Energy Conservation of Combustion air ratio and air preheating

Content
2 Optimization of air ratio 3 The air ratio is calculated from the O2 content (O2%) in the exhaust gas. 4 Larger air ratio leads to larger heat loss with the exhaust gas. 5 Fuel saving by air ratio improvement 6 Effect of air ratio reduction 7 Criteria for air ratio (standard values) 8 Criteria for air ratio (target value) 9 Energy conservation by air preheating 10 Utilization of waste heat of exhaust gas air preheating 11 Criteria for exhaust gas temperature 12 Criteria for factories
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Optimization of air ratio

The excess air for combustion such as that in a boiler contributes only to an increase in heat loss with the exhaust gas. The degree of excess air is expressed by air ratio. The air ratio at 1 (one) represents the theoretical combustion. The air ratio is expressed by 21/(21-O2%) where O2 is oxygen content in the exhaust gas. The Criteria of the Law for Rational Use of Energy set both standard and target values of air ratios for boilers and industrial furnaces.

Before adjust
Exhaust gas heat loss Combustion air Boiler / furnace Fuel Required heat

After adjust
Combustion air Fuel Boiler / furnace

Exhaust gas heat loss

Required heat

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The air ratio is calculated from the O2% of the exhaust gas.

The simplified equation for obtaining the air ratio is: Air ratio = 21/(21 O2% value) where O2 is the oxygen content obtained by analysis (dray base value). Normally, the air ratio may be calculated by this equation. The criteria of the Law Concerning Rational Use of Energy specify this equation. As the air ratio becomes large, the difference between the result obtained by the simplified equation and the real value becomes large. (See the graph.) The air ratio is defined as real air value/theoretical air volume. The air ratio of 1 (one) represents an ideal state in which no more than required air is used for combustion (theoretical combustion). The air in excess of air ratio at 1 (one) is called excess air which causes heat loss by carrying out air from the stack at heated state. The air ratio short of 1 (one) causes incomplete combustion, associated with the incomplete combustion heat loss.

Air ratio and oxygen in the exhaust gas

12%

10%

Oxygen in the exhaust gas

8%

6%

4%
13A gas

2%

Fuel oil A Simplified equation

0% 1.0 1.2 1.4 1.6 1.8 2.0

Air ratio

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Larger air ratio leads to larger heat loss with the exhaust gas.
Rate of heat loss of the exhaust gas (13A gas) (13A)
100% 90%
Rate of heat loss of the exhaust gas (net heating value base) ()
200 400 800 300 600

Rate of heat(A) loss of the exhaust gas (fuel oil A)

100% 90%
Rate of heat loss of the exhaust gas (net heating value base) ()
200 400 800 300 600 1000

25

25

1000

80% 70% 60% 50% 40% 30% 20% 10% 0% 1.0

Exhaust gas volume

Exhaust gas volume

20
(Nm^3/Nm^3) Exhaust gas volume (Nm^3/Nm^3)

80% 70% 60% 50% 40% 30% 20% 10%

20

15

15

10

10

0
1.2 1.4 1.6 Air ratio 1.8 2.0

0% 1.0 1.2 1.4 1.6 1.8 2.0

Air ratio

(Nm^3/kg) Exhaust gas volume (Nm^3/kg)

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Fuel saving by air ratio improvement

with graph

Effect (13A) of air ratio reduction (13A gas)

(Exhaust(=200) gas temperature = 200C)

This in turn leads to fuel saving. The graph illustrates result of air ratio reduction. In fuel saving rate, 13A gas and fuel oil A differ only very little. At lower exhaust gas temperatures, the effect is small. (Example) If air ratio can be reduced from the present 1.6 (O2 = 8.4%) to 1.2 (O2 = 3%), a fuel saving of 2.8% is realizable.

Fuel saving() rate (against pre-improvement performance)

Reduction of the air ratio (reduction of O2% in the exhaust gas) reduces heat loss with the exhaust gas.

4.5% 200 4.0% 3.5% 3.0% 2.5% 2.0% 1.5%

3.8 2.8% 8.4%
Exhaust gas O2 O2

16% 14% 12% 10% 8% 6% 4% 2%

1.2 1.6

AR=1.6

1.0% 0.5% 0.0% 1.0 1.2

0% 1.8 2.0

1.4

1.6

Air ratio before and after reduction (AR1AR2) (AR1AR2)

Exhaust gas O2 O2

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The graphs are developed on the assumption that a change in air ratio does not affect the exhaust gas temperature.
Effect(A) of air ratio reduction (fuel oil A)
18%
Fuel saving rate (against pre-improvement performance) ()

Effect of air ratio reduction

18% 200 300 400 Exhaust O2 gas O2 16% 14% 12%
Exhaust gas O2 O2

Effect of air ratio reduction (13A gas) (13A)

18% 16%
Fuel saving rate (against pre-improvement performance) ()

18% 200 300 400 Exhaust O2 gas O2 16% 14% 12% 10% 8% 6% 4% 2% 0% O2 Exhaust gas O2

16% 14% 12% 10% 8% 6% 4% 2% 0%

14% 12% 10% 8% 6% 4% 2% 0% 1.0 1.2 1.4

10% 8% 6% 4% 2% 0% 1.6 1.8 2.0

1.0

1.2

1.4

1.6

1.8

2.0

Air ratio before and after reduction (AR1AR2) (AR1AR2)

Air ratio before and after reduction (AR1AR2) (AR1AR2)

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Criteria for air ratio (standard values)

(the Law Concerning Rational Use of Energy)
Standard air ratio for boiler
Type Load factor, % 75100 Solid fuel Fixed bed Electric utility service Fluidized bed 1.051.2 1.051.1 Liquid fuel Gaseous fuel Blast furnace gas, etc. Byproduct gas 1.2

Other service (Quantity of evaporation, tons/h) 30 1030 510 5

Summary of note

50100 50100 50100 50100

1.31.45 1.31.45

1.21.45 1.21.45

1.11.25 1.151.3 1.21.3 1.21.3

1.11.2 1.151.3 1.21.3 1.21.3

1.21.3

After periodical inspection / stable operation state / air ratio at the boiler outlet Additional notes on pulverized coal combustion on fixed beds Use the fuel of higher mixing ratio in case of mixed fuel combustion. Exemption: Small boilers specified by the Labour Safety and Health Law, boilers for which the fuel has been changed after installation, boilers burning an industrial waste with fuel Boilers burning either black liquor or waste tires, byproduct gas of a heating value of 3,800kj or lower, or burning a poisonous gas for treatment purpose Boilers for the purpose of using waste heat, using a heating medium, operating unsteadily, or for the purpose of development, research and test manufacturing 7/12

Criteria for air ratio (target value)

(the Law Concerning Rational Use of Energy)
Target air ratio for boiler
Type Load factor, % 75100 Solid fuel Fixed bed Electric utility service Fluidized bed 1.051.1 1.051.1 Liquid fuel Gaseous fuel Blast furnace gas, etc. Byproduct gas 1.151.2

Other service (Quantity of evaporation, tons/h) 30 1030 510 5 50100 50100 50100 50100 1.21.3 1.21.3 1.21.25 1.21.25 1.051.15 1.151.25 1.151.3 1.151.3 1.051.15 1.151.25 1.151.25 1.151.25 1.21.3

Summary of note: almost the same as those of the table of standard values

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Energy conservation by air preheating

Before adjust

Exhaust gas

Combustion air Required heat Fuel

Boiler, furnace

Air preheating preheats the combustion air using the heat of the combustion gas. The preheated combustion air carries heat to the boiler / furnace; therefore, the required fuel is reduced. Consequently, heat loss attributable to the exhaust gas is reduced. The effect of air preheater becomes higher as the air ratio is higher.
gas Exhaust
Combustion air

After adjust
Preheated air

/ Air preheater / recuperator

Required heat Fuel

Boiler, furnace

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Effect of air preheating

If the heat contained in the exhaust gas is recovered by installing an air preheater, the temperature of the exhaust gas is lowered and the required fuel is reduced.
Effect of air preheating
13A gas, 13AA,200 fuel oil A, exhaust gas temperature at 200C

13AA,400 13A gas, fuel oil A, exhaust gas temperature at 400C 20%

Effect of air preheating

8%

Fuel reduction () rate (against that without air preheating)

6%

Fuel reduction rate (against that without air preheating) ()

15%

4%

10%

13A gas, AR = 1.0 13A,AR=1.0

13A gas, AR = 1.2 13A,AR=1.2 13A gas, AR = 1.6 13A,AR=1.6

2%

13A gas, AR = 1.4 13A,AR=1.4

5%
13A gas, AR = 1.0 13A,AR=1.0 13A gas, AR = 1.4 13A,AR=1.4 13A gas, AR = 1.2 13A,AR=1.2 13A gas, AR = 1.6 13A,AR=1.6

A,AR=1.0 Fuel oil A, AR = 1.0

Fuel oil A, AR = 1.4 A,AR=1.4

A,AR=1.2 Fuel oil A, AR = 1.2

Fuel oil A, AR = 1.6 A,AR=1.6

A,AR=1.0 Fuel oil A, AR = 1.0

Fuel oil A, AR = 1.4 A,AR=1.4

A,AR=1.2 Fuel oil A, AR = 1.2

Fuel oil A, AR = 1.6 A,AR=1.6

0% 100 110 120 130 140 150

Air preheating temperature (C) ()

0% 100 200 300 400

Air preheating temperature (C) ()

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Criteria for exhaust gas temperature

(the Law Concerning Rational Use of Energy)
Criteria for boilers, standard / target exhaust gas temperature
Type Solid fuel Fixed bed Electric utility service Other service (Quantity of evaporation, tons/h) 30 1030 510 5
Summary of note

Liquid fuel 145/135

Gaseous fuel 110/110

Blast furnace gas, etc. Byproduct gas 200/190

Fluidized bed

200/180 200/180

200/170 200/170 /300 /320

200/160 200/160 220/180 250/200

170/140 170/140 200/160 220/180

200/190

After periodical inspection / 20C at air feeder inlet, load factor at 100%, boiler outlet (heat recovery, flue gas treatment facility outlet) Additional notes on pulverized coal combustion on fixed beds, use the fuel of higher mixing ratio in case of mixed fuel combustion, the target temperature for black liquor combustion being 180C Exemption: Small boilers specified by the Labour and Health Law, boilers for which the fuel has been changed after installation, boilers burning an industrial waste with fuel Boilers burning either black liquor or a poisonous gas for treatment purpose Boilers for the purpose of using waste heat, using a heating medium, operating unsteadily, or for the purpose of development, research and test manufacturing 11/12

Criteria for factories (the Law Concerning Rational Use of Energy)

The criterion should be observed to the extent economically and technically possible. The target is the objective to pursue to achieve a reduction of energy unit consumption of 1 (one) percent per year (average).
Subjects of criteria (matters concerning standards)

1. Rationalization of fuel combustion. 2. Rationalization of heating, cooling and heat transfer. 3. Prevention of heat loss by radiation, conduction, etc. 4. Recovery of waste heat. 5. Rationalization of heat conversion into power, etc. 6. Prevention of electricity loss by resistance, etc. 7. Rationalization of conversion of electricity into power, heat, etc.
Quantitatively specified item of criteria (standard value, target value) 1. Air ratio for boilers 2. Air ratio for industrial furnaces 3. Outer wall temperature of industrial furnaces 4. Exhaust gas temperature for boilers 5. Waste heat recovery rate of industrial furnaces 6. Facility for which power factor should be improved 7. Target efficiency of high-efficient totally-enclosed electric motors (02 to 37kw)

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