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December 2006
Excellence in measurements
Summary
Combustion Theory Fuels Combustion with Methane / Natural Gas Combustion in practice Flue Gases Boilers Loss & Efficiency Regulations
December 2006
Excellence in measurements
Combustion
Combustion or burning is a chemical process, an exothermic reaction between a substance (the fuel) and a gas (the oxidizer), usually O2, to release thermal energy (heat), electromagnetic energy (light), mechanical energy (noise) and electrical energy( free ions and electrons ). In a complete combustion reaction, a compound reacts with an oxidizing element, and the products are compounds of each element in the fuel with the oxidizing element. For example: CH4 + 2 O2 CO2 + 2 H2O + Heat ( +light/noise/ions ) Fuel
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Gas
Combustion & Flue Gas Analysis 3
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Fuels
Fuels composition
Most fuels are mixtures of chemical compounds called hydrocarbons ( combinations of hydrogen H2 and carbon C ). Fuels are available as gaseous, liquid and solid. Solid fuels Solid natural fuels include Coal, Peat, Lignite and Wood. Solid artificial fuel is Coke derived from Coal. High contents of Sulphur and Ash. Liquid Fuels Liquid fuels are processed at refineries from Petroleum. Light, medium and Heavy Fuel Oil, Gasoline and Kerosene are the most common used. Gaseous Fuels Natural gas is a gaseous natural fossil fuel consisting primarily of methane. It is found in oil fields and natural gas fields. Town gas is manufactured from Coal ( half calorific value of Natural gas ). LPG ( Liquid Propane Gas ) is manufactured from Petroleum and usually supplied in pressurized steel bottles ( cooking is a typical application ). Gaseous fuels include also Coke oven gas and Blast furnace gas.
December 2006
Excellence in measurements
Calorific Power
The principal characteristic of a fuel is his power calorific. This represents the amount of heat developed in the reaction of combustion in conditions predefined standard. Generally is measured in kcal/kg for the solid and liquid, while for the gases is expressed with kcal/m3. In many fuels, that contain hydrogen, has distinguished a superior calorific power (that it includes the heat of condensation of the water vapor that shape in the combustion) and a inferior calorific power (than it does not consider such heat). Inferior calorific power of some fuel (p.c.i.) Fuel p.c.i. (kcal/kg - kcal/m3) Firewood to burn 2500 - 4500 Peat 3000 4500 Firewood coal 7500 Lignite 4000 - 6200 Coke 7000 Fuel oil 9800
Diesel oil Benzine for car LPG Natural gas Coke oven gas Blast furnace gas
December 2006
Excellence in measurements
Combustion
Complete combustion In complete combustion, the reactant will burn in oxygen, producing a limited number of products. When a hydrocarbon burns in oxygen, the reaction will only yield carbon dioxide and water. When elements such as carbon, nitrogen, sulfur, and iron are burned, they will yield the most common oxides. Carbon will yield carbon dioxide. Nitrogen will yield nitrogen dioxide. Sulfur will yield sulfur dioxide. Iron will yield iron(III) oxide. Complete combustion is generally impossible to achieve unless the reaction occurs where conditions are carefully controlled (e.g. in a lab environment). Fuel + Oxygen Heat + Water + Carbon dioxide.
December 2006
Excellence in measurements
Combustion
Combustion Stoichiometry ( Theoretical ) If sufficient oxygen is available, a hydrocarbon fuel can be completely oxidized, the carbon is converted to carbon dioxide (CO2) and the hydrogen is converted to water (H2O). During combustion, each element reacts with Oxygen to release heat : C + O2 -> CO2 + Heat H2+ O2 -> H20 + Heat Pure Oxygen is rarely available so Air is mainly used for combustion. It contains 21 percent of Oxygen O2 and 79 percent of Nitrogen N2. A complete burning, with nothing but Carbon Dioxide, Water, and Nitrogen as the end products is known as the stoichiometric combustion. The stoichiometric air/fuel ratio refers to the proportion of air and fuel present during a theoretical combustion. The heat released when the fuel burns completely is known as the heat of combustion
December 2006
Excellence in measurements
Combustion
Practical Combustion ( Excess of Air Lambda )
Due to fluctuations in fuel flow and the lack of perfect mixing between fuel and air in the combustion zone, excess air is required to achieve more complete combustion of the fuel. Without this extra air, the formation of partial products of combustion such as carbon monoxide and soot may occur. However, supplying too much excess air will decrease combustion efficiency and a balance between too much air and not enough air must be maintained.
December 2006
Excellence in measurements
December 2006
Excellence in measurements
Combustion of Methane
Theoretical with pure O2 CH4 + O2 => CO2 + H2O + Heat CH4 + 2 O2 => CO2 + 2 H2O + Heat 1 m3 CH4 + 2 m3 O2 => 1 m3 CO2 + 2 m3 H2O + Heat
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Combustion of Methane
Theoretical with Air
Air : 21% O2 + 79% N2
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Combustion of Methane
Theoretical with Air
1 m3 CH4 + ( 2 m3 O2 + 7,52 m3 N2 ) 1 m3 CO2 + 2 m3 H2O + 7,52 m3 N2 +Heat
For a complete burning of 1 m3 of Methane you need 9.52 m3 ( 2+7,52 ) of air ( Stoichiometric ). It develops 10.52 m3 ( 1+2+7,52 ) of wet flue gases. It develops 8.52 m3 ( 10.52 less 2 H20 ) of dry flue gases. 1 m3 of Carbon Dioxide CO2 is generated each 1 m3 of Methane. On dry flue gas contents is 11.7% ( 1 m3 1/ 8.52 m3). Oxygen is not present in flue gases ( Stoichiometric ).
Combustion & Flue Gas Analysis 12
December 2006
Excellence in measurements
Combustion of Methane
Practical Excess of Air
1m3 CH4 + (2 m3 O2 + 7,52 m3 N2) + (1 m3 O2 + 3,76 m3N2) Theoretical Air Excess of Air => 1 m3 CO2 + 2 m3 H2O + 1 m3 O2 + 11,28 m3 N2 +Heat
You use for burning 1 m3 of Methane 14.28 m3 ( 2+1+3,76+7,52 ) of air. It develops 15.28 m3 ( 1+2+1+11,28 ) of wet flue gases. It develops 13.28 m3 ( 15.28 less 2 H20 ) of dry flue gases. 1 m3 of Carbon Dioxide CO2 is generated each 1 m3 of Methane. On dry flue gas contents is 7.5% ( 1 m3 / 13.28 m3). Oxygen is 7.5% ( 1 m3 / 13.28 m3)
Combustion & Flue Gas Analysis 13
December 2006
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Combustion of Methane
Practical Excess of Air
Theoretically you use 9.52 m3 ( 2+7,52 ) of air ( Stoichiometric ). Practically you use 14.28 m3 ( 2+1+3,76+7,52 ) of air. Lambda = Volume (Practical Air / Theoretical Air) =14.28/9.52= 1.5 Excess of Air = ( Lambda 1 ) * 100 = ( 1,5 1 ) * 100 = 50% Excess of Air measured from O2 ( 7.5% ) = %O2 measured * 100 / ( 20.9 - %O2 measured ) x Coeff KL= 50% To little excess of air is inefficient because it permits unburned fuel, in the form of combustibles, to escape up the stack. But too much excess of air is also inefficient because it enters the burners 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 of air is supplied so that the sum of both unburned fuel loss and flue gas heat loss is minimized.
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Combustion in practice
To obtain the most efficient combustion you need a slight excess of air Flue gas volume will be more than theoretical combustion ( stoichiometric ). Carbon dioxide will be less than maximum achievable ( CO2 max ) Oxygen will be always present in flue gas.
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Combustion in practice
Reduce as much as you can the Excess of Air to reach the maximum level of Carbon Dioxide CO2
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Combustion in practice
Carbon Monoxide is the result of incomplete combustion. This could mean a a deficiency of air at the burner.
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Carbon Monoxide - CO
Carbon monoxide is a colorless, odorless, tasteless, flammable and highly toxic gas. It is a major product of the incomplete combustion of carbon. It is called the Silent Killer.
Concentration 9 ppm 35 ppm Effects The maximum allowable concentration for short term exposure in a living ambient ( ASHRAE ) The maximum allowable concentration for continuous exposure in any eight hour period. According to US federal law The maximum allowable concentration for any time. According to OSHA. Headaches, fatigue, nausea after 2-3 hours Nausea and convulsion within 45 minutes. Death in 2-3 hours. Headaches and nausea within 5-10 minutes. Death within 30 minutes.
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200 ppm
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Boilers
Wall-hang type : The body of the boiler is fitted on the wall 20-30 KW Floor-installation type : The boiler is fitted on the support or on the floor. 30-100 KW
Heating + Hot Water or Hot Water only Instantaneous supply type The main heat exchanger or heat exchanger for hot water inside the boiler body supplies hot water. Storage Tank type Hot water is stored in the separate storage tank and is supplied when necessary.
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Boilers
(92/42 European Directive) Classification ( Stars ) European standards (UNI EN 297 and UN 483) classify boilers in 5 classes according to their NOx emissions.
Atmospheric Boiler
Condensing Boiler
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Boilers
Boiler Type A
It takes combustion air from the indoors and vents exhaust gas in surrounding ambient.
Boiler Type B
It takes combustion air from the indoors and vents exhaust gas through the exhaust stack
Boiler Type B
It takes combustion-use air from additional strack from outside and vents exhaust gas through the exhaust stack ( dual stack ).
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For these reasons combustion analysis is a must and Flue Gas Analyser is a fundamental tool for plumbers.
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Analysis Methods
During combustion with an excess of air =1.1 it develops 11.5 m3 of flue gases ( for each m3 of burned gas) as : (CO2) 1.0m3 + (O2) 0.2m3 + (N2) 8.3m3 + (H2O) 2.0m3 = 11.5 m3 Analysis on Dry basis If you remove all water contents from flue gases, condensating, the analyzer will measure Oxygen as O2 = 0.2 : 9.5 = 2.1%. This is a measurement on dry basis as we refer to Oxygen contents to the volume of dry flu gases (9.5 m3) with excess of air =1.1 Analysis on Wet basis If we dont remove all water contents the analyzer will measure Oxygen as O2 = 0.2 : 11.5 = 1.7% This is a measurement on wet basis as we refer to Oxygen contents to the volume of dry flu gases (11.5 m3) with excess of air =1.1 Flue gas analyzers use electrochemical sensors that need dry gas to measure. For this reason all measurements are obtained on dry basis.
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Units of measurements
The gas concentration is measured in ppm. Ppm means part per millions. 100 ppm is equivalent to 0.01% 1000 ppm is equivalent to 0.1% 10000 ppm is equivalent to 1% Pollutants can be measured in mg/Nm3 ( milligrams per cubic meter ) this is mass refer to a volume in normal condition ( 0C 1013 mBar ). Ppm is converted in this unit with a coefficient different for each gas. Example : CO mg/Nm3 = CO ppm x 1,25 mg/kWh ( milligrams per kilowatt-hour of energy ) the conversion from ppm to energy-related unit will use coefficient different for each fuel. Example : CO mg/kWh = CO ppm x 1,074
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Example
Boiler : 20.000 kcal/hour ( Gross Heat input ) 10 liter/minutes. with DT=30C Water use 300kCal/minutes that is equivalent to 18.000 kCal/hour ( useful output ) The useful efficiency will be 90% ( 18.000 / 20.000 ).
1kCal is the heat quantity necessary to grow 1C in 1 liter of water.
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Loss
Loss for radiation, wall, opening and conveyor are negligible on modern boiler.
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Combustion Efficiency
Sensible heat is the amount of energy in the form of heat that is required to grow temperature of water. Latent heat is the amount of energy in the form of heat that is required for water to undergo a change "change of state".
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Regulation UNI 10389 provide similar formula using Oxygen to calculated CO2 and pertinent factors related to different fuels
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Italian Regulation
1990 - Law 10 Energy saving legislation 1993 - D.P.R. 412 Legislation on efficiency control and reduction of fuel consumption. Minimum Efficiency for boilers. 1994 - UNI 10389 Technical regulation on flue gas analyzers, how to perform analysis and maximum limit definition for CO and Smoke. 2000 - D.P.R. 551 Legislation upgrade of D.P.R. 412 2005 - D.L 192 Execution of European directive 2002/91/CE
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flue gas analyzers (O2+CO) Three measurements every 2 minutes Formula to be used for Efficiency Calculation with factors for the different fuels Stack Draft measurement CO undiluted referred to 0% O2 ( max 1000 ppm ) CO2 calculation Smoke measurement for Oil boiler
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EN50379
According to the CENELEC, all national directives not compliant with EN 50379-2 will expire as of March 1, 2007 and will be replaced by EN 50379. The norm consists of three parts. Part 1 describes the general requirements and test procedures. Part 2 defines the requirements for devices used in statutory inspections and assessments. This means that inspections and measurements required by law may only be made with EN 50379-2 certified devices. Part 3 describes the requirements for devices in non-regulated areas in the maintenance of gas-fuelled heating facilities. This means that measurement results produced by devices tested according to part 3 have no legal relevance at all but may be used to set up boilers and determine maintenance intervals. Therefore, the user must carefully check the certification of a device. After March 1, 2007, statutory maintenance may only be performed with EN 50379-2 certified devices
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December 2006