Texas Technology Showcase: Abstracts on Low NOx

2006 Texas Technology Showcase

9/7/06 Abstracts on Low NOx

Session Number	Paper Title	Authors/Contact Info	Paper Number	Short Summary
10	High Heat Density Applications of Next Generation Ultra Low NOx Burners	Galen Coupe – Shell Global Solutions Kurt Kraus Callidus Technologies	13	To maximize furnace capacity, many Ultra Low NOx burner applications require placing burners in compact, high –density arrangements. Successfully accommodating tight burner layouts require understanding and responding to field conditions with a flexible, robust and versatile burner platform. Application of lessons learned from case studies involving field experimentation coupled with computational fluid dynamic modeling and comprehensive multi-burner performance testing are essential to delivering the burners’ fullest performance.
10	Plant-wide NOx Reduction Strategies	C. Baukal, T.Webster & D. Waibel – John Zink Co., LLC; R.G. Kunz – RGK Environmental Consulting, LLC; E. Shepherd, Chevron Global Refining, Richmond, CA	6	This paper will explore the various NOx reduction methods, with a particular focus on combustion modifications, and the factors that should be considered when developing a plant-wide emissions strategy. Some actual case studies will be presented including one project at the Chevron Richmond refinery that employed a combination of work on the plant’s boilers, ultra low NOx burners on some heaters, and limited application of SCRs and another project involving a gas co-gen facility that used a combination of gas turbine modifications in conjunction with low NOx duct burners to avoid an SCR.
10	Advancements in Gas Turbine Dry Low NOx Combustion Systems	Joseph V. Citeno – GE Energy David M. Havlik – Dow Chemical	15	In an effort to meet stricter emissions regulations in the Houston-Galveston-Brazoria area, Dow Chemical and GE Energy have teamed up to install the next generation for GE’s Dry Low NOx combustion system. The intent of this presentation is to highlight some of the key features and benefits of this next generation Dry Low NOx combustion system and some of the innovative approaches that are being used to reduce emissions and ensure total gas turbine system reliability.
14	NOx Reduction from Implementing CO Based Combustion Control—A Case Study	Mike Brown - Bambeck Systems Gerald Holmes - Valero Energy	1	A case study of a process heater retrofitted with CO based combustion control at Valero’s Texas City refinery. This project provides the ideal opportunity to examine and quantify the benefits of NOx reductions made available by applying the technology to this heater. We will review the heater characteristics prior to installation, provide an explanation of the technology implemented, and detail the resultant performance benefits. In addition to the emissions reductions, we will see improved heater efficiency and the associated savings.
14	Efficient Lean Premix Emissions Solutions for the HGA	Fred McMann – North American Manufacturing Terry Welsh Shintech	12	Large scale lean premix combustion technology continues to be applied to thermal processes in Houston, Texas. Lean premix based combustion systems have proven to be capable of achieving the stringent HGA requirements with NOx production operating below the 0.01 1b/MMBtu target without sacrificing other emissions performance. Two different types of applications will be presented: a low temperature drying kiln for gypsum board and multiple water tube boilers at Shintech, a petrochemical plant. These two application types illustrate the flexibility of lean premix based combustion systems, operating both a low temperature process while achieving low CO emissions in addition to the ultra low NOx emissions and operating in a standard boiler application with similar emission performance over a 6.5:1 turndown. Startup benefits such as short outages for burner retrofit and rapid compliance with required emissions levels have been experienced. In the past, system acoustical issues have played havoc with Ultra Low NOx burner operation. Here in the HGA, harmonics ranging from 1 Hz - 250 Hz have been successfully mitigated without entering the boiler after startup. Longer term benefits such as consistent low emissions and efficient performance have been achieved by using repeatable very low DP measuring devices, exact control of flows at over 20 points and using a minimum of excess air and/or FGR. Documented results showing efficient operation with minimum maintenance over years of operation will be discussed.
14	Optimization of Low NOx Burner Installation through Simulation	Hossam Metwally – Fluent Inc.	11	Because of ozone non-attainment in the Houston-Galveston area, local refiners and petrochemical companies are under increasing pressure to reduce NOx output. With the high expense of selective catalytic reduction (SCR) systems, installation of low NOx burners in process furnaces has become increasing popular. Unfortunately, low NOx burners generally cannot simply replace older burners in the same location within a furnace, because flame shape and heat transfer behavior are impacted by the higher performance. Burner spacing, flame length, flame interaction, and the CO/NOx trade-off must all be taken into account, requiring the furnace to be engineered holistically to optimize both low pollutant and heat transfer characteristics. This presentation will cover two case studies showing how three-dimensional simulation was used to optimize low NOx burner retrofit projects, inexpensively resolving flame rollover problems that would have resulted with a simple burner replacement approach. This saved money in two ways for the operator – providing the opportunity to sell NOx credits, and avoiding a lengthy and expensive trial and error approach to eliminate flame rollover.
18	Plant-wide NOx Reduction Strategies	C. Baukal, T.Webster & D. Waibel – John Zink Co., LLC, Tulsa, Ok R.G. Kunz – RGK Environmental Consulting, LLC, Hillsborough, NC E. Shepherd and J. Seebold, Chevron Global Refining, Richmond, CA	6	This paper will explore the various NOx reduction methods, with a particular focus on combustion modifications, and the factors that should be considered when developing a plant-wide emissions strategy. Some actual case studies will be presented including one project at the Chevron Richmond refinery that employed a combination of work on the plant’s boilers, ultra low NOx burners on some heaters, and limited application of SCRs and another project involving a gas co-gen facility that used a combination of gas turbine modifications in conjunction with low NOx duct burners to avoid an SCR.
18	Affordable Low NOx Burner Retrofits – Valero Refining Applications	Scott D. Reed – Zeeco	8	In this presentation, Zeeco will provide an overview of applications that include multiple varieties of fired heaters for various services within the Valero refineries. Applications include cabin, vertical cylindrical, natural draft, and forced draft air preheat service. Tools utilized to ensure a successful retrofit to low NOx burners will be shared as well as field performance emission results and lessons learned.