Beruflich Dokumente
Kultur Dokumente
COMBUSTION
HANDBOOK
SECOND EDITION
Volume 3
APPLICATIONS
THE JOHN ZINK HAMWORTHY
COMBUSTION
HANDBOOK
SECOND EDITION
Volume 3
APPLICATIONS
Edited by
Charles E. Baukal, Jr.
List of Figures ix
List of Tables xxi
Foreword to the First Edition xxiii
Preface to the First Edition xxv
Preface to the Second Edition xxvii
Acknowledgments xxix
Editor : xxxi
Contributors xxxiii
Prologue xxxvii
1. Process Burners 1
Erwin Platvoet, I.-Ping Chung, Michael G. Claxton, and Tami Fischer
2. Oil Burners 35
I.-Ping Chung, Steve Londerville, Michael G. Claxton, and William Johnson
4. Duct Burners 93
Peter F. Barry, Stephen L. Somers, and Steve Londerville.
I
Si
x List of Figures
Figure 1.33 (a) LPMF burner assembly and (b) flame photo 18
Figure 1.34 (a) RTW test burner and (b) CFD-calculated result 18
Figure 1.35 (a) Modified RTW burner and (b) CFD-calculated result 19
Figure 1.36 (a) PXMR-DS burner and (b) flame photo 19
Figure 1.37 Premix radiant wall burner array. 20
Figure 1.38 PMS premix gas burner assembly. 20
Figure 1.39 PMS flame (front view) 21
Figure 1.40 PMS flame (side view) 21
Figure 1.41 Hamworthy Walrad burner assembly. 21
Figure 1.42 LPMW radiant wall burner array. 22
Figure 1.43 LPMW with elbowed venturi 23
Figure 1.44 LPMW with in-line venturi and staged-fuel adaptor/tip 23
Figure 1.45 LPMW with in-line venturi for RFS integration 23
Figure 1.46 FPMR radiant wall burner cutaway. 24
Figure 1.47 (a) FPMR burner assembly and (b) cutaway. 24
Figure 1.48 Oil gun with concentric tube design 25
Figure 1.49 MEA oil gun with dual (parallel)-tube design 25
Figure 1.50 John Zink EA oil atomizer and tip 25
Figure 1.51 John Zink MEA oil atomizer and tip 25
Figure 1.52 Hamworthy SAR oil atomizer and tip 26
Figure 1.53 Hamworthy DS oil atomizer and tip ! 26
Figure 1.54 John Zink PM atomization system (port mix) 27
Figure 1.55 The HERO gun 27
Figure 1.56 Standard combination burner 28
Figure 1.57 PLNC staged-air combination burner 29
Figure 1.58 DEEPstar low-NOx gas/oil combination burner 29
Figure 1.59 (a) DEEPstar oil flame and (b) gas flame 30
Figure 1.60 ST-l-S manual pilot 31
Figure 1.61 ST-l-SE electric ignition pilot. 31
Figure 1.62 ST-1-SE-FR electric ignition pilot with an integral flame rod : 31
Figure 1.63 KE-l-ST electric ignition pilot 31
Figure 1.64 ST-2 manual pilot 32
Figure 1.65 KE-2-ST electric ignition pilot 32
Figure 2.1 Typical liquid fuel atomizer-spray tip configurations 37
Figure 2.2 Oil gun capacity curves for heavy oil and light oil for one specific oil gun 38
Figure 2.3 Oil gun capacity curves for steam atomizing and air atomizing for one specific oil gun 38
List of Figures xi
Figure 3.11 (a) Hamworthy ECOjei flame, (b) Natural gas firing at 30 MW (100 x 106 Btu/h)
at Hamworthy test facility. 70
Figure 3.12 Schematic of a QLN burner. 70
Figure 3.13 Coen QLN burner flame with 20 ppm NOx firing natural gas without FGR 71
Figure 3.14 Coen RMB burner equipped with an air isolation sliding barrel damper 72
Figure 3.15 Fuel risers of a Coen RMB burner 72
Figure 3.16 Enhanced images of the gas-fired RMB flame 73
Figure 3.17 Coen D-RMB burner mounted inside the wind box 73
Figure 3.18 Coen D-RMB burner performance in a large package boiler 74
Figure 3.19 Coen QLA burner schematic 74
Figure 3.20 Assembled Coen QLA burner (side) 75
Figure 3.21 Assembled Coen QLA burner (front) 75
Figure 3.22 Coen QLA burner flame with 7 ppm NOx (natural gas firing) 75
Figure 3.23 Peabody LVC burner for firing BFG 75
Figure 3.24 Modified Coen LCF burner for simultaneous low-NOx firing of multiple fuels of variable
composition 75
Figure 3.25 NOx reduction with FGR mixed with combustion air or fuel 76
Figure 3.26 Large Coen QLN burners mounted inside wind boxes 77
Figure 3.27 Coen QLN-II burner inside a furnace 78
Figure 3.28 Row of boilers equipped with Coen QLN-IPM burners rated to 63 and 90 x 106 Btu/h
(18.5-26 MWt) 78
Figure 3.29 Typical NOx performance of QLN-II burner with FGR 79
Figure 3.30 Large 350 x 106 Btu/h (103 MW) DAF burner for firing (a) syngas and (b) natural gas 79
Figure 3.31 Flames of DAF burner firing (a) natural gas and (b) syngas 80
Figure 3.32 Schematic of Coen Delta Power burner 80
Figure 3.33 Examples of NOx reduction with air staging and FGR in utility boilers when firing natural gas
(various boilers) 82
Figure 3.34 Effect of fuel biasing on the NOx 83
Figure 3.35 Effect of FGR on thermal portion of NOx in different utility boilers 84
Figure 3.36 NOx emissions firing #6 oil with 0.54% FBN 84
Figure 3.37 Low-NOx natural gas flame 85
Figure 3.38 Main components of a fixed geometry burner for a gas and oil T-fired boiler 86
Figure 3.39 Spinners for tilting burners 86
Figure 3.40 Flame stabilizers and buckets of tilting (a) gas-fired burner and (b) oil-fired burner 87
Figure 3.41 Corner of a T-fired boiler with tilting burners with some heat damage 87
Figure 3.42 Coen warm-up gas burners 88
Figure 3.43 Conceptual design of low-CO flue-gas reheat system for refinery gas firing 89
Figure 3.44 Coen ProLine burner flames at low- (left) and high-fire (right) operation 90
List of Figures xiii
Figure 5.8 AMOxsafe GCU temperature profile as predicted by CFD modeling 124
Figure 5.9 Hamworthy Combustion DF register burner 124
Figure 5.10 Fuel-gas valve enclosure for FPSO engine room boiler 125
Figure 5.11 Hamworthy Combustion's triple 120 metric-ton/h (132 U.S. ton/h) steam boiler module for FPSO 126
Figure 5.12 Hamworthy Combustion's high-pressure steam boiler module for power generation 126
Figure 5.13 Hamworthy Combustion's fuel-gas knockout pot on an FSO 127
Figure 5.14 Hamworthy Combustion's DFL low-NOx register burner 127
Figure 6.1 Typical heater types 132
Figure 6.2 Vertical cylindrical furnace arrangement 133
Figure 6.3 Two vertical cylindrical fireboxes with common convection section 133
Figure 6.4 Box-type heater with horizontal tubes 134
Figure 6.5 Box-type heater with horizontal tubes 134
Figure 6.6 Cabin heater 135
Figure 6.7 Typical coker furnace 136
Figure 6.8 Double wide coker furnace 136
Figure 6.9 Top-fired reformer 137
Figure 6.10 Side-fired reformer 138
Figure 6.11 Terrace wall-fired reformer 138
Figure 6.12 Bottom-fired reformer 139
Figure 6.13 Typical cracking furnace firebox layout 140
Figure 6.14 Variations of typical cracking furnace firebox layout 140
Figure 6.15 Radiant wall burners t 141
Figure 6.16 Large heat release floor burners 141
Figure 6.17 Example of flame rollover in a pilot-scale cracking furnace 141
Figure 6.18 Spectral absorptivity of C02 at 830 K and 10 atm for a path length of 38.8 cm 143
Figure 6.19 Radiation to a single row of tubes backed by a refractory wall 144
Figure 6.20 Incident radiation to a single-tube row, which is backed by a refractory wall 145
Figure 6.21 Effective emissivity of a single-tube row backed by a refractory wall, plotted for various
tube emissivities 145
Figure 6.22 Relationship of reduced firing density and reduced efficiency. 146
Figure 7.1 Direct-fired air heater 150
Figure 7.2 Horizontal direct-fired air heater with side outlet 150
Figure 7.3 Direct-fired air heater with separate combustion air inlet 150
Figure 7.4 Oil-fired air heater 151
Figure 7.5 All-metal air heater 151
Figure 7.6 AH 11/2 pilot with retractable igniter 153
Figure 7.7 Retractable high-energy igniter 153
List of Figures xv
Figure 10.3 Combination of an SCR and a catalytic oxidizer for a greenhouse application 242
Figure 10.4 FRIGOSOLVER unit 243
Figure 10.5 Cooling coil 244
Figure 10.6 Direct condensation in a liquid bath of deep cooled solvents, here called the FRIGOSOLVER
unit 246
Figure 10.7 Combination of condensation unit and catalytic waste combustion 247
Figure 10.8 Saturated concentration in accordance with saturation temperature 248
Figure 11.1 Typical early 1950s flare performance 252
Figure 11.2 An early model smokeless flare 253
Figure 11.3 Major flaring event 253
Figure 11.4 Typical elevated single-point flare 254
Figure 11.5 Typical pit flare installation 254
Figure 11.6 A grade-mounted, multipoint LRGO flare system 254
Figure 11.7 Elevated multipoint LRGO flare system 254
Figure 11.8 Multiple ZTOF installation in an ethylene plant 255
Figure 11.9 Combination elevated flare system (left) and ZTOF (right) 255
Figure 11.10 Combination elevated LRGO and utility flare system 255
Figure 11.11 Comparison of the flame produced by burning (a) 25 MW wellhead natural gas, (b) propane,
and (c) propylene 258
Figure 11.12 General arrangement of a staged flare system, including a ZTOF and an elevated flare 260
Figure 11.13 Flare test at the John Zink Co. test facility in Tulsa, Oklahoma 261
Figure 11.14 Liquid carryover from an elevated flare 263
Figure 11.15 Thermogram of a flare flame 266
Figure 11.16 API radiation geometry. 266
Figure 11.17 Comparison of stack height and relative cost for various radiation calculation methods 267
Figure 11.18 Effectiveness of steam in smoke suppression 268
Figure 11.19 Effectiveness of air in smoke suppression 268
Figure 11.20 Steamizer steam-assisted smokeless flare 269
Figure 11.21 Typical nonassisted flare 270
Figure 11.22 ZDR severe service flare tip 270
Figure 11.23 Simple steam-assisted flare 271
Figure 11.24 Perimeter/area ratio as a function of tip size for a simple steam-assisted flare 271
Figure 11.25 Schematic of an advanced steam-assisted flare 272
Figure 11.26 A comparison of the perimeter/area ratio for simple and advanced steam-assisted flares 273
Figure 11.27 Steamizer flare burner and muffler 273
Figure 11.28 State-of-the-art Steamizer XP 273
Figure 11.29 Air-assisted smokeless flare with two blowers in a refinery. 274
xviii List of Figures
Figure 13.6 Elevated flare pilot and main flame thermocouples 314
Figure 13.7 Radiation isoplot (Btu/h-ft2) 314
Figure 13.8 Enclosed flare gas manifold 314
Figure 13.9 Enclosed flare gas manifold with flanged flare tips 315
Figure 13.10 Enclosed flare air damper louvers 315
Figure 13.11 Enclosed flare interior insulation and thermocouples 315
Figure 13.12 Landfill gas flame 316
Figure 13.13 Flame lengths 316
Figure 13.14 Sample ports 317
Figure 13.15 Zink Ultra Low Emission (ZULE) enclosed flare 318
Figure 13.16 ZULE static mixing chamber. 318
Figure 13.17 View inside ZULE enclosed flare 319
Figure 13.18 Single-stage fans in a landfill application 324
Figure 13.19 Multistage blowers 324
Figure 13.20 A cutaway of a multistage blower showing eight impellers 325
Figure 13.21 As the gas travels through each impeller, it increases temperature 325
Figure 13.22 1-2-3 Fan law. 326
Figure 13.23 Siloxane removal system 327
Figure 13.24 P&ID of gas utilization and a single flare 328
Figure 13.25 P&ID of gas utilization and dual flares 329
Figure 14.1 Example of an air-assisted flare during testing 332
Figure 14.2 Example of a flare being oversteamed during testing 333
Figure 14.3 Example of waste-gas flows to a flare in a typical refinery over approximately an 8-month
period 333
j Figure 14.4 Generalized flare-gas recovery process schematic 335
Figure 14.5 FGRS at FHR West Plant in Corpus Christi, Texas : 337
Figure 15.1 Splash loading method 342
Figure 15.2 Submerged fill pipe 342
Figure 15.3 Bottom loading 343
Figure 15.4 Vapor control stage 1 343
Figure 15.5 Summary of U.S. VOC emissions 345
Figure 15.6 Adsorption versus absorption 346
Figure 15.7 Single particle of granular activated carbon 347
Figure 15.8 Pore structure with adsorbate molecules in the pores of the activated carbon 347
Figure 15.9 Carbon adsorption-absorption (ADAB) process 351
Figure 15.10 Three carbon bed zones 352
Figure 15.11 John Zink DVP VRU 353
xx List of Figures
xxi