Heat transfer in industrial combustion

Title:

Personal Author:

Baukal, Charles E.

Publication Information:

Boca Raton : CRC Press, c2000

Physical Description:

545 p. : ill. ; 27 cm.

ISBN:

9780849316999

Subject Term:

Heat -- Transmission

Combustion engineering

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Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010310071	TJ260 B359 2000	Open Access Book	Gift Book	Searching... Unknown

Industry relies heavily on the combustion process. The already high demand for energy, primarily from combustion, is expected to continue to rapidly increase. Yet, the information is scattered and incomplete, with very little attention paid to the overall combustion system. Designed for practicing engineers, Heat Transfer in Industrial Combustion eclipses the extant literature with an emphasis on the aspects of heat transfer that directly apply to industry.

From a practical point of view, the editor organizes relevant papers into a single, coherent resource. The book encompasses heat transfer, thermodynamics, and fluid mechanics, including the little-covered subjects of the use of oxygen to enhance combustion and flame impingement. Maximizing applications and minimizing theory, it covers modes of heat transfer, computer modeling, heat transfer from flame impingement, from burners, low temperature, high temperature, and advanced applications, and more.

The theoretical focus of most literature has created a clear need for a practical treatment of the heat transfer as it applies to industrial combustion systems. With detailed coverage and extensive references, Heat Transfer in Industrial Combustion fills this void.

Features

Author Notes

Charles E. Baukal, Jr., Ph.D., P.E., is the Director of the John Zink Company LLC R and D Test Center in Tulsa, OK. He has 20 years of experience in the fields of heat transfer and industrial combustion and has authored more than 50 publications in those fields, including editing the book Oxygen-Enhanced Combustion (CRC Press, Boca Raton, FL, 1998). He has a Ph.D. in mechanical engineering from the University of Pennsylvania, is a licensed Professional Engineer in the state of Pennsylvania, has been an adjunct instructor at several colleges, and has eight U.S. patents.

Chapter 1 Introduction
1.1 Importance of Heat Transfer in Industrial Combustion	p. 1
1.1.1 Energy Consumption	p. 1
1.1.2 Research Needs	p. 1
1.2 Literature Discussion	p. 6
1.2.1 Heat Transfer	p. 6
1.2.2 Combustion	p. 7
1.2.3 Heat Transfer and Combustion	p. 7
1.3 Combustion System Components	p. 8
1.3.1 Burners	p. 8
1.3.1.1 Competing Priorities	p. 9
1.3.1.2 Design Factors	p. 10
1.3.1.3 General Burner Types	p. 13
1.3.2 Combustors	p. 18
1.3.2.1 Design Considerations	p. 18
1.3.2.2 General Classifications	p. 19
1.3.3 Heat Load	p. 21
1.3.3.1 Process Tubes	p. 21
1.3.3.2 Moving Substrate	p. 21
1.3.3.3 Opaque Materials	p. 22
1.3.3.4 Transparent Materials	p. 22
1.3.4 Heat Recovery Devices	p. 23
1.3.4.1 Recuperators	p. 23
1.3.4.2 Regenerators	p. 23
References	p. 24
Chapter 2 Some Fundamentals of Combustion
2.1 Combustion Chemistry	p. 29
2.1.1 Fuel Properties	p. 29
2.1.2 Oxidizer Composition	p. 30
2.1.3 Mixture Ratio	p. 30
2.1.4 Operating Regimes	p. 33
2.2 Combustion Properties	p. 34
2.2.1 Combustion Products	p. 34
2.2.1.1 Oxidizer Composition	p. 34
2.2.1.2 Mixture Ratio	p. 37
2.2.1.3 Air and Fuel Preheat Temperature	p. 38
2.2.1.4 Fuel Composition	p. 40
2.2.2 Flame Temperature	p. 40
2.2.2.1 Oxidizer and Fuel Composition	p. 40
2.2.2.2 Mixture Ratio	p. 41
2.2.2.3 Oxidizer and Fuel Preheat Temperature	p. 43
2.2.3 Available Heat	p. 43
2.2.4 Flue Gas Volume	p. 46
2.3 Exhaust Product Transport Properties	p. 48
2.3.1 Density	p. 49
2.3.2 Specific Heat	p. 51
2.3.3 Thermal Conductivity	p. 53
2.3.4 Viscosity	p. 55
2.3.5 Prandtl Number	p. 58
2.3.6 Lewis Number	p. 60
References	p. 64
Chapter 3 Heat Transfer Modes
3.1 Introduction	p. 65
3.2 Convection	p. 65
3.2.1 Forced Convection	p. 66
3.2.1.1 Forced Convection from Flames	p. 66
3.2.1.2 Forced Convection from Outside Combustor Wall	p. 68
3.2.1.3 Forced Convection from Hot Gases to Tubes	p. 68
3.2.2 Natural Convection	p. 68
3.2.2.1 Natural Convection from Flames	p. 68
3.2.2.2 Natural Convection from Outside Combustor Wall	p. 69
3.3 Radiation	p. 69
3.3.1 Surface Radiation	p. 72
3.3.2 Nonluminous Radiation	p. 82
3.3.2.1 Theory	p. 82
3.3.2.2 Combustion Studies	p. 90
3.3.3 Luminous Radiation	p. 102
3.3.3.1 Theory	p. 102
3.3.3.2 Combustion Studies	p. 105
3.4 Conduction	p. 109
3.4.1 Steady-State Conduction	p. 110
3.4.2 Transient Conduction	p. 113
3.5 Phase Change	p. 114
3.5.1 Melting	p. 114
3.5.2 Boiling	p. 114
3.5.2.1 Internal Boiling	p. 116
3.5.2.2 External Boiling	p. 116
3.5.3 Condensation	p. 117
References	p. 117
Chapter 4 Heat Sources and Sinks
4.1 Heat Sources	p. 123
4.1.1 Combustibles	p. 123
4.1.1.1 Fuel Combustion	p. 123
4.1.1.2 Volatile Combustion	p. 123
4.1.2 Thermochemical Heat Release	p. 124
4.1.2.1 Equilibrium TCHR	p. 126
4.1.2.2 Catalytic TCHR	p. 127
4.1.2.3 Mixed TCHR	p. 127
4.2 Heat Sinks	p. 127
4.2.1 Load	p. 128
4.2.1.1 Tubes	p. 128
4.2.1.2 Substrate	p. 129
4.2.1.3 Granular Solid	p. 129
4.2.1.4 Molten Liquid	p. 131
4.2.1.5 Surface Conditions	p. 132
4.2.2 Wall Losses	p. 140
4.2.3 Openings	p. 143
4.2.3.1 Radiation	p. 143
4.2.3.2 Gas Flow Through Openings	p. 143
4.2.4 Material Transport	p. 145
References	p. 145
Chapter 5 Computer Modeling
5.1 Combustion Modeling	p. 149
5.2 Modeling Approaches	p. 150
5.2.1 Fluid Dynamics	p. 151
5.2.1.1 Moment Averaging	p. 151
5.2.1.2 Vortex Methods	p. 152
5.2.1.3 Spectral Methods	p. 152
5.2.1.4 Direct Numerical Simulation	p. 153
5.2.2 Geometry	p. 153
5.2.2.1 Zero-Dimensional Modeling	p. 153
5.2.2.2 One-Dimensional Modeling	p. 153
5.2.2.3 Multi-dimensional Modeling	p. 154
5.2.3 Reaction Chemistry	p. 154
5.2.3.1 Nonreacting Flows	p. 155
5.2.3.2 Simplified Chemistry	p. 155
5.2.3.3 Complex Chemistry	p. 156
5.2.4 Radiation	p. 156
5.2.4.1 Nonradiating	p. 156
5.2.4.2 Participating Media	p. 157
5.2.5 Time Dependence	p. 158
5.2.5.1 Steady State	p. 158
5.2.5.2 Transient	p. 158
5.3 Simplified Models	p. 159
5.4 Computational Fluid Dynamic Modeling	p. 159
5.4.1 Increasing Popularity of CFD	p. 159
5.4.2 Potential Problems of CFD	p. 161
5.4.3 Equations	p. 162
5.4.3.1 Fluid Dynamics	p. 162
5.4.3.2 Heat Transfer	p. 164
5.4.3.3 Chemistry	p. 169
5.4.3.4 Multiple Phases	p. 170
5.4.4 Boundary and Initial Conditions	p. 171
5.4.4.1 Inlets and Outlets	p. 172
5.4.4.2 Surfaces	p. 172
5.4.4.3 Symmetry	p. 172
5.4.5 Discretization	p. 173
5.4.5.1 Finite Difference Technique	p. 173
5.4.5.2 Finite Volume Technique	p. 174
5.4.5.3 Finite Element Technique	p. 175
5.4.5.4 Mixed	p. 175
5.4.5.5 None	p. 175
5.4.6 Solution Methods	p. 175
5.4.7 Model Validation	p. 176
5.4.8 Industrial Combustion Examples	p. 177
5.4.8.1 Modeling Burners	p. 177
5.4.8.2 Modeling Combustors	p. 178
References	p. 181
Chapter 6 Experimental Techniques
6.1 Introduction	p. 195
6.2 Heat Flux	p. 195
6.2.1 Total Heat Flux	p. 195
6.2.1.1 Steady-State Uncooled Solids	p. 196
6.2.1.2 Steady-State Cooled Solids	p. 196
6.2.1.3 Steady-State Cooled Gages	p. 197
6.2.1.4 Transient Uncooled Targets	p. 198
6.2.1.5 Transient Uncooled Gages	p. 198
6.2.2 Radiant Heat Flux	p. 200
6.2.2.1 Heat Flux Gage	p. 200
6.2.2.2 Ellipsoidal Radiometer	p. 203
6.2.2.3 Spectral Radiometer	p. 204
6.2.2.4 Other Techniques	p. 204
6.2.3 Convective Heat Flux	p. 206
6.3 Temperature	p. 207
6.3.1 Gas Temperature	p. 207
6.3.1.1 Suction Pyrometer	p. 207
6.3.1.2 Optical Techniques	p. 209
6.3.1.3 Fine Wire Thermocouples	p. 209
6.3.1.4 Line Reversal	p. 213
6.3.2 Surface Temperature	p. 213
6.3.2.1 Embedded Thermocouple	p. 213
6.3.2.2 Infrared Detectors	p. 214
6.4 Gas Flow	p. 216
6.4.1 Gas Velocity	p. 216
6.4.1.1 Pitot Tubes	p. 216
6.4.1.2 Laser Doppler Velocimetry	p. 218
6.4.1.3 Other Techniques	p. 219
6.4.2 Static Pressure Distribution	p. 219
6.4.2.1 Stagnation Velocity Gradient	p. 219
6.4.2.2 Stagnation Zone	p. 220
6.5 Gas Species	p. 221
6.6 Other Measurements	p. 221
6.7 Physical Modeling	p. 223
References	p. 223
Chapter 7 Flame Impingement
7.1 Introduction	p. 231
7.2 Experimental Conditions	p. 233
7.2.1 Configurations	p. 234
7.2.1.1 Flame Normal to a Cylinder in Crossflow	p. 235
7.2.1.2 Flame Normal to a Hemispherically Nosed Cylinder	p. 236
7.2.1.3 Flame Normal to a Plane Surface	p. 236
7.2.1.4 Flame Parallel to a Plane Surface	p. 238
7.2.2 Operating Conditions	p. 238
7.2.2.1 Oxidizers	p. 238
7.2.2.2 Fuels	p. 240
7.2.2.3 Equivalence Ratios	p. 240
7.2.2.4 Firing Rates	p. 243
7.2.2.5 Reynolds Number	p. 243
7.2.2.6 Burners	p. 243
7.2.2.7 Nozzle Diameter	p. 246
7.2.2.8 Location	p. 246
7.2.3 Stagnation Targets	p. 246
7.2.3.1 Size	p. 247
7.2.3.2 Target Materials	p. 248
7.2.3.3 Surface Preparation	p. 248
7.2.3.4 Surface Temperatures	p. 250
7.2.4 Measurements	p. 250
7.3 Semianalytical Heat Transfer Solutions	p. 250
7.3.1 Equation Parameters	p. 257
7.3.1.1 Thermophysical Properties	p. 258
7.3.1.2 Stagnation Velocity Gradient	p. 261
7.3.2 Equations	p. 263
7.3.2.1 Sibulkin Results	p. 263
7.3.2.2 Fay and Riddell Results	p. 263
7.3.2.3 Rosner Results	p. 264
7.3.3 Comparisons With Experiments	p. 264
7.3.3.1 Forced Convection (Negligible TCHR)	p. 264
7.3.3.2 Forced Convection with TCHR	p. 266
7.3.4 Sample Calculations	p. 268
7.3.4.1 Laminar Flames Without TCHR	p. 268
7.3.4.2 Turbulent Flames Without TCHR	p. 269
7.3.4.2 Laminar Flames with TCHR	p. 270
7.3.5 Summary	p. 270
7.4 Empirical Heat Transfer Correlations	p. 271
7.4.1 Thermophysical Properties	p. 272
7.4.2 Flames Impinging Normal to a Cylinder	p. 272
7.4.2.1 Local Convection Heat Transfer	p. 273
7.4.2.2 Average Convection Heat Transfer	p. 273
7.4.2.3 Average Convection Heat Transfer with TCHR	p. 274
7.4.2.4 Average Radiation Heat Transfer	p. 274
7.4.2.5 Maximum Convection and Radiation Heat Transfer	p. 275
7.4.3 Flames Impining Normal to a Hemi-Nosed Cylinder	p. 275
7.4.3.1 Local Convection Heat Transfer	p. 275
7.4.3.2 Local Convection Heat Transfer with TCHR	p. 276
7.4.4 Flames Impinging Normal to a Plane Surface	p. 276
7.4.4.1 Local Convection Heat Transfer	p. 276
7.4.4.2 Local Convection Heat Transfer with TCHR	p. 279
7.4.4.3 Average Convection Heat Transfer	p. 279
7.4.5 Flames Parallel to a Plane Surface	p. 280
7.4.5.1 Local Convection Heat Transfer With TCHR	p. 280
7.4.5.2 Local Convection and Radiation Heat Transfer	p. 281
References	p. 281
Chapter 8 Heat Transfer from Burners
8.1 Introduction	p. 285
8.2 Open-Flame Burners	p. 285
8.2.1 Momentum Effects	p. 285
8.2.2 Flame Luminosity	p. 285
8.2.3 Firing Rate Effects	p. 287
8.2.4 Flame Shape Effects	p. 292
8.3 Radiant Burners	p. 296
8.3.1 Perforated Ceramic or Wire Mesh Radiant Burners	p. 300
8.3.2 Flame Impingement Radiant Burners	p. 301
8.3.3 Porous Refractory Radiant Burners	p. 302
8.3.4 Advanced Ceramic Radiant Burners	p. 307
8.3.5 Radiant Wall Burners	p. 311
8.3.6 Radiant Tube Burners	p. 311
8.4 Effects on Heat Transfer	p. 316
8.4.1 Fuel Effects	p. 316
8.4.1.1 Solid Fuels	p. 316
8.4.1.2 Liquid Fuels	p. 316
8.4.1.3 Gaseous Fuels	p. 316
8.4.1.4 Fuel Temperature	p. 317
8.4.2 Oxidizer Effects	p. 318
8.4.2.1 Oxidizer Composition	p. 318
8.4.2.2 Oxidizer Temperature	p. 318
8.4.3 Staging Effects	p. 320
8.4.3.1 Fuel Staging	p. 321
8.4.3.2 Oxidizer Staging	p. 322
8.4.4 Burner Orientation	p. 322
8.4.4.1 Hearth-Fired Burners	p. 323
8.4.4.2 Wall-Fired Burners	p. 324
8.4.4.3 Roof-Fired Burners	p. 325
8.4.4.4 Side-Fired Burners	p. 326
8.4.5 Heat Recuperation	p. 326
8.4.5.1 Regenerative Burners	p. 327
8.4.5.2 Recuperative Burners	p. 329
8.4.5.3 Furnace or Flue Gas Recirculation	p. 331
8.4.6 Pulse Combustion	p. 331
8.5 In-Flame Treatment	p. 335
References	p. 337
Chapter 9 Heat Transfer in Furnaces
9.1 Introduction	p. 345
9.2 Furnaces	p. 346
9.2.1 Firing Method	p. 347
9.2.1.1 Direct Firing	p. 347
9.2.1.2 Indirect Firing	p. 347
9.2.1.3 Heat Distribution	p. 349
9.2.2 Load Processing Method	p. 351
9.2.2.1 Batch Processing	p. 351
9.2.2.2 Continuous Processing	p. 351
9.2.2.3 Hybrid Processing	p. 352
9.2.3 Heat Transfer Medium	p. 352
9.2.3.1 Gaseous Medium	p. 352
9.2.3.2 Vacuum	p. 353
9.2.3.3 Liquid Medium	p. 353
9.2.3.4 Solid Medium	p. 354
9.2.4 Geometry	p. 354
9.2.4.1 Rotary Geometry	p. 355
9.2.4.2 Rectangular Geometry	p. 358
9.2.4.3 Ladle Geometry	p. 358
9.2.4.4 Vertical Cylindrical Geometry	p. 360
9.2.5 Furnace Types	p. 360
9.2.5.1 Reverberatory Furnace	p. 360
9.2.5.2 Shaft Kiln	p. 362
9.2.5.3 Rotary Furnace	p. 362
9.3 Heat Recovery	p. 363
9.3.1 Recuperators	p. 364
9.3.2 Regenerators	p. 364
9.3.3 Gas Recirculation	p. 366
9.3.3.1 Flue Gas Recirculation	p. 366
9.3.3.2 Furnace Gas Recirculation	p. 366
References	p. 367
Chapter 10 Lower Temperature Applications
10.1 Introduction	p. 369
10.2 Ovens and Dryers	p. 369
10.2.1 Predryer	p. 369
10.2.2 Dryer	p. 372
10.3 Fired Heaters	p. 375
10.3.1 Reformer	p. 376
10.3.2 Process Heater	p. 378
10.4 Heat Treating	p. 384
10.4.1 Standard Atmosphere	p. 387
10.4.2 Special Atmosphere	p. 387
References	p. 391
Chapter 11 Higher Temperature Applications
11.1 Introduction	p. 395
11.1.1 Furnaces	p. 395
11.1.2 Industries	p. 395
11.2 Metals Industry	p. 396
11.2.1 Ferrous Metal Production	p. 396
11.2.1.1 Electric Arc Furnace	p. 396
11.2.1.2 Smelting	p. 399
11.2.1.3 Ladle Preheating	p. 399
11.2.1.4 Reheating Furnace	p. 402
11.2.1.5 Forging	p. 407
11.2.2 Aluminum Metal Production	p. 408
11.3 Minerals Industry	p. 410
11.3.1 Glass	p. 411
11.3.1.1 Types of Traditional Glass-Melting Furnaces	p. 412
11.3.1.2 Unit Melter	p. 412
11.3.1.3 Recuperative Melter	p. 412
11.3.1.4 Regenerative or Siemens Furnace	p. 412
11.3.1.5 Oxygen-Enhanced Combustion for Glass Production	p. 414
11.3.1.6 Advanced Techniques for Glass Production	p. 416
11.3.2 Cement and Lime	p. 417
11.3.3 Bricks, Refractories, and Ceramics	p. 419
11.4 Waste Incineration	p. 419
11.4.1 Types of Incinerators	p. 422
11.4.1.1 Municipal Waste Incinerators	p. 422
11.4.1.2 Sludge Incinerators	p. 423
11.4.1.3 Mobile Incinerators	p. 424
11.4.1.4 Transportable Incinerators	p. 425
11.4.1.5 Fixed Hazardous Waste Incinerators	p. 425
11.4.2 Heat Transfer in Waste Incineration	p. 426
References	p. 428
Chapter 12 Advanced Combustion Systems
12.1 Introduction	p. 433
12.2 Oxygen-Enhanced Combustion	p. 433
12.2.1 Typical Use Methods	p. 434
12.2.1.1 Air Enrichment	p. 434
12.2.1.2 O[subscript 2] Lancing	p. 435
12.2.1.3 Oxy/Fuel	p. 435
12.2.1.4 Air-Oxy/Fuel	p. 436
12.2.2 Operating Regimes	p. 437
12.2.3 Heat Transfer Benefits	p. 437
12.2.3.1 Increased Productivity	p. 437
12.2.3.2 Higher Thermal Efficiencies	p. 438
12.2.3.3. Higher Heat Transfer Efficiency	p. 438
12.2.3.4 Increased Flexibility	p. 438
12.2.4 Potential Heat Transfer Problems	p. 439
12.2.4.1 Refractory Damage	p. 439
12.2.4.2 Nonuniform Heating	p. 440
12.2.5 Industrial Heating Applications	p. 440
12.2.5.1 Metals	p. 440
12.2.5.2 Minerals	p. 440
12.2.5.3 Incineration	p. 441
12.2.5.4 Other	p. 441
12.3 Submerged Combustion	p. 441
12.3.1 Metals Production	p. 441
12.3.2 Minerals Production	p. 443
12.3.3 Liquid Heating	p. 444
12.4 Miscellaneous	p. 444
12.4.1 Surface Combustor-Heater	p. 445
12.4.2 Direct-Fired Cylinder Dryer	p. 445
References	p. 446
Appendices
Appendix A Reference Sources for Further Information	p. 449
Appendix B Common Conversions	p. 451
Appendix C Methods of Expressing Mixture Ratios for CH[subscript 4], C[subscript 3]H[subscript 8], and H[subscript 2]	p. 453
Appendix D Properties for CH[subscript 4], C[subscript 3]H[subscript 8], and H[subscript 2] Flames	p. 459
Appendix E Fluid Dynamics Equations	p. 497
Appendix F Material Properties	p. 501
Author Index	p. 521
Subject Index	p. 535

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