The John Zink Hamworthy Combustion Handbook, Second Edition: Volume 3 - Applications

442 Pages·2013·34.037 MB·English

by  Charles E. Baukal Jr.

THE JOHN ZINK HAMWORTHY
COMBUSTION
HANDBOOK
SECOND EDITION
Volume 3
APPLICATIONS
© 2014 by Taylor & Francis Group, LLC
IndustrIal combustIon serIes
Series Editors:
Charles E. Baukal, Jr.
The Coen & Hamworthy Combustion Handbook:
Fundamentals for Power, Marine & Industrial Applications
Stephen Londerville and Charles E. Baukal, Jr.
The John Zink Hamworthy Combustion Handbook, Second Edition
Volume 1—Fundamentals
Volume II—Design and Operations
Volume II1—Applications
Charles E. Baukal, Jr.
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Charles E. Baukal, Jr.
The John Zink Combustion Handbook
Charles E. Baukal, Jr.
Computational Fluid Dynamics in Industrial Combustion
Charles E. Baukal, Jr., Vladimir Gershtein, and Xianming Jimmy Li
Heat Transfer in Industrial Combustion
Charles E. Baukal, Jr.
Oxygen-Enhanced Combustion
Charles E. Baukal, Jr.

© 2014 by Taylor & Francis Group, LLC
THE JOHN ZINK HAMWORTHY
COMBUSTION
HANDBOOK
SECOND EDITION
Volume 3
APPLICATIONS
Edited by
Charles E. Baukal, Jr.

© 2014 by Taylor & Francis Group, LLC
CRC Press
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© 2014 by Taylor & Francis Group, LLC
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Version Date: 20130524

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© 2014 by Taylor & Francis Group, LLC
Dedication
The staff at John Zink Company dedicates this book to Robert E. Schwartz. Bob, as he is known by his friends,
worked for John Zink from 1967 till his retirement in 2011. During his tenure at John Zink, Bob served in many
key roles, including vice president of the company. His expertise was wide ranging and included significant
technological achievement in the areas of process burners, flares, and vapor recovery systems. Bob authored
numerous publications and is named as an inventor on 52 U.S. patents. As a result of his proficiency in these
areas, Bob is widely considered an expert in the industry. Active in the American Petroleum Institute, Bob made
significant contributions to several standards, and in 2011 he received a lifetime achievement award for his many
years of valuable service. Bob was a major contributor to the design, construction, and operation of the extensive
combustion testing facility at John Zink Company headquarters located in Tulsa, Oklahoma. As a colleague, Bob
always made himself available to anyone seeking his advice and took particular care with inexperienced engineers
to provide them not only the advice they sought but also to teach them critical thinking and problem-solving skills.
Bob is known and respected by combustion experts the world over. He left an indelible mark on the company he
called home for over 44 years, and his legacy will be long lasting. Thank you, Bob, for your dedicated service. Your

knowledge, wisdom, and friendship will be treasured for years to come.
© 2014 by Taylor & Francis Group, LLC
© 2014 by Taylor & Francis Group, LLC
Contents
List of Figures ............................................................................................................................................................................ix
List of Tables ............................................................................................................................................................................xxi
Foreword to the First Edition .............................................................................................................................................xxiii
Preface to the First Edition ....................................................................................................................................................xxv
Preface to the Second Edition ............................................................................................................................................xxvii
Acknowledgments ................................................................................................................................................................xxix
Editor.......................................................................................................................................................................................xxxi
Contributors ........................................................................................................................................................................xxxiii
Prologue..............................................................................................................................................................................xxxvii
1. Process Burners ..................................................................................................................................................................1
Erwin Platvoet, I.-Ping Chung, Michael G. Claxton, and Tami Fischer
2. Oil Burners ........................................................................................................................................................................35
I.-Ping Chung, Steve Londerville, Michael G. Claxton, and William Johnson
3. Burners and Combustion Systems for Industrial and Utility Boilers ..................................................................57
Vladimir Lifshits
4. Duct Burners .....................................................................................................................................................................93
Peter F. Barry, Stephen L. Somers, and Steve Londerville
5. Marine and Offshore Applications .............................................................................................................................117
Richard Price
6. Process Heaters ..............................................................................................................................................................129
Erwin Platvoet, David Brown, and Rasik Patel
7. Air Heaters ......................................................................................................................................................................149
Carl A. Connally, Lothar Schulz, and Timothy Webster

8. Thermal Oxidizer Basics ..............................................................................................................................................159
Jay Karan, Bernd Reese, Klaus-Dieter Zschorsch, and Wolfgang Klaus
9. Thermal Oxidizer Control and Configurations .......................................................................................................211
Bernd Reese, Wolfgang Klaus, Jay Karan, and Juergen Foelting
10. Selected Pollution Control Equipment .....................................................................................................................239
Klaus-Dieter Zschorsch
11. Flares ................................................................................................................................................................................251
Robert E. Schwartz, Jeff White, and Wes Bussman
12. Pilot, Ignition, and Monitoring Systems ..................................................................................................................299
Adam Bader and John Bellovich
13. Biogas Flaring .................................................................................................................................................................307
Tim W. Locke, Brandy S. Johnson, and Jason P. Rolf
vii
© 2014 by Taylor & Francis Group, LLC
viii Contents
14. Flare Gas Recovery ........................................................................................................................................................331
Jeff Peterson, Nick Tuttle, Harley Cooper, and Charles E. Baukal, Jr.
15. Hydrocarbon Vapor Control Technology .................................................................................................................339
Roger E. Blanton
Appendix A: Units and Conversions ................................................................................................................................365
Appendix B: Physical Properties of Materials ................................................................................................................369
Appendix C: Properties of Gases and Liquids ...............................................................................................................377
Appendix D: Properties of Solids .....................................................................................................................................397
Appendix E: Trademark Disclaimer .................................................................................................................................401
Index ........................................................................................................................................................................................405

© 2014 by Taylor & Francis Group, LLC
List of Figures
Figure 1.1 General burner construction. ...........................................................................................................................3
Figure 1.2 PVYD-M natural-draft, gas-only burner (with air inlet noise suppression). ............................................4
Figure 1.3 PFFG gas-only flat-flame burner. .....................................................................................................................4
Figure 1.4 PMA round flame combination gas and liquid burner. ...............................................................................4
Figure 1.5 HEVD premix burner assembly. ......................................................................................................................4
Figure 1.6 Staged-air combustion. ......................................................................................................................................5
Figure 1.7 HAWAstar staged-air, gas-fired burner assembly. ........................................................................................5
Figure 1.8 LNC staged air combination gas/liquid burner assembly. .........................................................................5
Figure 1.9 Hamworthy Enviromix 2000 staged-air burner assembly. ..........................................................................6
Figure 1.10 Hamworthy EEP flat-flame staged-air burner assembly. .............................................................................7
Figure 1.11 Staged-fuel combustion. ....................................................................................................................................7
Figure 1.12 PSFG burner assembly. ......................................................................................................................................8
Figure 1.13 PSFFG flat-flame staged-fuel burner assembly. .............................................................................................8
Figure 1.14 Ultralow-NOx stoichiometry. ...........................................................................................................................9
Figure 1.15 Ultralow-NOx flame development. .................................................................................................................9
Figure 1.16 (a) PSMR ultralow-NOx burner assembly and (b) flame photo. ...............................................................10
Figure 1.17 Relative NOx emissions versus flame stoichiometry. .................................................................................10
Figure 1.18 LPMF lean premix staged-fuel burner assembly. ........................................................................................11
Figure 1.19 The COOLstar folded flame (flower shape when looking down from the top of the tile). ....................12
Figure 1.20 COOLstar® burner cutaway. ...........................................................................................................................12
Figure 1.21 CFD simulation results for CO concentration contours on COOLstar burner. .......................................13
Figure 1.22 CFD simulation results for temperature contours of COOLstar burner. .................................................13
Figure 1.23 COOLstar flame photo. ....................................................................................................................................13
Figure 1.24 Entrainment around a Coanda surface. .......................................................................................................14
Figure 1.25 Coanda tile surface. .........................................................................................................................................14
Figure 1.26 HALO flame photo. .........................................................................................................................................14
Figure 1.27 Freestanding burners. .....................................................................................................................................14
Figure 1.28 MDBP burner firing PSA off gas (view looking up at burner). .................................................................15
Figure 1.29 PDSMR MK-II tile and fuel tips. ....................................................................................................................16
Figure 1.30 (a) PDSMR Mk-II burner assembly and (b) flame photo. ...........................................................................16
Figure 1.31 (a) PXMR burner assembly and (b) flame photo. ........................................................................................17
Figure 1.32 PSFFR burner assembly. .................................................................................................................................17
ix
© 2014 by Taylor & Francis Group, LLC
x List of Figures
Figure 1.33 (a) LPMF burner assembly and (b) flame photo. .........................................................................................18
Figure 1.34 (a) RTW test burner and (b) CFD-calculated result. ...................................................................................18
Figure 1.35 (a) Modified RTW burner and (b) CFD-calculated result. .........................................................................19
Figure 1.36 (a) PXMR-DS burner and (b) flame photo. ...................................................................................................19
Figure 1.37 Premix radiant wall burner array. .................................................................................................................20
Figure 1.38 PMS premix gas burner assembly. ................................................................................................................20
Figure 1.39 PMS flame (front view). ...................................................................................................................................21
Figure 1.40 PMS flame (side view). ....................................................................................................................................21
Figure 1.41 Hamworthy Walrad burner assembly. ..........................................................................................................21
Figure 1.42 LPMW radiant wall burner array. .................................................................................................................22
Figure 1.43 LPMW with elbowed venturi.........................................................................................................................23
Figure 1.44 LPMW with in-line venturi and staged-fuel adaptor/tip. .........................................................................23
Figure 1.45 LPMW with in-line venturi for RFS integration. ........................................................................................23
Figure 1.46 FPMR radiant wall burner cutaway. .............................................................................................................24
Figure 1.47 (a) FPMR burner assembly and (b) cutaway. ................................................................................................24
Figure 1.48 Oil gun with concentric tube design. ............................................................................................................25
Figure 1.49 MEA oil gun with dual (parallel)-tube design. ...........................................................................................25
Figure 1.50 John Zink EA oil atomizer and tip. ...............................................................................................................25
Figure 1.51 John Zink MEA oil atomizer and tip. ...........................................................................................................25
Figure 1.52 Hamworthy SAR oil atomizer and tip. .........................................................................................................26
Figure 1.53 Hamworthy DS oil atomizer and tip. ............................................................................................................26
Figure 1.54 John Zink PM atomization system (port mix). ............................................................................................27
Figure 1.55 The HERO gun. ................................................................................................................................................27
Figure 1.56 Standard combination burner. .......................................................................................................................28

Figure 1.57 PLNC staged-air combination burner. ..........................................................................................................29
Figure 1.58 DEEPstar low-NOx gas/oil combination burner. ........................................................................................29
Figure 1.59 (a) DEEPstar oil flame and (b) gas flame ......................................................................................................30
Figure 1.60 ST-1-S manual pilot. .........................................................................................................................................31
Figure 1.61 ST-1-SE electric ignition pilot. .........................................................................................................................31
Figure 1.62 ST-1-SE-FR electric ignition pilot with an integral flame rod. ...................................................................31
Figure 1.63 KE-1-ST electric ignition pilot. .......................................................................................................................31
Figure 1.64 ST-2 manual pilot. ............................................................................................................................................32
Figure 1.65 KE-2-ST electric ignition pilot. .......................................................................................................................32
Figure 2.1 Typical liquid fuel atomizer-spray tip configurations. ...............................................................................37
Figure 2.2 Oil gun capacity curves for heavy oil and light oil for one specific oil gun ...........................................38
Figure 2.3 Oil gun capacity curves for steam atomizing and air atomizing for one specific oil gun ...................38
© 2014 by Taylor & Francis Group, LLC