Gas Balance

GAS IN
No Items Measurement Units
1 Cooling Fans Cooler Fans 1A to 10 (13Fans) MIS Figures Nm3/hr
2 Other Cooling Airs Primary Air + LowNOx + Pyroclon Fans KHD Manual Nm3/hr
3 Calcination [CO2] Kiln Feed X 0.35% [LOI] X (22.4/44) X 1000 Calculation Nm3/hr
4 Gas Combustion Theoritical Combustion based on Coal Properties Calculation Nm3/hr
5 In Leaks Balance between gas in & gas out - Nm3/hr

GAS OUT
No Items Measurement Units
1 Preheater Exhaust Gas Out thru preheater exhaust Physical measurement Nm3/hr
2 Cooler Exhaust Gas Out thru cooler exhaust Physical measurement Nm3/hr

Remarks
Air In Leaks in the system is the different of gas in and gas out from the system.
 THEORETICAL OXYGEN AND AIR COMBUSTION

Ultimate basis Ash basis Molecule 1 kmol C + 1 kmol O2 --> 1 kmol CO2
Content O 2 needed (g) Gas formed
% g % g Weight (g) 1 kmol H2+ 1/2kmol O2 --> 1 kmol H2
C 76.90 769.00 69.98 699.79 12 1866.11 2565.90 1 kmol S+ 1kmol O2 --> 1 kmol SO2
H2 5.54 55.40 5.04 50.41 2 403.31 453.73
S 0.31 3.10 0.28 2.82 32 2.82 5.64
H 2O 0.00 0.00 5.00 50.00 18 50.00
N2 1.72 17.20 1.57 15.65 28 15.65
O2 15.53 155.30 14.13 141.32 32
Ash 0.00 0.00 4.00 40.00
100.00 1000.00 100.00 1000.00 2272.24 3090.92

O 2 needed 2130.917 1.492

g Nm3

Theoretical air to fuel ratio will be 9.265 7.137

kg Nm3
0.53625
Avogadro's law (Combustion Gas)

Content g Nm 3

CO 2 2565.90 1.306
H 2O 503.73 0.627
SO 2 5.64 0.002
N2 7149.59 5.720
10224.86 7.655
 Combustion Gas (Volume Increase) 0.518 Nm3/kg-coal

Items Kiln Total system

Excess air 59.01 % 13.67 %
Total Nm3 11.349 Nm3 8.112 Nm3
Excess air 4.212 Nm3 0.975 Nm3
Excess O2 0.884 Nm3 0.205 Nm3
Excess N2 3.327 Nm3 0.771 Nm3
Air volume produced by coal combustion 0.518 Nm3 0.518 Nm3
(not included combustion air)

New combustion New combustion

Content Nm3 % Content Nm3
CO2 1.306 11.01 CO2 1.306
H2O 0.627 5.28 H2O 0.627
SO2 0.002 0.02 SO2 0.002
N2 9.047 76.24 N2 6.490
O2 0.884 7.45 O2 0.205
Total 11.867 100.00 Total 8.630
mol C + 1 kmol O2 --> 1 kmol CO2
mol H2+ 1/2kmol O2 --> 1 kmol H2O
mol S+ 1kmol O2 --> 1 kmol SO2
combustion
%
15.14
7.26
0.02
75.20
2.37
100.00
 Ash basis Molecule Kmol O2
Content O 2 needed (kmol)
% g Weight required
C 74.10 12 6.18 6.18 1 kmol C + 1 kmol O2 --> 1 kmol CO2
H2 5.10 2 2.55 1.28 1 kmol H2+ 1/2kmol O2 --> 1 kmol H2O
S 0.95 32 0.03 0.03 1 kmol S+ 1kmol O2 --> 1 kmol SO2
H 2O 5.00 18 0.28 -
N2 1.35 28 0.05 -
O2 9.50 32 0.30 -0.30
Ash 4.00 #DIV/0! -
100.00 0.00 9.38 7.18

Air to be supplied
34.203869 kmol/100 kg coal
7.6274628 m3 air/kg coal
9.88491815 kg air/kg coal Mol wt air=28.9
 + 1 kmol O2 --> 1 kmol CO2
2+ 1/2kmol O2 --> 1 kmol H2O
+ 1kmol O2 --> 1 kmol SO2
Sufficient air will help to release the potential heat contained in the fuel.
Insuffecient air-Loss of potential heat (incomplete combustion)
Excess air-Large loss of sensible heat (heat possible to used/recover)
 Lmin flow = minimum combustion air is used as basis for primary or kiln air calculation. (k

Abbreviation Units Values Lmin,flow (kg/h) Lmin, flow (kg air/h)

P Production tpd 4000 162.634 162.643

F,fuel Fuel Flow tph 11.652

kg/
Lmin,heat Min Comb air 1000kcal 1.4272357
lower heat
Hi,fuel kcal/kg 9780
value

Heat
X kcal/kg cl 683.7
consumption
primary or kiln air calculation. (kg air/hr), [Nm2 air/min] Lmin,flow
Lmin,Heat
Lmin,Fuel
Lmin,heat= Minimum combustion air based on ratio between
= Units (kg air/1000kcal),(Nm3 air/MJ)

Lmin fuel 13.958365

Hi, fuel 9780

Lmin,heat 1.4272357
 Units Values
Density of Atmospheric air kg/Nm3 1.293 0.0430871
Density of Oxygen kg/Nm3 1.429

Component % Formula Lmin,fuel

C 85.2 =(32/12)*D35 227.2 13.958365 kg air/kg oil
H 11.6 =(16/2)*11.6 92.8
O 0.2 =-(D37) -0.2
S 2.1 =(D38) 2.1
N 0.9 =(32/14)*D39 2.0571429
Total 100
kg air/kg oil