Chapter 5

Basics of Combustion and Balancing

Version 08/2007
KHD Humboldt Wedag GmbH

5 Basics of Combustion and Balancing

5.1 Combustion basics

5.2 Balancing basics

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KHD Humboldt Wedag GmbH

5 Basics of Combustion and Balancing

5.1 Combustion basics

Ash

Combustion
• Exhaust gas (CO2, H2O, N2, O2)
Fuel
• Energy
• Emissions (NO)

Combustion air (Oxygen)

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5 Basics of Combustion and Balancing

5.1 Combustion basics
Minimal oxygen demand for solid and liquid fuels

Educt Product omin [Nm³/kgfuel]

C CO2 1,867 x C

H H2O 5,6 x H

S SO2 0,7 x S

O - - 0,7 x O

omin = 1,867 x C + 5,6 x H + 0,7 x S – 0,7 x O [Nm³/kg fuel]

Example: C + O2 → CO2 , C = 12 kg/kmol, 1 kmol Gas = 22,414 Nm³

22,414 /12 = 1,867

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5 Basics of Combustion and Balancing

5.1 Combustion basics
Minimal oxygen demand for gaseous fuels

Educt Product omin [Nm³/Nm³fuel]

CO CO2 0,5 x v(CO)
H2 H2O 0,5 x v(H2)
CxHy CO2 x x v(CxHy)
CxHy H2O y/4 x (CxHy)
H2S H2O 0,5 x v(H2S)
H2S SO2 1 x v(H2S)
O2 - - v(O2)
∑ = omin

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5 Basics of Combustion and Balancing

5.1 Combustion basics

Minimal air demand (dry)

lmin,d = 100/21 x omin = 4,76 x omin

Minimal air demand (wet)

lmin,w = lmin,d + fw x 1,244 x 10-3 x lmin,d humidity fw in g/Nm³

Actual air demand (dry)

ld = λ x lmin,d

Actual air demand (wet)

lw = λ x lmin,w

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5 Basics of Combustion and Balancing

5.1 Combustion basics
Combustion gas (wet) for solid and liquid fuels

Educt Product v [Nm³/kgfuel]

C CO2 1,867 x C
H H2O 11,20 x H
S SO2 0,7 x S
O - -
Nfuel N2 0,8 x N
N2,air N2 0,79 x ld
Wfuel H2O 1,244 x Wfuel
Wair H2O fW x 1,244 x 10-3 x ld
O2, excess air O2 0,21 x (ld – lmin,d)
∑ = vw

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KHD Humboldt Wedag GmbH

5 Basics of Combustion and Balancing

5.1 Combustion basics
Combustion gas (wet) for gaseous fuels
Educt Product v [Nm³/Nm³fuel]
CO CO2 v(CO)
H2 H2O v(H2)
CxHy CO2 X x v(CxHy)
CxHy H2O Y/2 x v(CxHy)
H2S H2O v(H2S)
H2S SO2 v(H2S)
CO2 CO2 v(CO2)
SO2 SO2 v(SO2)
Nfuel N2 v(N2)
N2,air N2 0,79 x ld
W fuel H2O 1,244 x fgasl
Wair H2O fW x 1,244 x 10-3 x ld
O2, excess air O2 0,21 x (ld – lmin,d)

∑ = vw

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Reactor
Educts Products

Mass balance
Rule of mass conservation
∑ mIN - ∑ mOUT = 0
Energy balance
Rule of energy conservation (First Law of Thermodynamics)
∑ EIN – ∑ EOUT = 0

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5 Basics of Combustion and Balancing

5.1 Balancing basics
Balancing in practice

• layout and dimensioning of new plants

• simulation of existing plants
• basis for calculation of plant conversions („zero test“ or data from client)
• performance test (documentation of achievement of garantuee figures)
• checking and adjusting of layout and dimensioning parameters
→ improvement of layout and dimensioning reliability

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Preheater
raw meal preheater exhaust gas
(combustion gas, dust, CO2 from
conveying air calcination, moisture of kiln feed, false air)

heat losses

positive and/or negative heat of reactions

false air
pre-heated meal

calciner exhaust gas

[electrical and / or
mechanical energy] calcined meal

control volume
hot meal to kiln

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Calciner
false air
[Electrical and/or mechanical energy]

positive and/or negative heat of reactions

heat losses
fuel + conveying air

calcined meal pre-heated meal (from 2nd lowest cyclone stage)

calciner exhaust gas
tertiary air + dust

Kiln exhaust gas + dust

control volume

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Rotary Kiln

heat losses positive and/or negative heat of reactions

control volume

secondary air
kiln exhaust gas + dust
+ dust

fuel + primary air

hot meal

false air [electrical and/or hot clinker

mechanical energy]

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Clinker Cooler
heat losses cooler exhaust gas

tertiary air + dust

recuperation air

secondary air + dust

cold clinker
hot clinker

control volume [electrical and/or

cooling air
mechanical energy]

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Overall Process
exhaust gas
(combustion gas, dust, CO2 positive and/or cooler exhaust gas
from calcination, moisture of negative heat of (+ middle air)
kiln run, false air) reactions

raw meal control volume

conveying air

false air
fuel + primary air
[electrical and/or mechanical energy]

cold clinker
heat losses cooling air

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Mass balance
dust losses:
PH exhaust gas ≈ 50 g/Nm³
Bypass ≈ 150 g/Nm³
cooler exhaust gas ≈ 10 g/Nm³

Reactor
raw material clinker

raw meal – clinker factor: fuel ash

• theoretical (LOI) ≈ 1,55
• practical ≈ 1,6 LOI:
(dust losses ↑ , ash input ↓) CaCO3 → CaO + CO2
100 → 56 + 44 g/mol
CaCO3 ≈ 70% of raw mixture
0,5% residual moisture

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Gas balance

combustion gas bypass extraction

CO2 from calcination

Reactor
• cooling air • preheater exhaust gas
• primary air • cooler exhaust gas
• conveying air (raw meal, fuel)
false air

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Heat balance radiation

heat of reaction dust losses

Reactor
• calorific value of fuel • PH exhaust gas
• recuperation air • cooler exhaust gas
• cold clinker

sensible heat (fuel, raw meal,

primary + false + conveying air)

QGas = V * cp * ∆T
QSolid = m * cp * ∆T
QFuel = m * Hu

cp values for solids acc. to VT10, for gas acc. to Knacke, Kubaschewski, Hesselmann,
„Thermochemical properties of inorganic substances“, Springer 1991
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5 Basics of Combustion and Balancing

5.1 Balancing basics

Specific heat capacity of clinker according to VT 10

cp [kJ/kg K]

T [°C]

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5 Basics of Combustion and Balancing

5.1 Balancing basics

Specific heat capacity of hot and cold clinker

cp [kJ/kgK]
Example:

hot clinker 6000 t/d clinker

= 250000 kg/h
∆Q = Q1400°C -Q100°C ≈ 360 GJ/h

is equal to
14 t/h coal with Hu= 25000 kJ/kg
cold clinker

T [°C]
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5 Basics of Combustion and Balancing

5.1 Balancing basics

Specific heat capacity of gases according to VT 10

cp SO2, CO2
[kJ/Nm³K]

H2O

O2
N2, Luft
H2

T [°C]
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5 Basics of Combustion and Balancing

5.1 Balancing basics
Parameters for dimensioning a new plant

ambient parameters: ambient temperature, ambient pressure (m.a.s.l.)

raw material data: heat of clinker formation, emissions and voltile circuits (bypass)
raw meal feed: conveying air (airlift or bucket elevator)
fuel data: calorific value, elementary analyses, content of ash and
moisture → combustion
fuel dosing: primary and conveying air
false air: experience values
general conditions:
• machinery layout
• production
• reserves
• „carry-over of parts“ of built plants
•…

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