One (1) Reducing Heater

System for Jindal DR

Plant at Angul, Orissa,
India
Project No:

7618 3258 / 7610A04J

Code:

Angul-Jindal / Angul 1

Doc No:

Client
Project No:

H3003HEA01

Client Code:

&AD B-DE 4100

Client Doc. No.:

Page 1 of 7

Burner Datasheet
for
Reducing Gas Heater

Status

06

06/08/2015

MJ

VL

VL

Revised as per JSPL comments

05
04

16/07/2015
22/07/2011

MJ
RA

KG
VL

KG
VL

Supplier`s Information added

03

18/11/2010

MJ

FMS

FMS

Revised as marked

Revised for new syngas tips

02

27/08/2010

MJ

FMS

FMS

Revised as marked

01
Issue

23/07/2010
Date

MJ
Prepared by

FMS
Checked by

FMS
Approved by

For inquiry
Remark

Refer to protection notice ISO 16016

Komm.- Nr. / Job-No.

Burner - Datasheet

SELAS-LINDE
GMBH

7618 3258
Iss-Nr./No.

6
1
2

Client:
SL - Inquiry N.:

vom/of

&AD B-DE 4100

Seite/Page

06.08.15
Jindal

Seiten/Pages
von/of

Client Reference N.:

Project:

Angul

GENERAL SITE DETAILS

Site Location

Equipment Location

Outside, steel mill

Altitude

170 m

Barometric Pressure

995.5 mbar

Ambient Temperature

Min: 5 C

10

Relative Humidity

Max: 100 %

11

Rainfall

Annual average: 1542 mm

12

Maximum Wind Velocity

180 km/h

13

Seismic Condition

UBC zone 2A, India seismic zone III

14

Area Classification

HOLD

15

Weather Protection

16

Electrical Supplies

HOLD

17

Allowable Noise Level

85 dB(A) in 1 m distance for complete heater, fans and burners included

18

General site details are given for information only and pertain to the site as a whole. This information is superseded if stated elsewhere in

Angul, India

19

this or other associated documents specific to the equipment / instrument.

20

STANDARDS

21

Acceptable Standards

22

Applicable Standards

23

Flanges

ANSI B31.3

24

Piping

ANSI B31.3

25

Noise

OSHA, AMCA

26

Inspection

27

Manufacturer Certificates

28

Electrical Equipment

29

Electrical Certificates

30

REFERENCE DOCUMENTS

31

&AD B-SP 4100 Technical Specification

32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
50
51
52

NOTES
(*)

to be filled by vendor

API 560

NEMA, NEC, ISA, IEC

Average: 27.3 C

Max: 48 C

Heaviest (24h): 257 mm

Komm.- Nr. / Job-No.

Burner - Datasheet

SELAS-LINDE
GMBH

7618 3258
Iss-Nr./No.

vom/of

6
1

&AD B-DE 4100

Seite/Page

06.08.15

Seiten/Pages
von/of

GENERAL DATA

7
Rev.

Manufacturer

Zeeco, Inc., Tulsa, OK, USA

Burner designation

Q10HEA01BRN A01-A10, B01-B10, C01-C10, D01-D10, E01-E10

Number of burners

30 x 100 % burners, 20 x 60 % burners

Scope of delivery

50 replacement tips for increased syngas capacity and new COG fuel + spares 5)

Type of burner

Low NOx

Standard

Location

Floor

Arch

Flame direction

horizontal

parallel to wall

Sidewall

vertical upwards

vertical downwards

Fuel

Gas

Oil

11

Air feed

Forced draft

Natural draft

12

Type of furnace

Cracking furnace

Refinery furnace

Incinerator

Reduction gas heater

Main flame

Pilot flame

10

13
14

Flame safeguard

15
16

Gas/Oil Combination
Reformer
5

GUARANTEE DATA

17

Type of burner

18

Fuel Oil / Gas

19

Heat duty (LHV-Basis)

20
21

Pressure at burner inlet

100 %
MW

60 %

F1/F2

F1/F2

F3

F4

F5

F6

5 (7)

3 (7)

F1/F4

F2

22

Fuel gas

bar,g

1.9

0.1

23

Fuel oil

bar,g

Atomising medium

24

bar,g

25

Combustion air pressure drop

mbar

26

Turndown

20

8:1 (6)

5:1

27

Excess air

10

28

Combustion Air Temperature

225

29

Emission (guaranteed) (1)

30

NOx

mg/Nm

320 (8)

31

CO (2)

mg/Nm

50

Dust

mg/Nm

32
33

Noise data (3)

34

Sound Pressure Level (4)

dB(A)

35

Sound Power Level

dB(A)

36

Flame dimensions

75
(9)

37

Max. flame diameter

<1

38

Max. flame length

< 7.9

39
40

NOTES

41

(*)

to be filled by vendor

42

(1)

Based on dry fluegas at 0C and 1013,25 mbar (abs), corrected to 3 Vol% O2, 1090 C bridgewall temperature,

43

225 C combustion air temp. and 10 % excess air. Emission guarantee for Fuel F1 / F2 from min. to 110 %

44

burner load.

45

(2)

46

(3)

47
48

CO levels at the tube walls must be below 250 mg/Nm (dry, no O2 correction) at all points.
No measuring tolerances are accepted.
The sound pressure level measurements are performed in accordance with DIN 45 635 (Part 1 and 8).

(4)

at 1 m distance from the outer contours of the equipment.

49

(5)

Spares: 3 tips for 100 % burner, 2 tips for 60 % burner

50

(6)

Maximum turndown for F1 is occurs when available amount of F2 is not sufficient for heat input and hence

51

a small amount of F1 is needed. Vendor to advise the maximum turndown for this operation. Given value is for

52

F1/F4-only operation with 2 vol-% oxygen in the flue gas.

53

(7)

Pilot burner heat release not included

54

(8)

Re-design of the F1/F4 tip shall consider that no staged air slots are available.

55

(9)

The burner shall have a straight upwards flame for all fuels and full range of operations

Komm.- Nr. / Job-No.

Process - Datasheet
Fuel data

SELAS-LINDE
GMBH

7618 3258
Iss-Nr./No.

vom/of

6
1

&AD B-DE 4100

Seite/Page

06.08.15

Seiten/Pages
von/of

FUEL OIL

Oil Number

Low Heating Value (LHV)

kJ/kg

Wobbe number (LHV-Basis)

kJ/kg

Stoechiometric air demand

kg/kg

Density

kg/m

Viscosity by

Pas

Viscosity by

Pas

10

Pressure at burner

bar,g

11

Temperature at burner

12

H/C ratio

13

Vanadium content

ppm

14

Bounded nitrogen

Wt %

15

Sulphur

Wt-%

16

Soot

Wt%

17

Water

Wt%

18

Asphaltene / Conradson

Wt %

19

FUEL GAS

20

Fuel gas number

21

Low Heating Value (LHV)

22

High Heating Value (HHV)

23

Stoechiometric air demand

kg/kg

(*)

(*)

24

kg/kmol

13.5

16.3

bar,g

3.5

0.2

26

Molecular weight
Pressure in network
(norm/max)
Max pressure at burner

bar,g

1.9 3)

27

Temp. at burner (norm/max)

50

28

Analysis

29

H2

52.01

30

N2 + Ar

Mol-%

0.45

2.64

2.76

31

CO

Mol-%

32.21

20.13

19.81

32

CO2

Mol-%

3.04

16.03

15.96

33

H2O

Mol-%

5.69

34

CH4

Mol-%

12.01

35

O2

Mol-%

36

C2H4

37

DELETED

COG

F1

F2 Max 1)

F2 Norm 1)

F2 Min 1)

DELETED

F4 3)

kJ/kg

23413

13454

13333

12051

37500 (5)

kJ/kg

(*)

(*)

(*)

16.3

16.3

10.5 (5)

0.2

0.1

2.5

0.1

0.1

0.05

*) 3)

42

42

42

30 - 45

50.57

50.28

47.84

56 - 60

3.28

4-6

18.45

5-8

15.67

1.5 - 3

6.28

10.68

1.0 2.5

4.94

4.91

3.90

23 - 27

0.3 0.8

Mol-%

1.0

C2H6

Mol-%

0.25

1.0

38

NH3

Mol-%

0.01

39

HCN

Mol-%

0.04

40

CH3OH

Mol-%

0.03

2)

41

C3H8

ppm(vol)

30

2)

42

H2S

ppm(vol)

100

10

10

10

0.04 4)

43
44

TOTAL

100

100

100

100

45

NOTES

25

Syngas fuel

7
Rev.

FUEL DATA

Mol-%

Top gas fuel

100

46

(*)

to be filled by vendor

47

1)

Composition and heating value change with operating cases as follows: Fuel "F2 Max" shows the composition of

Case I (p.5), "F2 Norm" shows composition of Case II and "F2 Min" shows composition for case VI.

48
49

2)

Benzene: < 0.85 Mol-%, Toluene: < 0.75 Mol-%

50

3)

The new syngas tips must be suitable for syngas F1 and coke oven gas F4, all given heat releases for F1 shall be

possible with F4 as well. Tips to be designed for the available maximum pressure with F1, pressures for F4 to be

51
52

provided by Zeeco with heat release curves

53

4)

Mol-%

54

5)

Depending on composition range as given below

Komm.- Nr. / Job-No.

Process - Datasheet
Burner

SELAS-LINDE
GMBH

7618 3258 &AD B-DE 4100

Iss-Nr./No.

vom/of

6
1

Seite/Page

06.08.15

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POWER DATA AND CONSUMPTION

HEATER OPERATING CASES

Operating case

Denomination

Fired duty

Fuel

Gas

Case I

Case II

Case III

Case IV

7
Rev.

Case VI

Max. operation

Norm. operation

Min. operation

Start-up

F2 only

194

171

54.5

94

91.6

MW
F1/F4 1)

wt%

- / 11.4

- / 9.4

- / 100

- / 100

-/-

F2

wt%

- / 88.6

- / 90.6

-/-

-/-

- / 100

F3

wt%

-/-

-/-

-/-

-/-

-/-

1090

1069

928

941

980

10
11
12
13

Bridgewall temperature

14
15

BURNER OPERATING CONDITIONS

16

Load case

17

Denomination

18

Fuel (Oil / Gas)

19

Heat duty (LHV basis) 3)

MW

20

Fuel gas pressure at burner

bar,g

21

Fuel gas temperature at burner

22

Fuel oil pressure at burner

23

Fuel oil temperature at burner

24

25

Comb. Air temperature at

burner
Excess air (Max/Norm/Min)

26

Pressure drop, Air side

27

Draft at burner

28

norm

29

max

MAX (110%)

NORM (87%)

MIN (27%)

MAX F1/F4

60 % / 100 % burn.

60 % / 100 % burn.

60 % / 100 % burn.

60 % / 100 % burn.

F2
2.27 /
3.78
0.1

F1/F4
0.35 /
0.59
(*)

F2
2.06 /
3.44
0.1

F1/F4
0.75 /
1.25
(*)

F2

F1/F4

0/0

1.34 / 2.24

1.9

42

50

42

50

42

42

bar,g

225

228

111

Amb. - 225

10

10

10

10

mbar

15

(*)

(*)

(*)

mbar,g

-2.3

-2.3

-2.3

-2

mbar,g

-2.8

-2.8

-2.8

-2.8

30

Atomising medium pressure

bar,g

31

Atomising medium temperature

32

Atomising medium
consumption
Flame dimensions (expected)

kg/kg

33

F1/F4
0.76 /
1.26
(*)

Flame diameter

(*)

(*)

35

Flame length

(*)

(*)

36

Emissions (expected)

34

37

NOx (Oil / Gas)

mg/Nm

(*)

(*)

(*)

38

CO (Oil / Gas)

mg/Nm

(*)

(*)

(*)

39

Dust (Oil / Gas)

mg/Nm

40

Noise data (expected)

41

Sound Pressure Level

dB(A)

42

Sound Power Level

dB(A)

43

< 75

(at 1 m distance from the outer contours of the equipment)

Octave band

44

Frequency

Hz

63

125

250

500

1k

2k

4k

8k

45

Sound

dB

75

79

72

76

66

62

64

62

46
47

NOTES

48

(*)

to be filled by vendor.

49

1)

Fraction of F1 can drop to 1.3 wt-% in split operation with F2. Vendor to advise maximum turndown for F1

50

during F2 in operation and vice versa. Pilot fraction of F1 only considered in Case V.

51
52
53

3)

Without pilot burner

Komm.- Nr. / Job-No.

Mechanical Datasheet
Burner

SELAS-LINDE
GMBH

7618 3258
Iss-Nr./No.

vom/of

6
1
2

&AD B-DE 4100

Seite/Page

06.08.15

Seiten/Pages
von/of

MECHANICAL REQUIREMENTS

7
Rev.

FURNACE CONSTRUCTION DATA

3
4

Burner Position (2)

mm

Burner CL to tubes CL
Burner CL to unshielded
refractory side wall // end wall
Clearance between burners
CL- CL
Burner Circle Diameter

mm

Burner CL to arch / roof tube CL

mm

13600 / 13200

6
7

60 % burner / 100 % burner

1380 / 1750

mm

1130 / - // 1650 / 1650

mm

1580 / 1580

10
11

Insulation thickness / Type

12

Floor

mm

406 + 15 mm projecting length

13

Sidewall

mm

X + 15 mm projecting length

14

Arch

mm

X + 15 mm projecting length

mm

15

Furnace casing thickness

16
17

BURNER REFRACTORY BLOCK / FASTENINGS

18

Material

19

Min. allowable temperature (3)

20

Bulk density

kg/m

21

Seger cone

S-K

22

Cold crushing strength

N/mm

23

State of supply

(4)

24

Number of segment(s) (1)

25

Mortar

26

Burner tile fastening

27
28

MATERIAL

29

Medium

30

Burner tip

31

Burner gun

32

Burner casing

33

Mounting bolts

Burner tile

> 60% Al2O3

Burner tile

1650C

Fastening

(*)

Fastening

(*)

2600

burnt

(min. 350 C)

unburnt
1

lower part welded / upper part screwed

Fuel Gas F1/F4

Fuel Gas F2

Comb. Air

UV Scanner

Pilot

1.4841

1.4841

A297-HK

SS

SS

A312 TP304

CS

Casing thickness

mm

26 Cr Mo 4

34

Silencer casing

35

Perforated plate in silencer

36

Air tube

37

Gas Flange

38

CONNECTIONS / NOZZLES

39

Medium

40

Type

41

Size

42

Rating

43

Gasket form

Spiral wound

44

Norm / Standard

ASME B16.20

45

Hose connection

46
47
48

NOTES

60 % / 100 %

Fuel Gas F1/F4

Fuel Gas F2

Comb. Air

UV Scanner

Pilot

flanged

flanged

flanged

flanged

(*)/(*)

DN 100 / DN 150

DN 300 / DN 400

DN 15 / DN 15

300

150

150

300

Spiral wound

Spiral wound

Spiral wound

ASME B16.20

ASME B16.20

ASME B16.20

49

(*)

to be filled by vendor.

50

(1)

If the burner blocks are to be delivered in segments, the mortar is to be supplied by the vendor

51

(2)

supplier to adjust flame dimensions so that below mentioned installation conditions do not influence burner

53

(3)

Max. service temp. of fastenings shall be designed with at least 120C safety margin.

54

(4)

Blocks pre-fired according requirements in &AD B-SP 4100. Chemically bonded tiles may be supplied without pre-firing.

52

performance, emissions etc.

Komm.- Nr. / Job-No.

Mechanical Datasheet
Burner / Pilot Burner

SELAS-LINDE
GMBH

7618 3258 &AD B-DE 4100

Iss-Nr./No.

vom/of

6
1
2

Seite/Page

06.08.15

Seiten/Pages
von/of

MECHANICAL REQUIREMENTS

7
Rev.

COATING / PAINTING

Coating system

Treatment of surface

See attached client specification &AD A-PE 3843 GN-12S

4

5
6

Colour

Coat thickness, dry

Prime coat

Intermediate coat

Top coat

Dimetcote 9,
Inorganic Zink Primer
55-75

Amercoat 385,
Epoxy
100-150

Amercoat 450HS,
Alipahtic Polyurethane
40-60

4
4

8
9

WEIGHT

10

Burner tile

kg

11

Burner with/without packaging

kg

210

12
13

OTHERS

14

Burner outside wall temperature C

(1)

15
16

PILOT BURNER

17

GENERAL

18

Manufacturer

19

Denomination

20

Number per burner/total

21

Type (2)

Forced draft

Natural draft

22

Type of ignition

Manual

Electrical

23

Operation

Intermittent

24

Flame safeguard

Zeeco
1 / 50

Continuous
Ionisation rod deactivated

Design : 60, Normal operation: 40

25
26

PROCESS DATA

27

Heat duty

kW

28

Pilot gas type

F1 / F3
1.5 / 0.8

29

Pilot gas pressure

bar,g

30

Pilot air pressure

mbar,g

n.a.

31

Draft at pilot burner

mbar,g

norm: -2.36

32
33

MATERIAL

34

Ignition tube

35

Venturi

IN 800 H for Firebox Temperature > 1000C

SS 310 (1.4841) for Firebox Temperature < 1000C
A732GR1A-1020

36

Pilot gas tip

37

Silencer

A297HK

38

Ignition electrode

Kanthal

39

Ionisation electrode

Kanthal

40

Insulation of electrode

41

NOTES

Dense Ceramics e.g Alsint 99

42

(1)

Based on XXC ambient air temperature and X m/s wind velocity.

43

(2)

Vendor to advise

44
45
46
47
48
49
50
51
52
53