Transcript Презентация PowerPoint - Science and Technology

Low-emission flat-flame burners for
industrial furnaces
"From Science to Business" Workshop
11 – 12 October, 2006
Kiev
Dr.Sc. (Eng.), Prof. Boris SOROKA
Tel/FAX: (38-044) 455-59-98
E-mail: [email protected]
Gas Institute, National Academy of Sciences,
Kiev, UKRAINE
Talk outline
 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
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.
Problem 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.
Flat-Flame Burner (FFB) of GPP LE type
External view and Arrangement at Submerged Combustion Water Heater
Flat-Flame burners of GPP LE type (brief description)
The main specific feature of the FlatFlame 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.
Features of FFB-equipped furnaces
flames
corrosion layer
slab
Flame burners: Non uniform high-corrosion preheating
flame
corrosion layer
slab
FFB: Uniform low-corrosion preheating
State of the art
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.
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.
State of the art
Stage of the GPP LE burners development
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.
Duty of facility
Range of operating temperatures
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.
Duty of facility
Temperature ranges of the plants with GPP LE burners
°C
F
100
212
200
392
300
572
400
752
heating plants with SCA (water and solutions
heating); pickling bathes; electro plating bathes;
low-temperature (LT) heat treatment / LT
tempering furnaces;
petroleum refining tube furnaces
500
932
spelter pots; separate zones of sintering furnaces
600
1112
700
1292
800
1472
900
1652
middle (MT) and high (HT) temperature heat-treatment:
MT and HT tempering, hardening, normalizing /
chamber and continuous furnaces including bell-type;
hydrocarbon pyrolisis furnaces;
Duty of facility
Temperature ranges of the plants with GPP LE burners
°C
F
1000
1832
1100
2012
1200
2192
Rolling, forging, forming processes by plastic steel working /
reheating furnaces of continious and of batch type:
pusher-type, walking-beam, roller hearth
1300
2372
Firing of ceramics / tunnel type kilns, roller hearth furnaces
1400
2552
1500
2732
1600
2912
1700
3092
Sintering furnaces
Thermal, chemical and thermal treatment of nonmetallic materials / tunnel type kiln of firing the salts
of Mn-Zn and other iron-garners
Glass-melting /
direct firing recuperative furnaces
Duty of facility
The 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 manufacturing
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.
Duty of facility
 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)
Surpassed of environmental standards and of the best world data
NOx emission
[NOx](O2=3%),ppm
TA Luft norms (Germany)
Operation data for HG-F burners (Germany)
“Blauer Engel”
standard, upper limit
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
CO emission
325
“Blauer Engel”
standard, upper
limit
[CO], ppm
300
275
120
Optimal
range
100
80
60
FLOX system
40
20
0
1
1.05
1.1
1.15
1.2
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.
Surpassed of environmental standards and of the best world data.
Range of combustion stability within cold furnace
for FFB HG-F (Germany) under
high temperatures
1
3
2
Maximum value for
FFB BIO, ZIO
(G.Kromschröder AG)
Performance characteristic of natural gas combustion by means of flat-flame burner GPP-4 LE
1 - stable burning by divergent (180° angle) flame;
2 - stable burning by conical flame;
3 - burning quench condition.
Advantages of the furnace plants equipped with
GPP LE burners
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
GPP LE 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).
Advantages of the furnace plants equipped with
GPP LE burners
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…”
Competition
The western companies engaged in the FFB’s R&D, manufacturing and
industrial implementation
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
Benefits
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.
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;
Benefits
Improvement of energetical characteristics.
Reduction of fuel consumption
• power (thermal) efficiency:
- HT and MT furnaces with heat recovery
systems 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 mill
in dependence on furnace output: low – high (optimal)
75 - 85 %;
40 - 45 %;
30 - 40 %;
10 - 20 %;
3 - 1 GJ/t;
HT – high-temperature
MT – middle temperature
LT – low temperature
Benefits
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 %;
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.
Transfer opportunities
We propose various ways of transferring the
object of development to CUSTOMER
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 opportunities
We propose various ways of transferring the object of
development to CUSTOMER
2. Transfer of the manufacturing rights including nonexclusive 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”.