Method for generating combustion by means of a burner assembly and burner assembly therefore
09651248 · 2017-05-16
Assignee
- L'Air Liquide Société Anonyme Pour L'Étude Et L'Exploitation Des Procedes Georges Claude (Paris, FR)
Inventors
- Nicolas Docquier (Philadelphia, PA, US)
- Robert Kalcevic (Versailles, FR)
- Magnus Mortberg (Frankfurt am Main, DE)
- Remi Pierre Tsiava (Saint Germain-les-Corbeil, FR)
Cpc classification
F23D14/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23M2900/05021
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D2900/00013
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D14/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F23D14/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A method for generating combustion by means of a burner assembly and corresponding burner assembly are disclosed. The burner assembly comprises a refractory block, a fuel supply system and an oxidant supply system. The refractory block defines along one plane P1 at least one fuel passageway extending from a fuel inlet port to a fuel outlet port, and along a second plane P2 at least one oxidant passageway extending from an oxidant inlet port to an oxidant outlet port, said first and second planes intersecting along a line that is beyond said outlet ports, said oxidant supply system comprising a pair of oxidant supply means, an inlet of the inner oxidant supply means being connected to a source of a first oxidant having a first oxygen concentration and an inlet of the concentric outer oxidant supply means being connected to a source of a second oxidant having a second oxygen concentration, the method having improved flexibility in oxygen concentration in the oxidant.
Claims
1. A method of generating combustion by means of a burner assembly comprising a refractory block, a fuel supply system and an oxidant supply system including an inner oxidant supply and an outer oxidant supply, the oxidant being supplied comprising first and second oxidants, wherein: multiple fuel passageways extend along a first plane through the refractory block from a fuel inlet port to a fuel outlet port, multiple oxidant passageways extend through the refractory block from an oxidant inlet port to an oxidant outlet port, each of the oxidant passageways comprising an upstream portion extending from said oxygen inlet port along a plane, each of the oxidant passageways comprising a downstream portion terminating at said oxygen outlet port and extending along a second plane that intersects said first plane along a line beyond said outlet ports, said upstream portions are angled to respective ones of said downstream portions so as to form a bend in each of said oxidant passageways, said inner oxidant supply comprising multiple straight oxidant lances each one of which is concentrically disposed within a respective one of said upstream portions and extends to a point in between a respective one of said bends and said oxidant outlet port, said oxidant lances fluidly communicating with a source of a first oxidant, said outer oxidant supply comprising multiple spaces each of which is defined by an outer surfaces of a respective one of said oxidant lances and an inner surface of a respective one of said oxidant passageways, said spaces fluidly communicate with a source of a second oxidant, the method comprising the steps of: (a) selectively supplying the lances with a first oxidant, said first oxidant containing at least 70% vol. of oxygen; (b) selectively supplying the spaces with a second oxidant, said second oxidant being air; (c) melting a charge in a furnace using the burner assembly with heat from the combustion of oxidant and the fuel; and (d) varying the ratio between said first and second oxidants being supplied to the lances and spaces, respectively, said step of varying the ratio comprising: supplying oxidant to the lances and spaces at the start of a melting phase such that at least 50% of the oxidant is supplied as the first oxidant to said lances for combustion with the fuel downstream of the burner assembly and not the second oxidant, at the end of the melting phase, a ratio between a flow of the second oxidant through the outer oxidant supply and a flow of the first oxidant through the inner oxidant supply is increased; and during a fining phase following the melting phase, the burner assembly is operated so that more than 50% vol. of the oxidant supplied by the burner assembly is second oxidant provided by the outer oxidant supply.
2. The method of claim 1, wherein portions of said upstream portions between said bends and said oxidant oulet port define respective mixing chambers for pre-mixing said first oxidant with said second oxidant when said first oxidant is supplied to said lances at the same time second oxidant is supplied to said spaces.
3. The method of claim 1, wherein the oxidant passageways are positioned above the fuel passageways in the refractory block.
4. The method of claim 1, whereby said oxidant supply system further comprises means controlling the flow rate into said oxidant passageway of at least one of said first and second oxidants.
5. The method of claim 1, wherein the or each said fuel passageway comprises a fuel injector nozzle having a clearance surrounding it, and wherein means are provided which bleed a portion of oxidant from said oxidant supply system into said clearance of said fuel passageway, said oxidant bleed means being configured to feed its bled-off oxidant in the form of a shield surrounding the outside of said fuel injector nozzle.
6. The method of claim 5, wherein said oxidant bleed means comprises a first connexion between the inner oxidant supply means and said clearance of said fuel passageway which bleeds a portion of the first oxidant into said clearance of said fuel passageway when said oxidant supply system supplies first oxidant to the outlet port of said at least one oxidant passageway and whereby said oxidant bleed means further comprises a second connexion between the outer oxidant supply means and said clearance of said fuel passageway which bleeds a portion of the second oxidant into said clearance of said fuel passageway when said oxidant supply system supplies second oxidant to the outlet port of said at least one oxidant passageway.
7. The method of claim 1, wherein said fuel comprises a hydrocarbon fuel comprising natural gas or heavy fuel oil or pulverized solid hydrocarbon fuel.
8. The method of claim 1, wherein heat from the combustion is used in a melting process or melting furnace.
9. The method of claim 1, wherein heat from the combustion is used to preheat a ladle.
10. The method of claim 1, whereby heat is provided by the one or more burner assemblies by combusting fuel with oxidant, said process including: an initial heating up phase, a subsequent temperature equilibrating phase, and whereby: during the heating up phase, the one or more burner assemblies are operated so that more than 50% vol. is first oxidant provided by the inner oxidant supply, the inlet of which is connected to a source of the first oxidant, and during the temperature equilibrating phase, the one or more burner assemblies are operated so that more than 50% vol. and more preferably the totality of the oxidant is second oxidant provided by the outer oxidant supply, the inlet of which is connected to a source of the second oxidant.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1) The present invention will now be described by way of example and with reference to the accompanying drawings, in which:
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DETAILED DESCRIPTION OF THE INVENTION
(11) In
(12) Referring to the drawings, a burner assembly 10 comprises a refractory block 12 through which are defined a series of passageways. The refractory block 12 may be a separate block or assembly of blocks, for example of ceramic. It may be integrated into a wall of a furnace.
(13) Attached to the back of the refractory block 12 is a mounting bracket 14, a fuel supply system 18 and an oxidant supply system 20.
(14) In the illustrated embodiment, the mounting bracket also supports an igniter 16. The presence of an igniter is optional, and may in particular not be required in furnaces, such as glass-melting furnaces, in which the temperature of the furnace atmosphere is sufficiently high to cause spontaneous ignition of the fuel with the oxidant.
(15) The igniter 16 is configured to supply a pilot light/ignition flame through an igniter passageway 22 to a pilot jet orifice 24 on a furnace-facing front face 26 of the refractory block 12.
(16) In the illustrated embodiment, the mounting bracket further supports a flame detector 50, typically a UV flame detector which is capable of detecting the presence or absence of a flame downstream of the burner through a separate flame detection passageway 52 through the refractory block 12. The presence of such a flame detector is likewise optional.
(17) The fuel supply system 18 includes a fuel inlet port 28 for introducing fuel into one or several fuel passageways defined through the refractory block 12.
(18) In the non-limiting embodiment illustrated in
(19) In the non-limiting embodiment illustrated in
(20) The term fuel according to this invention includes hydrocarbon fuel in liquid or gaseous form. This means, for example, methane, natural gas, propane, atomized oil or the like (either in gaseous or liquid form) at either room temperature (25 DEG C) or in preheated form. The fuel may also be a pulverized solid fuel.
(21) Alternative embodiments may comprise several fuel passages with associated atomizers or solid fuel lances, a single fuel passage or a combination of one or more liquid fuel passages with one or more gaseous fuel passages, etc. whereby when several fuel passages are present, these are advantageously situated on the same plane P1.
(22) Turning now to the oxidant supply system 20, an oxidant inlet port 34 is positioned on the mounting bracket 14 above the fuel inlet port 28 and is configured to be connected to an oxidant source (referred to hereafter as second oxidant source) for the supply of an oxidant (referred to hereafter as second oxidant) for example in the form of air.
(23) The inlet pipe 34 branches outwards in Y form into a pair of reduced diameter branch pipes 40A, 40B that turn back forwards just to the rear side of the mounting bracket 14, through which they pass and lead through a rear face 44 of the refractory block 12 into a pair of oxidant passageways 42A, 42B defined through the refractory block 12 from its rear face 44 to its front face 26.
(24) The oxidant passageways 42A, 42B pass approximately halfway through the refractory block 12 along respective centrelines co-planar with the centreline of inlet pipe 34 and therefore also on a plane substantially parallel to plane P1 of the fuel passageway 28B, respectively fuel passageways 28A, 28B and 28C.
(25) At a point 60 about halfway through the refractory block 12, the oxidant passageways are angled downwards and exit the front face 26 of the refractory block 12 through respective oxidant outlet ports 46A, 46B. The downwards angle of the oxidant outlet port centrelines lies along a plane P2 that intersects the plane P1 of the fuel passageways 28A, 28B, 28C at a point that is spaced apart from the front face 26 of the refractory block 12. This ensures that the oxidant supply will meet the fuel supply at a point that is beyond their respective outlet ports 28A, 28B, 28C, 46A, 46B. The plane P2 is represented in the drawings by the drop in the line B-B to the left of the point 60 in
(26) There is a tapping out of the large bore pipe 34, in the form of an oxidant bleed pipe 48, which is configured to bleed a portion of oxidant out of oxidant pipe 34 and down to the fuel box 18 (also known as fuel block or fuel supply system). The bled-off oxidant is then used to surround the injection of atomized liquid fuel or gaseous fuel or pulverized solid fuel as it comes out of the fuel passageway 28B, respectively out of the fuel passageways 28A, 28B, 28C, so as to maximise flexibility of operation and flame stability.
(27) The oxidant supply system further comprises an additional and separate oxidant supply means, configured to supply oxidant from a further oxidant source (referred to hereafter as first oxidant source) along the same oxidant supply passageways 42A, 42B as does the second oxidant supply 34, 40A, 40B.
(28) The apparatus used to deliver the separate first oxidant supply (the oxidant supplied by the first oxidant source being hereafter referred to as first oxidant and having a higher oxygen content than the second oxidant) is in the form of an inner oxidant lance 58A, 58B, located one in each oxidant branch pipe 40A, 40B.
(29) According to the illustrated embodiments, in the installed position, the oxidant lances 58A, 58B are straight and extend further beyond the point 60 in the oxidant passage 42A, 42B at which the oxidant passage 42A, 42B is angled downwards. The outlet of each of the oxidant lances 58A, 58B is thus substantially concentric along at least part of the length of their associated oxidant passages 42A, 42B, but, due to the downwards angle, the outlets of the oxidant lances 58A, 58B are higher up in those passageways 42A, 42B. This is best seen with particular reference to
(30) Such an embodiment, in which the oxidant lances 58A and 58B are only minimally directed downwards, is particularly useful in furnaces containing a charge, situated below the burner, which is susceptible to unwanted oxidation. In that case, when the burner according to the invention injects only the second oxidant having a low oxygen content, such as air, into the furnace, said second oxidant is injected downwards towards the charge, thereby increasing convective heat transfer to the charge. As this second oxidant has only a low oxygen concentration, there is little or no oxidation of the charge. When, on the other hand, only the first oxidant, which has a high oxygen content, is injected into the furnace, oxidation of the charge by the oxidant is limited or prevented as the first oxidant is only slightly inclined towards the charge and there is little or no direct contact between the first oxidant and the charge, the first oxidant being entirely or almost entirely consumed during combustion of the fuel before reaching the charge. When a combination of first and second oxidant is injected, the overall oxygen concentration of the oxidant is situated between the oxygen concentration of the first oxidant and the oxygen concentration of the second oxidant, and the overall injection direction of the oxidant is likewise in between the injection direction when only the first oxidant is injected and the injection direction when only the second oxidant is injected. It will be appreciated that, when the furnace contains a charge which is not or only slightly susceptible to unwanted oxidation, both the oxidant passages and the oxidant lances may be directed (downwards) towards the charge in order to increase convective heat transfer.
(31) The oxidant lances 58A, 58B stop short of their respective outlets of the oxidant passageways 42A, 42B and the region of the oxidant passageways 42A, 42B that lies in between the ends of the oxidant lances 58A, 58B and those outlets defines respective pre-mixing chambers 42C, 42D. The pre-mixing chambers 42C, 42D serve to homogenise the mixture between the two separately drawn oxidants prior to discharge, in the event that both oxidant supplies might be in use simultaneously.
(32) The supply side of each oxidant lance 58A, 58B is connected to an oxidant supply means 62 that is separated from the oxidant supply that feeds into the large bore oxidant inlet port 34. The connection to the separate oxidant supply is in the form of a tubular spigot 64 that joins a log manifold 66 in its centre, the log manifold 66 spanning horizontally over the branch pipes 40A, 40B.
(33) The oxidant lances 58A, 58B themselves are in the form of L-shaped tubes that drop down from the end regions of the log-manifold 66 and extend into the branch pipes 40A, 40B at the point at which those branch pipes 40A, 40B straighten up and go into the oxidant passageways 42A, 42B. In this manner, the oxidant lances 58A, 58B need only one elbow so as to turn along the oxidant passageways 42A, 42B.
(34) There is a narrow bore pipe 68 tapped off the log manifold 66, which drops down into the fuel box 18. In similar fashion to the oxidant bleed pipe 48 that is taken out of the large bore pipe 34, this narrow bore pipe is configured to bleed a portion of the separate first oxidant supply out of the log manifold down to the fuel box 18. As with the other bleed pipe 48, the oxidant bled-off by the narrow bore bleed pipe is also used to surround the injection of atomized liquid fuel or of gaseous fuel as it comes out of respectively the fuel passageway 28B or the fuel passageways 28A, 28B, 28C, so as to improve flame stability and operation flexibility.
(35) By providing an oxidant bleed pipe 48, 68 off each oxidant supply, the structure of the preferred embodiment ensures that there is always a supply of bled-off oxidant around the gaseous fuel injection for flame stabilisation, regardless of which oxidant supply is being used, either alone or in combination with the other. Flame stabilisation is in this case achieved by injection of some of an oxidant around the fuel injector and the remainder at some distance from the fuel injector.
(36) The method of the invention using this specific design of the burner permits:
(37) (a) to vary the oxygen the oxygen content of the oxidant by controlling the ratio between the first and second oxidant,
(38) (b) to control the injection velocities of the oxidant, regardless of whether only the first, only the second or a combination of both oxidants is injected,
(39) (c) to obtain wide, and consequently more homogeneous, flame coverage of the charge due to the multiple oxidant passageways, and
(40) (d) to ensure low intensity combustion reaction that gives very low emissions of oxides of nitrogen (NOx) for this type of burner design.
(41) The NOx emissions are minimal when the oxidant consists essentially of pure oxygen, but tend to rise as oxygen levels in the oxidant decrease and nitrogen levels correspondingly increase.
(42) The present invention provides the physical structure for two separate supplies of oxidant into a furnace and enables flexible use of those oxidants, either completely one or the other, or any mixture between the two. One oxidant may for example be air and the other oxygen, such that operation can take place from 21% oxygen concentration (air only) through to 100% oxygen or substantially 100% oxygen.
(43) Aluminium use has increased more than any other metal in recent years and a growth rate greater than that of the other metals is also expected for many years to come. Today nearly 30% of the world production of aluminium results from recycling.
(44) Secondary aluminium melting is done in reverbatory or rotary furnaces and the particularly high price of fuel, in particular in Europe and Japan, makes the use of oxygen combustion increasingly interesting. Indeed, the ever-higher price of fuel justifies more and more the use of oxygen or air enriched with oxygen in melting furnaces, in order to decrease the energy consumption and related costs.
(45) In accordance with the present invention, a batch aluminium smelting process, and in particular a secondary aluminium smelting process may be conducted as follows.
(46) The smelting process is conducted in a furnace equipped with one or more burner assemblies according to the invention.
(47) The first oxidant is an oxygen-rich gas having an oxygen content of at least 70% vol., and preferably at least 90% vol. and more preferably at least 95% vol.
(48) The second oxidant has an oxygen content of not more than 25% vol. and is preferably air.
(49) Said process includes the following phases: a charging phase, a melting phase, a fining phase and a discharge phase.
(50) Different requirements of temperature, energy, etc. apply to the melting and maintenance phases. The most power or energy (per weight of material) is required during the melting phase, whereas less power or energy (per weight of material) is required during the fining phase.
(51) In accordance with the present invention, at the start of the melting phase, the one or more burner assemblies are operated so that the oxidant consists mainly (i.e. for more than 50% vol. and advantageously for more than 75% by volume) of the first oxidant. In other words, the main portion (more than 50% vol. and advantageously for more than 75% by volume) of the oxidant is provided by the inner oxidant supply means, the inlet of which is connected to a source of the first oxidant. Preferably the oxidant consists entirely of the first oxidant. In other words, the entirety of the oxidant is provided by said inner oxidant supply means supplying the oxygen-rich first oxidant gas.
(52) At the end of the melting phase, the oxygen content of the oxidant is decreased by increasing the portion of the oxidant which consists of the second oxidant (i.e. air). This is achieved by increasing the ratio between (a) the supply (or flow or flow rate) of the second oxidant through the outer oxidant supply means and (b) the supply (or flow or flow rate) of the first oxidant through the inner oxidant supply means. This increase can be a stepwise increase or a gradual or progressive increase. Use is made thereto of the means of the burner assembly for controlling the respective flows. A gradual increase is preferable for reasons of flame stability.
(53) During the fining phase, the one or more burner assemblies are operated so that the oxidant consists mainly (i.e. for more than 50% vol. and advantageously for more than 75% by volume) of the second oxidant, i.e. air. In other words, the main portion (more than 50% vol. and advantageously for more than 75% by volume) of the oxidant is provided by the outer oxidant supply means, the inlet of which is connected to a source of the second oxidant/air. During the fining phase, the oxidant preferably consists entirely of the second oxidant. In other words, the entirety of the oxidant is air provided by said outer oxidant supply means supplying the second oxidant which has a relatively low oxygen content, in particular air.
(54) When the raw material contains combustible matter, for example lacquers, paint and oil present in scrap metal, this combustible matter may act as fuel in the early stages of the melting phase. During said early stages of the melting phase, the ratio between, on the one hand, the amount (flow or flow rate) of fuel supplied by the one or more burner assemblies through the one or more fuel outlet ports and, on the other hand, the amount (flow of flow rate) of oxygen supplied as part of the oxidant through the one or more oxidant outlet ports may temporarily be reduced. In this manner the fuel contribution of the raw material is taken into account.
(55) When using the above method of the invention, the temperature rapidly increases at the start of the melting phase and melting occurs more rapidly. Energy efficiency is also increased due to the highly radiative flame and the consequent high radiative energy transfer to the charge.
(56) During the fining phase, the aluminium is in molten form and at high temperature, which results in an increased risk of oxidation and consequent increased risk of loss of material formation of dross.
(57) The risk of loss of material can be reduced by creating a substantially homogeneous or uniform temperature profile of the atmosphere above the charge along the furnace.
(58) In practice, a reduction in the loss of material during the fining stage is achieved by operating, during the fining stage, the one or more burner assemblies so that the oxidant consists mainly and preferably entirely of air. This results in a higher momentum (I) to power (P) ratio of the one or more burner assemblies as illustrated by line 2 in
(59) As the energy requirement is lower during the fining phase, air can be used as the oxidant during this phase without reducing the overall efficiency of the melting process.
(60) The use of air as oxidant during the fining phase entails the presence of nitrogen in the furnace atmosphere at this stage. However, this does not lead to substantial NOx formation due to the lower temperature of the air-fuel flame, as compared to the significantly higher temperatures of oxy-fuel flames.
(61) Although the process of the invention has been described here above with respect to an aluminium melting process, it can also advantageously be used in other melting processes comprising a melting and a fining phase, such as, for example, glass melting processes, and in particular batch glass melting processes.
(62) In accordance with the present invention, a ladle preheating process may be conducted as follows: an initial phase with the objective of heating up the ladle vessel to an elevated temperature. During this phase the oxygen content of the oxidiser is chosen to be high in order to increase the energy intensity of the process and consequently reducing the time necessary for the process step. A second phase, following the initial phase, is the holding phase in which the ladle vessel is maintained at an elevated temperature, allowing an uniform temperature distribution throughout the refractory material. During this second phase, the energy input is reduced in order to only maintain the desired temperature. Depending on the variable costs of fuel, oxygen and air the optimum mixture of oxygen and air can be chosen in order to obtain the lowest possible overall operational costs.
(63) In accordance with the present invention, at the start of the initial phase, the one or more burner assemblies are operated so that the oxidant consists mainly (i.e. for more than 50% vol and advantageously for more than 75% by volume) of the first oxidant. In other words, the main portion (more than 50% vol and advantageously for more than 75% by volume) of the oxidant is provided by the inner oxidant supply means, the inlet of which is connected to a source of the first oxidant. Preferably the oxidant consists entirely of the first oxidant. In other words, the entirety of the oxidant is provided by said inner oxidant supply means supplying the oxygen-rich first oxidant gas, thereby accelerating the preheating of the ladle vessel.
(64) It will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. Thus, the present invention is not intended to be limited to the specific embodiments in the examples given above.
(65) During the subsequent temperature equilibrating phase which has lower energy requirements, the one or more burner assemblies are operated so that the oxidant consists mainly (i.e. for more than 50% vol. and advantageously for more than 75% by volume) of the second oxidant, i.e. air. In other words, the main portion (more than 50% vol. and advantageously for more than 75% by volume) of the oxidant is provided by the outer oxidant supply means, the inlet of which is connected to a source of the second oxidant/air. During this phase, the oxidant preferably consists entirely of the second oxidant. In other words, the entirety of the oxidant is air provided by said outer oxidant supply means supplying the second oxidant which has a relatively low oxygen content, in particular air.
(66) The present invention therefore allows a user to better adapt the oxidant composition to the cycle requirements, such as for example to furnace load or to the power requirements in the melting cycle. In addition or in the alternative, the furnace can also be optimized to the instantaneous market price of oxidants and fuel, e.g. 100% oxygen when the fuel is expensive and 100% air when fuel is cheap, or any mixture between the two.
(67) It is also of note that the structure disclosed herein is permanently in place and therefore does not need physical connections to be remade so as to swap between the oxidants it can supply and a stepwise swap or progressive change can therefore be made without interrupting the operation of the burner assembly.