Coal Flow Balancing

TABi Energy's proprietary Coal Flow Balancing (CFB) technology is designed to correct coal and primary air maldistribution among coal pipes — one of the most common root causes of high unburned carbon, combustion instability, and elevated emissions. Installed on 30+ utility-scale units, the system delivers immediate and measurable improvements under real plant operating conditions.

Measured Performance Improvements

Field data before and after implementation consistently show:

Unburned carbon reduction of 50% or more (typical average: ~9.0% → ~4.1%)
More uniform burner heat release
Improved flame stability and turndown capability
Lower CO emissions and reduced slagging risk
Improved boiler efficiency and availability

All improvements are verified through on-site measurements and operational data.

Why Coal Flow Balancing Matters

Even well-designed pulverizers experience outlet-to-outlet imbalance over time. TABi Energy's Coal Flow Balancing solution:

Actively corrects coal distribution across burners
Requires minimal downtime
Avoids major mill modifications
Delivers fast payback with low CAPEX

How We Work

Baseline Testing

Flow Diagnosis

CFB Installation

Post-Implementation Validation

This disciplined approach ensures repeatable, sustainable results across different coal qualities and boiler designs.

Technical Documentation

Mill upgrade engineering: drawings to CFD

CFD modeling of coal flow through the mill

CFD view inside the beater wheel and riser ducts

Baseline classifier: flap position barely affects fineness

Classifier upgrade lifts fineness from ~55% to 69%

Unburned carbon reduced 9.0%→4.1% after coal flow balancing

Proven in the Field

TABi Energy's Coal Flow Balancing solutions are trusted by plant operators worldwide to stabilize combustion, reduce losses, and improve day-to-day operability.