Rapid Mix Burner™ Case Study 105*Patented

TODD Ultra Low EmissionsBurner Installation

The SituationIn the summer of 1996, a new 230,000 lb/hr

Nebraska boiler at a paper plant in Staten Island,NY, was supplied with a TODD® Combustion DualRapid Mix Burner (D-RMB) utilizing induced FlueGas Recirculation (FGR). The D-RMB was selectedto meet the specified NOx and CO limits of 0.011lb/MMBtu (approximately 9 ppm) on natural gas firing. For this unit, TODD provided the burner,windbox and fuel trains for gas and oil

The BoilerA natural gas and No. 2 oil fired, 272 MMBtu/hr

D-RMB was installed on a Nebraska ‘A’ type packagewatertube boiler rated for 230,000 lb/hr steam flowand equipped with an economizer. The TODDCombustion Group supplied one dual fuel D-RMB,an insulated windbox with baffles to provideuniform combustion air distribution, main andignitor gas valve trains, a No. 2 fuel oil valve train,and an atomizing steam valve train. A fullymetered, cross-limited control system and PLC-based Burner Management Systems were bothprovided by others.

The TODD ResultFig. 2 illustrates the NOx results over the load

range as obtained by a Continuous EmissionsMonitoring System (CEMS). The NOx rangedbetween 7 and 8 ppm across the load range. The excess O2 varied from about 5% at a minimum loadto 3% at full load. FGR rates ranged between 30% and

35%. The CO emissions varied between 0 ppm and 9ppm. The CO and NOx numbers are corrected to 3% O2.

Field Test Data

Load % O2 % CO ppm NOx ppm

20 4.8 2 8

50 3.5 3 7

90 3.4 6 7

0 25 50 75 100

9876543210

40.0

35.0

30.0

25.0

20.0

15.0

10.0

5.0

0.0

NOx ppm, O2 % FGR %

Load %

NOx O2% FGR%

Fig. 2: Emissions Data

Fig. 1

®

Developing Clean Air Solutions for Planet Earth®

John Zink Company, LLCTODD Combustion Group2 Armstrong Road, Third FloorShelton, Connecticut 06484 U.S.A.

800-225-0085 or +1-203-925-0380Fax: +1-203-925-0384www.toddcombustion.comwww.johnzink.com

®

*Covered by one or more of the following patents:U.S. Pat. No. 5407347, 5470224

TODD COMBUSTION is a mark registered in the CTM countries.The abbreviated mark TODD is registered in the USA.

Copyright © 2003 by John Zink Company, LLC Printed in USA No. 34898-CS105