How to measure false air

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Introduction

False air is any unwanted air entering the system between two points (see figure below). The exact
amount of false air is difficult to measure. An indicator of false air amount can be the oxygen increase
between two points (usable for gas stream containing less than 21% of oxygen).
point 1

point 2

gas

false air entering

Objectives

Increase capacity of system (when the fan is pneumatically limited)

Decrease power consumption of the fan (less gas for transport)
Decrease risk for coal mill shop
Increase gas drying efficiency
O2 after pre-heater and in stack
Note that each 1% increase of oxygen means approximately 5% increase of gas volume (also nitrogen
is introduced from air)

Results

Prepare an action plan for reducing false air together with production and maintenance departments
Do measurement on a regular basis and follow-up on progress.

Safety aspects

Measuring of false air is only possible during kiln line in operation.

Never make any measurement alone and without contact to the central control room operators.

Personal Protective Equipment is a requirement with special precaution in high temperature areas in the
lower pre-heater tower.

Prerequisites

Constant kiln operation at nominal capacity.

Additional equipment: Sampling probes, coarse dust filter, fine dust filter and silica gel package for
drying.

Calibrated portable oxygen analyzer.

Ensure that the pump of the portable gas analyzer is strong enough to extract the gases from the
measurement location:
e.g: after raw mills: ~90 [mbar] / after pre-heater tower ~110 [mbar]

Procedure Template developed by

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Sampling probes

< 800 [C]: heat resistant steel pipe (simple)

> 800 [C]: Water cooled or ceramic probe (simple, see picture in tools) to avoid oxidation of the
carbon in the steel (O2 0,0% / CO > max. Val)

Depending on the scope also installed oxygen analyzers can be used. ( take care about calibration)
Openings for measuring located with reference to false air critical parts (existing, accessible and open)

Time frame

Depending on measurement scope.

Never forget to add some spare time for blocked measurement locations.

Tools

Calculation formula:

VFalseAir = VPo int 2

(%O2 Po int 2 %O2 Po int 1 )

(% O2 Air %O2 Po int 1 )

Requirement: all values must be used on same basis, dry or wet. Recommendation is to do it on dry
basis. Be aware this is also valid for flow measurement.

Typical equipment set up:

Water cooled probe:

Procedure Template developed by

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Action Steps
1.

Make sure the oxygen analyzer is calibrated properly

2.

Measure the oxygen content

at the beginning (point 1) and at the end (point 2) of the inspected section (the shorter the section, the
easier it is to find leaks)

3.

At point 2 additional measurement or calculation of volume flow

4.

Simplified approach

5.

Measure always on dry basis!

6.

can be the calculation of the percentage false air

Avoiding influences of evaporation effects.

In sampling probe part of the water is immediately condensing influencing result.
Modern gas analyzers measure with electrochemical cells which are sensitive against condensation.
Comparison with installed gas analyzers all are on dry basis.
Final preparation step: drying with silica gel.

Make sure the oxygen analyzer is calibrated properly

Make sure that no chemical reaction influencing O2 content is taking place between point 1
and point 2 (decarbonisation, combustion)

Make sure that your measurement is not distorted by false air entering a measuring opening
(tighten free space around a measuring probe) Excel spreadsheet (check-list, calculation
sheet)

Reporting the false air

Reporting of false air on a wet basis is preferable. This requires the measurement or estimation of the
moisture content of the gases to make the conversion from dry to wet basis.

Procedure Template developed by