overview of the gaz de france r&d activities on flameless...
TRANSCRIPT
RESEARCH AND DEVELOPMENT DIVISION
WGC2006 – June 2006
Overview of the Gaz de France R&D activities on flameless oxidation applied
to high temperature processes
By Frédéric AGUILE and Alain QUINQUENEAU
Research andDevelopment
Division
WGC2006 – June 2006
Main goals and driving forces of the R&D activities
Energy savings
• Improving energy efficiency
• Optimisation of processes
Reduction of pollution
• CO2
• NOx
• Noise
Product quality
Process reliability
Research andDevelopment
Division
WGC2006 – June 2006
Main available techniques in high temperature processes
Oxy-combustion
• Low combustion product flow rate
Heat recuperation
• Preheating of the combustion air
• Recuperative systems
• Regenerative systems
Research andDevelopment
Division
WGC2006 – June 2006
Flameless oxidation
High efficiency and low pollution
• Historically linked to the use of regenerators
• Also used with oxy-combustion, liquid and solid fuels
• NOx reduction techniques : air and gas staging, high recirculation
High NOx emissions
2% O2 in the oxidant
Oxi
dant
Tem
pera
ture
No combustion
III Flameless combustion
zone
II Hot flames
IStandard combustionzone
21 % 3 %
AIR
GAZ
Recirculation
Recirculation
AIR
GAZ
Recirculation
Recirculation
Research andDevelopment
Division
WGC2006 – June 2006
Conventional modeFlameless combustion
Flameless oxidation characteristics
Better temperature homogeneity in the chamber
Conventional mode Flameless oxidation mode
« Invisible » flame
Better radiative heat transfer to the load
Low NOx emissions
Low noise emissions
Research andDevelopment
Division
WGC2006 – June 2006
Industrial situation in the metallurgy field
Many industrial applications in Japan in metallurgy processes
A few ones in Europe
Up to 20% of energy savings or 20% productivity increase
More than ten years of R&D in Gaz de France to promote this technology
Research andDevelopment
Division
WGC2006 – June 2006
Burners characterisation in Gaz de France’s test furnaces (1)
Testing of burners operating in flameless mode in partnerships with burner manufacturers
• Regemat de WS GmbH (Germany)
• NOX Beta 600 R de Stordy (UK)
• FFR de North American Manufacturing Co (USA)
• HRS de NFK (Japan)
Research andDevelopment
Division
WGC2006 – June 2006
Burners characterisation in Gaz de France’s test furnaces (2)Main conclusions
NO<300mg/m3(n) and η > 75% whatever the operating conditions
Design tools needed to help industrials in implementing this technique (product quality, efficiency, guaranties…)
0
100
200
300
400
500
600
700
800
900
1000
1000 1050 1100 1150 1200 1250 1300 1350 1400
T furnace (°C)
NO
x (m
g/m
3(n)
@ 3
% O
2)
Research andDevelopment
Division
WGC2006 – June 2006
Development of design tools
InterNOx and Odyssée R&D projects (R&D actions since 2000)
• Implementing this technology in the metallurgy field
• Collaboration: Gaz de France, Arcelor Research, Stein-Heurtey and funds from the French environmental agency Ademe
� Technological survey
� Study of the heating equipment
� Study at semi-industrial scale and validation of the tools
� Validation and demonstration project at industrial scale
Research andDevelopment
Division
WGC2006 – June 2006
Development of design tools Detailed measurement in the flame – main results
Fields of the mean temperatures
Fields of CO concentration and
mean temperatures
Chemiluminescence's emission of the OH* radical
min maxmin maxmin max
0
400
800
1200
1600
0%4%8%12%16%20%
Oxygen concentration %D
ilute
d ai
r te
mpe
ratu
re (
°C)
Tair = ambient Tair = 600°C Tair = 1000 °C
A : Ordinary flameB : Hot flameC : Flameless combustionD : No reaction
A
B
C
D
Research andDevelopment
Division
WGC2006 – June 2006
Development of design tools Semi-industrial test furnace
Objectives:
• To validate the modelling tools developed in parallel
• To assess the performance of the flameless-oxidation burners in conditions close to an industrial furnace
• To acquire a technical expertise to apply this technology in the industry
Research andDevelopment
Division
WGC2006 – June 2006
Development of design tools Simulation of the semi-industrial furnace
t [h]P
[kW
]0 0.5 1 1.5 2 2.5 3
-300
-200
-100
0
100
200
gazairfuméesparois (internes)supportscharge
Zone model approach
Calculation of the heating time
Research andDevelopment
Division
WGC2006 – June 2006
Demonstration operation and references
Overview of potential applications in metallurgy sector
Industrial references inArcelor’s group are at decision level
A new regenerative reheating furnace built recently in China by Stein-Heurtey
SISCO furnace built in 1995
Research andDevelopment
Division
WGC2006 – June 2006
Fundamental work on flameless oxidation (characterisation)
Work at laboratory scale (CORIA in Rouen )
• Test several configurations for air and gas injection
• In-flame measurements: laser diagnostics
• Tests with gas at low calorific value (syngas, steel gas, biogas, etc.)
interchangeablesolid blocks
burner
chimney
interchangeablewindow block
Research andDevelopment
Division
WGC2006 – June 2006
Fundamental work on flameless oxidation (modelling)
Network of ideal reactors (PSR code) + Residence time distribution measurements (RTD) + Natural Gas detailed kinetic scheme (GDF-Kin® -collaboration with CNRS Orléans and Lille )
This approach is particularly adapted to flameless oxidation due to the quite diluted combustion and stirred flow
Gas input
Recirculation of combustion products
Perfectly s tirred r e actor Plug flow reactor
A ir input
Co mbustion p roducts at the chim ney
Heat transfer s
Numerical RTD experiment with CFD
0
0,01
0,02
0,03
0,04
0,05
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0,07
0,08
0,09
0,1
0 5 10 15 20 25 30 35 40
Time (s)
RTD
Response at the chimney to a pulse injection at air input
Research andDevelopment
Division
WGC2006 – June 2006
Flameless combustion in industrial processes (1)
Glass industry: melting glass furnaces
• NOx reduction
• Potential increase in the radiativeheat transfer to the glass
• Lower thermal impact on the refractory
Chemical and petrochemical industry
• Lower thermal impact on the process tubes
• Increase thermal efficiency
• New design of process
Research andDevelopment
Division
WGC2006 – June 2006
Flameless combustion in industrial processes (2)
Other potential industrial sectors:
• Steam, ceramics, waste treatment, etc.
Oxy-flameless combustion for the CO2 capture
Gas turbines
• NOx reduction
• Low calorific gases
• Increase life time
Research andDevelopment
Division
WGC2006 – June 2006
Conclusion and perspectives
Expertise of Gaz de France and its partners in flameless combustion
Development of tools to apply this technique and to be able to give guarantees (performance of the furnace, quality of the products, etc.)
Other potential industrial applications in the future
Gaz de France: a partner for innovation with its industrial customers and manufacturers
Research andDevelopment
Division
WGC2006 – June 2006
Thank-you for your attention