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Under Control
Fuel Type Fuel handling Heat Transfer Excess Air Burner momentum Emission
Outside Control
Secondary air momentum Tertiary air momentum Kiln aerodynamics Calciner aerodynamic
Combustion since is the since of exothermic chemical reactions in flow of heat and mass transfer
Gas
H2 or natural gas
Fuel : Liquid
Solid
CO2
H2O SO2
C + O2
CO2 + ( 94 kCal/mole)
2H + O2
2H2O
+ 137 kCal/mole Water condensed
G.C.V: H.H.V:
Water condensed
High heating values
N.C.V: L.H.V:
Not all of the carbon in the fuel will be oxidized to carbon dioxide but some will be partially oxidized to carbon monoxide
Carbon monoxide: Reduce the heat release from the fuel
2C + O2
2CO + O2
2CO + ( 53 kCal/mole)
2CO2 + ( 41 kCal/mole)
Natural gas requires more combustion air per kCal of heat released than most other fuels, produces more exhaust gases, smallest CO2
Physics of Combustion
Combustion Stages
Mixing
slow
Ignition
Chemical reaction
Dispersal of product
Very fast
1 Kg fuel
Or
1 Nm3 fuel
Oxygen is required Combustion equation Fuel analysis is known Air Empirical formula Heat Value is known
21% Oxygen
The kiln gas consists of : combustion products excess air of combustion false air gas from the raw meal
carbon dioxide (CO2 ) water vapor sulfur absorbed (Circulation Phenomena)
Orsat-analysis
Excess air factor n Incomplete combustion Heat consumption False air
Nm3 / kg fuel
C + O2
1 KM 12 Kg 1 KM 32 Kg 22.4 = Volume occupied by 1 Mol 12 = Molecular wt of carbon
CO2
1 KM 44 Kg
H2 + O2
1 KM 2 Kg KM 16 Kg
H2O
1 KM 18 Kg
S +
1 KM
O2
1 KM
SO2
1 KM
H2 CO CxHy +
+ +
O2 O2
( X + Y/4 ) O2
By Weight
0.232 O2 0.768 N2
By Volume
0.21 O2 0.79 N2
H4
+ O2 = 2H2O
C +
O2 = CO2
CH4 + 2 O2
(12+4) : 2 x 32
16 : 64
= CO2 + 2H2O
1 kg fuel : 4 kg of Oxygen
4 0.232
= 17.24
Kg air Kg Ch4
Nm3
CH4
2 0.21
= 9.521
Amin =
Omin 0.21
Combustion Products
CO2 , H2O , some SO2
a) Complete Combustion CO2 , H2O , N2 , & O2 excess from combustion
b) Incomplete Combustion
V min =
1.855 C
CO2
0.6841 S
SO2
Dry Combustion
Water Vapor
0.8 =
22.4 28 22.4 18
CO2
N2
0.6841 =
SO2
11.21 =
22.4 2
1.244 =
H2 O
A = n* Amin
Heat of Combustion
Heat values are determined experimentally by calorimeters in which products of combustion are cooled to the initial temperature and the heat absorbed by the cooling medium is measured
Hu =
Ho =
1 Cal = 4.18 J
Minimum Air :
Amin = 0.26 * Hu
Vmin = 0.28* Hu
Each MJ (Megajoul) burnt in the firing requires 0.26 Nm3 minimum air and produces 0.28 Nm3 minimum combustion gas.
CaO
1 kMol 56.08 kg
CO2
1 kMol 22.26 Nm3
Mg CO3
CO2 R.M = 22.26
MgO
Ca CO3
100.09
+
+
CO2
Mg Co3
84.33
Nm3Co2
Kg R.M
CO2 RC = CO2 RM
* R
Nm3Co2
Kg clinker
CO2 RC =
22.26 100
Titration
Nm3Co2
Kg clinker
kg/kg RM
R=
mw 1 - mw mw 1 - mw
18 22.4
* *
R
R
0.8038
Kg/mol Nm3/mol
0.8038 =
kg Nm3
SO2
SO3
KOH solution, (Pyrogllic acid) + Potas hydroxide KOH solution, (Pyrogllic acid) + Potas hydroxide
cuprous chloride ( Cu2Cl2) final unabsorbed gas
n
N2
Amin
N2 n= N2 min
n=
N2 - N2
excess air
0.79 0.21
= 3.762
N2 N2 - 3.762 O2
If there is CO
n=
N2
(N2 - 3.762) * (O2 - 0.5 CO)
N2
OR
n=
1
(1 - 3.762) * (O2 - 0.5 CO)
N2
Incomplete Combustion
Co2 H2 CH4
= = =
12.64 MJ /Nm3 ( 3020 kcal/Nm3 ) 10.80 MJ / Nm3 ( 2580 kcal/Nm3 ) 64.34 MJ / Nm3 ( 15370 kcal/Nm3 )
CO2 O2 CO
H2
2.016
28.15 18.016 16.031
0.0899
1.2567 -0.7168
0.0695
0.9721 -0.5545
420.75
30.12 -52.89
(from air)
H2O CH4
N2
q
CO2f 1-CO2f
q=
CO2 RC
0.79 Amin Hu CO2t 1-CO2t
CO2 RC, Nm3 / kg Cli , CO2 from raw meal Amin Nm3 / kg fuel, Nm3 / Nm3 fuel Hu MJ / kg, low heat value of fuel CO2t = CO2 content in the exit gas if not excess air were present
CO2t =
CO2 + CO
1-
O2 - 0.5 co 0.21
CO2, CO and O2 are the volume fraction of the dry gas, as obtained by the Orsat analysis. CO2f = CO2 from combustion of fuel if no excess air were present
1 V min dry
1 V min dry
CO, CO2 and CXHy are volume fraction of the gaseous fuel.
False Air
n=
Amin
The false air is the difference of the total amounts A2 of air upstream and downstream A1of the leak.
Nm3/kg Clinker
Nm3/kg Clinker