This BAT reference document for the Iron and Steel Production forms part of a series presenting the results of an exchange of information between EU Member States, the industries concerned, non-governmental organisations promoting environmental protection and the Commission, to draw up, review, and where necessary, update BAT reference documents as required by Article 13(1) of the Directive on industrial emissions (2010/75/EU). This document is published by the European Commission pursuant to Article 13(6) of the Directive.

Best Available Techniques (BAT) Reference Document:for:Manufacture of Glass:Industrial Emissions Directive 2010/75/EU:(Integrated Pollution Prevention and Control)

An air separation unit separates air into an oxygen-rich and oxygen-deficient gas. Fuel gas and the oxygen-rich gas are preheated at heat exchangers through which hot flue gas flows. Combustion of the preheated fuel and oxygen-rich gases result in the hot flue gas. The hot flue gas is cooled at the heat exchangers and flows through a waste heat boiler. Water and/or steam flowing through the waste heat boiler absorbs energy from the cooled flue gas thereby producing heated steam. The heated steam flows through a turbine to produce power. The power is transferred to the air separation unit, thus reducing a power requirement of the air separation unit needed to separate the air.

Integrated heat recovery systems and methods for increasing the efficiency of an oxygen-fired furnace

High-temperature, natural gas-fired furnaces, especially those fired with preheated air, produce large quantities of NO{sub x} per ton of material processed. Regulations on emissions from industrial furnaces are becoming increasingly more stringent. In addition, competition is forcing operators to make their furnaces more productive and/or efficient. Switching from preheated air to industrial oxygen can increase efficiency and reduce NO{sub x}, but oxygen is significantly more costly than air and may not be compatible with the material being heated. What was needed, and what was developed during this project, is a technology that reduces NO{sub x} emissions while increasing furnace efficiency for both air- and oxy-fired furnaces. Oscillating combustion is a retrofit technology that involves the forced oscillation of the fuel flow rate to a furnace. These oscillations create successive, fuel-rich and fuel-lean zones within the furnace. Heat transfer from the flame to the load increases due to the more luminous fuel-rich zones, a longer overall flame length, and the breakup of the thermal boundary layer. The increased heat transfer shortens heat up times, thereby increasing furnace productivity, and reduces the heat going up the stack, thereby increasing efficiency. The fuel-rich and fuel-lean zones also produce substantially less NO{sub x} thanmore » firing at a constant excess air level. The longer flames and higher heat transfer rate reduces overall peak flame temperature and thus reduces additional NO{sub x} formation from the eventual mixing of the zones and burnout of combustibles from the rich zones. This project involved the development of hardware to implement oscillating combustion on an industrial scale, the laboratory testing of oscillating combustion on various types of industrial burners, and the field testing of oscillating combustion on several types of industrial furnace. Before laboratory testing began, a market study was conducted, based on the attributes of oscillating combustion and on the results of an earlier project at GTI and Air Liquide, to determine which applications for oscillating combustion would show the greatest probability for technical success and greatest probability for market acceptability. The market study indicated that furnaces in the steel, glass, and metal melting industries would perform well in both categories. These findings guided the selection of burners for laboratory testing and, with the results of the laboratory testing, guided the selection of field test sites.« less

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NOx Emission Reduction by Oscillating Combustion

A plurality of independently flow rate-controlled flows of fuel may be preheated at a heat exchanger (or both oxidant and fuel at separate heat exchangers) by heat exchange with a hot shell-side (heat transfer) fluid. The separate flows of hot fuel are directed to associated separate burners where they combust with flows of fuel to produce hot combustion gases. The hot combustion gases are used to preheat the hot shell-side fluid at a recuperator or regenerator.

Method and system for heat recovery from products of combustion and charge heating installation including the same

Glass in an energy intensive industry, and while fuel savings are found with oxy-fuel melting compared to preheated air combustion, an energy audit of an oxy-fuel melter indicates that approximately only 60% of the energy is directly used for melting glass. The remaining 40% of the energy is lost through the furnace superstructure and mostly by the flue gases, which contain up to 30% of the total energy input into the furnace. The purpose of this paper is to evaluate the feasibility and potential energy savings available with various heat recovery processes on oxy-fuel melters. The possible uses of the flue gas have been classified in three distinct areas: combustion modifications, co-production and input preheating. Estimations show that oxygen and fuel savings of 5-15% are possible.

Processes for heat recovery and energy savings in oxy-fired glass furnaces : A technology survey

Johns Manville gained invaluable experience with oxy-fuel combustion when they converted two fiberglass furnaces in Cleburne, Texas. In order to improve the performance beyond oxy-fuel firing, Johns Manville implemented Oscillating Combustion (OC) on one of their borosilicate wool fiberglass furnace in April 1999. The OC technology was tested continuously for ten months and it provided a 55% NOx reduction; a 10 to 12% reduction in specific oxygen consumption; a 4% fuel savings; and a 30 to 50°F reduction in hot-spot crown temperature without reduction in glass temperatures. The Oscillating Combustion has been transparent to the furnace operation and high quality glass is produced at maximum production capacity of the downstream machines.

Optimum oxy-fuel melter performance : Oscillating combustion

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Processes for heat recovery and energy savings in oxy-fired glass furnaces : A technology survey

Optimum oxy-fuel melter performance : Oscillating combustion