1. A plant is burning limestone analyzing 47% CaCO3, 45% MgCO3 and 8% inerts.

The kiln is
fired with producer gas containing 25.3% CO, 13.2% H2, 0.4% CH4, 5.4% CO2, 0.5% O2
and 55.2% N2. The wet kiln gas is sampled and the average analysis is found to be 21.97%
CO2, 3.54% CO and 5.28% H2. If the lime - fuel ratio is 20 kg of lime/kgmole of producer
gas, calculate:
a) % excess air
b) Complete analysis of the kiln gas

Solution:

¿
Limestone: Lime: 20 kg ¿ kgmole PG
47% CaCO3
45% MgCO3 21.97% CO2
8% inerts 3.54% CO
5.28% H2

Producer Gas:
25.3% CO
13.2% H2
0.4% CH4
5.4% CO2
0.5% O2
55.2% N2

Basis: 100 kgmol producer gas

H
Theo O2=atC + −mole O 2
4

28
¿ 31.1+ −18.55=19.55
4

kg ¿=100 kgmol PG × 20 kg ¿ ¿ =2000 kg ¿

1 kgmole PG

Basis: 100 kg Limestone

 44
VM ¿ CaC O 3=47 × =20.68
100

44
VM ¿ MgC O 3=45 × =23.57
84

VM total=20.68+ 23.57=44.25

NVM=100 – 44.25=55.75

2000
kg limestone= =3587.44
0.5575

Using C bal: C PG +C limestone=C kiln

3587.44(0.4425)
25.3+0.4 +5.4+ =( 0.2197+ 0.0354 ) moles kiln
44

moles kiln=263.34

moles C O 2 kiln=263.34 × 0.2197=57.86

moles C Okiln =263.34 ×0.0354=9.32

moles H 2 kiln =263.34 × 0.0528=13.90

Let y=excessO 2

O 2 ¿ air= y+ 19.55

79
N 2 ¿ air=( y +19.55)( )
21

9.32 13.9
free O 2= y +0.5+ + = y +12.11
2 2

Kiln Gas bal:

263.34=57.86+9.32+13.90+ y +12.11+ ( y+ 19.55 ) ( 7921 )+55.2

y=8.70

8.70
a.) % excess air = ×100=44.5 %
19.55
moles H 2 O kiln =14−13.90=0.1

moles O2 kiln =8.70+12.11=20.81

moles N 2kiln =( 8.70+ 19.55 ) ( 7921 )+55.2=161.47

b.) Complete Analysis of the kiln gas

Gases n &
CO2 57.86 21.96
CO 9.32 3.54
O2 20.81 7.90
N2 161.47 61.29
H2 13.90 5.28
H2O 0.1 0.038
Total 263.46 100
2. A high sulfur fuel oil containing 75.2% C, 9.59% S and negligible N is burned in excess
air to supply the heat necessary to calcine a stone consisting of 52.3% CaO, 2.5% MgO,
43.1% CO2 and 2.1% moisture. The operation of the kiln is such that the lime is
incompletely burned and contains 6.2& CO2. The average orsat analysis of the kiln gas
shows 25.4% CO2, 1.9% CO, 0.5% SO2, 5% O2 and 67.2% N2. Calculate:
a) Complete ultimate analysis of the fuel
b) Fuel ratio

excess air

fuel lime
75.2% C 6.2% CO2
9.59% S

kiln gas
limestone 25.4% CO2
52.3% CaO 1.9% CO
2.5% MgO 0.5% SO2
43.1% CO2 5% O2
2.1% moisture 67.2% N2

Solution:

Basis: 100 kgmole of kiln gas

N2 air = 67.2

O2 air = 67.2 (21/79) = 17.86

1.9
excess O2 = 5 - [ ] = 4.05
2

theo O2 = 17.86 – 4.05 = 13.81

S bal:

0.0959(wt . of fuel oil)

= 0.5
32

wt. of fuel oil = 166.84 kg

% O & H in fuel oil = 100 – 75.2 – 9.59 = 15.21

C in fuel oil = 0.752 (166.84) = 125.46

S in fuel oil = 0.0959 (166.84) = 16

O & H in fuel oil = 0.1521 (166.84) = 25.376

let x = moles of O in fuel oil

25.376 – x = moles of H in fuel oil

125.46 25.376−x 16 x
theo O2 = + + - = 13.81
12 4 32 32

x = 12.405

therefore:

O = 12.405

H = 25.376 – 12.405 = 12.97

% O in fuel oil = (12.405/166.84) x 100 = 7.435%

% H in fuel oil = (12.97/166.84) x 100 = 7.774%

a. Complete ultimate analysis of the fuel

75.2% C, 9.59% S, 7.435% O, 7.776% H ANS

% NVM in limestone = 100 – 43.1 – 2.1 = 54.8

NVM bal:

(1-0.062)(wt. of lime) = 0.548 (wt. of limestone)

C bal:

125.46 0.431(wt . of limestone) 0.062(wt . of ¿)

+ = + 27.3
12 44 12

but

( 1−0.062 ) (wt . of ¿)
wt. of limestone in NVM bal =
0.548

substituting it to the C bal:

125.46 0.431(1−0.062)(wt . of ¿) 0.062(wt . of ¿)

+ = + 27.3
12 0.548 x 44 12

wt. of lime = 1452.154 kg

¿
b.) Fuel ratio = 1452.154 kg of ¿ 166.84 kg of fuel oil = 8.7 ANS
3. A fuel gas made up of a mixture of methane and ethane is burned in excess air and the
heat given off is used to calcine completely a stone containing 95% CaCO3 and 5% inerts.
Complete analysis of kiln gas shows 21.42% CO2, 5.54% O2, 62.54% N2 and 10.5% H2O.
Calculate the analysis of the fuel gas and the Lime-Fuel ratio.

Excess Air

21.42% CO2
95% CaCO3
BURNER 5.54% O2
5% inerts
62.54% N2
10.5% H2O
CH4
C2H6
Basis: 100 kgmole kiln gas

N2, air = 62.54 kgmole

O2, air = 62.54 (21/79) = 16.62 kgmole

Let x = no. of moles of CH4

y = no. of moles of C2H6

no of moles C H
CH4 x x 4x
C2H6 y 2y 6y
TOTAL x + 2y 4x + 6y

O2, theo = O2, air - O2, excess

O2, theo = 16.62 – 5.54 = 11.08 kgmoles

O2, theo = C + H/4

11.08 = C + 21/4
 C = 5.83 kgmole

x + 2y = 5.83 equation 1

4x + 6y = 21 equation 2

x = 3.51 kgmoles

y = 1. 16 kgmoles

a. Analysis of Fuel gas

no. of moles Percentage

CH4 3.51 75.16 %
C2H6 1.16 24.84 %
Total 4.67 100%

Wt. Fuel = [(3.51) + 2(1.16)](12) + [4(3.51) + 6(1.16)](1) = 90.96 kg

b. Lime-Fuel ratio

For 100 kg Limestone

kg
44 CO 2
Volatile Matter=95 kg CaCO 3
100( kgmole
kg
kgmole
CaCO 3 )
=41.8 kg CO 2

NonVolatile Matter=100−41.8=58.2 kg ¿

CO2, limestone = CO2, kiln gas - CO2, fuel

CO2, limestone = 21.42 – 5.83

CO2, limestone = 15.59 kgmole

15.59 kgmole CO 2 ( 1 kgmole CaCO 3 100 kg CaCO 3

1kgmole CO 2 )( 1 kgmole )
=1559 kg CaCO 3

0.95 ( Wt. Limestone ) = 1559 kg CaCO3

Wt. Limestone = 1641.05 kg

1641.05 kg Limestone ( 58.2kg ¿¿¿ 100 kg Limestone )=955.062 kg ¿

 ¿ =955.062 kg ¿ ¿ =10.5
Fuel 90.96 kg Fuel

4. A kiln is used to calcine a limestone analyzing 52% CaCO 3, 30% MgCO3, 5% Al2O3, 4%
inerts, 6% SiO2 and 3% moisture. Coal is burned to supply heat of calcination. Analysis of coal
shows 13.8% VCM, 8.6% ash, 3% moisture, negligible N and S with a calorific value of 32.95
MJ/kg. Analysis of the kiln gas shows 18.57% CO2, 1% CO, 0.22% H2, 8.39% O2 and 1.82% N2.
Calculate:

a. kg Limestone/ kg coal

b. Lime-Fuel ratio

Excess Air

18.57% CO2
52% CaCO3 1% CO
BURNER
30% MgCO3 0.22% H2
5% Al2O3 8.39% O2
4% inerts 71.82% N2
6% SiO2 3%
moisture
13.8% VCM
8.6% ash
3% moisture
negligible N and S
CV = 32.95 MJ/kg

FC = 100-VCM-A-M

FC = 100-13.8-8.6-3

FC = 74.6 %

VCM 1.55
C = 5.88 + 2.206 (CV – 0.094S) + 0.0053 (80-100 )
FC
 13.8 1.55
C = 5.88 + 2.206 (32.95) + 0.0053 (80-100 )
74.6

C = 81.709 %

CV= 0.338C + 1.44 net H + 0.094S

32.95 = 0.338(81.709) + 1.44 net H

net H = 3.70%

CW = 100-C-netH-M-Ash-N-S

CW= 100=81.709-3.703-3-8.6

CW=2.988%

CW + M = 2.988 + 3 = 5.988%

% H in CW + M = 5.988 (2/18) = 0.665%

% O in CW + M = 5.988 (16/18) = 5.323%

HTOTAL = 0.665 + 3.703 = 4.368 %

Ultimate Analysis: C = 81.709%, H = 4.368%, O = 5.323%, Ash = 8.6%

Basis: 100 kgmole kiln gas,

N2, air = 71.82 kgmole

O2, air = 71.82 (21/79) = 19.09 kgmole

O2, theo = O2, air - O2, excess

O2, excess = O2, free - H2/2 - CO/2

O2, theo = 19.09 – ( 8.39 – 0.22/2 -1/2) = 11.31 kgmole

Volatile Matter = 52( 44/100) + 30 (44/84.30) = 38.54 % CO2 in Limestone

Non Volatile Matter = 100-38.54-3 = 58.46 % Lime

For 100 kg Fuel

O2, theo = 81.709/12 + 4.368/4 -5.323/32 = 7.734 kgmole

Tie substance: O2, theo

(100/7.734) (11.31) =146.24 kg coal

C balance:

0.3854 ( LS )
( 0.81709
12 )
(146.24)+ (
44 )=18.57+1
Limestone = 1097.34 kg

Lime = 1097.34 ( 0.5846) = 641.505 kg

a. kg Limestone/kg Coal

1097.34 kg
= 7.50
146.24 kg

b. Lime-Fuel Ratio

641.505 kg
= 4.4
146.24 kg
5. A plant is burning limestone which analyzes 52% CaO, 41% CO2 and 7% inerts using coke
that analyzes 90% C and 10% ash. The lime product obtained contains 3% CO2 and 1%
unburned C. The top gas shows 24.1% CO2, 1% CO and 74.9% N2. Calculate:

a) kg limestone/ kg coke

b) Lime-fuel ratio

Air Kiln(K)

24.1% CO2

1%CO

74.9%N2

Burner

(LT) Lime(L)

52%CaO 3% CO2

41%CO2 1%C

7% Inerts Coke 96%NV

(C)

90%C

Assume: 100 kg (LT)

41%CO2

59% NVM

59=0.96(L)

(L)= 61.4583kg

Let C= kg coke (C) K=kmol (K)

At C balance:

41 0.9 0.03(61.4583) 0.01(61.4583)

+ ( C )=( 0.241+0.01 ) K + +
44 12 44 12

O2 balance:

41 21 0.01 0.03(61.4583)
+0.749 ( K )= ( K )+ 0.241 K +
44 79 2 44

K= 18. 9752kmol

C= 52.3211kg

100
a) Kg limestone/kg coke= =1.9113
52.3211
61.4583
b) ¿−fuel ratio= =1.175
52.3211
 6. A plant produces lime analyzing 53% CaO, 35% MgO and 12% inerts. Water gas analyzing
38.3% CO, 52.8% H2, 0.4% CH4, 5.5% CO2, 0.1% O2 and 2.9% N2 is used as fuel. Analysis of
the kiln gas shows 15.71% CO2, 3.31% CO, 6.61% H2, 9.81% O2 and 64.56% N2. Calculate:

a.) weight of limestone/mole water gas

b.) %excess air

Air

Limestone: Kiln:

53% CaO 15.71% CO2

35% MgO 3.31% CO

12% inerts 6.61% H2

Lime 9.81% O2

64.56% N2

Water Gas

38.3% CO

52.8% H2

0.4% CH4

5.5% CO2

0.1% O2

2.9% N2
Solution:

Gas n atC atH mole O2

CO 38.3 38.3 ----- 19.15
H2 52.8 ----- 105.6 -----
CH4 0.4 0.4 1.6 -----
CO2 5.5 5.5 ----- 5.5
O2 0.1 ----- ----- 0.1
N2 2.9 ----- ----- -----
100 44.2 107.2 24.75

atH
Theo O 2=atC + −mole O 2
4

107.2
¿ 44.2+ −24.75=46.25
4

CO H
ExcessO 2=free O 2− −
2 2

¿ 9.81−3.31/2−6.61/2=4.85

N 2 ¿ fuel ¿+ N 2 for theoO 2=64.56−4.85 ( 7921 )=46.31

Theo O 2¿ fuel analysis

N 2 ( fuel )+ N 2( theoO 2 )=2.9+ 46.25 ( 7921 )=176.89

46.25
Theo O 2=( )(46.31)=12.11
176.89

excessO 2 4.85
%excess O 2= x 100= x 100=40 %
theo O2 12.11