Implementing Overfire Air Technology in Coal-Fired Power Plants to Promote Environmentally Friendly Energy Generation

This paper presents a numerical study on the deployment of Overfire Air (OFA) technology in coal-fired thermal power plants in Kazakhstan to reduce harmful emissions. The simulation utilized a digital model of the combustion chamber of the BKZ-75 boiler at Shakhtinsk thermal power plant, which utilizes high-ash Karaganda coal containing 35.10% ash. During the development of two-stage combustion technology, different methods of supplying extra air via OFA injectors were examined. Various positions within the combustion chamber were evaluated for their placement: at heights of h = 0.165 m; 0.75 m; 1.375 m; 2.25 m; 2.5 m; 8 m; 9.4 m; 10 m; 11 m; and 12 m. The baseline combustion mode (OFA = 0%) and several additional air injector settings were analyzed, including OFA levels of 5%, 10%, 15%, 18%, 20%, 25%, and 30% of the total air volume. Numerical simulations generated temperature distributions along with carbon monoxide (CO) and nitrogen (NO) concentration fields, both inside and outside the combustion chamber outlet. Research indicates that the most effective reduction in pollutant emissions happens when OFA injectors are positioned at 9.4 m and supply supplementary air at an OFA rate of 18%. Under these settings, the carbon monoxide concentration at the combustion chamber outlet decreases by approximately 36%, while nitrogen oxide levels drop by 25%, compared to the baseline condition (OFA = 0%). These insights can be utilized to upgrade boiler units, promoting cleaner fuel combustion in coal-fired thermal power plants.