A Furnace Combustion System Conversion by
FlammaTec during Operation at Libbey Inc.
shows how Flame Geometry Improvement and
Excess Air Control contributes to Fuel Savings
Dan Cetnar – Libbey, Inc.
Petr Vojtech – FlammaTec, Ltd.
Erik Muijsenberg – Glass Service, Inc.
July 2013
ICG Prague
PRESENTATION
FlammaTec Flex Burners
Practical results of an application of a
flexible dual gas injector
INTRODUCTION
Contents of Presentation
● Introduction and history
● FT flex burner design and operating principles
● FT flex burner design and simulation
● Installation
● Production results at Libbey, Inc.
● Benefits
INTRODUCTION
The new situation in the world reflecting the
economy and strong ecological request
● Increasing price of combustion oil
● Very strong ecological limits and higher penalties
● Growing interest in use of natural gas in glass furnaces
● NOx production
● Conversion from oil combustion to gas firing
● New and advanced burner system FLAMMATECTM
FLEX
INTRODUCTION
History of Dual Gas Injector Burners
●
Advantages of a new burner concept were developed for
the FlammaTec burner in 2006/2007.
●
FlammaTec utilizes a complete two (2) gas stream concept with
new advanced features such as:
 Two (2) fully separate gas flows and control and measurement
 Adjustable burner nozzle
 Optimized burner tip
●
Practical results confirm the newly advanced burner concept with
a technical advantage.
FT BURNER DESIGN AND OPERATING PRINCIPLES
Dual gas injector with precision adjustments
of inner nozzle to have additional flame control
next to volume flow control to each nozzle externally
FLAMMATEC BURNER DESIGN AND SIMULATION
FT Design Optimized by Computer Modeling
Turbulence Optimization
FT BURNER DESIGN AND OPERATING PRINCIPLES
LIBBEY FLAMMATEC BURNER INSTALLATION
LIBBEY REQUIREMENTS
Libbey FlammaTec Burner Evaluation
Goal:
●
Investigate and evaluate any benefits from using a dual flow low-NOx
burner with independent flow control through both primary and
secondary fuel streams.
●
Two (2) furnaces were evaluated
LIBBEY REQUIREMENTS
Libbey FlammaTec Burner Evaluation
Comments:
●
Several different types of burners have been evaluated over the recent
years in an effort to improve efficiency, each with varying degrees of
success. The most recent improvement (prior to the FlammaTec
burners) was used as the baseline.
●
The Libbey experiences with combustion control have provided them
with very specific understandings of their limitations as it pertains to
emission rates, glass quality, efficiency, and redox.
LIBBEY REQUIREMENTS
Libbey FlammaTec Burner Evaluation
Trial Procedures:
●
The simple goal of these installations were to convert from the existing
burners to the FlammaTec burners over a 6-8 week period without
negatively impacting any of the primary criteria.
●
The burners were changed port by port, and the furnace was observed
after each port conversion.
●
The fuel distribution profile was not changed from the previous
conditions.
LIBBEY FURNACE CONVERSION
Libbey FlammaTec Burner Evaluation Furnace “C”
●
Libbey Shreveport “C” furnace has been continuously operated since
2006, producing high quality, low iron, soda lime glass for tableware
production, with a carbon / sulfate fining system.
●
“C” furnace is a 5 port furnace with one burner per port, and is
equipped with independent fuel flow control on each port.
●
Typical pull rates range between 150 and 190 US tpd, and will run for
multiple months at a pull rate of +/- 10 US tpd. The cullet ratio is 28%.
●
The furnace has multiple oxygen sensors that are used for continuous
monitoring and control of furnace atmosphere.
●
“C” furnace was converted to the FT burners in March 2011.
FT FURNACE C INSTALLATION
Furnace type : cross fired
Glass type: soda lime
Pull: 160 MTPD
Cullet: 28 %
Flammatec burners
Melter area : > 86 m2
Glass depth melter: > 1.4 m
Spec. energy consumption: < 5 MJ/kg
Total gas consumption :
xxxx Nm3/h
Heat value of gas :
11645 kcal/kg
Combustion heat :
xxxx kW
Electric boosting :
NO OPERATED
NOx:
xxx mg/Nm3 (8% O2)
ACTUAL LIBBEY OPERATION ON PORT 3
ACTUAL LIBBEY OPERATION ON PORT 3
ACTUAL LIBBEY OPERATION ON PORT 5
ACTUAL LIBBEY OPERATION ON PORT 5
FURNACE “C” OPERATING COMPARISON
Y axis graduated in 0.5 mm btu / ton increments
6,5
6
5,5
5
Previous Inj.
FlammaTec
Polyg. (Previous Inj.)
4,5
Polyg. (FlammaTec)
4
3,5
3
Y
140
145
150
155
160
165
170
175
180
185
190
LIBBEY FURNACE CONVERSION
Libbey FlammaTec Burner Evaluation Furnace “A”
●
Libbey Shreveport “A” furnace has been continuously operated since
January 2012, producing high quality, low iron, soda lime glass for
tableware production, with a carbon / sulfate fining system.
●
“A” furnace is a 5 port furnace, electrically boosted, with one burner per
port, and is equipped with independent fuel flow control on each port.
●
Typical pull rates range between 160 and 230 US tpd. The cullet ratio is
18-28%.
●
The furnace has multiple oxygen sensors that are used for continuous
monitoring and control of furnace atmosphere.
●
“A” furnace was converted to the FT burners during a routine furnace
rebuild in December 2011.
LIBBEY SUMMARY
• The use of FlammaTec burners has enabled the melting
operation to be adjusted to run with lower oxygen
content without negatively impacting glass color. The
sustained operation at a lower oxygen content results is
an improvement in melting efficiency on an energy per
ton basis. The average reduction over the entire
operating range is in excess of 2.5% mm btu/ton.
• The FlammaTec burners have provided a more stable
combustion process that was unachievable with previous
burners, resulting in both a stabilization and a slight
positive shift in glass redox.
• Burner adjustments throughout the operating range have
been reduced from previous burners.
MORE PROJECTS
REALIZED FLAMMATEC FLEX PROJECTS
In total over 1000 burners already installed in 5 years
FT Flex Furnace projects per year
30
25
20
15
10
5
0
1
2
3
4
5
ORIGINAL BURNER CONTAINER FURNACE INSTALLATION
Furnace type : container
Glass type: green
Pull: 251 MTPD
Cullet: 53 %
Old burners
Melter area : 82.8 m2
Glass depth melter: 1150 mm
Spec. pull : 3.03 MTPD/m2
Spec. energy consumption: 3.66 MJ/kg
Total gas consumption :
1005 Nm3/h
Heat value of gas :
11192 kcal/kg
Combustion heat :
9550 kW
Electric boosting :
1082 kW
NOx:
920 mg/Nm3 (8% O2)
FLAMMATEC CONTAINER FURNACE INSTALLATION
Furnace type :container
Glass type: green
Pull: 251 MTPD
Cullet: 53 %
Flammatec burners
Melter area : 82.8 m2
Glass depth melter: 1150 mm
Spec. pull : 3.03 MTPD/m2
Spec. energy consumption: 3.54 MJ/kg
Total gas consumption :
968 Nm3/h
Heat value of gas :
11192 kcal/kg
Combustion heat :
9201 kW
Electric boosting :
1082 kW
NOx:
650 mg/Nm3 (8% O2)
FLAMMATEC FLOAT FURNACE INSTALLATION
Total gas consumption : 4300 Nm3/h
Heat value of gas :
10910 kcal/kg
Combustion heat :
41939 kW
NOx:
< 1000 mg/Nm3 (8% O2)
Melter area : 522 m2
Glass depth melter: 1325 mm
Spec. pull :
1,34 MTPD/m2
Spec. energy consumption: 5,18 MJ/kg
FLAMMATEC CONCLUSIONS
CONCLUSIONS
• The FlammaTec burners have truly independent gas
flow adjustment for both the inner and outer nozzles
• Improved flame shape control is available, and therefore
“tighter” flame stability, more flame luminosity, and
therefore improved furnace operational performance
• Improved flame shape control and therefore excess
oxygen levels within the furnace can yield an improved
energy efficiency
FLAMMATEC CONTACT
Our sincere appreciation goes to Libbey, Inc.,
and their Shreveport, Louisiana facility to
make this presentation possible
FLAMMATEC CONTACT
Thank you for your attention
Děkuji Vám za Vaši pozornost
Contact:
FlammaTec, Ltd.
Rokytnice 60, 755 01 Vsetin
Czech Republic
T: +420 571 498 566
F: +420 571 498 599
[email protected]
www.flammatec.com
Download

LIBBEY REQUIREMENTS Libbey FlammaTec Burner Evaluation