KACC & U-KACC Boiler
Kawasaki Advanced Clean Combustion&Upgraded KACC Boiler for Petroleum Cokes Firing

More than 120 years have passed since Kawasaki produced and delivered its first boiler in 1880.
In 1998, Kawasaki developed the KACC (Kawasaki Advanced Clean Combustion) Technology forresidual fuel oil combustion.
This technology has succeeded in reducing NOx gases and dust generated in flue gas substantiallycompared to conventional boilers.
This enables the total elimination of both dust collection and de-NOx equipment for certainemission levels mandated by regulations in Japan.
In 1999, we installed a KACC boiler that uses asphalt as fuel, and this boiler is still operatingsmoothly today.
Later, in 2008, we developed the U-KACC boiler, which burns solid petroleum coke, while alsooffering extremely low NOx and dust emissions.

KACC & U-KACC Features

１. Low NOx and Low Dust in Flue Gas
even when Low-Grade Oil is used
・REDUCES FUEL COSTS・ENVIRONMENT-CONSCIOUS

２. Minimizes Capital Investment
in Dust Collection and De-NOx Equipment

Refractory Material

・REDUCES CAPITAL REQUIREMENTS
Water WallIn KACC boiler, residual fuel oil is gasified through hightemperature deoxidization combustion in the lowerfurnace. Following this process, the gas is burned
off completely under low-temperature oxidization
combustion conditions in the upper furnace.

KACC

Principle for Reducing NOx
The KACC NOx reduction system is based on the principle
shown in this graph. It illustrates the relationship between
NOx and burner air ratio at different combustion temperatures.
As the graph shows, in a deoxidization atmosphere, NOx

Upper furnace●Low temperatureoxidization zone
●Injection of two-stagedcombustion air(Total air ratio: >1.0)

emissions fall as the gas temperature rises, while in anoxidization atmosphere, NOx emissions fall as the gas
temperature falls. The KACC system, which combines hightemperature deoxidization combustion in a lower furnace and●Complete combustion●Water wall material:
Carbon steel tube

TS airlow-temperature oxidization combustion in an upper furnace.

Σ（HCN+NH3+N [ppm]10001315℃
1093℃

100871℃
538℃

10●High temperaturedeoxidization zoneBurner●Low air ratio (<1.0)●Gasification of fuel byhigh temperature gas00.1

Lower furnace

Upper furnace

Lower furnace

0.01
0.5

0.6

0.7

0.8

0.9

1.0

1.1

●Water wall material:
Composite tube
(Carbon steel+ Stainless steel)

Refractory Wall

1.2

Air Ratio [-]Data source;(EPA/EPRI
Primary NOx
SourceSymposium
NOx Symposium
1985)
Data source;(EPA/EPRI
Primary Source
1985)

Expected Performance of KACC & U-KACC

Advantage of KACC & U-KACC on Flue Gas Treatment

Expected performance (Boiler outlet)

Bunker-C
O2=4%, dry
Asphalt, VR
O2=4%, dry
Pet. cokes
O2=6%, dry

Conventionalboiler

KACC / U-KACC

NOx [ppm]

150

≦ 100

Dust [mg/Nm3]

300

≦ 100

NOx [ppm]

240

≦ 120

Dust [mg/Nm3]

700

≦ 300

300〜700≦ 250

NOx [ppm]

GRBO

ILER

SC

F

SimplifR
PRA
EH IREATERCOD
LL USTEC
TO
R

Schem

ati

cd

FG

iagramD

Applicable Fuels
Residual oil products, such as asphalt and VR (vacuum residue),Applicable fuelare characterized by high viscosity and high sulfur, nitrogen,

Fuel characteristics

residual carbon, and vanadium content. Petroleum coke isSulfur

poorer quality, with factors such as its solid state and high ash
content making it more difficult to burn than asphalt and VR.
Residual oil products and bitumen are burned in the KACCboiler, while petroleum coke is burned in the U-KACC boiler ina stable and clean fashion.

Bunker-C

Asphalt, VR

Pet. cokewt %≦34〜64〜7

Nitrogen

wt %

≦ 0.2

0.5〜0.7

1〜3

Residual carbon

wt %≦ 1225〜30

87〜90

Vanadium

wt ppm≦ 60

200〜300≦ 1500

Ash

wt %

-0.03

0.2〜1.0

KACC

KACC

U-KACC

Boiler type

U-KACCPetroleum coke
(Solid fuel)Crude oilRefractory Wall

Upper furnace●High temperaturedeoxidization zone

BurnerAtmospheric distillation●Low air ratio (<1.0)●Gasification of fuel byhigh temperature gas

Residue●Water wall material:
Composite tube
(Carbon steel+ Stainless steel)TS airVacuum distillation

Lower furnace

Residue●Low temperatureoxidization zone

Delayed coker

U-type gas flow

●Injection of two-staged
combustion air(Total air ratio: >1.0)●Complete combustion

Asphalt and VR(Liquid fuel)●Water wall material:
Carbon steel tube

Residue
Bottom ash discharge●There is no need for a GRF (gas re-circulation fan) because the
KACC & U-KACC alone can deliver low NOx emissions.
●The SCR (de-nox equipment) can be downsized or even
BOication

ILE

eliminated completely, depending on the maximum permissible
RPRA
EH IR
EAT

NOx-emission values.
ERWetFG Type
D●There is no need for a dust collector, if wet-type desulfurizationequipment is installed.
Schemati

cdiagramHokuetsu Kishu Paper Co., Ltd. (Mie, Japan in 1998)
Boiler Spec.

Design FuelNOx(Design / Actual)SOx(Design / Actual)
Dust(Design / Actual)

Capacityt/h130

Steam press.

MPa

10.3

Steam temp.

℃

533

Sulfur content%

3.0 (max.)

Nitrogen content%0.35 (max.)

Residual carbon%-Boiler outlet

ppm

120 / 98

SCR outlet

ppm-

FGD outlet

ppm

75 / 16

Boiler outlet

mg/Nm3

Kind

Stack

High viscosity bunker C

3

mg/Nm

300 / 100
50 / 10JX Nippon Oil & Energy Corporation (Aichi, Japan in 1999)
Boiler Spec.

Design FuelNOx
(Design / Actual)
SOx(Design / Actual)
Dust(Design / Actual)

Capacity

t/h200

Steam press.

MPa

11.4

Steam temp.

℃515

KindAsphalt

Sulfur content%

6.0 (max.)

Nitrogen content%0.7 (max.)

Residual carbon%

28 (max.)

Boiler outlet

ppm

120 / 110

SCR outlet

ppm

35 /26

FGD outlet

ppm

60 / 7

Boiler outlet

mg/Nm3

Stack3mg/Nm

300 / 250
38 / 7

Nippon Daishowa Paperboard Co., Ltd. (Hiroshima, Japan in 2001)
Boiler Spec.

Design FuelNOx
(Design / Actual)
SOx(Design / Actual)
Dust(Design / Actual)

Capacity

t/h100

Steam press.

MPa

10.3

Steam temp.

℃

Kind533
Bunker C

Sulfur content%

3.0 (max.)

Nitrogen content%

0.27 (max.)

Residual carbon%

15 (max.)

Boiler outlet

ppm

90 / 83

SCR outlet

ppm-FGD outlet

ppm

50 / 38

Boiler outlet

mg/Nm3200 / 152

Stackmg/Nm3

50 / 24

Overseas Sales Section, Energy Plant Sales Department, Plant & Infrastructure Company
1-14-5, Kaigan, Minato-ku, Tokyo 105-8315, Japan
Phone +81-3-3435-6642
http://www.khi.co.jp/english/kplant/index.html

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