Dynamic burner reconfiguration and combustion system for process heaters and boilers

Abstract

A furnace combustion system includes a plurality of burners adapted to generate a plurality of flames and an oxidant port disposed between and surrounded by at least two of the burners. Each burner is spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame. The oxidant port is adapted to transmit at least one jet of the first oxidant or the other oxidant axially between at least two of the flames. The at least one jet is transmitted from the oxidant port at a controlled flow rate. At least a portion of the first oxidant or the other oxidant in the jet is required to complete combustion of at least a portion of at least one stream of the first fuel or the other fuel.

1 . A furnace combustion system, comprising: 
 a plurality of burners adapted to generate a plurality of flames, including 
 a first burner adapted to combust a first stream of a fuel with a first stream of a first oxidant and to generate a first flame, and  
 a second burner spaced apart from the first burner and adapted to combust a second stream of the fuel, or a stream of an other fuel, with a second stream of the first oxidant, or a first stream of a second oxidant, and to generate a second flame; and  
   an oxidant port disposed between and surrounded by at least two of the plurality of burners, including the first burner and the second burner, the oxidant port adapted to transmit at least one jet of the first oxidant, the second oxidant, or an other oxidant, axially between at least two of the plurality of flames, including the first flame and the second flame,    wherein the at least one jet is transmitted from the oxidant port at a controlled flow rate, and    wherein at least a portion of the first oxidant, or the second oxidant, or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one of the first stream of the fuel and the second stream of the fuel, or the stream of the other fuel.    
   
   
       2 . A furnace combustion system as in  claim 1 , wherein the controlled flow rate is controlled at least in part by a damper.  
   
   
       3 . A furnace combustion system as in  claim 1 , wherein the oxidant port is substantially equidistant from the first burner and the second burner.  
   
   
       4 . A furnace combustion system as in  claim 1 , wherein the at least one jet includes a swirling stream.  
   
   
       5 . A furnace combustion system as in  claim 4 , wherein the swirling stream has a swirl number in the range of about 0.2 to about 0.6.  
   
   
       6 . A furnace combustion system as in  claim 1 , wherein the at least one jet has an oxygen concentration in the range of about 5 vol. % to about 50 vol. %.  
   
   
       7 . A furnace combustion system as in  claim 1 , wherein the at least one jet provides about 5% to about 50% of a total oxidant required to operate a furnace operated with the furnace combustion system.  
   
   
       8 . A furnace combustion system as in  claim 1 , wherein the at least one jet has a velocity in a range of about 20 ft/sec. to about 1,000 ft/sec.  
   
   
       9 . A furnace combustion system as in  claim 1 , wherein at least one of the first flame and the second flame is fuel-rich.  
   
   
       10 . A furnace combustion system as in  claim 1 , wherein the first flame merges with the second flame.  
   
   
       11 . A furnace combustion system as in  claim 1 , wherein at least one of the first burner and the second burner is adapted to transmit a variable distribution of at least one of the fuel and the other fuel.  
   
   
       12 . A furnace combustion system, comprising: 
 a plurality of burners adapted to generate a plurality of flames, each burner being spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame; and    an oxidant port disposed between and surrounded by at least two of the plurality of burners, the oxidant port adapted to transmit at least one jet of the first oxidant or the other oxidant axially between at least two of the plurality of flames,    wherein the at least one jet is transmitted from the oxidant port at a controlled flow rate, and    wherein at least a portion of the first oxidant or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one stream of the first fuel or the other fuel.    
   
   
       13 . A furnace combustion system in a furnace having an interior and a longitudinal axis, comprising: 
 a plurality of burners adapted to generate a plurality of flames, each burner being spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame, the plurality of burners being disposed in the interior of the furnace in a substantially circular pattern spaced around the longitudinal axis of the furnace; and    an oxidant port disposed in the interior of the furnace between and surrounded by the plurality of burners, the oxidant port being substantially equidistant from each burner and adapted to transmit at least one jet of the first oxidant or the other oxidant axially between at least two of the plurality of flames,    wherein the at least one jet is transmitted from the oxidant port at a controlled flow rate, and    wherein at least a portion of the first oxidant or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one stream of the first fuel or the other fuel.    
   
   
       14 . A furnace combustion system as in  claim 13 , further comprising a plurality of fuel staging lances, each fuel staging lance spaced apart from another fuel staging lance, the plurality of fuel staging lances surrounding at least one of the burners, wherein at least one fuel staging lance is adapted to transmit a flow of at least one of the first fuel and the other fuel at a first flow rate different than a second flow rate at which another flow of at least one of the first fuel and the other fuel is transmitted by at least one other fuel staging lance.  
   
   
       15 . A furnace combustion system in a furnace having an inner wall, comprising: 
 a plurality of burners adapted to generate a plurality of flames, each burner being spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame; and    a plurality of oxidant ports, each oxidant port disposed between and surrounded by at least two of the plurality of burners, each oxidant port adapted to transmit at least one jet of the first oxidant or the other oxidant axially between at least two of the plurality of flames, the plurality of the burners forming a first matrix and the plurality of the oxidant ports forming a second matrix adjacent the first matrix, and    wherein the at least one jet is transmitted from the oxidant port at a controlled flow rate, and    wherein at least a portion of the first oxidant or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one stream of the first fuel or the other fuel.    
   
   
       16 . A furnace combustion system, as in  claim 15 , wherein the first matrix and the second matrix are each formed on or near the inner wall of the furnace.  
   
   
       17 . A furnace combustion system in a furnace having a top and a bottom opposite the top, comprising: 
 a plurality of burners adapted to generate a plurality of flames, each burner being spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame; and    an oxidant port disposed between and surrounded by two of the plurality of burners, the oxidant port adapted to transmit at least one jet of the first oxidant or the other oxidant axially between two of the plurality of flames, the oxidant port and the two of the plurality of the burners being adjacent the top of the furnace, and the two of the plurality of the flames being transmitted from the two of the plurality of the burners toward the bottom of the furnace, wherein the at least one jet is transmitted from the oxidant port at a controlled flow rate, and    wherein at least a portion of the first oxidant or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one stream of the first fuel or the other fuel.    
   
   
       18 . A method for combusting a fuel in a furnace, comprising the steps of: 
 providing a plurality of burners adapted to generate a plurality of flames, including 
 a first burner adapted to combust a first stream of the fuel with a first stream of a first oxidant and to generate a first flame, and  
 a second burner spaced apart from the first burner and adapted to combust a second stream of the fuel, or a stream of an other fuel, with a second stream of the first oxidant, or a first stream of a second oxidant, and to generate a second flame;  
   combusting the first stream of the fuel with the first stream of the first oxidant;    combusting the second stream of the fuel, or the stream of the other fuel, with the second stream of the first oxidant, or the first stream of the second oxidant;    generating the plurality of flames, including the first flame and the second flame;    providing an oxidant port disposed between and surrounded by at least two of the plurality of burners, including the first burner and the second burner, the oxidant port adapted to transmit at least one jet of the first oxidant, the second oxidant, or an other oxidant, axially between at least two of the plurality of flames, including the first flame and the second flame; and    transmitting the at least one jet from the oxidant port at a controlled flow rate axially between at least two of the plurality of flames, including the first flame and the second flame,    whereby at least a portion of the first oxidant, or the second oxidant, or the other oxidant in the at least one jet completes combustion of at least a portion of at least one of the first stream of the fuel and the second stream of the fuel, or the stream of the other fuel.    
   
   
       19 . A method as in  claim 18 , wherein the controlled flow rate is controlled at least in part by a damper.  
   
   
       20 . A method as in  claim 18 , wherein the oxidant port is substantially equidistant from the first burner and the second burner.  
   
   
       21 . A method as in  claim 18 , wherein the at least one jet includes a swirling stream.  
   
   
       22 . A method as in  claim 21 , wherein the swirling stream has a swirl number in the range of about 0.2 to about 0.6.  
   
   
       23 . A method as in  claim 18 , wherein the at least one jet has an oxygen concentration in the range of about 5 vol. % to about 50 vol. %.  
   
   
       24 . A method as in  claim 18 , wherein the at least one jet provides about 5% to about 50% of a total oxidant required to operate the furnace.  
   
   
       25 . A method as in  claim 18 , wherein the at least one jet has a velocity in a range of about 20 ft/sec. to about 1,000 ft/sec.  
   
   
       26 . A method as in  claim 18 , wherein at least one of the first flame and the second flame is fuel-rich.  
   
   
       27 . A method as in  claim 18 , wherein the first flame merges with the second flame.  
   
   
       28 . A method as in  claim 18 , wherein at least one of the first burner and the second burner is adapted to transmit a variable distribution of at least one of the fuel and the other fuel.  
   
   
       29 . A method for combusting a fuel in a furnace, comprising the steps of: 
 providing a plurality of burners adapted to generate a plurality of flames, each burner being spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame;    combusting the stream of the first fuel or the other fuel with the stream of the first oxidant or the other oxidant;    generating the plurality of flames;    providing an oxidant port disposed between and surrounded by at least two of the plurality of burners, the oxidant port adapted to transmit at least one jet of the first oxidant or the other oxidant axially between at least two of the plurality of flames; and    transmitting the at least one jet from the oxidant port at a controlled flow rate axially between at least two of the plurality of flames,    whereby at least a portion of the first oxidant or the other oxidant in the at least one jet completes combustion of at least a portion of at least one stream of the first fuel or the other fuel.    
   
   
       30 . A method for combusting a fuel in a furnace having an interior and a longitudinal axis, comprising: 
 providing a plurality of burners adapted to generate a plurality of flames, each burner being spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame, the plurality of burners being disposed in the interior of the furnace in a substantially circular pattern spaced around the longitudinal axis of the furnace;    combusting the stream of the first fuel or the other fuel with the stream of the first oxidant or an other oxidant;    generating the plurality of flames;    providing an oxidant port disposed in the interior of the furnace between and surrounded by the plurality of burners, the oxidant port being substantially equidistant from each burner and adapted to transmit at least one jet of the first oxidant or the other oxidant axially between at least two of the plurality of flames; and    transmitting the at least one jet from the oxidant port at a controlled flow rate axially between at least two of the plurality of flames,    wherein at least a portion of the first oxidant or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one stream of the first fuel or the other fuel.    
   
   
       31 . A method as in  claim 30 , comprising the further steps of: 
 providing a plurality of fuel staging lances, each fuel staging lance spaced apart from another fuel staging lance, the plurality of fuel staging lances surrounding at least one of the burners, wherein at least one fuel staging lance is adapted to transmit a flow of at least one of the first fuel and the other fuel at a first flow rate different than a second flow rate at which another flow of at least one of the first fuel and the other fuel is transmitted by at least one other fuel staging lance;    transmitting from the at least one fuel staging lance the flow of at least one of the first fuel and the other fuel at the first flow rate; and    transmitting from the at least one other fuel staging lance the another flow of at least one of the first fuel and the other fuel at the second flow rate.    
   
   
       32 . A method for combusting a fuel in a furnace having an inner wall, comprising: 
 providing a plurality of burners adapted to generate a plurality of flames, each burner being spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame;    providing a plurality of oxidant ports, each oxidant port disposed between and surrounded by at least two of the plurality of burners, each oxidant port adapted to transmit at least one jet of the first oxidant or the other oxidant axially between at least two of the plurality of flames, the plurality of the burners forming a first matrix and the plurality of the oxidant ports forming a second matrix adjacent the first matrix; and    transmitting the at least one jet from the oxidant port at a controlled flow rate axially between at least two of the plurality of flames,    wherein at least a portion of the first oxidant or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one stream of the first fuel or the other fuel.    
   
   
       33 . A method as in  claim 32 , wherein the first matrix and the second matrix are each formed on or near the inner wall of the furnace.  
   
   
       34 . A method for combusting a fuel in a furnace having a top and a bottom opposite the top, comprising: 
 providing a plurality of burners adapted to generate a plurality of flames, each burner being spaced apart from another burner and adapted to combust a stream of a first fuel or an other fuel with a stream of a first oxidant or an other oxidant and to generate a flame;    combusting the stream of the first fuel or the other fuel with the stream of the first oxidant or an other oxidant;    generating the plurality of flames;    providing an oxidant port disposed between and surrounded by two of the plurality of burners, the oxidant port adapted to transmit at least one jet of the first oxidant or the other oxidant axially between two of the plurality of flames, the oxidant port and the two of the plurality of the burners being adjacent the top of the furnace, and the two of the plurality of the flames being transmitted from the two of the plurality of the burners toward the bottom of the furnace; and    transmitting the at least one jet from the oxidant port at a controlled flow rate axially between at least two of the plurality of flames,    wherein at least a portion of the first oxidant or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one stream of the first fuel or the other fuel.    
   
   
       35 . A method for reducing nitrogen oxide emissions from a plurality of products of combustion generated during combustion of a fuel in a furnace, comprising the steps of: 
 providing a plurality of burners adapted to generate a plurality of flames, including 
 a first burner adapted to combust a first stream of the fuel with a first stream of a first oxidant and to generate a first flame, and  
 a second burner spaced apart from the first burner and adapted to combust a second stream of the fuel, or a stream of an other fuel, with a second stream of the first oxidant, or a first stream of a second oxidant, and to generate a second flame;  
   combusting the first stream of the fuel with the first stream of the first oxidant;    combusting the second stream of the fuel, or the stream of the other fuel, with the second stream of the first oxidant, or the first stream of the second oxidant;    generating the plurality of flames, including the first flame and the second flame;    providing an oxidant port disposed between and surrounded by at least two of the plurality of burners, including the first burner and the second burner, the oxidant port adapted to transmit at least one jet of the first oxidant, the second oxidant, or an other oxidant, axially between at least two of the plurality of flames, including the first flame and the second flame, wherein the at least one jet has an oxygen concentration in the range of about 5 vol. % to about 50 vol. %; and    transmitting the at least one jet from the oxidant port at a controlled flow rate axially between at least two of the plurality of flames, including the first flame and the second flame, wherein the controlled flow rate is controlled at least in part by a damper,    whereby at least a portion of the first oxidant, or the second oxidant, or the other oxidant in the at least one jet completes combustion of at least a portion of at least one of the first stream of the fuel and the second stream of the fuel, or the stream of the other fuel, wherein the at least one jet provides about 5% to about 50% of a total oxidant required to operate the furnace.    
   
   
       36 . A system for reducing nitrogen oxide emissions from a plurality of products of combustion generated during combustion of a fuel in a furnace, comprising: 
 a plurality of burners adapted to generate a plurality of flames, including 
 a first burner adapted to combust a first stream of a fuel with a first stream of a first oxidant and to generate a first flame, and  
 a second burner spaced apart from the first burner and adapted to combust a second stream of the fuel, or a stream of an other fuel, with a second stream of the first oxidant, or a first stream of a second oxidant, and to generate a second flame; and  
   an oxidant port disposed between and surrounded by at least two of the plurality of burners, including the first burner and the second burner, the oxidant port adapted to transmit at least one jet of the first oxidant, the second oxidant, or an other oxidant, axially between at least two of the plurality of flames, including the first flame and the second flame, wherein the at least one jet has an oxygen concentration in the range of about 5 vol. % to about 50 vol. %,    wherein the at least one jet is transmitted from the oxidant port at a controlled flow rate controlled at least in part by a damper, and    wherein at least a portion of the first oxidant, or the second oxidant, or the other oxidant in the at least one jet is required to complete combustion of at least a portion of at least one of the first stream of the fuel and the second stream of the fuel, or the stream of the other fuel, wherein the at least one jet provides about 5% to about 50% of a total oxidant required to operate the furnace.