Burnerdesignoperationmaintenancenh3plants 150105170005-conversion-gate02
•
0 likes•227 views
The document discusses burner design, operation, and maintenance on ammonia plants. It covers reformer burner types and designs, including premix and staged burners. It also addresses combustion characteristics like excess air and fuel viscosity effects. Maintenance best practices like checking burner pressures and atomizing steam temperatures are emphasized. Low NOx equipment uses techniques like staged air, fuel, and flue gas recirculation to reduce emissions. Good combustion requires attention to design, operation, maintenance, and partnership among related roles.
Recommended
Recommended
More Related Content
What's hot
What's hot (20)
Similar to Burnerdesignoperationmaintenancenh3plants 150105170005-conversion-gate02
Similar to Burnerdesignoperationmaintenancenh3plants 150105170005-conversion-gate02 (20)
Recently uploaded
Recently uploaded (20)
Burnerdesignoperationmaintenancenh3plants 150105170005-conversion-gate02
- 1. Burner Design, Operation and Maintenance on Ammonia Plants
- 2. Brief History Reformer Burner Types/Design Types of Reformers Combustion Characteristics Excess Air/Heater Efficiency Maintenance, Good Practice Low Nox Equipment Summary WWW.GBHENTERPRISES.COM
- 3. Usage of Fuels on Ammonia Plants Worldwide 0 50 100 150 200 250 300 350 400 450 Total No Plants Natural Gas Heavy Fuel Oil Naphtha Syngas Others Fuels NumberofOperatingPlants WWW.GBHENTERPRISES.COM
- 4. CURRENT LEGISLATION LIMITS Country Start Year Heat release Furnace Capacity NOx CO (ppm) Particulates mg/Nm3 Gas Oil Gas Oil Gas Oil France 1998 >170 MMBtuh 171 219 - - 5 50 UK 1998 Any 146 219 115 1999 Any 97 171 80 Germany 1996 <170 MMBtuh 122 80 219 85 50 <340 MMBtuh 97 50 5 TA Luft >170:<1020 mmBtuh 171 219 25 87 5-100 50 97 171 25 87 5-100 50 Market demand All 39 73 5 50 171 5 50 Eastern Europe As Germany Italy 1992 >170:<1020 mmBtuh 171 219 5 50 USA - All 30-100 WWW.GBHENTERPRISES.COM
- 5. Brief History Burner design Burner Types Types of Reformers Combustion Characteristics Heater Efficiency Maintenance, Good Practice Low Nox Equipment Summary WWW.GBHENTERPRISES.COM
- 6. ◦ Historically trial and error ◦ Empirical methods now backed up with the following sciences Chemical engineering Process engineering Thermodynamics Materials engineering ◦ A good understanding of the above creates good combustion WWW.GBHENTERPRISES.COM
- 7. ◦ Computational fluid Dynamic’s (CFD) is playing a strong role. Good but be cautious ◦ Can be difficult to predict upsets Good for replacing flow modelling Model the Burner and the Furnace box to ensure best possible results ◦ Becoming an essential tool for waste incineration predictions WWW.GBHENTERPRISES.COM
- 8. Burner testing in the manufacturer’s facility should always be considered Confirms burner performance Turndown CO,CO2,NOX Etc Always use the specified fuels that are to be used in service Highlights flame envelope and lift off limits, pilot/light up issues. Air flow distribution WWW.GBHENTERPRISES.COM
- 9. Brief History Burner design Types of Reformers Reformer Burner Types/Design Combustion Characteristics Heater Efficiency Maintenance, Good Practice Low Nox Equipment Summary WWW.GBHENTERPRISES.COM
- 10. Side Fired Top Fired Terraced wall WWW.GBHENTERPRISES.COM
- 11. Natural Draft Forced Draft Premix Post Mix Low Nox ◦ Fluegas Recirculation ◦ Staged Air ◦ Staged fuel Single fuel/Dual fuel WWW.GBHENTERPRISES.COM
- 13. Gas Nozzle Primary Air Primary Air Pre-Mix Burners Venturi Primary Fuel • Fuel & air mixed before combustion zone • Fuel pressure drop occurs in the nozzle. WWW.GBHENTERPRISES.COM
- 17. Nozzle Mix Gas Burner Included Angle Burner Block Burner Throat Port Circle Heater Refractory Flame Holder Pilot Gas Air Fuel Connection FUEL WWW.GBHENTERPRISES.COM
- 19. Nozzle Mix Gas Burner Top or Bottom Fired WWW.GBHENTERPRISES.COM
- 23. Nozzle Mixing Gas Burner Advantages • No possibility of flashback • To some extent, the ability to burn a wide variety of fuels with differing heating values. • A high turndown ratio WWW.GBHENTERPRISES.COM
- 24. Brief History Reformer Burner Types/Design Types of Reformers Combustion Characteristics Heater Efficiency Maintenance, Good Practice Low Nox Equipment Summary WWW.GBHENTERPRISES.COM
- 25. Increasing excess air • reduces flame length • reduces particulates • increases NOx to a peak, further introduction of air leads to a reduction • Increasing liberation • increases flame length WWW.GBHENTERPRISES.COM
- 26. • Increasing fuel viscosity • increases flame length • increases particulates • reduces NOx levels • Increasing combustion air temperature • reduces particulates • increases NOx levels WWW.GBHENTERPRISES.COM
- 29. Brief History Reformer Burner Types/Design Types of Reformers Combustion Characteristics Heater Efficiency Maintenance, Good Practice Low Nox Equipment Summary WWW.GBHENTERPRISES.COM
- 30. Draught Inches WG -13 -27 -41 -55 Top firebox Bottom Firebox FD Section Atmosphere After Convection After damper After ID Fan Atmosphere 13 27 41 55 83 WWW.GBHENTERPRISES.COM
- 32. Brief History Reformer Burner Types/Design Types of Reformers Combustion Characteristics Heater Efficiency Maintenance, Good Practice Low Nox Equipment Summary WWW.GBHENTERPRISES.COM
- 35. Burners can be maintained on or off line ◦ On line less popular due to safety concerns, guns can be with drawn ◦ basic tip changes can be carried out ◦ potential to change burner settings WWW.GBHENTERPRISES.COM
- 36. ◦ Off line during shutdowns (every 3-4 years) ◦ Relatively easy to perform Need for access ◦ Important to maintain settings tile to gun position tip port dimensions surface finish of holes centricity of gun condition of tile and security of fixings condition of metallurgy (oxidation) WWW.GBHENTERPRISES.COM
- 43. Check Burner gas Pressures ◦ at the burners, not the just the rail pressure Check Combustion air pressures ◦ All to often the system is not balanced correctly For oil firing ◦ it is very important atomising steam is dry and at the correct temperature WWW.GBHENTERPRISES.COM
- 44. Brief History Reformer Burner Types/Design Types of Reformers Combustion Characteristics Heater Efficiency Maintenance, Good Practice Low Nox Equipment Summary WWW.GBHENTERPRISES.COM
- 45. ◦ Currently being fitted on new plants ◦ More difficult to control ◦ The very nature of low Nox burner designs requires the flames to be produced in a much slower manner ◦ Even more sensitive to dimensional changes during maintenance, burner’s tend to be more complex ◦ Flames tend to be less well defined, with large whispery edges WWW.GBHENTERPRISES.COM
- 46. Types ◦ Staged Air ◦ Staged Fuel ◦ Flue Gas Recirculation Integral with the burner external to the burner ◦ Combination of all above WWW.GBHENTERPRISES.COM
- 47. Brief History Reformer Burner Types/Design Types of Reformers Combustion Characteristics Heater Efficiency Maintenance, Good Practice Low Nox Equipment Summary WWW.GBHENTERPRISES.COM
- 48. Good Combustion, this can only be achieved if the following is considered. Attention to detail ◦ Good maintenance ◦ Good operation ◦ Good design Partnership between:- Operation, Maintenance and Design. WWW.GBHENTERPRISES.COM
- 49. ◦ You've carefully thought out all the angles ◦ You've done it a thousand times ◦ It comes naturally to you ◦ You know what you're doing, its what you've been trained to do your whole life ◦ Nothing could possibly go wrong, right ? WWW.GBHENTERPRISES.COM