2. Steam Generator/ Boiler 3. Nozzles 4. Steam Turbines 5. Gas Turbines 6. Air Compressors Recommended Books i. Applied Thermodynamics for Engineering Technologists By: T.D. Eastop & A. McConkey ii. Basic Thermodynamics By: Reynar Jeol iii. Thermodynamics An Engineering Approach By: Yunus A. Cengel & M.A. Boles iv. Thermodynamics for Engineers BY: Bhalchandra V. Karlekar Reference Books i Text book of Thermal Engineering By: R.S. Khurmi ii Thermal Engineering By: Sarao What is a Fuel ? Any material that can be burned to release thermal energy is called a Fuel. Most familiar fuels consist primarily of hydrogen and carbon. They are called hydrocarbon fuels and are denoted by the general formula C n H m . Type of Fuels i. Liquid (gasoline) ii. Solid (coal) iii. Gas (natural gas) Liquid Fuels Furnace oil Light diesel oil Petrol / Gasoline Kerosene Ethanol LSHS (low sulphur heavy stock) Liquid Fuels and Calorific value Fuel Oil Gross Calorific Value (kCal/kg) Kerosene 11,100 Diesel Oil 10,800 L.D.O 10,700 Furnace Oil 10,500 LSHS 10,600 Contamination of Liquid Fuel 1. Sulphur content: 1. Depends on source of crude oil and less on the refining process 2. Furnace oil: 2-4 % sulphur Effects: Sulphuric acid causes corrosion 2. Ash content Inorganic material in fuel Typically 0.03 - 0.07% Effects: Corrosion of burner tips and damage to materials / equipments at high temperature 3. Carbon residue Tendency of oil to deposit a carbonaceous solid residue on a hot surface Residual oil: >1% carbon residue 4. Water content Normally low in furnace oil supplied (<1% at refinery) Effects: Can damage furnace surface and impact flame Solid Fuels Coal classification Anthracite: hard and geologically the oldest Bituminous Lignite: soft coal Further classification: semi- anthracite, semi-bituminous, and sub-bituminous Physical properties Heating or calorific value (GCV) Moisture content Volatile matter Ash Chemical properties Chemical constituents: carbon, hydrogen, oxygen, sulphur Solid Fuel Contents 1. Moisture content 0.5 to 10% of moisture in fuel Effects: Reduces heating value of fuel Weight loss from heated and then cooled powdered raw coal 2. Volatile matter Methane, hydrocarbons, hydrogen, CO, other Typically 25-35% Easy ignition with high volatile matter Weight loss from heated then cooled crushed coal 3. Ash Impurity that will not burn (5-40%) Important for design of furnace Ash = residue after combustion 4. Fixed carbon Fixed carbon = 100 (moisture + volatile matter + ash) Carbon + hydrogen, oxygen, sulphur, nitrogen residues Heat generator during combustion Analysis of Coal 1. Proximate analysis of coal Determines only fixed carbon, volatile matter, moisture and ash Useful to find out heating value (GCV) Simple analysis equipment 2. Ultimate analysis of coal Determines all coal component elements: carbon, hydrogen, oxygen, sulphur, other Useful for furnace design (e.g flame temperature, flue duct design) Laboratory analysis Gaseous Fuels Classification of gaseous fuels 1. Fuels naturally found in nature Natural gas Methane from coal mines 2. Fuel gases made from solid fuel Gases derived from coal Gases derived from waste and biomass From other industrial processes 3. Gases made from petroleum Liquefied Petroleum gas (LPG) Refinery gases Gases from oil gasification 4. Gases from some fermentation Comparing of Fuels Constituents Fuel Oil Coal Natural Gas Carbon 84 41.11 74 Hydrogen 12 2.76 25 Sulphur 3 0.41 - Oxygen 1 9.89 Trace Nitrogen Trace 1.22 0.75 Ash Trace 38.63 - Water Trace 5.98 - Advantages of Gaseous Fuel They are free from all solid and liquid impurities. Simplest burners systems Burner systems require least maintenance Environmental benefits: lowest GHG and other emissions They do not produce smoke and ash. They undergo complete combustion with minimum air supply. A good fuel should have: Low ignition point High calorific value Freely burn with high efficiency, once it is ignited Not produce harmful gases Produce least quantity of smoke and gases Economical , easy to store and convenient for transportation Calorific Value of Fuels It is amount of heat given out by complete combustion of one kg of fuel, solid, liquid or gas. It is expressed in terms of kJ/kg of fuel. Types of calorific value i. Gross/higher calorific value (H.C.V) ii. Net/lower calorific value (L.C.V) i. Gross/higher calorific value: Total amount of heat produce by one kg of fuel ii. Net/lower calorific value: Net amount of heat used to produce steam per kg of heat L.C.V = H.C.V Heat of steam formed during combustion What is Combustion ? A chemical reaction during which a fuel is oxidized and a large quantity of energy/ heat is released is called combustion . Necessary Constituents of Combustion: i. Fuel ii. Supporter of combustion(Air/oxidizer) iii. Ignition / kindling temperature Ignition temperature for different fuels Fuel Ignition Temperature ( o C) Gasoline / Petrol 260 Carbon 400 Hydrogen 580 Carbon monoxide 610 Methane 630 The oxidizer most often used in combustion processes is air, which is free and readily available. Pure oxygen O 2 is used as an oxidizer only in some specialized applications, such as cutting and welding. Oxygen is the key to combustion Principle of Combustion Composition of Air Types of combustion Process 1. Complete combustion 2. Incomplete combustion 1. Complete Combustion Process A combustion process is complete if all the carbon & hydrogen in the fuel burns to form, CO 2 ,& H 2 O. All the sulfur (if any) burns to SO 2 . It means, all the combustible components of a fuel are burned to completion during a complete combustion process. 2. Incomplete Combustion Process The combustion process is incomplete if the combustion products contain any unburned fuel or components such as, C, H 2 , CO, or OH. Insufficient oxygen is an obvious reason for incomplete combustion, but it is not the only one. Incomplete combustion occurs even when more oxygen is present in the combustion chamber than is needed for complete combustion. Another cause of incomplete combustion is dissociation, which becomes important at high temperatures. (During adiabatic combustion max. Temp. Lower than the calculated one) Chemical equations are balanced on the basis of the conservation of mass principle (or the mass balance), Stated as follows: The total mass of each element is conserved during a chemical reaction. That is, the total mass of each element on the right-hand side of the reaction equation (the products) must be equal to the total mass of that element on the left-hand side (the reactants). Even though the elements exist in different chemical compounds in the reactants and products. Example: 2H 2 + O 2 2H 2 O Reactants Product Theoretical / Stoichiometric Combustion Process The ideal combustion process during which a fuel is burned completely with theoretical air(stoichiometric air) is called the stoichiometric or theoretical combustion process. For example, the theoretical combustion of methane is notice that the products of the theoretical combustion contain no unburned methane and no C, H 2 , CO, OH, or free O 2 . Stoichiometric air: Minimum mass / volume of air required for completed combustion of 1kg of fuel is known as Stoichiometric air. Actual combustion process In actual combustion processes, it is common practice to use more air than the stoichiometric amount to increase the chances of complete combustion or to control the temperature of the combustion chamber. Excess Air The amount of air in excess of the stoichiometric amount is called excess air. The amount of excess air is usually expressed in terms of the stoichiometric air as percent excess air or percent theoretical air. For example, 50 percent excess air is equivalent to 150 percent theoretical air, 200 percent excess air is equivalent to 300 percent theoretical air. Deficiency of Air Amounts of air less than the stoichiometric amount are called deficiency of air and are often expressed as percent deficiency of air. For example, 90 percent theoretical air is equivalent to 10 percent deficiency of air. Air-Fuel Ratio A frequently used quantity in the analysis of combustion processes to quantify the amounts of fuel and air is the airfuel ratio (AF). AF represents the amount of air used per unit mass of fuel during a combustion process It is usually expressed on a mass basis and is defined as, The mass m of a substance is related to the number of moles N through the relation m= NM, where M is the molar mass. Example: The airfuel ratio can also be expressed on a mole basis as the ratio of the mole numbers of air to the mole numbers of fuel. But we will use the former definition. The reciprocal of airfuel ratio is called the fuelair ratio. Example: One k mol of octane (C 8 H 18 ) is burned with air that contains 20 kmol of O 2 . Assuming the products contain only CO 2 , H 2 O, O 2 , and N 2 , determine the mole number of each gas in the products and the airfuel ratio for this combustion process. Assume the molar mass of air is 29.0 kg/kmol. The chemical equation for this combustion process, X, y,z and w represent the unknown mole numbers of the product, these unknowns are determined by applying the mass balance to each of the elements. For Carbon(C): 8 = x x = 8 For Hydrogen (H): 18 =2y y = 9 For Oxygen (O) 20x2=2x+ y+2z z =7.5 For Nitrogen (N 2 ): (20)(3.76) =w w = 75.2 Now, substitute the values and yields Note that the coefficient 20 in the balanced equation above represents the Number of moles of Oxygen, not the number of moles of air. The latter is obtained by 20x3.76 =75.2 moles of nitrogen to the 20 moles of oxygen. Therefore, total moles of air is 95.2 The air-fuel ratio (AF) is determine by AF = 24.2 kg air / kg fuel It mean 24.2 kg of air is required to burn each kilogram of fuel during this Combustion process. Combustion Equations of Solid Fuels When carbon burns in sufficient quantity of oxygen and produced carbon dioxide along with large amount of heat. C + O 2 = CO 2 +Heat 1mol + 1mol =1mol 12kg + 32kg = 44kg 1kg + 8/3kg = 11/3 It means that 1kg of carbon requires 8/3 kg of oxygen for its complete combustion and produces 11/3 kg of carbon dioxide gas. If sufficient oxygen is not available, then combustion process is not complete and produces carbon monoxide instead of carbon dioxide. 2C + O 2 = 2CO 2mol + 1mol =2mol (by volume) 2x12kg + 2x16kg =2x28kg (by mass) 1kg + 4/3kg = 7/3 It means that 1kg of carbon requires 4/3 kg of oxygen and produces 7/3 kg of carbon monoxide. If carbon monoxide burn further and produces carbon dioxide 2CO + O 2 = 2CO 2 2mol + 1mol =2mol (by volume) 2x28kg + 2x16kg =2x44kg (by mass) 1kg + 4/7kg = 11/7 It means that 1kg of carbon monoxide requires 4/7 kg of oxygen and produces 11/7 kg of carbon dioxide. When sulphur (if any) burns with oxygen and produced sulphur dioxide. S + O 2 = SO 2 1mol + 1mol =1mol (by volume) 32kg + 2x16kg = 64kg (by mass) 1kg + 1kg = 2kg It means that 1kg of sulphur requires 1 kg of oxygen for its complete combustion and produces 2 kg of sulphur dioxide gas. Combustion Equations of Gaseous Fuels Gaseous fuels are generally measured by volume (m 3 ) than by mass When carbon monoxide burns with oxygen and produced carbon dioxide. By Volume: 2CO + O 2 = 2CO 2 2volumes + 1vol =2vol 2m 3 + 1m 3 = 2m 3 By mass: 2CO + O 2 = 2CO 2 2x28kg + 1x32kg= 2x44kg 1kg + 4/7 kg = 11/7kg It means that 1kg of carbon monoxide requires 4/7 kg of oxygen and produces 11/7 kg of carbon dioxide gas. When hydrogen burns with oxygen produces: By Volume: 2H 2 + O 2 = 2H 2 O 2volumes + 1vol =2vol 2m 3 + 1m 3 = 2m 3 By mass: 2H 2 + O 2 = 2H 2 O 2x2kg + 1x32kg= 2x18kg 1kg + 8 kg = 9 kg It means that 1kg hydrogen requires 8 kg of oxygen and produces 9 kg of water or steam. For burning of CH 4 with O 2 , CH 4 + 2O 2 =CO 2 + 2H 2 O 16kg + 2x32kg =44kg + 2x18kg 1kg + 4 kg = 11/4 kg +9/4kg Now, consider 1kg of a Fuel, which contains C,H and S Let, Mass of Carbon = C kg Mass of Hydrogen = H kg Mass of Sulphur = S kg We know that for the complete combustion of fuel requires sufficient Oxygen for constituent element such as, 1kg Carbon (C) 8/3 kg of Oxygen 1kg Hydrogen (H) 8 kg of Oxygen 1kg Sulphur (S) 1 kg of Oxygen Therefore, total oxygen required for complete combustion of 1 kg of fuel = 8/3 C +8 H 2 +1 S kg If some quantity of oxygen is already present in the fuel, then =[8/3 C +8 H 2 + S kg]- O 2 kg We know that oxygen is obtained from the atmospheric air for the combustion Which mainly consists of Nitrogen, Oxygen and negligible quantity of Carbon dioxide and inert gases (Neon, Argon and Krypton). For the calculations these negligible quantities are not considered. Therefore, N 2 = 77% and O 2 = 23% By mass N 2 = 79% and O 2 = 21% By volume It is obvious that for obtaining 1kg of oxygen, amount of air req. =100/23=4.35kg =100/23[(8/3 C+8H 2 +S)-O 2 ] Example: A fuel has the following composition by mass, Carbon 86%, Hydrogen 11.75% and Oxygen 2.25%. Calculate the theoretical air supply per kg of fuel and the mass of products of combustion per kg of fuel. Solution: C=0.86 kg, H 2 = 0.1175kg, O 2 = 0.0225kg (i) Theoretical air supply per kg we know that Air theo = 100/23[(8/3C+8 H 2 +S)- O 2 ] kg Substitute the values Air theo = 100/23[(8/3x0.86+8 x0.1175 +0)- 0.0225] kg Air theo = 13.96 14kg (ii) Mass of products of combustion We know that, C+O 2 =CO 2 2H 2 + O 2 = 2H 2 O We know that 1kg of carbon produces 11/3 kg of carbon dioxide and 1kg of hydrogen produces 9 kg of water. Therefore, total mass of the products of combustion, =11/3xC+9H 2 kg = 11/3x0.86+9x0.1175 = 4.21 kg Example: Calculate the stoichiometric A/F ratio for the combustion of a sample of dry Anthracite of the following composition by mass C90% ;H 3%; O 2 2.5% ; N1% ; S 0.5% and ash 3% Determine the A/F ratio and the dry and wet analysis of products of combustion By volume, when 20% excess air is supplied. Constituent Mass/kg Combust: Equation Oxygen (O 2 ) req./ kg Products / kg C 0.9 C+O 2 CO 2 12kg+32 44 kg 0.9x 32/12= 2.4kg 0.9x 44/12 =3.3kg of CO 2 H 0.03 2H 2 +O 2 2H 2 O 1kg + 8kg 9kg 0.03x8= 0.24kg 0.03x9 = 0.27 kg H 2 O O 0.025 0.025kg -0.025kg N 0.01 0.01kg N 2 S 0.005 S+O 2 SO 2 32kg+32kg=64kg 0.005x32/32 =0.005kg 0.005x64/32 =0.01kg SO 2 Ash 0.03 Total 1.0 2.62kg From table O 2 required per kg of coal =2.62 kg Therefore, (i) Air required per kg of coal = 2.62/0.233= 11.25kg (Assume 23.3% O 2 by mass) (ii) N 2 associated with this air =0.767x11.25 =8.63kg Total N 2 in product =8.63+0.01=8.64kg The stoichiometric A/F ratio = 11.25/1 For an air supply which is 20% excess We know that % excess air = A/F (Actual) - A/F (Stioch) / A/F (Stioch) A/F (Actual) =11.25+20/100x11.25=1.2x11.25 A/F (Actual) =13.5/1 Therefore, N 2 supplied =0.767x13.5=10.36kg O 2 supplied =0.233x13.5=3.144kg In the products, we have N 2 =10.36+0.01= 10.37kg and excess oxygen O 2 =3.144-2.62=0.524kg Example: The volumetric analysis of a flue gas is CO 2 14% ,CO 1%, O 2 5% and N 2 80% Calculate the flue gas composition by mass. Solution: By volume CO 2 = 0.14m 3 ,CO=0.01m 3 , O 2 =0.05m 3 and N 2 = 0.8m 3 The volumetric analysis may be converted into mass analysis by Completing following table Constituent Volume of gas (m 3 ) (a) Molecular mass (b) Proportional Mass c=axb Mass in/kg d=c/c %by mass dx100 CO 2 0.14 44 6.16 6.16/30.44= 0.202 20.2% CO 0.01 28 0.28 0.28/30.44= 0.009 0.9% O 2 0.05 32 1.60 1.60/30.44= 0.053 5.3% N 2 0.80 28 22.40 22.40/30.44 =0.736 73.6% Total 1.00 c=30.44 1.00 100 The flue gas composition by mass is given in the last column CO 2 =20.2% CO = 0.9% O 2 =5.3% N 2 = 73.6% Example: A flue gas has the following percentage composition by mass CO 2 13.3% ,CO 0.95%, O 2 8.35% and N 2 77.4% Calculate the flue gas composition by volume. Solution: By volume CO 2 = 13.3% ,CO=0.95% , O 2 = 8.35% and N 2 = 77.4% The mass analysis may be converted into volumetric analysis by Completing following table Constituent % mass analysis (a) Molecular mass (b) Proportional volume c=a/b Volume in (m 3 ) d=c/c %volumetric dx100 CO 2 13.3 44 13.3/44= 0.302 0.302/3.357 =0.090 9.0 CO 0.95 28 0.95/28= 0.034 0.034/3.357 =0.010 1.0 O 2 8.35 32 8.35/32= 0.261 0.261/3.357 =0.078 7.8 N 2 77.4 28 77.4/28= 2.76 2.76/3.357= 0.822 82.2 Total 100.0 c=3.357 1.00 100 The flue gas composition by volume is given in the last column CO 2 =9% CO = 1% O 2 =7.8% N 2 = 82.2% Ans