Fuels and Combustion

Presented By D.Mishra Sr.A.Chemist NTPC-Vindhyacghal

Training Agenda: Fuels & Combustion

Introduction Type of fuels Performance evaluation Energy efficiency opportunities

Fuel

A substance which produce heat either by combustion or by nuclear fission / fusion

Introduction The Formation of Fuels

Solar energy is converted to chemical energy through photosynthesis in plants Energy produced by burning wood or fossil fuels
Fossil fuels: coal, oil and natural gas

Combustion
Combustion is the conversion of a substance called a fuel into chemical compounds known as products of combustion by combination with an oxidizer. The combustion process is an exothermic chemical reaction, i.e., a reaction that releases energy .

Combustion

Combustion or burning is a complex sequence of exothermic chemical reactions

between a fuel (usually a hydrocarbon) and

an oxidant accompanied by the production

of heat or both heat and light.

Fuel + Oxidizer => Products of combustion + Energy

Fundamental Definitions

Basic Flame types

Premixed: Fuel and oxidizer are mixed first and burned later Non-premixed: Combustion and mixing occur simultaneously
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Combustion
Air-Fuel

Ratio; A/F Oxygen-Fuel Ratio; O/F

Stoichiometric or Theoretical A/F Excess Air

% excess air = 100[(A/F)actual - (A/F)theo ]/(A/F)theo

120% of theoretical air ?

Fuel- Rich flame: If there is an excess of fuel Fuel - lean flame : if there is an excess of oxygen
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Combustion

1 kg of C needs ? kg of O2 1 kg of H2 needs ? Kg of O2 1 kg of Sulphur needs ? kg of O2

Fundamental Definitions

Calorific value Amount of heat librated by the combustion of unit quantity of fuel. kcal/ kg , kcal / m3 Gross Calorific Value (G.C.V) or HCV heating value measurement in which the product water vapour is allowed to condense Net Calorific Value (N.C.V) or LCV heating value in which the water remains a vapor and does not yield its heat of vaporization
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Fundamental Definitions
Flash Point The lowest temperature at which a liquid fuel gives enough vapours in air which produce a momentary flash when exposed to a flame Fire point The lowest temperature at which a liquid fuel vapours in air produces a continuous flame when exposed to a flame

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Fundamental Definitions
Density Specific gravity Viscosity Pour Point Carbon Residue

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Fundamental Definitions
Theoretical Flame Temperature:

It is the temperature attained by the products of combustion of fuel when there is no loss of heat to the surroundings Flue Gas: It is the gaseous product of combustion of fuel
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Training Agenda: Fuels & Combustion

Introduction Type of fuels Performance evaluation Energy efficiency opportunities

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Type of Fuels Liquid Fuels

Usage
Used extensively in industrial applications

Examples
Furnace oil Light diesel oil Petrol Kerosine Ethanol

LSHS (low sulphur heavy stock)

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Type of Fuels Liquid Fuels

Density
Ratio of the fuels mass to its volume at 15 oC,

kg/m3
Useful for determining fuel quantity and quality

UNEP 2006

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Type of Fuels
Liquid Fuels
Specific gravity
Ratio of weight of oil volume to weight of same water volume at a given temperature Specific gravity of water is 1 Hydrometer used to measure
Table 1. Specific gravity of various fuel oils Fuel oil type Specific Gravity LDO (Light Diesel Oil) 0.85-0.87 Furnace oil 0.89-0.95 LSHS (Low Sulphur Heavy Stock) 0.88-0.98

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Type of Fuels
Liquid Fuels
Viscosity
Measure of fuels internal resistance to flow Most important characteristic for storage and use

Decreases as temperature increases

Flash point
Lowest temperature at which a fuel can be heated so that the vapour gives off flashes when an open flame is passes over it Flash point of furnace oil: 66oC
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Type of Fuels
Liquid Fuels
Pour point
Lowest temperature at which fuel will flow Indication of pumped temperature at which fuel can be

Specific heat
kCal needed to raise temperature of 1 kg oil by 1oC (kcal/kgoC) Indicates how much steam/electricity it takes to heat oil to a desired temperature
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Type of Fuels
Liquid Fuels
Calorific value
Heat or energy produced Gross calorific value (GCV): vapour is fully condensed Net calorific value (NCV): water is not fully condensed
Fuel Oil Kerosene Diesel Oil L.D.O Furnace Oil LSHS Gross Calorific Value (kCal/kg) 11,100 10,800 10,700 10,500 10,600

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Type of Fuels
Liquid Fuels
Sulphur content
Depends on source of crude oil and less on the refining process Furnace oil: 2-4 % sulphur Sulphuric acid causes corrosion

Ash content
Inorganic material in fuel Typically 0.03 - 0.07% Corrosion of burner tips and damage to materials /equipments at high temperatures
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Type of Fuels Liquid Fuels

Carbon residue
Tendency of oil to deposit a carbonaceous solid residue on a hot surface Residual oil: >1% carbon residue

Water content
Normally low in furnace oil supplied (<1% at refinery)
Free or emulsified form Can damage furnace surface and impact flame
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Type of Fuels Liquid Fuels

Storage of fuels
Store in cylindrical tanks above or below the ground Recommended storage: >10 days of normal consumption

Cleaning at regular intervals

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Type of Fuels
Liquid Fuels
Typical specifications of fuel oils
Properties Furnace Oil
Density (Approx. g/cc at 150C)
Flash Point (0C) Pour Point (0C) G.C.V. (Kcal/kg)

Fuel Oils L.S.H.S

0.88-0.98
93 72 10600

L.D.O
0.85-0.87
66 18 10700

0.89-0.95
66 20 10500

Sediment, % Wt. Max.

Sulphur Total, % Wt. Max. Water Content, % Vol. Max. Ash % Wt. Max.

0.25
< 4.0 1.0 0.1

0.25
< 0.5 1.0 0.1

0.1
< 1.8 0.25 0.02
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Type of Fuels Solid Fuels

Coal classification
Anthracite: hard and geologically the oldest Bituminous Lignite: soft coal and the youngest Further classification: semi- anthracite, semi-bituminous, and sub-bituminous
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Type of Fuels Solid Fuels

Physical properties
Heating or calorific value (GCV) Moisture content Volatile matter Ash

Chemical properties
Chemical constituents: carbon, hydrogen, oxygen, sulphur
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Type of Fuels
Solid Fuels (Physical properties)
Heating or calorific value
The typical GVCs for various coals are: Parameter Lignite (Dry Basis) 4,500 Indian Coal 4,000 Indonesian Coal 5,500 South African Coal 6,000

GCV (kCal/kg)

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Type of Fuels Solid Fuels (Physical properties)

Moisture content
% of moisture in fuel (0.5 10%) Reduces heating value of fuel Weight loss from heated and then cooled powdered raw coal

Volatile matter
Methane, hydrocarbons, hydrogen, CO, other Typically 25-35% Easy ignition with high volatile matter Weight loss from heated then cooled crushed coal
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Type of Fuels
Solid Fuels (Physical properties)
Ash
Impurity that will not burn (5-40%) Important for design of furnace Ash = residue after combustion

Fixed carbon
Fixed carbon = 100 (moisture + volatile matter + ash) Carbon + hydrogen, oxygen, sulphur, nitrogen residues Heat generator during combustion
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Type of Fuels
Solid Fuels (Physical properties)
Proximate analysis of coal
Determines only fixed carbon, volatile matter, moisture and ash Useful to find out heating value (GCV) Simple analysis equipment

Ultimate analysis of coal

Determines all coal component elements: carbon, hydrogen, oxygen, sulphur, other Useful for furnace design (e.g flame temperature, flue duct design) Laboratory analysis
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Type of Fuels Solid Fuels (Physical properties)

Proximate analysis
Typical proximate analysis of various coals (%)
Indian Coal
Moisture
Ash Volatile matter Fixed Carbon

Indonesian Coal
9.43
13.99 29.79 46.79

South African Coal

8.5
17 23.28 51.22
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5.98
38.63 20.70 34.69

Type of Fuels Solid Fuels (Chemical Properties)

Ultimate analysis
Typical ultimate analysis of coal (%)
Parameter Moisture Mineral Matter (1.1 x Ash) Carbon Hydrogen Nitrogen Sulphur Oxygen Indian Coal, % 5.98 38.63 41.11 2.76 1.22 0.41 9.89 Indonesian Coal, % 9.43 13.99 58.96 4.16 1.02 0.56 11.88

GCV (kCal/kg)

4000

5500
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Type of Fuels Solid Fuels (Chemical Properties)

Storage, Handling & Preparation
Storage to minimize carpet loss and loss due to spontaneous combustion Reduce carpet loss: a) a hard surface b) standard concrete/brick storage bays Coal preparation before use is important for good combustion

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Type of Fuels Gaseous Fuels

Advantages of gaseous fuels
Least amount of handling Simplest burners systems Burner systems require least maintenance Environmental benefits: lowest GHG and other emissions
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Type of Fuels Gaseous Fuels

Classification of gaseous fuels
(A) Fuels naturally found in nature -Natural gas -Methane from coal mines (B) Fuel gases made from solid fuel -Gases derived from coal -Gases derived from waste and biomass -From other industrial processes (C) Gases made from petroleum -Liquefied Petroleum gas (LPG) -Refinery gases -Gases from oil gasification (D) Gases from some fermentation
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Type of Fuels
Gaseous Fuels
Calorific value
Fuel should be compared based on the net calorific value (NCV), especially natural gas
Typical physical and chemical properties of various gaseous fuels
Fuel Gas
Natural Gas Propan e Butane

Relative Density
0.6 1.52 1.96

Higher Heating Value kCal/Nm3

9350 22200 28500

Air/Fuel ratio m3/m3

10 25 32

Flame Temp oC
1954 1967 1973

Flame speed m/s

0.290 0.460 0.870

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Type of Fuels
Gaseous Fuels
Liquefied Petroleum Gas (LPG)
Propane, butane and unsaturates, lighter C2

and heavier C5 fractions

Hydrocarbons are gaseous at atmospheric pressure but can be condensed to liquid state
LPG vapour is denser than air: leaking gases can flow long distances from the source

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Type of Fuels
Gaseous Fuels
Natural gas
Methane: 95% Remaing 5%: ethane, propane, butane, pentane, nitrogen, carbon dioxide, other gases High calorific value fuel Does not require storage facilities

No sulphur
Mixes readily with air without producing smoke or soot
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Type of Fuels Comparing Fuels

Fuel Oil
Carbon Hydrogen Sulphur 84 12 3

Coal
41.11 2.76 0.41

Natural Gas
74 25 -

Oxygen
Nitrogen Ash Water

1
Trace Trace Trace

9.89
1.22 38.63 5.98

Trace
0.75 39

Training Agenda: Fuels & Combustion

Introduction Type of fuels Performance evaluation Energy efficiency opportunities

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Performance Evaluation
Principles of Combustion
Combustion: rapid oxidation of a fuel
Complete combustion: total oxidation of fuel (adequate supply of oxygen needed)

Air: 20.9% oxygen, 79% nitrogen and other

Nitrogen: (a) reduces the combustion efficiency (b) forms NOx at high temperatures Carbon forms (a) CO2 (b) CO resulting in less heat production
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Performance Evaluation
Principles of Combustion
Control the 3 Ts to optimize combustion: 1T) Temperature 2T) Turbulence 3T) Time Water vapor is a by-product of burning fuel that contains hydrogen and this robs heat from the flue gases
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Performance Evaluation Principle of Combustion

Oxygen is the key to combustion

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Performance Evaluation
Stochiometric calculation of air required
Stochiometric air needed for combustion of furnace oil Theoretical CO2 content in the flue gases

Actual CO2 content and % excess air

Constituents of flue gas with excess air Theoretical CO2 and O2 in dry flue gas by volume
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Performance Evaluation Concept of Excess Air

Measure CO2 in flue gases to estimate excess air level and stack losses

Excess air (%)

Carbon dioxide (%)

UEP 2006
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Performance Evaluation
Concept of Excess Air
Measure O2 in flue gases to estimate excess air level and stack losses

Excess air (%)

Residual oxygen (%)

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Performance Evaluation
Draft System
To exhaust combustion products to atmosphere

Natural draft:
Caused by weight difference between the hot gases inside the chimney and outside air No fans or blowers are used

Mechanical draft:
Artificially produced by fans Three types a) balanced draft, b) induced draft and c) forced draft
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Training Agenda: Fuels & Combustion

Introduction Type of fuels Performance evaluation Energy efficiency opportunities

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Energy Efficiency Opportunities

Four main areas
Preheating of combustion oil Temperature control of combustion oil Preparation of solid fuels Combustion controls

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Energy Efficiency Opportunities Preheating of Combustion Oil

Purpose: to make furnace oil easier to pump
Two methods:
Preheating the entire tank
Preheating through an outflow heater as the oil flows out

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Energy Efficiency Opportunities

Temperature Control of Combustion Oil
To prevent overheating
With reduced or stopped oil flow

Especially electric heaters

Using thermostats

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Energy Efficiency Opportunities Preparation of Solid Fuels

Sizing and screening of coal
Important for efficient combustion Size reduction through crushing and pulverizing (< 4 - 6 mm) Screen to separate fines and small particles Magnetic separator for iron pieces in coal

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Energy Efficiency Opportunities Preparation of Solid Fuels

Conditioning of coal:
Coal fines cause combustion problems Segregation can be reduced by conditioning coal with water Decrease % unburnt carbon
Decrease excess air level required

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Energy Efficiency Opportunities Preparation of Solid Fuels

Blending of coal
Used with excessive coal fines
Blending of lumped coal with coal containing fines

Limits fines in coal being fired to <25%

Ensures more uniform coal supply

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Energy Efficiency Opportunities

Combustion Controls
Assist burner to achieve optimum boiler efficiency through the regulation of fuel supply, air supply, and removal of combustion gases Three controls:
On/Off control: burner is firing at full rate or it is turned off High/Low/Off control: burners with two firing rates Modulating control: matches steam pressure demand by altering the firing rate
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Training Session on Energy Equipment

Fuels & Combustion

THANK YOU FOR YOUR ATTENTION

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