Confidential•1
Burners for co-generation applications
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Gas and Oil fired Post Combustion Burners
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Fresh air fan
TEG FIRING
FRESH AIR FIRING (auxiliary mode)
Gas turbine generator
HRSG
Electricpower
Steam turbine generator
Fuel gas
By-pass stack
Source : Pillard
TYPICAL COMBINED CYCLE/COGENERATION SCHEME
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Our burners have been developed and testedin our test center in Marseilles for 25 years
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TEST RIG FOR INDUCT BURNERS 2 stages combustion 2 x 4 MW
water cooler
NOx, CO, temp.measurement
VALIDATATION OF CFD MODELS:SIMULATION OF BURNER AT RESEARCH CENTER
GOAL OF THE SIMULATIONS:
� Validation of physical cfd models: Comparison of temperature profiles, shape and flame length with experimental results
� "CFD" is a tool for comparative prediction of possible solutions
CHARACTERISTICS OF THE SIMULATIONS:
� unsteady
� hybrid mesh (1M cells)
� turbulence: kepsilon "realizable" model
� combustion: Eddy dissipation/finite rate model
� species: O2, CO2, H2O, CH4, CO, N2
� radiation: P1
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First Solution: Induct burners
Row type, Gas Firing
REBURNFLAMDuct Burner Systems
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Scanner coolingair header
Ignitor gasheader
Main gasheader
Flame scannerIgnitorShield
Thermal insulation
Rigid steel frame
GAS-FIRED INDUCT BURNERSIdentification of Main Components
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Source : Pillard
GAS-FIRED INDUCT BURNERSBurner Overview
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Gas fired induct burners
(Patents : FR 87/14686, CAN 580.005,Europe 88.402659.2).
Applications: HRSG supplementary firing.
Advantages: Performances in compliance with the latest European Standards for emission
TEG mode: Reburning of a part of NOx from GT: (downstream rate < upstream rate).
Fresh air mode, natural gas firing:
(mg/Nm3 eq. NO2, 3 % O2, dry basis)NOx < 200 without FGR
NOx < 100 with FGR
REBURNFLAM® GAS FIRED INDUCT BURNERSPerformances at a glance….
DIFFERENT BURNER DESIGNSDEVELOPED IN OUR TEST CENTER
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Along the 25 past years we developed and tested num erous designs to cope with:• More and more stringent TEG characteristics
– Lower O2 content
– Higher water vapour
• Burner installation between modules– Lower temperature
– Lower TEG velocity
– Shorter space available to develop the flames
• Requirements concerning the temperature profile
• NOx, CO emissions
• Operation with fresh air
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GAS-FIRED INDUCT BURNERSElementary Burner Shield Module
Design flexibility• Suitable to any duct configuration
Combustion advantages• High flame stability over wide velocity range
• High turn-down
• Even temperature distribution
• Low pressure drop
Mechanical reliability• Heat resistant: refractory materials
• Strong and precise (Wax castings)
• Designed to allow thermal expansion
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GAS-FIRED INDUCT BURNERSElementary Burner Shield Module type 1
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Basic wings
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GAS-FIRED INDUCT BURNERSElementary Burner Shield Module type 1 + central tip
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Basic wings + central tip
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GAS-FIRED INDUCT BURNERSElementary Burner Shield Module type 3
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Large wings
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GAS-FIRED INDUCT BURNERSElementary Burner Shield Module type 4
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Very large wings
SELECTION OF INDUCT BURNER DESIGN1st CRITERIA: TEG CARACTERISTICS
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0
100
200
300
400
500
600
700
10 12 14 16 18 20
TE
G T
empe
ratu
re (
°C)
TEG Oxygen (% vol.)
Standard wings
Large wings
Very large wings
Operating zone
Non Operating zoneAugmenting Air Required
SELECTION OF BURNER DESIGN2nd CRITERIA: TEG VELOCITY
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Design Basic Large wing Very large wing
Range of TEG velocity (m/s)
20 to 40 16 to 25 12 to 25
Burner output (kW/m)
2600 2600 3600
Flame length (m) 4,5 4,5 4
Above data are typical and differ according to the operating conditions
SELECTION OF INDUCT BURNER DESIGN2nd CRITERIA: TEG VELOCITY
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Flame length of basic shield according to output
SELECTION OF INDUCT BURNER DESIGNSelection based on the following criteria
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Price
TEG characteristics: O2 / Temperature
Temperature profile / vs Flame length
About the same emissions (NOx, CO) in TEG
TEMPERATURE PROFILE:MAIN PARAMETERS
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1. Distance from burner to first HRSG tubes
2. Heat release per shield (i.e number of rows)
3. Overall flow distribution
4. Type of shield
In house CFD Study
A team of experts in CFD & Combustion simulation
FLUENT Software
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Before correction
Flow correction devices (if necessary) Final result
Temperature distribution (top view)
HRSG’s inlet temperature distribution
Temperature distribution (side view)
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Some References
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Dubai Electricity Water Authority (Power Production & Desalting Water Treatment )
T.E.G. mode :
Upstream temp. : 275 to 550 °C (530/1020 °F)
Downstream temp. : 620 °C (1150 °F)
O2 content in T.E.G. : 14,3 vol %
T.E.G flow : 1 254 000 kg/hr (2 765 000 Lb/hr)
Burner characteristics :
Heat release : 128 MW[LHV] ie(485 MMBtu/hr [HHV])
24 rows of 16 shields each
Nat. Gas firing
Inside dimensions
Height : 6 m ( 19'8")
Width : 7 m (23')
GAS FIRED INDUCT BURNERSDUBAI
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GAS FIRED INDUCT BURNERSReferences: ANSALDO – SONDEL Millazzo (It)
Client : Ansaldo (Italy) for Sondel Milazzo
Height : 15m67 (51’5’’) Width : 8m47 (27’10’’)
T.E.G. mode:
Upstream/ Downstream temp. : 330/640°C (626/1184°F)
T.E.G. flow : 1 125 000 kg/h (2 700 000 Lb/hr)
O2 content : 13.77 %
Gas turbine model : GE Frame 9
Ambient air (A.A.) mode :
Upstream/ Downstream temp. : 20/640°C (68/1184°F)
Fresh Air mode : 824 000 kg/h (1 815 000 Lb/hr)
Burner characteristics:
Max. heat capacity : 170 MW LHV (644 MMBtu/hr HHV)
10 rows of 35 shields each
GAS FIRED INDUCT BURNERSANSALDO – Nehuenco (Chile)
T.E.G. mode :• Upstream T°: xx °C
• Downstream T°: xx °C
• O2 content in T.E.G.: 13.5 %vol
Gas turbine model : V97 3A
Burner Characteristics• Max Heat Input 60 MW TEG
• 4 rows of 39 shields each
Height : 9 m Width : 9 m
GAS FIRED INDUCT BURNERSALSTOM FRANCE – Eurolysine, Amiens (F)
Burner characteristics: • 87 MW Heat Input
• 4 vertical rows x 31 shields each
Gas turbine model : LM 6000
Low NOx emission, in fresh air mode : 157 mg/m3 (at 3% O2)
Height : 7.1 m Width : 3.9 m
GAS FIRED INDUCT BURNERSDOOSAN – RAS LAFFAN Water & Power (Qatar)
Four(4) Units, 150 MW
Upstream T°: 560 °C
Upstream T°: 863 °C
O2 content in T.E.G.:
Low NOx emission:• TEG mode:
• Partial Reburning of NOx produced by GT(NOx downstream rate < upstream rate).
• Fresh air mode, nat. gas firing:
• (mg/sm3 eq. NO2, 3 % O2, dry basis)
• NOx < 200 without FGRNOx < 100 with FGR
(4 Units)
T.E.G. mode :• Upstream / Downstream T°: 560 / 863°C
• O2 content in T.E.G.:
Burner characteristics:• Max. heat capacity : 150 MW
• 11 rows of 32 shields each
Low NOx emission:• TEG mode:
– NOx downstream rate < upstream rate (Partial Reburning of NOx produced by GT).
Height : 11.3 m Width : 6.5 m
GAS FIRED INDUCT BURNERSHHI For PP11 (Ryad, Saoudi Arabia)
(7Units)
T.E.G. mode :• Upstream / Downstream T°: 550°C/850°C
• O2 content in T.E.G.: 11.98 to 12.40%
Burner characteristics:• Max. heat capacity : 140 MW
• 7 rows of 20 MXW each
NOx, CO emissions < 50 mg/MJHeight : 20.4 m Width : 7.7m
GAS FIRED INDUCT BURNERSMACCHI – PETROBRAS (Brazil)
(2 Units)
T.E.G. mode :• Upstream / Downstream T°: 532°C/871°C
• O2 content in T.E.G.: 13.57%
Burner characteristics:• Max. heat capacity : 111 MW
• 12 rows
Height : 18 m Width : 4 m
GAS FIRED INDUCT BURNERSCERREY – Salamanca (Mexico)
(2 Units)
T.E.G. mode :• Upstream / Downstream T°: 632°C / 706°C
• O2 content in T.E.G.: 12.69%
Burner characteristics:• Max. heat capacity : 26 MW
• 2 rows
Height : 13 m Width : 6.2 m
GAS FIRED INDUCT BURNERSEM ALLIANCE – NOVOBEREZNIKOVSKAYA RUSSIA
(2 Units)
Burner characteristics:• Max. heat capacity : 46.8
MW
• 4 rows 1 post
Height : 12 m Width : 4.5 m
GAS FIRED INDUCT BURNERSNOOTER ERIKSEN IT – FACILITY D (QATAR)
(6 Units)
T.E.G. mode :• Upstream / Downstream T°: 600°C / 706°C
• O2 content in T.E.G.: 10.75%
Burner characteristics:• Max. heat capacity : 160 MW
• 6 rows
Height : 13 m Width : 6.2 m
GAS FIRED INDUCT BURNERSCOFELY FOR PEUGEOT (France)
T.E.G. mode :• Upstream / Downstream T°: 545°C / 850°C
• O2 content in T.E.G.: 13,4% vol.
• Flow rate: 37,89 kg/s
• Output: 15 MW
Fresh air mode + FGR• Upstream / Downstream T°: 90°C / 930°C
• O2 content in mixture: 18% vol.
• Total flow rate: 31,3 kg/s (of which 23,6 kg/s of FA)
• Output: 32 MW
FLAME 13,5m/s 10,7% O2 500kw
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VIDEO FLAME 13,5m/s 10,7% O2 500kw
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RAS LAFFAN (DOOSAN-Qatar) 150MW TEG
SONDEL MILAZZO (ANSALDO-Sicilia) 170MW AA / 70MW TE G
SHARJAH (ANSALDO-UAE) 45MW TEG
NEHUENCO (ANSALDO- Chile) 60MW TEG
TIOXIDE (Standard Fasel Lentjes – Calais France) 90M W TEG
ALHIDD II (ALSTOM POWER– Bahrain) 3x160MW TEG
GAS FIRED INDUCT BURNERSOther References High Power range…
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Second Solution: Duct Burner with Mobile Flaps
(Row Burner, Gas Firing)
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GAS FIRED INDUCT BURNERSWith Mobile Flaps for Fresh Air mode
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GAS FIRED INDUCT BURNERSReferences: CNIM BABCOCK – Salins Varangevilles (F)
74 MW, equipped with automated dampers for optimiz ed FA mode
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Third Solution: Circular GRC Burner
(Swirl type, Gas and/or Oil Firing Burners with or without mobile flaps)
GRC INDUCT DUAL FUEL FIRED BURNERSPerformances at a glance…
Patented concept: Europe .430005.3, USA 09/032-717; Europe 430026.5.
High flame stability
Removable combustion heads & Oil guns
Low emissions in TEG and Fresh air Mode
Left: ALSTOM - ARKEMA Marseilles (F):
2 x 26 MW Heat Input
Natural Gas & Heavy OIl
Gas turbine model : MARS 100
GRC INDUCT DUAL FUEL FIRED BURNERS Oil gun removal enables frequent cleaning (HFO burning)
Principle of Oil Gun removal (from side)
GRC INDUCT DUAL FUEL FIRED BURNERSOPERATING CONDITIONS
Aumenting air ratio depends on operating conditions (from stoechiometric)• 2% for operating conditions above the blue line
• 8% for operating conditions between the blue and the red lines
GRC INDUCT DUAL FUEL FIRED BURNERSFLAME LENGHT
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0 5 10 15 20 25 30
Fla
me
leng
th (
m)
TEG Velocity (m/s)
Flame Length (550°C - O2 = 13% vol.)
20 m/s
30 m/s
35 m/s
40 m/s
GRC INDUCT DUAL FUEL FIRED BURNERS HHI - PETROBRAS (Romania)
Natural Gas & Extra Heavy Fuel Oil
4 x 15 MW
GT Model: M5 5001.2
GRC INDUCT DUAL FUEL FIRED BURNERSOMAN REFINERY Co.
2 Units
Process Gas & Diesel Oil
TEG & Fresh Air Mode• TEG mode 2 x 18 MW
• FA mode 2 x 45 MW
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GRC INDUCT DUAL FUEL FIRED BURNERS DOOSAN: FUJAIRAH 1 (UAE)
4 x 235 MW GRC induct Burner
Main fuel: Natural Gas
Secondary Fuel: Diesel Oil
Operating in Gas Turbine Exhaust
TEG characteristics:
• Flow 268 to 402 kg/s
• Temperature 445 to 593 °C
• O2 contain 12,85 to 15,64 %vol .
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GRC INDUCT DUAL FUEL FIRED BURNERS ALSTOM: FUJAIRAH 2 (UAE)
5 x 240MW GRC induct Burner
Main fuel: Natural Gas
Secondary Fuel: Diesel Oil
Operating in Gas Turbine Exhaust Gases stream:
Flow (min – max): 280 to 630 kg/s
Temperature (min – max): 445 to 585 °C
O2 contain (min – max): 9.8 to 16.5 %vol
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60 DUAL FUEL BURNER HEAD of 20 MW each
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60 DUAL FUEL BURNER HEAD of 20 MW each
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60 DUAL FUEL BURNER HEAD of 20 MW each
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60 DUAL FUEL BURNER HEAD of 20 MW each
Interconnecting piping / wiring
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HIGH PRESSURE PUMPING SET
ROWS LOOSE SUPPLIED
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Exemple of burner insert
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Cabling and Wiring
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Typical PID
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Typical FCD
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CFD DWG
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NATURAL GAS MAIN FUEL SKID
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NATURAL GAS MAIN FUEL SKID
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OIL MAIN FUEL SKID
GAS PRESSURE REDUCING STATION
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Duct / Duct insulation
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INDIVIDUAL SHUT OFF SKID
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COOLING AIR FAN
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FOB DELIVERY
Reference List
Formation 17-02-2015 Duct Burners
•DUAL FIRED INDUCT BURNERS•Around 200 burner heads•More than 3 000 MW
•GAS FIRED INDUCT BURNERS•Around 300 burners•More than 4 700 MW
GRC INDUCT DUAL FUEL FIRED BURNERS …and more than 30 other references worldwide…
T.E.I. – Tate & Lyle Sugar (UK): 1 x 55 MW
BABCOCK – SONATRACH Arzew (Al) 1 x 76 MW
DESA OTAC – ZORLU Energy (Tur) 6 x 8 MW
…… ( see our reference list)
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