Methane Gas Cofiring Effects on Combustion and NOx Emission in 550 MW Tangentially Fired Pulverized-Coal Boiler

A shift from coal to liquefied natural gas for electricity generation can mitigate CO2 emissions and respond to the intermittent and variable characteristics of renewable energy. With this objective, numerical simulation was performed in this study to determine the optimal position of the methane injector and evaluate the achievable reduction in NO x emissions before applying methane cofiring to an existing 550 MW tangentially fired pulverized-coal boiler (Boryeong Unit 3). The combustion and NO x reduction in the furnace were intensively analyzed based on the methane cofiring rate (up to 40%). The optimal position of the methane injector was found to be inside the oil port based on the spatial distribution of NO x and the stoichiometric ratio along the furnace height. The NO x reduction rate was logarithmically proportional to the methane cofiring rate, and compared to the base case, a 69.8% reduction was achieved at the 40% cofiring rate. In addition, the fraction of unburned char at the boiler outlet was equivalent to that of the existing boiler as the increase in the flow rates of the close-coupled and separated overfire air improved fuel and air mixing. Simultaneously, methane cofiring led to a reduction in the total fuel loss and CO emissions. Finally, this study showed that the recommended optimum cofiring rate was 20% based on the furnace exit gas temperature. Under the 20% methane cofiring condition, the boiler achieved a 57.3% reduction in NO x emissions and a 7.4% improvement in fuel loss.