U.S. patent application number 10/310197 was filed with the patent office on 2003-07-17 for process and apparatus of combustion for reduction of nitrogen oxide emissions.
Invention is credited to Bourhis, Yves, Bugeat, Benjamin, Marin, Ovidiu, Penfornis, Erwin.
Application Number | 20030134241 10/310197 |
Document ID | / |
Family ID | 26977273 |
Filed Date | 2003-07-17 |
United States Patent
Application |
20030134241 |
Kind Code |
A1 |
Marin, Ovidiu ; et
al. |
July 17, 2003 |
Process and apparatus of combustion for reduction of nitrogen oxide
emissions
Abstract
A combustion control system allows the dramatic reduction of NOx
emission levels from industrial combustion processes without having
recourse to expensive flue gas clean up methods. The system
combines the technique of oscillating combustion with an adapted
system for post combustion burn out of the excess of CO resulting
from the low-NOx combustion zone. A process for fuel combustion
includes generating an oscillating combustion zone by oscillating
at least one of the fuel flow and the oxidant flow to achieve a
reduced nitrogen oxide emission, selecting oscillating parameters
and furnace operating parameters to maximize nitrogen oxide
reduction efficiency to the detriment of carbon monoxide
production, and combusting carbon monoxide downstream of the
oscillating combustion zone by injecting a post combustion
oxidant.
Inventors: |
Marin, Ovidiu; (Lisle,
IL) ; Penfornis, Erwin; (Oak Park, IL) ;
Bourhis, Yves; (Westmont, IL) ; Bugeat, Benjamin;
(Oak Park, IL) |
Correspondence
Address: |
BURNS, DOANE, SWECKER & MATHIS, L.L.P.
P.O. Box 1404
Alexandria
VA
22313-1404
US
|
Family ID: |
26977273 |
Appl. No.: |
10/310197 |
Filed: |
December 3, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60348661 |
Jan 14, 2002 |
|
|
|
Current U.S.
Class: |
431/9 ;
431/115 |
Current CPC
Class: |
F23L 7/007 20130101;
F23C 6/045 20130101; F23C 99/00 20130101; F23C 7/00 20130101; F23C
2900/06041 20130101; Y02E 20/344 20130101; F23L 2900/07005
20130101; F23K 2900/05003 20130101; Y02E 20/34 20130101 |
Class at
Publication: |
431/9 ;
431/115 |
International
Class: |
F23L 001/00; F23M
003/00 |
Claims
What is claimed is:
1. A process for fuel combustion, comprising: supplying a flow of
fuel and a flow of oxidant to a burner; generating an oscillating
combustion zone by oscillating at least one of the fuel flow and
the oxidant flow to achieve a reduced nitrogen oxide emission;
selecting oscillating parameters and furnace operating parameters
to maximize nitrogen oxide reduction efficiency; and combusting
carbon monoxide downstream of the oscillating combustion zone by
injecting a post combustion oxidant at a post combustion injection
location to minimize carbon monoxide in an exhaust gas.
2. The process of claim 1, wherein the supplied fuel is a gaseous
fuel.
3. The process of claim 1, wherein the supplied oxidant is air,
oxygen-enriched air, or substantially pure oxygen.
4. The process of claim 1, wherein the post combustion oxidant is
injected at a sufficient velocity to penetrate flue gas and to
allow mixing of flue gas and post combustion oxidant.
5. The process of claim 1, wherein the post combustion oxidant is
injected through a swirler or through a multi-orifice injector with
various injection angles in order to distribute as evenly as
possible the oxidant in the post-combustion zone and thus to
improve mixing.
6. The process of claim 1, wherein the step of combusting carbon
monoxide also combusts unburned hydrocarbons.
7. The process of claim 1, comprising controlling a temperature of
the post combustion injection location to a temperature of about
800.degree. C. to about 1100.degree. C.
8. The process of claim 7, wherein the temperature is controlled by
injecting a cooling agent comprising water inside the flame to cool
a flame hot zone and to inhibit nitrogen oxide formation.
9. The process of claim 7, wherein the temperature is controlled by
the injection of additional fuel to the post combustion injection
location.
10. The process of claim 1, wherein the post combustion oxidant is
injected in an oscillating pattern to improve mixing and inhibit
nitrogen oxide formation.
11. The process of claim 1, wherein the post combustion oxidant is
air, oxygen-enriched air, or substantially pure oxygen.
12. The process of claim 1, wherein the selected oscillating
parameters include the flow amplitude, the frequency, and the duty
cycle which are selected to maximize nitrogen oxide reduction
efficiency to the detriment of carbon monoxide production.
13. The process of claim 1, wherein an air/fuel ratio of the
supplied fuel and oxidant is selected to be approximately
stoichiometric or lower to reduce nitrogen oxide formation.
14. The process of claim 1, wherein an air/fuel ratio of the
supplied fuel and oxidant is selected to be below stoichiometric by
reduction of the oxidant flow rate supplied to the burner, and
wherein the balance of oxidant is supplied at the post-combustion
injection location in order to complete the combustion and reduce
nitrogen oxide formation.
15. The process of claim 12, wherein the flow amplitude is about
30% or higher.
16. The process of claim 12, wherein the flow amplitude is about
70% or higher.
17. The process of claim 12, wherein the duty cycle is about 50% to
about 70%.
18. The process of claim 12, wherein the frequency is about 3 Hz or
less.
19. The process of claim 12, wherein the frequency is about 0.5 Hz
or less.
20. The process of claim 1, wherein the post combustion injection
is located where the oxidant will not interact significantly with
the oscillating combustion.
21. A combustor having an emissions control system, comprising: a
combustion chamber; at least one burner positioned to direct a
flame into the combustion chamber, the burner having at least a
first channel for delivering fuel and at least a second channel for
delivering an oxidant; a supply of fuel connected to the first
channel; a supply of oxidant connected to the second channel; a
pulsating mechanism arranged to pulse the flow of at least one of
the fuel supply and the oxidant supply to the burner to create an
oscillating combustion zone in the combustion chamber; a controller
for controlling oscillating parameters of the burner to maximize
nitrogen oxide reduction efficiency; and a post combustion oxidant
injection system located downstream of the oscillating combustion
zone and arranged to burn excess carbon monoxide.
22. The combustor of claim 21, wherein the post combustion oxidant
injection system includes at least one oxidant injection nozzle
having a swirler or multi-orifice injector with various injection
angles.
23. The combustor of claim 21, wherein the post combustion oxidant
injection system includes a post combustion nozzle positioned
between the oscillating combustion zone and an exhaust of the
furnace.
24. The combustor of claim 23, wherein the combustor is an
industrial boiler, of either firetube or watertube type.
25. The combustor of claim 23, wherein the furnace is an end fired,
single burner furnace, and the post combustion nozzle is positioned
at an opposite end or side of the furnace from the burner.
26. The combustor of claim 21, wherein the post combustion oxidant
injection system includes an oscillating device for oscillating a
post combustion oxidant flow.
27. The combustor of claim 21, wherein the controller monitors flue
gas composition and temperature and commands post combustion
parameters according to an operator-defined model.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 60/348,661 filed Jan. 14, 2002, which is
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a method and apparatus to reduce
nitrogen oxide emissions from industrial combustion processes, and
more particularly the invention relates to a method and apparatus
to reduce nitrogen oxide emissions without affecting other
emissions, such as carbon monoxide, by combining the technique of
oscillating combustion with a system of post combustion removal of
carbon monoxide.
DESCRIPTION OF THE RELATED ART
[0003] High-temperature, gas-fired furnaces, especially those fired
with preheated air or industrial oxygen, produce significant
quantities of nitrogen oxides (NOx) per unit of material processed.
At the same time, regulations on emissions from industrial furnaces
are becoming increasingly more stringent, especially in areas such
as California.
[0004] Operators have been looking for improved combustion
technologies allowing reduced NOx formation at a reasonably low
cost. Different solutions have been developed, including low-NOx
burners using staged combustion or Flue Gas Recirculation methods,
with different levels of effectiveness.
[0005] One of these technologies, which has already proved to give
good results, is Oscillating Combustion, where fuel-rich and
fuel-lean zones are created within the flame, thus retarding NOx
formation by avoiding stoichiometric combustion. However, if higher
levels of NOx reduction are to be achieved while still maintaining
carbon monoxide (CO) emissions at safe levels, a modified technique
may be required.
[0006] Industrial Combustion processes, such as high-temperature,
natural gas-fired furnaces, produce NOx emissions. These nitrogen
oxides (primarily NO and NO.sub.2) being a major cause of air
pollution as well as a significant health hazard in ambient air,
they have been defined as a criteria pollutant by the Clean Air Act
Amendment (CAAA), which has established environmental limits in
determined locations.
[0007] Because of the competition, operators of such processes are
thus facing a difficult challenge: to increase their productivity
under the more and more stringent constraints of higher efficiency
and reduced NOx emissions. Lower-cost and more efficient compliance
technology and combustion equipment is thus required by these
industries in order to remain competitive.
[0008] In the combustion of natural gas, NOx are formed by
oxidation of nitrogen in the combustion air under high
temperatures. NOx emissions can be controlled by suppressing NOx
formation or by reducing NOx to molecular nitrogen after they are
generated. The most effective and most widely applied NOx control
technologies so far are as follows.
[0009] Combustion Control Techniques
[0010] Combustion control is a category of technologies which are
intended to minimize NOx emissions by 1) lowering the temperature
in the combustion zone to suppress NOx formation, 2) decreasing the
oxygen concentration available for NOx formation in the high
temperature zones, and/or 3) creating conditions under which NOx
can be reduced to molecular nitrogen by reacting with hydrocarbon
fragments. Technologies of this kind include the following four
techniques.
[0011] Low excess air reduces the available oxygen to the point
which is just sufficient to oxidize the fuel but not so much as to
cause emissions such as NOx and CO.
[0012] Staged combustion involves combusting by arranging the
inlets of fuel or air to achieve off-stoichiometric firing
conditions in the different zones of combustion.
[0013] Flue gas recirculation (FGR) involves recirculation of the
flue gas to the combustion zone as a diluent to reduce flame
temperature and oxygen concentration.
[0014] Gas reburning involves introducing fuel gas to burn in the
post combustion zone to generate various types of hydrocarbon
fragments which reduce the NOx formed in the main combustion zone
to molecular nitrogen.
[0015] Flue Gas Clean Up Techniques
[0016] These technologies are the final alternatives when the
previously described techniques fail to produce an acceptable NOx
emission rate.
[0017] Selective Non-Catalytic Reduction (SNCR) involves injecting
reagents such as ammonia or urea in the furnace. In the temperature
window between about 1800.degree. F. and 2000.degree. F., the NOx
formed during combustion can be reduced to molecular nitrogen by
reacting with the reagent.
[0018] Selective Catalytic Reduction (SCR) is a post combustion
control technology. The reduction of NOx by the injected reagents
such as ammonia or urea is enhanced by the presence of catalysts.
The reaction requires a temperature window between 500.degree. F.
and 750.degree. F., which is suitable for flue gas scrubbing.
[0019] Oscillating Combustion
[0020] An alternative method to the different techniques presented
above is the technology of Oscillating Combustion. This process,
which is already documented in U.S. Pat. Nos. 5,302,111; 5,522,721;
and 4,846,665, has already been tested and its efficiency has been
proved. In addition, European Patent No. 1139022, deals with
methods to optimize the implementation of oscillating combustion in
a furnace and to control its operation, and focuses mainly on
multiburner, side-fired furnaces.
[0021] Oscillating combustion involves the forced, out-of-phase
oscillation of the fuel and/or oxidant flow rate(s) provided to a
burner to create successive fuel-rich and fuel-lean zones within
the flame, thus increasing heat transfer by enhancing flame
luminosity and turbulence, and retarding NOx formation by avoiding
stoichiometric combustion.
[0022] Oscillating combustion implemented alone has allowed up to
approximately 60% NOx reduction on various industrial processes.
However, this optimum reduction depends on the characteristics of
the burner, process or combustion chamber under consideration, and
the setting of parameters of oscillation.
[0023] In terms of NOx reduction, the SCR currently offers the best
result (75-90%). Oscillating combustion, according to what has been
demonstrated so far in both laboratory and field tests, provides
the second best results (50-60%), as well as some other advanced
combustion control techniques (optimized staged combustion and FGR
methods). The reduction efficiency of both SNCR and less advanced
combustion control techniques is low (30-50%).
[0024] In terms of cost-effectiveness, the SCR and SNCR systems
tend to have extremely high capital and maintenance costs. On the
contrary, oscillating combustion is a simple and low-cost
technology that can be applied to a wide variety of combustion
processes.
[0025] However, with the new stringent emissions standards to be
met, most of the NOx generating facilities are currently forced to
use the most effective, but also the most expensive NOx reduction
technology, namely SCR.
SUMMARY OF THE INVENTION
[0026] The present invention relates to a low-cost technology of
combustion control allowing the dramatic reduction of NOx emission
levels from industrial combustion processes which is capable of
achieving low NOx emissions without having recourse to expensive
flue gas clean up methods. The present invention combines the
technique of oscillating combustion with an adapted system for post
combustion burn out of the excess of CO resulting from the low-NOx
combustion zone.
[0027] According to one aspect of the present invention, a process
for fuel combustion includes the steps of:
[0028] supplying a flow of fuel and a flow of oxidant to a
burner;
[0029] generating an oscillating combustion zone by oscillating at
least one of the fuel flow and the oxidant flow to achieve a
reduced nitrogen oxide emission;
[0030] selecting oscillating parameters and furnace operating
parameters to maximize nitrogen oxide reduction efficiency; and
[0031] combusting carbon monoxide downstream of the oscillating
combustion zone by injecting a post combustion oxidant at a post
combustion injection location to minimize carbon monoxide in an
exhaust gas.
[0032] According to another aspect of the present invention, a
combustor includes a combustion chamber, at least one burner
positioned to direct a flame into the combustion chamber, the
burner having at least a first channel for delivering fuel and at
least a second channel for delivering an oxidant, a supply of fuel
connected to the first channel, a supply of oxidant connected to
the second channel, a pulsating mechanism arranged to pulse the
flow of at least one of the fuel supply and the oxidant supply to
the burner to create an oscillating combustion zone in the
combustion chamber, a controller for controlling oscillating
parameters of the burner to maximize nitrogen oxide reduction
efficiency, and a post combustion oxidant injection system located
downstream of the oscillating combustion zone and arranged to burn
excess carbon monoxide.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0033] The invention will now be described in greater detail with
reference to the preferred embodiments illustrated in the
accompanying drawings, in which like elements bear like reference
numerals, and wherein:
[0034] FIG. 1 is a graph of the NOx levels for stoichiometric,
fuel-rich, and fuel-lean conditions.
[0035] FIG. 2 is a schematic diagram of a burner with oscillating
combustion;
[0036] FIG. 3 is a graph of the oscillating fuel-oxidant ratio for
oscillating combustion;
[0037] FIG. 4 is a graph of the NOx and Co emissions vs.
oscillating flow frequency where only fuel flow rate is
oscillated;
[0038] FIG. 5 is a graph of the NOx and CO emissions vs.
oscillating flow frequency wherein both the fuel and oxidant flow
rates are oscillated;
[0039] FIG. 6 is a schematic diagram of a single burner end fired
furnace according to the present invention with an oscillating
combustion burner and CO post combustion;
[0040] FIG. 7 is a schematic diagram of a cross fired furnace
according to one embodiment of the invention operating in
oscillating combustion and subsequent CO post combustion;
[0041] FIG. 8 is a schematic diagram of an industrial boiler
according to one embodiment of the invention with an oscillating
combustion burner and subsequent CO post combustion; and
[0042] FIG. 9 is a schematic diagram of a furnace with a control
system according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0043] The present invention relates to a low-cost technology of
combustion control allowing the dramatic reduction of NOx emission
levels from industrial combustion processes. The present invention
is capable of achieving NOx emissions which meet the most stringent
NOx emission standards without having recourse to expensive flue
gas clean up methods.
[0044] The furnace and the process of the present invention combine
the technique of oscillating combustion with an adapted system for
post combustion burn out of the excess of CO resulting from the
low-NOx combustion zone.
[0045] The principles of the proposed system are to implement the
already proven concept of oscillating combustion in an improved
manner, so as to amplify its NOx reduction effect through an
optimized fine-tuning of the oscillating parameters, even if it
turns to be to the detriment of the CO production.
[0046] The possible detrimental effect of the NOx minimization is
allowed by the presence before the exhaust of the combustion
chamber of the post combustion device designed to reduce the
effluent level of CO below environmentally regulated levels,
without producing additional NOx.
[0047] A principle of the proposed process is to implement the
proven concept of oscillating combustion (or "pulsed combustion")
but, by amplifying its NOx reduction effect through an optimized
fine-tuning of the oscillating parameters, namely the flow
amplitude, the frequency and the duty cycle, as well as the oxygen
to fuel ratio.
[0048] The achievement of additional NOx reduction compared to
existing oscillating combustion systems is made possible by the
fact that NOx performances of such processes have been limited by
their CO emission levels. Actually, CO and unburned hydrocarbon
emissions are dependent on the same three basic factors that
influence NOx emissions: temperature, oxygen concentration, and
residence time at elevated temperatures. Unfortunately, each of
these must be controlled in the opposite direction from that of NOx
reduction: if all three factors are increased, CO production can
essentially be eliminated but NOx production is enhanced, and vice
versa. As CO emissions can rarely be sacrificed for reduced NOx
because a low emission system must keep both pollutants to a
minimum, it is often impossible to fully minimize the NOx
production of conventional oscillating combustion systems.
[0049] In the present invention, there is no limitation regarding
the amount of CO produced by the oscillating combustion device
because the process has the advantage of providing an effective
system of post combustion, which allows the CO oxidation to take
place in a location of the furnace where NOx concentrations are
already frozen and where temperature is adapted to a reliable CO
ignition.
[0050] The post combustion system includes a stream of oxidizing
gas injected by one or several dedicated lance(s) toward the
CO-rich stream resulting from the oscillating combustion zone. The
post combustion injection system is designed to allow an enhanced
mixing between the oxidant and the molecules of CO and unburned
hydrocarbons. The location of the lance(s), even if it can vary
from a process to another, is preferably chosen near the exhaust of
the combustion chamber, where the CO concentration is supposed to
be higher. Optional devices are also proposed so as to increase the
efficiency of CO post combustion, such as means to adjust flue gas
temperature in the zone of post combustion or means to reduce the
additional formation of nitrogen oxides. Finally, the flow of
oxidizing gas injected as well as the overall post combustion
operation are controlled by a process control system based on the
monitoring of process parameters, such as the composition of the
flue gas, its temperature or oscillating combustion parameters.
[0051] Due to its concept, this innovative method of NOx reduction
remains simple, low-cost and can be applied to a wide range of
high-temperature air/gas- or oxygen/gas-fired industrial processes
such as glass melters, steel reheat furnaces, aluminum melters,
boilers, refinery and petrochemical combustors, etc.
[0052] Both single-burner and multiple-burner systems are addressed
by this invention. However, the proposed technique is particularly
adapted and effective for single burner processes, and more
especially for industrial boilers (both firetube and watertube
types), where unburned products of combustion can't be burned out
by additional burners.
[0053] As already mentioned, it is an object of the invention to
propose a customized version of the oscillating combustion process,
enabling to minimize the generation of nitrogen oxides. The
principle of the technique of pulsed combustion, already documented
in patents previously cited, is summarized below.
[0054] Oscillating Combustion
[0055] FIG. 1 shows the NOx formation for fuel rich, fuel lean, and
stoichiometric combustion. It has been shown that NOx formation is
sensitive to temperature and oxygen concentration. An excess of
either fuel or oxygen reduces the flame temperature. The maximum
flame temperature is realized with excess air level close to
stoichiometric concentrations of fuel and oxygen. At higher oxygen
concentrations the dilution effect lowers the flame temperature
sufficiently to reduce the NOx emissions. At lower oxygen
concentrations, there is insufficient oxygen to achieve a high
temperature flame. As a result of this sensitivity to temperature
and fuel to oxidant proportions, both fuel-rich and fuel-lean
flames can generate less NOx than a stoichiometric flame, as shown
in FIG. 1.
[0056] The concept of oscillating combustion is thus to create
successive, NOx retarding, fuel rich and fuel-lean zones within the
flame. Oscillating combustion involves forced oscillation of the
fuel and/or oxidant flow rates provided to the burner. FIG. 2 shows
schematically a burner 100 in which the fuel flow rate is
oscillated with the valve 110 to achieve a flame 120 with fuel rich
zones 122 and fuel lean zones 124. FIG. 3 illustrates the fuel rich
and fuel lean zones for the flame of FIG. 2. In the example of
FIGS. 2 and 3, the level of NOx formed in each zone is
significantly lower than that which would occur if the combustion
took place without fuel oscillation but at the same overall average
fuel flow rate. When the fuel-rich zone 122 and fuel-lean zone 124
eventually mix in the furnace, after heat has been transferred from
the flame to the load and the flame temperature is lower, the
resulting burnout of combustible gases occurs with little
additional NOx formation. Additionally, the increased flame
luminosity resulting from the fuel-rich combustion zones combined
with the increased turbulence created by the flow oscillations
provide increased heat transfer to the furnace load. To achieve
these results, the technology only requires that an oscillating
valve package be installed on the fuel and/or oxidant supply line
ahead of each burner.
[0057] The oxidant fluid provided for the oscillating combustion
process can be either air, oxygen-enriched air or substantially
pure oxygen.
[0058] Optimized Oscillating Combustion
[0059] In order to optimize the performance of the oscillating
combustion in the present invention, mainly three parameters must
be adjusted to suit any particular application. The frequency of
the oscillated flow corresponds to the number of oscillations
cycles per unit of time. The amplitude of the oscillation is the
relative change in gas flow rate during the oscillation cycle,
above or below the average flow rate. The amplitude is described as
a percentage of the average flow rate. The duty cycle describes the
fraction of time the gas flow rate is above the average flow rate
during each oscillating cycle.
[0060] Oscillating combustion implemented alone has allowed up to
approximately 60% NOx reduction on various industrial processes.
The setting of parameters that allows such optimum NOx performances
along with reasonably low CO emissions is usually about the
following: around 70% flow amplitude, 0.5 Hz frequency, and 50%
duty cycle. The NOx reduction also depends on the characteristics
of the burner, process, and combustion chamber under
consideration.
[0061] The present invention provides preferred settings of
oscillating parameters and furnace operating parameters to be set
allowing to further increase the NOx reduction efficiency of the
pulsed combustion system, even if it turns to be to the detriment
of the CO production. Indeed, one advantage of the proposed
invention is that such a generation of CO in the combustion zone is
made possible by the presence of a post combustion system,
downstream, before the combustion chamber exhaust.
[0062] Optimization of the parameters also takes into account
maintaining acceptable flame characteristics that offer stability
and low maintenance operation of the process.
[0063] The following section will thus provide preferred trends for
optimizing oscillating parameters so as to achieve additional NOx
reductions. These trends are based on various test results obtained
on different types of combustion processes. However, each process
installation should be fine-tuned more precisely on case-by-case
basis for meeting high emission performance and flame patterns, and
this based on its own characteristics.
[0064] FIG. 4 displays experimental results collected during tests
on an industrial side-fired oxyglass furnace, operating with
several burners. The influence of frequency on NOx and CO is shown
for a case where solely the fuel flow rate is oscillated and where
the excess oxygen in the flue gas is kept constant (approx. 3% of
oxygen in the flue gas). It is noted that the ratio of the emission
rate of NOx to a reference system without pulsation (NOx(ref))
varies from 50% to 100% as pulsation frequency is increased from
0.2 to 10 Hz (10 Hz being fairly representative of a normal steady
operation). In general, oscillations with lower frequencies produce
greater NOx reductions and heat transfer increases, but at the same
time, CO emissions are also higher. If the oscillation frequency is
decreased beyond 0.5 Hz, particularly beyond 0.2 Hz and preferably
around 0.1 Hz, NOx generation is further reduced but CO emissions
then increase dramatically: in this case, the fuel-lean and the
fuel-rich zones are too large to mix and burn out the CO within the
furnace.
[0065] Accordingly, the frequency for the present invention is less
than 3 Hz, preferably less than about 0.5 Hz, and more preferably
between about 0.1 Hz about 0.5 Hz. This frequency has to be
optimized case-by-case, according to the combustion chamber design
and to the flue gas residence time in this chamber.
[0066] It is also clear from different tests of oscillating
combustion conducted in the laboratory and in the field that higher
amplitude gives higher NOx reduction. Actually, for a given
stoichiometric ratio, higher amplitude provides better mixing and
higher excess oxygen in the flue. An increase of the oscillating
amplitude thus enables possible reduction in stoichiometric ratio,
which increases the potential of NOx reduction. Beyond a certain
amplitude (usually around 90%), and especially at low frequency,
fuel-rich zones are no longer diluted enough by products from the
preceding local combustion zones, which can produce high CO
emissions. But in the context of the invention, this does not
constitute any limitation since the produced CO can be burned out
before the exhaust of the process. Thus, the higher the amplitude
is, the lower the NOx production is. An amplitude of the present
invention is about 30% or higher, and preferably about 80% or
higher. However, this oscillating amplitude should still be
optimized on case-by-case basis since a very high amplitude is
sometimes not recommended for certain furnaces. For example,
problems of flame length may occur at high flow rates and/or
retraction within the burner block may occur at low flow rates.
[0067] The duty cycle can also play a significant role in the
reduction of NOx generation. It has been proven that duty cycles
slightly higher than 50%, preferably about 60% or greater, and more
preferably between 60% and 70%, enable further NOx reduction. As
described above, the duty cycle is the fraction of time during each
cycle that the gas flow rate is above the average flow rate.
[0068] A purpose of the preferred configurations of oscillating
parameters described above is to enhance the effects of local
staged combustion naturally created by the pulsed combustion. By
decreasing the frequency and increasing both the amplitude and the
duty cycle (as close as possible to their technical limits), this
invention allows increasing the duration and influence of fuel-rich
zones, where little oxygen is available and where peak flame
temperatures are avoided. In this manner, even if more CO is
generated, very little NOx production occurs.
[0069] The setting of parameters of oscillation, as discussed
above, allows efficient operation at lower stoichiometric ratio
since the mixing between oxygen and fuel is further enhanced.
Depending on the process, stoichiometric ratios below 2, and more
likely around 1.95, are made possible by such a setting of
oscillating parameters, allowing reduced oxygen consumption and
thus operating costs.
[0070] In another embodiment of this invention, it is proposed to
induce flow variations in both the streams of fuel and oxidant, at
a frequency which is common to both flows and with a dephasing of
at least .pi./2 between them. FIG. 5 represents the NOx and CO
emissions observed during tests carried out on a single-burner
pilot furnace where both the flows of natural gas and oxygen are
oscillated at same frequency.
[0071] In this example, it must be noted that there is a very
important reduction of the emissions of NOx for pulsation
frequencies lower than 2 Hz, this reduction reaching 90% for
frequencies below 0.3 Hz, with a dephasing of at least .pi./2
between the pulsations of the fuel and of the oxidant. However,
below 0.3 Hz CO emissions are also increasing in dramatic
proportions (up to 3% of the flue gas volume at 0.25 Hz), to the
extent that the process may not be safely operated. The interest of
the invention in this context is to provide an adapted post
combustion system able to burn out such levels of CO in the flue
gas, thus guaranteeing at the same time high NOx reductions and
safe operation.
[0072] Post Combustion CO Removal
[0073] The present invention provides an optimized post combustion
system downstream of the oscillating combustion zone to
post-combust CO generated during this first phase of the process.
The post combustion system may also remove other exhaust gas
species if required.
[0074] The function of the post combustion system is to minimize
the effluent level of CO below environmentally regulated levels
without producing additional NOx so as not to affect the benefits
achieved in the first zone of combustion.
[0075] The oxidizing gas used for this post combustion system
should be air or more preferably oxygen enriched air or pure
oxygen.
[0076] In order to efficiently burn out the CO and unburned
hydrocarbons resulting from the oscillating combustion, three
parameters should be carefully addressed by the post combustion
system:
[0077] the location of the post combustion oxidizing gas
injection,
[0078] the quality of mixing between the post combustion oxidizing
gas and CO, and
[0079] the temperature of the post combustion zone.
[0080] The location of the post combustion system including the
post combustion oxidant injection locations should be decided
according to a process which is described herein. This choice is
driven by several criteria which are discussed hereafter. First,
the oxidizing gas should be injected in or close to a zone where
the CO concentration is high, and preferably locally in areas where
the CO concentration is substantially higher than the average CO
concentration in the furnace exhaust gases. Moreover, the oxidant
injection should occur in a zone where the flue gas temperature
will guarantee a reliable CO ignition and rapid burning. Finally,
the stream of oxidizing gas should be blown into the combustion
chamber in a location where it does not interact significantly with
the oscillating combustion so as to allow this first stage of
oscillating combustion to complete before additional oxidation. The
oxidizing gas should consequently be injected in one or several
local areas through at least one injector means, most likely close
to the exhaust of the combustion chamber, and preferably in an area
where temperature is suitable for CO post combustion. FIGS. 6-8
present some examples of possible locations for post combustion
oxidant injection for different types of combustion processes,
namely: a) end-fired furnaces, b) multiple-burner side-fired
furnaces, and c) industrial boilers.
EXAMPLES
[0081] FIG. 6 illustrates schematically the implementation of a
process for fuel combustion in a single burner end fired furnace
600. The oscillating flame 610 is illustrated with the low and high
flames represented. The post combustion oxidant is injected at a
one or more locations represented by the arrows 620. The post
combustion oxidant injection locations are selected to be where the
injected oxidant will not interact with the oscillating combustion
and where the flue gas temperature is the lowest in the furnace.
These locations in the furnace are generally along the back wall
and along the exhaust gas path on the side of the furnace. The
furnace 600 of FIG. 6 may be any known end fired furnace, such as a
glass furnace or steel making furnace.
[0082] FIG. 7 illustrates schematically the implementation of a
process for fuel combustion in a multiple burner, cross fired
furnace 700. The plurality of oscillating flames 710 are
illustrated on both sides of the furnace with the low flames shown
on one side and the high flames represented. The post combustion
oxidant is injected at one or more locations represented by the
arrows 720. The post combustion oxidant injection locations are
selected to be where the injected oxidant will not interact with
the oscillating combustion and where the flue gas temperature is
the lowest in the furnace, i.e. near the flue gas exhaust. The
furnace 700 of FIG. 7 may be any known cross fired furnace, such as
a glass furnace or steel making furnace.
[0083] FIG. 8 illustrates schematically the implementation of a
process for fuel combustion in an industrial boiler 800. The boiler
includes a single end fired burner 810 operated in oscillating
combustion to create an oscillating flame 812. The oscillating
flame 812 is illustrated with the low flame and high flames
represented. The post combustion oxidant is injected into the
boiler 800 at one or more locations represented by the arrows 820.
The post combustion oxidant injection locations are selected to be
where the injected oxidant will not interact with the oscillating
combustion and where the flue gas temperature is the lowest in the
furnace, i.e. near a location where the flue gas is exhausted
around a plurality of boiler pipes 830.
[0084] Optimizing Post Combustion CO Removal
[0085] In single burner systems, products of combustion do not flow
through a subsequent combustion zone, such as in side-fired
furnaces, where unburned hydrocarbons can be burned out within the
flames generated by facing burners. This is one reason why the
present invention is particularly well adapted to single-burner
processes and preferably to industrial boilers.
[0086] Another factor in achieving an effective oxidation of CO is
the quality of the mixing between the injected oxidizing gas and
the molecules of CO. For this purpose, the oxidant can be blown
into the reactor space not only with high momentum but also with a
swirl effect. The first condition for high momentum is to connect
the injector means to a pressurized source of oxygen or oxygen
containing gas, to enable injection of such gas through a lance. If
air or enriched-air is used, a blower may be used to bring the gas
to the required pressure. In case of pure oxygen, the post
combustion oxidant injection nozzle(s) should be connected to a
liquid oxygen tank; the liquid oxygen can thus be compressed to the
required pressure and then be vaporized prior to injection.
[0087] In addition, the supply conduit used for injection of the
oxidizing gas should have the outlet opening arranged as the
converging/diverging profile of a Laval nozzle to provide for
subsonic or supersonic velocity of injected gas. In any case, the
purpose here is to create a high enough velocity to penetrate the
incoming flow of flue gas and thus to enhance the mixing of these
two streams. Additionally, within this outlet opening, there may be
a helical swirler for imparting circumferential motion to oxidizing
gas issuing therefrom. Different designs can be envisaged here, but
the swirler can include a helical baffle mounted on pipe, which
decreases in pitch towards a tip of the nozzle. An alternative to
the swirler could also be a multi-orifice injector, with various
injection angles in order to spray the post combustion oxidant
through the flue gas stream. The action of the swirler or of the
multi-orifice injector, combined with the high gas velocity,
results in a good distribution of the oxidizing gas within the flue
gas stream and thus in an optimal mixing with the CO molecules. It
should also be understood that, in these conditions, the injection
of highly oxygen-enriched air is a favorable factor for an
effective CO oxidation since it reduces the dilution of reactants
within nitrogen molecules.
[0088] Once the oxidizing gas is injected in the preferred
location, and optimally distributed within the CO-rich flue gas, an
adequate temperature is still required in order to induce the CO
oxidation. The invention can provide methods for controlling this
temperature.
[0089] If the temperature of the exhaust gases in the post
combustion zone is below a predetermined temperature preset for
reliable CO ignition and rapid burning, the post combustion
burner/injector means may supply the oxidizing gas along with fuel
so as to generate a hot flame and to maintain the temperature
within the required range. The predetermined temperature is above
about 800.degree. C. (1500.degree. F.), preferably above about
930.degree. C. (1700.degree. F.) and even more preferably about
980.degree. C. (1800.degree. F.). This post combustion zone
temperature is also a function of the dimensions of the combustion
chamber. With smaller size chambers there is less retention time
and a higher temperature may be needed. However, it is also noted
that the temperature is preferably maintained below about
1100.degree. C. (2000.degree. F.).
[0090] High-temperature conditions provide for rapid NO generation
when combustion products containing a substantial amount of
nitrogen are inspired inside of the flame envelope containing
highly concentrated oxygen. Thus, to minimize additional NOx
generation under such conditions, a cooling agent such as sprayed
water or steam may be introduced inside the flame. Moreover, the
introduction of water also creates conditions to enhance CO post
combustion in the exhaust gases passing through the combustion
chamber. Actually, the kinetics of CO post combustion shows
dependency of the rate of change of CO mole fraction on the
H.sub.2O concentration, assuming that the injected water
temperature is the same as the one of the flue gas. Thus, spraying
water through the hottest zone of the hot oxygen rich flame will
simultaneously accomplish two functions: first, it preheats the
water entering the combustion chamber (which will speed CO post
combustion reactions) and, second, it cools the flame hot zone by
using the heat released in this zone for heating, volatizing, and
superheating of the injected water (which will inhibit NOx
formation).
[0091] The CO emissions from the process and apparatus of the
present invention are preferably about 3,000 ppm or less, and more
preferably about 400 ppm or less.
[0092] One example of the invention is illustrated in FIG. 9 in
which a furnace 900 includes a burner 910 for creation of an
oscillating combustion zone in the furnace. A fuel supply 912 and
an oxidant supply 914 are connected to a the burner via one or more
valves 916, 918 for oscillating the fuel and oxidant to create the
pulsed combustion. The furnace also includes a post combustion zone
920 into which an oxidant is supplied from a post combustion
oxidant supply 924 through nozzles 922. As discussed above, the
post combustion oxidant nozzles 922 may include swirlers for
imparting a swirling motion to the flow and/or a valve 926 for
pulsatile delivery of the oxidant.
[0093] The invention also can include a post combustion control
system 930 which insures not only an effective post combustion by
ensuring complete oxidation of CO without additional generation of
NOx, but also an efficient operation by injection of the minimum
amount of oxygen.
[0094] The flows of oxidizing gas, extra fuel, and water injected
by the post combustion means are controlled by the post combustion
control system 930 and are based on the combination of process
parameters actively measured and/or controlled by this system.
[0095] The method of controlling the post combustion system
includes the steps of measuring the content of oxygen in the
exhaust gases, the content of CO, and/or alternative process
parameters influencing CO emissions by one or more sensors 932
within the furnace during the oscillating combustion. The results
of these measurements are communicated to the post combustion
control system 930, then compared with a control model to predict
the deficiency of oxygen in the flue gas as well as the necessary
amount of extra oxidant which should be added to minimize the
effluent level of CO below environmentally regulated levels. A
controlled flow of post combustion oxidizing gas is thus injected
accordingly in the post combustion zone in order to reduce and/or
eliminate the deficiency of oxygen and preferably to insure the
presence of excessive oxygen in hot exhaust gases traveling through
and leaving the combustion chamber. The prediction of the
deficiency can be performed by using a computer model based on
furnace inputs developed from empirical data.
[0096] Similarly, the flows of extra fuel and water injected in
order to adjust the reaction temperature and to inhibit NOx
formation are also controlled by the post combustion control system
through monitoring of the temperature of the hot flue gas in the
combustion chamber.
[0097] The use of an oxygen-rich oxidizing gas for the post
combustion CO removal stage provides advantages in the present
invention. Specifically, the use of oxidizing gas with an oxygen
content higher than air increases the amount of heat being released
per standard cubic feet of the newly formed combustion products and
at the same time increases the temperature of the flame introduced
in the combustion chamber. This way, when the post combustion of CO
and unburned hydrocarbons occurs under conditions permitting the
heat released to be efficiently transferred to the load, the
process throughput capacity and thermal efficiency can even be
increased.
[0098] This can be particularly valuable in certain operating
configurations described before where high NOx reductions are
accompanied by significant CO generation as a counterpart (as high
as a few percents of the flue gas volume). It can even be more
valuable in the case of combustion staging, as also mentioned
above, where fuel combustion needs to complete in the post
combustion zones.
[0099] According to an additional embodiment of the invention, the
post combustion oxidant flow provided for post combustion of
unburned hydrocarbons can be oscillated by a valve 926 as shown in
FIG. 9. The purpose of oscillating the post combustion oxidant is
to further limit any additional formation of NOx (through a
phenomenon based on the same principle as mentioned before), while
still post-combusting the products resulting from the first stage
of combustion.
[0100] The present method of NOx reduction is applicable to any
industrial combustion process, as well as the described
apparatus.
[0101] The promoted configuration of oscillating combustion
allowing high NOx performances generally aims at enhancing the
effects of local staged combustion naturally created by pulsed
combustion in the fuel-rich and fuel-lean zones. The present
invention can achieve NOx reduction levels as high as 90%, but with
dramatic increase of the CO formation as a counterpart. This excess
of CO is oxidized before the combustion chamber exhaust through the
post combustion CO removal apparatus positioned in a thermally
adapted location and controlled by an optimized system, thus
guaranteeing both an effective and efficient operation.
[0102] Through this innovative concept, the invention thus proposes
a low-cost and effective compliance technology providing operators
of industrial combustion processes with a competitive alternative
to the expensive flue gas clean up techniques such as SCR. Being
preferably suited for single-burner systems, the promoted technique
will be of particular interest for industrial boiler processes,
both firetube and watertube types.
[0103] A further embodiment of the invention promotes a large-scale
staged combustion in this process. The local phenomenon of
combustion staging induced in fuel-rich and fuel-lean combustion
zones is further increased. It is thus proposed to decrease the
stoichiometric ratio at the oscillating combustion level, by
decreasing the oxidant flow rate. The post combustion system
located near the exhaust of the combustion chamber then provides
the balance of oxidant so as to complete combustion. By this way,
NOx reductions achieved through oscillating combustion can be
further enhanced, while still controlling CO emissions. Moreover
the effectiveness of this staged combustion system is guaranteed by
the location of the post combustion system far from the primary
combustion zone, thus allowing the primary reaction to be completed
before secondary injection of oxidant.
[0104] While the invention has been described in detail with
reference to the preferred embodiments thereof, it will be apparent
to one skilled in the art that various changes and modifications
can be made and equivalents employed, without departing from the
present invention.
* * * * *