In the quest to reduce NOx emissions and improve combustion efficiency, Low NOx burners have long been hailed as a solution. But what if the very conditions inside your fuel piping are sabotaging their performance?
Welcome to the hidden challenge of
coal ribboning—and the patented technology that finally solves it: the
SAS Global In-Line Diffuser.
The Problem: Is Your Low NOx Burner Really Performing?
Modern coal-fired power plants rely on specific, pre-engineered stoichiometric air-to-fuel ratios to achieve optimal combustion and reduced NOx formation. Low NOx burners are designed to operate within, often unobtainable or inconsistent, air-to-fuel ranges to stage combustion, suppress peak flame temperatures, and limit nitrogen oxide formation.
But there’s a catch...
At the inlet to every burner is an elbow, or scroll; a design that inadvertently creates segregated strands of coal and air, better known as
“coal ribbons.” This phenomenon causes wild variations in the air/fuel ratio across the burner face:
- Too much air: Leads to premature ignition, high NOx, and damage to burner tips.
- Too much coal: Leads to delayed combustion, slagging, unburned carbon (LOI), and wasted heat.
These uneven flow conditions violate the very principle Low NOx burners rely on a homogeneous fuel/air mixture. The result? Poor combustion stability, higher emissions, costly maintenance, and diminished heat rate performance.
The SAS Global Solution: Patented In-Line Diffuser Technology
The SAS Patented In-Line Diffuser is engineered to
disrupt coal ribboning just upstream of the burner tip. Its job is simple but powerful: force the mixture of coal and air into a
uniform, homogeneous flow profile before entering the boiler.
With a consistent fuel-to-air mixture:
- Combustion begins at the intended location—not prematurely or too far down the flame path.
- Burner tips are protected from localized wear and overheating.
- NOx reduction strategies (like secondary and over-fire air) become more effective.
- The boiler heat rate improves, and so does fuel efficiency.
Proof in the Flame: Before & After Performance:
WALL FIRED BURNER EXAMPLE
