Technology Overview

• A front end combustion optimization system that provides online boiler cleaning to remove slag buildup
• Increases fuel efficiency and lowers gaseous emissions
• System uses a special aerosol injected by a very low pressure constant volume system into the combustion air or onto the fuel
• Each application is custom designed for optimum performance based on boiler type, fuel type and burner type
• Application process is ISO9001 Certified
• Aerosol compositions are internationally and USA patented

Installation in Pennsylvania

• 440,000 #/Hour
• 48 MWe
• Pulverized coal-fired boiler
• Tanks filled every two weeks with dilute oxidizer solution

Summary of Benefits

• No upfront capital investment 90 day trail provided to demonstrate benefits
• Cleans boiler online without loss of boiler availability and downtime for cleaning
• Improved heat transfer and ash handling
• Immediate installation & results with minimal site specific engineering
• Minimal supervision & maintenance of the injection system
• Reduced greenhouse gases
• Extensive financial and performance benefits based on improved efficiency
  

Fuel Savings

• Improve Heat Transfer
• Improve Boiler Efficiency
• Reduce Heat Rate
• Improved Flame Characteristics
• Higher Flame Temperature
  

On-Line Boiler Cleaning

• Increased Boiler Availability
• Eliminate/Reduce Soot Blowers - Superheat/Wall Blowers
• Better Control of Steam Temperature
• State of the Art On-Line Boiler Cleaning
• Eliminate Slag Falls and Damage to Boiler Tubes
• Reduce Tube Corrosion
  

Emission Reduction

• Reduction of SO₂
• Reduce Greenhouse Gases - CO₂
• Slight Acid Neutralization of Emissions
• Reduce Heavy Metal Emissions
• Reduce LOI

How It Works

• Injection of heavy metal aerosol molecules in the combustion air
• quantity injected is less than 1 PPM (part-per-million) to fuel ratio
• quantity injected is less than 1% of the same heavy metals in fuel
• Injected solution activate existing heavy metals from the fuel to propagate chemical combustion reactions
• Enhanced oxidizing reaction causes the flame to shorten, burn brighter and hotter which increases thermal radiation.
• Improved heat transfer and flame characteristics allows for reduced excess air
  
  

Benefits

• Removal of slag buildup improves heat transfer to yield improved efficiency
• Lower LOI and reduced unburned hydrocarbon emissions, also improves efficiency
• Boiler tube surfaces cleaned by increased oxidization of unburned carbon compounds and coating the boiler tubes with a non-stick layer using metals from the fuel
• Improved flame performance allows for reduction of excess air
• Protection of surfaces from new deposit formations
• Combustion flame concentration resulting in higher radiation heat transfer
• Improved boiler convection heat transfer in boiler backpass
• Reduction/elimination of soot blowing better ash handling
• Temperature and pressure stabilization of superheated steam
• Slight reduction of SO3 and SO2 emissions
• Inhibition of acid oxidation of the heat exchangers metal surfaces
• Slight emissions reductions of CO and VOCs
• Reduction of greenhouse gases from improved boiler efficiency

How Our System Is Unique:

• The injection system is installed with limited site specific engineering, allowing for installation within hours for most boilers, while the boiler is on-line.
• The system allows for cleaning of the gas side boiler tubes while the boiler is in operation, allowing for the reduction/elimination of soot blowings.
• The injection rate is based on a parts per million ratio of the fuel consumed, not parts per thousand, as most other competing technologies.
• This front-end technological approach is a form of pollution prevention, not end of the pipe treatment.
• The overall improvements in the flame characteristics provides for several boiler operating benefits that reduce the operating cost of the combustion unit.
• The overall cost of the system is easily paid for by the reduction in boiler operating costs.

United States ExperiencePlant T1

Boiler Data

• Permanent Installation at Plant T1, PA
• Arch fired coal boiler rated at 48 MWe
• Fuel: waste anthracite, bituminous and petroleum coke

Operating Data

• Started June 2006
• The boiler was in use for 14 months since previous cleaning dirty boiler
• Boiler remained online during installation
• Cleaned boiler on-line
• Reduced slagging
• Improved boiler heat rate 5% to 10%
• Reduced SO2 by 4% to 5%
• Reduced LOI by 50%
• Improved boiler availability
• Reduced soot blowing by 75%
• Reduced corrosion of boiler tubes

U.S. Experience Plant T1

United States Experience Plant T2

Boiler Data

• Permanent Installations at Plant T2, PA
• Four (4) Arch fired coal boiler rated at 48 MWe each
• Fuel: bituminous coal

Operating Data

• Started May/June 2007
• Boilers remained online during installation and start-up
• Cleaned boiler on-line to keep in operation
• Reduced slagging
• Improved boiler heat rate
• Reduced SO2
• Improves boiler operation
• Reduced corrosion of boiler tubes
• Reduced heavy metals in ash per unit output
  

Ash Performance Data

Permanent Installation at a Power Plant in PA

** (Click image for a larger version) **

United States ExperiencePlant T3

Boiler Data

• 90 Day Trial at Plant T3, PA
• CFB (circulating fluidized bed) waste coal boiler , 36 MWe Limestone is used for in-bed (90%) SO2 reduction
• 36 MW electric turbine

Operating Data

• Boiler in use for 6 months since previous cleaning
• Boiler remained online during installation
• Cleaned boiler on-line; reduced soot blowing
• Increased steam temperature to design value
• Reduced corrosion of boiler tubes
• Improved boiler heat rate by 1% to 2%
• Improved handling of bottom ash
• Small reductions in limestone use
• Test showing possible Hg stack emissions reduction

United States ExperiencePlant T4

Boiler Data

• 60 Day Trial at Plant T4, SC
• Wall fired low NOx burners bituminous coal
• 156 MWe

Operating Data

• Boiler in use for 3 months since previous cleaning
• Boiler not stopped for Flame Tech's combustion technology start-up
• Cleaned boiler on-line; Reduced soot blowing by 75%
• Removed old slag build-up in corners
• Reduced corrosion of boiler tubes
• No influence on ash LOI or PH
• Reduced excess air from 35% to 10%
• Reduced stack opacity at this reduced excess air
• Small reduction in SO2 and NOx emissions
• Improved boiler heat rate by 5%+ based on CO2 data