Low NOx Technology Seminar. The Gas Company April 30 th, 2003 Downey,CA. Presentation Overview

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Kenneth Weaver
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1 Low NOx Technology Seminar Sponsored by The Gas Company April 30 th, 2003 Downey,CA David Thornock Presentation Overview Who is Overview of the FIR Burner Burner design Demonstrations and Installations Summary 1

Johnston Burner Products AR Burner Low NOx 30-25 PPM NOx on NG Standard 60-80 PPM NOx on NG A Burner Low NOx 30 PPM NOx on NG Standard 90-110 PPM

on NG (Gas only burner) FIR BURNER Burner was developed at the Gas Technology Institute Licensed Technology to Johnston Boiler Co.

2 Johnston Burner Products AR Burner Low NOx PPM NOx on NG Standard PPM NOx on NG A Burner Low NOx 30 PPM NOx on NG Standard PPM NOx on NG S Burner Low NOx 30 PPM NOx on NG Standard PPM NOX on NG J Burner Standard PPM NOx on NG FIR Burner Low NOx Under 9 PPM NOx on NG (Gas only burner) FIR BURNER Burner was developed at the Gas Technology Institute Licensed Technology to Johnston Boiler Co. for Firetube Market Funded by SMP, GRI, SoCalGas, and DOE Retrofit or new Premixed staged combustion Forced internal recirculation No efficiency loss Lowest cost premium 2

3 Johnston s FIR Burner The FIR Burner was chosen to address the Under 20 PPM to Under 9 PPM NO x requirement Gas only applications Targeted towards the non-attainment areas like California, Texas, and isolated areas on the east coast We are using the FIR burner for new and retrofit applications FIR Burner Cross Section High Velocity Premixed Nozzle Pilot Assembly Gas Supply Recirculation Sleeve Air Inlet 3

4 FIR Burner Mechanics High Velocity Premixed Nozzle Flue Gas Recirculation Recirculation Sleeve FIR Burner Installations The FIR Burner has been installed and tested on 3 different Firetube Boilers Vandenberg AFB 50 hp Kewanee GTI s Laboratory 250 hp Johnston 2-pass Ohio Special Fullerton College (2) 250 hp Johnston 4-pass boilers An 800 hp FIR burner has been tested at Johnston and we are now in the process of building and testing a 900 hp 4

VANDENBERG AFB DEMO Firetube Boiler 20 vppm NO x FIRETUBE BOILER DEMONSTRATION SITE: Vandenberg AFB in Santa Barbara County, California Pilot site

5 VANDENBERG AFB DEMO Firetube Boiler 20 vppm NO x FIRETUBE BOILER DEMONSTRATION SITE: Vandenberg AFB in Santa Barbara County, California Pilot site for ENVVEST program (EPA/DoD partnership to achieve regulatory compliance via pollution prevention) 45 firebox and firetube boilers located at site 5

Demonstration >1800 hours unattended operation for >2300 cycles Meets all emissions targets

6 BOILER: 2.5 X 10 6 Btu/h Kewanee firetube Burner fabricated by Detroit Stoker Company FIR Firetube Boiler Demonstration >1800 hours unattended operation for >2300 cycles Meets all emissions targets Continue to monitor and address long-term reliability Firetube Boiler: NO x BEFORE AND AFTER 100 NO x, vppm Uncontrolled with FIR burner Firing Rate, X 106 Btu/h 6

7 FIR BURNER The FIR Burner on Johnston s 2-Pass Ohio Special Challenging application because of the Boiler design A 70 hp boiler that is fired at 250 hp Typically a smaller furnace Typically a larger pressure drop 7

8 Installed at GTI s Lab running at 250 hp 4.2% O 2 and 11 PPM NO x 8

9 Fullerton College (2) 250 hp boilers used for heating 15# steam design Gas firing only Requires under 12 ppm NO x Fullerton College 9

10 Fullerton College Fullerton College Load Requirements Seasonal heating load with winter the highest and summer non-existent Early morning largest day load Load tapers off in the afternoon and evening 10

11 Fullerton College Operating Results NOx Performance Comparison NOx Corrected to 3%O2 (PPM) Old Kewanee 200hp New Johnston 250 hp Min Firing Pin Number Fullerton College Operating Results Oxygen Performance Comparison Oxygen ( % by volume Dry) Old Kewanee 200hp New Johnston 250 hp 0.0 Min Firing Pin Number 11

12 Fullerton College Operating Results Stack Temperature Comparison Stack Temperature (F) Old Kewanee 200hp New Johnston 250 hp Min Firing Pin Number 86.0 Fullerton College Operating Results Efficiency Comparison 85.0 Efficiency (%) Old Kewanee 200hp New Johnston 250 hp Min Firing Pin Number 12

13 Thermal Efficiency and Excess Air 84.5 Boiler Thermal Efficiency Hp Johnston Boiler Operating at 10 psig Excess Air (%) Dry Gas Loss and Excess Air 300,000 Dry Gas Incremental Energy Loss (Btu/hr) 250, , , ,000 50, Hp Johnston Boiler Operating at 10 psig Excess Air (%) 13

14 Summary The FIR Burner is an Efficient solution for Firetube Boiler Low NOx applications (under 10 ppm) Burner operation at 4% O2 through travel Simple controls Standard boiler packages The FIR burner optimizes energy use: No external FGR No need for large hp fans to push extra FGR or Excess Air Summary The FIR burner has now been demonstrated for small firetube boiler applications hp Will be extended to 1000 hp this summer and installed in Houston GTI and Johnston Burner company are committed to move the FIR Burner and all of its benefits into the firetube market place 14

The New Coen Micro-NOx

The New Coen Micro-NOx COEN The New THE COST-EFFECTIVE SOLUTION FOR FIRETUBE & INDUSTRIAL BURNER APPLICATIONS FOR TODAY S TOUGH APPLICATIONS THE NEW MICRO-NOX SOLUTION Performance Coen s New Micro-NOx burner is specifically