Combustion Engineering: Technical Development Program For Process Performance Engineers

Download as ppt, pdf, or txt
Download as ppt, pdf, or txt
You are on page 1of 36

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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
Agenda

 Objectives

 Basic Definitions

 Combustion Calculation

 False Air Investigation

4
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
Agenda

 Objectives

 Basic Definitions

 Combustion Calculation

 False Air Investigation

6
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
Combustion
Calculations Excess air

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

O2,dry%
Excess Air  Gasdry,combustion  raw meal 
21 %  O2,dry%
16
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
Combustion
Calculations Moisture

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 
Moisturecombustion  raw meal  M cli   0.01  0.03 q
 kg cli MJ 
17
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
Combustion
Calculations Typical exhaust gas quantities

at kiln system outlet


19
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
CC-99069.dsf / Kma 17.2.99
Agenda

 Objectives

 Basic Definitions

 Combustion Calculation

 False air investigation

21
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
False Air
Investigation
Gas Analysers

 Portable analysers

 Birrer
 TESTO
 …..

 Fix installed analysers

 Siemens
 ABB
 …

23
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
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
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21
Combustion
Calculations Gas Conversion to between Actual and Normal

36
© 2008 Holcim/Switzerland Combustion Engineering 04.06.21

You might also like