State of the Art Combustion Equipment for Emissions and Energy Reduction November 2009.

State of the Art Combustion Equipment for Emissions and Energy Reduction

November 2009

Honeywell Proprietary2

Callidus.com

• Emissions is the primary driver for combustion equipment. Energy efficiency is a secondary but growing driver

• Impact

– Burners: Emissions and Energy

– Flares: Emissions and Energy

– Thermal oxidizers: Emissions and Energy

– Vapor control systems: Emissions

– NOx and CO catalyst systems: Emissions

– Services: Emissions and Energy

Burners

FlaresThermal

Oxidizers

Field Service& Parts

VaporControl

Systems

NOx & COCatalystSystems

Combustion & Emission

Honeywell Proprietary3

Callidus.com

Requirements in addition to Technology

• Uncompromising Product/System Safety

• Proven Reliability

• Operational Performance (Guarantee)– Emissions reduction

• Ease of Product Operation

Honeywell Proprietary4

Callidus.com

Callidus Market Segments Served

Power PlantsSCR for simple cycle power generationSCR for HRSGSCR for process heater

Refineries Petrochemical Plants

Others (Flares)Terminals

LNG storageCarbon black

Steel productionBio-fuels

Exploration & Production

Ethylene productionFertilizer production

Hydrogen productionFlares

Thermal oxidizers

Refinery process heatersReforming furnacesCracking furnacesCoking furnacesFlaresThermal oxidizers

Honeywell Proprietary5

Callidus.com

Advanced Process Heater Burners

• Advanced Burner Design

– Future transition in India from oil firing to gas firing

– Improved efficiency: reduction in combustion air = less wasted heat and less fuel needed therefore improvement in efficiency and cost savings.

– Reduced emissions footprint: reduction from 25% excess air to 15% excess air = 25% reduction in NOx emissions per burner

6

Callidus.com

100 ppm 50 ppm(200 Mg/Nm3) (100 Mg/Nm3)

“CRG” “CSG” 25 ppm“LE”

(50 Mg/Nm3)15 ppm“CUBL”

(30 Mg/Nm3)

15 ppm“CUB-LX”

(30 Mg/Nm3)

Reduction in NOx EmissionsReduction in NOx Emissions

Regulations and Burner Emissions Improvements

Oil firing200 ppm

Honeywell Proprietary7

Callidus.com

Process Heater Burners Application

• Using advanced fuel air ratio controls and O2 trimming, Callidus could potentially reduce the oxygen levels within the furnace, while maintaining the temperature and combustion efficiency

• The Callidus burner is designed to be stable over the entire operating range

• Assuming natural gas, a 1% reduction in oxygen should produce a 1.3% reduction in fuel gas needed

Current Fuel gas requirement (Ton/Year)

Annual savings from 1.3% reduction

(USD)

Payback Period

UOP Reforming Furnace

176,620

(180 burners)$1,331,715 14.5 months

*Note: Assuming fuel cost of 580USD/Ton, and annual operation of 8300 hr.

• Guaranteed 30 ppm NOx

Honeywell Proprietary8

Callidus.com

Flare Technology Emissions Improvements

Increased smokeless capacity

Pipe flare

Upper steamflare

Inner steam or Inner air flare

Demountable Derrick Flare

Multi-point ground flare

Honeywell Proprietary9

Callidus.com

Highlighting Totally Enclosed Ground Flares

• Totally Enclosed Ground Flares (TEGF)

– No visible emissions during normal operations

– Reduced radiation “signature”

– Reduced noise level

Non-Callidus flare smoking Callidus TEGF

Honeywell Proprietary10

Callidus.com

Flare Technology Energy Efficiency Improvements

• Flare Gas Recovery Unit (FGRU)

– Add-on equipment

– Allows capture of daily flaring rate

– Captured flare gas used in refinery processes

– Supports global gas flaring reduction efforts championed by World Bank

• Density Seals

– Flare purge gas reduction equipment

– Reduces amount gas needed to maintain safe flare operations

FGRU

Refinery

Flare

Honeywell Proprietary11

Callidus.com

Petrochina Dushanzi Flare / Flare Gas Recovery System

Recovery capacity 2X1.35 Ton/hr

EPC Total cost 1,800,000 USD

Flare Gas Recovered Per Year

1.35*0.6(8400+4000)

=10,044 Tons

Operation cost /Y 350,000 USD

Pay back (300USD/Ton)

9 months

Flare Application

• Low utility consumption (steam, fuel gas, N2, Instrument Air)

• High combustion efficiency & smokeless capacity to meet emission standards

Honeywell Proprietary12

Callidus.com

Thermal Oxidizers

• Thermal Oxidizers are capable of achieving 99.999% destruction efficiency

• Air Pre-heaters allow for less fuel/assist gas to be used in the operation of the thermal oxidizer

• Attached waste heat boilers allow for the use of steam for applications around the facility or “across the fence” in a co-generation applications

Honeywell Proprietary13

Callidus.comCallidus Incinerators Application

Waste Gas for treatment

Oxidizer vent gas, WAO, EO/EG

WHB Cost $1,044,000

Steam production

2.0MPa(g)

Normal: 15 Ton/hr

Design: 58 Ton/hr

Steam Quantity 124,500 Ton/Yr

Pay back Period ($22/Ton steam)

4.5 months

Thermal Oxidizer (Waste Heat Boiler) Application

Honeywell Proprietary14

Callidus.comCallidus Incinerators Application

Questions?