#1 DIRECT-FIRED, CABIN-STYLE, HEAT-MEDIUM HEATER, GAS BURNER RETRO-FIT

PETRO-CANADA MIDSTREAM GAS BURNER RETRO-FIT

50% Reduction in heater absorbed duty required new, natural gas burners, pilots & refractory tile to maintain fuel efficiency, heat release profile from the flames and reduce emissions

Six (6), 3.0MM Btu/Hr, up-fired, natural draft, gas-fired, nozzle-mix burners with automatic gas pilot burner and refractory burner tile, were supplied. This replaced eight (8), 5MM Btu/Hr, natural draft, gas-fired, pre-mix burners and tile assemblies

Results of heater operation over twelve months show that this specific 'nozzle-mix' burner application generates a long, luminous flame envelope reaching 60% of the radiant tube height.  Radiant, Shock and Convection tube temperatures are kept as close to design as possible in this fashion

All flames are stable throughout a normal 5:1 turn down and provide a smooth, even heat flux throughout the fire box

Similarly, this nozzle-mix burner application maintains a flame throughout the wide, and often rapidly changing range of 'gas plant' fuel gas, including the presence of dense, aerosol hydrocarbons


#2 DIRECT-FIRED, RADIANT WALL, KETENE HEATER, GAS BURNER RETRO-FIT

CELANESE CANADA KETENE HEATERS (2) BURNER RETRO-FIT

Reduction in the absorbed duty of two (2), radiant wall Ketene heaters provided the operator a chance to install more efficient, lower heat release burners.  Fourty four (44), 1.5MM Btu/Hr, natural draft, partial pre-mix, natural gas burners, pilots and refractory tile were supplied

Results after twelve months of operation show this configuration of partial pre-mix burner is providing a low, evenly distributed heat flux to the tubes and the operator is very pleased with the burner performance and the product resulting from heater operation


#3 REFINERY HEATER REBUILD & BURNER RETRO-FIT

HEAVY CRUDE OIL REFINING - MULTIPLE HEATER MODIFICATION, REBUILD & BURNER RETRO-FIT

More than three hundred (300) burners were applied to a variety of heater configurations and fuels

Burners were designed to be constructed locally to support the geographic isolation of the refinery.  Stainless steel burner nozzle and burner body parts were machined locally and the refinery carpentry shop constructed tile forms and poured refractory

The Hydrogen Reformer furnace was fitted with balanced draft, produced gas fired, partial pre-mixing, radiant wall burners

All other product heaters addressed were fitted with natural draft, internally steam atomized, heavy oil burners and refractory tile shapes. These burners fired 'bottoms', heavy-ends and residual crude with a sulfur content at and above 4%

To accommodate the high sulfur content fuel, half a dozen fired heaters with absorbed duties between 150MM and 300MM Btu/Hr had their fiber refractory and corroded steel walls and roof/stack replaced with pre-fabricated steel panels which were shop insulated with low-iron, monolithic cast refractory

Results of this work allowed the refinery to operate at 105% of design with substantially reduced particulate emission

A burner maintenance department was created to ensure on-going burner operation, local spare parts supply and overall heater maintenance.  Two hundred (200) refinery operations, engineering and maintenance personnel were trained in the finer points of their fuel combustion and how the new burners are designed to achieve that


#4 HIGH ENERGY, LOW OXYGEN, FORCED DRAFT, VORTEX BURNERS

WASTE GAS & FUEL GAS FIRED, HIGH ENERGY VORTEX BURNER @ 15MM Btu/Hr

WASTE OIL & FUEL OIL FIRED, HIGH ENERGY VORTEX BURNER @ 35MM Btu/Hr

Unlike the natural draft burner examples shown above which project a flame pattern into the firebox, these 'vortex generating' burners do not allow a flame to project beyond the burner tile face. 

This style of 'forced draft' burner relies on the energy available in rapidly moving air (and often the fuel/waste pressure as well) to create a whirl-wind within the burner tile.  So quickly does the air and fuel/waste mix that oxidation occurs 4 times faster than in a naturally aspirated flame, making the flame hotter and much more compact (shorter)

These burners then eject the rapidly expanding vortex of hot gas from the burner tile which quickly and evenly distributes heat throughout the firebox

Burners are applied to low oxygen, oxidation reactions and to sub-stoichiometric reducing reactions making them ideal for sulfur recovery and incinerator applications


#5 GAS "PILOT" BURNERS

SEE ALSO; INSTRUMENTATION

AIR/GAS PREMIXING PILOT BURNER WITH SPARK IGNITION & FLAME DETECTION

"Pilot" burners are applied to all gas-fired burners over 0.1MM Btu/hr including those used in heaters, sulfur reaction furnaces, incinerators and flares.  With few exceptions, Pilot burners are fitted with a high voltage spark generator for ignition, plus a means of detecting the presence of a flame.

A Pilot burner typically generates between five and ten percent of the total burner design heat release and is intended to be a stable source of ignition for the other ninety to ninety five percent of the fuel/waste gas which is introduced independently through 'main' burner nozzle(s)

Depending on the heat release and physical size of the overall burner, it may have more than one pilot burner 

PRE-MIXED AIR/GAS FUEL NOZZLE WITH INTERNAL SPARK IGNITION & FLAME DETECTION APPLIED TO LARGE BURNERS AND FLARES

As noted for the overall burner design, standards exist for the construction and operation of a Pilot, including that it be reliable in most atmospheric and process conditions.  However these requirments do not prevent 'creative' configurations often neccessary to replace old or atypical Pilots, or when creating new product for OEM's and end users


#6 INDIRECT FIRED HEATERS

RADIANT & IMMERSION TUBE BURNERS, SECONDARY AIR CONTROLS, STACK EXHAUST PLUME STABILIZERS, PLUS PROCESS AND BURNER MANAGEMENT CONTROL

Radiant Tube and Fire Tube, Immersion Tube and U-tube.  In this application the burner and flame are inside a tube and the heat medium surrounds it, rather than the flame being outside of the product tube surface as it is in a Direct-Fired heater as shown in examples #1 & #2 

Radiant Tubes transmit radiant heat from their external surface to elevate the temperature of a body or product passing close to the tube; examples include processing metal ingots or space heating.   A burner is positioned at one end of the tube and the flame and resulting hot gas elevate the tube temperature before being exhausted to atmosphere

Immersion Tubes are typically surrounded by a heat medium fluid (glycol/water, salt, amine) and not in contact with the end product.  The heat medium absorbs heat from the hot ImmersionTube wall and then transfers that heat to the product tube which is also immersed in the same bath.  This is done to prevent the product tubes from overheating

I am responsible for the design of half a dozen immersion tube heaters, plus several hundred fire-tube, burner, control and stack systems. This experience enables me to offer precise, efficient sizing of every facet of heater construction

It would be a pleasure to work with you in your application(s) and I invite your inquiries

U-TUBE WITH FLAME ARRESTOR HOUSING, BURNER, SECONDARY AIR CONTROL AND STACK


BURNERS - VARIOUS CONFIGURATIONS

All burners are designed to meet the safety, material, design, construction, operation and emssions requirements and codes of the intended application.  This includes both European and North American standards where applicable

Although standards exists to ensure safety and performance, burners can take on a variety of shapes and styles permitting an almost endless range of applications.  

2.5MM Btu/Hr RADIANT FLOOR BURNERS (16) PROVIDE INDIRECT RADIANT HEAT EXPOSURE TO THE TUBE SURFACES

DUCT STYLE, NOZZLE MIXING, FUEL AND/OR WASTE GAS BURNER FOR EXHAUST GAS REHEATING, AIR HEATING AND WASTE GAS INCINERATION- TO 300MM Btu/Hr

More Burner examples are provided in the different sections of this site related to Incineration, Thermal Oxidation and Flaring

It would be a pleasure to discuss your Burner application(s) and I invite your inquiry

Thank You,

T.L.Willis