Next Generation, UltraBlue Burner Installation Utilizing CO Control System

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Next Generation, UltraBlue Burner Installation
Utilizing CO Control System

• Case Study

2
Project Description

• Texas Refinery Site
• Low Sulfur Fuels Expansion Project
• New Furnace Installation
• Startup Date August 2003

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Emissions Drivers

• New TCEQ requirements for NOx yielded permitted
  limits of 0.02 lb/MMBtu(HHV)

4
Callidus Burner Technology

• Callidus UltraBlue Burner(CUB)
• Developed in the year 2000 for application in
  Houston/Galveston area
• Jointly developed by Callidus/ExxonMobil/TIAX
  utilizing DOE funding
• Technology has been installed in over 70 furnaces

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NOx Reduction with Internal Flue Gas
Recirculation
Flue Gas
Recycle Gas
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Staged Gas
CUB Flue Gas Recirculation
Tip
Primary Gas
Inert Flue Gas
Tile
Refractory Floor
Combustion Air
Fuel Gas
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UltraBlue? Technology
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Control Using CO and Draft
Actuator
CO Analyzer
O2 Analyzer
Draft
BSI
Control addition to DCS
Heater Limits
Registers
Courtesy Bambeck Systems
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Across-Stack CO Analyzer(Bambeck Systems)

• Source

Receiver
Purge Blower
High Speed Chopper
Flue Gas from Burners
Correlation Cell Low Speed Chopper
Air
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CO Control vs. O2

• 1. Controls directly on PV of concern direct
  drive CO control. The predecessor of
  combustibles.
• 2. Across-the-stack measurement of CO. Catches
  the worst burner in heater. O2 is a single point
  measurement.
• 3. High Sensitivity 0 to 0.1 (1000 ppm). CO
  is ten to fifty times more sensitive than
  Combustibles.
• 4. Fast speed of response ( 1/7 of a second).
  Detects and controls CO production before
  problems occur.
• 5. Tighter control. CO Control produces smother
  O2 variations.
• 6. Air leakage is not significant effect on CO.
  Leakage is a problem with O2 measurement.

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Test Furnace Details

• Vertical Cylindrical Furnace 13 Dia x 36 tall
• Two Burners Installed and Fired Simultaneously
• Natural Draft
• Simulated Refinery Gas

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CUB Burners Firing in Test Furnace
Low Fire
High Fire
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Test Furnace Data
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Refinery Furnace Details

• Vertical Cylindrical
• Tube Circle Diameter 18-8
• Radiant Section Height 50
• Number of Burners 8
• Burner Circle Diameter 8-10
• Space Between Burner Tile 9
• Cross Sectional Heat Density 385,000 Btu/hr/ft3
• Bridgewall Temperature 1490 F
• Natural Draft

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Conclusions

• NOx Emissions in Test Furnace Approximately
  Matched Field Numbers
• NOx and CO Permitted Levels Met in the Field
• Burner/CO System Operating with Stability
• Burner/CO System Dramatically Reduces NOx