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Fifth International Conference on Technologies and Combustion for a Clean Environment (Clean Air V),
Lisbon (Portugal), 12-15 July 1999,
Lecture 21.4 of Session "Application of Porous Media to Combustion Processes II"
and the higher combustion temperature, a significant part
of the heat has to be transferred by radiation from the gas
phase, which makes big gas volumes necessary.
Due to the high combustion temperature, oxy-fuel
burners result in a high primary efficiency also for
processes at high temperatures without the use of
recuperation. From the economic point of view, one has to
take into account the reduced investment costs, the higher
efficiency and compare them to the oxygen production
costs.
To illustrate the raise of the efficiency, if oxygen is used,
the efficiencies for the case of a radiation burner in an
adiabatic furnace were estimated. The energy fluxes of an
adiabatic furnace (adiabatic for losses through the furnace
wall) are shown in Figure 1 and the efficiency of a system
heated by direct combustion may be calculated by
Equation 1.
ABSTRACT
Major development activities are described which have
been carried out towards an innovative radiation burner
operated with pure oxygen instead of ambient air as
oxidant. The use of oxygen affects the combustion process
in two ways. On the one hand, the efficiency is increased
drastically. On the other hand, however, the resulting
temperatures usually exceed the temperature resistance of
all nowadays known materials. Therefore, the main issue
was to succeed in keeping the temperatures of the
radiation burner below the known material limits
(< 1800C), although pure oxy-fuel combustion was
realized, which normally yields to very high temperatures
(> 2800C). In order to meet this requirement, a new
concept for radiation burners has been developed and is
presented in this work. This novel concept is based on the
combination of the porous burner technology with staged
combustion. The constructive layout is discussed together
with numerical calculations of the temperature field taking
into account reduced chemical kinetics schemes as well as
all heat transport mechanisms relevant for high
temperature combustion processes in a porous medium. A
further application of the same principles and first results
of a very low NOx methane-air porous burner are also
presented.
Furnace
Q
P = m fuel HR
Figure 1:
Q exhaust
Radiation
Burner
Q
=
m fuel H R
P Q exhaust
P
(1)
Q=
T1
T2
A1
A2
1
2
INTRODUCTION
In industrial process engineering applications, like glass
melting furnaces, surface treatment, metal treatment, etc.
an uniform heating with a fast response is required.
Radiation heating is the best solution for such applications
and many different concepts are used, depending on the
necessary power density and the required temperatures.
In glass melting furnaces for example, conventional
burners are applied, which heat up the burner walls, so
that the major part of the heat is transferred by radiation
from the burner walls to the melt. Since the exhaust gas
temperatures are high, efficiency is low and only
expensive recuperation constructions may improve the
efficiency. Additionally NOx-emissions may be very high
depending on the furnace temperature and residence time
of the gases in the furnace.
Electric radiators are also used for these applications,
especially if compact design, low investment costs,
specific atmosphere composition of the furnace and
emissions are of interest. They have an almost 100%
efficiency in the furnace, but taking into account the
average electricity generation from primary energy
sources, efficiency is reduced to about 40% and emissions
may also be high.
Oxy-fuel burners are increasingly applied in such
applications because of the primary high efficiency without
recuperation (low investment costs) and the reduced NOx
emissions due to the very low nitrogen concentration in the
furnace environment. However, due to the relatively low
flow rates in comparison to conventional air-fuel burners
1
1
A1
A2
1
2
) (T
T2
1,0
0,9
0,8
0,7
max
0,6
0,5
0,4
0,3
0,2
0,1
0,0
0
500
1000
1500
2000
3700
100 vol. %
3500
Temperature [K]
50 vol. %
3300
33 vol. %
3100
20 vol. %
10 vol. %
3400
3200
5 vol. %
0 vol. %
3000
2800
2900
2600
2700
2400
2500
2200
2300
2000
2100
1800
1900
1600
1700
1400
1500
1200
1300
1000
1100
Entrance temperature: 25 C
Temperature [ C]
Figure 2:
800
900
0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0
Air ratio
Figure 3:
AM
dl
4
=
=
d 2l d
V
4
(4)
(5)
According to these estimations, detailed calculations for
a high-temperature radiation burner can be performed for
either a tube diameter of approx. 3 mm or for a burner
geometry with rectangular cross section. A flat burner has
to show a plate thickness of 1.5 mm. The relations
between the surface and the volume of a tube and a flat
plate are shown in Figure 5.
3000
tube (x = diameter)
plate (x = thickness h)
As/V [m/m]
2500
2000
1500
1000
1000
500
900
T2 = 1573 K
T1 = 1673 K
T1 = 1773 K
T1 = 1973 K
T1 = 2273 K
800
Q/A [kW/m]
700
600
0
0
10
x [mm]
Figure 5:
500
400
300
200
100
0
1
Figure 4:
10
1000
Ao
1
2
2500000 kW
m3
1000
kW
m2
=1250
m2
m3
(3)
d in mm
2.5
5.0
7.5
Table 1:
Tmax in K
1700
1780
1860
Tmax in K
1873
T max in K
L in mm
80
60
1773
40
L in mm
20
1673
0
0
d in mm
Figure 7:
Temperature
[K]
2073
0.15
2023
1973
0.1
Length [m]
1923
CH4 /O2
1873
Figure 8:
CH4
CH4
CH4
exhaust gas
1823
0.05
0.15
0.15
1773
Temperature
[K]
1873
0.15
0.15
1853
1723
1833
1813
1673
1573
0.05
0.05
1793
1773
Length [m]
Figure 6:
Length [m]
0
0.002
Radius [m]
Length [m]
1623
0.1
0.1
Length [m]
0.1
0.1
1753
1733
1713
0.05
0.05
1693
1673
1653
1633
1613
0
0
0
0.002
Radius [m]
st
1 stage
st
0
0
0.002
Radius [m]
nd
2 stage
0
0.002
Radius [m]
rd
3 stage
1 stage:
2nd stage:
3rd stage:
4th stage:
= 2.5,
= 1.82,
= 1.43,
= 1.18,
Figure 9:
Radiation
burner
with
combustion, Temperature in K
0
0.002
Radius [m]
1593
1573
th
4 stage
Tmax = 1800 K
Tmax = 1773 K
Tmax = 1773 K
Tmax = 1773 K
multi-staged
compressed air
mass flow
controller
1,2 MPa
mass flow
controller
magnetic
valve
mixing
chamber
exhaust gas
radiation burner
O2
20 MPa
mass flow
controller
magnetic
valve
CH4
20 MPa
da
di
t
oxygen
methane
exhaust
4.
Lean or Fat
Premixed
Fuel/Air
Mixture
Flue
Gas
Porous Medium
Quasi-continuous Stage
Zone A,
Flame
Insulation
Thermocouples
Arrestor
First Stage
Figure 16
1.6
70
60
20
un
st
ag
ed
100
1.2
30
130
0
13
0
14
1.3
80
1.4
90
140
1.5
140
50
1.1
0.7
0.8
0.9
1.1
1.2
1.3
1.4
1.5
1.6
NOX
[mg/kWh]
160
150
140
130
120
110
100
90
80
70
60
50
40
30
25
20
10
Figure 17: Part of the operation field of a quasicontinuous staged porous medium burner
The operation field can be subdivided into four regions:
The line where the primary air ratio is equal to the
total air ratio represents an unstaged or conventional
operation.
2. The region with primary air ratios smaller than 1.0 is
obtained by a fat combustion in the first stage and by
feeding air in the stages afterwards (fat-lean
combustion). One can see that maximum values of
about 160 mg/kWh can be received for stoichiometric
conditions in the first stage. For lower primary air
ratios a slight enhancement can be noticed.
3. The region below the line with unstaged operation
displays a lean combustion in the first stage, in the
following stages methane is added into the
combustion chamber (lean-lean combustion). An
improvement of the NOx emissions by up to a factor
1.
1400
Temperature [ C]
1300
1200
1100
1000
ACKNOWLEDGEMENTS
The authors gratefully acknowledge the financial
contribution of the Commission of the European Union
within the Copernicus project no. ERBIC 15 CT 960720.
The fruitful discussions with the project partners J.-M.
Samaniego and B. Labegorre from Air Liquide S. A., Paris
and S. Zhdanok from Chemical Physics Technologies,
Minsk are also gratefully acknowledged.
The authors also thank the following manufacturers and
suppliers who performed research activities on hightemperature resistant materials and provided porous
materials and structures for the experiments: IABG,
Germany; Fraunhofer Gesellschaft IKTS, Germany.
900
20
30
40
50
60
70
80
90
100
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