How advanced engineering revolutionized coal combustion through innovative burner technology and staged combustion processes
For generations, coal has powered nations but at a significant environmental cost. The billowing plumes from power plant stacks contained invisible threats—acid rain-causing sulfur oxides (SOx), smog-forming nitrogen oxides (NOx), and fine particulates that impacted both human health and the environment.
At the core of the LEBS solution was the development of an advanced low-NOx burner prototype, employing sophisticated staged combustion technology 3 .
Initial combustion with limited oxygen minimizes NOx formation from fuel-bound nitrogen
Gradual air addition completes combustion while avoiding peak temperatures that create thermal NOx
Cooler exhaust gases recirculated to dampen temperatures and further reduce NOx formation
Researchers at B&W's Clean Environment Development Facility (CEDF) in Alliance, Ohio, conducted meticulous testing to validate the prototype burner technology 2 .
The advanced low-NOx burner configuration successfully demonstrated continuous NOx emissions below the 0.2 lb/MBtu threshold using combustion techniques alone 3 .
| Test Parameter | Standard Burner | LEBS Prototype | Improvement |
|---|---|---|---|
| NOx Emissions | 0.65 lb/MBtu | 0.18 lb/MBtu | 72% reduction |
| Combustion Efficiency | ~98% | ~99% | 1% increase |
| CO Emissions at Low NOx | High | Controlled levels | Significant improvement |
Essential technologies that powered the LEBS program's success in emissions reduction.
Controls mixing of fuel and air in zones to minimize NOx formation by preventing localized hot spots.
Recirculates cooled exhaust back to combustion chamber to lower peak flame temperature.
Injects alkaline materials into flue gas to capture SOx compounds before stack emission.
The knowledge gained from the LEBS program informed a generation of cleaner coal technology and continues to influence modern energy solutions 2 3 .
Pioneered low-NOx burner technology and staged combustion processes
Integration of computational modeling and real-time emission monitoring
Includes SolveBright™ carbon capture and BrightLoop™ hydrogen production technologies 5
The systematic approach of fundamental research, rigorous testing, and technology integration provides a model for addressing today's energy decarbonization challenges.