Excess Air

Optimization

1
Combustion

All conventional fossil fuels (solid, liquid, or gaseous) contain basically carbon
and or hydrogen when burnt react with oxygen of air forming carbon di oxide,
carbon monoxide or water vapor.

2
Requirement for Combustion

• Fuel
• Oxygen
• The 3 “T’s”
• Time
• Temperature
• Turbulence

3
Concept of Excess Air

• For optimum combustion, the real amount of combustion air must be greater
then that required theoretically. This additional amount of air is called excess
air.
• A certain amount of excess air is needed for complete combustion of fuel.
• Too much excess air leads to heat losses and too little excess air leads to
incomplete combustion.
• You can tell if there is too little or too much excess air by measuring the CO2.
• The amount of excess air required depend on various factors like type of fuel
used, type of firing system and size of firing system.

4
 Saving by Controlling Excess Air (Theoretical Basis
at 0.5% Excess Air)
Stoichiom
Excess O2 Heat Coal Loss Per
Coal Air Required Stoichiom etric at Excess Excess Air CP Air at CP Air at Loss/Hea Loss @ Coal Loss
Requireme Price Year@300
Works Month Consumpti Per Kg Coal etric Air nt + 1 % Calciner in Air at Volumetric 25°C 900°C t Gained
on (Nm3/Kg Required Oxygen for addition Calciner Flow Rate (Kcal/Nm3. (Kcal/Nm3. by Excess 5800 (PKR/ Per Day days per
(Kg/hr) Coal) (Nm3/hr) to 1% O2 (%) (Nm3/hr) °C) °C) 2.44% Air Kcal/Kg Kg) (PKR/D year
complete (%) (Kcal/hr) (Kg/hr) ay) (PKR/year)
burning

HTR Nov 20,672 7.1 146,768 154,107 0.5 2.44 3,758 0.3104 0.3343 78,604 13 19
5,912 1,773,551

FRQ-I Nov 18,892 7.1 134,134 140,840 0.5 2.44 3,435 0.3104 0.3343 12 19
71,837 5,521 1,656,391

FRQ-II Oct 31,972 7.1 227,003 238,353 0.5 2.44 5,813 0.3104 0.3343 121,575 20 19 9,260 2,777,929

CHK-I Nov 28,395 7.1 201,603 211,683 0.5 2.44 5,163 0.3104 0.3343 18 19
107,971 8,046 2,413,873

CHK-II Oct 27,752 7.1 197,039 206,891 0.5 2.44 5,046 0.3104 0.3343 105,527 18 19 8,031 2,409,237

KKR Nov 33,850 7.1 240,333 258,814 0.5 2.44 6,312 0.3104 0.3343 21 19
132,011 9,638 2,891,316

Microsoft Excel
Worksheet
Total All Works 46,408 513,922,297
 Saving by Controlling Excess Air
(Actual)
Stoichiomet
Heat
Air Required Stoichiomet ric Excess O2 Excess Air CP Air at CP Air at Loss/Heat Coal Loss Coal Loss Per Loss Per
Coal Requiremen at Calciner Excess Air
Works Month Consumption Per Kg Coal ric Air Volumetric 25°C 900°C Gained by @ 5800 Price Year@300
Kcal/Kg (PKR/ Day days per year
t+1% in addition at Calciner
(Nm3/Kg Required Flow Rate (Kcal/Nm3.° (Kcal/Nm3.°C Excess
(Kg/hr) Oxygen for to 1% O2 (%)
Coal) (Nm3/hr) complete (%) (Nm3/hr) C) ) 2.44% Air (Kg/hr) Kg) (PKR/Da (PKR/year)
(Kcal/hr) y)
burning

HTR Nov 20,672 7.1 146,768 154,107 0.3 1.45 2,233 0.3104 0.3343 46,707 8 19 3,513 1,053,849

FRQ-I Nov 18,892 7.1 0.4 1.94 2,734 0.3104 0.3343 57,191 10 19 4,396 1,318,680
134,134 140,840

FRQ-II Oct 31,972 7.1 227,003 238,353 0.3 1.45 3,454 0.3104 0.3343 72,240 12 19 5,502 1,650,654

CHK-I Nov 28,395 7.1 0.2 0.96 2,035 0.3104 0.3343 42,566 7 19 3,172 951,623
201,603 211,683

CHK-II Oct 27,752 7.1 197,039 206,891 0.2 0.96 1,989 0.3104 0.3343 41,602 7 19 3,166 949,795

KKR Nov 33,850 7.1 0.7 3.45 8,924 0.3104 0.3343 186,637 30 19 13,626 4,087,723
240,333 258,814

Total All Works 33,374 6

10,012,324
Possible Saving by Controlling SHC during
Petcoke Utilization

Clinker Production Petcoke Used SHC Cost Saving Saving In-terms of Petcoke

TPD Ton Kcal/Kg Clinker PKR/Tons Clinker PKR/Tons Clinker Tons PKR/Tons

3,601
363 786 2,287  
3,601 463,752
342 750 2,158 129 20
3,601 567,355
338 740 2,129 158 25

Microsoft Excel
Worksheet

7
Acid Dew Point of High Sulphur
Fuels
• The acid dew point of a flue gas is the temperature, at a given pressure, at
which any gaseous acid in the flue gas will start to condense into liquid acid.

Sulphur in Fuel Acid Dew Point

1% 130 oC
2% 133 oC
3% 138 oC
4% 143 oC
5% 150 oC

8
Thanks