Method and system for fuel gas combustion, and burner for use therein
Power cycle generation equipment is operated in a more efficient and economical manner by using an uncooled (and potentially uncleaned) fuel gas supplied to the equipment directly from a gasification process, i.e., without first quenching or pressurizing the gas. In one embodiment, a burner used in conjunction with the power cycle generation equipment accepts such fuel gas directly from a syngas generator (or perhaps after particulate removal). The burner preferably operates with fuel gas and oxidizer inputs reversed as compared to existing configuration.
Latest ZE-GEN, INC. Patents:
The present invention relates generally to enhancing the efficiency of conventional boilers or steam generators using a non-cooled, non-pressurized fuel gas.
BACKGROUND OF THE RELATED ARTThe products generated in high temperature gasification of hydrocarbon materials give high concentrations of carbon monoxide and hydrogen, small quantities of sulfide, fluoride and chloride-bearing compounds, as well as some particulate. To utilize this gas in high efficiency cycles, typically it is cleaned of particulate, acid and condensable gases to a very high efficiency, pressurized, and then supplied to a conventional burner.
BRIEF SUMMARYPower cycle generation equipment is operated in a more efficient and economical manner by using an uncooled (and potentially uncleaned) fuel gas supplied to the equipment directly from a gasification process, i.e., without first quenching or pressurizing the gas. In one embodiment, a burner used in conjunction with the power cycle generation equipment accepts such fuel gas directly from a syngas generator (or perhaps after particulate removal). The burner preferably operates with fuel gas and oxidizer inputs reversed as compared to existing configuration. In one preferred embodiment, the burner operates with a syngas gas composition, such as 50/50 mixture of carbon monoxide and hydrogen, at a fuel gas temperature in excess of 1500° F. The syngas may be provided from a liquid metal gasifier, although this is not a limitation. The energy content of the fuel gas, excluding heat, preferably ranges from 200-500 BTU's/cubic foot. The oxidizer (air or oxygen) preferably is pressurized from 0.1-5 atmospheres. Although not limiting, an induced draft fan may be used to draw the fuel gas into the burner.
The burner may be implemented as an add-on to existing power cycle generation equipment such as a boiler, a kiln, or a steam generator; alternatively, the burner is built into such equipment anew. Preferably, the burner comprises a set of injectors, with each injector or injectors supporting at one end one or more flame holder wings. Each flame holder wing includes a set of apertures. When positioned in the fuel gas stream, the uncooled, uncleaned fuel gas passes through the apertures in the flame holder wing where it is mixed with an oxidizer (air or oxygen) that is supplied to the burner under pressure and exits one or more openings in each injector. The fuel may auto-ignite, or a separate pilot burner may be used for initial ignition. The flame holder wings create a recirculation zone adjacent the injectors. As compared to the prior art, where the oxidizer is the primary stream and the cooled and pressurized fuel gas is provided through the injectors, the preferred approach here is to invert these inputs to the burner and without any requirement that the fuel gas been cooled or pressurized before being combusted.
The foregoing has outlined some of the more pertinent features of the invention. These features should be construed to be merely illustrative. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention as will be described.
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
In another embodiment, illustrated in
As noted above, preferably the burner injector comprises flame holder “wings” that are perforated metal especially designed to minimize thermal stresses in their attachment to the main oxidizer header. A preferred construction is illustrated in
The burner illustrated above may be retrofitted to existing boilers, kilns or other such equipment, or it may be built into such equipment originally. The burner may be used with any fuel gas source, such as syngas, and it is preferred that the fuel gas be provided to the burner directly as opposed to being first cooled, pressurized and/or cleaned. As such, the fuel gas is a “hot” (uncooled) and/or “dirty” (uncleaned) fuel source that is drawn through the burner, preferably using an induced draft fan, while the oxidizer is provided to the burner under pressure. As compared to the prior art, the burner inputs are inverted, and it has been found that this structural and process arrangement provides energy efficiencies and reduced emissions as compared to the prior art.
In one preferred embodiment, the fuel gas is provided by a liquid metal gasifier. It is known in the prior art to provide gasification systems that convert municipal solid waste (MSW) and construction and demolition waste (C&D) into clean energy. As described in U.S. Publication No. 2006/0228294, which is representative, these systems may comprise a refractory, induction furnace that receives the feed material into a molten metal bath, wherein a mix of organic and non-organic material is treated resulting in metal recovery and efficient production of synthesis gas (syngas). The syngas can be used to fuel a combined-cycle generator to provide municipalities with clean, renewable electricity.
While the above describes a particular order of operations performed by certain embodiments of the invention, it should be understood that such order is exemplary, as alternative embodiments may perform the operations in a different order, combine certain operations, overlap certain operations, or the like. References in the specification to a given embodiment indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Further, while given components of the system have been described separately, one of ordinary skill will appreciate that some of the functions may be combined or shared in given systems, machines, devices, processes, and the like.
In operation, the burner accepts fuel gases preferably directly from fuel gas generator without a requirement of significant cleaning and pressurization. The burner has the ability to utilize gases with gas compositions, such as 50/50 mixtures of carbon monoxide and hydrogen, at fuel gas temperatures in excess of 1500° F. The energy content of the fuel gas, excluding sensible heat, preferably ranges from 200-500 BTU's/cubic foot. Existing combustion systems would require cooling, cleaning and compressing of the fuel gas and injecting into the combustor under pressure. The oxidizer (air or oxygen) source would normally be at very low pressures. In contrast, a preferred combustor accepts fuel gases directly from the syngas generation process without significant cleaning and pressurization. The oxidizer (air or oxygen) is pressurized from 0.1-5 atmospheres.
Claims
1. A method of releasing energy, comprising:
- receiving a fuel gas from a fuel source;
- drawing the fuel gas through a burner while simultaneously injecting an oxidizer at a higher pressure relative to a pressure of the fuel gas;
- wherein the fuel gas is drawn through the burner without first cooling, pressurizing or fine cleaning.
2. The method as described in claim 1 wherein the fuel gas is syngas.
3. The method as described in claim 2 further including separating particulates from the syngas prior to the drawing step.
4. The method as described in claim 1 wherein the fuel gas is drawn through the burner using an induced draft fan.
5. A burner, comprising:
- a refractory-lined duct and burner inlet section that receives fuel gas directly from a gas source without first cooling, pressurizing or fine-cleaning the fuel gas; and
- an oxidizer injector operating downstream of the burner inlet section.
6. The burner as described in claim 5 wherein the oxidizer injector comprises at least one free-standing injector comprising one or more flame holder wings.
7. The burner as described in claim 6 wherein each flame holder wing comprises one or more apertures through which the fuel gas is drawn.
8. The burner as described in claim 5 further including a secondary oxidizer injector downstream of the oxidizer injector.
9. The combustor as described in claim 5 wherein air or oxygen is injected by the oxidizer injector at less than stochiometric amounts to reduce formation of nitrogen oxides.
10. A method of energy generation, comprising:
- retrofitting or providing energy generation equipment with a burner having first and second input sources;
- receiving, as the first input source, a fuel gas; and
- injecting, as the second input source, an oxidizer, where the oxidizer is injected at a higher pressure relative to a pressure of the fuel gas;
- wherein the fuel gas is received from a fuel source without first cooling, pressuring or fine cleaning the fuel gas.
Type: Application
Filed: Aug 8, 2008
Publication Date: Feb 11, 2010
Applicant: ZE-GEN, INC. (Boston, MA)
Inventors: William H. Davis (Winchester, MA), Irving B. Morrow, Jr. (Harvard, MA)
Application Number: 12/188,857
International Classification: F23N 1/02 (20060101); F23C 5/08 (20060101); F23D 14/22 (20060101); F23K 5/06 (20060101);