BOILER ROOM BASICS

PRINCIPLES OF COMBUSTION

The process of combustion is a high speed, high temperature chemical reaction. It is a rapid
union of an element or a compound with oxygen that results in production of heat – resulting in
a controlled explosion.
Combustion occurs when the elements in the fuel combine with oxygen to produce heat. All
fuels, whether there are solid, liquid or in gaseous form, consists primarily of compounds of
carbon and hydrogen called hydrocarbons. Sulfur is also present in these fuels.

PRODUCTS OF COMBUSTION

When hydrogen and oxygen combine, intense heat and water vapor is formed. When carbon
and oxygen combine, intense heat and carbon monoxide or carbon dioxide is formed. When
suphur and oxygen combine, suphur dioxide and heat are formed.
These chemical reactions take place in a furnace during the burning of fuel, provided there is
sufficient air (oxygen) to completely burn the fuel.
If there is insufficient air or inadequate mixing of fuel and air for complete combustion, the
carbon reaction will not be completed, forming carbon monoxide. Carbon particles that cool
before they can combine with oxygen to form CO2 or CO form smoke, glowing carbon particles
largely causes the yellow color in flames.
All common fuels contain some non combustible materials.
 Residual oils contains up to 5% ash, nitrogen, oxygen, sediment and water.
 Distillate oil contains up to 1% ash, nitrogen, oxygen, sediment and water.
 Natural gas contains up to 6% carbon dioxide, nitrogen and moisture

TYPES OF COMBUSTION

There are three types of combustion

Perfect Stoichiometric Combustion is achieved when all the fuel is burned using only the
theoretical amount of air. Perfect combustion cannot be achieved in a boiler, because mixing of
fuel and air in the furnace is imperfect.

Complete Combustion is achieved when all the fuel is burned using the minimal amount of air
above the theoretical amount of air needed to burn the fuel. Complete combustion is always

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the goal. With complete combustion the fuel is burned at highest combustion efficiency with
the lowest release of particulates.

Incomplete Combustion occurs when all the fuel is not burned, which results in formation of
soot and smoke.

AIR REQUIREMENTS

Oxygen for combustion is obtained from the atmosphere, which is about 21% oxygen by
volume or 23% by weight. About 1600 cubic feet of air is required to burn 1 gallon of #2 fuel oil
at 15% excess air at sea level. About 11.2 cubic feet of air is required to burn one cubic foot of
natural gas at 15% excess air at sea level.
A 100 HP boiler requires 48,000 cubic feet of fresh air per hour for combustion to take place.
Most of the 79% of air that is not oxygen is nitrogen, with traces of other elements. Combustion
air requirements are based on the composition of the fuel used. Fuels commonly used contain
nitrogen, ash, oxygen, suphur, carbon and hydrogen.
Nitrogen is nearly inert at ordinary flame temperature and forms few compounds as a result of
combustion. Nitrogen is unwanted parasite that must be accepted in order to obtain the
oxygen. It contributes nothing to combustion, it increases the volume of combustion products
to be vented, it steals heat from the reaction and creates environmental problems as well.

Air required in combustion is classified as:

Stoichiometric is a theoretical amount of air required to completely burn the fuel.

Primary air is the air that supplies the base of the burner flame. Simple burners may use only
primary air.

Secondary or Tertiary air flows are introduced into an established flame to control combustion
characteristics.
Excess air can have a chilling effect on the flame. If too much excess air is present localized
temperatures can be too low for combustion and small amounts of fuel can pass up the stack
unburned.

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Water vapour is a byproduct of burning hydrogen. It too subtracts the heat from the flame and
becomes steam at flue gas temperature, passing out of the vent as vapor mixed with the
combustion products.

Natural gas contains more hydrogen and less carbon per unit of heat content than oil and
consequently its combustion produces more water vapor which carries a great amount of heat
up the stack. Therefore gas efficiency is always slightly less than oil efficiency.

Air requirements for combustion are generally expressed in cubic feet of air per gallon of oil or
per cubic foot of gas for convenience because fans, ducts and other air moving devices are
rated in cubic feet per minute or cubic feet per hour. The Fuel/Air ratio for combustion is
actually a weight ratio based on the required weight of oxygen for a given weight of fuel.

Altitude Differences:

At sea level or at altitudes up to 2000 feet, the weight of oxygen per cubic foot of air does not
vary sufficiently to create major problems. At higher altitudes air density has to be taken into
consideration. At 5000 feet above sea level air has approximately 85% of its weight at sea level
therefore about 15% more air by volume must be introduced to obtain the required oxygen for
combustion. Fuel gas obeys the same physical laws as air- at 5000 feet above sea level 15%
greater gas volume is required to obtain sea level weight of combustibles. A gallon of fuel oil
has the same weight at any altitude and no fuel input increase is necessary.

FORCED / NATURAL DRAFT

When considering air requirements two roles must be considered.

To accomplish this requires draft, which is simply air movement through the boiler. Since the
inner structure of the boiler offers resistance to combustion gas movement (commonly called
draft loss). The draft must be strong enough to overcome this resistance.
With forced draft, air is delivered to the combustion zone by the burner blower in sufficient
volume to provide the combustion air at sufficient pressure to expel the combustion products
from the vent against the draft resistance of the boiler. The combustion zone is consequently
under positive pressure - pressure higher than atmospheric.
With natural draft, the draft required to move the combustion products through the boiler is
created by a stack or chimney. A stack or chimney creates a draft because the column of the
combustion products it encloses is lighter in weight than the surrounding air. That buoyancy
creates a negative pressure – pressure less than atmospheric – so the combustion zone is under
negative pressure.

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If the stack or chimney provides inadequate negative pressure to vent the products of
combustion an induced draft fan may be used to compensate for the deficiency of the stack. In
that case the burner still operates with negative draft in the combustion zone.

THE COMBUSTION PROCESS

To summarize:

The combustion process occurs when fuel combines with oxygen to produce heat
The goal is to achieve complete combustion – the burning of all the fuel with a minimal
amount of excess air.

There are four requirements for complete combustion or MATT

M – Proper mixture of air and fuel is required. The air/fuel ratio is controlled for all firing
rates. High fire requires more air and fuel proportionally than low fire.
A – Proper atomization of liquid fuel is required. Atomization is the process of breaking
up liquid fuel into small droplets to allow rapid vaporization of the liquid (a process
called pyrolysis).
T – Proper air, fuel and zone temperatures must be maintained to achieve complete
combustion.
T – Proper time must be provided to complete the combustion process before the gases
of combustion come in contact with the heating surface.

Note that the heating surface is where there is water on one side and gases of combustion on
the other. If the gases of combustion come in contact with the heating surface before
combustion is complete, they will cool and cause formation of soot and smoke.

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