GasHandlingManual K1
GasHandlingManual K1
CENTRE TECHNIQUE
EUROPE CENTRALE
CTEC
Training Handout
GAS HANDLING
By
Wolfgang Kurka
September 2004,
Darica, Turkey
EXECUTIVE SUMMARY
Objective:
Objective of the training session is to provide operational skills to:
Determine / calculate gas properties using appropriate gas laws
Perform simple heat and mass balances to systematically approach process
optimization problems
Test and qualify an installed fan performance
INTRODUCTION:
All kind of gases play an important role in our cement manufacturing process. Gases
are uses for several reasons:
Transport (e.g.: pneumatic systems…)
Heat transfer (e.g.: combustion gases, cooling gases…)
Combustion (e.g.: oxygen supply, fuel supply…)
Etc…
The day-to-day work of a process engineer is related to optimize existing systems,
support in design of new systems. In order to be able to further optimize a system it is
important to get to know the system key parameters and its behavior. The „Gas
Handling“-training will focus on the following topics,
Application of Ideal Gas Law, Gas Properties (T, p, V, humidity) + Calculations
Measurement methods (T, p, v, Gas composition,…)
Basics / Review on Thermodynamics simple heat balances
Fan laws, Fan performance evaluation
in order to provide necessary tools for a systematic approach to a process problem. To
be finally able to perform the typically required steps for a process balance as follows
[1]:
1) Identify the system (boundary limits). In other words define the boundaries around the
system that you intend to study. Choose carefully since you'll need to measure/calculate
everything that crosses the borders.
2) Identify all mass inputs and outputs that cross the boundaries you've just
defined. This includes all solids, liquids and gases. Eventually you will need to know how
much heat each stream carries across the boundary, so plan accordingly. You'll need to know
the rate, composition, temperature and pressure (where applicable) so that you can eventually
work out how much heat has gone into the control volume and how much has come out.
3) Identify all energy inputs and outputs that cross the same boundaries. This
includes electricity, wall losses, chemical reactions (which is either absorbed or released energy),
including vaporization and burning.
4) Measure mass and energy inputs and outputs, recording the appropriate
temperatures, pressures and other values, as well as sampling to determine
mass compositions where needed - over a period of time when the system is
stable. Sometimes it is useful to make redundant measurements so that you can cross check
values. The cross check will either support your measurements or it will show what values
should not be trusted. For example, the difference between the feed moisture and product
residual moisture should equal the water vapor found in the drying gas stream less its starting
humidity. This is particularly important where direct measurements are impossible and you can
only determine it by inference or by difference.
6) Do a mass balance first. Adjust mass flow measurements within reasonable error limits so
that inputs equal outputs. Does any of the cross-checks work out well? Do you need to make
more assumptions? Usually it is easier if you convert gas flows into mass flows. Does the mass
balance make sense?
7) Finally do a heat balance. Determine the energy carried by each mass flow, using the
results from the mass balance. You'll also need to know the compositions so you'll be able to
figure out the aggregate heat capacity. With temperatures and Cp's you'll be able to calculate
heat flows. Then include the energy inputs and outputs. Again adjust the values within
reasonable error limits until the total inputs and total outputs balance.
8) Does the balance make sense? Recognize that there is more than one way to make
everything balance but only one is right. Often there are erroneous assumptions made. It is
always helpful to make physical observations to support your findings. For example inleakage
must be high if the seal is missing or you could measure a negative pressure above the rotary
feeder. Sometimes knowing the equipment limitations can help rule out certain results as simply
impossible. In other cases comparing results with previous balances or similar studies done at
other plants will shed some light.
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INTRODUCTION: Page 4 of 57
TABLE OF CONTENTS
EXECUTIVE SUMMARY 2
OBJECTIVE: 2
INTRODUCTION: 2
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INTRODUCTION: Page 5 of 57
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FUNDAMENTAL GAS LAWS Page 6 of 57
p ⋅V = n ⋅ R ⋅ T
p ⋅V
= const
T
p0 ⋅V0 p1 ⋅V1
=
T0 T1
n = number of moles
R = universal gas constant = 8.3145 [J/mol K]
The index 0 refers to normal condition (also called STP for standard
temperature and pressure), which is used widely as a standard reference
point for expression of the properties and processes of ideal gases. The
standard temperature is the freezing point of water and the standard
pressure is one standard atmosphere. These can be quantified as follows:
T0 Standard temperature: 0 [°C] = 273.15 [K]
p0 Standard pressure = 1 [atm] = 760 [mmHg] = 1013.25 [mbar]
Standard volume of 1 [mole] of an ideal gas at normal conditions: 22.4 [l]
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FUNDAMENTAL GAS LAWS Page 7 of 57
V&N [Nm³ / h]
= n& [kmol / h]
VM [ = 22.4 Nm³ / kmol ]
In a further step we convert molar flow [kmol/h] to a mass flow [kg/h] using the molar
mass of the gas.
MM [kg / kmol ] • n& [kmol / h] = m
& [kg / h]
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FUNDAMENTAL GAS LAWS Page 8 of 57
For minor components use values from standard tables, because they are not ideal gas.
In our day-to-day problems this mainly concerns SO2:
SO2 = M = 64.06 [kg/kmol] from ideal calculations we would get ρo = 2.86 [kg/Nm³],
but in literature we can find different values ρo = 2.92 [kg/Nm³]. Therefore it is
recommended to use in such cases standard tables especially for environmental
calculations!
The pressure of a gas can be defined as the sum of the partial pressures created by
each of the components entering in the gas composition. This is DALTON's law.
ptotal = p1 + p2 + ... + pi
with
p1 : pressure created by the component 1 alone
p2 : pressure created by the component 2 alone and so one...
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FUNDAMENTAL GAS LAWS Page 10 of 57
PSYCHROMETRIC CHART 13
5
14
0
14
5
15
0
15
5
16
0
40
Sea Level 13 45
0 17
BAROMETRIC PRESSURE 760 mm of Mercury 5
44
12
5 43
35 17
35 0
.96
.98
1.00
12 42
0
41
11 35 16
5 40 5
11 39
0 16
38 0
10
5 35 37
W
ET 15
10 BU 36 5
0 LB
TE 30 35
M
95 PE 34 15
RA 0
T UR HUMIDITY RATIO - GRAMS OF MOISTURE PER KILOGRAM OF DRY AIR 33
E
90
.94
30 -°
C 30 32 14
5
85 31
30 14
AIR
25 0
80 29
RY
30 28
75 13
5
°C
O
27
KG
E-
26
UR
70
.92
R
13
PE
AT
25 0
SPE
KJ
ER
65 25 24
-
MP
CIFIC
20 25
PY
12
TE
23
AL
5
90%
60
TH
VOLU
TIO
22
EN
RA
55 25 21 12
ME
0
TU
.90
80%
20
m³/kg
SA
50
19 11
5
OF D
20 18
%
45 15
20
70
RY A
17
11
40 0
16
IR
.88
%
20
60
15
35 10
14 5
25 15
13
%
30
50
20 10 10
12 0
15
.86
15
11
%
10
40
10 10 95
10 9
5
10
.84
0 % 8
30 90
-5 5 7
DEW POINT - °C
-1 5 5 6
0
.82
85
-1 0 20% 5
5 0 0
-2 IDIT Y 4
0 HUM
.80
-5
TIVE 80
-2 RELA 3
5 -10 10%
.78
-15 -10 2
.76
-25 -20 1
-20 75
-40
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
15 20 25 30 35 40 45 50 55 60 65
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FUNDAMENTAL GAS LAWS Page 11 of 57
Psychrometric Terms
The chart might seem a little overwhelming in the number of parameters it represents
and their relationship to one another but we will look at its components individually in
the following order:
Absolute humidity (AH) is the vapor content of
air, given in grams of water vapour per kg of air,
i.e. [g/kg]. Air at a given temperature and
pressure can support only a certain amount of
moisture and no more. This is referred to as the
saturation humidity (SH). If this is plotted on a
graph against the dry bulb (air) temperature
(DBT), we have the basis of the psychromeytric
chart and we get what is called the saturation
humidity line.
Relative humidity (RH) is an expression of the
moisture content of a given atmosphere as a
percentage of the saturation humidity at the
same temperature:
RH = 100 x AH/SH [%]
Relative humidity lines are plotted on the
psychrometric chart by halving each SH ordinate
to obtain the 50 [%] curve, and further
proportionate subdivision gives any
intermediated RH curve.
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PROCESS MEASUREMENTS Page 13 of 57
2. PROCESS MEASUREMENTS
Perform manual process measurements related to gases (flow, velocity,
temperature, pressure, gas composition…)
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PROCESS MEASUREMENTS Page 14 of 57
Undisturbed entering zone before sampling point: 3* diameter (for rectangular cross
section: hydraulic diameter), undisturbed leaving zone after sampling point:
2*diameter
you can cross check values. The cross check will either support your measurements or
it will show what values should not be trusted. Before doing a measurement we should
re-think several points:
What do we going to measure?
How long/often we are going to measure?
Do we have all necessary equipment (e.g.: measurement equipment: to measure
length, time, temperature, pressure, flow, gas composition,…)?
Is the equipment adequate to the conditions measurement range?
Is the equipment calibrated accordingly?
Do we have the necessary tools (e.g.: wrench to open measurement point, gloves
for high temperatures, cloth/rubber to plug opening, electrical power for gas
analyser, water for water cooled gas probe, compressed air, marker to mark length
on PITOT tube….)?
How we are going to record the data (electronically, protocol)?
Is it safe to measure (who has to be informed, what has to be locked out,….)?
How will our measurement interfere operation (e.g.: influence on process control
sensors by opening measurement points (pressure) interlockings!!)
…
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PROCESS MEASUREMENTS Page 17 of 57
Gas Flow
Radiation pyrometer
Adjust the right settings for the pyrometer (normally the manual gives different ε-values
for different surfaces). The pyrometer has to be focused on the point, which is to be
measured. Many pyrometers have a laser pointer to support this focusing.
ρ ⋅ v2
p dyn =
2
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PROCESS MEASUREMENTS Page 18 of 57
Additionally to static and dynamic pressure it is also common to measure the difference
between to static pressures = differential pressure e.g.: pressure drop due to design,
clogging….).
Gas Flow
- 65 [mbar]
Leak air
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PROCESS MEASUREMENTS Page 19 of 57
gas ambient…) because only standard conditions allow us to convert the volumetric
flow into heat flow or molar mass flow!
The tricky part of flow (=dynamic pressure or velocity) measurements is that the flow is
not equal over the cross-section. Therefore several measurements have to be
distributed over the cross-section. In order to get a representative picture the so-called
“Traverse Points” – concept should be applied.
For circular cross section, the points are The shaded portions
are of equal area. 1
located on two perpendicular diameters and
XI
2
3
at the centroidal axis of equal areas of the
cross section. 4
ΦD
Sampling plane area Duct diameter Minimum number of Minimum number Minimum number
sampling lines of sampling points of sampling points
per diameter per plane
m² m (diameters) Center point Center point
Incl. Excl. Incl. Excl.
0,07 to 0,38 0,3 to 0,7 2 3 2 5 4
0,38 to 0,79 0,7 to 1 2 5 4 9 8
0,79 to 3,14 1 to 2 2 7 6 13 12
> 3,14 >2 2 9 8 17 16
Table 1: Minimum number of sampling points for circular ducts having cross-sectional areas > 0,07 m²
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PROCESS MEASUREMENTS Page 20 of 57
For the training an Excel spreadsheet is prepared, which calculates the distances “xi”
from the inner duct wall for circular cross-sections. The program is based on ISO-Norm
10780:1994CE, where you find more details to this topic.
Beside a PITOT tube also S-tube are used. The S-Tube has smaller dimensions of the
tube head, which helps for narrow measurement points. The “S” type must be corrected
because it gives a higher velocity pressure than the PITOT tube for the same gas
stream. Best is to calibrate the S-tube against a PITOT tube or by an outside company
to know the calibration factor “k”:
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PROCESS MEASUREMENTS Page 21 of 57
2pd
v=k [m/s]
ρ
The average gas velocity in the duct is determined from the (dynamic pressure )
velocity measurment at each of the traverse points with a Pitot / S-tube and a differential
manometer.
Anemometer
Propeller anemometers are used for manual flow speed measurement. Propeller
anemometers are sensitive to pollution and humidity (condensation). Their use is also
limited by a maximum operating temperature (applied in e.g.: cooling fans, blowers…),
which is specific to the design of the individual device. The measurement probe is held
in the flow of waste gas. The flow of waste gas drives an impeller wheel, the speed of
which is recorded on a no-contact basis (e.g. inductively). At a constant density of waste
gas, the waste gas speed is proportional to the speed of the wheel..
Velocity calculation
∑ p d
= 0,933
As the velocity is the square root of N
the pressure term, the average
speed v [m/s] has to be either
calculated using the mean of the
square roots for pressure as in the
following example
Measured dynamic pressures:
[mbar]
0,2
0,8
1,6 2
Σ pd
1,9 = 0,826
0,7 N
0,4
or calculate the velocity in every measurement point and from this directly the average
velocity.
Flow Calculation:
Knowing the velocity (v in [m/s]) and the cross-section (A in [m²]) we can calculate the
volumetric flow in actual conditions [m³/h].
V& [m ³ / h] = A [m ²] ⋅ v [m / s ] ⋅ 3600 [s / h]
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PROCESS MEASUREMENTS Page 22 of 57
Power (BHP)
15 28
one temperature. 14 24
13 20
12 16
11 12
10 8
9 Volume (acfm x 1000) 4
8 0
0 1 2 3 4 5 6 7 8 9 10
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THERMODYNAMICS Page 25 of 57
3. THERMODYNAMICS
About a hundred years or so ago, J.P. Joule carried out a series of experiments which
are fundamental to the understanding of the first law of thermodynamics. In one of his
experiments, he placed measured amounts of water in an insulated container and
agitated the water with a rotating stirrer. The amount of work done on the water by the
stirrer was measured as well as the temperature changes of the water. He found that a
definite amount of work was required per mass of water for every degree of temperature
rise. The original temperature of the water was then restored through contact with a
cooler object.
The conclusion was that there exists a quantitative relationship between work and heat,
and thus, heat is a form of energy.
The question comes to mind about what happens with this energy between the time it is
added to the water as work and extracted as work. The energy should assume some
form in the water. We define this form of energy as internal energy U.
Although energy assumes many forms, the total quantity of energy is constant =
If energy disappears in one form, it appears simultaneously in other forms.
If we then define a closed system as a system which do not permit the exchange of
mass between the system and its surrounding, the only means of energy transfer is
through heat and work. Assuming no changes in external, potential or kinetic energy,
this simplifies to:
∆U = Q − W
U is internal energy, Q is heat and W is work.
3.2 Enthalpy
If the volume of the system does not stay constant, like in our process, volumetric work
is done and therefore the change in internal energy is no more equal to the added heat.
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THERMODYNAMICS Page 26 of 57
In this case the heat of the system is better represented by the enthalpy assuming
constant pressure:
H = U + p ⋅V
Where H is enthalpy, U internal energy, p is pressure and V is volume.
Enthalpy has no absolute value, only changes in enthalpy can be calculated. The
restriction is a closed system with no mass exchange. These processes are rare in
industry. Therefore the introduction of steady state flow came along.
Steady state means that the conditions at all points in the apparatus are constant with
time. Thus all rates must be constant and no accumulation of energy or material may
take place.
For calorimetric measurements, the normal base that is selected is that H = 0 [J/kg],
[J/Nm³] at 0 [°C].
Heat capacity is the amount of energy required to raise the temperature of a unit mass
or mol of substance by one degree.
Not to be mixed up with specific heat (although often used interchangeably with heat
capacity) is the ratio of the heat capacity of a substance over that of a reference
substance.
Practical application
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THERMODYNAMICS Page 27 of 57
Base Equation:
Cp = a + bT + cT2 + dT-2
T − T0 T − T0
Since we are looking for a Cp at 2400 K (i.e. the 1800 to 3999 range) the integral has
to be split up into three parts:
799 1799 2400
∫ cp
273 .15
( 273 −799 ) ⋅ dT + ∫ cp
800
( 800 −1799 ) ⋅ dT + ∫ cp
1800
(1800 −2400 ) ⋅ dT =
However, the following graph illustrates the difference between the straight equation
and the longer way of doing things.
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THERMODYNAMICS Page 28 of 57
Point Cp vs Mean Cp
0.3000
0.2500 mean Cp
0.2000
0.1500 Point Cp
0.1000
0.0500
0.0000
20
80
140
200
260
320
380
440
500
560
620
680
Temperature (C)
For mixtures of gases, given the fact that we're assuming an ideal gas (i.e. no molecular
interactions) we can add the individual components Cp's proportionally to their
percentage of the mixture
c pmix = x1 ⋅ c p1 + x 2 ⋅ c p 2 + x 3 ⋅ c p 3
Where x refers to the mass/molar percentage, depending of the unit of Cp’s ([kJ/(kg K)],
[kJ/(Nm³ K)], [kJ/(kmol K)]…). All the preceding also applies to solids and liquids with
the appropriate cp equations.
For practical use the latent heats of vaporization of water have been extensively
tabulated in various steam tables and other references (also Lafarge EXCEL process
calculation tools….).
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SIMPLE HEAT BALANCE EXERCISES Page 29 of 57
Don't forget to add or subtract this latent heat when you're calculating enthalpies !
The latent heat is quite often more significant than the sensible heat required to get the
liquid to boiling temperature or from boiling to the temperature you're evaluating the gas
at.
GROUP DISCUSSION:
1 [kg] of liquid water at 20 [°C] is vaporized to a gas at 80 [°C]. What is the quantity of
heat required per [kg] ?
First elaborate theory than calculate by using the VADEMECUM, finally calculate by
using the EXCEL Add In “Thermodynamic Functions”
In order to solve a 3-junction problem it is sufficient to know only e.g. mass flow, but
knowing one property of all 3 flows (e.g.: heat, O2 content, BLAINE). As this is a very
simple and well-known concept lets try an exercise together:
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SIMPLE HEAT BALANCE EXERCISES Page 30 of 57
cp=1,0057 kJ/kg.K
EXERCISE 4.2 – Heat Balance (Fresh Air Cooling, Water Quenching, Gas Mixing,
Defining Boundary Limits)
Malogozscz plant in Poland is planning to build a Cl-Bypass, where part of the kiln inlet
gas is extracted, cooled by fresh air in a mixing chamber and de-dusted in a bag filter.
In parallel the plant is executing a second project which covers the complete re-design
of the gas conditioning tower (hereinafter called GCT) plus a new kiln filter. The clean
bypass gas is mixed with the preheater exit gas after ID fan before GCT. The mixed
gases are conditioned in the GCT and de-dusted in the kiln filter before going to the
stack.
The bypass system is well sized, but the kiln filter and GCT need to be mathematically
checked, if the proposed water amount for injection is sufficient (11 [m³/h]) for the
proposed bag quality (P84: continuous operation temperature 220 [°C]) and the
proposed filtration area (6400 [m²]) is sufficient for an air to cloth ratio of 1 [m³/(min m²)].
All relevant values to start the calculation will be worked during the discussion, how to
understand this exercise.
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APPENDICES Page 31 of 57
5. APPENDICES
APPENDIX A: SOLUTIONS OF EXERCISES 32
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APPENDIX Page 32 of 57
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APPENDICES Page 34 of 57
m b RT b
Vb =
p bM
138903 [ kg/h] × 8.31434 [N m/(mole K)] × 493.15 [º K]
Vb =
100625 [N/m²] × 28.966 [ g/mole]
V b = 195378.4 [ m³/h]
r = 1.2 [m³/(m².min)]
Vb 195378.4 [m³/h]
A = = = 2713 [m²]
r 1.2 [m³/(m².mi n)] x 60 [min/h]
Dust collector size: 2713 [m²]
The design area is bigger as the demanded area. Therefore the existing system is able
to handle the 5 [%] air inleakage (by mass).
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)
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APPENDICES Page 35 of 57
Question A Question B
Dry-bulb temperature (°C) 80 120
Wet-bulb temperature (ºC) 45 45
Humidity (kg/kg dry air) 0.05 0.032
Dew point temperature (ºC) 40 33
Calculate the dew point temperature of the gas after the water spray.
Gas composition:
% volume Nm³/h kg/h
Total 100.00 80500.0 118135.7
O2 1.66 1336.3 1907.8
CO2 32.43 26106.2 51260.2
SO2 0.24 193.2 552.2
N2 59.50 47897.5 59864.1
Ar 0.71 571.5 1018.6
H2O 5.46 4395.3 3532.8
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APPENDICES Page 36 of 57
mH2O 10355,8
Humidity: ω = = = 0.0904 [ kg H2 O/kg dry gas]
m dry gas 124958.7 − 10355.8
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APPENDICES
PPENDICES Page 37 of 57
Heat (kJ/kg)
vapor
evaporation
liquid
0 100 200
Temperature (°C)
cp=1,0057 kJ/kg.K
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APPENDICES Page 38 of 57
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APPENDICES Page 39 of 57
Type bypass gas 1 bypass gas 1 Air 4 Air 4 2clinker 1rawmix Type Mix Mix
Vol Flow [Nm³/h] 4000 38000 Flow [Nm³/h] 42000
Mass Flow [kg/h] 5471 0 48917 0 1600 Mass flow [kg/h] 54388 1600
T [°C] 1200 30 1200 T [°C] 200 200
O2 [vol%] 3.00% 3.00% 20.94% 20.94% O2 [vol%] 19.2%
N2 [vol%] 65.00% 65.00% 79.06% 79.06% N2 [vol%] 77.7%
CO2 [vol%] 22.00% 22.00% 0.00% 0.00% CO2 [vol%] 2.1%
H2Ov [vol%] 10.00% 10.00% 0.00% 0.00% H2Ov [vol%] 1.0%
O2 [Nm³/h] 120 0 7957.2 0 O2 [Nm³/h] 8077
N2 [Nm³/h] 2600 0 30042.8 0 N2 [Nm³/h] 32643
CO2 [Nm³/h] 880 0 0 0 CO2 [Nm³/h] 880
H2Ov [Nm³/h] 400 0 0 0 H2Ov [Nm³/h] 400
O2 [kg/h] 171 0 11360 0 O2 [kg/h] 11532
N2 [kg/h] 3250 0 37557 0 N2 [kg/h] 40807
CO2 [kg/h] 1728 0 0 0 CO2 [kg/h] 1728
H2Ov [kg/h] 321 0 0 0 H2Ov [kg/h] 321
O2 [kcal/h] 51630 0 74690 0 O2 [kcal/h] 515072
N2 [kcal/h] 1059260 0 280158 0 N2 [kcal/h] 2032078
CO2 [kcal/h] 572964 0 0 0 CO2 [kcal/h] 75303
H2Ov [kcal/h] 394075 0 0 0 H2Ov [kcal/h] 0
H2O [kcal/h] 0 0 H2O [kcal/h] 219908
Solid [kcal/h] 473032 0 Solid [kcal/h] 63448
Heat Losses [kcal/h]
Total Heat In 2905810 Total Heat Out 2905810
Total Mass In 55988 Total Mass Out 55988
Difference in Heat in/out 0
Type PHT exit 2 Air 4 Air 4 1rawmix 1rawmix Type Mix Mix
Vol Flow [Nm³/h] 42000 150000 Flow [Nm³/h] 192000
Mass Flow [kg/h] 54388 213180 0 0 22500 Mass flow [kg/h] 267568 22500
T [°C] 200 330 330 T [°C] 307 307
O2 [vol%] 19.23% 4.00% 20.94% 20.94% O2 [vol%] 7.3%
N2 [vol%] 77.72% 60.00% 79.06% 79.06% N2 [vol%] 63.9%
CO2 [vol%] 2.10% 28.00% 0.00% 0.00% CO2 [vol%] 22.3%
H2Ov [vol%] 0.95% 8.00% 0.00% 0.00% H2Ov [vol%] 6.5%
O2 [Nm³/h] 8077.2 6000 0 0 O2 [Nm³/h] 14077
N2 [Nm³/h] 32642.8 90000 0 0 N2 [Nm³/h] 122643
CO2 [Nm³/h] 880 42000 0 0 CO2 [Nm³/h] 42880
H2Ov [Nm³/h] 400 12000 0 0 H2Ov [Nm³/h] 12400
O2 [kg/h] 11532 8566 0 0 O2 [kg/h] 20098
N2 [kg/h] 40807 112510 0 0 N2 [kg/h] 153317
CO2 [kg/h] 1728 82467 0 0 CO2 [kg/h] 84195
H2Ov [kg/h] 321 9637 0 0 H2Ov [kg/h] 9958
O2 [kcal/h] 515072 644864 0 0 O2 [kcal/h] 1400969
N2 [kcal/h] 2032078 9326837 0 0 N2 [kcal/h] 11792472
CO2 [kcal/h] 75303 6257306 0 0 CO2 [kcal/h] 5886095
H2Ov [kcal/h] 219908 7190348 0 0 H2Ov [kcal/h] 0
H2O [kcal/h] 0 0 H2O [kcal/h] 7318440
Solid [kcal/h] 1707438 0 Solid [kcal/h] 1571178
Heat Losses [kcal/h]
Total Heat In 27969154 Total Heat Out 27969154
Total Mass In 290068 Total Mass Out 290068
Difference in Heat in/out 0
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Only Fill yellow cells and pull down menus! 362649.2352 6044.15392
rawmix rawmix
GCT inlet Water to
Input gas GCT
PHT exit dust Output Gas Solid
Type PHT exit 2 Air 4 Air 4 1rawmix 1rawmix Type Mix Mix
Vol Flow [Nm³/h] 192000 Flow [Nm³/h] 205697
Mass Flow [kg/h] 267568 0 0 0 11000 22500 Mass flow [kg/h] 278568 22500
T [°C] 307 20 307 T [°C] 208 208
O2 [vol%] 7.33% 4.00% 20.94% 20.94% O2 [vol%] 6.8%
N2 [vol%] 63.88% 60.00% 79.06% 79.06% N2 [vol%] 59.6%
CO2 [vol%] 22.33% 28.00% 0.00% 0.00% CO2 [vol%] 20.8%
H2Ov [vol%] 6.46% 8.00% 0.00% 0.00% H2Ov [vol%] 12.7%
O2 [Nm³/h] 14077.2 0 0 0 O2 [Nm³/h] 14077
N2 [Nm³/h] 122642.8 0 0 0 N2 [Nm³/h] 122643
CO2 [Nm³/h] 42880 0 0 0 CO2 [Nm³/h] 42880
H2Ov [Nm³/h] 12400 0 0 0 H2Ov [Nm³/h] 26097
O2 [kg/h] 20098 0 0 0 O2 [kg/h] 20098
N2 [kg/h] 153317 0 0 0 N2 [kg/h] 153317
CO2 [kg/h] 84195 0 0 0 CO2 [kg/h] 84195
H2Ov [kg/h] 9958 0 0 0 H2Ov [kg/h] 20958
O2 [kcal/h] 1400969 0 0 0 O2 [kcal/h] 937269
N2 [kcal/h] 11792472 0 0 0 N2 [kcal/h] 7964389
CO2 [kcal/h] 5886095 0 0 0 CO2 [kcal/h] 3840862
H2Ov [kcal/h] 7318440 0 0 0 H2Ov [kcal/h] 7574030
H2O [kcal/h] 219578 0 H2O [kcal/h] 6856606
Solid [kcal/h] 1571178 0 Solid [kcal/h] 1015577
Heat Losses [kcal/h]
Total Heat In 28188732 Total Heat Out 28188732
Total Mass In 301068 Total Mass Out 301068
Difference in Heat in/out 0
With 11 [m³/h] water injection the inlet gas to the filter will be 206000 [Nm³/h] @ 208 [°C]
363000 [m³/h] = 6050 [m³/min] 6040 [m²] filtration area would be sufficient to reach
air to cloth ratio of 1 [m³/(m² min)]. Also the Tmax of the bags is sufficient.
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25
m
The Exercise 5.3 is to measure gas flow including all relevant parameters for
standardisation and the oxygen/NO/CO content in the exit gas.
The Exercise 5.2 is to measure gas flow including all relevant parameters for
standardisation.
The Exercise 5.3 is that each group takes 3 of the totally 9 cooling fans and measures
the flow by anemometer plus pressure. Finally all cooling fan flows + pressures should
have been measured.
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AcidDewPoint
Calculates the acid dew point temperature. This is the highest temperature where one
of the acids that are present in the gas will condense. The function considers sulfuric
acid (H2SO4) and hydrochloric acid (HCl).
Parameters
Input: Water fraction by volume (m³ water/m³ gas or no unit)
SO3 fraction by volume (m³ SO3/m³ gas or no unit)
HCl fraction by volume (m³ HCl/m³ gas or no unit)
Absolute gas pressure, unit: mm Hg
Output: Acid dew point temperature (ºC)
Note
If the SO2 fraction in the gas stream is known but not the SO3, assume a conversion
rate of SO2 to SO3. According to Ganapathy, 2% is a typical conversion rate. This is
by mass. To get the SO3 fraction from the SO2 fraction and the conversion rate,
multiply the conversion rate by the SO2 fraction and then by the ratio of molecular
weight of SO2 to SO3.
Example
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A flue gas at 749 mm Hg contains, by volume, 12% water, 1% hydrochloric acid and 1%
SO2. The conversion rate of SO2 into SO3 is 2%, by mass. Calculate the temperature
where acid will start to condense.
AtmPressure
Calculates the standard atmospheric pressure at the specified altitude
Parameters
Input: Altitude (elevation above sea level), unit: meter
Output: Standard atmospheric pressure, unit: mm Hg
Example
=AtmPressure(150) returns 746.58
The atmospheric pressure at 150 meters above sea level is 746.58 mm Hg.
Cpgas
Calculates the mean heat capacity of a given gas at the specified temperature.
Cpgas is simply calling the Cpmean function. It is there only for compatibility reasons
with the old Cpgas macro used in many spreadsheets. Using Cpgas or Cpmean strictly
gives the same result.
Parameters
Input: Gas name, between quotes (“ “), no unit
Gas temperature, unit: ºC
Output: Gas mean heat capacity, unit: kcal/kg.ºC
Examples
=Cpgas(“O2”,125) returns 0.2213
The mean heat capacity of oxygen (O2) at 125ºC is 0.2213 kcal/kg.ºC.
=1250*Cpgas(“CO2”, 220)*220 returns 60534.266
The heat content of 1250 kg of CO2 at 220ºC is 60534.266 kcal
Note
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1 kcal/kg.ºC = 1 btu/lb.ºF
Cpmean
The mean heat capacity is defined as the heat required, by mass unit, to raise the
temperature of a substance from 0ºC to a specified temperature. It differs from the heat
capacity in the sense that it considers the full integration path to get to that temperature.
The mean heat capacity can be used to calculate the enthalpy of a material (gas, liquid
or solid) at a given temperature:
Since it returns the heat change between 0ºC and T, there is only one temperature to
specify. The heat difference between two temperatures, T1 and T2, is obtained by
subtracting one enthalpy from the other:
Parameters
Input: Material name, between quotes (“ “), no unit
Material temperature, unit: ºC
Output: Material mean heat capacity, unit: kcal/kg.ºC
Examples
=Cpmean(“O2”,125) returns 0.2213
The mean heat capacity of oxygen (O2) at 125ºC is 0.2213 kcal/kg.ºC.
=100*(Cpmean("SiO2",600)*600-Cpmean("SiO2",150)*150) returns 11805.209
The heat required to warm up silica from 150ºC to 600ºC is 11805.209 kcal
Note
1 kcal/kg.ºC = 1 btu/lb.ºF
Cpmat
Calculates the mean heat capacity of a given solid at the specified temperature.
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Cpmat is simply calling the Cpmean function. It is there only for compatibility reasons
with the old Cpmat macro used in many spreadsheets. Using Cpmat or Cpmean strictly
gives the same result.
Parameters
Input: Material name, between quotes (“ “), no unit
Material temperature, unit: ºC
Output: Material mean heat capacity, unit: kcal/kg.ºC
Examples
= Cpmat("Clinker",920) returns 0.2341
The mean heat capacity of clinker at 920ºC is 0.2341 kcal/kg.ºC.
=500*Cpmat(“CaCO3”, 300)*300 returns 34824.523
The heat content of 500 kg of CaCO3 at 300ºC is 34824.523 kcal
Note
1 kcal/kg.ºC = 1 btu/lb.ºF
Enthalpy
Returns the enthalpy of a material, either a gas, a liquid or a solid, at the specified
temperature. Since the reference temperature is 0ºC, it is the heat required to raise the
temperature of the material from 0ºC to the specified temperature. The Enthalpy
function uses the Cpmean function and applies the temperature to calculate the
enthalpy directly.
Parameters
Input: Material name, between quotes (“ “), no unit
Material temperature, unit: ºC
Output: Material enthalpy, unit: kcal/kg
Examples
=Enthalpy("O2",125) returns 27.6574
The enthalpy of oxygen at 125ºC is 27.6574 kcal/kg.
The heat required to raise oxygen temperature from 0ºC to 125ºC is 27.6574 kcal/kg.
=Enthalpy("C3S",950) returns 221.6072
The enthalpy of C3S at 950ºC is 221.6072 kcal/kg.
The heat required to raise C3S temperature from 0ºC to 950ºC is 221.6072 kcal/kg.
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Note
For the inverse calculation, that is the temperature of a material from its enthalpy, use
the function Temperature.
GasDensity
Returns the gas density for a gas at a given temperature and pressure.
Parameters
Input: Gas name, between quotes (“ “), no unit
Gas temperature, unit: ºC
Absolute gas pressure, unit: atm
Output: Gas density, unit: kg/m³
Example
=GasDensity("Air",125,912) returns 1.0639
The density of air at 125ºC and 912 mm Hg is 1.0639 kg/m³
HvapWater
GasViscosity
Temperature
Returns the temperature of a material (solid, liquid or solid) from its enthalpy.
Parameters
Input: Material name, between quotes (“ “), no unit
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ThermalConductivity
The Cpmean and Cpgas functions can be calculated for the following gases:
O2 oxygen
N2 nitrogen
CO2 carbon dioxide
H2 hydrogen
CO carbon monoxide
SO2 sulfur dioxide
NO nitrous oxide
H2Ov water vapor
Ar argon
CH4 methane (273.15 to 1500°K)
C2H6 ethane (273.15 to 1500°K)
C3H8 propane (273.15 to 1500°K)
Air standard air
For all those gases, unless noted otherwise, the allowable temperature range is 0 to
5727ºC (273.15 to 6000°K). If the specified temperature is outside that range, the
function returns a value of –1.
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The Cpmean and Cpgas functions can be calculated for the following solids:
Temperature range Temperature range
(ºC) (ºC)
SiO2 0 to 2727 K2SO4 0 to 2727
Al2O3 0 to 3727 Na2SO4 0 to 1727
Fe2O3 0 to 2227 CaSO4 0 to 1127
CaO 0 to 3727 CaSO4.2H2O 0 to 727
MgO 0 to 3727 KCl 0 to 1727
K2O 0 to 1727 NaCl 0 to 2227
Na2O 0 to 3227 CaCl2 0 to 2727
TiO2 0 to 3727 CaF2 0 to 2427
P2O5 0 to 427 C3S 0 to 2327
Mn2O3 0 to 1077 C2S 0 to 2130
CaCO3 0 to 927 C3A 0 to 2227
MgCO3 0 to 727 C4AF 0 to 2227
Clinker 0 to 2727 Coal 0 to 2227
RawMix 0 to 927
If the specified temperature is outside the allowable temperature range, the function
returns a value of –1.
Standard Air
The standard composition of the air is:
% volume % mass
N2 78.09 75.53
O2 20.95 23.15
Ar 0.93 1.28
CO2 0.03 0.04
with a molecular weight of 28.966 g/gmole.
At normal conditions (0ºC, 760 mm Hg), the density is 1.2923 kg/Nm³.
Mass
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Volume
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DewPoint
The DewPoint function returns the dew point temperature of a mixture of gas and water.
The dew point is the temperature where water of the mixture starts to condense. It
depends on the humidity of the mixture and the absolute pressure.
Parameters
Input: Absolute pressure of the gas mixture, unit: mm Hg
Humidity of the gas, unit: kg water/kg dry gas
Molecular weight of the gas: g/gmole
Output: Dew point temperature, unit: ºC
Example
=DewPoint(760,0.45,28.966) returns 77.3367
The dew point temperature of a gas/water mixture of 0.45 kg water/kg dry gas, for a gas
having a molecular weight of 28.966 (air) at a pressure of 1 atmosphere (760 mm Hg) is
77.3367ºC. It means that water will not condense until the temperature of the mixture is
above 77.3367ºC.
VaporPressure
Returns the vapor pressure of water at a given temperature.
The function is valid from 0 to 374.2ºC. If the temperature is larger 374.2ºC, then the
function returns the value 99999.
Parameters
Input: Water temperature, unit: ºC
Output: Vapor pressure, unit: mm Hg
Example
=VaporPressure(120) returns 1492.18 mm Hg
The vapor pressure of water at 120ºC is 1492.18 mm Hg.
MolecularWeight
This function returns the molecular weight of a gas from the name of that gas. A
reference to a cell containing the name of the gas can also be used.
Parameters
Input: Gas name, between quotes (“ “), no unit
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VelocityPressure
Calculates the velocity pressure of a gas with a given density and a given velocity.
Parameters
Input: Gas density: kg/m³
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WetDryBulb
Calculates the absolute humidity of a air / water vapor mixture from wet bulb and dry
bulb temperatures.
Parameters
Input: WBTemp: wet bulb temperature (ºC)
DBTemp: dry bulb temperature (ºC)
Pressure: absolute pressure of gas (mm Hg)
Output: WetDryBulb: absolute humidity (kg water / kg dry air)
Example
=WetDryBulb(55,125,760) returns 0.0815
The absolute humidity of a wet air when the wet bulb temperature is 55ºC, the dry bulb
temperature is 125ºC and the absolute pressure 760 mm Hg, is 0.0815 kg water/kg dry
air.
Humidity
Calculates the absolute humidity of a air / water vapor mixture from the relative humidity
of the mixture, its absolute pressure and temperature.
Parameters
Input: RelativeHumidity: relative humidity of mixture (fraction or %)
Pressure: absolute pressure of mixture (mm Hg)
Temperature: temperature of gas (ºC)
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PPENDICES Page 57 of 57
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