Effect of Fuel Moisture

on Combustion in a Bagasse
K. S. Shanmukharadhya
Department of Mechanical Engineering,
Bannari Amman Institute of Technology,
Sathyamangalam 638 401, India
e-mail: kssbit05@yahoo.co.in
K. G. Sudhakar
Principal and GM (Advanced Studies)
Government Tool Room & Training Centre,
Bangalore 560 044, India
Fired Furnace
Sugar cane bagasse, a biomass material that is readily available, has been used as a fuel
for well over 4 decades. However, combustion of bagasse has its own special set of
problems which appear to be due largely to the high moisture content of the fuel. In this
present research work, in order to gain insight into the effect of moisture on the flame
front, an experimental program is carried out on an operating, industrial size bagasse-
fired furnace. The furnace is modeled by the three-dimensional CFD package FLUENT.
The results of modeling show a considerable delay to ignition due to the drying of fuel.
The effect of fuel moisture on drying and heating up of the fuel is the key feature for the
investigation done in this work. DOI: 10.1115/1.2748816

Keywords: bagasse, combustion, turbulence, fuel moisture, CFD

1 Introduction various operating parameters on bagasse combustion. Both

Bagasse moisture has long been known to be a source of igni-
tion instability in suspension type bagasse fired furnaces. Moisture
is the single factor limiting the further development of bagasse
suspension firing 1. In fact, one of the key motivations for this
present research is the detrimental effect that the fuel moisture can
have upon the boiler operation. For this reason, in addition to gas
species and thermal measurements, numerous observations of the
furnace behavior during periods of instability were noted during
the crushing season. The test furnace is actually designed for ba-
gasse as the main fuel and also uses coal during the off season
when sugar cane is not available. Here crushing season means
sugar crushing time. The results of these observations are re-
corded. The effect of the fuel moisture on steady-state model pre-
dictions is examined.
2 Related Research
A major work in the field of computational modeling of bagasse
furnaces was done by Luo and Stanmore 2 and they have re-
ported good agreement between steady-state calculations and ex-
periment for temperature, oxygen, and radiation. Dixon 1 made
studies on the combustion behavior of bagasse and pointed out
that the flame front is not attached to the bagasse spreaders. He
concluded that it is highly desirable to have a continuously burn-
ing bed at the rear of the furnace to stabilize the combustion. Luo
and Stanmore 3 performed steady-state calculations of a bagasse
furnace and made some observations concerning the effects of
fuel moisture. They found that the total burnout for the furnace
suddenly decreases at a fuel moisture content of 60%. Stubington
and Aiman 4 examined some of the effects that the fuel moisture
has upon pyrolysis and found that higher temperatures were re-
quired for flash ignition of the wetter particles. Abbas et al. 5
reported that fuel moisture in biomass materials can affect com-
bustion intensity and energy efficiency. Stanmore and Arici 6
conducted experimental investigations related to bagasse drying
and concluded that the heat conduction through the dry outer shell
is a controlling factor in the drying of bagasse cylinders. Wood-
field et al. 7 did work on prediction of unstable regimes in the
operation of bagasse fired furnaces by considering the influence of
Contributed by the Advanced Energy Systems Division of ASME for publication
in the JOURNAL OF ENERGY RESOURCES TECHNOLOGY. Manuscript received March 17,
2006; final manuscript received August 23, 2006. Review conducted by Sarma V.
Pisupati.
steady-state and time dependant calculations suggest a higher
level of instability than indicated by measurements of the test
furnace.
The work done by Woodfield et al. 7 on the prediction of
unstable regimes in a bagasse fired furnaces has been considered
the measurement of flue gas temperature above the grate. The
combustion was aided by jets of over fire air nozzles from the rear
and front side. Here in the present work the temperatures are
measured at various points in the furnace to locate the maximum
temperature zones, and pattern of flame propagation within the
furnace. The test furnace has tangential over fire air system to aid
the combustion of bagasse in suspension and under grate air is the
primary air. Moreover, the prediction of operating characteristics,
flow pattern, and the model of mixing in a furnace with the tan-
gential over fire air system has not been adequately investigated
8.
3 Furnace Operating Conditions and Experiment
The furnace has a tangential over fire air system to aid the
suspension burning of the fuel. It is a spreader stoker furnace with
a traveling grate. Air and bagasse are the two main input param-
eters for the furnace. The main sources of air for combustion are
under grate air 60% of the forced draft FD air, tangential over
fire air 30% of the FD air, and distributor air 5% of the FD air.
There are five air distributors placed below the bagasse spreaders.
The test boiler operates at a nominal power of 20 MW. The ba-
gasse spreaders 5 Nos are spaced evenly in a horizontal direction
on the front wall of the furnace. The air coming from the ducts
forms a large vortex in the furnace. The size of the vortex depends
on the tilt angles and dimensions of the furnace. These air flows
from all four ducts result in efficient mixing, due to vortex, rapid
contact between fuel and air, and flame interaction, that would
ensure a reliable combustion with uniform temperature distribu-
tion.
In order to gain insight into the operation and conditions lead-
ing to instability, an experimental program was carried on an op-
erating, industrial size bagasse fired furnace. The boiler operating
parameters were noted regularly during the test period. The per-
centage of moisture of the fuel was tested during the test period
using a MB45 moisture analyzer. A specially built k-type
chromelalumel thermocouple in a flexible 316 stainless steel
SS tubing 8 mm was used to measure the temperature. A digi-
tal temperature indicator was used to record the temperature.

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 Table 1 Operating conditions of the furnace

C % dry ash free 50.51

H % dry ash free 6.31
N % dry ash free 0.12
O % dry ash free by difference 43.06
H2O % wet 51.00
Ash % dry 5.75
Fuel specific energy HHV kg/kg dry ash free 19,554
Bagasse flow kg/s/ wet 9.13
Under grate air kg/s 26
Distribution air kg/s 2
Tangential air kg/s 15
Bagasse flow m/s 37
Undergarte air flow m/s 7
Distribution air flow m/s 37
Tangential air flow m/s 22
Furnace wall temperature K 623
Stochiometric air/fuel ratio 3.76:1
Equivalence air/fuel ratio at which furnace operated 4.2:1

1
dV
mp V U
= A pcdU V + g 1
dt 2
The drying model for the entrained particles is based on Spald-
ings B number approach 9,7. Conservation of energy gives the
thermal B number

cgT T p
BT = 2
qcond
qrad
h fg
mw

Fig. 1 Meshed furnace used for modeling where cg is the gas specific heat; T p is the particle temperature; T
is the free stream temperature; qrad is the radiation flux to particle;
qcond is the conduction heat to flux particle; h fg is the latent heat of
water evaporation; and mw is the water evaporation rate. Conser-
vation of species involves the transport B number
Samples of bagasse were tested for thermogravimetric TG and
differential thermal analysis DTA analysis by using an STA Y w, Y w,s
1500 analyzer. Throughout the test period, the boiler was observed BD = 3
Y w,s 1
to run continuously, not showing signs of gross instability while
samples of bagasse had moisture contents as high as 54% and as Pyrolysis of bagasse is modeled by using Arrhenius kinetic
low as 47%. All the flame temperature measurements were taken mechanism following the work by Drummond and Drummond
while the bagasse moisture content was within this range. When 10
the boiler did experience problems, additional samples of bagasse
were collected and tested at the laboratory for moisture level, and d
found to be on the higher side. At these times there was a notice- = k* 4
dt
able dulling of the light coming from the windows at the grate
level and large mounds of bagasse could be seen to be piling up Here is the mass of volatiles released divided by the original dry
on the grate. The mounds of bagasse at times were in excess of sample mass; * is the ultimate mass of volatiles released divided
1 m high. by the original dry sample mass. The ultimate mass of volatiles
The meshed furnace used in computations is shown in Fig. 1. * is determined as fraction of the original dry sample mass,
The operating conditions and properties of the fuel at 100% including ash. Here k is the Arrhenius coefficient given by
maximum capacity rating MCR are summarized in Table 1.
The test furnace is designed to operate from 60% to 110% MCR.
It depends on the cane crushing capacity of the plant. k = A exp
E
RT
5

The kinetic parameters are determined by Drummond and Drum-

4 Computational Modeling of the Furnace
The bagasse-fired furnace is modeled using FLUENT, a three-
dimensional computational fluid dynamics package. The FLUENT
code solves the three-dimensional Favre-averaged equations for
weakly compressible flows. FLUENT uses a finite volume particle
source in cell approach to model the fundamental transport equa-
tions. Closure is achieved via the k turbulence model. Bagasse
particles are tracked using Lagrangian particle tracking in order to
obtain particle trajectories as given in Eq. 1
mond 9 for sugarcane bagasse under conditions approximating
the flash pyrolysis experienced in the furnace. In Eq. 5, the
preexponential A = 2.13 106s1 and the activation energy E
= 92.6kJ/ mol. The ultimate yield for bagasse volatiles is 98.8%
on a dry ash free basis 9. The values are global reaction values
and follows first-order reaction.
Radiation heat transfer between the gas, the bagasse particle
stream, and the furnace walls is modeled by P1 model similar to
the discrete transfer method of Lockwood and Shah 11. Equa-
tion 6 gives the change in intensity with respect to distance
traveled along the path of a single beam of radiation intensity I

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 Fig. 2 TG and DTA result of bagasse
dI
ds
= ka + k p + ksI + kaT4g + k pT4p +
ks
4
4
Id 6
The gas absorption, particle absorption, and particle scattering co-
efficients are given in Eq. 7.
ka = 0.28 exp Tg
1135
kp = A Q
j
c apn j
ks = A Q
j
c spn j 7
where ka = gas absorption coefficient for radiation; and k p
= particle absorption coefficient.
The coefficients in Eq. 7 ideally should be a function of par-
ticle surface properties and size. The coefficients of Qap and Qsp
are obtained from the work of Mann 12 on coal furnace model-
ing. The expression for ka is a global expression for gas radiation
in coal furnaces 12. The values of the parameters depend on the
concentrations of the gases most responsible for absorption at the
furnace conditions as well as on temperature.
There are two distinctly different mechanisms for the combus-
tion of solid material. The first has been termed flaming combus-
tion, where volatiles are released as gases from the fuel and the
chemical reactions take place in the gas phase. For the second,
char combustion, the chemical reactions take place at the sur-
face of the solid fuel. During flash pyrolysis, diffusion of oxygen
to the particle surface is inhibited by the flow of the volatile ma-
terial away from the particle and by the consumption of oxygen in
the flame surrounding the particle. A combination of these factors
and relatively lower solid material temperatures during pyrolysis
prevent char combustion from occurring at a significant rate until
pyrolysis is nearing completion. Once pyrolysis has progressed to
beyond the specified ultimate yield of the combustibles, char com-
bustion is assumed to commence. Char combustion is modeled
using the coal-char model of Smith 13, with char combustion
kinetics determined by Luo and Stanmore for bagasse 3.
The grate is modeled as an array of cells on the furnace floor.
The model is time dependent and operates in two stages: mass
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accumulation and drying. Drying occurs by both radiation and
convection. The intensity of the radiation incident on the top sur-
face of the fuel is obtained from the radiation model. Convective
heat transfer within the pile is calculated assuming the pile can be
represented by a porous block at a uniform temperature. Equation
8 gives the heat transfer correlation for drying in a packed bed
14
2.06 Re0.575
Nu = Re Pr1/3 8
5 Results and Discussions
In bagasse-fired furnaces, a large low-temperature preignition
zone appears between the fuel spreaders and the combustion front.
This delay to ignition is due to drying and heat-up of the fuel. The
location of the ignition front and hence overall furnace stability is
found to be affected by fuel moisture, pyrolysis kinetics, and com-
bustion activity on the grate. The computational model developed
agrees qualitatively with experimental data collected.
The kinetics of the pyrolysis of sugar cane bagasse and other
biomass materials at high temperatures and high heating rates has
been the subject of much discussion. The result of the TGA analy-
sis carried out for the fuel is given in Fig. 2. The sample used for
the test was collected at 48% moisture.
In Fig. 2, the first step weight loss in the TG trace occurs
between the temperatures 25 C and 67 C and is attributed to
moisture loss of about 10%. The sample is thermally stable along
the curve 2-3 between temperatures 67 C and 253 C. The
sample starts degrading after 253 C and continues up to 355 C
and the weight loss in the second step comes roughly around 53%.
Second step weight loss is faster and steeper compared to first step
weight loss due to the thermal degradation of the sample.
The third step weight loss also attributed to degradation path
4-5 along the curve occurs between the temperatures 355 C and
500 C. The rate of weight loss is less in this step compared to the
second step. The weight loss in the third step degradation is
roughly around 15% and is much less than that in the second step.
Hence the major thermal decomposition of the sample occurs be-
tween the temperatures 253 C and 355 C.
Transactions of the ASME
 Fig. 3 Moisture loss details of the particles

Fig. 4 Temperature profiles of the particles on the grate

Beyond 500 C and above the residual weight is around 18%
and this may be attributed to ash due to incomplete thermal de- gasse stream near the spreader. As the particle is projected further
composition or any thermally stable cross linked carbonaceous out into the furnace, its temperature increases and moisture mass
materials and mineral matters if any. loss progresses at a finite rate. m / m0 is the mass of volatile matter
The DTA trace of the sample indicates that the maximum moisture remaining in the particle divided by the mass at time
weight loss corresponding to second step in TG occurs at 355 C zero. The surface area to volume ratio of the 181 m particle is
and the maximum weight loss in the third step occurs at 439 C.
around 4.5 times that of the 668 m particle. Furthermore, the dry
As seen from TG analysis, there are three distinct zones or regions
density of the larger particle is 3.8 times that of the smaller. The
that occur during the bagasse pyrolysis. The first zone is from the
net result of this is that, per unit surface area, the 668 m particle
ambient temperature to onset of active pyrolysis 25 253 C
contains about 17 times as much moisture as the 181 m particle.
path 1-2-3. The second zone represents the major decomposition The temperature profile for particles 181 m and 668 m are
of the material and is considered to occur between the initial tem-
shown in Fig. 4. The 181 m particle reaches the maximum tem-
perature 253 C and the final temperature 355 C path 3-4. The
perature around 0.2 s and reaches around 1630 K, while 668 m
third zone represents temperature above the final temperature of
particle reaches around 800 K, lesser than the 181 m particle
active pyrolysis zone 355 C. In this zone, the amount and rate of
due to its moisture content. The temperatures shown in the figure
mass loss is lower and slower than the active pyrolysis zone. The
are combustion temperatures. The adiabatic temperature calcu-
third zone occurs between the temperatures 355 C and 500 C
lated was 1650.8 K. The temperatures attained by the particles are
path 4-5. In this zone the carbon and ash content of the material
slightly less than the adiabatic temperature calculated. In the fig-
increases.
ure it is observed that as soon as the particle enters the furnace its
A typical sample of bagasse encompasses a very wide range of
temperature starts rising and the particle releases its volatile con-
particle sizes. Bagasse particles typically have dimensions on the
tent in around 0.15 s, then follows the thermal degradation. At the
order of 100 m while the largest particles have maximum di-
end of the curve it can be observed that due to some thermally
mension of a few centimeters. The smallest particles follow the
stable minerals present in the fuel ash, the difference in tempera-
gas stream quite closely and are swept upward after entry to the
ture along the curve is negligible as the particle passes over the
furnace, while the larger particles fall to the grate. Particles size
grate.
distributions made by Dixon 1 is used in the present work. Fol-
Figure 5 shows that the 181 m particle reaches maximum
lowing are some of the particle dimensions used in the calcula-
velocity due to the influence of distributor air jet. Due to high
tion. The smallest particle selected has a nominal diameter of
velocity distribution air jet, the bagasse particles gain high veloc-
181 m which is the diameter of an equivalent cylindrical par-
ity when they comes out of the spreader. The 181 m particle
ticle. It means the diameter of the particle selected has the same
reaches a maximum velocity around 0.02 s during which the par-
length and the same surface area to volume ratio.
ticle dries and later it follows devolatilization and char burning.
The geometry of bagasse particles is quite difficult to charac-
terize. Dixon 1 and Luo and Stanmore 3 describe the particles Similarly, for the 668 m particle, due to its size and moisture
as cylinders with a characteristic length and a diameter based on content, it reaches its maximum velocity around 0.1 s. These two
an equivalent cross-sectional area. For the purpose of calculations,
Luo and Stanmore 3 describe the particles as equivalent volume
spheres. Here the area and volume of the sphere are in the same
ratio to the area and volume of a circumscribed straight cylinder.
Figure 3 gives the drying history for the particles 181 m and
668 m. The heat transfer takes place via both convection and
radiation. The Spalding transport B number approach is used to
determine the mass transfer. The convection heat transfer coeffi-
cients are used in computing the drying history of the particles.
In Fig. 3, the 181 m particle is dry after about 0.9 s from
entry to the furnace at a position nearly 7 m above the grate and
for the 668 m particle, drying takes about 2 s and appears to be
complete adjacent to the high-temperature zone near the back wall
of the furnace. The moisture histories for both particles show an
initial region where negligible drying occurs 0 0.2 s for the
181 m particle and 0 0.8 s for the 668 m particle. This is the
result of the particle temperature being too low and the moisture
content in the gas phase being too high in the concentrated ba- Fig. 5 Velocity of the particles on the grate

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 Fig. 6 Temperature zone in K along the spreader plane
results indicate as the particle size increases, their velocity de-
creases. The observation of the furnace also justifies the large
clumps of fuel accumulation on the grate in front of the spreader
to support the above.
From Fig. 6, it is apparent that the low-temperature zone
stretches across the full furnace width. This low-temperature re-
gion is the result of the delay to ignition due to the drying and heat
up of the fuel and is the key feature for the investigation con-
nected with this work. There are two main zones of intense com-
bustion activity in the furnace. One is located on and above the
sloping rear wall of the furnace. It is due to the combustion of
larger particles which are projected to the back of the furnace by
the spreaders. Temperatures in excess of 1500 K arise in this re-
gion. Here the combustion activity predicted on the rear wall ex-
tends for the complete width of the furnace. This can be seen in
Fig. 6, which is for a horizontal plane 2.625 m above the grate.
A second combustion zone arises in the upper part of the fur-
nace beyond the cool preignition zone. This high-temperature re-
gion is due to the ignition of lighter bagasse particles that are
swept upward by the vertical gas stream. Finally near the neck of
the furnace the temperature rises to 1600 K.
Figure 7 shows the measured and predicted values at the grate
level. During measurements, temperatures were recorded along
the grate depth at grate level. The trend in increasing temperature
toward the back wall matches the predicted temperature. It indi-
cates the delay to ignition due to drying and heat up of the fuel.
Fig. 7 Measured and predicted temperatures along the grate
depth
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Also this high temperature at the rear of the furnace is due to
combustion of larger particles which are projected to the back of
the furnace by the spreaders.
6 Conclusions
The pyrolysis kinetics of bagasse plays an important role in
prediction of the thermal fields and ultimately stability of the fur-
nace. This influence is particularly significant in the predicted de-
lay to ignition of the fuel. Size and shape of the fuel also have a
major influence insofar as the location and rate of deposition of
the fuel on the grate. The computational model developed agrees
qualitatively with experimental data collected. The results shows
that the fuel moisture does significantly affect the size of the pre-
ignition zone and hence furnace stability. Fuel moisture plays a
very important role in the initiation of instability in bagasse fired
furnaces. Actual observations of the furnace suggest that sudden
changes in bagasse moisture, which arise due to problems with
mill operation, appear to have a great effect on the furnace behav-
ior. If the cane entering the mill is mixed with a considerable
amount of dirt, stability problems appear to occur more fre-
quently.
The results of modeling show a considerable delay to ignition
due to the drying of fuel. Also, the important role of the particle
size for fuel drying has been clearly demonstrated. This issue is
particularly relevant to bagasse furnaces due to the very large
range of particle sizes in a given sample of bagasse. It is also
found that increasing the effective surface area for heat and mass
transfer can result in a significant shorter delay to fuel ignition.
Acknowledgment
The authors gratefully acknowledge the support provided by
BAS Cogeneration staff and workers in carrying out this research
work.
Nomenclature
Ac effective cross sectional area of the particle
m2
A p particle surface area
B spalding transport number
Cd drag coefficient
Cg gas specific heat
E activation energy
g gravity vector
Transactions of the ASME
 h fg latent heat of water evaporation bed void fraction
I intensity of radiation
k reaction rate coefficient References
ka gas absorption coefficient for radiation
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