Industrial Fuel Combustion Systems for Engineers

Name: Industrial Fuel Combustion Systems for Engineers
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Designing Combustion Systems for Solid, Liquid, and Gaseous Fuels with Flue Gas Emissions Analysis

Created byOZIS Academy

Last updated 3/2024

English

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What you'll learn

Understanding the importance of air and its proper ratio for efficient combustion.
Exploring design factors influencing combustion system performance.
Exploring coal preparation and burner configuration optimization for efficient combustion.
Evaluating criteria for selecting the right solid fuel type based on specific applications for different combustion systems.
Examining various combustion systems designed for solid fuels, considering factors essential for their effective operation.
Studying the dynamics of solid fuel bed combustion and the factors that impact its efficiency.
Investigating pulverized fuel combustion, its advantages, and limitations, to gain a comprehensive understanding.
Learning about fluidized bed combustion technology and its benefits, while addressing potential drawbacks.
Exploring atomization techniques, burner types, and ignition systems used for liquid fuels.
Understanding combustion mechanisms for liquid fuels and recognizing different flame properties.
Examining combustion characteristics, flame types, and flame propagation of gaseous fuels.
Analyzing various types of burners designed specifically for gaseous fuels.

Course content

4 sections • 39 lectures • 5h 6m total length

Inro to the Course : Combustion of Fuels6:23
Explore the combustion of solid, liquid, and gaseous fuels and its role in engines, furnaces, metallurgy, and electricity generation. Engage in problem solving on heat release, stoichiometry, and pollutant formation.
Air Required for COmbustions Process19:10
Explore how air supports combustion, from stoichiometric and excess air to lambda and air-to-fuel ratios, including primary, secondary, and tertiary air for optimal, cleaner burning.
Combustion System Design Factors6:32
Explore combustion system design factors that ensure reliable ignition, flame stability, emissions control with CFD modeling, high efficiency, durability, and modularity across solid, liquid, and gaseous fuels.

Combustion Systems for Solid Fuels2:43
Explore solid fuel combustion mechanisms across stationary bed, pulverised fuel, and fluidized bed systems, examining air flow, particle size, burner design, combustion kinetics, and environmental sustainability.
1 - Solid Fuel Bed Combustion on Hearth or Grate3:37
Explore solid fuel bed combustion on hearth or grate, covering the fuel bed, air supply, ignition, ash removal, grate design, and basic control systems for efficiency.
Smith Shop Furnace3:42
Explore the smith shop furnace used for heating metal in blacksmithing, and inspect its core components and drawbacks, including limited size, manual operation, and energy inefficiency.
Pit Melting Furnace3:39
Explore the pit melting furnace, a ground-based solid-fuel bed furnace on a grate that melts large quantities of metal in foundries, detailing coke bed, air blower, ash discharge, and crucible.
Small Scale Boiler4:14
Explore how the small scale boiler uses a coalbed and grate to support combustion and heat water into steam, detailing core components from water inlet to chimney.
Combustion Mechanism of Solid Fuel Bed Combustion8:23
Explore the solid fuel bed combustion mechanism, covering preheating, combustion zones, thick bed carbon gasification, ash formation, and CO oxidation by secondary or tertiary air.
Factors Affecting Solid Fuel Bed Combustion4:17
Examine moisture, volatile matter, fixed carbon, ash content, ash fusion temperature, and carbon reactivity in solid fuel bed combustion on a fixed grid, and note effects on ignition and efficiency.
Selection of Fuel for Solid Fuel Bed Combustion for Different Applications5:24
Select solid fuels for bed combustion by furnace type and operating needs. Use high fixed carbon, low reactivity fuels like coke or anthracite with proper size and airflow.
2 - Pulverized Fuel Combustion through Burner2:08
Explore pulverised fuel combustion through burner, where coal is ground to a fine powder, mixed with air, injected and ignited, transferring heat to steam for electricity in turbines.
Merits and Limitations of Pulverized Fuel Combustion6:23
Explore the merits and limitations of pulverised fuel combustion, from efficiency and precise furnace control to costs, safety hazards, sulfur concerns, and wear on boiler parts.
Types of Coal and their Selection for Pulverised Fuel Combustion9:04
Explore coal types and selection for pulverised fuel systems, analyzing fixed carbon, volatile matter, and sulfur content to predict flame dynamics, combustion characteristics, and emissions.
Preperation of Coal for Pulverised Fuel Combustion through Burner3:45
Explore coal preparation for pulverised fuel combustion: cold drying, grinding to a fine powder, and the hardgrove grindability index; compare direct versus indirect firing systems and their storage risks.
Burner Designs & Firing Positins for Pulverised Fuel Combustion11:37
Explore burner design and air supply in pulverised fuel combustion, detailing primary, secondary, and tertiary air, annular and nozzle configurations, and firing positions to optimize mixing, heat distribution, and emissions.
Combustion Mechanism of Coal in Pulverised Fuel Combustion through Burner3:49
Explore the combustion mechanism of coal in a pulverized coal burner, from primary air injection to volatile release, char oxidation, and fly ash implications for cement use.
Application of Pulverised Fuel Combustion in Power Plant3:32
Understand pulverised fuel combustion in coal-fired power plants: grind coal to powder, mix with air, burn in the boiler, generate steam and electricity, and manage pollutants.
3 - Solid Fuel Combustion in Fluidised Bed4:20
Explore fluidized bed combustion, differentiating fixed bed, loose bed, and fluidized bed, while showing how air suspends fuel particles to increase surface area, improve combustion rate, and reduce emissions.
Merits and Limitations of Fluidised Bed Combustion5:43
Explore the merits and limitations of fluidized bed combustion, highlighting fuel flexibility, enhanced efficiency, sulfur capture, and lower emissions, while noting erosion risks and the need for precise air control.
Working of Fluidised Bed Fuel Combustion4:44
Operate a fluidized bed boiler to combust coal with limestone for sulfur capture. Rely on preheated air from an air distributor to fluidize the bed and generate steam for electricity.
Combustion Mechanism of Fluidised Bed Fuel Combustion3:54
Learn the fluidized bed combustion mechanism for coal, including limestone sulfur capture, devolatilization, volatile and char combustion, calcination, and ash and flue gas exit.
Selection of Coal for Fluidised Bed Combustion6:36
Explore how coal properties affect fluidized bed combustion, focusing on char reactivity, ash content, and ash composition. Analyze moisture and calorific value to understand design parameters and boiler efficiency.
Numerical Problem - 14:26
A bed of 12 kg graphite (100% C) is burnt in air.
Calculate the following:
(i) Theoretical air required in m3 ,
(ii) Volume of products of combustion in m3 and (
iii) Flue gas per cent analysis.
Numerical Problem - 221:00
Coal analyses C–84%, H – 4%, N–1.4%, O–1.8%, S–0.64%, and total inorganic oxides (ash) 8.16%. This coal was burnt in pulverized form with excess air to ensure complete combustion. The dry gaseous product of combustion analysed CO2 –15.7%, O2 –3.6%, SO2 –0.04% and N2 –80.7% at STP.
Calculate the following:
(i) Theoretical amount of air needed for combustion in cubic meters per kg coal
(ii) Percent of excess air used for combustion
(iii) Total dry gaseous product of combustion in cubic meters per kg coal.
Numerical Problem - 319:02
A dry coal analyzing 78% carbon, 8% hydrogen, 2% oxygen, 2% nitrogen and 10% ash was burnt in a furnace. The furnace used 10% excess air during combustion.
Calculate the following:
(i) The amount of theoretical air needed for combustion in m3 /kg coal
(ii) The amount of actual air used during combustion in m3 / kg coal
(iii) Flue gas volume using excess air in m3 /kg coal
(iv) Flue gas analysis on dry basis using excess air.
Numerical Problem - 411:13
5 A coal contains 78% carbon, 4% hydrogen, 2% oxygen, 1.8% sulphur and rest as non-combustibles.
Calculate the following:
(i) Gross calorific value of the coal in GJ/ton using Dulong’s Formula 337 C + 1442 [H – (O/8)] + 93 S kJ/kg where C, H, O and S are percentages of carbon, Hydrogen, oxygen and sulphur respectively.
(ii) Amount of coal needed per day to burn in a 10 MW power plant working with 32% thermal efficiency (Given 1 kWh = 3.6 MJ).

Automising Liquid Fuels for Combustion3:28
Explore how atomizing liquid fuels enhances combustion efficiency by increasing surface area and better air mixing. Learn centrifugal, mechanical, and pneumatic atomization techniques and their roles in burners and engines.
Types of Burners used for Liquid Fuels9:50
Explore types of burners for liquid fuels and their atomization principles. Learn pressure atomization with orifice, swirling nozzle, pneumatic, rotary cup, and low-pressure air methods, with their advantages.
Liquid Fuel Ignition Systems4:25
Learn how liquid fuel ignition systems start burners with spark or pilot flame, detailing electrode placement near the oil stream, electric spark ignition, and practical reliability and safety considerations.
Flame Detection Systems6:27
Explore flame detection systems that safeguard burners by confirming flame presence and triggering fuel shutoff. Compare photoelectric cell based and ionization probe based detection, including ultraviolet and visible sensors.
Combustion Mechanism of Liquid Fuels2:24
Explore the combustion mechanism of fuels, from atomization and air mixing to vaporization, oxidation, and flame formation, and learn how burner design and airflow shape flame characteristics.
Complete and Incomplete Combustion of Liquid Fuels5:06
Learn to distinguish complete and incomplete combustion in oil burners, recognizing blue flame with minimal emissions versus yellow smoke and unburnt droplets, and optimizing atomization and air–fuel mix for efficiency.
Flame Properties of Liquid Fuels6:43
Explore how flame stability, turndown ratio, lift-off and flashback affect burner performance, flame length and shape, and luminosity to optimize industrial liquid fuel combustion.

Gaseous Fuel Combustion & Types of Flames6:18
Explore gaseous fuel combustion using a Bunsen burner, comparing premixed and diffusion flames and their blue, lean, and non-luminous varieties, with attention to temperature and emissions.
Flame Propagation of Gaseous Fuels7:51
Explore flame propagation of gaseous fuels, focusing on flammability limits, stoichiometric ratios, and how laminar versus turbulent gas flow shapes methane and n-heptane flames.
Types of Burners used for Gaseous Fuels24:02
Discover gaseous-fuel burner types, from atmospheric non-mechanical to mechanical with forced, induced, and balanced drafts, and how venturi mixing and primary air control improve efficiency and safety in industrial heating.
Numerical Problem - 520:14
A natural gas analyses as: CH 4 – 85%, C 2 H 4 – 3%, C 6 H 6 – 3%, H 5%, N 2 – 4%. It is burnt with 20% excess air. The air is moist containing 1.5% water vapour.
Calculate the following:
(i) the dry theoretical air needed for burning one cubic meter of natural gas,
(ii) volume of moist air used for burning including excess air
(iii) volume of product of combustion at STP and its analysis.
Numerical Problem - 620:33
Consider 100 m3 of the mixed gas is used for combustion which contains 80% (or 80 m3 ) blast furnace gas and 20% (or 20 m3 ) coke oven gas whose gas analysis is provided in the problem.

Requirements

Basic understanding of chemistry and thermodynamics.
Proficiency in mathematical calculations and problem-solving skills.

Description

This course delves into the intricate processes and design considerations involved in combustion, a cornerstone of energy production across various industries. From solid to liquid and gaseous fuels, students will explore the complexities of combustion systems, gaining invaluable insights into optimizing efficiency and minimizing environmental impact.

The importance of air in the combustion process is emphasized, alongside the crucial factors influencing combustion system design. Solid fuels are studied in depth, covering combustion systems ranging from smith shop furnaces to small-scale boilers. Students will learn the mechanics of solid fuel bed combustion, including fuel selection and preparation, as well as the merits and limitations of pulverized fuel combustion.

In the realm of liquid fuels, the course delves into atomization techniques, burner types, and ignition systems, ensuring students grasp the nuances of combustion mechanisms and flame properties. The distinction between complete and incomplete combustion is highlighted, emphasizing the importance of efficiency and emissions control.

Gaseous fuels are also explored, with a focus on combustion behavior and flame propagation. Various burner types used for gaseous fuels are analyzed, providing students with a comprehensive understanding of combustion systems across different fuel types.

Throughout the course, practical applications in power generation and environmental sustainability are underscored. Students will emerge equipped with the knowledge and skills necessary to tackle real-world challenges in engineering, environmental science, and related fields, making meaningful contributions to energy efficiency and environmental stewardship.

Who this course is for:

Students pursuing degrees in engineering, environmental science, or related fields, looking to gain practical knowledge in combustion of fuels, a fundamental aspect of energy production and environmental sustainability.
Engineers and professionals working in fields such as mechanical, chemical, or energy engineering seeking to deepen their understanding of combustion processes and technologies.
Professionals from industries reliant on combustion processes, including power generation, manufacturing, transportation, and aerospace, aiming to enhance their expertise and stay abreast of advancements in combustion technology for improved efficiency and emissions control.

Industrial Fuel Combustion Systems for Engineers

What you'll learn

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Course content

Introduction to Combustion of Fuels3 lectures • 32min

Combustion Systems for Solid Fuels24 lectures • 2hr 37min

Combustion Systems for Liquid Fuels7 lectures • 38min

Combustion Systems for Gaseous Fuels5 lectures • 1hr 19min

Requirements

Description

Who this course is for: