EP1335163B1 - Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoss - Google Patents

Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoss Download PDF

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Publication number
EP1335163B1
EP1335163B1 EP03001381A EP03001381A EP1335163B1 EP 1335163 B1 EP1335163 B1 EP 1335163B1 EP 03001381 A EP03001381 A EP 03001381A EP 03001381 A EP03001381 A EP 03001381A EP 1335163 B1 EP1335163 B1 EP 1335163B1
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EP
European Patent Office
Prior art keywords
burner
fuel
flame
ultra low
staging
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP03001381A
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English (en)
French (fr)
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EP1335163A1 (de
EP1335163B2 (de
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Mahendra Ladharam Joshi
Kevin Ray Heier
Aleksandar Georgi Slavejkov
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Air Products and Chemicals Inc
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Air Products and Chemicals Inc
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Priority claimed from US10/062,597 external-priority patent/US6752620B2/en
Priority claimed from US10/067,450 external-priority patent/US6773256B2/en
Application filed by Air Products and Chemicals Inc filed Critical Air Products and Chemicals Inc
Priority to DE60308071T priority Critical patent/DE60308071T3/de
Publication of EP1335163A1 publication Critical patent/EP1335163A1/de
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/46—Details, e.g. noise reduction means
    • F23D14/48—Nozzles
    • F23D14/58—Nozzles characterised by the shape or arrangement of the outlet or outlets from the nozzle, e.g. of annular configuration
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C5/00—Disposition of burners with respect to the combustion chamber or to one another; Mounting of burners in combustion apparatus
    • F23C5/08—Disposition of burners
    • F23C5/32—Disposition of burners to obtain rotating flames, i.e. flames moving helically or spirally
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C6/00—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion
    • F23C6/04—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection
    • F23C6/045—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection with staged combustion in a single enclosure
    • F23C6/047—Combustion apparatus characterised by the combination of two or more combustion chambers or combustion zones, e.g. for staged combustion in series connection with staged combustion in a single enclosure with fuel supply in stages
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/20—Non-premix gas burners, i.e. in which gaseous fuel is mixed with combustion air on arrival at the combustion zone
    • F23D14/22—Non-premix gas burners, i.e. in which gaseous fuel is mixed with combustion air on arrival at the combustion zone with separate air and gas feed ducts, e.g. with ducts running parallel or crossing each other
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23M—CASINGS, LININGS, WALLS OR DOORS SPECIALLY ADAPTED FOR COMBUSTION CHAMBERS, e.g. FIREBRIDGES; DEVICES FOR DEFLECTING AIR, FLAMES OR COMBUSTION PRODUCTS IN COMBUSTION CHAMBERS; SAFETY ARRANGEMENTS SPECIALLY ADAPTED FOR COMBUSTION APPARATUS; DETAILS OF COMBUSTION CHAMBERS, NOT OTHERWISE PROVIDED FOR
    • F23M5/00—Casings; Linings; Walls
    • F23M5/02—Casings; Linings; Walls characterised by the shape of the bricks or blocks used
    • F23M5/025—Casings; Linings; Walls characterised by the shape of the bricks or blocks used specially adapted for burner openings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C2201/00—Staged combustion
    • F23C2201/20—Burner staging
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C2202/00—Fluegas recirculation
    • F23C2202/40—Inducing local whirls around flame
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D2900/00—Special features of, or arrangements for burners using fluid fuels or solid fuels suspended in a carrier gas
    • F23D2900/00011—Burner with means for propagating the flames along a wall surface

Definitions

  • the present invention is directed to a gaseous fuel burner for process heating.
  • the present invention is directed to a burner for process heating which yields ultra low nitrogen oxides (NOx) emissions.
  • NOx nitrogen oxides
  • LNBs Low NOx Burners
  • Table I (Source: North American Air Pollution Control Equipment Market, Frost & Sullivan) gives the LNB market share based on industry for the year 2000.
  • An objective for new burners is to target the industrial sectors that have the largest need for LNBs based on geographic region and local air emission regulations.
  • Table I Low NOx Bumer Market Year Generation Public Utilities (%) Incineration (%) Refinery or CPI (%) Power Generation (%) Paper, Food, Rubber, Other (%) 2000 46.5 15 21.3 6.4 10.8
  • NOx Nitrogen oxides
  • California law also requires a fixed temperature window (315,6°C to 426,7°C) (600°F to 800°F) for >90% NOx removal efficiency as well as the avoidance of ammonia slip below 5 ppmv.
  • a typical SCR unit for a 105,5 GJ/h (100 million Btu/hr) process heater would cost approximately $700,000 in capital costs with annual operating costs of $200,000. See, for example, Table 2 of R. K. Agrawal and S.C. Wood, "Cost-Effective NOx Reduction", Chemical Engineering , February 2001.
  • LNBs In order to comply cost-effectively for NOx emissions, many combustion equipment manufacturers have developed LNBs. See, e.g ., D. Keith Patrick, "Reduction and Control of NOx Emissions from High Temperature Industrial Processes", Industrial Heating , March 1998.
  • the cost effectiveness of an LNB compared to the SCR system would generally depend on the type of burner, consistent NOx emissions from burner, burner costs and local compliance levels.
  • the LNBs for >42,2 GJ/h (40 MM Btu/hr) have not been capable of producing low enough NOx emissions to comply with regulations or provide an alternative to SCR units. Therefore, SCR remains today as the only best available control technology for large process heaters and utility boilers.
  • the greatest challenge in designing a low NOx burner is keeping NOx emissions consistently at sub 9 ppmv level or comparable to NOx emissions at the outlet of the SCR system.
  • the prior art includes low NOx or ultra low NOx burners that produce low NOx emissions using various fuel/oxidant mixing techniques, fuel/oxidant staging techniques, flue gas recirculation, stoichiometry variations, fluid oscillations, gas reburning and various combustion process modifications.
  • most burners are unable to produce NOx emissions at less than 9 ppmv and those that do so in a lab, cannot reproduce such NOx levels in an industrial setting.
  • the technical reasons or challenges in designing a sub 9 ppmv low NOx burner will become evident as described below.
  • nozzle mixing type burners Most large capacity gaseous fuel fired industrial burners used for process heating applications are nozzle mixing type burners. As the name implies, the gaseous fuel and combustion air do not mix until they leave various fuel/oxidant ports of this type of burner.
  • the principal advantages of nozzle mix burners over premix burners are: (1) the flames cannot flash back, (2) a wider range of operating stoichiometry; and (3) a greater flexibility in burner/flame design.
  • most nozzle mix air-fuel burners require some kind of flame holder/arrester for maintaining flame stability.
  • FIG. 1 One prior art generic nozzle mix burner is shown in FIG. 1, where a metallic flame holder disk is used for providing flame stability.
  • combustion air is induced surrounding the main fuel pipe with flame holder in a large box type burner shell.
  • FIG. 1 shows staging fuel for secondary combustion to reduce overall NOx formation.
  • FIG. 2 shows a typical flame holder geometry in which a multiple-hole fuel nozzle is located in the center and several perforated slots are used on the flame holder conical disk outside for passing through a small amount of combustion air for mixing with the injected fuel.
  • the bluff body shape flame holder creates an air stream reversal as shown in FIG. 2.
  • the opposite direction air stream creates almost stagnant condition (zero axial velocity) for air fuel mixing at the inside cavity of the flame holder cone. This stagnant air-fuel mixture with almost no positive firing axis velocity component is used for attaching the main flame to the flame holder base.
  • Flame holders of various hole patterns and external shapes are used for anchoring flames.
  • U. S. Patent No. 5,073,105 (Martin, et al.) and U.S. Patent No. 5,275,552 (Schwartz et al.) describe low NOx burner devices where such flame holders are used to anchor the flame.
  • a primary fuel (30 - 50% of total fuel) is injected radially inwardly over the flame holder disk with flue gas entrainment (through a hole in the burner tile) for anchoring the primary flame.
  • the remaining, secondary fuel is injected surrounding and impacting the external burner block (tile) surface for fuel staging and furnace gas recirculation. Combustion air mixing with the primary fuel takes place inside the burner block over the flame holder and some NOx is formed due to limited heat dissipation volume inside the burner block cavity and due to creation of locally fuel rich regions.
  • a main disadvantage associated with flame holders for use in ultra low-NOx burners is localized stagnant zones of fuel-rich combustion that are generally anchored at the inner base of a flame holder cone or disk. These zones are located on the solid ridges between adjacent air slots/holes due to pressure conditions created by the outer air stream.
  • a further NO x burner for a furnace and the method of operating the burner is known from U.S. Patent No. 4,505,666.
  • the NO x burner has a primary and secondary combustion zone wherein staged fuel and air to both combustion zones is provided. About 40 to 60 % of the liquid or gaseous hydrocarbon fuel along with about 90 % of the total air required is combusted in the first reaction zone which is a central zone. The remaining fuel together with the remaining 10 % of the total air required is combusted in one or more secondary reaction zones adjacent to the central zone.
  • the burner of U.S. Patent No. 4,505,666 is a low NO x burner not suitable to be operated below 20 ppm NO x , which is not sufficiently low.
  • the present invention is directed to an ultra low NO x gaseous fuel burner for process heating applications such as utility boilers, process heaters and industrial furnaces.
  • the novel burner utilizes two unique dependent staged processes for generating a non-luminous, uniform and combustion space filling flame with extremely low ( ⁇ 9 ppmv) NOx emissions. This is accomplished using: (1) a flame stabilizer such as a large scale vortex device upstream to generate a low firing rate, well-mixed, low-temperature and highly fuel-lean (phi 0.05 to 0.3) flame for maintaining the overall flame stability, and (2) multiple uniformly spaced and diverging fuel lances downstream to inject balanced fuel in several turbulent jets inside the furnace space for creating massive internal flue gas recirculation.
  • the resulting flame provides several beneficial characteristics such as no visible radiation, uniform heat transfer, lower flame temperatures, combustion space filling heat release and production of ultra low NOx emissions.
  • the burner generates NOx emissions of less than 9 ppmv at near stoichiometry conditions.
  • the at least one hole and the divergence angles are adapted to provide a flat flame pattern. In a third embodiment, the at least one hole and the divergence angles are adapted to provide a load shaping flame pattern
  • each staging nozzle has between 1 hole and 4 holes.
  • the radial divergence angle is between 8° and 24° and the axial divergence angle is between 4° and 16°.
  • the velocity of fuel exiting the nozzle is preferably between 91,44 m/s to 274,32 m/s (300 to 900 feet per second) for a natural gas staging fuel.
  • the distance from the forward end of the burner to a point where mixing of staging flame and flame stabilizer flame occurs is preferably approximately 0,2032 m to 1,2192 m (8 to 48 inches).
  • the fuel rate of the staging for natural gas fuel is from 70% to 95% of the total fuel firing rate of the burner.
  • the flame stabilizer is preferably a large scale vortex device where the flame has a peak flame temperature of less than approximately 1093°C (2000° Fahrenheit).
  • the burner may include a burner block coaxial to the flame stabilizer.
  • the burner block is cylindrical or slightly conical, or rectangular in shape.
  • FIG. 1 is a simplified side elevational view of a prior art air-fuel burner with a flame holder.
  • FIG. 2 is a simplified side elevational view of a prior art flame holder for an air-fuel burner.
  • FIG. 3 is a simplified side elevational view of a fluid based large scale vortex flame stabilizer for use with an ultra low NOx burner of the present invention.
  • FIG. 4A is a graphical representation of NOx emissions vs. average flame temperature.
  • FIG. 4B is a graphical representation of NOx emissions vs. excess oxygen in exhaust gas.
  • FIG. 5A is a simplified, side elevational view of an ultra low-NOx burner in a circular staging configuration in accordance with the present invention.
  • FIG. 5B is a simplified, front firing, end view of an ultra low-NOx burner in a flat staging configuration in accordance with the present invention.
  • FIG. 5C is a simplified, front firing, end view of an ultra low-NOx burner in another flat staging configuration in accordance with the present invention.
  • FIG. 6 is a simplified front and side view of fuel nozzles and flame pattern of the flame stabilizer of FIG. 3 in combination with the ultra low-NOx burner of FIG. 5A.
  • FIG. 7A is a cross-sectional, top plan view of a fuel staging nozzle used in the burner of FIG. 5A.
  • FIG. 7B is a cross-sectional, side elevational view of the fuel staging nozzle of FIG. 7A.
  • FIG. 7C is a right side view of the fuel staging nozzle of FIG 7B.
  • FIG. 8 is a simplified side elevational view of the burner of FIG. 5A depicting interaction of a flame stabilizer fuel flame and a staging fuel flame.
  • FIG. 9 is a is a graphical representation of NOx emissions with respect to oxidant/oxygen under diluted conditions.
  • FIG. 10 is a graphical representation of lab measurements of a burner flame using a suction pyrometer depicting flame temperature vs. radial distance.
  • FIG. 11 A through FIG. 11 D are a schematic illustrations of various flat staging configurations of ultra low-NOx burners in accordance with the present invention tested in a lab furnace.
  • FIG. 12A is a simplified illustration of a load shaping staging configuration in an industrial boiler using multiple flame stabilizers.
  • FIG. 12B is a simplified illustration of a load shaping staging configuration in an industrial boiler using a single flame stabilizer.
  • FIG. 13A is a simplified illustration of a wall-fired power boiler firing configuration with rows of stabilizers and fuel staging lances.
  • FIG. 13B is a simplified illustration of a tangential-fired power boiler firing configuration with rows of stabilizers and fuel staging lances.
  • FIG. 3 a device for stabilization of a flame in the form of a large scale vortex (LSV) device 12 for use with an ultra low NOx burner 10 (see FIGS. 5A and 8) in accordance with the present invention.
  • the LSV device 12 is comprised of an inner (secondary) air or oxidant pipe 14 recessed inside a fuel pipe 16, which is further recessed inside an outer (primary) air or oxidant pipe 18.
  • the primary oxidant e.g ., air
  • the secondary oxidant e.g ., air
  • Table I gives an example of specific velocity ranges and dimensionless ratios for obtaining a stable stream-wise vortex in the primary oxidant pipe 18.
  • V pa the velocity of the primary oxidant
  • V f the velocity of the fuel
  • V sa the velocity of the secondary oxidant
  • D f the diameter of the fuel pipe 16
  • L f the distance between the forward end of the fuel pipe 16 and the forward end of the primary oxidant pipe
  • D pa the diameter of the primary oxidant pipe
  • L sa the distance between the forward end of the secondary oxidant pipe 14 and the forward end of the fuel pipe 16
  • D sa the diameter of the secondary oxidant pipe 14.
  • the preferred average velocity ranges for fuel is about 0,610 is to 1,829m/s (2 to 6 ft/sec) for primary oxidant is 9,144 m/s to 27,432 m/s (30 to 90 ft/sec) and for secondary oxidant is 4,572m/s is to13,716 m/s (5 to 45 ft/sec).
  • the LSV flame stability is maintained at high excess airflow due to fluid flow reversal caused by a stream-wise vortex which, in turn, causes internal flue gas recirculation and provides preheating of air/fuel mixture and intense mixing of fuel, air and products of combustion to create ideal conditions for flame stability.
  • the LSV flame is found to anchor on the fuel pipe tip 22, i.e ., its forward end. Under normal operation, most LSV internal components remain at less than 537,8°C (1000°F).
  • FIGS. 4A and 4B show general NOx trends as a function of flame temperature and excess oxygen measured in the exhaust gas.
  • the LSV device 12 operation at extremely fuel lean conditions for ultra low-NOx emissions necessitates that combustion of the remaining fuel downstream be accomplished in a strategic manner to complete combustion, to avoid additional NO or CO formation, and to operate the burner system with a slight overall excess of oxygen (2 to 3%) in the exhaust.
  • FIG. 5A shows a schematic of the ultra low-NOx burner 10 in accordance with the present invention which combines the aforementioned LSV device 12 with strategic fuel staging lances 24 in a circular configuration.
  • the overall burner process can be described in three process elements: 1) extremely fuel-lean combustion, 2) large scale vortex for flame stability, and 3) fuel staging using strategically located fuel lances 24.
  • the LSV device 12 is surrounded in a cage type construction using multiple fuel staging lances 24.
  • the lances 24 are long steel pipes with specially designed staging nozzles 26 at the firing end. According to lab experiments, the optimum number of staging lances 24 can vary from 4 to 16 and each staging lance 24 has multiple diverging holes 28 (see FIGS.
  • the number of holes 28 per staging nozzle 26 can vary from a single hole for a less than 1,055 GJ/h (1 MM Btu/hr) burner to, for example, 4 holes for higher firing rate burners.
  • the number of staging holes 28 and their divergence angles (alpha and beta as described below) are chosen to accomplish complete circumferential coverage of the LSV flame for a circular configuration (see FIG. 5A), a flat configuration (see FIGS. 5B and 5C) or to accomplish a load shapping pattern (see FIGS. 12A and 12B).
  • FIG. 6 shows a schematic for a 4,22 GJ/h (4 MM Btu/hr) burner with a 0,254m (10 inch) diameter burner block.
  • Eight uniformly distributed staging fuel lances 24 (on a 0,178m (7 inch) pitch circle radius) and two diverging holes per staging lance provide a circular pattern.
  • FIGS. 7A, 7B and 7C show one typical design of staging lance nozzle 26 and geometry of staging holes 28 (note angles alpha and beta).
  • the complete envelope of staging fuel that is significantly diluted with combustion gases produces a very low temperature and combustion space filling flame.
  • the preferred range for angle alpha is between 8° and 24° and for angle beta is between 4° and 16°.
  • the holes 28 vary in size depending on staging fuel injection velocity range.
  • the preferred nozzle exit velocity range is between 91,44 m/s to 274,32 m/s (300 to 900 feet per second) for natural gas staging fuel.
  • For a single hole staging nozzle preferably, only an axial divergence angle alpha is used.
  • the above velocities (or nozzle hole sizes) vary depending on the fuel composition (and heating value) and burner firing capacity.
  • the complete ultra low NOx burner with LSV flame upstream and fuel staging downstream is illustrated in FIG. 8.
  • the various combustion processes are also shown. Referring to FIG. 8, the various burner flame processes are now described:
  • the LSV flame has a very low peak flame temperature (less than ⁇ 1093 °C ( ⁇ 2000° Fahrenheit) and produces very low NOx emissions. This is due to excellent mixing, avoidance of fuel-rich zones for prompt NOx formation (as observed in traditional flame holders) and completion of overall combustion under extremely fuel-lean conditions.
  • the recycling of exhaust gas in the LSV device 12 also reduces flame temperature due to product gas dilution. Table II gives laboratory firing data on the LSV device 12 under fuel lean firing conditions.
  • LSV device 12 produces very low NOx emissions at low firing rates and under extremely fuel-lean conditions.
  • high oxygen concentration and low CO 2 concentration indicate excess air operation accompanied by leakage of outside are through refractory cracks in the lab furnace.
  • Table II LSV lab firing data; LSV Firing Only, Furnace between 537,8°C and 815,6°C (1000° and 1500° Fahrenheit) LSV Firing Rate (MM Btu/hr) GJ/h Comb. Air Theo.
  • the LSV device 12 is generally fired at equivalence rations of 0.05 to 0.1. For example, if there is a total firing rate of 4,22 GJ/h (4 MM Btu/hr), the LSV device 12 is firing at 0,422 GJ/h (0.4 MM Btu/hr) and fuel staging lances 24 are set to inject fuel at 3,80 GJ/h (3.6 MM Btu/hr) the LSV device 12 will then supply total combustion air for 4,22 GJ/h (4.MM Btu/hr) or air at a 900% level for 0,422 GJ/h (0.4MM Btu/hr)firing rate.
  • the LSV flame is extremely fuel-lean, it is diluted with combustion air, and products of combustion from vortex action and the resulting peak flame temperature (as measured by a thermocouple probe before staging fuel jets meet the LSV flame) are less than 1093,3°C (2000° Fahrenheit).
  • the merge distance, X, between the LSV flame and the staging jets from the furnace wall is maintained at approximately 0,2032m to 1,2192m (8 to 48 inches) from the end of the burner and this distance depends on the burner-firing rate and staging fuel divergence angle (beta).
  • a measured merge distance was approximately 0,610m (24"). This distance is critical in keeping the flame free from visible radiation, providing combustion space filling characteristics, having low peak flame temperatures, and producing ultra low NOx emissions.
  • the dilution of combustion air using LSV products of combustion is also very important for reducing localized oxygen availability. For example, if 1019,59 m 2 /h (36,000 scfh) of combustion air (at ambient temperature) is mixed with approximate 815,5°C (1500°F) products of combustion from an LSV device 12 firing at 0,422 GJ/h (0.40 MM Btu/hr) firing rate, there is a localized dilution of combustion air. Additionally, oxygen concentration in the combustion air decreases from about 21% to 19%. This reduction in oxygen availability (which may be higher locally due to volumetric gas expansion) can reduce NOx emissions further when already diluted staging fuel reacts with the preheated air of reduced oxygen concentration. This dual effect of fuel dilution and air dilution are explained below under Circular Staging configuration.
  • Peak temperatures of the spacious flame occur outside the center core region of overall flame.
  • the temperature profile is a reflection of circular staging pattern and lower temperatures exist in the core region due to fuel-lean LSV products of combustion.
  • the peak flame temperatures never exceeded 1148,9°C (2100° Fahrenheit) at any transverse cross section along furnace length.
  • the fuel staging is performed using a circular staging configuration with multiple diverging lances 24 installed around the LSV device 12 or the burner block 17 exterior.
  • the fuel jets are injected in the furnace space using nozzles 26 of specific hole geometry. See FIGS. 7A, 7B, and 7C.
  • the resulting combustion (above auto ignition temperature) is controlled by chemical kinetics and by fuel jet mixing with the furnace gases and oxidant.
  • the carbon contained in the fuel molecule is drawn to complete oxidation with the diluted oxidant stream instead of the pyrolitic soot forming reactions of a traditional flame front.
  • combustion takes place in two stages.
  • fuel is converted to CO and H 2 in diluted, fuel rich conditions.
  • the dilution suppresses the peak flame temperatures and formation of soot species, which would otherwise produce a luminous flame.
  • CO and H 2 react with diluted oxidant downstream to complete combustion and form CO 2 and H 2 O.
  • a fuel jet significantly diluted (with N 2 , CO 2 and H 2 O) using furnace gas entrainment can readily react with furnace-oxidant to form a combustion space filling low-temperature flame.
  • the Handbook of Combustion, Vol. II illustrates lower NOx formation under diluted conditions as shown in FIG. 9.
  • FIG. 9 it is shown that the oxygen available under diluted conditions for NOx formation is further curtailed if oxidant is preheated to higher preheat temperatures.
  • the LSV device 12 supplies a preheated oxidant stream, which is also diluted in oxygen concentration due to mixing with it own products of combustion.
  • the amount of fuel staging (for natural gas fuel) can be anywhere from 70% to 95% of the total firing rate of the burner. This range provides extremely low NOx emissions (1 to 9 ppmv). Fuel staging range less than 70% can be used for spacious combustion if NOx emissions are not of concern. The fuel staging range above 95% can be used for gases containing hydrogen, CO or other highly flammable gases.
  • the burner also used less than 38,1 mm (1.5 inches) of water column pressure drop for the combustion air in the LSV device.
  • the preferred construction of the ultra low NOx burner uses concentric standard steel pipes or standard tubes welded in a telescopic fashion to satisfy the key LSV flow, velocity and dimensionless ratios (see above).
  • nominal firing rate LSV device 12 mav be built using standard 3 inch Schedule 40 pipe for the secondary oxidant pipe 14, a 0,1524 m (6 inch) Schedule 40 pipe for the fuel pipe 16, and an 0,2032m (8 inch) Schedule 40 pipe for the primary oxidant pipe.
  • the burner block 17 see FIG. 8) may be built using standard 0,254 m (10 inch).
  • the lances 24 may be 0,0127m (1 ⁇ 2 inch) schedule 40 pipe with nozzles 26 welded or threaded thereon.
  • These pipes may be made from, for example, carbon steel, aluminized steel, stainless steel, or high temperature alloy steels.
  • the cylindrical burner block 17 for the LSV flame is sized using a standard pipe size.
  • the burner block 17 may be sized one or two pipe sizes larger than the primary oxidant pipe 18 in the LSV device 12.
  • the primary oxidant pipe 18 may be an 0,203m (8 inch) Schedule 10 pipe.
  • the burner block was selected as 0,254 m (10 inch) 40 pipe (one standard pipe size larger).
  • the burner block 17 length is generally the same as the furnace wall thickness (e.g., about 0,305m (12") to 0,356m (14").
  • the design objective of the cylindrical burner block is to avoid LSV flame interference on the inside surface of the burner block, keeping burner block material cool (preventing thermal damage), and reducing the frictional pressure drop for the incoming combustion air.
  • the burner block cavity is preferred to be cylindrical or slightly conical (half cone angle less than 10°) in shape for several reasons. First, any staging fuel infiltration (back flow) into the burner block cavity is avoided. For large conically divergent blocks, it is very likely that the staging fuel may enter the low-pressure recirculation region inside burner block cavity to initiate premature combustion and overheating. Second, LSV flame envelope symmetry is maintained with corresponding fuel staging geometry in circular staging configuration. Finally, LSV flame momentum is fully maintained to create a stronger large scale vortex and to create delayed mixing with diluted fuel jets.
  • FIGS. 5B and 5C Schematic diagrams of flat staging configurations are shown in FIGS. 5B and 5C.
  • the staging lances 24a, 24b are placed in a linear fashion on both left and right sides of an LSV device 12a, 12b.
  • burner blocks 17a FIG. 5B
  • 17b FIG. 5C
  • the flame envelopes 30a, 30b are shown in dotted lines.
  • the separation distances "s" (see FIG. 5B) and "h” (see FIG. 5C) were determined experimentally based on NOx reduction and least amount of CO formation.
  • FIGS. 11A through 11D show several flat staging configurations for 4,22 Gjh (4 MM Btu/Hr) total firing rate and approximately 815,5°C (1500°F) average furnace operating temperature.
  • the lances 24, 24d, 24e, 24f were of various holes sizes, number of holes, and various radial and axial divergence angles. These values are noted in FIGS. 11 A through 11 D.
  • the lance locations and hole geometry was varied to understand the effect on staging fuel supply pressure as well as emissions of NO and CO. It was noticed that higher staging fuel supply pressure produced lower NOx emissions and vice-versa.
  • Some hydrogen furnaces in particular, reformers, which are direct-fired chemical reactors consisting of numerous tubes located in the furnace (firebox) and filled with catalyst. Conversion of hydrocarbon and steam to an equilibrium mixture of hydrogen, carbon oxides and residual methane takes place inside the catalyst tubes. Heat for the highly endothermic reaction is provided by burners in the firebox.
  • a Large Steam Methane Reformer (SMR) is usually of a top fired design. Top fired reformers have multiple rows of tubes in the firebox. The burners, for example, as many as 150, are located in an arch on each side of the tubes and heat is transferred to the tubes by radiation from the products of combustion. A burner utilizing flat staging would be ideal for top-fired SMR furnaces.
  • the ultra low NOx burner is configured in the shape identical to load geometry.
  • Each lance 24g has a pipe having a fuel staging nozzle at a firing end thereof and having at least one hole at end for staging fuel injection, as described above for the previous embodiments.
  • Each hole has a radial divergence angle and an axial divergence angle, as described above for the previous embodiments.
  • the hole or holes and the divergence angles provide a load shape coverage.
  • the burner in this configuration also provides NOx emissions of less than 9 ppmv.
  • single or multiple LSV devices 12g, 12g' are used and fuel staging lances 24g, 24g' are strategically placed parallel to load, such as boiler water tube envelope surface 42a, 42b, geometry (square, rectangle, trapezoidal, circular, elliptical or any other load shape by combination of various primary shapes).
  • load such as boiler water tube envelope surface 42a, 42b, geometry (square, rectangle, trapezoidal, circular, elliptical or any other load shape by combination of various primary shapes).
  • the objective of above staging strategy is to entrain relatively cooler furnace gases in the vicinity of load surface (e.g. water or process tubes) and create a low-temperature overall spacious flame.
  • staging lances 24g, 24g' are used per LSV device 12g and each staging nozzle has between 1 hole and 4 holes.
  • the lances 24g, 24g' can be configured parallel to the load geometry and can be positioned in several parallel rows.
  • the radial divergence angle is between 8° and 24° and the axial divergence angle is between 0° and 16°.
  • the velocity of fuel exiting the nozzle is preferably between 91,44 m/s to 274, 32 m/s (300to 900 feet per second) for a natural gas staging fuel.
  • the load shaping staging can be implemented using either wall fired firing boiler 34 configuration, see FIG. 13A or tangentially fired firing configuration 36. see FIG. 13B.
  • Most power boilers are much larger in capacity and use anywhere from 10 to 20 burners per firing wall and typical firing capacity is about 1,055 GJ/h ( 1 billion Btu/hr).
  • the burners are placed in several rows and they share common manifold 38 for combustion air.
  • the low NOx burners 12g can be placed in similar geometrical locations and share common combustion air supply through a rectangular air manifold 38.
  • the most important design aspect for achieving low NOx emissions would be to use multiple fuel lances 24g on the firing wall in several rows between LSV devices 12g to create spacious flame 32.
  • Furnaces gases are entrained in the staged fuel jets before combusting with combustion air discharged from LSV device 12g.
  • the power boilers have refractory line combustion chamber or radiation zone where most of the fuel is combusted and then hot products of combustion travel upward to heat water-tubes or load in the convection zone, and then economizer section before discharged out to the stack.
  • over-fired air portion of combustion air 5 to 25%
  • Figure 13B shows tangentially-fired power boiler, where all four corners are used to create a swirling or tangential flow pattern 40 inside a square furnace radiation zone 42.
  • the combustion air supplied by air registers and the proposed low NOx burners are mounted in several rows on all four corners.
  • the load shaping fuel lances 12g can be installed in several rows between LSV devices 12g to create a tangential or swirling spacious flame.
  • each staging nozzle has between 1 hole and 4 holes.
  • the lances can be configured parallel to the load geometry and can be positioned in several parallel rows.
  • the radial divergence angle is between 8° and 24° and the axial divergence angle is between 0° and 16°.
  • the velocity of fuel exiting the nozzle is preferably between 91,44 m/s to 274,32 m/s (300 to 900 feet per second) for a natural gas staging fuel.
  • an oxidant with an oxygen concentration between 10 and 21% may be used or an enriched oxidant, i.e., greater than 21% and less than 50% oxygen content may be used.
  • the oxidant is at ambient conditions to a preheated level, for example 93,3°C to 1315,5°C (200 degrees F to 2400 degrees F).

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
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  • General Engineering & Computer Science (AREA)

Claims (31)

  1. Brenner für Prozessheizung mit sehr niedrigem (ultraniedrigem) NOx Ausstoß mit:
    a) einem fluid-basierten Flammenstabilisator, der eine brennstoffmagere Flamme bei dem Äquivalenzverhältnis im Bereich von phi = 0,05 bis phi = 0,3 zur Verfügung stellen kann;
    b) mehreren Brennstoff-Lanzen mit gestufter Feuerungsführung (fuel staging lances) (24, 24a-24g'), die den Flammenstabilisator umgeben, wobei jede Lanze (24, 24a-24g') ein Rohr mit einer Abstufungsdüse (26) an ihrem Feuerende aufweist und jede Lanze (24, 24a-24g') wenigstens ein Loch (28) für die abgestufte Brennstoffinjektion jedes Loch (28) einen radialen Divergenzwinkel und einen axialen Divergenzwinkel hat;
    dadurch gekennzeichnet, dass dieses wenigstens eine Loch (28) und die Divergenzwinkel angepasst sind, um eine vollständige Umfangsabdeckung der brennstoffmageren Flamme zur Verfügung zu stellen, wodurch NOx Emissionen von weniger als 9 ppmv bei nahezu stoichiometrischen Bedingungen erzeugt werden.
  2. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei das wenigstens eine Loch (28) und die Divergenzwinkel angepasst sind, um ein flaches Flammmuster zur Verfügung zu stellen.
  3. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei das wenigstens eine Loch (28) und die Divergenzwinkel angepasst sind, um ein lastformendes Flammenmuster zur Verfügung zu stellen.
  4. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei die Brennstoff-Abstufungslanzen (24, 24a-24g') zwischen 4 und 16 Abstufungslanzen (24, 24a-24g') pro Flammenstabilisator aufweisen.
  5. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei jede Abstufungsdüse (26) zwischen einem Loch (28) und vier Löchern (28) hat.
  6. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei der radiale Divergenzwinkel zwischen 8° und 24° beträgt.
  7. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei der axiale Divergenzwinkel zwischen 4° und 16° beträgt.
  8. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei die Düse (26) angepasst ist, so dass Brennstoff aus der Düse (26) bei einer Rate von 91,44 m/s bis 274,32 m/s (300 bis 900 Fuß pro Sekunde) für Erdgas-Abstufungs-Brennstoff austreten kann.
  9. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei der fluid-basierte Flammenstabilisator eine großformatige Vortexvorrichtung (12) ist.
  10. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei die großformatige Wirbelvorrichtung (12) angepasst ist, um eine brennstoffmagere Flamme zur Verfügung zu stellen, die eine Spitzenflammentemperatur von weniger als näherungsweise 1093°C (2000° Fahrenheit) hat.
  11. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei das Äquivalenzverhältnis im Bereich von phi = 0,05 bis phi = 0,1 beträgt.
  12. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei der Abstand von dem vorderen Ende des Brenners zu einem Punkt, wo das Mischen der Abstufungsflamme und der Flamme des Flammenstabilisators auftritt, näherungsweise 0,2032 m bis 1,2192 m (8 bis 48 Zoll) beträgt.
  13. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei das Brennstoffverhältnis der Abstufung für Erdgas-Brennstoff von 70% bis 95% der Gesamtbrennstoff-Feuerungsrate des Brenners ist.
  14. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1 mit einem Brennerblock (17) der koaxial zu dem Flammenstabilisator ist.
  15. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 14, wobei der Brennerblock (17) eine leicht konische Form hat.
  16. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 14, wobei der Brennerblock (17) eine rechtwinklige Form hat.
  17. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 1, wobei der fluid-basierte Flammenstabilisator die Form einer großformatigen Vortex- bzw. Wirbelvorrichtung (12) hat, die eine brennstoff-magere Flamme bei einem Äquivalenzverhältnis im Bereich von phi = 0,05 bis phi = 0,3 zur Verfügung stellen kann und zwischen 4 und 16 Brennstoff-Abstufungslanzen (24, 24a-24g') pro Flammenstabilisator in der Nähe des Flammenstabilisators aufweist, wobei weiterhin jede Lanze (24, 24a-24g') ein Rohr mit einer Abstufungsdüse (26) an ihrem Feuerungsende aufweist, jede Lanze (24, 24a-24g') zwischen einem und vier der Löcher (28) für die Abstufungs-Brennstoff-Injektion hat und jedes Loch (28) einen radialen Divergenzwinkel und einen axialen Divergenzwinkel hat.
  18. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei die Brennstoff-Abstufungs-Lanzen (24, 24a-24g') den Flammenstabilisator und das wenigstens eine Loch (28) umgeben und die Divergenzwinkel angepasst sind, um eine vollständige Umfangs-Abdeckung der brennstoff-mageren Flamme für die zirkulare Abstufung zur Verfügung zu stellen.
  19. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei die Brennstoff-Abstufungs-Lanzen (24, 24a-24g') in einer linearen bzw. linienförmigen Art in einer einzigen oder mehreren Reihen auf jeder Seite des Flammenstabilisators positioniert sind, und wobei das wenigstens eine Loch (28) und die Divergenzwinkel angepasst sind, um ein flaches Flammenprofil zur Verfügung zu stellen.
  20. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei die Brennstoff-Abstufungs-Lanzen (24, 24a-24g') in einer linearen bzw. linienförmigen Art in einer einzigen oder mehreren Reihen auf jeder Seite des Flammenstabilisators positioniert sind, wobei das wenigstens eine Loch (28) und die Divergenzwinkel angepasst sind, um eine Flamme zur Verfügung zu stellen, die zwischen zwei parallelen flachen Ebenen beschränkt bzw. eingeschränkt bzw. begrenzt ist.
  21. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei die Brennstoff-Abstufungs-Lanzen (24, 24a-24g') in einer geometrischen Art und nahezu parallel zu einer Lastgeometrie in einer einzigen oder mehreren Reihen und nahe bei dem Flammenstabilisator positioniert sind, wobei das wenigstens eine Loch (28) und die Divergenzwinkel angepasst sind, um eine Flamme zur Verfügung zu stellen, die zwischen zwei parallelen flachen Ebenen eingeschränkt bzw. begrenzt ist.
  22. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei der radiale Divergenzwinkel zwischen 8° und 24° liegt, während der axiale Divergenzwinkel zwischen 4° und 16° beträgt.
  23. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei die Düse (26) angepasst ist, so dass der Brennstoff aus der Düse (26) bei einer Rate von 91,44 m/s bis 274,32 m/s (300 bis 900 Fuß pro Sekunde) für Erdgas-Abstufungs-Brennstoff austreten kann.
  24. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei die großformatige Wirbelvorrichtung angepasst ist, um eine brennstoffmagere Flamme zur Verfügung zu stellen, die eine Spitzenflammentemperatur von weniger als näherungsweise 1093°C (2000° Fahrenheit) hat.
  25. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei das Äquivalenzverhältnis im Bereich von phi = 0,05 bis phi = 0,1 liegt.
  26. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei der Abstand von dem vorderen Ende des Brennstoff-Rohrs des Flammenstabilisators zu einem Punkt, wo das Mischen der Abstufungsflamme und der Flamme des Flammenstabilisators auftritt, näherungsweise 0,2032 m bis 1,2192 m (8 bis 84 Zoll) beträgt.
  27. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei die Brennstoff-Rate der Abstufung für Erdgas-Brennstoff von 70% bis 95% der Gesamt-Brennstofffeuerungsrate des Brenners beträgt.
  28. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17 mit einem Brennerblock (17), der koaxial zu dem Flammenstabilisator ist.
  29. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 28, wobei der Brennerblock (17) eine leicht konische Form hat.
  30. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 28, wobei der Brennerblock (17) eine rechtwinklige Form hat.
  31. Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoß nach Anspruch 17, wobei der Trennungsabstand zwischen einzelnen Brennstofflanzen (24, 24a-24g') ungefähr 5,08 cm bis 30,48 cm (2 bis 12 Zoll) beträgt.
EP03001381A 2002-01-31 2003-01-27 Brenner für Prozessheizung mit sehr niedrigem NOx Ausstoss Expired - Lifetime EP1335163B2 (de)

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US10/062,597 US6752620B2 (en) 2002-01-31 2002-01-31 Large scale vortex devices for improved burner operation
US62597 2002-01-31
US67450 2002-02-05
US10/067,450 US6773256B2 (en) 2002-02-05 2002-02-05 Ultra low NOx burner for process heating

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EP1335163B1 true EP1335163B1 (de) 2006-09-06
EP1335163B2 EP1335163B2 (de) 2012-05-09

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EP1335163A1 (de) 2003-08-13
DE60308071T2 (de) 2007-03-01
ES2271391T5 (es) 2012-07-02
DE60308071D1 (de) 2006-10-19
EP1335163B2 (de) 2012-05-09
DE60308071T3 (de) 2012-10-25
ATE338916T1 (de) 2006-09-15
ES2271391T3 (es) 2007-04-16

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