© BNG SPRAY SOLUTIONS PRIVATE LIMITED, 2020
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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We Deliver Energy Efficiency
SPRAY CHARACTERISTICS AND COMBUSTION
PERFORMANCE OF INDUSTRIAL BURNERS
Spray Delivery and Combustion Systems Supplier for Industrial Applications
Industrial Furnace Burners | Dust Suppression | Spray and Combustion Testing
© BNG SPRAY SOLUTIONS PRIVATE LIMITED, 2020
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
2
WEBINAR SESSION 1:
INTRODUCTION TO COMBUSTION AND FURNACE BURNERS
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
© BNG SPRAY SOLUTIONS PRIVATE LIMITED, 2020
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Mr. Arindam Ghatak
Founder and Managing Director
IIT Kharagpur (BTech in Mechanical Engineering)
The Ohio State University at Columbus (MS in Mechanical Engineering)
14+ years exp. incl. 10 years in upstream oil and gas industry in
Houston, Texas
Mechanical system design, project management
© BNG SPRAY SOLUTIONS PRIVATE LIMITED, 2020
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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AGENDA FOR SESSION 1
§ Fundamentals of Combustion
§ Boiler and Burner Efficiency
§ Combustion Mechanisms
§ Furnace Burner Types
§ Flame Types and Characteristics
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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FUNDAMENTALS OF COMBUSTION
SOLID FUELS
GASIFICATION BY
PYROLYSIS
GASEOUS FUELS
LIQUID FUELS
GASIFICATION BY
VAPORISATION
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TYPES OF COMBUSTION
STOICHIOMETRIC COMBUSTION
(IDEAL SCENARIO, Φ = 1, λ = 1)
INCOMPLETE COMBUSTION
(RICH F/A MIXTURE, Φ > 1, λ < 1)
Fuel-Air Equivalence Ratio,
Air-Fuel Equivalence Ratio, λ = AFR / AFRst = 1/Φ
COMPLETE COMBUSTION
(LEAN F/A MIXTURE, Φ < 1, λ > 1)
= FAR / FARst
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MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
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AIR / FUEL RATIO
CxHy + a (O2 + 3.76 N2) -> x CO2 + y/2 H2O + 3.76a N2
a = x + y/4
Air-Fuel Stoichiometric Ratio, AFRst = a (32 + 3.76 x 28) / (12x + y)
Air-Fuel Ratio, AFR = (1 + e) x AFRst where e = % Excess Combustion Air
CxHy + a(1+e) (O2 + 3.76 N2) -> x CO2 + y/2 H2O + ae O2 + a(1+e)(3.76) N2
% Excess O2 by Volume in Flue Gas (Wet Basis) = ae / (x + y/2 + ae + 3.76a(1+e))
% Excess O2 by Volume in Flue Gas (Dry Basis) = ae / (x + ae + 3.76a(1+e))
§ Therefore, using Emission Analyzer, % O2 in the flue gas can be measured to determine
% excess combustion air
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STOICHIOMETRIC AIR / FUEL RATIO
Fuel
Stoichiometric AFR
(AFRst)
AFRactual if Excess Air =
10%
% Excess O2 (Dry Basis)
in Exhaust
Ethane (C2H6)
16.0
17.6
2.1%
Diesel (C12H23)
14.6
16.1
2.0%
Furnace Oil
(C20H42 ~ C70H142)
14.7 ~ 14.8
16.2 ~ 16.3
2.0%
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MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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BOILER LIFECYCLE COST
§ Installation of cutting edge equipment (CAPEX) and maintenance costs minimal, but impact energy
cost enormously
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MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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BURNER AND BOILER EFFICIENCY
§ Thermal efficiency determination methodology given in BS845-1:1987
A. More the excess combustion air, lower the boiler efficiency
B. More the unburnt or incompletely burnt fuel, lower the combustion and boiler efficiency
C. Higher the fuel and combustion air temperatures, higher the combustion efficiency
D. Lower the stack temperature, higher the boiler efficiency
(Net Stack Temperature = Stack Temperature – Combustion Air Temperature)
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MINIMIZE STACK TEMPERATURE
REDUCE SCALING AND SOOT LOSSES
§ Every rise of 6°C in boiler feed water
§ Every milimeter thickness of soot coating
temperature through waste heat recovery would
offer about 1% fuel savings
§ For every reduction in flue gas temperature by
22°C for heat recovery, fuel savings of about 1%
can be achieved
Source: https://www.slideshare.net/MagdyAly2/5-energy-efficiency-opportunities-in-boilers
increases the stack temperature by 55°C
§ A deposit of 3mm of soot can cause an increase
in fuel consumption by 2.5%
§ A 1mm thick scale (deposit) on the water side
could increase fuel consumption by 5% to 8%
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MINIMIZE HEAT LOSS FROM BOILER INSULATION
§ Expected saving of up to 5% of fuel
consumption to the boiler
§ Running boiler with deteriorated thermal
insulation will lead to high fuel
consumption and high thermal losses
Source: https://www.slideshare.net/MagdyAly2/5-energy-efficiency-opportunities-in-boilers
© BNG SPRAY SOLUTIONS PRIVATE LIMITED, 2020
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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REDUCE EXCESS AIR
AVOID INCOMPLETE COMBUSTION
§ To minimize escape of heat through flue gases,
§ Incomplete combustion can arise from
reduce excess air to reach 2 – 3% O2 at the flue gas
§ Every 1% reduction in excess O2 increases boiler
efficiency by 1%
Source: https://www.slideshare.net/MagdyAly2/5-energy-efficiency-opportunities-in-boilers
shortage of air or poor distribution of fuel
© BNG SPRAY SOLUTIONS PRIVATE LIMITED, 2020
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
14
MECHANISMS OF LIQUID FUEL SPRAY COMBUSTION
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MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
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MECHANISMS OF LIQUID FUEL SPRAY COMBUSTION
§ Smaller the spray droplets, faster is the
combustion
§ Better the fuel-air mixing, more uniform
and efficient is the combustion
Source: Chiu and Croke (1981)
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
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MECHANISMS OF GASEOUS FUEL COMBUSTION
Nozzle Mix Burner: Flames from co-flow burner; fuel is supplied
through core pipe and oxidizer through the annular region
Premix Burner: Atmospheric partially aerated burner
Source: Combustion technology: essentials of flames and burners
© BNG SPRAY SOLUTIONS PRIVATE LIMITED, 2020
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
17
BURNER TYPES AND CONSTRUCTION
On the basis of fuel, four main types of burners
are in common use:
On the Basis of Construction, two main types of
burner in common use:
§ Gaseous Fuel Burner
§ Monobloc burners
§ Liquid Fuel Burner
§ Dualbloc burners
§ Solid Fuel Burner
§ Dual / Combination Fuel Burner
Source: ISH
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GASEOUS FUEL BURNER
NOZZLE MIX GAS BURNER
PREMIXED GAS BURNER
LOW NOX STAGED AIR NOZZLE MIX
GAS BURNER
Source: API RP 535:2014
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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LIQUID FUEL BURNER
Nozzle Assembly
Fuel Pipe
Atomizing Air Pipe
Combustion Air Pipe
Fuel Supply Line Interface
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DUAL / COMBINATION FUEL BURNER
OIL AND GAS COMBINATION BURNER
LOW NOX STAGED AIR COMBINATION BURNER
Source: API RP 535:2014
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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FURNACE BURNER SETUP
Accessories Include:
§ Air compressor for atomizing air
(optional)
Furnace Wall
Compressor
(Atomizing Air)
§ Steam generator for atomizing
steam (optional)
Fuel Pump
§ Centrifugal fan for combustion
air
§ Heat exchanger (recuperator)
for flue gas heat recovery
Fuel Tank
Bricks
Furnace Burner
Air Heater (Recuperator)
Centrifugal Fan
(Combustion Air)
Conveyor Belt
§ Fuel pump and heated
(optional) storage tank
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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BURNER FLAME TYPES
Source: https://www.ispatguru.com/burners-and-flames-in-industrial-furnaces/
Flame
Type
A
Feather shaped flame with no swirl
Flame
Type
F
Long luminous and lazy flame
C
Ball shaped with substantial swirl
G
Long luminous flame with a ‘fire hose’ appearance
E
Flat Flame
H
Flame with high velocity and low swirl
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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BURNER FLAME CHARACTERISTICS
§
Flame dimensions (length and diameter) are governed by heating requirement
§
More the fuel flow rate (burner power output), longer will be the flame (~2.5m/MW for low NOx burners)
§
More the fuel-air mixture swirl, smaller the flame length, larger the flame diameter
§
Faster the combustion, smaller the flame dimensions, higher the flame temperature, more the chances of NOx generation
§
Staged air low NOx burners have larger flame dimensions
TURBULENT FLAMES
Source: Combustion technology: essentials of flames and burners
LAMINAR FLAMES
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MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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ASSIGNMENT
If a fuel droplet of diameter, D, is atomized into droplets of diameter, D/4, then find the following:
§ How many droplets has this large droplet broken down into ?
Ans: 64
§ What is the ratio of the new cumulative surface area to the surface area of the large droplet ?
Ans: 4
MISSION: HELP INDUSTRIES ACHIEVE ENERGY AND ENVIRONMENTAL SUSTAINABILITY
VISION: MAKE INDIA THE MOST ENERGY EFFICIENT COUNTRY GLOBALLY
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THANK YOU
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