Steamizer XP next generation steam flare technology - presentation

Steamizer XP Next Generation Steam Flare Technology Scott Fox John Zink Company, LLC Background John Zink Company developed the modern Flare System over 50 years ago. One of the key drivers for technology development is smokeless combustion of the waste gases. Smoke suppression is directly related to the supply of combustion air and its proper mixing with the waste gas. Several generations of steam flares have been developed with increasing demands of smokeless capacity and smokeless efficiency. C 2009 by John Zink Company, LLC First Generation of Steam Flares- Basics The first designs installed in the 1950s, consisted of steam injection around the perimeter of the flare tip. The injection of high pressure fluid (steam) promotes the eduction of surrounding air into the flame. Smokeless capacities achieved proved sufficient for the environmental demands of the industry. C 2009 by John Zink Company, LLC First Generation Steam Flares air steam waste gas Single or multiple port steam nozzles steam C 2009 by John Zink Company, LLC First Generation Steam Flares 1950's style tip C 2009 by John Zink Company, LLC Current style tip First Generation of Steam Flares - Basics Many "tweaks" to this technology focused on reducing noise generation as well as improving overall efficiency. However, the limited penetration of the steam jets and the educted air into the core of the flame limits the application of this technology to small burner sizes and limited smokeless capacities. C 2009 by John Zink Company, LLC Second Generation Steam Flares An increase of capacity of facilities as well as higher demands for smokeless performance lead to 2nd Generation steam flare technology. Steam injection is performed through multiple tubes installed inside the flare tip body. C 2009 by John Zink Company, LLC 2nd Generation Steam Flares - Internal Tubes upper steam nozzles pilots center steam nozzle Steam tubes Lower steam nozzles muffler C 2009 by John Zink Company, LLC Lower steam manifold 2nd Generation Steam Flares C 2009 by John Zink Company, LLC Third Generation Steam Flares - Steamizer ® The third Generation of Steam Flares was achieved through improvement of the 2nd Generation after years of operational experience and a better understanding of flare dynamics: - Improved steam nozzles and eductor tubes. - Optimization of number of air tubes for specific applications. - Perimeter control of the flame to resist against wind effects and improve main steam injection. - Optimization of mufflers to attenuate noise emmitted by the steam injection system. C 2009 by John Zink Company, LLC UPPER STEAM RING WASTE GAS/AIR/STEAM MIXING ZONE STEAM/AIR TUBES ENHANCED STEAM/AIR TUBES UPPER STEAM HIGH EFFICIENCY MUFFLER FOR NOISE REDUCTION OPTIMIZED STEAM NOZZLES LOWER STEAM C 2009 by John Zink Company, LLC GAS INLET 3rd Generation Steam Flares - Steamizer ® C 2009 by John Zink Company, LLC Third Generation of Steam Flares - Steamizer ® The Steamizer ® has been proven very efficent for moderate and high smokeless capabilities and it is recognized as best technology for most high performance applications. Limitations: - Multiple steam lines (for highest efficiency and best operational control) - Non-forgiving steam control system - Significant continuous steam supply for mechanical integrity - Nuisance noise and smoke in growing facilities C 2009 by John Zink Company, LLC Industry Needs • Greater Smokeless Capacity • Increased Steam Efficiency (reduced operating costs) • Reduced noise emissions • Reduced installation costs • Ease of operation of the steam control • Increased tip life C 2009 by John Zink Company, LLC Fourth Generation Steam Flare Technology eXtreme Performance Development Project • Conceptual Design • Simulation (CFD / FEA) • Testing - Cold Flow Tests - Firing Tests John Zink Research and Development Center Tulsa, Oklahoma, USA C 2009 by John Zink Company, LLC 4th Generation Steam Flare Technology Steamizer® XP™ 1) 2) 3) 4) 5) 6) C 2009 by John Zink Company, LLC Higher Smokeless Capacity Less Smokeless Steam Less Cooling Steam Lower Noise Lower Complexity Higher Reliability XP™ Flare Design Features Moderated Shear Mixing Enhanced Secondary Air Entrainment Optimized Primary Air Eduction C 2009 by John Zink Company, LLC Moderated Shear Mixing C 2009 by John Zink Company, LLC WASTE AIR WASTE WASTE AIR AIR Enhanced Secondary Air Entrainment - Multiple Nozzles Air C 2009 by John Zink Company, LLC Air Enhanced Secondary Air Entrainment - Multiple Nozzles • Distributing the waste gas into multiple nozzles increases the interface of contact between secondary air and the waste gas. • Nozzle spacing is designed to maximize the secondary air entrainment capability while optimizing the overall size of the burner. C 2009 by John Zink Company, LLC Optimized Primary Air Eduction • Straight air/steam tubes reduce pressure losses compared to angled tubes, resulting in improved eduction efficiency • Reduction of noise transmission to grade due to lower reflectivity C 2009 by John Zink Company, LLC SECONDARY AIR PRIMARY AIR C WASTE GAS 2009 by John Zink Company, LLC STEAM XP PERFORMANCE • Increased smokeless performance: >40% • Reduction of steam consumption : >30% • Significant reduction of cooling steam consumption during day to day operations: Varies by application • Reduction of noise • Less tip damage risk due to simplified operation • Lower installation costs due to lower steam requirements and single steam line C 2009 by John Zink Company, LLC Capping Upper steam Lower steam Center steam Waste gas C 2009 by John Zink Company, LLC Validation of XP Smokeless Capacity • Full scale XP testing conducted in Fall of 2006 • Flaring of propane and propylene in the smokeless range (R0 and R1) • Confirmation of flame stability with no capping effect. • Confirmation of internal temperatures under purge and low flow operating conditions. C 2009 by John Zink Company, LLC Full Scale Performance Demonstration Determination of smokeless performance, noise, radiation, local temperatures,purge rates on C3 and C3=. Improvement between 30 and 40% over 3rd generation designs. C 2009 by John Zink Company, LLC XP-42 firing Propylene at Ringlemann 0 at S/HC <0.3 C 2009 by John Zink Company, LLC XP-42 firing Propylene at Ringlemann 1 with S/HC <0.2 C 2009 by John Zink Company, LLC XP-42 firing Propane at Ringlemann 0 at S/HC ~ 0.2 C 2009 by John Zink Company, LLC Steam and Environmental Savings Annual steam consumption considering 5% operation at maximum smokeless rate with remainder at minimum turndown (cooling rates): 3rd Generation: 54,588 mtons/year XP: 20,693 mtons/year Steam savings: 33,895 mtons/year Green House Gas Emissions Reduction: NOx reduction: 2,675 kg/year (*) CO2 reduction : 6,290,100 kg/year (*) (*) based on reduced boiler fuel gas usage for steam generation C 2009 by John Zink Company, LLC XP Operational Experience Over two years operational experience with exceptional customer satisfaction: Mechanical integrity Operational savings, Reduced noise, Simplicity C 2009 by John Zink Company, LLC C 2009 by John Zink Company, LLC C 2009 by John Zink Company, LLC Conclusions XP technology is a "leapfrog" advancement in Steam Flare Technology. The XP design minimizes utility requirements, achieves improved smokeless performance, reduces noise, and is far more simple than other high performance designs. The XP technology provides significant reduction in installation and operational costs. C 2009 by John Zink Company, LLC • World Leader In Advanced Clean-Air Solutions And Low-Emissions Combustion Technologies. C 2009 by John Zink Company, LLC