High Performance Industrial Furnace (4H5924)

Furnace and Combustion Efficiency

Blasiak Wlodzimierz, Prof. Weihong Yang Associate Prof.

Royal Institute of Technology School of Industrial Engineering and Management Division of Energy and Furnace Technology Stockholm, Sweden weihong@mse.kth.se
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Objectives
To equip the student with enough knowledge about the importance and need of the energy conservation in industry especially in furnaces and getting knowledge in the fields:
Evaluating the thermal performance of furnaces Energy conservation measures in furnaces

Lecture Contents
1. 2. 3. 4. Introduction Energy Balance and Efficiency Measuring Method Methods of Efficiency increase (Energy Saving Measures)
Combustion Efficiency Improvement Waste Heat Recovery Refractory and Insulation

Introduction
Extensive experience work with furnace users has shown that operating cost savings of 10 30 % can often be achieved
With little or no capital outlay. Top management willingness. Proper management system. Applying effective management technique

The enviromental issues and legislation are already haveing a significant impact on furnace operators and this likely to increase CO2, CO,SO2, NOX. Save Energy Increase Profitability Protect the environment

Lecture Contents
1. 2. 3. 4. 5. Introduction Furnace and combustion efficiency Factors determining furnace efficiency Measuring efficiency Methods of Efficiency increase (Energy Saving Measures)
Combustion Efficiency Improvement Waste Heat Recovery Refractory and Insulation

Energy Balance
Energy balance is an analyses of a process in which all energy states and flows (inputs and outputs) through a predefined envelope (system boundary) are quantified. It is a tool to evaluate the furnace performance and efficiency. 1st Law:

dE sys & Vi 2 Vo2 & &i & + + = + + + Q sys + m h gZ m h gZ i i o o + W sys dt 2 2

Assume steady state conditions in a furnace Neglect kinetic and potential energy For furnace, Qsys is Qsur (surface losses)

Qexhaust QFGR

& & (h ) = m & (h ) + Q m

i i o o

sur

Qloss

The continuity equation is in FGR stock loss

Q +Q

=Q

+ Q + Qexhaust
Qin

& = m & m
i

Qstock
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Energy Balance
A energy balance should been obeyed . i.e.

Qin=Qout
Q1 , Sensible heat of wast gases (upto 60-80%) Q2, Heat losses from the furnace surface,etc Q3, Incomplete combustion of the fuel Qin

Q4, Heat required by chemical re taking place in the charge Q5 Efficieny heat

Sankey diagram Qout=Q1+Q2+Q3+Q4+Q5

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Efficiencies Definition

all losses

Thermal efficiency is 100 % minus the summation of

te =

Q stock 100 Q in

or
te =
Q in Q loss 100 Q in

Available Heat is thought of as the total energy contained per kg (or m3) of fuel minus the energy carried away by the hot flue gasses exiting through the stack, expressed as a percentage.

ah =

Q exhaust 100 Q in

Lecture Contents
1. 2. 3. 4. Introduction Energy Balance and Efficiency Measuring Method Methods of Efficiency increase (Energy Saving Measures)
Combustion Efficiency Improvement Waste Heat Recovery Refractory and Insulation

Energy Balance

... Methods
There are two methods of measuring efficiency: Input-Output method

te =
heat loss method

Q stock 100 Q in

te =

Q in Q loss Q loss 100 = (1 ).100 Q in Q in

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Energy Balance
Heat loss method

... Methods
te =

Q in Q loss Q loss 100 = (1 ).100 Q in Q in

The losses measured are: heat loss due to unburned carbon in refuse, heat loss due to dry flue gas, heat loss due to moisture in as fired fuel, heat loss due to moisture from burning hydrogen, heat loss due to moisture in the air, heat loss due to heat in the atomizing medium (steam, air), heat loss due to formation of carbon monoxide, heat loss due to unburned hydrogen, heat loss due to unburned hydrocarbons, heat loss due to surface radiation and convection, heat losses in ash pit

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Energy Balance

The calculation of energy balance requires the measurements of Weight of feedstock used, ms
Weight of kiln car and kiln furniture (moving parts through the system), mfur Amount of energy used (fuel flow, mf and combustion air flow, ma) Walls temperature, Tw Ambient temperature, Tamb Combustion air temperature, Ta Fuel temperature, Tf Flue gas temperature, Tg Fuel composition, molar or mass fractions (C, H, S, O2, N2, ash, moisture...etc) Flue gas composition (at least O2 or CO2)

... Measurement

Minimum measuring equipment required:

Flue gas analyser (CO2 or O2) Flow meters, (fuel or air) Immersion temperature probe (flue gas, Combustion Air, fuel) Surface temperature probe (furnace surface walls, feedstock) Balance (stock and kiln furniture weights) Length measaure Fuel ultimate analysis (weight basis); C, H, S, H2O, ... Etc.

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Energy Balance ... Combustion Analysis

The following parameters should be determined in order to calculate the flue gases losses and therefore the Energy balance:
1. Theoretical Air (TA): This is the minimum amount of air that supplies sufficient oxygen for the complete combustion of all the fuel

C + O 2 + 3,76 N 2 CO 2 + 3,76 N 2
N O 2 M O 2 + 3,76 N N 2 M N 2 TA = = 11 .44 M The following equation can N beC used in C general:

(kg air)

TA = 11 ,5(%C) + 34 ,5(%H 2 -(%O 2 )/ 8 ) + 4 ,32 (%S)

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Energy Balance ... Combustion Analysis

2. % Excess air in flue gas (EA): An additional quantity is required to achieve

CO 2 MAX EA = 1 CO 2 100 % Act .

3. The actual air fuel ratio (AF): is the actual total air supplied for 1 kg of fuel (kg air)

4.

Total flue gas:

EA + 1 AF = TA 100

(kg flue gases)

TFG = ( AF + 1)
5. 6. Act. H2O in combustion air = if O2 rather than CO2 is measured (kg vapor)

SH AF

O2 % CO 2 % = 1 CO 2 Max 21
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Energy Balance

... Energy Input to the system

Inputs:

& & (h ) = m & (h ) + Q m

i i o o

sur

1) Chemical enthalpy in fuel 2) Sensible heat (physical enthalpy) in fuel 3) Sensible heat (physical enthalpy) in air 4) Sensible heat in moisture contained in combustion air

& f HHV Qf = m
& f Cp f dt Q f , sen = m
TR Tf

& a Cp a dt Q a , sen = m
TR

Ta

& f AF SH Cp H 2 O dt Q H 2 O, air = m
TR

Ta

5) Energy contained in stock

& s C (Ts ,in TR ) Q stock ,i = m

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Energy Balance
Outputs:

... Energy Output from the system

& & (h ) = m & (h ) + Q m
i i o o sur

1) Energy contained in feedstock useful energy

& s C(T s,out TR ) Q stock,o = m

2) Physical enthalpy in exhaust gas loses

i.

Sensible heat in flue gases

& f (TFG) Q g,sens = m
Tg

ii. Sensible heat due to moisture in air

TR

x Cp
i

dt

& f AF SH Cp H 2 O dt Q H 2 O, air = m
TR

Tg

iii. Latent heat due to H2 in fuel

& f 0 ,09 (%H) h fg Q g, Latent , H 2 = m

iv. Latent heat due to water in fuel

& f (%H 2O) h fg Q g , Latent , H 2 O = m

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Flue Gases Losses

Energy losses in flue gas (%)

Propane 70%

60%
Tg = 800oC

50%

40%

600oC

Can be determined by only knowing

Tg and CO2 or O2 in flue gases

30%

400oC

20%

Flue gases losses increases with

Flue gas temperature Tg Excess air, O2%
0%
14 CO2 % 12 10 8
0 2 4 6

200oC

10%

10

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Oxygen in flue gas, on dry basis (%)

CO2 Max for Propane is 13,8%

6 0 2 4 6 8 10 12 O2% in flue gases, dry basis

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Flue gases losses due to H2 in Fuel.

Heat loss due to burning hydrogen in fuel can be a high portion in flue gases This amount of energy might not appear in the analysis of energy balance if the lower heating value were chosen. However they exist in flue gases and can be recovered.

Heat loss due to burning hydrogen in fuel

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Energy Balance
... Heat losses from the system

& & (h ) = m & (h ) + Q m

i i o o

sur

Radiation and convection losses through furnace walls surface losses

Losses by radiation are calculated as

Losses by convection can be calculated as

& = T T Q r sur
4

4 amb

) A

(Watt)

sur

(Watt)
.25 & = Consequently, Q The Total heat loss due radiative and convective heat C surface Asur (T Tamb )1to c sur transfer (Watt)

& +Q & Q sur = Q r c

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Energy Balance Balance Sheet ...

Input
1 2 3 4 Feedstock Fuel /enthapy of comb Fuel/sensible Combustion air Total T/hr 30 0,5 8 MWH 0,200 5,833 0,009 0,089 6,131 % 3,3% 95,1% 0,1% 1,4% 1 2 3 4 5

Outputs
Product Off-Spec Product Flue gas/ sensible Flue gas/ latent Surface losses Total T/hr 27 3 8,5 0,9 MWH 2,192 0,325 2,361 0,611 0,642 6,131 % 35,7% 5,3% 38,5% 10,0% 10,5%

Specific energy consumption = 0,0185 (kg fuel oil / kg Product) Useful energy () = 32,4 % A Balance sheet shows all possible energy conservation measures
Flue gases heat recovery Surface losses from furnace walls Off-spec products

Flue gas/ latent 10%

Surface losses 11% Product 36%

Flue gas/ sensible 38%

Off-Spec Product 5%

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Lecture Contents
1. 2. 3. 4. Introduction Energy Balance and Efficiency Measuring Method Methods of Efficiency increase (Energy Saving Measures)
Combustion Efficiency Improvement Waste Heat Recovery Refractory and Insulation

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Factors determining Furnace Efficiency

Excess air Air infiltration Stack loss Combustion losses

Qexhaust QFGR Qloss

Qin Qstock
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Increase combustion efficiency

Efficient combustion requires the correct air/fuel ratio and adequate mixing High excess air levels result in
Dilution of the flue gases due to increasing of the total air supplied. Reduction in flue gas temperature. Reduction in heat transfer rate. Increasing in flue gas losses. Reduction in combustion efficiency.

Low excess air operation can cause

unburned hydrocarbons to discharged leads to fuel wastage, reduce throughput, poor product quality, excessive emissions and/or structure damage to the furnace.

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Increase combustion efficiency

Many factors may cause undesirable deviations:
Burner wear Hysteresis in control system Variation in fuel properties Variation in combustion air temperature Variation in furnace pressure

Measures
Modern automatic control (A/F, Pfur) Routing eficiency monitoring (CO2%, Tg) Regular burner and controls maintenance

Pay back could be immediate

Rule of thumb: 10% reduction of EA 1% increase in eficiency 24

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Saving Energ from Stock gas

How to recover the energy from waste gas :

& i (hi ) Q exhaust = m

1) Reduce the final exhaust flue gas temperature Recuperation, made of metallic or ceramic elements, heat recover efficient 10-50%, preheated air temperature Max.800 K. Regeneration, made of honeycomb, heat recover efficient 80-90%, preheat air temperature, 1500 K. (HTAC)

2) Reduce waste gases mass, mwaste Rich oxygen combustion Pure oxygen combustion (OXY-FUEL)
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Saving Energ from Stock gas

Available heat vs exhaust gas temperature for C3H8 combustion at 2% oxygen concentration in exhaust gases
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Oxyfuel Combustion
C O2 11% H2 O 10% O2 4%

4132 nm3/h wet 3725 nm3/h dry

576 nm3/h wet 337 nm3/h dry N2 O2 9% 4% CO2 46% H2O 41%

N2 75%

3.4 MW Air/Fuel

2.0 MW
AGA

Oxygen/Fuel

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Waste Heat Recovery

1,6% Energy savings every 20 C reduction in flue gases

For Propane, energy saving by 20C recovery from flue gases is approximately ranging between 0,7% and 1,5% depending on the level of excess air in the combustion process

1,4%

1,2%

1,0%

0,8%

Rule of thumb: 20C reduction of Tg 1% increase in efficiency

0,6% 0% 50% 100% 150%

Excess air level

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Waste Heat Recovery

Up to 50% energy saving is possible, payback (1 5 years). Economy: The retrofit modification is more applicable to large, continuous furnaces and least applicable to smaller, intermittent ones. The heat sink can be to the furnace itself by raising the combustion air temperature.
1234flue gas recuperation self recuperative burners flue gas regeneration stock recuperation

Lower Tg will reduce problems after chimney X higher combustion air higher flame temperature increase Nox.

Rule of thumb: 20C reduction of Tg 1% increase in efficiency 29

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Waste Heat Recovery

Recovery heat can also be transferred for use in other processes:
1234drying space heating process steam steam for power generation (waste heat boiler)

Heat available and heat required should match in

quantities, temperature timing

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Waste Heat Recovery ... Flue Gas Recuperators

This is the most popular the characteristics of the heat sink and source are inevitably match. A range of heat exchanger are available made of
steel, high temperature alloys or ceramic.

! !

Flame temp. and Nox emission will increase. Large heat recovery system.

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Regenerative Burners
Uses a short-term cyclic heat storage device as the means of achieving waste heat recovery.

Efficiency ~ 65 95% Combustion air preheated to very high temperatures, up to 50 degrees below the furnace operating temperature. NOx emission can be very high.?! Flame temperature is very high.?!

! !

(But can be reduced if the right combustion technology is used)

Example of the ceramic regenerators

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Operation of two pairs of compact regenerative burners

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Stock Recuperation
Incoming feedstock can be preheated using waste heat contained in flue gases as a useful means of heat recovery. Easily applied to continuous furnaces No problems in matching the timing Applicable to intermittent furnaces.

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Refractory and Insulation

1. 2. 3. 4. 5. 6. 7.

Consideration for selecting refractory: Maximum operating temperature Efectiveness as insulator: Thermal mass (LTM); Ceramic fibber, specially for intermittent furnaces Corrosion resistance Errosion resistance Coefficient of expansion Longevity: replacement is expensive. They are often made of layers Monitoring the surface temperature of the furnace from time to time.

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Improving Furnace Yield

Furnace yield: quantity of usable product per unit feedstock.
Increase furnace yield Increase throughput and Minimize waste

There is often a trade off between throughput and product quality Throughput is limited by
Loading and unloading Rate of heat transfer Upstream and downstream processes

Measures to increase furnace yield:

Optimise the furnace operation for maximum yield furnace. Consider other processes when scheduling furnace operation. Feedstock must be on-spec to prevent wasted firing. Ensure the correct temperature profile and furnace atmosphere. Continually monitor the yield by weighing the feedstock and product. Monitor the key variables that affect throughput and product quality Use effective Quality Assurance techniques, e.g. hot inspection.

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Thank You For Your Attention !

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