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

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Research and Development

  • Link:http://www.osti.gov/bridge/advancedsearch.jsp
  • Source:http://www.osti.gov/rdprojects
  • Resource Type:Technical Report
  • OSTI Identifier:765375
  • Published Date:2008-02-04
  • Subject:32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; AIR QUALITY; CAPACITY; COMBUSTION; EFFICIENCY; ENERGY EFFICIENCY; GAS BURNERS; MELTING; OXYGEN
  • Description: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 i ...Show More
  • Description: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. ...Show Less
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