moonunits
Mechanical
- Jun 26, 2011
- 3
I'm working as an intern at a factory that produces refractory bricks, mainly doing measurements on a tunnel kiln they use for firing the bricks. The bricks are heated with several natural gas burners in a firing zone. To determine the required air for both stoichiometric and excess-air burning (?=1,1 and 1,2), I've done some basic combustion calculations we used to do back at the University. However, I'd like to check whether I've made correct assumptions and/or if I've simplified the problem too much.
The composition of the used natural gas is roughly the following (with mole-%):
and hence MNG=?xi*Mi = 17,822 g/mole
I've assumed that the reactants combust completely and that both CO2 and N2 do not react. I've also assumed the following combustion reactions (is this oversimplifying things?):
1) CH4 + 2 O2 -> CO2 + 2 H2O
2) 2 C2H6 + 7 O2 -> 4 CO2 + 6 H2O
3) C3H8 + 5 O2 -> 3 CO2 + 4 H2O
4) 2 C4H10 + 13 O2 -> 10 H2O + 8 CO2
5) C5H12 + 8 O2 -> 5 CO2 + 6 H2O
6) 2 C6H14 + 19 O2 -> 14 H2O + 12 CO2
While considering combusting 1 mole of natural gas, I've then calculated (with the reactions above) the required amount of O2 (for methane nO2=2?nCH4, ethane nO2=7/2?nC2H6 etc):
N2 in the air = 3,77 * 2,1867 = 8,243859 moles
=> tot. required air for stoichiometric combustion =
= (2,1867 + 8,243859) mole = 10,430559 moleair/molenatural gas
So then the molar stoichiometric AF ratio would be 10,43 (with ?=1,1 it would be 10,43*1,1 = 11,47 and with ?=1,2 => 12,52).
And then the stoich. AF ratio using masses would be
mair/mNG = 10,43 ? Mair/MNG
Now the question is: are these calculations correct or should I approach this in some completely different way? Am I simplifying things too much / am I not taking something essential into account (that might render these calculations useless)? I know you tend to make these assumptions in classes, but how well do they transfer to practical situations in real life?
What I am trying to determine is the ? value for each burner. Apparently we've had some reducing atmosphere on one side of the kiln, and I'm trying to figure out if this could be caused by poor adjustment of a burner/some burners (you manually set the (constant) air and gas flow rates). If I measure the volumetric flow rate of natural gas to a burner (by measuring the differential pressure over an orifice plate assembly) and convert it to massflow, can I then use
mair = 12,52 ? mNG ? Mair/MNG
to set the desired inlet airflow for ?=1,2? Do you have any other thoughts on my method or calculations? Thanks in advance!
The composition of the used natural gas is roughly the following (with mole-%):
Code:
mole-%
Methane CH4 89,51
Ethane C2H6 5,8
Propane C3H8 2,25
Butane i-C4H10 & n-C4H10 0,9
Pentane i-C5H12 & n-C5H12 0,21
Hexane C6H14 0,06
Carbon dioxide CO2 0,85
Nitrogen N2 0,42
and hence MNG=?xi*Mi = 17,822 g/mole
I've assumed that the reactants combust completely and that both CO2 and N2 do not react. I've also assumed the following combustion reactions (is this oversimplifying things?):
1) CH4 + 2 O2 -> CO2 + 2 H2O
2) 2 C2H6 + 7 O2 -> 4 CO2 + 6 H2O
3) C3H8 + 5 O2 -> 3 CO2 + 4 H2O
4) 2 C4H10 + 13 O2 -> 10 H2O + 8 CO2
5) C5H12 + 8 O2 -> 5 CO2 + 6 H2O
6) 2 C6H14 + 19 O2 -> 14 H2O + 12 CO2
While considering combusting 1 mole of natural gas, I've then calculated (with the reactions above) the required amount of O2 (for methane nO2=2?nCH4, ethane nO2=7/2?nC2H6 etc):
Code:
moles O2 required (moles)
CH4 0,8951 1,7902
C2H6 0,058 0,203
C3H8 0,0225 0,1125
C4H10 0,009 0,0585
C5H12 0,0021 0,0168
C6H14 0,0006 0,0057
CO2 0,0085 0
N2 0,0042 0
===============
1 2,1867
N2 in the air = 3,77 * 2,1867 = 8,243859 moles
=> tot. required air for stoichiometric combustion =
= (2,1867 + 8,243859) mole = 10,430559 moleair/molenatural gas
So then the molar stoichiometric AF ratio would be 10,43 (with ?=1,1 it would be 10,43*1,1 = 11,47 and with ?=1,2 => 12,52).
And then the stoich. AF ratio using masses would be
mair/mNG = 10,43 ? Mair/MNG
Now the question is: are these calculations correct or should I approach this in some completely different way? Am I simplifying things too much / am I not taking something essential into account (that might render these calculations useless)? I know you tend to make these assumptions in classes, but how well do they transfer to practical situations in real life?
What I am trying to determine is the ? value for each burner. Apparently we've had some reducing atmosphere on one side of the kiln, and I'm trying to figure out if this could be caused by poor adjustment of a burner/some burners (you manually set the (constant) air and gas flow rates). If I measure the volumetric flow rate of natural gas to a burner (by measuring the differential pressure over an orifice plate assembly) and convert it to massflow, can I then use
mair = 12,52 ? mNG ? Mair/MNG
to set the desired inlet airflow for ?=1,2? Do you have any other thoughts on my method or calculations? Thanks in advance!