Comprehensive Problem

Laurito, E. R. (n.d.). Stoichiometry of Fuel Combustion and

Related Process Industries (2nd ed.)

CHE 202 Chemical Engineering Calculations 2

Engr. Jean Raynell S. Bello, MSc.

Technological Institute of the Philippines
Example 4. A blast furnace gas analyzing 27% CO, 12% CO2, 2% H2 , 5% CH4 , and 54% N2
at 25° C and 98 kPa and saturated with water vapor is used as a fuel in Fire-tube Boiler.
Air is supplied 15% in excess at 30°C, 762 torrs and also saturated with water. Ninety
percent of total carbon in the fuel is converted to CO2 , the rest to CO. Molar ratio of H2 to
CO is 1:4 in the stack gas which leaves at 200° C and 750 torrs. Calculate:
a. Orsat analysis of the stack gas
b. Air-fuel ratio by volume
c. Moles stack gas/mole fuel
d. Gross Calorific Value of the fuel in kJ/SCM
e. Adiabatic Flame Temperature
f. % of the calorific value lost due to
i. Unburnt combustibles
ii. Uncondensed water vapor
iii. Sensible heat
g. Thermal efficiency
Solution
Basis: 1 kg mole dry Blast Furnace Gas

Air (15% Excess)

30°C, 762 Torrs, 100% RH
Fuel

100% RH, 25° C, 98 kPa Stack Gas

200° C, 750 torrs 200°C, 750 Torrs

27% CO, Fire-Tube Boiler

12% CO2,
2% H2 ,
5% CH4
54% N2
H2 : CO = 1:4
90% C → CO2
10% C → CO
 GAS moles at.C at.H Mole O2
COMPONENT

CO 0.27 0.27 - 0.135

CO2 0.12 0.12 - 0.12

H2 0.02 - 0.04 -

CH4 0.05 0.05 0.2 -

N2 0.54 - - -

TOTAL 1.00 0.44 0.24 0.255

Preliminary Calculations:

Theo O2 = 0.44 + (0.24/4) - 0.255 = 0.245 kgmol O2

Excess O2 = 0.15 x 0.245 = 0.03675 kgmol O2
O2 from air = 0.245 + 0.03675 = 0.28175 kgmol O2
N2 from air = 0.28175 x (79/21) = 1.06 kgmol N2
C converted to CO2 = 0.9 x 0.44 = 0.396 kgmol CO2
C converted to CO = 0.044 kgmol CO
H2 unburned = 0.044 x (¼) = 0.011 kgmol H2
H2O formed = (0.24/2) - 0.011 = 0.109 kgmol H2O
Free O2 = 0.03675 + (0.044/2) + (0.011/2) = 0.06425 kgmol O2
N2 = N2 from fuel + N2 from air = 0.54 +1.06 = 1.6 kgmol N2
A. Orsat Analysis
GAS moles %
CO2 0.396 18.72

CO 0.044 2.08

H2, 0.011 0.52

O2 0.06425 3.04

N2 1.6 75.64

Total 2.11525 100.00%

Fuel: At 25° C or (25 + 273)K ;
PS = exp (73.649 - 7258.2/T - 7.3037ln(T) + 4.1653 x 10-6T2)
PS = 23.568 mm Hg

Air: At 30° C or (30 + 273)K ;

PS = exp (73.649 - 7258.2/T - 7.3037ln(T) + 4.1653 x 10-6T2)
PS = 31.687 mm Hg

23.568 𝑚𝑚𝐻𝑔
Moles water from fuel = 𝑛𝐻2𝑂 =
760 𝑚𝑚𝐻𝑔
(1) = 0.033
98 𝑘𝑃𝑎 − 23.568 𝑚𝑚𝐻𝑔
101.325 𝑘𝑃𝑎

31.687 𝑚𝑚𝐻𝑔
Moles water from air = 𝑛𝐻2𝑂 =
760 𝑚𝑚𝐻𝑔
(1.06 + 0.28175) = 0.058
762 𝑇𝑜𝑟𝑟 760 𝑇𝑜𝑟𝑟 − 31.687 𝑚𝑚𝐻𝑔
B. Air-Fuel Ratio by Volume
𝑚3 760 𝑇𝑜𝑟𝑟 273 + 30 𝐾
3
𝑚 𝑎𝑖𝑟 0.28175 + 1.06 + 0.058 22.4
𝑘𝑔𝑚𝑜𝑙 762 𝑇𝑜𝑟𝑟 273 𝐾
=
𝑚3 𝑓𝑢𝑒𝑙 𝑚3 101.325 𝑘𝑃𝑎 273 + 25 𝐾
1 𝑘𝑔𝑚𝑜 𝑓𝑢𝑒𝑙 + 0.033 22.4
𝑘𝑔𝑚𝑜𝑙 98 𝑘𝑃𝑎 273 𝐾
𝒎𝟑 𝒂𝒊𝒓
= 1.329 𝒎𝟑 𝒇𝒖𝒆𝒍

C. Moles Stack Gas/ Mole Fuel

(2.11525 + 0.109 + 0.033 + 0.058) 𝒎𝒐𝒍𝒆𝒔 𝑺𝑮
= 𝟐. 𝟐𝟒𝟏
(1 + 0.033) 𝒎𝒐𝒍𝒆𝒔 𝒇𝒖𝒆𝒍
D. Gross Calorific Value of the fuel in KJ/SCM
GCV = 0.27 (283.18) + 0.02 (286.03) + 0.05 (890.95)
= 126.73 MJ/kgmol
Or 126.73[0.0416] = 5.27 MJ/SCM
Calorific Value Losses
A. Losses due to combustion
1. Due to CO = moles CO × 282.99 MJ/kgmol
2. Due to H2 = moles H2 × 285.84 MJ/kgmol
B. Losses due to sensible heat (heat used to “heat” the combustion gases exiting the
gas stack)
𝐶𝑉 𝐿𝑜𝑠𝑠𝑒𝑠 𝑑𝑢𝑒 𝑡𝑜 𝑆𝑒𝑛𝑠𝑖𝑏𝑙𝑒 𝐻𝑒𝑎𝑡 = 𝑛 × 𝐶𝑃 × (𝑇𝑆𝐺 − 𝑇0 )

Where: Cp = Specific Heat Capacity (MJ/kgmol-K)

TSG = Temperature of Stack Gas (°C)
T0 = Datum Temperature (assumed 25°C)
C. Losses due to uncondensed H2O vapor
= moles H2O from combustion × 44.04 MJ/kgmol H2O
F. Calorific Value Losses
i. %CV lost due to

%CV lost due to

iii. %CV lost due to

 ii. Calorific Value Lost Due to Sensible Heat of the Stack Gas
Stack Gas n Cp n × Cp

CO2 0.396 0.044 0.01741

CO 0.044 0.0296 0.0013

H2 0.011 0.0293 0.0013

O2 0.0643 0.0308 0.00198

N2 1.6 0.0295 0.04715

H2 O 0.2 0.0349 0.00699

Total 2.3153 0.07516 MJ/°C

%CV lost due to

Adiabatic Flame Temperature (TAF)
• The temperature that results from a complete combustion process that
occurs without any work, heat transfer or changes in kinetic or potential
energy.

• The temperature attained when all of the chemical reaction heat released
heats combustion products.

Calculation of Flame Temperatures:

1. Adiabatic Flame Temperature – based on Stoichiometric Combustion
Gases (considering combustion is stoichiometric without any excess air)
2. Flame Temperature of Stack Gases – based on the actual calculations of
combustion gases exiting the stack.
E. Determination of the Adiabatic Flame Temperature: TAF
1. Assume TAF
2. Calculate Cp of each component gas using the DIPPR data for
heat capacity and using T = TAF

1. Calculate the heat capacity of the gas in MJ/°C

2. Check the assumed TAF
𝐺𝐶𝑉 = 𝑛 × 𝐶𝑝 × (𝑇𝐴𝐹 − 25℃)
5. Iterate if TAF ≠ assumed TAF
TABLE 2-156 Heat Capacity at Constant Pressure of Inorganic and Organic
Compounds in the Ideal Gas State Fit to Hyperbolic Functions Cp [J/(kmolK)]

Gas Component C1 X E-05 C2 X E-05 C3 X E-03 C4 X E-05 C5

Carbon dioxide 0.2937 0.3454 1.428 0.264 588
Carbon monoxide 0.29108 0.08773 3.0851 0.084553 1538.2
Hydrogen 0.27617 0.0956 2.466 0.0376 567.6
Nitrogen 0.29105 0.086149 1.7016 0.001035 909.79
Nitrous oxide 0.29338 0.3236 1.1238 0.2177 479.4
Oxygen 0.29103 0.1004 2.5265 0.09356 1153.8
Sulfur dioxide 0.33375 0.25864 0.9328 0.1088 423.7
Sulfur trioxide 0.33408 0.49677 0.87322 0.28563 393.74
Water 0.33363 0.2679 2.6105 0.08896 1169

Values in this table were taken from the Design Institute for Physical Properties (DIPPR) of the American
Institute of Chemical Engineers (AIChE), copyright 2007 AIChE and reproduced with permission of AICHE
and of the DIPPR Evaluated Process Design Data Project Steering Committee.
 Stoichiometric n Cp n x Cp
Combustion Gases

CO2 0.44 0.0612 0.027

N2 0.922 0.0362 0.033

H 2O 0.12 0.0524 0.0063

Total 0.0663 MJ/°C

Check TAF
GCV(MJ/kgmol) = n x Cp x (TAF -25°C)
126.73 MJ/kgmol = 0.0663 MJ/°C x (TAF -25°C)
TAF = 1927.956845 °C
E. Determination of the Flame Temperature of combustion
products: Tf
1. Assume TF
2. Calculate Cp of each component gas using the DIPPR data for heat capacity
and using T = TF

3. Calculate the heat capacity of the gas in MJ/°C

4. Check the assumed TAF
𝐺𝐶𝑉 = 𝑛 × 𝐶𝑝 × (𝑇𝐹 − 25℃)
5. Iterate if TF ≠ assumed TF
 Combustion Gases n Cp n x Cp
CO2 0.396 0.0595 0.024
CO 0.044 0.036 0.00157
H2 0.011 0.033 0.00157
O2 0.0643 0.0369 0.00237
N2 1.6 0.0353 0.056
H2 O 0.2 0.048 0.00975
Total 0.094 MJ/°C

Check TF
GCV(MJ/kgmol) = n x Cp x (TF -25°C)
126.73 MJ/kgmol = 0.0663 MJ/°C x (TF -25°C)
TF = 1329.894071°C
G. Thermal Efficiency

Thermal Efficiency = 100% - %CV losses

Thermal Efficiency = 100% - (%CV lost due to CO + %CV lost due to H2 + %CV lost
due to sensible heat +%CV lost due to uncondensed H2O)

Thermal Efficiency = 100 - (9.83 + 2.48 +10.38 +3.79) = 73.52%

Additional Question:
Calculate the Dew Point of the stack gas:

Total moles of water in the stack gas: 0.109 (from combustion) + 0.033 (from
fuel) + 0.058 (from air) = 0.2 kgmol H2O
𝑃𝐻2 𝑂 𝑛𝐻2𝑂
Partial Pressure of water in the stack gas: 𝑃 = 𝑛
𝑇 𝑇
0.2 𝑘𝑔𝑚𝑜𝑙 𝐻2 𝑂 101325 𝑃𝑎
𝑃𝐻2𝑂 = 750 𝑇𝑜𝑟𝑟 × = 𝟖𝟔𝟑𝟕. 𝟔𝟕 𝑷𝒂
2.11525 + 0.109 + 0.033 + 0.058 𝑘𝑔𝑚𝑜𝑙 𝑆𝐺 760 𝑇𝑜𝑟𝑟

Use the Ps equation for water to calculate the dew point (T):
𝐶2
𝐶1+ 𝑇 +𝐶3 ln 𝑇 +𝐶4𝑇 𝐶5
𝑃𝐻2𝑂 = 𝑒 T = 316.118 K (42.97°C)