Why Oxy/Fuel?
Transcript of Why Oxy/Fuel?
Why Oxy/Fuel?
A Superior Method of Firing
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O2/Methane Reaction
CH4 + 2O2 = CO2 + 2H2O + Heat
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Air/Methane Reaction
CH4 + 2O2 + 8N2 = CO2 + 2H2O + 8N2 + (1000 BTU)
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Tri-Atomic Atmosphere TransfersHeat Better Than Di-Atomic
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Environmental ConcernsFacing Industry
• Emissions• Permitting• Repeatability of Reporting
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Air-Fired Environmental Results
• High NOx
• High Firing Rates• High Fuel Consumption• Problems with Repeatability
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Oxy-Fired Environmental Results
• Low NOx
• Lower Firing Rates• Lower Fuel Consumption• Stable Repeatability
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Exhaust Differences
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Oxy/Fuel Produces Less Volume
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Examples
Exhaust Volumes @ 1 Million BTU/HR
Air/Gas - - 11,000 CU.FT. Produced
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Examples
Exhaust Volumes @ 1 Million BTU/HR
Oxy/Gas - - 3000 CU.FT. Produced
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Exhaust Breakdown
Air/Gas
CO2 - - - 8% - - - 880 CU. FT. ProducedH2O - - - 16% - - 1760 CU. FT. ProducedNOx - - - 75% - - 8250 CU. FT. Produced
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Exhaust Breakdown
Oxy/Gas
CO2 - - - 30% - - - 900 CU. FT. ProducedH2O - - - 66% - - - 1980 CU. FT. Produced
NOx - - 3% - - - 90 CU. FT. Produced 99% LESS !
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Advantages of Less Exhaust
• Smaller Exhaust System• Less Capital• Less Cost in Post Cleaning (if Necessary)
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Why Oxy/Fuel Summary
• Faster Heat Up• High Luminosity Generated from Flame• Tri-Atomic Atmosphere• Higher Heat Transfer• Highest Level of Radiation Available• Low NOx
• Reduced Exhaust Volumes
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Primefire® SeriesOxy-Fuel Burners
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Primefire® 100 Series Burners
• Produces a conventional shape flame• Currently in use in 50 furnaces worldwide
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Primefire® 100 Series Burners
• Design Features– High flame luminosity– Adjustable flame shape– Adjustable flame momentum– Low emissions (NOx and particulate)– Multi-fuel capabilities (natural gas and fuel oils)– No maintenance design
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Primefire® 100 SeriesOxygen-Gas Burner
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Primefire® 100 SeriesOxygen-Gas Burner 2-8 MM Btu/hr Capacity Burner
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Primefire® 100 Series BurnerCombustion Tec Lab Firing
Oxygen-Gas Firing at 3.5 MM Btu/hr
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Primefire® 100 Oxy-Gas Burners Visible Flame Length (feet)
Combustion Tec and Field Oxygen-Gas Firing DataVarious Burner Sizes and Tips
0
5
10
15
20
25
30
1 2 4 6 8 10 14 18 20Firing Rate (MM Btu/hr)
C
5 68
10
13
15
20
2324
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0
2
4
6
8
10
12
Oxy
gen
Pre
ssu
re a
t Bu
rner
(IW
C)
0.5 1 1.5 2 2.5 3 Firing Rate (MMBtu/Hr)
Oxy-Gas Primefire® 100 Burner1-4 MMBtu/Hr Natural Gas
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2
4
6
8
10
Nat
ura
l Gas
Pre
ssu
re a
t Bu
rner
(IW
C)
0.5 1 1.5 2 2.5 3 Firing Rate (MMBtu/Hr)
Oxy-Gas Primefire® 100 Burner1-4 MMBtu/Hr Natural Gas
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Primefire® 100 Series Oxygen-OilBurners
• Dual fuel design• Variable momentum• Variable flame• Better heat distribution than higher velocity burners
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Primefire® 100 Series Oxygen-OilBurners
2-8 MM Btu/hr capacity burner
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Primefire® 100 Series Oxygen-OilBurners
Visible Flame Length (feet) Combustion Tec and Field Oxygen-Oil Firing Data
Various Burner Sizes and Tips
0
2
4
6
8
10
12
14
16
1 2 3 4 5 6 7 8 9Firing Rate (MM Btu/hr)
C
4
6
7.5
910
10.511
12
13.5
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Primefire® 100 Series Oxygen-OilBurner
Oxygen-Oil Firing at 3 MM Btu/hr
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Primefire® 100 Series Oxygen-GasBurner
Firing in a Fiberglass Furnace
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Primefire® 100 Series Oxygen-OilBurner
Firing in a Fiberglass Furnace
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Primefire® 300 Series Burners
• New generation oxy-fuel burners• Produce fish-tail or fan-shaped flame• Flat flame by momentum shaping• Higher luminosity than round-flame oxygen-
fuel burners
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Primefire® 300 Series Burners
• Wider and longer flame than round-flameoxygen burners
• Increased flame radiation• Adjustable flame shape
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Primefire® 300 SeriesBurner Design
• Flat flame is generated by streamwiseconditioning of both fuel and oxygen in aconverging and diverging burner body
• Patented precombustor creates a veryluminous and low momentum flame
Flat Flame by Momentum Shaping
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Primefire® 300 Series Burners
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Primefire® 300 SeriesOxygen-Gas Burner
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Primefire® 300 Series Oxygen-GasBurner
Oxygen-Gas Firing at 3.5 MM Btu/hr
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Primefire® 300 Series Oxygen-GasBurner
Oxygen-Gas Firing at 3.6 MM Btu/hr
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Primefire® 300 Series Oxygen-GasBurner
Oxygen-Gas Firing at 4.6 MM Btu/hr
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Primefire® 300 Series Oxygen-GasBurner Field Trial
Oxygen-Gas Firing at 8.0 MM Btu/hr
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ssur
e @
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ner
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0 1 2 3 4 5 Firing Rate (MM Btu/Hr)
Primefire® 300 Series Oxygen-Gas0.75 to 3.00 MM; 2" O2 & 2" Gas Inlets
Oxygen
Gas
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0
2
4
6
8
10
Vis
ible
Fla
me
Len
gth
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t)
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ible
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me
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th (F
eet)
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 Firing Rate (MM Btu/Hr)
Primefire® 300 Oxygen-Gas0.75-3.00 MM; Unsealed Lab Firing
+1Flush-1/2
Length
Width
+1
Flush-1/2
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5
10
15
20
25
30
35
Fla
me
Co
vera
ge
(ft^
2)
1 2 3 4 5 6 7 8 Firing Rate (MMBtu/Hr)
2-8 MMBtu/Hr Primefire® 300 Oxy-GasFlame Coverage
Primefire® 300
Primefire® 100
Adjustability
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10
15
20
25
30
35
40
45
Hea
t Flu
x M
eter
Rea
ding
1 2 3 4 5 6 7 8 Firing Rate (MMBtu/Hr)
2-8 MMBtu/Hr Primefire® 300 Oxy-GasRadiation Measurements
Primefire® 300
Primefire® 100
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Primefire® 300 Series BurnerSummary
• Gas and oil firing capabilities• Lower flame momentum• Adjustable flame shape• Lower peak flame temperatures• Higher flame radiation• Lower fuel and oxygen pressures• Enhanced flame coverage• Minimum maintenance
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Primefire® 300 Series BurnerAdvantages
• Fuel savings due to increased radiation• Lower oxygen consumption• Higher flame radiation• Lower crown temperatures• Improved control• Improved productivity
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Oxygen and GasControl Equipment
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Oxygen Concerns
• Safety• Supply• Metering• Control• Training
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Gas and Oxygen Metering andFlow Control Train
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Main Gas Train
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Main Oxygen and Natural GasSafety Trains
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Oxygen-Gas Boosting Train
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Primefire® 100 Series Oxygen-OilBurners and Burner Accessory
Panels
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Metering Flow ControlsInstallation - Heavy Fuel Oil
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Heavy Fuel Oil Pipe Train
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Circulating Pump Skid
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Steam Booster Heater
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Oil Suction Heater - Heavy OilPreheat System
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Mixing Station
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Main Instrumentation ControlStation