EP1531303B1 - Alimentation en carburant étagée pour utilisations à faibles émissions de NOx - Google Patents

Alimentation en carburant étagée pour utilisations à faibles émissions de NOx Download PDF

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Publication number
EP1531303B1
EP1531303B1 EP04026942A EP04026942A EP1531303B1 EP 1531303 B1 EP1531303 B1 EP 1531303B1 EP 04026942 A EP04026942 A EP 04026942A EP 04026942 A EP04026942 A EP 04026942A EP 1531303 B1 EP1531303 B1 EP 1531303B1
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Prior art keywords
fuel
conduit
stream
outlet
outtake
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German (de)
English (en)
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EP1531303A1 (fr
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Mahendra Ladharam Joshi
Xianming Jimmy Li
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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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L7/00—Supplying non-combustible liquids or gases, other than air, to the fire, e.g. oxygen, steam
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23K—FEEDING FUEL TO COMBUSTION APPARATUS
    • F23K5/00—Feeding or distributing other fuel to combustion apparatus
    • F23K5/002—Gaseous fuel
    • F23K5/007—Details
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23R—GENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
    • F23R3/00—Continuous combustion chambers using liquid or gaseous fuel
    • F23R3/28—Continuous combustion chambers using liquid or gaseous fuel characterised by the fuel supply
    • 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
    • F23C2202/20—Premixing fluegas with fuel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23K—FEEDING FUEL TO COMBUSTION APPARATUS
    • F23K2900/00—Special features of, or arrangements for fuel supplies
    • F23K2900/05004—Mixing two or more fluid fuels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L2900/00—Special arrangements for supplying or treating air or oxidant for combustion; Injecting inert gas, water or steam into the combustion chamber
    • F23L2900/07002—Injecting inert gas, other than steam or evaporated water, into the combustion chambers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L2900/00—Special arrangements for supplying or treating air or oxidant for combustion; Injecting inert gas, water or steam into the combustion chamber
    • F23L2900/07009—Injection of steam into the combustion chamber

Definitions

  • the present invention relates to fuel staging processes and systems for reducing nitrogen oxide (NOx) emissions, and in particular to such processes and systems using fuel dilution tips in low NOx burners.
  • NOx nitrogen oxide
  • CPI Chemical Process Industry
  • waste fuels contain a cocktail of higher C/H ratio gases which combust with very luminous flames due to carbon oxidation and also produce soot particles or carbon depending on the combustion process.
  • Typical refinery fuel composition contains varying amounts of fuels and inert gases (e.g. , C1, C2, C3,...Cn, olefins, hydrogen, nitrogen, CO2, water vapor). If carbon or soot particles are formed on the fuel tips, the soot structure generally grows under favorable pressure and temperature conditions existing near the tip exit.
  • Dirty refinery fuels consisting of higher carbon and containing gases such as acetylene, ethane, propane, butane and olefins (e.g. , ethylene and propylene) generally produce soot particles if fuel tips are subjected to:
  • the burner or tip design significantly affect tip overheating, soot production, tip plugging, and resulting frequent maintenance for the burner equipment. These problems are compounded by changing process conditions, such as low end of process turndown and/or interruption of fuel flows, which affect required cooling needed on the fuel tips. Changing process conditions and fuel composition changes are common in refinery operation.
  • low NOx burners have not consistently produced less than 10 ppm NOx in various process heating applications, such as steam methane reformers (SMR), crude heaters, ethylene crackers, or boilers. For this reason, the use of low NOx burners has not been certified by regulating agencies as the BACT. In other words, SCR currently is the only commercially viable solution for meeting stringent NOx levels in ozone attainment regions where ground level ozone concentration exceeds legal limits.
  • the common NOx control methods include utilization of low NOx burners equipped with higher levels of fuel staging and dilution of air/fuel with flue gas recirculation (FGR).
  • FGR flue gas recirculation
  • these methods require additional piping and energy costs associated with the transport of flue gas.
  • the field data published in the literature do not indicate that these methods achieve less than 10 ppm NOx performance.
  • U.S. Patent Application No. 2003/0148236 discloses an ultra low NOx burner using staged fuel nozzles.
  • the burner has eight fuel staging lances located around the main burner body. The center part of the burner is used for supplying 100% of the combustion air and a very small amount of fuel ( ⁇ 10%) is injected for overall flame stability. The rest of the fuel (- 90%) is injected using multiple fuel staging lances.
  • the fuel staging lances have special fuel nozzle tips with two circular holes.
  • these lances have axial and radial divergence angles for delayed mixing with the combustion air and entraining furnace gases due to a relatively high jet velocity (152 to 305 m/s (500 to 1,000 feet/sec) or 34500 to 103000 N/m 2 (5 to 15 psig) fuel supply pressure depending on the firing rate).
  • U.S. Pat. No. 6,383,462 discloses a method and an apparatus which has a mixing chamber outside of the "burner and furnace" for mixing flue gases from the furnace with the fuel gas, as shown in Figure 2 .
  • a converging diverging venturi mixer is utilized to further dilute the fuel gas with additional flow motivating gas.
  • the resulting mixture (diluted fuel with flue gas) is then sent to the burner wherein the mixture is combined with the combustion air and burned in the furnace.
  • a NOx emission reduction from 26 ppm to 14 ppm may be obtained.
  • This apparatus and method do not reduce NOx emissions below 10 ppm and the results are not comparable to those typically achieved with SCR technology.
  • U.S. Pat. No. 6,481,209 discloses a fuel staging system suitable for gas turbine engines. Efficient combustion with air is achieved with lower NOx and CO emissions by splitting fuel injection in two stages: 1) injectors installed in swirl mixers, and 2) injectors installed in the trapped vortex region of the combustor.
  • this injection scheme is not suitable for large furnaces where trapped vortex zones are not possible due to furnace and load geometry.
  • U.S. Pat. No. 6,558,154 discloses a control based fuel staging strategy for an aero engine in which two separate instrumented fuel staging nozzles are used.
  • a set of emission and pulsation sensors are installed downstream of each staging zone. These sensors measure the quality of combustion products issued from each staging zone and then a control unit varies relative amounts of fuels injected in each zone depending on changing operating and environmental conditions.
  • U.S. Pat. No. 5,601,424 discloses a method for reducing NOx using atomizing steam injection control.
  • the NOx levels are lowered by adding to the burner flame atomizing steam, which is available for fuel oil atomization.
  • 30% NOx reduction approximately 0,227 kg steam/0,454 kg of fuel flow (0.5 lb steam/lb of fuel flow) is necessary.
  • a large amount of steam is necessary to reduce flame temperature and obtain a required NOx reduction.
  • a large amount of steam is used for flame quenching, there is a possibility of flame instability and sputtering.
  • the gas turbine industry also uses a similar steam injection technique for NOx control.
  • a large economic penalty is paid in order to reduce NOx emissions.
  • the steam consumption is very large, and the technique is relatively inefficient and not cost effective for NOx control.
  • the present invention is a method and a system for diluting a fuel to reduce nitrogen oxide emissions through fuel staging.
  • the invention also includes a fuel dilution device that may be used in the method or the system.
  • the first step is to provide a fuel dilution device, which includes: a first conduit having an inlet and an outlet spaced apart from the inlet, the first conduit adapted to transmit a stream of the fuel entering the inlet and exiting the outlet at a first thermodynamic state and a first fuel index; and a second conduit having an intake and an outtake spaced apart from the intake, the second conduit adapted to transmit a stream of a fluid entering the intake and exiting the outtake at a second thermodynamic state and a second fuel index, the second fuel index being different from the first fuel index by at least about 0.1 and the second thermodynamic state being different from the first thermodynamic state, whereby a potential for mixing exists between the stream of the fuel exiting the outlet of the first conduit and the stream of the fluid exiting the outtake of the second conduit.
  • the second step is to feed the stream of the fuel to the inlet of the first conduit, said stream of the fuel exiting the outlet of the first conduit at the first thermodynamic state and the first fuel index.
  • the third step is to feed the stream of the fluid to the intake of the second conduit, said stream of the fluid exiting the outtake of the second conduit at the second thermodynamic state and the second fuel index, whereby at least a portion of the stream of the fuel exiting the outlet of the first conduit mixes with at least a portion of the stream of the fluid exiting the outtake of the second conduit at a location proximate both the outlet and the outtake, thereby generating at least one diluted fuel stream having an intermediate fuel index between the first fuel index and the second fuel index.
  • the fourth step is to provide a source of an oxidant.
  • the fifth step is to combust a portion of the oxidant with at least a portion of at least one of the stream of the fuel, or the stream of the fluid, or the diluted fuel stream, thereby generating a gas containing a reduced amount of nitrogen oxide, said reduced amount of nitrogen oxide being less than a higher amount of nitrogen oxide that would be generated by combusting the fuel using a means other than the fuel dilution device.
  • the fluid is a fuel.
  • the fluid is selected from a group consisting of steam, flue gas, carbon dioxide, nitrogen, argon, helium, xenon, krypton, other inert fluids, and mixtures or combinations thereof.
  • the first conduit is adjacent the second conduit.
  • at least a substantial portion of the second conduit is disposed in the first conduit.
  • the second conduit has an equivalent diameter (D c ) and the outtake of the second conduit is located at a distance behind the outlet of the first conduit, said distance being in a range of about (2 D c ) to about (20 D c ).
  • a second embodiment of the method for diluting a fuel to reduce nitrogen oxide emissions through fuel staging is similar to the first embodiment but includes two additional steps.
  • the first additional step is to provide a swirler disposed in the second conduit.
  • the second additional step is to transmit at least a portion of the stream of the fluid through the swirler, thereby swirling at least a portion of the fluid exiting the second conduit.
  • a zipper nozzle is provided in fluid communication with the outlet of the first conduit. This enables to transmit through the zipper nozzle at least a portion of a diluted fuel stream.
  • Another embodiment of the method is similar to the first embodiment but includes the additional step of placing the fuel dilution device in fluid communication with a furnace containing a quantity of a furnace gas, whereby at least a portion of the quantity of the furnace gas mixes with at least a portion of the diluted fuel stream.
  • the first step is to provide a fuel dilution device, which includes: a first conduit having an inlet and an outlet spaced apart from the inlet, the first conduit adapted to transmit a stream of the fuel entering the inlet and exiting the outlet at a first pressure, a first velocity, and a first fuel index; and a second conduit having an intake and an outtake spaced apart from the intake, the second conduit adapted to transmit a stream of a fluid entering the intake and exiting the outtake at a second pressure, a second velocity, and a second fuel index, the second fuel index being different from the first fuel index by at least about 0.1 and at least one of the second pressure and the second velocity being different from at least one of the first pressure and the first velocity, whereby a potential for mixing exists between the stream of the fuel exiting the outlet of the first conduit and the stream of the fluid exiting the outtake of the second conduit.
  • the second step is to feed the stream of the fuel to the inlet of the first conduit, said stream of the fuel exiting the outlet of the first conduit at the first pressure, the first velocity, and the first fuel index.
  • the third step is to feed the stream of the fluid to the intake of the second conduit, said stream of the fluid exiting the outtake of the second conduit at the second pressure, the second velocity, and the second fuel index, whereby at least a portion of the stream of the fuel exiting the outlet of the first conduit mixes with at least a portion of the stream of the fluid exiting the outtake of the second conduit at a location proximate both the outlet and the outtake, thereby generating at least one diluted fuel stream having an intermediate fuel index between the first fuel index and the second fuel index.
  • the fourth step is to provide a source of an oxidant.
  • the fifth step is to combust a portion of the oxidant with at least a portion of at least one of the stream of the fuel, or the stream of the fluid, or the diluted fuel stream, thereby generating a gas containing a reduced amount of nitrogen oxide, said reduced amount of nitrogen oxide being less than a higher amount of nitrogen oxide that would be generated by combusting the fuel using a means other than the fuel dilution device.
  • the first element is a first conduit having an inlet and an outlet spaced apart from the inlet, the first conduit adapted to transmit a stream of a fuel entering the inlet and exiting the outlet at a first thermodynamic state and a first fuel index.
  • the second element is a second conduit having an intake and an outtake spaced apart from the intake, the second conduit adapted to transmit a stream of a fluid entering the intake and exiting the outtake at a second thermodynamic state and a second fuel index, the second fuel index being different from the first fuel index by at least about 0.1 and the second thermodynamic state being different from the first thermodynamic state, whereby a potential for mixing exists between the stream of the fuel exiting the outlet of the first conduit and the stream of the fluid exiting the outtake of the second conduit, whereby at least a portion of the stream of the fuel exiting the outlet of the first conduit mixes with at least a portion of the stream of the fluid exiting the outtake of the second conduit at a location proximate both the outlet and the outtake, thereby generating at least one diluted fuel stream having an intermediate fuel index between the first fuel index and the second fuel index.
  • the third element is a source of an oxidant.
  • the fourth element is a means for combusting a portion of the oxidant with at least a portion of at least one of the stream of the fuel, or the stream of the fluid, or the diluted fuel stream, thereby generating a gas containing a reduced amount of nitrogen oxide, said reduced amount of nitrogen oxide being less than a higher amount of nitrogen oxide that would be generated by combusting the fuel using a means other than the fuel dilution device.
  • the fluid is a fuel.
  • the fluid is selected from a group consisting of steam, flue gas, carbon dioxide, nitrogen, argon, helium, xenon, krypton, other inert fluids, and mixtures or combinations thereof.
  • the first conduit is adjacent the second conduit.
  • at least a substantial portion of the second conduit is disposed in the first conduit.
  • the second conduit has an equivalent diameter (D c ) and the outtake of the second conduit is located at a distance behind the outlet of the first conduit, said distance being in a range of about (2 x D c ) to about (20 x D c ).
  • the fuel dilution device is in fluid communication with a furnace containing a quantity of a furnace gas, whereby at least a portion of the quantity of the furnace gas mixes with at least a portion of the diluted fuel stream.
  • a second embodiment of the fuel dilution device is similar to the first embodiment but includes a swirler disposed in the second conduit.
  • the fuel dilution device includes a zipper nozzle in fluid communication with the outlet of the first conduit.
  • the first element is a first conduit having an inlet and an outlet spaced apart from the inlet, the first conduit adapted to transmit a stream of a fuel entering the inlet and exiting the outlet at a first pressure, a first velocity, and a first fuel index.
  • the second element is a second conduit having an intake and an outtake spaced apart from the intake, the second conduit adapted to transmit a stream of a fluid entering the intake and exiting the outtake at a second pressure, a second velocity, and a second fuel index, the second fuel index being different from the first fuel index by at least about 0.1 and at least one of the second pressure and the second velocity being different from at least one of the first pressure and the first velocity, whereby a potential for mixing exists between the stream of the fuel exiting the outlet of the first conduit and the stream of the fluid exiting the outtake of the second conduit, whereby at least a portion of the stream of the fuel exiting the outlet of the first conduit mixes with at least a portion of the stream of the fluid exiting the outtake of the second conduit at a location proximate both the outlet and the outtake, thereby generating at least one diluted fuel stream having an intermediate fuel index between the first fuel index and the second fuel index.
  • the third element is a source of an oxidant.
  • the fourth element is a means for combusting a portion of the oxidant with at least a portion of at least one of the stream of the fuel, or the stream of the fluid, or the diluted fuel stream, thereby generating a gas containing a reduced amount of nitrogen oxide, said reduced amount of nitrogen oxide being less than a higher amount of nitrogen oxide that would be generated by combusting the fuel using a means other than the fuel dilution device.
  • the first element is a fuel dilution device, which includes: a first conduit having an inlet and an outlet spaced apart from the inlet, the first conduit adapted to transmit a stream of the fuel entering the inlet and exiting the outlet at a first thermodynamic state and a first fuel index; and a second conduit having an intake and an outtake spaced apart from the intake, the second conduit adapted to transmit a stream of a fluid entering the intake and exiting the outtake at a second thermodynamic state and a second fuel index, the second fuel index being different from the first fuel index by at least about 0.1 and the second thermodynamic state being different from the first thermodynamic state, whereby a potential for mixing exists between the stream of the fuel exiting the outlet of the first conduit and the stream of the fluid exiting the outtake of the second conduit.
  • the second element is a means for feeding the stream of the fuel to the inlet of the first conduit, said stream of the fuel exiting the outlet of the first conduit at the first thermodynamic state and the first fuel index.
  • the third element is a means for feeding the stream of the fluid to the intake of the second conduit, said stream of the fluid exiting the outtake of the second conduit at the second thermodynamic state and the second fuel index, whereby at least a portion of the stream of the fuel exiting the outlet of the first conduit mixes with at least a portion of the stream of the fluid exiting the outtake of the second conduit at a location proximate both the outlet and the outtake, thereby generating at least one diluted fuel stream having an intermediate fuel index between the first fuel index and the second fuel index.
  • the fourth element is a source of an oxidant.
  • the fifth element is a means for combusting a portion of the oxidant with at least a portion of at least one of the stream of the fuel, or the stream of the fluid, or the diluted fuel stream, thereby generating a gas containing a reduced amount of nitrogen oxide, said reduced amount of nitrogen oxide being less than the high amount of nitrogen oxide that would be generated by combusting the fuel using a means other than the fuel dilution device.
  • the first element is a fuel dilution device, which includes: a first conduit having an inlet and an outlet spaced apart from the inlet, the first conduit adapted to transmit a stream of the fuel entering the inlet and exiting the outlet at a first pressure, a first velocity, and a first fuel index; and a second conduit having an intake and an outtake spaced apart from the intake, the second conduit adapted to transmit a stream of a fluid entering the intake and exiting the outtake at a second pressure, a second velocity, and a second fuel index, the second fuel index being different from the first fuel index by at least about 0.1 and at least one of the second pressure and the second velocity being different from at least one of the first pressure and the first velocity, whereby a potential for mixing exists between the stream of the fuel exiting the outlet of the first conduit and the stream of the fluid exiting the outtake of the second conduit.
  • the second element is a means for feeding the stream of the fuel to the inlet of the first conduit, said stream of the fuel exiting the outlet of the first conduit at the first pressure, the first velocity, and the first fuel index.
  • the third element is a means for feeding the stream of the fluid to the intake of the second conduit, said stream of the fluid exiting the outtake of the second conduit at the second pressure, the second velocity, and the second fuel index, whereby at least a portion of the stream of the fuel exiting the outlet of the first conduit mixes with at least a portion of the stream of the fluid exiting the outtake of the second conduit at a location proximate both the outlet and the outtake, thereby generating at least one diluted fuel stream having an intermediate fuel index between the first fuel index and the second fuel index.
  • the fourth element is a source of an oxidant.
  • the fifth element is a means for combusting a portion of the oxidant with at least a portion of at least one of the stream of the fuel, or the stream of the fluid, or the diluted fuel stream, thereby generating a gas containing a reduced amount of nitrogen oxide, said reduced amount of nitrogen oxide being less than a higher amount of nitrogen oxide that would generated by combusting the fuel using a means other than the fuel dilution device.
  • Figure 1A is a cross-sectional plan view of a prior art fuel staging nozzle used in an ultra low-NOx burner
  • Figure 1B is a cross-sectional elevation view of the prior art fuel staging nozzle of Figure 1A ;
  • Figure 1C is a side view of the prior art fuel staging nozzle of Figure 1 B;
  • Figure 2 is a cross-sectional elevation view of a prior art mixing chamber for mixing flue gases from a furnace and a flow motivating gas with a fuel gas;
  • Figure 3 is a schematic diagram illustrating a cross-sectional view of one embodiment according to the prior art.
  • Figure 4 is a schematic diagram illustrating a cross-sectional view of another embodiment according to the prior art.
  • Figure 5A is a schematic diagram illustrating another embodiment according to the prior art which uses strong jet-weak jet entrainment
  • Figure 5B is a schematic diagram illustrating a cross-sectional view of another embodiment according to the prior art; which uses a swirl induced entrainment;
  • Figure 6 is a schematic diagram illustrating a cross-sectional view of another embodiment according to the prior art.
  • Figure 7 is a schematic diagram illustrating a cross-sectional view of an embodiment of the invention which includes a zipper tip or nozzle;
  • Figure 8A is a schematic diagram illustrating a front view of a zipper tip or nozzle
  • Figure 8B is a schematic diagram illustrating a side view of a zipper tip or nozzle attached to a lance, such as that shown in Figure 7 ;
  • Figure 8C is a schematic diagram illustrating a plan view of a zipper tip or nozzle
  • Figure 8D is a schematic diagram illustrating a portion of the front view of the zippertip or nozzle in Figure 8A in detail for dimensioning.
  • Figure 9 is a schematic diagram illustrating a cross-sectional view of another embodiment of the invention which includes a zipper tip or nozzle.
  • the present invention addresses a number of issues encountered in combustion equipment design, such as burners used for heating reformers, process heaters, boilers, ethylene crackers, or other high temperature furnaces.
  • the invention relates to an improved fuel staging process.
  • two general approaches that provide for rapid dilution and mixing, depending on the required process objectives, are:
  • FI fuel index
  • FI fuel index
  • C i x i / ⁇ x i the number of carbon atoms and the mole fraction of component i, respectively.
  • the fuel indices of a number of fuels and inerts are listed in Table I. Generally, a fuel with a higher fuel index cracks more easily and produces more NOx through the prompt NOx mechanism. H2 is a special case in this definition.
  • H2 does not have any carbon atoms
  • H2 addition in natural gas increases NOx emissions.
  • the literature suggests that about a 30% higher NOx emission occurs for pure H2 flames as compared to methane flames.
  • the increased NOx emission from H2 flames is attributable to higher flame temperatures via the thermal NOx mechanism. Since the fuel index is used as an indicator for NOx emissions herein, a value of 1.3 is assigned to H2 to be consistent with its NOx emission potential.
  • Table I Fuel Indices for Selected Fuels and Inerts Fuels or Inerts Fuel Index H2 1.3 H2O 0 CO2 0 CO 1 N2 0 CH4 1 C3H8 3 ROG (1) 1.434 PSA offgas (2) 0.57 Natural gas (3) 1.08 Natural gas (4) 1.14 (1) ROG: H2 18%, CH4 44%, C2H2 38%. (2) PSA offgas: H2 30%. CH4 18%, CO2 52%. (3) Natural gas: CH4 91 %, C2H6 4%, C3H8 3%, N2 1%, CO2 1%. (4) Natural gas: CH4 84%, C2H6 12%, C3H8 2%, N2 2%.
  • thermodynamic state is defined as a state of existence for a matter. This definition is based on the generally known concept of thermodynamics, but with an extension to include not only the usual temperature and pressure but also velocity, concentration, composition, volume fraction, flow rate, electric potential, etc. , to completely characterize a stream. This definition is used to precisely define mixing as the result of a difference in the thermodynamic state between two streams.
  • This approach may be used to combust refinery waste fuels at a high supply pressure that contain a blend of hydrogen and higher C/H fuels (ethane, propane, butane, olefins, etc. ) with a second relatively cleaner, low-pressure fuel gas.
  • C/H fuels ethane, propane, butane, olefins, etc.
  • Maintenance problems arise with such refinery waste fuel due to thermal cracking of the high C/H fuels and subsequent soot build-up in the burner fuel tips.
  • combustion of such fuels results in higher than normal NOx emissions.
  • the dirty fuel is diluted with a relatively cleaner (secondary) fuel stream (e.g. , hydrogen, syngas, natural gas, or a low kg (BTU) fuel blend).
  • a relatively cleaner (secondary) fuel stream e.g. , hydrogen, syngas, natural gas, or a low kg (BTU) fuel blend.
  • a high-pressure refinery fuel gas containing high C/H ratio fuel gases
  • a relatively clean, low-pressure fuel gas such as natural gas, syngas, process gas, PSA off gas (recycled fuel gas after removing product hydrogen from PSA adsorbent beds), etc is injected through an annular region 33 between the center lance 32 and an outer lance 34.
  • the exit 36 of the center lance is recessed a preferred distance from the exit 38 of the outer lance.
  • This distance preferably is 2 to 20 times the equivalent diameter (Dc) of the center lance.
  • the distance preferably is 1,59 to 25,4 mm (about 1/16" to 1").
  • the arrangement shown in Figure 3 allows the dirty high-pressure refinery fuel gas to mix with the cleaner low-pressure fuel gas due to turbulent jet interaction.
  • the velocity of the high-pressure refinery fuel gas through the center lance 32 preferably is 274 to 427 m/s (about 900 to 1400 feet/sec) (preferably sonic or choked velocity).
  • the velocity of the low-pressure fuel gas through the annular region 33 between the center lance 32 and the outer lance 34 preferably is 30,5 to 274 m/s (about 100 to 900 feet/sec), depending on the available supply pressure of the low-pressure gas.
  • the higher velocity gas stream exiting the exit 36 of the center lance entrains the lower velocity gas stream approaching the exit 38 of the outer lance and provides "first stage" mixing before the streams exit through an orifice(s) 40.
  • the outer lance orifice geometry, angles, etc. are designed for optimum "second stage” mixing in the furnace atmosphere.
  • a very large amount of furnace gas 42 is entrained for second stage dilution, thereby lowering the peak flame temperatures and subsequent reduction in NOx emissions.
  • Figure 4 illustrates an arrangement for liquid fuel (F-F) staging.
  • a high-pressure (and high C/H ratio) liquid fuel e.g. , fuel oil, diesel, bunker C, waste liquid fuel, etc.
  • a low-pressure fuel gas for example, heavy fuel oil can be atomized with an atomizing fluid, such as steam, and then diluted with a low-pressure fuel gas for soot free (clean) combustion inside the furnace.
  • This embodiment also decreases NOx emissions due to lower peak flame temperatures.
  • X is the distance from the exit of the center lance 32 to the back face of the exit for the outer lance 34.
  • D c is the flow area-equivalent diameter of the exit of the center lance, that is, the total flow areas of the exit of the center lance is the same as a circle of diameter D c .
  • D e is the flow area-equivalent diameter of the outer lance, that is, the total flow area of the exit of the lance is the same as a circle of diameter D e .
  • FIG. 5A Two other embodiments of (F-F) staging are shown in Figures 5A and 5B .
  • a strong jet - weak jet interaction takes place between the high-pressure refinery fuel gas and the low-pressure fuel gas.
  • the high-pressure refinery fuel gas is injected in a high-pressure lance 52 at a high velocity 274 to 427 m/s (about 900 to 1400 feet/sec) in a preferred direction, and a low-pressure fuel gas, which is injected in a low-pressure lance 54, is entrained by the high-pressure refinery fuel gas.
  • the high-pressure refinery fuel gas is swirled in a center lance 32 using a fuel swirler 56, and the low-pressure fuel gas is entrained in the collapsed region (central region) of the high velocity swirl.
  • This allows good mixing of the high-pressure refinery fuel gas and the low-pressure fuel gas before they exit the outer lance 34 and enter the furnace (not shown), where additional dilution takes place with the furnace gases 42.
  • This approach is beneficial for applications requiring a short flame profile or a smaller combustion space.
  • the high-pressure fuel gas is generally a supply of natural gas or a refinery off-gas which is generally classified as a trim fuel.
  • the high-pressure fuel gas is injected in the center lance 32.
  • the low-pressure fuel gas injected in the annular region 33 between the center lance 32 and the outer lance 34 is generally PSA (pressure swing adsorption) off-gas or clean vent stream from PSA that contains CO2 ( ⁇ 45%), hydrogen ( ⁇ 30%), methane ( ⁇ 15%), and CO ( ⁇ 10%) with a fuel index of about 0.64.
  • PSA pressure swing adsorption
  • the PSA off-gas is permeate out of the adsorption bed after hydrogen product is separated.
  • the high-pressure trim fuel accounts for between 10% to 30% of a total energy for typical reformers having PSA for hydrogen separation.
  • a secondary advantage of this staging application is to improve PSA recovery by increasing the range of PSA pressure cycle, particularly at the low end.
  • this is achieved by creating a low-pressure region inside the outer lance 34.
  • the high velocity central jet 72 shown in Figure 7 creates a low-pressure region around the jet body where the slower moving low-pressure fuel gas is entrained by the faster moving central jet. Due to an active entrainment process, the supply pressure for the low-pressure fuel gas is reduced for the same fuel flow rate.
  • the supply pressure of low-pressure PSA off-gas was reduced from 13800 to 11000 N/m 2 (2 psig to 1.6 psig) (20% reduction). This was achieved by injecting the high- pressure fuel gas at 172000 N/m 2 /396 m/s (25 psig) (1300 feet/sec velocity). The combustion energy split between the high-pressure fuel gas and the low-pressure fuel gas was 30:70 respectively.
  • the high-pressure fuel gas was injected in a center lance 32 made of standard tubing having a 9,53 mm (3/8'')diameter x 0,88 mm (0.035") wall thickness, which was placed concentrically in an outer lance 34 made of pipe of 19,1 mm (3 ⁇ 4") sch 40.
  • a zipper tip 74 was attached to the end of the pipe.
  • the zipper tip was sized for 13 mm (0.51") equivalent diameter and, as shown in Figures 8A-8D , had four vertical slots and one horizontal slot.
  • the divergence angles ( ⁇ 1 and ⁇ 2) for the vertical slots were 18° and 6° respectively for the axial zipper nozzle tip geometry as follows: 1) a series of vertical structures at intersecting planes between adjacent primary shapes; 2) flow induced downstream instabilities; and 3) a high level of molecular (small-scale) mixing between the first fluid (fuels) and the second fluid (furnace gases). The above mixing also was achieved in the shortest axial distance.
  • Table II provides a preferred firing range, dimensions, dimensionless ratios and injection angles for a proposed lance-in-lance configuration. Simple circular tubing was used for high-pressure refinery fuel whereas a zipper tip was used for the low-pressure PSA off-gas fuel. These lances are critical components of a low NOx burner because the reliability of burner performance directly affects steam methane reformer on stream performance. Table II: Dimensional parameters for Lance-in-Lance fuel staging tips Low pressure zipper tip High Prs. Cyl.
  • back zipper tip inlet 8 (1/32-1) 0,79-25,4 (1/4 -2) 0,25-50,8 1.6 (1-3) 3.7 (2-6) 15 (0 - 30) 7 (0- 30) 0.625 (0.05-3) (0.305) (1/16-2) 7,75 1,59-50,8 4 (2-20) 5.2 (1/32-1) 0,79-25,4 (1/4-2) 0,25-50,8 1.6 (1-3) 3.7 (2-6) 15 (0 - 30) 7 (0 -30) 0.625 (0.05-3) (0.277) (1/16-2) 7,04 1,59-50,8 4 (2-10)
  • the above dimensional ranges are valid for a variety of fuels, such as natural gas, propane, refinery off gases, low kg (BTU) fuels, etc.
  • the nozzles are optimally sized depending on fuel composition, flow rate (or firing rate) and supply pressure available at the burner inlet
  • Table II the dimensions, ratios and ranges are estimated for a 2,11 ⁇ 10 6 to 10,6 ⁇ 10 6 kg/h (2 to 10 MM Btu/Hr) burner firing rate.
  • these dimensions and ranges can be scaled up for higher firing rate burners >10,6 ⁇ 10 6 kg/h (> 10 MM Btu/Hr) using standard engineering practice of keeping similar flow velocity ranges.
  • the improved fuel staging with high-pressure inert gases is performed with low-pressure fuel gases to reduce NOx emissions.
  • the staging fuels that may be used include but are not limited to natural gas; low kg (BTU) process gas (consisting of hydrogen and other refinery fuels); and PSA off-gas.
  • BTU low kg
  • the injection tip configurations are similar to those shown in Figures 3-7 .
  • the main objective is to further reduce NOx emissions.
  • a preferred embodiment is illustrated in Figure 9 .
  • a high pressure 207000 to 689000 N/m 2 (30 to 100 psig) saturated or dry steam is sent through the center lance 32 at about 274 to 427 m/s (900 to 1400 feet/sec) and low-pressure fuel gas is sent through the annular region 33 between the center lance 32 and the outer lance 34.
  • a high velocity steam jet 92 entrains the fuel gas for first stage dilution (and mixing) inside the annular region.
  • the resulting mixture then exits through a zipper tip 74 at a high velocity of about 183 to 427 m/s (about 600 to 1400 feet/sec) for second stage dilution in the furnace (not shown) using furnace gases (not shown).
  • the second stage dilution is very effective due to high steam velocities and entrainment loops set up by individual flames formed by the zipper tip. Due to the zipper tip geometry and steam-assist, improved fuel dilution is obtained. The peak flame temperatures are further reduced and ultra low NOx emissions are obtained. Table III provides estimated steam consumption numbers for a large steam methane reformer furnace.
  • Table III Steam Consumption Economics with Proposed (F-I) Staging Process steam injection rate kg stm/kg fuel (lb_stm/lb_fuel) 0.02 0.05 firing rate kg/h (mmbtu/hr LHV) 89 ⁇ 10 8 , (850) 89.10 8 , (850) fuel heating value mg/Nm 3 (btu/scf, LHV) 37,2 (1000) 37,2 (1000) fuel cost $/1,06 ⁇ 10 6 kg ($/mmbtu, LHV) 6 6 fuel molecular weight 18 18 steam needed kg/h m 3 (lb/hr) (mmscfd) 366 (806) (0.408) 0,9 (2.016) (1.02) 11600 28900 energy required to generate steam at 689000 N/m 2 (100 psia) and 204,4°C (400 F) from water at 15,5°C (60 F) (btu/scf) mg/Nm 3 (btu/lb
  • the amount of steam required for (F-I) staging is from about 2% to 10% on a kg per kg (lb per lb) basis when compared to the low-pressure fuel.
  • the high velocity of steam is used for a two-stage dilution process: 1) inside the lance tube using steam and low-pressure fuel gas, and 2) in the furnace space using high velocity fuel-steam mixture and furnace gases.
  • the NOx emission is reduced from about 10 ppm (corrected at 3% O2) for no inert gas in the center to about 7 ppm (corrected at 3% O2) with nitrogen gas in the center.
  • the favorable results achieved by the present invention are driven by two differences in the streams exiting the two conduits.
  • the first difference is a difference in the thermodynamic states of the respective streams
  • the second difference is a difference in the fuel indices of the respective streams.
  • thermodynamic states of the two streams is expressed in terms of the pressure differential (i . e ., a "high pressure” fluid in one conduit, and a "low pressure” fluid in the other conduit).
  • the differential in thermodynamic states may also be expressed in terms of, and achieved as a result of, differences in velocity, temperature, concentration, composition, volume fraction, flow rate, electric potential, etc .
  • the arrangement of the low pressure and high pressure streams may be reversed ( i . e ., the low pressure lance may be the inner lance, and the high pressure lance may be the outer lance).
  • Thermal cracking is a main concern for many refinery furnaces where fuel compositions contain hydrocarbons ranging from C1 to C4. The cracked carbon is found to plug burner nozzles and create over heating of burner parts, reduced productivity and poor thermal efficiency. Thus, having maintenance free operation (using F-F or F-I staging) is a critical advantage for the refinery operator.

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Claims (9)

  1. Dispositif de dilution de carburant pour diluer un carburant dans le but de réduire les émission d'oxydes d'azote par l'intermédiaire d'une alimentation en carburant étagée, comprenant:
    un premier conduit (32) qui présente une entrée et une sortie espacée de l'entrée, le premier conduit (32) étant adapté pour transmettre un courant d'un carburant qui entre par l'entrée et qui sort par la sortie; et
    un deuxième conduit (34) qui présente une admission et une évacuation espacée de l'admission, le deuxième conduit (34) étant adapté pour transmettre un courant d'un fluide qui entre par l'admission et qui sort par l'évacuation, la sortie du premier conduit (32) et l'évacuation du deuxième conduit (34) définissant un point de mélange qui est situé à proximité à la fois de la sortie et de l'évacuation, caractérisé en ce que le dispositif comprend en outre:
    une buse avec une ouverture à motif de fermeture éclair (74) en communication fluidique vers l'aval avec la sortie du premier conduit (32) et le point de mélange.
  2. Dispositif de dilution de carburant selon la revendication 1, dans lequel le premier conduit (32) est situé à proximité du deuxième conduit (34).
  3. Dispositif de dilution de carburant selon la revendication 1, dans lequel le deuxième conduit (34) est disposé dans le premier conduit (32).
  4. Dispositif de dilution de carburant selon l'une quelconque des revendications 1 à 3, comprenant en outre un tourbillonneur (54) qui est disposé dans le deuxième conduit (34).
  5. Dispositif de dilution de carburant selon l'une quelconque des revendications 1 à 4, dans lequel le deuxième conduit (34) présente un diamètre équivalent (Dc), et l'évacuation du deuxième conduit (34) est située à une certaine distance derrière la sortie du premier conduit (32), ladite distance étant comprise dans la gamme d'environ (2 x Dc) à environ (20 x Dc), et/ou
    dans lequel le dispositif de dilution de carburant est en communication fluidique avec un four contenant une quantité de gaz de four.
  6. Procédé pour diluer un carburant dans le but de réduire les émissions d'oxydes d'azote par l'intermédiaire d'une alimentation étagée en utilisant un dispositif de dilution de carburant selon l'une quelconque des revendications 1 à 5, comprenant les étapes suivantes:
    a) amener un courant de carburant jusqu'à l'entrée du premier conduit (32), faire passer le courant de carburant qui entre dans l'entrée à travers le premier conduit (32); ledit courant du carburant sortant par la sortie du premier conduit (32) dans un premier état thermodynamique et à un premier indice de carburant;
    b) amener un courant de fluide jusqu'à l'admission d'un deuxième conduit (34); faire passer le courant de fluide qui entre dans l'admission à travers le deuxième conduit (34), ledit courant de fluide sortant par l'évacuation du deuxième conduit (34) dans un deuxième état thermodynamique et à un deuxième indice de carburant, le deuxième indice de carburant étant différent du premier indice de carburant d'au moins environ 0,1, et le deuxième état thermodynamique étant différent du premier état thermodynamique;
    c) établissant ainsi un potentiel pour réaliser un mélange entre le courant de carburant qui sort par la sortie du premier conduit (32) et le courant de fluide qui sort par l'évacuation du deuxième conduit (34);
    d) mélanger au moins une partie du courant de carburant qui sort par la sortie du premier conduit (32) avec au moins une partie du courant de fluide qui sort par l'évacuation du deuxième conduit (34) en un point qui est situé à proximité à la fois de la sortie et de l'évacuation;
    e) générer ainsi au moins un courant de carburant dilué qui présente un indice de carburant intermédiaire entre le premier indice de carburant et le deuxième indice de carburant;
    f) transmettre au moins une partie du courant de carburant dilué à travers la buse avec une ouverture à motif de fermeture éclair;
    g) prévoir une source d'oxydant; et
    h) brûler une partie de l'oxydant avec au moins une partie du courant de carburant dilué.
  7. Procédé selon la revendication 6, dans lequel le fluide est un carburant, ou dans lequel le fluide est sélectionné dans un groupe comprenant de la vapeur, un gaz de fumée, du dioxyde de carbone, de l'azote, de l'argon, de l'hélium, du xénon, du krypton, d'autres fluides inertes et des mélanges ou des combinaisons de ceux-ci.
  8. Procédé selon la revendication 6 ou 7, qui utilise un dispositif selon la revendication 4, comprenant l'étape supplémentaire qui consiste à transmettre au moins une partie du courant de fluide à travers le tourbillonneur (56), faisant ainsi tourbillonner au moins une partie du fluide qui sort du deuxième conduit.
  9. Procédé selon l'une quelconque des revendications 6 à 8, qui utilise un dispositif de dilution de carburant selon la revendication 5, comprenant l'étape supplémentaire qui consiste à placer le dispositif de dilution de carburant en communication fluidique avec un four contenant une quantité de gaz de four, mélangeant de ce fait au moins une partie de la quantité du gaz de four avec au moins une partie du courant de carburant dilué.
EP04026942A 2003-11-14 2004-11-12 Alimentation en carburant étagée pour utilisations à faibles émissions de NOx Active EP1531303B1 (fr)

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US20100089020A1 (en) * 2008-10-14 2010-04-15 General Electric Company Metering of diluent flow in combustor
CA2856834C (fr) * 2011-12-01 2016-11-29 Air Products And Chemicals, Inc. Bruleurs a oxy-carburant a etage et procedes d'utilisation de ceux-ci
JP2016003847A (ja) * 2014-06-19 2016-01-12 Ｊｆｅケミカル株式会社 二段燃焼方法
CN105699413B (zh) * 2016-02-25 2018-06-29 上海交通大学 工作于室温温区的用于热力学排气系统研究的模拟系统
CN113280354B (zh) * 2021-05-19 2023-07-04 光大环境科技（中国）有限公司 一种活性炭制备过程高温尾气并气耦合入炉的工艺方法
CN113503538B (zh) * 2021-07-25 2024-09-13 扬州超威燃烧器有限公司 一种炭黑尾气低氮燃烧器及其使用方法

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DE602004031916D1 (de) 2011-05-05
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JP4299225B2 (ja) 2009-07-22
CN1616884A (zh) 2005-05-18
CA2487146A1 (fr) 2005-05-14
CA2487146C (fr) 2009-01-20
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KR100738863B1 (ko) 2007-07-16
EP1531303A1 (fr) 2005-05-18
CN100356104C (zh) 2007-12-19
JP2005147656A (ja) 2005-06-09

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