NOx Reduction via Combustion Optimization

1. NOx Reduction via Combustion Optimization

2. Agenda What is the ZoloBOSS TVA Project Description Data Validation TVA Project Results Summary

3. What is the ZoloBOSS Laser-based combustion sensor Measure along any line-of-sight In the combustion zone In the backpass O2, CO, CO2, Temperature, H2O, NH3 No calibration 15 paths per instrument Auto-aligned transmitter / receiver Automated “port-rodders” for slag clearing

4. What is the ZoloBOSS Multiple paths enable “CAT scans” Measure combustion process directly ZoloBOSS-enabled solutions: Combustion data + Control systems + = Value Optimization expertise + Better measurements mean better results

5. What is the ZoloBOSS Better measurements mean better results Emissions reductions Slagging control Heat rate improvement Faster ramp rates Variable fuel mixtures Consistency / reliability

6. The Project TVA Gallatin Unit 3. Completed in 1959 284 MW, T-fired, split furnace design Low-NOx burners Over-fired air 85% PRB. 15% Bituminous EPRI TC

7. The Project Project Goals: Reduce NOx Minimize tube wastage risk Project Objectives: Lower excess air Modify combustion staging Balance temperature Project Methodology: Validate economizer data Validate combustion data Man-in-the-loop tuning DCS tuning

8. The Project Install: Feb 2005 15 path system Above burners: 4 paths Above SOFA: 6 paths At furnace exit: 1 path In economizer: 4 paths

9. Data Validation 3 side-by-side HVTs at TVA EPRI participation Combustion zone issues: Point vs path average HVT temperature problems CO issues with extraction O2 issues with extraction Overall successful validation

10. Data Validation, Temperature Temp agrees to within 2% in combustion zone

11. Data Validation, O2 Consistent offset in O2 combustion zone. CO ?

12. Combustion Optimization Data validation via HVT Data validation via ZrO2 Operational verification testing Burner tilts Damper settings Sootblowing Combustion staging Backpass O2 settings New operating condition(s) evaluated

13. Project Results Project Methodology: ? Validate economizer data Yes ? Validate combustion data Yes ? Man-in-the-loop tuning Yes DCS tuning Project Objectives: ? Lower excess air Done ? Modify combustion Done Balance temperature Project Goals: ? Reduce NOx 25% ? Tube wastage No observed increase

14. Project Results 25% NOx reduction 0.21 to 0.16 lb / MMBtu $685,000 NOx season savings* Little change to O2 along walls No observed increase in tube wastage Trials with 100% PRB promising Heat rate improvement not quantified yet *$2,700 $/ton NOx

15. Summary Laser-based combustion sensors: 18 month run-time Data validation Numerous installs ZoloBOSS-enabled solutions: Unique combustion data + Control systems + = Value Optimization expertise + 25% NOx reduction