Industrial / Commercial Burners

CEC – Natural Gas Public Interest Research Program

Large Industrial/Commercial Equipment

Gas Quality Stakeholders’ Technical Committee Meeting

Gas Company TowerLos Angeles, CAJanuary 10, 2006

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

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

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

1. Mixing Type

2. Fuel Type

3. Oxidizer Type

4. Draft Type

5. Heating Type

6. Burner Geometry

Industrial Burner Classification Criteria

Major Burner Control Methods

> On / Off Operation

> High / Low Operation

> Modulating or variable firing rate

Major Process Control Variables

> Furnace Temperature

> Load Temperature

> Load Temperature Uniformity

> Oxygen Trimming

> Moisture Content

> Time-temperature profile

> Time at setpoint temperature

Burner Applications

1. Radiant Burners

2. High Velocity Burners

3. Regenerative Burners

4. Natural Draft Burners

5. Boiler Burners

6. Linear Grid / In-Duct Burners

7. Oxygen Enhanced / Oxy-Fuel Burners

8. Flare Burners

> Thermal Radiation– Drying

– Plastic thermoforming

– Paint curing

> Radiant Tube– Indirect heating

> Radiant Wall– Process Industry

Burner Applications

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Metals Industry

> Ceramic/Glass Industry

Burner Applications

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Zinc Distillation

> Metals Industry

> Glass Industry

Burner Applications

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Chemical and Hydrocarbon Process Industries

Burner Applications

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Steam Generation

> Water Heating

> Space Heating

Burner Applications

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Space Heating

> Turbine Exhaust

> Uniform Spread Heating

Burner Applications

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Metal Heating

> Metal Melting

> Glass Melting

> Mineral Calcining

Burner Applications

1. Radiant Burners




5. Boiler Burners



8. Flare Burners > Petrochemical Industries

Industrial Natural Gas Demand by Sector in California (2000-2004)

Source: California Energy Commission

Petroleum

35%

Oil and Gas

extraction

13%

Chemical4%

Primary Metal

4%

Fabricated Metal

3%

Glass

3%

Nonmetallic Mineral3%

Other18%

Food and Beverage

10%Sugar and Frozen

Food7%

.

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

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)

Burner Evaluation Criteria

Heat Flux

FlameShape

Emissions

Stability

Incomplete Combustion

TurndownRatio

Noise

FurnaceTemperature

ExhaustTemperature

IgnitionLimits

Air-FuelRatio

FlameTemperature

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

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

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

Gaseous Fuel Ranges for theState of California

Source: California Energy Commission

SDG&E/SoCalGas Service Area

36

63 55

58 12

25 26 11 21

1304 - 1407 103

72

68

64 58

50

46 46

39 1302 - 1374

1335 - 1403

1321 - 1385 1318 - 1376

1332 - 1382

1317 - 1363 1317 - 1363

1333 - 1372

Wobbe Number Range Wo Range Wo Values

BTU Districts

Potential Sources of LNG to CAProject Name Location Major Owners Status LNG Composition

(source: GTI)LNG Values

Sakhalin Energy Russia, off east Coast

Shell, Mitsui, Mitsubishi

Under construction; startup 2008

92.2% methane4.9% ethane1.9% butane0.8% propane

HHV=1105Btu/scfSpG=0.613Wobbe=1411Btu/scfZ=0.9975

Tangguh Project Indonesia BP, CNOOC, various local partners

96.4% methane2.0% ethane0.4% propane1.4% butane


Malaysia TIGA Malaysia Petronas, Shell, Mitsubishi

Operational 91.2% methane5.2% ethane3.3% propane1.4% C4+


Northwest Shelf Train 5

Australia Woodside, Shell, BP, BHP, Chevron, Mitsubishi/Mitsui

Under const. 2006

89.3% methane7.1% ethane2.5% propane1.0% C4+


Darwin Australia ConocoPhillips Under const. 2008

Fields have high liquids content so LNG could be “hot” but this will depend on the design of the plant.

Peru LNG Peru Hunt Oil, Repsol, SK

Planned; 2009 N/A

Burner Classification Criteria

1. Mixing Type

2. Fuel Type

3. Oxidizer Type

4. Draft Type

5. Heating Type

6. Burner Geometry

Classification Criteria

> Diffusion Mixed– Non-Staged

– Air Staged

– Fuel Staged

> Partial Pre-mixed– Non-Staged

– Air Staged

> Pre-Mixed– Non-Staged

1. Mixing Type

2. Fuel Type

3. Oxidizer Type

4. Draft Type

5. Heating Type

6. Burner Geometry

> Gas

> Liquid

> Solid

> Dual


1. Mixing Type

2. Fuel Type

3. Oxidizer Type

4. Draft Type

5. Heating Type

6. Burner Geometry


> Air

> Oxygen

> Oxygen Enriched Air

> Preheated Air

1. Mixing Type

2. Fuel Type

3. Oxidizer Type

4. Draft Type

5. Heating Type

6. Burner Geometry


> Forced Draft

> Natural Draft

> Inspirated

> Aspirated

1. Mixing Type

2. Fuel Type

3. Oxidizer Type

4. Draft Type

5. Heating Type

6. Burner Geometry


> Direct

> Indirect

1. Mixing Type

2. Fuel Type

3. Oxidizer Type

4. Draft Type

5. Heating Type

6. Burner Geometry


> Round Nozzle

> Rectangular Nozzle

> Swirl

Burner Physical Types

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Radiant Wall

> Thermal Radiation

> Radiant Tube

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Radiant Wall– Natural Draft

– Forced Draft

> Pre-mixed

> Non-Premixed

> Thermal Radiation

> Radiant Tube

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Radiant Wall

> Thermal Radiation– Porous Ceramic

– Ported Ceramic

– Fiber Metal

– Flame Impingement

– Catalytic

– Perforated Ceramic

– Porous Refractory

– Wire Mesh

> Radiant Tube

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Radiant Wall

> Thermal Radiation

> Radiant Tube– Non-Circulating

– Recirculating

– Forced Draft

– Inspirating

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Pre-mixed

> Diffusion Mixed

> Partially Pre-mixed

> Air Staged

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> One Box

> Two Box

> Rotary / Heat Wheel

> Radiant Tube

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Round Flame

> Wall Fired Flat Flame

> Radiant Wall

> Flat Flame

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Low NOx

> Ultra Low NOx

> Conventional

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Low NOx– External Flue Gas Recirculation

(EFGR)

– Air Staged

– Fuel Staged

– Fuel Induced Recirculation

> Ultra Low NOx

> Conventional

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Low NOx

> Ultra Low NOx– Pre-mixed

– Partially Premixed

– Rapid Mix

– Internal Flue Gas Recirculation

> Conventional

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Low NOx

> Ultra Low NOx

> Conventional– Swirl

– Register

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Duct– Linear Grid

– Grid

> Make-up Air

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Air-Oxy Fuel– Concentric Pipe

– Multiple Nozzle

– Flat Flame

– Staged

> Oxy-Fuel– Polishing

– Forehearth

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Single Point– Non Assisted

– Simple Steam Assisted

– Advanced Steam Assisted

– Low Pressure Air Assisted

> Multi-point

> Enclosed

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Single Point

> Multi-point– Non Assisted




> Enclosed

Burner Types

1. Radiant Burners




5. Boiler Burners



8. Flare Burners

> Single Point

> Multi-point

> Enclosed– Non Assisted




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Industrial / Commercial Burners

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