Facts At Your Fingertips
Industrial Gas Burners
Department Editor: Scott Jenkins
fombustion in industrial burn-
ers is a critical operation in the
‘chemical process industries
(CP) for supplying thermal energy
‘for heat transfer, fluid heating, steam
generation, distilation, endothermic
chemical reactions, metal melting and
others. Burners are mechanical devio-
es utiized for mixing proper quantities
of fuel and air, and also for maintaining
a stable flame inside fred equipment.
Included here are brief descriptions of
key aspects of industrial bumer com-
ponents and operation,
Fuel-air mix
Industrial process burners can be
Classified in several ways, including
the type of fusl-air mixing invoked
(diffusion or premixing)
Raw-gas bumers are used for
most appiications. In these burners,
the fuel gas passes through orifices
in the gas tip and is injected directly
into the combustion zone, where it
mixes with air. A stabilizer cone is lo-
cated just below the gas to improve
combustion stability, These burners
are suitable for mounting in plenum
chambers (the area where air enters
the burner), and can be used with
preheated combustion at.
Pre-mix burners are those in which
fuel and air are mixed prior to com-
bustion. Pre-mix bumers are some-
times used in specialized applica-
tions. In these burners, the kinetic
energy made available by the ex-
pansion of the fuel gas through the
fuel-gas orice introduces about half
of the combustion air (called primary
ait) into the Venturi mixer. This: mix-
ture then exits through a large bumer
tip, where itis mixed with the balance
of the combustion air (secondary at).
This secondary airflow enters the
bburmer through the outer, secondary
air register. Premix bumers require
less furnace draft than raw-gas burn-
ers. Premix burners can produce a
wide range of flame shapes.
Reducing NOx
Combustion operations frequently
create nitrogen oxides (NOx), spe-
Gifically NO-and NO2, which must
Fl ie Fal
be highly controlled, as they can be
harmful pollutants. Currently, three
burner configuration methods exist
for reducing nitrogen oxides in bur-
fers: staged air, staged fuel and inter-
nal fluegas recirculation combined
with staged air or staged fuel
‘Staged air burners. These types of
burners work by introducing 100% of
the fuel into the burner and only part
of the combustion air (primary air,
thus oreating a sub-stoichiometric
flame. This flame has a reduced tem-
perature and therefore inhibits NOx
formation. The flame is completed
with the addition of the secondary
air to complete the combustion pro-
‘cass. This process allows for greater
control at lower burner loads and
also accommodates a wider range
of fuels.
Staged fuel burners. This burner
method introduces 100% of the
‘combustion air into the burner and
spits the fuel supply into primary and
secondary volumes (Figure). The pri-
maty fuel mixes with the combustion
air to create a flame. As with staged
air burners, the peak flame tempera-
ture is lower, and NOx formation is
reduced. Secondary fuel is added to
‘complete the combustion process.
‘Staged fuel burners provide greater
NOx reduction, as the fuel supply
has a larger effect on NOx forma-
tion. This method is more commonly
used when a consistent fuel supply
is available.
Internal fluegas recirculation burn-
ers. This method combines either
staged air or staged fuel with internal
fluegas recirculation to help reduce
NOx formation. The best results are
obtained where internal fluegas re-
Circulation is used to dilute the fuel
gas in a staged fuel burner, creating
gas with a low calorific value.
Flame size
The size of the burner flame is an im-
portant parameter in controling the
heat transfer to tubes in the furnace
The flame size and shape should be
such that the tubes impingement of
the flame upon the tubes they are
heating is avoided.
Maximum flame diameter can be
calculated using Equation (1).
J D, (a)
Dr may = Maximum flame dia., f
L¢= Flame length, f
SVjamo = Specitic volume of flame,
feb
SVuet + ai = Specific volume of fuel
and air mixture, f9/b
Vp= Flame propagation velocity, fs
where:
Maximum burner length can be
calculated from Equation (2)
DLW,
ones, =3.14 Ye 2
The diameter of the bumer flame
should be evaluated at maximum
bumer-flame length,
Burner spacing
‘Bumer spacing is normally 2 to 5 ft, or
sufficient to provide reasonable burn-
er-to-burner clearance, as based on
‘the maximum burner-fiame diameter.
Bumer-to-tube clearance must also
be such that minimum clearance Is
based on a reasonable distance be-
tween burner outside-flame diameter
and outside diameter of the tubular
heating surfaces. 7
Editor's note: The cont peered ne olin as
adzoed tome ‘Coss ln rod Hea
Bune Petomance, Chon. Eng, At 2008, cp 44-47
ad ALHej, MH, Bune ston and Mantra,
Chem Eng, Novoriot 2014, 93 40-45
CHEMICAL ENGINEERING WWW.CHEMENGONLINECOM JULY 2016