Combustion Engineering: Technical Development Program For Process Performance Engineers

Combustion Engineering
Technical Development Program

for Process Performance Engineers
Sven Ritschard
HGRS / CMS Thermal Process Technology
© 2008 Holcim/Switzerland
Content
 Objectives
 Basic Definitions
 Combustion Calculation
 False Air Investigation
2
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
Objectives
 Know how to calculate the required air volume for

combustion
 Know how to determine the exhaust gas flow in a kiln
 Know how to determine the amount of false air in a kiln

system
3
Agenda
 Objectives
4
Basic
Definitions Definition of conditions
 Actual conditions
 actual absolute pressure
 actual temperature
 Normal conditions
 1013 mbar (ambient pressure at sea level)
 273.15 K (water freezing temperature = 0°C)
 Standard conditions (US)

 30 inch Hg (1016 mbar)
 60°F (15.6°C = 288.7 K)
5
Agenda
 Objectives
6
Combustion
Calculations What are the combustion reactions and products ?
C + O2  CO2
S + O2  SO2
C
H
S 4H + O2  2H2O
Ash
O
H2O N2  N2
N
Air
(N2, O2)
Ash 7
Combustion
Calculations Amin and Vmin
Minimum combustion air Amin:

Required air for complete combustion without any
excess of oxygen (stoichiometric combustion)
Minimum Exhaust gas Vmin:

Sum of all combustion gases from a stoichiometric
combustion (CO2, SO2, N2, H2O), including the humidity
of the fuel and the inert parts of the combustion air (N2,
H2O)
8
Combustion
Calculations What is Amin for the combustion of 1 kg fuel?
Amin = 8.89 x C + 26.6 x H + 3.3 x S - 3.3 x O Nm3/kgfuel
C, H, S, O must be weight fractions !
Example (bituminous coal):

 CVnet = 28 MJ/kg Comp Calculation Nm3/kgcoal
 C = 71% C 8.89 x 71% 6.312
 H=4%
H 26.6 x 4% 1.064
 O = 6%
 N = 1.5% S 3.3 x 1% 0.033
 S = 1% O -3.3 x 6% - 0.198
 H2O = 0.5% Total 7.211
 Ash = 16%
Amin = 7.21 Nm3/kgcoal = 0.26 Nm3 /MJ
9
Combustion
Calculations What is Vmin from the combustion of 1 kg fuel?
Vmin = 1.87 x C + 0.8 x N + 0.79 x Amin + 0.7 x S

+ 11.2 x H + 1.24 x H2Ofuel+ H2Oair x Amin Nm3/kgfuel
C, N, H, S, H2O must be weight fractions !
Example (bituminous coal):

Comp Calculation Nm3/kgcoal % Vmin
CO2 1.87 x 71% 1.328 17.7
N2 0.8 x 1.5% + 0.79 x 7.211 5.709 76.1
SO2 0.7 x 1% 0.007 0.1
H2 O 11.2 x 4% + 1.24 x 0.5% 0.454 6.1
Total 7.498 100
Vmin = 7.50 Nm3/kgcoal = 0.27 Nm3 /MJ
10
Combustion
Calculations Approximate calculation with factors Amin and Vmin
Minimum combustion air Amin:
Amin Factor  0.26 Nm3/MJ
Minimum Exhaust gas Vmin:
Vmin Factorwet  0.28 Nm3/MJ (wet)
Vmin Factordry  0.25 Nm3/MJ (dry)
11
Combustion
Calculations Factors for Amin and Vmin of some fuels
Amin-Factor Vmin-Factor
Fuel
(Nm3/MJ) (Nm3/MJ)
Anthracite, Petcoke at 1% humidity 0.26 0.27
Bituminous coal at 1...2% humidity 0.26 0.28
Lignite (high humidity) at 10% humidity 0.26 0.29
Wood / Peat at 10...15% humidity 0.26 0.30
Light oil 0.26 0.29
Heavy oil (bunker C) 0.26 0.28
Tar 0.26 0.28
Waste tires (rubber) 0.26 0.27
Natural gas (high CH4 content) 0.27 0.30
Natural gas (approx. 24% C2H6) 0.26 0.30
12
Combustion
Calculations
Kiln exhaust gas components
Raw meal
H2 O
CO2
Kiln exhaust gas

Fuel
H2O
Vmin,wet Vmin,dry
Amin CO2, SO2, N2
Excess air O2, N2
Air False
air
13
Combustion
Calculations Approximate calculation of gas from raw meal
CO2
H2O
CO2,raw meal  0.27 Nm3/kgcli
H2Ovapor  0.01 Nm3/kgcli
For dry kiln, if no dust is

discarded !
14
Combustion
Calculations Combustion gases and gases from raw meal
H 2O
CO2 H2Ovapor
Kiln exhaust gas

Fuel Vmin,dry
H2Ovapor
&
Vmin,wet Vmin,dry CO2,raw meal
Amin CO2, SO2, N2
Excess air O2, N2
Excess Air
Air False
air
 Nm 3
Nm 3 
Gasdry ,combustion raw meal  M cli   0.27  0.25 q
 kg cli MJ 
Mcli = clinker production rate, q = spec. heat consumption [MJ/kg cli] 15
Combustion
Calculations Excess air
H 2O
CO2 H2Ovapor
Kiln exhaust gas

Fuel Vmin,dry
H2Ovapor
&
Amin CO2, SO2, N2
Excess air O2, N2
Excess Air
Air False
air
O2,dry%
Excess Air  Gasdry,combustion  raw meal 
21 %  O2,dry%
16
Combustion
Calculations Moisture
H 2O
CO2 H2Ovapor
Kiln exhaust gas

Fuel Vmin,dry
H2Ovapor
&
Amin CO2, SO2, N2
Excess air O2, N2
Excess Air
Air False
air
 Nm 3
Nm 3 
Moisturecombustion  raw meal  M cli   0.01  0.03 q
 kg cli MJ 
17
Combustion
Calculations Summary
 Nm 3
Nm 3 
Moisturecombustionraw meal  Mcli   0.01  0.03  q
H2Ovapor  kgcli MJ 
Kiln exhaust gas
Vmin,dry
 Nm 3
Nm 3 
&
Gasdry ,combustion raw meal  M cli   0.27  0.25 q
CO2,raw meal
 kg cli MJ 
O2,dry%
Excess Air Excess Air  Gas dry,combustion raw meal 
21 %  O2,dry%
 Nm 3
Nm 3  Nm 3
Nm 3  O2,dry% 
VKilngas,wet  M cli  0.28  0.28  q   0.27  0.25 q 
 kg cli MJ  kg cli MJ  21 %  O 2 , dry% 
18
Combustion
Calculations Typical exhaust gas quantities
at kiln system outlet

19
Gas Volume at Kiln Inlet
  %decarb   % PC    %decarb   % PC   O2,dry% 

VKilnInletgas,wet  M cli  0.27  1    0.28  q  1    0.27  1    0.25  q  1     
  100   100    100   100    21 %  O 2 , dry% 
%decarb = calcination degree

%PC = precalciner firing rate Kiln ID Fan
q = kiln heat consumption

%O2,dry= O2 at kiln inlet
Meal Dosing
Precalciner Fuel Dosing
Suspension Preheater
Kiln Fuel Dosing
Precalciner
Tertiary Air
Burner
KILN INLET
Clinker
20
CC-99069.dsf / Kma 17.2.99
Agenda
 Objectives
 False air investigation
21
False Air
 O 2 out - O 2 in 
%VFA     100
 21 - O 2 out 
%VFA = False air as portion of flow before false air intake
O2,out, in = O2 content before and after false air intake
Guide values for low false air intake:
22
False Air
Investigation
Gas Analysers
 Portable analysers
 Birrer
 TESTO
 …..
 Fix installed analysers
 Siemens
 ABB
 …
23
False Air
Investigation False air investigation
1. How much false air is entering the kiln system

between preheater exit and ID-Fan?
2. What is the total exhaust gas flow at ID-Fan
Suspension Preheater Kiln:
O2:
Production: 2400 t/d 3.5%
Heat cons.: 3400 kJ/kg
Water
5 t/h
O2:
5%
24
False Air
Investigation 1. False air investigation exhaust gas system
Preheater Exit 1 2 ID-Fan

CT
Water
H2Ovapor
Kiln exhaust gas H2Ovapor
Vmin,dry Vmin,dry
& &
CO2,raw meal CO2,raw meal
Excess air
EPHexit Excess air EID-Fan
False
False Air = EID-Fan – EPHexit air
25
False Air
Investigation 1. False air between preheater exit and ID-Fan
a) Dry exhaust gas volume preheater exit:
t cli  Nm3 Nm3 MJ  Nm3
Gdry, comb.raw mat.,PHexit  100  0.27  0.25  3 .4   112'000
h  kgcli MJ kgcli  h
b) Excess air at ID-Fan:

Nm3 5% Nm3
ExcessAirID Fan  112'000   35'000
h  21% - 5% h
c) Excess air at preheater exit:

Nm3 3.5% Nm3
ExcessAirPH exit  112'000   22'400
h  21% - 3.5% h
d) False air:
Nm3 Nm3
FalseAirPH exit  EA ID Fan  EA PH exit  12'600  0.126
h kgcli
26
False Air
Investigation 2. Total exhaust gas flow at ID-Fan
t cli  Nm 3
Nm3
MJ  Nm 3
H2Ocomb.hydrate  100   0.01  0.03  3.4   11'200
h  kgcli MJ kgcli  h
kgH2O 3 3
H2Ocooling tower  5'000  1.244 Nm  6'220 Nm
h kgH2O h
3
Gasdry,combustion raw meal  112 '000 Nm
h
3
Excess Air  35'000 Nm
h
3 3
G  H2Ocomb .hydrate  H2Ocooling tower  Gasdry,c rm  Excess A ir  164'420 Nm  1.64 Nm
h kgcli
27
Key messages
 Determine and reduce the amount of false air in your

kiln system frequently
 Any false air intake increases heat consumption,
increases power consumption or reduces production
capacity (if fan limited)
28
Additional Information
© 2008 Holcim/Switzerland
Definition of a Mol
 1 kMol are 6.02 * 1026 molecules

 1 kMol of gaseous molecules need 22.4 Nm3 of space
30
Definition of calorific values
Gross Calorific Value:
CVgross = Combustion Energy referred to 20°C
=> including condensation of H2O
=> measured in the bomb calorimeter
Net Calorific Value:

CVnet = CVgross - H2Ocombustion * 2450 kJ/kgH2O
CVgross - (H2Ofuel+ 9 H)* 2450 kJ/kgH2O

31
Combustion
Calculations What is the required minimum combustion air ?
22.4 Nm3O2 1 Nm3Air
A min,C   Nm3O2
 8.89
12 kgC 0.21 Nm3 kgC
Air
22.4 Nm3O2 1 Nm3Air

A min,H   Nm3O2
 26.6
4 kgH 0.21 Nm3 kgH
Air
22.4 Nm3O2 1 Nm3Air

A min,S   Nm3O2
 3.3
32 kgS 0.21 Nm3 kgS
Air
22.4 Nm3O2 1 Nm3Air

A min,O    Nm3O2
 - 3.3
32 kgO 0.21 Nm3 kgO
Air
32
Combustion
Calculations How much combustion gas is produced ?
22.4 Nm3CO2 Nm3CO2
Vmin,C   1.87
12 kgC kgC
22.4 NmH3 2O NmH3 2O

Vmin, H   11.2
2 kg H kg H
22.4 Nm3SO2 Nm3SO2

Vmin,S   0.7
32 kgS kgS
22.4 NmN3 2 NmN3 2

Vmin,N,Fuel   0.8
28 kgN kgN
33
Combustion
Calculations Additional Volumes of Vmin?
NmN3 2
Vmin,N2 ,Air   0.79  A min 
kgFuel
22.4 NmH3 2O NmH3 2O

Vmin,H2O,Fuel   1.24
18 kgH2O kgH2O
NmH3 2O

Vmin,H2O,Air  Volume% H2O,Air  A min  kgFuel
34
Combustion
Calculations Gases from Kiln Feed/Raw Meal (detailed calculation)
For wet kilns and/or dust filter dust is discarded/extracted
H2O from raw meal/slurry moisture:
 w  Nm 3
VH 2O  M cli  R   H 2Ocryst   1.24
 1 w  kg H 2O
CO2 from raw meal:

VCO2  M cli  R   LOI KF  1  H 2Ocryst   dustloss  LOI FD   0.509
3
Nm
kgCO2
Mcli = Clinker production rate
R = Kiln feed/clinker - Factor = 1/[(1-LOIKF)*(1-dustloss)]
LOI = % loss on ignition/100%
dustloss = % dust leaving the kiln system
(wet kilns: smoke chamber, dry kilns: preheater exit)
H2Ocryst = %crystal water/100% (chemically bonded water)
KF = Kiln Feed
FD = Filter Dust
w = moisture content of raw meal 35
Combustion
Calculations Gas Conversion to between Actual and Normal
36

Combustion Engineering: Technical Development Program For Process Performance Engineers

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Combustion Engineering

Technical Development Program

 False Air Investigation

 Know how to calculate the required air volume for

 Know how to determine the exhaust gas flow in a kiln

 Know how to determine the amount of false air in a kiln

 False Air Investigation

 Standard conditions (US)

 False Air Investigation

Minimum combustion air Amin:

Minimum Exhaust gas Vmin:

Amin = 8.89 x C + 26.6 x H + 3.3 x S - 3.3 x O Nm3/kgfuel

C, H, S, O must be weight fractions !

Example (bituminous coal):

Vmin = 1.87 x C + 0.8 x N + 0.79 x Amin + 0.7 x S

Example (bituminous coal):

Minimum combustion air Amin:

Amin Factor  0.26 Nm3/MJ

Minimum Exhaust gas Vmin:

Vmin Factorwet  0.28 Nm3/MJ (wet)

Vmin Factordry  0.25 Nm3/MJ (dry)

Kiln exhaust gas

CO2,raw meal  0.27 Nm3/kgcli

H2Ovapor  0.01 Nm3/kgcli

For dry kiln, if no dust is

Kiln exhaust gas

Kiln exhaust gas

Kiln exhaust gas

at kiln system outlet

  %decarb   % PC    %decarb   % PC   O2,dry% 

%decarb = calcination degree

q = kiln heat consumption

Precalciner Fuel Dosing

 False air investigation

Guide values for low false air intake:

 Fix installed analysers

1. How much false air is entering the kiln system

Preheater Exit 1 2 ID-Fan

b) Excess air at ID-Fan:

c) Excess air at preheater exit:

 Determine and reduce the amount of false air in your

 1 kMol are 6.02 * 1026 molecules

Net Calorific Value:

CVgross - (H2Ofuel+ 9 H)* 2450 kJ/kgH2O

22.4 Nm3O2 1 Nm3Air

22.4 Nm3O2 1 Nm3Air

22.4 Nm3O2 1 Nm3Air

22.4 NmH3 2O NmH3 2O

22.4 Nm3SO2 Nm3SO2

22.4 NmN3 2 NmN3 2

22.4 NmH3 2O NmH3 2O

CO2 from raw meal:

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