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Fuels, Lubricants & Polymers

Fuels — classification, characteristics of a good fuel, calorific value (gross and net), Dulong's formula and bomb calorimeter; solid fuels — coal formation and ranks, proximate and ultimate analysis, carbonisation and coke; liquid fuels — petroleum refining, knocking, octane and cetane numbers, biodiesel and ethanol; gaseous fuels — natural gas, CNG, LPG, biogas, producer and water gas, hydrogen; combustion calculations — minimum air required; lubricants — functions, mechanisms, types (liquid, semi-solid, solid) and properties (viscosity index, flash and fire point, cloud and pour point); polymers — classification, polymerisation (addition, condensation), thermoplastics and thermosets, elastomers and vulcanisation, important polymers, fibre-reinforced polymers and polymers in construction — with fully worked numericals.

📑 Contents (10 sections)

Last reviewed 16 Sept 2026 · 12 min read

Fuels

A fuel is a combustible substance that releases heat energy on burning.

Classification

Origin Solid Liquid Gaseous
Primary (natural) Wood, peat, lignite, coal Crude petroleum Natural gas
Secondary (derived) Charcoal, coke, briquettes Petrol, diesel, kerosene, fuel oil, biodiesel, ethanol Producer gas, water gas, coal gas, LPG, biogas, hydrogen

Characteristics of a good fuel

High calorific value; moderate ignition temperature; low moisture and ash; low sulphur and non-polluting combustion products; controllable combustion; easy storage, transport and handling; low cost and availability.

Calorific value

Calorific value (CV) — heat liberated by complete combustion of unit mass (or volume) of fuel.

Term Meaning
Gross (higher) calorific value, HCV/GCV Heat released when combustion products are cooled to room temperature — water vapour condensed, latent heat recovered
Net (lower) calorific value, LCV/NCV Heat actually available when water vapour escapes — HCV minus latent heat of steam formed
FormulaCalorific value relations

Dulong's formula (HCV of coal from ultimate analysis, percentages):

Net calorific value:

(H in %; 587 kcal/kg ≈ latent heat of steam; 9 kg of water forms per kg of hydrogen.)

Bomb calorimeter (solids and liquids): (with corrections), where W = water mass, w = water equivalent of calorimeter, x = mass of fuel. Junkers gas calorimeter — for gaseous fuels.

1 kcal ≈ 4.187 kJ.

Solid fuels — coal

Formation and rank

Plant matter → peat → lignite (brown coal) → sub-bituminous → bituminous → anthracite (coalification with increasing pressure, temperature and time).

With increasing rank: carbon content and calorific value increase; moisture and volatile matter decrease; ignition becomes more difficult (anthracite burns with little smoke).

Analysis of coal

Analysis Determines Significance
Proximate analysis Moisture (at 105–110 °C), volatile matter (925 °C, covered crucible), ash (~700–750 °C, open), fixed carbon (by difference) Practical assessment: high moisture and ash reduce CV; high volatile matter → long smoky flame; high fixed carbon → higher CV
Ultimate analysis C, H, N, S, O (elemental) Calorific value calculation (Dulong), combustion air, pollution (S)

Carbonisation

Heating coal in absence of air:

  • Low-temperature carbonisation (~500–700 °C) — semi-coke, domestic fuel.
  • High-temperature carbonisation (~900–1200 °C) — metallurgical coke (strong, porous, low sulphur) for blast furnaces; by-products coal gas, tar, ammonia (Otto–Hoffman by-product ovens).

Liquid fuels

Petroleum refining

Crude oil is separated by fractional distillation into fractions (approximate boiling ranges): LPG gases → petrol (gasoline) → naphtha → kerosene → diesel → fuel oils → lubricating oils, waxes → bitumen (residue — used in road construction). Cracking (thermal/catalytic) breaks heavy fractions into lighter, more valuable ones; reforming improves octane.

Knocking, octane and cetane numbers

Concept Petrol (SI) engines Diesel (CI) engines
Knocking Premature auto-ignition of unburnt end gas → metallic knock, power loss, damage Long ignition delay → accumulated fuel burns suddenly (diesel knock)
Rating Octane number — % of iso-octane (ON = 100) in a mixture with n-heptane (ON = 0) that knocks like the fuel Cetane number — % of cetane (n-hexadecane) (CN = 100) in mixture with α-methylnaphthalene (CN = 0)
Good fuel High octane (branched chains, aromatics) High cetane (straight-chain paraffins)
Additives Anti-knock agents (earlier tetraethyl lead — phased out; now MTBE, ethanol) Cetane improvers
  • Straight-chain hydrocarbons have low octane but high cetane — so a good petrol is a poor diesel and vice versa.

Alternative liquid fuels

  • Biodiesel — methyl esters from vegetable oils/animal fats by transesterification; renewable, biodegradable, lower sulphur.
  • Ethanol — from sugarcane molasses, grains; blended with petrol (ethanol blending programmes increase blend ratios over time).
  • Power alcohol, methanol.

Gaseous fuels

Fuel Main constituents (approx.) Features / uses
Natural gas Mainly methane High CV; piped gas, power plants, fertilisers
CNG Compressed natural gas (methane) at high pressure Cleaner vehicle fuel
LPG Propane + butane (liquefied under pressure) Domestic cooking, industry; heavier than air (leaks settle low); odorant added
Biogas Methane (roughly 55–65%) + CO₂ Anaerobic digestion of cattle dung, sewage sludge, organic waste; manure by-product
Producer gas CO + N₂ (+ H₂) Air + steam over hot coke; low CV; furnaces
Water gas CO + H₂ Steam over red-hot coke; higher CV
Coal gas H₂, CH₄, CO Carbonisation by-product
Hydrogen H₂ Highest CV per unit mass, clean (water only); storage/safety challenges; green hydrogen from electrolysis using renewable power

Advantages of gaseous fuels: clean combustion, easy control, little excess air, no ash; disadvantages: storage and leakage hazards.

Combustion calculations

FormulaCombustion relations (by mass)
  • C + O₂ → CO₂ : 12 kg C needs 32 kg O₂ (→ 44 kg CO₂)
  • 2H₂ + O₂ → 2H₂O : 4 kg H₂ needs 32 kg O₂ (1 kg H needs 8 kg O₂; forms 9 kg H₂O)
  • S + O₂ → SO₂ : 32 kg S needs 32 kg O₂

Minimum O₂ per kg fuel (C, H, O, S as mass fractions) Air contains about 23% O₂ by mass (≈ 21% by volume):

Actual air includes excess air for complete combustion.

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