United States Air Pollution Training Institute (APTI) June 2003 Environmental Protection Environmental Research Center, MD 17 Agency Research Triangle Park, NC 27711 Air Combustion Source Evaluation Student Manual APTI Course 427 Third Edition Author Brian W. Doyle, PhD, PE Doyle Engineering Inc Developed by ICES Ltd. EPA Contract No. 68D99022 Acknowledgments The author gratefully acknowledges the contributions of Dr. Sumana Keener, Ph.D. PE, who conducted the peer review of this document. ii Notice This is not an official policy and standards document. The opinions and selections are those of the author and not necessarily those of the Environmental Protection Agency. Every attempt has been made to represent the present state of environmental knowledge as well as subject areas still under evaluation. Any mention of products or organizations does not constitute endorsement or recommendation by the United States Environmental Protection Agency. This project has been funded wholly or in part by the United States Environmental Protection Agency under Contract No. 68D99022 to ICES Ltd. Availability This document is issued by the Air Pollution Training Institute, Education and Outreach Group, Office of Air Quality Planning and Standards, USEPA. This workbook was developed for use in training courses presented by the U.S. EPA Air Pollution Training Institute and others receiving contractual or grant support from the Institute. Other organizations are welcome to use the document. This publication is available, free of charge, to schools or governmental air pollution control agencies intending to conduct a training course on the subject matter. Submit a written request to the Air Pollution Training Institute, USEPA, MD 17, Research Triangle Park, NC 27711. Others may obtain copies, for a fee, from the National Technical Information Service (NTIS), 5825 Port Royal Road, Springfield, VA 22161. Sets of slides and films designed for use in the training course of which this publication is a part may be borrowed from the Air Pollution Training Institute upon written request. The slides may be freely copied. Some films may be copied; others must be purchased from the commercial distributor. This consent does not extend to copying or transmission by any means – graphic or electronic – for any other purpose, such as for advertising or promotional purposes, for creating a new collective work, for resale, or for information storage and retrieval systems. State and local air pollution control agencies, U.S. EPA offices, and federal offices designated by U.S. EPA are authorized to make copies of this document in connection with telecourses. Printed on recycled paper in the United States of America. iii Course Description APTI 427: Combustion Source Evaluation is a four-day, resident instructional course designed to introduce combustion-related pollution problems such as estimating the actual and potential air pollution emissions from combustion sources; reviewing applications for permits to construct combustion facilities; and developing recommendations to improve the performance of malfunctioning combustion equipment. The course is intended primarily for those with an engineering and/or scientific degree, or completion of course RE100 and OL 2000, or six months of equivalent work experience. Major topics discussed include: • Combustion sources burning • Combustion principles liquid and solid wastes • Combustion sources burning • Design and operational fossil fuel parameters • Combustion engines (diesel • Selected fundamental engines, gas turbines, etc.) calculations • Pollution control devices • Fuels How to Use This Workbook This workbook is to be used during classroom instruction, telecourse sessions, and individual study. The workbook contains instructional objectives and materials for each of the seven chapters. Each chapter provides a lesson goal, instructional objectives, subject narrative, and reference materials that may guide your study. Each chapter also contains a reproduction of selected lecture slides intended to guide your notetaking. The slides are presented to generally follow the course outline; however, the instructor may on occasion vary the order of presen- tation or present material not included in the workbook. Each student, therefore, should take thorough notes of the lecture content throughout the course, but not rely solely upon graphic reproductions for the course content. iv DISCLAMER This document is for education and training only and does not constitute U.S. Environmental Protection Agency policy. Mention of trade names or commercial products does not constitute endorsement or recommendation for use. v TABLE OF CONTENTS TABLE OF CONTENTS...............................................................................................................vi LIST OF FIGURES .....................................................................................................................xiv LIST OF TABLES........................................................................................................................xvi ACRONYMS ..............................................................................................................................xvii USEFUL DATA…………………………………………………………………………………………..xx FORWARD .................................................................................................................................xxi Chapter 1 1.0 Overview of Combustion Sources 1-1 1.1 Significance of Combustion Sources................................................................ 1-2 1.2 Carbon and Energy.......................................................................................... 1-3 1.3 Fuels................................................................................................................. 1-4 1.4 Air Pollution...................................................................................................... 1-6 1.4.1 Emission Rates............................................................................ 1-7 1.4.2 Types of Pollutants...................................................................... 1-8 1.5 Overview of Sources...................................................................................... 1-10 1.5.1 Engines...................................................................................... 1-10 1.5.2 Boiler Systems........................................................................... 1-11 1.5.3 Other Combustion Sources........................................................1-12 Review Exercises 1-14 Review Answers 1-16 References 1-17 Chapter 2 2.0 General Types and Characteristics of Combustion Sources 2-1 2.1 Combustion Systems.......................................................................................... 2-3 2.2 Types of Combustion Systems............................................................................ 2-4 2.2.1 Engines and Turbines........................................................................... 2-5 2.2.1.1 Reciprocating Engines: Lean/Rich, Diesel/Gas................. 2-5 2.2.1.2 Combustion Turbines.......................................................... 2-7 vi 2.2.1.3 Combined Cycles and Cogeneration.................................. 2-9 2.2.2 Boilers...... .......................................................................................... 2-10 2.2.2.1 Suspension Versus Grate Firing....................................... 2-12 2.2.2.2 The Basic Burner Design.................................................. 2-13 2.2.2.3 Suspension Firing – Burner Arrangements....................... 2-16 2.2.2.4 Stoker Fired – Coal, Wood, and Solid Waste....................2-18 2.2.2.5 Fluidized Bed Combustors................................................ 2-24 2.2.3 Thermal Oxidizers and Other Combustion Systems........................... 2-27 2.2.3.1 High Temperature Oxidizers ............................................. 2-27 2.2.3.2 Catalytic Oxidizers............................................................ 2-28 2.2.3.3 Flares ................................................................................ 2-29 2.2.3.4 Kilns and Other Devices................................................... 2-30 2.3 Fuel Storage, Handling and Processing............................................................ 2-33 2.3.1 Natural Gas and Oil............................................................................ 2-33 2.3.2 Solid Fuels – Storage, Feeding.......................................................... 2-34 2.3.2.1 Coal................................................................................... 2-34 2.3.2.2 Wood and Waste.............................................................. 2-35 2.4 Combustion Air Pollution Controls..................................................................... 2-35 2.4.1 Load Variations – Base, Swing, Peaking, Emergency........................ 2-35 2.4.2 Control Systems................................................................................. 2-36 2.4.2.1 Fuel and Overall Control................................................... 2-37 2.4.2.2 Air Flow and Controlling Air-Fuel Ratio............................. 2-37 2.4.3 Air Moving Components – Fans and Draft Levels .............................. 2-38 2.5 Steam System Components.............................................................................. 2-39 2.5.1 Steam Generation............................................................................... 2-40 2.5.2 Steam Turbines.................................................................................