Presentation on theme: "Low-emission flat-flame burners for industrial furnaces"— Presentation transcript:
1Low-emission flat-flame burners for industrial furnaces "From Science to Business" Workshop11 – 12 October, 2006KievDr.Sc. (Eng.), Prof. Boris SOROKATel/FAX: (38-044)Gas Institute, National Academy of Sciences,Kiev, UKRAINE
2Talk outline Problem Description & Market Need Flat-Flame burners of GPP LE type (brief description)Features of FFB-equipped furnacesState of the artDuty of facilitySurpassed of environmental standards and of the best world dataAdvantages of the furnace plants equipped with GPP LE burnersCompetitionBenefitsTransfer opportunities
3Proprietary 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.
4Problem Description & Market Need 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.
5Flat-Flame Burner (FFB) of GPP LE type External view and Arrangement at Submerged Combustion Water Heater
6Flat-Flame burners of GPP LE type (brief description) 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.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.
7Features of FFB-equipped furnaces flamescorrosion layerslabFlame burners: Non uniform high-corrosion preheatingflamecorrosion layerslabFFB: Uniform low-corrosion preheating
8State of the artThe 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.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.
9Stage of the GPP LE burners development State of the artStage of the GPP LE burners developmentDesign 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.
10Range of operating temperatures Duty of facilityRange of operating temperaturesThe 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 ( °C), middle( °C) to high temperature ( °C).Arrangement of the furnaces with FFB of GPP LE type ensure technological, energetical and environmental advantages in combination.
11Temperature ranges of the plants with GPP LE burners Duty of facilityTemperature ranges of the plants with GPP LE burners°CF1002122003923005724007525009326001112700129280014729001652heating plants with SCA (water and solutions heating); pickling bathes; electro plating bathes;low-temperature (LT) heat treatment / LT tempering furnaces;petroleum refining tube furnacesspelter pots; separate zones of sintering furnacesmiddle (MT) and high (HT) temperature heat-treatment: MT and HT tempering, hardening, normalizing / chamber and continuous furnaces including bell-type;hydrocarbon pyrolisis furnaces;
12Temperature ranges of the plants with GPP LE burners Duty of facilityTemperature ranges of the plants with GPP LE burners°CF1000183211002012120021921300237214002552150027321600291217003092Sintering furnacesRolling, forging, forming processes by plastic steel working /reheating furnaces of continious and of batch type:pusher-type, walking-beam, roller hearthFiring of ceramics / tunnel type kilns, roller hearth furnacesThermal, chemical and thermal treatment of non-metallic materials / tunnel type kiln of firing the salts of Mn-Zn and other iron-garnersGlass-melting /direct firing recuperative furnaces
13About 100 FFB of GGP type have been installed at the furnace roof. Duty of facilityThe Low-emission flat-flame burners GPP LE have been developed for the following processes: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 manufacturing170 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.
14Duty of facilityfiring 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)
15Surpassed of environmental standards and of the best world data NOx emissionTA Luft norms (Germany)“Blauer Engel” standard, upper limitOperation data for HG-F burners (Germany)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 … , ♦“middle” temp … , ■“high” temp … , ▲
16Surpassed of environmental standards and of the best world data CO emission“Blauer Engel” standard, upper limitFLOX systemDependence 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.
17Surpassed of environmental standards and of the best world data Surpassed of environmental standards and of the best world data. Range of combustion stability within cold furnacefor FFB HG-F (Germany) under high temperaturesMaximum value for FFB BIO, ZIO (G.Kromschröder AG)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.
18Advantages of the furnace plants equipped with GPP LE burnersSuper-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.
19Advantages of the furnace plants equipped with GPP LE burners Low-emission combustion in comparison with the national and international (Germany, USA, EU) standardsSuper-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).
20Advantages of the furnace plants equipped with GPP LE burnersWide-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…”
21CompetitionThe western companies engaged in the FFB’s R&D, manufacturing and industrial implementationCompany (country)Type of FFBHans Hennig VDI e.K., Ratingen (Germany)HG-FWS Warmeprozesstechnik GmbH, Renningen (Germany) in cooperation with Buderus, Edelstahlverke AG, (Germany)FLOXG. Kromsshroder AG, Osnabrück (Germany) and KROMSCHRODER INC, Hudson, OH (USA)BIO, ZIONorth American Mfg CO, Cleveland, OH (USA)4831-#(0; 1)4832-#(2 -7)NA – STORDY Combustion Limited, Wolverhampton (England) and some European departments (5 countries)SFFGEclipse Inc., Rockford, IL (USA)DSF/DSF-C
22Benefits The plants equipped with GPP LE type burners provide: high-quality super-stable fuel combustion;combine of high efficiency of fuel utilization andlow-emission stable combustion process.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;
23Benefits Improvement of energetical characteristics. Reduction of fuel consumptionpower (thermal) efficiency:- HT and MT furnaces with heat recoverysystems and LT furnaces %;- HT furnaces without heat recovery %;reduction of specific fuel consumption :- existing furnaces renovation %;- new furnaces erection %;specific fuel heat consumption by steel before rolling millin dependence on furnace output: low – high (optimal) GJ/t;HT – high-temperatureMT – middle temperatureLT – low temperature
24Benefits Improvement of preheated articles quality high temperature uniformity at the surface to be preheated - deviationfrom average temperature (depending on process temperature) ±5 - 10°C;reduction of the metal losses caused by oxidation anddecarburization (depending on type of the steel blanks) %;Improvement of the environmental characteristicsfor high temperature processreduction of the toxic substances emission, no less than 2 times;specific NOx yield by air preheating temperature 300 °C,(depending the furnace output) g/t;NOx concentration at 3% O2 by air preheatingtemperature 300 °C ppm.
25Transfer opportunities We propose various ways of transferring the object of development to CUSTOMER1. 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.
26Transfer opportunities We propose various ways of transferring the object of development to CUSTOMER2. 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 $275,000.3. Joint R&D, engineering, industrial and commercial partnership.4. Applications for joint EU, USA etc. patents and further share holding by “know-how”.