GROUP 4

HEAT BALANCE AND COMBUSTION EMISSIONS

ANALYSIS OF A BOILER
SKPG 3721 SN02
DATE: 15 MARCH 2017

LECTURER:
DR. MOHD DINIE MUHAIMIN BIN SAMSUDIN
TECHNICANS/TEACHING ASSISTANTS:
EN. JAMAL ASRI BIN OTHMAN

GROUP MEMBERS:
NO. TEAM MEMBERS MATRIC NUM

1. MUNISRAU A/L KRISHNAPPARAO A15KP0091

2. MUVINES A/L RAJENDRAH A15KP0092

3. NUR HIDAYAH BINTI ABDULLAH A15KP0104

TABLE OF CONTENT

1.0 ABSTRACT……………………………………………………………………… 3

2.0 INTRODUCTION………………………………………………………………... 4-5

2.1 Background…………………………………………………………………….......4

2.2 Problem Statement…………………………………………………………........... 4

2.3 Objective………………………………………………………………………...... 5

3.0 LITERATURE REVIEW………………………………………………………… 6

4.0 METHODOLOGY……………………………………………………………...... 7

5.0 RESULTS……………………………………………………………………….... 8-12

5.1 GRAPHS………………………………………………………………………….10-11

5.2 SANKEY DIAGRAM……………………………………………………………. 12

6.0 DISCUSSION…………………………………………………………………….13-14

7.0 CONCLUSION…………………………………………………………………… 14

8.0 REFERENCES……………………………………………………………………. 14

9.0 APPENDICES……………………………………………………………………15-26
1.0 ABSTRACT

Combustion occurs when fossil fuels, such as natural gas, fuel oil, coal or gasoline,
react with oxygen in the air to produce heat. The heat from burning fossil fuels is used for
industrial processes, environmental heating or to expand gases in a cylinder and push a
piston. Boilers, furnaces and engines are important users of fossil fuels. Boiler is a pressure
vessels type of heat exchanger equipment designed to heat water or produce steam. Boiler
use gas and oil to fire a control combustion of the fuel to heat water. For given fuel, the
efficiency of combustion, from hot combustion gases to water is significantly affected by
the ratio of fuel and air fed to the boiler.
From this experiment, result obtained from manipulated of the air flow rate and
water flow rate. By this manipulation, air inlet temperature, flue gas temperature, water
inlet temperature, water outlet temperature and analysis of flue gas obtained. When air flow
rate being reduce, amount of air inserted the boiler during combustion was little and it can
be observed by the time taken for the boiler to operate. During the operation of the boiler,
air was in excess and it effecting the thermal and combustion efficiency as the excess air
must be sufficient not too much not too little and the excess air reduces the flame
temperature.
2.0 INTRODUCTION

2.1 Background

A boiler is a closed pressure vessel type of heat exchanger equipment where water
is heated (heat energy from flue gases) to produce hot water or steam. The heated or
vaporized fluid exits the boiler for use in various processes or heating applications. Boiler
can be categorised into two categories which are steam boiler and hot water boiler. Steam
boiler can be used for building space heating in low pressure application and generate
power in high pressure application.

2.2 Problem Statement

Combustion-generated pollution is emission or release of polluting species because

of human or nature activities involving combustion process. Combustion-generated
pollutants of major concern, carbon dioxide (CO2), carbon monoxide (CO), volatile
organic compounds (VOC) or unburnt hydrocarbon (UHC), oxides of nitrogen (NOx),
oxides of sulphur (SOx) and particulates. Addressing heat loss through high flue gas
temperatures often involves installing economizers or combustion air heaters to recoup heat
for the boiler system. (Bennett, 1977). Fuel specification should be of concern for industrial
boilers that rely on natural gas, due to the typically high hydrogen content. (Bennett, 1977)
Some of this hydrogen inevitably becomes water during combustion, which monopolizes
energy that could otherwise be used in the combustion process. Some boiler burners require
excess air because their combustion process would be too fuel rich otherwise. Whatever
the reasons for the use of excess air, it inevitably absorbs some of the combustion heat,
reducing the efficiency of the heat transfer to the boiler water. Flue gas moisture from fired
power plant mainly comes from the release of hydrogen in coal combustion process and
water carried by flue gas from wet flue gas desulfurization system. High humidity flue gas
emission increases the overall humidity in the lower atmosphere, which is not conducive
to the pollutants diffusion in low atmosphere and even affect the local climate around the
plant. (Shuangchen, 2017)
2.3 Objective

 Able to correlate the effect of fuel/air ratio on the heat loss and thermal efficiency
 Relate the influence of air/fuel ratio or excess air on the emissions, efficiency and
flame temperature of the LPG combustion
 Addressing how to reduce harmful species such as CO and NOx emitted from
combustion process
 Identify the safety aspects of the boiler operation.
 Identify the other factors that affect the boiler performance
3.0 LITERATURE REVIEW

Boiler is a pressure vessels type of heat exchanger equipment designed to heat

water or produce steam. Boiler use gas and oil to fire a control combustion of the fuel to
heat water. The key boiler components involved in the process were burner, combustion
chamber, heat exchanger and controls. For given fuel, the efficiency of combustion, from
hot combustion gases to water is significantly affected by the ration of fuel and air fed to
the boiler. Boilers are classified differently based on their working pressure and
temperature, fuel type, draft method, size and capacity, and whether they condense the
water vapor in the combustion gases. The two types of boilers include Firetube and
Watertube boiler. (Capehart, B., Turner, 2006)

The real-time combustion diagnosis system and combustion state control system for
burner is discussed by Kim et al (2002). The evaluation of burner status is very important
because the combustion process in turn affects the environment. The pollution of the
environment can be minimised if the thermal efficiency is higher and the content of
oxygen in the exhaust gas is less. The emissions of NOx and CO should be within limits
to reduce the environmental problem. The colour of the flame is used for judging the
combustion status. Algorithms like linear regression, linear multi-nominal expression and
constructed inference algorithms were used to find the amount of NOx and CO emissions.
The features extracted from the flame were useful in identifying the combustion status.
The results in this paper explain the possibility for deriving the properties which has more
accurate relationship with the concentration of NOx and CO.

There are various algorithms proposed in the literatures in this area for the past ten
years were reviewed so far and it was found that there is a tremendous scope available to
develop an indigenous technique for flame monitoring and flue gas emissions to optimize
the operation of the combustion chamber of the boiler.
4.0 METHODOLOGY

1. The cooling water was let to pass through the boiler and the valve was adjusted to
obtain the desired flow rate.

2. The start button was switched on and the air was let to pass through the boiler for a few
minutes.

3. The air damper was set to obtain the desired air flow rate.

4. The ignition button was switched on and the LPG was slowly fed to initiate
combustion.

5. The conditions were allowed to stabilize and the readings were recorded on the
observation sheet.

6. The air damper position was increased by one graduation.

7. Again, the conditions were allowed to stabilize and the readings were recorded.

8. The air flow was increased in stages until maximum setting has been reached or
combustion cannot be sustained.

9. The LPG feed was stopped and the air was allowed to pass through the boiler before
the boiler was shut down.
5.0 RESULTS

DATA 1

Water flow rate (L/min) 222

Gas flow rate (g/s) 1.389

Air flow rate (g/s) 3.8 3.6 3.4 3.2

Air inlet temperature (ºC) 31 31 31 31

Flue gas temperature (ºC) 776.3 790.3 778.3 806.8

Water inlet temperature (ºC) 27 27 27 27

Water outlet temperature (ºC) 43 40 42 41

Analysis of flue gas

% O2 (Dry) 4.04 3.29 2.82 1.43

% CO2 (Dry) 10.6 12.3 12.2 13.9

ppm CO (Dry) 0 0 0 0

ppm NOX 52 61 59 65

Flame color blue blue blue Light blue

Observation Fuel rich Fuel rich Small orange Small orange

combustion combustion spark spark with
vigorous flame
DATA 2

Water flow rate (L/min) 182

Gas flow rate (g/s) 1.443

Air flow rate (g/s) 3.8 3.6 3.4 3.2

Air inlet temperature (ºC) 32 32 32 32

Flue gas temperature (ºC) 779.5 764.7 787.8 784.0

Water inlet temperature (ºC) 27 27 27 27

Water outlet temperature (ºC) 41 43 46 49

Analysis of flue gas

% O2 (Dry) 3.93 3.78 2.78 1.89

% CO2 (Dry) 11.2 7.1 9.3 6.9

ppm CO (Dry) 0 0 0 0

ppm NOX 49 41 49 46

Flame color blue blue blue blue

Observation Small orange Small orange Small orange Long orange

spark spark spark with spark with
vigorous flame turbulence flow
5.1 GRAPHS

Figure 1: Graph of air-fuel ratio(%) versus thermal efficiency(%)

Excess air vs Thermal Efficiency

30

25

20
Excess air

15
Data 1

10 Data 2

0
40 50 60 70 80 90 100
Thermal efficiency

Figure 2: Graph of air-fuel ratio(%) versus flue gas temperature(ºC)

Excess air vs Flue Gas Temperature

30

25

20
Excess Air

15
Data 1

10 Data 2

0
760 770 780 790 800 810
Flue Gas Temperature
 Figure 3: Graph of excess air (%) versus flame temperature(ºC)

Flame temperature vs Excess air

30

23.96
25 23.09
22.02

18.68
20
15.6
Excess air

15.03
15
9.92
10 7.35

0
1780 1800 1820 1840 1860 1880 1900 1920 1940 1960
Flame temperature

Figure 4: Graph of NOx emissions (%) versus flame temperature(ºC)

Nox Emissions (ppm) vs Flame Temperature

70 65
59 61
60
52
49 49
Nox Emissions (ppm)

50 46
41
40

30

20

10

0
1780 1800 1820 1840 1860 1880 1900 1920 1940 1960
Flame Temperature
5.2 SANKEY DIAGRAM

P
o
t
e
b
t
u
a
l
o
s
s
s

Heat input Boiler Useful Heat

M S
o e
i n
s s
t i
u b
r l
e e

L L
o o
s s
s s

Diagram 1: Sankey Diagram which shows the energy flow

Data 1

When air flowrate is calibrated at 3.8 g/s, the nett loss recorded is 38.7% which accounts
potential, wet and dry loss. The net loss is recorded 38.1%, 37% and 36.4% respectively
for calibration 3.6g/s, 3.4g/s and 3.2g/s.
Data 2

When air flowrate is calibrated at 3.8 g/s, the nett loss recorded is 38.7% which accounts
potential, wet and dry loss. The net loss is recorded 37.8%, 37.3% and 36.0% respectively
for calibration 3.6g/s, 3.4g/s and 3.2g/s.

6.0 DISCUSSION
In this experiment, result obtained only by two data due to the problem of the boiler.
Boiler was manipulated with water flow rate and major manipulated with air flow rate.
Taking air flow rate from 3.8 to 3.2 in both data. Combustion that occur during the burning
of the fuel was perfectly complete combustion because no CO produced. However, NOx
was produced during the combustion. To control the emission of the CO and NOx, hot flue
gas need to recycle also been suggested to reduce furnace size and increasing O2
concentration. (Isabel Cabrita,2015)

From the graph in Figure 1, excess air is inversely proportional to the thermal
efficiency and inversely proportional to flue gas temperature. Excess air can enhance the
oxidation, lower the flue gas temperature. In other word, excess air must be sufficient
amount in operation the boiler to the efficient result. NOx also effected when it decreased
with the increasing excess air. (J.C. Lou,1999) The presence of excess air has a significant
increase on the thermal efficiency and directly reduce flue gas temperature. But too much
excess air will reduce the thermal efficiency as it may cause the formation NOx gases.
Increasing excess air can minimized the waste flue gases and heating rate of the boiler.
Excess air for the combustion reduce the flame temperature of the LPG, therefore
improving the heat transfer rate and production. (M. Lalovic Et Al,2006) Excess air also
increasing the combustion efficiency due to the oxygen provide larger heat.

While doing the experiment, some factors contributing to the inaccuracy of the
experiment result were insufficient amount of water flow rate. Water flow rate must higher
than 150 L/min to conduct this experiment. Then, make sure the air flow rate was suitable
to conduct a combustion in the boiler. Other factor was flue gas temperature which known
as ‘stack temperature’, fuel specification, excess air and radiation and convection losses.
 Safety aspects that need to be taken when operating the boiler is one should know
what all the buttons do. One cannot simply turn off and on a button. If one having a trouble
in operating the boiler, one should call for assistance from the lab technician. Next,
whenever operating the boiler, do not play around with your partners. This is a dangerous
act and strictly not allowed to do when operating the boiler. Later, one should be alert with
any malfunction that occurs and immediately tell to the lab technicians nearby. In all cases,
one must not try to operate or repair any malfunction on his or her own.

7.0 CONCLUSION

While it’s important to look at the efficiency of your industrial boiler equipment itself,
there are also several environmental factors that should be taken into account. The Sankey
diagram sketched gave us clear idea on performing energy analysis and calculating both
thermal and combustion efficiency. Based on flue gas analysis, we manage to identify that
Nitric Oxide and Carbon Dioxide as pollutants from LPG-burning boiler. Based on flue gas
analysis, excess air leads to lower flame temperature. That means less heat gets into the
system. Also, excess air must heat up to flue gas temperature, which consumes extra
energy. Total energy saving is affected by excess air, combustion air temperature, flue
gas temperature, cost of fuel. Lastly, the thermal efficiency is highest observed highest at
94.94% when calibrated at the lowest excess air at 9.92 %. This proves high excess air
stuns the thermal efficiency.

8.0 REFERENCES
1) FLAME TEMPERATURE AS A FUNCTION OF THE COMBUSTION, Milisav
Lalovic, Zarko Radovic, Nada Jaukovic University of Montenegro, Faculty of Metallurgy
and Technology Podgorica, Cetinjski put bb, 81000 Podgorica, Serbia and Montenegro,
2006-04-04

2) Bennett, R. &. (1977). Solving cold end boiler problems through innovative chemical
technology. In Combustion;, 48:7.
3) Shuangchen, M. J. (2017). Environmental influence and countermeasures for high
humidity flue gas discharging from power plants. Renewab
9.0 APPENDICES

CALCULATION

DATA 1

Air flow rate = 3.8g/s

̇ =222L x 1 min x 1kg =3.7 kg/s

Min 60s 1L

=0.1m3 x 1.89 kg = 1.389 kg/s

34 s m3

T= 43 ºC

X=h2
43  42 x  175.8

44  43 184.2  175.8

X= 180 kJ/kg

T= 27 ºC

X=h1
27  26 x  108.9

28  26 117.3  108.9

X= 113.1kJ/kg
HHV = (0.3)(50360) + (0.7)(49510) = 49765 kJ/kg

(3.7)(180  113.1)
ηth = x100 = 89.48%
(0.1389)( 49765)

Air flow rate = 3.6 g/s

= 3.7 kg/s

= 5.558x10-3 kg/s

T= 40 ºC

X=h2

X= 167.5 kJ/kg

T= 27 ºC

X=h1

X= 113.1kJ/kg

HHV = (0.3)(50360) + (0.7)(49510) = 49765 kJ/kg

ηth = 72.77%

Air flow rate = 3.4 g/s

= 3.7 kg/s

= 5.558x10-3 kg/s

T= 42 ºC

X=h2

X= 175.8 kJ/kg

T= 27 ºC
X=h1

X= 113.1kJ/kg

HHV = (0.3)(50360) + (0.7)(49510) = 49765 kJ/kg

ηth = 83.87%

Air flow rate = 3.2 g/s

= 3.7 kg/s

= 5.558x10-3 kg/s

T= 41 ºC

X=h2

X= 171.2 kJ/kg

T= 27 ºC

X=h1

X= 113.1kJ/kg

HHV = (0.3)(50360) + (0.7)(49510) = 49765 kJ/kg

ηth = 77.72%

Combustion efficiency,ηc = 100% - wet loss - dry loss

ηc,3.8 = 100% - 12% -26% =61.3%

ηc,3.6 = 61.85%

ηc,3.4 = 62.98%

ηc,3.2 = 63.63%
excess air (%) =measured % O2 x 100%

20.9-measured % O2

% 3.8 = 23.96%

% 3.6 = 18.68%

% 3.4 = 15.6%

% 3.2 = 7.35%

DATA 2

Air flow rate = 3.8 g/s

= 3.033 kg/s

= 5.906x10-3 kg/s

T= 41 ºC

X=h2

X= 171.65 kJ/kg

T= 27 ºC

X=h1

X= 113.1kJ/kg

HHV = (0.3)(50360) + (0.7)(49510) = 49765 kJ/kg

ηth = 60.42%

Air flow rate = 3.6 g/s

= 3.033 kg/s
 = 5.906x10-3 kg/s

T= 43 ºC

X=h2

X= 180 kJ/kg

T= 27 ºC

X=h1

X= 113.1kJ/kg

HHV = (0.3)(50360) + (0.7)(49510) = 49765 kJ/kg

ηth = 69.04%

Air flow rate = 3.4 g/s

= 3.033 kg/s

= 5.906x10-3 kg/s

T= 46 ºC

X=h2

X= 192.5 kJ/kg

T= 27 ºC

X=h1

X= 113.1kJ/kg

HHV = (0.3)(50360) + (0.7)(49510) = 49765 kJ/kg

ηth = 81.94%

Air flow rate = 3.2 g/s

 = 3.033 kg/s

= 5.906x10-3 kg/s

T= 49 ºC

X=h2

X= 205.1 kJ/kg

T= 27 ºC

X=h1

X= 113.1kJ/kg

HHV = (0.3)(50360) + (0.7)(49510) = 49765 kJ/kg

ηth = 94.94%

ηc,3.8 = 61.29%

ηc,3.6 = 62.19%

ηc,3.4 = 62.70%

ηc,3.2 = 64.03%

% 3.8 = 23.16%

% 3.6 = 22.28%

% 3.4 = 15.34%

% 3.2 = 9.94%