Design of Burners

Submitted To :Dr. S.A. Channiwala

Prepared By:Ramnarayan Meena Krishnat Patil Sudesh Powar Hitesh Thakare Ashish Mogra P11TD001 P11TD053 P11TD008 P11TD040 P11TD041

CONTENTS
History of Burners How does combustion occur? What is a burner? Mixing of air and gaseous fuel Characteristic features of jet Behavior of free (unconfined) and confined jet Role of primary air Degree of recirculation Selection of burner

History of Burners
History of burners dates back to early shipping days, when fuel oil first started replacing coal as the ship s primary fuel source. Since then, burner designs and construction has come a long way, but the principles behind their operation has remained the same.

 Why do we want to use Burners .. ??

Boilers Thermic fluid heaters Industrial oxidizers In drying applications

Burners - Introduction
The burner is the device used to combust the fuel with an oxidizer to convert the chemical energy in the fuel to thermal energy Specifically, it is a device used to provide a controlled exothermic oxidation reaction. However, the device itself is not consumed in the reaction. (e.g. wooden torch is not a burner.) A burner is designed to provide stable operation and an acceptable flame pattern over a specific set of operating conditions.

 To provide acceptable operation, burner must be designed to provide Five M s: Meter the fuel and air into the flame zone. Mix the fuel and air to efficiently utilize the fuel. Maintain a continuous ignition zone for stable operation over the range. Mold the flame to provide the proper flame shape. Minimize pollutant emissions.

Burner Design - Introduction

Fig. 1. Schematic of an industrial Combustion Process.

Components of Combustion System

1. Burner:It combusts the fuel with an oxidizer to release heat

2. Load:Material that will be processed.

3. Combustor (Furnace, Heater or Dryer):Inside which burner and load are located.

4. Heat Recovery Device:To increase the thermal efficiency of the overall combustion system.

5. Flow Control System:Uused to meter the fuel and the oxidant to the burners. 6. Air pollution control system:To minimize the pollutants emitted from the exhaust stack into the atmosphere

Need for Atomization

Even though fuel oil is classified as a flammable liquid, most fuels will not burn easily in a liquid state. If you were to drop a lit match in a container of fuel oil, it would PROBABLY go out almost immediately (don t try this .. !!). In order for fuel oil to burn, it must first be transformed from a liquid to a vaporised state atomised. Atomisation increases the exposure of the fuel to the oxygen in the air this promotes combustion. A nozzle rated at 0.60 US gallons/hr. can generate as many as 50 million droplets of oil in an hour.

EFFECTS OF BAD ATOMISING

If atomisation is incomplete, the droplet sizes are too large for complete combustion. The larger droplets will escape the flame only partially burnt. This can usually be seen as fire flies when looking at the flame. This will not only result in a poor flame, but also soot deposits being formed inside the combustion chamber. In addition the combustion plant s efficiency will reduce causing excessive fuel usage for the required energy output.

BURNER DESIGN FACTORS

Fuel :1. Whether liquid or gaseous fuel is used .. ?? 2. Adv of gaseous fuels over liquid fuel. 3. Need of Dual fuel burners. 2. Oxidizer 1. Predominantly, air is used as oxidizer . 2. However, problems associated with its use. 3. Preheated air and FlGR 3. Gas Recirculation 1. FuGR Technique used to induce furnace gases to be drawn into the burner to dilute the flame. 2. This dilution is accomplished to: a. minimize NOx emissions by reducing the peak temperatures in the flame. 1.

3. Gas Recirculation
1. FuGR Technique used to induce furnace gases to be drawn into the burner to dilute the flame. 1. This dilution is accomplished to:a. Minimize NOx emissions by reducing the peak temperatures in the flame b. To increase the convective heating from the flame because of the added gas volume and momentum.

BURNER COMPONENTS
Ignition System Plenums Burner Tile Controls Flame Safety System

Ignition System
important component in the burner system to ensure safe and reliable operation. Plenums:

Plenums
 It is used to homogenize the incoming gas flows to evenly distribute them to the outlet of the burner.  This is important to ensure proper operation of the burner over the entire range of operating conditions, especially at turndown.  If the plenum is too large, then the flows may be unevenly distributed across the burner nozzle outlet.  If the plenum is too small, then the pressure drop through the plenum may be excessive.

Burner tile/ block or quarl

it helps shape the flame and protects the internal parts from overheating. In the majority of designs, the burner tile is made of some type of ceramic that often contains alumina and silica, depending on the temperature requirements. There may be holes through the tile to enhance mixing of furnace gases with the gases fed into the burner. The tile may have bluff body components that enhance flame stability.

flame safety system

critical to the safe operation of the combustion system. include some type of flame scanner or flame rod to ensure that either the burner or the pilot is operating. These are connected to the fuel supply system so that the fuel flow will be stopped if the flame goes out to prevent a possible explosion for unignited fuel gases contacting a hot surface somewhere in the combustor

Calculating the Heat Release from a Burner HR = mf x HV

where, HR is the heat release of the burner, mf is the mass flow rate of the fuel, and HV is the heating value of the fuel.

Concept of Sonic & Subsonic Flow

Equations for Calculating Fuel Flow Rate

Step I:Determine if orifice is operating above or below the critical pressure. Critical Pressure ratio is given as:

2 Pc ! k  1
where

k /( k 1)

Pc = critical pressure ratio k = ratio of specific heats of the fuel.

 If Pc > (Pb / Pt), then the fuel exits the orifice at Sonic conditions.  If Pc < (Pb / Pt), then the fuel exits the orifice at Subsonic conditions. where, Pb = atmospheric pressure Pt = fuel pressure in absolute, respectively.

Continued ..
Step II:- Determine the mass flow rate of the fuel through the orifice. If the fuel exits the orifice at sonic conditions:-

Cd Pt g c A (1 2 ) 2 vk v mf ! k  1 (Tt Ru g c / MW )
If the fuel exits the orifice at subsonic conditions:-

k 1 2 ( k 1)

m f ! cd V e AM e ce
Me !
k 1 P k 2 t  1 k  1 P b

where

P b Ve ! Te Ru MW
The subscript e denotes the orifice exit, Me = Mach number of the fuel, Te = Temperature of the fuel, Ce = Speed of sound in the fuel, and = Density of the fuel. e

Tt Te ! k 1 2 1 Me 2

kTe Ru Ce ! MW

1 2

Atmospheric Gas Burners

Based on Bunsen Burners. Components: Fixed Orifice, Spud Controllable shutter for air supply, Venturi shaped mixing tube Burner head with ports drilled in it.

Fig. Atmospheric Gas Burner

Design Data for Simple Aerated Burners

Gas flow rate through the orifice

(p.P V ! 83,240 v Cd v A v TS
where,

..(1)

V = gas flow rate, Nm3/h Cd = Coefficient of Discharge, = 0.8 to 0.9 for fixed tubular orifice or spud A = Orifice Area, m2

(p ! pressure drop at the orifice, cm H 2O

P = initial gas pressure, cm Hg abs. T = gas temperature, K S = specific Gravity of Gas, (for air S=1)

Empirical Relation for Aeration Capacity of Burner

4 A A PS 300 m p 6 v 5 v 10 v v PA ! T CN Q 4

..( 2)

Where, PA = primary air, per cent of theoretical air P = gas pressure at orifice inlet, cm wg CN = net CV of gas, kcal/Nm3 Am = average area of mixing tube, m2 = (A1+A2)/2 A1 = throat area, m2, A2 = area of mixing tube outlet, m2. Ap = total port area, m2, Q = Heat input rate, kcal /h.

Primary air requirement:For water heaters, furnaces:A. if long flame is permitted 35-40% with NG and manufactured gases. 55% with LPG. B. For Radiant Heaters 65% C. Cooking Ranges 55-60%

Other Design Data

 Throat to total port area ratio  Air shutter area  Length of mixing tube  Slope of mixing tube  Area of burner head  Burner output rate is given by, = 0.2 to 1.0 = 1.25 to 2.25 times total port area

 Distance from gas orifice to throat = 0.5 to 2 times throat diameter = 6 times throat diameter ~ 3o = 1.5 to 2 times total port area.

Q ! LVC N where,L ! coefficient of combustion efficiency

Continued
Combining eq. (1) & (3), we get,

CN Qw S
Also, from eq. (2), we have for primary air supply,

PA w

1 CN S
0.5

CN where, the ratio is known as Wobbe index. S

It is a useful parameter in assessing the interchangeability of gases with respect to the aerated burners.

Oil burners

Fig. Main Components of Typical Furnace Oil Burner

 An oil burner is a heating device which burns fuel oil. The oil is atomized in to a fine spray usually by forcing it under pressure through a nozzle. This spray is usually ignited by an electric spark with the air being forced through by an electric fan.

Components
Fuel injection Oil pump Electromagnetic valve Fan Ignitors Photocell Capacitor start motor Order for starting an oil burner

 Oil burners consist of

an air register to control the combustion air flow and a means of stabilising the flame and the atomiser,

Figure 5.19 . An igniter may also be provided to assist start-up.

Pressure jet atomisers

The drop size produced by a pressure jet atomiser is strongly dependent on the fuel viscosity and the surface tension. Radcliffe developed an empirical expression for estimating the SMD ( Lefebvre 1989 ). Normally oil supply pressures of 3.5 MPa (500 psig) and above are needed with large burners utilising heavy fuel oil. The inner atomiser, usually known as the pilot, has a low capacity, typically 25 to 30% of full load while the outer, or main, atomiser carries 70 75% of full load.

Schematic and exploded view of duplex wide turndown pressure jet atomiser

 The drop size produced by a pressure jet atomiser is strongly dependent on the fuel viscosity and the surface tension. Radcliffe developed an empirical expression for estimating the SMD ( Lefebvre 1989 )

SMD ! 7.3W R m
0.6 0.2
where

0.25

(p

( 0.4 )

micron

= surface tension (N/m) = viscosity (m2 /s) m = mass flow (kg/s) p = differential pressure drop across atomiser (Pa) . Viscosities should be in the range 15 20 cSt for satisfactory atomisation.

THANK YOU
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