Zonal™ Combustion Optimization System

GE's Zonal™ Combustion Optimization System is a combination of sensors, proprietary software and adjustable burners, airflow and coal flow dampers.

Together these technologies work to reduce NOx and CO2 as well as improve efficiency.

The environmental challenge

One important part of the solution to energy scarcity is improving the efficiency of the existing infrastructure. GE saw an opportunity to improve already existing boilers help better the environment in the foreseeable future.

GE's innovative solution

GE developed Zonal Combustion Optimization system, a fully integrated solution that combines combustion monitoring, analysis and optimization in one package. Having all the components together allows the system to monitor the performance of each component, resulting in higher system performance and greater benefits for the customer. For the customer, this means dealing with a single party who carries the full responsibility for the system's performance.

This approach to optimizing combustion uses proven technology to improve conditions in any fossil-fired boiler; however, the Zonal system is works better in coal-fired boilers because of the complexity of coal milling, coal pipe balancing, airflow balancing and combustion. Slag related outages and load drops are minimized through an improved controlled temperature profile and improving gas composition. This results in higher availability of the unit, higher generating capacity and improved efficiency.

Environmental impact

TGE's Zonal Combustion Tuning can improve efficiency of coal-fired units. In one case, GE demonstrated efficiency improvements of 0.4 percent. On a typical 500 MW boiler this can result in a reduction of fly ash production by over 700 tons per year. The Zonal system can also maintain or improve carbon in ash and assist in optimizing mercury control to reduce ash disposal requirements.

GE's Zonal Combustion Tuning can significantly reduce nitrogen oxide emissions from coal-fired units. In one instance GE demonstrated nitrogen oxide reductions of 13 percent over baseline. On a typical 500 MW boiler, this reduces annual nitrogen oxide emissions by over 1,200 tons per year. This is the equivalent to removing 66,000 cars from U.S. roads annually

Reducing costs

The Zonal system consistently helps reduce greenhouse gas emissions and reduce boiler maintenance. The results include reduced fuel use, lower carbon dioxide, nitrogen oxide and sulphur oxide emissions, and improved performance, positively impacting the bottom line of operations.

Potential operating results include an increase in peak power capacity, reduction in operating costs, extended time between outages, improved burner and OFA performance and improved SCR performance.