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Title: High-Efficiency, High-Capacity, Low-NOx Aluminum Melting Using Oxygen-Enhanced Combustion

Abstract

This report describes the development and application of a novel oxygen enhanced combustion system with an integrated vacuum swing adsorption (VSA) oxygen supply providing efficient, low NOx melting in secondary aluminum furnaces. The mainstay of the combustion system is a novel air-oxy-natural gas burner that achieves high productivity and energy efficiency with low NOx emissions through advanced mixing concepts and the use of separate high- and low-purity oxidizer streams. The technology was installed on a reverberatory, secondary aluminum melting plant at the Wabash Aluminum Alloy's Syracuse, N.Y. plant, where it is currently in operation. Field testing gave evidence that the new burner technology meets the stringent NOx emissions target of 0.323 lb NO2/ton aluminum, thus complying with regulations promulgated by Southern California's South Coast Air Quality Management District (SCAQMD). Test results also indicated that the burner technology exceeded fuel efficiency and melting capacity goals. Economic modeling showed that the novel air-oxy-fuel (ADF) combustion technology provides a substantial increase in furnace profitability relative to air-fuel operation. Model results also suggest favorable economics for the air-oxy-fuel technology relative to a full oxy-fuel conversion of the furnace.

Authors:
Publication Date:
Research Org.:
USDOE Idaho Operations Office, Idaho Falls, ID; Air Products and Chemicals, Inc., Allentown, PA (US)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EE) (US)
OSTI Identifier:
765375
Report Number(s):
DOE/ID/13514
TRN: AH200102%%460
DOE Contract Number:  
FC07-97ID13514
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 2 Jun 2000
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; AIR QUALITY; CAPACITY; COMBUSTION; EFFICIENCY; ENERGY EFFICIENCY; GAS BURNERS; MELTING; OXYGEN; VACUUM SWING ADSORPTION (VSA); NOX; FURNACES; MIXING; OXIDIZER; ALUMINUM; BURNER TECHNOLOGY; EMISSIONS; ECONOMICS

Citation Formats

D'Agostini, M.D. High-Efficiency, High-Capacity, Low-NOx Aluminum Melting Using Oxygen-Enhanced Combustion. United States: N. p., 2000. Web. doi:10.2172/765375.
D'Agostini, M.D. High-Efficiency, High-Capacity, Low-NOx Aluminum Melting Using Oxygen-Enhanced Combustion. United States. doi:10.2172/765375.
D'Agostini, M.D. Fri . "High-Efficiency, High-Capacity, Low-NOx Aluminum Melting Using Oxygen-Enhanced Combustion". United States. doi:10.2172/765375. https://www.osti.gov/servlets/purl/765375.
@article{osti_765375,
title = {High-Efficiency, High-Capacity, Low-NOx Aluminum Melting Using Oxygen-Enhanced Combustion},
author = {D'Agostini, M.D.},
abstractNote = {This report describes the development and application of a novel oxygen enhanced combustion system with an integrated vacuum swing adsorption (VSA) oxygen supply providing efficient, low NOx melting in secondary aluminum furnaces. The mainstay of the combustion system is a novel air-oxy-natural gas burner that achieves high productivity and energy efficiency with low NOx emissions through advanced mixing concepts and the use of separate high- and low-purity oxidizer streams. The technology was installed on a reverberatory, secondary aluminum melting plant at the Wabash Aluminum Alloy's Syracuse, N.Y. plant, where it is currently in operation. Field testing gave evidence that the new burner technology meets the stringent NOx emissions target of 0.323 lb NO2/ton aluminum, thus complying with regulations promulgated by Southern California's South Coast Air Quality Management District (SCAQMD). Test results also indicated that the burner technology exceeded fuel efficiency and melting capacity goals. Economic modeling showed that the novel air-oxy-fuel (ADF) combustion technology provides a substantial increase in furnace profitability relative to air-fuel operation. Model results also suggest favorable economics for the air-oxy-fuel technology relative to a full oxy-fuel conversion of the furnace.},
doi = {10.2172/765375},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2000},
month = {6}
}