High tempreature air combustion : from energy conservation to pollution reduction

Title:

Series:

Environmental and energy engineering series

Publication Information:

Boca Raton, Fla. : CRC Press, 2003

ISBN:

9780849310362

Subject Term:

Combustion engineering

Environmental protection

Added Author:

Tsuji, Hiroshi

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Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
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Maximize efficiency and minimize pollution: the breakthrough technology of high temperature air combustion (HiTAC) holds the potential to overcome the limitations of conventional combustion and allow engineers to finally meet this long-standing imperative. Research has shown that HiTAC technology can provide simultaneous reduction of CO2 and nitric oxide emissions and reduce energy consumption for a specific process or requirement.

High Temperature Air Combustion: From Energy Conservation to Pollution Reduction provides the first comprehensive exposition of the principles and practice of HiTAC. With a careful balance of theory and practice, it reviews the historical background, clearly describes HiTAC combustion phenomena, and shows how to simulate and apply the technology for significant energy savings, reduced equipment size, and lower emissions. It offers design guidelines for high performance industrial furnaces, presents field trials of practical furnaces, and explores potential applications of HiTAC in other fields, including the conversion of solid waste fuels to cleaner fuels, stationary gas turbine engines, internal combustion engines, and other advanced energy-to-power conversion systems.

Developed through an intensive research project sponsored by the Japanese government, HiTAC now promises to revolutionize our paradigm for using all kinds of fossil, alternative, waste, and derived fuels for energy conversion and utilization in industry. This book is your opportunity to understand its principles, learn about the technology, and begin to use it to the benefit of your application, your company, and the environment.

Author Notes

Tsuji, Hiroshi; Gupta, Ashwani K.; Hasegawa, Toshiaki; Katsuki, Masashi; Kishimoto, Ken; Morita, Mitsunobu

Chapter 1 Introduction	p. 1
1.1 Historical Background of High Temperature Air Combustion	p. 1
1.1.1 Environment and Energy Conservation	p. 1
1.1.2 Reduction of Pollutant Emissions and Energy Crisis	p. 2
1.1.3 Panorama of High Temperature Air Combustion Technology	p. 4
1.2 Innovation of High Temperature Air Combustion	p. 6
1.2.1 Fundamentals of Combustion	p. 6
1.2.1.1 Heat Recirculating Combustion	p. 6
1.2.1.2 Definition of High Temperature Air	p. 10
1.2.1.3 Heat Recirculation and Exhaust Gas Recirculation	p. 10
1.2.2 Principle of Combustion Control for CO[subscript 2] and NO[subscript x] Reduction	p. 13
1.2.2.1 Carbon Dioxide	p. 13
1.2.2.2 Nitric Oxides	p. 15
1.2.3 Heat Transfer in High Temperature Air Combustion	p. 17
1.2.3.1 Convection Heat Transfer of High Temperature Air Combustion	p. 18
1.2.3.2 Radiant Heat Transfer of High Temperature Air Combustion	p. 20
1.2.3.3 Effect of Wall as Wavelength Conversion Body in High Temperature Air Combustion	p. 21
1.2.4 Thermodynamics of High Temperature Air Combustion	p. 23
References	p. 28
Chapter 2 Combustion Phenomena of High Temperature Air Combustion	p. 29
2.1 Introduction	p. 29
2.2 Flame Features	p. 30
2.2.1 Flame Stability	p. 30
2.2.1.1 Temperature Profiles	p. 32
2.2.1.2 Influence on NO[subscript x] Emissions	p. 34
2.2.2 Thermal Field Behavior	p. 34
2.2.2.1 350 kW-Scale Combustion Test	p. 34
2.2.2.2 Cold Flow Model Test	p. 34
2.2.2.3 Temperature Profiles	p. 36
2.2.2.4 Flow Patterns	p. 38
2.2.3 Flame Structure, Radicals, and Species	p. 39
2.2.3.1 Experimental Furnace for Optical Measuring	p. 39
2.2.3.2 Combustion Conditions	p. 39
2.2.3.3 Optical Measurement Results	p. 42
2.2.3.4 Summary	p. 48
2.2.4 Flame with Heat and Combustion Products Recirculation	p. 49
2.2.4.1 Improved Heating Method	p. 49
2.2.4.1.1 Heat and Combustion Product Recirculation	p. 49
2.2.4.2 Heat Balance in the System	p. 50
2.2.4.2.1 Gross Heat Input	p. 50
2.2.4.2.2 Heat Transfer in Furnace	p. 51
2.2.4.2.3 Heat Output	p. 53
2.2.4.2.4 Equation Arrangement	p. 53
2.2.4.3 Calculation Results	p. 53
2.2.4.3.1 Effect of Gas Recirculation	p. 53
2.2.4.3.2 Heat and Gas Recirculation	p. 54
2.2.4.3.3 Thermal Efficiency	p. 57
2.2.4.4 Discussion	p. 57
2.2.4.5 Summary	p. 60
2.3 Fundamentals of Gaseous Fuel Flames	p. 60
2.3.1 Extinction Limit and No[subscript x] in Laminar Diffusion Flame	p. 60
2.3.1.1 Experimental Apparatus	p. 61
2.3.1.2 Velocity Field and Temperature Field	p. 62
2.3.1.3 Extinction and Re-ignition Temperatures of Laminar Diffusion Flame	p. 64
2.3.1.4 Distributions of Temperature and Concentrations of Species	p. 66
2.3.1.5 Effect of Flame Temperature on NO[subscript x] Formation	p. 68
2.3.1.6 Relationship between Flame Temperature and the Critical Velocity Gradient	p. 69
2.3.1.7 Summary	p. 70
2.3.2 Burning Velocity	p. 71
2.3.2.1 Simulation Model	p. 71
2.3.2.2 Simulation Results and Discussion	p. 72
2.3.2.2.1 Preheated but Not Diluted Premixed Flames	p. 72
2.3.2.2.2 Preheated and Diluted Premixed Flames	p. 73
2.3.2.2.3 Fuel Flux	p. 74
2.3.2.2.4 NO Formation	p. 75
2.3.2.3 Summary	p. 78
2.3.3 Mixing in Furnace	p. 79
2.3.3.1 Jet Mixing	p. 79
2.3.3.2 Unmixedness	p. 83
2.3.3.3 Well-Stirred Reactor	p. 85
2.3.4 Pollutant Formation	p. 86
2.3.4.1 Nitric Oxides	p. 86
2.3.5 Pollutant Formation and Emission	p. 90
2.3.5.1 Calculation Method	p. 91
2.3.5.2 Results and Discussion	p. 91
Ignition of O = 5 Mixture	p. 91
Ignition of O = 2 Mixture	p. 98
Summary	p. 100
2.3.6 Radiation	p. 100
2.4 Fundamentals of Liquid Fuel Flames	p. 107
2.4.1 Liquid Fuel Flame Characteristics and Stability	p. 107
2.4.1.1 Experimental Apparatus	p. 107
2.4.1.1.1 Spraying Device	p. 107
2.4.1.1.2 Combustion Device	p. 108
2.4.1.1.3 Spray Nozzle	p. 108
2.4.1.2 Experimental Method	p. 109
2.4.1.2.1 Air Preheating	p. 109
2.4.1.2.2 Spray Pressure	p. 111
2.4.1.2.3 Spraying Method	p. 111
2.4.1.2.4 Measurement of Flame	p. 112
2.4.1.3 Experimental Results	p. 112
2.4.1.3.1 Temperature of Blowout	p. 112
2.4.1.3.2 Flame Form and Flame Color	p. 113
2.4.1.4 Discussions	p. 114
2.4.1.4.1 Blowout of Flame	p. 114
2.4.1.4.2 Changes in Flame Form and Flame Color	p. 115
2.4.1.4.3 Spray Combustion in the High Temperature Preheated Diluted Air	p. 117
2.4.1.5 Summary	p. 117
2.4.2 Emissions in Liquid Fuel Flame	p. 117
2.4.2.1 Emissions on Liquid Fuel Combustion	p. 117
2.5 Fundamentals of Solid Fuel Flames	p. 118
2.5.1 Solid Fuel Flame Characteristics	p. 118
2.5.2 Combustion Process of Coal	p. 121
2.5.2.1 Properties of Coal	p. 122
2.5.2.2 Combustion Phenomena around Particles	p. 123
2.5.2.3 Combustion Phenomena inside a Particle	p. 126
2.5.2.4 Final Stage of Combustion	p. 126
2.5.2.5 Combustion Behavior of Coal at Synthetic Air Condition of High Temperature	p. 127
2.5.2.6 Summary	p. 130
2.5.3 Emissions in Solid Fuel Flames	p. 130
2.5.3.1 The Furnace Setup	p. 131
2.5.3.2 Fuel Properties (Natural Gas/Coal)	p. 133
2.5.3.3 Experimental Program	p. 133
2.5.3.4 In-Flame Measurements	p. 135
2.5.3.4.1 Heat and Mass Balance	p. 136
2.5.3.4.2 Gas Composition	p. 136
2.5.3.4.3 Temperature Measurements	p. 138
2.5.3.4.4 Velocity Measurements	p. 139
2.5.3.4.5 Burnout	p. 141
2.5.3.4.6 Solid Concentration	p. 142
2.5.3.4.7 Total Radiative Heat Flux	p. 145
2.5.3.4.8 Total Radiance	p. 146
2.5.3.5 Input/Output Measurements	p. 148
2.5.3.5.1 Coal Gun Position	p. 150
2.5.3.5.2 Coal Transport Air Mass Flow	p. 152
2.5.3.5.3 Precombustor NO[subscript x] Level	p. 155
2.5.3.6 Summary	p. 156
2.5.4 Combustion Rate of Solid Carbon	p. 157
2.5.4.1 Combustion Field and Solid Carbon Specimens	p. 158
2.5.4.2 Experimental Results	p. 159
2.5.4.3 Combustion Rate in Room Temperature Airflow	p. 159
2.5.4.4 Combustion Rate in High Temperature Airflow	p. 160
2.5.4.5 Dynamic Analysis of Reactive Gas	p. 161
2.5.4.5.1 Combustion Rate	p. 161
2.5.4.6 Lower Limit of Oxygen Concentration	p. 163
2.5.4.7 Surface Temperature When a CO Flame Is Formed	p. 166
2.5.4.8 Combustion Rate in High Temperature Airflow	p. 166
2.5.4.9 Summary	p. 168
References	p. 168
Chapter 3 Simulation Models for High Temperature Air Combustion	p. 171
3.1 Present State of Combustion Simulation in Furnaces	p. 171
3.1.1 Introduction	p. 171
3.1.2 Problems of Existing Combustion Models	p. 172
3.1.2.1 Arrhenius Type One-Step Global Reaction Model	p. 172
3.1.2.2 Mixing-Is-Reacted Model	p. 173
3.1.2.3 Eddy-Break-Up Model	p. 174
3.1.2.4 Problems in Temperature Calculation	p. 176
3.2 Combustion Model for High Temperature Air Combustion	p. 176
3.2.1 Characteristics of High Temperature Air Combustion	p. 176
3.2.2 Proposed Improvements	p. 177
3.2.3 Temperature Correction for Thermal Dissociation	p. 178
3.2.4 Reaction Model for High Temperature Air Combustion	p. 182
3.2.4.1 One-Step Global Reaction Model (Coffee)	p. 182
3.2.4.2 Four-Step Reaction Model (Jones and Lindstedt)	p. 183
3.2.4.3 Four-Step Reaction Model (Srivatsa)	p. 184
3.2.5 Comparison of Reaction Models	p. 185
3.2.5.1 Comparison of Flame Lifted Height by Different Reaction Models	p. 186
3.2.5.2 Comparison of Maximum Flame Temperature by Different Reaction Models	p. 188
3.2.5.3 Influence of Jet Velocity on Flame Lift Height	p. 188
3.3 Heat Transfer Model for High Temperature Air Combustion	p. 190
3.3.1 Heat Transfer Models	p. 190
3.3.1.1 Gray Model	p. 190
3.3.1.2 Weighted-Sum-of-Gray-Gases Model	p. 192
3.3.1.3 Nongray Models	p. 194
3.3.2 Radiative Heat Transfer Using Nongray Property of Radiation	p. 195
3.4 Examples of Practical Application	p. 197
3.4.1 Nitric Oxide Emission	p. 198
3.4.1.1 Thermal NO	p. 198
3.4.1.2 Prompt NO	p. 199
3.4.1.3 NO Reduction Mechanism (Reburning)	p. 199
3.4.1.4 Results and Discussion	p. 201
3.4.2 Transient Behavior of Furnaces	p. 202
3.4.2.1 Fluid Dynamics Model	p. 202
3.4.2.2 Radiation Heat Transfer Model	p. 203
3.4.2.3 Combustion Model	p. 204
3.4.2.4 Temperature Distribution during Fuel Changeover	p. 205
3.4.2.5 Comparison with Measured Temperatures by Suction Pyrometer	p. 206
3.4.2.6 Calculation on Wide Regenerative Furnace	p. 207
References	p. 208
Chapter 4 Practical Combustion Methods Used in Industries	p. 211
4.1 Historical Transition of Industrial Furnace Technologies	p. 211
4.1.1 Energy Technologies Discussed at COP3	p. 211
4.1.2 Conventional Technologies of Energy Saving and Combustion Control for Industrial Furnaces	p. 215
4.1.3 Development of High Performance Industrial Furnaces	p. 219
4.2 Energy Conservation	p. 230
4.2.1 Basic Approach	p. 230
4.2.2 Effect of Improvement	p. 230
4.3 Pollution Reduction	p. 235
4.3.1 Basic Concept of Low NO[subscript x] Combustion	p. 235
4.3.2 Results of the Test	p. 237
4.3.3 Pollution Reduction	p. 238
References	p. 241
Chapter 5 Design Guidelines for High Performance Industrial Furnaces	p. 243
5.1 Flowchart on General Design	p. 243
5.1.1 Design Concept of a High Performance Industrial Furnace	p. 243
5.1.2 Optimal Design for Furnace Length and Height	p. 243
5.1.3 Optimal Design for Other Furnace Configuration	p. 248
5.1.3.1 Pitch and Capacity of Burner	p. 248
5.1.3.2 Partition Wall	p. 248
5.1.3.3 Analytical Study of the Effect of a Partition Wall	p. 249
5.1.3.4 Lower Part of Furnace	p. 251
5.1.3.5 Furnace Width and Maximum Combustion Capacity	p. 262
5.2 Heat Balance and Performance Estimation with Simulation Program	p. 263
5.2.1 Outline of Simulation Program	p. 263
5.2.2 Basic Functions of the Simulator	p. 265
5.2.2.1 Estimation Method of Fuel Flow Volume and Exhaust Gas Temperatures Using Heat Balance	p. 266
5.2.2.2 Calculation Method of the Internal Temperature of the Semifinished Steel	p. 266
5.2.3 Calculation of Preheated Air Temperatures and Exhaust Gas Temperatures after Heat Exchange	p. 269
5.2.4 Radiation Heat from the Furnace Body and Heat Loss by Cooling Water	p. 269
5.2.5 Outlines of System Operation Method and Simulation Result	p. 271
5.2.6 Comparison of Calculation and Measurement	p. 271
5.2.7 Effect of Fuel Calorific Value on the Fuel Consumption of Reheating Furnaces	p. 272
5.3 Combustion Control System	p. 280
5.3.1 Basic Combustion Control System for Stable Operation	p. 284
5.3.2 Signal Processing Method	p. 287
5.3.3 Disturbance Suppression Control of Door Open and Close	p. 292
5.3.4 Future Trends of Combustion Control Technology Using High Temperature Air Combustion	p. 295
5.4 Application Design of High Performance Furnace	p. 296
5.4.1 Reheating Furnace	p. 296
5.4.1.1 Specifications and Performance of Facility	p. 297
5.4.1.2 Detailed Specifications of Facility	p. 301
5.4.1.3 Attachments	p. 302
5.4.2 Billet Reheating	p. 305
5.4.3 Heat Treatment Furnace	p. 307
5.4.3.1 Heat Balance and Evaluation Method of Furnace Performance	p. 308
5.4.3.2 Furnace Scale-Up for Commercial Production	p. 312
5.4.3.3 Test Design of Heat Treatment Furnace	p. 314
5.4.4 Melting Furnace	p. 320
5.4.4.1 Energy Savings and Exhaust Gas Regulation	p. 320
5.4.4.2 Size Reduction	p. 322
5.4.4.3 Method of Improving the Heat Transfer Efficiency inside the Furnace	p. 324
5.4.4.4 A Design Example of High Performance Aluminum-Melting Furnace	p. 325
5.5 Field Trials and Experiences Obtained through Field Test Demonstration Project	p. 327
5.5.1 Outline of the Field Test Project	p. 328
5.5.2 Applications for the Field Test in Fiscal Years 1998 and 1999	p. 328
5.5.3 Characteristic Aspects of the 1998 Field Test Project	p. 333
5.5.4 Effects of Modifications in the Field Tests	p. 334
5.5.5 Summary	p. 337
References	p. 339
Chapter 6 Potential Applications of High Temperature Air Combustion Technology to Other Systems	p. 341
6.1 Introduction	p. 341
6.2 Combustion of Wastes and Solid Fuels	p. 344
6.2.1 Formation of Dioxins and Furans	p. 350
6.2.1.1 Refuse (or Waste) Derived Fuel	p. 350
6.2.1.2 Applied Technology for RDF	p. 351
6.2.1.3 Changes in the Calorific Value of Municipal Wastes	p. 351
6.2.1.4 Problems with Waste Derived Fuel Production and Combustion	p. 352
6.3 Burning of Coals and Lowgrade Coals	p. 353
6.4 Volatile Organic Compounds	p. 354
6.5 Ash Melting	p. 354
6.6 Compact Boilers	p. 355
6.7 Gas Turbine Combustion, Micro Gas Turbines, and Independent Power Production	p. 355
6.8 Paints, Oily Wastes, and Heavy Fuel Oils	p. 356
6.9 Fuel Cells	p. 356
Example 1	p. 357
6.10 High Temperature Air Combustion Using Pure Oxygen	p. 358
6.11 Summary	p. 359
References	p. 359
Appendix A Results of Investigations on the Current State of Japanese Industrial Furnaces	p. 361
A.1 Introduction	p. 361
A.2 Items and Methods of Investigation	p. 361
A.3 Results of Investigation	p. 362
A.3.1 Results of the Questionnaire with Users	p. 362
A.3.2 Results of Interview with Users	p. 362
A.3.3 Results of Estimate of Number of Installed Industrial Furnaces and Energy Consumption	p. 364
A.4 Evaluation Based on Results of Investigation	p. 368
A.4.1 Evaluation of Estimated Number of Industrial Furnaces	p. 368
A.4.2 Evaluation of the Presumed Values of Energy Consumption of Industrial Furnaces	p. 371
A.4.3 Consideration of the Results of Interviews--Efficiency of Industrial Furnaces	p. 372
A.5 Effect of Energy Saving by Development of High Performance Industrial Furnaces	p. 373
A.5.1 Assumptions of Calculations	p. 373
A.5.2 Results of the Calculation	p. 376
A.6 Summary	p. 377
References	p. 378
Appendix B Constants and Conversion Factors	p. 379
B.1 Universal Constants and Conversion Factors	p. 379
B.2 Nondimensional Parameters	p. 381
B.3 Nomenclature	p. 382
Index	p. 387

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