INDUSTRIAL ENERGY EFFICIENCY PROJECT TRAINING Module: Fuels & Combustion

Fuels for Industrial applications

Liquid fuels like Furnace Oil, IDO, etc

Fuels for Industrial application s

Solid fuels like Coal, Bio mass, etc

Gaseous fuels like Natural gas, LPG, etc.

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Selection of Fuels

Availability

Criteria for Selection of fuels for Industrial applications

Storage & Handling Pollution Cost of Fuel Fuel properties

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Properties of Fuels
Density
Ratio of mass of fuel to volume of fuel at a reference temperature (Typically 15 0C) Unit of Density: Kg/m3 Density of the fuel relative to that of water. Unit of Specific gravity: Ratio & hence no units Examples: Specific gravity of IDO: 0.85-0.87 Specific gravity of Furnace Oil: 0.89-0.95 A measure of internal resistance to flow. Measured in terms of Stokes/Centistokes, Engler, Saybolt or Redwood seconds

Specific Gravity

Viscosity

Viscosity

Temperature
Influences the degree of pre-heat required for handling, storage and satisfactory atomisation
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Properties of Fuels
Flash Point
The lowest temperature at which the fuel can be heated so that the vapour gives off flashes momentarily when an a open flame is passed over it. Ex. Flash point for furnace oil is 660c The lowest temp. at which it will pour or flow when cooled under prescribed conditions. It is a very rough indication of the lowest temp. at which fuel oil is readily pumpable. It is the amount of kcals needed to raise the temperature of 1 kg of oil by 1oC.

Pour Point

Specific Heat

The unit of specific heat is kcal/kgoC. Varies from 0.22 to 0.28 depending on oil specific gravity. It helps to quantify how much steam or electrical energy required for preheating.

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Properties of Fuels
Calorific value is the measurement of heat or energy produced and is measured either as gross calorific value or net calorific value. Carbon Hydrogen Sulphur Moisture Water Vapour Water Vapour

Water vapour

Calorific Value

GCV 10,500 Kcal/kg NCV 9800 Kcal/kg The difference being the latent heat of condensation of the water vapour produced during the combustion process.
Typical Gross Calorific values of some of commenly used fuels Fuel Kerosene Diesel Oil IDO Furnace Oil Low Sulphur Heavy Stock Indian Coal GCV, Kcals/Kg 11,100 10,800 10,700 10,500 10,600 3,500-6000
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Properties of Fuels
Depends mainly on the source of the crude oil and to a lesser extent on the refining process. The normal sulphur content for residual fuel oil (heavy fuel oil) is in the order of 2-4 %.
Typical Sulphur content figures of Fuel Oil Fuel % Sulphur Kerosene 0.05-0.2 Diesel Oil 0.3-1.5 IDO 0.5-1.8 Furnace Oil 2.0-4.0 Low Sulphur Heavy Stock <0.5

Sulphur Content

Risk of Corrosion
Cold end corrosion in cool parts of the chimney or stack, air pre-heater and economiser. Carbon Hydrogen Sulphur Moisture SO2 SO3 SO3

H2SO4

Water Vapour SO2 SO3 Water Vapour SO3 SO2

Water vapour
H2SO4

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Properties of Fuels
Ash content depends on the inorganic material in the fuel oil. These salts may be compounds of sodium, vanadium, calcium, magnesium, silicon, iron, aluminum, etc.

Ash Content

Typically ash values are in the range of 0.03 0.07 %. Excessive ash values in liquid fuels can cause fouling deposits in the combustion equipment. Ash has erosive effect on the burner tips, causes damage to the refractories at high temperatures and give rise to high temperature corrosion and fouling of equipments. Indicate the tendency of oil to deposit a carbonaceous solid residue on a hot surface, such as a burner or injection nozzle, when its vapourisable constituents evapourate. Residual oil contain carbon residue ranging from 1% or more

Carbon Residue

Distillate Residue
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Properties of Fuels
Water contents of furnace oil when supplied is normally very low as the product at refinery site is handled hot and maximum limit of 1% is specified in the standard. Water may be present in free or emulsified form

Water Content

Water can cause damage to the inside of furnace surfaces during combustion especially if it contains dissolved salts It can also cause spluttering of the flame at the burner tip, possibly extinguishing the flame and reducing the flame temperature or lengthening the flame
Typical Specifications of Fuel Oils IDO FO125 FO180 FO280
0.985 66 21-24 10287 0.15 4 0.75 10287 0.15 3.5 0.75 0.985 66 21-24 10287 0.15 4 0.75 0.985 66 66 12 12-15 10718 0.02 1.8 0.25 0.02 0.45

Typical specificat ions of fuel

Density, Kg/L at 15 Deg. C Flash Point, Deg C Pour Point, Deg C GCV, Kcals/Kg Sediment, % Wt. Max Sulphur, % Wt. Max Water content, % Vol. Max Ash, % Wt. Max Carbon Residue, % Wt. Max

0.915

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Storage of Fuel Oil

Hazardou s Stored in Cleaning of Tanks Leaks
To store furnace oil in barrels. Cylindrical tanks - either above or below the ground. Annually for heavy fuels & every two years for light fuels. From joints, flanges and pipelines must be attended at the earliest. LOSS OF EVEN ONE DROP OF OIL EVERY SECOND CAN COST OVER 4000 LITERS AN YEAR. Approximately 80,000 KSh/Year

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Removal of Contaminants
Fuel Oil should be free from contaminants such as dirt, sludge and water before it is fed to the combustion system

Coarse Strainer Finer Strainers

To prevent contaminants such as cotton waste, loose nuts or bolts entering coarse strainer of 10 mesh size (not more than 3 holes per linear inch) is positioned on the entry pipe to the storage tanks. To prevent finer contaminants such as dust and dirt, sludge or free carbon, filters are provided in duplicate to enable one filter to be cleaned while oil supply is maintained through the other

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Pumping fuel Oil

Heavy Fuel Oils IDO
Best pumped using positive displacement pumps Circulation gear pumps are suggested (7000-10000 Hours service) Diaphragm pumps have a shorter life, but are easier and less expensive to repair

Centrifug al pumps Light fuels

High pressure applications

Generally not recommended for heavy fuels, because as the oil viscosity increases, the efficiency of the pump drops sharply and the horse power required increases
Best pumped with centrifugal or Turbine pumps

When higher pressures are required, piston or diaphragm should be used

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Heating of Oil for Pumping

Preheating of Oil in the storage tank is necessary to make it pumpable Entire tank may be preheated In this form of bulk heating, steam coils are placed at the bottom of the tank Advisable to insulate the tank where bulk heating is used Bulk heating is necessary, if flow rates are very high.

Oil may be heated as it flows out with an outflow heater Outflow heater is essentially a heat exchanger with steam or electricity as the heating medium

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Agro Residues & their Properties

Composition of some Agro Residues DeOiled Paddy Saw Coconut Bran Husk Dust Shell 7.11 19.77 36.59 4.15 0.82 0.54 31.02 3151 10.79 16.73 33.95 5.01 0.91 0.09 32.52 3568 37.98 1.63 48.55 6.99 0.8 0.1 41.93 4801 13.95 3.52 44.95 4.99 0.56 0.08 31.94 4565

Item

Moisture, % Mineral Matter, % Carbon Hydrogen, % Nitrogen, % Sulphur, % Oxygen, % GCV, Kcals/Kg

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COMBUSTION
A chemical reaction during which a fuel is oxidised and a large quantity of energy is released. High speed, high temperature chemical reaction. Rapid union of an element or compound with oxygen to liberate heat controlled explosion. Combustion occurs when elements of fuel such as carbon and hydrogen combine with oxygen.

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Chemical reaction in Combustion

Stoichiom etric or Theoretica l air

Ideal amount of air required for burning I Kg of Fuel

Eg: 1 Kg of Fuel Oil requires 14.1 Kg of air for complete combustion

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3Ts of Combustion
All combustion requires sufficient time which depends upon type of reaction.

Time

3Ts

Temperatur e

Temperature must be more than ignition temperature

Turbulence

Proper turbulence helps in bringing the fuel and air in intimate contact and gives them enough time to complete reaction
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Types of Combustion
Perfect Combustio n
Achieved when all the fuel is burned using only the theoretical amount of air, but perfect combustion cannot be achieved in practice. Achieved when all the fuel is burned using the minimal amount of air above the theoretical amount of air needed to burn the fuel. Complete combustion is always our goal. With complete combustion, the fuel is burned at the highest combustion efficiency with low pollution and energy loss.

Good/ Complete Combustio n

Incomplete Combustio n

Occurs when all the fuel is not burned, which results in the formation of soot and smoke.

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Combustion of Fuel Oil

Viscosity of 100 Redwood secs I at burners Atomising air 13 kg/cm2 (about 2% of total air requirement)
14 kg of air/kg fuel is required for complete combustion. Optimum efficiency with 10% excess air)

Flue gas should be analysed for CO2 or O2 Sulphur dew point at 160 300C below dew point.
0C.

Corrosion max. at

Slightest damage to burner tip may increase fuel consumption by 10 15% and hence worn out tips should be replaced immediately.

Oil pressure at burner should be 17 20 kg/cm2 Correct flame is normally short. Impingement on wall, tubes cause carbon formation
Too short a flame indicates excess air and air supply to burners should be adjusted for light haze brown out of chimney
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Burners
Burners Convert fuel oil into millions of small droplets process called atomisation

Surface to Volume Ratio

Basic type of Burners

High surface to volume ratio in oil to facilitate evaporation and combustion

3 basic types of burners are pressure jet, air or steam blast burners and rotary cup.

Turn Down Ratio

TURNDOWN ratio is the relationship between the max. and min. fuel input without affecting the excess air level. For example, a burner whose max. input is 250, 000 Kcals and min. rate 50, 000 Kcals, has a Turn-down Ratio of 5 to 1
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Pressure Jet Burner

Simple, inexpensive and widely used. Oil pumped at pressure through a nozzle Good efficiencies at lower loads. Low turndown ratio of 2 : 1

High oil pre-heat required for atomisation.

Prone to clogging due to dirt in oil requires fine filtration.

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Pressure Jet Burner

Spray at 10 psi pressure

Spray at 100-psi pressure

Spray at 300-psi pressure

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Air or Steam Blast Burner

High Turndown ratio of 4 :1. Good control of combustion over wide range Good combustion of heavier fuel oil Additional Energy required as steam or compressed air for atomisation

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Burner Controls
ON-OFF Burner firing at either full rate or OFF

High/Low/ Off

Burner operates at slow firing rate and full firing rate as per load

Modulating Type

Firing rate matches the boiler load.

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Combustion Inefficiencies
Flue gas Deficiency of Air H2O H2 CO Air Unburnt Fuel Soot

O2

CO2

N2 Fuel

N2

=
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Combustion Inefficiencies
Too much of Air Flue gas

Air O
2

H2O CO2

Excess O2

Excess O2

N2 Fuel

N2

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Combustion Inefficiencies
Stoichiometric Air

Air O2

Flue H2O CO2

N2 Fuel + =

N2

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Combustion Inefficiencies
Operating in this Zone results in wasted fuel
Zone of max. Combustion Efficiency

Operating in this Zone results in Excess heat loss up the stack

Air

Air

Air

Decrease

Unburnt Fuel Loss

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Increase Excess Air Loss

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CO2 & Excess Air

100 90 80

Excess air %

70 60 50 40 30 20 10 0 8.4 9 10 11 12 13 14

Carbon dioxide %

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Residual O2 & Excess Air

250

200

Excess air (%)

150

100

50

0 1 7 8 9 10 11 12 13 14 15 Oxygen (%) Relation between residual oxygen and excess air 2 3 4 5 6

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Effect of Excess air on CO2

Carbon di oxide in flue gas (%) when excess air is (%)

Fuel

10

20

40

100

Natural gas

12.0

10.7

9.8

8.3

5.7

Distillate oil

15.2

13.8

12.5

10.7

7.4

Residual oil

15.8

14.1

12.9

11.0

7.6

Anthracite coal

19.8

18.0

16.5

14.1

10.0

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Draft
Draft Function of draft is to exhaust the products of combustion into the atmosphere. Natural Draft : It is the draft produced by a chimney alone. It is caused by the difference in weight between the column of hot gas inside the chimney and column of outside air of the same height and cross section

Mechanical Draft: It is the draft artificially produced by fans. (Three basic types)

Balanced Draft: Forced-draft

fan pushes air into the furnace and an induced-draft fan draws gases into the chimney thereby providing draft to remove the gases from the boiler. (0.05 to 0.10 inch of water gauge below atmospheric pressure)

Induced Draft: Fan provides

enough draft for flow into the furnace, causing the products of combustion to discharge to atmosphere. Furnace is kept at a slight negative pressure below the atmospheric pressure
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Forced

This system uses a fan to deliver the air to the furnace, forcing combustion products to flow through the unit and up the stack
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Draft: