test number 3 IS somehow an anomaly AdditIOnal work IS necessary to evaluate the overall performance of the nue gas clean-up eqUIpment An mItIal reVIew of the partIculate slZlng and the gas velOCItIeS dId not gIve an mdIcatIOn of why the reduced emISSIOns at the collector mlet dId not 1 esult m SImIlar reductIOns at the collector outlet

At Abashev,>kaya Communal BOller House there was an average 8 percent Improvement 111 overall bOIler effICIency wIth the InstallatIOn of controls WIth a coal cost of $27 per ton the dnnual savIngs IS estImated at $52,000, which WIll repay the cost of eqUIpment dnd !n:.tallatIOl1 m approxImately 16 months Therefore, the ObjectIve IS clearly met, m thdt <;}gmficant reductIOns In emISSIOns from the boIler were obtamed based on partIculate load1l1gs gomg mto the collector

o

2.4 Ziryanovskaya Communal Boiler House

2.4.1 Plant Description

ThIS bOIler plant supplIes hot water for space heatIllg and domestic hot water for a resIdential communIty conSIstIng of employees of the coal mmes III the Zlryanovka DIstnct The reSIdentIal communIty currently has a populatIOn of 40,000 people living in 12,000 apartments: the apartments are the typIcal hIgh rise apartment blocks common throughout RUSSIa AddItIonal apartment UnIts are under construction to proVIde addItIOnal and upgraded lIvIng space. It IS antlcIpated that a 30 percent increase in boIler capaCIty WIll be needed to serVIce the new apartment space If the existing boilers continue to operate at theIr current low capacIty levels If the eXIstIng bOIlers can be made to operate at theIr rated capacItles, no new bOIler faCIlitIes WIll be required.

The coal mIne company currently operates the boiler plant, but It has turned over ownership to the CIty AdmInIstratIOn at the begInning of the year. The supply of hot water for space heating and domestIC hot water for the reSIdential complex are the only purposes of the bOIler facIhty.

Boiler Description. The bOIler plant has SIX RUSSIan model 20 gcallh. KB-TC-20 water boIler UnIts Each bOIler IS complete wIth an ash remover, 200 kW 1000-rpm ill fan, and a 75 kW exhaust fan The ash removers of two bOller umts are battery cyclones; the other four are eqUIpped WIth Ventun tubes WIth safety traps. There is no automatic control of the combustIOn process whatsoever, the control and measurement equipment set IS Incomplete CombustIOn In the boIler IS controlled manually based on the outlet water temperature and pressure. AIr flow' from the ID fan and In the zones IS not adjustable WIth changed coal loads

Modified Coal Firing System. The SIX bOllers at the ZIryanovskaya communal boiler house were modIfIed m 1995 and 1996 by a ChInese contractor using recIprocating grate stokers WhICh are more tolerant of fInes In the coal than the ongInal chain grate deSIgn. ThIS modIfIcatIOn reversed the flow of coal onto the grate and used a manually adjusted, vertIcally nsmg spreader gate to regulate the flow of coal onto the grate. The gate regulates the depth of the coal bed from 90 mm at 10 gcal/h to 125 rom at 20 gcallh. Varymg the length and frequency of stroke of the hydraulIcally driven grate proVIdes fIner control of the fmng rate The regIme card also speCIfIes the settmgs of various combustIOn air controls. At the same tIme as the grate modIfIcatIOn, the RUSSIans also added curtain walls to Isolate vanous burnIng areas and prOVIde additIOnal furnace reSIdence tIme for suspended flOes ThIS modIfIcatIOn elImmated the reCIrculatIon of fly . ash from the convectIOn pass back to the boIler and the use of overfire air, although the latter was apparently a matter of runnmg out of funds

2.4.2 Controls Evaluation Testing

BOIler performance testmg was conducted on BOller #5 before and after installation of the controls systems to Improve the effectIveness of burnIng coal and the reduction III emISSIOns ModIfIcatIOn of the mOnItorIng and control system included the additIOns of m-~Itu oxygen analyzer, automated control of the forced drafted fan, based on firing rate dnd flue gas oxygen content, control of the aIr dlstnbutIon in three zones under the grate,

()

and control of the coal feed rate Data were obtaIned on the qualIty of coal, but no attempt was made to try to control coal qualIty. Pre-InstallatIOn testmg was accomplIshed to provIde a reference POInt for evaluatIng the effectIveness of the controls to be Inst:l1led Dunng these tests the operators followed their normal procedures for boIler operatIon

FollOWIng the InstallatIOn of the combustIOn momtorIng and control eqUIpment. po~t­In~tallatIOn tests were conducted for comparIson with pre-1I1stallatlon results The new momtonng and control systems allowed the operators to adjust the combustIon proce<)s to maXImIze combustIon effICIency whIle mamtammg stable bOIler operatIOns

Data obtamed from the pre-mstallatIOn testmg are presented 111 AppendIx A and carry the "A" deSIgnator m the table number Data from the post-mstallatIOn testmg are presented In AppendIX B and carry the "B" deSIgnator m the table number

Boiler Efficiency Testing. BOller #5 at the ZIryanovskaya Communal BOller House \\IdS

e\ aluated WIth and wIthout the InstallatIOn of the controls systems eqUIpment CombustIon aIr was controlled to provIde adjustment for the fuel/aIr ratIO to allow reductIOns In excess aIr and enable the operators, and later the control system, to maXImIze combustIon effICIency Pre-Installation testIng was conducted on 9 January 1997 as I~ shown In Table IA Post-InstallatIOn testmg was conducted on 29 and 30 AprIl as noted m Table IB Two test runs were completed for the post-InstallatIOn testmg A thIrd run was started but a fmlure of the bOIler slag removal system caused the run to be termInated. Although post-InstallatIOn testIng was conducted after the clo::.e of the heatmg season, comparable test condItlons were obtamed as the bOIler house contInues to supply ~erVlce hot water to the dlstnct.

Test tImes, type of coal used, and defInItIOn of the test run codmg are defined In Tables I AlB The codmg used to IdentIfy test runs IS used In all of the follOWIng tables Data for each of the test SItes are contamed m each table to facIhtate locatIng and comparIng test condItIons and results.

Unsorted G mark coal was used for all tests. Coal SIze dIstnbutIOn and fuel charactenstlc III the form of an ultImate analYSIS are presented m Tables 2AIB and 3AIB respectIvely The re~ults of the ultImate analYSIS for the Bottom Ash (slag) and Cyclone Dust (fly ash) are presented III Tables 4AIB and 5AIB respectIvely. Dunng the pre-InstallatIOn testIng, partIcle SIze testmg was conducted of those partIcles In the flue gas stream entenng the cyclone separators The SIze dIstnbutIOn results are presented 111 Table 6A No partIcle SIze te~tlllg was conducted dunng the post-lllstallatIOn test1l1g BOller operatmg condItIOn::. for the tests are presented m Tables 7 AlB These tables In general demonstrate that comparable test condItIOns and fuel characterIstIc were obtaIned for the pre/post­lllstaIlatIOJ1 testIng

2.4.3 Summary of Test Results

Coal WIth a hIgh fmes content rangIng from 38 7-49 8 percent, Table 2AIB, of pdrtIcks '>Ized le'>s then 6 mm, WhICh IS charactenstlc of thIS bOIler type, was tested In the course of the expenment However, the 129-155 percent ash In coal IS not typIcal as the J\ CtdgC hgure would be 16-20 percent Overall, there was stable combustIOn of the CadI on the grate

10

Combustion Efficiency. CombustIOn test results are presented In Tables 9A1B. All data In these tables came from the Bacharach combustion analyzer except for the oxygen data In Table 9B For the post-mstallatIOn testIng, the In-SItu oxygen analyzer was in place and data from It were used to momtor oxygen level In the flue gas. Data from Table 8A/B were used to calculate the overall boIler heat balance data that are presented m Table 10AIB

Testmg at Zlryanovskaya resulted m unusually hIgh readmgs for the particulate sampling data that were not able to be resolved Measured air flow rate data, temperature data, partIculate emISSIon rate, and coal, fly ash and bottom ash charactenstics were used to calculate the heat losses from the flue gasses and carbon losses. Based on the overall bOIler heat balance data. there was no Improvement m energy efficiency in the post InstallatIOn testmg over the pre-InstallatIOn testmg However, the reductIOn In measured levels of oxygen In the flue gas as measured by the In-Situ probe and the Bacharach would mdlcate a sIgmficant reductIOn In excess air resulting In a significant improvement In effICIency Based on the Improvement In effiCIency IndIcated by the oxygen data, there IS a twelve (12) percent Improvement In effICIency between post and pre-installatIon tests. ThIS Improvement In effICIency occurs both In reductIOn of flue gas oxygen levels and of

mechamcal (unburned particulates) heat losses. Contnbutmg to the overall losses is a somewhat hIgh temperature of flue gases, whIch was observed In the outlet of the boiler. Temperature vaned from 234 to 340 C, whIle It was not supposed to exceed 220 C. The

SItuatIOn lead to addItIOnal heat losses WIth flue gases especially in the pre-installation testmg.

CO content fluctuated from 44 to 1,000 ppm, WhICh can be attnbuted to the lack of automated combustIOn process control or mabilIty to opumize the control of the air dlstnbutIOn through the three burnmg zones GIven time to work with the system, the operator WIll be able to OptImIze the aIr dlstnbutIOn control algorithms to proVIde Improved control of CO Values less than 200 ppm are considered acceptable.

Particulate Emission Results. Data for flue gas temperature, flue gas flow rate, and total captured weIght of partIculates from the Ziryanovskaya BOller #5 particulate testing are presented m Tables 8AIB Some of the calculated results, mcludmg particulate emission rates, are also presented The partIculate emISSIOn data from Tables 8AIB and the boiler fmng rate were used to produce the data In Tables llAIB The data of interest are the speCIfIc emISSIOns rate of kIlograms per gigacalone However, the post-InstallatIOn data showed sIgmflcantly hIgher emISSIOn rates than for the pre-InstallatIOn testing. A review of the raw test data proVIded no IndIcatIon of why the total captured weight should be so hIgh The data for the two post-mstallatIOn tests are conSIstent but cannot be reconciled agaInst the pre-InstallatIOn test It would be necessary to conduct additIonal testing to be able to draw conclUSIons regardIng post-InstallatIOn partIculate emiSSIOns.

At the ZirYdnovskaya Communal BOIler House there was an average 12 percent Improvement m overall boIler effiCiency With the InstallatIOn of controls as Indicated by the flue gas oxygen measurements WIth a value for the coal of $27 per ton, the annual savmgs I~ estImated at $70,000, WhICh WIll repay the cost of eqUIpment and lllstallatlOn in approxllnately 1:2 months

II

2.5 Novokuznetsk Refrigeration Plant

2.5.1 Plant Description

The Novokuznetsk RefrigeratIOn Plant manufactures ice cream products and provIdes low temperature refngerated storage for vanous food products. The boIler house provIdes heatmg, domestic hot water, and steam to the mdustrIal and admimstrative facilHIes of the RefngeratIOn Plant for the purposes of ventIlation as well as steam for the technology of lcecream productIOn The heat supply system IS of the closed-type four-pIpe desIgn The bOIler produces hot water at from 95 to 70°C for heatmg and ventIlatIOn, and at 60°C for hot water supply The water IS provIded to end consumers dependmg on the outsIde temperature m accordance wIth regIme cards. There IS no automatIC control of the heat supply TechnologIcal steam IS provIded at from 4 to 5 atm. Heat and steam flow rares are not momtored As part of the eqUlpment supplied to the Plant, a steam meter Vvas mstalled

2.5.2 Boiler Description

The bOIler plant has four RUSSIan model DKBP-41l3 steam bOIlers WIth output capacIty of -+ tonlh of steam for use m domestIc heatmg and as mdustrial process heat They are fIred by stokers WIth rotary overthrow coal dlstnbutors Bottom grates are manual tIltmg dump grates Coal IS dIstnbuted across the grates by the rotary dIStrIbutor but the fIre bed reqUlres frequent manuallevelmg, about every 20 to 30 mmutes Ash is dumped mto a water fIlled slUlce WhICh extends under all three bOIlers CombustIOn alr IS proVIded by a balanced draft system supplIed by a IS kW forced draft fan and a 20 kW mduced draft fan There IS also a small 3 kW "Sharp fmng " or overfire fan Both the FD and ID fans are eqUlpped WIth manually operated varIable mlet vanes (VIV) The VIV operators do not have an effectIve positIOnmg lock and qUlckly return to an mdetermmate posItIon after adjustment

A water SIde economIzer IS provIded to recover heat from the bOIler exhaust It IS

aesigned to reduce stack temperatures from approxImately 320°C to ISO-170°C

A smgle-stage, two-barrel cyclone IS proVIde for partIculate removal.

2.5.3 Controls Evaluation Testing

BOller performance testmg was conducted on Boller #2 before and after mstaliatIOn of the controls systems to evaluate the effectIveness of the controls systems to Improve the effectIveness of burnmg coal and reducmg emISSIons ModIfIcatIOn of the boIler performance momtonng system mcluded the addItlon of an m-situ oxygen analyzer Data were obtamed on the qualIty of coal but no attempt was made to try to control the qualIty of coal Pre-mstallatIOn testmg was accomplIshed to prOVIde a reference pomt for e\ aludtmg the effectIveness of the controls to be 1I1stalled. Dunng these tests the operators followed theIr normal procedures for boIler operatIOn Followmg the lI1stalIatIOn of the combustIon mOl11tonng and controls, SImIlar tests were conducted The momtormg and controls system allowed the operators to adjust the combustIOn process to tl1JXImIZe combustlOn effICIency whIle ma1l1ta1l1mg stable boller operatIon~ Data obtdlDed from the pre-mstallatlOn test1l1g are presented 10 AppendIX A dud cdrry the '"A"

desIgnator m the table number Data from the post-mstallatIOn testing are presented in Appendix B and carry the "B" desIgnator in the table number.

Boiler Efficiency Testing. BOller #2 at the Refrigeration Plant was evaluated with and wlthout the mstallatIOn of the m-situ oxygen analyzer CombustIOn air was controlled manually to provIde adjustment of the fuel/aIr ratIO to allow reductIOns in excess air and enable the operators to maXImIze combustIOn efficIency Pre-mstallatIOn testmg was conducted on 20 December as IS shown m Table IA Post-mstallation testing was conducted on 25 Apnl as noted in Table IB Although the post-mstallation testing was conducted after the close of the heatmg season, comparable test conditions were obtained as the boiler house contmued to supply process heat to the factory. However, severe problems arose WIth the qualIty of coal, WIth fmes m excess of 57 percent, so the post­mstallatIOn testmg was termmated WIthout obtammg any useful data.

Test tImes, type of coal used, and defimtIOn of the test run coding are defined in Tables 1 AlB The coding used to identIfy test runs IS used m all of the following tables. Data for each of the test sItes are contamed m each table to facilItate locatmg and comparing test condItIOns and results.

Unsorted T mark coal was used for all tests. Coal SIze dIstrIbutIOn and fuel characteristic m the form of an ultImate analYSIS are presented m Tables 2AIB and 3AIB respectively. The results of the ultImate analysIs for the Bottom Ash (slag) and Cyclone Dust (fly ash) are presented m Tables 4AIB and 5AIB respectIvely Dunng the pre-installation testing, particle SIze testing was conducted of those partIcles in the flue gas stream entering the cyclone separators The size dIstnbution results are presented m Table 6A. No particle SIZe testmg was conducted dunng the post-mstallatIOn testmg. Boiler operatmg conditIOns for the tests are presented m Tables 7 AlB These tables in general demonstrate that comparable test COnditIOnS and fuel charactenstic were obtained for the pre/post­mstallatIOn testmg

2.5.4 Summary of Test Results

Coal for the pre-mstallatIOn testmg had a hIgh fmes content ranging from lS-22.4 percent of partIcles SIzed less then 6 mm, charactenstic of this bOIler type, was tested m the course of the experiment However, for the post-mstallation testing the coal had 57 percent fines ThIS caused unstable operatIOn of the boIler and fusmg of the slag to the boIler grate. There was no opportumty to change the supply of coal so the post mstallatIon testmg was discontmued

Combustion Efficiency. CombustIOn test results are presented in Tables 9A1B, although only the pre-mstallatIOn testmg has any sIgmficance All data in these tables were obtaIned from the Bacharach combustIOn analyzer, except for the oxygen data m Tables 9B For the post-mstallation testmg, the In-situ oxygen analyzer was m place and data from It were used to momtor the oxygen level in the flue gas. Data from Table SAJB were used to calculate the overall boIler heat balance data that are presented in Table lOAIB Measured aIr flow rate data, temperature data, particulate emission rate, and coal, fly ash and bottom ash charactenstIcs were used to calculate the heat losses from the flue gasses and carbon losses ContnbutIng to the overall loss is a high level of excess mr In the flue gases at the outlet of the bOIler Temperatures of the flue gas vaned

11

If

from 202 ° to 22SoC, whIle the temperature followmg the economIzer was 122 ° - 1..J.0 °c

CO content fluctuated from 71 to 1,000 ppm, whIch can be attnbuted to the lack of automated combustIOn process control or abIlIty to OptImIZe the control of the aIr dI~tnbutIOn GIven tIme to work WIth the system, the operator WIll be able to OptImIze the aIr dIstnbutIon control algonthms to proVIde Improved control of CO Value~ less than 200 ppm are consIdered acceptable

Particulate Emission Results. The objectIve of the overall project was to demonstrate reduced emISSIOns at the very least because less coal would be burned to produce the same amount of heat due to an Improvement m the overall combustIOn effICIency of the bOIlers Data for flue gas temperature, flue gas flow rate, and total captured weIght of pdrtlculates from the RefngeratIOn Plant BOller #2 partIculate testmg are presented In Tables 8AIB Some of the calculated results, Includmg partIculate emISSIOn rates, are also presented The partIculate emISSIOn data from Tables 8AIB and the bOIler fmng rate were u~ed to produce the data m Tables 11 AlB Tables 12AIB summanzed the combIned bOIler effICIency and partIculate samphng data. As noted above, SInce the post-InstallatIon testIng was dIscontInued WIthout obtaIning any useful data, no compansons of partIculate reductIOns can be made.

2.6 Poultry Processing Plant

The project at the Poultry ProcessIng Plant focused on Increasmg energy effICIency at the pomt of use- In order to demonstrate the potentIal for redUCIng energy consumptIOn and thereby reducmg coal consumptIOn and emISSIOns No speCIfIc testIng was accomplIshed at the Poultry ProcessIng Plant as tfie heatmg season had concluded when the Imtial eqUIpment speCIfIed by the EPT project was mstalled.

ThIS large pOUltry plant IS a major supplIer of both eggs and chIcken meat In the area It IS Integrated both vertIcally and honzontally to maXImIze utIlIzatIOn of theIr pnmary and secondary resources In addItIon to theIr egg and meat productIOn, smaller anCIllary product hnes mclude dehydrated eggs, bakery products, noodles (uses eggs), pIllows (uses feathers), and fertIhzer (chIcken manure); a mayonnaIse plant IS under constructIOn All products are dIrectly marketed by company-owned trucks on a daIly baSIS Although sales are currently In balance WIth productIOn levels, It IS belIeved the fresh egg and meat market IS saturated and that future growth lIes WIth the hIgher value-added anCIllary markets such as mayonnaIse and pOSSIbly an expanSIOn of the marketmg area.

The company-owned bOIler house supplIes steam and hot water to the chIcken processlllg area dnd hot water to the employee housmg complex In addItIOn, the bOller house selb steam and hot water to an adjacent meat processmg plant The boiler house ha~ three model D KVP 20-13 steam bOIlers rated at 20 tons of steam per hour or 11 2 Geal However, due to poor coal qualIty, the bOIlers are de-rated about 10 percent The boIlers make steam at 13 Kg/cm2 pressure or 180 C

Normally. the hot water temperature IS controlled to meet the heat reqUIrements of the dpdrtment complex in accordance WIth a defIned schedule ba~ed on outSIde aIr temperature However, for 4-5 days per month when young ChICks are receIved. water temperature~ are Increased to supply the necessary heat for the ChICks Dunng these

1 •

perIods, the apartment complex and other bUIldmgs withm the chicken processmg area become overheated and the excess heat IS wasted by opemng windows or other ventIlation ports, approxImately 100 percent excess heat IS supplIed to the apartment complex.

The temperature of water to the housmg umts IS hIgher than necessary because, for part of the year, the temperature needs to be hlgh enough to provide the heat needed to keep the baby ChICk houses heated at the poultry plant DUrIng the remamder of the year water temperatures are hIgher than reqUIred and the excess heat is wasted.

Control of water temperature to the housing bUIldings was provided by the EPT Project usmg a three way valve, pump, and controller to provIde water temperature based on the outsIde air temperature. The cost for thIS adjustment was $85,000.

Savmgs of 10% are estImated due to better control and reductIOn of over heatmg during the heatmg season An addItIOnal 10% IS estImated to be saved dunng the tIme the water temperature IS mcreased to heat the baby ChICks Total fuel saved is estimated as 20% of heat for housmg mcludmg domestIc hot water'

Fuel saved = 0.25X73,090 gcallyr = 114,600 gcallyr Fuel cost saved = (14,600 Gcallyr/5.6 gcallt) X $27/t = $70,400 Payback = $85,000/$70,400 = about 1.2 year

A SIte reVIew of the mstallatIOn was conducted and all work appears to have been completed accordmg to the mstallatIOn plan. EvaluatIOn of the installation can be conducted when the 1997-98 heatmg season begms

2.7 ZapSib Combined Heat and Power Plant

The combmed heat and power plants in Novokuznetsk are facllities that are more than an order of magmtude larger than the boIler plants that provide heating alone or the mdustnal bOIlers addressed m the sectIOns above Since they bum such large quantities of coal they have sIgmficantly better momtorIng and control systems and better operating procedures Therefore the opportumtIes for Improvements WIth the level of funding in the EPT project would produce a smaller percentage of increase in energy effiCIency. However, It was determmed that cost-effective opportunitIes did exist and the ZapSib Combmed Heat and Power Plant was chosen for such a demonstration.

The mstalled capacIty for electrIC power generatIOn at the ZapSib Heat and Power Plant IS 550 MW The mstalled thermal capaCIty IS 700 Gcallhr from the ste'!,m cogeneration system The major Items of eqUIpment m the plant are the eleven steam boilers, seven steam turbmes. thermal water heat exchangers, water treatment system, cooling towers, steam and water dIstrIbutIOn system, and the voltage transformers.

Steam boIler umts 1 through 6 have 240 ton per hour steam capaCIty and were supplIed by Barnaul They were bUIlt m 1963 and use a common steam header to feed three turbmes rated at 1- 60 MW and 2- 50 MW BoIlers 7 - 1 I have 420 ton per hour steam capaCIty and were supplIed by T aganrog BOIlers, also of RUSSIan design, were completed III 1983, and supply steam to three 110 MW rated turbine units All boilers operate predomlllately on coal but have the capacIty to burn natural gas, coke gas, and blast

furnace gas BOllers 1 - 11 are connected Into a common header that supplIes steam at 150 bar, 550 C to a common header that feeds steam to seven turbInes

All bOllers have a dual combustIOn aIr/exhaust path where the exhaust gasses are used to pre-heat the combustion air The bOllers are operated wIth a balanced draft confIguratIOn BoIlers 1 -5 each have two forced draft fans wIth two speeds and ratIngs of 250 kW and 400 kW The two Induced draft fans also operate at two speeds wIth ratIngs of 700 1.. W and 1100 kW The large power of the induced draft fans IS reqUIred to overcome the pressure drop of the combustIOn aIr pre-heater BOller feed water IS supplIed by ~IX 4 MW pumps to a common header BOllers 7 - 11 have two speed forced draft fans WIth ratl11gs of 400 kW and 700 kW and two speed l11duced draft fans rated at 1000 kW and 1400 kW Both the forced draft and Induced draft fans have Inlet gUIde vanes to control aIr flow and to maIntaIn a negative pressure In the combustIOn chamber.

EstImated Cost of EqUIpment Installed $65,000 total for both bOllers #11 dnd #6 EstImated SavIngs $260,000 for a 3 month payback perIod

A SIte VISIt was conducted to reVIew the Installation of eqll1pment on bOller # 11 The oxygen analyzer was functIOnIng as expected and InfOrmatIOn, WhICh preVIOusly was not avaIlable to the operators, now was allOWIng them to operate the bOller WIth 4 8-5 :2 percent oxygen In the flue gas ThIS was the expected sIgmfIcant reductIOn In the level of oxygen, as measured In the earher audit, to confIrm the estImated savl11gs

16

\~

Section 3

Conclusions

The AudIt Task has demonstrated that a sigmflcant Improvement in aIr quality III

Novokuznetsk (and for other CItIes of the former SovIet Umon) is possible and even cost effectIve The project demonstrated that audits at boiler houses can develop cost-effective Improvements that reduce aIr emISSIOns In the short term, tunmg up boilers reduces emISSIOns and provIdes about a 3 percent Improvement m efficIency, paying for the effort ImmedIately In the longer term, mstallmg automated controls on the bOIlers provIdes an 8-10 percent Improvement m effIcIency, pays for the mvestment in about a year, and reduces emISSIOns by about 30 percent ProvIdmg faCIlItIes for sorting coal to reduce the fractIOns of fines was shown to produce SImIlar savmgs and aIr emiSSIOns reductIons at the heatmg only and mdustrIal bOIler houses In contrast, the Improvements in emissions and energy effICIency at the combmed heat and power plant are only on the order of 2 percent. However, even thIS 2 percent savmgs IS still suffIcient to provide a very short return on mvestment and a proportIOnal reductIOn m emISSIOns

The Audit Task has ensured replIcation of the results of thIS project at other boiler houses by providmg detaIled reports on the work that has been done, developing an experIenced local testing and bOIler performance assessment capabIhty, and helpmg these tramed local experts establIsh local representatIOn for eqUIpment supply. The information necessary and the personnel capable of supportmg the evaluatIon of equipment reqUIrements, selectIOn of controls eqUIpment, support m purchasmg equipment, and optIOns for fInancmg eqUIpment are aVaIlable m Novokuznetsk. Before the project was completed, the indIVIduals tramed In the project had already started to sell their services at other boIler houses and mdustnes m the Kemeovo reglOn.

The lessons learned by Ecougol would serve other CItIes In RUSSIa well, since the boiler houses found In Novokuznetsk are representatIve of those used throughout the former SOVIet Umon for communal and mdustnal heatmg.The sIgmfIcant results achIeved by local experts m Novokuznetsk usmg the control eqUIpment, tune-up techmques, and coal sorting methodology descnbed above are, therefore, replIcable In commumtIes across RUSSIa If the needed fundmg IS aVaIlable. EPT has recommended strongly that local speCIalIsts tramed under EPT apply for fundmg under USAID's Replication of Lessons Learned (ROLL) program to fInance boIler audIt and tune-up demonstrations in other CIties as a low-cost, fIrst step approach to demonstrating the potentIal for improving arr qualIty and health across RUSSIa

17

APPENDIX A

PRE-INSTALLATION TEST DATA and RESULTS

TESTING TlME AND DESIGNATION (PRE-INSTALLATION)

Date DesIgnatIOn

Start

1 01.0997 ZUI 11'50

2 01 0997 ZU2 14:00

3 01 0997 ZU3 16.00

LEGEND Z - boIler house of the Zyryanovskaya coal mme U - unadjusted mode R - adjusted mode AC- after dust collector Be - before dust collector 1,2,3 - test number

TIme

End

12:50

15:00

17'00

Table 1A

Coal type

unsorted G

unsorted G

unsorted G

11\

SIZE DISTRIBUTION OF COAL (PRE·INSTALLATION)

Table 2A Coal partIcle SIze,

mm SIze dIstnbutIOn , %

ZUl ZU2 Zr3

1 > 50 5,0 5.5 78

2 25-50 8,7 13,2 9 1

3 13-25 12,4 15.4 11.5

4 6-13 24,1 25,6 23 -1-

5 0-6 49,8 40,3 -1-8.2

6 0-3 35,1 32,6 32.1

Total. 100,0 100,0 1000

TESTING TIME AND DESIGNATION (PRE·INSTALLATION)

Date DesIgnatIOn

1 12.20.96 RUl

2 122096 RU2

3 122096 RU3

LEGEND R - bOIler house of the RefngeratIOn Plant U - unadjusted mode R - adjusted mode AC- after dust collector BC - before dust collector 1,2,3 .. - test number

Time Start End

11 00 12000

13:45 14'45

15:55 16:55

Table lA

Coal Type

Unsorted T

Unsorted T

Unsorted T

SIZE DISTRIBUTION OF COAL (PRE-INSTALLATION) Table 2A

Coal partIcle SIze, SIze dIstnbutIOn, % mm

RUl RU2 RU3

1 > 50 1,6 2,2 1.9

2 25-50 26,4 35,1 29.4-

3 13-25 26,9 27,7 30.0

4 6-13 22,7 17,0 19,6

5 0-6 22,4 18,0 19A

6 0-3 15,5 12,7 13,5

Total 100.0 100,0 100.0

vf

TESTING TIME AND DESIGNATION (PRE.INSTALLATION)

Date DesignatIon

Start

1 12 1496 AUl 11.05

2 12 1496 AU2 13:25

3 12 1697 AU3 10 00

LEGEND A- boIler house of the Abashevskaya coal mIne U - unadjusted mode R - adjusted mode AC- after dust collector Be - before dust collector 1,2,3 .. - test number

Time

End

12.05

14:25

11:00

Table 1A

Coal type

Unsorted G

Unsorted G

Unsorted G

SIZE DISTRIBUTION OF COAL (PRE-INSTALLATION)

Table 2A Coal partIcle SIze,

mm SIze distnbutton, %

AUl AU2 AU3

1 > 50 3,9 4,9 2,2

2 25-50 10,9 13,3 10,5

3 l3-25 18,2 18,5 22,8 ,

4 6-13 30,1 27,7 27,4

5 0-6 36,9 35,6 37,1

6 0-3 23,5 12,3 24,4

Total' 100,0 100,0 100,0

1

,

3

...J.

5

6

7

8

I

SIZE DISTRIBUTION OF DUST IN THE DUST COLLECTOR (PRE-INSTALLATION)

Dust partIcle SIZ- SIze dIstnbutIOn, %

mg, /lm

ZUl ZU2

> 3000 0 0

2000-3000 0 0

1000-2000 3,0 3,5

500-1000 9,2 9,6

200-500 10,5 9,5

100-200 47,8 45,5

40-100 18,6 19,9

<40 10,9 12,0

I I Total 100,0 100,0

Table 6A

ZU3

0

0

2.-1-

9.2

6,3

-, '"T J_, /

188

10,6

lOO})

1

2

3

4

5

6

7

8

SIZE DISTRIBUTION OF DUST IN THE DUST COLLECTOR (PRE-INST ALLA TION)

Dust partIcle SIze, IlID SIze dIstnbutlOn, %

RUl RU2

> 3000 0 0

2000-3000 0,05 0,1

1000-2000 0.25 0,05

500-1000 1,6 0,45

200-500 32,4 26,1

100-200 34,9 35,5

40-100 24,1 30,9

<40 6,7 6,9

Total 100,0 100,0

Table 6A

RU3

° ° ,

0,1

1,9

27,8

37,0

20,5

12,7

100,0

1

)

3

4

5

6

7

8

I

SIZE DISTRIBUTION OF DUST IN THE DUST COLLECTOR (PRE-INSTALLA TION)

Dust partIcle Size, Size dlstnbutlOn, % ~lm

AUl AU2

> 3000 0 0

2000-3000 0 0

1000-2000 2,0 1,7

500-1000 7,5 6,0

200-500 22,5 22,6

100-200 31.5 30,2

40-100 32,5 36,0

<40 4,0 3,5

I Total 100,0 100.0

AU3

0

0.1

33

9.5

21 7

31.3

27.6

65

1000

COlVIBUSTION TEST RESULTS (PRE-INSTALLATION) Table 9A

Tm1e Heat output Flue gases O2 content In CO content NO~ con- SOl In flue CombustIon of the botler, temp,OC flue gases, % In flue tent gases, ppm efficIency Gcallhr gases, ppm In flue as

gases, ppm measured, %

lUBC! 1150 9,00 250 14,8 71 92 65 75,3 1200 9,00 245 14,9 64 92 49 74,8 [2 10 9,25 252 14,7 78 94 87 79,8 1220 9,75 257 14,3 93 95 106 76,2 1230 9,75 254 14,5 93 90 122 75,7 [240 9,75 244 14,8 515 88 127 77,2 1250 9,75 239 15,1 121 89 122 76,3

Average value 9,46 249 14,7 148 91 97 76,5

lUBC2 1400 16.00 309 11.7 113 107 87 77,5 1410 IS,50 333 10,9 3S0 124 88 78,2 1420 15,25 318 11,9 72 111 87 77,3 1430 15,25 280 14,2 70 101 67 75,1 [440 11,75 247 IS,S 60 80 52 76,2 1450 10.00 237 15,9 44 81 28 77,1 IS 00 11,00 240 15,4 57 86 45 77,4

Average value 13,96 281 13,7 114 99 65 77,0

lUBC3 1600 16.50 329 11.1 1000 143 113 79,1 16 10 1650 326 11,0 716 141 113 80,2 1620 16,00 321 11,5 320 141 198 78,2 1630 16,25 329 11,1 773 141 156 81,6 1640 16,50 333 11.5 484 138 76 80,2 1650 15,50 340 11,3 612 141 52 78,1 17 00 15,50 338 11,5 740 140 81 79,2

Average value 16,11 331 11,3 664 141 113 79,5

COMBUTION TESTS RESULTS (PRE-INSTALLATION) Tab[e 9A

TIme Heat output F[ue gas 0, content In CO content NOx con- 502 Lontent In I Combu'itlon ot the temp, DC flue gas, % In flue gas tent In nue t1ue ga" ppm etnclency boIler ppm gas, ppm I as Gca[/hr meJsured

, C-c

RVBRI I [ 00 318 9.9 83 226 84 I [[ 10 317 12.3 79 [73 96 I [120 210 [6,5 277 113 59 I I 30 227 18,0 263 96 35 I II -1-0 248 15,7 132 127 60 1[50 265 15,5 228 148 52 I [200 310 13,5 84 149 70

A\erage value 134-1< 271 14,5 164 147 65

RVBR2 1340 282 14,0 156 240 61 I [350 315 10.2 91 234 92 I [400 276 169 371 88 70 I 14 lO 327 12,8 75 169 128 1420 278 16,7 460 103 70 1430 254 16.9 471 135 76 1440 318 16,9 53 III 69

Average I value 1.27.f' 293 14,9 240 154 81 I

RVBR3 IS 55 333 13,9 122 136 84 1605 351 14,9 27 131 71 I [6 15 239 18.8 368 98 22 1625 372 12,2 11 178 103 1635 306 16,0 261 94 75 1645 286 15,2 156 189 31 I 1655 364 14.8 8 110 73

Avewge value 1,31-1< 322 15,1 136 134 66

;- - Plea~e note that the table con tams only average values of the bOIler efficiency as they were calculated based on the volume of the flue gases, WhICh was due to the lack of J med~urement diaphragm and thermal meter.

COMBUSTION TESTS RESULTS (PRE-INSTALLATION)

Table 9A TIme Heat output Flue gas O2 content In CO content NOx con- S02 content In CombustIon

of the temp, flue gas, % m flue gas, tent In flue flue gas, ppm efficIency bOIler °c ppm gas, ppm as Gcallhr measured,

% AUBRI

1105 12.00 282 11,7 119 152 188 11 15 12.00 281 11,8 145 134 189 1125 10,50 283 11.8 135 132 189 II 35 12.00 293 11,0 259 133 207 1145 12.00 289 11,5 334 123 194 II 55 11,70 288 12.0 230 117 190 1205 11,70 284 11,9 170 121 190

Average value 11,70 286 11,7 199 130 192

AUBR2 1325 12.90 287 11,7 79 175 191 1335 12.30 281 12,2 82 158 176 1445 12,00 275 12,7 64 164 172 1455 9,90 272 12,7 75 176 166 1405 11 70 285 12,2 69 180 177 14 15 10,80 277 12,7 72 176 167 1425 9,90 262 14,3 89 151 138

Average value 11.36 276 12,6 76 168 169

AUBR3 10 00 17,1 357 7,3 776 263 266 1010 16.2 347 8,6 44 270 232 10 20 13,5 324 10,0 52 315 199 10 30 l3,8 316 10,5 60 316 195 10 40 135 317 10,5 69 324 204 10 50 9,0 291 13,1 95 263 149 11 00 7,5 254 14,0 141 242 124

Average value 12,94 315 10,6 178 285 196

BOILER PERFORMANCE TEST CONDITIONS (PRE-INST ALLA TION)

Table 7 A Time Heat output Water flow Water temp Water temp Water pres- Water pres-

ot the through the In the bolier In the boller sure In the sure In the bolier bolier, outlet, °c Inlet, °c bolier botler !Ole! Gcallhr m3lhr outlet, kgf/c.m2

kgf/cm3 , ZUI I

1150 9,00 250 99 63 8,4 II I

1200 900 250 99 63 8,4 II I 12 10 9,25 250 100 63 8A 11 1220 9,75 250 102 63 8,4 II 123O 9,75 250 102 63 8,4 II 12 .. to 975 250 102 63 8,4 II 1250 9,75 250 102 63 8,4 11

Average value 946 250 100,8 63 8,4 II

ZU2 1400 16,00 250 129 65 8,4 II [4 10 [850 250 [39 65 8.4 [ [

[420 [5,25 250 [26 65 8.4 11 1430 15,25 250 126 65 8,4 11 1440 11.75 250 112 65 8,4 II 1450 10,00 250 105 65 8,4 II 1500 11,00 250 109 65 8,4 II

A\erage value 13,96 250 120,8 65 8.4 II

ZU3 [600 1650 250 128 62 8,4 1 [ 1610 16,50 250 128 62 8,4 II 1620 16,00 250 126 62 8,4 II 16 JO [625 250 127 62 8.4 [ [

16 .. +0 [650 250 128 62 8.4 1 [ 165O 15,50 250 [24 62 8,4 II [700 15,50 250 124 62 8,4 II

A\erage value 16,11 250 126,4 62 8,4 11

BOILER PERFORMANCE TEST CONDITIONS (PRE·INSTALLATION)

Table 7A TIme Heat output Total steam Feedmg Feedmg Steam pres-

of the flow rate, water temp water temp sure, boller, tfhr 10 the outlet 10 the mlet kgf/cm2

Gcal/hr of econo- of econo-mIzer, °c mIzer, °c

RUl 1100 123 83 5,2 II 10 129 84 4,8 1120 129 84 4,9 II 30 130 85 5,0 1140 128 84 5,2 1150 124 85 4,5 1200 123 83 4,7

Average value 1,34* 2,05-1< 126,6 84 4,9

RU2 1340 129 86 5,0 1350 129 86 5,6 1400 127 84 5,2 1410 126 83 5,0 142O 126 83 4,6 1430 126 83 5,0 1440 128 83 5,2

Average value 1,27* 1,94* 127.3 84 5,1

RU3 1555 129 86 5,0 1605 128 86 5,0 16 15 119 87 4,5 1625 120 86 4,0 1635 128 86 5,5 1645 120 86 5,0 1655 120 86 5,0

Average value 1,31 *" 2,01* 120 86,1 4,8

* - Please note that the table contams only average values of the boiler efficiency as they were calculated based on the volume of the flue gases, which was due to the lack of a measurement dIaphragm and thermal meter.

BOILER PERFORMANCE TEST CONDITIONS (PRE·INSTALL~ TION) Table 7A

Time Heat output Total steam FeedIng FeedIng Water Water of the flow rate, water temp water temp pressure In pre,>~ure 10

boller tfhr In the boller In the bOIler the bOIler the boller Gcal/hr outlet, °c Inlet. °c outlet. tnlet

kgt/cm2 kf!t/cmc \Ul

[[ 05 12.00 300 100 60 8 [3 II 15 1200 300 100 60 8 13 11 25 10 50 300 95 60 8 13 I II 35 1200 300 102 62 8 13 11..J.5 1200 300 102 62 8 13

. II 55 11 70 300 101 62 8 13 1205 I I 70 300 101 62 8 13

Average I \ alue 11 7 300 100,1 61,1 8 13 I

UJ2 1325 1290 300 105 62 8 13 1335 12.30 300 103 62 8 13 I 14..J.5 12.00 300 102 62 8 13 I I..J. 55 9.90 300 95 62 8 13 1405 11 70 300 101 62 8 13 I..J. 15 10 80 300 98 62 8 13 I..J. 25 990 300 95 62 8 13

-\ \ erage \ .llue 11 36 300 99,8 62 8 13

\U3 \0 00 17 I 300 120 63 8 13 10 10 162 300 116 62 8 13 1020 13.5 300 108 63 8 13 1030 13 8 300 108 62 8 13 10 ..J.O 135 300 107 62 8 13 1050 90 300 92 62 8 13 1100 7,5 300 86 61 8 13

I\verage value 12,94 300 105,3 62,1 8 13

, I

"

I

I

2

3

4

5

6

TOTAL AND SPECIFIC PARTICULATE EMISSIONS (PRE-INSTALLATION)

Table llA BOller heat PartIculate ermSSIOns after

Run output, PartIculate emISSIOns before the ash remover Gcal/hr the ash remover

kg/hr kg/Gcal kg/hr kg/Gcal

ZUBCl 64,13 6,78 9,46

ZUACl 5,04 0,53

ZUBC2 105,21 7,54 13,96

ZUAC2 6,00 0,43

ZUBC3 81,52 5,06 16,11

ZUAC3 31,67* 1,97*

* - EmISSIOns mcreased due to water supplIed to the safety trap and Ventun tube be­mg cut off durmg test 3

N~

1

'1 -

3

4

5

6

TOTAL AND SPECIFIC PARTICULATE EMISSIONS (PRE·INST~LLATION) Table 11A

BOller heat Run # output, PartIculate emISSIOns before PartIculate emI~~IOns after

Gcallhr ash remover dsh remover kg/hr kg/Geal kg/hr br/Gcal

RUBCl 26.64 19.88 1,34

RUACl 2.28 L70

RUBC2 17,47 13,76 1,27

(

I RUAC2 'J ,.,.., 1.7 6 _._.J

RUBC3 33,27 25.40 1.31 I

RUAC3 1.90 1 .15

1

2

3

4

5

6

TOTAL AND SPECIFIC PARTICULATE EMISSIONS (PRE-INSTALLATION)

Table llA BOller heat

Run output, PartIculate emISSIOns before PartIculate emissions after Gcal/hr ash remover ash remover

kg/hr kg/Gcal kgihr kg/Gcal

AUBCl 97,78 8,36 11,70

AUACl 34,23 2,93

AUBC2 93,60 8,24 11,36

AUAC2 33,13 2,92

AUBC3 121,38 9,38 12,94

AUAC3 78,60 6,07

CALCULATED FUEL PARAMETERS (PRE-INSTALLATION) T<lhle 3A

Run COLd I yp~ hiLi L(IIllPO,>IlHlII, % I owc,>1 L,dll- YOC pcr I-hglK'>1 IlhL volluc, volume ot LollonflL kc,d/kg Lombu~llbl value,

C'>, % kL,d/kg

MOI~ture A~h S C H2 N2 l'1 O2 QI y dll Qs

I ZUl Unsorted G 8,0 13,6 0,38 63,6 4,3 1,8 0,018 8,2 5971 39,5 6253

2 ZU2 UnsOiled G 9,0 13,3 0,37 62,8 4,4 1,8 0,019 8,3 5913 40,7 6204

3 ZU3 Unsorted G 9,5 ..... L .. 14,5 0,26 62,0 4,2 1,7 0,019 7,8 5777 41,1 6059

CALCULATED FUEL PARAMETERS (PRE-INSTA LLA TION)

Table 3A Lowest YOC per Highest

Run COoll Type Fuel composition, % c,llOllhL volume ot collonflc volluc, LOInbu~tIb volluc, kcal/kg les, % kcal/kg

MOisture Ash S C H2 N2 CI O2 QI ydat Qs

I RUl Unsorted T 10,0 8,6 0,27 73,4 3,0 1,7 0,019 3,0 6679 12,3 6896

2 IW2 LJ Il'>orted r 9,0 8,9 0,25 73,9 .1,0 1,7 (J,n 18 3,2 6728 13,0 6945

3 RU3 UII"'Orl~d r ...

13,0 9,3 0,25 70,4 2,1) 1,6 0,018 .... 2,7 61-11 11,9 6575 ._--- --------

~~

.S­o

I

2

3

1

2

3

Run Coal Type

AUt Unsorted G

AU2 Unsorted G

AU3 Unsorted G

Run

MOIsture ,

ZUI 0,10

ZU2 0,52

ZU3 0,12

CALCULATED FUEL PARAMETERS (PRE-INSTALLATION)

Fuel compOSitIOn, %

MOisture Ash S C Ih N2 CI O2

10,0 13,9 0,40 61,5 4,1 1,7 0,009 8,4

6,0 14,0 0,41 64,6 4,3 1,8 0,010 8,9

16,0 ... 1t1,~_ 0,34 56',5 3,9 1,7 0,011 7,1 - _. --_._-----

BOTTOM ASH PARAMETERS (PRE-INSTALLATION)

Bottom ash composItiOn, %

Ash C H2 N2 S

78,82 20,41 0,30 0,28 0,09

57,00 40,82 0,36 0,67 0,19

67,82 30,97 0,33 0,37 0,09

Table 3A Lowest VOC per Highest calonflc volume ot calOllflc value, combustlb value, lcalllg les, % kcal/kg

QI V Qs

5881 40,3 6165

6185 41,0 6454

5309 41,7 5613 ---- - ---_._-----

Table 4A Lowest VOC per Highest calonflc volume of calonflc value, combustibles value, kcallkg ,% kcallkg

O2 Ql V Qs

° 1138 4,28 1155

0,44 3267 3,71 3290

0,30 2509 3,47 2528 .. - -----

CYCLONE DUST PARAMETERS (PRE-INSTALLATION)

Table 5A Lowest VOC per Highest

Run Dust compositIOn, % calonflc volume of calonflc value, combustibles value, kcallkg ,% kcallkg

MOisture Ash C H2 N2 S O2 QI V Qs

I ZUl 0,42 46,13 51,56 0,21 0,72 0,25 0,71 4147 4,06 4161

2 ZU2 0,61 47,91 49,58 0,20 0,63 0,22 0,85 3943 4,27 3957 I

c

~ ZU3 '----

0,55 ... 54,90 41,57 0,12 0,53 0,21 2,12 3316 2,31 3326 ----- -_._---

BOTTOM ASH PARAMETERS (PRE-INSTALLATION)

Table 4A Lowest VOC per Highest

Run Bottom ash cOmpOSition, % calonflc volume of ' calonfic value, combustibles value, kcallkg ,% kcallkg

MOisture Ash C H2 N2 S O2 QI V Qs ,

I RUl 0,37 55,00 43,07 0,62 0,61 0,12 0,21 3547 2,17 3583

2 RU2 0,10 60,24 38,15 0,48 0,56 0,11 0,36 3142 2,49 3169

3 RU3 0_,I_I_ .. ~43 33,43 0,40 0,51 0,14 1,98 2801 3,28 2823

.s. /

CYCLONE DUST PARAMETERS (PRE-INSTALLATION)

Table 5A Lowe'>t VOC pel vol- Hlghe~t

RUIl Dust l-OmposItIOll, % l-<lIOIlfll- ume of com- l-,IiOI I11l-v,llue , bustIble~, % v<llue, kCdl/kg kl-dll(..g

MOisture Ash C H2 N2 S O2 QI V Qs

I RUl 0,88 24,37 70,61 0,69 1,38 0,36 1,76 5854 5,20 5897

2 RU2 1,00 23,04 71,48 0,74 1,36 0,36 2,02 5951 5,14 5997

3 RU3 1,14 21,75 72,48 "0,66 1,30 0,36 2,31 6040 4,64 6082

BOTTOM ASH PARAMETERS (PRE-INSTALLATION)

Table 4A Lowest VOC per vol- Highest

I Run Bottom ash compositIOn, % calonflc ume of com- calonflc

value, bustIbles, % value, I

kcal/kg kcal/kg

MOisture Ash C H2 N2 S O2 Qt V Qs

I AUl 0,10 74,85 24,20 0,07 0,67 O,ll 0 1596 2,00 1600

2 AU2 0,12 72,37 26,46 0,12 0,41 0,11 0,41 1873 2,79 1880 •

3 AU3 0,21 78,20 20,85 0,06 0,57 0,11 0 1376 2,11 1380 -- --- ---

~

CYCLONE DUST Pt\RAl\1ETEI{S (PRE-INSTALL,\'I10N)

Table SA I OWL'>! VOC' PCI vol- IlIghL~1

Run lJu~1 LOlllpo~lIlon, % L.dOlllle ullle 01 COIll- LJ.hlllllL v.due , bu~tlbles, % v.due, hL.d/hg hL.d/hg

MOI~ture Ash C H2 N2 S O2 QI V Q~

I Aut 0,11 63,50 35,51 0,17 0,50 0,21 0 2180 3,38 3190

2 AlJ2 0,13 52,H7 46,09 0,15 0,53 0,23 0 3091 3,75 3100

3 AU3 0,2~ __ .. 63,58 35,23 ' 0,13 0,64 0,19 0 2192 2,02 2200 ._- .. -

~

>­S-_

I

2

3

4

5

6

Run

ZUBCl

ZUACl

ZUBC2

ZUAC2

ZUBC3

ZUAC3

AvelUge tlue gJ~ dULl temp, DC

202,3

122,1

244,4

131,3

284,6

194,8

PARTICULATE EMISSION TESTING DATA (PRE-INSTALLATION)

Static pres- Measured Average Flue gdS flow rate Isokmetlc Total cap-sUle m the volume, tlow rate In VUl latIons, tUl ed flue ga~ III

3 the gdS % weIght, duct, duct, g mm water m/sec

acmm dscmm

-144,8 0,852 27,45 1779 1027 97,3 0,8871

-300,0 1,458 24,20 1568 1012 90,8 0,1209

-144,8 0,871 29,08 ' 1884 982 104,0 1,5563

-340,0 1,304 23,33 1512 928 88,5 0,1407

-144,8 0,797 27,93 1810 863 108,4 1,2560

-340,0 1,272 24,92 1612 851 94,2 0,7897

Table 8A Particulates MOIsture In Particulate concentI dUO the ga~ emISSlon~,

n, duct, kg/hr g/dscmm %

1,041 2,3 64,13

0,083 7,8 5,04

1,786 4,0 105,21

0,108 9,9 6,00

1,575 5,4 81,52

0,621 10,5 31,67

PARTICllLATE EMISSION TESTIN(; DATA (PRE-INSTALLATION)

Tdblc 8A Avel,Jge St,lI1C pi C'i- Me,l~urcd Avcr,lgc Flue g,J~ Ilow r,lte 150lll1etic Tot,11 cap- PaJ tlUll.ltC'> MOI<,ture Parllull,lte

Run /luc g,l\ :"1lI C \11 the voluJJle, now 1,lle In V ,II 1,1110\1<" IIncd U )J]ccntr ,It J( l\l, 1\1 the g,I'> ellll'>'>11 111'>, dULl tUlip, lIue g,I'> ~ thc g,I'> % weight, g/d'>UIlIll duct, 19/ill III

°c duct, duct, g % mm water m/sec

acmm dscmm

1 RUnCl 204,0 -18,3 0,539 8,85 237 136 98,5 1,7647 3,275 4,3 26,64

2 RUACI 122,4 -168 0,889 12,72 181 127 98,3 0,2693 0,300 1,5 2,28

3 RUBC2 205,8 -183 0,781 8,40 225 129 98,6 1,7564 2,250 3,3 17,47

4 RUAC2 132,8 -168 0,947 14,62 208 J4J 92,8 0,2487 0,263 1,9 2,23 -

5 RUBC3 224,7 18,3 0,789 8,64 232 129 100,0 3,3904 4,298 2,6 33,27

6 .... R(jAC3 139,9 -!68_ 0,925~ 14,75 210 141 91,1 0,2084 0,225 1,6 1,90 - -

~,

~ -<""'

I

2

3

4

5

6

Run

AUBCI

AUACI

AUBC2

AUAC2

AUBC3

AUAC3

Average flue gas duct temp, °c

345,H

243,3

244,7

244,1

283,3

278,8

PARTICULATE EMISSION TESTING DATA (PRE-INSTALLATION)

Static pre~- Measured Average Isokmetlc Total cap-sUle In the volume, flow rate In Flue gas flow rate vanatlOns, tured flue gas m3 the gas % weight, dUd, duct, g Illlll water Ill/sec

acmm dscmm

-33,0 0,698 13,57 1368 612 110,9 1,8574

-117 0,821 13,29 1563 825 113,7 0,5677

, -33,0 1,018 12,54 1264 682 95,8 2,3288

-117 1,116 13,70 1611 862 93,7 0,7150

-5,0 1,081 14,65 1477 727 95,4 3,0074

-117 1,214 15,88 1867 927 94,7 1,7156

Table 8A Particulates MOI~ture PartlculJte concentration, m the gas emISSlon~,

gkbc III 111 duct, kg/hr %

2,661 4,9 97,78

0,692 5,7 34,23

2,228 4,1 93,60

0,641 4,2 33,13

2,781 4,9 121,38

1,413 3,9 78,60

KB-TC-20 BOILER HEAT BALANCE (PRE-INSTALLATION)

Tdble lOA Run BOilel heat out- COdl lonsump- Boller

put, twn, Hedt los~es In the boller, % efflclcnl y, GCdl/hr kg/hr %

q2 q3 q4 qs q6

I ZUl 9,46 2316 25,1 0,4 5,0 0,15 0,1 68,4

2 ZU2 13,96 3551 19,4 0,22 12,6 0,15 0,2 66,5

3 ZU3 16,11 3950 18,4 1,06 9,5 0,15 0,3 70,6 I ----

q2 - he..!l lo~~e~ trom tlue gasc~

q3 - heat losses due to chemIcal Incompleteness of combustIOn

q4 - heat losses due to mechal1lcal Incompleteness of combustion

qs - heat losses due to low outsIde temperature

q6 - he,ll lo~~e~ trom bottom ash

~

DK-BP-4/13 BOILER HEAT BALANCE (PRE-INSTALLATION)

Table lOA N~ Run N~ BOiler heat out- Coal consump- Boller

put, tlOn , Heat losses In the bOiler, % ettiLienc y, GCdl/hr kg/hr %

q2 q3 q4 q5 q6

I RUt 1,34 320 21,5 0,4 145 09 0,1 62,6

2 RU2 1,27 298 235 0,6 11,5 09 0,2 635

3 RU3 1,31 351 23,4 0,3 162 09 0,2 590 .... ...

q2 - hedt losses from flue gases

q3 - heat losses due to chemical IIlcompleteness of combustIOn

q4 - heat losses due to mechalllcal IIlcompleteness of combustIOn

q5 - heat losses due to low outside temperature

q6 - heat losses from bottom ash

~

J:-.. ~

KB-TC-20 BOILER HEAT BALANCE (PRE-INSTALLATION)

N~ Run N~ Bmler heat out- Co,ll UHl'>lII1lP-

put, tHlIl, He,lt lo.,.,e~ III the bOIler, % GCdlllu t-g/hr

q2 q3 q4

1 Aut 11,70 2699 20,5 0,34 5,7

2 AU2 11,36 2579 20,4 0,12 6,8

'1 Am 12,94 '1'172 22,0 0,29 .... 7 --- -

q2 - he,ll losses from flue gases

q3 - hedt losses due to chemIcal Incompleteness of combustion

q4 - heat losses due to mechanical ll1completeness of combustIOn

q) - heat los~es due to low outsIde temperature

q6 - he,ll lo.,~es hom bottom ash

Table IDA Boller

etllLh~nLY,

%

q5 q6

0,05 0,28 737

0,05 0,26 712

0,05 0,10 72,1

u' o

I

2

3 ---~

I

2

3

Run

ZUI

ZU2

ZU3

Run

RUl

RU2

RU3

BOILER EFFICIENCY SUMMARY TABLE (PRE·INSTALLATION)

BOIler heat Load, Coal consumptIOn, BOIler effl- Total particulate emiSSIOns, Dust col-output, % clency kg/hr lector eftt-GL,d/hr (q), % clency, %

kg/hr kg/Gcal followmg followmg dust burner collector

9,46 47,30 2316 244 68,4 64,13 5,04 92,14

13,96 69,80 3551 254 66,5 105,21 6,00 94,30

'---16,~ 80,55 3950 _ 21~ , 70,6 81,52 31,67 ~ 61,15

-----~.-~ ~ -- --- ~---

BOILER EFFICIENCY SUMMARY TABLE (PRE·INSTALLATION)

BOiler heat Load, Coal consumption, BOiler effl- Total particulate emiSSions, Dust col· output, % clency kg/hr lector efft-Gcallhr (q), % ctency, %

kg/hr kg/Gcal followmg followmg dust burner collector

1,34 59,82 320 238 62,6 26,64 2,28 91,44

1,27 56,70 298 234 63,5 17,47 2,23 87,24

1;31 __ __ }~,-1_8_ 351 267 59,0 33,27 1,90 94,29 -- ----- ---

Table 12A Specific particulate eml~Slons,

kg/Gcal

follOWing follOWing dU5t burnel collector

6,78 0,53

7,54 0,43

5,06 1,97 -- -

Table 12A SpeCifiC particulate emiSSions,

kg/Gcal

follOWing followlIlg dust burner collector

19,88 1,70 I

!

13,76 1,70

25,40 1,45

"-,j ...... --

1

2

3

Run

AUt

AU2

AU3

Boller heat output, Gcallhr

11,70

11,36

12,94

BOILER EFFICIENCY SUMMARY TABLE (PRE-INSTALLATION)

Table 12A Load, Coal con~umptlon, BOilel effl- Total particulate emiSSions, Dust col- Specific particulate emiSSions,

% clency kglhr lecto! effl- kg/Gcal (q), % clency, %

kglhr kg/Gcal followmg followmg dust followmg followmg dust burner collector burner collector

58,50 2699 231 73,7 97,78 34,23 64,99 8,36 2,93

56,80 2579 227 71,2 93,60 33,13 64,60 8,24 2,92

64,70 3372 2260 c 72,3 121,38 78,60 35,24 9,38 6,07

APPENDIX B

POST-INSTALLATION TEST DATA and RESULTS

TESTING TIME AND DESIGNATION (POST-INSTALLATION)

Date DesIgnatIOn

Start

1 050897 ZR1 1025

2 050897 ZR2 1240

3 050897 ZR3 1430

LEGE\D

Z - boIler house of the Zyryanovskaya coal mine U - unadjusted mode R - adjusted mode AC- after dust collector BC - before dust collector 1,2,3 - test number

TIme

End

11 25

1340

1440

SIZE DISTRIBUTION OF COAL (POST-INSTALLATION)

Coal particle size, mm Size dIstnbutIOn , %

ZR1 ZR2

1 > 50 7,7 10,4

2 25-50 14,2 10,3

3 13-25 18,5 17,2

4 6-13 20,9 19,5

5 0-6 38,7 42,6

6 0-3 27,3 31,0

Total 100,0 100,0

Table 1 B

Coal type

unsoned G

unsorted G

unsoned G

Tabl;; 28

ZR3

58

109

1 k t::: vv

234

44 1

31 ° 100,0

TESTING TIME AND DESIGNATION (POST-INSTALLATION)

Date DesignatIOn

1 250497 RU1

LEGEND R - bOIler house of the RefngeratIOn Plant U - unadjusted mode R - adjusted mode AC- after dust collector BC - before dust collector 1,2,3 - test number

Time Start End

1055 11 55

SIZE DISTRIBUTION OF COAL (POST-INSTALLATION)

Coal partIcle SIze, SIze dIstnbutIOn, % mm

RR1

1 > 50 0,6

2 25-50 4,8

3 13-25 14,4

4 6-13 23,1

5 0-6 57,1

6 0-3 43,0

Total 100,0

Table 18

Coal Type

Unsorted T

Table 28

TESTING TIME AND DESIGNATION (POST-INSTALLATION)

Date DesignatIOn

Start

1 290497 AR1 1400

2 290497 AR2 1610

3 30 04 97 AR3 11 00

4 30 04 97 AR4 14 05

LLGC\D

1\- boIler house of the Abashevskaya coal mme U - unadjusted mode R - adjusted mode AC- after dust collector BC - before dust collector 1,2,3 - test number

Table 1 B

Time Coal type

End

1500 Unsorted G

17 10 Unsorted G

12 00 Unsorted G

15 05 Vnsorted G

I ~') J

SIZE DISTRIBUTION OF COAL (POST-INSTALLATION) Table 28

Coal partIcle SIze, mm Size distribution, %

AR1 AR2 AR3 AR4

1 > 50 3,3 1,8 1,8 1,0

2 25-50 10,5 8,8 16,6 10,0

3 13-25 21,1 19,4 32,8 25,0

4 6-13 29,2 29,1 23,0 24,9

5 0-6 35,9 40,9 24,9 39,1

6 0-3 24,1 27,9 16,5 26,5

Total 100,0 100,0 100,0 100,0

COMBUSTION TEST RESULTS (POST-INSTALLATION) Table 98

Time Heat output Flue gases O2 content In CO NOx 802 m CombustIOn of the temp, °c flue gases, 0/0 content m content flue efficiency as boder. flue m flue gases, measured, Gcallhr gases, gases, ppm %

ppm ppm ZRBC1 1025 10 1 252 88 320 132 13 1035 103 241 89 111 135 6 1045 10 1 243 90 228 126 4 1055 100 246 89 241 125 3 11 05 100 243 88 212 128 0 11 15 100 242 98 202 117 2 11 25 99 247 92 186 124 0

A'verage value 100

ZRBC2 12 10 102 237 90 1200 1220 99 234 94 840 1230 98 237 93 1100 1240 98 236 90 240 1250 96 244 95 118 1300 94 244 89 820 13 10 96 228 86 1800

Average value 97

ZRBC3 1430 136 262 90 1440 136 264 90

COMBUTION TESTS RESUL TS (POST-INSTALLATION) Table 98

TIme Heat Flue gas O2 content In CO NOx S02content Combustl output of temp,OC flue gas, % content in content in In flue gas, on the bOIler flue gas, flue gas, ppm efficiency Ton/hr ppm ppm as

measured, %

RRBC1 1055 1 66 213 17,5 602 11 15 1 68 208 17,3 384 11 25 1 69 278 10,2 580 11 35 1 58 205 18,6 620 57 20 11 45 1 81 214 15,1 525 181 55 11 55 081 242 15,7 408 220 71 1205 083 230 15,2 431 220 69

Average value

COMBUSTION TESTS RESULTS (POST-INSTALLATION) Table 98

Tune Heat Flue gas O2 content In CO NOx S02content ComDustlOn output of temp, °c flue gas, a/a content In content In In tlue gas, efficIency as the bOIler flue gas, flue gas, ppm measured. Gcal/hr ppm ppm %

AUBR1 1400 92 226 11 2 92 114 166 14 10 74 215 123 137 101 144 1420 86 218 120 152 94 140 1430 104 213 11 7 170 90 141 14 LiO 83 230 126 130 94 135 1450 78 228 127 200 90 130 1500 65 225 133 98 88 140

Average \ alue 83 222 12 1 140

AUBR2 16 10 102 234 103 274 86 50 1620 98 228 11 1 84 86 50 16 30 96 227 11 3 150 86 I 16 LiO 93 230 11 3 140 89 1650 95 226 108 230 87 1700 96 228 to 3 215 90 17 10 94 234 102 280 101

A\ t:Iage value 96 229 108 215 99

COMBUSTION TESTS RESUL TS (POST-INSTALLATION) Table 98

TIme Heat Flue gas O2 content In CO NOx S02content Combustion output of temp,OC flue gas, % content In content in In flue gas, efficiency as the boIler flue gas, flue gas, ppm measured, Gcal/hr ppm ppm %

AUBR3 11 00 13 1 260 10.4 38 204 28 11 10 13 1 260 10 1 43 222 149 11 20 140 261 102 60 231 164 11 30 148 262 9 1 53 228 180 11 40 140 253 97 50 193 162 11 50 132 250 105 51 190 170 1200 12 1 246 109 44 194 159

Average value 136 256 10 1 48 209 145

AUBR4 1405 142 261 102 129 264 188 14 15 14 1 263 98 132 232 196 1425 136 259 102 202 202 205 1435 132 255 10 1 230 195 203 1445 11 3 240 11 2 293 147 181 1455 123 245 90 167 201 1505 135 257 89 183 242

Average value 132 254 99 199 202

BOILER PERFORMANCE TEST CONDITIONS (POST-INSTALLATION) Table 78

TIme Heat Water Water Water Water Water output of flow temp m temp m pressure pressure the bOIler through the bOiler the bOiler mthe m the Gcal/hr the boller, outlet, mlet, DC bOiler boIler

m3Jhr DC outlet, mlet, kgf/cm3 kgf/cm 2

ZR1 1025 10 1 267 954 577 8,4 11 1035 103 266 965 578 8,4 11 1045 10 1 265 956 576 8,4 11 1055 100 265 957 578 8,4 11 11 05 100 265 958 582 8,4 11 11 15 100 268 956 583 8,4 11 11 25 99 266 956 584 8,4 11

Average value 100 266 957 580 8,4 11

ZR2 12 10 102 269 963 583 8,4 11 1220 99 270 949 582 8,4 11 1230 98 270 945 584 8,4 11 1240 98 270 9.49 588 8,4 11 1250 96 270 942 588 8,4 11 13 00 94 268 939 590 8,4 11 13 10 96 269 94.6 589 8,4 11

A\ erage value 97 269 948 58.6 8,4 11

ZR3 1430 136 271 106 56 1440 136 271 106 56

BOILER PERFORMANCE TEST CONDITIONS (POST-INSTALLATION) Table 78

TIme Heat Total Feedmg Feedmg Steam output of steam water water temp. pressure, the bOller, flow rate, temp m m the mlet kgf/cm 2

Gcal/hr tIhr the outlet of of economIzer, economiz °c er, °c

RR1 1055 091 1 66 133 51 5 11 05 092 1 68 133 51 5 11 15 093 1 69 127 49 5 11 25 087 1 58 130 50 5 11 35 1 05 1 81 135 52 5 11 45 045 081 131 51 5 11 55 046 083 134 52 5

Average value 093 1 69 132 51 5

BOILER PERFORMANCE TEST CONDITIONS (POST -INSTALLATION) Table 7B

Time Heat Total Feedmg Feedmg Water Water output of water water water pressure pressure the boller. flow rate, temp m temp. m m the m the Gcal/hr m3/hr the boller the bOller boIler bOller

outlet, DC mlet, DC outlet, mlet, kgf/cm 2 kgf/cm2

AR1 1400 92 308 667 369 8 13 14 10 74 310 61 3 373 8 13 1420 86 309 652 374 8 13 1430 104 308 71 3 374 8 13 1440 83 309 643 373 8 13 1450 78 307 61 9 366 8 13 15 00 65 308 585 374 8 13

Average value 83 308 65 1 371 8 13

AR2 16 10 102 306 684 353 8 13 1620 98 307 673 353 8 13 1630 96 301 690 373 8 13 1640 93 301 685 376 8 13 1650 95 302 686 37 1 8 13 1700 96 300 697 377 8 13 17 10 94 300 691 376 8 13

A\ erage value 96 302 687 368 8 13

BOILER PERFORMANCE TEST RESULTS (POST-INSTALLATION) Table 78

TIme Heat Total Feedmg Feedmg Water Water output of water water water pressure pressure the boller, flow rate, temp m temp m mthe mthe Gcallhr m3/hr the bOIler the boIler bOIler boiler

outlet, °c mlet, DC outlet, inlet, kgf/cm 2 kgf/cm2

AR3 11 00 13 1 308 962 538 8 13 11 10 13 1 307 967 54.1 8 13 11 20 140 308 978 52.2 8 13 11 30 148 308 1005 52.5 8 13 11 40 140 308 978 522 8 13 11 50 132 308 948 52.1 8 13 1200 13 1 308 91 5 52.1 8 13

Average value 136 308 965 530 8 13

AR4 1405 142 310 934 477 8 13 14 15 14 1 310 932 478 8 13 1425 136 309 91 6 475 8 13 1435 132 310 906 481 8 13 1445 11 3 310 848 483 8 13 1455 123 309 878 481 8 13 1505 135 310 91 7 481 8 13

Average value 132 310 905 479 8 13

1

2

3

4

5

6

7

8

TOTAL AND SPECIFIC PARTICULATE EMISSIONS (POST-INSTALLATION) Table 118

BOller heat Run output, Particulate emISSIOns before Particulate emissions after

Gcallhr ash remover ash remover

kg/hr kg/Gcal kg/hr kg/Gcal

AUBC1 49,9 5,8 8,9

AUAC1 34,23 2,93

AUBC2 64,6 6,7 9,6

AUAC2 33,13 2,92

ARBC3 88,4 6,6 13,4

ARAC3 41,4 3,1

AUBC4 79,9 6,1 13,2

AUAC4 46,2 3,5

! ~)

~ ~

1

2

3

1

Run

ZR1

ZR2

ZR3

Run

RR1

Coal Type

Unsorted G

Unsorted G

Unsorted G

Coal Type

Unsorted T

CALCULATED FUEL PARAMETERS (POST-INSTALLATION)

Fuel composition, % Lowest calonfic value, kcallkg

MOIsture Ash S C H2 N2 CI O2 QI

11,00 12,86 0,24 61,75 4,24 1,81 - 8,13 6095

, 10,50 15,49 0,26 60,66 4,08 1,69 - 7,32 5964

7,0 13,66 0,29 64,48 4,27 1,67 - 8,63 6307

CALCULATED FUEL PARAMETERS (POST-INSTALLATION)

Lowest Fuel composItIon, % calonfic

value, kcallkg

MOIsture Ash S C H2 N2 CI O2 Q(

3,0 13,3 0,27 75,92 3,22 1,59 - 2,7 7095

Table 38

VOC per HIghest volume calonfic of value, combust! kcallkg bles, %

V Qs

I !

I

Table 38 VOC per HIghest volume of calollfic combusttbl value, es, % kcallkg

V Qs I

I j

-~~-~

CALCULATfi:ll IfUI~L I)ARAMfi:Tfi:RS (POST-INSTALLATION) Table 38

Lowest VOC HIghest Run Coal Type Fuel compositIOn, % calonfic per calonfic

value, volume value, kcallkg of kcallkg

combust lbles, %

MOIsture Ash S C H2 N2 CI O2 Q\ V Os

1 AR1 Unsorted G 12,0 15,39 0,35 58,59 4,00 1,6 - 8,07 5842 c

2 AR2 Unsorted G 10,0 15,47 0,35 60,52 4,01 1,72 - 7,93 5909

3 AR3 Unsorted G 98 13,97 0,35 62,10 4,04 1,59 - 8,15 6053

4 AR4 Unsorted G 8,50 15,10 0,38 62,65 4,12 1,52 - 7,73 6092

~

BOTTOM ASII PARAMETERS (POST-INSTALLATION) Table 4B

Lowest VOC pel HIghest Run Bottom ash composition, % calOilfic volume of calonfic

value, combustlbl value, kcallkg es, % kcallkg

MOisture Ash C H2 S O2 + N2 Q. V Qs

1 ZR1 0,69 61,10 35,44 0,74 - 0,19 1,84 2992

2 ZR2 0,70 59,90 38,04 0,22 - 0,19 0,95 3094 ,

c

3 ZR3 0,69 60,80 35,43 0,50 - 0,18 2,40 3011 I - -- ---

CYCLONE DUST PARAMETERS (POST-INSTALLATION) Table 5B

Lowest VOC per HIghest Run Dust composItion, % calorific volume of calonfic

value, combusttbl value, kcallkg es,% kcallkg

MOisture Ash C H2 S O2 + N2 Q. V Qs

1 ZR1 0,73 71,20 26,59 0,05 - 0,25 1,22 2135 I

I 2 ZR2 0,68 71,40 27,19 0,06 - 0,23 0,44 2163 I

3 ZR3 _0-,4~_ 82,00 15,86 0,12 - 0,20 1,37 1132 - ------- ---------- ----

S e::.r--

BOTTOM ASH PARAMETERS (POST-INSTALLATION)

Table 48 Lowest VOC per HIghest

Run Bottom ash compositIOn, % calOrIfic volume of calOrIfic value, combustIbl value, kcallkg es, % kcallkg

MOisture Ash C H2 S O2 + N2 a, v as I

1 RR1 2,00 74,50 422,54 0,29 - 0,05 0,62 1909

CYCLONE DUST PARAMETERS (POST-INSTALLATION) Table 58

Lowest VOC per Highest I Run Dust composItIOn, % calorific volume of calOrIfic

value, combustIbl value, kcallkg es, % kcallkg

MOisture Ash C H2 S 02+ N2 a, v as ,

1 RR1 1,46 17,70 73,56 1,40 - 0,34 5,54 6485

~ 0 __

.,.-'<o~-::.tj

'. ~ 0-0

1

2

3

4

5

,~

Run

ZRBC1

ZRAC1

ZRBC2

ZRAC2

ZRBC3

ZRAC3

Average Hue gas duct temp,

°c

243,1

97,2

228,5

90,8

248,0

85,8

PARTICULATE EMISSION TESTING DATA (POST-INSTALLATION)

StatIc Measured Average Flue gas flow rate Isokll1etic Total pressure volume, flow rate VaIlatlOns captured 111 the flue 111

3 111 the gas ,% weight,

gas duct, duct, 9 mm m/sec water

acmm dscmm

-115 0,756 24,96 1617 847 104,6 2,2889

-300,0 1,211 20,69 1341 903 81,5 0,2018

-115 0,737 24,11 1563 841 102,8 3,0789

-300,0 1,161 19,70 1277 878 79,9 0,2830

-115 0,107 27,74 1797 862 111,4 0,6415

-300,0 0,390 26,81 1737 1170 80,9 0,0,705

Table 98 Particulate MOlstllle Particulat concen- 111 the gas emiSSIOns, tratlOn, duct, kg/hl g/dscmm %

3,029 5,2 153,99

0,0173 11,0 9,36

4,176 5,3 210,74

0,254 10,6 13,39 I

5,973 12,0 309,05

0,0705 13,8 13,17

PARTICULATE EMISSION TESTING DATA (POST-INSTALLATION) Table 88

Average StatIc Measured Average Flue gas flow rate Isokmetic Total Particulates MOIsture PartIculate Run flue gas pressure volume, flow rate vanatIons captured concen- 10 the gas emISSIons,

duct 10 the flue 3 10 the gas ,% weIght, tration, duct, kglhr m temp, DC gas duct, duct, 9 agdscmm %

mm rn/sec water

acmm dscmm

1 RRBC1 187,6 -20 0,501 7,40 198 121 105,1 2,8605 5,705 2,6 41,10

2 RRAC1 141,2 -168 0,922 14,07 201 134 95,6 0,1902 0,206 3,1 1,65 ,

I

~

PARTICULATE EMISSION TESTING DATA (POST-INSTALLATION) Table 88

Average Static Measured Avelage Isokmettc Total PartIculate MOIsture PartIculate Run nue gas plessure volume, How late Flue gas flow late vanatIOns captured concen- m the gas emISSIons,

duct III the flue 3 III the ga~ ,0/0 weIght, trahan, duct, kg/hr 111

temp, gas duct, duct, 9 g/dscmm % DC mm m/sec

water acmm dscmm

1 ARBC1 212A -33,0 0,868 9,80 988 547 98,3 1,3291 1,531 6,9 49,88

2 ARAC1 173,0 -90 0,799 9,35 1099 667 133A 0,5162 0,646 5,1 25,85

3 ARBC2 249,9 -33,0 0,579 11,08 1117 566 98,3 1,1341 1,900 7A 64,57

4 ARAC2 175,2 -92 0,957 10,65 1252 760 94,1 0,6239 0,652 4,5 29,71

5 ARBC3 279,3 -60 0,707 12,63 1273 621 87,8 1,6775 2,372 5,7 88A5

6 ARAC3 211,5 -155 1,065 12,54 1475 810 98,2 0,9070 0,852 6,0 41,39

7 ARBC4 271,9 -60 0,713 12,68 1279 632 87,8 1,3535 1,897 5,8 79,94

8 ARAC4 211,3 -155 1,050 12,22 1437 78 99,5 1,0271 0,978 6,2 46,25

~

KB-TC-20 BOILER HEAT BALANCE (POST-INSTALLATION) Table 108

Run BOller heat Coal BOller ,

output, consumption, Heat losses III the boller, % efficIency, Gcallhr kg/hr %

q2 q3 q4 q5 q6

1 ZR1 9,9 2449 23,5 0,43 8,7 - 0,28 66,4

2 ZR2 96 2451 21,9 0,22 10,9 - 0,19 65,7

3 ZR3 - - - - - - - -.... - -- ... < ---

q2 - heat losses from flue gases

q3 - heat losses due to chemIcal incompleteness of combustion

q4 - heat losses due to mechanical incompleteness of combustIOn

q5 - heat losses due to low outside temperature

q6 - heat losses from bottom ash

~ ~::,. ~"'''M''~'''"''-~'';:-

DK-BP-4/13 BOILER HEAT BALANCE (POST-INSTALLATION) Table 108

Run Botlel heat Coal Botler output, consumptIOn, Heat losses 111 the boiler, % efficIency, Gcal/hr kg/hr %

q2 q3 q4 q5 q6

1 RR1 0,79 214 25,2 0,41 21,2 - 0,15 '--~~------ --~---~- ---

q2 - heat losses from flue gases

q3 - heat losses due to chemIcal Incompleteness of combustIOn "

q4 - heat losses due to mechamcalmcompleteness of combustIOn

q5 - heat losses due to low outside temperature

q6 - heat losses from bottom ash

:L

-.,. _"U"aMr"", IF, G: 1Q'8! *"'¢~"~-'

.-l ~

KB-TC-20 BOILER HEAT BALANCE (POST-INSTALLATION)

Run Boiler heat Coal output, consumptIOn, Heat losses 111 the boiler, % Gcallhr kg/hr

q2 q3 q4

1 AR1 8,6 1948 17,8 0,34 5,1

2 AR2 9,6 2112 17,7 0,12 3,9

3 AR3 13,4 3012 13,8 0,29 8,2

4 AR4 13,2 2751 16,8 0,29 3,5

q2 - heat losses from flue gases

q3 - heat losses due to chemical incompleteness of combustIOn

q4 - heat losses due to mechanical incompleteness of combustion

q5 - heat losses due to low outside temperature

q6 - heat losses from bottbm ash

Table 10B BOller

efficiency, %

qs q6

- 0,28 75,6

- 0,26 772

- 0,30 73,5

- 0,30 78,8

\. ~

BOILER EFFICIENCY SUMMARY TABLE (POST-INSTALLATION)

BOiler heat Load, Coal consumptIon, BOller Total particulate emiSSIOns, Dust Run output, % efficiency kg/hr collector

Gcal/hr. (q), % effiCiency ,%

kglhr kg/Gcal following followmg burner dust

collector

1 ZU1 9,9 49,5 2449 247 66,4 154,0 9,4 93,9

2 ZU2 9,6 48,0 2451 255 66,5 210,7 13,4 93,6

3 ZU3 -- ---.--~--- --

BOILER EFFICIENCY SUMMARY TABLE (POST-INSTALLATION)

Boller heat Load, Coal consumptIOn, Boiler Total partIculate emissions, Dust Run output, % effiCIency kg/hr collector

Gcal/hr , 0/0 efficIency ,%

kg/hr kg/Gcal following following burner dust

collector

1 RU1 0,79 35,9 ~1~_ lZL 52,3 41,1 1,65 96,0 - --- - - -~------ ---- -----

Table 12B Specific particulate emiSSIOns, kg/Gcal

following following dust burner collector

15,6 0,94

21,9 1,40

Table 12B Specific particulate emissions, kg/Gcal

followmg following dust burner collector

52.0 2,1 - --

BOILER EFFICIENCY SUMMARY TABLE (POST-INSTALLATION) Table 12B

BOller heat Load, Coal consumptlOn, Boiler Total particulate emissions, Dust SpecIfic particulate Run output, % efficiency kglhr collector emissions, kg/Gcal

Gcal/hr. ,0/0 efficiency ,%

kg/hr kg/Gcal following following following following dust burner dust burner collector

collector

1 AU1 8,6 43,0 1948 226 735,6 49,9 25,8 48,3 5,8 3,0

2 AU2 9,6 48,0 2112 220 77.2 64,6 29,7 54,0 6,7 3,1

3 AU3 13,4 67,0 3012 225 73,5 88,4 41,4 53,2 6,6 3 1

4 AU4 13,2 _66,0 __ ~ .. 2751 208 78,8 79,9 __ 4t.1,~~ 42.2 6 1 35 ------------ .. ~ - ._- - - -- ---- - --- ------

~~ ---~~