Fuel = Natural Gas

1. The function of RTO is to treat waste gas that flow into it. The method of treatment
is breaking the molecular bond of VOC gas component and react with oxygen to form
new harmless gases.

2. Natural gas is use as sprak for the ignition and after the burning start, VOC will play it
role as fuel for continue the combustion.

3. RTO need to be heated up until 820°C before any waste gas flow into it as heating up of
air will also required energy.

Energy that supply to the RTO = Energy that required to break the molecular bond of
VOC gas component / Enthalpy of formation for reactant

8.3) PENGIRAAN TERPERINCI SYSTEM PEMBAKARAN BAHAN API-RTO

8.3) DETAIL CALCULATION FOR FUEL BURNING SYSTEM -Regenerative Thermal Oxidiser

8.3.1 Heat energy supplied by burner of the RTO

*For calculation purpose, we will use case 6 for reference because among 6 cases,
case 6 have largest air flowrate & highest rate of VOC enter RTO.

Case no. for reference = Case 6

Total Enthalpy of formation for

= 280204 kcal/h (Refer to appendix 8B)
reactant, ∆H°f reactant

* As rateVOC gas enter the RTO may differ from time to time, for conservative estimation,
we need to apply some safety factor. We make assumption of adding extra 30% of energy
for the combustion.

Safety Factor = 1.3

Power required by burner = Total Enthalpy of formation for

x safety factor
reactant, ∆H°f reactant

= 280204 kcal/h x 1.3

= 364265 kcal/h

No. of burner for RTO = 2

Heat energy need to supply by 364265 kcal/h

=
each burner 2
= 182132 kcal/h
8.3.2 RTO Data (Feul = Natural Gas)

a) Heat Ouput Capacity, Q = 182,132 kcal/h

= 762,552 kJ/hr
= 762.55 MJ/hr

b) No. Of Burner, n = 2 No.

c) Type Of Fuel = NATURAL GAS
d) Gross Calorific Value, Cv = 55,245 KJ/kg (Refer appendix 8.4)
= 55.25 MJ/kg
e) Efficiency of burner, e = 75.0 % (Refer appendix 8.5)

f) Fuel Consumption, W = (Q x n x 100) /(Cv x e)

762.55 X 2 X 100
55.25 X 75.0
= 36.81 kg/hr

3
Density of natural gas = 0.709 kg/m (Refer appendix 8.6, at 26°c )

36.81 kg 0.709 kg
Fuel Consumption, W = /
1 hr 1 m3

=
36.81 kg
x
1 m3
1 hr 0.709 kg
= 51.92 m3/hr

Check Heat Input Capacity for = 1,016,736 KJ/Kg

each burner, ( (W X Cv) / 2) = 963,731 btu/hr

8.3.3 Calculation Of Uncorrected Chimney Height for VLS Fuels

WB (Refer appendix 8.7)

Q =
3600
W X B
=
3600
36.81 X 55.25
=
3600
=
0.565 MW
Where,
Q = Heat Input in MW
W = Maximum rate of combustion of fuel in kg/h
B = Gross calorific value in MJ/kg
 For heat inputs less than 30MW, the equation is as below for uncorrected chimney
height (U) :

U = 1.36 Q 0.6
= 1.36 X ( 0.565 ) 0.6
= 0.97 Meter

8.3.4 Calculation Of Corrected Chimney Height

Uncorrected chimney height, U = 0.97 m

Within 5U = 5xU
= 4.83 m

Condition: if U <2.5 height of building (Hf) within 5U, then correction of chimney is needed

Height of building where chimney attached, H = 12 m

Height of highest point of building within 5U from chimney, Hf = 20 m

2.5 Of highest point of building Hf = 50 m

Since 'U' = 0.97 m; less than 2.5 of highest point Hf（5U） = 50

correction is needed as follow ,

Corrected chimney height, C = Hf + 0.6U
= 20.000 + ( 0.6 X 0.97 )
= 20.579 M

Proposed Chimney Height = 30.681 M

(From Finish Floor Level)
* Clause 26: Proposed chimney height, 30.681M > Height of roof where Chiney attached+ 3 Meter,15.765M
* Clause 25: Proposed chimney height, 30.681M > Height of roof building within 5U, 20M
* Further adjustment is not required (meet clause 25 & 26), the final chimney height is the same as
the proposed chimney height.
8.3.5 Air To Fuel Ratio Calculation
Fuel composition by mass :
Fuel Carbon (%)Hydrogen (%) Sulphur (%)
NATURAL GAS 75.85 24.15 0 (Refer appendix 8.8)

1 kg of natural gas contains :

Fuel Carbon (kg)
Hydrogen (kg) Sulphur (kg)
NATURAL GAS 0.759 0.242 0
Also,
1 kg of NATURAL GAS contains :
0.7585 mole C , 0.2415 mole H2, 0 mole S
12 2 32

Let oxygen required for complete combustion is X mole , the nitrogen supply with
oxygen is 79/21 X mole

1 kg of FUEL the combustion equation is therefore as follow :

0.759 C + 0.2415 H2 +X(O2 +3.76N2) + 0 S

12 2 32
Combustion

a CO2 + b H2O + 3.76X N2 + 0 S

32

Carbon balance : 0.7585 = a a = 0.0632083 mole

12

Hydrogen balance : 0.2415 = b b = 0.12075 mole

2

Oxygen balance : 2X = 2a+b X = 0.12358333 mole

Mass for 1 mole oxygen (O2) : 32 kg

Oxygen required = 0.123583333 x 32

= 3.954666667 kg of oxygen/kg of fuel

Air required per kg of fuel = 3.954666667

0.21 (21% O2 and 79% N2 by mass)
= 18.83174603 kg
Theoretical Air to Fuel Ratio by Mass = 18.83 kg : 1 kg
8.3.6 Calculation for flue gas constant

Total mass of product :

0.063 mole CO2 + 0.121 mole H2O + 0.4647 mole N2

+ 0.000 mole S = 0.6486 mole
Wet analysis :

0.06 x 100 % = 9.7449 % CO2

0.65

0.12 x 100 % = 18.616 % H2O

0.65

0.46 x 100 % = 71.639 % N2

0.65

0.000 x 100 % = 0 % S
0.65
Total = 100 %

Find R value for 0% excess air

R for CO2 = 8.314 x 0.0974 = 0.0184 KJ/kgK

44

R for H2O = 8.314 x 0.1862 = 0.0860 KJ/kgK

18

R for N2 = 8.314 x 0.7164 = 0.2127 KJ/kgK

28

R for S = 8.314 x 0.0000 = 0.0000 KJ/kgK

32

R for value for 0% excesss air = 0.317 KJ/kgK

Find Total R Value With Additional 20% excess air

R for value for air = 0.287 KJ/kgK

R value for 20% Excess air 20% =x 0.287 = 0.0574 KJ/kgK

R value for theoretical Excess

80%air = x 0.317 = 0.2537 KJ/kgK

Total R Value With Additional 20% excess air = 0.3111 KJ/kgK

8.3.7 Volume of Combustion Product(Detail calculation)

Typical air to fuel ratio = 18.83 : 1 kg/kg

Ideal gas law m = P

V RT
Where,
m = mass (kg)
P = Absolute Pressure (N/m^2)= 101325
R = Gas constant(J/kg K) = 311.09
T = Absolute Temperature(K) = 820 °C
= 1093 K
V = volume(m^3) (refer appendix 8.2)
Page 9
Hence, m = 0.298 kg/m^3
V

For 18.83 kg of air = 63.20 m^3/kg

Typical Volume Of Combustion Product, QComb = 63.20 m^3/kg

(Volumetric Flowrate)
Fuel Consumption, W = 36.81 kg/hr

Volumetric Flowrate, Q = (Qcomb x W)/3600

= 0.65 m^3/s
= 2,326 m^3/h
= 1,369 CFM

Actual Supply = 1,550 CFM

AIR COMBUSTION FAN Fan Model =

Flowrate, Q = 1,766 CFM (calc data: 1550 CFM )

= 3,000 CMH (calc data: 2633 CMH )
= 0.83 CMS (calc data: 0.73 CMS )

Static Pressure, SP = 20.1 " WG

= 5000.00 Pascal

Fan Serial No. = F-F801 (Refer to appendix 8.2 / CATALOG)

Fan power = 11.0 kw
Fan speed = unknown rpm
8.3.8 Pressure drop for RTO machine.

Estimate pressure drop for new RTO machine = 2.38 kPa

(Refer appendix 8.9)
= 2380 Pa

= 9.564 " wg

8.3.9 Retention time.

Volumetric air flow rate in RTO machine, Q = 23000 cfm

Cross sectional area for combustion chamber, A = 107.865 ft2

(Refer appendix 8.10)

Velocity of air across the RTO machine, V = 213.229 ft/min

= 3.554 ft/s
= 1.083 m/s

Shortest air travel distance from chamber 1 (in)

= 2.785 m
to chamber 2 (out)
(Refer appendix 8.10)

Min Retention time or time travel from chamber 2.785 m

=
1 (in) to chamber 2 (out) 1.083 m/s

= 2.571 s

*From appendix 8.11, Minimum design retention time is 2 s, current case have 2.571 s of retention time which
is more than 2s.
8.3.10 Ash loading calculation
1) Ash content

Ash content by mass = 0.0000 % (Refer appendix 8.8)

This mean,
1kg of NATURAL GAS contain 0 kg of ash.

2) Air to fuel ratio

Combustion of 1 kg of NATURAL GAS will required 16.97 kg & 22.38 m3 of air

Thus, 1 m3 of air can combust 1 / 22.4 or 0.0447 kg of natural gas

3) Ash content in 1 m3 of air

0.04468 kg of NATURAL GAS will contain 0.00000000 kg of ash

Mean , 1 m3 of air contain 0.00000000 kg of ash or 0.000 mg of ash

4) Ash loading concentration

Ash loading concentration = 0.00 mg/m3