no slide title...©zeeco, inc. conclusion zeeco supplied 105 gb single jet inserts for a downfired...
TRANSCRIPT
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© ZEECO, INC.
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© ZEECO, INC.
Nitrogen & Syngas Conference 2019
Nick Johnson
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© ZEECO, INC.
Burner Revamp to Increase Primary Reformer Efficiency & Lower Emissions
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© ZEECO, INC.
Presentation Outline
▪ Application overview
▪ Zeeco Single Jet ultra-low NOx emissions burner
▪ CFD study
▪ Combustion testing
▪ Burner installation
▪ Conclusion
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© ZEECO, INC.
Application Overview
▪ Downfired primary reformer furnace
▪ European ammonia production facility
▪ 105 downfired burners > 40 years old
▪ NOx emissions in range of 250-300 mg/Nm3
▪ Customer wanted to reuse burner windbox and damper
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© ZEECO, INC.
Zeeco Solution▪ Supply GB Single Jet ultra-low emissions kit:
⚫ Gas lance / tips
⚫ Stabilisation cone
⚫ Burner tile
▪ Retain existing:
⚫ Windbox
⚫ Damper / damper controls
⚫ Pilot
▪ Guaranteed NOx emissions of 120 mg/Nm3 on natural gas
▪ Design for 10% excess air (≈2.1% O2 by vol. of dry flue gas)
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© ZEECO, INC.
Zeeco Solution
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© ZEECO, INC.
Zeeco Single-Jet Ultra-Low Emissions Burners
Inert Flue
Gas
Combustion Air
Fuel Gas
Firing Ports
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© ZEECO, INC.
Zeeco Single-Jet Ultra-Low Emissions Burners
IFGR Zone
Combustion Air Zone
Staged Air Zone
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© ZEECO, INC.
Primary Reformer Radiant Section - Plan View
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© ZEECO, INC.
Radiant Section – Heater Process Information
Type of Reformer Furnace Ammonia Reformer
Type of Draft Forced
Direction of Firing Downfired
Primary Reformer Width, m 14
Primary Reformer Length, m 16.4
Primary Reformer Roof Area, m2 229.6
Total Number of Burner Rows 7
Distance Tube to Tube Between Tube Rows, m 2.2
Total Maximum Heat Release for Reformer, MW 158.19
Total Normal Heat Release for Reformer, MW 131.84
Heat Release per Roof Area at Maximum Duty, MW/m2 0.689
Heat Release per Roof Area at Normal Duty, MW/m2 0.574
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© ZEECO, INC.
Radiant Section – Burner Process InformationType of Burner Zeeco GB Single Jet
Inner Burners
Zeeco GB Single Jet
Outer Burners
Total Number of Burners 75 30
Number of Burners per Row 15 15
Number of Rows of Burners 5 2
Maximum Heat Release per Burner, MW 1.674 1.088
Normal Heat Release per Burner, MW 1.395 0.907
Turndown 6:1 6:1
Design Excess Combustion Air, % 10 10
Combustion Air Temperature, degrees C 300 300
Furnace Temperature, degrees C 1200 1200
Total Heat Release at Maximum Duty, MW 125.55 32.64
Percentage of Total Heat Release, % 79.4 20.6
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© ZEECO, INC.
CFD Study
▪ Gas temperature contours
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© ZEECO, INC.
CFD Study
▪ CO contours confirmed minimum flame interaction
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© ZEECO, INC.
CFD Study
▪ Location A: Inert products of combustion drawn into fuel gas
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© ZEECO, INC.
Burner Testing at ZEECO
▪ Combustion test performed at Zeeco Global HQ.
▪ Multi-Burner testing to verify NOx emissions
▪ 80-90 mg/Nm3 NOx at 2.0% O2
▪ Confirmation of no flame-to-flame interaction
▪ Proven flame stability at 1.1% O2 (dry basis)Zeeco Test Furnace
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© ZEECO, INC.
Burner General Arrangement Drawing
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© ZEECO, INC.
Installation
▪ Burners were installed early 2018
▪ Retrofit kits minimised installation time and labour requirements
▪ Burners utilised Zeeco ProFlameTM scanners for flame detection
▪ Flexible hoses used for gas connections
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© ZEECO, INC.
Burner Performance
▪ Burners are achieving 90 mg/Nm3 NOx
⚫ Significantly lower than the guaranteed NOx (120 mg/Nm3)
▪ 3.0% O2 measured in the flue gas; therefore, further reductions
will improve NOx
▪ No flame-to-flame interaction
▪ Improved heat flux profile
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© ZEECO, INC.
Conclusion
▪ Zeeco supplied 105 GB Single Jet inserts for a downfired reformer at a European
ammonia facility
▪ NOx emissions, heat flux profile, and flame-to-flame interaction were confirmed by
CFD and burner testing
▪ Current NOx emissions average 90 mg/Nm3 at 3% O2 which meets European
legislation and NOx guarantees
▪ Burners are operating with lower excess air; therefore, fuel gas consumption rate is
lowered in the radiant section
▪ NOx emissions can be reduced further if the furnace excess air is trimmed
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© ZEECO, INC.
Questions?