may 20may 20ththth 20052005 scott d. scott d. reed · 2005. 6. 14. · zeeco burner design features...
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May 20May 20May 20ththth 200520052005
Scott D. Scott D. Scott D. ReedReed
Zeeco WorldwideInstallations in over 43 Countries
22 International Locations10 Domestic Locations
Quality Assurance
• ISO 9001:2000 Accredited Engineering, Manufacturing and Testing facility
• ASME Section VIII Code Shop; U, R & S Stamps
• UL Certified
• CE Certified
• Lack of warranty claims
Is your Low Emission burner designed for low
maintenance and sustainable emission control??
UltraLow NOx Burner Design Considerations
• Easy to install -- Small footprint
• Easy to operate -- no operator input
• Easy to Maintain -- air & Fuel
• Short flame -- Minimize interaction
• Stable -- wide range of fuel gases
• Long life -- durable construction
• Sustainable NOx control
• Affordable burner & spares pricing
Zeeco Freejet Burner Design Features
• Small footprint – Freejet burner has no metal stabilization devise in the throat area, which keeps the burner smaller in diameter and therefore typically results in no furnace modifications when retrofitting existing furnaces, saving installation cost
• East to operate – Freejet burner has one air control handle and one fuel gas connection
Free JetFree Jet ConceptConcept
Inert Flue GasInert Flue Gas
Conditioned Inert Flue Gas + Fuel Conditioned Inert Flue Gas + Fuel Gas MixtureGas Mixture
Fuel Gas ManifoldFuel Gas Manifold
Combustion AirCombustion AirCombustion Air
Combustion AirCombustion AirCombustion AirFuel Gas Free Jet PortFuel Gas Free Jet Port
Zeeco Burner Design Features
• Short flame – Freejet burner flame is tailored to match furnace configuration
• Minimize flame interaction – Freejet burner has no swirling of the combustion air orfuel gas, which reduces potential for flame to flame interaction (interaction can lenghten flame and increase NOx)
Free JetFree JetMinimal Flame InteractionMinimal Flame Interaction
Zeeco Burner Design Features
• Stable flame – Freejet burner can fire natural gas to refinery fuel gas on same set of gas tips and offer over a 10:1 turndown since all gas tips are on one perimeter. Other competing designs require communication up and over the tile btw primary and secondary gas tips. Pilot is optional and not required for stability.
Zeeco Burner Design Features
• Freejet is Easy to Maintain with sustainable emission control
– Air control – sealed bearing gear driven
– Burner tile – single piece design
– Fuel Delivery – Patented design for low maintenance
Freejet - Sealed bearing air control
Freejet - Gear driven air control
Single Piece Tile Design
• Multiple Piece tile can easily be moved out of tolerance during routine burner maintenance
• Single piece tile is preferred design
Freejet - Single Piece Burner Tile
Gas Tip / Riser Fouling Concerns
• High gas pressure trips
• Poor flame quality
• Higher NOx emissions
• Tube impingement
• Burner damage
• Safety concerns
Gas Tip / Riser Foulingproblems it creates
Gas Tip / Riser FoulingPotential Causes
• Large mass gas tip design
• Riser exposed to radiant heat
• Gas tip exposed to radiant heat
• Low velocity in gas riser
• Liquids / scale in fuel gas system
• Burner design requires shutting in of tips to achieve turndown ---tips get heat soaked
Exposed gas tips and risers
Exposed Gas Tips and Risers
NOT Zeeco burners
Gas Riser Failure
gas riser failure due to exposure to radiant firebox
Not Zeeco burner
Gas Tip / Riser FoulingPotential remedies
• Knock out drum in fuel gas system • Re-route dirty fuel gas streams• Proper fuel gas take off points• Sloping of fuel gas lines• Heating of the fuel gas• Use of strainers and or
coalescing filters• Fuel gas piping material• Better burner design by the
burner vendors
Patented Burner and gas tip design = FREEJET
Gas Tip / Riser Foulingbetter burner design
• Low mass gas tips
• Low exposure gas tip location
• Low exposure riser design
• Small cross sectional area risers
• Eliminate need for ignition ports
• High turndown without having to shut in tips
Gas Risers protected
• Gas Risers Not exposed to High Combustion APH temp
Gas Risers & Manifold outside APH
Gas Tip Design and Sizing
• Zeeco Freejet does not use small “ignition or stability” ports that are proven to plug thus compromising stability
• Zeeco Freejet utilizes patented gas tip design to reduce propensity for pluggage
FreeJet patented Gas Tip Design
• Enhanced flue gas entrainment
• low mass tip design
• low radiant profile
• low cross sectional area tip design
• Single port design
• Only brn with patented gas tips
Gas Tip Comparison
• Standard Low NOx gas tip on the left – may have as many as (6) ports
• Patented Freejet Gas Tip on the right – single port design
FreeJet Port Sizing
• FreeJet operates at lower pressure (keep ports large) and achieves better turndown
• FreeJet has one port per tip
• FreeJet has no “ignition or stability” ports required
Freejet Burners inField Service
Improving the prediction of field NOx performance
larger, multiple burner test furnaces can more accurately simulate actual process conditions and lead to a greater degree of certainty in predicting field NOx and process performance.
CFD can be a directionally useful tool in utilizing burner design and test data to identify potential problems in the field and determine solutions
CFD model geometry
Combustion air inlet Burner discharges –
note numbering sequence
12
34
56
78
Model assumes symmetry and only analyzes
flow through 8 burners
Burner pressure drop• Firebox pressure held at 0 in”
WC, so burner DP ~ 2.6 inWC
• Close-up shows duct pressures approaching burners is ~2.6 in” WC
Test Furnace No. 12• Designed for Multi-
Burner Testing
• Heat Release up to 100 MM Btu/hr
• Dimensions 17.5’ dia. X 40’
• 5.33m x 12.19m
• Water tubes for firebox temperature control
• Forced or Natural Ambient, Preheated air or Turbine Exhaust
• Burner Orientation
– Up-fired
Test Furnace No. 13• Designed for Multi-Burner
Testing
• Heat Release up to 50 MM Btu/hr (12.6 MM Kcal/hr)
• Dimensions 10’ X 27’ X 21’
• 3.05m x 8.23m x 6.4m
• Water tubes for firebox temperature control
• Forced or Natural Ambient, Preheated air or Turbine Exhaust
• Burner Orientation
– Horizontal
– Up-fired
Test Furnace No. 13Freejet Burners
Free JetFree JetField ResultsField Results
• Field results have been very favorable, meeting guarantee points typically between 5-15 ppmv, depending on fuel composition and box temperature
• Customer feedback indicates Freejet burner is very stable and easy to operate
Free JetFree JetField ResultsField Results
It is critical to provide accurate operating and design data that represents field operating conditions for burner testing -- if we match expected operating conditions in our test facility, the data between the test furnace and the field are very close
Free JetFree JetField ResultsField Results
Why Test / Field Data do not Match:
• Floor / radiant temp
• Air preheat temp
• Tramp air leakage
• Fuel gas comp (NH3 and =)
• Use of outdated data sheets that do not represent actual operating conditions
Freejet - Commercially proven Design
• Over 1300 sold / installed to date
• Multiple repeat customers
• Process heater applications
• Cracking furnace applications
Freejet - Commercially proven Design
• exxonMobil
• Valero Refining
• BP refining
• ChevronTexaco
• ConocoPhillips
• Huntsman Chem
• NCRA Refining
• Dow Chemical
• Flying J Refining
• Sinclair Refining
• Nisseki Chem
• Frontier Refining
• Murphy Oil
• Chevron
• Scanraf
• Cosmo Oil
Costs to consider
• Equipment Cost
(Burner Price)
• Installation cost
(floor / refractory rework)
• Spares Cost (long term costs)
Zeeco Field Support
NOT JUST EQUAL – BETTER
ZeecoZeecoNOx Reduction TechnologyNOx Reduction Technology
For specific questions regarding Zeeco’s Free Jet technologycall us at:
Ph. 918.258.8551Fax 918.251.5519
or email us at:[email protected]
or on the web at:www.zeeco.com
For specific questions regarding For specific questions regarding Zeeco’s Free Jet technologyZeeco’s Free Jet technologycall us at:call us at:
Ph.Ph. 918.258.8551918.258.8551FaxFax 918.251.5519918.251.5519
or email us at:or email us at:[email protected]@zeeco.com
or on the web at:or on the web at:www.zeeco.comwww.zeeco.com