Dilute Oxygen Combustion Phase IV Final Report

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Novel furnace designs based on Dilute Oxygen Combustion (DOC) technology were developed under subcontract by Techint Technologies, Coraopolis, PA, to fully exploit the energy and environmental capabilities of DOC technology and to provide a competitive offering for new furnace construction opportunities. Capital cost, fuel, oxygen and utility costs, NOx emissions, oxide scaling performance, and maintenance requirements were compared for five DOC-based designs and three conventional air5-fired designs using a 10-year net present value calculation. A furnace direct completely with DOC burners offers low capital cost, low fuel rate, and minimal NOx emissions. However, these benefits do not offset the cost ... continued below

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Riley, M.F. April 30, 2003.

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Novel furnace designs based on Dilute Oxygen Combustion (DOC) technology were developed under subcontract by Techint Technologies, Coraopolis, PA, to fully exploit the energy and environmental capabilities of DOC technology and to provide a competitive offering for new furnace construction opportunities. Capital cost, fuel, oxygen and utility costs, NOx emissions, oxide scaling performance, and maintenance requirements were compared for five DOC-based designs and three conventional air5-fired designs using a 10-year net present value calculation. A furnace direct completely with DOC burners offers low capital cost, low fuel rate, and minimal NOx emissions. However, these benefits do not offset the cost of oxygen and a full DOC-fired furnace is projected to cost $1.30 per ton more to operate than a conventional air-fired furnace. The incremental cost of the improved NOx performance is roughly $6/lb NOx, compared with an estimated $3/lb. NOx for equ8pping a conventional furnace with selective catalytic reduction (SCCR) technology. A furnace fired with DOC burners in the heating zone and ambient temperature (cold) air-fired burners in the soak zone offers low capital cost with less oxygen consumption. However, the improvement in fuel rate is not as great as the full DOC-fired design, and the DOC-cold soak design is also projected to cost $1.30 per ton more to operate than a conventional air-fired furnace. The NOx improvement with the DOC-cold soak design is also not as great as the full DOC fired design, and the incremental cost of the improved NOx performance is nearly $9/lb NOx. These results indicate that a DOC-based furnace design will not be generally competitive with conventional technology for new furnace construction under current market conditions. Fuel prices of $7/MMBtu or oxygen prices of $23/ton are needed to make the DOC furnace economics favorable. Niche applications may exist, particularly where access to capital is limited or floor space limitations are critical. DOC technology will continue to have a highly competitive role in retrofit applications requiring increases in furnace productivity.

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  • Report No.: DOE/ID/13331-4
  • Grant Number: FC36-95ID13331
  • DOI: 10.2172/877124 | External Link
  • Office of Scientific & Technical Information Report Number: 877124
  • Archival Resource Key: ark:/67531/metadc879938

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  • April 30, 2003

Added to The UNT Digital Library

  • Sept. 21, 2016, 2:29 a.m.

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  • Oct. 31, 2016, 6:19 p.m.

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Riley, M.F. Dilute Oxygen Combustion Phase IV Final Report, report, April 30, 2003; United States. (digital.library.unt.edu/ark:/67531/metadc879938/: accessed December 16, 2017), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.