Urea-based mixing process for increasing combustion efficiency and reduction of nitrogen oxides (NOx)

1. A method for reducing NOx formation, comprising the steps of:

providing a staged combustion system including a furnace with a plurality of asymmetrical injection devices for introducing at least one reagent to the reactor by asymmetrical injection at predetermined, spaced apart locations;

injecting fuel with primary air through a first stage prior to injection of a second air;

injecting secondary air and aqueous urea solution within the reactor at temperatures above about 2000° F. through the plurality of injection devices; wherein the aqueous urea solution has a urea concentration greater than about 20% w/w and is injected at furnace locations with temperatures above about 2000° F., and wherein injection at the temperature range may be achieved without special chemicals; and

creating turbulence within the reactor by controlling the asymmetrical injection of secondary air to produce the turbulence resulting in dispersion of the urea solution into the reaction system at temperatures above about 2000° F., thereby increasing the residence time of the combustion gases in the furnace and providing reduced NOx formation in the reaction process during a staged combustion system,

wherein the velocity of the secondary air is such that the ratio of the velocity to the reactor width is between about 2 sec −1 to about 150 sec −1 ; thereby increasing reagent dispersion via swirl, peripheral turbulence, and rotation-induced turbulence of the reactor.

2. The method according to claim 1 , wherein the urea solution is sprayed as a fine mist.

3. The method according to claim 1 , wherein the urea solution concentration is greater than about 20% w/w.

4. The method according to claim 1 , wherein the temperature is above about 2050° F.

5. The method according to claim 2 , wherein the temperature is above about 2050° F. and the urea solution is greater than about 20% w/w.

6. The method according to claim 1 , wherein the reactor space is humidified.

7. The method of claim 6 , further including the step of increasing the relative humidity in the droplet environment by injecting water into the droplet environment at a predetermined location and at a predetermined rate such that the injected solvent disperses and evaporates in the reactor.

8. The method according to claim 1 , further including the step of adding additional said fluids in stages, spaced apart in location and time.

9. The method according to claim 1 , wherein the secondary air and urea solution are introduced at a plurality of injection devices, asymmetrically positioned in an opposing manner.

10. The method of claim 1 , wherein the injection step includes injecting at least two levels of injection devices.

11. The method of claim 10 , wherein the injection step includes injecting at least three levels of injection devices.

12. A method for reducing NOx formation, comprising the steps of:

providing a staged combustion system including a furnace with a plurality of asymmetrical injection devices for introducing at least one reagent to the reactor by asymmetrical injection at predetermined, spaced apart locations;

injecting fuel with primary air through a first stage prior to injection of a second air;

injecting secondary air and aqueous urea solution within the reactor at temperatures above about 2000° F. through the plurality of injection devices; wherein the aqueous urea solution has a urea concentration greater than about 20% w/w and is injected at furnace locations with temperatures above about 2000° F. and wherein injection at the temperature range may be achieved without special chemicals, and the velocity of the injected secondary air is such that the penetration of the injected fluids is greater than the reactor width by at least about 1.5 widths; and

creating turbulence within the reactor by controlling the asymmetrical injection of secondary air to produce the turbulence resulting in dispersion of the urea solution into the reaction system at temperatures above about 2000° F., thereby increasing the residence time of the combustion gases in the furnace and providing reduced NOx formation in the reaction process during a staged combustion system, and

wherein the velocity of the secondary air is such that the ratio of the velocity to the reactor width is between about 2 sec −1 to about 150 sec −1 ; thereby increasing reagent dispersion via swirl, peripheral turbulence, and rotation-induced turbulence of the reactor.

13. The method according to claim 12 , wherein the urea solution is sprayed as a fine mist.

14. The method according to claim 12 , wherein the urea solution concentration is greater than about 20% w/w.

15. The method according to claim 12 , wherein the temperature is above about 2050° F.

16. The method according to claim 13 , wherein the temperature is above about 2050 ° F. and the urea solution is greater than about 20% w/w.

17. The method according to claim 12 , wherein the reactor space is humidified.

18. The method of claim 17 , further including the step of increasing the relative humidity in the droplet environment by injecting water into the droplet environment at a predetermined location and at a predetermined rate such that the injected solvent disperses and evaporates in the reactor.

19. The method according to claim 12 , further including the step of adding additional said fluids in stages, spaced apart in location and time.

20. The method according to claim 12 , wherein the secondary air and urea solution are introduced at a plurality of injection devices, asymmetrically positioned in an opposing manner.

21. The method of claim 12 , wherein the injection step includes injecting at least two levels of injection devices.

22. The method of claim 21 , wherein the injection step includes injecting at least three levels of injection devices.

23. A method for increasing combustion furnace efficiency and reducing NOx, comprising:

providing a reactor with a plurality of reagent injection devices, asymmetrically positioned in an opposing manner; and

injecting NOx-reducing fluids comprising at least one nitrogenous agent through the devices in the proximity of high-velocity secondary air in stages during a staged combustion system within the reactor at temperatures above about 2000° F., wherein one of the at least one agents is urea at a concentration greater than about 20% w/w and the temperature is above about 2000° F., wherein injection at the temperature range may be achieved without special chemicals, and

wherein the velocity of the secondary air is such that the at least one injected reagent is dispersed and the combustion gas column rotates at least one half revolution prior to exiting the reactor; thereby reducing NOx via mixing and rotation of the reagents and gases in the reactor, and

wherein the velocity of the secondary air is such that the ratio of the velocity to the reactor width is between about 2 sec −1 to about 150 sec −1 ; thereby increasing reagent dispersion via swirl, peripheral turbulence, and rotation-induced turbulence of the reactor.

24. The method according to claim 23 , wherein the urea solution is sprayed as a fine mist.

25. The method according to claim 23 , wherein the temperature is above about 2050° F.

26. The method according to claim 23 , wherein the urea solution is greater than about 20% w/w.

27. The method according to claim 23 , wherein the reactor space is humidified.

28. The method of claim 27 , further including the step of increasing the relative humidity in the droplet environment by injecting water into the droplet environment at a predetermined location and at a predetermined rate such that the injected solvent disperses and evaporates in the reactor.

29. The method according to claim 23 , further including the step of adding additional said NOx-reducing fluids in stages, spaced apart in location and time.

30. The method according to claim 23 , wherein the secondary air and urea solution are introduced at a plurality of injection devices, asymmetrically positioned in an opposing manner.

31. The method according to claim 23 , wherein the injection step includes injecting at least two levels of injection devices.

32. The method according to claim 31 , wherein the injection step includes injecting at least three levels of injection devices.