Chevron Phillips
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In May 2001,
Jerry Lang was contacted by key ChevronPhillips
(CPC) personnel in the Following an initial assessment of NOx reduction potential in CPC’s Cedar Bayou, Sweeny, Technical Center, and Alamo facilities, JLCC recommended a burner-solution path forward that could meet emission regulation demands and potentially save the company several million dollars by eliminating and/or significantly reducing the need for expensive stack gas cleaning technology. JLCC contracted with Kellogg Brown & Root, CPC’s primary engineering firm, to provide combustion and emission consulting services for the CPC/KBR NOx Reduction Project. For the past three years, JLCC has been an integral part of the overall team, and has provided several unit-specific recommendations. For example,
at the In anticipation of startup of the 1st 450,000#/hour boiler with new Todd/Zink LCF burners, JLCC provided operating & maintenance procedures and conducted on-site training for ChevronPhillips operating personnel. Additionally, throughout the installation and construction process, JLCC was on-site for periodic inspection and quality control checks. Items addressed included FIR/FGR inlet issues, burner openings and refractory issues, air register alignment issues, oil gun fit & air curtain issues, FGR fan inlet baffle issues, and final walk through prior to startup. JLCC was on-site for the initial start-up and tuning. The Todd/Zink LCF burners create a diluted low-btu fuel by inducing flue gas directly into the fuel stream at the burner tips, a process commonly referred to as FIR (Fuel-Induced Recirculation). Steam injection into the FIR ducting was also included to provide additional motive force for inducing flue gas. FGR (with steam injection capability) into FD fan provides further NOx reduction potential. Start-up commenced in mid-April 2002, and within a week’s time the unit was performing satisfactorily – unit operators were pleased with flame stability and pattern. NOx levels immediately dropped 60-70% from a base level of 200-220ppm, and following various tuning efforts, NOx levels as low as 12ppm were demonstrated. However, pending further study of a more efficient steam sparger in the FIR line, the boiler was set to run in the mid-30ppm range. During 2003, the remaining two 450,000 #/hour boilers were converted. Have questions, or would like references? Please email jerry@knocksout.com |