15 DECEMBER 2012 FIROZABAD INDIA
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1 Executive Committee Meeting of the All India Glass Manufacturers Federation 15 DECEMBER 2012 FIROZABAD INDIA
2 FT BURNERS PRACTICAL APPLICATION RESULTS OF NEW GAS BURNER IN FLOAT, CONTAINER AND TABLEWARE GLASS INDUSTRY
3 Contents of Presentation Introduction and history FT burner design and operating principles FT burner design and simulation Installation Production results Benefits
4 INTRODUCTION AND HISTORY Optimized natural gas combustion process Furnace design Regenerator design Technology level Control system level Batch composition Combustion system design especially burner design
5 INTRODUCTION AND HISTORY The new situation in the world reflecting the economy and strong ecological request Increasing price of combustion oil Very strong ecological limits and higher penalties Growing interest in use of natural gas in glass furnaces NOx production Conversion from oil combustion to gas firing New and advanced burner system FLAMMATEC TM FLEX
6 INTRODUCTION AND HISTORY History of Dual Gas Injector Burners Dual gas injector burners are not a new technology and have been known since at least the 1960 s. This concept was used by Corning and had two (2) concentric pipes with two (2) separate gas streams. Dual gas injector burner was broadly used in eastern Europe since The construction was simple without any optimization. The burner required two (2) gas inlets with different pressure GAZ de France published their Twin Gas burner. A similar burner was used by Tokyo Gas in Other burner manufacturers introduced additional burners in the late 1990 s. These burners had only one (1) gas inlet with the two (2) gas streams separated inside the burner.
7 INTRODUCTION AND HISTORY History of Dual Gas Injector Burners The common feature of all of these burners is that the gas enters the burner by only one (1) pipe with the second gas stream separated inside the burner. Advantages of a new burner concept were developed for the FlammaTec burner in 2006/2007. FlammaTec utilizes a complete two (2) gas stream concept with new advanced features such as: Two (2) fully separate gas flows and control and measurement Adjustable burner nozzle Optimized burner tip Practical results confirm the newly advanced burner concept with a technical advantage.
8 FT BURNER DESIGN AND OPERATING PRINCIPLES BURNER SCHEME
9 FT BURNER DESIGN AND OPERATING PRINCIPLES BURNER SCHEME
10 FT BURNER DESIGN AND OPERATING PRINCIPLES
11 FT BURNER DESIGN AND OPERATING PRINCIPLES Underport burner
12 FT BURNER DESIGN AND SIMULATION FT Design Optimized by Computer Modeling Turbulence optimization
13 FT BURNER DESIGN AND SIMULATION FT Design Optimized by Computer Modeling Flame temperature FlammaTec burner Conventional burner
14 FT Design Optimized by Computer Modeling FlammaTec burner FT BURNER DESIGN AND SIMULATION Flame velocity Conventional burner
15 FT BURNER DESIGN AND SIMULATION FT Design Optimized by Computer Modeling Optimum burner block location
16 FT BURNER DESIGN AND SIMULATION FT Design Optimized by Computer Modeling Optimum burner block location
17 FT BURNER INSTALLATION UNDERPORT VERSION
18 FT BURNER INSTALLATION SIDEPORT VERSION
19 FT BURNER INSTALLATION
20 FT BURNER INSTALLATION
21 FT BURNER INSTALLATION Furnace type : tableware Glass type: SODA LIME Glass Pull: 100 MTPD Cullet: 23 % Total gas consumption : Heat value of gas : Combustion heat : 648 Nm3/h kcal/kg 6029 KW Old burners Melter area : 34.2 m2 Glass depth melter: 1245 mm Spec. pull : 2.92 MTPD/m2 Spec. energy consumption: MJ/kg
22 FT BURNER INSTALLATION Furnace type : tableware Glass type: SODA LIME Glass Pull: 100 MTPD Cullet: 23 % Total gas consumption : Heat value of gas : Combustion heat : 612,3 Nm3/h kcal/kg 5697 KW Flammatec burners Melter area : 34.2 m2 Glass depth melter: 1245 mm Spec. pull : 2.92 MTPD/m2 Spec. energy: MJ/kg
23 FT BURNER INSTALLATION Furnace type : container Glass type: green Pull: 251 MTPD Cullet: 53 % Total gas consumption : 1005 Nm3/h Heat value of gas : kcal/kg Combustion heat : 9550 kw Electric boosting : 1082 kw NOx: 920 mg/nm3 (8% O2) Old burners Melter area : 82.8 m2 Glass depth melter: 1150 mm Spec. pull : 3.03 MTPD/m2 Spec. energy consumption: 3.66 MJ/kg
24 FT BURNER INSTALLATION Furnace type :container Glass type: green Pull: 251 MTPD Cullet: 53 % Total gas consumption : 968 Nm3/h Heat value of gas : kcal/kg Combustion heat : 9201 kw Electric boosting : 1082 kw NOx: 650 mg/nm3 (8% O2) Flammatec burners Melter area : 82.8 m2 Glass depth melter: 1150 mm Spec. pull : 3.03 MTPD/m2 Spec. energy consumption: 3.54 MJ/kg
25 FT BURNER INSTALLATION Furnace type : Float Glass type: white Pull: 700 MTPD Cullet: 30 % Melter area : 522 m2 Glass depth melter: 1325 mm Spec. pull : 1,34 MTPD/m2 Spec. energy consumption: 5,18 MJ/kg Total gas consumption : 4300 Nm3/h Heat value of gas : kcal/kg Combustion heat : kw NOx: < 1500 mg/nm3 (8% O2)
26 FT BURNER INSTALLATION Furnace type : Float Glass type: white Pull: 650 MTPD Cullet: 25 % Melter area : 520 m2 Glass depth melter: 1250 mm Spec. pull : 1,25 MTPD/m2 Spec. energy consumption: 5,64 MJ/kg Total gas consumption : 4744 Nm3/h Heat value of gas : kcal/kg Combustion heat : kw NOx: 1950 mg/nm3 (8% O2)
27 FT BURNER INSTALLATION Furnace type : tableware Glass type: white Pull: 85 MTPD Cullet: 15 % Total gas consumption : Heat value of gas : Combustion heat : NOx : 543 Nm3/h kcal/kg 5052 kw 2375 mg/m3 (8%O2) Old burners Melter area : 53 m2 Glass depth melter: 1150 mm Spec. pull : 1.6 MTPD/m2 Spec. energy consumption 5135 MJ/kg
28 FT BURNER INSTALLATION Furnace type : tableware Glass type: white Pull: 85 MTPD Cullet: 15 % Total gas consumption : Heat value of gas : Combustion heat : Nox : 514 Nm3/h 8000 kcal/kg 4782 kw 1625 mg/m3 (8%O2) Flammatec burners Melter area : 53 m2 Glass depth melter: 1150 mm Spec. pull : 1.6 MTPD/m2 Spec. energy consumption 4861 MJ/kg
29 FT BURNER INSTALLATION Furnace type : Float Glass type: white Pull: 600 MTPD Cullet: 25 % Melter area : 465 m2 Glass depth melter: 1280 mm Spec. pull : 1,29 MTPD/m2 Spec. energy consumption: 5,62 MJ/kg Total oil consumption : Heat voile of oil : Kg/h kcal/kg
30 FT BURNER INSTALLATION Furnace type : Float Glass type: white Pull: 600 MTPD Cullet: 25 % Melter area : 465 m2 Glass depth melter: 1280 mm Spec. pull : 1,29 MTPD/m2 Spec. energy consumption: 5,62 MJ/kg Total gas consumption : Nm3/h Heat value of gas : 9070 kcal/kg NOx: mg/nm3 (8% O2)
31 FT BURNER INSTALLATION Furnace type : tableware Glass type: soda-lime Pull: 160 MTPD Cullet: 28 % Total gas consumption : 1096 Nm3/h Heat value of gas : kcal/kg Combustion heat : kw Old burners Melter area : 86,9 m2 Glass depth melter: 1448 mm Spec. pull : 1,84 MTPD/m2 Spec. energy consumption 5597 MJ/kg
32 FT BURNER INSTALLATION Furnace type : tableware Glass type: soda-lime Pull: 160 MTPD Cullet: 28 % Total gas consumption : Heat value of gas : Combustion heat : 1061 Nm3/h kcal/kg kw Flammatec burners Melter area : 86,9 m2 Glass depth melter: 1448 mm Spec. pull : 1.84 MTPD/m2 Spec. energy consumption 5135 MJ/kg
33 FT BURNER INSTALLATION - COMPARISON PREVIOUS BURNERS FT BURNERS DIFFERENCE End fired furnace - tableware Total energy consumption Nm3/hr ,3 5,51 Specific energy consumtion MJ/T ,51 End fired furnace - container Total energy consumption Nm3/hr ,18 Specific energy consumtion MJ/T 3,66 3,54 3,28 End fired furnace - tableware Total energy consumption Nm3/hr ,34 Specific energy consumtion MJ/T ,34 Cross fired furnace tableware Total energy consumption Nm3/hr ,2 Specific energy consumtion MJ/T ,2
34 PRODUCTION RESULTS The practical results fully confirmed the expected benefits flame is easy to tune from short turbulent shape up to a long low turbulent shape and highly luminous flame highly luminous stable flame is achieved batch melting was enhanced after a change to FLAMMATEC burner creating shorter batch piles bottom temperatures were visibly increased, allowing glass quality improvements and a fuel reduction
35 Contact: FlammaTec, Ltd. Rokytnice 60, Vsetin Czech Republic T: F:
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