Fuels, Furnaces & Refractories
MTT-102 (3L + 4T)
Dr. Jyotirmaya Kar (Assistant Professor)
Department of Metallurgical and Materials Engineering
Marks Distribution
Mid Semester End Semester TA
30 50 20
Text Books:
✓ Elements of Fuels, Furnaces & Refractories ……………… [O.P. Gupta]
✓ Fuels, Furnaces and Refractories ……………… [R.C. Gupta]
✓ Fuels, Furnaces and Refractories ……………… [J.D. Gilchrist]
✓ Fuels, Furnaces, Refractories and Pyrometry ……………… [A.V.K. Suryanarayana]
✓ Elements of Refractory Technology ……………… [O.P. Gupta]
✓ NPTEL lecture series : IIT Kanpur ……………… [Prof. S.C. Koria] 2
Syllabus
Unit I- Fuels: Definition, their importance in human life (historical background). Comparative study of solid,
liquid, and gaseous fuels. Primary and Secondary fuels. Constitution, classification and grading of coal.
Characterization of Coal: Proximate analysis, Ultimate analysis, Calorific value. Coal washing. Coal blending and
its importance in metallurgical industries.
Unit II- Carbonization of coal: Caking, Coking and Non-coking Coals. Metallurgical coke preparation, Testing
and properties of coke. Formed coke, Dry quenching of coke. Manufacture, properties and uses of Producer
gas and Water gas. Properties and uses of Blast furnace gas and Coke oven gas.
Unit III- Combustion Stoichiometry: Estimation of minimum amount of air required for a fuel of known
composition, theoretical and actual combustion processes - Air fuel ratio, estimation of dry flue gases for
known fuel composition, calculation of the composition of fuel and excess air supplied from exhaust gas
analysis,
Unit IV- Furnaces: Definition and Classification of Furnaces, Major furnace components. Furnace
atmosphere. Natural, forced, induced, and balanced draft. Chimney height. Heat losses in furnaces and
minimization. Waste heat recovery. Various types of heating elements and Electric Furnaces viz. Resistance,
Arc, and Induction furnaces
Unit V- Refractories: Desirable properties of refractories. Methods of classification. Modes of failure of
refractories in service and their prevention. Manufacturing methods and properties of Fireclay, Silica,
Magnesite, and Chrome-Refractories. Testing of Refractories. Applications of refractories in the
metallurgical industries. 3
Combustion
83
Combustion : Basics
✓ Combustion is an act or process of burning. (Emission of heat & Light)
✓ Process in general needs an oxidizing agent for rapid oxidation.
✓ Combustion may not always involve oxygen.
Conditions for Good Combustion:
Temperature.
Turbulence.
Time.
♦ C + O2 → CO2
♦ H2 + O2 → H2O
♦ CH4 + 2O2 → CO2 + 2H2O
♦ 2C2H6 + 7O2 → 4CO2 + 6H2O
♦ C3H8 + 5O2 → 3CO2 + 4H2O 84
Combustion : Important Terminologies
Combustion
Oxidation Smoldering
Smoldering
Combustion Explosion
Explosion
Gasification
85
Combustion : Types
Complete Combustion
Incomplete Combustion Air-hole Air-hole
Open Closed
Luminous Flame Non-Luminous Flame
֎ ֎
֎ ֎
֎ ֎
֎ ֎
֎ ֎ 86
Combustion Systems
Combustion Process Requirements:
Fuel Preparation
Supply of Air
Use of Appropriate Combustion System
Raising the Fuel Temp to Kindling Point
Combustion System Design Factor:
Operation Factor
Environmental Regulations
Performance
Durability 87
88
Combustion : Air
Theoretical / Stoichiometric Air
Excess Air
Total / Actual Air
Air to Fuel Ratio & Air to Fuel Equivalence Ratio
Primary, Secondary & Tertiary Air
89
Combustion Systems
Composition of Dry Air:
Composition of dry air on molar basis is : 78.09% N2, 20.95% O2, 0.93% Argon and 0.03% CO2.
Molecular Weight of air: 28.97kg/kmol. Density of air: 1.2754kg/m3.
✓ On Volume basis air composition: 79% N2 & 21% O2.
✓ On Gravimetric basis air composition: 77% N2 & 23% O2.
Actual Air − Stochiomatric Air Required
Percentage of Excess Air :
Stochiomatric Air Required
Mass of Air Moles of Air
Air – Fuel Ratio : Mass Basis : // Molar Basis :
Mass of Fuel Moles of Fuel
90
Qt-20: Calculate the theoretical air to fuel ratio on molar basis and mass basis for the following
fuels:
(a) Pure Carbon (C) ::: C + O2 = CO2
Ans: Molar Basis: 4.76. //// Mass Basis: 11.59.
(b) Pure Hydrogen (H) ::: H2 + 0.5O2 = H2O
Ans: Molar Basis: 2.38. //// Mass Basis: 34.78.
(c) Methanol (CH3OH) ::: CH3OH + 1.5O2 = CO2 + H2O
Ans: Molar Basis: 7.14. //// Mass Basis: 6.464.
(d) Petrol (C8.5H18.4) ::: C8.5H18.4 + 13.1O2 = 8.5CO2 + 9.2H2O
Ans: Molar Basis: 62.356. //// Mass Basis: 15.
91
Combustion Systems
♽ Complete Combustion:
♽ Incomplete Combustion:
Loss due to Zone of Loss due to
unburnt fuel Maximum Heat in Stack
Efficiency
92
Combustion Systems : Important Factors
Moisture Content Ash Fusion Temperature
Volatile Matter Content Reactivity of Carbon
Fixed Carbon Fuel Bed Thickness
Ash Content Fuel Particle Size
93
Qt-21: Determine the air-fuel ratio and the theoretical amount of air required (mass basis) for
complete combustion of fuel containing 85% Carbon, 8% Hydrogen, 3% Oxygen, 1% Sulphur and the
remaining as Ash.
▪ If 40% excess air is used, what is the volume of air at 27°C and 1.05bar pressure.
▪ Also find out the air-fuel equivalence ratio.
Ans:
Theoretical Air: 12.55kg/kg of fuel
Theoretical Air to Fuel Ratio: 12.55 (mass basis)
Actual Air: 17.57kg/kg of fuel
Actual Air: 14.407m3/kg of fuel at 27°C and 1.05bar pressure
Air to Fuel Equivalence Ratio: 1.4 (mass basis)
94
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