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Application of Lean Premix Burnersto Reduce NOx in Ethylene Furnaces

S. G. (Chell) Chellappan

Equistar Chemicals, LP

and

R. T. Waibel

John Zink Co., LLC

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2004 by John Zink Company, LLCC

Equistar Chemicals Ethylene Facilities

in Houston Galveston Area

Chocolate Bayou

Channelview

Laporte

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2004 by John Zink Company, LLCC

Equistar Chemicals NOxCompliance Technology

Ultra-Low NOx Burners

SCR Units

FGR

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2004 by John Zink Company, LLCC

Ethylene Furnace NOx Reduction Challenges

Operating Temperature ~2250 oF

Prescribed Radiant Flux Profile

Tube Metal Temperatures

Coil Outlet Temperature

Fuel Composition

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2004 by John Zink Company, LLCC

Furnace Performance Requirements

Capacity

Run Length

Efficiency

Reliability

Operability

Safety

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2004 by John Zink Company, LLCC

Ultra-Low NOx Burner Application

Combination Hearth & Wall FiredFurnace

Solution - John Zink Solar NOxReduction System

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2004 by John Zink Company, LLCC

Solar NOx Reduction System

Ultra-Lean Premix Technology

Quasi - Flameless Technology

Integrated NOx Reduction System

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2004 by John Zink Company, LLCC

NOxFormation Characteristics

Stoichiometry

Mixture

Design Excess Air

(Typ 10%)

Diffusion Flame

Flammability

Limit

Premix Flame

Lean CombustionRich Combustion

Excess Air

RelativeNO

x

Em

issions

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2004 by John Zink Company, LLCC

Lean Premix Combustion

Design and Operational Considerations

Flashback

Lift-off / Blow-off

Noise

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2004 by John Zink Company, LLCC

Operating Envelope Example for Premix Burner

(34%Nat Gas / 35%H2 / 31%Propane Fuel)

1

1.5

2

2.5

3

3.5

4

4.5

5

5.5

6

Premix Flame Equivalence Ratio "" (Air req/Air actual)

FiringRate(MMB

TU/hr)

Flashback

Blowoff

Eductor

Capacity

10 ppm NOx

20 ppm

NOx

Theoretical

Flamability

Limit

More Lean

Burner Performance Envelope

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2004 by John Zink Company, LLCC

Ultra-Low NOx Burner Design

Ultra-Lean Premix Technology

Quasi - Flameless Technology

Integrated NOx Reduction System

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2004 by John Zink Company, LLCC

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2004 by John Zink Company, LLCC

Flameless Combustion

Fuel and Air Injected Separately

Both Mix with Furnace Gases

High Temperature Furnaces Gasesare Required

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2004 by John Zink Company, LLCC

Flameless Combustion

Combustion Occurs in Dilute, Diffuse Regions

Difficult to Operate at Low Furnace Temperatures

Very Low NOx Emissions

Quasi Flameless Combustion Achieves Most ofBenefits While Mitigating Disadvantages

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2004 by John Zink Company, LLCC

Solar NOx Reduction

System

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2004 by John Zink Company, LLCC

Burner Retrofit Strategy

Collaborative Effort:

Owner - Equistar Chemicals, LP

Burner Supplier - John Zink Co., LLC

Process Designer - ABB Lummus

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2004 by John Zink Company, LLCC

Keys to Success

Collaborative Effort

Detailed CFD Modeling

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2004 by John Zink Company, LLCC

Base Case Analysis

ABBLummusGlobal-21

Comparative Wall Surface Temperatures

Lyondell Base Case Lyondell Base Case CFDBase Case Base Case - CFD

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2004 by John Zink Company, LLCC

ABB Lummus Modeling

O2 Mass Fraction Burner Midplane

Original Burners Case A Case B Case C

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2004 by John Zink Company, LLCC

Keys to Success

Collaborative Effort

Detailed CFD Modeling

Single & Multiple Burner Tests

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2004 by John Zink Company, LLCC

Single Burner Test Furnace

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2004 by John Zink Company, LLCC

Multi-Burner

Test Furnace

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2004 by John Zink Company, LLCC

Keys to Success

Collaborative Effort

Detailed CFD Modeling

Single & Multiple Burner Tests

Performance Testing at Site

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2004 by John Zink Company, LLCC

Equistar

FurnaceSolarSystem

HearthBurners

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2004 by John Zink Company, LLCC

Equistar

FurnaceSolarSystem

WallBurners

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2004 by John Zink Company, LLCC

Equistar Furnace Solar System

Hearth Burners

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2004 by John Zink Company, LLCC

Equistar

FurnaceSolarSystem

WallBurners

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2004 by John Zink Company, LLCC

Performance Testing at Site

NOx

Run Length

Efficiency

Reliability

Operability

Safety

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2004 by John Zink Company, LLCC

Keys to Success

Team Effort!