roe Whats False air False air is nothing but atmospheric air infiltrating / ingressing into process equipment that operates under vaccum/negative pressure ‘Atmospheric air other than process air is considered as false air. ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright lawSources of false Main sources of false air is thru 1, Openings: 2. Fittings 3. Cracks 4, Leakage in expansion joints 5. Badly sealed openings 6, Inlet seals 7. Inspection doors 8. Dampers ete. Implications of False air Has an direct impacton Thermal efficiency (Increase in Specific fuel consumption) in Pyro Process systems. Excess false air increases load on induced draft fans, causing an increase in power consumption. Incteases the risk of fire hazards especially in fuel grinding operating in inert atmosphere, Cause an undesirable drop in temperature which may cause corrosion and eventually result in corrosion problems, ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright lawMeasurement and Calculation of False air The quantity of false air is determined on the basis of O. or CO; analysis at any two given points in the system. False air is usually expressed in the peroent of unmixed gases at the inlet measuring point. In the calculations atmospheric air is reckoned to contain 0 % CO; and 21 % 0, Measurement and Calculation of False air Measuring point | ‘Measuring point Il Q1=Nm? of smoke QII=Nm* mix of gases smoke gases + false 0, 1- % Oxygen air False air Op % Oxygen 0,=21% False air (Nm®) = Qi - Qi Nm? Oxygen = 0.21" (Ql - Ql) From the above Qll (Nm‘) = Ql * (210.1) _Nm? 21-04) [oor ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright lawMeasurement and Calculation of False air Ifthe air and gas quantities are unknown , the percentage of false air may simply be calculated on the basis of the oxygen contents False air = ©, Outlet—O, Inlet * 100 “24 =O; Outlet Worked out example Using ©, gas analysis measurements 0; @ Cyclone inlet: 2.4 % ©; @ Cyclone outiet: 3.9 % Simplified form of above formula = Q, Outlet = 0, Inlet 21-0, Outlet = @9-24)x100 21-39) Percentage of False air= 8.77 % ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright lawMeasurement of False ail if O, & CO, % are known, % False air on O, basis = ), Outlet — 0, Inlet 721 =O; Outlet % False air on CO2basis. = GO, Inlet CO. Outlet CO; Outlet-0 The average of above two values shall be considered as percentage of false air. Calculation of false air across Cooler filter Inlet air False air ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright lawCalculation of false air across Cooler filter Inlet ait M, (kgfkg Clinker) — unknown T ; (Deg C) — Known Cp, (Kealfkg Deg C ) - Known False ait M, (kg/kg Clinker) — unknown T (Deg C) — Known Cp, (Kcavkg Deg C ) - Known Calculation of false air across Cooler filter- contd Create two equations Equation 1 M, +M,=M, Equation 2 M,Cp,T, + M.Cp;T. = M.Cp.T; ‘Solving two equations for the leak air M, gives pity = Cpa, My (Cp,T, - Cp,T) = RAD } RAD — Radiation loss is often minimal and can be neglected Qutlet air - Stack M, (kg/kg Clinker) — known T., (Deg C) = Known Cp, (Kcalikg Deg C) - Known ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright lawEstimation of false air at openings (In a Sharp edged hole ) g=oeixax Px - fo symbols: "A, =Diferenta Stati Pressure [Pa] 1X Hole area (om) = Atal Density Team 28 Volume ors) irfgas Mass (ars) Increase in false air intake by 0.1 kg/kg Clinker Kiln inlet | Kiln Peso) Se er ‘Specific fuel ‘Consumption 19 16 16 14 (an Kealkg Clinker) Exit gas temperature (eg 6) * . . a ‘Specie power ‘consumption 25 53 53 76 % ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright law [m/s] Qy=061xAx JEXORXP Iko/3]Increase in false air intake by 0.4 kg/kg Clinker Description | cyclone 1 | cyclone 2 | Cycione 3 | Cyclone 4 | cyclone Specific fuel ‘Consumption at 33.3 89 +120 “9 (in Kealkg Clinker) Exit gas temperature “10 60 143 +10 423 (Degc) Specific power consumption’ +78 +39 +133 18 425 2) Wet basis and Dry Basis Wet basis Itis the analysis without removing water from flue gas Dry basis Itis the analysis by removing water from flue gas, Mainly air pollution regulations are written on a moisture — free Basis since moisture can be a highly variable quantity in some Processes. ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright lawConversion from Wet to Dry basis Cone. .o,.= Concentration (wet) (7100 % - Volume % H.0) 100% Where : Cone i oy and Conc i jy.) Can be expressed as, any concentration format. Difference between wet and dry concentration Wet basis Dry Basis ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright lawExample 4 Conversion to Dry basis concentration (0, Volume % wet to dry) Np = 74% , = 6%, CO;= 11 % &H,O=9 %. Conc. i joy —__6 % O, (wet (100 % - 9%. H;0) 100 % = 6.59% O> wy Example 2 Conversion to Dry basis concentration (SO, ppm wet to dry) SO, = 0.15 % oF 1500 ppmH,0 = 8 % CONC. pony 15009pm SO, Welbasis) (100% - 8% H,0)/ 100 1630 ppm SOroyy ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright law 10Wet basis and Dry basis In general volume of flue gas comes down when the H,O content in the flue gas comes down General the dust emissions and other gaseous emissions (SO, and NO, )shall be indicated in dry basis to have common platform In general for gas caloulations either wet or dry basis shall be used as it has only minor variations. ‘The information contained or referenced inthis presentation is proprietary te FLSmidth ands protected by copyright law 1