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Industrial / Commercial Burners

CEC – Natural Gas Public Interest Research Program Large Industrial/Commercial Equipment Gas Quality Stakeholders’ Technical Committee Meeting Gas Company Tower Los Angeles, CA January 10, 2006. Industrial / Commercial Burners. Area with least interchangeability data

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Industrial / Commercial Burners

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  1. CEC – Natural Gas Public Interest Research ProgramLarge Industrial/Commercial EquipmentGas Quality Stakeholders’ Technical Committee MeetingGas Company TowerLos Angeles, CAJanuary 10, 2006

  2. Industrial / Commercial Burners • Area with least interchangeability data • GTI is conducting a survey with California focus for 11-member sponsor group of • Work is currently underway • Expected completion of Jan. 31, 2006 • Data to be input into CEC project • CEC Project planned for 2006 • GTI – industrial burner interchangeability testing • LBNL – appliance air quality

  3. Task 1 – Industrial Burners • Burners • Classification • Applications • Physical types • manufacturers • California industrial gas use by industry • California burner population • Burner performance variables • Burner test protocols • Current range of California gas • Established current California gas ranges • Anticipated LNG and off-spec gas

  4. Upcoming CEC Project • Expected start in March, 2006 • Stakeholders committee to monitor usefulness of project results • Technical advisory committee relying on expertise to assist project team as project proceeds • Activities • Selection of performance variables, test protocols, burners with control systems • Testing in GTI laboratory furnaces • Modeling of burner sensitivity to fuel changes

  5. Industrial Burner Classification Criteria • Mixing Type • Fuel Type • Oxidizer Type • Draft Type • Heating Type • Burner Geometry

  6. Major Burner Control Methods • On / Off Operation • High / Low Operation • Modulating or variable firing rate

  7. Major Process Control Variables • Furnace Temperature • Load Temperature • Load Temperature Uniformity • Oxygen Trimming • Moisture Content • Time-temperature profile • Time at setpoint temperature

  8. Burner Applications • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Thermal Radiation • Drying • Plastic thermoforming • Paint curing • Radiant Tube • Indirect heating • Radiant Wall • Process Industry

  9. Burner Applications • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Metals Industry • Ceramic/Glass Industry

  10. Burner Applications • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Zinc Distillation • Metals Industry • Glass Industry

  11. Burner Applications • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Chemical and Hydrocarbon Process Industries

  12. Burner Applications • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Steam Generation • Water Heating • Space Heating

  13. Burner Applications • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Space Heating • Turbine Exhaust • Uniform Spread Heating

  14. Burner Applications • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Metal Heating • Metal Melting • Glass Melting • Mineral Calcining

  15. Burner Applications • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Petrochemical Industries

  16. Petroleum 35% Other 18% . Nonmetallic Mineral 3% Glass Oil and Gas 3% extraction 13% Fabricated Metal 3% Primary Metal Food and Beverage 4% 10% Sugar and Frozen Chemical Food 4% 7% Industrial Natural Gas Demandby Sector in California (2000-2004) Source: California Energy Commission

  17. Burner Use in California • Petrochemical(53.3% of Natural Gas Usage) • Natural Draft Burners • Radiant Burners • Boiler Burners • Flare Burners • Food Processing(17.0% of Natural Gas Usage) • Radiant Burners • Linear Burners • Glass and Cement Industry (7.3% of Natural Gas Usage) • Regenerative Burner Systems • Oxy-Fuel Burners • Air-Staged Diffusion Mixed

  18. Burner Use in California • Metal Industry(7.2% of Natural Gas Usage) • Radiant Burners • Oxy-fuel Burners • High Velocity Burners • Boiler Burners • Regenerative Burner Systems • Paper and Textile Industry(7.2% of Natural Gas Usage) • Boiler Burners • Radiant Burners • Other Use(combined total 7.9% of Natural Gas Usage)

  19. Burner Evaluation Criteria Incomplete Combustion Flame Temperature Noise Heat Flux Emissions Turndown Ratio Stability Air-Fuel Ratio Exhaust Temperature Furnace Temperature Flame Shape Ignition Limits

  20. Major Affected Parameters • Stability • Flashback, lift-off, blowout, pressure fluctuations • Flame shape • Flame length and diameter • Emissions • CO, NOx, UHC, VOC • Burner noise • Flame heat release • Flame and flue gas temperature, heat flux • Turndown ratio

  21. Burner Evaluation - Traditional • Flue gas and furnace temperature • Suction pyrometer (aspirator) • Thermocouples • Stability • Air pressure/noise fluctuation • Visual lift-off & flashback (premixed) • Flame shape and length • Visual observation (template measurement) • Heat release • Optical heat flux probe • Heat balance calculations • Noise • Microphone • Emissions • Gas sampling to external analyzers

  22. Burner Evaluation - Advanced • Exhaust and furnace temperature • Laser diagnostics • Thermal imaging • Stability • Optical sensor observation of flame stability • Acoustic measurements • Flame shape and length • Optical sensor monitor of flame shape • Composition monitoring of flame envelope (chemical length) • Emissions • Laser diagnostics (FT-IR) • Doping induced luminescence • Flame temperature • Laser diagnostics

  23. Gaseous Fuel Ranges for theState of California

  24. SDG&E/SoCalGas Service Area Source: California Energy Commission

  25. Potential Sources of LNG to CA

  26. Burner Classification Criteria

  27. Diffusion Mixed Non-Staged Air Staged Fuel Staged Partial Pre-mixed Non-Staged Air Staged Pre-Mixed Non-Staged Classification Criteria • Mixing Type • Fuel Type • Oxidizer Type • Draft Type • Heating Type • Burner Geometry

  28. Classification Criteria • Mixing Type • Fuel Type • Oxidizer Type • Draft Type • Heating Type • Burner Geometry • Gas • Liquid • Solid • Dual

  29. Classification Criteria • Mixing Type • Fuel Type • Oxidizer Type • Draft Type • Heating Type • Burner Geometry • Air • Oxygen • Oxygen Enriched Air • Preheated Air

  30. Classification Criteria • Mixing Type • Fuel Type • Oxidizer Type • Draft Type • Heating Type • Burner Geometry • Forced Draft • Natural Draft • Inspirated • Aspirated

  31. Classification Criteria • Mixing Type • Fuel Type • Oxidizer Type • Draft Type • Heating Type • Burner Geometry • Direct • Indirect

  32. Classification Criteria • Mixing Type • Fuel Type • Oxidizer Type • Draft Type • Heating Type • Burner Geometry • Round Nozzle • Rectangular Nozzle • Swirl

  33. Burner Physical Types

  34. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners

  35. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Radiant Wall • Thermal Radiation • Radiant Tube

  36. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Radiant Wall • Natural Draft • Forced Draft • Pre-mixed • Non-Premixed • Thermal Radiation • Radiant Tube

  37. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Radiant Wall • Thermal Radiation • Porous Ceramic • Ported Ceramic • Fiber Metal • Flame Impingement • Catalytic • Perforated Ceramic • Porous Refractory • Wire Mesh • Radiant Tube

  38. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Radiant Wall • Thermal Radiation • Radiant Tube • Non-Circulating • Recirculating • Forced Draft • Inspirating

  39. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Pre-mixed • Diffusion Mixed • Partially Pre-mixed • Air Staged

  40. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • One Box • Two Box • Rotary / Heat Wheel • Radiant Tube

  41. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Round Flame • Wall Fired Flat Flame • Radiant Wall • Flat Flame

  42. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Low NOx • Ultra Low NOx • Conventional

  43. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Low NOx • External Flue Gas Recirculation (EFGR) • Air Staged • Fuel Staged • Fuel Induced Recirculation • Ultra Low NOx • Conventional

  44. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Low NOx • Ultra Low NOx • Pre-mixed • Partially Premixed • Rapid Mix • Internal Flue Gas Recirculation • Conventional

  45. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Low NOx • Ultra Low NOx • Conventional • Swirl • Register

  46. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Duct • Linear Grid • Grid • Make-up Air

  47. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Air-Oxy Fuel • Concentric Pipe • Multiple Nozzle • Flat Flame • Staged • Oxy-Fuel • Polishing • Forehearth

  48. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Single Point • Non Assisted • Simple Steam Assisted • Advanced Steam Assisted • Low Pressure Air Assisted • Multi-point • Enclosed

  49. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Single Point • Multi-point • Non Assisted • Simple Steam Assisted • Advanced Steam Assisted • Low Pressure Air Assisted • Enclosed

  50. Burner Types • Radiant Burners • High Velocity Burners • Regenerative Burners • Natural Draft Burners • Boiler Burners • Linear Grid / In-Duct Burners • Oxygen Enhanced / Oxy-Fuel Burners • Flare Burners • Single Point • Multi-point • Enclosed • Non Assisted • Simple Steam Assisted • Advanced Steam Assisted • Low Pressure Air Assisted

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