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Training Services

Low NOx Burners

FH/7-1

Low NOx

Time - Temperature - Turbulence key to NOx


formation
Flue Gas Recirculation
Staged Air Burners
Staged Fuel Burners

FH/7-2

Staged Air Burner


I.D.
O.D.

Tertiary Air Control


Handle
Secondary Air Control
Handle
1/2 Pilot Gas Conn.
(Female N.P.T.)
1/2 Oil Conn.
(Female N.P.T.)

Gas Conn.
(Female N.P.T.)
1/2 Steam Conn.
(Female N.P.T.)

HTR-R00-63

FH/7-3

Staged Air Burner

Slow Combustion

50% Tertiary Air

Excess Fuel in Primary


Results in Lower Flame
Temperature

Very Long Flames

FH/7-4

Staged Air Burner

50% Combustion Air


Outside Burner Tile

Do Not Puck Annular


Area

FH/7-5

Staged Air Burner

Slow Burning

Long Flames

FH/7-6

Staged Air Burner

Coking on Oil Tip

FH/7-7

Staged Air Burner

Firing Gas

Long Flames

Cracking in Flame
(Yellow Color)

FH/7-8

Staged Air Burner

Burning No. 2 Oil

Bright color on primary


tile indicates problem

FH/7-9

Suspended Flame Burner

Swirl Stabilizer replaces primary tile

Ignition occurs above Swirler

High air side design pressure drop


6 H20 ( 150 mm)

FH/7-10

Suspended Flame Combination Burner

John Zink PSFR

Burning Methane in Test Furnace

Staged fuel burner

FH/7-11

Suspended Flame Combination Burner

John Zink PSFRC

Burning No. 6 Oil in Test Furnace

Ignition occurs above Swirler

FH/7-12

Suspended Flame Combination Burner

John Zink PSFRC

Only Burner suitable for


oil and gas firing
simultaneously

High air side pressure


drop 3 H20 ( 75 mm)
makes up for low fuel
pressures

Short, Wide Flame

FH/7-13

Staged Fuel Burner


Secondary
Combustion
Secondary Fuel

High Air to
Fuel Ratio in
Primary Zone

Combustion
Air
Primary
Fuel Connection
HTR-R00-64

Secondary
Fuel Connection
FH/7-14

STAGED FUEL BURNER

Staged Combustion

30% Primary Fuel

70% Secondary Fuel

High Excess Air in


Primary Tip Results in
Low Flame Temperature

Low O2 in Secondary Tip


Results in Longer
Combustion Time

50% Longer Flame

40 ppm NOX
FH/7-15

Staged Fuel Burner

Primary Tips Aligned to


Secondary Tips

Proper Tile Installation

Uniform Annular Area

FH/7-16

Staged Fuel Burner

Flat Flame VersionJohn Zink PSFFG

Used for smaller heat


releases, 3-5 MM
Btu/h(0.9-1.5MW)

Has two staged gas tips


so holes can be larger
to prevent plugging

FH/7-17

Staged Fuel Burner

Tile Alignment Ring Ensures


Proper Installation

John Zink PSFG

FH/7-18

Staged Fuel Burner

Tile Alignment Ring Ensures Proper Installation

310 SS waste gas nozzle

Limit waste gas to 3-5% of burner heat release per nozzle

FH/7-19

Staged Fuel Burner

John Zink PSFR- four individual primary gas tips


Better turndown operations
Mistake-tile is not level
Mistake- expansion joint between burner tile and floor filled
with castable- should be fiber

FH/7-20

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Staged Fuel Burner

Operating Burner at 20 psig


(1.4 kg/cm)

Blue Flame

Methane Fuel

FH/7-21

Staged Fuel Burner

Turndown Operation at 3 psig


(0.21 kg/cm)

Yellow Flame

Cracking in Flame

FH/7-22

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Staged Fuel Burner

Operating Burner at 32 psig


(2.2 kg/cm)

Low excess air 2% O2

Soft Hazy Flame Ends at low


excess air

Blue flame (good fuel-air


mixing)

Refinery Fuel

FH/7-23

Staged Fuel Gas Burner

Improper Secondary
Tip Location in center
of burner

FH/7-24

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Staged Fuel Burner

Improper Secondary Tip


Location

Poor Combustion

FH/7-25

Ultra Low NOx Burner

FH/7-26

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Ultra Low NOx Burner

Flue Gas Recirculation

Lowest NOX

Very Long Flames

Potential Stability Problems

FH/7-27

Ultra Low NOx Burner

Callidus LE Burner

Hourglass Shaped Flame

Low Temperature

High Combustion Time

30 ppm NOX

FH/7-28

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Ultra Low
NOx Burner

Callidus LE Burner

Damaged Flame
Holder

Prefer 1 diameter
spacing between
tiles

NOx levels track


floor temperatures

FH/7-29

Ultra Low NOx Burner

Callidus LE Burner

New Design Flame


Holder, 8 Secondary Tips

Tangential primary

FH/7-30

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Ultra Low NOx Burner

Callidus LE Burner

Flame is behind
flameholder, It will
burn up

Flameholder needs to
lowered

FH/7-31

Catalytic De-NOx

Very Expensive

Operates at 400-700F

Used in Retrofits when


Ultra-Low NOx cannot
be used

Coupled with air


preheat system

FH/7-32

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