2 - Combustion Principle & Flue Gas Calculation - IPHO Jan 2016 - YP

1/17/2016
COMBUSTION PRINCIPLE
& FLUE GAS CALCULATION
_______________________________________________________________
PT. Indonesia Power

– Head Office
Jakarta, January 2016
Prepared & Presented By :

Organized By : Youdhiyan Prasetyo
PT. Energy Duta Utama (EDU) youdhiyan.prasetyo@gmail.com
+62-811886021
Combustion Principle & Flue Gas Calculation Youdhiyan Prasetyo © 2016 1/42
PT. Indonesia Power – Head Office
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800
O
C
Char
burning Heat
production
Ignition
200-
300
Pyrolysis Heat consumption
105
Volatiles Char
Moisture
80-90 % 10-20 %
evaporation
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13 Essentials of Optimum Combustion

Fuel Preparation
1. Fuel feed quality and size shall be consistent.

2. Fuel feed shall be measured and controlled as accurately as
possible. Load cell equipped gravimetric feeders are preferred.
3. Fuel line fineness >75% passing a 200-mesh screen, and
50 mesh particles <0.1%.
Distribution to Burners
4. Primary airflow shall be accurately measured and controlled

to ±3% accuracy.
5. Primary air to fuel ratio shall be accurately controlled when
above minimum.
6. Fuel line minimum velocities shall be ~ 15m/s.
7. Fuel lines shall be balanced by “Clean Air” test to within 2% of
average.
8. Fuel lines shall be balanced by “Dirty Air” test to within 5% of
average.
9. Fuel lines shall be balanced in within 10% of average.
13 Essentials of Optimum Combustion

(cont.)
Combustion
10. Over-fire air shall be accurately

measured and controlled to ±3
%
accuracy.
11. Furnace exit shall be oxidizing;
3% oxygen is preferable.
12. Mechanical tolerances of
burners and dampers shall
be ±1/4’’.

13. Secondary air distribution to
burners shall be within 5-10%
of average.
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Furnace Residence Time
Point at Flame Quench Zone

which
combustion
should be
completed
What is combustion ?
Combustion, or burning, is the combination of
Oxygen with Fuel, resulting in the release of
Heat
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What is a Flame ?
Flame Front
Combustion reaction occurs
at a rate the produces
visible radiation, fuel-air
mixture and combustion
process.
Flame Envelope
Contour along which the
combustion starts, dividing
line between the fuel-air
mixture and the combustion
process.
Flame Safeguarding
Definition
A system which is detects the presence

or absence of a flame in burner in order
to prevent uncontrolled combustion.
Every Burner
Needs A Detector !!!
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Types of Radiation in
Combustion
UV = least available (1%).
Visible = 10% of flame.
Infrared = 90% of flame.
Flame Discrimination Defined
Background Flame
Target Flame
Field of View
Detector
DISCRIMINATION :
The ability to distinguish the target flame from all other flames
in the furnace and the Background
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Applications of the
Combustion Equation
Stoichiometric proportions for finding the correct
air supply rate for a fuel.
Composition of the combustion products is useful
during the design, commissioning and routine
maintenance of a boiler installation.
On-site measurements of flue gas composition and
temperature are used as a basis for calculating the
efficiency of the boiler at routine maintenance
intervals.
Combustion Air Requirements

: Gaseous Fuels
Calculating the air required for gaseous fuels
combustion is most convenient to work on a
volumetric basis.
The stoichiometric combustion reaction of methane

is :
CH4 + 2O2 → CO2 + 2H2O
which shows that each volume (normally 1 m3) of
methane requires 2 volumes of oxygen to complete
its combustion.
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If we ignore the components which are present in
the parts per million range, air consists of about
0.9% by volume argon, 78.1% nitrogen and 20.9%
oxygen (ignoring water vapor). Carbon dioxide is
present at 0.038%.
For the purposes of combustion calculations the

composition of air is approximated as a simple
mixture of oxygen and nitrogen :
oxygen 21%
nitrogen 79%
Flue Gas Composition

: Gaseous Fuels
The composition of the stoichiometric combustion
products of methane is:
1 volume CO2
7.52 volumes N2
2 volumes H2O
Given a total product volume, per volume of fuel

burned, of 10.52 if water is in the vapor phase, or
8.52 if the water is condensed to a liquid.
The two cases are usually abbreviated to “wet” and

“dry”.
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The proportion of carbon dioxide in this mixture is

therefore
1
100%  9.51% wet and
10.52
1
100%  11.74% dry
8.52
The instruments used to measure the composition

of flue gases remove water vapor from the mixture
and hence give a dry reading, so the dry flue gas
composition is usually of greater usefulness.
Considering the combustion of methane with 20%

excess air, the excess air (0.2×9.52) of 1.9 volumes
will appear in the flue gases as (0.21×1.9) = 0.4 vol

of oxygen and (1.9-0.4)=1.5 volumes of nitrogen.
The complete composition will be:

constituent vol/vol methane
CO2 1
O2 0.4
N2 9.02
H2O 2
giving a total product volume of 12.42 (wet) or

10.42 (dry).
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The resulting composition of the flue gases,

expressed as percentage by volume, is:
Constituent % vol (dry) % vol (wet)

CO2 9.6 8.1
O2 3.8 3.2
N2 86.6 72.6
H2O – 16.1
Combustion Air Requirements

: Solid and Liquid Fuels

The way in which the combustion equation is used
reflects the available information on the analysis of
the solid or liquid fuels.
This takes the form of an element-by-element

analysis (referred to as an ultimate analysis) which
gives the percentage by mass of each element
present in the fuel.
An example of an ultimate analysis of a liquid fuel

(oil) might be :
Component % by mass
Carbon (C) 86
Hydrogen(H2) 14
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Each constituent is considered separately via its own

combustion equation.
For the carbon:

C + O2 → CO2
12kg 32kg 44kg
or for 1 kg of fuel
32 44
0.86  0.86   0.86  (kg)
12 12
So each kg of oil requires 2.29 kg oxygen for
combustion of its carbon and produces 3.15 kg CO2
as product.
Similarly
H2 + ½ O2 → H2O
2kg 16kg 18kg
or per kg of fuel
16 18
0.14  0.14   0.14  (kg)
2 2
In order to burn the hydrogen content of the oil 1.
12 kg oxygen are needed and 1.26 kg water is
formed.
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The total oxygen requirement is thus (2.29 + 1.12)

or 3.41 kg.
A given quantity of air consists of 21% by volume

of oxygen.
We can simply transform to a mass basis thus:
Component vol fraction(vf) vf × MW Mass fraction
6.72
Oxygen 0.21 6.72  0.233
28.84
Nitrogen 0.79 22.12 22.12
 0.767
28.84
We can now establish that 3.41 kg oxygen, which is

the stoichiometric requirement, will be associated
with:
0.767
3.41  11.23 kg nitrogen
0.233
The stoichiometric air-to-fuel ratio is thus
3.41 + 11.23 = 14.64 : 1
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Combustion Products
: Solid and Liquid Fuels
The stoichiometric combustion products
from combustion of the oil are:
CO2 3.15 kg
H2O 1.26 kg
N2 11.23 kg
The combustion products would normally be

needed as a volume percentage, so the reverse
operation to that which was performed for air
above is required.
Combustion Calculation for a Coal.

An example of coal has the following ultimate
analysis:
% by mass
Carbon 90
Hydrogen 3
Oxygen 2.5
Nitrogen 1
Sulfur 0.5
Ash 3
Calculate:
(a) the volumetric air supply rate required if 500
kg/h of coal is to be burned at 20% excess air.
(b) the resulting %CO2 (dry) by volume in the
combustion products.
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Solution:

Lay out the calculation on a tabular basis using 1 kg coal:
Mass (per kg) O2 Required Products
Carbon 0.9 0.9 
32
 2.4 0.9 
44
 3.3
12 12
18
Hydrogen 0.03 0.03 
16
 0.24 0.03   0.27
2 2
32 64
Sulfur 0.005 0.005   0.005 0.005   0.01
32 32
Oxygen 0.025 -0.025 -

Nitrogen 0.01 - 0.01
Ash 0.03 - -
(a) Oxygen required to burn 1 kg coal

= 2.4 + 0.24 + 0.005 - 0.025 = 2.62 kg.
Air required = 2.62

 11.25 kg
0.233
Actual air supplied = 11.25 × 1.2 = 13.5 kg
Assuming a density for air of 1.2 kg/m3, the flow
rate will be:
500
13.5   1.56 m3 /s
1.2  3600
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(b) To get the %CO2 in the combustion products
we need to know the amounts of oxygen and
nitrogen in the flue gases.
Air supplied = 13.5 kg per kg coal, of which

oxygen is 13.5 × 0.233 = 3.14 kg, and
nitrogen 13.5 – 3.14 = 10.36 kg.
The combustion products will thus contain:
3.14 – 2.62 = 0.52 kg O2 and

10.36 + 0.01 = 10.37 kg N2.
A second tabular procedure can now be used for the volumetric composition
of the flue gases:
Product Mass/kg coal Mol. Wt. kmoles/kg coal % volume
CO2 3.3 44 0.075=(3.3/44) 16.25=(0.075/0.4614)
SO2 0.01 64 0.000156 0.03
O2 0.52 32 0.0162 3.51
N2 10.37 28 0.37 80.20
0.4614
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COMBUSTION PROBLEM ??
FOULING
SLAGGING
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AFT TO FORM SLAGGING

W=H
H = 19
H H H = 1.5 MM
IT. ST HT FT
6.35 W=H W = 2H
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1900 - 2200 0F
1038 - 1204 0C
1-2 S
3000 0F
1649 0C
SLAGGING / FOULING IMPACT

TO THE HEAT ABSORPTION PROCESS
t1 t1
L1 L2
T2’
T2
SLAGGING ( MASSIVE ) FOULING ( POROUS )
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% MILL TEMP.
HOT AIR REQUIRED
C
B
5.1 % A
MOISTURE
FLAMMABILITY LIMITS
PERCENTAGE OF STOICHIOMETRIC AIR
FUEL MINIMUM MAXIMUM
NATURAL GAS 64 % 247 %
OIL 30 % 173 %
COAL 8% 425 %

Thank You……..
21

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1/17/2016

PT. Indonesia Power

Prepared & Presented By :

PT. Indonesia Power – Head Office

PT. Indonesia Power – Head Office

PT. Indonesia Power – Head Office

13 Essentials of Optimum Combustion

1. Fuel feed quality and size shall be consistent.

4. Primary airflow shall be accurately measured and controlled

13 Essentials of Optimum Combustion

10. Over-fire air shall be accurately

PT. Indonesia Power – Head Office

Point at Flame Quench Zone

A system which is detects the presence

PT. Indonesia Power – Head Office

UV = least available (1%).

Visible = 10% of flame.

Infrared = 90% of flame.

Flame Discrimination Defined

Combustion Air Requirements

The stoichiometric combustion reaction of methane

PT. Indonesia Power – Head Office

For the purposes of combustion calculations the

Flue Gas Composition

Given a total product volume, per volume of fuel

The two cases are usually abbreviated to “wet” and

PT. Indonesia Power – Head Office

The proportion of carbon dioxide in this mixture is

The instruments used to measure the composition

Considering the combustion of methane with 20%

will appear in the flue gases as (0.21×1.9) = 0.4 vol

The complete composition will be:

giving a total product volume of 12.42 (wet) or

PT. Indonesia Power – Head Office

The resulting composition of the flue gases,

Constituent % vol (dry) % vol (wet)

Combustion Air Requirements

: Solid and Liquid Fuels

This takes the form of an element-by-element

An example of an ultimate analysis of a liquid fuel

Each constituent is considered separately via its own

For the carbon:

The total oxygen requirement is thus (2.29 + 1.12)

A given quantity of air consists of 21% by volume

We can simply transform to a mass basis thus:

Component vol fraction(vf) vf × MW Mass fraction

We can now establish that 3.41 kg oxygen, which is

PT. Indonesia Power – Head Office

The combustion products would normally be

Combustion Calculation for a Coal.

PT. Indonesia Power – Head Office

Oxygen 0.025 -0.025 -

(a) Oxygen required to burn 1 kg coal

Air required = 2.62

PT. Indonesia Power – Head Office

Air supplied = 13.5 kg per kg coal, of which

The combustion products will thus contain:

3.14 – 2.62 = 0.52 kg O2 and

PT. Indonesia Power – Head Office

PT. Indonesia Power – Head Office

AFT TO FORM SLAGGING

PT. Indonesia Power – Head Office

SLAGGING / FOULING IMPACT

SLAGGING ( MASSIVE ) FOULING ( POROUS )

2 - Combustion Principle & Flue Gas Calculation - IPHO Jan 2016 - YP

2 - Combustion Principle & Flue Gas Calculation - IPHO Jan 2016 - YP