CURRENT TECHNOLOGIES IN IMPROVING REHEAT ... Technologies...Vice President – Sales and Marketing...
Transcript of CURRENT TECHNOLOGIES IN IMPROVING REHEAT ... Technologies...Vice President – Sales and Marketing...
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CURRENT TECHNOLOGIES IN IMPROVING REHEAT FURNACE EFFICIENCY AND CONTROLLING EMISSIONS
Steven J O’ConnorSenior Applications Engineer
John C DormireVice President – Sales and Marketing
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Energy and Environment
• US Industry is facing difficult regulations
• Fuel costs are significantly higher than a few years ago
• To survive in today global economy companies must reduce fuel use and emissions cost effectively
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Emissions Reduction
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NOx Increase with Peak Flame Temperature
• Difficult to measure• Not practical to use for process control• Can evaluate with CFD
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NOx Increase with Furnace and Air Temperature
NO
X
Air, oF
• Easy to measure• Practical to use for process control• Tracks flame temperature• Use as predictor instead of
flame temperature
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Effect of Burner Capacity on NOxEmissions
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Effect of Wall Area to Port Area Ratio on Potential to Emit NOx
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Effect of Port Length to Diameter Ratio on Potential to Emit NOx
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Geometry and System Design Factors
• POC induced into the flame (internal exhaust gas re-circulation, IEGR)
• How & where air & gas are mixed together– air staging– Uniform flame temp Air Staging
1st stage air < 100%
100% of fuel Partialcombustion
1 or more additionalstages of air
Combustioncompleted
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• Bloom Uses Air Staging!– gas always surrounded by air
» better air-fuel mixing» better control of the
flame geometry as furnace wears
» protects process from unwanted reducing atmosphere
– no field adjustments– good flame shape in all
modes of operation– Ultra low NOx at all furnace
temperatures
Geometry and System Design Factors for Reduction of NOx Production
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Application of Low NOx technology:
• Application of Modern Low NOx technology is critical to success
• Must use modern control techniques, yet still be flexible enough for day to day use (little change for current mass flow type systems)
• Burner designs should be specific to the application requirement
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Low NOx technology – Key factors:
• Flame shape must be appropriate for the furnace
• Flame development must result in the correct furnace atmosphere – O2 levels should be minimum at the steel surface – no reducing atmosphere
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Available Low NOx Technology:
As low as 0.035 to 0.040 lbs/MMBTU in most reheat furnace applications using hot air
As low as 0.050-0.060 lbs/MMBtu when using regenerative type burners
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Low Nox burners on Steel Reheat Furnace
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PROVEN RESULTS
• SLAB FURNACE EASTERN U. S0.07 LBS/MMBTU• SLAB FURNACE TEXAS0.045 LBS/MMBTU• BILLET FURNACE UTAH0.037 LBS/MMBTU• SLAB FURNACE MIDWEST0.06 LBS/MMBTU• BILLET FURNACE MIDWESTO.O4 LBS/MMBTU• AND MANY OTHERS
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EFFICIENCY IMPROVEMENT
• FUEL SAVINGS• REGENERATIVE BURNERS
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Regenerative Burners
Burners are installed in pairs
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Bloom Regenerative Burners Cycle A
Hot air
Warm POC
Hot POC
Gas
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Bloom Regenerative BurnersCycle B
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ADVANTAGES
• FUEL SAVINGS FROM HIGHER AIR PREHEAT
• SHORTER UNFIRED SECTION DUE TO PULLBACK
• LOWER NOx WITH IMPROVED BAFFLE DESIGN
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RECENT APPLICATIONS
• PLATE MILL FURNACE - KOREA• HSM RETROFIT - CHINA• FORGE FURNACE - KOREA
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PLATE MILL FURNACE - KOREA
• SIX ZONE WALKING BEAM FURNACE
• REPLACED BOTTOM PREHEAT ZONE BURNERS WITH REGENERATIVE BURNERS
• NATURAL GAS• 10-12% FUEL SAVINGS ON
ENTIRE FURNACE
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PLATE MILL FURNACE - KOREA
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PLATE MILL FURNACE - KOREA
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HSM FURNACE RETROFIT - CHINA
• EIGHT ZONE WALKING BEAM FURNACE
• REPLACED BOTTOM HEAT1 AND BOTTOM HEAT2 ZONES WITH REGENERATIVE BURNERS
• MIXED GAS (200 BTU/SCF HHV)• 12-18% FUEL SAVINGS ON
ENTIRE FURNACE
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SOAK
58.74 METERS EFFECTIVE LENGTH
HEAT 2 HEAT 1PREHEAT
HSM FURNACE RETROFIT - CHINA
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HSM FURNACE RETROFIT - CHINA
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HSM FURNACE RETROFIT - CHINA
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FORGE FURNACE - KOREA
• BATCH FURNACE TWO ZONES• REGENERATIVE BURNERS ON
TOP• REGENERATIVE FLAT FLAME
BURNERS ON BOTTOM• NATURAL GAS• 20-25% FUEL SAVINGS
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WORK IN PROGRESS - NEW HSM FURNACE - CHINA