EPA-650/2-75-017
Environmental Protection Technology Series
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U. S. Environ-
mental Protection Agency, have been grouped into series. These broad
categories were established to facilitate further development and applica-
tion of environmental technology. Elimination of traditional grouping was
consciously planned to foster technology transfer and maximum interface
in related fields. These series are:
1. ENVIRONMENTAL HEALTH EFFECTS RESEARCH
2. ENVIRONMENTAL PROTECTION TECHNOLOGY
3. ECOLOGICAL RESEARCH
4. ENVIRONMENTAL MONITORING
5. SOCIOECONOMIC ENVIRONMENTAL STUDIES
6. SCIENTIFIC AND TECHNICAL ASSESSMENT REPORTS
9. MISCELLANEOUS
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY scries. This series describes research performed to
develop and demonstrate instrumentation, equipment and methodology
to repair or prevent environmental degradation from point and non-
point sources of pollution. This work provides the new or improved
technology required for the control and treatment of pollution sources
to meet environmental quality standards.
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EPA-650/2-75-017
IDENTIFICATION AND CHARACTERIZATION
OF THE USE
OF MIXED CONVENTIONAL
AND WASTE FUELS
by
Gopal K. Mdlhur
The M. W. Kellogg Company
Research and Engineering Development
Iloubton, Texas 77046
Contract No. 68-02-1308 (Task 5)
ROAP No. 21BCC-042
Program Element No. 1AB014
EPA Project Officer: David G. Lachapelle
Control Systems Laboratory
National Environmental Research Center
Research Triangle Park, North Carolina 27711
Prepared for
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
February 1975
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EPA REVIEW NOTICE
This report has been reviewed by the National Environmental Research
Center - Research Triangle Park, Office of Research and Development,
EPA, and approved for publication. Approval does not signify that the
contents necessarily reflect the views and policies of the Environmental
Protection Agency, nor does mention of trade names or commercial
products constitute endorsement or recommendation for use.
This document is available to the public for sale through the National
Technical Information Service, Springfield, Virginia 22161.
11
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ABSTRACT
This report presents the results of a study to determine types
of mixed and waste fuels and the extent of their usage in sta-
tionary combustion equipment. Where possible, pollutant emis-
sion levels resulting from combustion of these fuels have been
determined. Industries surveyed included Utilities, Petroleum
Refineries, Petrochemical, Chemical Processing, Glass, Cement
and Textiles. Of the industries surveyed, about 70% of the
refineries, 45% of the utilities, 20% of cement, glass and tex-
tile manufacturers and 10% of petrochemical and chemical pro-
cessing plants have reported using mixed fuels to some extent.
This report was submitted in fulfillment of Contract 68-02-1308,
Task 5, by the M. W. Kellogg Company under the sponsorship of
the Environmental Protection Agency. Work was completed as of
December 1974.
111
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TABLE OF CONTENTS
Page
LIST OF TABLES V
LIST OF FIGURES vi
SUMMARY AND CONCLUSIONS 1
RECOMMENDATIONS 3
INTRODUCTION 5
BASIS OF EVALUATION 6
DATA COLLECTION 8
Mixed Fuel Firing by Petroleum Refineries 11
Refinery Emissions from Mixed Fuels 14
Mixed Fuel Firing by Petrochemical Plants 16
Petrochemical Plant Emissions from Mixed Fuels 17
Mixed Fuel Firing by Cement 18
Cement Plant Emissions from Mixed Fuels 19
Mixed Fuel Firing by Textile Plants 20
Textile Plant Emissions from Mixed Fuels 21
Mixed Fuel Firing by Utilities 22
Mixed Fuel Firing by Glass Plants 24
Mixed Fuel Firing by Chemical Processing Industries 25
MIXED FUEL BURNER MANUFACTURERS 26
APPENDIX 36
IV
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LIST OF TABLES
Table Title Page
1 Mixed Fuel Firing by Petroleum Refineries 11
2 Refinery Emissions from Mixed Fuels 14
3 Mixed Fuel Firing by Petrochemical Plants 16
4 Petrochemical Plant Emissions from Mixed Fuels 17
5 Mixed Fuel Firing by Cement Plants 18
6 Cement Plant Emissions from Mixed Fuels 19
7 Mixed Fuel Firing by Textile Plants 20
8 Textile Plant Emissions from Mixed Fuels 21
9 Mixed Fuel Firing by Utilities 22
10 Mixed Fuel Firing by Glass Plants 24
11 Mixed Fuel Firing by Chemical Processing Industries 25
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LIST OF FIGURES
Figure Title
1 Coppus Engineering Corporation's FANMIXR Burner 27
2 John Zink Company's Series MA Burner 28
3 John Zink Company's Series DBA Burner 29
4 John Zink Company's Series FFC Burner 30
5 Maxon Corporation's OVENPAKR Gas/Oil Burner 32
6 National Airoil Company's Dual Stage Fuel Oil
Burner 33
VI
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SUMMARY AND CONCLUSIONS
Based on information received from the various industries stud-
ied, it appears that the burning of mixed fuels is not practiced
on a scale large enough to classify Petrochemical, Chemical Pro-
cessing, Cement, Glass and Textile industries as mixed fuel us-
ers. Petroleum Refineries and Utilities burn mixed fuels to
some extent. Of the sources surveyed about 70% of the refin-
eries, 45% of the utilities, 20% of cement, glass and textile
manufactures and 10% of petrochemical and chemical processing
plants have reported using mixed fuels.
Stationary sources utilizing mixed fuels are boilers (both for
power generation and process steam), process heaters and fur-
naces, kilns and incinerators. Mixed fuels are used mainly for
steam generation and heat. The use of mixed fuels in connec-
tion with waste disposal has been reported in only two instances.
Sufficient information required for calculating emission factors
from mixed fuel firing was not generally available. Emissions
data were not available from the industries which have reported
using mixed fuels. In a few cases estimated emissions or aver-
age emissions have been provided. Only a few of these emissions
have been matched with the source and the fuels. There are no
indications whether any emission control devices are in oper-
ation. Another area of uncertainty is the ratio of fuels mixed.
One textile manufacturer has stated that fuel ratio varies vir-
tually from hour to hour depending on the availability of nat-
ural gas. To calculate emission factors it is imperative to
have the stack gas analysis at constant fuel ratio and without
any variations in fuel composition and other variables such as
temperature and excess air. Unfortunately, this type of data
was not available from the manufacturers, state air pollution
control agencies and regional offices of the U.S. Environmental
Protection Agency. Therefore, no conclusions can be made re-
garding emissions from the use of mixed fuels.
-------
Petroleum refineries have not indicated any significant changes
in fuel mixing trends. In all other categories manufacturers
have expressed an inability to predict fuel mixing trends due
to uncertainty in their fuels supply situation. One manufac-
turer of textiles reports that they would not mix fuels if an
adequate supply of a single fuel was available. A glass man-
ufacturer, currently mixing fuel on a very limited scale, has
reported future plans to change facilities to handle mixed
fuels, but no specific details were provided. One cement man-
ufacturer has reported abandoning the use of mixed fuels (coal
and petroleum coke) due to higher heat losses. At this time
there are no indications of any definite changes in fuel mix-
ing trend.
According to the reasons cited by manufacturers in all the in-
dustrial categories, supply of fuels is the dominant reason to
burn mixed fuels. Supply is followed by economics and pollu-
tion standards as a rationale for mixing fuels. Apart from
supply, more utilities have cited pollution standards than
economics as a reason for burning mixed fuels. For example,
utilities burn natural gas mixed with high sulfur fuel (oil
or coal) to reduce total sulfur oxide emissions.
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RECOMMENDATIONS
As indicated by the responses from manufacturers in the catego-
ries of Petrochemical, Chemical Processing, Cement, Glass and
Textile, it does not appear worthwhile to carry out further
general investigations of mixed fuel firing. As stated earlier,
mixed fuels are used by only a very few manufacturers in these
categories. It may be worthwhile to investigate mixed fuel
firing for Petroleum Refineries and Utilities. However, changes
in fuel supply or in pollution control standards may alter the
situation in the future.
Two approaches are suggested to study the effect on emissions
from firing of mixed fuels. Stack gas testing at utilities and
refineries or experimentation with a pilot scale system can
provide the data needed to evaluate emission factors and com-
bustion control techniques.
Stack gas testing at the industrial installations will have the
obvious advantage of being data from actual operating systems.
However, there are some operational limitation regarding the
range of fuel ratios, excess air and temperatures, particularly
on large utility boilers. Stack gas testing is advantageous as
far as mixing of refinery waste gases is concerned since the
composition and amount of waste gas available changes from time
to time and different fuel ratios would be available.
A pilot scale study can cover a wide ranges of fuel ratios,
fuel composition, flame temperatures, excess air and other
operating conditions. A pilot scale system would re-
quire devices to measure fuel and air rates, a combustion cham-
ber with appropriate instrumentation, stack gas analyzers and
accessories. Effects of variables can be studied over a wide
range and it may be possible to optimize conditions for the
lowest level of pollutant emissions. The data obtained from
-------
actual stack testing, either on industrial installations or on
pilot scale system, would be more comprehensive and generally
applicable than the limited amount of data made available from
the industrial sources surveyed in this study.
-------
INTRODUCTION
The major objective of this study was to identify and classify
types and properties of mixed fuels presently in use, and types
of stationary processes utilizing mixed fuels. A second objec-
tive was to determine present usage of mixed fuels and future
trends. Emission factors for NO , SO , particulate and related
X X
pollutants were to be developed for various fuel combinations
and processes. The rationale for burning mixed fuel was to be
determined.
The purpose of this study was to provide some of the background
information required to determine if there is a need for a re-
search and development program to develop emission control tech-
nology for this source category.
Types of mixed fuels include mixed oils; oil and gas; coal and
oil; coal and gas; by-product gases and fuels; by-product chem-
ical waste; and mixtures of chemical wastes and conventional
fossil fuels. The scope of the task covered industries in the
category of Utilities, Petroleum Refineries, Petrochemical,
Chemical Processing (excluding fertilizer), Glass, Cement and
Textile. A list of manufacturers of mixed fuel burners was
developed.
The EPA Task Officer approved a work plan which specified that
data be collected from industries in each category and be sup-
plemented with data from federal and state agencies and trade
associations. Only the sources which burn mixed fuels on a re-
gular basis were considered in this report. Alternate firing
or supplementing fuels on an intermittent basis was not inter-
preted as burning of mixed fuels.
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BASIS OF EVALUATION
Fuels Mixed
Coal, oil, natural gas and waste fuels (refinery gases or organ-
ic solutions) are used as mixed fuels. Petroleum refineries use
oil, natural gas and waste fuels as constituents of mixed fuels
and the use of coal has not been reported. Utilities do not
indicate burning any waste fuel and only conventional fuels are
used as mixed fuels. It is not possible to categorize the types
of fuels mixed in Petrochemical, Chemical Processing, Glass,
Cement and Textile industries because the majority of manufac-
turers in these categories do not burn mixed fuels. Glass and
cement manufacturers who have reported mixed fuel burning mix
only conventional fuels. Manufacturers reporting the use of
mixed fuel in the category of Petrochemical, Chemical Process-
ing and Textile mix waste fuel with conventional fuels.
Typical analyses of coal, oil, natural gas and waste fuels used
as mixed fuels are as follows:
Coal, wt% as fired Oil, wt%
C 70.65 85.9
H 4.59 11.0
0 6.19 0.9
S 1.56 1.0
N 1.29 0.7
Moisture 3.72 0.2
Ash 12.00 0.3
HHV, Btu/lb 12519 18600
-------
Natural Gas Analyses (Mole %)
Louisiana
Florida Utility Texas Refinery Petrochemical
CH4 95.44 94.00 95.0
N2 0.51 1.00 0.9
C02 0.51 1.50 0.9
C2 3.44 3.30 2.2
C3 0.10 0.20 0.5
C4 0.00 0.00 0.2
HHVfBtu/SCF 1000 1018 1028
Waste Fuel Analyses for Petroleum Refineries (Mole %)
Location: California Illinois
CO o.l 1.1
N2 1.2 0.5
H2 66.7 14.8
C1 26.8 58.4
C2 2.7 13.8
C3 1.4 9.4
C4 1.2 0.8
C5 - 0.8 -
C02 - 0.3 -
S - 0.3 100 ppm H2S
HHV,BtU/SCF 600 1190 860
Waste Fuel Analyses for Textile Plants
Gaseous Waste, mole % Liquid waste, wt %
N2 0.9 C 92.0
A 13.5 H 6.8
02 5.1 S 0.7
CH4 43.1 Ash 0.01
C2 30.3 HHV, Btu/lb 16,500
C02 6.8
H20 0.3
HHV, Btu/SCF 921
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DATA COLLECTION
An attempt was made to gather data on mixed fuels from federal
agencies, trade associations, state air pollution control
agencies, and manufacturers in the categories of Petroleum re-
finery, Utility, Petrochemical, Chemical Processing, Cement,
Glass and Textile.
Regional offices of the U. S. Enviromental Protection Agency
in Atlanta, Boston, New York, Philadelphia, San Francisco and
Seattle indicated that data on mixed fuels were not available.
U. S. Bureau of Mines data show only fuel consumption and not
how fuels are fired. The American Petroleum Institute and
American Textile Manufacturers Institute do not collect exten-
sive data on fuel consumption and suggested that major man-
ufacturers in these categories be contacted directly.
Air pollution control agencies in the states of California,
Illinois, Louisiana, New Jersey, New York, Ohio, Oklahoma,
Pennsylvania and Texas were contacted as potential data
sources. Letters outlining the objectives of the study were
forwarded to each agency and afterwards, agency personnel
were contacted by phone.
Trips were made to the pollution control agency offices of
Louisiana, New Jersey and Oklahoma. After consultation with
the agency personnel and review of their permit files, it be-
came apparent that data were never collected to show mixed
fuel combustion. Moreover, data were collected for the entire
plant (point source) and not by individual source.
Data were available by individual source at the pollution con-
trol agencies of Illinois, Ohio and Pennsylvania. Sample
printouts were requested and received from agencies of Illinois
and Pennsylvania. These date were filed by individual source.
Their data did indicate if an individual source burned more
-------
than dhe fuel but did not specify the mode of firing - i.e.,
simultaneous, alternate or both. Moreover, the estimated
emissions were based on the more polluting fuel. Therefore,
the data available at Illinois and Pennsylvania air pollution
control agencies were not suitable for this study. Ohio has
data in 5 district and 13 regional offices and it was not pur-
sued further because the time required would have been beyond
the scope of this task.
State agencies of California, New York and Texas expressed their
inability to provide data on mixed fuels.
Questionnaires were forwarded to major manufacturers in each
industrial category with the hope of getting additional data.
Questionnaire were usually addressed to Vice President of
Manufacturing or Director of Fuel Purchases or General Manager.
Samples of the questionnaires are included in the Appendix.
From the responses obtained it appears that some individual
companies either did not have the data or were less than will-
ing to provide all the needed information. Most of the quest-
ionnaires were returned incomplete for various reasons. Some
did not reply at all in spite of reminding them through letters
and phone calls. The data collection from industrial sources
was not adequate to classify industries, other than petroleum
refineries and utilities, as mixed fuel users.
The tables that follow are a compilation of data received from
the categories surveyed. Tables 1, 3, 5, 7, 9, 10 and 11 list
the use of mixed fuels reported by the categories responding to
the questionnaires. Shown is the annual fuel consumption by
type for an individual plant and the percentage of that type
fuel used as mixed fuel. Based on the amounts of fuels mixed,
the percentage of total heat derived from mixed fuel burning
has been determined. Fuel combinations, end use (e.g., heat,
power or steam) and rationale for burning the fuel mixture is
-------
given.
Tables 2, 4, 6 and 8 list emissions reported by the manufactur-
ers in the categories of Petroleum Refineries, Petrochemical,
Cement and Textile. Listed are sources e.g., boiler, furnace,
kiln etc., size of the unit where available; annual fuels
consumption for the source and thus the mixing ratio and emis-
sions for S00, NO , CO and particulates. In a few cases SO-
Xg *
emissions in gm/10 cal have been calculated from sulfur content
and heating values of the fuel. All the emissions reported
in terms of ppm have been provided by the manufacturers. Emis-
sions in ppm have been converted to gm/10 cal wherever flue
gas rates were provided.
10
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Table 1
MIXED FUEL FIRING BY PETROLEUM REFINERIES
ANNUAL FUEL CONSUMPTION
Oil
in
1000 Bbls
465
180
160
_
86
1,099
-
Gas
in
MMCF
29,200
1,430
1,013
1,258
2,108
1,760
4,936
Waste
Fuel in
10* Btu
G-Gaseous
L-Liquid
1,552(G)
4,163(G)
2,372(G)
2,255(G)
2,788(G)
15,813(G)
3,036(G)
% FUEL MIXED
Oil
100
100
100
—
100
100
-
Gas
100
100
90
50
100
100
100
Waste
Fuel
100
100
100
100
100
12
100
% HEAT
FROM
MIXED
FUELS
100
100
96
82
100
43
100
FUEL
COMBINA-
TIO>7
USED
0, G
G, W
G, W
O, G, W
0, G
G, W
0, G, W
0, G
G, W
0, G, W
0, G
O, W
r=, W
MIXED
FUEL
USED
FOR
Heat,
Power,
Steam
Heat,
Steam
Heat,
Steam
Heat,
Steam
Heat,
Steam
Heat,
Power ,
Steam
Heat,
Steai?.,
Waste
Disposal
RATIONALE
Supply,
Gas Curtail-
ment
Supply,
Pollution
Standards
Supply,
Pollution
Standards
Supply
Supply
Supply
Suooly
-------
Table 1 (Cont'd.)
MIXED FUEL FIRING BY PETROLEUM REFINERIES
ANNUAL FUEL CONSUMPTION
Oil
in
1000 Bbls
1,952
215
-
2,730
608
171
Gas
in
MMCF
74,470
58,983
23,292
-
-
2,024
10,790
Waste
Fuel in
in9 Btu
G-Gaseous
L-Liquid
33KL)
42,653(G)
92 (G)
20,688(G)
4,196(G)
3,769(G)
349 (G)
% FUEL MIXED
Oil
100
100
-
98
100
100
Gas
2
84
16
-
-
87
21
Waste
Fuel
100
96
100
45
67
100
100
% HEAT
FROM
MIXED
FUELS
16
88
16.5
69
83
96
22
FUEL
COMBINA-
TION
USED
O, G
O, G, W
G, W
0, G, W
G, W
0, W,
O, W
G, W
O, G, W
O, G
G, W
MIXED
FUEL
USED
FOR
Heat,
Power ,
Steam
Heat ,
Power ,
Steam
Steam,
Power
Heat,
Power ,
Steam
Heat,
Steam
Heat,
Steam
Heat,
Steam
RATIONALE
Supply
Suoply,
Economic
Supply,
Economic,
Pollution
Standard
Energy
Conservation
Supply
Supply,
Economic
Supply
Supply
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Table 1 (Cont'd.)
MIXED FUEL FIRING BY PETROLEUM REFINERIES
ANNUAL FUEL CONSUMPTION
Oil
in
1000 Bbls
-
1,900
390
-
180
1,742
_
3,832
Gas
in
MMCF
18,831
-
130
4,300
8,600
9,585
31,164
5,256
waste
Fuel In
109 Btu
3-Gaseous
J-Liquid
28,515(G)
1,375(G)
4,953(G)
21,000(G)
9,420(G)
1,131(G)
9,649
-
% FUEL MIXED
Oil
-
90
100
-
100
100
—
51
Gas
55
-
100
100
76
93
100
29
Waste
Fuel
100
90
63
100
75
100
100
-
% HEAT
FROM
MIXED
FUELS
81
90
79
100
89
97
100
47
VUEL
COMBINA-
TION
USED
G, W
O, W
G, W
O, G, W
G, W
O, W
G, W
0, G, W
0, G,
0, G, W
G, W
O, G
MIXED
FUEL
USED
FOR
Heat
Heat
Heat,
Steam
Heat,
Steam
Heat,
Steam
Heat,
Power ,
Steam
Heat,
Steam
Heat,
Steam
RATIONALE
Supply
Supply
Supply,
Pollution
Standards
Supply
Supply,
Economic
Supply,
Pollution
Standards
Supply
Supply ,
Economic
Pollution
Standards
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Table 2
REFINERY EMISSIONS FROM MIXED FUELS
SOURCE
Boiler
Process
Furnace
Reboiler
Heater
Heater
Heater
Heater
Heater
Heater
SIZE OF
UNITS
MMBTU/Hr.
3455
213
62.7
46.2
43.2
52.5
200
85
223
ANNUAL FUEL CONSUMPTION
OIL
IN
1000
BBLS.
3433
311
-
-
-
-
-
-
91.5
GAS
IN
MMCF
7844
113
348
354
291
208
1098
246
650
WASTE FUEL
IN
IO'BTU
G-GASEOUS
330.5 (G)
-
213.7 (G)
218.3 (G)
178.7 (G)
128 (G)
676 (G)
151 (G)
-
% FUEL
MIXED
HEAT
BASIS
Oil - 72
Gas - 27
Waste - 1
Oil - 61
Gas - 39
Gas - 63
Waste - 37
Gas - 63
Waste - 37
Gas - 63
Waste - 37
Gas - 63
Waste - 37
Gas - 63
Waste - 37
Gas - 63
Waste - 37
Oil - 40
Gas - 60
EMISS
so2
GM/106CAS
(LB/106BTU)
1.36
(0.756)
1.77
(0.985)
0.688
(0.382)
0.778
(0.432)
0.718
(0.399)
0.494
(0.275)
0.449
(0.249)
0.839
(0.466)
2.235
(1.241)
PPM
370
475
200
200
200
100
100
200
550
N0x
GM/106CAL
(LB/106BTU)
1.34
(0.744)
0.96
(0.534)
0.040
(0.022)
0.040
(0.022)
0.040
(0.022)
0.040
(0.022)
0.040
(0.022)
0.040
(0.022)
-
PPM
507
359
16.3
14.4
15.6
11.4
12.5
13.4
10
ONS
CO
GM/106CAL
(LB/106BTU)
0.040
(0.022)
0.041
(0.022)
-
-
-
-
-
-
-
PPM
25
25
-
-
-
-
-
-
2
PARTICULATE
GM/106CAL
(LB/106BTU)
0.065
(0.036)
0.085
(0.047)
0.042
(0.023)
0.039
(0.219)
0.039
(0.219)
0.042
(0.023)
0.042
(0.023)
0.039
(0.022)
-
PPM
39
49
26
22
22
26
26
20
-
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Table 2 tContd.l
REFINERY EMISSIONS FROM MIXED FUELS
U1
SOURCE
Vacuum
Heater
Steam
Superheater
Heater
Boilers
Furnaces
Furnace
Heater
Boilers
SIZE OF
UNITS
MHBTU/Hr,
105
28.3
54.2
437.2
10 to 290
50
79
£40
ANNUAL FUEL CONSUMPTION
OIL
IN
1000
BBLS.
-
-
-
-
-
50
-
GAS
IN
MMCF
594
54
82
1608
10340
-
578
3757
WASTE FUEL
IN
109BTU
G-GASEOUS
365.6 (G)
33.2 (G)
50.7 (G)
987.3 (G)
28515 (G)
162.5 (G)
196.6 (G)
91.8 (G)
% FUEL
MIXED
HEAT
BASIS
Gas - 63
Haste - 37
Gas - 63
Waste - 37
Gas - 63
Waste - 37
Gas - 63
Waste - 37
Gas - 41
Waste - 59
Oil - 67
Waste - 33
Gas - 75
Waste - 25
Gas - 98
Waste - 2
EMISSIONS
so2
GM/106CAL
(LB/106BTU)
0.569
(0.316)
0.687
(0.382)
0.689
(0.382)
0.689
(0.382)
-
2.409
(1.338)
2.055
(1.142)
0.532
(0.296)
PPM
100
200
200
200
30
800
495
200
NOX
GM/106CM.
(LB/106BTU)
0.040
(0.022)
0.040
(0.022)
0.040
(0.022)
0.040
(0.022)
-
0.141
(0.078)
0.89S
(0.497)
0.191
(.106)
PPM
9.8
16.3
16.3
16
40
65
300
LOO
CO
GM/106CAL
(LB/106BTU)
-
-
-
-
-
-
-
PPM
-
-
-
-
50
5*
-
PARTICULATES
GM/106CAL
(LB/106BTO)
0.039
(0.021)
0.041
(0.023)
0.041
(0.023)
0.032
(0.018)
-
-
0.032
(0.018)
.032
(0.018)
PPM
14.8
25.6
25.6
20
NIL
-
16.8
27
Hydrocarbon
-------
Table 3
MIXED FUEL FIRING BY PETROCHEMICAL PLANTS
ANNUAL FUEL CONSUMPTION
Coal
in
Tons
64,000
-
-
Oil
in
1000
Bbls.
9
17
60
Gas
in
MMCF
5,200
305
7,500
1,700
23,500
Waste
Fuel in
109 Btu
G-Gas
L-Liq .
49. 7 (G)
87. 2 (G)
-
17 (G)
3598 (G)
7045 (L)
% FUEL MIXED
Coal
100
-
-
Oil
.
100
100
0
Gas
69
100
10
1
70
(taste
Fuel
100
100
-
100
100
% HEAT
FROM
MIXED
FUELS
70
100
11
-
80
"•UEL
COMBINA-I
TION
USED
G, W
C, 0, W
G, W
o, n
G , W
G, W
MIXED
FUEL
USED
FOR
Steam,
Power
Heat
Steam
Steam
Waste
Disposal
Heat,
Steam
RATIONALE
Economic ,
Pollution
Standards
Supply
Economic
Supply
Pollution
Standards
Supply ,
Economic ,
Pollution
Standards
-------
Table 4
PETROCHEMICAL PLANT EMISSIONS FROM MIXED FUELS
SOURCE
Boilers
Boilers
Boilers
Incinerator
Boilers
Furnaces
ANNUAL FUEL CONSUMPTION
COAL
IN
TONS
-
64000
-
-
—
GIL
IN
1000
BBLS.
-
9
17
-
-
—
GAS
IN
MMCF
3600
180
7500
21
4100
12400
WASTE
IN
10 9 BTU
G-GASEOUS
L-LIQUID
49.7 (G)
™
-
16.9 (G)
1208 (G)
7045 (L)
2391 (G)
% FUEL
MIXED
HEAT
BASIS
Gas - 98.7
Waste - 1.3
Coal - 92.3
Oil - 3.1
Gas - 4.6
Oil - 1.4
Gas - 98.6
Gas - 51
Waste - 49
Gas - 31.8
Waste_10>0
Waste eo i
Liquid 5B>'
Gas - 83
Waste - 17
EMISSIONS
S02
GM/106 CAL
(LB/106 BTU)
-
6.889
(3.827)
0.047
(0.026)
-
0.889
(0.494)
-
PPM
-
_
-
-
260
210
-
N0x
GM/106 CAL
(LB/106 BTU)
-
-
-
-
-
_
-
PPM
106
-
-
90
-
170
70
CO
GM/106 CAL
(LB/106 BTU)
-
-
-
-
-
_
-
PPM
-
-
-
-
130"
_
500
P ARTICULATES
GM/106 CAL
(LB/106 BTU)
NIL
0.288
(0.160)
NIL
-
-
-
PPM
-
-
-
-
-
-
HC1
-------
Table 5
MIXED FUEL FIRING BY CEMENT PLANTS
ANNUAL FUEL CONSUMPTION
Coal
in
Tons
63,589
65,000
100,000
Oil
in
-
-
18
Gas
in
1000 Bbls
1,056
71
1,080
% FUEL MIXED
Coal
100
100
100
Oil
-
-
100
Gas
100
100
100
% HEAT
FROM
MIXED
FUELS
100
100
100
FUEL
COMBINA-
TION
USED
C, G
C,
-------
Table 6
CEMENT PLANT EMISSIONS FROM MIXED FUELS
SOURCE
Kiln
Kiln
Kiln
Kiln
Kiln
ANNUAL FUEL CONSUMPTION
COAL
IN
TONS
100000
41437
22152
65000
100000
COKE
IN
TONS
32000
-
-
-
—
GAS
IN
MMCF
-
734
272
71
720
% FUEL
MIXED
HEAT
BASIS
Coal - 69
Coke - 31
Coal - 55
Gas - 45
Coal - 63
Gas - 37
Coal - 95
Gas - 5
Coal - 74
Gas - 26
so2
GM/106JCAL
(LB/100 BTU)
8.038
(4.465)
2.344
(1.302)
6.016
(3.343)
2.374
(1.319)
10.386
(5.770)
PPM
-
-
-
-
—
EMISSIONS
NOX
GM/106JCAL
(LB/100 BTU)
-
-
-
-
—
PPM
-
-
-
-
—
CO
GM/106JCAL
(LB/10* BTU)
-
-
-
-
—
PPM
-
-
-
-
—
P ARTICULATES
GM/10°JCAL
(LB/100 BTU)
-
-
-
-
—
PPM
70
17.6
20
60
~
-------
Table 7
MIXED FUEL FIRING BY TEXTILE PLANTS
ANNUAL FUEL CONSUMPTION
Coal
in
Tons
175,000
287,000
-
-
-
412,000
Oil
in
1000
Bbls.
-
4
-
22
-
43
Gas
in
MMCF
1,227
2,517
14,172
305
14,959
615
Waste
Fuel in
109 Btu
G-Gas
L-Liq.
-
84 (G)
870 (L)
-
494 (L)
40. 6 (G)
Coal
29
0
-
-
-
•
&% FUEL MIXED
Oil
-
0
—
100
-
™
Gas
12
17
44
93
15
29
Waste
Fuel
-
100
100
-
100
100
% HEAT
FROM
MIXED
FUELS
25
6
48
95
18
24
FUEL
COMBINA-
TION
USED
C, G
G, W
G, W
O, G
G, W
G, W
MIXED
FUEL
USED
FOR
Steam
Heat
Steam,
Waste
Disposal
Heat,
Steam
Heat,
Steam,
Power,
Waste
Disposal
Heat
RATIONALE
Supply,
Economic
Economic
Economic
Suoply
Economic
Economic
-------
Table 8
TEXTILE PLANT EMISSIONS FROM MIXED FUELS
SOURCE
Boilers
Boilers
Incinerator
Boiler
Boiler
ANNUAL FUEL CONSUMPTION
COAL
IN
TONS
50000
-
-
-
-
GAS
IN
MIICF
1.5
6060
220
1056
1150
WASTE
IN
109 BTUI
L-LIQUID
-
429.2 (L)
440.8 (L)
78.8 (L)
78.8 (L)
% FUEL
MIXED
HEAT
BASIS
Coal - 99.9
Gas - 0.1
Gas - 93
Waste - 7
Gas - 33
Waste - 67
Gas - 93
Waste - 7
Gas - 94
Waste - 6
EMISSIONS
so2
GM/106 CAL
(LB/106 BTU)
4.478
(2.488)
-
-
-
-
PPM
697
-
-
0.94 *
0.25 *
N02
GM/106 CAL
(LB/106 BTU)
-
-
-
-
-
PPM
-
600
1000
231
245
CO
GM/106 CAL
(LB/106 BTU)
-
-
-
-
-
PPM
-
-
-
1.24
1.35
PARTICULATES
GM/106 CAL
{LB/106 BTU)
-
-
-
-
-
PPM
938
9.8
1914
17
17.3
ro
Hydrocarbons
-------
Table 9
MIXED FUEL FIRING BY UTILITIES
ANNUAL FUEL CONSUMPTION
Coal
in
Tons
834,400
47,705
77,521
-
963,966
_
_
_
Oil
in
1000
Bbls.
_
-
-
162
25
11425
1737
12393
Gas
in
MMCF
15,006
1,515
579
1,067
6,238
7,990
9,883
4,262
% FUEL MIXED
Coal
100
100
100
-
20
-
_
_
Oil
_
-
-
100
100
100
100
100
Gas
100
100
100
100
64
100
100
100
% HEAT
FROM
MIXED
FUELS
100
100
100
100
32
100
100
100
FUEL
COMBINA-
TION
USED
C,G
C,G
C,G
0,G
C,G
0,G
0,G
0,G
0,G
RATED
GENERATION
:APACITY
[N MW
486.6
48
46
75
518
1,540
462
1,826
RATIONALE
Supply,
Economic,
Pollution
Standards
Supply,
Economic,
Pollution
Standards
Supply,
Economic,
Pollution
Standards
Supply ,
Economic,
Pollution
Standards
Supply,
Pollution
Standards
Supply,
Pollution
Standards
Supply,
Pollution
Standards
Supply ,
Pollution
Standards
ro
Is]
-------
Table 9 (Cont'd.)
MIXED FUEL FIRING BY UTILITIES
ANNUAL FUEL CONSUMPTION
Coal
in
Tons
-
-
-
-
-
-
-
676,348
Oil
in
1000
Bbls.
690
2194
4102
4375
145
7559
5749
41
Gas
in
MMCF
13,868
4,081
15,112
18,140
406
27,217
8,850
12,361
% FUEL MIXED
Coal
-
-
-
-
-
-
-
100
Oil
67
100
100
100
100
100
100
100
Gas
100
100
100
100
100
100
100
100
% HEAT
FROM
MIXED
FUELS
92
100
100
100
100
100
100
100
1
FUEL
COMBINA-
TION
USED
0,G
O,G
0,G
0,G
O,G
0,G
0,G
O,G
C,G
RATED
3ENERATION
:APACITY
IN MW
346.25
312.5
739.6
804.1
46
1254.6
804.1
463.8
RATIONALE
Supply,
Pollution
Standards
Supply,
Pollution
Standards
Supply,
Pollution
Standards
Supply,
Pollution
Standards
Supply ,
Pollution
Standards
Supply,
Pollution
Standards
Supply,
Pollution
Standards
Supply,
Economic
Pollution
Standards
-------
Table 10
MIXED FUEL FIRING BY GLASS PLANTS
ANNUAL FUEL CONSUMPTION
Oil
in
1000
Bbls.
2
22
62
3
188
7
6
Gas
in
MMCF
164
1,615
980
1,986
714
851
711
Waste
Fuel
-
~
—
—
~
™
% FUEL MIXED
Oil
100
100
100
100
100
100
100
Gas
59
47
74.5
1.9
48.8
75.2
62
Waste
Fuel
-
~
™
••
~
™
%. HEAT
FROM
MIXED
FUELS
65
51
81
3
80
76
64
FUEL
COMBINA-
TION
USED
O,G
O,G
O,G
O,G
0,G
O,G
0,G
MIXED
FUEL
USED
FOR
Heat
Heat
Heat,
Steam
Heat,
Steam
Heat,
Steam
Heat
Heat,
Steam
RATIONALE
Supply
supply ,
Economic
Supply,
Economic
Supply,
Economic
Supply,
Economic
Supply ,
.Economic
Supply,
Economic
-------
Table 11
MIXED FUEL FIRING BY CHEMICAL PROCESSING INDUSTRIES
ANNUAL FUEL CONSUMPTION
Oil
in
1000
Bbls.
120
~
~
Gas
in
MMCF
8,600
8,500
20,600
15,600
Waste
Fuel in
109 Btu
G-Ga$eous
L- Liquid
1,1001L)
15, 700 (G)
14, 900 (G)
6,400(G)
% FUEL MIXED
Oil
100
™
™
Gas
100
100
100
100
Waste
Fuel
100
100
100
100
% HEAT
FROM
MIXED
FUELS
100
100
100
100
FUEL
COMBINA-
TION
USED
0,G,W
G,W
G,W
G,W
MIXED
FUEL
USED
FOR
Steam,
Power
Heat,
Steam
Heat,
Steam
Heat,
Steam
RATIONALE
Supply,
Economic
Supply,
Economic
Supply,
Economic
Supply,
Economic
-------
MIXED FUEL BURNER MANUFACTURERS
A list of mixed fuel burner manufacturers, along with a brief
description and drawing of their burners, is provided below.
The information contained herein has been supplied by the
manufacturers.
Coppus Engineering Corporation
Coppus manufacture type DG combination gas-oil burners, which
employ the FANMIXR principle. Gas is discharged from rotating
driver arms, exerting sufficient reaction power to the fan to
deliver the proper amount of air in relation to the fuel gas
rate. A separate set of driver arms is provided for discharge
of steam-atomized oil to give the reaction power required for
the fan to deliver the correct amount of air in relation to the
fuel oil rate. The two fuels may be fired simultaneously in
any ratio; however, the manufacturer suggests using at least 10%
gas when oil is the main fuel in order to keep the gas orifice
clean. This burner is available in six different sizes ranging
from 8 MMBtu/hr to 58 MMBtu/hr heat release capacity and can
be mounted in either vertical or horizontal positions.
John Zink Company
Series M-A, DBA and FFC burners are manufactured to operate on
gas, oil or gas-oil combination.
Series M-A burner can operate at excess air as low as 1%. The
gas ports are so located in relation to oil ports, that even
a severe upset in the oil burning cannot cause plugging of the
gas ports. This burner will burn any oil that can be pumped and
still burn any fuel gas. Series M-A burners are available in
various sizes up to 18 MMBtu/hr heat release capacity.
Series DBA burner is similar to series M-A but is especially
26
-------
Figure No. 1
GAS
OIL mm
STEAM
ATOMIZED OIL
OIL INLET
Sectional view ol FANMIX Type DG Gas-Oil Burner.
Courtesy of Coppus Engineering Company
QA8 INLET
GUIDE STUDS
27
-------
Figure No. 2
PART Sfr,TtQNAl ELEVATION
MOUNTING DETAIL
t tOLTt IMUMI TM
M MMTI JMC LOUTIO
PARTS LIST «* lURHIR
CAPACITY CHART FOR SERIES "MA"
JOHN ZINK COMBINATION GAS a OIL
BURNERS AT STANDARD CONDITIONS
BASED ON 15% EXCESS AIR
WHEN FIRING OIL OR GAS.
Mioirtoina*-svisri iw I.BJ
Ok iUN HECEIVEK
OIL BODY
CLEVIS H/mOLE
usutn
• INDIMTH IUHNEH SIZE
» OPTIONAL EauiracNT
HOTf: DflvfeM Iftmi fey thii dnwim 11* ctvtrw by U.S. md F
Courtesy of John Zink Company
1.5
.10 J5 .2 .25 .3 .4 .5
DRAFT LOSS "INCHES H20
28
-------
Figure No. 3
DIMENSION LEGEND
SIZE
DBA-14
DBA- 16
DBA-IS
DBA-20
DBA 22
DBA 24
A
16
18
20
22
24
26
B
18'A"
20'A
22 Vi
24 W
26 VT
28W
c
20VY
22
24
26
28
30
0
22'A"
22'A"
22'V
22'/4
24V4"
24'A"
E
14U
14V4
14'/.'
14'A"
16V4
16V4
F
IVi"
IVt"
1W "
2
2"
2
G
6V*"
7
8'/4"
8'V
9M."
10K."
H
9V4"
10'/4"
ll'/4
12W
13'/4"
14'/4
J
/'^4
7V
7%"
8H
8H
8^1
K
3'-4"
3-4
3'-4"
3-4
3-7
3-7
L
8
8
8
6
8
8
IONDINO M01TAR OF DUlPPiNO CONSISTENCY
I- TILE NOTCHED TO FIT OVCIt MIN4 WOUNTtMQ
MOUNTING DETAIL
-GAS TIPS ON 00 <4.l«.i|
•CAS TIPS ON DO JO
GAS TIPS ON OB-11,14
PLAN VIEW
EXPANSION JO«NT^ I
OIL GUN DETAIL
MAIN CAS
GAS RRlNfl HEAOCM
V»LV| -
PART SECTIONAL ELEVATION
INSTALL OIL S STEAM
PIPING AS SHOWN TO
FACILITATE REMOVAL
OF GAS MANIFOLD
5AS PHESSUHE CAGE CONN
BOTTOM VIEW
SUGGESTED PIPING
HEM
1
1
1
|
1 ""
I
1
11
It
M
Ti~~
n
»
M
n
n
n
it
n
M
ii
31
QIT
PARTI LKT P(N tU
OflCRIPTION
•URNlft FLOOR Till
•ICON mi
•AI TIP!
QAI NIW.lt
MOUNTING HIH«
OIL MA IMC VtlVI
STl»M FINIMC VALVI
AI* »ICISII» tTATO*
AIM HUI1TIR HOTOH
AIR •IlltTIt HANQLt
FRONT rim
U> MMirOLD
MIMARV AI* ITATOR
PtltURT AI* HCHOK
f HOT TIP
PILOT NIPPLI
PILOT HUM
PILOT Mil
tUlDI TU»
OIL RUN ItCCIVtR
CLIVII HINDU
• ICON Till CTL1N01R
UWITI
•WIN H.IIVI
OUIOI PIMl
CLIVII
on TIP
ITOMItlR
IIUVC
OIL run
ITUM TUII
OIL 10 DT
«•
PART NO
OIA T •
HAM-T.
Ol-l
¥>- PIPI
01-1 <*A
IIH-IM
1C* -Ml
«I-S-*A
n« » -»
014
0» 1 '»
01 II •«
00-10
Otlt
n v.
H PIPI
KM *.
'IS
r PIPI
I-N-i
J M*
• TC-
1-IH
I-H-I
I-M-I
I-M-1
m
H-PWf
1 PlH
1-U-l
MAT'l
• 1C
• "
C.I.
STIIL
Till
TIIL"
Till"
Till
Till
Till
Till
1.
1.
vcmi
• -NI"
Till"
.1."
I
•Till
Ducmi
•Till
BTHL
COPM*
STIIL
•TIIL
DWCTILI
C« tTHl
••All
CR ITEIL
1TIII
STIIl
OUCTIll
CAPACITY CHART FOR SERIES "DBA"
JOHN ZINK COMBINATION GAS & OIL
BURNERS AT STANDARD CONDITIONS
BASED ON 20% EXCESS AIR WHEN
FIRING GAS AND 20% EXCESS
AIR WHEN FIRING OIL
.10 .15 .2 .25 .3 .4
DRAFT LOSS = INCHES H20
Courtesy of John Zink Company
29
-------
Fiaure No. 4
AIR 000* HANDLE
-FRONT ELEVATION =
VICW WITH OIL «UM 1 tAS PIMM KEMOVED
1'MOUNTING STUM WITH I* PflOJ.
(NOT BY J I CO)
i'tXPtNSIOH
* JOWT
AMOUNTING DETAIL'
'SECTION "B"-"B"
runs LIST PC* BURNER
ITEM
1
11
17
tl
II
20
21
22
23
24
QUANTITY
DESCRIPTION
BURNER TILE
RECON TILE
RECON TILE CASE
STATIONARY REGISTER
AD1USTAILE DOOR
AAS TUIES
GAS TIPS
PRIMARY AIR ROTOR
PRIMARY AIR STATOR
OIL IODY RECEIVER
OIL BODY
CLEVIS
OIL IOOY SEAL
CLEVIS HANDLE
OIL GUN GUIDE TU1E
STEAM TUIE
OIL TUIE
SLEEVE
OIL TIP
ATOMIZER
CASKETS
PILOT NIPPLE
PILOT TIP
PILOT MIXER
MATERIAL
I.F.C.
i.F.C.
STEEL
STEEL
STEEL
STEEL
C.I.
DUCTILE
C.I.
DUCTILE
DUCTILE
DUCTILE
DUCTILE
STEEL
STEEL
STEEL
STEEL
CARION STEEL
CARBON STEEL
BRASS
COPPER
STEEL
CARION STEEL
CARBON STEEL
CAPACITY CHART FOR SERIES "FFC"
JOHN ZINK COMBINATION GAS 8 OIL
BURNERS AT STANDARD CONDITIONS
BASED ON 20% EXCESS AIR
NOTE: DEVICES SHOWN BY THIS DRAWING ARE COVERED BY U. S. AND FOREIGN
PATENTS GRANTED AND PENDING
DIMENSION LEGEND (
SIZE
FFC-1B
FFC-MA
FFC-4SA
A
IiV4"
JIVi"
2IW
1
11"
20"
aw
c
1W
1IW
22"
D
»VT
13"
14"
E
It
ir
ir
G
14
14
ir
:ou
H
14V4"
ir
ir
rte£
j
ia
ir
13
K
ir
ir
22-
jy
of John Zin'c Comp£.ny
DRAFT LOSS • INCHES H20
30
-------
suited to burn pitches or other heavy fuels. When burning oil
it is desirable to have a viscosity of approximately 300 SSU
(60 centistokes) at the burner. The gas burner is designed
to handle either hydrogen or heavy hydrocarbon fuels with no
adjustment. These burners are available in sizes up to 18
MMBtu/hr heat release capacity.
Series FFC burner is specifically designed to produce a thin,
flat flame for process heaters. It can burn gas, oil or both.
Gas burning ports are isolated from oil burners to prevent plug-
ging or other interferences. FFC burners are available in
sizes up to 6.5 MMBtu/hr.
Maxon Corporation
Model "500" ovenpak burner is designed to burn gaseous fuels
and distillate oils separately or in combination. These burners
also can fire fuels such as methanol, gasoline and different
types of waste oils and are available in sizes up to 6 MMBtu/hr
heat release.
National Airoil Burner Company
NAO flat flame burner units are available for a single fuel or
gas or a combination of these fuels. The unit for combination
fuels comprises a centrally positioned oil atomizer plus a pair
of gas manifolds having standpipe mounted gas tips. Gas tips
are arranged to obtain a flat shape of flame. The oil burner is
equipped with a yoke-type detaching gear which admits both the
oil and atomizing steam. Oil and gas manifolds are removable.
Combustion can be continued with the alternate fuel while either
fuel element is withdrawn. This burner can be mounted for hor-
izontal, vertical or intermediate angle firing and is available
in sizes up to 8.5 MMBtu/hr. NAO dual stage oil burners atom-
ize oil in two stages. First stage is mechanical and second
31
-------
Model "500"
OVENPAK® Gas/Oil Burners
Figure No. 5
Dimensions
FOUR ft" DIA.
MOUNTING HOLES
'A" NPT
GAS PRESSURE
TEST CONNECTION
V NPT
AIR PRESSURE
TEST CONNECTION
CONTROL
MOTOR «>
All FILTER
ASSEMIIY
'*" NPT
AM SWITCH
CONNECTION
V
UV SCANNER
MOUNTING
MAIN GAS INLET
CONNECTION
SIZE
OVENPAK
BURNER
508
515
525
535
550
MO1
HP
FRA
%
%
%
i
3
FOR
&
ME
56
56
56
56
145T
DIMENSIONS IN INCHES
A
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I5i
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CO
i
ij
15
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•NOT CERTIFIED, BUT ACCORDING TO THE
MOTOR MANUFACTURER'S SPECIFICATIONS
©FOR CONNECTING BRACKET S LINKAGE ASSEMBLIES FOR ADAPTING CUSTOMER'S CONTROL
MOTORS TO MAXON OVENPAK BURNER ASSEMBLIES, PLEASE SEE CATALOG PAGE 4104.
OADD 1/4" MINIMUM TO DIMENSION "H" WHEN CUTTING OPENING FOR DISCHARGE SLEEVE.
OVENPAK BURNER CAN BE MOUNTED IN ANY POSITION (SUBJECT TO THE LIMITATIONS SET BY MANUFACTURER OF CONTROL MOTOR AND UV SCANNER!.
#90-25663 SPARK IGNITOR
LOCKING BUSHING
(LOOSEN TO ADJUST FOR "A")
INSULATOR
•NPT
BURNER SIZE
SOS ft SSO
515
525 ft 535
"A"
1-5/16"
1-15/32"
1-7/32"
(#90-18722 PROTECTIVE RUBBER COVER
INCLUDED WITH SPARK IGNITOR)
Courtesy of Maxon Corporation
32
-------
Figure No. 6
GENERAL ASSEMBLY OF DUEL
STAGE FUEL OIL BURNER
226-4 CQHE TIP
:T~SIE—i OUTER •
«f
Courtesy of National Airoil Burner Company
33
-------
stage is steam. Steam can be substituted by natural and by-
product gases under pressure. Fuel gas for atomization, by
reason of its contributing heat value, reduces the oil require-
ment by approximately one-third. Dual stage burners are avail-
able in four sizes from 60 to 500 GPH oil at 350 Ib pressure.
Riley Stoker Corporation
Riley manufactures flare-type burners which can fire pulverized
coal, gas or oil alone or in combination. Intertube burners
are available for gas and oil firing. Flare type burners de-
signed for combination firing are equipped with an oil gun
utilizing mechanical or steam atomization and is inserted
through the gas gun assembly. The special alloy steel gas gun
complete with a nozzle, is installed and secured in the spreader
tube of the coal firing equipment which is equipped with a inner
spinner assembly of stainless steel. The end of the coal spread-
er nozzle is equipped with an outer spinner assembly. Flare-
type burners for pulverized coal firing, when burning oil or
center-fired gas in combination, are equipped to supply tertiary
air to improve combustion of fuels and provide cooling air for
the burner components. When a suitable gas supply is available
these burners are furnished with a gas burner ring. When not
in use the gas burner ring is adequately protected from high
furnace heat by the flow of secondary air stream, and by the
position of throat refractory. Flare-type burners for firing
gas and oil are provided with separate oil and gas guns. A
special diffuser of cast alloy attached at the nozzle end as-
sures proper mixing of gas and/or oil and air. Both gas and
oil guns are retractable when not in use. According to the
manufacturer, heat liberations of over 150 MMBtu/hr have been
obtained with the flare-type burners.
In addition to the above, Babcock & Wilcox have in service burners
for almost every fuel combination. Their burner information is
so extensive that it comprises a large volume of their standards,
34
-------
much of which is proprietary and cannot be divulged. They man-
ufacture burners up to 200 MMBtu/hr size.
Combustion Engineering, Inc. has advised that they can design
and manufacture burners to mix conventional and waste fuels in
almost all combinations. They have.a case where 13 different
fuel streams are burnt together.
35
-------
Appendix
36
-------
CONFIDENTIAL
MIXED FUEL SURVEY QUESTIONNAIRE FOR PETROLEUM REFINERIES
1. Name of the company
2. Amount of crude processed for the year 19 :
3. Annual fuel consumption for the year 19 :
Coal tons, Oil BBLS, Nat. Gas
, Plant location_
, Plant capacity
MMCF, Waste Fuel
4. Fuel used for generation of heat [] , power [] , steam [] , waste disposal []
SR.
NO.
SOURCE (l)
IDENTI-
FICATION
SIZE OF
UNIT
MMBTU/HR
FUEL(S) DESIGNED
FOR
C-COAL, O-OIL
G-NAT . GAS
W-WASTE FUELS
ANNUAL FUEL CONSUMPTION
COAL IN
1000
TONS
OIL IN
1000
BBLS
NAT. GAS
IN
MMCF
WASTE*
FUEL
MAX.
EXHAUST
GAS FLOW
IN MACFM
EXHAUST
GAS
TEMP.
op
STACK
NO.
u>
•J
(*) Specify waste fuel and its units
(1) Boiler, Furnace, Heater, Incinerator, etc.
-------
U)
oo
5. Fuel Analysis (If there are more than one composition for any category of fuel, please-match
them with appropriate source number):
COAL fl WT% OIL [1 WT% NAT' " WT% WASTE " WT%
WAlj u Wi* uxij [j MOLE% GAS [] MOLE% FUEL [] MOLE%
Source No.:
C C CH4
H H N2
00 C02
S S C2
N N C3
2 4
ASH ASH S
HHV HHV HHV
6. Exhaust Gas Analysis in mole % (Please identify the source no. or stack no.)
Source/Stack No.:
co2
CO
N2
°2
H2
so2
A
HCl
NOX (ppm)
Particulates
Grains/SCF
or Specify Units
-------
7. Rationale for mixed fuel burning: [] Supply [] Pollution Standards
[] Economic [] Others (Please specify)
8. What % of each fuel consumed for the whole plant was burned as mixed fuel?
COAL % OIL % NAT. GAS % WASTE FUEL %
In 1971
1972
1973
Anticipated in
1974
1975
1976
vo
9. For sources burning mixed fuels, they are burned:
(1) [] Simultaneously [] Separately
(2) [] Through Separate Burners [] Together through same burner
10. Remarks, if any:
Person to Contact , Title , Telephone
-------
CONFIDENTIAL
MIXED FUEL SURVEY QUESTIONNAIRE FOR PETROCHEMICAL INDUSTRY
1. Name of the company
2. Major products:
Plant location
3. Annual fuel consumption for the year 19
Coal
tons, Oil BBLS, Nat.
4. Fuel(s) used for the generation of heat [] , power
Sr. No.
SOURCE *^
IDENTIFICATION
FUELS DESIGNED
FOR
C-COAL, O-OIL
G-NAT. GAS
W-WASTE FUEL
MODE OF
FIRING
FUELS (2)
Gas MMCF, Waste Fuel*
[] , steam [] ,
waste" dispos.al [ ]
ANNUAL FUEL CONSUMPTION
COAL
IN
1000 TONS
OIL
IN
1000 BBLS
NAT. GAS
IN
MMCF
WASTE FUEL*
*Specify waste fuel and its units. (1) Bo-iler, Furnace, Heater, Incinerator etc.
(2) Simultaneous - S, Alternate - A
5. Rationale for mixed fuel burning []Supply, [JEconomic, [JPollution Standards, [JOthers (Please Specify)
6. What % of each fuel consumed for the whole plant was burned as mixed fuel?
Coal %, Oil %, Nat. Gas %, Waste Fuel %
-------
Fuel Analysis:
COAL [1 WT%
C
H
O
S
N
H20
ASH
H.H.V.
OIT " WT%
°IL [] MOLE%
C
H
O
S
N
-
ASH
H.H.V.
NAT
GAS
CH4
N2
co2
C2
C3
C4
-
H.H
[] WT.% WASTE [] WT.% 9.
[] MOLE% FUEL [] MOLE %
V.
8. Exhaust Gas Analysis:
PAST & ANTICIPATED FUTURE
USE OF MIXED FUELS
YEAR
1972
1973
1974
1975
1976
COAL %
OIL %
NAT
GAS %
WASTE
FUEL %
Sr. No.
MAX. EXHAUST
GAS FLOW
IN
MACFM
TEMP
IN
°F
SERVED
BY
STACK
NO.
COMPOSITION
MOLE%
co2
CO
*2
°2
H20
A
CONCENTRATION
IN PPM
so2
N0x
HC1
H'C
PART I -r
CULATE
(3)
NOTE: If two or more sources have approximately the same fuel mixtures or ratios, there is no need to
repeat the exhaust gas analysis; please identify repeated cases by serial no.
(3) Please specify units
Person to contact , Title Telephone
-------
CONFIDENTIAL
MIXED FUEL SURVEY QUESTIONNAIRE FOR CEMENT INDUSTRY
1. Name of the company
2. Production for the year 19 : (preferably 73)
i) Major Products:
ii) Process Type:
3. Annual fuel consumption for the year 1973
•
Coal TONS, Oil BBLS, Nat. Gas
, Plant location
MMCF, Waste Fuel
4. Fuel used for generation of heat [], power [] , steam [], waste disposal [J
SR.
NO.
SOURCE £1>
IDENTI-
FICATION
FUEL(2)
DESIGNED
FOR
TYPES* J
OF
BURNERS
ANNUAL FUEL CONSUMPTION
COAL
IN
1000
TONS
OIL
IN
1000
BBLS
NAT. GAS
IN
MMCF
WASTE
FUEL*
MAX.
EXHAUST
GAS FLOW
IN
MACFM
EXHAUST
GAS
TEMP.
STACK
NUMBER
(*) Specify waste fuel and its units
(1) Boiler, Furnace, Heater, Incinerator, Kiln etc.
(2) C-Coal, O-Oil, G-Nat. Gas, W-Waste Fuels
(3) Use numbers shown in parenthesis on right hand side
Type of Burners
C-Spreader (1)
Underfeeder (2)
Overfeeder (3)
Pulverized (4)
Other (5)
O-Air Atomizing (6)
Steam Atomizing(7)
Press/Mech. (8)
Rotary (9)
Other (10)
G-Atmospheric
Injection (11)
Power
(a) Premix (12)
(b) Nozzle Mix(13)
Other (14)
-------
5. Fuel Analysis (If there are more than one composition for any category of fuel, please match
them with appropriate source number) :
roAL ri WT% OIL [1 WT% NAT- [] WT% WASTE [1 WT%
COAL [] WT* OIL t] MQLE% GAS [j MOLE% FUEL [] MOLE%
Source No.:
C C CH4
H H N2
00 C02
S S C2
N N C3
H20 - C4
ASH ASH S
HHV HHV HHV
«.
u
6. Exhaust Gas Analysis in mole % (Please identify the source no. or stack no.)
Source/Stack No. :
CO,
CO
N2
°2
H2
so2
A
HC1
NOX (ppm)
Particulates
Grains/SCF
or Specify Units
-------
7. Rationale for mixed fuel burning: [] Supply [] Pollution Standards
[] Economic [] Others (Please specify)
8. What % of each fuel consumed for the whole plant was burned as mixed fuel?
COAL % OIL % NAT. GAS % WASTE FUEL %
In 1971
1972
1973
Anticipated in
1974
1975
1976
9. For sources burning mixed fuels, they are burned:
(1) [] Simultaneously [] Separately
(2) [] Through Separate Burners [] Together through same burner
10. Remarks, if any:
Person to Contact , Title , Telephone
-------
CONFIDENTIAL
MIXED FUEL SURVEY QUESTIONNAIRE FOR TEXTILE INDUSTRY
1. Name of the company
2. Production for the year 19 : (preferably 73)
i) Major Products:
ii) Process Type:
3. Annual fuel consumption for the year 1973
•
Coal TONS, Oil BBLS , Nat. Gas
, Plant location
MMCF, Waste Fuel
4. Fuel used for generation of heat [] , power [] , steam [] , waste disposal []
U1
SR.
NO.
t
SOURCE ()
IDENTI-
FICATION
FUEL(2)
DESIGNED
FOR
TYPES (3)
OF
BURNERS
ANNUAL FUEL CONSUMPTION
COAL
IN
1000
TONS
OIL
IN
1000
BBLS
NAT. GAS
IN
MMCF
WASTE
FUEL*
MAX.
EXHAUST
GAS FLOW
IN
MACFM
EXHAUST
GAS
TEMP.
STACK
NUMBER
(1) Boiler, Furnace, Heater, Incinerator, Kiln etc.
(2) C-Coal, O-Oil, G-Nat. Gas, W-Waste Fuels
(3) Use numbers shown in parenthesis on right hand side
Type of Burners
C-Spreader (1)
Underfeeder (2)
Overfeeder (3)
Pulverized (4)
Other (5)
O-Air Atomizing (6)
Steam AtomizingC7)
Press/Mech. (8)
Rotary (9)
Other (10)
G-Atmospheric
Injection (11)
Power
(a) Premix (12)
(b) Nozzle Mix(13)
Other (14)
-------
5. Fuel Analysis (If there are more than one composition for any category of fuel, please match
them with appropriate source number):
rvMir ri WT» OTT M WT% NAT. [] WT% WASTE [] WT%
COAL [] WT» OIL {] MOLE% GAS (j MOLE% FUEL [] MOLE%
Source No.:
C C CH4
H H N2
00 (X>2
S S C2
N N C3
H20 - C4
ASH ASH S
HHV HHV HHV
6. Exhaust Gas Analysis in mole % (Please identify the source no. or stack no.)
Source/Stack No.:
co2
CO
N2
°2
H2
so2
A
HC1
N0x (ppm)
Particulates
Grains/SCF
or Specify Units
-------
7. Rationale for mixed fuel burning: [] Supply [] Pollution Standards
[] Economic [] Others (Please specify)
8. What % of each fuel consumed for the whole plant was burned as mixed fuel?
COAL % OIL % NAT. GAS % WASTE FUEL %
In 1971
1972
1973
Anticipated in
1974
1975
1976
9. For sources burning mixed fuels, they are burned:
(1) [] Simultaneously [] Separately
(2) [] Through Separate Burners [] Together through same burner
10. Remarks, if any:
Person to Contact , Title , Telephone
-------
itfc
00
CONFIDENTIAL
MIXED FUEL SURVEY QUESTIONNAIRE FOR ELECTRIC UTILITY PLANTS
1.
2.
3.
Name of the company
Number of boilers , Number of generators
Annual fuel consumption for the year 19 :
, Plant location
, Number of stacks
Coal
tons, Oil
BBLS, Nat. Gas
MMC.ft., Was te Fue1
4. BOILER DATA:
BOILER
NO.
FUELS DESIGNED FOR
C-COAL, O-OIL
G-NAT. GAS.
W-WASTE FUELS
C
TPH
100% R
]>ESIGN P
O
BBLH
ATING
PEL RATE
G
MSCFH
W *
NOTE: Please use additional sheet if necessary *Please spec
5. How many boilers have the capability of burning more than one fi
**
-------
8. Data for boilers having capability of burning more than one fuel
Data for the year (preferably 73)
BOILER
NO.
GENERATED
KWH
ANNUAL FUEL CONSUMPTION
COAL
IN
1000
TONS
OIL IN
1000
BBLS
NAT. GAS
IN
MMCF
WASTED
FUEL
% OF EACH TYPE
FUEL BURNED BY
WT. OR BY BTU'S
TOTAL
HOURS OF
OPERATION
AVERAGE
CAPACITY
FACTOR
STACK
NO.
VO
(2) Please specify the waste fuel
9. Fuel Analysis (If there are more than one composition for any category of fuels, please match
them with appropriate source number):
COAL [] WT%
OIL
(1
[]
WT%
MOLE%
NAT.
GAS
WT%
MOLE%
WASTE
FUEL
WT%
MOLE%
Boiler No.:
C
H
O
S
N
H20
ASH
HHV
C
H
O
S
N
ASH
HHV
CO.
S
HHV
-------
10. Flue Gas Analysis in mole % (Please match with appropriate boiler number(s))
Boiler Number (s)
co2
CO
N2
°2
H20
SO,
A
HC1
NOX (ppm)
Particulates
Grains/SCF
or Specify Units
11. What % of each fuel consumed for the whole plant was burned as mixed fuel?
COAL % OIL % NAT. GAS % WASTE FUEL %
In 1971
1972
1973
Anticipated in
1974
1975
1976
12. Remarks, if any:
Person to contact , Title , Telephone
-------
CONFIDENTIAL
MIXED FUEL SURVEY QUESTIONNAIRE FOR GLASS INDUSTRY
1. Name of the company
2. Production for the year 19 :
3. Annual fuel consumption for the year 19
Coal tons, Oil
Plant location
Major Products
Process Type
BBLS, Nat. Gas
4 Fuel(s) used for the generation of heat [], power [], steam [],
Source (1)
Identifi-
cation
Fuels (2)
Designed
For
Types of '
Burners
ANNUAL FUEL CO!
Coal
In
1000 Tons
Oil
In
1000 BBLS
SUMPTION
Nat. Gas
In
MMCF
Waste*
Fuel
waste disposal
Max.
Exhaust
Gas Flow
In MACFM
Exhaust
Gas
Temp.
OF
MMCF, Waste Fuel
(*) Specify waste fuel and its units
(1) Boiler, Furnace, Heater, Incinerator, Kiln, etc.
(2) C-Coal, O-Oil, G-Nat. Gas W-Waste Fuels
(3) Use numbers shown in parenthesis on right hand side
Type of Burners
C-Spreader
Underfeeder
Overfeeder
Pulverized
Other
O-Air Atomizing
Steam Atomizing
Pres/Mech.Atomizing(8)
Rotary (9)
Other (10)
G-Atmosphere Injec . (11)
Power(a) Premix (12)
(b) Nozzle Mix (13)
Other (14)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
-------
5. Fuel Analysis (If there are more than one composition for any category of fuel, please match
Source No.:
C
H
O
S
N
them with appropriate source number):
COAL [] WT%
[J WT%
01L [] MOLE%
C
H
O
S
N
NAT. [] WT%
GAS [] MOLE%
N,
CO,
WASTE [] WT%
FUEL [] MOLE%
ASH
HHV
01
to
ASH
HHV
S
HHV
6. Exhaust Gas Analysis in mole % (Please identify the source no. or stack no.)
Source/Stack No.:
CO,
CO
N.,
H2
so2
A
HC1
NOx (ppm)
Particulates
Grains/SCF
or Specify Units
-------
Ul
W
7. Rationale for mixed fuel burning: [] Supply [] Pollution Standards
[] Economic [] Others (Please specify)
8. What % of each fuel consumed for the whole plant was burned as mixed fuel?
COAL % OIL % NAT. GAS % WASTE FUEL %
In 1971
1972
1973
Anticipated in
1974
1975
1976
9. For sources burning mixed fuels, they are burned:
(1) [] Simultaneously [] Separately
(2) [] Through Separate Burners [] Together through same burner
10. Remarks, if any:
Person to Contact , Title , Telephone
-------
CONFIDENTIAL
MIXED FUEL SURVEY QUESTIONNAIRE FOR CHEMICAL PROCESSING INDUSTRY
1. Name of the company
2. Major products:
Plant location
3. Annual fuel consumption for the year 19
Coal tons, Oil BBLS,
Nat. Gas
MMCF,
Waste Fuel*
4. Fuel(s) used for the generation of heat [], power [], steam [] , waste disposal []
Sr.No
SOURCE (J
IDENTIFI-
CATION
FUELS DESIGNED
FOR
C-COAL, O-OIL
G-MAT. GAS
ff-WASTE FUEL
MODE OF
FIRING
FUELS v2'
(3)
TYPE OF
BURNERS
ANNUAL FUEL CONSUMPTION
COAL
IN
TONS
OIL
IN
LOOO BBLS
NAT. GAS
IN
MMCF
* WASTE
FUEL
TYPES OF BURNERS
C-Spreader (1)
Underfeeder (2)
Overfeeder (3)
Pulverized (4)
Other (5)
O-Air Atomizing (6)
Steam Atomizing (7)
Pres/Mech. Atomizing(8)
Rotary (9)
Other (10)
G-Atmosphere Injection(11)
Power(a) Premix (12)
(b) Nozzle Mix (13)
^Specify waste fuel and its units. (1) Boiler, Furnace, Heater, Incinerator etc.
(2) Simultaneous - S, Alternate - A
(3) Use numbers shown in parenthesis on right hand side
5. Rationale for mixed fuel burning []Supply, []Economic, []Pollution Standards, []Others (Please specify)
6. What % of each fuel consumed for the whole plant was burned as mixed fuel?
Coal % Oil % Nat. Gas % Waste Fuel %
-------
Fuel Analysis:
COAL [] WT%
C
H
O
S
N
H20
ASH
H.H.V.
OTT I] WT%
OIL [] MOLE%
C
H
O
S
N
-
ASH
H.H.V.
NAT
GAS
CH4
N2
co2
C2
C3
C4
~
H.H
[] WT.% WASTE [] WT.% 9.
[] MOLE% FUEL [] MOLE %
.V.
8. Exhaust Gas Analysis:
PAST & ANTICIPATED FUTURE
USE OF MIXED FUELS
YEAR
1972
1973
1974
1975
1976
COAL %
OIL %
NAT
GAS %
WASTE
FUEL %
Sr. No.
MAX. EXHAUST
GAS FLOW
IN
MACFM
TEMP
IN
op
SERVED
BY
STACK
NO.
COMPOSITION
MOLE%
co2
CO
N2
°2
H20
A
CONCENTRATION
IN PPM
so2
N0x
HC1
H'C
PARTI T
CULATE
(3)
U1
U1
NOTE: If two or more sources have approximately the same fuel mixtures or ratios, there is no need to
repeat the exhaust gas analysis; please identify repeated cases by serial no.
(3) Please specify units
Person to contact , Title Telephone_
-------
TECHNICAL REPORT DATA ,
(Plate nod laitniellont on tht reverie btfort completing}
1. REPORT NO.
EPA-650/2-75-017
2.
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Identification and Characterization of the Use of
Mixed Conventional and Waste Fuels
B. REPORT DATE
February 1975
6. PERFORMING ORGANIZATION CODE
7. AUTHORIS)
Gopal K. Mathur
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING OR6ANIZATION NAME AND ADDRESS
The M.W. Kellogg Company
Research and Engineering Development
Houston, Texas 77046
10. PROGRAM ELEMENT NO.
1AB014; ROAP 21BCC-042
11. CONTRACT/GRANT NO.
68-02-1308 (Task 5)
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
NERC-RTP, Control Systems Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
IB. SUPPLEMENTARY NOTES
16. ABSTRACT
The report gives results of a study to determine types of mixed and waste fuels and
the extent of their usage in stationary combustion equipment. Where possible,
pollutant emission levels resulting from combustion of these fuels have been deter-
mined. Industries surveyed included utilities, petroleum refineries, petrochemical,
chemical processing, glass, cement, and textiles. Of the industries surveyed, about
70% of the refineries, 45% of the utilities, 20% of the cement, glass, and textile
manufacturers, and 10% of the petrochemical and chemical processing plants have
reported using mixed fuels to some extent.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIEHS/OPEN ENDED TERMS
c. COSATI Field/Group
Air Pollution
Fuels
Mixtures
Wastes
Flue Gases
Utilities
Refineries
Petrochemistry
Chemical Industry
Glass Industry
Cements
Textile Industry
Air Pollution Control
Stationary Sources
Mixed Fuels
Waste Fuels
13B, 08G
21D, 07A
07D, 11B
13C
21B, HE
19. SECURITY CLASS (This Report)
Unclassified
IS. DISTRIBUTION STATEMENT
Unlimited
21 NO. OF PAGES
61
20 SECURITY CLASS (Till* page)
Unclassified
EPA Perm 2220-1 (»-7J)
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