Efficiency calculation for Boiler#1

Boiler Data
Flue gas measurements
Fluegas condition used for calculation
After economiser
APH inlet
APH outlet
Date & time 7/1/2006 17:00
7/1/2006
hr
11:00
7/1/2006
hr
12:00 hr
b Eco A APH
O2 (%)
2.37
2.37
6.05
O2 (%)
2.37
6.05
CO (PPM)
1204.0
1204.0
61.0
CO (%)
0.120
0.006
CO2 (%)
15.040
14.30
11.92
Max CO2
18.60
18.60
EA (%)
12.72
12.72
40.47
CO2 (%)
16.41
13.22
FGT (oC)
362.0
362
169.00
AMB (oC)
35.0
35.0
35.0
FGT (oC) corrected
201.73
Another formula for calculating excess air
11.54

3.20
0.19480526

DATA
Theoretical air requirement
N2 in flue gas
Dry flue gas quantity
Nitrogen quantity in flue gas
Inlet dry air quantity
Ambient temperature
Ambient WBT
Heat released by burning 1 kg of carbon

5.03
81.10
5.91
4.37
5.66
35.0
25.0
8084

5.03
80.73
7.30
5.44
7.05
35.0
25.0
8084

kg/kg of fuel
% in flue gas
kg/kg of fuel
kg/kg of fuel
kg/kg of fuel
o
C
o
C
kCal/kg

Flue gas (mass basis)

%Vol
Oxygen
Carbon Dioxide
Carbon Monoxide
Nitrogen

Mol wt.
2.37
16.41
0.120
81.10

32
44.01
28.01
28.01

75.84
722.3762
3.372404
2271.49
3073.079

% Mass
2.5
23.5
0.1
73.9

A APH
% Vol
% Mass
6.05
193.6
6.38
13.22 581.6535
19.15
0.006 0.170861
0.01
80.73 2261.177
74.46
3036.602
Coal & Air mixture temperature

Specific heat calculation of flue gas

Gas temp
474.7 K
CO2
1.00 kJ/kg C
CO
1.06 kJ/kg C
O2
0.97 kJ/kg C
N2
1.05 kJ/kg C
Specific heat
1.0361 kJ/kg C
Mean specific heat
1.0181
Moisture calculation
Air
DBT
WBT
Humidity ratio
Moisture content of air
Heat with pulvarised coal
GCV of coal(as fired)
Total heat of coal
Fuel
Moisture in fuel
Hydrogen in fuel
Total moisture in flue gas
Specific heat of moisture
Data on Ash
Unburnt carbon in fly ash
Unburnt carbon in bottom ash

Gas temp
CO2
CO
O2
N2
Sp heat
KJ/kg C

35
27.00
0.02
0.0200
-18
3580
3563

35
27.00
0.02
0.02
-17.50
3580.00
3562.50

0.08
0.0250
0.417
0.4498

0.08
0.0250
0.445
0.4498

308.0
0.86
1.05
0.91
1.05
1.0000

K
kJ/kg C
kJ/kg C
kJ/kg C
kJ/kg C
kJ/kg C

o
95 F
o
80.60 F

C
C
kg/kg of dry air
kg/kg of dry air
kCal/kg
kCal/kg
kCal/kg

kg per kg of fuel
kg per kg of fuel
kg per kg of fuel
Kcal/kg-oC

0.90 %
3.60 %

Losses
Dry flue gas loss
Heat loss due to CO in flue gas
Heat loss due to moisture in air
Heat loss due to moisture and hydrogen in the fuel
Heat loss due to unburnt in bottom ash
Heat loss due to unburnt in fly ash
Sensible heat loss in bottom ash
Sensible heat loss in fly ash
Radiation and unaccounted heat loss

239.50
15.63
8.49
198.62
21.69
21.69
9.59
12.42
35.63

Kcal/kg
6.72%
Kcal/kg
0.44%
Kcal/kg
0.24%
Kcal/kg
5.58%
Kcal/kg
0.61%
Kcal/kg
0.61%
Kcal/kg
0.27%
Kcal/kg
0.35%
Kcal/kg
1.00%
Manufacturer's margin
Heat credit
Total heat loss
15.81%
Thermal Efficiency 84.19%

%
%

31.28
34.11

239.50 Kcal/kg

5.58%

0.88%
0.96%
1.84%

0.00

Due to Hydrogen &

Moisture in the fuel

Dry Flue gas Loss

6.72%

Design Values
5.08
0.00
0.12
5.95
0.90
0.00
0.38
0.18
0.17
0.50
-0.71
12.57
87.43

%
%
%
%
%
%
%
%
%

Due to Formation of CO

198.62 Kcal/kg

0.44%

15.63Kcal/kg

100 %
84.19%

Heat Input

0.24% 8.49
Kcal/kg
Due to Moisture in Air

0.88%

31.28Kcal/kg

Due Unburnt bottom Ash

0.96%

34.11
Kcal/kg

Unburnt Carbon in fly Ash

1.00%

35.63
Kcal/kg

Radiation & Unaccounted

losses

BOILER DATA # 01
Coal Analysis (used for calculation)
Proximate Analysis % by mass
Moisture % Volatile
Ash %
matter %
8.00
24.70

Fixed carbon GCV kcal/kg

%
40.50
26.80
3580

Ultimate Analysis (wet basis; as fired condition, converted from AES Laboratries report)
Moisture %
C

H
38.02

N
2.50

O
1.48

S
5.00

Ash
0.38

37.26

8.00

Proximate Analysis % by mass (on wet basis from NTPC on 6.1.2006)

Moisture % Volatile
Ash %
matter %
8.00
24.70

Fixed carbon GCV kcal/kg

%
40.50
26.80
3580

Ultimate Analysis (on dry basis)-received from AES Laboratries

C

H
2.72

1.61

5.44

0.41

40.50

GCV
3580.00

Coal analysis report

Date
Total Moisture
(%)
1/5/2006
14.50
1/6/2006
14.10
1/7/2006
14.30
1/8/2006
14.60
1/9/2006
14.40
1/10/2006
14.00
1/11/2006
14.00
14.27

Ash
(%)
35.60
34.50
34.70
35.70
34.70
34.10
34.30
34.80

Volatile matter
(%)
26.00
26.90
26.60
25.80
26.50
27.20
27.00
26.57

Fixed carbon
(%)
23.90
24.50
24.40
23.90
24.40
24.70
24.70
24.36

GCV
kCal/kg
3570.00
3704.00
3670.00
3548.00
3664.00
3746.00
3734.00
3662.29

100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00

41.33

Ash

100.00

AES Laboratries report)

92.65

100.00

92.01

Surface heat loss of Boiler# 1

Ambient temperature
Emissivity
Air velocity
Top surface area
Length of the boiler
Width
Location

Elevation 8.5m to 12m

Front
Rear
Left
Right
Elevation 12m to 17m
Front
Rear
Left
Right
Elevation 17m to 23m
Front
Rear
Left
Right
Elevation 23m to 29m
Front
Rear
Left
Right
Elevation 29m to 35m
Front
Rear
Left
Right
Elevation 35m to 43m
Front
Rear
Left
Right
Elevation 43m to 48m
Front
Rear
Left
Right
Elevation 48m to 55m
Front
Rear
Left
Right
Elevation 55m to 60m
Front
Rear
Left
Right
Elevation 60m to 66m
Front
Rear
Left
Right
Elevation 66m to 70m
Front
Rear
Left
Right
Elevation 70m to 73m
Front
Rear
Left
Right
Elevation 73m to 76m
Front
Rear
Left

23.90
0.50
0.5
294.17
17.280
17.024

Fuel burnt per hour

Calorific value of fuel
Heat supplied to boiler
Structural heat loss

m/sec
m
m
m

Avg temp Film coeff Area

(kCal/m2-hr)(m2)

Delta T
(oC)

332.66
3580
1190928395
1237577

Heat loss
(Kcal/hr)

37.5
37.5
37.0
37.0

7.8
7.8
7.7
7.7

254.71
254.71
29.79
29.79

13.6
13.6
13.1
13.1

26928.2
26928.2
3012.9
3012.9

37.0
38.0
33.0
49.0

7.7
7.8
7.2
8.8

86.40
86.40
85.12
85.12

13.1
14.1
9.1
25.1

8737.7
9534.2
5601.3
18735.5

46.5
35.0
37.5
39.5

8.6
7.5
7.8
8.0

103.68
103.68
102.14
102.14

22.6
11.1
13.6
15.6

20107.6
8620.1
10798.9
12710.9

39.3
39.0
36.5
40.5

8.0
7.9
7.7
8.1

103.68
103.68
102.14
102.14

15.4
15.1
12.6
16.6

12656.3
12411.5
9864.7
13687.6

46.5
43.0
37.0
40.5

8.6
8.3
7.7
8.1

103.68
103.68
102.14
102.14

22.6
19.1
13.1
16.6

20107.6
16429.1
10329.9
13687.6

44.5
47.8
52.5
43.3

8.4
8.7
9.0
8.3

138.24
138.24
136.19
136.19

20.6
23.9
28.6
19.4

23983.9
28607.4
35113.2
21919.7

42.3
48.5
66.7
54.5

8.2
8.7
9.9
9.1

86.40
86.40
85.12
85.12

18.4
24.6
42.8
30.6

13050.0
18560.5
35929.9
23826.2

47.5
47.5
47.0
48.8

8.7
8.7
8.6
8.8

120.96
120.96
119.17
119.17

23.6
23.6
23.1
24.9

24715.4
24715.4
23728.7
25914.3

51.5
66.0
43.5
49.3

8.9
9.8
8.3
8.8

86.40
86.40
85.12
85.12

27.6
42.1
19.6
25.4

21334.0
35768.5
13912.2
18961.3

57.0
57.0
55.0
51.5

9.3
9.3
9.2
8.9

103.68
103.68
102.14
102.14

33.1
33.1
31.1
27.6

31939.3
31939.3
29161.6
25221.5

67.2
67.2
48.7
51.8

9.9
9.9
8.7
9.0

69.12
69.12
68.10
68.10

43.3
43.3
24.8
27.9

29598.9
29598.9
14748.2
16999.3

47.5
60.0
44.5
49.3

8.7
9.5
8.4
8.8

51.84
51.84
51.07
51.07

23.6
36.1
20.6
25.4

10592.3
17759.4
8860.7
11376.8

46.8
46.8
50.3

8.6
8.6
8.9

51.84
51.84
51.07

22.9
22.9
26.4

10187.9
10187.9
11967.7

Tons
kCal/kg
kCal/hr
kCal/hr

Right
Elevation 76m to 81m
Front
Rear
Left
Right
Elevation 81m to 92m
Front
Rear
Left
Right
Top

55.0

9.2

51.07

31.1

14580.8

42.5
42.5
42.5
52.5

8.3
8.3
8.3
9.0

86.40
86.40
85.12
85.12

18.6
18.6
18.6
28.6

13263.0
13263.0
13066.5
21945.8

45.8
45.8
44.8
46.3
53.0

8.5
8.5
8.4
8.6
9.0

190.08
190.08
187.26
187.26
294.17

21.9
21.9
20.9
22.4
29.1

35559.2
35559.2
32963.2
35834.8
77458.7
1237577.1

O2
2.3700
EA
0.1272
inlet dry air quantity
5.6635
Dry FG quantity
5.9078
Existing FGT
169.0000
Moisture in flue gas
0.4169
heat to raise the ingress air temp.(amb. To FGT)
Heat required to raise the ingress moisture temp.(amb. To FGT)
Total
Raise in FGT in the absence of ingress air
Actual FGT

Gas temp
Air
Gas temp
Air
Mean sp. Heat

442
1.02
308.00
0.99
1.008

oK
Kj/kg-oK
oK
Kj/kg-oK
Kj/kg-oK

6.0500 %
0.4047 %
7.0545
7.2998 per kg of coal
oC
0.4447 per kg of coal
44.87 Kcal/kg of fuel
1.68 Kcal/kg of fuel
46.55 Kcal/kg of fuel
32.7 oC
201.73 oC

0.28

0.24