Days 1+2 - Learning Objectives

■ At the end of the 2 days the trainee shall be able to :

❏ determine for gas mixtures,

using the appropriate gas laws

■ gas density
■ mixture molecular weight
■ convert from mass fraction to volume fraction
and vice versa
❏ read a psychrometric chart
❏ perform manual process measurements
related to gases (T, p, F, v, gas composition)

CTEC Training Offer 1

 Day 1 : Gas Fundamentals and Basics
Morning Session
■ Exercises
❏ Ideal gas

❏ Gas density

❏ Mass fraction

❏ Size of a dust collector

■ Water vapor

CTEC Training Offer 2

 The “Ideal Gas Law”

pV=nRT
 p V / T = constant

po = 1013,25 [mbar]
To = 273,15 [°K]
R = 8,31441 [J/(mole.K)]
Hereinafter Nm³ refers to po and To

CTEC Training Offer 3

 Exercise - Ideal Gas Law
Question
■ The flow rate of gas in a kiln stack is 127 300 [m³/h] at
a temperature of 325 [ºC] and a relative negative
pressure of 50 [mbar].
■ Calculate that flow rate at normal conditions.

CTEC Training Offer 4

 Exercise - Ideal Gas Law Answer
■ The flow rate of gas in a kiln stack is 127 300 [m³/h] at
a temperature of 325 [ºC] and a relative negative
pressure of 20 [mbar].
■ Calculate that flow rate at normal conditions.
Actual conditions Normal conditions
p1 = 1013,25 - 50 = 963,25 mbar po = 1013,25 mbar
T1 = 325 + 273,15 = 598,15ºK To = 273,15ºK
V1 = 127 300 m3/h Vo = ?

p1 To 963,25 mbar 273,15º K

Vo = V1 = 127300 m 3 / h × ×
T1 p o 598,15º K 1013,25 mbar
Vo = 55263 Nm3/h
CTEC Training Offer 5
 Influence of the Altitude
If absolute pressure available = OK
If not OK call the weather service for the absolute pressure
related to sea level or use a barometer in plant
➪ to correct with altitude

5,255
 0,0065×h 
p=p o  1− 

 273,15 + t 

CTEC Training Offer 6

 Exercise - Gas Density - Question

■ Calculate the density of air at 100ºC and a relative

negative pressure of 27 mbar.

CTEC Training Offer 7

 Exercise - Gas Density - Answer
Calculate the density of air at 100ºC and a relative negative
pressure of 27 mbar (= 2700 Pa).
(molecular weight of air: 28,966 g/mole)

pM (101323 − 2700)N/m² x 28,966g/mole

ρ= =
RT 8,31434Nm/mole.K x (100 + 273,15)K

ρ = 920,78 g/m3 = 0,921 kg/m3

[1Pa = 1N/m²]
[1J = 1Nm]

CTEC Training Offer 8

 Gas Density

Warning!
For minor components use values from standard tables, because they
are not ideal gas.

This mainly concerns SO2:

SO2 = M = 64,06 g/mole
ρ o = 2,858 kg/Nm³
In tables ρ o = 2,92 kg/Nm³
=> Use standard tables for environmental calculations!

CTEC Training Offer 9

 Exercise - Mass Fraction - Question

The following gas composition, on volume basis, was

measured at the back of a kiln. Calculate it on mass basis.
O2 : 2,99% Ar : 0,74%
CO2 : 30,11% SO2 : 1600 ppm
N2 : 62,18% H2O : 3,82%

Please remember!
%volume  %mole (1 kmole = 22,414 Nm³)

CTEC Training Offer 10

 Exercise - Mass Fraction - Answer
The following gas composition, on volume basis, was measured at the back
of a kiln. Calculate it on mass basis.
O2 : 2,99% Ar: 0,74%
CO2 : 30,11% SO2: 1600 ppm
N2: 62,18% H2O: 3,82%

Basis: 100 Nm3

Nm3 MW kg % mass

O2 2,99 31,9988 4,27 2,93

CO2 30,11 44,0098 59,12 40,51
N2 62,18 28,0134 77,71 53,24
Ar 0,74 39,948 1,32 0,90
SO2 0,16 64,0588 0,46 0,32
H2O 3,82 18,0154 3,07 2,10
Total 100,00 145,95 100,00
CTEC Training Offer 11
CTEC Training Offer 12
 Exercise - Size of a Dust Collector -
Question
The vent air system of a clinker cooler is designed to handle
200 000 [m³/h] at 250 [ºC] and relative negative pressure 20 [mbar]
(system A).
What would be the size of a dust collector, in term of filtering area,
for that vent system, assuming a 5% (by mass) air inleakage
with a air-to-cloth ratio of 1,2 [m³/(m².min)] (system B)?
Assume a dust collector inlet temperature of 220 [ºC]
and inlet pressure of 7 [mbar].

Cooler Bag Filter

+5% 220 °C; -7 mbar 200000 m³/h @ 250 °C, 20 mbar

CTEC Training Offer 13
 Day 1 : Gas Fundamentals and Basics
Morning Session
■ Exercises
■ Water vapor
❏ Vapor pressure & Humidity

❏ Dew point temperature

❏ Wet-Bulb & Dry-Bulb temperatures

❏ Psychrometric chart

❏ Exercise 2 : Calculation of the dew point

temperature after the water spray

CTEC Training Offer 14

 Vapor Pressure and Humidity (1)

■ Vapor Pressure

Gas pgas = Vapor Pressure = f(T)

Liquid

CTEC Training Offer 15

 Vapor Pressure & Humidity (2)

■ Partial pressure in a gas mixture

❏ In a gas mixture

❏ Total gas pressure = Sum of partial gas pressure

❏ Partial gas pressure for gas i

pi = xi . pgas
where
xi = % (volume=mole) of gas i in gas mixture
pgas = total gas pressure

CTEC Training Offer 16

 Vapor Pressure & Humidity (3)

■ Condensation

Gas (T, p) Condensation, when

pi > pv (T)

CTEC Training Offer 17

 Vapor Pressure & Humidity (4)
■ Relative humidity:
❏ Ratio of the mole fraction of water vapor to mole fraction of
vapor in a saturated water/gas mixture at this temperature and
pressure
❏ Ratio of partial pressure of water in mixture to the saturation
vapor pressure n p
φ= H 2O
=
H 2O

nH 2O saturated pv ( T , p )
■ Humidity ratio (absolute humidity):
❏ Ratio of the mass of water vapor to the mass of dry gas
mH 2 O
ω=
kg H 2 O
kg dry gas
mdry gas
CTEC Training Offer 18
 Dew Point Temperature

■ The temperature at which vapor condenses if a gas is

cooled at constant pressure

■ The saturation temperature corresponding to the actual

vapor pressure

CTEC Training Offer 19

 Wet-Bulb & Dry-Bulb Temperatures
■ To measure humidity in air
■ Dry-bulb thermometer: air temperature
■ Wet-bulb thermometer: bulb covered with cotton wick
saturated with water
■ Air flowing on the bulb evaporates water
■ Temperature drops from heat transfer from bulb to water
■ Evaporation depends on air moisture content

CTEC Training Offer 20

 Psychrometric Chart
100% relative 55ºC WB 0.10
humidity
0.09
50ºC WB

Moisture content (kg/kg dry air)

0.08
50%
25% 0.07
45ºC WB
10% 0.06
5% relative 0.05
40ºC WB
humidity
0.04

30ºC WB 0.03
0.02
20ºC WB
0.01
0.00
20 30 40 50 60 70 80 90 100 110 120
Dry bulb Temperature (ºC)

⇒
64ºC dry bulb 0.057 kg water/kg dry air
45ºC wet bulb 29.7% relative humidity
CTEC Training Offer 21
 Exercise 1 - Psychrometric Chart
Question
■ Dew point temperature: temperature where humidity in
a gas starts to condense.
■ Wet-bulb temperature: temperature resulting from
evaporative cooling of the bulb

Dry-bulb temperature (ºC) 80 120

Wet-bulb temperature (ºC) 45 45
Humidity (kg/kg dry air)
Dew point temperature (ºC)

CTEC Training Offer 22

 Exercise 1 - Psychrometric Chart
Answer
■ Dew point temperature: temperature where humidity in
a gas starts to condense.
■ Wet-bulb temperature: temperature resulting from
evaporative cooling of the bulb

Dry-bulb temperature (ºC) 80 120

Wet-bulb temperature (ºC) 45 45
Humidity (kg/kg dry air) 0,0498 0,0323
Dew point temperature (ºC) 40,3 32,9

CTEC Training Offer 23

 Exercise 2 - Calculation of the Dew Point T
The Process Engineer was able to determine the
gas conditions at the back of a long dry kiln:

1) Flowrate: 80500 Nm³/h 5) Composition (before water

2) Temperature: 520ºC (before water spray) spray) : % volume
3) Water is injected at the back of the kiln to reduce the gas O2 1,66
temperature to 359ºC.
CO2 32,43
4) Water spray: 6823 kg/h
SO2 0,24

N2 59,50
Calculate the dew point temperature of the gas
after the water spray. Ar 0,71
H2 O 5,46
CTEC Training Offer 24