POWER October 2012 - 56

COAL COMBUSTION
8. Primary superheater tubes after
using Aurora. Courtesy: JEA
becomes sticky and bonds with other particulate
matter that comes in contact with
the surface, increasing in size. The process
repeats itself to form larger agglomerated
ash formations. As the quantity of bonded
ash grows, more fuel is required to achieve
adequate steam temperatures, reducing the
efficiency of the boiler.
Aurora chemically captures the alka9.
Sticky ash is gone. Primary superheater
tubes after two years of continuous operation
show little ash accumulation. Compared
with Figures 1 and 2, the reduction in ash agglomeration
is remarkable. Courtesy: JEA
lis before they can form low-melting point
compounds. Aurora forms an intermediate
compound at boiler operating temperatures
that is highly porous and reacts with high
efficiency. The intermediate compound then
reacts with alkalis to form alkali aluminosilicates,
which exhibit much higher melting
point temperatures and lack the stickiness of
the alkali compounds at CFB temperatures.
Back in Business
The NGS CFB boilers have not experienced
any significant ash buildup-related incidents-such
as cyclone plugs, unit deratings
due to ash removal system problems, or unit
shutdowns for boiler cleaning-since use of
the Aurora additive began in June 2008. The
backpass of the boiler, which prior to 2008
required explosive blast cleaning every three
to six months, has not been cleaned in any
form in almost three years. The unit forced
outage rate has improved from over 13% to
less than 1%, by 2011. Figures 5 through 9
illustrate the improved boiler cleanliness that
has resulted from using the Aurora additive.
Long-term performance trends show
key performance metrics-such as gross
megawatts, heat rate, bed level, ammonia
use, main steam temperatures, and the
like-have all improved with Aurora use
(Figures 10 and 11). The loop seals and
portions of the furnace grid that required
up to 10 days of jack-hammering to remove
agglomerated ash are now cleaned with a
vacuum truck in a few hours. Convection
tubes are found to be clean with drastically
reduced scale buildup. JEA units are now
operating for a third year with no backpass
cleaning and zero cyclone plugs. Previously,
two or three cleanings were required
every year. By 2011, the forced outage rate
was less than 1% and the units exceeded
design megawatt output-a record that
continues today.
In addition to performance improvement,
there was tangible improvement to
the plant's air emissions when using the
Aurora additive. Simultaneously, there
were no net changes in NOx
and SOx
emisCIRCLE
31 ON READER SERVICE CARD
56
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POWER | October 2012

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POWER October 2012

Table of Contents for the Digital Edition of POWER October 2012

Contents
POWER October 2012 - Cover1
POWER October 2012 - Cover2
POWER October 2012 - Contents
POWER October 2012 - 2
POWER October 2012 - 3
POWER October 2012 - 4
POWER October 2012 - 5
POWER October 2012 - 6
POWER October 2012 - 7
POWER October 2012 - 8
POWER October 2012 - 9
POWER October 2012 - 10
POWER October 2012 - 11
POWER October 2012 - 12
POWER October 2012 - 13
POWER October 2012 - 14
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POWER October 2012 - 17
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POWER October 2012 - 21
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POWER October 2012 - 28
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POWER October 2012 - 30
POWER October 2012 - 31
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POWER October 2012 - Cover3
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