Steven J. O Connor Senior Applications Engineer Bloom Engineering Company
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1 Steven J. O Connor Senior Applications Engineer Bloom Engineering Company
2 Burners Evaluated Regenerative Burners Very efficient with high air preheat entering the burner head 80% of the waste gases leave the regenerator at a low temperature Oxy fuel burners High flame temperature Elimination of Nitrogen from the combustion process reduces waste gas volume approximately 75%
3 Furnaces Evaluated TPH Walking Beam Furnace 44 Ton Batch Furnace
4 CONTINUOUS FURNACE PARAMETERS 200 TPH 100 EFFECTIVE LENGTH SIX ZONES (3 TOP 3 BOTTOM) 8 X47 X30 SLABS 850 F AIR PREHEAT 2250 F AVERAGE DISCHARGE TEMPERATURE PLAIN CARBON STEEL NATURAL GAS FIRED (1000 BTU/SCF HHV)
5 CONTINUOUS FURNACE 200 TPH 24 UNFIRED 28 PREHEAT 24 HEAT 24 SOAK
6 HEATING CURVE: WALKING BEAM FURNACE TPH: 8"X47"X30' SLABS FURNACE 2000 TOP TEMPERATURE (F) CENTER AVERAGE BOTTOM DISTANCE (FT) BASELINE CONVENTIONAL FIRING BLOOM ENGINEERING COMPAN
7 REGENERATIVE FURNACE 220 TPH
8 HEATING CURVE: WALKING BEAM FURNACE TPH: 8"X47"X30' SLABS FURNACE 2000 TOP TEMPERATURE (F) CENTE CENTER BOTTOM DISTANCE (FT) REGENERATIVE FIRING BLOOM ENGINEERING COMPA
9 OXY FUEL FURNACE 220 TPH
10 HEATING CURVE: WALKING BEAM FURNACE TPH: 8"X47"X30' SLABS 2000 FURNACE TOP TEMPERATURE (F) CENTER BOTTOM AVERAGE DISTANCE (FT) OXYGEN FIRING BLOOM ENGINEERING COMPAN
11 FUEL SUMMARY FUEL RATE CONVENTIONAL: MMBTU/TON FUEL RATE REGENERATIVE: MMBTU/TON FUEL RATE OXY FUEL MMBTU/TON
12 OPERATING COST BASIS CONTINUOUS FURNACE FUEL $3.37/1000SCF ELECTRICITY $0.075/KWH OXYGEN $0.20/ 100 CUBIC FEET TOTAL FUEL 232 MMBTU/Hr BOTH CASES 561 OPERATING HORESPOWER FOR REGENERATIVE FANS SCFH OXYGEN
13 OPERATING COSTS REGENERATIVE FUEL $781.84/HOUR ELECTRICITY $31.39/HOUR MEDIA REPLACEMENT $0.89/HOUR TOTAL $814.12/HOUR OXY FUEL FUEL $781.84/HOUR OXYGEN $995.28/HOUR TOTAL $ /HOUR
14 ENVIRONMENTAL CONSIDERATIONS REGENERATIVE NOx from FURNACE.08 LB/MMBTU NOx from ELECTRIC POWER GENERATION.002 LB/MBTU CO2 from FURNACE 118 LB/MMBTU CO2 from ELECTRIC POWER GENERATION 5.2 LBS/MMBTU TOTAL NOx LB/MMBTU TOTAL CO LB/MMBTU OXY FUEL NOx FROM FURNACE.04 LB/MMBTU NOx from MANUFACTURE of OXYGEN.026 LB/MMBTU (SEPARATION ONLY) CO2 from FURNACE 118 LB/MMBTU CO2 from MANUFACTURE of OXYGEN LB/MMBTU (SEPARATION ONLY) TOTAL NOx.066 LB/MMBTU TOTAL CO LB/MMBTU
15 CAPITAL COSTS REGENERATIVE BURNERS $3,000,000 OXY FUEL BURNERS $480,000 CONVENTIONAL BURNERS $1,200,000 PRICING DOES NOT INCLUDE PIPING, RECUPERATORS OR INSTALLATION
16 HYBRID FURNACES INVESTMENT AND OPERATING COSTS BECOME MORE REASONABLE EASIER TO MODIFY AN EXISTING FURNACE WITHOUT INCORPORATING ANY SPECIAL DESIGN
17 HYBRIDS CONSIDERED REGENERATIVE PREHEAT ZONES OXY FUEL PREHEAT ZONES BLAST FURNACE GAS REGENERATIVE OXYGEN ENRICHMENT TO 27% OXYGEN
18 REGENERATIVE HYBRID 200 TPH 24 UNFIRED 28 PREHEAT 24 HEAT 24 SOAK
19 OXYFUEL HYBRID 200 TPH 24 UNFIRED 28 PREHEAT 24 HEAT 24 SOAK
20 REGENERATIVE HYBRID BLAST FURNACE GAS 200 TPH 24 UNFIRED 28 PREHEAT 24 HEAT 24 SOAK
21 OXYGEN ENRICHMENT FURNACE 200 TPH 24 UNFIRED 28 PREHEAT 24 HEAT 24 SOAK
22 FUEL SUMMARY FUEL RATE CONVENTIONAL: MMBTU/TON FUEL RATE REGENERATIVE: MMBTU/TON FUEL RATE OXY FUEL MMBTU/TON FUEL RATE HYBRID REGENERATIVE: MMBTU/TON FUEL RATE HYBRID OXY FUEL: MMBTU/TON FUEL RATE BFG HYBRID: MMBTU/TON; 48% NATURAL GAS REDUCTION FUEL RATE OXYGEN ENRICHMENT: MMBTU/TON
23 OPERATING COSTS PER TON BASE CASE: $4.13/TON REGENERATIVE FURNACE: $3.70/TON OXY FUEL FURNACE: $ 8.08/TON REGENERATIVE HYBRID: $3.82/TON OXY FUEL HYBRID: $5.48/TON BLAST FURNACE GAS HYBRID: $2.38/TON OXYGEN ENRICHMENT: $5.09/TON
24 ENVIRONMENTAL CONSIDERATIONS BASE CASE:.057 LB/MMBTU NOx; LBS/MMBTU CO2 REGENERATIVE FURNACE: LB/MMBTU NOx ; LB/MMBTU CO2 OXY FUEL FURNACE: LBS/MMBTU NOx; LBS/MMBTU CO2 REGENERATIVE HYBRID:.07 LB/MMBTU NOx; LBS/MMBTU CO2 OXY FUEL HYBRID: LB/MMBTU NOx; LB/MMBTU CO2 BFG HYBRID: LB/MMBTU NOx; LB/MMBTU CO2 OXYGEN ENRICHMENT: LB/MMBTU NOx; LB/MMBTU CO2
25 CAPITAL COSTS BASE CASE: $1,200,000 REGENERATIVE BURNERS $3,000,000 OXY FUEL BURNERS $480,000 REGENERATIVE HYBRID: $2,200,000 OXY FUEL HYBRID: $1,150,000 BFG HYBRID: $2,800,000 OXYGEN ENRICHMENT: CASE DEPENDENT
26 BATCH FURNACE 44 TON LOAD 8-20 X20 X194 PIECES COLD AIR FIRING NATURAL GAS (1000 BTU/SCF) 2250 F AVERAGE DISCHARGE TEMPERATURE
27 BATCH FURNACE CONVENTIONAL FIRING DOOR BACK
28 HEATING CURVE: BATCH FURNACE 2500 FURNACE 2000 TEMPERATURE (F) TOP CENTER BOTTOM TIME (MINUTES) ONE SIDE HEATING BLOOM ENGINEERING COMPAN
29 BATCH FURNACE REGENERATIVE FIRING DOOR BACK
30 BATCH FURNACE OXY FUEL FIRING DOOR BACK
31 FUEL SUMMARY COLD AIR FIRING: MMBTU = MMBTU/TON REGENERATIVE FIRING: MMBTU = MMBTU/TON OXY FUEL FIRING: MMBTU = MMBTU/TON
32 OPERATING COSTS REGENERATIVE FUEL $15.94/HOUR ELECTRICITY $1.68/HOUR MEDIA REPLACEMENT $0.03/HOUR TOTAL $17.65/HOUR OXY FUEL FUEL $15.94/HOUR OXYGEN $20.34/HOUR TOTAL $36.28/HOUR
33 ENVIRONMENTAL CONSIDERATIONS REGENERATIVE NOx from FURNACE.08 LB/MMBTU NOx from ELECTRIC POWER GENERATION.002 LB/MMBTU CO2 from FURNACE 118 LB/MMBTU CO2 from ELECTRIC POWER GENERATION 5.2 LBS/MMBTU TOTAL NOx LB/MMBTU TOTAL CO LB/MMBTU OXY FUEL NOx FROM FURNACE.04 LB/MMBTU NOx from MANUFACTURE of OXYGEN.026 LB/MMBTU (SEPARATION ONLY) CO2 from FURNACE 118 LB/MMBTU CO2 from MANUFACTURE of OXYGEN LB/MMBTU (SEPARATION ONLY) TOTAL NOx.066 LB/MMBTU TOTAL CO LB/MMBTU
34 CAPITAL COSTS REGENERATIVE BURNERS $375,000 OXY FUEL BURNERS $50,000 CONVENTIONAL BURNERS $100,000 PRICING DOES NOT INCLUDE PIPING, RECUPERATORS OR INSTALLATION
35 CONCLUDING REMARKS Regenerative Burners HIGH CAPITAL COST ACCEPTABLE OPERATING COST ACCEPTABLE ENVIRONMENTAL ISSUES INTANGIBLES ARE MAINTENANCE AND THE AMOUNT OF SPACE THAT THEY TAKE UP Oxy Fuel Burners LOW CAPITAL COST HIGH OPERATING COST ACCEPTABLE ENVIRONMENTAL ISSUES INTANGIBLES ARE POTENTIAL SAFETY ISSUES AND MORE EXPENSIVE COMPONENTS AND REFRACTORIES
36 CONCLUDING REMARKS HYBRID FURNACES MAY BE MORE COST EFFECTIVE A NEW GENERATION REGENERATIVE BURNER WILL BE RELEASED IN LATE 2013 WITH LOWER NOx VALUES THAN STATED HERE
37
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