Flameless Burners - Dilute Oxygen Combustion

While techniques for air preheating (i.e. regenerative and recuperative furnaces) are widely used in the preheating furnaces, they have the drawback of increasing NOx emissions. The flameless burner technologies carry out out combustion under diluted oxygen conditions using internal flue gas recirculation and the flame becomes invisible. Flameless airfuel combustion uses air as oxidizer, while flameless oxyfuel uses commercial oxygen as an oxidant. Flameless oxyfuel gives high thermal efficiency, higher levels of heat flux, and reduced fuel consumption compared to conventional oxyfuel These benefits are combined with low NOx emissions and better thermal uniformity.  

In addition to significantly reducing fuel consumption and CO2 and NOx emissions, by convering to a flameless oxy-fuel combustion system enabled a plant in the US to increase material throughput by 25% and reduce scale formation by 50% (US EPA, 2010. p. 28).

Development Status Products
Commercial
Hot rolled steel

Flameless Burners - Dilute Oxygen CombustionCosts & Benefits

Parent Process: Rolling Mills
Energy Savings Potential

EU Flag A plant in France reduced furnace fuel consumption by 40% by converting five pit furnaces to flameless oxyfuel furnaces- excluding additional electricity requirement for oxygen production. The production of 1 Nm3 of Oxygen requires approximately 0.5 kWh of electricity (Worrell et al., 2010. p. 102).

US flag A plant in the US reduced furnace fuel coonsumption by 60% by implementing a flameless oxy-fuel operation on its rotary-hearth steel-reheat furnace - compared to the original air-fuel operation. 

CO2 Emission Reduction Potential

US flag In a US based plant, swithinc over to flameless oxyfuel burners reduced CO2 emissions by 60% and NOx emissions by 92%. 

Costs

Flameless Burners - Dilute Oxygen Combustion Publications

Energy Efficiency Improvement and Cost Saving Opportunities for the U.S. Iron and Steel Industry

The U.S. Environmental Protection Agency’s (EPA) energy guide, Energy Efficiency Improvement and Cost Saving Opportunities for the U.S. Iron and Steel Industry, discusses energy efficiency practices and technologies that can be implemented in iron and steel manufacturing plants. This guide provides current real world examples of iron and steel plants saving energy and reducing cost and carbon dioxide emissions.

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