Report On Boiler Modification For 100% Over Bed Firing

30 December, 2012
REPORT ON BOILER DESIGN & PERFORMANCE IMPROVEMENT STUDY AND FOR

TROUBLE FREE OPERATION WITH FIBROUS AGRO FUELS
By Venus Energy Audit System
About the boiler
The boiler parameters are 15 TPH, 64kg/cm2 g, 485 deg C with feed water temperature at 105 deg C.
Design fuel is 100% rice husk. The boiler is provided underbed feeding system of rice husk. The
boiler is bottom supported at water drum level. The bed coils are bottom supported. There are two
compartments. Totally six 150 nb husk feed lines are used. Boiler is with radiant SH ( primary) and
secondary SH, boiler bank, economiser and airpreheater. Husk is fed by rotary feeder. Boiler was
originally designed for under bed firing system and over bed fuel. Over bed feeding system was
commissioned in the month of November 2004.

Modification carried out
The boiler was later modified for multi fuel agro fuel firing. The fuels currently fired are rice husk,
Channa gram straw, Ground nut shell, Soya straw.
a) Rice Husk and Rice based fuel 5-7%
b) Ground nut shell 15-20%
c) Soya straw, mustard straw, Gram straw etc. 73-80%
The boiler capacity is derated as per OEM to 80%, that is 12 TPH.
Agenda for the study- as expressed by plant personnel
The following are the problems reported and the requirements by the plant.
1. There is variance in Superheated Steam temperature between 455
0
-540
0
C whereas the desired
range is 485 5
0
C. This is to be reduced.
2. There is frequent variation in steam pressure whereas the requirement is a constant pressure of
75.0 kg/Cm2.
3. Fuel consumption per KWH is very high 1.70 whereas the desired Fuel consumption per KWH is
1.25.
4. Auxiliary power consumption of the plant is 20% and this is high.
5. There is no control on the sizing and percentage fines, moisture content and calorific value of the
fuel being used for the boiler. But whatever is the situation, optimum output from power plant is
desired against existing reduced output of a level 80-82%. Up to Sept. 2006, a maximum of
40% Soya straw, Gram straw & Mustard straw were used. The steam parameters were under
control and turbine capacity utilisation was at 90-95%. But after increasing the fibrous fuels to
100%, overheating of super heater tubes took place. Once melting of super heater tubes took
place. In the month of Sept 2009, complete set of super heater tubes replaced with new one.
6. Turbines nozzle chest body cracking was experienced in the month of Nov 2011. Steam
temperature excursions need to be under control to avoid this problem.
7. An optimized fuel feeding arrangement of a combination of agro based fuels having less calorific
value compared to rice husk is required. The SPM from the boiler stack while using such fuels.
8. The suitability of existing super heater tube arrangements in the boiler needs to be reviewed for
the fuels being used currently.
9. We want some type of automation with regard to controlling the temperature of the super heater
tubes within the OEM recommended range and its interlocking with boiler feeding system.
10. The rated MCR of the boiler is desired using a mixture Soya straw, Gram straw, Mustered straw
and other local fuels.
11. The Superheated Steam temperature has to be under control in the desired range of 485 5
0
C.
12. The steam pressure variance has to be avoided.
13. The boiler efficiency needs to be improved and power consumption needs to be reduced.

Combustor design review of the boiler for 100% rice husk

The rice husk fuel GCV is reported as 3150 Kcal/kg and with a moisture of 8.68%. This matches
with the standard analysis adopted for boiler design.
The furnace design calculations are made and enclosed in annexure 5. The calculations are made for
15 TPH output. For underbed firing 20% excess air has been considered. The findings are as below.
The furnace layout is made and the furnace volume is calculated from drawing. The present furnace
volume above the bed is working out to be 52.456 m3. The present bed cross section is 2.95 m x 2.95
m. The area is 8.7 m2. The fluidisation velocity works out to be 2.74 m/s as against a requirement of
2.6 m/s and less. The DP nozzle pressure drop with 10% secondary air works out to be 162 mmWC.
This is in order. The bed coil length immersed in the bed works out to be 237 m as against
requirement of 226 m. The gas residence time in the furnace works out to be 2.2 sec.
Inadequacy of furnace volume for overbed feeding of any fuel

Agro fuels are low density fuels and bulk density ranges from 90 kg/m3 to 120 kg/m3. They also
have high volatile matter with a minimum of 50%. We may see the fuel analysis report given by the
plant personnel in annexure 4. Due to this fact any overbed feeding of agro fuels need more furnace
volume. As the moisture content increases, even as much as 3-4 seconds of furnace residence time is
provided. After the site visit and drawing study, it is found possible to increase the furnace volume
by lowering the DP plate. As such the underbed feeding system is troublesome due to fibre content in
fuel and the stones. It is seen that the dechoking is being done regularly resulting in drop in steam
pressure and temperature during such time.

Due to above problem, it is proposed to adopt open hopper design with sparger air nozzles to drain
off the stones and to go for 100% overbed feeding of all fuels. With this concept we can go for a 1.5
m pit below the open hopper.

Thermax themselves have supplied boiler for agro waste with such arrangement. See the
arrangement in annexure 6. Open hopper combustor design is offered by many boiler makers for
sponge iron plants where the fuel ash contains have iron particles.

Combustor design of the boiler for 100% rice husk by over bed feeding new

The agro fuels moisture content varies and GCV also varies depending upon the decay during
storage. Currently the fuel mix GCV reported at plant is 3320 kcal/kg for underbed fuel mix
(moisture 7.78%) and 3640 kcal/kg (moisture 9.1%) for overbed fed soya straw. The ash for
underbed fuel mix is reported to be 5.98% and 2.88% for overbed. For design check, 100% overbed
firing of rice husk is considered, as this is the worst fuel and a consistent analysis is available from
many plants.
A layout is made with the proposed modification of the boiler. See views of the drawings in
annexure 7. The modification suggested is extension of waterwall below the present operating floor.
With this the effective furnace volume (above bed) is seen to increase from 52.456 m3 to 85.4 m3.
The furnace design calculations are made and enclosed in annexure 7. The calculations are made for
15 TPH output. The excess air will be in the range of 35% for overbed combustion of fuels. The
findings are as below. The furnace layout is made for the case of new combustor and the furnace
volume is calculated from drawing. See the figure in annexure 7.
The revised bed cross section is 3.145 m x 3.145 m. The bed cross sectional area is 9.89 m2. This
is due to removal of refractory wall and due to extension of waterwall itself to form furnace
walls. The furnace wall tube OD is 63.5 and stud length is 16 mm. The studs will be lined with
high alumina phosphate bonded refractory. The fluidisation velocity works out to be 2.44 m/s for
15 TPH generation. Due to overbed combustion, actual velocity at bed will be less by a factor of
0.9.
The residence time for 35% Excess air condition is seen to be 3.19 sec above the bed.
The height gain by this modification will be 2.7 metres. Due to this the waterwall projected
heating surface will increase by 4*3.24*2.7 =36.72 m2. This will help in bringing down the gas
inlet temperature at APH outlet. But the temperature can vary as per the fines and dryness. It is
not possible to increase the furnace height any further. Furnaces with 4 seconds residence time
can handle the fuels more efficiently.
There will be no PA fan or SA fan requirement. Since the wind box pressure will be around 450
mmWC and the furnace depth is 1.6 m (one side), the FD air itself will suffice for turbulence.
That is SA tapping will be from APH outlet itself. There will be power saving in this respect.
Since the combustion takes place overbed, the bed coil HTA comes down. The bed coil is formed
from the side waterwall tubes. The bed coils are studded with 5 x 4 pattern of SS studs. The front
wall and rearwall tubes now participate for heat transfer. The free board heat release will be as
high as 30%. Any adjustment required to achieve better bed temperature is possible by covering
the bed tube with refractory coating.
The new air nozzles are to be made of SS tip. The DP drop is designed for 176 mmWC. About
25% of the air will be used for SA & fuel spreading.
The FD fan capacity and ID fan capacity are found to be inadequate. The fan flow and head data
are taken from the torque speed curve provided to us. See the details in the annexure 7. For 15
TPH steam generation, this will change. However looking at the present load of 12 TPH & the
high exit temperature, margin may be available to some extent. The fan KW may not change.
Some details about the modifications that are required are as below

Waterwall
The waterwall is extended to create additional furnace volume. In addition the openings are made
for overbed feeding of the both rice husk and mustard stalk. The overbed ports are lowered
appropriately. New seal boxes are added at all fuel feed points.
Waterwall support
At present the waterwall is supported at the extended header portion of front & rear bottom
headers. Now the waterwall is to be supported at the panel but at the same elevation. Support is
taken from the fins. The support is known as girth support.
Downcomer
The downcomer routing is changed. The waterwall bottom headers are now connected by the
four downcomers.
Bed coils
At present two rows of bed coils are provided. For overbed feeding and for agro fuels, the heat
transfer area of bed coils required is less and the extended waterwall area come in to heat
transfer. For this the two side waterwall tubes are bent to form the bed coils. The bed coils are
studded for erosion protection. Seal boxes are added at the bed coil zone. The bottom side of the
front waterwall and rear waterwall (about 1 m above air nozzle) are also studded and plastered
with heat conducting refractory. The refractory lining is for erosion protection of vertical tubes,
as they generally get polished in six years time.
Bottom drains
The bottom headers are now shifted below the concrete floor. There are four drains provided in
the header ends. The drain piping are to be rerouted at site suiting the present layout.
Open hopper FBC furnace
Stones ingress in rice husk and other agro fuels lead to defluidisation and accelerated bed coil
erosion. Open hopper FBC furnace is the ideal choice for removal of stones without boiler
stoppage. The combustion air is now supplied through five no sparger header fitted with SS
tipped air nozzles. The hopper is suspended from the waterwall bottom headers. There are four
outlets to this hopper. Each outlet is provided with roller gates for draining the bed material / bed
ash as the bottom thermocouples become dead due to settled stones. The sparger headers get air
supply from the hot FD air ducts. Each sparger header is provided with drain pipes for removing
the seeped bed material. These headers are provided with dampers for turning down the load and
for start up purpose.
There are six direct ash drain pipes provided directly below the over bed fuel feed points for
direct draining oversize stones.
The open hopper is sealed with waterwall bottom header with provisions for taking care of
differential thermal expansion.
In order to operate the hopper drain gates and ash drain gates, the present ground floor is to be
excavated by 1.5 m. The approach to the pit is to be made from right side of the furnace.
Instrumentation for the fluidised bed
The bed thermocouples are inserted in guide pipes from the bottom. There are eight
thermocouples envisaged. The guide pipes are welded to the open hopper walls. The air box
pressure tappings are to be located at each of the sparger header.
Fuel feeding system- rice husk
Overbed feeding system is proposed due to reasons explained below.
One is that the furnace has to be lowered to have additional furnace volume for burning of fuel
fed from overbed. For this total underbed feed system has to be lowered. Then the pit area will
have to be including the underbed and for the fuel cross drains. At present stone ingress is there
with rice husk. The mixing nozzles and cross dechoking requirement is quite frequent. Hence the
objection was about the free access for operation. When the bed is present with ash
accumulations falling from superheater, the bed fluidisation gets disturbed. Hence overbed
feeding system was chosen.
Rotary feeder system is now removed. To take of horizontal transportation to overbed feed
points, screw feeders are proposed. Screw feeders drop the fuel in to the over bed feed chutes
provided at the left side waterwall.
The air for pushing the fuel and for sealing is taken from main FD air duct itself. A 100 nb line
with a damper is provided at each of the four feed chutes.
Part of the overbed feed chute will be of SS material.
Screw feeders are to be provided with VFD. Each screw feeder is provided with slide gate for
isolation purpose.
Fuel feeding system Fibrous fuels
At present there is single feed point at the furnace. This is made as two numbers for better use of
furnace volume.
At present there is no control of over feeding of the fuel. In case of excess feeding the
superheater temperature will shoot and there is risk of header failures. To control this, a drum
feeder is added below the present hopper. This drum feeder is same as the one used in bagasse
fired boiler at sugar mills. This drum feeder is also to be provided with VFD.
The drum feeder discharge is bifurcated in to two and connected to over feed chutes. The furnace
side of chute is made of SS. Air for pushing and sealing is taken from FD header. Two no 100 nb
pipes with dampers are considered for this.
Secondary air system
The secondary air (SA) system is now modified as explained here. The existing SA headers are
used. New SS tube tips are welded to waterwall. These tips are inclined to promote turbulence for
volatile matter combustion and increased residence time for particles.
The air tapping for SA system is taken directly from the APH outlet. The SA headers are
provided with draft tappings to indicate SA header pressure. Two number draft gauges are to be
provided. The SA tappings are provided only at front and rear walls.
Refractory in seal boxes, waterwall and open hopper
Refractory castables are to be poured in all over bed chute seal boxes.
In the front and rear waterwall tubes at bed zone, refractory lining is done. This refractory is high
alumina plastic refractory. This is done only up to stud tips. Same is applicable for two vertical
tubes in side walls.
The bottom headers are refractory lined to protect direct heating of the headers. This is done by
high alumina castable to a thickness of 75 mm.
The open hopper is provided with 40 thick refractory tiles of IS 8 grade
Insulation
The extended portion of the waterwall is to be insulated with 100 mm thick light resin bonded
mattress. The seal boxes are to be insulated with 40 mm thick mattress. Open hopper is not to be
insulated. The air ducts are to be insulated with 50 mm thick Light resin bonded mattress.
For further details, the detailed drawings would have to be referred.
OBSERVATIONS AT PLANT

The boiler was inspected during the shut down. Further the boiler was seen in operation as well. The
following are the observations at the plant. Some recommendations are given as well.

See annexure 1- ash fouling and combustion at superheater section

The fuel feed point at present is with horizontal spreading air. The height of the SH coil bottom
from the fuel feed point is 2.3 m. This is too less. Hence the combustion takes place around
superheater area resulting in temperature swings. This has resulted in burning of the superheater
alignment bands. When the modification is taken up the alignment bands have to be reinstated.
Mustard straw, GN shell and soya straw contain alkali (Sodium, Potassium) ash and this can
form ash deposits. The deposit effect is reduced by the silica ash from rice husk. Deposits are
seen at superheater sections. However it is seen, it is not to extent of blocking the passage.
APH tube plugging & failure occurs due to condensation of fuel moisture & fuel hydrogen. The
presence of rice husk ash may reduce the plugging to some extent. The cold end tubes of APH
need replacement every two years.

See annexure 2- Fuel handling / feeding system

The mix of fuels for underbed contains fibres and long pieces. Generally this poses bridging
problem above feeder and above venturi.
The stones present in this fuel mix can block the venturi. The stones settle at fuel cross and
demand frequent dechoking. The fuel consumption goes high due to this. Whenever fuel feeding
is disturbed in the furnace, the steam pressure & steam temperature would swing.
By overbed feeding both the problems are eliminated. At present, only 25% of the total fuel is
being handled by underbed. Open hopper design will eliminate the problem of PA line choking.
However hopper drains have to be operated as required to lower the settled stones.
The overbed feeding system needs an improvement. A rotating leveller is required at the main
conveyor to ensure a fairly constant feeding is available. The present capacity of the conveyor
seems inadequate. Spillage is seen. The conveyor may be provided with skirt board to complete
length or the increasing of belt speed may be reviewed with manufacturer.

See annexure 3- Flame test and air ingress report

The boiler is not leak proof on gas side. There are air ingress points. They can be seen in the
photographs in annexure 3. The air ingress from outside loads the ID fan. This increases the
power consumption.
There is considerable air ingress in the roof panel. This matters a lot with respect to secondary
combustion in superheater area.
Such leakages are encountered at many plants. The causes are design defects, incomplete seal
box work during boiler installation / maintenance. It is advised to seal the roof from leakages by
using plaster of paris. A typical photograph at another plant and the application procedure are
presented in annexure 3.

See annexure 4- Observations in boiler operation

Stones are present in the fuel fed in to the boiler. This affects the fluidisation and leads to
overbed burning. The bed coil erosion also would take place due to haphazard gas flow in the
bed.
The dechoking process in underbed is a nuisance for boiler operation personnel. There is no way
the stone ingress can be avoided. Also the separation by any mechanical screen system is not
possible.
Due to inadequate furnace volume & heating surface, the boiler exit gas temperature goes up to
211 deg C, even for a load of 12 TPH. There is a need to increase furnace heat transfer area to
reduce the exit gas temperature.
Due to bed defluidization, the bed temperatures are seen to be haphazard. This makes the bed
coils inefficient to heat trasfer. Thus freeboard temperatures rise further.
It is seen that the Trema cyclone outlet draft is as high as -350 mmWC, whereas the fan design
itself is 370 mmWC.
It is seen that fuel moistures are under control. This is seen to be less than 10%. As the
percentage goes higher, the boiler efficiency comes down and the flue gas quantity increases.
Boiler capacity will be derated mainly due to this factor.
Ash fouling is related to ash chemical analysis. Presence of sodium and potassium in straw leads
to fouling and calls for periodical cleaning. This is unavoidable. Usage of sand as bed material
and the mix of rice husk can bring down the fouling to some extent.

Conclusions

1. Combustor volume can be increased to the extent possible to take care of residence time
requirement. Thus problems related to high exit temperature & high steam temperature can be
controlled.
2. Elimination of PA fan results in power savings.
3. For emission control Electrostatic precipitator is advised. This will result in power savings as
well. The fan head requirement will come down to 150 mmWC as against the present 370
mmWC. The power required by ESP is much lesser.
4. Overbed fuel feed control is the key point on swings of steam temperature. A leveller would help.
Further the rotary feeder, below the fuel surge hopper will avoid the excess feeding even if there
is more feeding from conveyor.
5. Boiler efficiency is dependent on excess air, boiler exit temperature and fuel moisture. The
combustion efficiency will be 80% theoretically. Actual efficiency would by lower by 2% due to
blow down, fuel GCV variance and fuel moisture variance and fuel mix consistency. Online O
2

meter / CO meter is recommended so that the incomplete combustion can be known immediately
by the operator.
It is feasible to increase the furnace volume in the present boiler layout. The feasibility of lowering
the combustor was studied at plant by our engineer and discussions were held. Based on the
problems faced in underbed feed system, it was proposed to switch over to open hopper system.
Accordingly the detailed layout drawings, production drawings and specifications would be
furnished.

ANNEXURE 1 OBSERVATIONS INSIDE THE BOILER

Photo 01: Generally the boiler designed for Biomass fuel should have large furnace volume in order to make
effective combustion. This boiler is originally designed for Underbed and later overbed provisions were made.
The free board height is physically measured to be 2300mm only. So once the fuel enters the boiler it will fly
away to superheater zone allowing the combustion to occur in Superheater area. The least residential time of 3
Secs will not be able to achieved here.

Photo 02: The above picture shows the boiler design data. The boiler is originally designed for rice husk fuel
and the fuel firing is only through underbed system. Hence furnace volume was designed optimally.
Photo 03: The above photo is showing the condition of Secondary superheater support clamps. The clamps
were seen to have failed long time ago. This is due to high gas temperature.

Photo 04: In one of the RSH coils, the binding clamp is burnt off. The furnace temperature sometimes
touches even 1000 Deg C. Due to this some clamps have got melted.

Photo 05: Along the CSH zone most of the support clamps have failed and the coils have come out of
position. This will restrict the flue gas path and thus leading the way to ash choking along the CSH flue path.

Photo 06: The Supports given for coil expansion for CSH coils have failed.
Photo 07: The Ash deposition is also seen in Economiser coil but its deposition rate is low as compared to
Superheater coils and Bank tubes. Sonic soot blower is installed in economiser zone.
Photo 08: It is seen that around 15 APH tubes are dummied because of leakage. APH tubes are subject to
corrosion in agro waste. The flue gas moisture condenses inside the tube.

ANNEXURE 2 FUEL HANDLING / FEEDING DETAILS

Fuel Mixing Ratio:
Rice Husk - 16 Scoops per Shift
Ground nut Shell +Gram staw - 35 Scoops per Shift (Grounut Shell 90%, Gram Straw 10% if
available)
Soya Straw - 20 Trolley per Shift.

1 Scoop of rice husk / Gn shell = 180 Kg.
1 Trolley = 1200 Kg.
So,
Rice Husk = 2880 Kg (8.7%)
Ground nut Shell +G. Straw = 6300 Kg (19.0%)
Soya Straw = 24000 Kg (72.3%)
Note: Soya straw alone is fed into the bunker through Overbed. Other fuels are fed through Underbed.
Photo 01: The above photo shows the grinding of Ground nut shell and Channa straw together. Channa straw
will be fed into the bunker only if it is available.
Photo 02: The above photo shows the mixture of ground nut shell and gram straw. The size of Channa straw
is varying and sometimes it causes choking above the rotary feeder. As the fiber content increases rotary
feeder will not be able to handle this.
Photo 03: A tractor brings the rice husk from nearby place and mixes it with Ground nut shell and Channa
straw. The mixing is done by tractor.
Photo 04: The above photo shows the fuel mix done by tractor. At some place the volume of Ground nut shell
seems to be more and in some place the volume of rice husk is more.
Photo 05: This is the closer view of Ground nut shell, Rice husk & Gram straw mixed together. The size of
gram straw alone not uniform as this may sometime leads to choking in rotary feder, mixing nozzle throat.
Photo 06: There is an vibratory feeder in the fuel yard into which Soya straw is fed manually by worker. There
is no controlling for the size, foreign particle of the fuel.
Photo 07: Since the fuel is fed manually, there is no regularity in fuel flow in the overbed Conveyor. This
irregular fuel flow highly impacts the main steam parameters as there is no Rotary or Screw feeder on the
overbed bunker.
Photo 08: Irregular fuel flow through Overbed belt conveyor. Skirt board system is advised to avoid spillage.
In addition a rotary leveller can be added to achieve somewhat uniform feeding. The belt speed may have to
be increased to avoid spillage.
Photo 10: Recently VFD is installed at Overbed conveyor motor to control the conveyor RPM and there by
controlling Steam parameters. This will work better with uniformity in fuel flow to the conveyor.
Photo 11: Irregular fuel flow through Overbed belt conveyor.
Photo 12: Recently they had gone for VFD to Overbed conveyor motor to control the conveyor RPM and
there by controlling Steam parameters. This will not work unless there is uniformity in fuel flow in the
conveyor.
Photo 13: This panel photo shows the interlock made between main steam pressure and overbed conveyor
motor. The steam pressure set point is 62 Kg/cm
2
.

Photo 14: The closer picture showing the physical appearance of Soya straw. This fuel can be fed in over bed
only.

Photo 15: Stones present in fuel.
Photo 16: Bulk density of different fuels. The bulk densities are fairly same. However flowability
can vary due to size distribution.

ANNEXURE 3 FLAME TEST AND AIR INGRESS REPORT

Photo 01: It is found that there is some leakage in Eco/APH hopper. Due to this additional atmospheric air
gets into the boiler leading to ID fan loading.

Photo 02: Some Air ingress has been observed in the seal box where the Soot blower line is located. All seal
box should be fully welded to avoid air ingress.

Photo 03: Air ingress along the boiler rear side panel.

Photo 04: Air ingress along the Radiant SH O/L header. It is seen that the sealing is not proper at roof.

Photo 05: The condition of roof panel is very poor as there is considerable amount of ash seen above the roof.
Entire roof panel needs insulation rework as this leads to poor efficiency and secondary combustion at SH
area.
Photo 06: It is seen that the sparks are coming out of the roof panel. This is because the sealing is not good.
Photo 07: The above photo shows the application of Plaster of paris for better sealing of roof. This
avoids the air ingress from the roof. This insulation is so hard finished; the persons can walk over the
roof.

Photo 08: General drawing of plaster of paris / Cement +Mineral wool +Sand mastic finishes on
insulation which helps on sealing. This shall be done at roof tube area.

Photo 09: This is a typical sealing arrangement in the roof zone where the superheater coils enters. 150 thk
mineral wool should be applied over the seal box. Above that 12 thk plaster of paris has to be applied. Finally
it shall be covered with Hessian cloth with two coats of black bitumen paint.
ANNEXURE 4 OBSERVATIONS IN BOILER OPERATION

Photo 1: Stones present in bed ash.

Photo 2: Fuel lines being dechoked due stones ingress. Due to stones, there is fuel loss and there is
operational disturbance.
Photo 3: The economiser outlet gas temperature will have to be around 260 deg C and APH outlet
gas temperature has to be around 160 deg C. The APH outlet gas temperature is 211 deg C. There is
considerable heat loss roughly the loss can be around 4.5%. The bed temperatures are haphazard
indicating settling of bed with stones. The low temperatures can be due to over bed firing. The higher
amount of bed coil also causes this low temperature. This is with a less load of 11.5 TPH.

Photo 4: Trema cyclone outlet draft is -350 mmWC. This is too high. Across dust collector nearly
290 mmWC drop is seen. The hot air temperature is quite high. Normally it is designed for 150 deg
C.

Photo 5: The as fired moisture in fuel is well within control. GCV of fuel mix is also good.

Photo 6: The above is the data collected from plant on fuel ultimate and proximate analysis. The ash
analysis was not available. The fuel ash from mustard straw / soya straw / gram straw can contain
alkalis which can deposit over the superheater tubes.
ANNEXURE 5- COMBUSTOR DESIGN CALCULATIONS FOR 100% RICE HUSK FIRING BY
UNDERBED

EWS 604

PROJECT :
INPUTS FOR COMBUSTION CALCULATIONS
AIR & GAS CALCULATIONS
Ta Ambient temperature 40 Deg C
P1 Relative humidity 60 %
Ma Moisture in dry air ( from tables) 0.02851 kg/kg
E Excess air 20 %
Te Boiler outlet gas temperature 160 Deg C
El Site elevation 300 Metres
P Flue gas pressure 5 mmwc
Constituents of fuel
FUEL Std husk
C Carbon 35.51 % by wt 38.5
H Hydrogen 5.08 % by wt 3.7
O Oxygen 34.55 % by wt 36.31
S Sulphur 0.01 % by wt 0
N Nitrogen 0.12 % by wt 0.46
M Moisture 8.68 % by wt 8
A Ash 16.06 % by wt 20
100.00
GCV Gross GCV of fuel 3150.00 Kcal /kg 3200
INPUTS FOR EFFICIENCY CALCULATIONS
HLS1 Carbon loss ( calculated ) 1.36 %
HLS6 Radiation loss ( assumed ) 1 %
HLS7 Manufacturer margin (assumed ) 0.5 %
Locations
A1 % Ash collection at location 1 Bed 5 %
A2 % Ash collection at location 2 Bank 5 %
A3 % Ash collection at location 3 Economiser 5 %
A4 % Ash collection at location 4 Airheater 5 %
A5 % Ash collection at location 5 MDC 60 %
A6 % Ash collection at location 6 Trema 20 %
100
T1 Temperature of ash at location1 900 Deg C
INPUTS FOR BOILER DUTY CALCULATIONS
Steam generation rate Nett 15000 Kg/h
Main steam pressure 64 kg/cm2 g
Main steam temperature 490 Deg C
Feed water inlet temperature 105 Deg C
Superheater Pressure drop 3 kg/cm2 g
Saturated steam flow from drum 0 kg/h
Deepak spinners - 100% rice husk- as per lab report- underbed
Rice husk
EWS 604
Boiler efficiency Calculated 80.86
Boiler efficiency 80.00 %
INPUTS FOR AIR,GAS DUCT,CHIMNEY SIZING CALCULATIONS
Flue gas ducting Gas temp
Boiler bank outlet 350 Deg C
Economiser outlet 235 Deg C
Airheater outlet 160 Deg C
Air ducting Air temp
Design velocities
Design velocity in gas duct 14 m/s
Chimney design gas velocity 15 m/s
Design velocity in air duct 12 m/s
INPUTS FOR FAN SIZING CALCULATIONS
Design air velocity in fuel piping 16 m/s

No off compartments 2
Total no of fuel feed points 7
Fan sizing
FD fan capacity (% MCR ) 100 %
FD fan efficency 75 %
ID fan capacity (% MCR) 100 %
ID fan efficency 75 %
PA fan capacity (% MCR ) 100 %
PA fan efficiency 70 %
FD fan design head 750 mmwc
PA fan design head 700 mmwc
ID fan design head 370 mmwc

Margin on FD fan flow 20 %
Margin on PA fan flow 20 %
Margin on ID fan flow 20 %
INPUTS FOR FLUIDISED BED SIZING CALCULATIONS
Design bed temperature = 850 Deg C
Fluidisation velocity = 2.6 m/s
INPUTS FOR DUST EMISSION CALCULATIONS
Percentage ash entering dust collector = 50 %
Efficency of Dust collector = 99.5 %
EWS 604
COMBUSTION CALCULATIONS FOR FUEL PER KG BASIS Date & time: 12/30/12 7:50 AM
PROJECT :
INPUTS FOR AIR & GAS CALCULATIONS Rice husk
Ta, Ambient temperature = 40 deg C
P1, Relative humidity = 60 %
Ma, Moisture in dry air = 0.02851 kg / kg
E, Excess air = 20 %
Constituents of fuel ( % by weight )
C, Carbon = 35.505 %
Carbon lost in ash = 0.53 %
carbon burnt = 34.975 %
H, Hydrogen = 5.077 %
O, Oxygen = 34.546 %
S, Sulphur = 0.009 %
N, Nitrogen = 0.119 %
M, Moisture = 8.68 %
A, Ash = 16.063 %
Air requirement calculations
O2 reqd, kg/kg of Carbon in fuel = 2.644 kg/kg
O2 reqd, kg/kg of Hydrogen in fuel = 7.937 kg/kg
O2 reqd, kg/kg of Sulphur in fuel = 0.998 kg/kg
Solid crbon unburnt from Efficiency calc, = 0.0053 kg/kg
O2 reqd, for the Carbon in fuel =( 0.35505 - 0.0053)x2.644 /100) kg/kg
= 0.925 kg/kg
O2 reqd, for the Hydrogen in fuel =( 7.937x5.077 /100) kg/kg
= 0.403 kg/kg
O2 reqd, for the Sulphur in fuel =( 0.998x0.009 /100) kg/kg
= 0.000 kg/kg
Stochiometric O2 reqd / kg of fuel = O2 reqd for C,H,S in fuel - O2 in fuel) kg/kg
Stochiometric O2 reqd / kg of fuel = ( 0.925+0.403+0.000) -(34.546 / 100) kg/kg
= 0.98254 kg /kg of fuel
Excess O2 required / kg of fuel = ( 0.98254x / 100 ) kg /kg of fuel
= ( 0.98254x 20 / 100 ) kg /kg of fuel
= 0.196508 kg/kg
Total O2 required / kg of fuel = ( 0.98254+ 0.196508) kg/kg
= 1.179048 kg/kg
Weight fraction of O2 in atmospheric air = 0.23 kg/kg
Dry air required for Combustion, kg/kg of fuel =( 1.179048/ 0.23) kg/kg
= 5.126 kg/kg
Due to relative Humidity, wet air reqd, kg/kg of fuel =( 1 + 0.02851) x 5.126) kg/kg
Wet air required, kg /kg of fuel fired = 5.272 kg/kg
Dry air required, kg /kg of fuel fired = 5.126 kg/kg

EWS 604
Gas weight constituents calculations
CO2 produced, kg/kg of Carbon in fuel = 3.644 kg/kg
H2O produced, kg/kg of Hydrogen in fuel = 8.937 kg/kg
SO2 produced, kg/kg of Sulphur in fuel = 1.998 kg/kg
CO2 produced, for the Carbon in fuel =( 3.644x34.975 /100) kg/kg
= 1.274 kg/kg
H2O produced, for the Hydrogen in fuel =( 8.937x5.077 /100) kg/kg
= 0.454 kg/kg
H2O in combustion air = 0.02851x5.126 kg/kg
= 0.146 kg/kg
H2O due to moisture in fuel = 8.68/100 kg/kg
= 0.0868 kg/kg
H2O due to air & H2 combustion& fuel moisture =( 0.146+0.454+0.0868) kg/kg
= 0.6868 kg/kg
SO2 produced, for the Sulphur in fuel =( 1.998x0.009 /100) kg/kg
= 0.000 kg/kg
O2 in flue gas ( Excess O2 added ) = 0.196508 kg/kg
N21,Nitrogen due to fuel = N kg/kg
= 0.00119 kg/kg
Weight fraction of Nitrogen in Dry Air = 0.77 kg/kg
N22 due to Air, kg per kg of fuel = 0.77 x 5.126 kg/kg
= 3.947 kg/kg
Total N2 in flue gas , kg/kg of fuel fired = N21+N22 kg/kg
= ( 0.00119+3.947) kg/kg
= 3.94819 kg/kg of fuel
Qfgw, Total wet flue gas produced per kg of fuel fired = 1.274+0.6868+0.000+0.196508+3.94819
= 6.105498 kg/kg
Wet flue gas produced, kg /kg of fuel fired = 6.105 kg/kg
Qfgd, Total dry flue gas produced per kg of fuel fired = 1.274+0.000+0.196508+3.94819
= 5.419 kg/kg
Dry flue gas produced, kg /kg of fuel fired = 5.419 kg/kg
wet gas
kg / kg of
fuel
Mol.
weight
CO2 1.274 44.04
H2O 0.687 18.02
SO2 0.000 64.06
O2 0.19651 32.00
N2 3.94819 28.01
Total 6.1055 Total moles = 0.029+0.038+0.000+0.006+0.141=0.214
Mole.wt of flue gas = ((13.55x 44.01)+(17.76x 18.02)+(0.00x64.06)+(2.80x32)+(65.89x28.01)) / 100
Mole.wt of flue gas = 28.52
100x1.274/6.105498=20.866 1.274/44.04 = 0.029 100x0.029/0.214=13.55
100x0.038/0.214=17.76
Flue gas ( wet ) composition
by % wt
Flue gas ( wet ) composition by %
vol
No of moles / kg of
fuel
Composition of Flue gas
100x0.6868/6.105498=11.249
100x0.000/6.105498=0.000
100x0.196508/6.105498=3.21
0.6868/18.02 = 0.038
100x3.94819/6.105498=64.66
100x0.000/0.214=0.00
100x0.006/0.214=2.80
100x0.141/0.214=65.89
0.000/64.06 = 0.000
0.196508/32 = 0.006
3.94819/28.01 = 0.141

EWS 604

Results Summary
Dry Flue gas produced, kg /kg of fuel fired = 5.419 kg/kg
Flue gas produced, kg /kg of fuel fired = 6.105 kg/kg
Flue gas composition summary
Wet by vol % Dry by vol%
Carbon di oxide = 13.55 % = 16.48 %
Water vapour = 17.76 % = 0 %
Sulfur di oxide = 0.00 % = 0.00 %
Oxygen = 2.80 % = 3.40 %
Nitrogen = 65.89 % = 80.12 %

EWS 604
DESIGN EFFICIENCY CALCULATIONS Date & time : 12/30/12 7:50 AM
PROJECT :
HLS1, assumed unburnt carbon loss = 1.36 %
HLS6, Assumed radiation loss = 1 %
HLS7, Manufacturer margin = 0.5 %
Rh, Relative humidity = 60 %
Te, Boiler outlet gas temperature = 160 Deg C
A1, % Ash collection at location 1 = 5 % Bed
A2, % Ash collection at location 2 = 5 % Bank
A3, % Ash collection at location 3 = 5 % Economiser
A4, % Ash collection at location 4 = 5 % Airheater
A5, % Ash collection at location 5 = 60 % MDC
A6, % Ash collection at location 6 = 20 % Trema
T1, Temperature of ash at location1 = 900 deg C
H, Hydrgen = 5.077 %
A, Ash = 16.063 %
GCV, Gross calorific value of fuel = 3150 kcal /kg
DESIGN EFFICENCY CALCULATIONS
Assumed heat loss through unburnt carbon in ash
Heat loss through unburnt carbon in furnace ash
A, Ash content in fuel = 0.16063 kg/kg
M1, % ash collection in furnace hopper = 5 % 5
LOI in ash = 1 %
Calorific value of carbon = 8050 kcal/kg
Fuel GCV = 3150 kcal/kg
Carbon Loss =M1x A x LOI x 8050 / ((100-LOI) x 3150) %
=5 x 0.16063 x 1 x 8050 /( (100-1 ) x 3150) %
HLS1-1, Unburnt carbon loss in furnace ash = 0.0207 %
EWS 604
LOI in ash = 3.5 %
=90 x 0.16063 x 3.5 x 8050 /( (100-3.5 ) x 3150) %
HLS1, Total unburnt carbon loss = 1.36 %
Solid carbon loss = 1.36x3150 / 8050 %
= 0.53 %
HLS1, Unburnt carbon loss = 1.36 %
Calculations for Heat loss though ash
C, Specific heat of ash = 0.22 kcal/kg Deg C
HLn, % Heat lost through ash at n'th location = A x (An /100 ) x C x (Tn-Ta) x 100 / GCV
HL1, % Heat lost through ash at a location 1 = 0.16063x (5 / 100 ) x0.22x (900-40) x 100 / 3150 %
HL1, % Heat lost through ash at a location 1 = 0.05 %
HLS2, Total Heat loss through the ash = HL1+HL2+HL3+HL4+HL5+HL6
= ( 0.05+0.01+0.01+ 0.01+0.07+0.02 )%
HLS2, Total Heat loss through the ash = 0.17 %
Calculations for Heat loss through moisture in air
Ww, wieght of water in air = 0.02851 kg/kg
Wd, Dry air required per kg of fuel = 5.126 kg/kg from combustion calc
Cp1, specific heat of water vapor at boiler exit temp = 0.4872 kcal/kg C
Cp2, specific heat of water vapor at ambient temp = 1 kcal/kg C
Te, Boiler exit temperature = 160 deg C
EWS 604
HLS3, % Heat lost through moisture in air = Ww x Wd x{(Cp1x Te)-(Cp2 x Ta)}x100/(GCV)
= 0.02851x5.126x[(0.4872x160)-(1x40]x100 /(3150)
HLS3, % Heat lost through moisture in air = 0.18 %
Calculations for Heat loss through moisture & hydrogen in fuel
H, hydrogen in fuel = 0.05077 kg/kg
M, moisture in fuel = 0.0868 kg/kg
Cp1, Specific heat of water vapor at boiler exit temp = 0.4872 kcal/kg
L, latent heat of water = 595.4 kcal/kg
HLS4, % Heat lost through moisture & H2 in fuel ={M+(8.94 x H)} x [595.4+(Cp1 x Te) -Ta] x 100 / (GCV)
HLS4, % Heat lost through moisture & H2 in fuel
= 10.87 %
Calculations for Heat loss through dry flue gas
Qfgd, Dry flue gas produced per kg of fuel = 5.419 kg/kg
Cp3, specfic heat of flue gas at boiler exit temp = 0.243 kcal/kg deg C
Cp4, specfic heat of flue gas at ambient temp = 0.236 kcal/kg deg C
HLS5, % Heat lost through dry flue gas =Qfgd x{ (Cp3 x Te) - (Cp4 x Ta)} x100/(GCV)

HLS5, % Heat lost through dry flue gas = 5.06 %
Assumed heat loss through radiation
HLS6, Radiation loss = 1 %
Manufacturer margin
Total efficiency break up
HLS3, Heat lost through moisture in air = 0.18 %
HLS4, Heat lost through moisture & H2 in fuel = 10.87 %
HLS5, Heat lost through dry flue gas = 5.06 %
Total losses = 1.36+0.17+0.18+10.87+5.06+1+0.5
= 19.14 %
Therefore, Boiler efficiency, = 100 - 19.14 %
Boiler Efficiency = 80.86 %
={ 0.0868+ (8.94 x 0.05077)}x [ 595.4+(0.4872x 160) -
40]x100/(3150) %
=5.419x { ( 0.243 x 160) - (0.236x40)} x 100/(3150) %
EWS 604
BOILER HEAT DUTY CALCULATIONS Date & time: 12/30/12 7:50 AM
PROJECT :
Steam generation rate Nett = 15000 Kg/h
Main steam pressure = 64 kg/cm2 g
Main steam temperature = 490 Deg C
Feed water inlet temperature = 105 Deg C
Superheater Pressure drop = 3 kg/cm2 g
Saturated steam flow from drum = 0 kg/h
Selected boiler efficiency = 80 %
BOILER HEAT DUTY CALCULATIONS
Msup, Steam generation rate = 15000 kg / h
P1, Main steam pressure = 64 kg/cm2 g
Ts, Main steam temperature = 490 deg C
Tw, Feed water inlet temperature = 105 deg C
Hw, Feed water inlet enthalphy = 105 kcal / kg
Hs, Main steam enthalpy = 810.47 kcal / kg
H, Heat added per kg of water = ( Hs - Hw )
= ( 810.47 - 105) kcal / kg
H, Heat added per kg of water = 705.47 kcal / kg
Heat output of the boiler ( SH steam) = ( Msup x H) kcal / hr
= ( 15000 x 705.47) kcal / hr
Qo Heat output of the boiler ( SH steam) = 10582050 kcal / h
Msat Saturated steam flow from drum = 0 kg / h
Saturated steam enthalpy = 663.44 kcal/kg
Heat output thorugh the sat. steam = 0x( 663.44-105) kcal/kg
Qs heat output of the boiler ( saturated steam) = 0 kcal/hr
Qt Total heat output of the boiler = Qo+Qs kcal/hr
= ( 10582050 + 0 )kcal/hr
Qt Total heat output of the boiler = 10582050 kcal/hr
Calculated Boiler efficiency = 80.86 %
Selected Boiler Efficiency = 80 %
Fuel GCV = 3150 kcal /kg
Fuel firing rate = Qt x 100 / ( Eff x GCV )
= 10582050 x 100 / ( 80 x 3150 ) %
= 4,199 kg / hr
Results
Total heat output of the boiler = 10582050 kcal / hr
Calculated boiler efficiency = 80.86 %
Selected boiler efficency = 80%
Fuel firing rate = 4,199 kg / hr
Steam fuel ratio = 3.57 kg / kg
EWS 604
FAN SIZING CALCULATION Date & time:
PROJECT :
Site elevation = 300 metres
Gas temp at Airheater outlet = 160 deg C
Air temp at Airheater air inlet = 40 deg C
Airheater outlet = 150 deg C

Design air velocity in fuel piping = 16 m/s
Fan details No off compartments = 2
No of PA lines per compartment = 7
FD fan capacity (% MCR ) = 100 %
FD fan efficiency = 75 %
ID fan capacity (% MCR) = 100 %
ID fan efficiency = 75 %
PA fan capacity (% MCR ) = 100 %
PA fan efficiency = 70 %
FD fan design head = 750 mmwc
PA fan design head = 700 mmwc
ID fan design head = 370 mmwc
Flue gas generated per kg of fuel = 6.105 kg/kg
Molecular wt of flue gas = 28.52
Actual Fuel burnt rate = 4,199 kg/h
Wet air required per kg of fuel = 5.272 kg/kg
Margin on FD fan flow = 20 %
Margin on PA fan flow = 20 %
Margin on ID fan flow = 20 %
FAN SIZING CALCULATIONS
Calculations of volumetric gas flow rate
Wet flue gas produced per kg of fuel = 6.105 kg/kg
Fuel firing rate = 4,199 kg/h
Wet flue gas flow rate = 6.105 x 4,199 kg/h
= 25634.895 kg/h
Molecular wt of flue gas = 28.52 from air & gas calc
K, altitude correction factor = 0.965
Flue Gas volume flow rate at 0 deg C = 25634.895 x 22.4 / ( 28.52 x 0.965 )
= 20,864.25 Nm3 /hr
Flue Gas volume flow rate at 0 deg C = 5.80 Nm3 / sec
12/30/12 7:50 AM
EWS 604
Boiler exit temperature, deg C = 160 Deg C
Gas flow at boiler exit temperature = ( 5.80x ( 273 + 160 ) / 273 )m3 /sec
= 9.20 m3 /sec
Calculations of volumetric Air flow rate
Wet air flow rate = 5.272 x 4,199 kg/h
= 22137.13 kg/h
Molecular wt of wet air = 28.50
K, Altidue correction factor = 0.965
Wet air volume flow rate at 0 deg C = 22137.13 x 22.4 / ( 28.50 x 0.965)
= 18,030.06 Nm3 /hr
Wet air volume flow rate at 0 deg C = 5.01 Nm3 / sec
Air temp at Airheater air inlet = 40 Deg C
Hence, Volumetric Air flow rate = ( 5.80x ( 273 + 40 ) / 273 )m3 /sec
Volumetric air flow rate = 5.74 m3 /sec
Estimation of Fuel transport air flow
No of compartments = 2
No fof fuel lines = 7
Fuel flow per line = ( 4,199 / 7) = 600
Selected fuel line size, mm Nb, 100 / 125 / 150 = 150
Total Fuel air flow rate = 7 x 3.1416 x (150/2000)^2 x 16 m3/s
Total Fuel air flow rate = 1.979 m3/s
FD fan sizing
MCR airflow required for combustion = 5.74 m3/s
MCR airflow of FD fan = ( 5.74x 100 / 100 ) m3/s
MCR airflow of FD fan = 5.74 m3/s
Design Flow for FD fan = 5.74 x ( 100 +20 ) / 100 m3/s
= 6.89 m3/s
FD fan Design head = 750 mmwc
Assumed FD fan efficiency = 75 %
FD fan operating power required = 100 x 6.89 x 750/ ( 101 x 75 ) kw
= 68.2 kw
FD fan operating power BKW required = 100 x 5.74 x 750/ ( 101 x 75 ) kw
= 56.8 kw
Minimum motor power required = 1.15 x 68.2 kw
Minimum motor power required for FD fan = 78.4 kw
EWS 604
PA fan sizing
PA fan capacity (% MCR ) = 100 %
MCR fuel transport airflow required = 1.979 m3/s
MCR airflow of PA fan = ( 1.979x 100 / 100 ) m3/s
MCR airflow of PA fan = 1.979 m3/s
Margin on PA fan flow = 20 %
Design Flow for PA fan = 1.979 x ( 100 +20 ) / 100 m3/s
= 2.37 m3/s
PA fan Design head = 700 mmwc
Assumed PA fan efficiency = 70 %
PA fan operating power required = 100 x 2.37 x 700/ ( 101 x 70 ) kw
= 23.5 kw
PA fan operating power BKW required = 100 x 1.979 x 700/ ( 101 x 70 ) kw
= 19.6 kw
Minimum motor power required for PA fan = 27.0 kw
ID fan sizing
ID fan capacity (% MCR ) = 100 %
MCR gas flow produced = 9.20 m3/s
MCR gas flow of ID fan = ( 9.20x 100 / 100 ) m3/s
MCR gas flow of ID fan = 9.2 m3/s
Design Flow for ID fan = 9.2 x ( 100 +20 ) / 100 m3/s
= 11.04 m3/s
ID fan Design head = 370 mmwc
Assumed ID fan efficiency = 75 %
ID fan operating power required = 100 x 11.04 x 370/ ( 101 x 75 ) kw
= 53.9 kw
ID fan operating power BKW required = 100 x 20 x 370/ ( 101 x 75 ) kw
= 44.9 kw
Minimum motor power required for ID fan = 62.0 kw
Results summary
FD fan PA fan ID fan supply
m3/s 6.89 6.83 2.37 2.17 11.0 10.5
mmwc 750 750 700 700 370 370
Deg C 40 150 160
% 75 70 75
kw 68.2 23.5 53.9
kw 78.4 27.0 62.0
kw 90 90 30 30 75 75
Design flow
Design head
Design temperature
Selected motor Kw
Operating power
Min motor power
Assumed effciency
EWS 604
UNDER FED FLUIDISED BED SIZING Date & time : 12/30/12 7:55 AM
PROJECT :
INPUTS FOR FLUIDISED BED SIZING
Vf, Fluidisation velocity = 2.6 m/s
Tb, Design bed temperature = 850 Deg C
Steam generated nett = 15000 kg/h
Main steam pressure = 64 kg/cm2 a
Fuel burnt rate = 4,199 kg/h
Flue gas molecular weight = 28.52
Te, Boiler exit temperature = 160 Deg C
Tca, Combustion air temperature = 150 Deg C
Ta, Ambient temperature = 40 Deg C
Assumed carbon loss = 1.36 %
Ts, Saturation temperature = 283.9 deg C
M, Moisture = 8 %
A, Ash = 46.65 %
GCV, Gross calorific value of fuel = 3515.42 kcal /kg
UNDERBED FLUIDISED BED SIZING
Calculations for bed cross sectional area
= 25634.895 kg/h
Flue Gas volume flow rate at 0 deg C = 25634.895 x 22.4 / 28.52 x 0.965
= 20,864.25 Nm3 /hr
Gas flow at bed temperature = ( 5.80x ( 273 + 850 ) / 273 )m3 /sec
= 23.86 m3 /sec
Factor for over bed combustion = 1
Therefore, bed cross sectional area = 23.86 x 1 / 2.6
Bed cross sectional area required = 9.18 m2
EWS 604
bed length = 2950 m
bed width = 2950 m
Bed cross sectional area available = 8.7 m2
Therefore, corrected fluidisation velocity = 2.6x9.18 / 8.7
= 2.74 m/s
Calculations for bed heat transfer area
Unburnt carbon loss
HL1, % design Unburnt carbon loss = 3.5 %
Tb, Design bed temperature = 850 deg C
HL2, % Heat lost through ash = A x C x (Tb-Ta) x 100 / GCV
= 0.4665x 0.22x (850-40) x 100 / 3515.42 %
HL2, % Heat lost through ash = 2.36 %
Ww, weight of water in air = 0.02851 kg/kg
Cp1, specific heat of water vapor at bed temp = 0.5685 kcal/kg C
Cp2, specific heat of water vapor at ambient temp = 0.3592 kcal/kg C
Tca, Combustion air temperature = 150 deg C
HL3, % Heat lost through moisture in air = Ww x Wd x {(Cp1 x Tb) -(Cp2 x Tca)}x 100 / GCV
= 0.02851x5.126x[(0.5685x850)-(0.3592x150]x100 /351
HL3, % Heat lost through moisture in air = 1.78 %
Cpb, Specific heat of water vapor at bed temp = 0.5685 kcal/kg
HL4, % Heat lost through moisture & H2 in fuel ={M+(8.94 x H)} x [595.4+(Cpb x Tb) -Ta] x 100 / GCV
HL4, % Heat lost through moisture & H2 in fuel
= 8.92 %

={ 0.08+ (8.94 x 0.02484)}x [ 595.4+(0.5685x 850) -
40]x100/3515.42 %
EWS 604
Cpb, specific heat of flue gas at bed temp = 0.285478044013218 kcal/kg deg C
Cpa, specific heat of flue gas at Tca = 0.242431854976819 kcal/kg deg C
HL5, % Heat lost through dry flue gas =Qfgd x{ (Cp1 x Tb) - (Cp2 x Tca)} x 100 / GCV

HL5, % Heat lost through dry flue gas = 31.80 %
Calculation for Heat loss through radiation to waterwall
Ab, Bed cross sectional area = 8.7 m2
e, Emissivity of waterwall surface = 0.9
S, Steafan boltzmann constant = 4.9 x 10 ^ -8
Tb, bed temperature = 850 Deg C
Ts, saturation temperature = 283.921318253176 Deg C
Radiation heat loss to waterwall =Ab x e x S x {( Tb + 273 )^4 - ( Ts + 273 )^4}
= 8.7x0.9x4.9 x 10^-8x{( 850+273)^4-(283.9213182531
= 573,297 kcal/h
Fuel heat input in the bed = 4,199x 3515.42= 14761248.58 kcal/h
HL6, % Radiation loss to waterwall = 100x 573,297/ 14761248.58
HL6, % Radiation loss to waterwall = 3.88 %
Bed heat balance & HTA required
HL1, Unburnt carbon loss = 3.5 %
HL2, Total Heat loss through the ash = 2.36 %
HL3, Heat lost through moisture in air = 1.78 %
HL4, Heat lost through moisture & H2 in fuel = 8.92 %
HL5, Heat lost through dry flue gas = 31.80 %
Total losses = 3.5+2.36+1.78+8.92+31.80+3.88
= 52.24 %
Therefore, % heat to be transferred to Bed coil = 100 - 52.24 %
% Heat transferred to Bed coil = 47.76 %
Fuel heat input in the bed = 14761248.58 kcal/h
Actual heat to be transferred to Bed coil = 47.76 x 14761248.58/ 100
= 7,049,972 kcal/h
Ts, Saturation temperature = 283.9 Deg C
Temperature difference = (850 - 283.9)= 566.1 deg C
Heat transfer coeff = 220 kcal / kg m2 Deg C
Bed coil area required = 7,049,972/ ( 220 x 566.1)
Bed Coil HT area required, if plain = 56.61 m2
free board combustion = 20 %
Then, Bed Coil HT area with free board combn = 45.288 m2
=5.419x { ( 0.285478044013218 x 850) -
EWS 604
Bed Coil length required = 45.288/ ( 3.1416 x 0. 051)
= 282.6592 m
Bed coil required after considering stud effect = 226.12736 m
Checking the available bed area
Bed coil length per coil- type 1 = 2633 mm
No off bed coils- type 1 = 36 No
No off bed coils-type 2 = 36 No
Total eff length of bed coil = 169.236 m
Total length of bed coil with studs = 236.9304 m
Furnace residence time
Furnace volume as existing = 52.456 m3
Flue gas quantity at furnace temperature = 23.86 m/s
Furnace residence time = 52.456 / 23.86
= 2.2 sec
Summary of results
Bed Coil length required = 226.12736 m
Bed Coil length available = 236.9304 m
Furnace residence time = 2.2 sec
EWS 604
PROJECT :
INPUTS FOR DP NOZZLE SIZING CALCULATIONS
Airheater air outlet = 150 deg C
No off compartments = 2
Volumetric air flow rate = 5.01 Nm3/s
Fuel transport air flow = 1.979 m3/s
Air nozzle hole size 5 mm
No of hole per nozzle 9
fuel Line size 150 nb
Equiv no of nozzles per fuel feed point 0
No of air nozzles selected 641
Selected distributor plate length 2950 mm
Selected distributor plate width 2950 mm
Calculations of volumetric Air flow rate and air densities
Total airflow at 0 deg C = 5.01 Nm3 / s
Ta, ambient temperature = 40 deg C
V 40, Total airflow at ambient temperature = 5.01x ( 273 +40 ) / 273
V 40, Total airflow at ambient temperature = 5.744 m3/s

Air temp at Airheater air outlet = 150 Deg C
V 150, Total airflow after airheating = 5.01x ( 273 +150 ) / 273
V 150, Total airflow at after airheating = 7.763 m3/s
Air nozzle hole diameter = 5
No of holes per air nozzle = 9
Flow area per nozzle = 9 x 3.1416 x (5/ 2000 )^2
= 0.00018 m2
D0, Density of air at 0 deg C with elevation corr. = 1.233
D1, Density of air at 40 deg C = 273 x 1.233/ (273 +40)
= 1.075 kg/m3
= 0.796 kg/m3
Pressure drop in distributor plate during MCR flow condition
Sa + spreader % = 10 %
= 0.7763 m3/s
PA flow = 1.979 m3/s
MCR air flow through DP at hot condn = 7.763 - 0.7763 - 1.979
Design by:
Name:
Sign:
Approved by:
Name:
Sign:
EWS 604
= 5.0077 m3/s
Cd, Coefficient of discharge = 0.7
Actual No of air nozzles = 641
Air velocity through a nozzle hole = 5.0077/ (641x0.00018)
= 44.21 m/s
Pressure drop at MCR condition = 0.796 x 44.21^2 / ( 2 x 9.81 x 0.7^ 2)
Pressure drop at MCR condition = 162 mmwc
Pressure drop during MFC ( minimum fluidisation condition )
Selected distributor plate length = 2950
Selected distributor plate width = 2950 mm
Actual Distributor plate area provided = 2950 x 2950/ 1000000
= 8.7025 m2
Minimum fluidisation velocity at cold condition = 0.7 m/s
Minimum fluidisation airflow = 0.7 x 8.7025
= 6.09175 m3/s
Density of air at ambient condition = 1.075 kg/m3
No off nozzles provided = 641
Flow area per nozzle = 0.00018
Velocity through air nozzle hole = 6.09175 / ( 641x0.00018)
= 54 m/s
Pressure drop at Min fluidisation condition = 1.075 x 54^2 / ( 2 x 9.81 x0.77^2)
= 326 mmwc
Results summary
Selected distributor plate width = 2950 mm
Selected distributor plate length = 2950 mm
Pressure drop at Min fluidisation condition = 326 mmwc
Design by:
Name:
Sign:
Approved by:
Name:
Sign:
ANNEXURE 6 OPEN HOPPER DESIGN FOR AGRO FUELS

Photo 1: Open hopper design supplied by Thermax for high ah coal.

Photo 2: Typical FBC boiler with sparger nozzle system.
OPEN HOPPER FBC COMBUSTOR INSTALLATION BY THERMAX AT J OCIL, GUNTUR

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Chinchwad, Pune - 411019.
Tel: 91-20-4126464
http://www.tbwindia.com
Iechnicol Dolo
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LITERATURE ON OPEN HOPPER FBC COMBUSTOR

Bubbling Fluidized Bed Boilers
Experience and Research
For more than 130 years, industries worldwide have benefited
from Babcock & Wilcoxs (B&W) engineering, manufacturing
technology and operating experience as a major supplier of
steam generating equipment.
B&Ws involvement in fluid beds dates back to the 1950s and
the first combustor at its Alliance, Ohio, U.S.A. research center.
A technical cooperation agreement gives B&W combined global
experience of 34 units with more than 200 cumulative years
operating data. B&Ws fluid bed combustion facilities are helping
the world realize the promise of clean energy from a wide
variety of fuels.
B&W continues as a leader in the power generation industry
with its bubbling fluidized bed (BFB) boiler.
100 Percent Open Bottom Bed Drain System
Fluidized beds must have a system to remove oversized or foreign bed material
while the boiler is in operation. B&W uses the original open bottom design.
Fluidizing air bubble caps and pipes are mounted on widely spaced air distribution
ducts. Ample pipe spacing allows total draining from the entire bed area. This
design effectively removes rocks and debris that enter the furnace with the fuel
which would otherwise hinder good combustion.
The open bottom design minimizes the bed drain rate required for a given fuel.
The bed material is removed in small quantities and can take days to reach the
hopper outlet. This gives the material sufficient time to cool and eliminates the
need for water-cooled screw conveyors, saving capital and maintenance costs.
The material is cool enough that the hoppers are not insulated. Significant savings
are also realized as the small amount of material removed from the bed minimizes
landfilling or disposal costs.
As the supplier of the original open bottom design, B&W has drawn from four
decades of fluid bed experience.
Dome
Valve
Maintenance
Slide Gate
Header
Air Duct
Fuel Feed
Bubble Caps
Table
B&Ws Bubbling Fluidized Bed (BFB) Technology
B&Ws open bottom bed provides a clear path
for effective removal of oversized or foreign
bed material.
Batching
valves regulate
material flow
at the hopper
discharge.
Fluidizing air inlet bubble caps are mounted on
air distribution ducts arranged to allow total
draining capability from the entire bed area.
B&W was the first in
North America to offer
the open bottom BFB
design. Our 100 percent
open bottom design
results in complete
debris removal with
lower capital costs and
maintenance expenses.
14
12
10
8
6
4
2
0
1980 1981 - 1984 1985 - 1988 1989 - 1992 1993 - 1998
Through a technical cooperation agreement, B&W has steadily
increased its global experience base.
Fluidized Bed Boiler Installed Units
N
u
m
b
e
r

o
f

U
n
i
t
s
Top or Bottom Boiler Support Systems
B&W can supply either top supported or bottom supported BFB units,
depending on the desired size. Regardless of boiler support
arrangement, the hopper system is always bottom supported, reducing
capital.
B&Ws bottom supported hopper design isolates the bubbling bed
foundation and steel from the boiler steel. For top supported units,
this feature isolates the additional load of the bubbling bed and sand
from the boiler and eliminates modifications to boiler support steel.
Bottom supporting the bubbling bed also reduces potential mechanical
stresses between water cooled and non-cooled components, providing
long term reliability and reduced maintenance costs.
Other Design Benefits
B&Ws BFB furnace walls are constructed entirely of water cooled, gas tight, membraned
tubes. This eliminates the maintenance problems associated with the use of thick refractory.
For top supported boilers, a flexible expansion joint is provided
between the boiler and bottom supported bed hoppers.
The fuel feeding system consists of windswept spouts with no moving
parts coming in contact with the fuel. This simple design eliminates
the potential damage caused by debris, and is considered a distinct
advantage compared to a mechanical feeder. Fuel is introduced to
the furnace by natural downward forces. A blanket of high pressure
air sweeps the bottom of the spout and spreads the fuel evenly on
the bubbling bed surface. The spout is equipped with a rotating air
damper to vary air flow (and thus fuel trajectory) over a timed cycle.
This feature, along with an angled, adjustable spout bottom plate,
enhances fuel distribution.
B&Ws underbed ash removal system consists
of bottom supported hoppers which isolates
the bubbling bed foundation and steel from
the boiler steel. This design is considered an
advantage, particularly when retrofitting an
existing top supported unit to a BFB.
At this mill, B&W replaced two stoker-fired boilers with a BFB unit
directly into the existing boiler bay, minimizing structural modifications.
Windswept spouts
are considered a
design advantage
compared to a
mechanical fuel
feeder because of
their simple
design.
Features Benefits and Operating Results Features Benefits and Operating Results
Controlled Bed
Temperature
Staged air and low combustion temperatures limit NOx emissions
Prevents bed overheating
Simple Construction Low maintenance due to a lack of moving parts
High Bed Turbulence High combustion efficiency via prolonged solids-to-gas contact
Excellent fuel and air mixing for low unburned carbon losses without ash reinjection
Combustion Air System Completes combustion in a staged manner
Low CO emissions
Low NOx emissions
Low VOC emissions
Expansion Joint Allows for differential expansion of bed hoppers and boiler
100 Percent Open Bottom Clear vertical path eliminates debris without creating dead zones in the fluid bed
Even air distribution and bubble cap reliability
Low sand removal
Fuel Flexibility Bark and woodwastes
Paper mill and sewage sludges
Most high moisture fuels
tire derived fuel
oil or natural gas
coal
Leading the way in bubbling fluidized bed
technology, B&W combines experience, proven
designs and technical expertise to provide cost
effective solutions for your steam generation needs.
Babcock & Wilcox
Reduce Your Capital and Operating Costs
Are you considering a new process recovery boiler?
Convert your old recovery boiler to a BFB power boiler at a significantly lower
cost than a new boiler. The large furnace and plan area of a recovery boiler are ideal
for BFB technology and can provide a significant increase in steam production.
Is your existing stoker-fired power boiler limited by the amount of
sludge it can burn?
Convert it to a BFB boiler at a lower cost than a new boiler. The BFB requires
about the same plan area as the existing stoker.
Do you want to burn less expensive waste fuels?
A BFB is a reliable means to do so.
Are your sludge disposal costs too high?
A B&W open bottom BFB will minimize landfill needs.
Fuel Flexibility
B&Ws BFB boiler is uniquely suited for paper mill operations in
both new and retrofit applications. The strength of the BFB is its
ability to efficiently burn a wide range of fuels such as wood wastes
and sludges, in combination or alone. These fuels typically burn
cooler, and allow the required bed temperature to be maintained
without the use of an in-bed cooling surface. If desired, oil and
natural gas can be fired, as well as other fuels such as coal and tire
derived fuel. Where waste fuels are being consumed to generate
steam, they often replace more expensive fuels, thus reducing
operating costs.
Environmental Benefits
Significant environmental benefits are also achieved with BFB
technology. The BFB produces relatively low levels of nitrogen
oxides and carbon monoxide. With the addition of limestone, it
can remove high levels of sulfur dioxide without the expense of a
flue gas scrubber. Also, landfill operations are greatly reduced in
those cases where mill byproducts can be consumed as fuel.
Process:
Inert material, typically sand, and fuel form a bed in the bottom of the furnace which is suspended by a stream of upwardly
flowing fluidizing air. Fuel introduced to the bed is quickly volatilized. A significant amount of volatiles escape the bed and
are burned in the freeboard area above the bed. The remaining volatiles and fixed carbon burn in the bed. To achieve efficient
combustion and low emissions, the bed temperature is controlled in the range of 1400 F to 1600 F (760 C to 871 C).
Design features:
top or bottom supported
one or two drum designs
proven effective in retrofit applications
provides an option to reduce SO
2
and
NO
x
emissions
reduces sludge volume while
producing steam
superior to other technologies for
burning wet wood based fuels
between approximately 2800 and
3500 Btu/lb HHV (6513 and 8141 kJ/kg)
without support fuels
Steam pressure:
to 2400 psig (165 bar gauge) throttle pressure
Superheater outlet temperatures:
as required, up to 950 F (510 C)
Fuels:
able to burn a wide range of conventional
fuels and waste fuels with high moisture,
including:
wood wastes and bark
paper mill sludges
recycled paper facility sludges
sewage sludge
tire derived fuel
oil and natural gas
coal
Specifications
B&Ws BFB boiler for this customer significantly reduced the amount
of mill sludge which needed to be landfilled. The boiler produces
additional steam to feed the plants existing system while meeting
stringent emissions requirements.
Limestone, Sludge
and Wood
Fuel Mixing Screw
Superheater
Metering
Bin
Rotary Airlocks
Overfire Air
System
Burners
Fuel Spouts
Fluidized Bed
Ash
Conveyors
Economizer
Generating
Bank
Tubular
Air Heater
Forced
Draft Fan
Gas
Air
Steam Coil
Airheater
Silencer
Attemperator
Air
Gas
Water
Steam
Fuel
Bed Material
Whether a new BFB boiler, or a conversion of your recovery or stoker-fired power
boiler, fluidized bed combustion offers significant operational advantages:
fuel flexibility
high efficiency
low environmental emissions
reduced capital costs and operating expenses
Why B&Ws fluidized bed technology?
the original completely open bottom design has proven advantages
extensive research and development of fluid bed combustion
operating experience with a wide range of unit sizes and high moisture fuels
B&W offers quality and commitment to service
innovative design and technical expertise to increase production,
optimize equipment, and lower costs
capability, experience and track record to ensure your project
will progress on schedule and reach performance targets
a tradition of excellence since 1867
From engineering and
design through construction
and start-up, B&W provides
total support for your
complete BFB project.
E101-3161 5MR9B
While others may use the Babcock name, we are the original Babcock & Wilcox with more than 130 years of experience in
engineering, constructing and servicing steam generating systems. Insist on us by name.
For more information, or a complete listing of our sales and service offices worldwide, call 1-800-BABCOCK (222-2625)
in North America. Outside North America, call (330) 753-4511 or fax (330) 860-1886 (Barberton, Ohio, USA). Or access our
Web site at http://www.babcock.com.
Canada:
Cambridge, Ontario
Edmonton, Alberta
Montreal, Quebec
Saint John, New Brunswick
Vancouver (Richmond), British Columbia
Egypt: Cairo
India: Pune
Indonesia: Jakarta
Mexico: Mexico City
Peoples Republic of China: Beijing
Singapore: Singapore
Taiwan: Taipei
Turkey: Ankara
United States of America:
Atlanta, Georgia
Barberton, Ohio
Charlotte, North Carolina
Chicago (Downers Grove), Illinois
Cincinnati, Ohio
Dallas, Texas
Denver (Sheridan), Colorado
Fairfield, New Jersey
Houston, Texas
Kansas City, Missouri
Mt. Holly, New Jersey
San Francisco (Napa), California
St. Petersburg, Florida
Powering the World Through Teamwork and Innovation
SM
1999 The Babcock & Wilcox Company. All rights reserved.
The information contained herein is provided for general information purposes only and is not intended or
to be construed as a warranty, an offer, or any representation of contractual or other legal responsibility.
Powering the World Through Teamwork and Innovation is a service mark of The Babcock & Wilcox Company.
ANNEXURE 7- COMBUSTOR DESIGN CALCULATIONS FOR 100% RICE HUSK FIRING BY
OVERBED

EWS 604

PROJECT :
INPUTS FOR COMBUSTION CALCULATIONS
AIR & GAS CALCULATIONS
Ta Ambient temperature 40 Deg C
P1 Relative humidity 60 %
Ma Moisture in dry air ( from tables) 0.02851 kg/kg
E Excess air 35 %
Te Boiler outlet gas temperature 165 Deg C
El Site elevation 300 Metres
P Flue gas pressure 5 mmwc
FUEL Std husk
C Carbon 35.51 % by wt 38.5
H Hydrogen 5.08 % by wt 3.7
O Oxygen 34.55 % by wt 36.31
S Sulphur 0.01 % by wt 0
N Nitrogen 0.12 % by wt 0.46
M Moisture 8.68 % by wt 8
A Ash 16.06 % by wt 20
100.00
GCV Gross GCV of fuel 3150.00 Kcal /kg 3200
HLS1 Carbon loss ( calculated ) 1.36 %
HLS6 Radiation loss ( assumed ) 1 %
HLS7 Manufacturer margin (assumed ) 0.5 %
Locations
A1 % Ash collection at location 1 Bed 5 %
A2 % Ash collection at location 2 Bank 5 %
A3 % Ash collection at location 3 Economiser 5 %
A4 % Ash collection at location 4 Airheater 5 %
A5 % Ash collection at location 5 MDC 60 %
A6 % Ash collection at location 6 Trema 20 %
100
Steam generation rate Nett 15000 Kg/h
Main steam pressure 64 kg/cm2 g
Main steam temperature 490 Deg C
Feed water inlet temperature 105 Deg C
Superheater Pressure drop 3 kg/cm2 g
Saturated steam flow from drum 0 kg/h
Deepak spinners - 100% rice husk- as per lab report- OVERBED
Rice husk
EWS 604
Boiler efficiency Calculated 79.95
Boiler efficiency 79.00 %
INPUTS FOR AIR,GAS DUCT,CHIMNEY SIZING CALCULATIONS
Flue gas ducting Gas temp
Boiler bank outlet 350 Deg C
Economiser outlet 235 Deg C
Air ducting Air temp
Design velocities
Design velocity in gas duct 14 m/s
Chimney design gas velocity 15 m/s
Design velocity in air duct 12 m/s
Design air velocity in fuel piping 16 m/s

No off compartments 2
Total no of fuel feed points 0
Fan sizing
FD fan capacity (% MCR ) 100 %
FD fan efficency 75 %
ID fan capacity (% MCR) 100 %
ID fan efficency 75 %
FD fan design head 750 mmwc
ID fan design head 370 mmwc

Margin on FD fan flow 20 %
Margin on PA fan flow 20 %
Margin on ID fan flow 20 %
INPUTS FOR FLUIDISED BED SIZING CALCULATIONS
INPUTS FOR DUST EMISSION CALCULATIONS
Percentage ash entering dust collector = 50 %
Efficency of Dust collector = 99.5 %
EWS 604
COMBUSTION CALCULATIONS FOR FUEL PER KG BASIS Date & time: 12/30/12 8:20 AM
PROJECT :
INPUTS FOR AIR & GAS CALCULATIONS Rice husk
P1, Relative humidity = 60 %
Constituents of fuel ( % by weight )
C, Carbon = 35.505 %
Carbon lost in ash = 0.53 %
carbon burnt = 34.975 %
H, Hydrogen = 5.077 %
O, Oxygen = 34.546 %
S, Sulphur = 0.009 %
N, Nitrogen = 0.119 %
A, Ash = 16.063 %
Air requirement calculations
O2 reqd, kg/kg of Carbon in fuel = 2.644 kg/kg
O2 reqd, kg/kg of Hydrogen in fuel = 7.937 kg/kg
O2 reqd, kg/kg of Sulphur in fuel = 0.998 kg/kg
Solid crbon unburnt from Efficiency calc, = 0.0053 kg/kg
O2 reqd, for the Carbon in fuel =( 0.35505 - 0.0053)x2.644 /100) kg/kg
= 0.925 kg/kg
O2 reqd, for the Hydrogen in fuel =( 7.937x5.077 /100) kg/kg
= 0.403 kg/kg
O2 reqd, for the Sulphur in fuel =( 0.998x0.009 /100) kg/kg
= 0.000 kg/kg
Stochiometric O2 reqd / kg of fuel = O2 reqd for C,H,S in fuel - O2 in fuel) kg/kg
Stochiometric O2 reqd / kg of fuel = ( 0.925+0.403+0.000) -(34.546 / 100) kg/kg
= 0.98254 kg /kg of fuel
Excess O2 required / kg of fuel = ( 0.98254x / 100 ) kg /kg of fuel
= ( 0.98254x 35 / 100 ) kg /kg of fuel
= 0.343889 kg/kg
Total O2 required / kg of fuel = ( 0.98254+ 0.343889) kg/kg
= 1.326429 kg/kg
Weight fraction of O2 in atmospheric air = 0.23 kg/kg
Dry air required for Combustion, kg/kg of fuel =( 1.326429/ 0.23) kg/kg
= 5.767 kg/kg
Due to relative Humidity, wet air reqd, kg/kg of fuel =( 1 + 0.02851) x 5.767) kg/kg

EWS 604
Gas weight constituents calculations
CO2 produced, kg/kg of Carbon in fuel = 3.644 kg/kg
H2O produced, kg/kg of Hydrogen in fuel = 8.937 kg/kg
SO2 produced, kg/kg of Sulphur in fuel = 1.998 kg/kg
CO2 produced, for the Carbon in fuel =( 3.644x34.975 /100) kg/kg
= 1.274 kg/kg
H2O produced, for the Hydrogen in fuel =( 8.937x5.077 /100) kg/kg
= 0.454 kg/kg
H2O in combustion air = 0.02851x5.767 kg/kg
= 0.164 kg/kg
H2O due to moisture in fuel = 8.68/100 kg/kg
= 0.0868 kg/kg
H2O due to air & H2 combustion& fuel moisture =( 0.164+0.454+0.0868) kg/kg
= 0.7048 kg/kg
SO2 produced, for the Sulphur in fuel =( 1.998x0.009 /100) kg/kg
= 0.000 kg/kg
O2 in flue gas ( Excess O2 added ) = 0.343889 kg/kg
N21,Nitrogen due to fuel = N kg/kg
= 0.00119 kg/kg
Weight fraction of Nitrogen in Dry Air = 0.77 kg/kg
N22 due to Air, kg per kg of fuel = 0.77 x 5.767 kg/kg
= 4.441 kg/kg
Total N2 in flue gas , kg/kg of fuel fired = N21+N22 kg/kg
= ( 0.00119+4.441) kg/kg
= 4.44219 kg/kg of fuel
Qfgw, Total wet flue gas produced per kg of fuel fired = 1.274+0.7048+0.000+0.343889+4.44219
= 6.764879 kg/kg
Wet flue gas produced, kg /kg of fuel fired = 6.765 kg/kg
Qfgd, Total dry flue gas produced per kg of fuel fired = 1.274+0.000+0.343889+4.44219
= 6.060 kg/kg
Dry flue gas produced, kg /kg of fuel fired = 6.060 kg/kg
wet gas
kg / kg of
fuel
Mol.
weight
CO2 1.274 44.04
H2O 0.705 18.02
SO2 0.000 64.06
O2 0.34389 32.00
N2 4.44219 28.01
Total 6.76488 Total moles = 0.029+0.039+0.000+0.011+0.159=0.238
Mole.wt of flue gas = ((12.18x 44.01)+(16.39x 18.02)+(0.00x64.06)+(4.62x32)+(66.81x28.01)) / 100
Mole.wt of flue gas = 28.51
100x0.000/6.764879=0.000
100x0.343889/6.764879=5.08
0.7048/18.02 = 0.039
100x4.44219/6.764879=65.66
100x0.000/0.238=0.00
100x0.011/0.238=4.62
100x0.159/0.238=66.81
0.000/64.06 = 0.000
0.343889/32 = 0.011
4.44219/28.01 = 0.159
100x1.274/6.764879=18.833 1.274/44.04 = 0.029 100x0.029/0.238=12.18
100x0.039/0.238=16.39
Flue gas ( wet ) composition
by % wt
Flue gas ( wet ) composition by %
vol
No of moles / kg of
fuel
Composition of Flue gas
100x0.7048/6.764879=10.419

EWS 604

Results Summary
Dry Flue gas produced, kg /kg of fuel fired = 6.060 kg/kg
Flue gas composition summary
Wet by vol % Dry by vol%
Carbon di oxide = 12.18 % = 14.57 %
Water vapour = 16.39 % = 0 %
Sulfur di oxide = 0.00 % = 0.00 %
Oxygen = 4.62 % = 5.53 %
Nitrogen = 66.81 % = 79.91 %

EWS 604
DESIGN EFFICIENCY CALCULATIONS Date & time : 12/30/12 8:20 AM
PROJECT :
HLS1, assumed unburnt carbon loss = 1.36 %
HLS6, Assumed radiation loss = 1 %
Rh, Relative humidity = 60 %
Te, Boiler outlet gas temperature = 165 Deg C
A1, % Ash collection at location 1 = 5 % Bed
A2, % Ash collection at location 2 = 5 % Bank
A3, % Ash collection at location 3 = 5 % Economiser
A4, % Ash collection at location 4 = 5 % Airheater
A5, % Ash collection at location 5 = 60 % MDC
A6, % Ash collection at location 6 = 20 % Trema
A, Ash = 16.063 %
GCV, Gross calorific value of fuel = 3150 kcal /kg
DESIGN EFFICENCY CALCULATIONS
Assumed heat loss through unburnt carbon in ash
LOI in ash = 1 %
=5 x 0.16063 x 1 x 8050 /( (100-1 ) x 3150) %
EWS 604
LOI in ash = 3.5 %
=90 x 0.16063 x 3.5 x 8050 /( (100-3.5 ) x 3150) %
HLS1, Total unburnt carbon loss = 1.36 %
Solid carbon loss = 1.36x3150 / 8050 %
= 0.53 %
HLn, % Heat lost through ash at n'th location = A x (An /100 ) x C x (Tn-Ta) x 100 / GCV
HLS2, Total Heat loss through the ash = HL1+HL2+HL3+HL4+HL5+HL6
= ( 0.05+0.01+0.01+ 0.01+0.07+0.02 )%
Ww, wieght of water in air = 0.02851 kg/kg
Cp1, specific heat of water vapor at boiler exit temp = 0.4853 kcal/kg C
Cp2, specific heat of water vapor at ambient temp = 1 kcal/kg C
EWS 604
HLS3, % Heat lost through moisture in air = Ww x Wd x{(Cp1x Te)-(Cp2 x Ta)}x100/(GCV)
= 0.02851x5.767x[(0.4853x165)-(1x40]x100 /(3150)
HLS3, % Heat lost through moisture in air = 0.21 %
Cp1, Specific heat of water vapor at boiler exit temp = 0.4853 kcal/kg
HLS4, % Heat lost through moisture & H2 in fuel ={M+(8.94 x H)} x [595.4+(Cp1 x Te) -Ta] x 100 / (GCV)
= 10.91 %
Cp3, specfic heat of flue gas at boiler exit temp = 0.243 kcal/kg deg C
Cp4, specfic heat of flue gas at ambient temp = 0.236 kcal/kg deg C
HLS5, % Heat lost through dry flue gas =Qfgd x{ (Cp3 x Te) - (Cp4 x Ta)} x100/(GCV)

HLS5, % Heat lost through dry flue gas = 5.90 %
Assumed heat loss through radiation
Manufacturer margin
Total efficiency break up
HLS3, Heat lost through moisture in air = 0.21 %
HLS4, Heat lost through moisture & H2 in fuel = 10.91 %
HLS5, Heat lost through dry flue gas = 5.90 %
Total losses = 1.36+0.17+0.21+10.91+5.90+1+0.5
= 20.05 %
Therefore, Boiler efficiency, = 100 - 20.05 %
Boiler Efficiency = 79.95 %
={ 0.0868+ (8.94 x 0.05077)}x [ 595.4+(0.4853x 165) -
40]x100/(3150) %
=6.060x { ( 0.243 x 165) - (0.236x40)} x 100/(3150) %
EWS 604
BOILER HEAT DUTY CALCULATIONS Date & time: 12/30/12 8:20 AM
PROJECT :
Steam generation rate Nett = 15000 Kg/h
Main steam pressure = 64 kg/cm2 g
Feed water inlet temperature = 105 Deg C
Superheater Pressure drop = 3 kg/cm2 g
Saturated steam flow from drum = 0 kg/h
Selected boiler efficiency = 79 %
BOILER HEAT DUTY CALCULATIONS
Msup, Steam generation rate = 15000 kg / h
P1, Main steam pressure = 64 kg/cm2 g
Ts, Main steam temperature = 490 deg C
Tw, Feed water inlet temperature = 105 deg C
Hw, Feed water inlet enthalphy = 105 kcal / kg
Hs, Main steam enthalpy = 810.47 kcal / kg
H, Heat added per kg of water = ( Hs - Hw )
= ( 810.47 - 105) kcal / kg
H, Heat added per kg of water = 705.47 kcal / kg
Heat output of the boiler ( SH steam) = ( Msup x H) kcal / hr
= ( 15000 x 705.47) kcal / hr
Qo Heat output of the boiler ( SH steam) = 10582050 kcal / h
Msat Saturated steam flow from drum = 0 kg / h
Saturated steam enthalpy = 663.44 kcal/kg
Heat output thorugh the sat. steam = 0x( 663.44-105) kcal/kg
Qs heat output of the boiler ( saturated steam) = 0 kcal/hr
Qt Total heat output of the boiler = Qo+Qs kcal/hr
= ( 10582050 + 0 )kcal/hr
Qt Total heat output of the boiler = 10582050 kcal/hr
Calculated Boiler efficiency = 79.95 %
Selected Boiler Efficiency = 79 %
Fuel GCV = 3150 kcal /kg
Fuel firing rate = Qt x 100 / ( Eff x GCV )
= 10582050 x 100 / ( 79 x 3150 ) %
= 4,252 kg / hr
Results
Total heat output of the boiler = 10582050 kcal / hr
Calculated boiler efficiency = 79.95 %
Selected boiler efficency = 79%
Fuel firing rate = 4,252 kg / hr
Steam fuel ratio = 3.53 kg / kg
EWS 604
FAN SIZING CALCULATION Date & time:
PROJECT :
Site elevation = 300 metres
Gas temp at Airheater outlet = 165 deg C
Airheater outlet = 150 deg C

Fan details No off compartments = 2
FD fan efficiency = 75 %
ID fan capacity (% MCR) = 100 %
ID fan efficiency = 75 %
FD fan design head = 750 mmwc
ID fan design head = 370 mmwc
Flue gas generated per kg of fuel = 6.765 kg/kg
Molecular wt of flue gas = 28.51
Actual Fuel burnt rate = 4,252 kg/h
Calculations of volumetric gas flow rate
= 28764.78 kg/h
Flue Gas volume flow rate at 0 deg C = 28764.78 x 22.4 / ( 28.51 x 0.965 )
= 23,419.87 Nm3 /hr
Boiler exit temperature, deg C = 165 Deg C
Gas flow at boiler exit temperature = ( 6.51x ( 273 + 165 ) / 273 )m3 /sec
= 10.44 m3 /sec
12/30/12 8:20 AM
EWS 604
Calculations of volumetric Air flow rate
Wet air flow rate = 5.931 x 4,252 kg/h
= 25218.61 kg/h
Molecular wt of wet air = 28.50
K, Altidue correction factor = 0.965
Wet air volume flow rate at 0 deg C = 25218.61 x 22.4 / ( 28.50 x 0.965)
= 20,539.84 Nm3 /hr
Wet air volume flow rate at 0 deg C = 5.71 Nm3 / sec
Air temp at Airheater air inlet = 40 Deg C
Hence, Volumetric Air flow rate = ( 6.51x ( 273 + 40 ) / 273 )m3 /sec
Volumetric air flow rate = 6.55 m3 /sec
FD fan sizing
MCR airflow required for combustion = 6.55 m3/s
MCR airflow of FD fan = ( 6.55x 100 / 100 ) m3/s
MCR airflow of FD fan = 6.55 m3/s
Design Flow for FD fan = 6.55 x ( 100 +20 ) / 100 m3/s
= 7.86 m3/s
FD fan Design head = 750 mmwc
Assumed FD fan efficiency = 75 %
FD fan operating power required = 100 x 7.86 x 750/ ( 101 x 75 ) kw
= 77.8 kw
FD fan operating power BKW required = 100 x 6.55 x 750/ ( 101 x 75 ) kw
= 64.9 kw
Minimum motor power required for FD fan = 89.5 kw
ID fan sizing
ID fan capacity (% MCR ) = 100 %
MCR gas flow produced = 10.44 m3/s
MCR gas flow of ID fan = ( 10.44x 100 / 100 ) m3/s
MCR gas flow of ID fan = 10.44 m3/s
Design Flow for ID fan = 10.44 x ( 100 +20 ) / 100 m3/s
= 12.528 m3/s
ID fan Design head = 370 mmwc
Assumed ID fan efficiency = 75 %
ID fan operating power required = 100 x 12.528 x 370/ ( 101 x 75 ) kw
= 61.2 kw
EWS 604
ID fan operating power BKW required = 100 x 20 x 370/ ( 101 x 75 ) kw
= 51.0 kw
Minimum motor power required for ID fan = 70.4 kw
Results summary
FD fan Supply ID fan supply
m3/s 7.86 6.83 12.5 10.5
mmwc 750 750 370 370
Deg C 40 165
% 75 75
kw 77.8 61.2
kw 89.5 70.4
kw 90 90 75 75
Design flow
Design head
Design temperature
Selected motor Kw
Operating power
Min motor power
Assumed effciency
EWS 604
UNDER FED FLUIDISED BED SIZING Date & time : 12/30/12 8:20 AM
PROJECT :
INPUTS FOR FLUIDISED BED SIZING
Tb, Design bed temperature = 850 Deg C
Steam generated nett = 15000 kg/h
Main steam pressure = 64 kg/cm2 a
Fuel burnt rate = 4,252 kg/h
Flue gas molecular weight = 28.51
Te, Boiler exit temperature = 165 Deg C
Tca, Combustion air temperature = 150 Deg C
Ta, Ambient temperature = 40 Deg C
Assumed carbon loss = 1.36 %
Ts, Saturation temperature = 283.9 deg C
M, Moisture = 8 %
A, Ash = 46.65 %
GCV, Gross calorific value of fuel = 3515.42 kcal /kg
UNDERBED FLUIDISED BED SIZING
Calculations for bed cross sectional area
= 28764.78 kg/h
Flue Gas volume flow rate at 0 deg C = 28764.78 x 22.4 / 28.51 x 0.965
= 23,419.87 Nm3 /hr
Gas flow at bed temperature = ( 6.51x ( 273 + 850 ) / 273 )m3 /sec
= 26.78 m3 /sec
Factor for over bed combustion = 0.9
Therefore, bed cross sectional area = 26.78 x 0.9 / 2.6
EWS 604
bed length = 3144.5 m
bed width = 3144.5 m
Therefore, corrected fluidisation velocity = 2.6x9.27 / 9.89
= 2.44 m/s
Calculations for bed heat transfer area
Unburnt carbon loss
HL1, % design Unburnt carbon loss = 3.5 %
HL2, % Heat lost through ash = A x C x (Tb-Ta) x 100 / GCV
= 0.4665x 0.22x (850-40) x 100 / 3515.42 %
HL2, % Heat lost through ash = 2.36 %
Ww, weight of water in air = 0.02851 kg/kg
Cp1, specific heat of water vapor at bed temp = 0.5685 kcal/kg C
Cp2, specific heat of water vapor at ambient temp = 0.3592 kcal/kg C
HL3, % Heat lost through moisture in air = Ww x Wd x {(Cp1 x Tb) -(Cp2 x Tca)}x 100 / GCV
= 0.02851x5.767x[(0.5685x850)-(0.3592x150]x100 /351
HL3, % Heat lost through moisture in air = 2.01 %
Cpb, Specific heat of water vapor at bed temp = 0.5685 kcal/kg
HL4, % Heat lost through moisture & H2 in fuel ={M+(8.94 x H)} x [595.4+(Cpb x Tb) -Ta] x 100 / GCV
= 8.92 %

={ 0.08+ (8.94 x 0.02484)}x [ 595.4+(0.5685x 850) -
40]x100/3515.42 %
EWS 604
Cpb, specific heat of flue gas at bed temp = 0.284594539902954 kcal/kg deg C
Cpa, specific heat of flue gas at Tca = 0.242476289357631 kcal/kg deg C
HL5, % Heat lost through dry flue gas =Qfgd x{ (Cp1 x Tb) - (Cp2 x Tca)} x 100 / GCV

HL5, % Heat lost through dry flue gas = 35.43 %
Calculation for Heat loss through radiation to waterwall
Ab, Bed cross sectional area = 9.89 m2
e, Emissivity of waterwall surface = 0.9
S, Steafan boltzmann constant = 4.9 x 10 ^ -8
Ts, saturation temperature = 283.921318253176 Deg C
Radiation heat loss to waterwall =Ab x e x S x {( Tb + 273 )^4 - ( Ts + 273 )^4}
= 9.89x0.9x4.9 x 10^-8x{( 850+273)^4-(283.921318253
= 651,714 kcal/h
Fuel heat input in the bed = 4,252x 3515.42= 14947565.84 kcal/h
HL6, % Radiation loss to waterwall = 100x 651,714/ 14947565.84
Bed heat balance & HTA required
HL1, Unburnt carbon loss = 3.5 %
HL2, Total Heat loss through the ash = 2.36 %
HL3, Heat lost through moisture in air = 2.01 %
HL4, Heat lost through moisture & H2 in fuel = 8.92 %
HL5, Heat lost through dry flue gas = 35.43 %
Total losses = 3.5+2.36+2.01+8.92+35.43+4.36
= 56.58 %
Therefore, % heat to be transferred to Bed coil = 100 - 56.58 %
% Heat transferred to Bed coil = 43.42 %
Fuel heat input in the bed = 14947565.84 kcal/h
Actual heat to be transferred to Bed coil = 43.42 x 14947565.84/ 100
= 6,490,233 kcal/h
Ts, Saturation temperature = 283.9 Deg C
Temperature difference = (850 - 283.9)= 566.1 deg C
Heat transfer coeff = 220 kcal / kg m2 Deg C
Bed coil area required = 6,490,233/ ( 220 x 566.1)
Bed Coil HT area required, if plain = 52.11 m2
free board combustion = 30 %
Then, Bed Coil HT area with free board combn = 36.477 m2
=6.060x { ( 0.284594539902954 x 850) -
EWS 604
Bed Coil length required = 36.477/ ( 3.1416 x 0. 0635)
= 182.8502 m
Checking the available bed area
No off bed coils- type 1 = 22 No
No off bed coils-type 2 = 22 No
Total length of bed coil = 101.112 m
Total length of bed coil with studs = 101.112 x 1.4 m ( 1.4 effectiveness)
= 141.5568 m
rearwall & front wall tube area with studs = 2 x 26 x .85 x 1.4 m ht
= 61.88 m
Total length tubes for heat transfer = 203.4368 m
Furnace residence time
Furnace volume as modified = 85.4 m3
Flue gas quantity at furnace temperature = 26.78 m/s
Furnace residence time = 85.4 / 26.78
= 3.19 sec
Summary of results
Bed Coil length required = 182.8502 m
Bed Coil length available = 203.4368 m
Furnace residence time = 3.19 sec
EWS 604
PROJECT :
INPUTS FOR DP NOZZLE SIZING CALCULATIONS
Airheater air outlet = 150 deg C
Volumetric air flow rate = 5.71 Nm3/s
Fuel transport air flow = 0.000 m3/s
Air nozzle hole size 3.4 mm
No of hole per nozzle 30
No of air nozzles selected 529
Selected distributor plate length 3144.5 mm
Selected distributor plate width 3144.5 mm
Calculations of volumetric Air flow rate and air densities
Total airflow at 0 deg C = 5.71 Nm3 / s
Ta, ambient temperature = 40 deg C
V 40, Total airflow at ambient temperature = 5.71x ( 273 +40 ) / 273
V 40, Total airflow at ambient temperature = 6.547 m3/s

Air temp at Airheater air outlet = 150 Deg C
V 150, Total airflow after airheating = 5.71x ( 273 +150 ) / 273
Air nozzle hole diameter = 3.4
No of holes per air nozzle = 30
Flow area per nozzle = 30 x 3.1416 x (3.4/ 2000 )^2
= 0.00027 m2
D0, Density of air at 0 deg C with elevation corr. = 1.233
= 1.075 kg/m3
= 0.796 kg/m3
Pressure drop in distributor plate during MCR flow condition
Sa + spreader % = 25 %
= 2.21175 m3/s
PA flow = 0 m3/s
MCR air flow through DP at hot condn = 8.847 - 2.21175 - 0
= 6.63525 m3/s
Cd, Coefficient of discharge = 0.7
Actual No of air nozzles = 529
Air velocity through a nozzle hole = 6.63525/ (529x0.00027)
Design by:
Name:
Sign:
Approved by:
Name:
Sign:
EWS 604
= 46.05 m/s
Pressure drop at MCR condition = 0.796 x 46.05^2 / ( 2 x 9.81 x 0.7^ 2)
Pressure drop during MFC ( minimum fluidisation condition )
Selected distributor plate length = 3144.5
Selected distributor plate width = 3144.5 mm
Actual Distributor plate area provided = 3144.5 x 3144.5/ 1000000
= 9.88788025 m2
Minimum fluidisation velocity at cold condition = 0.7 m/s
Minimum fluidisation airflow = 0.7 x 9.88788025
= 6.921516175 m3/s
Density of air at ambient condition = 1.075 kg/m3
Flow area per nozzle = 0.00027
Velocity through air nozzle hole = 6.921516175 / ( 529x0.00027)
= 48 m/s
Pressure drop at Min fluidisation condition = 1.075 x 48^2 / ( 2 x 9.81 x0.77^2)
= 258 mmwc
Results summary
Selected distributor plate width = 3144.5 mm
Selected distributor plate length = 3144.5 mm
Pressure drop at Min fluidisation condition = 258 mmwc
Design by:
Name:
Sign:
Approved by:
Name:
Sign:
FAN DATA FROM PLANT

VIEWS OF BOILER WITH PROPOSED OPEN HOPPER COMBUSTOR MODIFICATIONS

Report On Boiler Modification For 100% Over Bed Firing

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30 December, 2012

REPORT ON BOILER DESIGN & PERFORMANCE IMPROVEMENT STUDY AND FOR

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