Combustion

Under Control
Fuel Type Fuel handling Heat Transfer Excess Air Burner momentum Emission

Outside Control
Secondary air momentum Tertiary air momentum Kiln aerodynamics Calciner aerodynamic

Combustion since is the since of exothermic chemical reactions in flow of heat and mass transfer

Gas

H2 or natural gas

Fuel : Liquid
Solid

Alcohol or oil Na, pure carbon or coal

Carbon Hydro Carbons (fuels)

Hydrogen Sulfur

CO2
H2O SO2

C + O2

CO2 + ( 94 kCal/mole)

+ 116 kCal/mole Water as steam

2H + O2

2H2O
+ 137 kCal/mole Water condensed

G.C.V: H.H.V:

Gross calorific values

Water condensed
High heating values

N.C.V: L.H.V:

Net calorific values Water remain as steam Low heating values

The incomplete Oxidation of carbon

Not all of the carbon in the fuel will be oxidized to carbon dioxide but some will be partially oxidized to carbon monoxide
Carbon monoxide: Reduce the heat release from the fuel

2C + O2
2CO + O2

2CO + ( 53 kCal/mole)
2CO2 + ( 41 kCal/mole)

Reversible chemical reaction

Natural gas requires more combustion air per kCal of heat released than most other fuels, produces more exhaust gases, smallest CO2

Physics of Combustion

Combustion Stages
Mixing
slow

Ignition

Chemical reaction

Dispersal of product
Very fast

If its mixed, its burn

1 Kg fuel

Or

1 Nm3 fuel

Oxygen is required Combustion equation Fuel analysis is known Air Empirical formula Heat Value is known

21% Oxygen

Minimum air required = 4.762 times of the minimum Oxygen

A = Amin * n A = Air supplied to the kiln system.

Nm3/kg fuel or Nm3/Nm3 fuel

A min= minimum air required for combustion the kiln system.

n = Excess Air factor.

Ratio of air supplied Minimum air

Heat of Combustion or heat value

If combustion product contain water.

High heat value low heat value = the heat of vaporization of the water

The kiln gas consists of : combustion products excess air of combustion false air gas from the raw meal
carbon dioxide (CO2 ) water vapor sulfur absorbed (Circulation Phenomena)

Analysis of the Kiln Gases

By ORSAT (dry)
The Orsat - analysis is used to analyze the dry kiln gases

Combustion For Water content

Water content of the raw meal

Can be calculated from the dew point.

Orsat-analysis
Excess air factor n Incomplete combustion Heat consumption False air

Oxygen required for combustion of 1 kg fuel (liquid + solid fuel)

Nm3 / kg fuel

C + O2
1 KM 12 Kg 1 KM 32 Kg 22.4 = Volume occupied by 1 Mol 12 = Molecular wt of carbon

CO2
1 KM 44 Kg

22.4 )C) = 1.864 (C) 12 Nm3/Mol Kg(C)/Mol Nm3 Kg(C)

H2 + O2
1 KM 2 Kg KM 16 Kg

H2O
1 KM 18 Kg

22.4 )H) = 5.553 (H) 4

S +
1 KM

O2
1 KM

SO2
1 KM

22.4 )S) = 0.6982 (S) 32 22.4 )O) = 0.6997 (O) 32

O2 is used for above reaction

Omin. = 1.864 * C + 5.553 * H + 0.6982 * S - 0.6997 * 0

Nm3 of Oxygen / kg fuel

Oxygen Required for Combustion of 1 Nm3 Fuel

Nm3 fuel (Gas Fuel( Nm3 / Nm3 fuel

H2 CO CxHy +

+ +

O2 O2

H2O CO2 X CO2 + (Y/2) H2O

( X + Y/4 ) O2

Omin = 0.5 CO + (X + Y / 4 ) CxHy + 0.5 H2 O2

Nm3 of Oxygen / Nm3 of fuel

By Weight
0.232 O2 0.768 N2

By Volume
0.21 O2 0.79 N2

H4

+ O2 = 2H2O

C +

O2 = CO2

CH4 + 2 O2
(12+4) : 2 x 32
16 : 64

= CO2 + 2H2O

1 kg fuel : 4 kg of Oxygen

weight of air required per kg

Kg CH4

4 0.232

= 17.24

Kg air Kg Ch4

Volume of air required Nm3

Nm3

CH4

2 0.21

= 9.521

Nm3 air Nm3 Ch4

Amin =

Omin 0.21

Combustion Products
CO2 , H2O , some SO2
a) Complete Combustion CO2 , H2O , N2 , & O2 excess from combustion

b) Incomplete Combustion

CO2 , H2O , N2 , & CO

Combustion products of 1 kg fuel without excess air

V min =
1.855 C
CO2

0.6841 S
SO2

0.8 N2 + 0.79 A min

N2

Dry Combustion

+ 1.244 H2O + 11.21 H

1.855 =
22.4 12 22.4 32

Water Vapor
0.8 =
22.4 28 22.4 18

CO2

N2

0.6841 =

SO2
11.21 =
22.4 2

1.244 =

H2 O

Combustion products of Nm3 fuel without excess air

CO2 : V = CO + CO2 + X Cx Hy H2O : V = Y/2 CxHy +

H2

Nm3Co2 / Nm3 fuel Nm3 H2O / Nm3 fuel

Vmin = (CO + CO2 + XCxHy) + (Y/2 Cx Hy + H2 ) + N2 + 0.79 Amin

CO2 H2 O

Excess Air in Combustion

A = n* Amin

Nm3 air / kg or Nm3 fuel

V = Vmin + (n-1)* Amin

Nm3 gas kg or Nm3 fuel

Heat of Combustion
Heat values are determined experimentally by calorimeters in which products of combustion are cooled to the initial temperature and the heat absorbed by the cooling medium is measured

Hu =
Ho =

The low heat value is evaluated assuming no water vapor condensed

the high heat value is calculated assuming all water vapor condensed

Hu = Ho ( H2O + 9 H2) 2.499 Hu = Ho (H2O + 9 H2) 597)

MJ/kg fuel Kcal / kg fuel

1 Cal = 4.18 J

Empirical Rules for Air Requirement and Combustion

Minimum Air :

Amin = 0.26 * Hu

Minimum Combustion Products (wet) :

Vmin = 0.28* Hu
Each MJ (Megajoul) burnt in the firing requires 0.26 Nm3 minimum air and produces 0.28 Nm3 minimum combustion gas.

GAS FORM RAW MEAL

Carbon Dioxide from Raw Meal

CaCO3
1kMol 100.09kg

CaO
1 kMol 56.08 kg

CO2
1 kMol 22.26 Nm3

Mg CO3
CO2 R.M = 22.26

MgO
Ca CO3
100.09

+
+

CO2
Mg Co3
84.33

Nm3Co2
Kg R.M

R = Raw Mill Factor (1.55 1.95)

CO2 produced /kg Clinker

CO2 RC = CO2 RM

* R

Nm3Co2
Kg clinker

CO2 RC =

22.26 100

Titration

Nm3Co2
Kg clinker

Titration = % Weight of carbonate Kg Raw Meal

Kg Clinker

kg/kg RM

R=

 Water from Raw Meal

mw m H2O R.M = 1 - mw
m H2O = V H2O =
Kg H2O / kg dry R.M

mw 1 - mw mw 1 - mw
18 22.4

* *

R
R
0.8038
Kg/mol Nm3/mol

Kg H2O / kg clinker Nm3 H2O / kg clinker

0.8038 =

kg Nm3

18 = Molecular weight of water

22.4 = Volume occupied by 1 mol

 Sulfur from Raw Meal

Orsat Analysis
CO2 O2 CO N2

SO2

SO3

KOH solution, (Pyrogllic acid) + Potas hydroxide KOH solution, (Pyrogllic acid) + Potas hydroxide
cuprous chloride ( Cu2Cl2) final unabsorbed gas

Errors due to leakage and poor sampling

Excessive Air Factor

n=
A

n
N2

Amin

N2 n= N2 min

n=

N2 - N2

excess air

From the Orsat analysis the oxygen content O2

N2 O2
=

0.79 0.21

= 3.762

N2 excess air = 3.762 Oxygen excess air

n=

N2 N2 - 3.762 O2

If there is CO

n=

N2
(N2 - 3.762) * (O2 - 0.5 CO)
N2

OR

n=

1
(1 - 3.762) * (O2 - 0.5 CO)
N2

Incomplete Combustion

The specific heat consumption of the kiln increases

explosion in the kiln system

If the false air increase

then the secondary air decreases

The low heat value

Co2 H2 CH4

= = =

12.64 MJ /Nm3 ( 3020 kcal/Nm3 ) 10.80 MJ / Nm3 ( 2580 kcal/Nm3 ) 64.34 MJ / Nm3 ( 15370 kcal/Nm3 )

Density of the Kiln Gas

Gas Component Molecular Weight Density at Oo C, 760 mm Hg kg/m3 Relative Weight (Air = 1) 1.5291 1.1053 0.9669 Gas constant kgm/ kg k

CO2 O2 CO

44.00 32.00 28.00

1.9768 1.4289 1.2500

19.25 26.49 30.28

H2

2.016
28.15 18.016 16.031

0.0899
1.2567 -0.7168

0.0695
0.9721 -0.5545

420.75
30.12 -52.89

(from air)
H2O CH4

N2

Heat Consumption The specific heat consumption

q
CO2f 1-CO2f

q=

CO2 RC
0.79 Amin Hu CO2t 1-CO2t

CO2 RC, Nm3 / kg Cli , CO2 from raw meal Amin Nm3 / kg fuel, Nm3 / Nm3 fuel Hu MJ / kg, low heat value of fuel CO2t = CO2 content in the exit gas if not excess air were present

CO2t =

CO2 + CO

1-

O2 - 0.5 co 0.21

CO2, CO and O2 are the volume fraction of the dry gas, as obtained by the Orsat analysis. CO2f = CO2 from combustion of fuel if no excess air were present

CO2f = CO2 = 1.855 C

1 V min dry

C = weight fraction of carbon of the fuel

CO2f = CO2 = ( CO + CO2 + X CX Hy)

1 V min dry

CO, CO2 and CXHy are volume fraction of the gaseous fuel.

False Air

From the Orsat analysis

Excessive Air Factor

n=

Amin

The false air is the difference of the total amounts A2 of air upstream and downstream A1of the leak.

A false Air = A2 A1 = ( n2 n1) Amin

A false Air = ( n2 n1) Amin
*K

Nm3/kg Clinker

Nm3/kg Clinker

K = specific fuel consumption.

Kg fuel /kg Clinker

Nm3 fuel/kg Clinker