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Oxygen-Enhanced Combustion

Oxygen-enhanced combustion technologies can help improve furnace performance by displacing combustion air with oxygen. Even a small increase in oxygen concentration can have a dramatic impact on furnace operations, especially when using fuels with low heating values, and/or improving operations or regaining control of furnaces with failing heat recovery devices. By reducing or eliminating the introduction of inert nitrogen into the furnace, oxygen-enhanced combustion technologies have proven to increase production, decrease fuel consumption, and reduce emissions, while maintaining or even increasing product quality. See the attached article on all the oxy-fuel techniques we provide for glass melting. With a range of proprietary Cleanfire® burners, melting technologies, and modeling services, our global team can use their skills and experience to help you with design, start-up, and ongoing operation of the optimal system for your furnace.

Other Applications

Product NameDescription/BenefitsDownloads
Gases

Oxygen

Oxygen is required for any combustion process. By increasing the oxygen concentration of combustion air through the addition of relatively pure oxygen, flame temperature rises, heat transfer rates improve, and overall combustion efficiency increases.

Oxygen is required for any combustion process. By increasing the oxygen concentration of combustion air through the addition of relatively pure oxygen, flame temperature rises, heat transfer rates improve, and overall combustion efficiency increases.

Cleanfire® ThruPorte

This water-cooled, oxygen-staged oxy-fuel burner enables installation of oxy-fuel combustion technology on the fly through existing air-fuel regenerative furnace ports. It is ideal for restoring full production on furnaces crippled by failing regenerators, and is most often used either temporarily during regenerator repairs, or to extend furnace life near the end of a campaign. We offer optional state-of-the-art on-burner diagnostic sensors and wireless communications technology. With this addition, your key operating personnel can have instantaneous access to up-to-date burner operating parameters in your control room or remote computers and smart devices with your discretion. 

This water-cooled, oxygen-staged oxy-fuel burner enables installation of oxy-fuel combustion technology on the fly through existing air-fuel regenerative furnace ports. It is ideal for restoring full production on furnaces crippled by failing regenerators, and is most often used either temporarily during regenerator repairs, or to extend furnace life near the end of a campaign. We offer optional state-of-the-art on-burner diagnostic sensors and wireless communications technology. With this addition, your key operating personnel can have instantaneous access to up-to-date burner operating parameters in your control room or remote computers and smart devices with your discretion. 

Cleanfire® AOFi™ Burners

Similar to the Cleanfire AOF burner, but available in sizes ranging from 1 to 20+ MM Btu/hr.

Similar to the Cleanfire AOF burner, but available in sizes ranging from 1 to 20+ MM Btu/hr.

Cleanfire® AOF™ Burners

This is an air-oxy-fuel burner that serves as a back-up technology to the Cleanfire HR burner and/or as a primary burner to deliver differentiated flame characteristics. A variety of fuels can be fired as well as oxidizer gas with a wide range of oxygen content, from air to pure oxygen. The burner helps enable self-sufficiency in emergency situations, and helps to protect the furnace asset, especially when fused cast refractory superstructure exists. Available in sizes ranging from 2 to 20+ MM Btu/hr.

This is an air-oxy-fuel burner that serves as a back-up technology to the Cleanfire HR burner and/or as a primary burner to deliver differentiated flame characteristics. A variety of fuels can be fired as well as oxidizer gas with a wide range of oxygen content, from air to pure oxygen. The burner helps enable self-sufficiency in emergency situations, and helps to protect the furnace asset, especially when fused cast refractory superstructure exists. Available in sizes ranging from 2 to 20+ MM Btu/hr.

Cleanfire® Gen.1 Burners

This burner is the workhorse of the industry with well over 1,000 installed for full conversions and oxy-fuel boosting applications. Burners range from 1 up to 20+ MM Btu/hr and can be fired with gas, oil, or propane. The non-water-cooled tube in-tube design is very rugged and virtually maintenance free.

This burner is the workhorse of the industry with well over 1,000 installed for full conversions and oxy-fuel boosting applications. Burners range from 1 up to 20+ MM Btu/hr and can be fired with gas, oil, or propane. The non-water-cooled tube in-tube design is very rugged and virtually maintenance free.

Cleanfire® HRi™ Burners

These are the most efficient flat-flame, "high-radiation" oxy-fuel burners. They use a low-momentum, high-aspect-ratio flame design to maximize the radiation delivered to the glass. Proprietary staging technology allows exact flame shaping, minimizes emissions, reduces maintenance, and delivers the lowest cost per ton of glass melted. Additionally, the technology offers higher per burner turn-down capability and lower fluid inlet pressure requirements. The "HRi" technology is available in gas and oil versions. Available in sizes ranging from 0.25 to 20+ MM Btu/hr.

These are the most efficient flat-flame, "high-radiation" oxy-fuel burners. They use a low-momentum, high-aspect-ratio flame design to maximize the radiation delivered to the glass. Proprietary staging technology allows exact flame shaping, minimizes emissions, reduces maintenance, and delivers the lowest cost per ton of glass melted. Additionally, the technology offers higher per burner turn-down capability and lower fluid inlet pressure requirements. The "HRi" technology is available in gas and oil versions. Available in sizes ranging from 0.25 to 20+ MM Btu/hr.

Cleanfire® HR™ Burners

These are very efficient flat-flame, "high-radiation" oxy-fuel burners. They use a low-momentum, high-aspect-ratio flame design to maximize the radiation delivered to the glass. Proprietary staging technology allows exact flame shaping and minimizes emissions. The "HR" technology is available in gas and oil versions. Available in sizes ranging from 1 to 20+ MM Btu/hr.

These are very efficient flat-flame, "high-radiation" oxy-fuel burners. They use a low-momentum, high-aspect-ratio flame design to maximize the radiation delivered to the glass. Proprietary staging technology allows exact flame shaping and minimizes emissions. The "HR" technology is available in gas and oil versions. Available in sizes ranging from 1 to 20+ MM Btu/hr.

Flow Control Equipment

Air Products designs and builds state-of-the-art systems for applications from simple oxygen enrichment and lancing skids to oxy-fuel boost burner systems and full furnace multi-burner controls for the largest oxy-fuel float glass furnaces. We work with your custom control needs to deliver a cost-effective, reliable and safe system. Standard systems are available for oxygen, natural gas, LPG, oil, and other fuels.

Air Products designs and builds state-of-the-art systems for applications from simple oxygen enrichment and lancing skids to oxy-fuel boost burner systems and full furnace multi-burner controls for the largest oxy-fuel float glass furnaces. We work with your custom control needs to deliver a cost-effective, reliable and safe system. Standard systems are available for oxygen, natural gas, LPG, oil, and other fuels.

CFD Modeling

We have extensive in-house computational fluid dynamic (CFD) modeling service capabilities that can help when designing or investigating furnace performance. Our services have helped enable glassmakers to investigate and evaluate ways to increase productivity and cut costs without putting their production process at risk. Modeling studies provide quick, validated results along with recommendations for the type of system.

We have extensive in-house computational fluid dynamic (CFD) modeling service capabilities that can help when designing or investigating furnace performance. Our services have helped enable glassmakers to investigate and evaluate ways to increase productivity and cut costs without putting their production process at risk. Modeling studies provide quick, validated results along with recommendations for the type of system.

Engineering and Equipment Optimization



Installation and Start-up Support

We can help provide multi-disciplinary support - a combination of expertise in applications process knowledge, applications technologies, and equipment and instrumentation; conduct formal ORI - operational readiness inspection for safety and cleanliness prior to start-up; train your employees to operate and maintain new equipment safely and effectively.

We can help provide multi-disciplinary support - a combination of expertise in applications process knowledge, applications technologies, and equipment and instrumentation; conduct formal ORI - operational readiness inspection for safety and cleanliness prior to start-up; train your employees to operate and maintain new equipment safely and effectively.

Ongoing Operations

Services include operations audits and process optimization appraisals to help maximize operating performance and produce cost savings; technical support for equipment calibration, troubleshooting assistance, process analysis and testing; comprehensive gas delivery-system safety inspections and audits.

Services include operations audits and process optimization appraisals to help maximize operating performance and produce cost savings; technical support for equipment calibration, troubleshooting assistance, process analysis and testing; comprehensive gas delivery-system safety inspections and audits.

Preliminary Design/Project Initiation

We can provide site-specific evaluation of operations and guidance through project decision-making; selection of technology solutions, specifications for equipment; assistance with safety compliance, reviews, inspections, training; development of control and interface strategies; and system integration to help create ideal configurations for cost and performance requirements. We have fully automated combustion laboratories to help develop and test new technologies and to provide customer demonstrations.

We can provide site-specific evaluation of operations and guidance through project decision-making; selection of technology solutions, specifications for equipment; assistance with safety compliance, reviews, inspections, training; development of control and interface strategies; and system integration to help create ideal configurations for cost and performance requirements. We have fully automated combustion laboratories to help develop and test new technologies and to provide customer demonstrations.

Cleanfire® HGM™ - Hybrid Glass Melter

This technology is a new proprietary and patented furnace operating philosophy and furnace design that provides extremely flexible glass melting operations. The technology combines the best aspects of air-fuel and oxy-fuel melting. The value of this technology relative to other glass melting technologies is to reduce costs for melting glass to the lowest cost possible per ton of saleable glass under a variety of operating constraints.

This technology is a new proprietary and patented furnace operating philosophy and furnace design that provides extremely flexible glass melting operations. The technology combines the best aspects of air-fuel and oxy-fuel melting. The value of this technology relative to other glass melting technologies is to reduce costs for melting glass to the lowest cost possible per ton of saleable glass under a variety of operating constraints.

Full Conversion to Oxy-Fuel Melting

Oxy-fuel glass melting furnaces provide the most flexible and efficient means for melting glass in large tonnage production operations. The degree of benefits delivered vs. those possible with an oxy-fuel furnace are very dependent upon burner selection. The CLEANFIRE® HRi™ oxygen-staged flat-flame burner is the state-of-the-art, most efficient burner available in the marketplace for this application. Operational benefits provided by oxygen are maximized with full conversion: increase production, decrease fuel consumption, decrease emissions, improve glass quality, reduce maintenance, and extend the campaign life of a furnace.

Oxy-fuel glass melting furnaces provide the most flexible and efficient means for melting glass in large tonnage production operations. The degree of benefits delivered vs. those possible with an oxy-fuel furnace are very dependent upon burner selection. The CLEANFIRE® HRi™ oxygen-staged flat-flame burner is the state-of-the-art, most efficient burner available in the marketplace for this application. Operational benefits provided by oxygen are maximized with full conversion: increase production, decrease fuel consumption, decrease emissions, improve glass quality, reduce maintenance, and extend the campaign life of a furnace.

Oxy-Fuel Boosting

Oxy-fuel boosting is a flexible, efficient, cost-effective technology that can help improve furnace performance via the addition of oxy-fuel burners to complement the operation of an air-fuel furnace. Oxy-fuel boosting can help achieve the following benefits with minimal capital investment: increase production, decrease fuel consumption, decrease emissions, improve glass quality, and extend the campaign life of a furnace.

Oxy-fuel boosting is a flexible, efficient, cost-effective technology that can help improve furnace performance via the addition of oxy-fuel burners to complement the operation of an air-fuel furnace. Oxy-fuel boosting can help achieve the following benefits with minimal capital investment: increase production, decrease fuel consumption, decrease emissions, improve glass quality, and extend the campaign life of a furnace.

Oxy-Fuel Glass Conditioning (Refiners/Forehearths/
Distributors)

The conversion of glass conditioning combustion systems to oxy-fuel for refining, conditioning, and delivery of glass offers significant fuel savings since most traditional systems use air-fuel technology without any preheat of the combustion air.

The conversion of glass conditioning combustion systems to oxy-fuel for refining, conditioning, and delivery of glass offers significant fuel savings since most traditional systems use air-fuel technology without any preheat of the combustion air.

Oxygen Enrichment Systems

Oxygen enrichment is a simple, cost-effective technology that can help improve furnace performance via displacement of combustion air with oxygen. Oxygen is pre-mixed with the general flow of combustion air and uniformly enhances the entire combustion process. Enrichment can help achieve the following benefits with minimal capital investment: increase production, decrease fuel consumption, and extend the campaign life of a furnace.

Oxygen enrichment is a simple, cost-effective technology that can help improve furnace performance via displacement of combustion air with oxygen. Oxygen is pre-mixed with the general flow of combustion air and uniformly enhances the entire combustion process. Enrichment can help achieve the following benefits with minimal capital investment: increase production, decrease fuel consumption, and extend the campaign life of a furnace.

Oxygen Lancing

Oxygen lancing is a flexible, cost-effective system that can help improve furnace performance via placement of oxygen to replace combustion air specifically where it is mostly needed to improve furnace operations. Oxygen lancing can help achieve the following benefits with minimal capital investment: increase production, decrease fuel consumption, decrease emissions, and extend the campaign life of a furnace.

Oxygen lancing is a flexible, cost-effective system that can help improve furnace performance via placement of oxygen to replace combustion air specifically where it is mostly needed to improve furnace operations. Oxygen lancing can help achieve the following benefits with minimal capital investment: increase production, decrease fuel consumption, decrease emissions, and extend the campaign life of a furnace.

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