may 20may 20ththth 20052005 scott d. scott d. reed · 2005. 6. 14. · zeeco burner design features...

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:sales@zeeco.com

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:sales@zeeco.comsales@zeeco.com

or on the web at:or on the web at:www.zeeco.comwww.zeeco.com