DESIGN AND DEVELOPMENT OF FLAME BURNER DESIGN AND DEVELOPMENT OF FLAME BURNER PART 2”
N.H. BAKAR1, 2 , M.S. ZAKARIA1, 3 , F.A. ZAKARIA1, 4 , M.R. KHIYON1,5 1
Department of Mechanical Engineering, Faculty of Engineering, University Malaysia Pahang, Malaysia 2
Email:
[email protected] 3 4
Email:
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Email:
[email protected] 5
Email:
[email protected] ABSTRACT
This project is to design and development of flame burner. Burner is a device, as in a furnace, stove, torch, Bunsen burner or gas lamp which is lighted to produce a flame. In this proposal, an experimental study using torch for Moderate or Intense Low-oxygen Dilution (MILD) combustion inside the close furnace. This experiment is to investigate the temperature inside the close furnace. In addition, is to differentiate the colour of flame when the temperature inside the furnace increased. Furnace is a direct fire heater and used for many things, such as extraction of metal and other chemical plants. In this project, MILD combustion supplied heat energy to fuel the furnace. MILD combustion is one of the best technologies for clean and efficient combustion and has been testament to be a better combustion technology. Therefore, the flame test is proposed. It is to determine the temperature inside and outside the furnace and colour of flame with different percentage of valve and rate of combustion in different percentage of valve.
INTRODUCTION Burner is a device as in a furnace, stove, furnace or gas lamp which is lighted to produce a flame. A furnace is a common piece of laboratory equipment that produces a single open gas flame, which is used for heating, sterilization, and combustion. The gas can be natural gas (which is mainly methane) or a liquefied petroleum gas, such as propane, butane, or a mixture of both. The processes of combustion need three basic elements to initiate which are fuel, oxidiser and heat ignition. Other than that, the purpose of this is to investigate the effects of the tube length on the properties of flame using furnace. Gas valve is used to raise the flame to a suitable height for burning Gas valve is used to raise the flame to a suitable height for burning. In addition, the collar will affect the amount of air flow entering the burner through the air-holes. Therefore, the flame test is proposed. It is to determine the colour of flame, length of flame, flame swirl and temperature of flame. However, this study might be increase across the times. The gas that used in this experiment is liquefied petroleum gas (LPG). LPG is a hydrocarbon gas fuel that extracted from crude oil or natural gas. In the ambient temperature, LPG exists as gases but with applied moderate pressure, it is liquefied, therefore, it’s called liquefied petroleum gas. LPG is a mixtures of petroleum gases mainly butane and propane. The mixtures ratio is differ in countries around the world that having LPG (Prima Gas, 2011). In Malaysia, the commercial LPG might contain hydrocarbons mixture of propane, propylene, butane (normal-butane or iso-butane) and butylenes (including isomers). Ethyl mercaptan is added as an odorant to odourless LPG to detect it in case of leakage. LPG is a nontoxic, colourless and clean burning gas fuel that easily found available in the market. LPG has made the fuel for stoves in the restaurant, the fuel for heater and cooking appliances at homes, also used as a fuel in 1
DESIGN AND DEVELOPMENT OF FLAME BURNER
the transportations. In addition, the Moderate and Intense Low oxygen Dilution (MILD) combustion was take part in the furnace. MILD combustion is a new combustion technology that produces lower pollution emissions and increases thermal efficiency (Cavaliere and de Joannon, 2004; Dally, Karpetis and Barlow, 2002; Noor, Wandel and Yusaf, 2013).This kind of process can guide us to investigate about the rate of combustion, how much the fuel being used and to reduce the waste of the gas during the burning take place. The requirement for MILD combustion is the oxygen dilution in the oxidant stream and for the mixture temperature to be above the self-ignition for the fuel. The oxygen dilution and the heating of the oxidizer can be achieved by the use of exhaust gas recirculation (EGR) (Katsuki and Hasegawa, 1998; Yusaf, Noor and Wandel, 2013). The hot EGR will dilute the oxygen in the oxidant and preheat it. The oxygen content in the fresh air will reduce the dependence on the ratio of the fresh air and EGR. A requirement of MILD combustion is to preheat a mixture and dilute the oxygen content in the oxidant. In order to achieve this condition, EGR was utilized. In this experiment, we use LPG as a fuel, so we can see the ratio of the usage of oxygen, nitrogen and also the product of the combustion. Basically, the chemical equation used for combustion by using propane is as balanced equation below:
Theoretically, the balanced equation for complete combustion of Propane is as an equation below:
In this investigation, the pressure gauge plays a big role as we use this component to determine the heat release. The furnace pressure switch is designed to sense the negative pressure created by the draft inducer motor at furnace start up and to shut down furnace ignition if proper differential air pressures and venting are not maintained. Thus, by calculating all of this parameter can lead us to obtain the results of our stated objectives. Based on the objective to determine the velocity of the flame, we use Bernoulli Principles based on limitation on the use of Bernoulli equation. The limitation on the use of Bernoulli’s Equation including the conditions of steady flow, negligible viscous effect and flows along a streamline. Bernoulli Principles state that, when the speed of moving fluid or gas increases, the pressure within the fluid or gas decreases. The Bernoulli Equation is shown as below:
Where, P = Pressure of the gas; ρ = Density of the gas z = Height of the object g = Gravitational acceleration
FLAME BURNER DEVELOPMENT Design and development of flame burner is given into 3 stages, first project knowledge, second design brainstorming, third fabrication and software setup and lastly testing. The project knowledge is done after we successfully receive the title. It is done by gathering all related information for the flame burner from the design consideration, importance and the fabrication stage.
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DESIGN AND DEVELOPMENT OF FLAME BURNER
The burner for this project is divided into two main parts which is the burner and the furnace. In the burner section it is divided into three main zones. First zone is gas source Liquefied petroleum gas or liquid petroleum gas (LPG) propane. Gas connected to the system by the mean of hose and regulator. Hose is mounted to the regulator with the use of hose clip. To avoid leakage from happen two unit of screw hose clamp were use to tightly mount the hose to the regulator. The second zone is pressure control part. This part is the main part of the whole system where in this part it control the rate of pressure release by the use of one way valve. The pressure value in the piping is shown from the pressure gauge. Different fitting were use in this part in order to connect the one way control valve, pressure gauge, gas source and the burner section. Fitting were connected with the help of build in tread, meanwhile white tape were use in order to conceal the gap between each fitting to avoid gas leakage. Same as the first part all the connection to hose were tighten with the help of hose clamp, two unit of hose clamp were use for extra safety. Burner parts were the last part in this project, this part play an important role where the product or the flame projected thru the burner nozzle. The size of the flame burner nozzle is 3.5 cm while the n ozzle strainer opening is 0.1mm. The flame burner is build in with its own control screw. Furnace are being use in order to collect the experiment data of the flame. In this furnace part it is divided into two parts which is the furnace and the thermocouple. The furnace is made of rolled aluminium which then welded together in order to produce the round shape. The furnace is then drilled in to produce the hole for the thermocouple to be placed. In addition, K-type thermocouple was use for this experiment and the maximum temperature that the K-type thermocouple can withstand is up to 1200˚c. In order to collect the data from the thermocouple, National Instrument (NI) hardware was use to connect the positive and negative cable of the thermocouple. The hardware consists of 8 connections and therefore it produces 8 data to be recorded. Thermocouple cable was mounted to the NI hardware by the mean on internal clamp that available from NI component. The thermocouple wire was installed by following the instruction given from the software Data Acquisition (DAQ). The figure below shows the final flame burner development before start to analyze the flame.
Figure 1: Flame burner set up (Part 1)
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DESIGN AND DEVELOPMENT OF FLAME BURNER
Figure 2: Flame burner set up (Part 2)
SOFWARE SETUP
DAQ Set up a) NI-DAQ’s icon is clicked to enter the national measurement and instrument software. b) DAQ is clicked to create a new file. c) In task, Acquire signal is choose and Analog Input is selected.
Figure 3: NI-DAQ Set up 4
DESIGN AND DEVELOPMENT OF FLAME BURNER
d) The ports of the acquire signal which is temperature is selected according to the DAQ that connecting to thermocouple. (ai0 utntil ai7 for thermocouple) e) The name of the file is renamed (MSD TEST). f) Continuous sample is selected in acquisition mode in order to obtain a continuous graph in result. g) The DAQ is run and the graph produced is observed. h) After ensuring the graph obtained is correct, the file is saved. i)
Then we proceed with DASYLab.
DASYLab Set up a) The icon of Dasy Lab is clicked to enter the software platform. b) Then, NI-DAQmx is synchronized with MAX configuration. c) Appropriate module is dragged and dropped to design the circuit for the signal analysis.
Figure 4: DASYLab Set up
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DESIGN AND DEVELOPMENT OF FLAME BURNER
TESTING THE FLAME BURNER Setting The Apparatus A. The pressure regulator twists counter clockwise to ensure in close position and then mount to the LPG tank. B. The pressure regulators are then twist in clockwise direction to open, followed by the one way valve. C. The pressure in the system is then check from the pressure gauge meter. D. Burner torch screw twisted counter clockwise to allow gas flow out in low pressure amount. E. Lighter is then use to ignite the flame thru the torch nozzle. F. Torch is then directed into the furnace and place properly. G. The fire is then control by turning the torch screw to allow higher flow rate of gas to produce desired flame stage. H. The times taken were recorded throughout the process. I. The date is then collected from the DAQ user interface. J. All recorded data is then interpreted into excel to convert it into graph value.
SAFETY PRECAUTION WHILE RUNNING THE COMBUSTION There are several safety precautions while running the mini furnace. Firstly, wear jacket and safety shoes for mechanical protection. It is to prevent the skin is exposed to the fire. Then, check the integrity of the gas system. Make sure the cylinders are secured to immovable objects and that tubing and connectors do not have gas leaks. It is because the gas leak can exposed to the incineration. After that, check the integrity of the burner and the connection. Make sure there is no reverse flow of the gas to avoid explosion since we played with the fire. In addition, avoid viewing the flame or furnace unless wearing protective eyewear. It is to prevent the eyes prone to the fire. Never leave the flame unattended. Close the flow of the gas immediately after use. Besides that, a fire extinguisher is located nearby the combustion. It is MUST have during the investigation. Lastly, allow the burner head to cool to room temperature before handling.
RESULT AND DISCUSSION TEMPERATURE SENSORS AND DATA COLLECTION Thermocouples were installed at 8 different locations on the combustion chambers. The computer used for data recording is equipped with a National Instrument (NI) data acquisition system and DASYlab software. The temperature was measured using K-type and which were connected to an NI connector box. The measurement was displayed and recorded in a DASYlab graphical user interface (ASCII) and can be recorded and displayed in the format of an MS Excel spreadsheet. In this experiment, the National Instruments Data Acquisition (NIDAQ) system was used to measure and display the temperature measurement through thermocouples. DASYlab software was used to manage and store the data collected. It consists of a chassis NIDAQ 9219 with a number of signal conditioning amplifiers and analog to digital conversion modules. The analysis of temperature had been done to investigate the heat release during the combustion. In addition, 8 thermocouples were divided into 2 sections which are upper and lower of the furnace. The upper furnace is thermocouple series 5, 6, 7 and 8 while downward furnace is thermocouple series 1, 2, 3 and 4. The figure below shows the temperature of different locations with different pressure. 6
DESIGN AND DEVELOPMENT OF FLAME BURNER
75 18
18
(a)
(b)
FIGURE 5: Dimension of furnace (a) top view (b) side view
1
2
5
4
6
8
3
7
(a)
(b)
FIGURE 6: Thermocouple position (a) first level (b) second level
250
Location 1
200
Location 3
150
Location 4 100
Location 5 Location 6
50
Location 7 Location 8
0 1 26 51 76 101 126 151 176 201 226 251 276 301 326 351 376 401 426 451 476 501 526 551 576 601 626
Temperature
Location 2
Figure 7: Graph of experimental temperature versus time taken for 25% of valve 7
DESIGN AND DEVELOPMENT OF FLAME BURNER
The test was beginning when the valve is at 25%.. Based on figure 7, the average temperatures at 1 second for 8 locations were 86.5 o C and it started to rise when the test was begin. At 634 second the temperature inside the furnace was stopped. The temperatures for 8 locations were 177.2o C, 137.6o C, 136.6o C, 137.9, 229.9 o C, 201.0 o C, 193.3 o C and 177.0 o C. The maximum temperature is 229.9 o C and located at chamber 5.
350 Location 1 Location 2
250
Location 3
200
Location 4 150
Location 5
100
Location 6
50
Location 7
0
Location 8 1 24 47 70 93 116 139 162 185 208 231 254 277 300 323 346 369 392 415 438 461 484 507
Temperature (C)
300
Figure 8: Graph of experimental temperature versus time taken for 50% of valve
The next test was when valve is at 50%.. Based on figure 8, the average temperature at 1 second for 8 locations was 93.9 o C and it started to rise when the test was begin. At 523 second the temperature inside the furnace was stopped. The temperatures for 8 locations were 206.0 o C, 169.6o C, 174.5o C, 168.3 o C, 208.6 o C, 234.7 o C, 275.4o C and 331.8o C. The maximum temperature is331.8o C and located at chamber 8.
350
Location 1
300
Location 2
250
Location 3
200
Location 4
150
Location 5 Location 6
100
Location 7
50
Location 8 0 1 23 45 67 89 111 133 155 177 199 221 243 265 287 309 331 353 375 397 419 441 463 485 507
Temperature (Degree Celcius)
400
Figure 9: Graph of experimental temperature versus time taken for 75% of valve 8
DESIGN AND DEVELOPMENT OF FLAME BURNER
The valve for next test was 75%. Based on figure 9, the average temperature at 1 second for 8 locations was 42.4 o C and it started to rise when the test was begin. At 523 second the temperature inside the furnace was stopped. The temperatures for 8 locations were 171.8o C, o C, 144.8o C, 146.5 o C, 140.7 o C, 176.1 o C, 273.8 o C,338.9 o C and 181.1o C. The maximum temperature is 338.9 o C and located at chamber 7.
600
Temperature
500
Location 1 Location 2
400
Location 3 Location 4
300
Location 5 200
Location 6 Location 7
100
Location 8 1 23 45 67 89 111 133 155 177 199 221 243 265 287 309 331 353 375 397 419 441 463
0
Figure 10: Graph of experimental temperature versus time taken for 100% of valve
Lastly, the valve for next test was 100%. Based on figure 10, the average temperature at 1 second for 8 locations was 74.6 o C and it started to rise when the test was begin. At 469 second the temperature inside the furnace was stopped. The temperatures for 8 locations were 319.9o C, 260.9o C, 238.0 o C, 235.0o C, 383.6o C, 319.8o C, 476.9o C and 387.9o C. The maximum temperature is 476.9o C and located at chamber series 7. Based on the 4 figures for various percentage valve, it shows that the temperature will increase when the valve percentage increase. Since, the thermocouple located at 8 different chambers the temperature slightly different. In this investigation, the temperature at upper chamber higher than downward. It is due to the temperature at upper flame is higher than below. In addition, the graphs show that in certain times the curve performance is upward and downward. This is due to the windy condition while the project is running and significantly causes the flame inside the furnace near to the few thermocouples. After that, the colour of flames turns from orange to blue when the temperature increases. The colour of flame for 100% of valve is completely blue while for 75% of valve the colour of flame is blue and a little bit of orange colour. The colour for 25% valve is orange and for 50 % valve is orange and little amount of orange. COMBUSTION EQUATION In order to design the furnace, the combustion equation must be used. The balanced of the combustion process will not produce an unburned hydrocarbon which means that the combustion process
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DESIGN AND DEVELOPMENT OF FLAME BURNER
consumes all the fuels provided. The general hydrocarbon stoichiometric combustion equation can be writing as follow:
Since the fuel used in this combustion is Liquefied Petroleum Gas (LPG), choose propane since the propane has the major ratio in LPG mixture rather than butane. This is according to the Petronas specification in Malaysia 2011 which said that commercial LPG is a mixture of LPG products; with the primary component being propane at 70:30. Thus, since the propane has the greater ratio in LPG, the ratio of the butane can be neglect because of the ratio is too small. The hydrocarbon stoichiometric combustion equation is as follow:
FURNACE POWER CALCULATION The rate of heat released or the furnace power calculation can be obtain from the equation of: W = mass flow rate x gas heating value Sample Calculation
By using Bernoulli principle,
= 4.8422 m/s Area of the inlet,
= = Thus, the volume flow rate, Q 10
DESIGN AND DEVELOPMENT OF FLAME BURNER
4.8422 m/s = By referring Table 2, the density of the propane, the equation used is:
. To find the mass flow rates,
Therefore, the heat released by combustion is, W = mass flow rate x gas heating value
Where, gas heating value of the propane also can be obtained in the Table 2 below. Propane heating value = 50.3 MJ/kg Hence, W=( = 104.046 kW
Calculation for each of pressure: Pressure P, (KPa)
Inlet Velocity
20 40 60 80
9.3386 8.1213 6.6859 4.8422
Volume Flow Rate Q, ( )
Mass Flow Rate m, (kg/s)
Heat Release by Combustion W, (kW) 200.662 174.506 143.662 104.046
Table 1: Calculation of heat release for each pressure
Fuel Hydrogen Methane Ethane Propane
Composition H2 CH4 C2H6 C3H8
Molar mass g/mol 2.01 16.04 30.07 44.09
MJ/kg 141.8 55.5 51.9 50.3 11
Specific heat KJ/ mol BTU/Ib 286 61100 890 23900 1560 22400 2220 21700
Density kg/m3 0.0899 0.6680 1.2640 1.8820
DESIGN AND DEVELOPMENT OF FLAME BURNER
Natural gas Butane Octane Decane Gasoline Diesel Carbon Coal Wood
18 50.0 900 21600 C4H10 58.12 49.5 2877 20900 C8H18 114.23 47.9 5470 20600 C10H22 142.28 47.6 6773 20500 CnH1.87n 100-110 47.3 5400 20400 CnH1.75n 170-200 44.4 4480 19300 C 32.8 393.5 14100 21 275 11000 15 300 6500 Table 2 : Fuel Heating Value to calculate furnace power
0.8000 2.4890 703.00 730.00 719.70 832.00 2.2650 828.75 650.91
Source: (McAllister, 2011; Demirel, 2012; Noor et al., 2012e)
CONCLUSION In summary, the development of flame burner was successful in achieving a temperature inside the furnace using the thermocouple sensor. A K-type thermocouple that can withstand up to 1645K was used to measure the temperature inside the furnace. A data acquisition system was used to collect and record the data from the thermocouples. From the investigation, the temperature is increased when the pressure is increased. In addition, the temperature inside the furnace also effects the location of thermocouple. The 8 thermocouples were divided into 2 sections which are upper and lower of the furnace. The temperature in upper furnace is higher than the lower furnace. It is due to the higher flame have higher temperature than below. After that, the colours of flame turn to blue from orange when the percentage of valve is increased. The colour of flame for 100% of valve is completely blue. For the furnace power, as we use the propane gas as the fuel, the value of heat released of the propane obtained and as calculated in table based on its heating value. The objectives of this project have been achieved. At the end of the project, we find out that there is some sort of things that can be improve in order to get the accurate and precise value for the future study. The suggestion to improve this project is by f illing the inner part of the furnace with the concrete to increase the heat conduction of the furnace, build an igniters at the inlet to ease the fire to initiate and lastly by fixing the position of the burner.
ACKNOWLEDGEMENT We would like to thank the Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP) for providing financial support and the laboratory facilities. Our supervisor, Dr. Muhamad Bin Mat Noor who always supervise and guide us along the project was run to make sure that we got enough information.
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DESIGN AND DEVELOPMENT OF FLAME BURNER
48.
Noor, MM., Wandel, AP. and Yusaf, T. 2012e, Investigation of open furnace MILD combustion of biogas on bluff-body burner, USQ Combustion Meeting, 29 Aug, University of Southern Queensland, Australia
APPENDICES GANTT CHART
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DESIGN AND DEVELOPMENT OF FLAME BURNER
16
