FUEL TECH, INC. 120 Long Ridge Road  STAMFORD, CONNECTICUT 06902  PH: [203] 323-8401  FX [203] 967-2366 

 Alexander S. Dainoff 

 Regional Sales Manager 

 September 7, 2010 

Mr. Kenneth Yager 

Compliance Manager 

Ravenswood Generating Station 

TransCanada 

38-54 Vernon Boulevard 

Long Island City, NY 11101 

RE: FUEL TECH COMBINED NOx EMISSIONS CONTROL PROCESS 

UNITS 10, 20 AND 30, 

RAVENSWOOD GENERATING STATION 

 FUEL TECH PROPOSAL NO. 10-B-160 

Dear Ken: 

It was a pleasure meeting with you and Lorna Lynum the other week to discuss NOx control 

options for the Ravenswood Station. As you requested, Fuel Tech is pleased to enclose our 

initial budgetary estimate an integrated technology approach to reduce the NOx emissions 

on the three Ravenswood Generating station units to meet the pending NOx limit of 

0.15lbs/mmBTU while burning 100% fuel oil. For this estimate, we combined three proven 

technologies; Low NOx Burners (LNB), Separated Over-Fire Air (SOFA) and urea based 

SNCR; that in combination will provide the NOx reduction required while minimizing overall 

capital and O&M costs. 

Fuel Tech is a High Technology, Environmental Company that has developed internally and 

through acquisition a number of advanced air pollution control technologies as well as 

advanced combustion and CFD flow modeling capabilities. This has been built around a 

core of experienced professionals that can bring together a number of disciplines to provide 

economic, flexible and reliable solutions to meet environmental requirements. Therefore 

Fuel Tech can provide viable technological solutions with meaningful performance 

guarantees and has the resources to back them up. 

The evaluation for the Ravenswood units was based on the information provided to provide a 

combined total NOx reduction of approximately 40% from the current NOx emissions level of 

0.24lbs/mmBTU to a target level of 0.145lbs/mmBTU while burning 100% Fuel Oil. This is 

based on the following combined technologies: 

• LNB and SOFA providing a 29% NOx reduction from 0.24 to 0.17lbs/mmBTU 

• NOxOUT® Urea Based SNCR providing approximately 15% NOx reduction from 0.17 

to 0.145lb/mmBTU 
CONFIDENTIAL Do Not Duplicate 

Mr. Kenneth Yeager September 7, 2010 

Ravenswood Units 10, 20 and 30 Proposal No. 10-B-160 

NOx Control Evaluation Estimate Page 2 

Low NOx Burners: 

The Low NOx Burners upgrade would consist of specifically designed Low NOx Atomizers 

and curved bladed swirlers. The atomizer is designed to devolitilize the fuel oil in a fuel rich 

zone at the burner outlet This inhibits the conversion of fuel bound nitrogen to NOx. Oil 

droplets are controlled in a tight size range to ensure complete burnout and limited opacity. 

Separated Over-Fire Air: 

Fuel Tech’s SOFA system deeply stages combustion for enhanced NOx reductions. The 

SOFA system for these units would use the existing fans and divert air from the burners and 

existing Closed Coupled Over-Fire Air (COFA) system to a Separated OFA installed above 

the Windbox to create a fuel rich zone in the lower furnace. This reduces the fuel bound 

nitrogen conversion to NO. In addition, peak flame temperatures are reduced to limit thermal 

NOx formation. A high momentum air stream intersects the burner combustion gases in the 

upper furnace to complete combustion prior to the boiler convection section. 

The SOFA ports would be specifically sized and shaped to maximize combustion air 

penetration and furnace coverage. The combustion air is fed to the ports through 310SS 

ducts with automated damper controls to allow for tuning through the load range. 

Selective Non-Catalytic Reduction (SNCR) 

Fuel Tech’s NOxOUT® Selective Non-Catalytic Reduction NOx Control Process involves the 

injection of an aqueous urea based solution through injectors installed through the water 

walls in the upper furnace of each boiler to reduce NOx. The urea solution is injected into 

the gas stream and will react with NOx at temperatures between 1600 and 2200°F. Droplet 

size and dilution rates are automatically controlled to maximize the distribution of the reagent 

in the gas stream. 

The SNCR system for this application would consist of common 2 x 45,000gallon heated and 

insulted reagent storage tanks that would feed to a common circulation module installed in a 

heated prefabricated enclosure to be located near the tanks. A circulation loop will feed 

individual Independent Zone Metering Modules for each boiler. This in turn will automatically 

meter the urea reagent into a dilution water stream to feed one level of wall injectors per 

furnace. Distribution Modules at each injection level will control diluted reagent and air flow 

to each injector. 

The reagent feed is automatically controlled to maintain a targeted NOx level based on a 

load signal used as a feed forward with a feedback from the CEM. The control system has 

been successfully utilized in most of the over 600 SNCR systems installed world wide and 

can be specifically configured based on the plant requirements. 

The NOxOUT A® 50% urea based reagent would be delivered by tank truck from Licensed 

Reagent Suppliers. 
CONFIDENTIAL Do Not Duplicate 

Mr. Kenneth Yeager September 7, 2010 

Ravenswood Units 10, 20 and 30 Proposal No. 10-B-160 

NOx Control Evaluation Estimate Page 3 

Fuel Tech’s Advanced CFD Modeling capability would be utilized in the design of each of 

these technologies which would be integrated to maximize the combined performance. 

By integrating these technologies, the SNCR system has sufficient flexibility to act as a 

process trim by automatically adjusting reagent feed to maintain the overall NOx emissions 

target. 

Enclosed below is a summary of the estimated capital and O & M cost for the installation and 

operation of these technologies on the Ravenswood Station Units. 

This estimate is based on the following assumptions: 

 

 Unit 10 Unit 20 Unit 30S Unit 30N

Unit Size, MW 363 363 500 500 

Heat input, mmBTU/hr 3,195 3,195 4,218 4,218 

Capacity Factor 20% 

Annualized Capital Cost 10% 

Estimated Reagent Cost $1.25/gallon 

 (50% Urea) 

Baseline NOx 0.24lbs/mmBTU 

LNB and SOFA 

• NOx Reduction 29% 

• Target NOx 0.17lbs/mmBTU 

• Total Installed Cost $7 to $9/kw 

• O&M Minimal 

SNCR System 

• NOx Reduction 15% 

• Baseline NOx 0.17lbs/mmBTU 

• Target NOx 0.145lbs/mmBTU 

• Total Installed Cost $6 to $7/kw 

• O&M 

o Reagent Feed NSR (Normalized Stociometric Metric Ratio) of 0.9. 

o Utilities 

 Power 100 to 120KW (480 VAC, 3-Ф, 60 Hz) 

 Dilution Water 30 to 60gpm 

 Air 500 to 700scfm @ 60 to 80psig 
CONFIDENTIAL Do Not Duplicate 

Mr. Kenneth Yeager September 7, 2010 

Ravenswood Units 10, 20 and 30 Proposal No. 10-B-160 

NOx Control Evaluation Estimate Page 4 

3-Sep-10 TransCanada Ravenswood Units 10, 20 and 30 

ProForma Economics 

Proposal 10-B-160 

 

ASSUMPTIONS Unit 10 Unit 20 Unit 30 A Unit 30 B 

 Unit Size, kw 363,000 363,000 500,000 500,000 

 Heat Input mmBTU/hr 3,195 3,195 4,218 4,218 

 Capacity Factor, Oil 20.00% 

 Annualized Capital Cost 10.00% 

 Estimated Reagent Cost $/gal $1.25 

 

LNB and OFA 

 Baseline NOx lbs/mmBTU 0.24 0.24 0.24 0.24 

 Baseline NOx lbs/hr 766.8 766.8 1012.32 1012.32 

 

 Target NOX lbs/mmBTU 0.17 0.17 0.17 0.17 

 Target NOX lbs/hr 543.2 543.2 717.1 717.1 

 NOx reduced, lbs/hr 223.7 223.7 295.3 295.3 

 NOx Tons Reduced /year 195.9 195.9 258.6 258.6 

 

 Installed cost $/kw 8 8 8 8 

 Installed Cost $2,904,000 $2,904,000 $4,000,000 $4,000,000 

 Annualized Cost $290,400 $290,400 $400,000 $400,000 

 Treatment Cost $/ton of NOx removed $1,482.26 $1,482.26 $1,546.50 $1,546.50 

 

SNCR 

 Baseline NOx lbs/mmBTU 0.17 0.17 0.17 0.17 

 Baseline NOx lbs/hr 543.2 543.2 717.1 717.1 

 % NOx reduction 15% 15% 15% 15% 

 Target NOX lbs/mmBTU 0.145 0.145 0.145 0.145 

 Target NOX lbs/hr 463.3 463.3 611.6 611.6 

 NOx reduced, lbs/hr 79.9 79.9 105.5 105.5 

 NOx Tons Reduced /year 70.0 70.0 92.4 92.4 

 

 Installed System Cost $/kw 6.5 6.5 6 6 

 Installed System Cost $2,359,500 $2,359,500 $3,000,000 $3,000,000 

 System Annualized Cost $235,950 $235,950 $300,000 $300,000 

 O&M 

 NSR 0.9 0.9 0.9 0.9 

 Reagent Consumption gph 67.0 67.0 88.4 88.4 

 Annual Reagent Consumption, Gal 117,332 117,332 154,900 154,900 

 Estimated Reagent Cost $146,665 $146,665 $193,626 $193,626 

 Reagent Treatment Cost $/ton of NOx removed $2,096.10 $2,096.10 $2,096.10 $2,096.10 

 Total SNCR Treatment Cost $/ton NOx removed $5,468 $5,468 $5,344 $5,344 

 

TOTAL SYSTEM COST 

 Total NOx Removed, tons/year 265.9 265.9 351.0 351.0 

 Total Annualized Capital Cost $526,350 $526,350 $700,000 $700,000 

 Total Operating Cost/year $146,665 $146,665 $193,626 $193,626 

 Total Annualized Cost $673,015 $673,015 $893,626 $893,626 

 

TOTAL COST $/TON OF NOx REMOVED $2,531.20 $2,531.20 $2,545.78 $2,545.78 
CONFIDENTIAL Do Not Duplicate 

Mr. Kenneth Yeager September 7, 2010 

Ravenswood Units 10, 20 and 30 Proposal No. 10-B-160 

NOx Control Evaluation Estimate Page 5 

Therefore the combination of the LNB, SOFA and SNCR provides a proven, flexible and 

economic approach to meeting the new NOx requirements while burning 100%oil. By 

combining these technologies, they will typically operate within their respective “performance 

comfort zone”, mitigating potential downstream problems and increasing reliability. 

I hope this information is sufficient and look forward to the opportunity of meeting with you in 

the near future to review the details of this approach and the requirements for a more 

detailed proposal. Meanwhile, if you have any questions or if you need more detailed 

information on this application, please do not hesitate to call me. 

 Very truly yours, 

 Alexander S. Dainoff 

 

Enclosure: 

cc: Lorna Lynum, TransCanada 

 Bob Hall, AECOM 

William Cummings, Fuel Tech, Inc. 

 Terry Brown, Fuel Tech, Inc. 

Kevin Dougherty, Fuel Tech, Inc. 

Pete Hauser, Kissick Company 
CONFIDENTIAL Do Not Duplicate 

EXHIBIT C3

FUEL TECH, INC. STANDARD TERMS AND CONDITIONS

These terms and conditions shall be part of the attached proposal and shall become part of the contract entered into between 

FUEL TECH, INC. (Fuel Tech), and the Buyer. Deviations from these terms and conditions must be agreed to in a writing signed 

by Fuel Tech and the Buyer. Fuel Tech hereby gives notice of its objection to any different or additional terms or conditions 

unless such different or additional terms or conditions are agreed to in a writing signed by Fuel Tech and Buyer. 

1. TERMS OF PAYMENT: 

All invoices are payable net thirty (30) days from date of invoice. Buyer shall pay interest at the rate of ten percent 

(10%) per annum on all overdue amounts. Buyer shall pay all sales tax, use tax, excise tax, or other similar taxes. 

2. DELAYS:

If shipments are delayed by Buyer, payment shall be due on and warranty coverage shall begin to run from thirty 

days after the original shipment date specified in the contract or thirty (30) days after notification to Buyer that 

equipment is ready to ship, whichever is earlier. Risk of loss shall pass to Buyer at the time that equipment is 

identified, and any costs caused by such delay shall be borne by Buyer. 

If shipments are delayed by Buyer, Fuel Tech will ship the equipment no later than sixty (60) days after initial 

notification to the Buyer that the equipment is ready for shipment. Buyer agrees either (1) to provide Fuel Tech an 

appropriate “ship to” address and to accept delivery or (2) pay reasonable storage charges for the equipment 

beginning sixty (60) days after initial notification to Buyer that equipment is ready to ship. 

3. PERFORMANCE GUARANTEE: 

Buyer warrants that the operating conditions of the Unit are those specified in the Process Design Table. Buyer is solely 

responsible for the accuracy of that operating condition information, and all performance guarantees and equipment 

warranties granted by Fuel Tech shall be void if that operating condition information is inaccurate or is not met. All 

performance guarantees and equipment warranties are conditioned on Buyer timely providing all of the equipment, 

materials, chemicals, utilities, and services that it has agreed to provide, on operating the Unit within the operating 

conditions specified in the Process Design Table, and on using reagent of license grade quality in the operation of the 

Unit. 

4. EQUIPMENT WARRANTY: 

Fuel Tech warrants that the equipment it provides shall be free from defects in design, workmanship, and material 

at the time the equipment is delivered and for a period of twelve (12) months after initial operation, or eighteen (18) 

months from shipment of equipment, whichever occurs first. Fuel Tech does not warrant wear parts such as 

injection tips, cooling shields, pump diaphragms, check valves, solenoids, pump impellers, pump wear rings, pump 

seals, valve packing, and valve seats. 

All warranties made by the manufacturer of the equipment (if that manufacturer is any entity other than Fuel Tech) 

shall be assigned by Fuel Tech to the Buyer, if such assignment is permissible by law and contract. Warranty 

coverage starts at shipment of equipment or thirty (30) days after notification to Buyer that equipment is ready to 

ship. 

5. DISCLAIMER OF WARRANTIES: 

Fuel Tech warrants its equipment and the performance of its equipment solely in accordance with the equipment 

warranty and performance guarantee contained in this proposal and makes no other representations or warranties 

of any other kind, express or implied, by fact or by law. All warranties other than those specifically set forth in this 

proposal are expressly disclaimed. FUEL TECH SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES, 

EXPRESS OR IMPLIED, AND DISLCAIMS THE IMPLIED WARRANTY OF MERCHANTABILITY, THE IMPLIED 

WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND ANY OTHER IMPLIED WARRANTIES OF 

DESIGN, CAPACITY, OR PERFORMANCE RELATING TO THE EQUIPMENT.
CONFIDENTIAL Do Not Duplicate 

6. LIMITATION OF LIABILITY: 

Buyer’s sole remedy under the equipment warranty and the performance guarantee shall be to allow Fuel Tech, at Fuel 

Tech’s option, either to repair, replace, or supplement the equipment to meet the performance guarantee, or, in the 

event that those options are not feasible, to remove the Equipment and refund the contract price to Buyer. 

NOTWITHSTANDING ANYTHING TO THE CONTRARY, FUEL TECH’S TOTAL LIMIT OF LIABILITY ON ANY 

CLAIM, WHETHER FOR BREACH OF CONTRACT, BREACH OF WARRANTY, TORT, NEGLIGENCE, STRICT 

LIABILITY, OR ANY OTHER LEGAL THEORY, FOR ANY LOSS OR DAMAGE ARISING OUT OF, OR CONNECTED 

TO, OR RESULTING FROM THIS AGREEMENT, INCLUDING WITHOUT LIMITATION AMOUNTS INCURRED BY 

FUEL TECH OR BUYER IN ATTEMPTING TO REPAIR, REPLACE, OR SUPPLEMENT THE EQUIPMENT OR MEET 

A PERFORMANCE GUARANTEE PROVIDED BY FUEL TECH TO BUYER, IF ANY, SHALL BE LIMITED TO THE 

CONTRACT PRICE TO BE PAID BY BUYER PURSUANT TO THE CONTRACT. 

7. EXCLUSION OF CONSEQUENTIAL DAMAGES: 

NOTWITHSTANDING ANYTHING TO THE CONTRARY, IN NO EVENT SHALL FUEL TECH BE LIABLE FOR ANY 

INDIRECT, CONSEQUENTIAL, INCIDENTAL, SPECIAL, OR PUNITIVE DAMAGES, INCLUDING BUT NOT LIMITED 

TO LOSS OF CAPITAL, LOSS OF REVENUES, LOSS OF PROFITS, LOSS OF ANTICIPATORY PROFITS, LOSS 

OF BUSINESS OPPORTUNITY, DAMAGE TO EQUIPMENT OR FACILITIES, COST OF SUBSTITUTE NOx 

REDUCTION SYSTEMS, DOWNTIME COSTS, GOVERNMENT FINES, OR CLAIMS OF CUSTOMERS, EVEN IF 

ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. 

8. RESPONSIBILITY FOR THIRD PARTIES 

Buyer shall at all times be responsible for the acts and omissions of its subcontractors and of any other third parties 

hired or retained or contracted by Buyer to perform work or provide equipment related to the system provided by Fuel 

Tech, including but not limited to third party design, systems integration, equipment tie-in, or process design changes. 

Fuel Tech shall have no responsibility for ensuring the accuracy of any such work or the performance of any equipment 

provided by subcontractors or third parties hired or retained or contracted by Buyer, and Buyer assumes all liability for 

any such work or equipment and for any failures in Fuel Tech’s equipment caused by any such subcontractors or third 

parties hired or retained or contracted by Buyer. Buyer agrees to indemnify, hold harmless, and defend Fuel Tech from 

any claims, losses, damages, injuries, or failures caused by any such subcontractors or third parties. 

9. CONFIDENTIALITY: 

Buyer agrees that it shall hold Confidential Information received from Fuel Tech in the strictest confidence, shall not 

use the Confidential Information for its own benefit except as necessary to fulfill the terms of the agreement 

between the parties, shall disclose the Confidential Information only to employees, agents, or representatives who 

have a need to know the Confidential Information, shall not disclose the Confidential Information to any third party, 

shall not copy the Confidential Information, shall not disassemble, decompile, or otherwise reverse engineer the 

Confidential Information and any inventions, processes, or products disclosed by Fuel Tech, and, in preventing 

disclosure of Confidential Information to third parties, shall use the same degree of care as for its own information 

of similar importance, but no less than reasonable care. 

10. LICENSE AGREEMENT AND OTHER TERMS: 

Sale is subject to agreement on other terms and conditions, including a Sale of Equipment with License 

Agreement. 
CONFIDENTIAL Do Not Duplicate 

11. INDEMNIFICATION: 

Each party to the Agreement (“Party” or collectively “Parties”) shall defend, indemnify, and hold harmless the other 

Party and its employees, agents, and representatives from any third party claims, liabilities, lawsuits, costs, losses, 

or damages (collectively “Losses”) that arise out of or result from any negligent or willful acts or omissions of the 

indemnifying Party’s employees, agents, or representatives to the extent such Losses relate to personal injury or 

death or property damage (“Third Party Claims”). Where such Third Party Claims are the result of the joint or 

concurrent negligence or willful misconduct of the Parties or their respective agents, employees, representatives, 

subcontractors, or any third party, each Party’s duty of indemnification shall be in the same proportion that the 

negligence or willful misconduct of such Party, its agents, employees, representatives, or subcontractors 

contributed to the Third Party Claims. The Party entitled to indemnity under this Agreement shall promptly notify the 

indemnifying Party of any indemnifiable Third Party Claims. The Party responsible for indemnification under this 

Agreement shall conduct and control the defense of the Third Party Claims. The Parties shall use their best efforts 

to cooperate in all aspects of the defense of any Third Party Claims. The indemnifying Party shall not be bound by 

any compromise or settlement made without its prior written consent. 

12. FORCE MAJEURE 

The Parties shall be excused from liability for delays in manufacture, delivery, or performance due to any events 

beyond the reasonable control of the Parties, including but not limited to acts of God, war, national defense 

requirements, riot, sabotage, governmental law, ordinance, rule, or regulation (whether valid or invalid), orders of 

injunction, explosion, strikes, concerted acts of workers, fire, flood, storm, failure of or accidents involving either Party’s

plant, or shortage of or inability to obtain necessary labor, raw materials, or transportation (“Force Majeure”). Any delay 

in the performance by either party under this Agreement shall be excused if and to the extent the delay is caused by the 

occurrence of a Force Majeure, provided that the affected party shall promptly give written notice to the other party of 

the occurrence of a Force Majeure, specifying the nature of the delay, and the probable extent of the delay, if 

determinable. 

Following the receipt of any written notice of the occurrence of a Force Majeure, the parties shall immediately 

attempt to determine what fair and reasonable extension for the time of performance may be necessary. The 

parties agree to use reasonable commercial efforts to mitigate the effects of events of Force Majeure. 

No liabilities of any party that arose before the occurrence of the Force Majeure event shall be excused except to 

the extent affected by such subsequent Force Majeure. 

13. GOVERNING LAW 

This Agreement shall be governed by and interpreted in accordance with the laws of the State of Illinois, excluding 

its choice of laws rules. The parties shall attempt to settle any disputes, controversies, or claims arising out of this 

Agreement through consultation and negotiation in good faith and in a spirit of mutual cooperation. If those 

attempts fail, then any dispute, controversy or claim shall be submitted first to a mutually acceptable neutral advisor 

for mediation. Neither party may unreasonably withhold acceptance of a neutral advisor. The selection of the 

neutral advisor must be made within forty-five (45) days after written notice by one party demanding mediation, and 

the mediation must be held within six months after the initial demand for it. By mutual agreement, however, the 

parties may postpone mediation until they have each completed some specified but limited discovery about the 

dispute, controversy, or claim. The cost of mediation shall be equally shared between the parties. Any dispute that 

the parties cannot resolve through mediation within six (6) months after the initial demand for it may then be 

submitted to a state or federal court of competent jurisdiction within the State of Illinois for resolution. The use of 

mediation shall not be construed (under such doctrines as laches, waiver, or estoppel) to have adversely affected 

any party’s ability to pursue its legal remedies, and nothing in this provision shall prevent any party from resorting 

to judicial proceedings if good faith efforts to resolve a dispute under these procedures have been unsuccessful or 

interim resort to a court is necessary to prevent serious and irreparable injury to any party or others. 

14. ENTIRE AGREEMENT 

This Exhibit C3 and the Fuel Tech Proposal attached to it constitute the entire agreement between the parties and can 

be modified only in writing signed by authorized representatives of each of the parties. 
Ultra Low NOX

Burner Upgrades

Retrofit existing burners for 

40-60% NOX reduction 

Fuel Tech’s proprietary components upgrade existing 

burners to high efficiency Low NOX burners. Fuel 

rich and lean zones are developed at the burner 

outlet to deeply stage combustion for low NOX

control. 

Typical reductions range from 40% to 60% with 

minimal impact on flyash LOI.

Features Include:

• Ease of operat

• Patent pending 

five (5) zone 

burner

• Balanced 

perimeter airfl

• Homogeneous 

coal flow

• “Clean release” 

nozzle

• Accurate 

secondary airfl

measurement

Coal Burner Upgrade 

A homogeneous coal and primary air stream 

penetrates the Internal Re-circulation Zone (IRZ) at 

the burner outlet. Coal devolitizes in a low O2 zone 

to force the fuel-bound nitrogen to N2 instead of 

NO. Secondary air mixes further downstream to 

complete burn out and limit impact on unburned 

carbon.

The Hardware: Typically three components: a Low NOX Swirler, a Low NOX Coal 

Nozzle and a Low NOX Distribution Disk, are all that are needed to upgrade original 

OEM or Low NOX Burners. Components are fabricated from wear resistant alloys for 

extended life.

Coal T-Fired Burner Upgrade 

Fuel Tech’s Separated Over-Fire Air (SOFA) 

system for Tangentially- Fired boilers utilizes 

a high energy nozzle design that eliminates 

the need for Yaw and tilt control. The system 

controls airflow from the secondary air 

ducts to evenly distribute flow through 

ports above the top elevation of burners. 

The Hardware: Typically three 

components, a Low NOX

 fuel/air bucket, 

Coal Nozzle Insert and Distribution Disk, 

are all that are needed to upgrade original 

OEM or Low NOX burners. Components 

are fabricated from wear-resistant alloys to 

provide extended life.

Burner Upgrade IRZ

T-Fired Fuel Bucket 
• Proven Low 

NOX Designs 

• Stabilize Low 

NOX Flames for 

Low Excess Air 

Operation and 

Consistent 

Flame Scanning

© Fuel Tech, Inc.

#FT - 109226 - AP

Gas Burner Upgrade 

Thermal NOX increases exponentially as a 

function of peak flame temperature. Lowerin

the peak flame temperature 190° F can redu

NOX 50%. Split flames are produced from the 

burner upgrade to stage combustion and 

reduce peak flame temperature.

The Hardware: Typically, only two 

components are needed to upgrade a single 

zone burner to a low NOX, high efficiency bu

– a curve bladed swirler and gas pokers. Each are made from 310 SS for long 

in a high temperature environment.

Oil Burner Upgrade 

Oil spray from Fuel Tech’s Low NOX atomizer devolitizes in a fuel rich zone at 

burner outlet. This zone inhibits the conversion of fuel-bound nitrogen to NO

Oil droplets are controlled in a tight size range to ensure complete burnout 

limit opacity. Computational Fluid Dynamics (CFD) modeling is used to valid

designs prior to fabrication.

The Hardware: Typically only two 

components are needed to upgrade a 

single zone burner to a low NOX, high 

efficiency burner— a curve bladed swir

and Low NOX

 Atomizer. Each are made f

310 SS for long life in a high temperatur

environment.

State of the art 

components 

provide control 

over the following:

• NOX Emissions

• Flame Shaping

• CO Emissions

• Burner Eyebrows

• Flyash LOI

• Furnace Slagging

Installed Gas Burner

Low NOX Oil Atomizer

Temperature comparison in degrees 

Fahrenheit from non-Low NOX 

Burner (top) and our Low NOX

Burner (bottom)

www.ftek.com | (US) 800.666.9688 • (China) 86.10.8487.1742 • (Italy) 39.0331.701110

27601 Bella Vista Parkway | Warrenville, IL 60555
Over-Fire Air 

(OFA) Systems 

Deep-Staging for Maximum 

NOX Reduction

Over-Fire Air (OFA) System 

Fuel Tech’s Over-Fire-Air (OFA) 

system deeply stages combustion for 

enhanced NOX reductions. Additional 

NOX reductions of 35% to 50% are 

possible on Wall, Tangential, Turbo or 

Cyclone fired boilers of all fuel types. 

The unique port design will enhance 

mixing to limit impact on combustion 

efficiency.

How Fuel Tech’s OFA System Will Reduce NOX Emissions 

Combustion air is diverted from the burners to create a fuel rich zone in the 

lower furnace. Fuel-bound nitrogen conversion to NO is inhibited on coal and 

oil fired boilers. Peak flame temperatures are reduced on gas fired boilers to 

limit thermal NOX formation. A high momentum air stream intersects the 

burner combustion gasses in the upper furnace to complete combustion 

prior to the boiler convective section. 

The Hardware

The OFA port is shaped 

by refractory “boot” with 

combustion air fed through 

a 310 SS duct for long life. 

Automated damper controls 

allow for tuning through 

the load range. Full furnace 

Computational Fluid Dynamics 

modeling is performed on 

each project. OFA port sizes 

and shaping are determined to maximize combustion air penetration and 

furnace coverage.

The port utilizes a venturi design with zone disk to accurately 

control airflow through the OFA port. 

· OFA ports fabricated from 1⁄4” 310 SS material.

· OFA register assemblies fabricated from 1⁄4” 310 SS material.

Features Include:

•	 Additional NOX

reductions of

35-50%

•	 Custom designed

port geometry

•	 Stainless steel

construction

•	 OFA flow control

dampers for

automatic

operation

New

OFA Duct

New Rear

Wall OFA Ports

Existing

Secondary

Air Duct
OFA Systems

Deep-Staging for Maximum 

NOX Reduction

© Fuel Tech, Inc.

#FT - 109230 - AP

OFA System

T-Fired OFA System

CFD Model of Fuel Tech re-design of customer’s OFA system 

(left) to SOFA system (right).

Fuel Tech Low NOX Burners 

& OFA Wall-Fired Coal 

Boiler NOX vs. BZHR 

This graph illustrates NOX

reduction capabilities for both 

eastern bituminous and sub 

bituminous coal. Fuel Tech’s 

Low NOX burners and OFA 

systems provide maximum 

NOX reduction across a wide 

range of Burner Zone Heat 

Release (BZHR) values. 

Over Fire Air 

NOX Reduction

Over fire air is injected 

into the furnace above the 

top row of burners and 

completes the combustion 

of the unburned CO prior 

to the gases passing 

through the superheater.

Fuel Tech’s modeling expertise and proven field results allow us 

to guarantee OFA system performance.

www.ftek.com | (US) 800.666.9688 • (China) 86.10.8487.1742 • (Italy) 39.0331.701110

27601 Bella Vista Parkway | Warrenville, IL 60555
SNCR

Proven solutions for flexible, 

cost-effective NOx reduction

NOxOUT® 

Process Injection 

• High momentum 

injectors

• Maximize performance

• Adjustable for NOx

reduction downstream 

of injection point

SNCR 

Technology

 • CFD/CKM Modeling

 • Reliable equipment

 • On-site optimization

HERTTMHigh Energy Reagent 

Technology Injection

• High energy, low 

momentum injectors

• Maximize performance with 

minimal ammonia slip

• Localized NOx reduction

Fuel Tech’s urea-based Selective Non-Catalytic Reduction (SNCR) Process 

is a post-combustion NOx reduction method that reduces NOx through a 

controlled injection of an aqueous urea solution into the combustion gas 

of utilized industrial sources including: fossil-fired units, waste-fired boilers, 

furnaces, incinerators, or heaters. 

Fuel Tech has enhanced the basic SNCR technology by developing 

chemical injection hardware, widening the applicable temperature range, 

and applying process control expertise required for commercial applications.

Fuel Tech has two urea-based SNCR technologies: NOxOUT® systems, 

which utilize low energy and air atomized injectors, and HERTTM High 

Energy Reagent Technology, which utilize mechanically atomized injectors 

and carrier air for injection into the furnace.

The NOx-reducing reaction is temperature sensitive: the optimum 

temperature range is specific to each application. The reagent needs to 

be distributed within this optimum temperature zone to obtain the 

best performance.

The most commonly used reagent consists of a 50% urea solution. 

This reagent is readily available and requires no special safety precautions 

for handling.

SNCR Processes

Fuel Tech’s SNCR Processes are designed with the aid of Computational 

Fluid Dynamics (CFD) and Chemical Kinetic Modeling (CKM) in addition 

to results from field tests. The CFD model simulates flue gas flows and 

temperature inside a unit while the CKM calculates the reaction between 

urea and NOx based on temperature and flow information from CFD. The 

combination of these two models determines the optimum temperature 

region and the optimum injection strategy to distribute the reagent.

25-50% NOx reduction

• Customized solution for 

each application

• Easy to retrofit – little 

downtime required

• Low capital cost

• Can be combined with other 

NOx reduction technologies

– 60-70% reduction with 

Combustion Modification

– Up to 80% reduction as 

part of Fuel Tech’s ASCRTM 

Advanced SCR process

• Safe reagent

SNCR Injectors

SNCR Injection 

Process

NOXOUT®and HERTTM Processes
© Fuel Tech, Inc. 

NOxOUT® is a registered 

trademark and HERTTM and 

ASCRTM are trademarks of 

Fuel Tech, Inc.

FT - 109108 - AP

Chemical injectors developed by Fuel Tech facilitate 

the reagent distribution. The NOxOUT® injection system 

utilizes air-atomized injectors which direct the urea 

solution into the combustion gas path. The droplet 

size distribution and spray coverage promote efficient 

contact between the chemical and the NOx in the 

flue gas.

The HERTTM injection system utilizes mechanical 

atomizers which carry the urea into the furnace using 

a high energy air stream. Fuel Tech evaluates both for 

each specific application and offers the best solution 

for the customer’s needs. 

Fuel Tech’s SNCR Processes provide effective boiler 

load following capabilities to maximize overall 

NOx reduction.

Through computer modeling and proven field 

experience, an injection strategy is developed that 

makes use of multilevel injection, control of reagent 

concentration, droplet size and spray patterns, as 

well as jet penetration. NOxOUT® and HERTTM systems 

are applicable on various types of units firing many 

different fuels, which has been verified by years of 

field-testing. Since SNCR is a post-combustion 

process, unit size, boiler type and fuel type can be 

accommodated in the customized process design.

www.ftek.com | (US) 800.666.9688 • (China) 86.10.8487.1742 • (Italy) 39.0331.701110

27601 Bella Vista Parkway | Warrenville, IL 60555

Over 580 

APC system 

installations

worldwide on wide 

range of fuels and 

combustion units.

• Wall-Fired

• Cyclone-Fired

• Tangentially-Fired

• Stokers

• CFB/BFB Boilers

• Municipal Waste

• Coke Ovens

• Cement Kilns

• CO Boilers

Fuels:

• Coal

• Lignite

• Oil

• Gas

• Sludge

• Wood

• Biomass

CFD Models of NOxOUT® and 

HERTTM SNCR Processes

Independent 

Zone Metering 

Module