CONCEPT OF DUAL BURNER

From the above calculations we nd that the amount of hydrogen is not sufcient
for the full production of steam. That is we cannot produce steam only using
hydrogen as only the fuel. In that case we are thinking about a dual fuel concept.
Hydrogen and furnace oil are used for the production of steam at the same time.
The dual fuel burners are good solutions for saving non-conventional energy
resources. Dual fuel burners will reduce amount of furnace oil and the same time
the free hydrogen can effectively utilized. In dual fuel burner we can use either
hydrogen or furnace oil according to our condition. Dual fuel burners are not much
complicated, but its lines are simple.

DUAL BURNERS

Industrial burners operate on oil (SR series), gas (SRG series) and dual fuels like oil
and gas (SROG series). They have been designed and manufactured to high
standards in order to meet the widest demand. These burners can be used on a
wide range of equipment like boilers, hot oil heaters, hot air generators and
furnaces. High turndown ratios can be achieved without deterioration in combustion
quality. Operation can be totally automatic and dual fuel burners can be supplied for
combined fuel burning.
Hi-cal burners are designed for low excess air and are totally compatible with one
line oxygen trimming systems which regulates excess air thus ensuring good
combustion at all loads. They supply oxygen trimming systems for all burners.
Custom made burners for fuels like blast furnace gas and other lean gases can be
supplied on request. Proper selection of burners is based upon factory such as
equipment capacity, furnace pressures, type of load and design of furnaces. The
burners can be supplied with blower, control panel, oil pumps, oil pre-heaters,
duplex lters and gas trains etc.
SRG series burners are capable of ring natural gas, biogas and gases like methane,
butane etc. Turndown ratios of 1:5 on gas are normally available. The gas nozzles,
pilot and combustion head are made of stainless steel. The gas pilot is ignited by a
high voltage electric spark. The burners can be supplied with or without gas train,
but they are always supplied with the gas butterfly valve and air regulator for
continuous regulation of fuel and air. The dual fuel burners are supplied with
separate igniter and provision for separate flame scanners for each fuel. A manual
change over switch is provided to switch fuels.
SROG burners can be always supplied with combined fuel ring with gas as the
primary fuel. The controls require for the burners will be specially designed for this
purpose.

The burner system offered is dual fuel type. Hydrogen gas and furnace oil are red.
The furnace oil is modulated based on the boiler load. LPG is used as the ignition
fuel. Furnace oil is ignited by LPG and once oil flame stabilized hydrogen gas line is
open. Boiler modulation is done in oil line if the pressure is high Hydrogen line is cut
off.

Working of a STS burner

The STS Burner consists of primary and secondary air zones equipped with movable
flow control dampers. The primary air passage contains a manually adjustable
sleeve damper for controlling flow split between the two zones. The automatic
burner air shroud controls total burner air and makes it possible to achieve an
excellent burner to burner air flow balance. The electrically operated air shroud
drive mechanism with adjustable limit switches is mounted at the top of the front
plate and provides reliable, non-binding movement.
The secondary air register has axial swirl vanes, which provide excellent swirl
control and low pressure drop. No register blades are required for primary air, since
the primary swirler induces swirl.
Separating the swirl control and flow control adjustments gives the STS burner
signicantly more control and allows for higher turndown capability. Primary air is
delivered through the center of the burner which houses the gas canes, oil gun, and
primary air swirler. Secondary air flows through the outer most annulus surrounding
the primary air. A separation gap maintains a distinct separation between the
primary and secondary combustion zones, reducing the formation of thermal NOx.
The secondary air swirl vanes are manually adjusted and the position remains
constant throughout load range. The swirl vanes are used to control the degree of
swirl, the fuel/air mixture, and flame shape. The ability to independently control
swirl imparted to the secondary air provides flexibility in controlling flame length
and shape.
For natural gas ring, a series of externally adjustable gas canes are provided
uniformly spaced in a circular pattern inside the primary air barrel. Adjustments
include both axial and rotational tip position, and can be made while the unit is on
line ring gas. These adjustments are used to eliminate any combustion induced
vibration if necessary and control fuel/air mixing. A centrally located steam
atomized oil gun is provided for oil ring.
The hydrogen produced per hour is 1154.04m 3. But this hydrogen is not fully
available for boilers. Because in TCC a small amount of hydrogen is used in
concentration plant for production of NaOH flakes. The production rate of each
product is varied by the company as per the market demands. When the production
rate of NaOH is varied then the hydrogen availability also reduces. So we have to x

a value for hydrogen which will be easily available and do not vary with the
variation in production of NaOH flakes.
In the boiler we can select three types of fuels

Furnace oil alone is used

Hydrogen gas alone is used
Combination of oil and furnace oil are used

Furnace oil alone is used when the production of hydrochloric acid is at the
maximum rate. Hydrogen gas alone can be used when the steam production rate is
reduced. Considering all the features combination of both the fuels is the practical
method which can be easily installed.
Actually we get hydrogen only corresponding to production of 90 tons of liquid
chlorine. As considering the working efficiency, the amount of hydrogen required for
the production of 8 tones/hr. is 2770.4m3/hr. But our availability is only
1152.04m3/hr. This available value can also be vary according to the production of
other products in the company.
So we have to x a value for hydrogen which will be easily available and
independent of the production of other products. So we x

600m3/hr. as the maximum value.

400m3/hr. as the medium value.
200m3/hr. as minimum value.

If we are fixing the amount of hydrogen as 600m3/hr. the cost reduction

can be calculated as follows.

At maximum capacity of 8 tones/hr.

Amount of furnace oil for
Maximum production of steam

Corresponding amount of energy

Corresponding amount of hydrogen needed =

Available value of hydrogen =
So rest energy is supplied by furnace oil =
Amount of furnace oil needed =
Reduction in furnace oil consumption =
Net cost reduction per hour =
Net cost reduction per day =

In this system we are xing the value of hydrogen and vary the furnace oil
consumption. This method is known as Modulation of fuel. There will be regulator for
adjusting the amount of hydrogen.

STORAGE OF HYDROGEN

Hydrogen is the most abundant element in universe, but it is rarely found in its
uncombined form in the universe. If the hydrogen is obtained as element storage of
hydrogen is a big problem. Hydrogen is normally a gas and it can be compressed
and stored in cylinders. It can be also kept at liquid at temperature of -423.3 degree
Fahrenheit. But in TCC we get hydrogen directly from the electrolytic cells as the
electrolysis is done. This hydrogen is directly transferred to a hydrogen holder. The
mechanism of hydrogen holder 1is simple.
In TCC liquid sealed hydrogen holding system is employed. A xed tank carrying a
floating cylinder inverted is the main part of this system. Fixed tank carries almost
full of water. Hydrogen gas produced in the electrolytic cell is passed through pipe
line to hydrogen holder. Hydrogen enters to the floating cylinder through the
bottom, and lls inside the cylinder. Entering hydrogen will lift the cylinder up to its
maximum capacity. As the capacity reached, there will be an opening, called Flame
trap, through which excess hydrogen will escape.

Types of Oil and Gas Fired Burners

Because no two burner applications are the same, a variety of robust combination
oil and gas red burners. Our extensive product offering provides owners and
operators with the technological solutions.

SFFC Series

The SFFC, a staged fuel, flat flame, combination oil and gas burner is a prime
solution for applications with tight tube-to-burner spacing. Because the burner can
be red simultaneously with oil and gas, the SFFC is ideal for customers who re oil
in substitution of gas. Although designed to combust oil and gas, the SFFC can like
the SFFG, re just gas fuels.

PFLD Series

The PFLD is a dual-fuel; down-red burner utilized in hydrogen and ammonia

reformers. It can be used in turbine exhaust gas applications where the flue
products from a gas turbine provide the combustion air stream. The PFLD handles a
wide variety of fuels including a PSA or purge gas. This burner can be used in
induced-draft systems or in forced-draft applications with air preheat. The burner
can also be adapted to use a Naphtha or Diesel-oil make-up fuel.

LNFC Series

The LNFC, a low NOx, flat-flame combination oil and gas burner, is advantageous in
applications with tight tube-to-burner spacing. The LNFC can simultaneously re oil
and gas. The LNFC burner employs staged air to provide reduced NOx emissions
when ring only oil. However, when ring gas, users will benet with lower NOx
emissions using SFFC burner than with the LNFC.

LNC Series

The LNC combination round-flame oil and gas burner utilizes staged-air technology
to reduce NOx in almost every application requiring both oil and gas fuels. Although
NOx emissions from gas ring are not as low as with a staged-fuel burner, the LNC
burner provides the added flexibility of oil is ring and some NOx control via air
staging. Whether a forced-draft air-preheat or natural-draft application, the LNC can
combust liquid fuel such as Naphtha.

HEROTM

Combusts heavy fuel oil in a manner similar to fuel gas - reducing both emissions
and energy consumption. The High Efficiency Residual Oil-gun.
HERO employs phased atomization to lower combustion emissions and operating
costs while improving ring control. The efficient use of steam energy in the phased
atomization prepares a spray with a median liquid droplet size that is approximately
50% the size of droplets formed by Conventional atomization techniques.

DEEPTM star Series

The DEEP star burner employs the next evolution in clean-burning combination oiland gas-fuel technology. When used in conjunction with the HERO, the DEEP star

combination round-flame oil and gas burner, provides maximum NOx control. The
deep regeneration tile provides superior flame stability. When ring gas, the DEEP
star employs fuel staging to enhance NOx control. And, when ring oil, the
revolutionary combination burner employs staged air to reduce NOx, providing
optimum control for dual oil and gas combustion.

PFLD-C Series

The PFLD is a dual-fuel; down-red burner utilized in hydrogen and ammonia

reformers. It can also be used in turbine exhaust gas applications where the flue
products from a gas turbine provide the combustion air stream. The PFLD handles a
wide variety of fuels including a PSA or purge gas. This burner can be used in
induced-draft systems or in forced-draft applications with air preheat. The burner
can also be adapted to use a Naphtha or Diesel-oil make-up fuel.