Overview of the Gaz de France R&D activities on flameless oxidation applied to high temperature processes

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1 Overview of the Gaz de France R&D activities on flameless oxidation applied to high temperature processes By Frédéric AGUILE and Alain QUINQUENEAU RESEARCH AND DEVELOPMENT DIVISION

2 Main goals and driving forces of the R&D activities Energy savings Improving energy efficiency Optimisation of processes Reduction of pollution CO2 NOx Noise Product quality Process reliability

3 Main available techniques in high temperature processes Oxy-combustion Low combustion product flow rate Heat recuperation Preheating of the combustion air Recuperative systems Regenerative systems

4 Flameless oxidation High efficiency and low pollution Historically linked to the use of regenerators Also used with oxy-combustion, liquid and solid fuels NOx reduction techniques : air and gas staging, high recirculation Oxidant Temperature High NOx emissions II Hot flames I Standard combustion zone III Flameless combustion zone No combustion AIR AIR GAZ GAZ Recirculation Recirculation Recirculation Recirculation 21 % 3 % % O2 2 in the oxidant

5 Flameless oxidation characteristics Better temperature homogeneity in the chamber «Invisible» flame Better radiative heat transfer to the load Low NOx emissions Low noise emissions Conventional mode Flameless combustion Conventional mode Flameless oxidation mode

6 Industrial situation in the metallurgy field Many industrial applications in Japan in metallurgy processes A few ones in Europe Up to 20% of energy savings or 20% productivity increase More than ten years of R&D in Gaz de France to promote this technology

7 Burners characterisation in Gaz de France s test furnaces (1) Testing of burners operating in flameless mode in partnerships with burner manufacturers Regemat de WS GmbH (Germany) NOX Beta 600 R de Stordy (UK) FFR de North American Manufacturing Co (USA) HRS de NFK (Japan)

8 Burners characterisation in Gaz de France s test furnaces (2) Main conclusions NO<300mg/m 3 (n) and η > 75% whatever the operating conditions N O x (m g/m 3% O 2) T furnace ( C) Design tools needed to help industrials in implementing this technique (product quality, efficiency, guaranties )

9 of design tools InterNOx and Odyssée R&D projects (R&D actions since 2000) Implementing this technology in the metallurgy field Collaboration: Gaz de France, Arcelor Research, Stein- Heurtey and funds from the French environmental agency Ademe Technological survey Study of the heating equipment Study at semi-industrial scale and validation of the tools Validation and demonstration project at industrial scale

10 of design tools Detailed measurement in the flame main results min max Fields of CO concentration and mean temperatures Chemiluminescence's emission of the OH* radical Diluted air temperature ( C) Tair = ambient Tair = 600 C Tair = 1000 C A B D C A : Ordinary flame B : Hot flame C : Flameless combustion D : No reaction 0 Fields of the mean temperatures 20% 16% 12% 8% 4% Oxygen concentration % 0%

11 of design tools Semi-industrial test furnace Objectives: To validate the modelling tools developed in parallel To assess the performance of the flameless-oxidation burners in conditions close to an industrial furnace To acquire a technical expertise to apply this technology in the industry

12 of design tools Simulation of the semi-industrial furnace Zone model approach Calculation of the heating time P [kw] gaz air fumées parois (internes) supports charge t [h]

13 Demonstration operation and references Overview of potential applications in metallurgy sector Industrial references in Arcelor s group are at decision level A new regenerative reheating furnace built recently in China by Stein-Heurtey SISCO furnace built in 1995

14 Fundamental work on flameless oxidation (characterisation) Work at laboratory scale (CORIA in Rouen) Test several configurations for air and gas injection In-flame measurements: laser diagnostics Tests with gas at low calorific value (syngas, steel gas, biogas, etc.) chimney interchangeable solid blocks interchangeable window block burner

15 Fundamental work on flameless oxidation (modelling) Network of ideal reactors (PSR code) + Residence time distribution measurements (RTD) + Natural Gas detailed kinetic scheme (GDF-Kin - collaboration with CNRS Orléans and Lille) This approach is particularly adapted to flameless oxidation due to the quite diluted combustion and stirred flow Recirculation of combustion products 0,1 0,09 0,08 Numerical RTD experiment with CFD Response at the chimney to a pulse injection at air input Gas input Plug flow reactor Perfectly s tirred r e actor Co mbustion p roducts at the chim ney 0,07 0,06 RTD 0,05 0,04 0,03 0,02 A ir input Heat transfer s 0, Time (s)

16 Flameless combustion in industrial processes (1) Glass industry: melting glass furnaces NOx reduction Potential increase in the radiative heat transfer to the glass Lower thermal impact on the refractory Chemical and petrochemical industry Lower thermal impact on the process tubes Increase thermal efficiency New design of process

17 Flameless combustion in industrial processes (2) Gas turbines NOx reduction Low calorific gases Increase life time Other potential industrial sectors: Steam, ceramics, waste treatment, etc. Oxy-flameless combustion for the CO2 capture

18 Conclusion and perspectives Expertise of Gaz de France and its partners in flameless combustion of tools to apply this technique and to be able to give guarantees (performance of the furnace, quality of the products, etc.) Other potential industrial applications in the future Gaz de France: a partner for innovation with its industrial customers and manufacturers

19 Thank-you for your attention

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