Flameless Combustion and its Applications

Transcription

1 Flameless Combustion and its Applications Joachim G. Wünning WS, 2004 Noordwijkerhout, May 2004

2 Driving Forces for New Technology Energy Prices Carbon Tax Pollution Limits (NO x ) Productivity Quality.

3 Natural Gas Prices Source: Energy Information Administration /Annual Energy Review 2002

4 Natural Gas Prices In the 90 s, stable or falling prices were prognosed for a long period of time Current forcasts have changed Additional uncertainty comes from CO2 policies

5 Whats the role of flameless combustion in all these issues? Improving processes or enabling new processes Enabling high air preheat and low NO x Fuel flexibility Less thermal burner stress Uniform temperature distribution.

6 What is flameless oxidation? Stable combustion without a flame and defined recirculation of hot combustion products For gaseous, liquid and solids fuels With and without air and/or fuel preheat For direct and indirect heating For rich near stoichiometric and very lean combustion (e.g λ = 0.3 3) For diffusion, partial premixed and premixed combustion

7 What is FLOX? FLOX is a registered trademark by WS GmbH, Renningen There are several intelectual property rights Licences were granted to partners

8 What is not required for flameless combustion? It is not necessary to use preheated air It is not necessary to operate with low oxygen levels No catalysts are required There is no need for large combustion chamber volumes Separate injection of fuel and air not required

9 FLOX and Flame What s the visible difference reacting fuel & air fuel air Flame FLOX WS GmbH test lab, 1989

10 FLOX and Flame, temperature field flame supervision and ignition flame stabilization flame fronts Flamme fuel air temperature supervision < C mixing of air and fuel with exhaust prior to reaction (no flame front) strong recirculation Flamme FLOX fuel air < C

11 FLOX and Flame, flame fronts Temperature [mm] [K] Height = 13.0 mm 3200 [a.u.] [mm] OH LIPF Intensity FLAME [mm] 18.0 [mm] [mm] 2100 [K] 1500 Height = mm [a.u.] [mm] [mm] FLOX [mm] [mm] [mm] Temperature [K] OH-LIPF Intensität [a.u.] Plessing, Peters and Wünning, 27th Symposium on Combustion

12 FLOX and Flame, S-shape curve flameless oxidation N. Peters, Turbulent combustion, 1999

13 FLOX and Flame, combustion noise 1600 C 1400 lifted flame, x NO60ppm, 92 db(a) probe Temperature noise of the air alone 78 db(a) flame, x 160ppm, 98 db(a) NO FLOX, x NO 6ppm, 82 db(a) ,5 5 Time 7,5 s 10

14 FLOX and Flame, NOx NOx (2% O) ppm air preheat ϑε (=0,65) L C 800 TA-Luft Flame air staged jet burner radiant tube direct fired Flameless Oxidation FLOX combustor C1600 furnace temperature ϑ Ofen

15 Flameless Combustion, Applications Steel & Metals Glass & Ceramics & Cement Chemical Power Generation Process Heat Waste incineration Domestic Transport

16 Flameless Combustion, Applications Steel & Metals Glass & Ceramics & Cement Chemical Power Generation Process Heat Waste incineration Domestic Transport

17 Self recuperative FLOX burner

18 Single ended radiant tube

19 Double-P-tube

20 A-tube

21 Steel, 54 t/h Silicon Steel Strip Line

22 Steel, 116 t/h Galvanizing Line

23 Steel, 20 t/h Tube Reheating

24 Compact regenerative FLOX burner

25 Compact regenerative FLOX burner

26 Steel, 30 t/h Tube Reheating

27 Steel, 80 t/h stainless A&P

28 Steel, Forge Box Furnace

29 Steel Car bottom furnaces Roller hearth furnaces Mesh belt furnaces Pit furnaces Carburizing furnaces

30 Chemical, FLOX NH 3 combustion BASF Domschke, Becker, Wünning

31 Chemical, Reformer & Cracker

32 Power Generation, FLOX combustor

33 Power Generation, FLOX combustor Optical Combustion Chamber with FLOX combustor 200 mm 2 windows with cooling air inside! 5-30 bar! λ = 2 3! g/s natural gas, 300 K! g/s air, up to 690 K

34 Power Generation, FLOX combustor High Pressure Test Rig

35 Power Generation, CHP Stirling

36 Power Generation, CHP, H 2 -Reformer exhaust reformer gas controls ignition transformer FLOX -Reformer water pump gas compressor air blower * FLOX- Reformer in a test rig

37 Power Generation, coal combustion Investigations in a test rig (RWTH Aachen, WÜK) for pressurized coal combustion flamemode, coal FLOX mode, oil FLOX mode, coal

38 Power Generation, coal combustion polish hard coal pressurized 3 bar liquid ash NO x 232 mg/m 3 (reduced from 638mg/m 3 )

39 Outlook The role of energy conservation will gain importance in the future Near zero NO emissions will be possible There are many opportunities There is a lot to do for R&D

40 ??