Low-emission flat-flame burners for industrial furnaces

Low-emission flat-flame burners for industrial furnaces

"From Science to Business" Workshop11 – 12 October, 2006

Kiev

Dr.Sc. (Eng.), Prof. Boris SOROKADr.Sc. (Eng.), Prof. Boris SOROKA

Tel/FAX: (38-044) 455-59-98E-mail: [email protected]

Gas Institute, National Academy of Sciences, Kiev, UKRAINE

Problem Description & Market Need Flat-Flame burners of GPP LE type (brief description) Features of FFB-equipped furnaces State of the art Duty of facility Surpassed of environmental standards and of the best world data Advantages of the furnace plants equipped with GPP LE burners Competition Benefits Transfer opportunities

Talk outlineTalk outline

Proprietary information statement

• The technology material presented in this talk is available for licensing or joint product development.

• None of the slides contain any confidential or proprietary information which would prevent patenting the technology.

There are a lot of thermal units, first of all-industrial furnaces of various types and purpose-those need sources of uniform intensive heat supply.

The Flat-Flame Burners (FFB) of new generation (of GPP LE type) fully meet this demand. Moreover, these FFB ensure combination of technological, operation, energetic and environmental advantages.

The potential market of the Flat-Flame Burners including various standard sizes of GPP LE is numbered in the hundred (thousands) of the furnaces and in the thousands (tens of thousands) of GPP LE burners.

Problem Description & Market Need

Flat-Flame Burner (FFB) of GPP LE type

External view and Arrangement at Submerged Combustion Water Heater

The main specific feature of the Flat-Flame Burners (FFB) is unusual form of the flame – the fan (disk) – shaped one, adjacent to the furnace refractory setting.

Flat-Flame burners of GPP LE type (brief description)Flat-Flame burners of GPP LE type (brief description)

Due to implementation of the Coanda effect in the firing conditions the flame is propagating in the plane, perpendicular to the burner axis in radial direction along the refractory setting. The flame has no axial velocity.

Because of flame form, the furnaces being heated with the FFB ensure intensive uniform radiative heating of the materials and the product to be treated.

Features of FFB-equipped furnaces

Flame burners: Non uniform high-corrosion preheating

FFB: Uniform low-corrosion preheating

slab

slab

corrosion layerflames

flame corrosion layer

The basic version of Flat-Flame burners of GPP series - have been patented in many countries (Gr. Britain, France, Germany, Japan etc.),-have been commercialized, and widely used in various branches of the industry.

State of the artState of the art

More than 300 furnaces, developed and patented by the Gas Institute, NASU, and equipped with the Flat-Flame burners of the GPP series are now under operation in the industry at more than 70 enterprises:

- integrated iron-and-steel works and non-ferrous metallurgical works, - engineering and metal-working plants,- chemical (including oil refinery) plants,- building materials (ceramics) factories and the glass works.

Stage of the Stage of the GPP LEGPP LE burners burners developmentdevelopment

Design of Flat-Flame burners of new generation - GPP LE type of some standard sizes- have been developed. - have been tested at the firing rigs (stands) and by industrial conditions (at the furnaces), - are available for demonstration and for field testing.

State of the artState of the art

The Flat Flame burners (FFB) are intended to provide high intensive uniform heat input for the industrial furnaces of various purpose, beginning from those operating at low (300-500°C), middle (750-1100°C) to high temperature (1250..1700°C).

Arrangement of the furnaces with FFB of GPP LE type ensure technological, energetical and environmental advantages in combination.

Range of operating temperaturesRange of operating temperatures

Duty of facilityDuty of facility

°C F

100 212

200 392

300 572

400 752

500 932

600 1112

700 1292

800 1472

900 1652

heating plants with SCA (water and solutions heating); pickling bathes; electro plating bathes;


low-temperature (LT) heat treatmentlow-temperature (LT) heat treatment / LT tempering furnaces;

hydrocarbon pyrolisis furnaces;

petroleum refining tube furnaces

spelter pots; separate zones of sintering furnaces

middle (MT) and high (HT) temperature heat-treatment: MT and HT tempering, hardening, normalizing / chamber and continuous furnaces including bell-type;

Temperature ranges of the plants with GPP LE burners

°C F

1000 1832

1100 2012

1200 2192

1300 2372

1400 2552

1500 2732

1600 2912

1700 3092

Thermal, chemical and thermal treatment of non-metallic materials / tunnel type kiln of firing the salts of Mn-Zn and other iron-garners

Rolling, forging, forming processes by plastic steel working /reheating furnaces of continious and of batch type:pusher-type, walking-beam, roller hearth

Firing of ceramics / tunnel type kilns, roller hearth furnaces

Glass-melting / direct firing recuperative furnaces

Temperature ranges of the plants with GPP LE burners

Sintering furnaces


170 t/h heating furnace of pusher type with FFB at DUNAFERR RT (HUNGARY) rolling mill.About 100 FFB of GGP type have been installed at the furnace roof.

reheating, thermal and chemical-thermal treatment of ferrous and non-ferrous metals, as well as of non-metallic materials.

Branches of industry: ferrous and non-ferrous metallurgy,

powder metallurgy, machine manufacturing

The Low-emission flat-flame burners GPP LE have been developed for the following processes:


firing of ceramics, radio-ceramics, ferrites, metallic

compounds, salts and oxides of metals;

pyrolysis of the petroleum products;

melting of glass and mineral glass wool;

heating facilities for the premises (water heater).


Industrial premises heating plant based upon Submerged Combustion unit equipped with 800 kW FFB of GPP LE type (Multi-purpose factory, Krivoy Rog, Ukraine)

Dependence of NOx formation ([NOx] - concentration) on combustion air preheating temperature Ta by various furnace temperature, Tfur, °C. Natural gas consumption = 40 m3/hr. Air excess factor = 1.05- “low” temp 200…1000 - 1, ♦- “middle” temp 1000…1300 - 2, ■- “high” temp 1300…1500 - 3, ▲

Surpassed of environmental standards and of the best world data NONOxx emission emission

Operation data for HG-F burners (Germany)

“Blauer Engel” standard, upper limit

TA Luft norms (Germany)

Dependence of CO concentration in dependence on air excess factor β by furnace space temperature Тfur = 1100…1300° C, combustion air preheat temperature Ta = 20…100 °C. Natural gas consumption ~40 m3/hr.

“Blauer Engel” standard, upper limit

FLOX system

0

20

40

60

80

100

120

1 1.05 1.1 1.15 1.2

[CO

], p

pm

325

275

300

O ptim a l ran ge

Surpassed of environmental standards and of the best world data CO emissionCO emission

1

2

3

Performance characteristic of natural gas combustion by means of flat-flame burner GPP-4 LE1 - stable burning by divergent (180° angle) flame;2 - stable burning by conical flame;3 - burning quench condition.

Surpassed of environmental standards and of the best world data.

Range of combustion stability within cold furnace

Maximum value for FFB BIO, ZIO (G.Kromschröder AG)

for FFB HG-F (Germany) under high temperatures

Super-wide range of combustion stability by

temperature variation, by range of flowrates (heat

outputs) and by air excess factors. The burner is ready for

operation within the whole control range beginning the

ambient (room, indoor) temperature.

Advantages of the furnace plants equipped with Advantages of the furnace plants equipped with GPP LEGPP LE burners burners

Low-emission combustion in comparison with the national and international (Germany, USA, EU) standards


Super-uniform heat receiver temperature profile and the resulting heat fluxes: deviation no more than ±(2.0 – 0.5)% – by temperatures and no more ±4% - by heat flux values within the range of 300 – 1600ºC heat receivers temperature (only word application – no quantity information about non-uniformity in case of WS FFB (Germany) in FLOX-mode of operation).

Wide-range temperature general-purpose (universality of the application possibilities and the areas of utilization) in contrast to other known (competitive) types of FFB:-FLOX (flameless combustion) method and burner facilities (WS WARMEPROCESS technique GmbH (Germany, USA), is used beginning from 800ºC)). - Special warning about the difficulties, accompanying the firing processes under cold and moderate temperature conditions is indicated for the North American Mfg Co (USA) FFB (see notice in Bulletin № 4832 “Low NOx Flat-Flame Gas Burners): “In tight, cold furnaces, 4832 Burners are not stable on stoichiometric air/gas ratio. Alternatives during start-ups until furnace reachers approximately 1400F…”


Company (country)Type of FFB

Hans Hennig VDI e.K., Ratingen (Germany) HG-F

WS Warmeprozesstechnik GmbH, Renningen (Germany) in cooperation with Buderus, Edelstahlverke AG, (Germany)

FLOX

G. Kromsshroder AG, Osnabrück (Germany) and KROMSCHRODER INC, Hudson, OH (USA)

BIO, ZIO

North American Mfg CO, Cleveland, OH (USA)4831-#(0; 1)4832-#(2 -7)

NA – STORDY Combustion Limited, Wolverhampton (England) and some European departments (5 countries)

SFFG

Eclipse Inc., Rockford, IL (USA) DSF/DSF-C

CompetitionThe western companies engaged in the FFB’s R&D, manufacturing and

industrial implementation

The main advantages of the furnaces equipped with the burners of GPP LE type :

• reduction of fuel consumption;• improvement of preheated articles quality;• improvement of the environmental characteristics;

The plants equipped with GPP LE type burners provide:

•high-quality super-stable fuel combustion;• combine of high efficiency of fuel utilization and low-emission stable combustion process.

BenefitsBenefits

• power (thermal) efficiency: - HT and MT furnaces with heat recovery

systems and LT furnaces 75 - 85 %;

- HT furnaces without heat recovery 40 - 45 %;• reduction of specific fuel consumption :

- existing furnaces renovation 30 - 40 %; - new furnaces erection 10 20 %; • specific fuel heat consumption by steel before rolling mill in dependence on furnace output: low – high (optimal) 3 1 GJ/t;

Improvement of energetical characteristics.Reduction of fuel consumption

HT – high-temperature

MT – middle temperature

LT – low temperature

BenefitsBenefits

Improvement of the environmental characteristics for high temperature process

• reduction of the toxic substances emission, no less than 2 times;

• specific NOx yield by air preheating temperature 300 °C, (depending the furnace output) 100 30 g/t;

• NOx concentration at 3% O2 by air preheating temperature 300 °C 75 ppm.

Improvement of preheated articles quality

• high temperature uniformity at the surface to be preheated - deviation

from average temperature (depending on process temperature) ±5 10°C;

• reduction of the metal losses caused by oxidation and

decarburization (depending on type of the steel blanks) 30 50 %;

BenefitsBenefits

1. Delivery of the party (parties) of Flat-Flame Burners GPP LE type including the metallic and refractory assemblies. The metallic unit (housing) can be manufactured of cast iron or steel welded construction.

The price of the burner makes 1500 – 2500 USD per 1 piece in dependence on standard size and complete equipment.

Transfer opportunitiesTransfer opportunitiesWe propose various ways of transferring the We propose various ways of transferring the

object of development to CUSTOMERobject of development to CUSTOMER

3. Joint R&D, engineering, industrial and commercial partnership.

Transfer opportunitiesTransfer opportunitiesWe propose various ways of transferring the object of We propose various ways of transferring the object of

development to CUSTOMERdevelopment to CUSTOMER

2. Transfer of the manufacturing rights including non-exclusive license “know-how” and the design plans and specification for manufacturing the series of standard sizes of GPP LE type. The estimated cost of the complex: license “know-how” + documentation makes $275,000.

4. Applications for joint EU, USA etc. patents and further share holding by “know-how”.

Documents

Low-emission flat-flame burners for industrial furnaces