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SP 0191

01

1/11

ENGINEERING

EQUIPMENT/BULK MATERIAL:

GAS BURNERS for PRIMARY REFORMER

PRIMARY REFORMER
H-2001
RADIANT SECTION

SPECIFICATION FOR GAS BURNERS

W - Mod. SE/E Sh. 1 - Rev. A

(*) AS APPROVED WITH MOM-PR-TR/0027

23/05/2002

ISSUED FOR PURCHASE TO JOHN ZINK

01/03/2002

REISSUED FOR INQUIRY (*)

PB

A
PA
REV.

19/02/2002
19/11/2001
13/11/2001
DATE

C. DI SANTO

L. FLAMMINI

L. FLAMMINI

C. DI SANTO

L. FLAMMINI

PROCESS ISSUE (*)

A. DI MICHELE

S. PAPA

S. PAPA

ISSUED FOR INQUIRY

C. DI SANTO

L. FLAMMINI

L. FLAMMINI

S. PAPA

D. CIMARELLI

WRITTEN BY

CHECKED BY

PROCESS ISSUE
STATUS

DOCUMENT REVISIONS

L. FLAMMINI

D. CIMARELLI
APPROV.

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SP 0191

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ENGINEERING

1. General Information
The present specification covers the conditions for design of gas burners for the radiant
section of a Topse tubular reformer furnace.
2. General Description
The burners have to be of the self-aspirating radiant wall type equipped with a dual nozzle
system.
The burners are to operate on three types of fuel:
A.

Natural gas having the composition given under point 3.1

B.

Untreated off-gas having the composition given under 3.2.1

C.

Treated off-gas having the composition given under 3.2.2

Natural gas shall be routed to one fuel nozzle and off-gas to the other nozzle.
The burners will be mounted in the wall of a brick-lined firebox (radiant section). It is essential
that no forward flame propagation should occur.
The radiant section is composed of two chambers, length = 25.84 m, height = 12 m.

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ENGINEERING

3. Fuel Gas Analysis

3.1.

Natural Gas
Composition, mole%

Design Case

Alternative Case

N2

0,26

0,30

CO2

0,01

0,01

CH4

83,31

78,98

C2H6

14,57

12,20

C3H8

1,60

5,76

C4H10

0,22

2,30

C5+

0,03

0,45

Total sulphur, vol ppm

max. 23

max. 23

40858

44680

LHV, kJ/Nm3
MW, kg/kmol

18,68

Temperature, C

30

Untreated Off-gas

65,12

30,54

N2

21,54

42,75

Ar

2,21

4,76

CH4

7,33

14,50

CO

0,01

0,01

CO2

3,28

6,44

H2O

0,51

1,00

NH3, vol ppm

10

10

MW, kg/kmol
Temperature, C
Pressure, bar(g)

1
1

To be verified by vendor

Treated Off-gas

H2

LHV, kJ/Nm3

5 1)

Off-gases
Composition, mole%

1)

30

5 1)

Pressure, bar(g)
3.2.

20,65

9649

8485

10,95

19,04

47

41

4,0

1)

4,0

1)

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ENGINEERING

4. Ambient Air Conditions

Temperature, C
Average
Maximum
Minimum

27
36
18

Relative humidity at 35C, %

Design

99

PB

5. General Specification
5.1.

Burner Type
The burners have to be self-aspirating radiant wall burners with a dual nozzle system, one
nozzle operating only on natural gas and the other on off-gases.
The fuel pressures must be determined so that they will allow the natural gas fuel to
overaspirate combustion air thus making the burner less sensitive to an interruption in the offgas fuel.

5.2.

Burner Arrangement
The burners are arranged in 6 horizontal rows on each side of the radiant chamber.
Number of burners

480

The burner row elevation, from bottom (m) is as follows:

Row 1
Row 2
Row 3
Row 4
Row 5
Row 6
5.3.

1.00
2.45
3.90
5.35
6.80
8.25

Burner Operation
The burners are to operate in three different firing scenarios:
A.

Natural gas alone having the composition given under point 3.1

B.

Combination of Natural Gas and Untreated off-gas having the composition given
under 3.2.

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SP 0191

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ENGINEERING

C.

Combination of Natural Gas and Treated Off-Gas having the composition given
under 3.2.

The burners must be able to provide the heat releases stipulated under point 5.4 when
burning off-gases (ref. point 3.2), the balance being natural gas (ref. point 3.1) in the range
specified in point 5.5.
Design excess air, %

10 1)

Maximum draught inside firebox, mm WG

Normal draught inside firebox, mm WG
Minimum draught inside firebox, mm WG

15
5
0

The average temperature of the combustion gases (from other burners installed) passing the
burner tip will be 1200C.
Long term stand-by of burners at a furnace temperature of 1200C must be possible.
The burners may, for a short duration after furnace trip, be exposed to minor backflow of hot
flue gas caused by a slight overpressure in the furnace box.
5.4.

Burner Heat Release

Large Burners

5.5.

(400 pieces)

Small Burners
(Row 1)
(80 pieces)

Normal heat release per burner, LHV, GJ/h

(The top row will be fired at only 75% of normal)

1,581

0,790

Max. heat release per burner, LHV, GJ/h

1,976

0,988

Rangeability
When operating on natural gas only, the heat release from each burner should be
adjustable between 25% and 125% of the normal heat release.
When operating on natural gas and one of the off-gases, the heat release from each burner
should be adjustable between 50% and 125% of the normal heat release.
The required fuel gas pressures are to be given by the burner manufacturer. The flame
pattern must be stable within the above ranges without adjustment of primary air throttling
device.
The burners must be able to operate in the above-mentioned turndown range on:

Combinations of Untreated Off-Gas and Natural Gas, with off-gas heat release in
the range of 0- 37% of total heat release, balance fuel being Natural Gas.

Stable performance of the burner must be ensured at 5% excess air. The 5% excess air should be obtained by
adjustment of the combustion air damper.

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SP 0191

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ENGINEERING

Combinations of Treated Off-Gas and Natural Gas, with off-gas heat release in the
range of 0- 18% of total heat release, balance fuel being Natural Gas.

Plant upset situations may cause loss of off-gas fuel to the burners. When the off-gas is lost
during combined fuel firing, the heat release should be maintained as high as possible and
preferably unchanged by natural gas substitution. Alternatively, in case treated off-gas is
lost, the heat release should be maintained by substitution of untreated purge gas. The
flame pattern must remain stable and min. 5% excess air must be achieved during and after
upset in the off-gas supply without adjustment of the burner and in particular the
combustion air damper.
6. Environmental Limitations
6.1.

Flue Gas
When the burners are operated on fuel combinations comprising natural gas and off-gas
with maximum and normal heat release at a furnace temperature around 1200 oC, the
emission from the reformer stack must not exceed the following limits:
NOx, vol ppm
CO, vol ppm

PB

6.2.

100 (on dry basis with 3% O2)

200 (on dry basis with 3% O2)

Permissible Noise Level

The level of total emitted noise from the burners (injection and combustion), when
measured in still air at a distance of 1 metre from any opening in the casing during normal
and maximum operation, must not exceed 84 dB(A).
When operating the reformer with all burners in operation there must be no acoustic
resonance from the furnace originating from the burners. In order to prevent this, the sound
pressure level must not exceed 75 dB in the frequency range 63-250 Hz.

7. Scope of Supply
The supply comprises complete burners with associated regulating devices for combustion
air. The inlet connections for fuels must be threaded with tapered pipe threads.

The fuel gas connections to the burners must be designed in such a way that it is possible
to remove the burner assembly for inspection and/or maintenance without removing any
piece of piping outside the scope of burners.
The burner block shall be made of Thermbond Formula Six (minimum 60% Al 2O3) and
shall be realized in one single piece.
The hot face of the block must project minimum 10 mm. The block may on no account be
recessed in relation to the lining.

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SP 0191

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ENGINEERING

The insulating material (multi-layer pack) between the burner block and the mounting plate
is to be of suitable thickness and quality to ensure that the temperature of the mounting
plate measured in still air during furnace operation does not exceed 70C above ambient.
The layer adjacent to the burner block should be of high temperature vacuum-formed
ceramic fibre block (or equivalent material) at least 50 mm thick.
Any packing material, which may be required between the barrel of the burner and the
block, must be included in the supply.
The burner block should be provided with anchors in high alloy steel to press the burner
block against the insulation and the casing plate.
The burner block must be provided with a hole suitably located to ensure that the burner
can be ignited by means of an electric igniter or a gas torch. An additional hole will be
provided as an observation port. It is important that the location of the holes at the hot face
of the block does not adversely affect the flame pattern of the burner at any operating level.
The supply must include nuts and bolts needed for the assembly of the above components.

8. Documentation
Documents to be submitted by the Vendor are listed in the Doc. no. VR.0191.01; in
particular at least the following documents will be supplied :
- Detailed arrangement drawing showing principal dimensions and materials of all parts of
the burner. The drawing must indicate which items are not included in vendors supply.
- Complete instructions for the installation, operation, and maintenance of the burner.
- List of recommended spare parts for two years of operation.
- Details of a recommended device for burner ignition.
- Proposed time schedule for the manufacture and testing of the burners.
- Material test and inspection certificates for burner components, including refractories and
burner performance test report.
- Heat release curves at expected site conditions
All documents must be in English.

9. Inspection

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ENGINEERING

See Document no.2098.00.SP.0191.01

10. Performance Test

10.1.

Performance Test Procedure

10.1.1

One large and one small burner are to be submitted to a performance test at conditions as
nearly identical to design conditions as possible, to the complete range of fuel analyses,
and to the entire range of heat release. Furthermore, the following off-gas trip tests must
be carried out when the burner operates at maximum and normal heat release on both
treated and untreated purge gas:
a) Off-gas interruption with sustained firing at the lower total heat release on natural gas
without adjustment of combustion air damper
b) Increased firing on natural gas by substitution, on heat release basis, of as much
natural gas as possible for the off-gas without adjustment of combustion air damper
c) Alternatively, in case treated off-gas is lost, the heat release should be maintained by
substitution of untreated purge gas without adjustment of combustion air damper.
The detailed programme for the performance test must as a minimum include the tests
found in section 10.2.

10.1.2

The test burners should also be subjected to air flow tests of the gas side as per point
10.1.8. The results of the air flow tests of the test burners should be used as acceptance
criterion for evaluation of the results of the air flow tests of the production burners as per
point 10.1.8. The amount of air entrained by the venturi must be verified.

10.1.3

In cases where design conditions cannot be simulated, vendor should propose methods
by means of which design data can be extrapolated from test results.
During testing, accurate records must be made of the following variables for each
operating level:

10.1.4

PB

Ambient temperature
Ambient pressure
Analyses of fuel gases, including lower heating value and specific gravity
Gas temperature at burner inlet, downstream regulating valve
Gas pressure at burner inlet, downstream regulating valve
Gas pressure upstream flow meter
Gas flow
Content of O2, combustibles, NOx and CO in flue gas
Flame pattern
Noise level
Temperature of gases in furnace
Sound pressure level in dB at Hz: 63/125/250/500/1K/2K/4K/8K
Combustion air damper opening

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ENGINEERING

10.1.5

On completion of the testing, a formal test protocol should be drawn up. The protocol
should include the above data plus any other information which may be relevant for
interpretation of the test results.

10.1.6

Any extrapolations or conversions, which may be necessary for deducing burner

performance at site conditions, should be included in the protocol. A figure for maximum
feasible turndown ratio without adjusting the air dampers must be arrived at.

10.1.7

Vendor should guarantee that the fuel and entrained air flows at normal heat release and
design fuel pressures for all burners in the consignment will be within 2.5% of the
consumption figures for the tested burner.

10.1.8

5% of production burners shall be subjected to an air flow test of the gas side of burners
to demonstrate a variation in air flow of less than 2.5%. Please also refer to point 10.2.
The amount of entrained air by the venturi must be verified.

10.1.9

Customers as well as vendors representatives must sign the performance test protocol.

10.2. Performance Test Programme

The following test programme shall be carried out as a minimum to demonstrate that
satisfactory combustion performance in the primary reformer furnace will be ensured. The
actual test sequence may be changed to facilitate testing. However, all tests must be
performed.
Fluctuation in furnace pressure shall be measured, if possible, to determine flame
instability/flashback.

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SP 0191

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10/11

ENGINEERING

Heat Liberation, % of total load

Test No.

*
*
*

*
*
*
*

1
2
3
4
5
6
7
8
9-1
9-2
9-3
10-1
10-2
10-3
11-1
11-2
11-3
12
13
14-1
14-2
14-3
14-4
15-1
15-2
15-3
15-4
16-1
16-2
16-3
16-4
17
18

Total Load,
% of normal
heat release
Ignition
125
100
75
50
25
Min. possible
Out of ratio
125
79 (OFG trip)
Max. possible
100
63 (OFG trip)
Max. possible
75
47 (OFG trip)
Max. possible
50
Min. possible
125
103 (OFG trip)
Max. possible
125
100
82 (OFG trip)
Max. possible
100
75
62 (OFG trip)
Max. possible
75
50
Min. possible

* Only test for large burner

Natural Gas

Untreated Off-gas

Treated Off-gas

100
100
100
100
100
100
100
100
63
100
100
63
100
100
63
100
100
63
63
82
100
100
82
82
100
100
82
82
100
100
82
82
82

0
0
0
0
0
0
0
0
37
0
0
37
0
0
37
0
0
37
37
0
0
0
18
0
0
0
18
0
0
0
18
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
18
0
0
0
18
0
0
0
18
0
0
0
18
18

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ENGINEERING

Notes
1)

Ignition shall be carried out in cold furnace at 15 mm WC furnace draught.

2)

The maximum load tests no. 2, 9-1 and 14-1 shall be demonstrated using both the
normal 10% excess air and maximum possible air entrainment.

3)

The normal load tests no. 3/4, 10-1/11-1 and 15-1/16-1 shall be carried out using
both 5% and 10% excess air. Tests no 3, 10-1 and 15-1 shall include demonstrations
with 10% excess air at both 5 and 15 mm WC furnace draught.

4)

Tests below 100% load shall be carried out with air door settings according to 10%
excess air at normal load.

5)

Minimum load tests 6, 12 and 17 shall also be demonstrated using 10% excess air.

6)

The duration of tests no. 12 and 13 must be minimum 15 minutes at highest possible
furnace temperature.

7)

The out of ratio test shall determine the minimum load where the flame becomes
unstable using air door setting according to 10% excess air at maximum load.

8)

The off-gas trip comprising tests no. 9-1/2/3 & 10-1/2/3 & 11-1/2/3 and 14-1/2/3/4 &
15-1/2/3/4 & 16-1/2/3/4 shall demonstrate the stability of the burner if the off-gas is
lost and determine the extent of natural gas or off-gas substitution aiming at excess
air around min. 5%. Adjustments of the burner and in particular the combustion air
damper must not take place during the trip test.