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Primary fuels Fuels which occur naturally such as coal, crude petroleum and natural
gas. Coal and crude petroleum, formed from organic matter many millions of years
ago, are referred to as natural or fossil fuels,
Secondary fuels Fuels which are derived from naturally occurring ones by a
treatment process such as coke, gasoline, coal gas etc.
Both primary and secondary fuels may be further classified based upon their physical
state as
[i] solid fuels
UNIT-2
[ii] liquid fuels and
UNIT-2
[iii] gaseous fuels.
UNIT-3
The quality of fuels depends upon the amount of heat liberated per unit quantity of
the fuel (calorific value) and their efficiency in combustion, the nature of the product
of combustion and safe storage
Ref 2.p. 5-13
Table 1.1. Classification of Fuels - Examples
Physical
Natural or
Prepared or secondary
state
primary
Solid
Coal, wood,
Coke, charcoal
peat, lignite,
Liquid
Alcohol, petroleum
Kerosene, gasoline
Gaseous
Natural gas,
hydrogen, methane
Air, O2
Coke, Coal
Air, O2
Special fuels
Ammonium
Nitrocellulose (NC)
perchlorate,
HTPB*, CTPB* ammonium nitrate,
nitrogen tetroxide
*HTPB: Hydroxy terminated poly butadiene
*CTPB: Carboxyl terminated poly butadiene
2.1.1. Rocket fuels
3
Solid propellant,
Rocket fuel,
Hybrid rocket
Ref 2. Page 11-13
These are special fuels known as propellants used to launch rocket engines and
missiles.
(i). Composite propellants
Both fuel and oxidiser are mixed in such a way that each constituent retains its
physical identity.
Eg: polybutadiene, hydroxyl terminated polybutadiene (HTPB), carboxyl terminated
polybutadiene (CTPB). Ammonium perchlorate and ammonium nitrate are some of
the commonly employed oxidisers.
(ii). Double phase propellants
The fuel and oxidiser are the major constituents and mixed in a molecular level.
Nitrocellulose (NC) and nitroglycerine (NG) are examples. Care to be taken during
handling them.
Ref 2. Page 12
2.2. Solid Fuels General Characteristics
Examples:
Wood, coal, charcoal, soft coke, biomass, animal dung etc.
Carbon and hydrogen are the major constituents.
Impurities:
Ash, Nitrogen, oxygen, sulphur and water (moisture).
The moisture in solids can occur in two forms free and bound.
Free water is more in wood and less in the pores of coke.
Bound water is held by physical adsorption.
The moisture content of the fuels affects the rate of combustion and overall efficiency
of the combustion system.
The impurities like N2 and S are converted into NOx and SO2 which pose
environmental hazard.
The inorganic materials present in the solid fuels will remain as residues even after
the fuel combustion (termed as Ash). They affect the performance of the combustion
system, causes corrosion and fouling of boilers and environmental problems in power
plants.
Ref 2.Page 11
2.2. Solid Fuel (Coal)
2.2.1. Solid Fuels Coal properties
Ignition point or Standard Ignition Temperature
It is the minimum temperature at which the fuel ignites in an oxidising atmosphere
without the help of any external source of fire. It is a characteristic property of the
fuel. It depends upon the other factors like the oxidiser, method of heating, nature of
container etc.
Carbonisation
The process carried out by heating the coal out of contact with air at a sufficiently
high temperature, so that the coal undergoes decomposition and yields a residue
which is rich in carbon content than the original fuel.
Gasification
4
The process of converting solid or liquid fuels into gaseous fuels. Carbonisation is
essentially a partial gasification process. In addition to the main gaseous fuel, some
liquid products are also obtained from gasification. The gaseous product may be
directly used as a fuel or as a raw material for the production of chemicals, fertilisers
and liquid fuels.
Ref 1. Page 19
Caking and coking of coal
Producing a lump state from a powdery state is called caking.
When carbonisation is carried out in commercial coke ovens at temp. > 1000 oC, the
resultant product is sufficiently hard called coke, and the process is known as coking
of coal.
The process of caking is general , while the process of coking is specific.
Cracking of coal
The thermal decomposition process carried out with or without a catalyst.
Larger molecules break down into smaller molecules.
Universally practiced in petroleum refining process.
When cracking is done in presence of hydrogen and catalyst, the process is known as
Hydrocracking.
Ref 1. Page 20
2.2.2. Coal classification and properties
Rank of coal.
Coal is classified into four major types namely anthracite, bituminous, lignite and
peat. However, there is no clear demarcation between them.
1. Peat: The initial stage
2. Lignite: soft coal and the youngest
3. Bituminous
4. Anthracite: hard and geologically the oldest.
The process of conversion from lignite to anthracite is known as metamorphism or
coalification. The position of coal in this metamorphic series is its rank or degree of
metamorphism.
Coal is further classified as semi-anthracite, semi-bituminous, and sub-bituminous.
Anthracite is the oldest coal from a geological perspective. It is a hard coal composed
mainly of carbon with little volatile content and practically no moisture.
Lignite is the youngest coal from a geological perspective. It is a soft coal composed
mainly of volatile matter and moisture content with low fixed carbon.
Fixed carbon refers to carbon in its free state, not combined with other elements.
Volatile matter refers to those combustible constituents of coal that vaporize when
coal is heated.
2.3. Coal properties
Physical properties
Heating or calorific value (GCV)
Moisture content
Volatile matter
5
Ash content
Chemical properties
Chemical constituents:
Carbon, hydrogen, oxygen, sulphur
Ref 1. p18-19
The common coals used in for example Indian industry are bituminous and subbituminous coal. The gradation of Indian coal based on its calorific value is as
follows:
Table 2.1. Gradation of coal
Grade
Calorific Value Range Calorific Value
(in kcal/kg)
Range (in kJ/kg)
A
Exceeding 6200
> 26000
B
5600 6200
23500-26000
C
4940 5600
20500-23500
D
4200 4940
17500-20500
E
3360 4200
14000-17500
F
2400 3360
10000-14000
G
1300 2400
5500-10000
Normally D, E and F coal grades are available to Indian industry. The chemical
composition of coal has a strong influence on its combustibility. The properties of
coal are broadly classified as physical properties and chemical properties.
Physical and chemical properties of coal
Physical properties of coal include the heating value, moisture content, volatile matter
and ash. The chemical properties of coal refer to the various elemental chemical
constituents such as carbon, hydrogen, oxygen, and sulphur. The heating value of coal
varies from coal field to coal field. The typical GCVs for various coals are given in
the Table below.
Table 2.2. GCV for various coal types
Parameter
Lignite
Indian Indonesian
South African
(Dry Basis) Coal
Coal
Coal
GCV (kcal/kg)
4500
4000
5500
6000
in kJ/kg
18850
16750
23000
25100
*GCV of lignite on as received basis is 2500 3000 kcal/kg (10500-12500 kJ/kg)
2.4. Analysis of coal
Ref 1. Page 18-19
There are two methods to analyze coal: ultimate analysis and proximate analysis. The
ultimate analysis determines all coal component elements, solid or gaseous and the
proximate analysis determines only the fixed carbon, volatile matter, moisture and
ash percentages. The ultimate analysis is determined in a properly equipped
laboratory by a skilled chemist, while proximate analysis can be determined with a
simple apparatus. (It may be noted that proximate has no connection with the word
approximate).
Measurement of moisture:
The determination of moisture content is carried out by placing a sample of powdered
raw coal of size 200- micron size in an uncovered crucible, which is placed in the
oven kept at 108 +2 oC along with the lid. Then the sample is cooled to room
temperature and weighed again. The loss in weight represents moisture.
Measurement of volatile matter:
A fresh sample of crushed coal is weighed, placed in a covered crucible, and heated
in a furnace at 900 + 15 oC. The sample is cooled and weighed. Loss of weight
represents moisture and volatile matter. The remainder is coke (fixed carbon and ash).
For detailed methodologies (including for determination of carbon and ash content),
refer to IS 1350 part I: 1984, part III, IV.
Measurement of carbon and ash:
The cover from the crucible used in the last test is removed and the crucible is heated
over the Bunsen burner until all the carbon is burned. The residue is weighed, which
is the incombustible ash. The difference in weight from the previous weighing is the
fixed carbon. In actual practice, fixed carbon or FC derived by subtracting from 100
the value of moisture, volatile matter and ash.
2.5. Proximate analysis
Ref 2. Page 13
Simple analysis equipment.
A few g of the fuel is heated inside a furnace at 378 K for 10 h till it attains constant
weight - moisture content.
The volatile matter is determined by heating the sample at 1173 K till it attains
constant weight.
The weight loss during burning the sample will determine the fixed carbon.
The weight of the residue after complete combustion of solid fuel will provide the ash
content.
The main disadvantage of this analysis is that it can not provide a split between
volatile matter and fixed carbon.
The proximate analysis indicates the percentage by weight of fixed carbon, volatiles,
ash, and moisture content in coal. The amounts of fixed carbon and volatile
combustible matter directly contribute to the heating value of coal. Fixed carbon acts
as a main heat generator during burning. High volatile matter content indicates easy
ignition of fuel. The ash content is important in the design of the furnace grate,
combustion volume, pollution control equipment and ash handling systems of a
furnace. A typical proximate analysis of various coal types is given in Table 2.3.
Table 2.3. Typical proximate analysis of various coals (percentage)
Parameter
Indian Coal
Indonesian Coal
South African Coal
Moisture
5.98
9.43
8.5
7
Ash
38.63
13.99
17
Volatile matter
20.70
29.79
23.28
Fixed Carbon
34.69
46.79
51.22
These parameters are described below.
Ref 1. Page 18-19
Fixed carbon:
Fixed carbon is the solid fuel left in the furnace after volatile matter is distilled
off.
Fixed carbon = 100 (moisture + volatile matter + ash).
It consists mostly of carbon but also contains some hydrogen, oxygen, sulphur
and nitrogen not driven off with the gases.
Fixed carbon gives a rough estimate of the heating value of coal.
Volatile matter:
Volatile matters are the methane, hydrocarbons, hydrogen and carbon
monoxide, and incombustible gases like carbon dioxide and nitrogen found in
coal.
Thus the volatile matter is an index of the gaseous fuels present.
A typical range of volatile matter is 20 to 35%.
It is the total weight loss the moisture content when the fuel is heated to
sufficiently high temperature out of contact with air and then cooled crushed
coal.
High volatile matter content indicates easy ignition of fuel.
Proportionately increases flame length, and helps in easier ignition of coal
Sets minimum limit on the furnace height and volume
Influences secondary air requirement and distribution aspects
Influences secondary oil support
Ash content:
Ash is an impurity that will not burn.
Typical range is 5% to 40%.
Ash = inorganic residue left after complete combustion of the fuel in air under
specified conditions
The ash content is important in the design of the furnace grate, combustion
volume, pollution control equipment and ash handling systems of a furnace.
Reduces handling and burning capacity
Increases handling costs
Affects combustion efficiency and boiler efficiency
Causes clinkering and slagging
Moisture content:
Moisture in coal must be transported, handled and stored. Since it replaces
combustible matter, it decreases the heat content per kg of coal.
Moisture:
8
40 45
15 - 70
0.1 1.0
Peat
Lignite coal
30 35
20 25
70 90
20 30
0.1 2.0
>5
Bituminous
coal
Anthracite
coal
3-5
10 - 5
>5
1-2
2-4
>5
The ultimate analysis indicates the various elemental chemical constituents such as
carbon, hydrogen, oxygen, sulphur, etc. It is useful in determining the quantity of air
required for combustion and the volume and composition of the combustion gases.
This information is required for the calculation of flame temperature and the flue duct
design etc. Typical ultimate analyses of various coals are given in the table below.
Laboratory analysis
The carbon and hydrogen content of the fuel can be estimated by burning the fuel
in air or O2 and by measuring the combustion products.
Nitrogen content is determined by chemical method.
The S content is evaluated by burning the sample (coal) completely in the
presence of oxygen, which converts S into sulphate (SO4) followed by
precipitation method.
The calorific values of both solid and liquid fuel are determined by using a Bomb
calorimeter.
Ref.1 p18 & Ref 2. p 13
Table 2.5. Typical ultimate analysis of coals
Parameter
Indian coal, (%) Indonesian coal, (%)
Moisture
5.98
9.43
Mineral Matter
38.63
13.99
(1.1 x Ash)
Carbon
41.11
58.96
Hydrogen
2.76
4.16
Nitrogen
1.22
1.02
Sulphur
0.41
0.56
Oxygen
9.89
11.88
Relationship between ultimate analysis and proximate analysis
%C = 0.97C+ 0.7(VM - 0.1A) - M(0.6-0.01M)
%H = 0.036C + 0.086 (VM -0.1 x A) - 0.0035M2 (1-0.02M)
%N2 = 2.10 -0.020 VM
Where
C = % of fixed carbon
A = % of ash
VM = % of volatile matter
M = % of moisture
Note: the above equation is valid for coal with greater than 15% moisture content.
2.8. Solid fuels (Physical properties) Heating values of the fuel
During combustion of a fuel heat is liberated.
The quantity of heat evolved by the combustion of unit quantity of the fuel (either
unit mass or unit volume) at normal temperature (298 K) and pressure (1 atm or
0.1MPa) is referred as its Calorific value or Heating value.
10
8.10
7.21
11
9.91
10.80
12
13
Fuel Oil
Specific
Gravity
4.3. Viscosity
Ref 2. Page 10
The viscosity of a fluid is a measure of its internal resistance to flow. Viscosity
depends on the temperature and decreases as the temperature increases. Any
numerical value for viscosity has no meaning unless the temperature is also specified.
Viscosity is measured in Stokes / Centistokes. Sometimes viscosity is also quoted in
Engler, Saybolt or Redwood.
Each type of oil has its own temperature - viscosity relationship. The measurement of
viscosity is made with an instrument called a Viscometer.
Viscosity is the most important characteristic in the storage and use of fuel oil. It
influences the degree of pre- heating required for handling, storage and satisfactory
atomization. If the oil is too viscous, it may become difficult to pump, hard to light
the burner, and difficult to handle. Poor atomization may result in the formation of
carbon deposits on the burner tips or on the walls. Therefore pre-heating is necessary
for proper atomization.
4.4. Flash point
Ref 2. Page 10
The flash point of a fuel is the lowest temperature at which the fuel can be heated so
that the vapour gives off flashes momentarily when an open flame is passed over it.
(or the liquid fuel will produce sufficient vapours to form a flammable mixture with
air and can produce a momentary flame) i.e. the max. temp at which the liquid fuel
can be stored without any fire hazard. The flash point for furnace oil is 66 0C.
4.5. Fire point
Lowest temperature at which the liquid fuel will produce sufficient vapours to form a
flammable mixture with air that continuously supports combustion establishing a
flame instead of just flashing even after the ignition is withdrawn.
Note that for the same fuel, the fire point is always higher than the flash point.
4. 6. Pour point
The pour point of a fuel is the lowest temperature at which it will pour or flow when
cooled under prescribed conditions. It is a very rough indication of the lowest
temperature at which fuel oil is ready to be pumped.
4.7. Smoke point
14
15
The amount of sulphur in the fuel oil depends mainly on the source of the crude oil
and to a lesser extent on the refining process. The normal sulfur content for the
residual fuel oil (furnace oil) is in the order of 2 - 4 %. Typical figures for different
fuel oils are shown in Table 4.4.
The main disadvantage of sulphur is the risk of corrosion by sulphuric acid formed
during and after combustion, and condensation in cool parts of the chimney or stack,
air pre-heater and economizer.
Table 4.4. Percentages of sulphur for different fuel oils
(adapted from Thermax India Ltd.)
Fuel oil
Percentage of sulphur
Kerosene
0.05 - 0.2
Diesel Oil
0.05 - 0.25
L.D.O
0.5 - 1.8
Furnace Oil
2.0 - 4.0
LSHS
< 0.5
4.12. Ash content
The ash value is related to the inorganic material or salts in the fuel oil. The ash levels
in distillate fuels are negligible. Residual fuels have higher ash levels. These salts
may be compounds of sodium, vanadium, calcium, magnesium, silicon, iron,
aluminum, nickel, etc.
Typically, the ash value is in the range 0.03 - 0.07 %. Excessive ash in liquid fuels
can cause fouling deposits in the combustion equipment. Ash has an erosive effect on
the burner tips, causes damage to the refractories at high temperatures and gives rise
to high temperature corrosion and fouling of equipments.
4.13. Carbon residue
Carbon residue indicates the tendency of oil to deposit a carbonaceous solid residue
on a hot surface, such as a burner or injection nozzle, when its vaporizable
constituents evaporate.
Residual oil contains carbon residue of 1 percent or more.
4.14. Water content
Typical specifications of fuel oils are summarized in the Table below.
Table 4.5. Typical specifications of fuel oils
(adapted from Thermax India Ltd.)
Properties
Fuel Oils
Furnace Oil
L.S.H.S
L.D.O
0
Density (approx. g/cc at 15 C)
0.89 - 0.95 0.88 - 0.98
0.85 - 0.87
0
Flash point ( C)
66
93
66
0
Pour point ( C)
20
72
18
G.C.V. (kcal/kg)
10500
10600
10700
Sediment (% Wt.max)
0.25
0.25
0.1
Sulphur Total (% Wt. max)
up to 4.0
up to 0.5
up to 1.8
16
1.0
0.1
1.0
0.1
0.25
0.02
The water content of furnace oil when it is supplied is normally very low because the
product at refinery site is handled hot. An upper limit of 1% is specified as a standard.
Water may be present in free or emulsified form and can cause damage to the inside
surfaces of the furnace during combustion especially if it contains dissolved salts. It
can also cause spluttering of the flame at the burner tip, possibly extinguishing the
flame, reducing the flame temperature or lengthening the flame.
Table 4.6. Properties of some Liquid Fuels
Liquid fuel
Gasoline Diesel Methanol Kerosene Aviation
fuel
Turbine
Fuel
(ATF:JP8)
Sp. Gravity
0.72-0.78 0.85
0.796
0.82
0.71
Kinematic viscosity at 293
0.8
2.5
2
6
K (m /s) x 10
Boiling point (K)
303-576 483-508
Flash Point (K)
230
325
Auto ignition temp. (K)
643
527
Stochiometric A/F
14.7
14.7
by weight
Heat of vaorisation (kJ/kg)
380
375
LHV (MJ/kg)
43.5
45
0.75
3.626
--
338
284
737
6.45
423-473
311
483
15
442
325
-15.1
1185
298.5
--
20.1
45.2
43.3
17
18
Air/O2
IC Engine
Biogas
Acetylene
Air/O2
Air/O2
--2.1
2.2
--0.4
0.8
--4.4
8.1
--13.5
6.3
Producer gas
Blast furnace
Biogas
2.2
----
97.3
6
---
0.5
94
---
1.55
2.04
0.42
0.44
----
----
----
0.86
1.02
0.8
Carbon Dioxide, and traces of other gases. Very small amounts of sulphur compounds
are also present. Since methane is the largest component of natural gas, generally
properties of methane are used when comparing the properties of natural gas to other
fuels.
Natural gas is a high calorific value fuel requiring no storage facilities. It mixes with
air readily and does not produce smoke or soot. It contains no sulphur. It is lighter
than air and disperses into air easily in case of leak. A typical comparison of carbon
contents in oil, coal and gas is given in the table below.
Table 5.5. Comparison of chemical composition of various fuels
Fuel Oil
Coal
Natural gas
Carbon
84
41.11
74
Hydrogen
12
2.76
25
Sulphur
3
0.41
Oxygen
1
9.89
Trace
Nitrogen
Trace
1.22
0.75
Ash
Trace
38.63
Water
Trace
5.98
Energy content of different fuels
22
Review Questions
General
1.What is meant by the term fuels? What are its constituents?
(2)
1. Write a brief note on the classification of fuels. Mention the nature of oxidiser
and their applications by giving examples.
2. Define ignition and standard Ignition temperature.
(5)
(2)
(2)
Solid Fuels
4. What is the most suitable fuel for a rocket engine: (i). gas, (ii). solid (iii). liquid?
Support your choice with some reasons.
(5)
(2)
(5)
(2)
8. Explain the different methods of analysis of coal? What type of information you
can get from such methods? What is the difference between the above methods
and describe the parameters analysed.
(10)
(5)
10.Discuss the influence of ash content in coal on its combustion properties. (2)
11.How the volatile matter present in coal is estimated?
(2)
(2)
(2)
14.Explain the process of obtaining coke from coal. Name the process.
(5)
15.Discuss the influence of impurities present in coal. How they affect the
combustion of coal?
(5)
16. Explain how the different varieties of coal differ in their physical properties. (5)
17. What is meant by d.a.f. coal and d.m.m.f. coal?
(2)
18. Explain the ultimate and proximate methods of analysis of carbon fuel. Explain
how they are inter-related.
(5)
23
19.Distinguish between High calorific value and Low calorific value. Explain their
relationship.
(2)
Liquid fuels
20.List out the merits and demerits of liquid fuels over solid fuels.
(5)
21.What do you mean by the term Flash point of a fuel? How can it be determined
experimentally?
(2)
22.Bring out the difference between flash point and fire point of liquid fuels. (2)
23.How can the smoke point of a fuel be determined experimentally? Why its value is
so important?
(2)
24. What is pour point of a fuel? Why does one need to know about it?
(2)
25.For a liquid fuel, the fire point is always higher than the flash point. Is it true?
Explain with suitable arguments.
(5)
26.Explain how the different physical properties of liquid fuels are estimated. (10)
27.Explain how the different liquid fuels differ in their physical properties. (5)
28.Discuss the influence of impurities present in liquid fuel oil. How they affect its
combustion characteristics
(5)
Gaseous fuels
29. What are the advantages of gaseous fuels?
(5)
30. Why is gaseous fuel preferred over solid or liquid fuels in recent times? (5)
31. What are the problems posed by the gaseous fuels?
(2)
32.Mention different types of gaseous fuels and their composition and their
applications.
(5)
33. Mention different types of gaseous fuels and explain how their different physical
properties are compared.
(10)
24
(5)