Patent Application
20130180289
The present invention relates to a method and a device for melting meltable stock, such as glass.
Melting glass using a glass furnace is known, the furnace being heated via a frontally attached burner port. Corresponding burners are typically referred to as frontal burners or U-flame burners; corresponding furnaces are referred to as a U-flame trough (English: “end-port furnace”). Such furnaces are typically operated regeneratively using two burner ports alternately, i.e., fuel and an oxidizer (typically air) is supplied to only one of the two burner ports, while the hot exhaust gases are exhausted via the air supply opening of the other burner port. The required heat for maintaining the glass melt is generated by the combustion of the fuel (the start up of the melt or “firing up” is typically performed slowly via separate auxiliary burners or the like). The combustion gases cover a U-shaped path in the furnace, because of which they are given the above designations. The burner ports are alternately operated in the function of a burner port and an exhaust gas port, a changeover occurring after a specific cycle time, for example, between 10 and 30 min., in particular 15 to 25 min. A heat exchanger (also referred to as a regenerator, English “regenerator”) is connected upstream from the supply opening of a burner port in each case in the supply path of the oxidizer (air). For example, heat storage bricks, which were previously heated by exhausted exhaust gas to temperatures of approximately 1500° C., are located in the heat exchanger. In the next cycle, oxidizer (air) is conducted via the heated heat storage bricks to the burner port, the inflowing air being able to be preheated to approximately 1350° C. This regenerative alternating operation (English: “swap”) of the two burner ports is the foundation for many industrial furnaces as the Siemens-Martin method.
The terms “upstream” and “downstream” refer hereafter, if reference is not explicitly made to another stream, to the main flow direction of the combustion gases, which exit from the burner port(s) and leave the furnace via the exhaust gas port(s). In the case of an end-port furnace, the combustion gases cover a substantially U-shaped path from the burner port through the furnace chamber back to the exhaust gas port. The main flow path extends from a burner port, which is located in one front side of the furnace, in the longitudinal direction of the furnace and then reverses, the combustion gases leaving the furnace via the exhaust gas port arranged in the front side adjacent to the burner port. After the two ports are switched over, the previous exhaust gas port operates as the burner port and the previous burner port operates as the exhaust gas port. The main flow direction in the furnace also reverses accordingly and extends opposite to the previous main flow direction.
Nitrogen oxides (NOx) may arise during the combustion. Efforts have been made to reduce the nitrogen oxide fraction in the exhaust gas. In metal smelting or in heat treatment furnaces, so-called FLOX combustion or flameless combustion is preferably used for this purpose. The exhaust gases are strongly recirculated in the combustion chamber and mixed with the combustion air in this case. In this way and due to the delayed mixing of air and combustion gas, a flame front can no longer form. At sufficiently high temperatures of at least 800° C., the fuel oxidizes in the entire combustion chamber volume while forming very homogeneous temperatures. The formation of nitrogen oxides, which occurs above all at the flame boundary having its high peak temperatures, is reduced. The application of flameless combustion in the case of molten glass is subject to restrictions, however, since in this case it is necessary to deviate from long-proven production methods having their empirically obtained production details.
More recently, NOx limiting values of 700 mg/Nm3 have been required. Known glass melting methods do not typically achieve this limiting value. Because of the high processing temperatures, thermal NOx arises, typically at over 1100 mg/Nm3 exhaust gas.
Substoichiometric operation of the burners in such a manner that carbon monoxide (CO) is generated is also known. Carbon monoxide reduces nitrogen oxides to form carbon dioxide and nitrogen. However, the occurring CO emissions result in elevated temperatures in the exhaust gas regenerator (heat exchanger) because of post-combustion, which can result in damage and even destruction of the regenerator. For this reason, this type of operation is generally precluded.
WO 2010/114714 A1, which also relates to an end-port burner, proposes another type of reduction of nitrogen oxides. A fuel burner, which is preferably arranged on the hotspot of the furnace or in its proximity and is preferably operated substoichiometrically i.e., fuel-rich, is located downstream from a burner port operated to form a combustion flame. A further fuel burner is arranged further downstream, which is operated superstoichiometrically, i.e., oxygen-rich. In practice, the two fuel burners are preferably located on the opposing side walls of the furnace in front of the outlet port for liquid glass. Oil or gas can be used as the fuels. The use of the fuel-rich, substoichiometrically operated burner results in an expansion of the fuel-rich areas in the furnace, so that the formation of NOx is decreased because of a lack of oxygen and because of the produced CO. Further downstream and therefore in the direction of the exhaust gas side of the furnace, the second oxygen-rich and therefore superstoichiometrically operated fuel burner ensures thorough mixing of the exhaust gases with an oxygen-rich flame and therefore the most complete possible post-combustion of incompletely combusted fuel components. The two fuel burners, which are also referred to as “hotspot burners”, are preferably arranged opposite one another in the third of the longitudinal walls of the furnace located further downstream, and are therefore located in the area of the U-shaped reversal of the combustion gas stream in the furnace. Alternating furnace operation is readily possible, in that the fuel burners are switched from substoichiometric to superstoichiometric operation (or vice versa). Significantly reduced NOx exhaust gas values have already been able to be measured using this method.
Moreover, a reduction of nitrogen oxides can typically also be performed by means of exhaust gas post-treatment and purification. Such exhaust gas purification devices are space-intensive and investment-intensive, and typically require high operating and maintenance costs. Alternatively or additionally, the melting area in the furnace could be significantly enlarged to reduce the specific heat load of the furnace. The disadvantage here would be a significantly larger furnace with unchanged performance.
One problem on which the present invention is based is therefore the reduction of the nitrogen oxide fraction in the exhaust gas of above-described melting furnaces, in particular for glass melting and glass processing. The solution is to be as space-saving and cost-saving as possible.
The invention is schematically shown on the basis of an exemplary embodiment in the drawings and will be described in detail hereafter with reference to the drawings.
The invention proposes a method and device for melting meltable stock, in particular glass, according to the claims. Other embodiments result from the claims and the following description.
The terms furnace and melting furnace are used synonymously in connection with the invention.
The invention relates to a method for melting stock, such as glass, in a furnace, which is implemented as an end-port furnace, two ports being provided in a front side of the furnace, which are alternately operated as the burner port and the exhaust gas port. A fuel and an oxidizer are supplied to the burner port and caused to react (combusted). The resulting combustion gases flow along an essentially U-shaped main flow direction through the furnace to the exhaust gas port. The two legs of the U-shaped main flow direction extend essentially perpendicularly to the furnace front side having the burner port and essentially parallel to the side walls of the furnace. Air is typically used as the oxidizer, which is supplied to the burner port, because of which the latter is also frequently referred to as an “air burner”. Downstream from this burner port, a fuel-rich fuel-oxygen mixture is introduced into the furnace via at least one substoichiometrically operated burner. This substoichiometrically operated burner is frequently also referred to as an “oxy-fuel burner” or, since it is advantageously arranged in the area of the hotspot of the furnace, as a “hotspot burner”, abbreviated “HSB”. This substoichiometrically operated burner results in an elevated energy introduction in the area of the hotspot of the furnace and therefore supports the convection of the melt in the furnace. On the other hand, it reduces the formation of NOx because of a lack of oxygen and the generation of CO connected thereto. According to the invention, it is additionally proposed that a gas stream containing oxygen be introduced or injected into the furnace downstream from the at least one substoichiometrically operated burner. In this way it is possible to inject gas containing oxygen at high speed into the combustion gases, in order to thoroughly mix the combustion gases and post-combust the CO. The introduction of the gas stream at high speed is advantageous, in order to suction in as much combustion gas as possible and mix it with oxygen, on the one hand, and to achieve recirculation of the combustion gases located in the furnace and thus dilute the oxidizer and fuel stream of the so-called air burner, on the other hand. This results in a reduction of the flame temperature, whereby the occurrence of NOx is in turn reduced. Since the post-combustion of CO within the furnace occurs on its exhaust gas side, a temperature increase in the exhaust gas regenerator (i.e., in the heat exchanger assigned to the exhaust gas port) can be prevented. The invention thus results in a further reduction of the NOx concentration in comparison to known melting methods, without the danger of thermal damage to heat exchangers used for the regenerative operation of the furnace.
In another embodiment of the invention, additionally or alternatively to the at least one substoichiometrically operated burner (oxy-fuel burner) for introducing a fuel-rich fuel-oxygen mixture into the furnace, only fuel (without oxygen), for example, pure natural gas, is introduced or injected into the furnace. This variant is possible since, through the introduction of the oxygen-containing gas stream, sufficient oxygen is available for combusting the additional fuel and for post-combusting incompletely burned fuel.
It is advantageous if air, oxygen-enriched air, or pure oxygen is used as the gas stream containing oxygen. As already mentioned, the injection of the gas stream at high speed is advantageous. Preferable lower limits of the inflow speed are 50 m/s, 100 m/s, or more preferably 150 m/s; preferred upper limits are 326 m/s (the speed of sound), preferably 200 m/s. It is advisable in this case to introduce or inject the gas stream as one or more thin jets into the furnace. To generate the high flow speeds, it is advantageous to inject the gas stream via a Laval nozzle or a Venturi nozzle. Known lances, such as oxygen lances, can be used for injecting the gas stream containing oxygen.
Before preferred injection points for the gas are described, the geometric conditions of a melting furnace are to be explained. The processing direction originates from the burner port (air burner). This is followed downstream by one or more oxy-fuel burners or the mentioned fuel nozzle(s) (or also a combination of these two arrangements). Flow gas nozzles for introducing the gas stream containing oxygen are provided further downstream on the furnace, which are in turn followed downstream by an exhaust gas port of the furnace.
The burner port and the exhaust gas port are located in the front side of the furnace. Both ports have one or more channels for the oxidizer supply (preferably air supply) and one or more channels for the fuel supply. The two ports are operated alternately, in the event of such a change, the previous burner port becoming the exhaust gas port and the previous exhaust gas port becoming the burner port. If a port is operated in its function as a burner port, an oxidizer (in particular air) is supplied thereto through the corresponding channels. The fuel supply occurs via the channels provided for this purpose. If a port is used as the exhaust gas port, the combustion gases are exhausted from the furnace via the channels otherwise provided for the oxidizer supply.
During the regenerative operation, the oxidizer or the combustion gases are conducted via the heat exchangers. The hot exhaust gases deliver their heat to the heat exchanger and in the next cycle the oxidizer (air) can absorb this heat again, whereby strongly preheated oxidizer (air) is available as the oxidizing agent for generating the burner flame. Both ports are arranged frontally on the same side in such an end-port furnace, and the U-shaped main flow direction of the combustion gases already described in the introduction to the description occurs. Such frontal melting furnaces (end-port furnaces) typically have their area of highest temperatures (hotspot) in an area in which the path of the combustion gases turns by 180°. This area is in the lower third of the furnace length, viewed from the front side of the furnace. The end side of the furnace, on which the outlet port for the liquid glass is located, lies opposite to the front side having the burner port and the exhaust gas port. The hotspot is located in the third of the furnace remote from the front side, which adjoins the end side. The furnace is bounded in the longitudinal direction, i.e., essentially perpendicular to the front side of the furnace, by side walls.
In the case of the above-described geometric conditions of typical melting furnaces, advantageous arrangements of the nozzles and burners may be understood easily. It is reasonable to introduce the gas stream by means of at least one flow gas nozzle from one or more of the following points into the furnace interior: a front wall, a side wall, or an arch of the furnace, in particular in the area and in proximity to an exhaust gas port of the furnace. For example, a flow gas nozzle is therefore located in proximity to the exhaust gas port, this nozzle being arranged in a side wall, in the front wall, or in the arch or roof of the furnace. In the case of a furnace having alternately operated burner ports (air burners), one burner port is alternately used as the exhaust gas port in each case, so that corresponding flow gas nozzles must be provided at both possible points. These points are then located in the area of the burner port or exhaust gas port, in particular in the side wall and/or the front wall and/or the arch of the furnace.
The gas stream is preferably introduced into the third of the furnace adjoining the front side having the exhaust gas port. The gas stream is thus injected into the part of the furnace which is delimited by the front side and the side walls and extends over one third of the furnace length. In further preferred embodiments, the gas stream is introduced into the quarter, fifth, or tenth of the furnace adjoining the front side having the exhaust gas port. In the furnace longitudinal direction, i.e., in the direction perpendicular to the front side, the distance of the flow gas nozzle from the front side is at most 33%, at most 25%, at most 20%, at most 15%, or at most 10% of the longitudinal extension of the furnace, the longitudinal extension referring to the distance between front side and inside.
An arrangement is preferably located in a side wall of the furnace (in the case of alternately operated burner ports therefore in both side walls of the furnace), in general the gas stream containing oxygen not being injected into the exhaust gas stream precisely perpendicularly to the furnace wall, but rather in a direction having a vectorial component in the direction of the main flow direction of the combustion gases.
The gas stream is to be introduced into the furnace on the exhaust gas side outside the burner flame generated by the burner port (air burner) in the furnace. As already explained, CO arising in this way can be post-combusted as optimally as possible and, on the other hand, the furnace exhaust gases (combustion gases) can be recirculated well, whereby oxidizer (combustion air) and fuel stream of the air burner are diluted.
In a further embodiment, an oxygen-rich fuel-oxygen mixture is introduced into the furnace via at least one superstoichiometrically operated burner downstream from the at least one substoichiometrically operated burner and upstream from the point of the introduction of the gas stream containing oxygen. In the mentioned further embodiment of the invention, an oxygen-rich fuel-oxygen mixture is correspondingly introduced into the furnace via at least one further superstoichiometrically operated burner downstream from the fuel nozzle, via which a fuel or fuel mixture is introduced into the furnace, and upstream from the mentioned injection of the gas stream containing oxygen. This superstoichiometrically operated burner is (like the substoichiometrically operated burner) advantageously arranged in the area of the hotspot of the furnace. Because of the oxygen excess, this burner (oxy-fuel burner or hotspot burner) supports the post-combustion of carbon monoxide (CO).
In this embodiment, the following arrangements are advisable in a frontal melting furnace (end-port furnace). Originating from a frontally arranged burner port, a first flow gas nozzle is located on one side wall or longitudinal side of the furnace, in particular in the first third of the longitudinal side adjoining the front side. In particular in the lower third of this longitudinal side, adjoining the end side opposite to the front side, and also in particular at the height of the hotspot of the furnace, the substoichiometrically operated oxy-fuel burner and/or a fuel nozzle for introducing pure fuel (for example, natural gas) is located. On the opposite longitudinal side, the superstoichiometrically operated burner (second oxy-fuel burner) is arranged in the lower third, in particular opposite to the oxy-fuel burner or the fuel nozzle. A second flow gas nozzle is located in the upper, i.e., first third of the longitudinal side adjoining the front side, in particular opposite to the mentioned first flow gas nozzle. A further port is in turn frontally arranged further downstream. This symmetric arrangement is particularly preferable in the case of the mentioned frontal melting furnace. Of course, multiple flow gas nozzles can be arranged, in particular symmetrically at various points of the furnace (for example, additionally on the front side or in the arch). This is also true for the oxy-fuel burner or the fuel nozzle.
Furthermore, the invention relates to a device for melting meltable stock, such as glass, having a furnace, which is implemented as an end-port furnace, two ports being provided in a front side of the furnace, which are alternately operable as burner port or exhaust gas port, and a heat exchanger being assigned to each of the ports. A fuel and an oxidizer can be supplied to the furnace via the burner port to implement a combustion reaction, in order to heat the furnace. The furnace has at least one substoichiometrically operable burner for introducing a fuel-rich fuel-oxygen mixture into the furnace and/or at least one fuel nozzle for introducing a fuel or fuel mixture into the furnace, the substoichiometrically operable burner and/or the fuel nozzle being arranged in the half of the furnace which does not adjoin the front side having the burner port and an exhaust gas port. Furthermore, the furnace has at least one flow gas nozzle for supplying a gas stream which contains oxygen into the furnace, the flow gas nozzle being arranged in the half of the furnace which adjoins the front side having the burner port and the exhaust gas port.
Reference is expressly made to the above explanations in connection with the method according to the invention with respect to advantageous embodiments of this device.
The melting furnace is alternately operable (regeneratively), and has at least two ports, which are alternately operable, the combustion gases being exhausted via a second burner port, which functions in this case as the exhaust gas port, during the generation of a burner flame by supplying the oxidizer to a first burner port. For a regenerative operation, a heat exchanger is assigned to each of the at least two ports, through which the oxidizer or the exhaust gas flows depending on the operational path. At least one pair of alternately operable flow gas nozzles is provided for introducing a gas stream containing oxygen, the flow nozzles being arranged upstream from the heat exchanger and in proximity thereto. With this arrangement, it is to be ensured that remaining CO is combusted as completely as possible before it enters the heat exchanger, to prevent thermal damage therein. Flow gas nozzles and ports are operated alternately in the same cycle.
Reference is made to the above explanations for advantageous arrangements of the oxy-fuel burner and/or the fuel nozzle(s) and the flow gas nozzles, in particular in a frontal melting furnace.
In practice, a flow gas provision device will be provided, which is designed and configured to provide a gas stream at such a pressure that the gas stream leaves the flow gas nozzle at a speed of advantageously at least 50 m/s, preferably at least 100 m/s, particularly preferably 150 m/s, the highest value of the speed being 326 m/s, particularly preferably 200 m/s. The gas stream is a gas containing oxygen, i.e., an oxidant, for example, air, oxygen-enriched air or pure oxygen.
An essential advantage of the invention is that required limiting values, currently of 700 mg/Nm3 exhaust gas for NOx, can be achieved, and existing furnace facilities in operation can be retrofitted to implement the invention. Constructing larger furnaces with the same performance or the additional construction of exhaust gas purification facilities can be dispensed with.
The regulation of the quantity of the gas containing oxygen or the pure oxygen via the flow gas nozzle or the lance can be performed with the aid of the measurement of the CO concentration or the residual oxygen concentration in the exhaust gas. The same regulation possibility results for the supplied fuel via the fuel nozzle.
The mentioned burners (oxy-fuel burners) or nozzles (flow gas and fuel nozzles) can be arranged essentially transversely to the flow direction in the furnace or also longitudinally to the flow direction. The use of flat flame burners is advantageous, in particular in the arch of the furnace, to achieve the best possible thorough mixing of combustion gas and oxygen or reducing agent (CO or CH4). Since the flat flame burners result in a type of “fishtail” flame (widespread but thinner than a conventional, round burner), better permeation of the reducing oxy-fuel burner exhaust gases with the exhaust gases from the air burner can be achieved and therefore CO can be post-combusted better, and also NOx can be reduced better.
The above-mentioned features and the features still to be explained hereafter are usable not only in the respective specified combination but rather also in other combinations or alone, without leaving the scope of the invention.
Charging front buildings (English: “doghouse”) 16, 18 via which material required to produce a glass is supplied to the furnace 10, are located in each case in the side walls 19, 21 and in proximity to the ports 24A, 26A. The supply direction is identified by 17. Two burners 20, 22 are arranged opposite to one another in the lower third of the side walls 19, 21 viewed from the front wall 13. Alternative or additional positions for a burner 20 are identified by 20A and 28. While the position 20A is located on the end wall 15, the positions 28 are located in the arch or ceiling of the furnace 10. Alternative or additional positions for a burner 22 are identified by 22A and 30. The position 22A is again located on the end wall 15, while the positions 30 are located in the arch or ceiling of the furnace 10. In the positions 20A and 22A, the burners are arranged along the flow direction.
An outlet port 11 for liquid, molten glass is located on the floor of the furnace 10.
In operation according to
In the next operating cycle, which is shown in
The hotspot, i.e., the area having the highest temperatures in the furnace 10, lies essentially between the burners designated by 20 and 22 and therefore in the area of the reversal of the main flow path. In the area of this hotspot, a low wall extends on the floor of the furnace 10, typically parallel to the end wall 15. The furnace is partitioned into a frontal trough area and a terminal refining area by this wall in the area of the hotspot. The hotspot and the wall extending therein are used to support the convection and optimize the glass melt. Further details on the construction and function of the components of a melting furnace 10 can be taken from the prior art.
The flow gas nozzles for supplying a gas stream containing oxygen into the combustion chamber 14 of the furnace 10 are identified by 1. In this exemplary embodiment, they have the form of oxygen lances. While the flow gas nozzle 1 arranged on the side wall 21 is active in the operating cycle according to
In the operating cycle according to
The burner 22 can be operated oxygen-rich, i.e., superstoichiometrically. In this case, a part of the occurring CO would already be reduced. It has been shown that it can also be advisable to operate the burner 22 substoichiometrically like the burner 20. This results in an amplification of the effect induced by the burner 20. Further effects due to the burners 20 and 22 are a dilution of combustion air (oxidizer) and fuel stream in the burner flame 29, whereby this burner flame 29 is cooled. Such a cooling of the flame temperature, in particular at the hot points of the flame, results in a reduction of thermally generated NOx.
A further effective reduction of the NOx concentration, using which the recently required limiting value of 700 mg/Nm3 exhaust gas can be reached, can be achieved via the introduction of a gas stream containing oxygen on the exhaust gas side of the furnace 10 via the flow gas nozzle 1 (on the side wall 21). The mode of operation is as follows in this case: the gas stream containing oxygen mixes with the combustion gas stream and causes post-combustion of CO. In this way, the regenerator 26 can be protected from thermal damage. The injection speed of the gas stream containing oxygen into the furnace 10 is to be sufficiently high to ensure that adequate recirculation of the furnace exhaust gases (combustion gases) is achieved, which in turn has the result that combustion air and fuel stream of the air burner (burner port 24A here) are diluted. This results in the reduction of the flame temperature and therefore a further decrease of NOx. Preferred injection speeds are between 100 and 200 m/s in this exemplary embodiment. A high outflow speed is also known to result in increased suctioning of exhaust gas and therefore stronger mixing with the oxygen of the gas stream containing oxygen. In this exemplary embodiment, pure oxygen is injected via oxygen lances into the furnace interior.
The quantity of the injected oxygen can be regulated with the aid of a measurement of the CO concentration. For this purpose, a CO concentration measurement is performed at a suitable point upstream from the flow gas nozzle 1. The quantity of the oxygen required for the complete post-combustion of the CO can be calculated based thereon. Alternatively or additionally, this regulation can be performed via a measurement of the residual oxygen concentration in the exhaust gas. Empirical measurements have shown that the residual oxygen content in the furnace exhaust gas, measured in the regenerator head, is to be at least 1.0-1.5%.
Similar observations apply to the operating cycle shown in
The injection direction of the gas stream containing oxygen can be oriented perpendicularly to the side wall 19 or 21. It has proven to be advantageous if the inflow direction of the gas stream containing oxygen has a vectorial component in the direction of the stream of the combustion gases (flow path 31 or 27). The angle of the oxygen lance shown can be set accordingly. Of course, only a planar section is shown in the figures; the orientation of the lance can be suitably performed in all three spatial directions.
Alternative or additional positions for the burner 20 are designated by 20A and 28. Alternative or additional positions for the burner 22 are designated by 22A and 30. Reference is made to publication WO 2010/114714 A1, which was already mentioned in the introduction to the description, for more detailed explanations of these alternative or additional positions. In the mentioned publication, the burner 20 is operated substoichiometrically and the burner 22 is operated superstoichiometrically in the operating cycle of
Finally, it is to be emphasized once again that, alternatively or additionally to the burners 20 and 22 shown in
In practice, the burner 20 according to
The present invention causes a further reduction of NOx in the exhaust gas of melting furnaces and therefore is particularly well suitable for meeting legal requirements.
| Number | Date | Country | Kind |
|---|---|---|---|
| 11002931.1 | Apr 2011 | EP | regional |
