## Budgetary Proposal P006876 – Revision 4

to



# AEP SWEPCO

for



## Flint Creek Unit 1

Low NOx Combustion System

submitted by:

June 20, 2013

This document is the property of Babcock & Wilcox Power Generation Group, Inc. (B&W) and is acceptable for distribution by AEP solely to United States Federal and/or State regulatory agencies, upon their request, for the sole purpose of considering environmental permitting issues as related to AEP SWEPCO’s Flint Creek Station, Unit 1.

 2013 BABCOCK & WILCOX COMPANY POWER GENERATION GROUP, INC.
ALL RIGHTS RESERVED.Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Table of Contents Page TC-1

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### TABLE OF CONTENTS

Introduc tion .................................................................................................................. 1

Technical Di scussion ................................................................................................... 2

Scope of S upply ........................................................................................................... 3

Not Used ...................................................................................................................... 4

Schedule ...................................................................................................................... 5

Expected Perf ormance ................................................................................................ 6

DRB-4ZTM Experience List ........................................................................... A ppendix A

AireJetTM Burner Experi ence List ................................................................. Appendix B

DRB-4ZTM and XCL Referenc e List ............................................................. Appendix CLow NOx Combustion System Proposal No. P006876-R4
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Section 1 Page 1-1

Introduction

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### 1. INTRODUCTION

The following Budgetary Proposal, P006876, is submitted to AEP SWEPCO in response to your request.

The purpose of this Budgetary Proposal is to provide engineering, material, fabrication and delivery for the applicati on of AireJetTM or DRB-4Z burners and OFA at Flint Creek Unit 1, which is B&W unit RB-528.

This Budgetary Proposal is being submitt ed by Babcock & Wilcox Power Generation Group, Inc. (B&W) which has its home offices in Barberton, Ohio USA. B&W is a full scope supplier of steam generating equipment and accessories to the Industrial and Utility industry. Babcock & Wilcox Power Generation Group, Inc. has over 140 years of experience in the supply of material s and highly engineered products as well as current state of the art technology.

Babcock & Wilcox Power Generation Group, Inc. wishes to thank AEP SWEPCO for the opportunity to submit this Budgetary Propos al and to assure you that should this Budgetary Proposal result in a Contract, the Contract will be executed in accordance with industry standards of good engineering practice, fabr icated, and delivered in a timely manner. The scope of supply, pricing and terms proposed are as stated in this Budgetary Proposal.

Points of contact for questions and/or additional information are as follows:

Jim Graves District Sales Manager Dallas, Texas Phone: (972) 772-6011 jkgraves@babcock.com

Mark Zeiger District Sales Manager Cincinnati, Ohio Phone: (513) 326-4362 mazeiger@babcock.com Kevin Thomas Proposal Manager – Comb. Systems Barberton, Ohio Phone: (330) 860-2038 krthomas@babcock.com

Denis Osowski Regional Service Projects Manager Barberton, Ohio Phone: (330) 860-1787 dmosowski@babcock.com

Brian Benz Project Manager Barberton, Ohio Phone: (330) 860-6290 brbenz@babcock.comLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 2 Page 2-1

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### 2. TECHNICAL DISCUSSION

In response to AEP SWEPCO’s request for low NOx combustion modifications, B&W has provided two options for a staged co mbustion design which employs B&W’s
AireJetTM low NOx burners or DRB-4ZTM bur ners in combination with the addition of Overfire Air (OFA).

B&W AireJetTM Burner

Previously, low NOx pc-fired burners were des igned to carefully regulate the rate of

combustion in order to lim it peak temperatures (therma l NOx), and limit oxygen availability to the origin of t he flame (to limit fuel NOx). Over Fire Air (OFA) was then added to the system to further reduce NO x emissions. The B&W DRB-4ZTM burner was designed according to t hese fundamental principles.

However, the AireJetTM Burner is fundamentally different. It is the culmination of an

extensive research and devel opment program directed at reducing emissions during the combustion process. From inception, this technology integrates the use of air staging (OFA), a concept first conceived an d patented by Ralph M. Hardgrove of The
Babcock & Wilcox Co.

Air staging is used to reduce the burner zone below theoretical air requirements, that is, to an air/fuel stoichiometry less than 1.0. The purpose of the burner then changes with a goal of accelerating the combustion process. Accelerating combustion under air staged, fuel rich conditions quickl y generates an oxygen def iciency, producing hydrocarbons which prevent oxidati on of nitrogen, and decompose NOx formed earlier in the earliest portion of the flame (whi ch is unavoidably air rich). Accelerating combustion in a unique way not only reduc es the NOx emissions, but reduces the

need for excess air.

The AireJetTM Burner is uniquely formed ar ound an air jet along the center axis of the

burner . Extensive computer modeling and resear ch revealed that supplying air to the root of the flame, in pr oper proportion and by proper m eans, will greatly intensify combustion at this point. Pu lverized coal is ignited in t he furnace by interaction with hot secondary air. The rate of ignition is limited by the “wett ed surface” of the fuel jet, that is, the boundary which interf aces with secondary air. In clusion of an air jet in the center of the flame requires the fuel nozzle to expand to a larger diameter to enclose this. The center air, or core air, provi des a large boundary area to contact the interior portion of the fuel jet. In addition, the fuel nozzle diamet er is expanded to provide a
further increase in air/fuel boundary at the outer periphery of the fuel jet. Combined, the ignition surfaces are more than doubled with this approach. Rapid ignition by the

AireJetTM burner translates to an extraordi narily stable flame over a wide range ofLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
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Section 2 Page 2-2

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. conditions, including reduced fi ring rates, uncharacteristic of many slow mix low NOx burners (LNB’s).

Outside Ignition
Layer Air Rich

Outer Layer High
Intensity

Combustion Fuel Rich

NO

x Reduction

Inside Ignition
Layer Secondary Air Secondary Air

Pulverized Coal

and Primary Air 

# B&W AireJet ® 

# Burner

“Inside Out / Outside In” Combustion

• Core air matched to coal properties

• Rapid, stable ignition

• Accelerate rate of combustion—bellows effect

• Fuel rich longer = much lower NO

x

• Cleaner burning= lower XS air, higher efficiency

Rapid ignition is only the first step. The nex t step is to supply additional oxidant (air)
to the center of the AireJetTM burner flame. In proper propor tion, this air feeds ignition and greatly accelerates combustion (like a bellows) and generates high temperatures
in the root of the fl ame. The high temperatures in t he flame root actually cause more of the coal particle mass to gasify, or dev olatize, and these gases also proceed to quickly burn. The coal burns more rapi dly, leaving less char for final burnout reactions. In the process, oxygen is quickly consumed producing a highly fuel rich flame core. Resultant hydrocarbons then r educe NOx formed in the earliest stage of the flame, and prevent further NOx formation downstream.

The two secondary air streams which outwardly surround the fuel jet act in concert to produce a large IRZ (internal recirculation zone). These cause combustion products at the outer periphery of the flame to be recirculated into the fuel rich center for
destruction of NOx.Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-3

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

# •

. Core Air Inlet

Duct

Core Damper

Actuator Sleeve Damper

Actuator

Coal + Primary Air Inlet Ceramic Lined Nozzle

And Core Components Sleeve Damper Pitot Grid Outer Spin

Vanes

Inner Spin

Vanes

Burner Support
System 

# AireJet ® 

# Burner

Rapid combustion with the AireJetTM burner re sults in cleaner combustion, as the fuel burns much more thoroughly from the inside ou t, as well as from the outside in. Much lower CO emissions result, which enables operation with less excess air. Lower excess air increases boiler efficiency and reduc es fuel consumption. Low excess air also provides even lowe r NOx emissions.

The AireJetTM Burner is designed to match the c enter air flow rate to the coal(s) fired,

in order to maximize combustion close in to the burner. The center air is drawn from

inside the burner windbox compartment. Each burner is equipped with a damper to adjust the flow of air to the center of the flame (core air) . The core is ducted to a center chamber and tube formed within an expa nded coal nozzle. The interior of the
coal nozzle and exterior of the core asse mbly are lined with ceramics for long wear life. The tips and other front end portions of the burner are high qu ality stainless steel (309H) for excellent temper ature resistance and extended wear. Secondary air is supplied to the dual air zone burner air assembly, and regulated by an adjustableLow NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-4

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. slide damper. These air “register” asse mblies share the mechanical integrity and heavy-duty shop-assembled constructi on of B&W’s well proven DRB-4Z TM burners.

An Advanced Over Fire Air System is in tegrated with the AireJe tTM burners. The rugged, adjustable Dual Zone NO x ports supply the remaining air (OFA) necessary to complete combustion. Correct separ ation between the OFA system and burners provides time for more NOx reduction, and provides more complete char burnout ahead of the OFA system.

B&W’s AireJetTM Burner, in combination with Advanced Over Fire Air, achieves much
lower NOx with lower CO and with lower
excess air than other low NOx burners.Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-5

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. The DRB-4ZTM Burner

The DRB-4ZTM was conceptually developed us ing proprietary computational fluid dynamic computer modeling. Modeling uncovered the advantages of an additional air zone surrounding the burner nozzle in order to better control critical aspects of mixing around the core of the flame. A protot ype burner was then designed, constructed, and refined through an extensive program of large-scale com bustion tests. The tests were performed in B&W's state-of-the-art Clean Environment Development Facility (CEDF) in Alliance, Ohio. Ultimately, the DRB-4Z reduced NOx significantly beyond
our most advanced dual zone low NOx burner . These reductions were accomplished on sub-bituminous (PRB) and several bituminous coals.

The advanced DRB-4Z burner is designed to produce very low NOx emissions by

means of a transition zone that interfac es between the central oxygen-lean zone and the secondary combustion air.

The transition zone acts as a buffer betw een the fuel rich flame core and the secondary air streams. The flow field pr oduced by the transition zone draws gases from the outer portions of t he flame inward toward the fl ame core. NOx formed in the oxygen-rich outer flame region is reduced back to other nitrogenous species in the process. This results in significantly lo wer NOx emissions than what is achieved by
dual zone low NOx burners.Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-6

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. The mechanical design of the DRB-4Z dr aws heavily on the DRB-XCL burner, which has demonstrated excellent reliability in the se vere conditions prevalent in utility boiler service. Adjustable vanes provide on-line t uning capability, in a well-proven design. Each burner has air flow controlled by an adjustable slide damper, with relative air flow measurement provided by a multi-point pitot grid. The burner is shop assembled in one unit which is ready to install, usi ng the mounting hardware provided. A burner slide rail system consisting of supporting re ctangular tubing, bridgi ng windbox steel, and saddle supports is provide for each burner such that the entire burner load is transferred directly to the windbox steel and furnace waterwalls. This support system

insures that the burner can accommodate expected thermal expansions without
distortion of the waterwal ls or windbox casing.

These burners are constructed with heavy, hi gh quality stainless steel plate combined with a system of stiffeners to maintain stru ctural integrity at high temperatures.Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-7

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. The proposed DRB-4Z Burner includes many s pecific design features assuring long term reliability with minimal maintenance. Th is design avoids the use of the scroll burner inlet, flame holder device (flame stabiliz ation ring), or complex coal nozzle exit geometry which are oft en prone to erosion, initiation of coal nozzle fires, coking and

overheat distortion.



### DRB-4Z Burner
Mechanical FeaturesLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
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Section 2 Page 2-8

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. B&W Dual Air Zone Overfire Air (NOx) Port

Dual zone NOx ports and associated sliding dampers, spin vanes and air monitors are proposed to supply secondary air to the furnace to complete the two-stage combustion process, and optimally lower NOx emissions.

Optimum over fire air mixing characterist ics can be achieved with the Dual Zone NOx Port through its independent control of total ai r flow, air swirl, and air split between the penetration inner zone and va riable swirl outer zone.

Each Dual Zone NOx Port will be equipped with an automated linear actuator, which regulates a control rod that extends through the cover plate and ties to the total air flow damper. Regulation of this drive and damper will control the air flow to the port and thus allow for the adjustm ent of the burner zone stoich iometry as well as optimal air flow balancing between the por ts. Similar to the DRB-4Z TM Burner design, pitot grid air flow measurement devices are s upplied on each port for relative air flow

indication.

Spin vanes, located in the outer air zone of each Dual Zone NOx Port, can be adjusted to control the swirl of air from the port. Imparting more tangential velocity, orLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
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Section 2 Page 2-9

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. swirl, will flare the air flow pattern and pr ovide less penetration. This results in improved air flow mixing with furnace gases along the furnace side walls.

In addition, a biasing damper can be set to vary the air flow split between the inner and outer zones. Thus, air swirl can be adjus ted without affecting the air flow split between these zones. Optimization of penetra tion, swirl, and biasing settings of the
Dual Zone NOx Ports will be done during unit commissioning.

The Dual Zone NOx Port shares many of the rugged design feat ures of the DRB-4Z TM

and DRB-XCL Burner. These similar featur es include: stainless steel sleeves and spin vanes, moment arm lever spin vane adjustment, longitudinal stiffeners, rugged control rod design and support design.

Combustion System Design

The successful application of a staged low NOx combustion system (burner system with overfire air) to an existing coal fired boiler generally requires a tailored approach to each specific application. Variations in primary furnace geometries, extended heat transfer surface arrangements, furnace temperat ure profiles, coal fuel properties, coal pipe distribution, burner design, and extern al obstructions greatly influences the overall design approach of any retrofit low NOx combustion system. These same variables also greatly impact the ul timate NOx/CO reduction potential.

Maximizing in-furnace NOx reductions requires careful coordination and design of a complete burner system which includes low NO x burners, overfire air ports, balanced fuel, and good primary and secondary air dist ribution. The AireJetTM and DRB-4Z burners are specifically designed to operate deficient of the required combustion air to complete the combustion process (sub-stoichio metric). The overfire air system then provides the balance of the combustion air to complete combustion prior to exiting the primary furnace.

Several design principles govern the over all OFA System desi gn. These include vertical placement(s) of the OFA ports, t he quantity of secondary air diverted to the OFA system (design bulk stoichiometry), t he arrangement of the OFA ports within the furnace envelope, and the functional char acteristics of OFA ports themselves.

Fundamentally, deeper staging with longer resi dence time under fuel rich conditions most effectively reduces NOx emissions. C onsequently, a key factor is the residence
time available in the furnace. This is a f unction of the furnace size, fuel input, air flow rate, and flue gas density. The furnac e shaft above the burners and ahead of the OFA ports provides residence time under fuel rich conditions to reduce NOx emissions. The furnace shaft beyond the OFA ports provides residence time toLow NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-10

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. complete mixing and combustion before enter ing the convection pass. The vertical placement of the OFA ports is therefore critical to both NOx reduction and overall combustion efficiency (CO and unburned carbon). Ports placed too close to the burner zone will impair NOx r eduction performance. Ports placed too close to the
furnace exit can result in elevated levels of CO and unburned carbon, increased slagging in the superheater and reheater, and shifts in furnace exit gas temperature.

The quantity of secondary air provided to the OFA system is also a key factor. NOx

as a function of burner zone stoichiometry reaches a minimum as a function of coal properties, burner design, and re sidence time. Overall, the proposed OFA system is designed to divert enough secondary air away from the burners to achieve a these
stoichiometries at MCR conditions. The quantity of OFA influenc es not only the NOx performance but the mixing capability of OFA in the upper furnace.

The number, arrangement, and sizi ng of the of OFA ports for a given applications is based on the furnace gas to OFA mass flux ra tios, drift/penetration criteria, minimum horizontal coverage criteria, and the burner firing pattern. The sizing, included functionality, and arrangement of the indivi dual OFA ports are designed to provide necessary and sufficient mixing to achieve uniform flue gas species, temperature profiles, and complete the combustion proce ss prior to reaching the furnace exit.

B&W primarily uses our Dual Zone NOx Port design in staged combustion system applications. The functional design feat ures of Dual Zone NOx ports mentioned above provide the flexibility to achieve optim um over fire air mixing characteristics with the ability to independently control total air flow, air swirl, and air split between the penetration inner zone and variable swirl outer zone. Imparting more tangential velocity, or swirl with the adj ustable spin vanes will flare the air flow pattern while providing less penetration. Alte rnatively, biasing air towards the ports inner core zone increases penetration and mixing towards the c enter of the furnac e. The ability to optimize the mixing characteri stics of the OFA with the onl ine adjustable features of the B&W Dual Zone NOx Port helps to ens ure optimal site specific emissions performance.

B&W’s design standards governing all of the principles above have been developed utilizing a combination of lab scale testing, full furnace CFD Modeling, and empirical
field data collect from over 150 low NOx combusti on applications.

AireJetTM or DRB-4Z burners combined with an advanced OFA system using Dual Zone NOx ports provide the means to ac hieve minimum emissions of NOx and unburned combustibles. Adjustable comp onents within the bur ners and NOx ports enable tuning to optimize perform ance given site specific variations in flows and

conditions.Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 2 Page 2-11

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Site Specific Considerations and Solutions

The Unit 1 boiler at the Flint Creek Generat ing Station is an opposed-wall coal-fired unit (RB-528) designed by the Babcock & Wilcox Company (B&W). The boiler is a duplicate to RB-514, RB-529 and RB-571 (Welsh Units 1-3, respectively). The boiler has a nominal rating of 550 MWe, with a combustion system consisting of 42 dual register burners, arranged as 7 columns by 3 rows on both the front wall and the rear wall. There are no existing OFA ports.

B&W can offer a choice between a low-NOx co mbustion system which consists of 42

AireJetTM burners or 42 DRB-4Z burners. In each case, B&W proposes 12 dual-zone NOx ports to upgrade the existing combusti on system. Ports near the sidewalls are expected to be slightly larger than thos e on the inner columns to assure good air coverage along the sidewalls where we have found that high concentrations of CO

can exist.

COMO SM modeling software will be used to evaluat e the performance of the proposed combustion system and examine different conf igurations of the OFA ports in order to optimize combustion performance. Perform ance will be evaluated by comparing gas temperature, carbon monoxide concentrati on and oxygen concentration distributions throughout the furnace.

Six (6) B&W 89 pulverizers each supply coal to seven burners. The unit is equipped with compartmented windboxes w herein the burners associated with each pulverizer are separated into their own windbox compartment. Secondary air for each compartment is measured by airfoils (original equipment), and regulated with automated dampers at each compar tment entrance, as a functi on of coal feed rate to the respective pulverizer. Each compartm ent is fed from each end. The original

burners are 44” diameter Dual Registers.Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-12

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. All of the new AireJetTM and DRB-4Z burner s will be located at the existing burner
locations. Either of the new burners will also be included with ceramic throat tiles to reduce the existing throat diameter.

As part of the base bid, B&W has include d an engineering analysis of the complete PC piping system to provide a relative bal ance of coal flows between the coal pipes common to each pulverizer. This appr oach includes theoretical resistance

calculations on each individual burner line. Ceramic lined, fl anged venturi type resistor sleeves (orifices) are then siz ed and applied to balance each theoretical line
resistance within a common mill to within +/-2 .5%. The specific number of required resistor sleeves is not known until the analysis is complete.

OFA and Duct System Design

While the future OFA compartment and f eeder elbows are already in place, the proposed OFA system is designed with windbox extensions to enclose the NOx ports above the top level of burners. The existing air foils in the future OFA compartment will need to be removed, and turning vanes and a new airflow monitoring system will

be installed.

FPS Equipment

Included in the base price of this proposal will be the supply of new FPS ignitors, ignitor scanners, main flam e scanners, and blower skids. It is assumed that the current valve racks can be used, however, during the contract phase it could be determined that the existing valv e racks may not be suitable.

B&W Modeling Services

Within the fossil power generation industr y, B&W has a unique capability in computational fluid dynamics (CFD) and co mbustion modeling. The substantial investment in computational modeling made by B&W over the past twenty-five years
has culminated in COMO SM , our proprietary flow and com bustion model. COMO uses

an unstructured mesh with a mixture of element shapes for greater geometric flexibility, and adaptive mesh refinement to control resolution in regions of high gradients (e.g. turbulent jets, diffusion flames , etc.). It includes advanced capabilities for simulating turbulent flow, energy and radi ation, heterogeneous reactions, particles, surface reactions, gas phase reactions, and tube banks. COMO includes advanced sub-models for coal devolatilization, char burning and fuel-nitr ogen release. Gas phase chemical kinetics are simulated with any number of species and reactions,Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-13

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. using established reaction mechanisms, and including the effect of turbulence on

kinetic rates.

COMO has been used routinely at B&W for over a decade to improve the design and operation of boilers and boiler components. A wide variety of boilers have been modeled, including wall-fir ed, tangentially-fired, downshot, cyclone, recovery, and stoker. The boiler components modeled have included air-heaters, burners, NOx ports, sorbent injection systems, windboxes , selective catalytic reduction systems, flue work, and convection passes. The di verse capabilities of COMO have been proven through unique applications in coal gasification, coal and natural gas reburning, and off-gas combustion from steel smelters.

When modeling a boiler, the geometry is carefully depicted using a collection of control volumes (also called a computational grid or mesh ), such as is shown in Figure 1 for a wall-fired unit. Fundamental c onservation principles (conservation of mass, momentum, and energy) are then applie d to each of these control volumes, resulting in a coupled set of governing equ ations that are subsequently solved on high-speed computer processors to predict steady-state furnace performance. This model is augmented with empirical data such as rate parameters for coal pyrolysis,

coal devolatilization and char oxidat ion, wall and tube bank heat transfer conductance, and pressure loss coefficients for the tube banks. T hese parameters, as well as the ultimate analysis of the coal and the furnace operating conditions, are used as inputs to the COMO model. Mo re specifically, burners and OFA ports are
included in the model as flow inlets to the furnace at the appropriate wall locations. Swirl is added to the burner and OFA por t flows consistent with specified vane settings.Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-14

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. A sample of static graphical output is s hown in Figures 2 and 3. Those figures show contours of gas temperatur e and carbon monoxide concentration, respectively, for a 600-MW coal-fired boiler.

Computational Mesh on Boiler Surface Full Mesh and Enlarged View of Sel ected Burner and OFA Port Inlets 600 MW wall-fired pulverized-coal boiler Mesh in middle burner region Mesh in OFA port regionLow NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-15

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### Numerical modeling predictions of a 600 MW wall-fired

pulverized-coal boiler: contours of gas temperature.Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-16

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved.

### Numerical modeling predictions of a 600 MW wall-fired pulverizedcoal boiler: contours of carbon monoxide concentration.Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
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Section 2 Page 2-17

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### Option A: B&W FocalPointTM Optimization System

In addition to our base proposal, Babcock & Wilcox Power Generation Group, Inc (B&W) recommends B&W’s FocalPoint TM Optimization System to enhance combustion system performance. The Foca lPoint system is a real-time, closed-loop system that leverages B&W’s combustion system design experience to continuously control CO
and NO
x emissions.

The proposed system will in clude B&W’s FocalPoint TM advanced optimization software, an O 2 /CO emissions grid for the c onvection pass of the boiler, and
automation of the core air zone of the OF A ports. The FocalPoint system will be configured with proven optimization strategies designed specifically for improved CO
and NO
x control using B&W’s dual-zone OFA ports.

The FocalPoint system is currently used at AEP Welsh 3 for combustion optimization to control NO x and CO emissions as we ll as Reheat Outlet Temperatures.

System Description

B&W’s experience has been that optimal low NO
x operation is achieved through effective mitigation of CO em issions that accompany low NO
x combustion. Further, it has been proven that proper continuous adjustment of B&W’s dual-zone OFA port
maintains reduced CO and NO
x emissions through varying operating conditions.Low NOx Combustion System Proposal No. P006876-R4
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Section 2 Page 2-18

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Figure 1 FocalPoint Optimization System

Figure 1 illustrates how the FocalPoint system integrates with the DCS to provide advanced supervisory control. The FocalPoint system includes twelve (12) O 2 and CO probes – one for each OFA port – to pr ovide emissions information that can be tied to each OFA port. The FocalPoint softwar e uses this information, in coordination with its optimization strategi es, to pinpoint the most effe ctive response to control CO
and NO
x emissions. The system then adjusts the air distribution at the OFA ports to
maintain low CO and NO
x emissions for the current conditions.

The optimization strategies utilized by the FocalPoint system are designed for effectiveness in all operating conditions. This ensures that CO and NO
x emissions are minimized throughout the entire load range and in all mill configurations.

FocalPoint Advanced Optimization Software

The FocalPoint software f eatures numerous models, f unctions, and algorithms that may be customized for any optim ization problem. Key to the system is the intuitive graphical analysis and logic development envir onment, as shown in Figure 2. The FocalPoint system can function as an advisor y or a supervisory system with the mode of operation being selectable by operations personnel. When employed as part of a combustion optimization system, the FocalPoint program includes advancedLow NOx Combustion System Proposal No. P006876-R4
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Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. combustion control algorit hms developed from B&W Res earch and Development and field experience. When in supervisory mode, FocalPoint typically effects changes in operations by influencing the biases associat ed with particular DCS control loops. In open-loop mode, FocalPoint provides t he operator with information on the best settings for control biases of the same DCS control loops.

Figure 2 FocalPoint Analysis a nd Logic Development Environment

An example of the effectiveness of the Foca lPoint Optimization System in closed-loop mode is shown in Figure 3 below. The system continuously works to reduce the
absolute NO
x and CO emissions so that optimal combustion can be achieved for the current operating conditions.Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 2 Page 2-20

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Figure 3 Results of FocalPoi nt Control of CO Emissions

Commissioning

These services comprise the effort nece ssary to commission the FocalPoint system once the burners have been tuned by B&W. It in cludes on-site service to assist with the installation and start up of the Foca lPoint system and conduct training. The FocalPoint training consists of classr oom training as well as hands-on training.

Software Maintenance

The FocalPoint Software Program is cont inually updated to include new features and capabilities. For example, new strategies and algorithms are fr equently added into
the FocalPoint software. Software Maint enance permits the user to receive all software program updates and upgrades. In order for the customer to receive these upgrades in a timely fashion, VPN access to the installed FocalPoint system is strongly suggested. The first year of softw are maintenance is included in the system price.Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 2 Page 2-21

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Engineering Support

Engineering Support provides the user wit h remote technica l support for the FocalPoint system. For this service to be mo st effective, VPN access to the installed FocalPoint system is needed. The first y ear of engineering support is included in the system price.

Scope of Supply

The specific scope of supply for the FocalP oint system for this project includes:

Twelve (12) ABB SMA O 2 & CO Smart Analyzers which will be installed in the vertical convection pass to provide O 2 and CO emissions information to the combustion optimization system . DCS programming to incorporate the analyzers into
the DCS is not included.

Twelve (12) Beck Linear Drives to automate the core air zone of the OFA ports. Mounting hardware will also be supplied with the drives. DCS programming to incorporate the drives into the DCS is not included.

One (1) FocalPoint Advanced Optimization Software to analyze combustion and implement advanced control to maintain low CO and NO
x emissions. The FocalPoint software operates on a Windows-based server that is supplied with the optimization system. The FocalPoint system also uses industry standard communications protocols like OPC and Modbus for integration with the DCS.

Engineering Services for installation support and startup of the system.

Installation Arrangement Drawings will be provided for the analyzers and drives to support the equipment installation. Mechani cal and electrical installation of the system is not included.

FocalPoint Software Maintenance – The FocalPoint Software program is continually updated to include new features and capabilities. FocalP oint Software Maintenance permits the user to receive all software program updates and upgrades. FocalPoint
Software Maintenance is made easier with VPN access to the installed FocalPoint system which allows B&W to install updates and upgrades remotely. However, VPN access is not required. The first year of software maintenance is included in the system price.Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 2 Page 2-22

Technical Discussion

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. FocalPoint Engineering Support - Engineering Support prov ides the user with remote technical support for the FocalPoint system. Engine ering Support is facilitated

with VPN access to the installe d system but it is not required. The first year of engineering support is included in the system price. FocalPoint Engineering Support

includes:

 Troubleshooting over the phone and via the VPN connection, if available

 Email contact supportLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-1 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### 3. SCOPE OF SUPPLY

Section 2, Technical Discussion, described the modifications that B&W proposes for
Flint Creek Unit 1. Following is the Scope of Supply lis ting that further defines B&W’s offer. Equipment and/or services not incl uded in this scope of supply listing are not included in this proposal offering. Please re fer to the terminal points listing, and other information in this proposal for further clarification of the proposed scope.

Item 1: Ultra Low NOx AireJetTM Burners

Qty 42 – B&W, AireJetTM, Low NOx bur ners equipped for coal firing.

Each burner to include:

 Externally adjustable out er air zone spin vanes

 Burner sliding air disk manual ratchet drive

 Pitot tube relative air flow meas uring device with ma gnehelic gage

 Provisions to accept new FPS Oil Ignitors

 Provisions to accept new FPS flame scanners

 Three Type K permanent thermocoupl es to monitor coal nozzle and burner outer sleeve temperature with common junction box shop mounted on burner coverplate

 Field insulated burner coverplate

 Burner support rails and attachment hardware

 Ceramic throat tile assemblies to reduce existing furnace waterwall openings

 Manual rotary handles for co re air butterfly dampers

 Segmented, ceramic lined coal elbow with removable backLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-2 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 1 Lot – Burner line resistor sleeve engi neering analysis to identify number and sizing of resistor sleeves. Each r equired resistor sleeve includes flanges, nuts, bolts, washers and gaskets. Pric ing supplied in Section 4 will be per resister sleeve – the exact quantity (up to 36) will be determined during the contract phase.

Qty 12 – Dual Zone OFA Ports

Each OFA port to include:

 Barrel assembly with pitot tube relative air flow measuring device

 Externally adjustable out er air zone spin vanes

 Manually adjustable biasing damper for adjustment of the air flow split

between the inner and outer zones

 Total air flow control damper with Beck linear drive

 Field insulated cover plate

 Slip seal ring for attachment and seal to the furnace wall

 Two, Type K permanent thermocouples to monitor core air sleeve and port outer sleeve temperatur e with common shop mounted thermocouple junction box

 Four - Mass Air flow measurem ent equipment for each OFA windbox feeder duct. Pitot grid type device to be supplied with integral temperature measurement for direct output of mass air flow.

 Dual Zone NOx Port support rails and attachment hardwareLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-3 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Qty 2 – New OFA windbox ex tension, one on the front fu rnace wall and one on the rear furnace wall, supplied to ho use the new OFA Ports and convey secondary air to the new OF A port inlets. Each exte nsion will be constructed with an internal suppor t steel structure with ca sing and stiffeners and designed for current NFPA internal pressu re requirements and be compatible with new boiler pressure in crease requirements.

Item 2 – Low NOx DRB-4Z TM Burners

Qty 42 – DRB-4Z Burner Assemblies (Plug-In) low NOx burners equipped for coal firing.

Each burner to include:

 Externally adjustable out er air zone spin vanes

 Externally adjustabl e transition zone damper

 Burner sliding air disk manual ratchet drive

 Pitot tube relative air flow meas uring device with ma gnehelic gage

 Ceramic lined coal nozzle, with alloy tip

 Ceramic lined coal elbow

 Coal nozzle diffuser and deflector f abricated from silicon carbide wear

material

 Provisions to accept new FPS Oil Ignitors

 Provisions to accept new FPS flame scanners

 Three Type K permanent thermocoup les to monitor coal nozzle and burner outer sleeve temperature with common junction box shop mounted on burner coverplate

 Ceramic throat tile assemblies to reduce existing furnace waterwall openings

 Field insulated burner coverplateLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-4 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved.  Burner support rails and attachment hardware

1 Lot – Burner line resistor sleeve engi neering analysis to identify number and sizing of resistor sleeves. Each r equired resistor sleeve includes flanges, nuts, bolts, washers and gaskets. Pric ing supplied in Section 4 will be per resister sleeve – the exact quantity (up to 36) will be determined during the contract phase.

Qty 12 – Dual Zone OFA Ports

Each OFA port to include:

 Barrel assembly with pitot tube relative air flow measuring device

 Externally adjustable out er air zone spin vanes

 Manually adjustable biasing damper for adjustment of the air flow split

between the inner and outer zones

 Total air flow control damper with Beck linear drive

 Field insulated cover plate

 Slip seal ring for attachment and seal to the furnace wall

 Two, Type K permanent thermocouples to monitor core air sleeve and port outer sleeve temperatur e with common shop mounted thermocouple junction box

 Four - Mass Air flow measurement equipment for each OFA windbox feeder duct. Pitot grid type device to be supplied with integral temperature measurement for direct output of mass air flow.

 Dual Zone NOx Port support rails and attachment hardwareLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-5 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Qty 2 – New OFA windbox ex tension, one on the front fu rnace wall a nd one on the rear furnace wall, supplied to ho use the new OFA Ports and convey secondary air to the new OF A port inlets. Each exte nsion will be constructed with an internal suppor t steel structure with ca sing and stiffeners and designed for current NFPA internal pressu re requirements and be compatible with new boiler pressure in crease requirements.

Item 3: Fossil Power Systems Oil Igniters (same scope applies to both Item 1 and Item 2)

Qty 42 – FPS 4.5” Oil Igniters will be supplied for ignition of the main fuel.

Each igniter includes:

 SunSpot ignitor flame detector elec tronic module (mounted in valve rack cabinet)

 SunSpot flame rod complete with hi gh temperature extension and metal braided flex conduit assembly

 Plasma Arc Ignition (PAI) system, wit h the burner-front Power Pack in a

NEMA 4 enclosure.

 Low voltage spark plug assembly complete with high temperature

extension and metal brai ded flex conduit assembly.

 1⁄4” X 48” stainless steel oil hose with quick coupler.

 3 ⁄

8 ” X 48” stainless steel air hose with quick coupler.

 Combustion/cooling air connection with gate valve for adjusting air flow. Each ignitor requires 140 SCFM of co mbustion air at 2-4” above furnace

pressure.

Item 4: OFA Insert Panels

 Qty 12 - New bent tube waterwall openings - 1 for each OFA port

 CFD modeling of the OFA systemLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-6 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Option A: B&W FocalPoint TM Optimization System

The proposed system will in clude B&W’s FocalPoint TM advanced optimization software, an O 2 /CO emissions grid fo r the convection pass of the boiler, and automation of the co re air zone of the OFA ports. The

FocalPoint TM system will be configured with proven optimization strategies designed specifica lly for improved CO and NO
x control using B&W’s dual-zone OFA ports.

Option B: Fossil Power Syst ems Main Flame Scanner System

B&W understands that Flint Creek 1 has a relatively new Forney flame scanning system and AEP is happy with its performance. B&W wishes to note that a new flame scanning syst em is not inherently required with the new burners. AEP may consi der the FPS scanner system as optional scope and not absolutely necessa ry if the existing system is will

be retained.

It should be recognized that reuse of the existing scanners may or may not require some modification to that system. Costs for modification of the Forney equipment for reuse wi th the new burners has not been included herein but B&W would expect such costs to be minimal if any.

FPS main flame scanning system to included:

Qty 42 – FPS rigid fiber-optic, dual-color (VIS/IR) flame scanners for monitoring main coal flames. The flame scanners shall be tuned for black furnace protection and individual burner

discrimination.

Qty 42 – FPS fiber optic scanner guide pipes and associated mounting hardware with cooling ai r connection. Guide tube is equipped with an attached plug / air flow rest rictor for installation in the guide tube when the viewing head is removed.

Qty 21 – Two-channel burner front j unction boxes complete with 23 ft prefabricated cables (2 each) for connecting to two scanner

heads.

Qty 1 – Skid mounted duplex blower assembly. Blower is sized to supply combustion air for 42, FPS 4.5” oil ignitors and cooling air for 42, FPS Fiber Optic Flame ScannersLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-7 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Option C: Fossil Power Systems Duplex Blower Skid and Air Piping

B&W understands that Flint Creek 1 has igniter combustion and scanner cooling air blower systems which are re latively new and it is likely these

blower and their associated air piping systems can be reused. However, if it is found that the air requirement of the new igniters cannot be met by the existing blower and/or a new scanner system is elected which requires more air than the existing system can supply, B&W offers to furnish a new FPS duplex blower ski d and associated piping to supply the required combustion and cooling air.

Skid mounted duplex blower assembly is sized to supply 125% combustion/cooling air for (42) FPS 4. 5” oil ignitors (42) main flame scanners. The duplex blower skid and piping will include:

Qty 2 – Blowers with direct drive, premium efficiency motors (Motors sized to handle unrestricted flow)

Qty 2 – Check valve and butterfly isolation valve on each blower outlet

Qty 1 – Common discharge pipe wit h pipe stub outlet and rubber sleeve with clamps

Qty 2 – Inlet filter-silencers

Qty 2 – Inlet pressure switches

Qty 2 – SPDT pressure switches to monitor discharge pressure, wired

into starter circuits to allow automatic switchover on loss of discharge pressure

Qty 2 – Air connections to pressure switches factory installed

Qty 2 – Circuit breaker type fu ll voltage combination starter assemblies in NEMA 4X enclosures, each with switches and indicators to allow local control and monitoring of blower operation. Starters are fa ctory mounted on blower skid and
wired such that loss of dischar ge pressure will automatically cause the standby blower to start

1 Lot – Pre-wired connections between motors, starters and pressure

switchesLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-8 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Qty 1 – Common Pipe Discharge (plain pipe end)

1 Lot – Air piping and supports from the blower ski d to the burner
fronts.

General Services Scope of Supply Included Unless Noted Otherwise

 Field Service Engineering support totali ng up to 50 man-days over the scheduled installation outage including pre-outage acti vity. B&W Field Service Engineer(s)
will assist AEP SWEPCO with on-site trai ning, commissioning and start-up of the new burner system and associated equipment furnished by B&W.

 Burner system operator training pe r the conformed specifications

 Tuning and Guarantee performance test ing services including temporary emissions monitoring equipment, gas samp ling test probes, and required test personnel. Performance testing will incl ude a combustion system design engineer for complete unit tuning. The provided te st sampling is intended for use during the optimization and tuning peri od. Due to the erosive flue gas environment, these probes would need to be removed from the duct and re-inserted on an as-needed basis and are not permanent instrumentation.

 Brickwork Refractory Insu lation & Lagging (BRIL) design

 Operating and Maintenance Manuals

 Delivery F.O.B. Flint Creek Power Station

 System Requirements Specification, I/ O Listing, Functional Logic Diagrams,

Process & Instrumentation Di agrams for supplied equipment

 Site visits to ensure fit up and confirm the design with regard to interferences

 Project ManagementLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-9 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. Items Not Included

The following list is provided as a convenien ce to illustrate the items and services NOT included in the proposed scope of supply. Items listed below may be required for proper unit operation but are outside the scope of this proposal. There is no implication that it ems not listed will be furnished by B&W.

 Coal line resistor sleeves, although t he engineering analysis to determine the necessary quantity is. Per unit resistor sl eeve pricing is provided in Section 4 of this proposal

 Burner related refractory, refracto ry re-work or refractory clean up

 Demolition or installation services

 Insulation and lagging ma terials or installation

 Permits, licenses, and other Governmental Agency permission required to construct and operate the proposed equipment

 Design, supply, and installation of existi ng control system I/O hardware additions (if required) for the proposed burner equipment

 Finish painting of B&W-furnished burner equipment. If applicable, the equipment would be provided with a shop-applied prim er coat. Vendor-supplied equipment
would be furnished with the vendor's standard finish

 Federal, State or Local sales and use taxes

 Bid bond, performance bonds , or security deposit

 Electrical and Controls-related items as follows:

o Site Specific Configuration drawings

o Control system hardware and/or software (including programming) except as noted in the scope of supply items listed above

o Confirmation or modification of existing logic

o Power supplies

o Wiring design, supply, or inst allation between Contractor’s equipment and the DCS or power supplies

 Ignitor oil main headers, regulating stat ions, pumps, or anything upstream of theLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 3 Page 3-10 Scope of Supply

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. inlet flanges at the FPS oil contro l valve racks on each burner elevation

 Hydrostatic testing

 Boiler circulation analysis

 Drawings in native file formats (i.e., .dwg).

 Commissioning Spares or replacement partsLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 4 Page 4-1

Not Used

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### 4. NOT USEDLow NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 6 Page 6-1 Expected Emissions Performance

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### 5. SCHEDULE

This budgetary schedule is based upon availability of Babcock & Wilcox Power Generation Group, Inc. resour ces at the time of this Budgetary Proposal. These resources are subject to conditions of prior sale which may affect the final contract schedule. Upon notification of award, this preliminar y information will be reviewed
with AEP SWEPCO and a contract schedule would be issued.

Milestone Weeks

Receipt of Acceptable Purchase Order 0

Engineering Release of Purchased Material Orders 8

CFD Modeling to Determine Size and Position of OFA Ports 10

Rev-0 General Arrangement Drawings Submitted 20

Start Pressure Part Fabrication 22

Start Burner Fabrication 26

Delivery to Site – Pressure Parts 34

Midpoint of Burner Fabrication 36

Delivery to Site – Burner Components 46Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 6 Page 6-1 Expected Emissions Performance

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. 

### 6. Expected Emissions Performance

When the steam generating unit is retrofi tted with new combustion equipment as described in this proposal, the Contractor expects the following unit performance.

The ranges of expected emissions perfo rmance below may be subject to some variation depending on the final, mutually agreed design/guarant ee basis operating conditions. Further, if the conditions duri ng performance testing differ from the design/guarantee basis, then the as measur ed performance will be corrected to the design/guarantee basis conditions in a ccordance with the ASME Power Test Code (PTC).

The precise NOx emission rate the unit ul timately runs at will depend on burning a

PRB coal with certain constituent limits. The ranges below attempt to capture the range of performance applying B&W’s known database of PRB coal.

Expected Emissions

A. Nitrogen Oxide (NOx) Emissi ons (“Full Load” Condition)

The average NOx emission rate over a si ngle 4 hour test period, expressed as NO 2 , leaving the economizer is expecte d to be with the following ranges:

Table 6.1: Expected NOx

Equipment Condition NOx ( lb/ 10 6 Btu/hr)

AireJet Burners (Item 1) 42 or 35 Burners in Service
@ MCR Load 0.145 – 0.20

DRB-4Z Burners (Item 2) 42 or 35 Burners in Service
@ MCR Load 0.165 – 0.218

The NOx ranges in Table 6.1 account for the number of burners in service at MCR

and also for the variation in fuel charac teristics that B&W has recorded as being associated with PRB coals of the type expec ted to be used at this facility.

The precise NOx and CO emission rates as measured at the time of the performance
test will be a result of the combustion equipment type and design selected and will also be a result of the specific operating cond itions and fuel characteristics associated with this facility as described in section 6.C and 6.D below.Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 6 Page 6-2 Expected Emissions Performance

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. B. Carbon Monoxide (CO) Emissions (“Full Load” Condition)

The average CO concentration in t he flue gas leaving the economizer and corresponding with the NOx emissions values presented in table 6.1 will not exceed 200 ppm by dry volume, corrected to 3% O 2.

C. Fuel Impacts

Certainly, coal quality impacts NOx emi ssions and changes from one analysis to the next can produce slightly different expectations for such emissions.

As part of the emissions performance evaluation above, B&W considered the approximately 50, “as-received” PRB coal analyses in our database. When NOx

emissions are considered ac ross the range of those PRB coals, B&W predicts that NOx emissions may fluc tuate about 0.03 lbs/10 6 Btu/hr across the range and this variation has been included in table 6.1 above. Fuel analysis fluctuation is one reason why sometimes day-to-day NOx perfo rmance of a boiler varies from the original guarantee values.

Indirectly, coal quality may affect unit operation which impacts NOx performance. One example of this would fuel that is more prone to slagging or fuel that is wet. In such instances, plant operations may requi re that excess air be raised to minimize slagging but increasing excess air almo st always means an increase in NOx

emissions.

D. Operational Impacts

B&W typically expects degradation in NO x emissions performance of about 10% given any one pulverizer group out of service except if that group is associated with a top burner row. For a top row pulverizer group out of service, NOx emissions would be expected to be no worse than with all burners in service. This variation has also been included in the range of perfo rmance listed in table 6.1.

Although it is not possible to quantify t heir precise effects, other operational parameters which may impact NOx and CO performance include excess air to combustion equipment, secondary air temperatur e, pulverizer exit temperature, line to line coal balance, and windbox static pressure.Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 6 Page 6-3 Expected Emissions Performance

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. E. Operational History

Other recent radiant boiler (R B) units with AireJet burners installed and without SCR’s

so EPA emissions data would be available to demonstrate day-in-day-out emission

levels are:

 Nebraska Public Power – Ge rald Gentleman Unit 2 (2012)

 Basin Electric – Laramie River Unit 1 (2012)

 PacifiCorp – Wyodak (2011)

 City of Sikeston (2013)

Other recent radiant boiler (RB) units with DRB-4Z burners with OFA installed and
without SCR’s so EPA emissions data would be available to demonstrate day-in-dayout emission levels are:

 Portland General Elec tric – Boardman (2011)

 AEP SWEPCO – Welsh Units 2 & 3 (2005, 2001)

 Public Service of New Mexico – San Juan Unit 3 & 4 (2008)Low NOx Combustion System Proposal No. P006876-R4
AEP SWEPCO June 20, 2013
Flint Creek Unit 1

Section 6 Page 6-4 Expected Emissions Performance

Copyright  2013 Babcock & Wilcox Power Generation Group Inc. All rights reserved. To provide additional detail on one of t he units above, the below chart shows the performance over the load range for Gerald Gent leman Unit 2. This unit was retrofit

with AireJet burners in 2012 and conti nues to operate within its guaranteed

emissions.

The plotted trend of load versus emissions is typical of the Aire Jet burner with higher NOx rates occurring at due to higher levels of excess air being applied.