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ptq
Q2 2009
ptq
Q2 2009
REFINING
GAS PROCESSING
PETROCHEMICALS
THERMAL COMBUSTION
SEPARATION
SPECIAL FEATURES
THERMAL COMBUSTION
SEPARATION
S
ince process heaters are typically
located outside, their operation
is subject to the weather. Variations in ambient conditions
Heaters are usually tuned to a given
set of conditions. However, the
actual operating conditions can vary
dramatically from season to season and
!TMOSPHERIC 7IND SPEED 4EMPERATURE (UMIDITY
sometimes even during a day. Wind, PRESSURE AND DIRECTION OF AMBIENT AIR OF AMBIENT AIR
ambient air temperature, ambient air
humidity and atmospheric pressure
can all significantly impact the O2
level, which impacts both the thermal
efficiency and the pollution emissions )MPACTS EXCESS /
from a process heater. Unfortunately, CONCENTRATION INSIDE HEATER
most natural draft process burners
are manually controlled on an
infrequent basis. Some type of $ECREASE IN )NCREASE IN )NCREASE IN $ECREASE IN
automated burner control, which EXCESS / EXCESS / AIR TEMPERATURE AIR HUMIDITY
is virtually non-existent today in
this application, is recommended to
adjust for the variations in ambient $ECREASE IN MIXING )NCREASE IN MIXING
conditions. RATE OF AIR AND FUEL RATE OF AIR AND FUEL
There continues to be great interest
in minimising pollutant emissions,
particularly nitrogen oxides (NOx) and )NCOMPLETE (IGHER FLAME
carbon monoxide (CO), from process COMBUSTION TEMPERATURE
heaters, because these pollutants pose a
health risk to the public and harm the
environment.1 In normal practice, most )NCREASE IN )NCREASE IN
heaters are operated with about 3% #/ ./X
excess oxygen (O2) to ensure low CO
emissions, high combustion efficiency
and to allow for variations in operating
conditions that may occur during Figure 1 Diagram showing potential pathways leading to increases in NOx and CO
normal operation.2 These variations emissions due to variations in ambient conditions
include daily and seasonal changes in
weather and minor variations in the CO emissions. It shows that changes in Effects of excess O2 on NOx
fuel gas composition or supply ambient air temperature and humidity, and CO
pressure. atmospheric pressure and wind can all Changes in ambient conditions can
Changes in ambient air temperature result in variations in the heater excess cause significant variations in heater
and humidity, atmospheric pressure O2 (red lines). An increase in excess O2 excess O2 that can impact NOx and CO.
and wind can all have a significant typically produces a more compact, In this section, experimental data will
impact on heater operating conditions. higher temperature flame that results in show the effects of excess O2 on NOx
These climate changes can result in higher NOx emissions. A decrease in and CO production. Mechanisms
variations in heater excess O2, excess O2 tends to reduce the mixing associated with these trends are
which impacts the flame temperature. rate of the air and fuel, causing poor discussed. Next, the impacts of ambient
This can lead to substantial increases combustion and leading to high CO temperature, relative humidity,
or decreases in both NOx and CO emissions. Figure 1 also shows that atmospheric pressure and wind on
emissions. changes in the ambient air temperature excess O2 are shown and demonstrate
Figure 1 shows several potential and humidity can lead to higher flame the potentially significant influence
pathways in which changes in ambient temperatures, resulting in higher they can have on NOx and CO
conditions can lead to higher NOx and NOx emissions. emissions.
NOx, normalised at 6% O2
NOx, at 6% O2 = x NOx, at 3% O2
NOx, normalised at 3% O2
1 4 24 3
NOx correction factor 1.33
in NOx.
The NOx vs excess O2 trend for 1.5
premix-style burners is different than 0% relative humidity
for diffusion-style burners. Figure 2 also 1.0
20% relative humidity
shows experimental data for a premix- 40% relative humidity
style burner designed to supply all of 60% relative humidity
the combustion air through the mixer 0.5 80% relative humidity
(no staged air). Test data show that NOx 100% relative humidity
emissions for this premix burner 0.0
decreased with increasing excess O2. 30 40 50 60 70 80 90 100 110 120
This trend occurred because as the Air temperature, °F
excess O2 increased, the primary fuel
gas became leaner. This resulted in
lower flame temperatures, thus reducing Figure 6 Percentage of O2 as a function of ambient air temperature and relative
NOx emissions. As staged air is humidity firing methane (or propane)
introduced into other types of premix
burners, the NOx reduction will not be oxygen and mixing. However, it can be style wall burner, where excess O2 is
as pronounced because the primary air- formed if there is insufficient oxygen measured at the top of the radiant
fuel mixture becomes more fuel rich, available for complete combustion. section. Data show that as the excess
resulting in higher flame temperatures. Figure 4 shows the effects of excess O2 decreases to about 1%, CO emissions
Eventually, as more and more staged air O2 on CO emissions for a diffusion- start to increase. As the excess O2
is supplied, the NOx vs O2 trend approaches 0.5%, the CO production
approaches that of the diffusion-style rapidly accelerates, which is often
burner. referred to as “CO breakthrough”.
“Experimental data clearly
Excess O2 effects on CO show that increasing Ambient temperature and
Carbon monoxide is produced by the relative humidity effects
incomplete combustion of fuels excess O2 results in a NOx Climatic changes in ambient air
containing carbon. CO burns by increase for diffusion-style temperature and humidity can
reacting with O2 to form carbon dioxide significantly impact the excess O2 in a
(CO2). CO is generally easy to convert burners” heater. If the excess air is not properly
into CO2 given sufficient temperature, controlled, it can ultimately lead to
{
2.0 58% increase in NOx summer months, the temperature drops
100% NG
to 50°F (10°C) and 0% relative humidity
(Figure 7a). If the operators fail to trim
{
1.5
the O2 during this climate the excess O2
40% increase in NOx will increase from 2% to approximately
1.0 4%, as shown in Figure 7a. Using the
data from the previously discussed
Figure 2, NOx will increase by 40% for
0.5 the NG fuel case and 58% for the
0 1 2 3 4 5 6 7 8 9
high-hydrogen fuel case (Figure 7b).
Furnace O2, % dry on volume basis
This demonstrates that dramatic
changes in NOx can occur if excess O2 is
not trimmed.
Figure 7 Example demonstrating how variations in ambient air temperature and High excess O2 levels can also reduce
humidity can result in dramatic changes in NOx heater thermal efficiency. A common
reaction to this is to increase the burner
dramatic changes in NOx and CO because part of the combustion air is firing rate to make up for the efficiency
emissions. displaced by the water vapour. The loss. Increasing the firing rate further
When the temperature of the ambient amount of water vapour that air can increases NOx emissions. Firing a heater
air changes, its density also changes. hold depends on the temperature and above its design limit can cause flames
For example, dry air at 60°F (16°C) and pressure. When the air cannot hold all to touch or engulf the process tubes or
14.7 psia (101 kPa) has a density of the water, the moisture condenses as furnace refractory, which is referred to
0.0765 lbm/ft3 (1.23 kg/m3). At 100°F dew. Relative humidity is the term as flame impingement.4 This can cause
(38°C) the density drops to 0.0710 lbm/ commonly used to describe the amount long-term problems such as refractory
ft3 (1.14 kg/m3). If a burner, operating of water vapour in the air and is defined damage, tube sagging or bowing and
at a given draft, experiences an increase as the amount of moisture in the air tube leakage or rupture.5
in air density due to a decrease in Next, consider a hypothetical
temperature, it will pull more example demonstrating changes in CO.
combustion air into the heater on a Suppose plant operators working the
mass basis, resulting in higher excess “The presence of water nightshift tune a heater with diffusion-
O2. Conversely, if the air temperature vapour in the combustion style burners to 2% excess O2. During
increases, excess O2 would decrease. adjustments, the ambient temperature
The presence of water vapour in the air can affect heater is 60°F (16°C) and 0% relative humidity.
combustion air can also affect heater excess O2 levels” As mid-day approaches, the weather
excess O2 levels. As the moisture in the conditions reach 100°F (38°C) and 80%
air increases, the excess O2 drops relative humidity. If the dayshift
above the measurement point. Low-
pressure areas have less air mass above
their location, whereas high-pressure
areas have more air mass above their
location. As the atmospheric pressure
changes, the air density also changes
due to the compression effect of the
air mass.
Natural variations in atmospheric
pressure occur as a consequence of
changing weather conditions. For
example, an incoming storm can cause
a large drop in atmospheric pressure. As
the atmospheric pressure drops, the
density of the air (at a constant
temperature) also drops. For a heater
operating at a given draft, this would (EATER EXCESS / DRY VOLUME
result in a reduction in excess O2
because the reduction in air density
results in less combustion air going Figure 8 Example demonstrating how variations in ambient temperature and
through the burner. humidity can result in dramatic changes in CO emissions
Figure 9 shows the effects of
atmospheric pressure on excess O2, Wind effects resulting in a reduction in heater draft.
where the baseline point is 3% O2 with Varying winds, especially storm force The pressure inside a stack, created by
ambient conditions of 60°F (16°C), 14.7 winds, can cause dramatic changes in wind blowing over the top, can be
psia (101 kPa). Results show that as the pressure inside the stack and at the estimated by:7
atmospheric pressure decreases, the O2 burner inlet. This can significantly
also decreases. The rate of change of impact heater draft, resulting in swings Cp,iρamb airV2wind
Pstack = +Patm
excess O2, with atmospheric pressure, is in excess O2. 2gc (1)
not significantly dependent on the air When wind blows over the top of a
temperature. stack, it can contribute to either a where the internal pressure coefficient,
Weather data show that atmospheric back pressure or a suction pressure Cp,i, is equal to a value of +0.1 if the
pressure, at a given location, can vary inside the stack. If the momentum of stack is operating and -0.8 if the stack is
as much as 0.6 psia (4 kPa) in a short the flue gas is low relative to the wind, closed. For example, using Equation 1,
period of time.6 This corresponds to a a negative pressure inside the stack can the potential variation in heater draft
change in heater excess O2 of about be formed. Since the heater box is in due to wind blowing over the top of a
0.5% based on the results in Figure 9. A direct dynamic communication with stack for an ambient air temperature of
drop of 0.5% in excess O2 can be the stack, this contributes to an increase 60°F (16°C), atmospheric pressure of
significant, especially, if a burner is in heater draft. On the other hand, if 14.7 psia (101 kPa) and a wind speed of
operating near the CO breakthrough the flue gas momentum is dominant, 30 mph (13 m/s) has the potential to
point. the wind can create a back pressure, create a draft variation of approximately
2.5
Air
open and the stack damper was set at
F
100 ° 58% open. The stack damper was
2.0
erat ure =
Air temp exposed to the full force of the wind,
1.5 while the burner inlet was somewhat
isolated from the wind due to equipment
1.0 and structures located in the area. For
the high-wind case, the speed ranged
0.5 from about 8–35 mph (3.6–16 m/s),
causing variations in draft of about 0.25
0.0 inches WC (0.062 kPa) and swings in
13.0 13.5 14.0 14.5 15.0
excess O2 of about 1%. However, for the
Atmospheric pressure, psia
low-wind case, the speed varied from
about 0–10 mph (0–4.5 m/s), causing
Figure 9 Calculated percentage of O2 as a function of atmospheric pressure firing variations in draft of 0.05 inches WC
methane (or propane) (0.012 kPa) and swings in excess O2 of
only about 0.2%. Clearly, the wind
blowing over a heater stack can have a
significant impact on the draft and
High wind condition Low wind condition excess O2. Next, consider the effects of
40 40
wind blowing past the air intake of a
Wind speed,
Wind speed,
30 30
burner.
mph
mph
20 20
Wind blowing past a burner intake
10 10
can have a significant impact on the
0 0
airflow rate into the heater. The impact
0.75 0.75
depends on the burner intake design,
inches W.C.
inches W.C.
Floor draft,
Floor draft,
dry volume
Excess O2,
Excess O2,
3 3
a crosswind direction. When wind
2 2
1 1
blows in a crosswind direction past a
0 0 burner intake, the wind tends to lower
the static pressure near the inlet plane.
The low pressure reduces the differential
Figure 10 Data trends showing wind effects on heater draft and excess O2 at high pressure that drives the air through the
and low wind speeds over a ten-minute period burner, resulting in lower excess O2.
A diffusion-style burner, firing NG at
its design maximum heat release of 10
x 106 Btu/hr (2.9 MW), was tested in a
4.0
crosswind direction with the damper
set at 100% open. Wind speeds up to 35
3.5 mph (16 m/s) were simulated using a
Excess O2 = 0.5 to 2.3%
Average excess O2, % dry