Low NOx Technology Seminar - Cleancleanboiler.org/files/2016/09/JohnstonFIR_pres.pdf · 2016-09-27 · 0 10 20 30 40 50 60 70 Excess Air (%) Boiler Thermal Efficiency 250 Hp Johnston

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Johnston Burner Company

Low NOx Technology Seminar

Sponsored by

The Gas Company

April 30th, 2003Downey,CA

David Thornock


Presentation Overview• Who is Johnston Burner Company• Overview of the FIR Burner

– Burner design– Demonstrations and Installations

• Summary

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Johnston Burner Products• “AR” Burner

– Low NOx – 30-25 PPMNOx on NG

– Standard – 60-80 PPM NOxon NG

• “A” Burner– Low NOx – 30 PPM NOx

on NG– Standard – 90-110 PPM

NOx on NG

• “S” Burner– Low NOx – 30 PPM NOx

on NG– Standard – 90-110 PPM

NOX on NG

• “J” Burner– Standard – 60-80 PPM NOx

on NG

• “FIR” Burner– Low NOx – Under 9 PPM

NOx on NG (Gas onlyburner)


FIR BURNER• Burner was developed at the

Gas Technology Institute

• Licensed Technology toJohnston Boiler Co. forFiretube Market

• Funded by SMP, GRI,SoCalGas, and DOE

• Retrofit or new

• Premixed staged combustion

• Forced internal recirculation

• No efficiency loss

• Lowest cost premium

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Johnston’s FIR Burner

• The FIR Burner was chosen to address theUnder 20 PPM to Under 9 PPM NOxrequirement

• Gas only applications• Targeted towards the non-attainment areas

like California, Texas, and isolated areas onthe east coast

• We are using the FIR burner for new andretrofit applications


FIR Burner Cross Section

Recirculation Sleeve

High Velocity Premixed Nozzle

Air Inlet

PilotAssembly

Gas Supply

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FIR Burner Mechanics

Recirculation Sleeve

High Velocity Premixed Nozzle

Flue Gas Recirculation


FIR Burner Installations

• The FIR Burner has been installed and tested on 3different Firetube Boilers– Vandenberg AFB 50 hp Kewanee– GTI’s Laboratory 250 hp Johnston 2-pass Ohio Special– Fullerton College (2) 250 hp Johnston 4-pass boilers

• An 800 hp FIR burner has been tested at Johnstonand we are now in the process of building andtesting a 900 hp

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VANDENBERG AFB DEMO

Firetube Boiler20 vppm NOx


FIRETUBE BOILERDEMONSTRATION

• SITE: Vandenberg AFB inSanta Barbara County,California

• Pilot site for ENVVESTprogram (EPA/DoDpartnership to achieveregulatory compliance viapollution prevention)

• 45 firebox and firetubeboilers located at site

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FIR Firetube BoilerDemonstration

• BOILER: 2.5 X 106 Btu/hKewanee firetube

• Burner fabricated byDetroit Stoker Company

• >1800 hours unattended operationfor >2300 cycles

• Meets all emissions targets

• Continue to monitor and addresslong-term reliability


Firetube Boiler:NOx BEFORE AND AFTER

0

20

40

60

80

100

0.0 0.5 1.0 1.5 2.0 2.5

Firing Rate, X 106 Btu/h

NO

x,

vp

pm Uncontrolled

with FIR burner

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FIR BURNER


The FIR Burner onJohnston’s 2-Pass Ohio Special

• Challenging application because of theBoiler design– A 70 hp boiler that is fired at 250 hp– Typically a smaller furnace– Typically a larger pressure drop

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Installed at GTI’s Lab running at 250 hp 4.2% O2 and 11 PPM NOx


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Fullerton College

• (2) 250 hp boilers used for heating• 15# steam design• Gas firing only• Requires under 12 ppm NOx


Fullerton College

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Fullerton College


Fullerton College

• Load Requirements– Seasonal heating load with winter the highest

and summer non-existent– Early morning largest day load– Load tapers off in the afternoon and evening

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Fullerton CollegeOperating Results

NOx Performance Comparison

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

Min 1 2 3 4 5 6 7 8 9 10

Firing Pin Number

NO

x C

orr

ecte

d t

o 3

%O

2 (

PP

M)

Old Kewanee 200hpNew Johnston 250 hp



Oxygen Performance Comparison

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

Min 1 2 3 4 5 6 7 8 9 10

Fi r ing P in Number

Ox

yg

en

(

% b

y v

olu

me

Dry

)..

Old Kewanee 200hp

New Johnston 250 hp

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Stack Temperature Comparison

0.0

50.0

100.0

150.0

200.0

250.0

300.0

350.0

400.0

Min 1 2 3 4 5 6 7 8 9 10

Firing Pin Number

Sta

ck T

em

pera

ture

(F

) ...

Old Kewanee 200hp

New Johnston 250 hp



Efficiency Comparison

80.0

81.0

82.0

83.0

84.0

85.0

86.0

Min 1 2 3 4 5 6 7 8 9 10

Firing Pin Number

Eff

icie

nc

y (

%)

Old Kewanee 200hp

New Johnston 250 hp

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Thermal Efficiency and Excess Air

81.0

81.5

82.0

82.5

83.0

83.5

84.0

84.5

0 10 20 30 40 50 60 70

Excess Air (%)

Bo

ile

r T

he

rma

l E

ffic

ien

cy

250 Hp Johnston BoilerOperating at 10 psig


Dry Gas Loss and Excess Air

0

50,000

100,000

150,000

200,000

250,000

300,000

0 10 20 30 40 50 60 70

Excess Air (%)

Dry

Gas In

cre

men

tal E

nerg

y L

oss

(Btu

/hr)

250 Hp Johnston BoilerOperating at 10 psig

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Summary• The FIR Burner is an Efficient solution for

Firetube Boiler Low NOx applications(under 10 ppm)– Burner operation at 4% O2 through travel– Simple controls– Standard boiler packages

• The FIR burner optimizes energy use:– No external FGR– No need for large hp fans to push extra FGR or

Excess Air


Summary• The FIR burner has now been demonstrated

for small firetube boiler applications50 – 250 hp

• Will be extended to 1000 hp this summerand installed in Houston

• GTI and Johnston Burner company arecommitted to move the FIR Burner and allof its benefits into the firetube market place

Documents

Low NOx Technology Seminar - Cleancleanboiler.org/files/2016/09/JohnstonFIR_pres.pdf · 2016-09-27 · 0 10 20 30 40 50 60 70 Excess Air (%) Boiler Thermal Efficiency 250 Hp Johnston