A comparative study of microwave plasma and fuel-oil ignition systems for pulverized coal boiler start-up: Technical, environmental, and economic aspects

Year 2026, Volume: 11 Issue: 1, 25 - 41, 17.03.2026

Uğur Tekir

https://doi.org/10.58559/ijes.1735146

https://izlik.org/JA73CY42KU

Abstract

A microwave-assisted plasma-based auxiliary burner has been developed as an alternative to conventional fuel-oil-fired start-up burners in pulverized coal-fired boilers. Considering the complete replacement of fuel oil and the improved ignition efficiency, this technology offers a potentially more cost-effective solution. However, its economic viability must be demonstrated for such a technology to be widely implemented. The auxiliary burner developed in this study operates based on the principle of combusting pulverized coal within a plasma flame generated by ionizing air directed into the burner using microwave energy. Microwave energy at a frequency of 915 MHz is generated by a magnetron with an output power of 75 kW. An experimental test setup was established at the industrial scale on Unit-1 of the 22 MW_e Soma A Thermal Power Plant to conduct the cost-effective analysis of the alternative auxiliary burner. This paper demonstrates that, based on start-up tests performed on the boiler, the use of microwave-based plasma technologies for the complete replacement of fuel oil during the start-up of a pulverized coal boiler is feasible, achieving ignition at approximately one-third of the fuel and energy cost compared to conventional start-up methods. Industrial-scale emission measurements were conducted during the test campaigns on a 50-meter-high stack, with sampling carried out at a fixed platform located 38 meters above ground level. Microwave-assisted plasma ignition reduced CO₂ emissions by 3.85 tons per boiler start-up compared to conventional fuel-oil methods. The results indicate that the microwave-assisted auxiliary plasma burner is a technically viable, energy-efficient, and environmentally friendly technology compared to conventional burners.

Keywords

Microwave energy , Pulverized coal , Plasma combustion , Auxiliary burner , Boiler start-up

References

• [1] Chu S, Majumdar A. Opportunities and challenges for a sustainable energy future. Nature 2012; 488: 294-303.
• [2] Glushkov D, Kuznetsov G, Chebochakova DA, Lyakhovskaya OE, Shlegel NE. Experimental study of coal dust ignition characteristics at oil-free start-up of coal-fired boilers. Applied Thermal Engineering 2018; 142: 371-379.
• [3] Share of electricity production from coal. Available online: https://ourworldindata.org/grapher/share-electricity-coal?tab=chart [Accessed: Jun. 10, 2025].
• [4] Messerle VE, Karpenko EI, Ustimenko AB. Plasma-assisted power coal combustion in the furnace of utility boiler: Numerical modeling and full-scale test. Fuel 2014; 126: 294-300.
• [5] Messerle V, Karpenko E, Ustimenko A, Lavrichshev O. Plasma preparation of coal to combustion in power boilers. Fuel Processing Technology 2013; 107: 93-98.
• [6] Gorokhovski MA, Jankoski Z, Lockwood FC, Karpenko EI, Messerle VE, Ustimenko AB. Enhancement of pulverized coal combustion by plasma technology. Combustion Science and Technology 2007;179(10): 2065-2090.
• [7] Messerle VE, Ustimenko AB, Tastanbekov AK. Plasma ignition of solid fuels at thermal power plants. Part 1. Mathematical modeling of plasma-fuel system. Thermophysics and Aeromechanics 2022; 29(2): 295-310.
• [8] Kanilo P, Kazantsev V, Rasyuk N, Schünemann K, Vavriv D. Microwave plasma combustion of coal. Fuel 2003; 82: 187-193.
• [9] Messerle V, Ustimenko AB. Modeling of coal ignition in plasma-fuel systems with an electric arc torch. IEEE Transactions on Plasma Science 2019; 48: 343-349.
• [10] Gorokhovski M, Karpenko EI, Lockwood FC, Messerle VE, Trusov BG, Ustimenko AB. Plasma technologies for solid fuels: Experiment and theory. Journal of the Energy Institute 2005; 78(4): 157-171.
• [11] Messerle V, Ustimenko AB. Modelling of the pulverized coal plasma preparation for combustion. Physical Sciences and Technology 2021; 8: 14-25.
• [12] Glushkov D, Matiushenko A, Nurpeiis A, Zhuikov A. An experimental investigation into the fuel oil-free start-up of a coal-fired boiler by the main solid fossil fuel with additives of brown coal, biomass and charcoal. Fuel Processing Technology 2021; 223: 106986.
• [13] Messerle V, Ustimenko AB. Thermodynamic and kinetic modeling and experiment on plasma ignition of pulverized high-ash coal. Applications in Energy and Combustion Science 2024; 17: 100248.
• [14] Karpenko EI, Karpenko YE, Messerle VE, Ustimenko AB. Using plasma-fuel systems at Eurasian coal-fired thermal power stations. Thermal Engineering 2009; 56(6): 456-461.
• [15] Butakov EB, Burdukov AP, Alekseenko SV, Yaganov EN. Plasma ignition system to start up pulverized coal boilers: Experimental simulation and full-scale test. Journal of Engineering Thermophysics 2022; 31(3): 375-383.
• [16] Youssefi R, Maier J, Scheffknecht G. Pilot-scale experiences on a plasma ignition system for pulverized fuels. Energies 2021; 14: 4726.
• [17] Pawlak-Kruczek H, Mularski J, Ostrycharczyk M, Czerep M, Baranowski M, Mączka T, Sadowski K, Hulisz P. Application of plasma burners for char combustion in a pulverized coal-fired (PC) boiler-experimental and numerical analysis. Energy 2023; 279: 128115.
• [18] Li S, Chen H, Yuan X, Pan P, Xu G, Wang X, Wu L. Energy, exergy and economic analysis of a poly-generation system combining sludge pyrolysis and medical waste plasma gasification. Energy 2024; 295: 130806.
• [19] Radoiu M, Mello A. Scaling up microwave excited plasmas-an alternative technology for industrial decarbonization. Plasma Processes and Polymers 2024; 21(3): 1-12.
• [20] Tekir U. Design and experimental study of a novel microwave-assisted burner based on plasma combustion for pulverized coal applications. Applied Sciences 2025; 15(9): 5190.
• [21] Mączka T, Pawlak-Kruczek H, Niedzwiecki L, Ziaja E, Chrozyczewski A. Plasma-assisted combustion as a cost-effective way for balancing of intermittent sources: Techno-economic assessment for 200 MWel power unit. Energies 2020; 13: 1-16.
• [22] Karpenko EI, Messerle VE, Ustimenko AB. Plasma-aided solid fuel combustion. Proceedings of the Combustion Institute 2007; 31(2): 3353-3360.
• [23] EPDK Enerji Piyasası Düzenleme Kurumu. Available online:https://www.epdk.gov.tr/detay/Icerik/3-0-1/elektriktarifeler [Accessed: May 27, 2025].