Calculation Basis

The total water volume in Boiler water wet circuit (Economizer + Drum and Waterwall) is at atmospheric temperature and pressure. This volume is to be raised to saturated liquid condition first. As Boiler drum remains under saturated steam condition, the saturated liquid is to be raised to saturated vapour condition. As there is huge density difference between saturated liquid and vapour, raising condition from saturated liquid to saturated vapour, displaces corresponding amount of saturated steam. Further, additional evaporation loss is assumed during the process. Thus, LDO consumption shall be calculated for following heat addition: 1. Raising parameter from atmospheric condition to satuarated liquid condition 2. Filling the drum steam space and superheater circuit with saturated steam 3. Expulsion of steam due to density difference and 4. Evaporation loss at fixed parameters

LDO Gun Capacity Details

Rated LDO consumption per Hour 2 Assumed LDO Density Rated LDO consumption per 3 Hour 4 GCV of LDO 1 TPH kg/m3 KL/Hr kcal/kg 2.3 880 2.61 10500.00

LDO Consumption Estimates for EDTA Cleaning

Parameters Temperature of final fluid Saturation Pressure Unit Deg C bar (g) Acid Cleaning Alkali Flushing Hot Water Rinsing and Passivation 150 140 150 3.75 2.6 3.75 150.96 655.58 2.54 916.69 504.62 355 30 145 30 140.68 652.65 1.97 925.89 511.97 355 30 145 30 150.96 655.58 2.54 916.69 504.62 355 30 145 30

Enthalpy of Saturated Liquid (kcal/ kg) kcal/ kg Enthalpy of Saturated Steam (kcal/kg) kcal/ kg Density of saturated steam Density of saturated liquid Latent Heat of Vaporization (kcal/kg) Water volume to be heated up Drum Volume filled with saturated steam SH Circuit volume filled with saturated steam Enthalpy Water at atmospheric condition kg/ m3 kg/m3 kcal/ kg m3 m3 m3 kcal/ kg

Heat consumed in raising temperature to saturated liquid kcal

kcal

39363401.95

36379514.35

39363401.95

Heat consumed in raising to saturated vapour of steam filled volume in kcal kcal Dryness Fraction of Steam in water circuit % Enthalpy of water filled volume with given dryness fraction Density of fluid at given dryness fraction

224303.59 100

176501.6575 100

224303.59 100

kcal/ kg kg/ m3

655.58 2.54

652.65 1.97

655.58 2.54

Heat required in raising water parameters to given dryness fraction from saturated liquid condition

kcal

455015.854

358046.2195

455015.854

Weight of steam displaced to reach given dryness fraction due to density difference kg Heat consumed in displacing the steam Total Heat consumed in raising parameters kcal kcal

353653.8 221238744.2 261281465.6 50 49.76789821

353955.9 220390641.1 257304703.4 50 49.01041969

353653.8 221238744.2 261281465.6 50 49.76789821

Boiler Efficiency considered in % % Corresponding LDO Requirement in Tons T Evaporation Loss considered in TPH @ 0.5% of BMCR TPH Time considered for evaporation in Hrs Hrs Heat consumed due to evaporation loss kcal Corresponding LDO requirements in Tons T LDO Consumption in the process T Total LDO Consumption in T T

9 5 28151100 5.362114286 55.1300125 213.288889

9 4 22415400 4.2696 53.28001969

9 6 33781320 6.434537143 56.20243535

Assumed LDO Density

kg/ m3

880 242.3737375

Total LDO Consumption in KL KL

aterwall) is at atmospheric temperature

is to be raised to saturated vapour

ng condition from saturated liquid to

on

Treated DM Water Rinsing 110 0.42 110.16 642.67 0.82 950.92 532.51 355 30 145 30

27060140.26

76415.185 100

642.67 0.82

155013.661

354565.4 217231583.6 244523152.7 50 46.57583861

9 2 11028060 2.100582857 48.67642147

880 242.3737375