Energy Saving and Low NOx Combustion Systems for
Energy Saving and Low NOx Combustion Systems for
Energy Saving and Low NOx Combustion Systems for
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© 2012, WS<br />
<strong>Energy</strong> Efficiency in Thai Industries, 16/10/2012<br />
<strong>Energy</strong> <strong>Saving</strong> <strong>and</strong> <strong>Low</strong> <strong>NOx</strong><br />
<strong>Combustion</strong> <strong>Systems</strong> <strong>for</strong> Industrial<br />
Furnaces<br />
Klaus Läpple<br />
WS – Wärmeprozesstechnik GmbH<br />
Germany<br />
www.FLOX.com
Global presence <strong>and</strong> worldwide service<br />
Headquarter in Germany<br />
Distributor in Thail<strong>and</strong><br />
Further representatives in:<br />
- USA, Lorain, Ohio / - China, Shanghai / - Korea / - Japan / - Czech Republic /<br />
- France, Paris / - Italy, Torino / - Spain, Bilbao / - Brazil, Sao Paulo / - Russia,<br />
Moskau
How to fight high energy prices<br />
Source: DOE, commercial prices<br />
• Use the hot exhaust gases to<br />
preheat the combustion air<br />
• Heat unheated preheat zone<br />
• Use the exhaust gases to heat other<br />
processes<br />
• Oxy-fuel (recommended only <strong>for</strong> special<br />
conditions, not <strong>for</strong> general furnace<br />
applications)<br />
• Switch to alternative fuels
Efficiency of fuel fired furnaces<br />
� Many furnaces are operating at temperatures in a range<br />
from 800°C to 1.300°C<br />
� Exhaust gas temperature are often above 1.000°C<br />
� This means waste gas losses of > 50% without heat<br />
recovery<br />
heating system<br />
comparison<br />
natural<br />
gas,<br />
no air<br />
preheat<br />
natural<br />
gas,<br />
st<strong>and</strong>.<br />
preheat<br />
natural<br />
gas,<br />
opt.<br />
preheat<br />
* 1000°C furnace temperature; ** german energy mix (Source: BMWi); *** O2: 0,5 kWh el / m 3<br />
natural<br />
gas,<br />
O 2 ***<br />
electric<br />
heating<br />
waste gas losses* 50% 30% 15% 15% -<br />
losses in the power plant - - - 7% 58%<br />
primary energy** (norm.) 2 1,4 1,2 1,3 2,4<br />
CO 2 -emissions (norm.) 2 1,4 1,2 1,6 2,6
Solutions <strong>for</strong> air - preheat<br />
Self - recuperative burners: Regenerative burners:<br />
Main goals by WS:<br />
• High efficiency by minimizing waste gas losses<br />
• Minimal <strong>NOx</strong> emissions<br />
• Usability / reliability<br />
• <strong>Low</strong> cost of ownership <strong>and</strong> long lasting customer relationship
efficiency<br />
Efficiency<br />
0.75<br />
0.5<br />
0.25<br />
0<br />
1<br />
482 932 1382 1832 2282°F 2732<br />
REGEMAT ®<br />
� = 1<br />
0.2<br />
� = 0<br />
0.8<br />
0.6<br />
REKUMAT ® 0.4<br />
central heat exchanger<br />
rel. air preheat<br />
air preheat temperature<br />
� ~ exhaust temperature<br />
0<br />
0 250 500 750 1000 1250°C 1500<br />
exhaust temperature<br />
(prior to the heat exchanger)
Heat exchanger per<strong>for</strong>mance
Self recuperative burner – Rekumat C150
Recuperative Gap flow burner – Rekumat S200
Self regenerative burner - Regemat 250
Self regenerative burner – Regemat 350
Radiant tube designs<br />
„old“ designs „new“ designs
Double P tube with Rekumat M250
Continous strip lines
Strip line furnace<br />
equipped with WS - SISIC radiant tubes<br />
- internal - view -
Fuel cost estimate of a large strip line<br />
furnace (500.000 ton/year, € 5 / GJ)<br />
Strip target temp.: 800°C<br />
Heat to load: 0.50 GJ/t<br />
well tuned regenerative system: 0.70 GJ/t (€1.75 Mio.)<br />
well tuned recuperative system: 0.85 GJ/t (€2.125 Mio)<br />
st<strong>and</strong>ard system (plug in recu): 1 GJ/t (€2.5 Mio.)<br />
poor system (no heat recovery): >1.4 GJ/t (>€3.5 Mio.)
Nox – reduction / FLOX® vs. Flame Mode<br />
Rekumat <strong>and</strong> Regemat burner<br />
< 850°C = Flame Mode<br />
> 850°C = FLOX® - Mode<br />
Advantage:<br />
• drastic <strong>NOx</strong> - reduction<br />
(more than 90 %)<br />
• Thermal stress of the burner front<br />
is minimized<br />
• improved temperature uni<strong>for</strong>mity<br />
reacting fuel & air<br />
FLOX® is a registered trademark by WS<br />
fuel<br />
air
Conclusion<br />
The role of energy conservation will gain more importance in<br />
the future<br />
<strong>Combustion</strong> air preheat is the most effective method to<br />
increase efficiency<br />
Flameless oxidation enables low <strong>NOx</strong> <strong>and</strong> high efficiency<br />
Close cooperation of supplier <strong>and</strong> customer is essential<br />
There is a lot to do <strong>for</strong> R&D
... more in<strong>for</strong>mations ? www.FLOX.com<br />
Thank you, <strong>for</strong> your attention !
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