Thesis: Sc. D., Massachusetts Institute of Technology, Department of Materials Science and Engineering, 1980 / Vita. / Includes bibliographical references. / by Balkishan Agrawal. / Sc. D. / Sc. D. Massachusetts Institute of Technology, Department of Materials Science and Engineering

This thesis deals with the design of a co-combustion gas boiler for coal gas and blast furnace gas mixture. The calculation includes stoichiometry, determinination of the boiler efficiency, steam production rate and heating surfaces sizing. This thesis also includes technical documentation of designed gas boiler. The calculation of the boiler meets the values specified by the scripts and also by documentation from PBS. The boiler was designed for 113.9 MW and 93.77 % efficiency.

The aim of this diploma thesis is to design a gas boiler for blast furnace gas combustion. At the beginning is performed stoichiometry of the used fuel to determine the optimal amount of combustion air and the actual amount of flue gas. Subsequently is determined the overall efficiency, together with heat and steam power of the boiler. The main part of the thesis is focused on the design of the combustion chamber and the dimensioning of heat exchange surfaces. At the end of the thesis are performed hydraulic and aerodynamic calculations to determine the pressure loss on the side of the working medium and flue gas. Drawing documentation can be found in attachments.

The aim of a diploma thesis is design of draft boiler for co-firing blast furnace gas and natural gas. In the first part is made the stoichiometric calculation for the gas mixture. Next is the proposal of combustion chamber and proposal of individual heating surfaces of boiler. Next part contains the thermal calculation and control of individual heating surfaces. Part of the work is also drawing documentation of boiler.

Fossil fuel reserves are projected to be decreasing, and emission regulations are becoming more stringent due to increasing atmospheric pollution. Alternative fuels for power generation in industrial gas turbines are thus required able to meet the above demands. Examples of such fuels are synthetic gas, blast furnace gas and coke oven gas. A common characteristic of these fuels is that they are multi-component fuels, whose composition varies greatly depending on their production process. This implies that their combustion characteristics will also vary significantly. Thus, accurate and yet flexible enough combustion sub-models are required for such fuels, which are used during the design stage, to ensure optimum performance during practical operating conditions. Most combustion sub-model development and validation is based on Direct Numerical Simulation (DNS) studies. DNS however is computationally expensive. This, has so far limited DNS to single-component fuels such as methane and hydrogen. Furthermore, the majority of DNS conducted to date used one-step chemistry in 3D, and skeletal chemistry in 2D only. The need for 3D DNS using skeletal chemistry is thus apparent. In this study, an accurate reduced chemical mechanism suitable for multi-component fuel-air combustion is developed from a skeletal mechanism. Three-dimensional DNS of a freely propagating turbulent premixed flame is then conducted using both mechanisms to shed some light into the flame structure and turbulence-scalar interaction of such multi-component fuel flames. It is found that for the multi-component fuel flame heat is released over a wider temperature range contrary to a methane flame. This, results from the presence of individual species reactions zones which do not all overlap. The performance of the reduced mechanism is also validated using the DNS data. Results suggest it to be a good substitute of the skeletal mechanism, resulting in significant time and memory savings. The flame markers commonly used to visualize heat release rate in laser diagnostics are found to be inadequate for the multi-component fuel flame, and alternative markers are proposed. Finally, some popular mean reaction rate closures are tested for the multi-component fuel flame. Significant differences are observed between the models’ performance at the highest turbulence level considered in this study. These arise from the chemical complexity of the fuel, and further parametric studies using skeletal chemistry DNS would be useful for the refinement of the models.

The aim of this Diploma thesis is design of steam boiler with steam reheating, for combustion the blast furnace gas. The fuel composition and primary parameters for calculation of the boiler were provided. In the first part the fuel composition is described. The main part of the thesis consists of stoichiometric calculations, establishing efficiency of the boiler, calculating combustion chamber as well as design and calculation individual heating surfaces. Part of the work is also drawing documentation of boiler.

The steel manufacturing industry is one of the largest emitters of CO2, accounting for upwards of 8.8% of all anthropogenic CO2 emissions. The governments are charging taxes on CO2 emissions, which incentivize the industry to further reduce CO2 emissions. At present, much of the CO2, produced in the steel manufacturing process occurs as a result of coke oven and blast furnace gas by-products. As such, two major strategies have been proposed to reduce steel-manufacturing-related CO2 emissions: producing more electricity via optimized combined cycle power plants (CCPP), and converting off-gas by-products into methanol (CBMeOH). The present research consists of an economic and environmental analysis of the status quo, CCPP, and CBMeOH systems for five locations: Ontario, the USA, Finland, Mexico, and China. The economic analysis considered factors such as carbon tax, electricity price, methanol price, electricity carbon intensity, power purchasing parity, and income tax. In the CCPP process, desulphurization is conducted using ProMax with MDEA as the solvent, while the CBMeOH process uses a membrane to separate the bulk H2S, with organic sulfurs such as thiophene being removed via CO2+steam reforming and middle-temperature removal. The results of the economic analysis revealed the CBMeOH plant to be the most profitable in Ontario, the USA, China, and Mexico, while the CCPP system was shown to be the most profitable in Finland. The environmental analysis was conducted using the TRACI, CML-IA, ReCiPe2016, and IMPACT2002+ tools in SimaPro V9, with the results showing the CBMeOH system to be the most environmentally option in Ontario, Finland, and China, and the CCPP system as the most environmentally friendly option in the USA and Mexico. / Dissertation / Doctor of Philosophy (PhD)

The diploma thesis deals with design of gas steam boiler with given parameters of steam. Blast furnace and coke oven gas are used as fuel. At the beginning of this work, both co-fired fuels are presented to us, their chemical analysis and stoichiometry are performed. The main part of the diploma thesis deals with the dimensioning of individual heat exchange surfaces such as steam superheaters, evaporators, economizers and air heaters. All heat exchange surfaces meet recommended parameters such as recommended steam rates, flue gas, etc. At the end, the total heat balance of the boiler is performed. Part of the work is also drawing documentation showing the main dimensions of the boiler. It is also indicated the connection of individual heat exchange surfaces.

This diploma thesis deals with the constructional and calculation design of boiler for blast furnace and coke gas mixture combustion, including sizing of the heating surfaces. The opening section is dedicated to a brief characterization of burned fuels. The following chapter shows the parameters and composition of the resulting fuel mixture. The main part of this thesis involves; determining the stoichiometric amount air required for combustion and the resulting flue gas, determining the boiler efficiency and steam production rate, calculations regarding the combustion chamber and the detailed design of the individual heat exchangers. At the end of the thesis the heat balance of the entire boiler is verified. Drawing documentation of boiler is also part of this diploma thesis.