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4.5.1.2 Flue Gas Recirculation (FGR) FGR is the most effective technique for reducing NOx emissions from industrial boilers with inputs below 100 MMBtu/hr. With FGR, a portion of the relatively cool boiler exhaust gases re-enter the combustion process, reducing the flame temperature and associated thermal NOx formation. It is the most popular and effective NOx reduction method for firetube and watertube boilers, and many applications can rely solely on FGR to meet environmental standards. External FGR employs a fan to recirculate the flue gases into the flame, with external piping carrying the gases from the stack to the burner. A valve responding to boiler input controls the recirculation rate. Induced FGR relies on the combustion air fan for flue gas recirculation. A portion of the gases travel via ductwork or internally to the air fan, where they are premixed with combustion air and introduced into the flame through the burner. Induced FGR in newer designs utilize an integral design that is relatively uncomplicated and reliable. The physical limit to NOx reduction via FGR is 80 percent in natural gas-fired boilers and 25 percent for standard fuel oils. 4.5.1.3 Low Excess Air Firing (LAE) Boilers are fired with excess air to ensure complete combustion. However, excess air levels greater than 45 percent can result in increased NOx formation, because the excess nitrogen and oxygen in the combustion air entering the flame combine to form thermal NOx. Firing with low excess air means limiting the amount of excess air that enters the combustion process, thus limiting the amount of extra nitrogen and oxygen entering the flame. This is accomplished through burner design modification and is optimized through the use of oxygen trim controls. LAE typically results in overall NOx reductions of 5 to 10 percent when firing with natural gas, and is suitable for most boilers. 4.5.1.4 Low Nitrogen Fuel Oil NOx formed by fuel-bound nitrogen can account for 20 to 50 percent of total NOx levels in oil-fired boiler emissions. The use of low nitrogen fuels in boilers firing distillate oils is one method of reducing NOx emissions. Such fuels can contain up to 20 times less fuel-bound nitrogen than standard No. 2 oil. NOx reductions of up to 70 percent over NOx emissions from standard No. 2 oils have been achieved in firetube boilers utilizing flue gas recirculation. 4.5.1.5 Burner Modifications By modifying the design of standard burners to create a larger flame, lower flame temperatures and lower thermal NOx formation can be achieved, resulting in lower overall NOx emissions. While most boiler types and sizes can accommodate burner modifications, it is most effective for boilers firing natural gas and distillate fuel oils, with little effectiveness in heavy oil-fired boilers. Also, burner modifications must be complemented with other NOx reduction methods, such as flue gas recirculation, to comply with the more stringent environmental regulations. Achieving low NOx levels (30 ppm) through burner modification alone can adversely impact boiler operating parameters such as turndown, capacity, CO levels, and efficiency. Catalog of CHP Technologies 4–17 Steam TurbinesPDF Image | EPA CHP Technologies Combustion Turbines Section 4
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