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November 2009. State of the Art Combustion Equipment for Emissions and Energy Reduction . Field Service & Parts. Vapor Control Systems. Burners. NOx & CO Catalyst Systems. Flares. Thermal Oxidizers. Combustion & Emission .
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November 2009 State of the Art Combustion Equipment for Emissions and Energy Reduction
Field Service & Parts Vapor Control Systems Burners NOx & CO Catalyst Systems Flares Thermal Oxidizers Combustion & Emission • Emissions is the primary driver for combustion equipment. Energy efficiency is a secondary but growing driver • Impact • Burners: Emissions and Energy • Flares: Emissions and Energy • Thermal oxidizers: Emissions and Energy • Vapor control systems: Emissions • NOx and CO catalyst systems: Emissions • Services: Emissions and Energy
Requirements in addition to Technology • Uncompromising Product/System Safety • Proven Reliability • Operational Performance (Guarantee) • Emissions reduction • Ease of Product Operation
Callidus Market Segments Served Refineries Petrochemical Plants Refinery process heaters Reforming furnaces Cracking furnaces Coking furnaces Flares Thermal oxidizers Ethylene production Fertilizer production Hydrogen production Flares Thermal oxidizers Power Plants Others (Flares) SCR for simple cycle power generation SCR for HRSG SCR for process heater Terminals LNG storage Carbon black Steel production Bio-fuels Exploration & Production
Advanced Process Heater Burners • Advanced Burner Design • Future transition in India from oil firing to gas firing • Improved efficiency: reduction in combustion air = less wasted heat and less fuel needed therefore improvement in efficiency and cost savings. • Reduced emissions footprint: reduction from 25% excess air to 15% excess air = 25% reduction in NOx emissions per burner
Regulations and Burner Emissions Improvements Oil firing 200 ppm
Process Heater Burners Application • Using advanced fuel air ratio controls and O2 trimming, Callidus could potentially reduce the oxygen levels within the furnace, while maintaining the temperature and combustion efficiency • The Callidus burner is designed to be stable over the entire operating range • Assuming natural gas, a 1% reduction in oxygen should produce a 1.3% reduction in fuel gas needed • Guaranteed 30 ppm NOx *Note: Assuming fuel cost of 580USD/Ton, and annual operation of 8300 hr.
Flare Technology Emissions Improvements Increased smokeless capacity Demountable Derrick Flare Inner steam or Inner air flare Upper steam flare Multi-point ground flare Pipe flare
Highlighting Totally Enclosed Ground Flares • Totally Enclosed Ground Flares (TEGF) • No visible emissions during normal operations • Reduced radiation “signature” • Reduced noise level Callidus TEGF Non-Callidus flare smoking
Flare Technology Energy Efficiency Improvements FGRU • Flare Gas Recovery Unit (FGRU) • Add-on equipment • Allows capture of daily flaring rate • Captured flare gas used in refinery processes • Supports global gas flaring reduction efforts championed by World Bank • Density Seals • Flare purge gas reduction equipment • Reduces amount gas needed to maintain safe flare operations Flare Refinery
Flare Application Petrochina Dushanzi Flare / Flare Gas Recovery System • Low utility consumption (steam, fuel gas, N2, Instrument Air) • High combustion efficiency & smokeless capacity to meet emission standards
Thermal Oxidizers • Thermal Oxidizers are capable of achieving 99.999% destruction efficiency • Air Pre-heaters allow for less fuel/assist gas to be used in the operation of the thermal oxidizer • Attached waste heat boilers allow for the use of steam for applications around the facility or “across the fence” in a co-generation applications
Callidus Incinerators Application Thermal Oxidizer (Waste Heat Boiler) Application
Callidus Incinerators Application Questions?