United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
Research and Development
EPA/600/S7-88/015 Dec. 1988
Project Summary
Fired Heaters: Nitrogen Oxides
Emissions and Controls
S. Anwar Shareef, Carol L. Jamgochian, and Lawrence E. Keller
The petroleum refining and chem-
ical manufacturing industries ac-
count for most of the fired heater
energy use. An estimated 4,600 fired
heaters are in operation in these two
industries, Nitrogen oxides (NOX) are
formed in fired heaters by two
mechanisms: thermal NOX and fuel
NOX. This study briefly describes the
design and operation of fired
heaters. Descriptions of the two
major industries with fired heaters
and the various heater applications
are presented. An estimate is made
of the growth in fired heater energy
demand and the number of new fired
heaters to be built in the next 5 years
in these industries. The factors
affecting NOX emissions from fired
heaters are discussed and quantita-
tive relationships are presented,
where available. Combustion modi-
fications and flue gas treatment
controls for NOX emissions are
described. Low excess air (LEA)
operation and low-NOx burners are
discussed in detail. Long-term
continuous NOX emissions data for
12 petroleum refinery heaters are
presented. Results of a regression
model to predict the effect of stack
oxygen level on NOX emissions are
used to evaluate LEA performance.
This study also presents capital and
annualized costs for LEA and low-
NOX burner controls.
This Project Summary was devel-
oped by EPA's Air and Energy Engi-
neering Research Laboratory, Re-
search Triangle Park, NC, to announce
key findings of the research project
that is fully documented in a separate
report of the same title (see Project
Report ordering information at back).
Introduction
The purpose of this study is to
characterize NOX emissions form fired
heaters, identify applicable control
techniques, and present the costs
associated with these control techniques.
A fired heater is a heat transfer device in
which heat liberated by the combustion
of fuels is transferred to fluids contained
in tubes. The major applications of fired
heaters are in the petroleum refining and
chemical manufacturing industries. There
are two basic functional categories of
fired heaters applications: (1) the
simplest are heaters designed to
increase the temperature of a feedstock
stream prior to additional processing
(e.g., distillation column feed preheaters
and reboilers); and (2) fired reactors in
which high-temperature chemical reac-
tions are carried out in the heater tubes
(e.g., steam-hydrocarbon reformers
used in ammonia and methanol
manufacturing, and pyrolysis furnaces
used in ethylene manufacturing). The
fuels used for fired heaters include
natural gas, refinery gas, and various
grades of fuel oil.
NOX is formed in fired heaters by two
mechanisms: thermal NOX formation and
fuel NOX formation. Thermal NOX is the
result of the reaction between atmos-
pheric nitrogen and oxygen, while fuel
-------
NOX is the result of the reaction between
fuel-bound nitrogen and oxygen. The
various heater designs and operating
parameters that affect NOX emissions are
described in this study. When available,
quantitative data are presented from
previous studies showing the relationship
between these parameters and NOX
emissions
This study also summarizes short-
term (1-2 hour) NOX emissions data for
about 150 fired heaters in various
applications. While most of these data
were collected and reported in previous
studies, some were obtained directly
form various plants specifically for this
study In addition, continuous long-term
NOX emissions data were obtained in this
study for 12 heaters at three petroleum
refineries, two of which continuously
monitor NOX emissions for regulatory
compliance purposes. Data on one
heater at the third refinery were collected
over a 45-day period in a previous EPA
study Table 1 describes the heaters in
the contmous long-term data base.
The continuous data included from
about 540 to 3,400 hourly data points for
each heater. The hourly measurements
included NOX emission rates, stack
oxygen levels, fuel firing rate, fuel gas
hydrogen content, and the energy basis
ratio of gas to oil (where applicable).
Table 2 presents a summary of the
long-term data. These data were
analyzed statistically to quantify the
effect of stack oxygen level on NOX
emissions. A multiplicative functional
form based on the Zeldovich mechanism
for thermal NOX formation was found to
adequately correlate the data.
The basic form of the model used is:
f-1 ft /-I p
9 1 d 5
E = CjL A (1 + R) (1 + H)
where:
E = NOX emissions (Ib/MM Btu)
L = fuel firing rate expressed as a fraction of
the design thermal energy release
. Fuel firing rate, Btu/hr
design thermal capacity, Btu/hr
A = stack oxygen (volume fraction of O2)
R = oil fraction, ratio of oil-fired heat release
to total fuel-fired heat release. When no
oil is fired, R = O and model parameter
C4 has no meaningful value.
H = fuel gas hydrogen content (volume
fraction of H2). When no fuel gas
hydrogen data are available, model
parameter C5 is assigned a value of zero.
CL, C2, C3, C4, and C5 = model coefficients
that indicate the effect of the
corresponding variables on NOX
emissions.
The model coefficients were fit to the
NOX emissions data using a statistical
procedure known as autocorrelative
regression. The autoregressive model
accounts for any effects on the
coefficients of autocorrelation associated
with the sequential nature of the data.
Using the results of the regression
analysis, NO levels were predicted for
the 12 heaters at various oxygen levels.
This allowed for a determination of the
effectiveness of low excess air (LEA)
operation on NOX emissions as well as
for a comparison of NOX emissions from
different heater/burner types at the same
stack oxygen level.
The two major combustion modi-
fication control techniques discussed in
this report were LEA operation and low-
NOX burners. LEA operation of fired
heaters can be achieved by (1) manual
damper control systems based on
oxygen monitoring and increased oper-
ator attention.and (2) automatic damper
control systems based on oxygen mon-
itoring (and/or other process monitoring)
and microprocessor control. Low-N0x
burners can be used alone or in
combination with LEA operation. The
major type of Iow-N0x burner is the
staged air burner which employs staged
air addition to the fuel stream. A more
recent type of Iow-N0x burner is the
staged fuel burner which also uses
staged combustion to reduce NOX
formation, but with reversed staging.
Cost estimates were made for LEA and
Iow-N0x burner controls. The energy
credits associated with LEA operation
were also estimated
Conclusions
The following conclusions were de-
rived from this study:
• The petroleum refining and petro-
chemical industries account for the
major fired heater use. The estimated
fired heater energy consumption in the
"To convert to metric 1 Btu = 10543 J or 0252
Kcal
petroleum refining industry in 1985 is
approximately 2.2 x 1014 Btu/yr.* The
1985 chemical industry fired heatei
energy consumption is estimated to be
6.8 x 1014 Btu/yr.
• The annual increase in fired heatei
energy consumption m the petroleum
refinery industry is estimated to be
14.6 x 1012 Btu/hr. It is projected tha
approximately 80 new fired heaters wil
be built in the petroleum refining
industry over the next 5 years.
• The annual increase in fired heate
energy consumption in the chemica
industry is estimated to be about 14.^1
x 1012 Btu/hr. About 100 fired heater;
are projected to be built in th«
chemical industry over the next 5
years.
• Almost 100 percent of the fired heate
applications in the petroleum refining
industry are low and mediurr
temperature heaters. About 81 percen
(energy basis) of the fired heate
applications in the chemical industn
are high temperature heaters (ethylem
pyrolysis furnaces and steam
hydrocarbon reformers).
• The major heater design parameter:
affecting NOX emissions are fuel typi
(i.e., N2 content of the fuel), burne
type, use of combustion preheat, an<
firebox temperature.
• The major neater operating parameter
affecting NOX emissions are excess ai
level, degree of combustion ai
preheat, and oil/gas ratio for heater
firing combined fuel.
• The control techniques that have beei
used on fired heaters in commercic
applications include low excess ai
(LEA) operation, low-NOx burners
staged air lances, flue gas recirculatior
selective catalytic reduction, am
selective noncatalytic reduction.
• LEA control systems are applicable t
all fired heaters. Manual and automati
damper control systems designed t
reduce excess air levels can be usei
with natural or mechanical draft ani
with gas, oil, or gas/oil combinatio
burners.
• At least 55 fired heaters use automati
LEA control systems and many other
use manual LEA control system
based on oxygen monitoring.
• The target stack oxygen level for mos
heaters operating with LEA is 2-3°
The lowest long-term average oxyge
level for heaters in the data base wa
2%.
• The average stack oxygen level fc
about 180 heaters for which data wer
obtained in this study was 5.5%.
-------
• Statistical analysis of continuous
long-term NOX emissions data for 12
petroleum refinery heaters indicated an
average of 9% reduction in NOX
emissions per 1% reduction in stack
oxygen level. The individual reduction
in NOX emissions ranged from 4.4 to
16.4%. Table 3 shows the predicted
variation in NOX at 100% load and
varying stack oxygen levels.
• No effect of burner or draft type was
found on the NOX/C>2 relationship.
• Two major burner vendors have
indicated that about 50 to 65% of their
new burner sales are Iow-N0x
burners.
• No conclusion about the performance
of low-NOx burners could be derived
from the continuous monitoring data
because other design differences
between heaters obscure the effect of
Iow-N0x burners
• Test-scale data from burner vendors
indicate that NOX emission reduction
with the use of staged air burners
ranges from 38 to 40% compared to
conventional burners NOX emission
reduction associated with the use of
staged fuel burners ranges from 70 to
72% compared to conventional
burners
• Staged combustion air lances have
been demonstrated for 15 days on a
natural-gas-fired, natural draft
heater. The same heater was retrofitted
with forced draft and tests were
conducted for 30 days with staged air
lances
• Regression modeling results showed
that at a fixed stack oxygen level,
natural draft air lances reduced NOX
emissions by 50 to 60% relative to
baseline (without staged air lances).
Forced draft air lances further reduced
emissions by 30 to 50% relative to
natural draft air lances.
-------
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-------
S. A. Shareef, C. L Jamgochian, and L E. Keller are with Radian Corp., Research
Triangle Park, NC 27709.
John H. Wasser is the EPA Project Officer (see below).
The complete report, entitled "Fired Heaters: Nitrogen Oxides Emissions and
Controls," (Order No. PB 88-245 741/AS; Cost: $21.95, subject to change) will
be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air and Energy Engineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
Official Business
Penalty for Private Use $300
EPA/600/S7-88/015
0000529 PS
PROTECTION AGENCY
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