3150360 Study of Combustion Process[1]

8/2/2019 3150360 Study of Combustion Process[1]

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Study of combustion process - Boilers

STUDY OF COMBUSTION PROCESS BOILERS

A Mini-Project ReportSubmitted In Partial Fulfillment Of

The Requirements For The Award Of The Degree Of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

Submitted

By

Mr. D. Venkata Suresh

Mr. Srinivas Balakrishnan Mr.CH. PranayajoshiMr. Sudhakar Mr.T. Sivaji

Under Estimated Guidance ofSri.Ch. Venkata Prasad (M.Tech)

Department of Mechanical Engineering

St.Anns College of Engineering and Technology(Affiliated to Jawaharlal Nehru Technological University)

Chirala 523155

St.Annscollage of Engineering & Technology


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ACKNOWLWDGEMENT

It is my bounded duty to acknowledge my gratefulness to the people whohave helped me directly or indirectly to prepare this project.

I am extremely thankful to Sri. K. Satyanarayana C.A general manager, for

his kind cooperation by giving valuable suggestions and continuous support

during the course of the project.

At the outset I wish to record my gratitude to Sri. P. Uma Maheswar Rao,

the production development manager of CAPOL, for his encouragement andvaluable support.

I express my sincere thanks to Sri. CH. Venkata Prasad, our project guide at

SACET, vetapalem, for giving continuous support in the period of project.

Also I am very much thankful to the in charges of the plant and the staff who

have cooperated with me.

(D. VENKATA SURESH)



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DECLARATION

I, D. VENKATA SURESH, here by declare that the project work titledSTUDY OF COMBUSTION PROCESS BOILERS is on my own effort.

This project report is submitted in partial fulfillment of requirements of the

award of the degree of Bachelor of Technology in Mechanical Engineering from

JNTU.

I also declare that this project report is a result of my own effort and I havenot submitted to any other university for the award of any other degree or

diploma.

Date:

Place:

(D. VENKATA SURESH)



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ABSTRACT

The combustion calculations play an important role in STUDY OFCOMBUSTION PROCESS. Combustion calculations by the designer are one

of the first step in proportioning the steam generator. The scope of these

calculations would include the determination of thermal efficiencies of the boiler,economizer the calculation of air and gas weights.

Combustion calculations were done as per the existing conditions in

CAPOL( CORAMANDAL AGRO PRODUCTS & OILS LTD.), Jandrapeta,

Chirala. Heat balance sheet is prepared for the obtain results.



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CONTENTS

COAL

Introduction

Fuel for combustion

Analysis of coal

COAL BURNING METHODS

Classification of coal burning methods

Pulverized fuel firing

Pulverized fuel and handling system

Unit system

Central or Bin system

COMBUSTION

Combustion equipment for steam boilers

The basic requirements of combustion equipment

Combustion for solid fuels selection considerationTypes of combustion

Stages of combustion

Temperature profile of pulverized coal combustion

Combustion reaction

Combustion of fuel

Combustion losses

Practical combustion

Fuels and corrosion

COMBUSTION CALCULATIONS

Data collection

Solution

Heat balance sheet

CONCLUSION



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INTRODUCTION

Combustion consists of process causing chemical reaction between the

combustible part of a fuel and oxygen, with a view to generate heat the products

formed as a result of process is CO2, CO and water vapor. CO2 is the result of

complete combustion of carbon whereCO is a result of incomplete combustion,

as compared to CO2, contains only half the amount of oxygen for unit weight of

carbon the oxygen for combustion is supplied from air which from combustion

considerations contains 21% oxygen and 79% of nitrogen by volume. Industrially

good combustion aims a producing maximum amount of heat by resulting from

combustion. The products of combustion, called flue gases, contain CO2, water

vapor, nitrogen and compounds of sulphur like SO2 and SO3.

The phenomenon of combustion may be considered in its chemical and

technical aspects. Besides the fuelsize, rate of firing, supply of primary air,secondary air and moisture content in coal also greatly affect the combustion



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FUEL FOR COMBUSTION (COAL)

Coal is the oldest fuel and still used on large scale throughout the world for

power generation. It has sustained most of our combustion activity until oil was

struck and even now continues to be a major source of energy.

In India, coal is the only source of power generation, and will play very

important role in coming years.

ANALISYS OF COAL

The classification of coal is based upon the physical and chemicalcomposition of the coal and it is there fore necessary to study about the chemical

composition of the coal.

The common tests, which are used to find the constituent value of the coal, are

proximate analysis and ultimate analysis of the coal.

Proximate analysis

The proximate analysis of the coal gives the composition of coal in respect of

moisture, volatile matter, ash and carbon. The proximate analysis of most coals

indicates the following ranges of various constituencies:

CONSTITUENTS PERCENTAGE

Moisture 3 to 30%

Volatile Matter 3 to 40%



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Ash 2 to 30%

Fixed Carbon 16 to 92%

The constituents given by the proximate analysis mostly decide the adoption of

coal and design of power plant. The role played by each constituent in adapting

coal for power plant is discussed below

Moisture

All coal contains some percentage of moisture and generally varies

from 1 to 40%.The moisture in the coal exists in two forms as inherent and

free moisture. The inherent moisture is the combined moisture and is held

in the ores of the coal. The percentage of inherent moisture is determined

by heating the coal to 1100 C in the current nitrogen. The inherent moisture

is never removed from the coal used for power plants, it is costly

procedure. The free moisture is defined as moisture present in the coalwhich can be removed just by exposing the coal to the natural airflow or by

drying with the help of air of 500.

Volatile Matter

The volatile matter present in the coal maybe as high as 50%. The

volatile matter present in coal may be combustible gases such as methane,

hydrogen, carbon monoxide and other hydrocarbons or incombustible gaseslike CO2 and N2. The presence of incombustible gases is always undesirable

as they do not add in heat value but increase the volume of furnace

required. Overall, the volatile undesirable as they do not add in heat value

but increase the volume of furnace required. Overall, the volatile matters

affect the furnace volume, and arrangement of heating sufaces.

Ash



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Ash is another most undesirable constituent of coal. The ash present in

the coal is of two forms as fixed ash and free ash. The fixed ash present in

the coal comes from the original vegetable matter and it cannot beremoved

from coal before burning the coal

COAL BURNING METHODS

The efficient combustion of fuel in the combustion chamber and efficient

transfer of heat energy to the water for steam generation are essential for

economical working of the boiler. The two commonly methods for burning coalare stoker firing and pulverized firing. The pulverized firing method is used for

pulverized coal. The selection of firing method adopted for a particular boiler

depends upon the following factors:

The characteristics of the available coal.

Capacity of the plant.

Load actor of the boiler

Nature of load fluctuation and Reliability and efficiency of various combustion equipments available.



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CLASSIFICATION OF COAL BURNING METHEDS

The classifications of the combustion system used for coal burning is given

below:

PULVERIZED FUEL FIRING

In pulverized fuel firing system the coal is reduced to fine particles with the

type of grinding mill and then projected into the combustion chamber with the

help oh air current. The amount of air required to complete the combustion is

supplied separately to the combustion chamber. The resulting turbulence in the

combustion chamber helps for uniform mixing of fuel and air and through

combustion. The amount of air which is used to carry the coal and to dry it beforeentering into the combustion chamber is known as primary air and the amount



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of air which is supplied separately for complete the combustion is known as

secondary air.

The efficiency of the pulverized fuel firing system mostly depends upon

the size of the powder. The fineness of the coal should be such as 70% of it

would pass through a 200 mesh sieve and 90% through 50 mesh sieve.

Advantages

Any grade of coal can be used since coal is powder before used.

The rate of feed of the fuel can be regulated properly resulting in the fuel

economy

Since there is almost complete combustion of the fuel there is increased the

rate of evaporation and higher boiler efficiency.

Greater capacity to meet peak loads.

The system is practically free from sagging and clinkering troubles.

No stand by losses due to banked fires.

Practically no ash handling problems.

No moving part in the furnace is subjected to high temperatures.

This system works success fully with or in combustion with gas and oil.

Much smaller quantity of air is required as compared to that of stroke

firing.

Disadvantages

High capital cost



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Lot of fly ash in exhaust, which makes the removing of fine dust

uneconomically

The possibility of explosion is more as coal burns like gas.

The maintenance of furnace is brick work is costly.

Special equipment is needed to start the system.

PULVERIZED FUEL HANDLING SYSTEMS

Two methods are in general use to feed the pulverized fuel to the combustion

chamber of the boiler. First is unit system and second is central or bin

system.

In unit system, each burner of the plant is fired by one or more unit pulverizes

connected to the burners, while in the central system, the fuel is pulverized in the

central plant and then distributed to each furnace with the help of high pressure

air current. Each type of fuel handling system consists of crushers, magnetic

separators, driers , pulverizing mills, storage bins, conveyors and feeders.

The arrangement of deferent equipments required in both systems is shown in

the figure:



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The coal received by the plant from the mine may vary widely in sizes. It is

necessary to make the coal of uniform size before passing the pulverizer for

efficient grinding. The coal received from the mine is passed through a

preliminary crusher to reducer the size to allowable unit (30mm). the crushed

coal is further passed over magnetic separator, which removes pyrites and tramp

iron.

Unit system

In a unit system, each burner or a group of burners and a pulverizer constitute a

unit. Crushed coal is fed to the pulvorizer through a feeder at a variable rate

governed by the combustion requirements of furnace and steam generating rate

required in the boiler. The arrangement of unit systems is shown the figure. Hot

air or fuel gases are passed through a feeder to dry the coal before feeding to thepulverizer. The pulverized coal is carried from the mill with the help of primary



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air fan as shown in the figure. This further carries the coal through short delivery

pipe to the burner. The secondary air is supplied to the burner before entering the

fuel in the combustion chamber as shown in the figure. A plant feeding 1 tone of

pulverized fuel per hour consumes approximately 10 to 15 kwhr.energy.

The advantages and disadvantages of unit system over central are listed

below:

Advantages

It is simple in lay out and cheaper than central system.

The coal transportation system is simple.

It allows direct control of combustion from the pulverizer.

The maintenance of charges are less, as spares required are less.

Coal which requires drying for satisfactory function of the central

system is generally supplied without drying in the unit system.

Disadvantages



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The advantages and disadvantages of unit system our central are listed

below:

Advantages

The central system is flexible and changes can be made to accommodate

quick changes in demand. There is always a supply of fuel available in

reserve in the boiler bunkers. Since any mill can be used to supply any

boiler, the outage of parts of the mills or even a short outage of entire

pulverizing plant will not cause a boiler plant outage.

There is greater degree of flexibility as the quantity of fuel and air can be

separately controlled.

The pulverizer always runs at its rated load irrespective of the load on the

plant, therefore its power consumption per ton of coal crushed per hour isless.

Burners can be operated independently of the operation of the coal

preparation.

Disadvantages

Central system is higher in first cost and occupies a large space.

There is possibility of fire hazard due to the coal pulverized coal.

Dryers are essential

COMBUSTION

The object of combustion with reference to the furnaces is to provide

orderly and uniform production of it to be transmitted to a heat absorbing

medium. One of the most important items is that the correct amount of oxygen

must be supplied per unit weight of the fuel burned to provide complete

combustion. In addition to the correct air-fuel mixer time must be allowed for



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complete mixing and burning and the furnace temperature must be such as to

support combustion.

The fuels used are hydrocarbons. The fuels appear in the forms solid, liquid

and gas. Chemically the hydrogen of the fuel and the oxygen of the air form

water, and the carbon and the oxygen form carbon dioxide and sometimes carbonmonoxide. These oxidation processes, when accompanied by rapid liberation of

heat are known as combustion. To start combustion the hydrocarbons and the

oxygen must be brought to certain minimum ignition temperature.

COMBUSTION EQUIPMENT FOR STEAM BOILERS.

The combustion equipment is a component of the steam generator. Since thesource of heat is the combustion of a fuel, a working unit must have, whatever,

equipment is necessary to receive the fuel and air, proportioned to each other and

to the boiler steam demand, mix, ignite and perform any other special

combustion duties, such as distillation of volatile from coal prior to ignition.

The fuels are mainly bituminous coal, fuel oil and natural gas mentioned

in order of importance. All composed of hydrocarbons and coal has as well

much fixed carbon and little sulphur to burn these fuels to the desired endproducts CO2 and H2O requires:

Air in sufficient proportions.

A good mixing of fuel and air.

A turbulence or relative motion between fuel and air.

The combustion equipment must fulfill these requirements and in addition,

be capable of close regulation of rate of firing the fuel for boilers which



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ordinarily operate an variable load coal firing equipment must also take a

means for holding and discharging the ash residue.

THE BASIC REQUIREMENTS OF COMBUSTION EQUIPMENT

Through mixing of fuel and air.

Optimum fuel air ratios leading to most complete combustion

possible maintained over full load range.

Ready and accurate response of rate of fuel feed to load demand.

Continues and reliable ignition of fuel.

Practical distillation of volatile components of coal.

Adequate control over point of formation and accumulation of ash,

when the coal is the fuel.

COMBUSTION EQUIPMENT FOR SOLID FUELS SELECTION AND

CONSIDERATION:

While selecting the combustion equipment for solid fuels the following

considerations should be taken into account.

Initial cost of the equipment. Sufficient combustion space and its ability to with stand high flame

temperature.

Operating cost.

Minimum smoke nuisance.

Arrangements for through mixing of air with fuel for efficient

combustion

TYPES OF COMBUSTION

Based upon the type of fuel combustion can be divided into two types.

1. Homogenous combustion

2. Heterogeneous combustion

HOMOGENOUS COMBUSTION



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Combustion of gaseous fuel atomized liquid fuel is called homogenous

combustion.

The rate of homogenous combustion at constant temperature at any particular

moment is the product of the concentration of the reacting species.

r = K x Cxfuel x Cyo2

where k is the rate constant which depends on the temperature and chemical

nature of the reagents.

C fuel = concentration of fuel

C02 = concentration of oxygen

x , y are the mole of fuel and oxygen involved in the stoichiometric chemicalequation.

HETROGENOUS COMBUTION

The combustion of solid fuel is called heterogeneous combustion. In

heterogeneous combustion the concentration of combustible substance is

constant and hence the rate of this relation is dependent only on the concentration

of oxygen on the surface of the solid fuel.

r = K. Cso2

where Cso2 concentration of oxygen on the fuel surface.



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COMBUSTION CALCULATIONS

Data collection:

Coal consumption : 0.375 tons/hr

Steam produces : 2 tons/hr

Boiler operating conditions:-

Steam pressure = 10 barSteam temperature = 179.90 C

Economizer :

Water temperature = 380 C

Flue gas temperature =250 C

Boiler house temperature = 370 C



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COAL ANALYSYS (BY WEIGHT)

CONSTITUENT PERCENTAGE (%)

C 62.5H 4.25

O 5.11

N 1.2

S 0.82

ASH 9.85

MOISTURE 16.24

TOTAL 100

FLUE GAS ANALYIS (BY VOLUME)

CONSTITUENT PERCENTAGE (%)

CO2 13.2

O2 4.85

N2 81.95

TOTAL 100

Gross caloric value = 30550 kj/kg

Boiler house temperature = 370 C

= 310k

SUBTANCES SPESIFIC HEATS [Kj/Kg]

Dry flue gas......... 1.005



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Water vapor in flue gas 2.095

Water 4.187

Solution :

Theatrical air requirement:

Basis : 100 kg coal

Constituent

Element

Percentage

By weight

Molecular

Weight

K Mol K mole of O2required for

combustion

C 62.5 12 5.208 5.208H 4.25 2 2.125 1.625

O 5.11 32 0.159 -0.159

N 1.2 28 0.042 .

S 0.85 32 0.027 0.027

ASH 9.85 .

MOISTURE 16.24 .

TOTAL = 6.1385

There, theatrical air requirement

= 6.1385(100/21)/ kg of coal

= 29.23 kmol/100 kg coal

= 29.23 (28.9) kg/kg coal

( 28.9 is the average molecular weight of air)

= 844.744 kg/kg coal

= 8.447 kg/kg coal

Actual air supplied:

100 kg coal contains 5.208 kmol of C.100 kmol of flue gas contains 13.2 kmol of C.



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Therefore the amount of flue gas produced,

= 5.208 (100/32) kmol/ 100 kg of coal

= 39.45 kmol/ 100 kg of coal

Let x mol of air be supplied per 100 kg of coal burnt.Therefore by nitrogen balance we get,

79x/100 + 0.042 = 81.95/100 (39.45)

x = 40.87 kmol/100kg coal

therefore the weight of air supplied

= 40.87 (28.9) kg/100kg of coal

= 1181.14 kg/100kg coal= 11.81 kg/kg coal

Excess air :

= actual air supplied theatrical air supplied x 100

Theatrical air supplied

= (11.81 8.447)(100/8.447)

= 39.81%.

WEIGHT OF FLUE GAS:

FLUE GAS

CONSTITUENT

KMOL MOLECULAR

WEIGHT

WEIGHT WEIGHT IN 39.45KMOLE OF FLUE

GAS

CO2 13.2 44 13.2 (44) 13.2(44)x39.45/100= 229.125

O2 4.85 32 4.85 (32) 4.8(32) x 39.45/100= 61.226

N2 81.95 28 81.95 (28) 81.95(28)x39.45/100= 905.219

TOTAL 1195.57



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Water produced due to combustion of hydrogen content of coal

= 2.125 kmol= 2.125 (18) kg

= 38.25 kg

Free moisture = 16.24 kg

Therefore the total weight of flue gas

= 119.57 + 38.25 + 16.24

= 1250.06 kg/100kg coal

= 12.50 kg/kg coal



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Thermal Efficiencies

1) Boiler :

Total heat content of steam at 10 bar

= 2776.2 kj/kg

Total content of feed water charged to boiler

= 4.187 x 38

= 159.106 kj/kg

The net heat transferred to the steam

= 2776.2 159.106

= 2617.094 kj/kg

The rate of steam generation/t of coal =

2 ton/hr

0.375 ton/hr= 5.33 t/t of coal

The heat transferred to steam / kg of coal burned

= 5.33 x 2617.094

= 13949.11 kj/kg

Gross calorific value of coal as fired

= 30550 (100-16.24)/100= 25588.68 kj/kg of coal

Thermal efficiency of the boiler

= 13949.1 / 25588.68

= 0.5451

= 54.51%



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ECONOMIZER

Net heat transferred to the boiler feed water

= 5.33 x 4.187 x 38

= 848.03 kj/kg

Thermal efficiency of the economizer

= (848.03 / 25588.68) 100

= 3.31%

HEAT LOST TO THE DRY FLUE GAS

Weight of the dry flue gas

= 11.95 kj/kg of coal

Enthalpy of the dry flue gas= 11.95 x 1.005 (523.15 310.15)

= 2558.076 kj/ kg

The percentage of heat lost to the dry flue gas

= (2558.076 / 25588.68) 100

= 10%.

HEAT LOST TO THE WET FLUE GAS

Water content in the flue gases when 100 kg of coal burnt

=38.25+16.24

=54.49kg/100kg coal

The weight of water vapor per kg of coal burnt

= 0.5449 kg/ kg coal



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Fluegas

Constituent

Kmol % composition

CO2 (13.2/100)39.45

= 5.2

12.24

O2 (4.8/100)39.45

= 1.9

4.47

N2 (81.95/100)39.45

= 32.33

76.13

H2O (54.49/18)

= 3.02

7.11

total 42.46 99.95

The vapor pressure of water vapor= (7.1/99.95) 101.32

= 7.2 kN/ m2

Which corresponds to the due point temperature of water vapor is 3110K and

latent heat of evaporation is 2411.2 kj/kg.

The enthalpy of water in flue gas

= 0.5449[2.095(523.15 311)+ 2411.2+4.187(523.15-310.15)]

= 2041.83 kj/kg

The percentage of heat lost to the wet flue gas

= 2041.83/25588.68

= 7.98%



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HEAT BALANCE SHEET

UNIT HEAT RECOVER

(KJ/KG)

% HEAT RECOVERY

BOILER 13949.11 54.51

ECONOMIZER 848.03 3.31

HEAT TO DRY FLUE

GAS

2558.076 10

HEAT TO WET FLUEGAS

2041.83 7.98

HEAT UNACCOUNTED 6191.63 24.2

TOTAL 25588.68 100

RESULTS

Theoretical air supplied = 8.4478 kg/ kg of coal

Actual air supplied = 11.81 kg/kg of coal

% Excess air = 39.81

THERMAL EFFICIENCIES

1) Boiler = 54.51%2) Economizer = 3.31%

PARCENTAGE HEAT LOSSES

Heat to dry flue gas = 10%

Heat to wet flue gas= 7.98%

Heat unaccounted = 24.2%



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Conclusion

From combustion calculations, it is found that the excess air should

be supplied in between 30 to 40% of theoretical air requirement for

the complete combustion of coal.

As shown in graph the relation between percentage of excess air

and percentage heat lost is that as the increase in excess air flow

there is a decrease in heat loss.

Thermal efficiencies of boiler, economizer are calculated and also

heat balance sheet is prepared for the obtained result.

3150360 Study of Combustion Process[1]

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