A Novel High-Heat Transfer Low-NO{sub x} Natural Gas Combustion System. Final Technical Report

摘要

A novel high-heat transfer low NO(sub x) natural gas combustion system. The objectives of this program are to research, develop, test, and commercialize a novel high-heat transfer low-NO{sub x} natural gas combustion system for oxygen-, oxygen-enriched air, and air-fired furnaces. This technology will improve the process efficiency (productivity and product quality) and the energy efficiency of high-temperature industrial furnaces by at least 20%. GTI's high-heat transfer burner has applications in high-temperature air, oxygen-enriched air, and oxygen furnaces used in the glass, metals, cement, and other industries. Development work in this program is focused on using this burner to improve the energy efficiency and productivity of glass melting furnaces that are major industrial energy consumers. The following specific project objectives are defined to provide a means of achieving the overall project objectives. (1) Identify topics to be covered, problems requiring attention, equipment to be used in the program, and test plans to be followed in Phase II and Phase III. (2) Use existing codes to develop models of gas combustion and soot nucleation and growth as well as a thermodynamic and parametric description of furnace heat transfer issues. (3) Conduct a parametric study to confirm the increase in process and energy efficiency. (4) Design and fabricate a high-heat transfer low-NOx natural gas burners for laboratory, pilot- and demonstration-scale tests. (5) Test the high-heat transfer burner in one of GTI's laboratory-scale high-temperature furnaces. (6) Design and demonstrate the high-heat transfer burner on GTI's unique pilot-scale glass tank simulator. (7) Complete one long term demonstration test of this burner technology on an Owens Corning full-scale industrial glass melting furnace. (8) Prepare an Industrial Adoption Plan. This Plan will be updated in each program Phase as additional information becomes available. The Plan will include technical and economic analyses, energy savings and waste reduction predictions, evaluation of environmental effects, and outline issues concerning manufacturing, marketing, and financing. Combustion Tec, Owens Corning, and GTI will all take active roles in defining this Plan. During Phase I, the first three objectives were addressed and completed along with the design component of the fourth objective. In Phase II, the fabrication component of the fourth objective was completed along with objectives five and six. Results of the Phase I work were reported in the Phase I Final Report and are summarized in this Final Technical Report. Work for Phase II was divided in four specific Tasks. Results of the Phase II work were reported in the Phase II Final Report and are also summarized in this Final Technical Report. No Phase III Final Report was prepared, so this Final Technical Report presents the results of Phase III commercial demonstration efforts. A description of each Task in Phases I, II, and III is presented in this report.