Combustion1.pdf

TECHNICAL MEET ON COMBUSTION TECHNOLOGY

27-28 JUNE 2006, BANGALORE

S. No Title Page No.

1. Overview of combustion by Mr. Nagesh Kumar, Sr. Deputy Director,

NPC

2

2. Improving Combustion Efficiency in Burners by Prof K Ramamurthi,

IIT-Madras

37

3. Flame Safety Requirement of Combustion System by Mr. Rajendra

Kumar, Durag India Instrumentation Pvt. Ltd

144

4. Boiler efficiency measurement and control by Mr. Yashasvi, Forbes

Marshall Ltd

179

5. Preheated combustion air and furnace recuperators by Mr. Nagesh

Kumar, Sr. Deputy Director, NPC

251

6. Combustion Improving Catalyst for Heavy fuel oil by Mr. T

Rangaprasad, Director, Pennar Chemicals

290

7. Emerging International standards and practices for programmable

electronics systems (PES) for BMS applications by Mr Rajiv Kurup,

Honeywell Automation India Ltd.

349

8. NOx and other emissions by Mr M V Deshmukh, Managing Director

Eclipse Combustion Pvt. Ltd.

395

9. Combustion Efficiency efforts in Industry- Case Study by Mr. Anil

Kewalramani, G M, IPCL

497

Overview of Combustion

J. Nagesh KumarSr. Deputy Director

National Productivity CouncilChennai 600098

[email protected]

Energy Sources

• The fuels commonly in use are those which occur naturally

• generally the remains of organic materials synthesized by solar heat then subject to differing levels of pressure

• Generally, the calorific values vary according to age and hardness.

• Solid, Liquid and Gaseous fuels

Properties of Coal

• Anthracite, bituminous, and lignite

Grade Calorific Value Range ( in kCal/kg)

A B C D E F G

Exceeding 6200 5600 – 6200 4940 – 5600 4200 – 4940 3360 – 4200 2400 – 3360 1300 – 2400

Chemical Properties

• Ultimate Analysis

Parameter Indian Coal, %

Indonesian Coal, %

Moisture 5.98 9.43 Mineral Matter (1.1 x Ash)

38.63 13.99

Carbon 41.11 58.96 Hydrogen 2.76 4.16 Nitrogen 1.22 1.02 Sulphur 0.41 0.56 Oxygen 9.89 11.88

Properties of Agro Residues

Deoiled Bran Paddy Husk Saw Dust Coconut ShellMoisture 7.11 10.79 37.98 13.95 Mineral Matter 19.77 16.73 1.63 3.52 Carbon 36.59 33.95 48.55 44.95 Hydrogen 4.15 5.01 6.99 4.99 Nitrogen 0.82 0.91 0.80 0.56 Sulphur 0.54 0.09 0.10 0.08 Oxygen 31.02 32.52 41.93 31.94 GCV (Kcal/kg) 3151 3568 4801 4565

Liquid Fuels

• Furnace oil• LSHS• LDO

Properties of Gaseous Fuels• liquefied petroleum gases (LPG)

– LPG is a predominant mixture of propane and Butane– Liquid LPG evaporates to produce about 250 times

volume of gas.• Natural Gas

– Methane is the main constituent of Natural gas and accounting for about 95%

– Natural gas is a high calorific value fuel requiring no storage facilities. It mixes with air readily and does not produce smoke or soot. It has no sulphur content. It is lighter than air and disperses into air easily in case of leak

Calorific Value

• The calorific value is the measurement of heat or energy produced, and is measured either as gross calorific value or net calorific value.

• The difference being the latent heat of condensation of the water vapour produced during the combustion process.

WatervapourCarbon

HydrogenSulphurMoisture

GCV – 10,500 Kcal/kg

Water Vapour

Water Vapour

NCV – 9800 Kcal/kg

What is Combustion ?• Combustion is a chemical reaction between oxygen and fuel which

releases heat energy.• To allow this chemical reaction to take place, there must be a

physical mixing of oxygen and fuel with sufficient closeness of contact, plus temperature, plus time for the chemical reaction to be completed.

• Fuel will not burn without oxygen.Smaller the fuel particle the morecontact with oxygen and therefore the quicker and more completethe combustion process

• Holding a match under a large block of wood will not ignite wood.• Holding a match under a fine splinter of wood will cause it to

immediately burn.– ie:- We have raised its temperature to ignition point.

• Type of fuel and size of fuel particle govern speed combustion.

Combustion Reactions

3 Ts of Combustion• Time - Any chemical reaction (combustion is a chemical

reaction) takes time. Depending on the fuel the reaction can take al little as one tenth of a second and as much as several seconds. The next two T's can effect the time of the reaction.

• Temperature - Reactions occur at different speeds depending on the temperature. In many cases if the temperature is increased the reaction time will decrease.

• Turbulence - Reactions are also greatly effected by turbulence. In hydrocarbon combustion, oxygen is an important aspect of the reaction. Without turbulence enough oxygen might not make it to the reaction and cause possibly unwanted compounds to form. For example Carbon Monoxide is formed if hydrocarbons are burned without enough oxygen.

Stoichiometric Combustion

• The amount of air required for complete combustion of the fuel depends on the elemental constituents of the fuel that is Carbon, Hydrogen, and Sulphur etc. This amount of air is called stoichiometric air

C onstituents % B y w eightCarbon 85.9 Hydrogen 12 Oxygen 0.7 N itrogen 0.5 Sulphur 0.5 H 2O` 0.35 Ash 0.05

Calculation for Requirement of Theoretical Amount of Air

Element Molecular Weight kg / kg mole

C 12 O2 32 H2 2 S 32 N2 28

CO2 44 SO2 64 H2O 18

C + O 2 C O 2 H 2 + 1 /2 O 2 H 2 O S + O 2 S O 2

C + O 2 CO 2 12 + 32 44

12 kg of carbon requires 32 kg of oxygen to form 44 kg of carbon dioxide therefore 1 kg of carbon requires 32/12 kg i.e 2.67 kg of oxygen

(85.9) C + (85.9 x 2.67) O2 315.25 CO2

229.07 kg of oxygen

Calculation for Requirement of Theoretical Amount of Air (contd.)

2H 2 + O 2 2H 2O 4 + 32 36

4 kg of hydrogen requires 32 kg of oxygen to form 36 kg of water, therefore 1 kg of hydrogen requires 32/4 kg i.e 8 kg of oxygen

(12) H2 + (12 x 8) O-2 (12 x 9 ) H2O

96 kg of oxygen


S + O 2 S O 2 3 2 + 3 2 6 4

32 kg of sulphur requires 32 kg of oxygen to form 64 kg of sulphur dioxide, therefore 1 kg of sulphur requires 32/32 kg i.e 1 kg of oxygen

(0.5) S + (0.5 x 1) O2 1.0 SO2

0.5 kg of oxygen


Total Oxygen required = 229.07+96+0.5

= 325.57 kg

Oxygen already present in = 0.7 kg100 kg fuel (given)

Additional Oxygen Required = 325.57 – 0.7

= 324.87 kg

Therefore quantity of dry air reqd. = (324.87) / 0.23(air contains 23% oxygen by wt.)

= 1412.45 kg of air

Theoretical Air required = (1412.45) / 100

= 14.12 kg of air/ kg of fuel

Calculation of theoretical CO2 content in flue gases

Nitrogen in flue gas = 1412.45 – 324.87= 1087.58 kg

Theoretical CO2% in dry flue gas by volume is calculated as below :

Moles of CO2 in flue gas = (315.25) / 44 = 7.16Moles of N2 in flue gas = (1087.58) / 28 = 38.84Moles of SO2 in flue gas = 1/64 = 0.016

= 15.5 %

100)(

% 22 x

drymolesTotalCOofMolesvolumebyCOlTheoritica =

100016.084.3816.7

16.7 x++

=

Calculation of constituents of flue gas with excess air

% CO2 measured in flue gas = 10% (measured)

1001%

%%2

2 xCOActual

COlTheoriticaairExcess ⎟⎟⎠

⎞⎜⎜⎝

⎛−= 1001

105.15% xairExcess ⎟

⎠⎞

⎜⎝⎛ −=

Theoretical air required for 100 kg of fuel burnt

= 1412.45 kg

Total quantity. of air supply required with 55% excess air

= 1412.45 X 1.55

= 2189.30 kg Excess air quantity = 2189.30 – 1412.45 = 776.85 kg.

O2 = 776.85 X 0.23 = 178.68

N2 = 776.85 - 178.68 = 598.17 kg

= 55%

CO2 = 315.25 kg

H2O = 108.00 kg

SO2 = 1 kg

O2 = 178.68 kg

N2 = 1087.58 + 598.17 = 1685.75 kg

Calculation of Theoretical CO2% in Dry Flue Gas By Volume

Moles of CO2 in flue gas = 314.97/44 = 7.16Moles of SO2 in flue gas = 1/64 = 0.016

Moles of O2 in flue gas = 178.68 / 32 = 5.58Moles of N2 in flue gas = 1685.75 / 28 = 60.20

100)(

% 22 x

drymolesTotalCOofMolesvolumebyCOlTheoritica = 100

20.6058.5016.016.716.7 x

+++= = 10%

Theoretical O2% by volume %5.7100956.72

10058.5== xx

Air for combustion

Optimizing Excess Air and Combustion

• In practice, mixing is never perfect, a certain amount of excess air is needed to complete combustion and ensure that release of the entire heat contained in fuel oil.

• If too much air than what is required for completing combustion were allowed to enter, additional heat would be lost in heating the surplus air to the chimney temperature. This would result in increased stack losses.

• Less air would lead to the incomplete combustion and smoke. Hence, there is an optimum excess air level for each type of fuel.

Control of Air and Analysis of Flue Gas

• By measuring carbon dioxide (CO2) or oxygen (O2) in flue gases by continuous recording instruments or Orsat apparatus or portable fyrite, the excess air level as well as stack losses can be estimated

• The excess air to be supplied depends on the type of fuel and the firing system.

• For optimum combustion of fuel oil, the CO2 or O2 in flue gases should be maintained at 14 -15% in case of CO2 and 2-3% in case of O2

Relation Between CO2 and Excess Air for Fuel Oil

Figure 1.3: Relation between Residual O xygen and Excess Air

050

100150200250

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15Res idua l Oxygen (%)

Excess a

ir (

%)

0

10

20

30

40

50

60

70

80

90

100

8.4 9 10 11 12 13 14

Carbon dioxide %

Exce

ss a

ir %

15

Oxygen vs Excess air

Advantages of measuring O2 vsCO2

• More precise• Independent of fuel• CO2 measurement does not let us know

which side of the stoichiometric curve we are on.

Oil Firing Burners

• The burner is the principal device for the firing of fuel.• The primary function of burner is to atomise fuel to

millions of small droplets so that the surface area of the fuel is increased enabling intimate contact with oxygen in air.

• The finer the fuel droplets are atomised, more readily will the particles come in contact with the oxygen in the air and burn.

• Normally, atomisation is carried out by primary air and completion of combustion is ensured by secondary air.

• Burners for fuel oil can be classified on the basis of the technique to prepare the fuel for burning i.e. atomisation.

Oil burner

Spray at 10 psi pressureSpray at 100-psi pressure

Spray at 300-psi pressure

Effects of ViscosityOn Nozzle Performance

High viscosity spray

Combustion of Coal• excess air required for coal combustion depends on the type

of coal firing equipment

• Hand fired boilers use large lumps of coal and hence need very high excess air.

• Stoker fired boilers use sized coal and hence require less excess air. Also in these systems primary air is supplied below the grate and secondary air is supplied over the grate to ensure complete combustion.

• Fluidised bed combustion in which turbulence is created leads to intimate mixing of air and fuel resulting in further reduction of excess air.

• The pulverized fuel firing in which powdered coal is fired has the minimum excess air due to high surface area of coal ensuring complete combustion.

Combustion of Gas

• The stoichiometric ratio for natural gas (and most gaseous fuels) is normally indicated by volume.

• The air to natural gas (stoichiometric) ratio by volume for complete combustion vary between 9.5:1 to 10:1

• Natural gas is essentially pure methane, CH4. Its combustion can be represented as follows:

• CH4 +2O2 = CO2 + 2H2O • So for every 16 kgs of methane that are

consumed, 44 kgs of carbon dioxide are produced.

Natural gas combustion

Turndown RatioRatio of burner’s Maximum firing capacity to minimum firing capacitySince turbulence is related to velocity, at higher turndown would require higher excess airBest burner will provide good turbulence with least excess airHigher turndown ensures better process controlHigher turndown means reduced maintenance costs

Furnace volume for different fuels

IMPROVING COMBUSTION IN BURNERS

K. RAMAMURTHI

MECHANICAL ENGINEERING DEPARTMENT

INDIAN INSTITUTE OF TECHNOLOGY MADRASCHENNAI

IMPROVING COMBUSTION IN BURNERS

• REVIEW MECHANISMS OF COMBUSTION IN BURNERS

• DETERMINE EVOLVING TRENDS:

- IMPROVING EFFICIENCY- REDUCING POLLUTION- BURNING LOW GRADE COMBUSTIBLES- LARGE POWER PLANTS, FURNACES,

KILNS, INCINERATORS

• DEVELOPMENTS IN THE NEAR FUTURE

• CONCLUSIONS AND RECOMMENDATIONS

DOMESTIC COAL FIRE

FRESH COAL PLACED AND HEAT TRANSFERRED FROM BELOW

EVAPORATION OF VOLATILE MATTERSMOKE

WHEN ADEQUATE TEMPERATURE REACHED : VOLATILE MATTER BURNS

LEAVES BEHIND A RESIDUE OF FIXED CARBON GLOWS AND SMOLDERS

NON-COMBUSTIBLE IN COAL FORMS ASHASH PERFORMS USEFUL FUNCTION OF PROVIDING INSULATION TO THE GRATE

Coal Stove

PRIMARY AIR : LIMIT OR ELSE QUENCHED

C + ½ O2 = COOXIDATION ZONE I

CO + ½ O2 = CO2 OXIDATION ZONE II

CO2 + C = 2CO REDUCTION ZONE

GREEN COAL

SEC. AIRBURNS WITH SECONDARY AIR : CO + O2 = CO2

EXOTHERMIC

ENDOTHERMIC

LARGE COAL BURNER

• SAME PRINCIPLE : COAL BURNING OVER GRATE

-- TANDOOR / BARBACUE

-- OVENS FOR BAKING

• A LARGE POWER PLANT : RAMAGUNDAM – 2600 MW (4X500+3X200)2600x106 J/S. CAL VALUE OF COAL ~ 30000 KJ/KGCOAL REQUIRED PER DAY : 2600x106 x24x3600/30000x103

7500 TONS PER DAY

• COAL TRAIN WITH 75 WAGONS WITH 100 T/WAGON PER DAYUNLOADER, DUMPER , GRATE - SURFACE AREA FOR

COMBUSTION - PULVERIZATION

RAMAGUNDAM 2600 MW NTPC

COMBUSTION PROCESS IN A HAND-FIRED GRATE

FIRE TUBE BOILER

Locomotive Boiler from D. A. Low

Independent Water and Power Production: Algeria 344 MW (IHI) – Including desalination

WOOD STOVE

• HEAT TRANSFER FROM FLAME TO WOOD CAUSES VOLATILE VAPOR TO FORM

• VAPOR MIXED WITH AIR IN SUITABLE PROPORTION BURNS AS IN THE CASE OF COAL VOLATILES

• WEAKLY BURNING WOOD SMOKES : INSUFFICIENT AIR – ONLY INTERMEDIATE PRODUCTS

OF VOLATILIZATIONTOO MUCH AIR – BLOWS OUT

• HEAT LOSSES PARTICULARLY IMPORTANTTRAPPED RADIATION WITHIN SPLINTERS

ENTRAPPED RADIATION CONTRIBUTES TO IGNITION AND MAINTAINING THE FLAME

Cast Iron Wood Stove

Barbecue

“THE HINDU” March 1, 2006

• PHILLIPS DEVELOPS “EFFICIENT”” STOVE – A WOOD STOVE

WHICH USES CONVENTIONAL ENERGY – WOOD – EFFICIENT,

REDUCES SMOKE AND TOXIC EMISSIONS 16 LAKH DEATHS A YEAR

WORLD’S POOREST COULD BENEFIT FROM THE INVENTION

• ELECTRONICALLY CONTROLLED FAN FORCES AIR TROUGH STOVEBETTER AIR-FUEL RATIOSSUITABLE TEMPERATURE

DOMESTIC GAS BURNER

F

VARIANT OF BUNSEN BURNER

GAS ENTERS A NARROW TUBE AND DRAWS PRIMARY AIR; MIXES IN MANIFOLD

SECONDARY AIR ENTRAINED ABOVE BURNER

FLAME ATTACHED TO RIM

Gas Stove

PARAMETERS

• SHAPE, DIAMETER OF JET

• DIAMETER OF BURNER PORT

• THROAT OF VENTURI

• STABILIZATION OF FLAME AT BURNER HEAD

GAS PROPERTIES IMPORTANTHEATING REQUIRED –

QUANTITY AND REQUIRED SIZE

2dT BURNER DIA

U

TURBULENCE LIMIT

5SU

gF

gB

2SU

LARGE INDUSTRIAL BURNERS

• MORE GAS – BOOST FUEL GAS SUPPLY PRESSUREEXPLOSION AND SAFETY ASPECTS

• INTRODUCE AIR AT HIGH PRESSURES FLAME TO BE ANCHORED

• BETTER MIXING STRATEGIES

ADD ON FEATURES FOR REDUCING NOx

INCREASING EFFICIENCY

NOx

• NOx : NO, NO2 SHORT LIFETIME IN ATMOSPHERE NO TO NO2 CONTRIBUTE TO PHOTOCHEMICAL SMOG

ACID RAINFINE PARTICULATESVISIBILTY DEGRADATION

NOx ISSUES : LOCAL, REGIONAL (HOURS TO DAYS)

N2O : LONG LIFETIMEGLOBAL WARMINGSTRATOSPHERIC OZONE CHEMISTRY

PROMPT NOx (FENIMORE : CH+N2=HCN+N). Thermal NOx (ZELDIVICH)FLAME ZONEN + O2 = NO + O RATE CONTROLLINGN2 + O = NO + N REDUCE BY AFTERBURNINGN + OH = NO + H LOWER TEMPERATURES

AMMONIA OR UREA LOW NOx BURNERS

CERAMIC PIPE

INTERNAL RECIRCULATION

OIL

AIR

“MAN” LOW NOx INDUSTRIAL BURNER

Jet Flame Swirl Flame

Kinedizer Low NOx Burner : NG ; Reinforced Refractory Block ( Kilns, furnaces, ….)

Weak Swirl Burner Arrangement

Merging Advanced Premixed Burner with Gas Pretreatment for NOx < 2ppm : Cheng 2002 ; Lawrence Berkley National Lab

Weak Swirl Burner Arrangement

Low Swirl : Low NOx Coal- oil Burner with rich central core region : Riley – Babcock Power

Staged Combustion to get low NOx : Delayed combustion in Primary and Secondary due to air deficiency ; Overfire air completes combustion

Foster Wheeler Series – Split Flame Low NOx Burner : Coal Nozzle with Biomass

Low NOx Pulverized Coal Burner – Babcock-Hitachi

NR NR 2 NR 3

A wider and shorter flame gives very low NOx and HIGH Combustion Efficiency – Babcock Hitachi

A. Feather-shaped Laminar Flame. All purpose combustion chambers

C. Ball-shaped. Swirl. Stoker fired Boilers, Fluidized Beds, Ovens

E. Flat: Coanda. Refractory Quarl. Radiation

F. Long, Luminous and Bouyancy Controlled – Long Chambers

G. Long, Luminous Fire Hose – Uniform coverage in Long Chambers

H. High Velocity low Swirl: Enhanced convection within and outside tile

Incinerator / Kiln / Furnace / Drier

COMBUSTION PROCESS IN AN OIL/PULVERIZED COAL – FIRED BOILER

Vaporizing Combustor - Rolls Royce

High Performance Alcohol Stove

CONTROLLED BURNING

• REGULATING AIR : THREE STAGES

• HEAT FEEDBACK TO EVAPORATE LIQUID FUEL

• QUENCHING FLAME TO FORM VAPOUR FLOW

• MIXING WITH AIR TO FORM PREMIXED MIXTURE

• BURNING WITH SECONDARY AIR

INCORPORATE FEATURES IN INDUSTRIAL BURNERS, BOILERS, FURNACES

CF6 – 50 ANNULAR COMBUSTOR General Electric Company

Oil power plant in Iraq

SUMMARY OF OBSERVATIONS

• VOLATILES BURN WHETHER WOOD / COAL / LIQUID FUEL

• RESIDUE FIXED CARBON/COKE IN CASE OF COAL. WOODLIQUID FUEL(?)

SOOT FORMED IN FUEL-RICH CONDITIONS

CONSTITUENTS: C, H, O, NDIFFERENT FOSSIL FUELS• GAS: NATURAL GAS – MAINLY METHANE

–Sour, Sweet, Wet, Noble Gas He, H2, CO2

• LIQUID PETROLEUM – HOMOGENEOUS SOLUTION CONTAINING 100S – 1000S OF INDIVIDUAL COMPOUNDS

-PARAFFINS, NAPHTHENES, AROMATICS, COMPUNDS WITH O,N,S

FOSSIL FUELS (Continued)

• SOLID : MACROMOLECULAR STRUCTURE WITH VARYING COMPOSITION65-95%C, 2-6%H2, 2-30%O2, 1-13%S, INORGANIC MATERIAL (ASH 1-25%), H2O

• COAL : ABUNDANTLY AVAILABLE IN DIFFERENT GRADESVOLATILE MATTER + FIXED CARBON

Anthracite, Bituminous, Subbituminous, Lignite• PULVERIZED COAL

UPTO 70% WATERASH

• LIQUIFACTION OF COAL BY HYDROGENIZATION AT HIGH TEMP. 400-500 CHIGH PR. 70 MPa

• COAL LIQUID MIXTURES : COM,CWM,CWO,CMM(Methanol)• GASIFICATION INTO SYNGAS

FOSSIL FUELS ( Contd.)

CALORIFIC VALUE (KJ/KG) H2

NATURAL GAS : 55,600

LIQUID PETROLEUM : 46,000

COAL : 25,000 – 35,000

LIGNITE : 20,000 – 25,000(~2500 MW – Neyveli Lignite Corp.)

O2

GASIFY AND USE : IGCC

O/C

H/C PEATLIGNITE

COAL

SEQUENCE OF TRANFORM

NATURAL GAS

• RESERVES: 171x1012 M3 AS OF JAN. 2005

ANNUAL CONSUMPTION ~ 2.6 TRILLION M3

GAS GRID – IMPORTANCE OF GAS BURNERSNTPC: 110/130/140 MW MODULES IN GUJRAT, RAJASTHAN, UPWB: RELIANCE

GASIFICATION OF LOW GRADE FUELS : IGCC

• RELOOK AT IMPROVEMENTS IN GAS BURNER CONTEXT OF RECENT COMBUSTION RESEARCH FINDINGS

LARGE POWER PLANTS OF NTPC

• COAL : ~ 21,000 MW(UNITS OF 500MW, 200 MW)

Korba, Ramagundam, Singrualli, Farakha, Vindhyachal, Rihand, Talchar..

• GAS : ~ 3600 MW(UNITS OF 140 MW, 110/105 MW, 60 MW)

Gautham Budh Nagar, Anta(Rajasthan), Faridabad, Kawas …

• LIQUID : ~ 350 MW(UNITS OF 110,130 MW)

Only one at Kayamkulam

NOT LIQUID; MOVE TOWARDS CLEAN COAL TECHNOLOGIES10th PLAN : 41,100 MW ADDITIONAL

NTPC GAUTAM BUDH NAGAR UP 817 MW GAS BASED

INTEGRATED GASIFICATION COMBINED CYCLE POWER PLANT

• GASIFY COAL/ LOW GRADE SOLID/LIQUID FUEL CO, H2 …. IMPROVEMENT OVER FLUIDIZED BED COMBUSTION

• USE IN A GAS TURBINE

• WITH HOT EXHAUST GENERATE STEAM IN RANKINE POWER PLANT

• MEETS EMISSION NORMS, EFFICIENT

• PROMISING OPTION WITH HYDROGEN FUEL CELLS(?)

Combined Cycle Power Plant

Combined Cycle Cogeneration Unit

500 MW combined cycle power plant by New York Power Authority- Cleanest Fossil fuelled Plant

Combined Cycle Power Plant New Zealand 395 MW , Florida Siemans

FLAMELESS COMBUSTION OR BURNINGSURFACE COMBUSTION ON A HOT POROUS BLOCK

• DIMENSIONS < QUENCHING DISTANCE

• NO FLAME : CHEMICAL REACTIONS OF HEATED AIR/FUEL MIXTURE

• SIMILAR TO MICRO / NANO COMBUSTION DEVICES

• VERY EFFICIENT HEAT RELEASE

• CONTROLLED EMISSION; NEEDS SYSTEMATIC STUDY

ATTRACTIVE FOR SUPERCRITCAL BOILERS

Bonecourt Boiler ( from: D. A. Low - Heat Engines)

POROUS MEDIUM BURNING (PMB)

FURTHER IMPROVEMENTS (?) – NEW BASIC DEVELOPMENTS

• VORTEX COMBUSTION

• COMBUSTION ACOUSTICS

• MIXING USING SOUND

• PULSED BURNING

a) Flame at burner rim b) Flame base lifted-off c) Flame base before from burner rim extinguish

0 4000 8000 12000 16000 20000Re

0

10

20

30

40

50

60Li

ftoff

Hei

ght /

Noz

zle

Dia

met

er

With CavityWithout Cavity

Blowoff

Blowoff

RMS SOUND PRESSURE LEVEL

SPECTRUM

0 20000 40000 60000 80000Re

0

10

20

30

40

50

60

70

80

90Je

t spr

eadi

ng a

ngle

, o

Swirled Jet

Non-swirled Jet

A

B

C D

EF

0 20000 40000 60000Re

40

45

50

55

60

65

70S

PL

at d

omin

ant f

requ

ency

, dB

Wall Jet Region

Turbulent JetRegion

FURNACE IS A CAVITY

)(2sinλ

π xAy = )(2sin atxAy −=λπ )(2sin atxAy +=

λπ

)(sin)(sin tkxAtkxAy ωω ++−=

tkxAy ωcossin2= STANDING WAVE

ANTINODES: ZONES OF LARGE VARIATIONS NODES: NO VARIATIONS

PUT BURNING ZONE / HEATING ZONE IN ANTINODE REGION

VARIANT OF AUGMENTATION IN ANTINODE REGIONCOMBUSTION ACOUSTICS

• RIJKE TUBE : LOUD NOISE

Q

SHOULD BURN POOR GRADE COMBUSTIBLE EFFICIENTLY

NEEDS TO BE ADEQUATELY INVESTIGATED

CONSTANT VOLUME COMBUSTION

• I C ENGINENATURE APPEARS TO PREFER A PULSED PROCESS

• PULSE JETS

• PULSE COMBUSTION BOILER EFFICIENCY:96% Futton Co., USALOW NITROGEN OXIDE EMISSIONSELIMINATES NEED FOR FANS, BLOWERS AND

CONVENTIONAL FLUES

RESONANT DESIGN OF COMBUSTION CHAMBER AND EXIT PIPE

FLUE GAS RECIRCULATION : Reduces NOx

Pulse Combustion Boiler – Southern California Gas Company

SUMMARY

• SEEM TO MOVE TOWARDS USE OF NG/CONVERSION OF LOW GRADE FUELS TO GAS

• MOST ASPECTS OF INDUSTRIAL COMBUSTION MET WITH IN DOMESTIC COMBUSTION ; ONLY SCALE UP

• WEAK SWIRL HAS BEEN ADEQUATELY EXPLOITED (NOx, η)

• USE OF ACOUSTICS ENHANCING COMBUSTION AND REDUCING EMISSIONS NEED STUDY / UNSTEADYNESS WITH

PULSE

• FIRE AND EXPLOSION SAFETY WITH REACTIVE GASES HAS TO BE ADDRESSED

GLOBAL BIOLOGICAL CYCLE

CO2

OCEAN PLANTS DEAD ORGANISMS ROCKS

ANIMALS (From: Schobert)

PHOTOSYNTHESIS : 6CO2 + 6H2O → C6H12O6 + 602

HEXOSE, GLUCOSE.. → FATS, WOOD,PROTEINS,..C6H12O6 + 602 →6CO2 + 6H2O

DECAY TO FORM PEAT →FUELANAEROBIC DECOMPOSITION, …C6H12O6 → 3CO2 + 3CH4

• DETOUR IN THE CARBON CYCLE : ULTIMATELY BURNT TO CO2

• PRESENT PROBLEM: COMBUSTION TODAY IS FASTER THAN PHOTOSYNTHESIS : NEED TO MAKE IT EFFICIENT

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2

Flame Safety Requirements of Combustion Systems

Technical Meet on Combustion TechnologyOrganised by FICCI at Atria Hotel-Bangalore

27-JUN-2006

BY

U RAJENDRA KUMARDIRECTOR

NTPC-FARAKKA STPS

Corporate Structuresl

i_du

rag_

grou

p_uk

_03_

01

Hans-Peter SchuldtHans-Peter Schuldt

Union Agricole Holding AGPinneberg, Germany

Dipl.-Kfm. Hartmut Krenz (Vorsitzender) · Hans-Peter Schuldt · Rudolf Buchleitner

Union Agricole Holding AGPinneberg, Germany

Dipl.-Kfm. Hartmut Krenz (Vorsitzender) · Hans-Peter Schuldt · Rudolf Buchleitner

Hamburg, Germany

Hans-Peter Schuldt

Ton Hameleers

Hamburg, Germany

Hans-Peter Schuldt

Ton Hameleers

Stuttgart, Germany

Hans-Peter Schuldt

Dr. Ulrich Greul

Stuttgart, Germany

Hans-Peter Schuldt

Dr. Ulrich Greul

Hamburg, Germany

Hans-Peter Schuldt

Hamburg, Germany

Hans-Peter Schuldt

Hamburg, Germany

Hans-Peter Schuldt

Rainer Böcher

Hamburg, Germany

Hans-Peter Schuldt

Rainer Böcher

Minneapolis, USA

Bangalore, India

France

China

United Kingdom

Minneapolis, USA

Bangalore, India

France

China

United Kingdom

DURAG INDIA Instrumentation Private Limited

BANGALORE102, SOPHIA’S CHOICE,ST. MARKS’ ROAD,BANGALORE-560 001.

PHONE :080-4112 0223FAX :080-4112 0224www.duragindia.com

Indian OEM Partners/Customers

BHEL/ CVL

JASUBHAIL&T/EMERSON

WESMAN

IL-KOTA

ABB

Thermax

BHEL

Pakistan

Bangla Desh

Sri Lanka

Indian Distributor Partners

ELMA

TECHMARK

ELMA

SUKAN/ICE

GREAVES/RELIANCE

SUKAN/ADVANCETECH

SSCE

INSINTRA

DURAG Products

Combustion :

- Flame Sensors/Monitors- Burner Controls- Electric Spark Ignitors- Industrial Burners (Oil & Gas)- Dual Fuel Burners- Pilot Burners- Online Video Spectroscopy System for

Coal fired Boilers

Emission :

- Optical Dust Concentration Monitors- Tribo Electric Filter Monitors- Volumetric Flow Monitors- Extractive Beta-gauge Particulate Monitors- Ambient Beta-gauge Particulate Monitors- Mercury Analysers- Computerised Emission Evaluators and

data processing systems

Combustion Basicssl

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COMBUSTION PRODUCTS

COMBUSTION BASICSsl

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FlameSensorD-LE 603

Steam

Purge Air

Control Unit D-UG 660of the Flame Detector

Device

Bar GraphDisplayD-ZS 129-30

Gas

Pneumatic RetractionUnit D-VE 500

High Energy Ignition DeviceD-HG 400 with Lance

Oil

Combustion Air

Combustion Basicssl

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FLAME IGNITION

Ignition of Flames: Ignition Energy

Pilot Flame /Ignition Burner

Electrical Spark Ignitor GasGas

Light OilLight Oil

Heavy OilHeavy Oil

CoalCoal

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DURAG Ignitor D-HG 400Energy per Spark: 4.5 JSpark rate: 20 Sparks / sTotal Energy: 90 J

DURAG Ignitor D-HG 1600Energy per Spark: 16 JSpark rate: 4 Sparks / sTotal Energy: 64 J

Comparing the Energysl

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Ignites Liquid and Gaseous Fuels in Burners of any CapacityCompact Design: Control Unit and Ignition Lance are one UnitUses a Thyristor instead of a Discharge Tube, therefore free of Wear and TearIn Conjunction with NFPA 8501/8502 Class 3 Special (Electrical Ignitor)Available also for Hazardous AreasAvailable also as Portable Ignitor

Highlights of the DURAG D-HG 400 Ignitorsl

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Ignition of Flames: Systems

High Voltage Ignitor (System DURAG)High Voltage Ignitor (System DURAG)

Gas Ignitor (System Hegwein)Gas Ignitor (System Hegwein)

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D-HG 400 High Energy Ignition Device

Ignition of liquid or gaseous fuels in high-capacity industrial burners

Compact design: control unit and ignition lance as one modular unit

Also available in explosion-proof version with separate ignition lance

Pneumatic Retraction Unit D-VE 500 for automatic burner ignition

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Dimensional Drawing of D-HG 400 / D-VE 500

E

>50

>50

L0

D

C

A

B

7531238153938591600 mm

6431128143828491500 mm

5331018133718391400 mm

423908123608291300 mm

EDCBAExpansion

Limit Switches Solenoid ValveProtection Tube

Mounting Flange

D-HG 400-50Ignitor Electronic

Twin Cut Connection

Expansion

Calculation of the Ignition Lance Length: L= L0 + B + 50mm

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D-HG 400-90 – Flexible High Energy Ignitor

ApplicationThe D-HG 400-90 High Energy Ignitor has a flexible ignition lance. It has been designed to ignite especially titling burners. The flexible hose of the ignition lance is able to follows the titling of the burner. Ignition is possible under all tilt angles.

Flexible Conduit

System ComponentsD-HG 400-90: Electronic Unit with attached

flexible Ignition LanceD-HG 400-91: Outer CarrierD-VE 500/.../F: Pneumatic Retraction Unit,

special version for flexible Ignition Lances

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Portable High Energy Spark Ignitor D-HG 400-80sl

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Combustion Basicssl

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FLAME MONITORING

Different Methods of Flame Monitoringsl

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Optical▲ Simple ▲ Good Selectivity▲ Fail-Safe▼ Expensive

Ionisation / Rectification▲ Simple and In-expensive▲ Good Selectivity▲ Fail-Safe▼ Poor sensitivity▼ Only for smaller burners

Spectroscopy / Video▲ Flame Analyses▲ Combustion Enhancement▼Not Fail Safe▼ Very Expensive

Acoustic▲ Simple▲ In-expensive▼ Not Fail-Safe▼ Not Selective

Flame Recognitionsl

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Flame Light Intensity (DC-Portion)

time t Zeit ttime t

i

i0

fF

UV 400 VIS 800 IR

Light Wavelength in nm

λ

i ∆λ

Flame Recognition A B C D∧ ∧ ∧Y / N

Flame Flicker Frequency in Hz

200

100

Distance from BurnerFlame Sensor

i

i∆

C

A

D

Bi > >00

∆λ=UV or IR

i>0∆

f >>0F

Flame Light Intensity

Flame Light Intensity (AC-Portion)Flame Light Intensity (DC-Portion)

time t Zeit ttime t

i

i0

fF

UV 400 VIS 800 IR

Light Wavelength in nm

λ

i ∆λ

Flame Recognition A B C D∧ ∧ ∧Y / N

Flame Flicker Frequency in Hz

200

100

Distance from BurnerFlame Sensor

i

i∆

C

A

D

Bi > >00

∆λ=UV or IR

i>0∆

f >>0F

Flame Light Intensity

Flame Light Intensity (AC-Portion)

Flame Light Emission and Sensor Sensitivity

Intensity of Flame Light Emission

Coal

UV Cell

UV VIS IR

Oil

Gas

Wavelength of Flame Light Emission in nm

10.000

1000

100

10

1100 400 800 1000 2000

Germanium Semiconductor

GaP Semiconductor

Silicium Semiconductor

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Influence of Dust and Steam

100%50%F1=30

Lin. KanalVerstärkung/Gain

Helligkeitsschwelle

PulsabzugPulse Adjust

Meßbuchse

Measuring OutletPulsausgang

Pulse Output

Brightness ThresholdFiltereinstellung/Filter Adjust

100%50%15

60120

f/Hz

15Hz60Hz

120Hz

LIN ein

Lin.ChannelEingangsfilter/Input Filter

LIN on

F1F2

Log. Kanal/Log. Channel

Pulsabzug/Pulse Adjust

M3

M2

M1

F2=150f/Hz

12

34

Burner

Adjusting Flange

UV-light

Dust / Steam

IR-light

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A Flame Monitor is always build from a Control Unit and a Flame Sensor

Multiple Burner FurnacesControl Unit: D-UG 660Flame Sensor: D-LE 603

Single Burner FurnacesControl Unit: D-UG 110 / 120Flame Sensor: D-LE 103

orCompact Flame Monitor: D-LX 100

Flame Monitor Overviewsl

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Stray Light Effect

B1

B2

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Eliminating the Stray Light Effect

Distance from Burner

150

200

100

0

High PassFilter Setup100Hz

B1

B2 50

f =160 Hz1

f =50 Hz2

Flame Flicker Frequency

f [Hz]

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Selection of Flame Sensors

CombustionCombustion

Single Burner SystemSingle Burner System

OilOil GasGas CoalCoal

FlameSensorD-LE…103 UA103 UAF103 IG103 IS

FlameSensorD-LE…103 UA103 UAF103 IG103 IS

FlameSensorD-LE…103 UL103 UA103 UAF

FlameSensorD-LE…103 UL103 UA103 UAF

FlameSensorD-LE…103 IS103 IG

FlameSensorD-LE…103 IS103 IG

Multi Burner SystemMulti Burner System

OilOil GasGas CoalCoal

FlameSensorD-LE…603 UA603 UAF603 IS603 IG

FlameSensorD-LE…603 UA603 UAF603 IS603 IG

FlameSensorD-LE…603 UH603 US603 UA603 UAF

FlameSensorD-LE…603 UH603 US603 UA603 UAF

FlameSensorD-LE…603 IS603 IG603 ISE603 ISO

FlameSensorD-LE…603 IS603 IG603 ISE603 ISO

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Components of D-LE 603 + D-UG 660sl

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D-ZS 033 I Ball Type

Adjustment Flange

D-ZS 133 IBall Valve

D-ZS 117 IHeat

Insulator

Purge Air

Flange

D-ZS 129Bar

Graph Display

D-UG 660Control Unit

Range SelectionSafety TimeThreshold

Flame Relay ContactStatus Relay ContactFlame Intensity

GainFrequency FilterPulse Reduction

D-LE 603Flame Sensor

Optional Second Flame Monitor

D-ZS 087- 20

D-LE 603: Selection Criteria

New! Dual colour flame sensor with UV and IR sensitivity, remote spectral range selection-++++++D-LE 603 UI

Dual channel flame sensors (LIN/LOG) for selective monitoring of single coal burners in multiple burner furnaces++D-LE 603 ISO

Dual channel flame sensors (LOG/LOG) for selective monitoring of single coal burners in multiple burner furnaces++D-LE 603 ISE

Selective monitoring of single burner for coal, oil or gas flames in multiple burner installations. +++++oD-LE 603 IG

Selective monitoring of single burners for coal or oil in multiple burner furnaces. ++++!D-LE 603 IS

Selective monitoring of single burners for oil or gas in multiple burner furnaces, especially on low NOxapplications. Remote gain control. ++++D-LE 603 UA

Selective monitoring of single burners for oil and gas in multiple burner furnaces. Good selectivity at high stray light levels, remote gain control.

++oD-LE 603 UAF

Selective monitoring of single burners for gas and oil in multiple burner furnaces with low UV radiation levels.++D-LE 603 US

Selective monitoring of single burners for gas and oil in multiple burner furnaces.o++ D-LE 603 UH

Characteristics WoodCoalOilGas

Suitable for Fuels Model

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D-LX 100 and D-ZS 087-20 Digital Display

D-LX 1009

0

9

0

D-ZS 087D-ZS 087

Status LEDsyellowgreenred

: Ready for operation: Flame ON: Fault

Reset button

Connection for D-ZS 087

Flame threshold adjustment

D-ZS 087- 20Reset Mode

Digital Display D-ZS 087-20(only for setup)

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Flame Sensor Interface

+20V

GND

Shutter

Signal

Signal

Shutter

1 s0,80,2

Shielding

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Arrangement of Flame Sensors

Burner 1.1

Burner 1.3

Burner 1.4

Burner 1.2D-LE 603

D-LE 603

D-LE 603

D-LE 603

D-UG 660

D-UG 660

D-UG 660

D-UG 660

6°

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5 Steps for an Optimum Flame Monitor Adjustment

Selection of the correct flame sensorThe flame sensor must be suitable to monitor the fuel under any condition.

Determine the best viewing positionThe flame sensor must see the root of the flame which shall be monitored and only the tips of other flames.

Correct alignment of the flame sensorAdjust the swivel mount so that the flame sensor has the best view to the root of the flame which shall be monitored.

Adjust the gain and frequency filter of the flame sensorA maximum difference for flame on and flame off pulse rates must be achieved.

Verify the setting for all burners and conditionsEnsure reliable flame monitoring on all burners and for all conditions

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Flame Scanner D-LE 603 mounted on a Burnersl

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Major Indian References

1. Neyveli Lignite Corporation : All Units in TS-II and TS-I expansion have Durag Scanners & IgnitorsAll Units in TS-I will have Durag Scanners & Ignitors by end of this year

2. CMS Energy-Neyveli :Durag Scanners and Ignitors

3. UPRVUNL-Parichha TPS 2x110 MW :Combustion Engineering Boiler supplied by BHEL.During R&M, successfully replaced with Durag Scanners and High Energy Ignitor.Oil ignitors replaced with High Energy ignitors, saving huge cost of oil

4. Following Refineries have Durag Scanners :Barauni, Gujarat, Mathura, Panipat, Numaligarh, Haldia

5. A total of 500+ scanners and Ignitors are in operation in India in various Power Plants,Refineries and other process plants

For details please contact

DURAG INDIA instrumentation Private Limited102, Sophia’s Choice, St. Marks’ RoadBangalore – 560 001Phone : +91 (0)80 4112 0223FAX : +91 (0)80 4112 0224Web : www.duragindia.com

Rajendra Kumar Director +91 98440 68047 [email protected]

Mahesh Mhatre Service Manager +91 98202 30711 [email protected]

Binny Phabian Asst Manager – Sales +91 98863 95650 [email protected]

Vipul Jain Service Engineer +91 98863 90879 [email protected]

Jayanthi Rozario Office Administrator +91 98454 07073 [email protected]

Boiler House Division Air

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Air to fuel ratio controlFICCI – June 2006 - Bangalore


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The Next Hour and a half

• Boiler Efficiency• Combustion basics• Traditional control systems• Oxygen trim control• Oxygen measurement• Ensuring optimum efficiency• Boiler Efficiency improvement packages


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Cost of operation–Oil fuels


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Cost of operation-Solid fuel


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Operating costs

• Capacity Oil Gas Coal• 1 TPH 110L 60L 35L• 5 TPH 690L 300L 172L• 10 TPH 1350L 600L 345L

• Cost of fuel Rs 22/kg Rs 9/Nm3 Rs 2/kg• Hours of operation 8000 8000 8000


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Estimated savings

• Capacity Oil Gas Coal• 1 TPH 5L 2.2L 1.5L• 5 TPH 25L 11L 7.5L• 10 TPH 50L 22L 15L

• Improvement 80 to 83 79 to 82 70 to 73• Cost of fuel Rs 22/kg Rs 9/Nm3 Rs 2/kg• Hours of operation 8000 8000 8000


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Boiler Efficiency

• Boiler efficiency depends on both, the heat generation and heat utilization process.

• Heat generation covers the combustion process itself

• Heat utilization coves heat transfer from combustion to water and other operational losses like radiation and blowdown.


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Boiler Efficiency-Losses

• Heat generation– Stack loss– Enthalpy loss

• Heat Utilization– Radiation loss– Blowdown loss


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Losses – Typical values


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Boiler Efficiency-Methods

• Direct Efficiency• In-Direct Efficiency

– BS– ASME– IS

• Energy balance• S:F


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Controllable losses

• Stack loss– Can be easily controlled– One of the chief contributes to total boiler

losses• Blowdown loss

– Automatic control helps• Other losses: Enthalpy, Radiation, Ash


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Combustion and efficiency• Combustion is the burning of a fuel with Air leading to

release of energy. It is the process by which the Chemical energy contained in the fuel is converted into Heat energy.

• All conventional fossil fuels whether Solid, Liquid or gaseous contain basically carbon and/or Hydrogen which invariably react with the oxygen in the air forming carbon dioxide, carbon monoxide or water vapor.

• The heat energy released as a result of combustion can be utilized for heating purposes or for generation of steam in a boiler.


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Heat generation process

• In fossil fuels there are only three elements of interest: carbon, hydrogen & sulfur.

• During combustion each reacts with oxygen to release heat:

• C + 02 CO2 + Heat• H2 + ½ O2 H20 + Heat• S + O2 SO2 + Heat• Pure carbon, hydrogen and sulfur are rarely used as fuels.

Instead, common fuels are made up of chemical compounds containing these elements.


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Heat generation process

• CnHn + O2 + N2 CO2 + H2O + N2 + Heat(Air)

• From the above equation it can be seen that hydrocarbon burns completely to produce water, CO2 & heat. This kind of complete burning is known as stoichiometric combustion.

• The heat released when the fuel burns completely is known as heat of combustion.

• Nitrogen doesn’t play a role in combustion and appears in the output as it is.


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Excess Air

• The Minimum amount of air required for the complete combustion of a fuel is known as “theoretical air “.

• In boilers, one always needs to supply more air than what is required by stoichiometric calculations . The extra air, that is needed for complete combustion, taking into realities of combustion, over and above the stoichiometric air is known as “ Excess air “.

• The fuel rich mixtures, or mixtures with stoichiometric or less than stoichiometric air give incomplete combustion that results in some quantity of undesirable carbon monoxide in the exhaust gases and also some loss of heat energy.


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Excess Air• Too little excess air is inefficient

because it permits unburned fuel, in the form of combustibles, to escape up the stack. But too much excess air is also inefficient because it enters the burner at ambient temperature and leaves the stack hot, thus stealing useful heat from the process.

• “Maximum combustion efficiency is achieved when the correct amount of excess air is supplied so that sum of both unburned fuel loss and flue gas heat loss is minimized”.

CO 2

O2

CO+H 2

Theoreticaloptimumpoint

Real worldoptimumpoint

% Excess Air0 3010- 20

% Flue gas concentration

Real World : Combustibles appeareven when excess air is supplied.


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Traditional control systems

• All burners operate with more air than required.

• Often, the most immediate way of improving efficiency and reducing emissions

• Reduction of oxygen by 1 % typically will increase efficiency by 0.5 %.


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What leads to variations

• Air temperature• Fuel temperature• Fuel pressure• Moisture in fuel• Loading pattern• Changing calorific value of fuel• Use of multiple fuels


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Effect of Air temperature

Air temperature deg C4.510

26.737.848.9

- Excess air (%)- 25.5- 20.2- 15.0- 9.6- 1.1


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Linkage Control

• Fixed setting of fuel and air

• No compensation for variation

• Typical of Oil and Gas fired boilers

• Gear back lash and deadband


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Parallel control

• One step above the jack shaft control

• Settings fixed for each point of fuel and air

• Settings can be changed easily


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Cross Limiting Control

• Based on feedback of actual fuel and air flow

• A better system to have• Involves more

instrumentation• Cannot cater to fuel

composition changes


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Oxygen trim control

• Control of air as per combustion requirements

• Sounds good• Complicated to implement• Needs study before implementation


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What is Oxygen trim control?

• Control of EXCESS air in the stack of the boiler

• Done by sensing oxygen percentage in the stack

• On-Line measurement of CO not necessary• Done by independent modulation of air

damper or VFD.


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Before trim controlOxygen level versus firing rate

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0

Firing rate (%)

Oxy

gen

leve

l (%

)

OXYLEVELBNR2A

Trend


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After trim controlOxygen level versus firing rate

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0

Firing rate (%)

Oxy

gen

(%)

OXYLEVELBNR1APoly. (OXYLEVELBNR1A)


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Basic system - Oil / Gas fired boilers

Motor Burner

Boiler

Controller

PTDamper

Plunger

Servo

EffiMax4000

ModulationON /OFF

TS

OL

BlowerVFD

Oil CirculationM t


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Basic system - Solid fuels

BlowerVFD EffiMax

4000

TT

O2

FT

DYNO DRIVE

PT

Primary Air

Fuel

FURNACE

ID FAN

TT


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Pre-Implementation Checks

• Observe the boiler operation for 1-2 hours.• Check if it is modulating continuously or

only in high low mode.• Observe the average load on the boiler -

Preferably it should be above 50 % load.• Check what the fuel/air modulation

mechanism is - Servo motor based, etc.


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• Check the Oxygen values at high fire, low fire and mid firing conditions.

• These values should be between 3-8% for oil fired boilers, 2-5 for gas fired boilers and 5 to 12% for FBC boilers.

• Also check the CO values. Typically these should be below 200 ppm.


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• Ask the boiler operator to tune the burner and try reducing oxygen as much as possible with CO being below 200 ppm.

• The pay back of the system and the improvement in efficiency will depend on the higher oxygen measured earlier and later.


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Implementation pre-requisites

• Need to ensure that there is a provision for installing an additional feed back mechanism for damper position feed back.


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Some considerations

• Simple PID cannot work because of the large dead-time involved– Dead time compensation technique is used

Time

Step change in damper

Response of Oxygen

Dead time


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Dead time compensation

• Basically holds the output of the PID controller till the dead time is over

• Effectively makes the controller wait till the response is fully over

Measure O2

Move damperWait for O2 change


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Some more considerations

• Air damper has to respond immediately, without waiting for the dead time to be over, when the firing of the boiler changes with a change in load.

• While moving, it has to replicate the curve of Oil-Air relationship of that particular burner


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Some more considerations

• The damper has to be moved to a particular position, normally fully open, during the purging time of the burner


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One final consideration

• The air damper can be either– servo motor controlled, which requires one

current output– power cylinder controller, which requires an

I/P converter and an analog signal output– VFD controlled, which requires an analog

signal


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Features of our trim control loop

• Accepts inputs from– Oxygen analyzer– Burner On/Off– Burner firing position

• Has a characterizer to replicate the response of a mechanical link

• Tracking / non-tracking set point

• Has – a bump-less A/M

station– Dead time

compensation

• Displays– Oxygen value (P & S)– Damper opening (%)

• Gives outputs to– Damper actuator


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Trim control for solids

• Additionally it has furnace pressure control also.

• The trim output is interlocked with the furnace pressure such that if the furnace pressure increases, the trim output and the boiler pressure control are reduced.

• It should also have bed temperature interlock.

Back to main Menu?


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l Oxygen measurement using zirconia technology is todays industry standard and is accepted as a costeffective and reliable measuring instrument.

Oxygen measurement


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A process gas (A) with unknown oxygen (O2)-concentration flows over a measuring probe, which is sealed against the process gas with a heated zirconia cell (B)

At high temperatures a voltage V is generated between the two surfaces of thecell, which, at constant cell temperature, depends only on the ratio of the oxygen concentrations (partial pressures) in A and C.

With air (oxygen content constant 20,95%) as reference gas the measured voltage is a direct measure for the oxygen concentration in the process gas A, as long as...

The reference gas air (C) with its known and constant O2 - concentrationcontacts the cell from the inside.

VBC

A

The Zirconium measuring principle (is very simple


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As long as

the seal between process and reference gas is absolutely and perfectly gas tight and therefore any influence to the measuring results are eliminated for ever !

Is very simple ,


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T Temperature, is kept constant

With a „leakproof“ fraction line and air as reference gas all values of the Nernst equation except P2 are constant! This means

The voltage output depends only on partial pressure P2 (process gas) and calibration is not required

Reference gas partial pressure P1

Process gas partial pressure P2

The Nernst equation The gas tight fraction line

C Constant offset

K Natural constant

V = log·T · + CP 1

P 2K

V Measured voltage

P1 Partial pressure of reference gas; is constant, if air is used as reference gas and mixture prevented with process gas

Nerst equation and the gas tight fraction line


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Other oxygen measuring methods require a two point calibration, which inpractice has been transferred to the zirconia measuring principle. This is not necessary, as the Nernst equation is a mathematical a linear function and with air as a known reference gas the only paramenter P1 is constant. Therefore calibration is not required!

Any leakage at the cell will cause a migration of process and reference gas that will make regular calibrations necessary.

Only one condition must be fulfilled:The measuring cell must have a totally gas tight seal between the process gas side and the reference gas side.

Calibration ?


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mV VoltageIon migration

Zirconia Electrodes

Seal Heater

Thermocouple

Process gas

ReferenzluftReference gas (air)

Design of the Oxytec Zirconia cell with the gas tight seal


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Special manufacturing process

Mechanical design

Special cell sealing technology

Production, Test & Quality Control to ISO 9001

Key factors for the reliable gas tight cell


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Ensuring optimum Efficiency

• How do you know correct set-points?• Continuous study and adjustment required.• Look at final performance parameters like

fuel consumption or direct efficiency.• Relate them to operating conditions to find

best operating points.


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Self learning logic

• Builds data base of operating conditions• Is simple to do, but has to be done

continuously• Compares past and present to alter

operating conditions• Better done through computer programs


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Self learning example


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Effect of boiler loading


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Effect of Oxygen variation


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Boiler Efficiency range of products

• EffiMax 1000 - Online steam to fuel ratio meter with direct efficiency calculations.– Measures Steam flow, Oil/gas flow, Steam

temperature and feed water temperature.– Calculates S:F, Direct efficiency, Steam

pressure, steam and fuel totalization.– Applications - Typically oil / gas fired boilers

below 2-3 TPH capacity.


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• EffiMax 2000 - Indirect Efficiency analyzer with automatic blow down control.– Measures Steam flow, temperature, stack

Oxygen, temperature, ambient temperature, Drum TDS and feed water temperature.

– Calculates Indirect efficiency, indirect S:F, % blowdown loss, steam and blowdown total.

– Application - 3 TPH and above oil, gas, solid fuel fired boilers.


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• EffiMax 3000 - Indirect Efficiency analyzer with ABCO and S:F measurement.– Measures Steam flow, temperature, oil/gas

flow, stack Oxygen, temp., ambient temp., Drum TDS and feed water temperature.

– Calculates Indirect efficiency, direct S:F, % blowdown loss, steam and blowdown total.

– Application - 3 TPH and above oil and gas fired boilers.


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• EffiMax 4000 - Indirect Efficiency analyzer with ABCO and Oxygen trim control.– Measures Steam flow, temp., stack Oxygen,

temp., ambient temp., Drum TDS, feed water temp., damper feedback and boiler on/off.

– Calculates Indirect efficiency, indirect S:F, % blowdown loss, steam and blowdown total.

– Application - 3 TPH and above oil, gas, solid fuel fired boilers.


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EffiMax 2000Touch Screen Based


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EffiMax 2000, the latest Touch Screen based offering

from the EffiMax range of on-line boiler efficiency

analyzers, provides a complete monitoring and data

acquisition solution for boiler performance. The

highlight of this product is the extremely visual Human

Interface and self explanatory mimic of the boiler on the

front display. It also allows for real time / historical

trending on the display.


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Boiler Efficiency Indication (%) in accordance with BS 845 based on indirect efficiency computation.

Stack Loss Indication (%),

Enthalpy Loss (%)

Radiation Loss Indication (%)

Combustion Loss (%)

Steam Flow Indication (kg/h),

Steam to fuel ratio (compensated for Feedwater Temp)

Oxygen Indication (%)


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A simple and cost effective package which monitors the following parameters ON LINE through a extremely visual

human interface and self explanatory touch screen mimic with a diagnostic report generation :-

1. All ealier features/data maintained in Touch screen.

2. The Manager can see the graphics on PC and the operator can see the same on the touch screen.

3. The operator too now has features like- Real time trending. - Customized alarms.

4. All range settings and calibrationis menu driven


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Blowdown loss totalization (kg), Average (kg/h)

Automatic Blowdown control

Steam and F.W. Temperature Indication - deg C

Stack Temperature Indication - deg C

All measured data displayed on a Mimic

Trending, Alarms and Data log.

Proprietary PC based software that provides graphical trending, datalogging, diagnostics, alarms

RS 485/ Modbus output to PC

Features


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Waste heat recoveryWaste heat recovery

2

Continuous Steel Reheating FurnaceContinuous Steel Reheating Furnace FeatureFeature

5

Heat Transfer in FurnaceHeat Transfer in Furnace

6

Furnace Energy BalanceFurnace Energy Balance

7

Furnace Energy balanceFurnace Energy balance

RecuperatorsRecuperators are heat are heat exchange devices that exchange devices that recover energy from furnace recover energy from furnace exhaust gases and return that exhaust gases and return that energy to the heating process energy to the heating process as preheated air to the as preheated air to the burners. Savings of 30% to burners. Savings of 30% to 40% of of fuel bills is 40% of of fuel bills is possible. Examination of possible. Examination of Diagrams below shows the Diagrams below shows the huge contribution that waste huge contribution that waste heat energy recovery can heat energy recovery can make towards furnace make towards furnace efficiency.efficiency.

8

Waste heat recoveryWaste heat recovery

9

Flue Gas Heat RecoveryFlue Gas Heat Recovery

One of the preferred solutions to recovering heat is to One of the preferred solutions to recovering heat is to preheat combustion air using exhaust gas. preheat combustion air using exhaust gas. The temperature of the air can be heated to the higher The temperature of the air can be heated to the higher level which is dependent on the furnace conditions. level which is dependent on the furnace conditions. In the glass and aluminum melting industries, preheats In the glass and aluminum melting industries, preheats can be as high as 900can be as high as 900°°C, recovered from the flue gas C, recovered from the flue gas temperatures of typically 1200temperatures of typically 1200--14501450°°C. C. The fuel saving in this case may be as much as 50%. The fuel saving in this case may be as much as 50%.

11

RecuperatorsRecuperators

A A recuperatorrecuperator is a gas to gas heat exchanger normally is a gas to gas heat exchanger normally employed to recover waste heat from hot gases. employed to recover waste heat from hot gases. Its main application is as a preheater for air entering Its main application is as a preheater for air entering boilers and furnaces. boilers and furnaces. The hot gases are cooled by the incoming combustion The hot gases are cooled by the incoming combustion air, which now carries additional energy into the air, which now carries additional energy into the combustion chamber and saving fuel. combustion chamber and saving fuel.

ConvectiveConvectiveRadiativeRadiative

12

RecuperatorsRecuperators

Convective Convective recuperatorsrecuperators are are generally used when the generally used when the flue gas temperatures are flue gas temperatures are below 900below 900°°C. Radiation C. Radiation recuperatorsrecuperators are used are used uptoupto14501450°°C. InC. In--between these between these temperatures a combination temperatures a combination of convective and of convective and radiationradiation methods can be methods can be used to ensure a good heat used to ensure a good heat recovery. recovery.

13

RecuperatorRecuperator

14

Convective Convective RecuperatorsRecuperators

15

Convective Convective -- RadiativeRadiative

16

Advantages claimed for the Advantages claimed for the recuperatorsrecuperators

Improve combustion efficiencyImprove combustion efficiency

Reduction of fuel requirementReduction of fuel requirement

Lower flue gas temperature in the chimney after the Lower flue gas temperature in the chimney after the RecuperatorRecuperator

Higher flame temperatures, resulting in better and faster heatinHigher flame temperatures, resulting in better and faster heating.g.Heat transfer is highest by radiation, and any increase in tempeHeat transfer is highest by radiation, and any increase in temperature rature difference increases heat transfer by a function of this temperadifference increases heat transfer by a function of this temperature ture difference to the fourth power. difference to the fourth power.

Faster furnace startup and cold charge heating for higher outputFaster furnace startup and cold charge heating for higher output. .

Improved combustion resulting in lower excess air requirement anImproved combustion resulting in lower excess air requirement and a d a brighter flamebrighter flame

17

Fuel SavingsFuel Savings

Fuel SavingsFuel SavingsThis depends on preheat This depends on preheat temperature, i.e. higher waste temperature, i.e. higher waste heat recovery. Higher the heat recovery. Higher the preheat, higher the savings. preheat, higher the savings. e.g., for a reheating furnace e.g., for a reheating furnace with flue outlet temperature with flue outlet temperature of 800of 800°°C, flue savings would C, flue savings would be ~14% with 300be ~14% with 300°°C C preheat, and ~19% with preheat, and ~19% with 400400°°C.C.

Fuel savings with recuperation Fuel savings with recuperation in some commonly used in some commonly used furnaces :furnaces :ReRe--rolling mill Rerolling mill Re--Heating Furnaces Heating Furnaces -- 15 15 -- 25%. 25%. AluminiumAluminium Melting Furnaces Melting Furnaces -- 12 12 --17%. 17%. Glass Melting Furnaces Glass Melting Furnaces -- 25 25 -- 40%. 40%. Heat Treatment Furnaces Heat Treatment Furnaces -- 12 12 -- 15%. 15%.

Forging Furnaces Forging Furnaces -- 15 15 -- 25%.25%.

18

Energy saving potentialsEnergy saving potentials

19

Recuperative burnerRecuperative burner

20

Regenerative burnerRegenerative burner

21

..

23

Thermal Regenerators:Thermal Regenerators:

Thermal regenerators are compact heat Thermal regenerators are compact heat exchangers in which heat is stored and exchangers in which heat is stored and released alternately using a heat storage released alternately using a heat storage matrix.matrix.

FixedFixed--bed regeneratorbed regeneratorRotary regeneratorRotary regenerator

25

Main categories of exchangerMain categories of exchanger

Heat exchangers

Recuperators Regenerators

Wall separating streamsWall separating streams Direct contact

26

RecuperatorsRecuperators/regenerators/regenerators

RecuperativeRecuperativeHas separate flow paths for each Has separate flow paths for each

fluid which flow simultaneously fluid which flow simultaneously through the exchanger transferring through the exchanger transferring heat between the streamsheat between the streams

RegenerativeRegenerativeHas a single flow path which the hot Has a single flow path which the hot

and cold fluids alternately pass and cold fluids alternately pass through.through.

Rotating wheel

27

FixedFixed--bed Regenerators:bed Regenerators:

Hot Period

Cold Period

28

Fixed Bed Regenerators in Fixed Bed Regenerators in Aluminum FurnaceAluminum Furnace

2020--40 mbar40 mbarPressure dropPressure drop900 C900 CCold OutletCold Outlet20 C20 CCold inletCold inlet300 C300 CHot outletHot outlet1200 C1200 CHot inletHot inletCeramic ballsCeramic ballsMaterialMaterial

29

Rotary RegeneratorsRotary Regenerators

Hot AreaCold Area

30

Rotary Regenerator in Aluminum FurnaceRotary Regenerator in Aluminum Furnace

31

Glass tank regeneratorGlass tank regenerator

32

StoichiometricStoichiometric CombustionCombustion

The amount of air required for complete combustion of the fuel dThe amount of air required for complete combustion of the fuel depends on epends on the elemental constituents of the fuel that is Carbon, Hydrogen,the elemental constituents of the fuel that is Carbon, Hydrogen, and and SulphurSulphuretc. This amount of air is called etc. This amount of air is called stoichiometricstoichiometric airair

C onstituents % B y w eightCarbon 85.9 Hydrogen 12 Oxygen 0.7 N itrogen 0.5 Sulphur 0.5 H 2O` 0.35 Ash 0.05

33

Calculation for Requirement of Theoretical Calculation for Requirement of Theoretical Amount of AirAmount of Air

Element Molecular Weight kg / kg mole

C 12 O2 32 H2 2 S 32 N2 28

CO2 44 SO2 64 H2O 18

C + O 2 C O 2 H 2 + 1 /2 O 2 H 2 O S + O 2 S O 2

C + O 2 CO 2 12 + 32 44

12 kg of carbon requires 32 kg of oxygen to form 44 kg of carbon dioxide therefore 1 kg of carbon requires 32/12 kg i.e 2.67 kg of oxygen

(85.9) C + (85.9 x 2.67) O2 315.25 CO2

229.07 kg of oxygen

34

Calculation for Requirement of Theoretical Amount Calculation for Requirement of Theoretical Amount of Air (contd.)of Air (contd.)

2H 2 + O 2 2H 2O 4 + 32 36

4 kg of hydrogen requires 32 kg of oxygen to form 36 kg of water, therefore 1 kg of hydrogen requires 32/4 kg i.e 8 kg of oxygen

(12) H2 + (12 x 8) O-2 (12 x 9 ) H2O

96 kg of oxygen

35


S + O 2 S O 2 3 2 + 3 2 6 4

32 kg of sulphur requires 32 kg of oxygen to form 64 kg of sulphur dioxide, therefore 1 kg of sulphur requires 32/32 kg i.e 1 kg of oxygen

(0.5) S + (0.5 x 1) O2 1.0 SO2

0.5 kg of oxygen

36


Total Oxygen required = 229.07+96+0.5

= 325.57 kg

Oxygen already present in = 0.7 kg100 kg fuel (given)

Additional Oxygen Required = 325.57 – 0.7

= 324.87 kg

Therefore quantity of dry air reqd. = (324.87) / 0.23(air contains 23% oxygen by wt.)

= 1412.45 kg of air

Theoretical Air required = (1412.45) / 100

= 14.12 kg of air/ kg of fuel

37

Calculation of theoretical COCalculation of theoretical CO22 content in flue content in flue gasesgases

Nitrogen in flue gas = 1412.45 – 324.87= 1087.58 kg

Theoretical CO2% in dry flue gas by volume is calculated as below :

Moles of CO2 in flue gas = (315.25) / 44 = 7.16Moles of N2 in flue gas = (1087.58) / 28 = 38.84Moles of SO2 in flue gas = 1/64 = 0.016

= 15.5 %

100)(

% 22 x

drymolesTotalCOofMolesvolumebyCOlTheoritica =

100016.084.3816.7

16.7 x++

=

38

Calculation of constituents of flue gas with Calculation of constituents of flue gas with excess airexcess air

% CO2 measured in flue gas = 10% (measured)

1001%

%%2

2 xCOActual

COlTheoriticaairExcess ⎟⎟⎠

⎞⎜⎜⎝

⎛−= 1001

105.15% xairExcess ⎟

⎠⎞

⎜⎝⎛ −=

Theoretical air required for 100 kg of fuel burnt

= 1412.45 kg

Total quantity. of air supply required with 55% excess air

= 1412.45 X 1.55

= 2189.30 kg Excess air quantity = 2189.30 – 1412.45 = 776.85 kg.

O2 = 776.85 X 0.23 = 178.68

N2 = 776.85 - 178.68 = 598.17 kg

= 55%

CO2 = 315.25 kg

H2O = 108.00 kg

SO2 = 1 kg

O2 = 178.68 kg

N2 = 1087.58 + 598.17 = 1685.75 kg

39

Calculation of Theoretical COCalculation of Theoretical CO22% in Dry Flue Gas % in Dry Flue Gas By VolumeBy Volume

Moles of CO2 in flue gas = 314.97/44 = 7.16Moles of SO2 in flue gas = 1/64 = 0.016

Moles of O2 in flue gas = 178.68 / 32 = 5.58Moles of N2 in flue gas = 1685.75 / 28 = 60.20

100)(

% 22 x

drymolesTotalCOofMolesvolumebyCOlTheoritica = 100

20.6058.5016.016.716.7 x

+++= = 10%

Theoretical O2% by volume %5.7100956.72

10058.5== xx

PENNAR CHEMICALS LIMITEDPENNAR CHEMICALS LIMITEDAN ISO 9001 – 2000 Certified Company

TECHNICAL PRESENTATION AT

FICCI TECHNICAL MEET

ON

COMBUSTION TECHNOLOGY

Sr. No.

CHARACTERISTICS Test metho

dsIS

1448

Grade LV Grade MV1 Grade MV2 GradeHV

1 Acidity, inorganic P-2 NIL NIL NIL NIL

2 Ash, % wt. max. P-4 0.1 0.1 0.1 0.1

3 Gross, calorific value, cal/g P-6 or 7

Not limited but to be reported

4 Relative Density at 15 0C P-32 Not limited but to be reported

5 Flash point, (PMCC) 0C, Min. P-21 66 66 66 66

6 Kinematic viscosity in centistokes at 50 0C

P-25 80 125 180 370

7 Sediment, % wt. max. P-30 0.25 0.25 0.25 0.25

8 Sulphur, total, % by wt., max. P-33 or P-35

3.5 4.0 4.0 4.5

9 Water Content, % by vol., max. P-40 1.0 1.0 1.0 1.0

SPECIFICATION FOR FURNACE OIL-IS 1593-1982

DEFINITION :

A dark viscous residual fuel obtained by blending mainly heavier components from crude distillation unit, short residue and clarified oil from fluidized catalytic cracker unit.

NOMENCLATURE

Bunker fuel, furnace oil , Fuel oil are other names for the same product. Though Fuel oil is a general term applied to any oil used for generation of power or heat, Fuel oil can included distillates and blends of distillates and residue such as Light Diesel Oil.

SPECIFICATION

Furnace oil in the current marketing range meets Bureau of Indian Standards Specification IS : 1593 - 1982 for fuel oils, grade MV2.

VISCOSITY

Viscosity is the most important characteristic in the furnace oil specification. It influences the degree of pre-heat required for handling, storage and satisfactory atomization. If the oil is too viscous it may become difficult to pump, burner may be hard to light and operation may be erratic. Poor atomization may result in the carbon deposits on the burner tips or on the walls. The upper viscosity limit for furnace oil is such that it can be handled without heating in the storage tank is excepting under server cold conditions. Pre-heating is necessary for proper atomization.

FLASH POINT

As per the Controller of Explosives classification, Furnace oil falls in the class "C" category with minimum flash point standard of 66 deg. C. Since Penskey Martens Closed Cup method is used, it is apparent that a small quantity of low boiling point hydrocarbons is sufficient to lower the flash point drastically.

POUR POINT

It is a very rough indication of the lowest temperature at which Furnace Oil is readily pumpable. In the specification the pour point of Furnace oil is not stipulated. However, for Furnace oil manufactured indigenously and for imported parcels, the pour point is such that current supplies normally can be handled without heating the fuel oil handling installation.

WATER

Water may be present in free or emulsified form and can on combustion cause damage to the inside furnace surfaces especially if it contains dissolved salts. It can also cause sputtering of the flame at the burner tip. Water content of furnaceoil when supplied is normally very low as the product at refinery site is handled hot and maximum limit of 1% is specified in the standard.

SEDIMENT

Furnace oil being a blend of residues contains some quantity of sediments. These have adverse effect on the burners and cause blockage of filters etc. However, the typical values are normally much lower than the stipulated value of maximum 0.25 percent, by mass.

ASH

Ash is incombustible component of the furnace oil and is expressed as a percentage mass of the furnace oil sample. Ash consists of extraneous solids, residues of organometallic compounds in solution and salts dissolved in water present in the fuel. These salts may be compounds of sodium, vanadium, calcium magnesium, silicon, iron etc.

Ash has erosive effect on the burner tips, causes damage to the refractories at high temperatures and gives rise to high temperature corrosion and fouling of equipments.

SULPHUR

Sulphur determination includes burning of known quantiy of oil, treating the sulphur oxidation products formed during combustion and weighing of sulphur in the form of sulphate.

The sulphur di oxide may come in direct contact with the product during the combustion process and may create adverse quality effects in the product.

CALORIFIC VALUE

Calorific value of a fuel is the quantity of heat generated in kilocalories by complete burning of one kilogram weight of fuel. Gross calorific value is higher than net calorific value to the extent of heat required to change water formed by combustion into water vapours.

COMPARISON OF FURNACE OIL, LSHS & CBFS

Sl.No. PROPERTY F.O

LSHS CBFS

Spec. IS 1593-1988 IS: 11489 - 1985

1. Specific Gravity 0.96 0.97 0.98 – 1.02

2. Viscosity, cSt 180 @ 50 0C 50 @ 100 0C 8 – 10 @ RT

3. Total Sulfur, Wt% 3.5 – 4.5% 1.0 % Max. 0.3 % Max.

4. Pour Point, 0C 21 0C 72 0C Max. < 20

5. Carbon Content 83% 86% 86 – 88%

6. Hydrogen Content 11 – 12% 12% 8 – 9 %

7. Gross Calorific Value Kcal / kg 10000 9500 – 10000 9800

8. Moisture content, % Not available Not available 0.5%

9. Free water, Max. 1 % 1 % 1 %

10. Flash Point 66 0C 93 0C 66 0C

11. Ash 0.1 % 0.1 % -

12 Sediments 0.25 % Max. 0.25 -

COMPARISON OF C9, KEROSENE, HSD, LDO & F.O.

Sr. PARAMETER RIL's C9 KEROSENE H.S.DIESEL LDO F.ONo.1 Density, @ 15 0C 0.925 - 0.935 0.785 - 0.825 0.82 - 0.84 0.88 - 0.9 0.94 - 0.972 Flash Point 32 0C min. 35 0C min. 32 0C min. 66 0C min. > 66 0C

(PMCC)3 Viscosity, Cst @ 5.0 max 1.0 - 1.4 2.0 - 5.5 2.5 - 15.7 80 - 370

38 0C Typical 1.2 - 1.8 10 (TYPICAL) @ 50 0C 4 Composition < C8 = 0.1% C7 ti C17 C20 Plus -- C65 Plus

C9 = 16 - 35% composition,C10 = 30 - 40% not defined inC10+ = 25 - 54% specs.

5 Aromatic content 20 - 30 % (typical) 18% 20% max -- --6 Sediment < 10mg/100 ml. not available 1 mg/100 ml. 0.10% wt. max 0.25%7 Gross Calorific 10,700 Kcals/Kg 11,000 Kcals/Kg 10,800 10,400 10,200

value, est. Kcals/Kg Kcals/Kg Kcals/Kg8 Cetane no. not available 38 (approx.) 45 min. 40 (approx.) < 209 Pour Point 0C < 0 0C < 0 0C > 6 0C Winter 12 25 0C

Summer 1810 Water content 500 ppm max. 500 ppm max. 500 ppm max. 0.25 % V max 1% max.11 Total Sulphur 0.03% 0.25% max. 0.25% max. 1.8 % max. 4.5 % max.

0.12% Typical 0.05% ULSD

1

PENNAR CHEMICALS LIMITEDPENNAR CHEMICALS LIMITEDAN ISO 9001 – 2000 Certified Company

TECHNICAL PRESENTATION TO

FICCI TECHNICAL MEET

ON

COMBUSTION TECHNOLOGY

2

STORAGESTORAGEPROBLEMSPROBLEMS

»» ASPHALTENES PRECIPITATION ASPHALTENES PRECIPITATION »» CLOGGING OF FILTERS AND PIPESCLOGGING OF FILTERS AND PIPES»» SATURATION OF SEPARATORSSATURATION OF SEPARATORS»» CLOGGING OF INJECTION SYSTEMCLOGGING OF INJECTION SYSTEM

ORIGINORIGIN»» ASPHALTENES PRECIPITATIONASPHALTENES PRECIPITATION

BLEND OF NONBLEND OF NON--COMPATIBLE FUELSCOMPATIBLE FUELSSTORAGE TEMPERATURESTORAGE TEMPERATURE

SOLUTIONSOLUTION»» ELF ACS 82ELF ACS 82

3

COMBUSTION PROCESS

&

LOSS OF ENERGY

4

COMBUSTION MECHANISMCOMBUSTION MECHANISM

Atomisation Vaporization

Combustion

Viscosity Distillate cuts

Distillate cutsDensityMetalsConradson Carbon

C/H Ratio

Ignition

5

SOOT

UNBURNT PARTICLESFLAME FRONT

FUELDROPLET

CENOSPHERE

EMISSIONS OF PARTICLES

0.02 µm

1 to 100 µm

LIGHT GASEOUS FRACTIONS

Simple droplet combustion modelSimple droplet combustion model

SOLID ACCUMULATION

6

CENOSPHERESCENOSPHERES

7

COMBUSTION EFFICIENCY

8

Basic Combustion Chemistry

C + O2 CO2 + 8084 kCal / kg 2C + O2 2CO + 2430 kCal / kg 2H2 + O2 2H2O + 28992 kCal / kg S + O2 SO2 + 2224 kCal / kg 2CO + O2 2CO2 + 5654 kCal / kg

10

EFFICIENCY EVALUATION OF BOILERS

There are two methods of evaluating the efficiency of Boilers:

1) Direct

2) Indirect Methods

DIRECT METHOD:

Heat Output Boiler Efficiency = ---------------

Heat Input

Steam flow rate X (steam enthalpy – feedwater enthalpy) = ----------------------------------------------------------------------

Fuel firing rate X Gross Calorific Value

11

ADVANTAGES:

• Is excellent for plant people to evaluate quickly the efficiency of boilers • Requires only a few parameters for computation • Needs only a simple instrumentation for monitoring

DISADVANTAGE:

Not being able to calculate losses under different heads to indicate why the efficiency is low

INDIRECT METHOD:

The disadvantages inherent in the Direct Method can be overcome by the second method

Total Heat Loss = Lfg + Lmf + Ln + Lma + Luc + Lco + Lsa + Lbd + Lst

12

Where as,

Lfg = Dry flue gas loss

Lmf = Heat loss due to moisture in fuel

Ln = Heat loss due to moisture from burning Hydrogen

Lma = Heat loss due to moisture in air

Luc = Heat loss due to combustibles in refuse

Lco = Heat loss due to formation of Carbon Monoxide

Lsa = Heat loss due to sensible heat in bottom ash

Lbd = Blowdown loss

Lst = Loss due to surface radiation and convection (Heat input per hour - total Thermal Efficiency = heat loss per hour) X 100% of boiler (%) ----------------------------------- Heat input per hour

13

TOTAL PERCENTAGE LOSS FOR LIQUID AND GASEOUS FUELS Total Percentage Loss = Dry flue gas loss + Loss due to refuse + Hydrogen & Moisture loss + Surface loss 1. Dry Flue Gas Loss: Ts = Stack Temperature 0C Ta = Ambient Temperature 0C % CO2 = Dry CO2 % in stack gas K (Ts – Ta) Dry Flue Gas Loss = ------------- % % CO2 Note : BS-845 indicates that a value of 0.56 can be taken on L.C.V. basis for all liquid pertroleum fuels 2. Hydrogen & Moisture loss = 6.6% approx. 3. Surface loss = 2 % approx.

1

PENNAR CHEMICALS LIMITEDAN ISO 9001 – 2000 Certified Company

TECHNICAL PRESENTATION TO

FICCI, Bangalore

ON

ELF AC 13S & ACS 82

2

ADDITIVES FOR HEAVY FUEL OILS

ADDITIVES FOR HEAVY FUEL OILS

CRUDE OILS AND FUEL OILSCRUDE OILS AND FUEL OILS

HEAVY FUEL OILSHEAVY FUEL OILS


POTENTIAL PROBLEMS AND SOLUTIONSPOTENTIAL PROBLEMS AND SOLUTIONS»» ACS 82, AC 13 SACS 82, AC 13 S

3

Viscosity,20°C

% asphaltenes

Gasoline (C5-80°)

Heavy gasoline (80-160°)

Kerosene (160-250°)

Middle distillate (250-300°)

Heavy distillate (300-400°)

Residue (400 +)

35.8

5.8

4.09

9.05

12.58

14.12

7.51

50.42

10.2

0.93

5.56

12.02

15.5

17.19

8.72

38.71

ARABIANHEAVY

ARABIANLIGHT

NIGERIANBONNY

11.2

0.08

5.06

15.0

9.32

25.2

44.6

FRACTIONS FROM 3 DIFFERENT CRUDESFRACTIONS FROM 3 DIFFERENT CRUDES

4

CHARACTERISTICS OF SOME CRUDE OILS

CHARACTERISTICS OF SOME CRUDE OILS

Viscosity,20 °C,cSt

Sulfur,%

Vanadium, ppm

Nickel, ppm

Asphaltenes, %

Conradson carbon,%

Arabianlight

9.2

1.8

15

5

0.7

5.1

Arabianheavy

40

2.8

30

10

2.7

Ekofisk

10

0.12

< 1

1.4

0.88

Nigerialight

6.7

0.11

2

6

0.08

0.86

Basrahheavy

57

3.58

54

22

8.3

Boscan

250000

5.2

1200

100

10.8

16.4

Ural

12.5

1.8

65

20

2.7

5

Gas

AD

VD

Reforming

Visbreak.

Hydrocr.

Coking

FCC

DA

Naphta

GasolinesKeroseneDiesel oils

Heavy fuels SR 1

2

3

Gasolines

GasolinesKero,Diesel

Heavy fuels

H2, no HeavyFuels 4

AsphaltsHeavy fuels

REFINERY SCHEMESREFINERY SCHEMES

6

CHEMICAL COMPOSITIONCHEMICAL COMPOSITION

RESIDUE OR HEAVY FUEL OILRESIDUE OR HEAVY FUEL OIL

ASPHALTENESASPHALTENESMALTENESMALTENES

"OIL""OIL"

"RESINS""RESINS"

SATURATED SATURATED AROMATICAROMATIC

7

MODEL OF ASPHALTENE MOLECULEMODEL OF ASPHALTENE MOLECULE

S

CH2

CH3

CH2

CH3

CH3

CH

CH2

CH2

CH3

CH2CH2CH3

CH2CH2

S

S

CH2

CH2

CH3

CH2

S

CHCH2

CH2

CH3

CH2

CH2

CH3

CH

CH2

CH2

CH3

CH2 CH2CH3

N

CH3

CH2

CH3

CH3

CH2

CH3

CH3

CH3

CH2CH2

O

CH2S

CH2

CH2

CH2

CH

CH2

CH2

CH3CH3

CH2CH3

CH3

CH3

8

ASPHALTENES CHARACTERISTICS

ASPHALTENES CHARACTERISTICS

Polycondensed aromaticPolycondensed aromatic structuresstructures withwith few alkylfew alkylchainschains

Contains heteroContains hetero--atomsatoms: S, N, O: S, N, O

Contains metalsContains metals: V, Ni, Na: V, Ni, Na

Not soluble inNot soluble in oiloil

Size ofSize of the micellarthe micellar unit: 8 unit: 8 -- 20 A20 A

Cannot boil even under reducedCannot boil even under reduced pressurepressure

MolecularMolecular structurestructure dependsdepends onon crude oil origincrude oil origin

9

RESINS CHARACTERISTICSRESINS CHARACTERISTICS

ChemicalChemical structure close tostructure close to asphaltenesasphaltenesstructure but:structure but:

LONGER ALKYL CHAINSLONGER ALKYL CHAINS

LESS CONDENSED RINGSLESS CONDENSED RINGS

MORE SOLUBLE IN OILMORE SOLUBLE IN OIL

MolecularMolecular structurestructure dependsdepends onon crude oil origincrude oil origin

Presence necessaryPresence necessary toto provideprovide aa good stabilitygood stabilitytoto thethe fuelfuel

10

HEAVY FUEL OILSHEAVY FUEL OILS

DISPERSED AND STABLE FLOCULATEDResins ensure seperation of heavy asphaltene molecules. Flocculated Asphaltene molecules tend to form sludge and settle at the bottom of the tank.

11


Atomisation Vaporization

Combustion

Viscosity Distillate cuts

Distillate cutsDensityMetalsConradson Carbon

C/H Ratio

Ignition

12

SOOT

UNBURNT PARTICLESFLAME FRONT

FUELDROPLET

CENOSPHERE

EMISSIONS OF PARTICLES

0.02 µm

1 to 100 µm

LIGHT GASEOUS FRACTIONS

Simple droplet combustion modelSimple droplet combustion model

SOLID ACCUMULATION

13

CENOSPHERESCENOSPHERES

14

PARTICULATE EMISSIONSPARTICULATE EMISSIONS

SOOT SOOT (Soot number from 0 to 9 Bacharach)(Soot number from 0 to 9 Bacharach)»» GAS PHASE COMBUSTIONGAS PHASE COMBUSTION

»» OH* increases the rate of oxidation of soot precursorsOH* increases the rate of oxidation of soot precursors

UNBURNT PARTICLES UNBURNT PARTICLES (mg/Nm(mg/Nm33))»» HETEROGENEOUS COMBUSTION HETEROGENEOUS COMBUSTION (CENOSPHERES)(CENOSPHERES)

2 H2O H2 + 2 OH*Catalyst M

CO + H2

Catalyst M ’Cenospheres + H 2 Ov

15

POTENTIAL PROBLEMSPOTENTIAL PROBLEMS

STORAGE STABILITY AND COMPATIBILITYSTORAGE STABILITY AND COMPATIBILITY

UNBURNT PARTICLESUNBURNT PARTICLES

16

STORAGESTORAGEPROBLEMSPROBLEMS

»» ASPHALTENES PRECIPITATION ASPHALTENES PRECIPITATION »» CLOGGING OF FILTERS AND PIPESCLOGGING OF FILTERS AND PIPES»» SATURATION OF SEPARATORSSATURATION OF SEPARATORS»» CLOGGING OF INJECTION SYSTEMCLOGGING OF INJECTION SYSTEM

ORIGINORIGIN»» ASPHALTENES PRECIPITATIONASPHALTENES PRECIPITATION

BLEND OF NONBLEND OF NON--COMPATIBLE FUELSCOMPATIBLE FUELSSTORAGE TEMPERATURESTORAGE TEMPERATURE

SOLUTIONSOLUTION»» ELF ACS 82ELF ACS 82

17

ELF ACS 82ELF ACS 82

Preventive actionPreventive actionCurative actionCurative action

Fuel without additive Fuel with ACS 82

18

ELF ACS 82ELF ACS 82DOSING RATEDOSING RATE

»» 1 LITRE FOR 2000 TO 5000 LITRES OF FUEL.1 LITRE FOR 2000 TO 5000 LITRES OF FUEL.

IMPROVES HEAVY FUEL OIL STABILITYIMPROVES HEAVY FUEL OIL STABILITY

PREVENTS ASPHALTENE PRECIPITATIONPREVENTS ASPHALTENE PRECIPITATION

AVOIDS COMPATIBILITY PROBLEMSAVOIDS COMPATIBILITY PROBLEMS

NON TOXIC PRODUCTNON TOXIC PRODUCT

NON TOXIC COMBUSTION PRODUCTSNON TOXIC COMBUSTION PRODUCTS

19

UNBURNT PARTICLESUNBURNT PARTICLESPROBLEMPROBLEM

»» EMISSIONS OF UNBURNT PARTICLESEMISSIONS OF UNBURNT PARTICLES»» HEATING SURFACES FOULINGHEATING SURFACES FOULING»» FREQUENT BOILER CLEANINGFREQUENT BOILER CLEANING»» COST OF EMISSION LIMITATIONSCOST OF EMISSION LIMITATIONS

ORIGINORIGIN»» NEED OF COMBUSTION IMPROVERNEED OF COMBUSTION IMPROVER»» VERY LOW METAL CONTENTVERY LOW METAL CONTENT

SOLUTIONSOLUTION»» ELF AC 13 SELF AC 13 S

20

EFFICIENCY OF ELF AC 13 SEFFICIENCY OF ELF AC 13 S

AB

C

FUEL

12

1 : + ELF AC 13 S (1/3000 l)2 : + ELF AC 13 S (1/2000 l)

Unburnt HCmg/th

Excess of air%

400

300

200

100

10 200

21

ELF AC 13 SELF AC 13 SDOSING RATE:DOSING RATE:

»» 1 LITRE FOR 2000 TO 4000 LITRES OF FUEL.1 LITRE FOR 2000 TO 4000 LITRES OF FUEL.

REDUCES EMISSIONS OF UNBURNT REDUCES EMISSIONS OF UNBURNT PARTICLES PARTICLES

»» MORE THAN 50 %MORE THAN 50 %

ALLOWS TO REDUCE EXCESS OF AIR.ALLOWS TO REDUCE EXCESS OF AIR.REDUCES FOULINGREDUCES FOULINGACHIEVES A MORE STABLE COMBUSTION ACHIEVES A MORE STABLE COMBUSTION YIELD.YIELD.REDUCES DEPOSITS ON HEAT TRANSFERS.REDUCES DEPOSITS ON HEAT TRANSFERS.NON TOXIC PRODUCTNON TOXIC PRODUCTNON TOXIC COMBUSTION PRODUCTSNON TOXIC COMBUSTION PRODUCTS

Pennar PENNAR ELF ACS 82 Pennar Elf ACS 82 is a stability and compatibility improvement additive for fuel

oils. It is a blend of totally organic copolymers dissolved in organic solvent. The

chemical structure of this ashless additive resembles that of resins in oil. ACS 82

acts as peptising agent between asphaltene molecules thereby preventing their

flocculation.

The additive performs the following functions :

a) Prevents asphaltene precipitation

b) Disperses sludge into oil

c) Separates water

d) Prevents corrosion induced by water (due to C)

e) Rejects inorganic impurities to the bottom

Pennar PENNAR ELF ACS 82

Efficacy of the additive can be tested (preliminary) in lab before using it on

large scale. Sludge dispersion can be tested by mixing sludge, additive & oil

and maintaining it at tank temp. for certain hours. The sludge quantity in

additive dosed mixture as compared to undosed mixture can be observed in

the bottom of beakers for comparision.

Similarly water separation can be tested by keeping dosed and undosed

mixtures in different separating funnels. Separated water collects at the

bottom.

Different dosages of additive, duration of action and temperature conditions

will be tried to arrive at desired end results.

Pennar MECHANISM OF ACTION OF PENNAR ELF ACS 82 The chemical structure of additive ACS 82 is similar to that of resins infurnace oils. When it is added to furnace oil, the additive molecules establish polar bondsbetween asphaltene molecules and keep them apart (stereo effect). This avoids flocculation. If already asphaltenes are flocculated, they will be deflocculated since thebond between additive – asphaltenes is stronger than that among asphaltenemolecules. The deflocculated asphaltenes will be dispersed in oil. Water separation from the sludge is effected by tensloactive effect of theadditive. It decreases the surface tension between water and oil. The inorganic particles in sludge are dispersed in oil by the additivemolecules through polar bonds (filmogene effect)

Pennar

Physical and chemical properties – ELF ACS 82

- APPEARANCE

* physical state: [S] : Liquid

* colour: : Brown - Red - ODOUR : [I] : Aromatic solvent - SPECIFIC TEMPERATURES OF CHANGE OF PHYSICAL STATE: [I]

: Pour point: < - 12°C

- DISTILLATION CHARACTERISTICS: [A] : Initial boiling point > 155°C - Flash point: [I] : > 62°C - SELF IGNITION TEMPERATURE: [A] : > 450°C - VAPOUR PRESSURE: [A] : < 10 hPa at 40°C - VAPOUR DENSITY: [A] : > 1 (air = 1) - DENSITY: [I] : 905-925kg/m3 at 15°C - SOLUBILITY : [I] * in water: [I] : insoluble * in organic solvents: [A] : Soluble in most organic solvents

- VISCOSITY : [I] : < 10cSt at 20°C

PennarCASE STUDIES – ELF ACS 82

POWER CO.

The company uses Low Sulfur Waxy Residue as fuel. Gradually over acourse of time, sludge in the form of solid lumps will be settled at the bottom.Practice was is to clean the tank for next fuel filling, by taking out this sludge manually and not utilizing it for burning. The project was taken up by Pennar Chemicals Ltd., to disperse sludge intooil. A series of axperiments were conducted in PCL lab to arrive ateconomical dosage of additive and sludge. Same experiment was repeated inTata Electric lab. To the main storage tank, having 100 KL of sludge, 900 KL of fresh LSWRwas added with appropriate dosage of additive (in this case 100 ppm). Tankwas put under circulation for thorough mixing. At the end of 5 days, water drain pipe was opened and 4.5 KL water got discharged. 60% of the sludgehad got dispersed into the oil and could be comfortably fired in the boiler. Thebalance sludge had become soft and smooth. Since it contained mostly silica,it was not advisable to use it any further. Even the disposal of this balancesludge was an easy task.

Pennar CASE STUDIES – ELF ACS 82

THERMAL POWER STATION This Power Station had long accumulated sludge in their FO tank. But they had no sparetank where the treated oil and sludge could be transferred. FO from this main tank has tobe directly sent to the boiler. Here a simple lab trial was done which revealed the additive dosage to be 200 ppm for

good sludge dispersion. But the sludge needs to be dispersed gradually or

else the heavy molecules may enter the oil line and block the oil filter in theinitial stages affecting oil firing. Hence 50 ppm dosage was added to the oil tank

containing FO and sludge. After 2 days another 50 ppm of Elf ACS 82 was added. After aweek another 100 ppm dosage was added. It was observed that even from the bottommost part of the tank, smooth oil delivery could be taken without any problems to oil flow.

Pennar

SLUDGE REDUCTION & WATER SEPARATION IN DG NO.7 AT A STEEL UNIT

Pre-Additive Data : (from 25/03/04 to 01/04/04) Initial level of sludge on 25/03/04 : 44 mm Dip level of Sludge+Water on 01/04/04 : 130 mm

Level after water draining : 75 mm Last level after total sludge drain-out : 25 mm Therefore, level of Water drained out in mm = (130-75) = 55 Level of Sludge formed during this period in mm = (75-44) = 31

Dimension of Sludge Tank : Length = 8770 mm Breadth = 2260 mm

Volume of Sludge formed during this period = (8770x2260x31) = 614 Ltrs (appx.) Volume of water drained out = (8770x2260x55) = 1090 Ltrs(appx.) FO Consumption in DG No.7 during this period = 214530 Ltrs

Hence % Sludge generated = (614/214530) x 100 = 0.286% % Water removed = (1090/214530) x 100 = 0.51%

Pennar Post-Additive Data : ( from 02/04/04 to 08/04/04) – STEEL UNIT Dip level of Sludge + Water on 09/04/04 : 107 mm Level after water draining : 30 mm

Last level after total sludge drain-out : 25 mm

∴ level of Water drained out in mm = (107-30) = 77

Level of Sludge formed during this period in mm = (30-25*) = 05 * Last level after total sludge drain-out on 01/04/04. The volume of Sludge formed = (8770x2260x05) = 99 Ltrs (appx.) The volume of water drained out = (8770x2260x77) = 1526 Ltrs (appx.) FO Consumption in DG No. 7 during this period = 201370 Ltrs Hence % Sludge generated = (99/201370) x 100 = 0.049% % Water removed = (1526/201370)x 100 = 0.76 % By the addition of ELF ACS 82 % Reduction in Sludge quantity observed = ((0.286-0.049)/0.286) x 100 = 82.9% % Improvement in emulsified water removal = ((0.76-0.51)/0.51x100 = 49%

Pennar

00.10.20.30.40.50.60.70.80.9

1%

Sludge % in FO Water removal in %

Pre-AdditivePost-Additive

Pre-Additive 0.286 0.51Post-Additive 0.049 0.76

Sludge % in FO Water removal in %

STEEL UNIT - Improvement in Sludge & Water treatment

Pennar

Pennar ELF ACS 82 Dosing Details –Polyester Unit CURATIVE DOSING: As part of curative dosing programme 200 ppm of Pennar ELF ACS 82 was added for the existing fuel (LDO) quantity. However, instead of adding entire 200 ppm, gradual dosing of the additive was done. Its purpose was to ensure that big size asphaltenes from the tank bottom don’t choke the line and filters due to powerful surfactant action of the additive.

DOSING NO. DATE TIME

VOL. OF LDO IN

STORAGE TANK (KL)

PENNAR ELF ACS 82 ADDED @ 50 ppm IN STORAGE TANK

I 03/12/99 11:20 A.M 148 KL 7.5 Lts. II 06/12/99 12:00 A.M 198 KL 10 Lts. III 13/12/99 12:00 A.M 203 KL 10 Lts. IV 20/12/99 12:30 P.M 160 KL 8.0 Lts.

PREVENTIVE DOSING: As part of preventive dosing, 100 ppm of Pennar ELF ACS 82 was added in every incoming tanker supply.

PennarCASE STUDY – POLYESTER UNIT - p 1

Effect of Pennar ELF ACS 82 on centrifuge sludge

DATE DAY NO. ELF ACS 82 DOSAGE

SLUDGE QUANTITY IN

KG. 3 / 12 / 1999 1 50 PPM 5.2

4 2 “ 5.1 5 3 “ - 6 4 “ 4.7 7 5 “ 4.9 8 6 “ 4.6 9 7 “ 4.5

10 8 “ 4 11 9 “ 3.7 12 10 50 PPM 3 13 11 “ 3.3 14 12 “ 3 15 13 “ - 16 14 “ 1 17 15 “ .8 18 16 “ .8 19 17 “ .7 20 18 “ .65

PennarCASE STUDY – POLYESTER UNIT – p 2



SLUDGE QUANTITY IN

KG. 21/12/1999 19 50 PPM -

22 20 “ - 23 21 “ - 24 22 “ .2 25 23 “ - 26 24 “ .2 27 25 “ .2 28 26 “ - 29 27 “ .2 30 28 50 PPM .2 31 29 “ .2

1/1/2000 30 “ .15 2 31 “ .15 3 32 “ .15 4 33 “ .15 5 34 “ .15 6 35 “ .15

Pennar

CASE STUDY – POLYESTER UNIT – p 3



SLUDGE QUANTITY IN

KG. 1/7/2000 36 1

8 37 2 9 38 1.5

10 39 2.3 11 40 2.2 12 41 2.5 13 42 2.5 14 43 1.6 15 44 1.5 16 45 - 17 46 1.5 18 47 1.5 19 48 1.5 20 49 1 21 50 1 22 51 1 23 52 1 24 53 1

PennarCASE STUDY – POLYESTER UNIT – p 4

Normally, in residual fuels like FO / LDO, the asphaltenes

content varies from batch to batch and it is advisable to

control the dosage of the additive based on the centrifuge

sludge operation.

In case the asphaltene level is high, a slightly higher

dosage of the additive can be used to control the sludge

operation within the desired level. Further, by controlled

bunkering, sludge accumulation can be minimized and the

amount of additive required can be optimized for. This

means that trucks are received regularly and bunching up of

4-5 trucks a day is avoided.

1

ROLE OF ADDITIVES IN HEAVY FUEL

PERFORMANCE IMPROVEMENT

T. RANGA PRASAD Executive Vice President

Pennar Chemicals Limited-Hyderabad Background The presentation covers only a few selected fuel additives, which play an important role

in industries consuming liquid petroleum energy. There are many additives being widely

used in the oil industries. The Oil Industry world over has been passing through a series

of quality improvement measures and new standards of specifications are being

introduced very often. Specs. for Petrol lays emphasis on Anti-knock index, RVP and

Benzene content. Specs. for HSD brings out the importance of HFRR lubricity, Cetane

Number and close Distillation range. Several of the performance related parameters and

specifications standards can be achieved only with the use of fuel additives. If the same

standards are sought to be achieved through refining, it will make the refining process

highly complex and cost un-economical.

Need for Residual Fuel Additives: In FO firing, in spite of the best atomisation, the emission of some unburnt

hydrocarbons, the formation of soot by vapour phase cracking and the formation and

deposition of cenospheres (hard sticky carbonaceous material) due to liquid phase

cracking are inevitable.

To overcome the above problems in operation and get optimum results in the process of

combustion, the addition of Chemical Catalyst has been found to be the most effective

and superior solution.

2

1) ELF AC 13S – COMBUSTION IMPROVER CATALYST: PRODUCT DETAILS: The product ELF AC 13S, is a combustion catalyst with a stable Organo-metallic complex

as the active ingredient in an aromatic solvent. The product has been developed some

years ago after through understanding of the chemistry of residual fuels and the

combustion process by the two process and research giants – ELF & IFP France.

The product has been evaluated and certified by the National Analytical Laboratory

(NAL) France, International Research Foundation for Flame Studies, Holland and by IFP.

It has also been evaluated in a range of Industrial boilers.

BENEFITS: The product catalyses the chemical reaction between water vapour and unburnt

hydrocarbons as well as carbon soot formed in the combustion process.

As a result of this the following benefits are achieved: a) Reduction in excess air for combustion b) A more complete combustion c) As a consequence, Higher Flame Temperature and more efficient radiant heat

transfer. d) Reduction of deposit formation and NOx emissions. e) Reduction deposits on heat transfer surfaces and consequently more efficient heat

transfer in the convection and radiation zones. f) Reduced emission of unburnt hydrocarbons and other solids by 50 – 60%. g) As a result of all the above factors, reduction in fuel consumption to the extent of 4

– 5%.

3

Dosage and Economics: The heavy fuel oil available in India has higher density, viscosity as well as higher

asphaltenes and metal contents. Considering these, the preferred dosage for optimum

results is fixed at 500 ppm i.e. 1 litre per 2000 litres of fuel oil.

The cost of additive treatment would be about 1.5% of FO cost at market price against

which fuel saving of 5% can be achieved. In addition, there will be several intangible

but very valuable benefits like cleaner heat transfer surface, reduced down time, lower

maintenance cost, reduced pollution and higher capacity utilisation of boilers and

furnaces.

2) AC S82 SLUDGE MODIFIER ADDITIVE FOR FURNACE OIL /

LSHS / LDO Heavy fuel oils are complex mixtures which can induce problem of instability,

compatibility and which can be contaminated with impurities such as water and mineral

sediments (e.g. salt, sand, rust etc.)

Instability Two kinds of instability have to be considered. a) Viscosity Increase: the viscosity of the fuel increases during storage and the fuel

becomes too viscous with respect to its viscosity specification.

b) Precipitation Instability: Where a good chemical continuity between the

different components does not exist (mainly fluxants and resins or resins and

asphaltenes) there is the occurrence of flocculation of the asphaltenes, followed by

their precipitation as “Sludge”.

4

Compatibility Incompatibility problems can occur while mixing two residual fuels, even if they are

perfectly stable in themselves. The stability of the resulting mixture is not always

ensurable because of difference in the chemical nature of the components.

Inorganic Impurities They are introduced into the fuel during its handling and its storage : sand particles

from the air borne dust, water enering the storage tank from atmospheric humidity

(during the filling operation) and the resultant rust particles from the insides of the

storage tank.

As a result, the sludge, usually present at the bottom of the storage tanks, is a complex

mixture of asphaltenes, water and inorganic sediments.

AC S82 is a blend of different dispersant molecules which acts on the fuel oil at different

stages.

Since it’s chemical structure is close to resins, it prevents the increase in viscosity of the

fuel, during storage and so avoids the flocculation of asphaltenes, by creating weak

polar bonds with asphaltenes. Besides, because of the presence of long fatty chain of

molecules, flocculation of asphaltenes is avoided (sterio effect).

If the asphaltenes have already flocculated, since the polar bond between additive and

asphaltenes is stronger than the polar bond between asphaltenes themselves, they

destroy slowly the agglomerates of asphaltenes (curative effect), resulting in dispersion

of the sludge.

Additionally AC S82, by effecting decrease of the surface tension between water and oil

(tensio active effect) and because of creation of bonds with inorganic particles

(filmogene effect) leads to sludge removal. These organic materials are not dissolved

into the fuel by the additive but dispersed.

5

CONCLUSION From the context of Energy Management one can observe that there are a number of

Additives manufactured by all the leading Petroleum MNCs in the World to suit various

applications. The applications range from Fuel savings to corrosion prevention to

pollution control. The results are easily realisable and the investment costs are basically

revenue in nature. The pay back period is always very attractive. Since BIS standards

are not existant in this field, the User Industry has to carefully evaluate the credentials

of the additive suppliers and choose the right type of additive to get the best results.

SAFETY MANAGEMENT SOLUTIONS

Honeywell

Burner Management Solutions Burner Management Solutions for Industrial Marketsfor Industrial MarketsSafeguarding ProfitabilitySafeguarding Profitability

Safety Management SolutionsPage 2

Industrial Burner Management Solutions

This photographer captured a “before” and “after” photograph of the initial blast at Kansas City Power & Light Co.



Power Plant Equipment Control System Maker Ordered to Pay $97 Million in Power Plant ExplosionST. LOUIS--In a lawsuit arising from an explosion that destroyed an electric power plant near Kansas City in 1999, the Kansas City Power & Light Co. won a $97. 6 million verdict March 5 against a company that provided computer controls for the plant's safety system (Kansas City Power & Light v. Bibb & Associates Inc., Mo. Cir. Ct., No. 01-CV-207987, verdict 3/05/04).

KCP&L charged that the control system provided by the defendant, Allen-Bradley Co., a division of Rockwell International Corp., allowed a release of gas into a boiler at the company's Hawthorn Generating Station during a shutdown of the boiler, and failed to prevent the gas from igniting.

As a result, the boiler exploded and was destroyed along with other KCP&L property. The company's total losses from the explosion were around $600 million, including property damage, costs of replacement power and lost profits, the company claimed.

KCP&L brought claims of strict liability and negligence against Allen-Bradley over the design of the control system and the contents of trouble-shooting guides and training provided by Allen-Bradley to KCP&L and its workers.

The jury assessed damages at $452 million, allocating 70 percent of fault to KCP&L and 30 percent to Allen Bradley.

Law Suit: Example of System causing accident…Law Suit: Example of System causing accidentLaw Suit: Example of System causing accident……



Industrial Burner Management SolutionsIndustrial Burner Management Solutions

• Agenda– Overview of International Function Safety Standard –

IEC61508– International Approvals - TUV– BMS specific standards-NFPA 85 and NFPA 86– BMS Benefits with Safety Systems– BMS application– Emerging trends - Integrated Systems– SMS Consultancy- TUV_FS Certification Program



Application of SIS for Industrial SolutionsApplication of SIS for Industrial Solutions

Power GenerationPower Generation– Burner Management Systems (BMS)

– Boiler/Furnace Interlocks (ESD)

Refining , Oil&GasRefining , Oil&Gas– (recovery) Boilers, Heaters, BMS

– Calciners, Incinerators

Pulp and PaperPulp and Paper– Power boilers– Recovery boilers

Metals, Minerals & MiningMetals, Minerals & Mining– (recovery) Boilers, Heaters, BMS

– Calciners, Incinerators



•• ANSI/ISA S84.01;ANSI/ISA S84.01; Application of safety instrumented systems for the process industries, 1996

•• IEC61508 (and IEC 61511);IEC61508 (and IEC 61511);Functional safety - safety related systems

•• NFPA 85;NFPA 85; Boiler and combustion systems hazard code

•• NFPA 86;NFPA 86; Standard for ovens and furnaces

BMS Important StandardsBMS Important StandardsBMS Important Standards



IEC 61508IEC 61508Functional safety of electrical/electronic/Functional safety of electrical/electronic/

programmable electronic safetyprogrammable electronic safety--related systemsrelated systems



Participating countries in IEC 61508 developmentParticipating countries in IEC 61508 development

• Australia• Austria• Finland• France• Germany• Italy• Japan • Norway

• Sweden• The Netherlands • United Kingdom • United States of America

+ 9 other countries reviewing and voting



Primary Cause of Control System FailuresPrimary Cause of Control System Failures

Specification44,1 %

Installation & Commissioning

5,9 %

Operation & Maintenance

14,7 %

Note: based on 34 investigated incidents in the UK : “Out of Control”, HSE

Changes after Commissioning

20.6 %Design &

Implementation14.7 %



IEC 61508 IEC 61508 -- A safety umbrella for the worldA safety umbrella for the world

IEC 61508

Specificationfailures

Design & implementationfailures

Installation & commissioningfailures

Operation & maintenancefailures

Modificationfailures

Randomfailures



Generic and application sector standardsGeneric and application sector standards

IEC61508

Machinery sectorMedical sector

Process sector . . . . . . sector

Nuclear sector

IEC61511

IEC61513

IEC62061



Strategy to achieve functional safety of SR systemsStrategy to achieve functional safety of SR systems

CompetenceOf persons

Technicalrequirements

Safety management

+

+

Safety life cycleSafety life cycle

Specification

Design & implementation

Changes after commissioning

Installation & commissioning

Operation & maintenance

Failure Causes



IEC 61508 IEC 61508 -- Key Item 1: risk reductionKey Item 1: risk reduction

Risk reduction achieved by all safety-related systems and external risk reduction facilities

Residualrisk

Residualrisk

Acceptable riskAcceptable risk EUC riskEUC risk

Necessary risk reduction

Actual risk reduction

Increasingrisk

Partial risk covered by external risk

reduction facilities

Partial risk coveredby E/E/PE

safety-related systems

Partial risk coveredby other technology

safety-related systems



SAFETY INSTRUMENTED FUNCTION

Logic Solver(PLC)

Temperaturetransmitter

Temperaturetransmitter

Level switch

Flowtransmitter

Shut-offvalveSolenoid

GlobevalveSolenoid

Pump

Definition of a Safety Instrumented FunctionDefinition of a Safety Instrumented FunctionDefinition of a Safety Instrumented Function

Safety Instrumented System



IEC 61508 IEC 61508 -- Key Item 2: Safety Integrity LevelsKey Item 2: Safety Integrity Levels

TABLE 2: SAFETY INTEGRITY LEVELS: TARGETFAILURE MEASURES

SAFETYINTEGRITY

LEVEL

(SIL)

Low demand modeof operation

(Average probabilityof failure to perform

its design function ondemand)

High demand orcontinuous mode

of operation (Probability of a

dangerous failure perhour)

4321 ≥ 10-2 to < 10-1 ≥ 10-6 to < 10-5

≥ 10-3 to < 10-2 ≥ 10-7 to < 10-6

≥ 10-4 to < 10-3 ≥ 10-8 to < 10-7

≥ 10-5 to < 10-4 ≥ 10-9 to < 10-8

Target failure measures for a safety function, allocated to an E/E/PE safety-related system



IEC 61508 : Safety LifecyclesIEC 61508 : Safety Lifecycles

Concept

Overall scope definition2

Overall Installation and commissioning

Overall safety validation

Decommissioning or disposal

Overall operation and maintenance and repair

12

13

16

14 Overall modification and retrofit15

Safety related systems: E/E/PES

9Realization (see E/E/PES

safety lifecycle)

External risk reduction facilities11

Realization

Back to appropriateoverall safetylife cycle phase

1

Safety related systems: other technologies

Realization

10Overall operation & maintenance planning

6

Overall planning

Hazard and risk analysis

Overall safety requirements4

3

Safety requirements allocation5

Overall validation planning

7Overall

installation and commissioning

planning

8

Overall Safety Lifecycle



Allocation of Safety requirements to designated

safety related systems

1

Phases 1 Phases 1 -- 5: Specify Requirements5: Specify Requirements

• Process Hazards• Safety-related functions• Safety Integrity Levels

REQUIRED• Allocation to systems

SPECIFY:Overall Scope Definition2

Hazard and Risk Analysis3

Overall Safety Requirements

4

5

Concept



Phases 6 Phases 6 -- 12: Implement System12: Implement System• Hardware• Software• Plan Validation, Operation

& Maintenance• Install• Commission

IMPLEMENT

Overall Validation Planning

7

Overall Operation & Maintenance

Planning

6

Overall Installation &

CommissioningPlanning

8

Overall Planning

Overall Installation12

Safety related systems E/E/PES

Realization (see E/E/PES Safety Lifecycle)

9



Phases 13 Phases 13 -- 15: Operate System15: Operate System

• Validate Safety Functions

• Operate• Maintain• Modify• Decommission

OPERATE

Back to the appropriateOverall Safety Lifecycle phase

Overall Modification and Retrofit15

Decommissioning16

Overall Operation and Maintenance14

Overall Safety Validation13



Competence of personsCompetence of persons• Competence of persons for all persons involved, including

management:– appropriate training– technical knowledge– experience– qualifications relevant to the specific duties

• Competence factors to be addressed:– engineering appropriate to the application area– safety engineering appropriate to the technology (e.g. software engineering)– knowledge of legal and safety regulatory framework– the consequences in the event of failure of the safety related system– the safety integrity levels of the safety related system– the novelty of the design, design procedures or application– previous experiences to the duties and technologies applied– relevance of the qualifications to specific duties to be performed



IEC 61508 ComplianceIEC 61508 Compliance

• Compliance of E/E/PES subsystems (and certified by a third-party organization such as TÜV) makes plant and system design much easier and cheaper.

• Third-party certificates are no guarantee that the products can only be used in a safe way!!! Therestrictions are listed in the report to the certificate.



• TUV is the global market leader for the certification of programmable controllers (PLC) related to Safety & Safety related systems

• It carries out all nationally & internationally standardized safety tests –Preferably beginning from design stage

• Multiple TUV organization. Three are of International prominence

- TUV SUD (Munich)- TUV Rheinland (Cologne)- TUV NORD (Honnover)

TUV (TUV (TechnischeTechnische UberwachungsUberwachungs VereinVerein))



TUV Certification means -• Thorough analysis of product hardware and software with

regard to quality, reliability and functional safety.

• The product hardware and software is consistent with known functional safety standards (IEC61508)

• The TUV report states the conditions and restriction identified during the testing phase of certification




Benefits of TUV-• TUV certification is de-facto standard in the Power Industries,

Oil& Gas industries. • The certification is based on mandatory & state of art

standards such as IEC,.DIN,VDE,UL,ISA.IEEE etc • TUV recertifies the systems based on standards upgrades &

revisions .So end user does not have to keep track of standards.

• High level of confidence associated with TUV certification • TUV certificate accepted globally.• Piece of mind for end user




TTÜÜVV--ReportReport

• lists all parts of the product which have been assessed• list of all standards considered with a brief description• describes how the tests have been executed• RESULTS OF TESTS ARE STATED

• The reports from TÜV-bodies state:– GUIDELINES– LIMITATIONS in use– WARNINGS– RESTRICTIONS



BMS Standards and Solutions BMS Standards and Solutions

What is NFPA 85?What is NFPA 85?NFPA 85 is a Boiler and Combustion system Hazards code that provNFPA 85 is a Boiler and Combustion system Hazards code that provides ides common and specific requirements forcommon and specific requirements for----Single burner boilerSingle burner boiler--Multiple burner boilerMultiple burner boiler--Heat recovery Steam Generator etcHeat recovery Steam Generator etc

What is NFPA 86?What is NFPA 86?NFPA 86 is a standard for Ovens and Furnaces and applies to ClasNFPA 86 is a standard for Ovens and Furnaces and applies to Class A and s A and Class B ovens, dryers and furnacesClass B ovens, dryers and furnaces




Common Requirements between NFPA 85 and 86Common Requirements between NFPA 85 and 86--Both standards apply to burners, the only difference being the aBoth standards apply to burners, the only difference being the application pplication of burnersof burners--Logic system for BMS shall be designed specifically so that singLogic system for BMS shall be designed specifically so that single failure le failure in that system does not prevent an appropriate SAFE shutdownin that system does not prevent an appropriate SAFE shutdown--BMS system shall generate system alarms to notify any internal fBMS system shall generate system alarms to notify any internal faults to aults to the operatorthe operator--The logic must be protected against any unThe logic must be protected against any un--authorized access and authorized access and changeschanges--Operator shall be provided with a manual switch for safe shutdowOperator shall be provided with a manual switch for safe shutdown of n of burnersburners




NFPA 85 NFPA 85 –– Specific Requirements to SIS:Specific Requirements to SIS:–– Independence of the SIS system from other logic systems (Boiler,Independence of the SIS system from other logic systems (Boiler,HRSG). Data communication to other logic system is permittedHRSG). Data communication to other logic system is permitted

•• NFPA 85: 1NFPA 85: 1--9.3.2.3(a thru e)9.3.2.3(a thru e)–– Master Fuel Trip (MFT) switch to be part of BMS for safe shutdoMaster Fuel Trip (MFT) switch to be part of BMS for safe shutdown of wn of burners on activation by operatorburners on activation by operator

•• NFPA 85: 1NFPA 85: 1--9.3.2.2(2)9.3.2.2(2)––Application design relatedApplication design related

Backward sheet transfers to be minimal to avoid delays in scan Backward sheet transfers to be minimal to avoid delays in scan time due to time due to looping effect looping effect -- NFPA 85:1.9.3.2.2(5)NFPA 85:1.9.3.2.2(5)BMS safety functions to include purge interlocks & timings, manBMS safety functions to include purge interlocks & timings, mandatory safety datory safety

shutdowns, trial timing for ignition and flame monitoring shutdowns, trial timing for ignition and flame monitoring –– NFPA 85: 1.9.3.2.3(b)NFPA 85: 1.9.3.2.3(b)–– Fuel ValvesFuel Valves

Logic sequences or devices that cause a safety shutdown shall caLogic sequences or devices that cause a safety shutdown shall cause burner use burner trip or Master fuel trip. trip or Master fuel trip. -- NFPA 85:1.9.3.2.4NFPA 85:1.9.3.2.4It is not permitted to install any momentary contact or resettinIt is not permitted to install any momentary contact or resetting device that can g device that can cause chattering between SIS and main/ignition fuel valves cause chattering between SIS and main/ignition fuel valves –– NFPA 85:1.9.3.2.5NFPA 85:1.9.3.2.5




NFPA 86 NFPA 86 –– Specific Requirements to SIS:Specific Requirements to SIS:–– Before startBefore start--up, application to be verified by end user for up, application to be verified by end user for functional safetyfunctional safety

•• NFPA 86: 5NFPA 86: 5--3.1.13.1.1

–– Any changes to the SIS hardware or software to be documentedAny changes to the SIS hardware or software to be documented•• NFPA 86: 5.3.3.3/5.3.4.1NFPA 86: 5.3.3.3/5.3.4.1

––Combustion safety functionsCombustion safety functionsLogic for combustion safety functions shall not interfere with Logic for combustion safety functions shall not interfere with other other

safety interlocks safety interlocks -- NFPA 86:5NFPA 86:5--3.23.2

–– Safety LogicSafety LogicAny other logic other than Safety logic needs to be separated frAny other logic other than Safety logic needs to be separated from om safety logic safety logic -- NFPA 86:5NFPA 86:5--3.4.33.4.3



BMS BenefitsBMS Benefits•• Improved ProfitabilityImproved Profitability

– Increased up-time due to the improved availability of the burner management system,

– Unreliable relay-based systems that tend to fail causing spurious trips of the process are eliminated

– Reduced maintenance costs inherent in self-checking and diagnostic capabilities that are readily available to control systems, information systems and plant personnel

•• Improved SafetyImproved Safety– Risk reduction for People, Plant, and Environment– Personnel safety will be improved by not having to access the old relay

boxes which may be located in hazardous and high-temperature areas of the boiler.

•• Regulatory ComplianceRegulatory Compliance– Honeywell BMS Solutions comply with strict safety standards with TÜV

approval for: DIN and VDE for function safety, EN 54-2 fire detection standard, IEC 61508, ANSI/ISA-S84.01, NFPA 8502

– First system approved for UL-1998 safety system, UL and CSA electrical



Protection of Equipment

Personnel Safety

EnvironmentalSafety

Profit

BMS Risk ManagementBMS Risk Management

Protection from Litigation

DCS

SIS



COMMUNITY EMERGENCY REPSONSE

PLANT EMERGENCY REPSONSE

PHYSICAL PROTECTION (DIKES)

PHYSICAL PROTECTION (RELIEF DEVICES)

AUTOMATIC ACTION SIS OR ESD

CRITICAL ALARMS, OPERATORSUPERVISION, AND MANUAL INTERVENTION

BASIC CONTROLS, PROCESS ALARMS,AND OPERATOR SUPERVISION

PROCESSDESIGN

LAH1

I

Layers of ProtectionLayers of Protection



• An Honeywell-based BMS Solution meets or exceeds the following standards and regulations:

A relayA relay--based or generalbased or general--purpose PLCpurpose PLC--basedbasedBMS system DOES NOT!!BMS system DOES NOT!!

BMS Regulatory ComplianceBMS Regulatory Compliance



• “S84.01 is a national consensus standard”

• “OSHA considers S84.01 to be recognized and generally accepted good engineering practice for SIS.”

• “Per 1910.119(f)(1)(iv) the employer is required to develop and implement written operating procedures …involving safety systems.”

• “If an employer documents per 1910.119(d)(3)(I)(F) that it will comply with S84.01 for SIS and it meets all S84.01…requirements, the employer will be considered in compliance with OSHA PSM requirements for SIS”

Effects of OSHA RulingEffects of OSHA Ruling



BMS Solutions Increase ProfitabilityBMS Solutions Increase Profitability

Ope

ratin

g C

osts

$Time

Cost of Spurious Trips

% of Boilers with FSC BMS Systems

• Improved Uptime– Production efficiency improves as process

stay running to meet production demand, and

– Capital Equipment remains efficient through protective BMS systems

• Reduction in Operations Costs– Honeywell SMS can significantly reduce

(several $M per year) the cost of operations through nuisance shutdown reduction.

– Old, aging relay based safety systems frequently case unwanted plant downtime

– Maintenance costs are reduced by replacing solid-state technology with extensive self-checking and diagnostic capabilities readily available to control systems, information systems, and plant personnel.



Application of Safety System in a Burner application

DCS Network

BurnerFrontPanel

FuelPurge

Air

MainFlame

IgnitionFlame

Damper

Damper

WindBox

MainFlame

Det

IgnitionFlame

DetCooling

Air

Main Burner

Igniter

IgnitionTransformer

BTGInsertPanel

(Option)

FTA and Marshalling

Cabinets

(Option)

Third party devicesHoneywell SM

IgnitionFlame

Damper

Igniter

IgnitionTransformer



BMS Logic DesignBMS Logic Design

OperatorInputsSheet

HrdWr

Com -SCAN

Com -GUS

LogicTrip/PurgeSheets

HrdWr HrdWr

OperatorOutputsSheet

Com -SCAN

Com -GUS

HrdWr

Furnace Inputs Furnace Outputs

• Modular Logic Blocks Allow Fast and Easy Customization– Compartmentalization of logic and operator interface– Multiple operator interfaces or filed switches– Logic independent of number of interfaces or filed

switches



Safety Builder engineering toolSafety Builder engineering tool

Application EditorApplication Editor

• IEC1131 compliant

• Explorer-based FLD browser

• TÜV approved logic library

• Drag-and-drop logic element programming

• Detailed Point properties

• Custom function Block programming



Fail Safe Controller

C200Controller

PM I/O&

Others

ControlNet

Experion Servers

Foundation Fieldbus, HART, DE, Others

DistributedSystem

Architecture

WANLAN

Fault Tolerant Ethernet

Investment Protection

TDC2KTDC3K

TPSFSC

Integration Node

Integrated Control and Safety Systems Integrated Control and Safety Systems

Safety Manager PKS

HART4-20 ma Devices

• FSC & Safety Manager PKS connects to the FTE network• Delivers a TÜV approved SIL 3 redundant fault tolerant

connectionControl, Safety

& Operations



Experion PKS IntegrationExperion PKS Integration

Algorithms

ControlS/W

:: : : : : :

Uniform, integrated operator interface

Integrated Sequence-of-Event (SOE) Reporting

Integrated Diagnostics

Establishes Unified Safety & Control Safety Platform



The TThe TÜÜVV--Rheinland Functional Safety ProgramRheinland Functional Safety Program……

• The business field Automation, Software and Information Technology (ASI), of TÜV Industrie Service GmbH, has developed an extended vocational training program together with national and international companies of the Functional Safety business.

• The TÜV Functional Safety Program supports engineers (and/or persons in the functional safety business) to deepen their knowledge and their experience in order to achieve a worldwide acknowledged know how and practical experience within the area of functional safety according to the IEC 61508 and IEC 61511 and further relevant international standards.



TTÜÜV Functional Safety ProgramV Functional Safety Program

The TÜV Functional Safety Program offers Courses and Trainings of different Companies concerning various subjects of functional safety. The focus is mainly on the following subjects:

• Safety Instrumented Systems • System-Hardware/Software-Designer • Safety of Machineries • Basic training for sales and marketing etc.



TTÜÜV QualificationsV Qualifications

Two qualifications can be obtained:

• TÜV Functional Safety Engineer

• TÜV Functional Safety Expert



RequirementsRequirementsEligibility requirements• The following requirements have to be met, to participate

in a training/course of the TÜV Functional Safety Program: • a minimum of 3 to 5 years experience in the field of

functional safety. • University degree, or • Equivalent engineer level responsibilities status certified

by employer

Validity of certificate• The certificate is valid for 5 years. • To prolong a certificate a written proof is necessary, either

in form of a short exam covering updates in standards and best practices in functional safety or a recent written case study.



Your partner for BMS SolutionsYour partner for BMS Solutions

• Honeywell offers a complete solution approach to BMS applications:– Consulting and Engineering Services performed by

Experienced Professionals– State-of-the-Art Software and Hardware technologies, and– Documentation and validation

• Throughout the Life-cycle of your Plant

Let Honeywell help you improve plant up-time, reduce safety system maintenance costs, ensure regulatory compliance, and reduce acceptable risk to plant and personnel for your BMS

applications over existing relay or general purpose PLC based BMS systems.



Question & AnswersQuestion & Answers

• TUV website– http://www.tuv-fs.com/plclist.htm– List of approved system, report for

vendors..etc

• Points to note– SIS for BMS application (SIL/AK Class

levels)– Restrictions in TUV report, Safety manual

Failsafe & Line Monitoring SignalsOn Line modificationAddition of Modules, I/O chassis

– Proven in use– Compliance to BMS specific Standards-

NFPA 85&86– Integrated BMS system

1Eclipse CombustionEclipse Combustion bvbv

WELCOMES WELCOMES ALL THE DELEGATES FOR ALL THE DELEGATES FOR

PRESENTATION ON PRESENTATION ON

NOxNOx, CO, , CO, SOxSOx And And OTHER EMISSIONSOTHER EMISSIONSTECHNICAL MEET ON TECHNICAL MEET ON

COMBUSITON TECHNOLOGYCOMBUSITON TECHNOLOGY


Pollutants and Emissions affect everyday life, health,Pollutants and Emissions affect everyday life, health,EnviornmentEnviornment, animals, plants & will affect future , animals, plants & will affect future generationsgenerationsPollution around Pollution around TajmahalTajmahalPollution in Pollution in ChemburChembur, , AnkaleshwarAnkaleshwar, , KurkumbhKurkumbh

Is itIs itSCIENCESCIENCEARTARTPOLITICSPOLITICSECONOMICSECONOMICS


NOx & Other EmissionsNOx & Other Emissions

Theory of CombustionTheory of CombustionNOxNOx FormationFormationCO FormationCO FormationEmission ControlEmission ControlEmission Norms & MeasurementsEmission Norms & MeasurementsEclipse Low Emission ProductsEclipse Low Emission Products


Theory of Theory of CombustionCombustion


What is Combustion?What is Combustion?A rapid chemical reaction or oxidation of a fuel resulting in A rapid chemical reaction or oxidation of a fuel resulting in

the production of combustion products, the production of combustion products, heat, heat, and usually, visible flame.and usually, visible flame.


Three Basic IngredientsThree Basic Ingredients

Fuel (C, H)Fuel (C, H)Oxygen (Air = 21% O2)Oxygen (Air = 21% O2)Ignition (spark = temperature)Ignition (spark = temperature)


Three Basic ConditionsThree Basic ConditionsMixing the air with fuelMixing the air with fuelRaising the temperature of the mixtureRaising the temperature of the mixtureAllowing room for the reactionAllowing room for the reaction


Various Combustion ConditionsVarious Combustion Conditions

Perfect combustion (Perfect combustion (stoichiometricstoichiometric))Excess air (lean mixture Excess air (lean mixture -- oxidizing atmosphere)oxidizing atmosphere)Excess gas (rich mixture Excess gas (rich mixture -- reducing atmosphere)reducing atmosphere)


Perfect CombustionPerfect CombustionWith air and fuel at proper proportions, With air and fuel at proper proportions, perfect combustion is achieved.perfect combustion is achieved.

CHCH44 + 2O+ 2O22 + ignition CO+ ignition CO22 + 2H+ 2H22O + heatO + heat


Excess AirExcess Air

AA LeanLean ReactionReaction//OxidizingOxidizing FlameFlame

CHCH4 4 + 3O+ 3O22 + ignition + ignition COCO22 + 2H+ 2H22O + OO + O22 + heat+ heat

results in a shorter and clearer flame with aresults in a shorter and clearer flame with a

reduction in flame temperature and heat output.reduction in flame temperature and heat output.


A A RichRich Reaction/Reaction/ReducingReducing FlameFlame

2C + O2C + O22 + ignition 2CO + heat+ ignition 2CO + heat

results in longer flames which may be smoky in results in longer flames which may be smoky in appearance. This is also known as appearance. This is also known as incomplete incomplete combustioncombustion..

Excess FuelExcess Fuel


Criteria Pollutants / Emissions

Nitrogen Compounds – NOxSulphur Compounds – SOx

OzoneCarbon Monoxide – CO

Particulates – PM & PM10Lead

Volatile Organic Compounds

Criteria Pollutants / Emissions

Nitrogen Compounds – NOxSulphur Compounds – SOx

OzoneCarbon Monoxide – CO

Particulates – PM & PM10Lead

Volatile Organic Compounds


EMISSION CONSIDERATIONS

EMISSION CONSIDERATIONS

NoxNox is harmful to humans, known to initiate reaction in production is harmful to humans, known to initiate reaction in production of ozone of ozone ( photo chemical smog ), acid rain, damage fabric, cause rubber ( photo chemical smog ), acid rain, damage fabric, cause rubber crack, crack, reduce visibility, damage buildings, harm forest / lakes, cause reduce visibility, damage buildings, harm forest / lakes, cause health issue health issue

SOxSOx reacts with water vapor to form sulfuric acid mist, fog, acid rreacts with water vapor to form sulfuric acid mist, fog, acid rain ain & snow, very corrosive& snow, very corrosiveCO contributes to ozone formation, readily absorbed in body & CO contributes to ozone formation, readily absorbed in body & impairs oxygen carrying capacity of hemoglobin affecting heart, impairs oxygen carrying capacity of hemoglobin affecting heart, brainbrainParticulate Matter PM & PM 10 are Particulate Matter PM & PM 10 are nitrates,sulfates,chlorides,fluorides,carbons,silicates, oxides nitrates,sulfates,chlorides,fluorides,carbons,silicates, oxides are are corrosive, toxic to animals, humans, cough, irritation, corrosive, toxic to animals, humans, cough, irritation, broncoytisbroncoytisOzone is a highly reactive form of oxygen formed by reaction of Ozone is a highly reactive form of oxygen formed by reaction of VOCs VOCs with with NOxNOx in sunlight; leads to smog, irritation in eyes, nose, in sunlight; leads to smog, irritation in eyes, nose, throat, lungs and damages crops. Harmful at ground but good in throat, lungs and damages crops. Harmful at ground but good in stratosphere to block UVstratosphere to block UVLead is poison leads to fatigue, headache,digestive upset, centrLead is poison leads to fatigue, headache,digestive upset, central al nervous system, gastrointestinal tract aching muscles problemsnervous system, gastrointestinal tract aching muscles problems


EmissionsEmissions

Oxides of Nitrogen (NO+NO2=Oxides of Nitrogen (NO+NO2=NOxNOx))Carbon Monoxide (CO)Carbon Monoxide (CO)Unburned HydroUnburned Hydro--carbons (carbons (CxHyCxHy))Aldehydes Aldehydes

Formaldehyde (HCHO)Formaldehyde (HCHO)Formic acid (HCOOH)Formic acid (HCOOH)


NOx NOx FormationFormation


NOx Formation

CombustionAir

N2

O2CH4

Natural Gas

Heat

CO2

H2O

N2

8N2 + 2O2 8N2 + CO2 + 2H2O+ CH4


How NOx is FormedHow NOx is Formed

HeatCombustionAir

N2

O2CH4

Natural Gas

NO

NO

NONO

NO2

NO2

NONO

NO

CO2

H2O

ThermalThermal NOxNOx::PromptPrompt NOxNOx::Fuel Fuel NOxNOx

O + N2 = NO + NO + N2 = NO + NCH + N2 = HCN + NCH + N2 = HCN + NReaction of fuel nitrogen with O2 in airReaction of fuel nitrogen with O2 in air


NOx Formation

CombustionAir

N2

O2CH4

Natural Gas

Heat

CO2

H2O

N2

NO

NO

NONO

NO2

NO2

NONO

NO

Thermal NOThermal NOxx::Prompt NOPrompt NOxx::

Fuel Fuel NOxNOx

O + NO + N22 = NO + N= NO + NCH + NCH + N22 = HCN + N= HCN + N


Nox EmisionsNox Emisions

Prompt Prompt Nox Nox –– formed in early low formed in early low temprature temprature stages of stages of combustion by reaction between N2 & O2 in air and combustion by reaction between N2 & O2 in air and hydrocarbons in fuel hydrocarbons in fuel –– small part in total small part in total NoxNoxThermal Thermal Nox Nox –– Combination of nitrogen and oxygen in air at Combination of nitrogen and oxygen in air at high high tempratures tempratures –– makes up makes up majoruty majoruty of of NoxNoxFuel Fuel Nox Nox –– formed by reaction of nitrogen in the fuel and formed by reaction of nitrogen in the fuel and oxygen in the air oxygen in the air –– about 50% of total about 50% of total NoxNox

About 95% About 95% Nox Nox is produced during combustionis produced during combustionAbout 80% About 80% NOxNOx is present in the atmosphere is from is present in the atmosphere is from combustioncombustionPrimary sources are automobiles, jet engines, power plantsPrimary sources are automobiles, jet engines, power plants


NOx Formationstandard nozzle mixing burner

NOx Formationstandard nozzle mixing burner

A B A B

Tem

pera

ture

ºC (º

F)

1400(2600)

High NOxx


NOx vs. TemperatureNOx vs. TemperatureHi

LoHot Cold

Flame Temperature (Flame Heat Flux)

NOx

Prompt NOx


NOX vs Air/Fuel RatioNOX vs Air/Fuel Ratio

90

100

120

05

Air/Fuel Ratio0 15% 20-25% 40%

Rich Lean

NOx


NOx Prevention TechniquesNOx Prevention Techniques

Lower flame temperatureLower flame temperatureShorten residence timeShorten residence timeEliminate nitrogenEliminate nitrogenEliminate oxygenEliminate oxygen


Premix & High Excess AirPremix & High Excess Air

A B A B

Tem

pera

ture

º C

(ºF)

1400(2600)1000

(1800)

Standard Nozzle

Premix Nozzle

With 50%Excess Air


CO FormationCO Formation


What causes CO formation?What causes CO formation?

Too lean gas/air mixture in combination with poor Too lean gas/air mixture in combination with poor mixingmixingFlame quenching by process air or burner Flame quenching by process air or burner constructionconstructionFlame is cooled by burner / system materialsFlame is cooled by burner / system materialsXSXS--gas combustion (reducing)gas combustion (reducing)


Carbon Monoxide FormationCarbon Monoxide Formation

CO is formed if flame temperature <750°CCO is formed if flame temperature <750°CCO is formed if, enough oxygen is not present to CO is formed if, enough oxygen is not present to complete combustioncomplete combustion


Carbon Monoxide Formation

Flame quenchingFlame quenching

Air / Gas mixingAir / Gas mixing

--Prevention TechniquesPrevention Techniques

(3 T’s)(3 T’s)-- Time Time (increase)(increase)

-- Temperature Temperature > 800º C (>1500º F)> 800º C (>1500º F)

-- Turbulence (increase)Turbulence (increase)


CO Formation

CombustionAir

N2

O2CH4

Natural Gas

Heat

CO2

H2O

N2

8N2 + 2O2 8N2 + CO2 + 2H2O+ CH4


CO Formation

CombustionAir

N2

O2CH4

Natural Gas

Heat

CO2

H2O

N2

CO

CO

2CH2CH44 + 3O+ 3O22 2 CO + 4 H2 CO + 4 H22OO


CO formationCO formationCO formation

ConvectiveBurne r Radiant

CO forms between the radiant and convective sections of the flame via quenching.


CO FormationCO Formation

ALDEHYDES, ACIDS & CARBON MONOXIDE

QUENCHED AREA

QUENCHED AREA

AIR

AIR


Time & Temperature Windowfor Simultaneous CO & NOx Control

Time & Temperature Windowfor Simultaneous CO & NOx Control

600 1000 1300 18000

20

40

60

80

100

Temperature, C

CO

(Nor

mal

ized

Sca

le) N

Ox

(Logarithmic S

cale)

1

2

3

4

CO

, 0.01Sec.

CO

, 0.1Sec.

NOx,

1se

c.NO

x,0.

1Se

c.

NOx,

0.01

Sec.


Effect Of Excess Air On Emissions(Typical Nozzle Mix Burner Firing Natural Gas)

0

10

20

30

40

50

60

70

0 10 20 30 40 50 60 70 80 90 100 110

Excess Air [%]

NO

x [p

pm @

3%

O2]

0

200

400

600

800

1000

1200

1400

CO

[pp

m @

3%

O2]

NOxCO

Burner adjustment typically has a small effect on NOx and large effect on CO.

Excess Air (%)

CO

(ppm

@ 3

% O

2)

NO

x(p

pm@

3%

O2)


EMISSION EMISSION CONTROLCONTROL


Emision ControlEmision Control

NOx NOx -------- Flame Geometry, temperature, nitrogen in Flame Geometry, temperature, nitrogen in fuel, heat release, excessfuel, heat release, excess air, comb air temp, Flue gas air, comb air temp, Flue gas recirculationrecirculation

SOx SOx -------- Low sulfur fuels,Low sulfur fuels, desulfurizingdesulfurizing, flue gas , flue gas desulfurizationdesulfurizationCO CO -------- Poor burner or firing conditions, air to fuel ratioPoor burner or firing conditions, air to fuel ratio

Particulate Matter Particulate Matter -------- Electrostatic precipitators, scrubbersElectrostatic precipitators, scrubbersOzone Ozone -------- Poor maintenance of furnace, boilers, avoid Poor maintenance of furnace, boilers, avoid VOCsVOCsLead Lead -------- Use Lead free fuelsUse Lead free fuels


Pollutant Emissionsfrom Fuel Gas Combustion

Oxides of NitrogenOxides of Nitrogen (NO(NOxx) ) NONOxx = NO & NO= NO & NO22

Carbon MonoxideCarbon Monoxide (CO)(CO)

Other pollutant emissionsOther pollutant emissions-- SOSOxx-- PM PM –– 10 10 (< 10 microns)(< 10 microns)-- HydrocarbonsHydrocarbons


Process Effects Upon EmissionsProcess Effects Upon Emissions

Direct Direct Air heating SystemsAir heating SystemsFurnaces & ovensFurnaces & ovensIndirect Fired HeatersIndirect Fired Heaters


CO forms where the flame envelope (>750°C) comes into contact with a surface (<750°C) and the flame is quenched

CO forms where the flame envelope (>750°C) comes into contact with a surface (<750°C) and the flame is quenched

Wall

Burner Radiant


CO forms where CO forms where cool gases quench cool gases quench the flame.the flame.

Process Air Stream

Burner

Chamber conditions affect CO more than NOxx.


External Flue Gas Recirculation (FGR)

Reduce Reduce NONOxx by lowering flame tempby lowering flame tempReduce OReduce O22 in combustion airin combustion airAbout 20% FGR is practicalAbout 20% FGR is practicalFGR is more effective if flue gases are FGR is more effective if flue gases are cooledcooledTypical NOTypical NOxx reduction is 30reduction is 30--60%60%


Internal Flue Gas RecirculationSwirl Vortex Generator

Eclipse Winnox40 – 60% excess airNozzle mixingFast mixing


Flue Gas Recirculation(NOx reduction vs. percentage FGR)

0

20

40

60

80

100

120

0 5 10 15 20 25Flue Gas Recirculation, %

NO

xra

tio (F

GR

/sta

ndar

d), -

High Velocity = Improved Temperature Uniformity

•Low NOx •Nozzle design

•Exhaust gas recirculation

500 ft/sec


EMISSION NORMS EMISSION NORMS &&

MEASUREMENTSMEASUREMENTS


Emission standardsEmission standards

Local regulationsLocal regulationsCustomer requirementsCustomer requirementsProduct requirementsProduct requirements


American ExampleAmerican ExampleCongress established Environmental Protection agencyCongress established Environmental Protection agencyNational Ambient Air Quality StandardsNational Ambient Air Quality StandardsClean Air Act AmendmentsClean Air Act AmendmentsPurpose to create awareness & follow state & local rules Purpose to create awareness & follow state & local rules ––affected by weather, geography, demographyaffected by weather, geography, demographyNew Source Performance Standards New Source Performance Standards –– eg eg BoilersBoilersAir Toxin RegulationsAir Toxin RegulationsBest Available Control TechnologyBest Available Control TechnologyState & Local regulations State & Local regulations –– emision emision inventory, start up & inventory, start up & operating permitsoperating permits

Evolution of regulatory process as technology changes, Evolution of regulatory process as technology changes, cleaner sources are available, and weather in cleaner sources are available, and weather in Kurkumbh Kurkumbh affects crops in affects crops in BaramatiBaramati


Emission standardsEmission standards

Standards in Germany TAStandards in Germany TA--LuftLuft for for direct air heating systems:direct air heating systems:

NOxNOx: 80: 80 ppmppm (100mg/m3) at 17% O2(100mg/m3) at 17% O2CO: 104 (200 mg/m3) at 17% O2CO: 104 (200 mg/m3) at 17% O2


How to check emission?How to check emission?

Emissions are stated inEmissions are stated in ppmppm (parts per million) or (parts per million) or mg/m3. Because dilution of flue gases influences mg/m3. Because dilution of flue gases influences the measured emission concentration, emissions the measured emission concentration, emissions are corrected to a fixed O2 level are corrected to a fixed O2 level


Correction of emission measurementsCorrection of emission measurements

Always measure emission and O2 in flue gasesAlways measure emission and O2 in flue gases

ppm(at %O2ref) = x ppm(measured)( 20,95 - %O2 ref )

( 20,95 - %O2 measured )


Correction of emission measurementsCorrection of emission measurementsExample: Burners on an oven:Example: Burners on an oven:

Measured: 80Measured: 80 ppm NOxppm NOx, 5,5% O2, 5,5% O2Regulations: 104Regulations: 104 ppm NOxppm NOx at 3% O2 at 3% O2 -- Is emission Is emission within this regulation?within this regulation?

ppm(at %O2ref) = x 80 ppm( 20,95 - 3 )

( 20,95 - 5,5 )

= 93 ppm at 3%


Correction of emission measurementsCorrection of emission measurementsExample: Burners on a direct air heater:Example: Burners on a direct air heater:

Measured: 50Measured: 50 ppmppm CO, 19,5% O2CO, 19,5% O2Regulations: 80Regulations: 80 ppmppm CO at 17% O2 CO at 17% O2 -- Is emission Is emission within this regulation?within this regulation?

ppm(at %O2ref) = x 50 ppm( 20,95 - 17 )

( 20,95 - 19,5 )= 136 ppm at 3%


Expressing EmissionsExpressing Emissions

ppmppmvv = Parts Per Million by volume= Parts Per Million by volume-- dry sample is assumeddry sample is assumedCorrected to standard conditionsCorrected to standard conditions

-- ppmppmvv at X% Oat X% O22

-- mass / timemass / timeppmppmvv (uncorrected concentration)(uncorrected concentration)


Expressing EmissionsExpressing EmissionsNorth AmericaNorth America

ppmppmvv at 3% Oat 3% O22lbs / hour, Tons / yearlbs / hour, Tons / yearlbs / million BTUlbs / million BTU“Standard” conditions “Standard” conditions

= 68º F (20º C) & 1 = 68º F (20º C) & 1 atmatm (14.7 (14.7 psipsi))Europe and AsiaEurope and Asia

ppmppmvv at 3, 11, or 17 % Oat 3, 11, or 17 % O22mg / Nmmg / Nm33 @ 17% O@ 17% O22“Normal” conditions “Normal” conditions

= 0º C (32º F) & 1 = 0º C (32º F) & 1 atmatm (1.01 bar)(1.01 bar)


Correcting to x% O2Correcting to x% O2

ppmppmvv, corrected to X%, corrected to X% = = ppmppmvv, test, test xx(20.9 – X%)

(20.9 – O2, test%)Example:

- Requirement is NOX less than 30 ppm at 3% O2.- Measured NOX = 18 ppm at 11.4% O2.- Is the requirement met?

MS Excel conversion, CONVERT emissions.xls


ECLIPSE LOW ECLIPSE LOW EMISSION EMISSION

PRODUCTSPRODUCTS


LinnoxLinnox (LX)(LX)WinnoxWinnox (WX)(WX)Minnox Minnox FurnnoxFurnnox (FN)(FN)VortoVorto, Low , Low NoxNoxThermjetThermjet

Others by applicationOthers by application

Eclipse Product for Low Emission (< 30 ppm NOx at 3% O2)


Premix & High Excess Air NOx Suppression in Air Heaters

40 – 60% excess airT < 1500º C (2700 oF)

Premix creates uniform flame temperatureExcess air lowers flame temperature

Eclipse Linnoxand Minnox


Secondary Air

Primary Air

Fuel Gas

Staged Air Gas Burner

NewEclipse Furnnox


FurnnoxFurnnox

Split air flow


50% air, all gas

50% air

FurnnoxFurnnox


FurnnoxFurnnox

-- Six burners installed at Six burners installed at Carlton Forge production Carlton Forge production furnacefurnace

-- Measured 23ppm at 2300°FMeasured 23ppm at 2300°F


Furnnox RLFurnnox RL-Fabricated body required for insulated version

-600°C pre-heat

-120°C Surface temperature standard

-Special option available for >60°C surface temperature

-5 sizes to be released up to 5mm Btu/hr


Furnnox RLFurnnox RL


Furnnox RLFurnnox RLNOx v's Input

0

5

10

15

20

25

30

35

0 200 400 600 800 1000 1200

Input 1000Btu/hr

NO

x @

3%

O2


Furnnox RLFurnnox RL-Do

-Follow the recommended combustion circuit

-Start with 50% gas 100% air

-Always use above 750°C


Furnnox RLFurnnox RL

-Ambient Air Furnnox.

- will be released Sept 2005

-Refractory Lined Furnnox-to be released Nov 2005

-Refractory Lined Furnnox 60°C surface temp.

- will be a special order.


Do NotDo NotObstruct the burner flow pathObstruct the burner flow pathDo not use gas richDo not use gas richDo not let customer manufacture the blockDo not let customer manufacture the block

ThermJet Burner


ThermJet Burner

Best velocity burner in the Best velocity burner in the worldworld


ThermJet BurnerUnique patented nozzle designUnique patented nozzle designHighest velocity Highest velocity

( Medium velocity available)( Medium velocity available)Highest turndownHighest turndownDirect Spark IgnitionDirect Spark IgnitionMultiple Fuel CapabilityMultiple Fuel CapabilityHigh Excess Air CapabilityHigh Excess Air CapabilityGas rich firingGas rich firingLow Low NOxNOxThree Firing Tube OptionsThree Firing Tube OptionsIntegral Air & Gas OrificesIntegral Air & Gas OrificesPlatform DesignPlatform DesignFixed Air or Proportional ControlFixed Air or Proportional ControlPrePre--heated airheated air


Nozzle DesignNozzle Design

NOZZLE COMBUSTION ZONES

I II III IV

NOZZLE Air Flow

NOZZLE,

Combustion ZonesZone I. Premix zone

NOZZLE

Combustion ZonesZone II. Base of nozzle

NOZZLE

Combustion ZonesZone III. Center of Nozzle

NOZZLE

Combustion ZonesZone IV, Front face of Nozzle and Firing Tube

PROPORTIONAL CONTROL


Minimum Input (10:1 turndown)


Maximum Input

FIXED AIR CONTROL

FIXED AIR CONTROL

Minimum Input (50:1 turndown)

FIXED AIR CONTROL

10% Input

FIXED AIR CONTROL

50% Input

FIXED AIR CONTROL

Maximum Input

NOx Emissions

30 ppm NOx at maximum capacity. ( natural gas)30 ppm NOx at maximum capacity. ( natural gas)

TJ0100

0

10

20

30

40

50

60

70

80

90

100

100 200 300 400 500 600 700 800 900 1000 1100

Input KBtu/hr

NO

x pp

m @

3%

O2

Ignition

Direct spark ignition at any input Direct spark ignition at any input Air must leadAir must leadDo not flood with gasDo not flood with gas

Alloy Combustion Tube

Alloy Firing TubesTJ0100

200

250

300

350

400

450

100 200 300 400 500 600 700 800 900 1000 1100

Input KBtu/hr

Com

bust

or T

empe

ratu

re °F

Multi Fuel

Large gas port Large gas port Air velocity provides mixingAir velocity provides mixingNo gas impingementNo gas impingement

Excess air

Flame retreats into the nozzleFlame retreats into the nozzleStabilized in the preStabilized in the pre--mix zone. mix zone. 4000% excess air on low fire (180°F flame temp)4000% excess air on low fire (180°F flame temp)

Excess Gas

Stabilized by the multi zones. Stabilized by the multi zones. As low as Lambda 0.5 possibleAs low as Lambda 0.5 possible


ThermJet Burner

Three Combustor optionsThree Combustor optionsAlloy tube 310 Alloy tube 310 StStStSt 950950°°C C 17501750°°F F Refractory block 1550Refractory block 1550°°CC 28002800°°FFSiC combustor 1370SiC combustor 1370°°CC 25002500°°FF

The ThermJet Range

14 Sizes TJ0015 to TJ200014 Sizes TJ0015 to TJ2000


ThermJet BurnerIntegral Air & Gas Orifices


ThermJet BurnerPlatform design

Rotate gas inletRotate Air InletNPT or BSP inlet blocksEasy access to spark and

flame rodRemove nozzle from rearO ring seals (reusable) DATE

MODEL NO.

�BTU/HR��KW�

MAX.INPUTSERIAL NO.

ThermJet

ECLIPSE COMBUSTION 17178


ThermJet BurnerUnique patented nozzle designUnique patented nozzle design

Highest velocity Highest velocity Highest turndownHighest turndownDirect Spark Ignition at any inputDirect Spark Ignition at any inputAlloy tube possibleAlloy tube possibleMultiple Fuel CapabilityMultiple Fuel CapabilityHigh Excess Air High Excess Air High Excess Gas High Excess Gas Low Low NOxNOx

Remove nozzle from rearRemove nozzle from rearRotate gas inletRotate gas inletRotate Air InletRotate Air InletEasy access to spark and flame rodEasy access to spark and flame rodIntegral air and gas orificeIntegral air and gas orificeO Ring sealsO Ring sealsAlloy tube, Alloy tube, SiCSiC tube or refractory block.tube or refractory block.Preheated airPreheated air


THANKS FOR THANKS FOR YOUR ATTENTION YOUR ATTENTION DURING ECLIPSE DURING ECLIPSE PRESENTATION PRESENTATION


Questions ?Questions ?

TECHNICAL MEET TECHNICAL MEET ON ON

COMBUSTION TECHNOLOGYCOMBUSTION TECHNOLOGY(27(27th th TO 28TO 28thth June ’06)June ’06)

Case Study on Efficient Combustion of Case Study on Efficient Combustion of Cheaper & Waste FuelsCheaper & Waste Fuels

By :By :Mr. Anil Mr. Anil KewalramaniKewalramani

General Manager (Technology)General Manager (Technology)IPCL, BarodaIPCL, Baroda

CONTENTSCONTENTS1. Purchased Fuels & Energy Bill.

2. Methodology of Burning of Cheaper & Waste Fuels.

3. Burning of CBFS.

4. Modifications Requirement.

5. Annual Savings with Waste fuels and Fuel switch

6. Burning of Waste fuels by blending.

7. Burning of Fuel Oil with additive.

8. Conclusion.

Fuel Oil forms a major part of the Purchased Energy of an industry.

Rising international price of crude per barrel is line justification increasing the cost of the Purchased Fuels.

It has become more Challenging to reduce the Purchased Energy Bill as reduced consumption of energy won’t reduce the Energy Bill.

Alternative is to go for :

- Burning of Cheaper Fuel

- Burning of various Waste Streams with low Sale value but has good Energy content.

- Burning of Fuel Oil with additive.

Purchased Fuels & Energy BillPurchased Fuels & Energy Bill

Methodology of burning of Cheaper & Methodology of burning of Cheaper & Waste Fuel StreamsWaste Fuel Streams

Detailed Analysis of Individual Alternative / Waste Stream

Parameters to be analyzed are:- Gross Cal. Valve, Kcal/Kg- Density at 15 oC, kg/m3- Viscosity, CS at 50 oC, 100 oC, 120 oC- Moisture , % wt, Sulphur, % wt- Pour Point, oC- Ash Content, % wt- Sediments, %wt - CCR (Conradson Carbon residue), % wt- Metals, PPM like Na, Fe, Ni, V, Cu- IBP, oC- Acidity, mgKOH/gm


Miscibility test based on the fuel composition between the main and waste stream.

Test helps to know whether there is precipitation on mixing or solid deposition is there or not.

For various proportions the above tests are done, like 5:1, 4:1, 3:1, 2:1, 1:1 & reverse.

Identification of limit of miscibility of fuels mixing ratios, based on the above results.

Based on this decision to burn individual or by mixing to be taken.


Once the mixing ratio between fuels are decided. Then following few analysis done:

Viscosity at 50 oC, 80 oC, 100 oC & 120 oCFlash point, oCIBP, oCCCR, % wt

In Dual fuel fired burner minimum gas firing helps in improving combustion of waste fuels.

Burning of Carbon Black Feed Stock (CBFS)Burning of Carbon Black Feed Stock (CBFS)CBFS is byproduct of Naphtha Cracker plant.Typical Analysis of CBFS is:

- Gross Calorific value, 9352 kcal/kg

- Sulphur content, 0.05 wt%

- Flash Point, 78 oC

- Pour Point, -21 oC

- Sediments, Nil % wt

- CCR, 12.1 % wt

Higher CCR means not easier to burn.

Coke formation tendency is there and due to which the Cal. Val. of the fuel is lower.

Burning of Carbon Black Feed Stock (CBFS)Burning of Carbon Black Feed Stock (CBFS)Combustion is also not good due to high CCR.

Lower viscosity creates problem in wear and tear of screw pump gears.

For such service best is centrifugal pump.

Lubricity improvement additives available to overcome from such problem or to go for special gear pump with gears mounted outside the pump.

Pump suction strainer of Fuel Oil pumping and heating unit gets choked with high CCR / high viscosity / high sediments.

Contd…

In our Aux. Boiler unit we have pump suction mesh size of 40 and with 30 on the discharge side.

CBFS storage temp. decided keeping flash point in mind.

Firing temp. at the Burner tip is decided keeping the viscosity in mind. It should be less than 10 cst.

Similar exercise carried out for Slop oil containing mainly spent Naphtha and Mixed containing py. Gasoline oil from other sites of IPCL.

Burning of Carbon Black Feed Stock (CBFS)Burning of Carbon Black Feed Stock (CBFS)

Contd…

Changeover of Purchased fuel from LSHS to cheaper RIL, Jamnagar furnace Oil was done.

Spent oil from LDPE plant was successfully burned by blending with CBFS.

Burning of Carbon Black Feed Stock (CBFS)Burning of Carbon Black Feed Stock (CBFS)

Modifications Required for Modifications Required for Burning of Waste Fuels & Fuel SwitchBurning of Waste Fuels & Fuel Switch

Changed fuel involved creation of infrastructure for storing of fuels for CBFS, Slop Oil and JN-FO and unloading station.

Field change order (modification proposal) for change of piping connections, new pump installation etc.

Installation of filters in the fuel unloading area based on the sediments content.

Annual Savings with Waste Fuels & Fuel SwitchAnnual Savings with Waste Fuels & Fuel Switch

a) Fuel switch from LSHS to FO from RIL, Jamnagar.

b) Burning of CBFS substituting expensive LSHS.

c) Burning of slop oil & mixed oil substituting expensive LSHS.

Annual saving is Rs. 907 Lakhs in 2004-05

Annual saving is Rs. 1903 Lakhs in 2005-06

Sr. no.

Test Spec. Fresh oil sample

29/09/2004 29/09/2004

11DA239 12DA239

1 Appearance Clear liquid Passes Dark yellow orange Yellow colour

2 Sp. gravity 1.085-1.095 1.088 1.087 1.078

3 ASTM colour 2 Max. 0.5 3 1.5

4 Acid no. mg KOH /gm 0.04 Max. 0.024 0.71 0.145

5 Flash point 230 Min. 260 225 197

6 Pour point - 3 Max - 12 - 15 - 12

7 Copper corrosion test 1b 1a 1a 1a

8 Kin. viscosity @ 40 0C @ 100 0C

260-32042 min

26545.6

25743

287.741.6

9 Viscosity index 200 min. 230 225 200

10 Moisture content 3000ppm 2000 6200 2800

11 Calorific value - 9914 9919 9982

Burning of LDPE Spent Oil with CBFSBurning of LDPE Spent Oil with CBFS

Sr. No.

Test Results

1 Moisture % wt 0.65

2 Free moisture Nil

3 Flash point,oC 80

4 Kin. Viscosity @ 40 0C cst 17.5

5 Kin. Viscosity @ 100 0C cst 3.95

6 Compatibility with CBFS 5 % Miscible

7 Calorific value 10558

Burning of LDPE Spent Oil with CBFS

Burning Fuel Oil with AdditiveBurning Fuel Oil with Additive

Growing concern with Fuel Availability is increased asphaltenes, carbon residue & ash.

Problems with such Fuels :

Poor combustion

Increased fouling

Reduced steam generation

Increased maintenance

Global warming

Contd…

Burning Fuel Oil with AdditiveBurning Fuel Oil with Additive

Requirement of fuel oil additive:

Fully compatible in all blends of liquid fuels.

Purely organic. If inorganic then metal content like Al, Si & Fe causes corrosion.

Should have neutral pH.

Easily blendable with Fuel Oil in various proportions.

Act as dispersant to disperse the sludge of hydrocarbon agglomerates and not separate the heavies.

Advantages of AdditivesAdvantages of Additives

Reduced surface tension of oil droplet results in improved atomization.

Improved combustion results in low excess air.

Disposal of sludge.

Reduced fuel consumption and hence energy bill.

Reducing Pollution.

Conserving Resources.

Removing hassle of storage problems.

Reducing of Energy Bill.

CONCLUSION

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