Improvement in Efficiency by Advanced Combustion & Control Solutions for Glass Furnaces
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1 UAS_Masterpräsentation_REV15, Folie 1 Improvement in Efficiency by Advanced Combustion & Control Solutions for Glass Furnaces Glassman Latin America 2015 Florian Stadler, Dipl.-Ing.(FH) UAS Messtechnik GmbH, Germany
2 UAS_Masterpräsentation_REV15, Folie 2 UAS Messtechnik GmbH Established: CEO: Managing Director: 1983 by Bernd Donaubauer Thomas Donaubauer Franz Knopf Employees: ~ 50 Annual Turn-over: Subsidiaries: ~ 10 Mio. EDSTA GmbH & Co.KG UAS Limited Shanghai Fields of Operation: - Furnace Control Systems - Process Automation - Combustion Technology - Electric Heating Systems - Waste Heat Recovery Systems
3 UAS_Masterpräsentation_REV15, Folie 3 UAS - Location Viechtach, Zwiesel München Munich
4 UAS_Masterpräsentation_REV15, Folie 4 GESCHÄFTSFELDER LINES OF BUSINESS Broschüre Broschüre Broschüre Broschüre
5 UAS_Masterpräsentation_REV15, Folie 5 OPTIMIZED COMBUSTION DCS-SYSTEM ENOx-System GAS-ANALYZER WOBBE-INDEX O2- ANALYZER ANALYZER SPS PLC-SAFETY-CONCEPT MAIN SKID OXYGEN / GAS SAMPLE CONDITIONING SYSTEM TOUCH PANEL Combustion Technology BURNER SKID OXYGEN / GAS FURNACE FLUE GAS OXYGEN NATURAL GAS DATA LINK MEASURING SIGNAL
6 UAS_Masterpräsentation_REV15, Folie 6 Combustion Technology
7 UAS_Masterpräsentation_REV15, Folie 7 Combustion Technology
8 UAS_Masterpräsentation_REV15, Folie 8 OPTIMIZED COMBUSTION Quality Measurements DCS-SYSTEM ENOx-System GAS-ANALYZER WOBBE-INDEX O2- ANALYZER ANALYZER SPS PLC-SAFETY-CONCEPT MAIN SKID OXYGEN / GAS SAMPLE CONDITIONING SYSTEM TOUCH PANEL BURNER SKID OXYGEN / GAS FURNACE FLUE GAS OXYGEN NATURAL GAS DATA LINK MEASURING SIGNAL
9 UAS_Masterpräsentation_REV15, Folie 9 Natural Gas Analysis German Example» significant changes in natural gas composition because of: -> mixture of different NG sources (GUS-Gas, NSG, LNG, ) -> injection of regenerative sources (biogas, P2G, SNG, ) Quelle:» unnoticed changes of gas composition may cause considerable problems for furnace and equipment, glass quality and emissions
10 UAS_Masterpräsentation_REV15, Folie 10 Natural Gas Analysis Effects of changing NG-composition» increase of wall temperature -> damage of refractory» negative effects on glass quality» exiding NOx- or CO-emissions in flue gas» higher energy demand for combustion Quelle:
11 UAS_Masterpräsentation_REV15, Folie 11 OPTIMIZED COMBUSTION DCS-SYSTEM ENOx-System ENOx-System GAS-ANALYZER WOBBE-INDEX O2- ANALYZER ANALYZER SPS PLC-SAFETY-CONCEPT MAIN SKID OXYGEN / GAS SAMPLE CONDITIONING SYSTEM TOUCH PANEL BURNER SKID OXYGEN / GAS FURNACE FLUE GAS OXYGEN NATURAL GAS DATA LINK MEASURING SIGNAL
12 UAS_Masterpräsentation_REV15, Folie 12 ENOx-System Overview» extractive measurement of O2, CO and NO» high precision of measurement» automatic calibration no measurement drift long-term stability of measuring results» higher durability then ZrO2-Sensor» multiple sensor systems possible
13 UAS_Masterpräsentation_REV15, Folie 13 U-Flame 2 Ports SAUERSTOFFMESSTECHNIK ENOX-System OXYGEN MEASUREMENT System 1 / 2P 4-20mA / Profibus DP Burnersignal / Combustion
14 UAS_Masterpräsentation_REV15, Folie 14 OPTIMIZED COMBUSTION DCS-SYSTEM Furnace Control ENOx-System GAS-ANALYZER WOBBE-INDEX O2- ANALYZER ANALYZER SPS PLC-SAFETY-CONCEPT MAIN SKID OXYGEN / GAS SAMPLE CONDITIONING SYSTEM TOUCH PANEL BURNER SKID OXYGEN / GAS FURNACE FLUE GAS OXYGEN NATURAL GAS DATA LINK MEASURING SIGNAL
15 Burner 2 Burner 4 Burner 6 Factor Factor Gas SP Burner 2 Gas SP Burner 2 Gas SP Burner 2 Factor Sum Factor Factor Gas SP Burner 1 Gas SP Burner 3 Setpoint (SP) Gas SP Burner 5 Factor Burner 1 Burner 3 Burner 5 UAS_Masterpräsentation_REV15, Folie 15 OPTIMIZED COMBUSTION Furnace temperatures X Gas Analysis O2 Sensor and / or ENOx- Measurement X X X + / PV PID OP OP HLM OP LLM A Factor X A Factor X HLM LLM A Factor HLM LLM A Factor X X HLM LLM A Factor HLM LLM A Factor X X HLM LLM Batch X
16 UAS_Masterpräsentation_REV15, Folie 16 Furnace Control
17 UAS_Masterpräsentation_REV15, Folie 17 Furnace Control
18 UAS_Masterpräsentation_REV15, Folie 18 OPTIMIZED COMBUSTION DCS-SYSTEM ENOx-System GAS-ANALYZER WOBBE-INDEX O2- ANALYZER ANALYZER SPS PLC-SAFETY-CONCEPT MAIN SKID OXYGEN / GAS SAMPLE CONDITIONING SYSTEM TOUCH PANEL BURNER SKID OXYGEN / GAS FURNACE Utilization of Oxyfuel Furnaces FLUE GAS OXYGEN NATURAL GAS DATA LINK MEASURING SIGNAL
19 UAS_Masterpräsentation_REV15, Folie 19 PREHEATING Actual Situation Air-fuel End-Port fired furnace Natural Gas (NG) + Air Air inlet Furnace: ~1000 C > 1200 C re-used energy For combustion-air preheating < 400 C Air inlet Regenerator: 25 C NG inlet: 25 C
20 UAS_Masterpräsentation_REV15, Folie 20 PREHEATING Actual Situation Oxyfuel < 400 C Oxyfuel Furnace Natural Gas (NG) + Oxygen (O2) un-used energy Mainly cooled by air/water quench > 1200 C NG inlet: 25 C O2 inlet: 25 C
21 UAS_Masterpräsentation_REV15, Folie 21 PREHEATING Oxyfuel 2.0 Oxyfuel Furnace Natural Gas (NG) + Oxygen (O2) < 400 C ~ 900 C > 1200 C un-used energy Mainly cooled by air/water quench re-used energy For preheating NG+O2 500 C 400 C 400 C NG inlet: 25 C O2 inlet: 25 C
22 UAS_Masterpräsentation_REV15, Folie 22 PREHEATING General» Preheating of gas and/or oxygen up to max. 400C» using the heat of the flue gas (directly or indirectly)» applicable for single burner / zone controlled furnaces» installation during rebuilds or running operation» independent of existing control systems (installation between flow control and burner)
23 UAS_Masterpräsentation_REV15, Folie 23 OPTIMIZED COMBUSTION DCS-SYSTEM > 3 % WOBBE-INDEX GAS-ANALYZER O2- ANALYZER 3 10 % ANALYZER ENOx-System -> 5 % SPS PLC-SAFETY-CONCEPT MAIN SKID OXYGEN / GAS > 2 % SAMPLE CONDITIONING SYSTEM TOUCH PANEL BURNER SKID OXYGEN / GAS FURNACE -> 8 10 % FLUE GAS OXYGEN NATURAL GAS DATA LINK MEASURING SIGNAL
24 UAS_Masterpräsentation_REV15, Folie 24 REFERENCES
25 UAS_Masterpräsentation_REV15, Folie 25 Thank you for your attention Visit booth E07
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