U.S. patent number 3,890,084 [Application Number 05/400,774] was granted by the patent office on 1975-06-17 for method for reducing burner exhaust emissions.
This patent grant is currently assigned to Coen Company, Inc.. Invention is credited to Temple S. Voorheis, Ralph R. Vosper.
United States Patent |
3,890,084 |
Voorheis , et al. |
June 17, 1975 |
Method for reducing burner exhaust emissions
Abstract
NO.sub.x exhaust emissions from furnace or boiler burners are
reduced by combusting fuel with low excess air (about 5 percent
more air than the theoretically required minimum air volume). The
fuel is combusted so that the maximum flame temperatures are less
than the theoretically obtainable maximum temperature. This is
achieved by cooling flames in the chamber through contact with
combustion chamber walls and by combusting central portions of the
flames in two stages. Burners in a vertically lower burner bank are
initially fired with insufficient air and burners in an upper
burner bank are fired with additional air to make up for the air
deficiency of the lower burners. The additional air is intermixed
with the uncombusted fuel from the lower burners and such fuel is
burned at a later stage downstream of and spaced from the burners.
The additional air supplied from the burners in the upper row is
measured to provide the above stated total of 5 percent excess air
for the furnace.
Inventors: |
Voorheis; Temple S. (Atherton,
CA), Vosper; Ralph R. (San Jose, CA) |
Assignee: |
Coen Company, Inc. (Burlington,
CA)
|
Family
ID: |
23584946 |
Appl.
No.: |
05/400,774 |
Filed: |
September 26, 1973 |
Current U.S.
Class: |
431/10; 431/174;
431/178; 431/179 |
Current CPC
Class: |
F23B
5/00 (20130101); F23B 2700/022 (20130101) |
Current International
Class: |
F23M
3/00 (20060101); F23M 3/04 (20060101); F23m
003/04 () |
Field of
Search: |
;431/8,10,174,2,178,179,180 ;60/DIG.11 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Myhre; Charles J.
Assistant Examiner: Anderson; William C.
Attorney, Agent or Firm: Townsend and Townsend
Claims
I claim:
1. A method of operating an existing industrial furnace at a low
NO.sub.x emission level, the furnace including at least two
vertically spaced burners, the method comprising the step of
modifying the combustion process in the furnace with the steps of
firing at least a portion of one of the burners with an off-ratio
air supply, firing at least a portion of the other burners with a
sufficient additional air supply to provide for a low excess air
firing of all burners, and combusting all fuel discharged by the
burners by first combusting a portion of the fuel adjacent the
burner and thereafter combusting another portion of the fuel at a
location spaced from the burners.
2. A method according to claim 1 including the step of firing at
least a portion of at least one of the burners with about 5 percent
excess air.
3. A method of modifying an existing furnace for operating it at a
low NO.sub.x emission level, the furnace having a plurality of
burners arranged in at least two vertically spaced rows, each
burner having a fuel discharge nozzle and an annular air supply
concentrically arranged about the nozzle, the method comprising the
steps of adapting at least a portion of at least one burner in the
lower bank to discharge more fuel than can be completely combusted
with the air supply for such burner to thereby leave a quantity of
unburnt fuel, and adapting a portion of at least one burner in the
upper bank proximate the adapted burner in the lower bank to
discharge a volume of additional air over and above the air
required by such burner for completely combusting said unburnt
fuel, and adjusting the air supplied by at least said one burner in
the upper bank to provide a total of no more than about 5% excess
air for all fuel discharged by the burners.
4. A method for combusting fuel discharged into a combustion
chamber from at least one lower nozzle and at least one upper
nozzle disposed above the lower nozzle, the method comprising the
steps of discharging fuel from each nozzle in a generally circular
pattern, discharging combustion air concentrically with respect to
the discharged fuel from each nozzle for admixture and combustion
with the fuel, limiting the air-to-fuel ratio in at least a section
of the lower nozzle adjoining the upper nozzle to less than the
stoichiometric ratio, injecting additional air in excess of the
stoichiometric ratio over a section of the upper nozzle adjoining
the lower nozzle, and combusting some of the fuel discharged from
the section of the lower nozzle with additional air from the
section of the upper nozzle at a point spaced from and downstream
of the nozzles to effect a complete fuel combustion at a relatively
low temperature to thereby reduce the emission of NO.sub.x.
5. A method according to claim 4 including outer nozzles disposed
on each side of each of the upper nozzle and the lower nozzle, and
including the step of discharging from the outer nozzles a quantity
of fuel and a quantity of air to effect a low excess air combustion
of fuel discharged by the outer nozzles.
6. A method according to claim 5 wherein the steps of discharging
air comprise the step of discharging approximately 5 percent more
air than the air required to effect a theoretically complete
combustion of all discharged fuel.
7. A method according to claim 4 wherein the step of discharging
air at the section of the lower nozzle comprises the step of
discharging approximately 10 percent less air than the air required
to effect a theoretically complete combustion of the fuel
discharged by such section.
8. A method according to claim 7 wherein the step of discharging
additional air from the section of the upper nozzle comprises the
step of discharging from the upper nozzle a quantity of additional
air sufficient to supply approximately 5 percent more air in the
chamber than theoretically required to effect a complete combustion
of all fuel discharged from the section of the lower nozzle.
9. A method for reducing the level of NO.sub.x emissions in exhaust
gases of a furnace comprising the steps of discharging fuel and
combustion air into a combustion chamber of the furnace from an
upper and a lower bank of burners, providing a total air volume
discharged into the chamber of no more than about 5 percent in
excess of the theoretically required air volume to effect a
complete combustion of the fuel, and maintaining the maximum gas
temperature within the chamber at less than the theoretically
attainable maximum gas temperature by discharging less air than the
theoretically required minimum amount of air from at least portions
of central burners in the lower bank facing the upper bank, and
discharging additional air from central burners in the upper bank
over and above the air volume required to effect a complete
combustion of fuel discharged by such burners, the additional air
being discharged over a portion of the central burners in the upper
bank adjoining the lower bank to effect an interfacing of fuel-rich
mixture discharged at the lower bank and air-rich mixture
discharged at the upper bank downstream of the burners.
10. A method according to claim 9 wwherein the step of discharging
additional air comprises the step of discharging sufficient
additional air to provide an overall excess combustion air for the
central burners of about 5 percent above the theoretical minimum to
effect a complete combustion of fuel discharged by such
burners.
11. A method for reducing NO.sub.x in exhaust gases from furnaces,
boilers and the like comprising the steps of arranging a plurality
of burners in at least two vertically spaced burner banks,
providing an overall air supply to the burners of no more than
about 5 percent above the required theoretical minimum air volume
for effecting a complete combustion of fuel discharged from the
burners, mixing approximately 5 percent excess combustion air with
fuel discharged by at least portions of burners defining sides of
the burner banks, discharging from at least a portion of at least
one of the burners in the lower bank insufficient air to effect a
complete combustion of the fuel discharged by such burner,
supplying sufficient additional air from at least one of the
burners in the upper bank to combust all uncombusted fuel
discharged by at least one burner in the lower bank, mixing such
additional air with the uncombusted fuel, and combusting the
uncombusted fuel with the additional air at a location spaced from
the burners.
12. A method according to claim 11 wherein there are provided two
burners in each bank, and wherein the step of discharging
insufficient air from the burners in the lower bank and additional
air from the burners of the upper bank comprises the step of
discharging such air from burner portions facing the other burner
in the same bank.
13. A method according to claim 12 wherein the step of discharging
approximately 5 percent excess air from the side burners comprises
the step of discharging the 5 percent excess air from portions of
the burners in the banks facing away from the other burner in the
same bank.
14. A method according to claim 11 wherein the burners discharge
fuel and air in a generally conical pattern, and wherein the step
of discharging the additional air comprises the step of discharging
such additional air over a downwardly facing section of at least
one burner in the upper bank.
15. A method according to claim 14 wherein the step of discharging
fuel and insufficient air from the burners in the lower bank
comprises the step of substantially evenly discharging fuel and
insufficient air from at least one burner in the lower bank in a
generally conical pattern, and including the further step of
intermixing the additional air with non-combusted fuel.
16. A method according to claim 15 including the step of
discharging approximately 5 percent excess air from remaining
sections of the burners in the upper bank.
Description
BACKGROUND OF THE INVENTION
Industrial furnaces, boilers, steam generators, and the like are a
main source of air pollution. Attempts are continuously being made
to reduce such industrial air pollution without compromising the
efficiency of the furnaces and boilers.
A major industrial pollutant discharged by furnaces and boilers
(hereinafter sometimes collectively referred to as "furnaces") are
the oxides of nitrogen (hereinafter NO.sub.x). NO.sub.x emission
levels are inversely related to the furnace oxygen concentration
and the flame temperatures. To a much lesser extent it also depends
on the nitrogen content of the fuel.
There are a number of methods for reducing NO.sub.x which include
increasing the furnace cooling surface, lowering the combustion air
temperature by increasing the air supply in the furnace,
recirculating the flue gas through the furnace burners, operating
the burners with low excess air, and two stage firing and
off-stoichiometric or biased (hereinafter off-ratio) firing of the
burners. Each method has certain advantages and disadvantages over
the others.
Increasing the furnace cooling surface is effective but requires a
high initial investment and cannot usually be used for modifying
existing furnaces. Lowering the combustion air temperature reduces
the efficiency of the furnace. Flue gas recirculation is highly
effective but again requires a high initial investment and is ill
adapted for modifying existing furnaces. Low excess air firing is
effective in reducing NO.sub.x emissions and enhances the
efficiency of the unit but requires a very accurate distribution of
the air in the combustion chamber. Two stage and off-ratio firing
provide good results for lowering NO.sub.x emissions but
traditionally require more excess air and thus reduce the
efficiency of the furnace unless the subsequently furnished
additional air is evenly distributed in the combustion chamber. A
failure in the even distribution of the additional air and low
excess air operation leads to an incomplete combustion and the
emission of particulates and smoke, highly undesirable
pollutants.
It has been recognized that a combination of low excess air firing
and off-ratio combustion aids in reducing NO.sub.x emissions and
is, therefore, highly desirable. Problems are usually encountered
in evenly mixing non-combusted fuel from off-ratio firing and the
necessary additional air to effect the complete combustion of the
fuel. This has been especially acute in modifying existing furnaces
which have a low or intermediate number of about 10 or less
burners.
Large scale utility type furnaces as employed in electric
generating plants and the like use relatively large numbers of
burners, usually well in excess of ten, which are arranged in two
or more vertically spaced rows. Furthermore, their combustion
chambers are very large. Under such conditions it is possible to
eliminate one or more burners and discharge therefrom additional
air only for off-ratio firing and a truly two-stage combustion in
which the additional air is derived from one or more auxiliary air
supplies. By properly selecting spaced apart burner locations for
the additional air discharge an even distribution of the additional
air can be obtained.
However, this approach is not suitable for smaller furnaces as are
commonly found in industrial heating, boiler or steam generating
plants which as a rule employ ten burners or less arranged in only
two vertically spaced apart rows or burner banks. If, in such a
situation, an existing burner were replaced with an air nozzle the
additional air would be unevenly distributed. Consequently,
portions of the combustion chamber would have too much air and
other portions would have insufficient air. The furnace would have
an inefficient and incomplete combustion yielding high pollutant
levels and an economically unsound operation, thereby defeating the
purpose for combining low excess air firing with off-ratio
combustion.
SUMMARY OF THE INVENTION
The present invention provides a method for reducing the emission
of NO.sub.x from furnaces without compromising the efficiency of
the furnace, increasing the emission of other pollutants such as
smoke or particulates, or requiring expensive equipment and
controls which may make the method economically unfeasible. The
invention is ideally suited for modifying small and intermediate
size existing furnaces so that they can be operated at reduced
NO.sub.x emission levels without increasing the emission of other
pollutants above levels for conventional low excess air firing.
Broadly speaking, this is accomplished by operating the furnace
with low excess air, that is with a total air volume of no more
than about 5% in excess of the theoretically required air volume to
effect a complete combustion of the fuel and as contrasted with a
normal excess air volume of between 12 -15%, and by further
maintaining the maximum flame temperatures in the combustion
chamber of the furnace below the theoretically obtainable maximum
flame temperature for low excess air operation. The temperature is
maintained at a relatively lower value through the off-ratio firing
of some of the centrally disposed furnace burners and burning
non-combusted fuel at a downstream location from the burners with
additional air provided from other burners.
The burners are arranged in at least two vertically spaced apart
rows, an upper and a lower burner row, with the burners in the
lower row being operated off-ratio and with the additional air
required for completely combusting all fuel discharged by the
burners in the lower row being provided from the corresponding
burners in the upper rows. The additional air volume is carefully
controlled so that the overall excess air for the furnace does not
exceed 5%. Burners disposed on the sides of the burner banks are
operated with low excess air without off-ratio firing since their
flames are immediately cooled by the surrounding furnace walls so
that the maximum theoretically obtainable flame temperatures are
never reached.
The present invention is adapted for use with relatively small
furnaces such as industrial furnaces having ten or less burners
arranged in at least two vertically spaced banks of aligned burner
pairs. The present invention is further particularly well suited
for modifying existing small and intermediate size industrial
furnaces for low NO.sub.x emission level operation since such
modification can be economically accomplished.
Instead of selecting one or more of the burners as an air inlet
only the present invention selectively controls the air-to-fuel
discharge of at least some of the burners over at least selected
portions thereof. For operational purposes aligned burners in the
upper and lower burner bank are constructed so that the lower
burner discharges more fuel than can be combusted with its air
supply for an off-ratio operation while the corresponding burner in
the upper bank is constructed so that it discharges additional air
that is directed into the flame of the lower burner so that the
additional air can combine with uncombusted fuel for burning
downstream at points spaced from the burners.
To avoid an excessive cooling of the flames from burners adjacent
the furnace walls, that is the side burners of each bank, such
burners are operated with low excess air at least over burner
portions which direct flames towards the furnace walls to prevent
an incomplete combustion of such flames due to excessive cooling.
Off-ratio firing is employed on burners between the side burners
and can also be employed on inwardly facing portions of the side
burners, or in instances in which there is only one burner in each
bank over the lower burner portion facing the upper burner. In this
manner the combustion temperature in the chamber is held at less
than the theoretically obtainable temperatures because the
combustion process is drawn out and generated heat has time for
dissipation and absorption before all fuel is combusted.
Consequently, the NO.sub.x emission level is lowered due to the
relatively low oxygen level and the relatively low combustion
temperature in the furnace.
The present invention also provides apparatus for operating
furnaces in accordance with the above-outlined method which
generally comprises at least two vertically spaced burners arranged
in an upper and a lower burner bank. Each burner has a fuel
discharge nozzle and means for mixing discharged fuel with
combustion air. Means is provided for discharging from at least a
portion of the burners in the lower bank more fuel than can be
completely combusted with air discharged by such burners. Means is
further provided for discharging from the corresponding burner in
the upper bank additional air, or less fuel than can be completely
combusted with the air discharged by such burner to effect an even
admixture of the non-combusted fuel discharged by the burners in
the lower bank with the additional air. This fuel--additional air
mixture is subsequently subjected to a secondary combustion at
locations spaced from the burners whereby the flame temperatures
are maintained below the maximum theoretically obtainable
temperature.
In the preferred embodiment of the invention each bank has a
plurality of burners and the fuel discharge nozzles are constructed
to discharge the desired fuel quantity in predetermined fixed
patterns. Each fuel discharge nozzle includes an end member which
has a plurality of fuel discharge apertures that are drilled
through the end member in a quantity and size so that the nozzle
discharges a controlled, predetermined volume of fuel. The
apertures are further positioned and oriented so that they form the
desired spray pattern. Thus, the fuel discharge apertures in the
end member of a nozzle can be rearranged to spray more or less fuel
in one or the other direction as may be dictated by the particular
location of a burner.
The fuel discharge aperture arrangement is utilized for discharging
the additional air from the upper burners in the direction of the
fuel discharged from the lower burners so as to burn uncombusted
fuel at a point spaced from the burners. Since the relative
positioning and arrangement of the burners in the banks is critical
and in order to attain the desired fuel and air discharge patterns
and to effect an intimate mixture of the excess fuel and excess air
discharged by the various burners, the present invention provides a
color coding that is applied to the different burners to assure
their proper replacement after removal for cleaning and
maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational view of furnace burners arranged
and constructed in accordance with the present invention;
FIG. 2 is a fragmentary side-elevational view, in section, of a
burner constructed in accordance with the present invention and is
taken on line 2--2 of FIG. 1;
FIG. 3 is a schematic side-elevational view through a furnace
having burners constructed and arranged in accordance with the
present invention and illustrates the interfacing of flames from
burners in the lower burner bank with flames from burners in the
upper burner bank of the furnace;
FIG. 4 is a schematic representation of a burner arrangement and
construction for one upper and one lower burner;
FIG. 5 is a view similar to FIG. 4 but illustrates an arrangement
for two upper and two lower burners;
FIG. 6 is an arrangement similar to FIG. 4 that illustrates three
vertically spaced burner banks each having four burners;
FIG. 7 is a diagram illustrating the NO.sub.x emission levels as a
function of the excess air volume;
FIG. 8 is a diagram illustrating the reduction in the NO.sub.x
emission level obtained from off-stoichiometric firing of a
burner;
FIG. 9 is an enlarged front-elevational view of a fuel nozzle
constructed in accordance with the present invention and is taken
on line 9--9 of FIG. 2; and
FIG. 10 is a fragmentary side-elevational view, in section, of the
nozzle and is taken on line 10--10 of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIGS. 1 through 3, a schematically illustrated
upright furnace 2 has a floor 4, vertical sidewalls 6 and an
exhaust duct 8 through which exhaust gases from a combustion
chamber 10 of the furnace are emitted to the atmosphere. The
furnace is of an intermediate, say industrial size, and in the
illustrated embodiment comprises a lower and an upper bank 12 and
14, respectively, of five burners 16 each. The burners in each bank
are vertically aligned with burners in the other bank and they are
concentrically disposed in openings 18 of the furnace sidewalls.
Each burner includes a fuel discharge nozzle 20 that is fluidly
connected with fuel supply (not separately shown) via a conduit 22.
Pressurized combustion air is provided through an annual space 24
for admixture with fuel discharged by the nozzle and for combusting
such fuel in chamber 10. The combustion air is provided from wind
boxes (not separately shown) via suitable ducts, directional guides
and combustion air flow control means which do not form part of
this invention. See U.S. Pat. No. 2,818,109 or 2,838,103 for
exemplary constructions of combustion air supplies.
As is schematically illustrated in FIG. 3, the fuel air mixture and
flame in combustion chamber 10 forms upwardly curved lower and
upper flame zones 26 and 28 from the burners in the lower and the
upper burner banks 14, 16, respectively. In the chamber the flames
are cooled through contact with the furnace sidewalls 6 as well as
heat exchangers (not shown) that may be present in the furnace and
the combustion gases from the flames are guided towards exhaust
duct 8 so that they leave the combustion chamber after they have
been cooled to the desired temperature by the transmission of heat
energy to the heat exchange components of the furnace.
As already indicated above, the present invention reduces NO.sub.x
emissions by employing low excess air, that is by employing no more
than about 5 percent excess air over the theoretically required
volume of air to fully combust the fuel, and through off-ratio
firing. Referring briefly to FIGS. 7 and 8, the diagram of FIG. 7
illustrates the NO.sub.x reduction attained from low excess air
firing. As compared to standard excess air firing, (15 percent
excess air) low excess air reduces the NO.sub.x emission by factor
of approximately one-third. In addition, thereto and as shown in
the diagram of FIG. 8, the off-ratio firing of a burner, as further
described hereinafter, at a stoichiometric ratio of 0.9 as compared
to the standard ratio (standard excess air) of 1.15 reduces
NO.sub.x emissions for that burner by an additional 40-45 percent.
Consequently, to minimize NO.sub.x emission in accordance with the
present invention, the furnace as a whole is operated with low
excess air and, in addition, off-ratio firing is employed to the
greatest extent possible.
Referring again to FIGS. 1 through 3, the burners 16 in each burner
12, 14 are identified as side burners 30 which are the burners
proximate sidewalls 6 of the furnace and central burners 32 which
are the three burners disposed intermediate the side burners. The
flames emanating from the side burners are in close proximity to
the furnace walls and are, therefore, immediately cooled. Since
off-ratio firing involves a combustion process in which the maximum
flame temperature is less than the attainable maximum and since the
flames from the side burners are subject to very significant and
immediate cooling, the side burners are operated with low excess
air without off-ratio firing to prevent the possibility of a
flame-out or of an incomplete combustion due to excessive flame
cooling. Thus, for the side burners a one-third NO.sub.x emission
level reduction is obtained from its low excess air operation.
The flames of the central burners 32 are not subjected to the rapid
cooling of the side burner flames; the lower central burners 32 (1)
are therefore operated off-ratio with only 90 percent of the
theoretically required minimum air (hereinafter 0.9 air). The upper
central burners 32u are divided into a first, lower segment 34 and
second upper segment 36, the first segment being the portion of the
upper burner adjacent the lower burners.
Referring now also to FIGS. 9 and 10, the two segments of the upper
burners are defined by an end plate or member 38 of fuel nozzle 20
which has a generally circular configuration and which covers a
similarly circular interior space 40 of the nozzle which, in turn,
communicates with nozzle conduit 22. A plurality of apertures 42
are drilled in the end plate so that pressurized fuel can be
discharged from the interior space of the nozzle into the
combustion chamber of the furnace. Generally speaking, the fuel
discharge apertures are arranged, that is, are oriented and
distributed so that the nozzle sprays and atomizes the fuel in
conical pattern as is schematically indicated by cone 44 in FIG.
2.
For the dual-segment upper central burners 32u, the segments are
defined by the distribution, orientation and size of the apertures.
FIGS. 9 and 10 are an illustration of such a dual segment nozzle.
It comprises a plurality of evenly spaced and distributed apertures
42a in the upper nozzle segment 36 and one or more equally spaced
apertures 42b in the lower nozzle segment 34. The apertures in the
lower segment have substantially lesser density and/or diameter so
that for a given combustion air flow through annular gap 24 less
fuel is discharged over the angle .alpha. of the lower segment than
can be combusted with the air volume entering through the air gap.
In other words, over the angular extent of the lower segment,
additional air is discharged. As is best seen in FIGS. 1 and 2,
apertures 40b in the lower nozzle segment are arranged so that the
projected cone surface as indicated by the lower leg 44a of cone 44
does not fully intercept the air flow through the lower portion of
air gap 24 and a given amount of air volume enters through an
arcuate air gap section 46 as is schematically illustrated by the
arrow 48 in FIG. 2. This additional air is directed generally
downwardly and into the flame from the corresponding central burner
32(1) in lower bank 12. The additional air is thus admixed with
uncombusted fuel discharged by the lower central burners due to
their off-ratio firing and the resulting insufficient air supply.
As is schematically illustrated in FIG. 3, the additional air from
the upper central burners mixes with lower flame zone 26 along
their common interface 50.
To assure complete combustion of all fuel, and low excess air
operation of the total furnace, that is of all burners combined,
the fuel and air volumes and the direction in which they are
discharged are closely controlled. In the exemplary arrangement
illustrated in FIG. 1, the lower central burners are operated with
0.9 air or with 85.5 percent of their 1.05 theoretical low excess
air requirement. The necessary additional air to assure a complete
combustion of the fuel discharged by the lower central burners, is
obtained by restricting the fuel discharge over the lower segment
34 of upper central burners 32u so that the arcuate air gap section
46 supplies the necessary additional air for the lower central
burners. In the example, and with a 5 percent overall excess air
operation for the furnace, in which the lower burners are fired
with 0.9 air and in which .alpha.=150.degree.for the lower section
of the upper burners, 14.3 percent of the air supplied to the upper
burners is used for combusting the unburned fuel of the lower
burner (1.05 .times. 0.143 = 0.15 additional air). This is obtained
by drilling end plate 38 of the lower burner segment 34 so that 66
percent of that segment operates with normal 5 percent excess air
while the remaining 34 percent of the lower segment operates with
100 percent air. In terms of the drawings, arcuate air gap section
46 occupies 34 percent of the lower segment and through it the
additional air required by the lower burners is supplied. It will,
of course, be apparent that the angle .alpha., the fuel discharge
volume and the air gap section 46 of the lower segment 34 of the
upper burners 32u can be varied to suit particular applications as
long as the required overall additional air volume is supplied.
In operation the side burners 30 are self-sustaining, that is they
have sufficient air to fully combust their fuel and they operate
with low excess air to reduce their NO.sub.x emission level as
above described. Fuel discharged from the upper segment 36 of the
upper burners 32u is also fully combusted since the upper segments
also operate with 5 percent low excess air in the same manner as do
the side burners. All of the lower burners 32(1) operate off-ratio
with only 0.9 air. The necessary additional air for a full
combustion of the fuel from the lower burners being supplied
through arcuate air gaps 46. That additional air gradually mixes
with the lower flame zone 26 through interface 50 in an upward
direction as is schematically illustrated by the phantom lines in
FIG. 3, so that all fuel is fully combusted when it reaches the top
of combustion chamber 10 with low excess air with the lower center
burners being additionally operated off-ratio.
Referring now briefly to FIG. 6, a burner arrangement similar to
that illustrated in FIG. 1 but having three vertically stacked
burner banks 54, 56 and 58 is illustrated. Side burners 60 are
again operated with 1.05 low excess air (LEA). Central burners 62
of the lowermost bank 54 are operated with 0.9 air. Central burners
64 of middle bank 56 are divided into upper and lower segments 66
and 68, respectively. The lower segment 68 is operated so that it
provides the additional air required for unburnt fuel from the
lowermost burners 62 as above described while the upper segments 66
are operated with 0.9 off-ratio air. Central burners 70 of
uppermost bank 58 are also divided into upper and lower segments 72
and 74, respectively with the lower segment again providing the
required additional air for fully combusting all fuel discharged by
the off-ratio operated upper segment 66 of burners 64 in the middle
row. The upper segments 72 of central burners 70 in the uppermost
bank 58 are operated with 1.05 low excess air in the same manner in
which the upper central burners 32u of the embodiment of FIG. 1 are
operated. The arrangement illustrated in FIG. 6 provides the same
advantages of NO.sub.x emission reduction as does the embodiment
shown as FIG. 1 by operating some of the burners off-ratio and
supplying the necessary additional air from other burners, the
remainder of which is operated with low excess air.
Referring now to FIG. 4, an arrangement for use with only two
vertically spaced apart upper and lower burners 76 and 78 is
illustrated. In the arrangement shown in FIG. 4, it is assumed that
there occurs a significant heat loss from the flame discharged by
the lower burner in a downward direction towards the furnace floor.
Consequently, only an upwardly directed segment 80 of the lower
burner is operated off-ratio with 0.9 air while the remaining
segment 82 is operated with 1.05 low excess air. The necessary
additional air for unburnt fuel from the upper segment of the lower
burner is provided by lower segment 84 of the upper burner 76 while
a remaining upper section of that burner is operated with 1.05 low
excess air. If heat losses in a downward direction are not very
large, the portion of the lower burner that is fired off-ratio can,
of course, be enlarged so that, for example, only the sides of the
burner are operated with 1.05 air.
Referring briefly to FIG. 5, yet another exemplary arrangement of
burners in accordance with the present invention is illustrated.
This arrangement comprises two vertically spaced banks 86, 88 of
two burners 90 each. Outer portions 92 of the burners are operated
with 1.05 low excess air while inner portions 94 of the lower
burners are operated off-ratio 0.9 air. Accordingly, inner portions
96 of the upper burners are constructed to provide the additional
air necessary for fully combusting all unburnt fuel discharged from
the inner portions 94 of the lower burners.
In all above-described embodiments of the invention, the essentials
of the operation are the same. The vertically lower burners or at
least portions thereof which are not subject to excessive and rapid
cooling are operated off-ratio to gain the above-noted reduction in
NO.sub.x emissions from off-ratio firing. The additional air
required for combusting fuel discharged by the lower burners and
not burnt due to the insufficient air supply is provided by the
most convenient portion of the adjacent upper burner which assures
an intimate intermixing of the additional air with the unburnt fuel
and a complete fuel combustion before discharge to the atmosphere.
Those portions of the burners or those burners the flames of which
are subject to rapid cooling, and the burners in the uppermost row
are operated with 1.05 low excess air.
Referring again briefly to FIGS. 1 through 3, the installation of
the burners and their relative orientations are, of course, of
great importance to assure a proper operation of the furnace
through an even and thorough admixing of all fuel and all available
air to attain a complete combustion of the fuel. Since it is
difficult to judge the fuel and air discharge capacities and
orientations of the burners from the arrangement of the fuel
discharge apertures in end plate 38 of the fuel discharge nozzle
20, it is preferred that the nozzles be color coded so that they
can be installed in the proper burner opening 18 without tedious
checking. Thus, burner end faces and/or backsides of the burners
are differently colored as is schematically illustrated in the
drawings by the indicated grating. Thus, the side burners 30
receive one, the lower central burners 32(1) receive another, and
the upper burners 32u receive yet a third color. Additionally,
proper orientation devices such as interengaging protrusions and
grooves (not shown) in the nozzles and the associated supporting
structures can be provided so that the nozzles, and particularly
the upper central nozzles 32 are always properly oriented.
* * * * *