OPTIMELT™ Implementation at Libbey Leerdam to Support … Implementation... · 2018. 12. 5. ·...

OPTIMELT™ Implementation at Libbey Leerdam to Support Energy Savings and Sustainability Goals

FURNACE SOLUTIONS 12; Thursday 8th June 2017

de Diego J. +++, Kobayashi H. ++, Laux S. ++, Bell R. ++, Francis A. ++

van Valburg M. +, Schuurmans F. +, + Libbey Holland, ++Praxair Inc., +++Praxair Euroholding

LIFE15 CCM/NL/000121 - LIFE OPTIMELT

Agenda

1

■ Libbey Leerdam goals by implementing OPTIMELT technology at L1 furnace

■ NOx, SOx, and particulates emission from oxy-fuel f ired furnaces

■ NOx, SOx, and particulates emission from oxy-synga s firing with OPTIMELT thermochemical regenerator

■ Projected NOx, SOx, and particulates emissions from a new Oxy-syngas fired furnace at Libbey, Leerdam

■ Installation & design challenges associated to OPTI MELT scale up and onsite Oxygen production system integration


OPTIMELT L1 Project at Libbey, Leerdam

2

http://www.lifeoptimelt.com/


■ Goal for Libbey • Reduce energy cost in glass melting • In combination with the use of best available technology that adresses the

environmental reduction requirements for the near by future. Align with the roadmap towards a carbon free economy by 2050

■ Change for Libbey Leerdam plant• From recuperative to oxy fuel combustion• Added with the Optimelt technology as the technology with highest potential

in energy saving compared to other existing options for using waste heat of flue gasses

OPTIMELT L1 Project at Libbey, Leerdam

3LIFE15 CCM/NL/000121 - LIFE OPTIMELT

OPTIMELT SYSTEM


OPTIMELT L1, Projected Reduction in Emissions

NOx EmissionsKey Factors and Data


Major Factors Influencing NOx Emissions in Oxy-fuel – OPTIMELT Fired Furnaces

6

■ Burner Selection• Staged versus Unstaged• Burner Specific NOx Response to Furnace Nitrogen

■ Control of Air Leakage • Sidewall Cooling, • Batch Charger Openings, • Video Camera Cooling • Peepholes and Other Openings• Furnace Maintenance

■ Nitrogen Content of Fuel and/or Oxidant• VPSA O2 supply vs. Cryogenic O2 supply• N2 in Natural gas• Nitrogen Content of oil

■ Niter (NaNO3, KNO3) in Batch


NOx Emissions. Data 50 tpd OPTIMELT Furnace

7

NO

x (

kg

/mto

n)

� Air leakage was very high for this furnace� NOx variation was in part due to left and right fir e difference


Projected NOx Emissions L1 OPTIMELT Furnace

8

BAT-AEL for Container Glass Air-fired: 0.75 - 1.2 kg/t (500 to 800 mg/Nm3) Oxy-Fuel: <0.5 - 0.8 kg/t

• NOx emissions of 0.1 to 0.4 kg/t are achievable with low NOx oxy-fuel burners• NOx emissions of 0.2 to 0.6 kg/t are projected for new L1 furnace at Leerdam

with OPTIMELT on place

0.9 kg/t

Projected range for L1(Air leak max 268 Nm3/h)


Particulates EmissionsTheory and Data


Mayor Factors Influencing Particulate Emissionsin Oxy-fuel – OPTIMELT Fired Furnaces

H2O

NaOH

NaOH (vapor, equilibrium)

Na20 in glass melt

v

Particulates(Na2SO4 )

• Alkali vapor volatilization is the main cause for particulates emission and silica crown corrosion

• Typically 80 – 90% of particulates emission is sub-micron particles of Na2SO4-• Furnace and burner designs make large difference on alkali volatilization rate

and particulates emissions


NaOH Volatilization Rates. Effects of burner height above glass (kg/day/m2)

11

Charge End

(a) Burner elevation low

Charge End

(b) middle

Charge End

(c) high

012345678 012345678 012345678

1514

1312

1110

98

76

54

32

10

1514

1312

1110

98

76

54

32

10

1514

1312

1110

98

76

54

32

10

• The high volatilization rate under each flame is caused by high local glass surface temperature and high local gas velocity, both of which are reduced by a higher burner elevation.

Par

ticul

ate

Em

issi

on (g

/kg-

Gla

ss)

0.7

Legend

Burner Elevation

PredictionTrend line

0.6

0.5

0.4

0.3

0.2

0.1

0.0

low middle high


Projected Particulate Emissions L1 OPTIMELT furnace

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• 50+ % reduction achieved by burner/furnace design optimization


Specific Pull, ton/(day.m2) *

Par

ticul

ate

Em

issi

ons,

g/k

g-gl

ass

lb/s

hort

ton-

glas

s

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0

0.0

0.8

1.2

1.60.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.0

Particulate (Oxy)(Europe)

All Sulfates (Oxy)

Na2SO4 (Oxy)

Particulate (Oxy) (EPA)

Particulate (Air) (EPA)

(* corrected for tpd by electric boost)

(EPA Method 5)


SOx EmissionsKey Factors and Data

• Reducing flame impinging on batch area should be avoided as it increases SOxevolution and reduces the fining action

• Oxy-fuel firing tends to increase SOx evolution due to the enhancement of fining reactions by water dissolution into glass

• Sulfate input for fining is typically reduced by 20-30% under oxy-fuel firing and the SOx emissions are reduced*

Batch Sulfate(Na2SO4 )

Sulfate in Glass(SO42- )

SO2 Emission

ParticulatesCondensable Vapors(Na2SO4 , Na2S2O7 NaHSO4 , H2SO4 )

No sulfur in Fuel(Natural gas)

Batchmelting

Fining

Example for flint glass

6.5 kg/t batch(4.0 kg/t as SO3)(0.4% wt)

2.5 kg/t as SO3(0.25 % wt)

0.3 kg/t particulate(0.15 kg/t as SO3 )

1.08 kg/t as SO2 (1.35 kg/t as SO3)

1.2 kg/t as SO2 (1.5 kg/t as SO3)

(34%)

(4%)

(62%)

(38%)

(100%)

Typical Sulfur Balance in Glass Melting

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*US Pat. 5,922,097: “Water enhanced sulfate fining”


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Sulfur EmissionsSO2 + SO3 + Sulfates in particulates

Sulfur inputBatch/cullet sulfates + sulfur in fuel

Sulfur retention in glassTypical Sulfur Retention in glass (as SO3)

*0.65, 0.88 lb/t in separate stack measurements

• SO2 emissions vary significantly depending on batch sulfates input and furnace operation

• Without filter 0.4 to 0.8 kg/t appears feasible for flint glass under oxy-fuel firing

• SO2 emissions from container furnaces

= -

SOx Emissions from Glass Furnace


Summary OPTIMELT Burner Design Features

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■ NOx reduction• Deeply staged combustion

■ Particulates reduction• Minimize hot spots and furnace gas velocity over glass/batch surface

■ SOx reduction• Avoid flame impingement over batch area

• Minimize batch sulfate consistent with glass quality



OPTIMELT L1 Project at Libbey site Challenges

OPTIMELT L1 Project at Libbey. Challenges

■ OPTIMELT installation on tableware furnace• Praxair VPSA oxygen supply with liquid oxygen backup• Libbey Motivation: fuel and oxygen savings, emissions, sustainability

■ Engineering and Design • Sorg: Furnace, Regenerators and Oxy-fuel system• Praxair: OPTIMELT system

and JL Oxy-fuel BurnersOxy-Fuel Port Neck

Downcomer for Flue Gas

OPTIMELT Port Necks

Right/Left RegeneratorOPTIMELT Flue Gas Skid

Oxy-fuel Burners

18


Praxair VPSA

O2


19


■ Select refractories (walls and checkers) based on P avisa experience• Praxair ran several test with major refractory suppliers at Pavisa (Mexico)• Test provided with important information to suggest best options to be used


20


OPTIMELT top view OPTIMELT lateral view


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OPTIMELT lateral view RFG system detail


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Oxy-fuel skid Oxy-fuel skid


Summary

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■ NOx, SOx and Particulates Emissions from oxy-fuel fu rnaces are significantly lower than those from air fired regen erative furnaces

■ Emissions from Oxy-Syngas fired furnace with OPTIME LT™ Thermochemical Regenerators (TCR) are similar to lo w emission oxy-fuel fired furnaces

■ Emissions (kg/t) from a new oxy-syngas fired tablew are furnace at Libbey, Leerdam are projected to be reduced by 25-60% compared to the current recuperative furnaces.

Praxair is committed to new technology development to support the cost reduction and sustainability goals of the glass industry


Thank You for your Attention!

LIFE15 CCM/NL/000121 - LIFEOPTIMELT

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OPTIMELT™ Implementation at Libbey Leerdam to Support … Implementation... · 2018. 12. 5. ·...

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