Mechanisms of Fuel Combustion

P M V Subbarao
Professor
Mechanical Engineering Department

A Basis for Development of Compact SG Systems

Coal Fired Steam Generator System

Basic Mechanisms of Solid Fuel

Combustion

Primitive Method of solid Combustion

O2+CO2+N2+H2O
Flame

Secondary Air
VM+CO+CO2+N2+H2

Green Coal
Incandescent coke
CO+CO2+N2+H2

ASH
Grate
Primary Air

Top-feed updraft combustor

Physics of Fixed Bed Combustion

A bed of stoker-sized coal particles is supported by a grate.

Air flows upwards through the grate and the fuel bed.
Upon heating, coal particles first undergo a stage of Thermal
preparation.
Evaporation of Moisture drying.
Distillation of VM (Pyrolosis)
Production of enough VM to start ignition.
Combustion of char.
The coal flows slowly downward at a velocity Vs, as the coal burns out
in the lower layer of the bed.

Automation in Fuel Bed Combustion

Also called Mechanical Stokers.

Travelling Grate Stoker
Chain Grate Stoker
Spreader Stoker
Vibrating Stoker
Underfeed Stoker

Travelling Grate Stoker

Boiler type: natural circulation
Firing method: stoker fired
Max. continuous rating:9,7 kg/s
Steam temperature outlet: 450C
Steam pressure outlet: 4,0 Mpa
Gross efficiency: 87%
Fuel type: Bituminous coal
Net

calorific

value:

23

MJ/kg

SPREADER-STOKER FIRED BOILER

Solid fuel- fired boiler system

Typical Size Distribution Coal for Stoker Furnace

Closing Remarks on Grate Firing

The first limit on grate firing is that of scale.

A practical engineering limit seems to be reached when the length and
width of the grate are about 9 m with grate area 80 m2.
At 2 MW/m2, the steam capacity at 85% efficiency would be 150 MW
or 270 tons per hour.
In practice stokers have rarely exceeded a capacity of 135 tons/hour.
The limitation is partly grate area and partly firing density.
The limitation on firing density exist due to:
The rate of movement of the reaction plane could not match the
opposed rate of fuel flow leading to blow-off.
The experience with grate combustion led to development of many
requirements for further development.

Parameters for Combustion Requirements

Heat Release Rate

Volumetric Combustion Intensity
Area Combustion Intensity
Effective Reactor Height
Coal Firing Density
Area Firing Density
Products of combustion Velocity
Air Velocity
Combustion time
Particle Heating Rate
Heat Transfer Fluxes
Heat exchange surface area per unit cross sectional area of combustion
chamber,

Heat Release Rate : A Capacity Limit

Most common Grate fired furnace ~ 30 MW.

Maximum obtained ~ 150 MW.
Maximum Power Generation Capacity ~ 50 MW
Future Projected Requirement ~ 3000 MW

Firing Densities Limits : An Optimal Choice

Firing densities are expressed in two ways:

A volumetric combustion intensity, Iv.
High value of Iv :
Compact furnace
Low Capital cost
Less time for combustion
Low Values of Iv
Bulky furnace
More time for combustion
Low Running Cost
Area Firing Intensity, IA
High value of IA
Sleek furnace
Higher combustion Temperatures
Better Ignition
Low Value of IA
Poor Ignition
Fat furnace
Low Nox
Solid Ash

Pulverized Fuel Combustion

Invented in 1920.
An universal choice for power plants till 1990.
Fine particles of coal ~ 75 microns.
Surface area : 150 m2/kg.
Huge heat release per unit area : 2 5 MW/m2.

Steam generation : 2000 tons/hour.

Fluid Mechanics of Solid Beds

Static Bed

Floating Bed

Velocity

Dynamic Bed

Interactive Combustion of PC Particles

For an isolated particle, a spherical envelope
flame is formed around the particle.
The flame acts as a sink for fuel and oxygen and
as a source for thermal energy.
If another burning particle is brought near the
particle, the CO released by the particles
competes for oxygen molecules.
Further the interstitial temperature and species
profiles are also affected.
At some point the flames surrounding each
particle will merge and a common flame is
formed around the particles.
If more particles are brought near, then a
common flame may be formed around an array
or cloud of particles.