Training Services

Burners

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-1

Section Outline

Pilot
Gas
Combination
Low NOx
Emissions

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-2

Pilot ST-1S Assembly

301

302
306

307

303
305

301
302
303
304
305
306
307

Pilot Tip
Pilot Nipple
Pilot Mixer
Orifice Spud
Air Door
Pilot Hub
Port Cover

304
HTR-R00-58

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-3

Pilot

UOP specifies continuous pilots for safety concerns

Natural gas is recommended fuel
John Zink ST-1S or equal
Pilot is a small inspirated gas burner with glow plug
head
Works at lower fuel pressure than standard gas
burners
Air adjusted at inspirator to maintain good air
mixing

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-4

Pilot Burner Problems

Long Yellow Flames

Prone to Blowout

Insufficient Primary Air

Open Air Register

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-5

Pilot Burners

Zink ST-1S

Ignition Source

Safety Device

90% Premix Burner

Short Blue Flame

Orange Color Tip

Blue Flame Spikes

on Side

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-6

Pilot Burners
Glowing Tip

Callidus Pilot

Similar to ST-1S

Flame Spikes
Saudi Aramco EDP 2004/2005
Fired Heaters 7a-7

Premix Gas

Inspirated Air Burners (Premix)

Advantages

Little fouling/plugging in tips

High efficiency air-fuel mixing

Disadvantages

Flashback (flame speed exceeds mixing speed)

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-8

Premix Gas Burner

Secondary Air

Air
2
3

Primary Air
Gas
HTR-R00-59

Air
Pilot Gas
Saudi Aramco EDP 2004/2005
Fired Heaters 7a-9

Premix Gas Burner

Oldest Burner Design

Inspirates 30-50% of
Combustion Air

Self Correcting on Excess Air

with Gas Pressure

Large Gas Orifice - No Fouling

High Noise

Potential Flashback (Flame

Speed Exceeds Mixing Speed)

Secondary
Air

Air

Primary
Air

Air
Gas

Pilot Gas

High NOX
Saudi Aramco EDP 2004/2005
Fired Heaters 7a-10

Premix Gas Burner

John Zink HEDV Burner

Round Flame Premix

Glowing Tile Indicates Improper

Tip Position

Gas Tips Should be 25/20 Cr/Ni

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-11

Premix Gas Burner

John Zink PFH

Flat Flame Premix

Improper Round Tile

Early 1970s Design

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-12

Premix Gas Burner

John Zink PFH

Flat Flame Premix

Proper Rectangular Tile

1990s Revamp

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-13

Raw Gas

Raw Gas or Nozzle Mix Burners

Advantages

High turndown ratio

No possibility of flashback
Can burn wide variety of fuels
Disadvantages
Fouling/plugging in tips
Lower efficiency air-fuel mixing

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-14

Raw Gas Burner

1
2

3
4

Air

Air

Gas
HTR-R00-60

Pilot Gas

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-15

Raw Gas Burner

Simple Construction

Can Burn Wide Range of Fuels

Short Flames

High Turndown Ratio

No Possibility of Flashback

Potential Fouling of Tips

Air

Air

Gas
Pilot Gas

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-16

Raw Gas Burner

110 ppm NOX

Slight Haze on End of Flame

Low Excess Air (2%)

Hot Flame Temperature

Bright Refractory Color

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-17

Raw Gas Burner

Improper Tile
Installation

High Air Close to Pilot

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-18

Raw Gas Burner

Flame Cone Located

too Low

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-19

Combination Burner

Air

Damper
Gas Control
Steam

Pilot Gas
Oil
HTR-R00-62

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-20

Oil Burners

Oil gun atomizes oil to fine spray of oil

droplets that approximate gas firing

Atomization done with steam, air, or

mechanically (high pressure)

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-21

Oil Burner

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-22

Dual Tube Oil Gun

Used for light oils

Prevents flashing and

pressure fluctuation with
light oils and naphtha

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-23

Combination Burner

Combines Raw Gas and

Oil Burner

Use Either Fuel When in

Service

Not Recommended to
Run Both Fuels at Same
Time

Light Oil Gun Off Main

Gas Not Pilot
Startup on Gas Until
Firebox is Hot

Air

Gas

Damper Control

Steam

Pilot Gas
Oil

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-24

Combination Burner

Oil Gun in Center of

Primary Tile, 1 (25 mm)
Below Tile Ledge

Gas Tips Located Between

Primary and Secondary
Tiles

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-25

Combination Burner

Oil Firing on Right Burner

High Emissivity Oil Flame

Gas Firing on Left Burner

Low Emissivity Gas Flame

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-26

Oil Gun Location

Proper position is critical to proper spray

pattern and air mixing

Proper location

HTR-R00-97

Too far in

Too far back

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-27

Combination Burner

Looking at Oil Flame

Through Primary Tile

Flame Recirculation

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-28

Combination Burner

Looking at Oil Flame

Through Primary Tile

Flame Recirculation with

No.2 Oil with Staged Air
Burner

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-29

Combination Burner

Oil Ash (Sodium

Vanadates) Attack
Refractory

Use 94% Alumina on

Primary Tile

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-30

Combination Burner

94% Alumina on Primary

Tile

60% Alumina on Secondary

Tile

Use Plywood Template to

Align Secondary Tile Pieces

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-31

Burner Excess Air Adjustment

Opening/closing air register or damper

Registers large clearances will pass 50% of
design air when fully closed
Dampers - tighter clearances will pass 12-25%
of design air when fully closed
Keep all burners lit if possible
Minimum pressure drop 0.10-0.15 in H2O
80% of burner pressure drop in throat 20% in
damper/register

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-32

Burner Air Controls

Concentric Register

Prone to Sticking

Difficult to Adjust

Leaks 50% Air when

Closed

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-33

Burner Air Controls

Damper Control

Tight Shutoff

Positive Position

Good Excess Air

Control

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-34

Burner Excess Air Adjustment

% Excess Air in Flue Gas

100

75
Register Type Burner

50
Burner w/ Inlet Damper

25

HTR-R00-65

Burner Air Register

Completely Closed
at this Point

Burner Air
Register Completely
Closed at this Point

25

75
50
% of Burner Design Firing Rate

100
Saudi Aramco EDP 2004/2005
Fired Heaters 7a-35

Emissions

National/local governments restrict emissions of:

NOx
SOx
CO
Particulate
Unburned hydrocarbons
Heavy metals
Others

Saudi Aramco EDP 2004/2005

Fired Heaters 7a-36