OIL AND GAS BURNERS

THERMAL ENGINEERING THE INTERNATIONAL WAY

THERMAX BABCOCK & WILCOX LIMITED

Liquid & Gas Burners from Thermax Babcock & Wilcox

Since 1988 Thermax Babcock & Wilcox has been supplying innovative solutions to meet the ever-changing energy needs of Industrial customers. Drawing upon the vast expertise of Babcock & Wilcox USA, with over 270,000 Megawatts of installed capacity in 85 countries, TBW offers the best value for money when it comes to energy generating equipment. We understand the need for reliable and efficient performance from your energy systems, while complying with increasingly stringent emission regulations. Through continuous product improvements and innovative technological advancements, our burners always represent the latest technology in maximizing energy generation at minimum cost. We engineer, design, manufacture, supply and commission burners for firing a wide range of liquid and gaseous fuels including : Heavy Oils Low Sulfur Heavy Stock (LSHS), Furnace oil (FO), Tar, Carbon Black Feed Stock (CBFS) and their likes. Light Oils Naphtha, Natural Gas Liquid (NGL), Light Diesel Oil (LDO), High Speed Diesel (HSD), Kerosene, C-9 and their likes. Gaseous fuels Rich Gases like Natural gas, Liquefied Petroleum Gas (LPG); Lean Gases like Coke Oven Gas (COG), Blast Furnace Gas (BFG). Multifuel : Two gas and one liquid fuel or one gas and two liquid fuel combinations.

The latest in Burner and control technology

Wide range of atomising media
TBW burners work with commonly available atomizing media like compressed air, steam or even other non-conventional media. The liquid atomizer has a state-of-the- art I-jet nozzle, proven for its superior atomization performance with all liquid fuels.

Wide turndown on all fuels

Liquid fuels can be handled with great stability even at a turndown as low as 5:1, while gaseous fuels can be turned down to as much as 6:1.

Low excess air requirement

Liquid fuel firing requires 10% to 15% excess air, while gas firing requires 7% to 10%, depending upon the furnace configuration, combustion air temperature and operating load.

State of the art controls

TBW burner systems are supplied with an independent Burner Management System (BMS). Tailored to suit specific operating requirements, the control system offers a wide choice from simple parallel un-metered combustion control to sophisticated lead-lag control for maintaining high combustion efficiency and quick response to load swings.

Systems designed for optimum performance

1) Oil Atomiser
The atomiser is fitted with an I jet nozzle, consisting of a mixing chamber and a sprayer cap. Suitable for heavy and light oils equally, this atomizer uses compressed air or steam as the atomising medium. A constant differential pressure control located before the burner ensures a constant DP of atomising medium over the fuel oil pressure. Atomizer components are available as spares on order.
Atomizer Head Coupler Assembly Atomizer Gasket Steam & Oil Barrels I-Jet

2) Observation ports
The burners have ergonomically placed safety observation ports to provide visual access to the flame root. Each observation port has temperature resistant glass protected with mica sheets fitted into the observation port with gasket packing, available as spares on order.

Tee bolt Enlarged view of I-Jet Atomiser tip

I Jet Atomizer Assembly

3) Pilot Ignitors
TBW burners have built-in stationary pilot igniters. Power consumption is negligible as the ignitor sparks only for 5 seconds for each firing cycle. The electrode is practically non consumable, eliminating any maintenance of this vital part of the burner. The ignitor is made of material which is able to withstand radiation from the flame without requiring any retraction while the burner is firing. This is accomplished with the strategic location of the inner end of the ignitor behind the diffuser and the refractory throat. Since no retraction is necessary, a lot of cumbersome hardware and instrumentation is avoided.
Cleaning/ Sealing Air Pipe Insulated Electric Supply Port Firing end Gas Pipe

4) Diffuser

Pilot Gas Igniter Assembly

The diffuser is a bowl like component, having a set of louvers through which a small part of the combustion air passes with a strong spin. The diffuser is made of stainless steel and is capable of withstanding the direct radiation of the flame. The design of diffuser used in a circular burner is such that the spin direction of its louvers matches with that of the register blades.

5) Air register assembly

The air register assembly conveys the combustion air from the wind box to the burner throat. The air registers consist of peripherally arranged blades designed to operate in unision. The register blades provide a varying degree of spin to the combustion air entering the burner throat. This spin angle controls the spread of the flame and is thus a vital tool in the hands of the boiler operator to have an online control of the flame shape in a given furnace geometry. Opening the register blades imparts a stronger linear velocity component than the peripheral velocity component, making the flame long and narrow. Closing the registers gives a counter effect thus making the flame wide and short. It is this feature of the TBW circular burner that makes them a perfect choice for retrofitting on existing furnaces.

6) Flame scanning system

Each burner is provided with flame scanners to monitor the flame on a continuous basis. The scanner unit is supplied with mounting arrangement, a cooling air port and a swivel base for adjusting the sighting line .

Single Throat Swirl (STS) Burners

STS burners are typically selected where the flames are required to be narrow and long, as in small packaged unit furnaces. This burner can fire both liquid and gaseous fuel in solo or combination mode. The BMS and the combustion control system are designed to suit the user requirement. The STS burners are available for heat release rates ranging from 45 to 300 Million Kilo-btu/ hour foe Gas firing and from 45 to 200 Million Kilobtu/ hour for oil firing. The STS burners are simple and have practically no requirement of online adjustments. Hence they have no registers, eliminating control requirements for this equipment. The STS burner has a built in gas fired pilot igniter, which can light up any of the two fuels. Auxiliary atomizers are available with STS burners also, as with CR burners.
Gas Igniter Gas Spuds Flame Scanner Port Oil Atomizer Fuel Gas Supply

Swirler

Oil Atomizer

Refractory Throat View Port

Scroll type Burners

These burners are offered for liquid fuel and lean gas fuel firing applications. The scroll type burners are available in the heat release rtes ranging upto 100 Million Kilo-btu/ hour. They have the features necessary for handling large volumes of the fuel gas and create adequate turbulence for effective air/ fuel mixing. The design is tailored for lean gases requiring combustion support, by providing low capacity oil atomizers as an integral part the burner assembly. In addition, the burners also carry a normal duty oil atomizer for generating upto 80% of the MCR heat release in case of shortage of gas supply.
Refractory Throat

Core Air Supply

Oil Atomizer

Scroll (for Lean gas)

TBW scroll burners are in service at quite a few steel plants, where Blast Furnace Gas is fired in our boilers to generate steam for power generation.

Windbox

Cleaning Ports

Blast Furnace Gas fired burner

Renovation and Modernisation of firing systems

TBW undertakes all-encompassing Engineering Studies of firing systems and offer innovative solutions. TBW also implement the solutions by design, engineering, manufacture, erection and commissioning of the suggestions by retrofitting the existing system, with performance guarantees. TBW is associated with a large family of happy customers who have revamped their firing system with TBW firing system for fuel upgrades, efficiency improvement and capacity enhancement.

As part of burner retofits TBW also provides new water panels to suit new burner dimensions.

View of Burners supplied as part of Fuel upgrade from Natural Gas firing to NGL firing carried out on 3 X 275 TPH boilers at a large fertilizer complex . All TBW burners are proven for their maintenance free operation. They are further backed by quick delivery of spares, in case of need.

Supplementary Systems
All TBW burners are supplied with necessary accessories and equipment like: ! Flame scanners for hook up with BMS and intensity indication in control room ! Oil Atomizers suitable for air/ steam atomization and for a variety of liquid fuels ! Fixed/ Adjustable Gas spuds with stabilizers, connected to a common ring header ! Fixed pilot igniters working on a gaseous fuel for reliable start. (High Energy Arc igniters can also be supplied against special requirements). ! Automatic and manual Shut off valves for oil/ gas/ atomizing and clearing media ! Fuel flow control valves ! Fuel flow meters ! Pilot gas/ main gas/ oil trains ! Flexible hose piping for easy connectivity ! Safety view ports for flame observation Complete Burner Management and firing control system, with necessary instrumentation, complying standards with globally approved standards and codes.

Circular Register Burners

Flame scanner ports

Fixed Igniter

Observation port

Air Register Lever

Gas input port

CR burners are available in the heat release rate range of 11 to 45 Million Kilo-btu/ hour for packaged boilers. For large boiler applications, they are available in capacities upto 200 Million Kilo-btu/ hour for Gas firing and upto 165 Million Kilo-btu/ hour for oil firing.

Supplied with an integral stationary pilot igniter, the CR burners have peripherally arranged combustion air vanes that can be steplessly modulated to a preset position by manual or automatic means. The opening of the vanes (registers) controls the flame spread without affecting the net burner pressure drop. Thus, the operator can have an on-line control over the flame shape. This feature renders the CR burners extremely suitable for retrofit applications where the new burner is required to perform within a pre-fixed furnace geometry.
Air Registers Diffuser Gas Spuds Air Registers Refractory throat

CR burners are available for any liquid and rich gas application. The two fuels can be fired in solo or in combination mode. The BMS and the combustion control system are designed to suit the user requirement.

CR burners are also available with an auxiliary oil atomizer per burner, which imparts a cent percent redundancy of oil firing capacity to each burner. The main oil atomizer can be withdrawn from service for cleaning or any other maintenance when needed, without stopping the oil firing, by transferring the load to the auxiliary atomizer. This feature enables single burner installations to be operated continuously and without interruptions, even where the fuel quality may demand occasional stoppage of the main atomizer for cleaning. The auxiliary atomizer can, alternatively be used for firing a second liquid fuel in combination with the primary liquid and gas fuels.

Thermax Babcock & Wilcox Limited

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