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 17:007/1/2006
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 3.20
FGT (oC) 362.0 362 169.00 0.19480526
AMB (oC) 35.0 35.0 35.0
FGT (oC) corrected
201.73
Another formula for calculating excess air 11.54
DATA
Theoretical air requirement 5.03 5.03 kg/kg of fuel
N2 in flue gas 81.10 80.73 % in flue gas
Dry flue gas quantity 5.91 7.30 kg/kg of fuel
Nitrogen quantity in flue gas 4.37 5.44 kg/kg of fuel
Inlet dry air quantity 5.66 7.05 kg/kg of fuel
o
Ambient temperature 35.0 35.0 C
o
Ambient WBT 25.0 25.0 C
Heat released by burning 1 kg of carbon 8084 8084 kCal/kg

Flue gas (mass basis) A APH

%Vol Mol wt. % Mass % Vol % Mass
Oxygen 2.37 32 75.84 2.5 6.05 193.6 6.38
Carbon Dioxide 16.41 44.01 722.3762 23.5 13.22 581.6535 19.15
Carbon Monoxide 0.120 28.01 3.372404 0.1 0.006 0.170861 0.01
Nitrogen 81.10 28.01 2271.49 73.9 80.73 2261.177 74.46
3073.079 3036.602
Coal & Air mixture temperature 0
Specific heat calculation of flue gas
Gas temp 474.7 K Gas temp 308.0 K
CO2 1.00 kJ/kg C CO2 0.86 kJ/kg C
CO 1.06 kJ/kg C CO 1.05 kJ/kg C
O2 0.97 kJ/kg C O2 0.91 kJ/kg C
N2 1.05 kJ/kg C N2 1.05 kJ/kg C
Specific heat 1.0361 kJ/kg C Sp heat 1.0000 kJ/kg C
Mean specific heat 1.0181 KJ/kg C

Moisture calculation
Air
o o
DBT 35 35 C 95 F
o o
WBT 27.00 27.00 C 80.60 F
Humidity ratio 0.02 0.02 kg/kg of dry air
Moisture content of air 0.0200 0.02 kg/kg of dry air
Heat with pulvarised coal -18 -17.50 kCal/kg
GCV of coal(as fired) 3580 3580.00 kCal/kg
Total heat of coal 3563 3562.50 kCal/kg
Fuel
Moisture in fuel 0.08 0.08 kg per kg of fuel
Hydrogen in fuel 0.0250 0.0250 kg per kg of fuel
Total moisture in flue gas 0.417 0.445 kg per kg of fuel
Specific heat of moisture 0.4498 0.4498 Kcal/kg-oC
Data on Ash
Unburnt carbon in fly ash 0.90 %
Unburnt carbon in bottom ash 3.60 %

Losses
Design Values
Dry flue gas loss 239.50 Kcal/kg 6.72% % 5.08
Heat loss due to CO in flue gas 15.63 Kcal/kg 0.44% % 0.00
Heat loss due to moisture in air 8.49 Kcal/kg 0.24% % 0.12
Heat loss due to moisture and hydrogen in the fuel 198.62 Kcal/kg 5.58% % 5.95
Heat loss due to unburnt in bottom ash 21.69 Kcal/kg 0.61% % 0.90 31.28 0.88%
Heat loss due to unburnt in fly ash 21.69 Kcal/kg 0.61% % 0.00 34.11 0.96%
Sensible heat loss in bottom ash 9.59 Kcal/kg 0.27% % 0.38 1.84%
Sensible heat loss in fly ash 12.42 Kcal/kg 0.35% % 0.18
Radiation and unaccounted heat loss 35.63 Kcal/kg 1.00% % 0.17
Manufacturer's margin 0.50
Heat credit -0.71
Total heat loss 15.81% % 12.57 0.00
Thermal Efficiency 84.19% % 87.43

Dry Flue gas Loss Due to Hydrogen &

Due to Formation of CO
Moisture in the fuel

6.72% 239.50 Kcal/kg 5.58% 198.62 Kcal/kg 0.44% 15.63Kcal/kg

100 %
Heat Input 84.19%

31.28Kcal/kg 0.96% 34.11 1.00% 35.63

0.88%
0.24% 8.49 Kcal/kg Kcal/kg
Kcal/kg
Due Unburnt bottom Ash Unburnt Carbon in fly Ash Radiation & Unaccounted
Due to Moisture in Air losses
 BOILER DATA # 01

Coal Analysis (used for calculation)

Proximate Analysis % by mass
Moisture % Volatile Ash % Fixed carbon GCV kcal/kg
matter % %
8.00 24.70 40.50 26.80 3580
Ultimate Analysis (wet basis; as fired condition, converted from AES Laboratries report)
Moisture %
C H N O S Ash
38.02 2.50 1.48 5.00 0.38 37.26 8.00

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

Moisture % Volatile Ash % Fixed carbon GCV kcal/kg
matter % %
8.00 24.70 40.50 26.80 3580
Ultimate Analysis (on dry basis)-received from AES Laboratries
C H N O S Ash GCV
41.33 2.72 1.61 5.44 0.41 40.50 3580.00

Coal analysis report

Date Total Moisture Ash Volatile matter Fixed carbon GCV
(%) (%) (%) (%) kCal/kg
1/5/2006 14.50 35.60 26.00 23.90 3570.00 100.00
1/6/2006 14.10 34.50 26.90 24.50 3704.00 100.00
1/7/2006 14.30 34.70 26.60 24.40 3670.00 100.00
1/8/2006 14.60 35.70 25.80 23.90 3548.00 100.00
1/9/2006 14.40 34.70 26.50 24.40 3664.00 100.00
1/10/2006 14.00 34.10 27.20 24.70 3746.00 100.00
1/11/2006 14.00 34.30 27.00 24.70 3734.00 100.00
14.27 34.80 26.57 24.36 3662.29 100.00
 100.00
AES Laboratries report)

92.65

100.00

92.01
Surface heat loss of Boiler# 1

o
Ambient temperature 23.90 C Fuel burnt per hour 332.66 Tons
Emissivity 0.50 Calorific value of fuel 3580 kCal/kg
Air velocity 0.5 m/sec Heat supplied to boiler 1190928395 kCal/hr
Top surface area 294.17 m Structural heat loss 1237577 kCal/hr
Length of the boiler 17.280 m
Width 17.024 m

Location Avg temp Film coeff Area Delta T Heat loss

(kCal/m2-hr)(m2) (oC) (Kcal/hr)

Elevation 8.5m to 12m

Front 37.5 7.8 254.71 13.6 26928.2
Rear 37.5 7.8 254.71 13.6 26928.2
Left 37.0 7.7 29.79 13.1 3012.9
Right 37.0 7.7 29.79 13.1 3012.9
Elevation 12m to 17m
Front 37.0 7.7 86.40 13.1 8737.7
Rear 38.0 7.8 86.40 14.1 9534.2
Left 33.0 7.2 85.12 9.1 5601.3
Right 49.0 8.8 85.12 25.1 18735.5
Elevation 17m to 23m
Front 46.5 8.6 103.68 22.6 20107.6
Rear 35.0 7.5 103.68 11.1 8620.1
Left 37.5 7.8 102.14 13.6 10798.9
Right 39.5 8.0 102.14 15.6 12710.9
Elevation 23m to 29m
Front 39.3 8.0 103.68 15.4 12656.3
Rear 39.0 7.9 103.68 15.1 12411.5
Left 36.5 7.7 102.14 12.6 9864.7
Right 40.5 8.1 102.14 16.6 13687.6
Elevation 29m to 35m
Front 46.5 8.6 103.68 22.6 20107.6
Rear 43.0 8.3 103.68 19.1 16429.1
Left 37.0 7.7 102.14 13.1 10329.9
Right 40.5 8.1 102.14 16.6 13687.6
Elevation 35m to 43m
Front 44.5 8.4 138.24 20.6 23983.9
Rear 47.8 8.7 138.24 23.9 28607.4
Left 52.5 9.0 136.19 28.6 35113.2
Right 43.3 8.3 136.19 19.4 21919.7
Elevation 43m to 48m
Front 42.3 8.2 86.40 18.4 13050.0
Rear 48.5 8.7 86.40 24.6 18560.5
Left 66.7 9.9 85.12 42.8 35929.9
Right 54.5 9.1 85.12 30.6 23826.2
Elevation 48m to 55m
Front 47.5 8.7 120.96 23.6 24715.4
Rear 47.5 8.7 120.96 23.6 24715.4
Left 47.0 8.6 119.17 23.1 23728.7
Right 48.8 8.8 119.17 24.9 25914.3
Elevation 55m to 60m
Front 51.5 8.9 86.40 27.6 21334.0
Rear 66.0 9.8 86.40 42.1 35768.5
Left 43.5 8.3 85.12 19.6 13912.2
Right 49.3 8.8 85.12 25.4 18961.3
Elevation 60m to 66m
Front 57.0 9.3 103.68 33.1 31939.3
Rear 57.0 9.3 103.68 33.1 31939.3
Left 55.0 9.2 102.14 31.1 29161.6
Right 51.5 8.9 102.14 27.6 25221.5
Elevation 66m to 70m
Front 67.2 9.9 69.12 43.3 29598.9
Rear 67.2 9.9 69.12 43.3 29598.9
Left 48.7 8.7 68.10 24.8 14748.2
Right 51.8 9.0 68.10 27.9 16999.3
Elevation 70m to 73m
Front 47.5 8.7 51.84 23.6 10592.3
Rear 60.0 9.5 51.84 36.1 17759.4
Left 44.5 8.4 51.07 20.6 8860.7
Right 49.3 8.8 51.07 25.4 11376.8
Elevation 73m to 76m
Front 46.8 8.6 51.84 22.9 10187.9
Rear 46.8 8.6 51.84 22.9 10187.9
Left 50.3 8.9 51.07 26.4 11967.7
 Right 55.0 9.2 51.07 31.1 14580.8
Elevation 76m to 81m
Front 42.5 8.3 86.40 18.6 13263.0
Rear 42.5 8.3 86.40 18.6 13263.0
Left 42.5 8.3 85.12 18.6 13066.5
Right 52.5 9.0 85.12 28.6 21945.8
Elevation 81m to 92m
Front 45.8 8.5 190.08 21.9 35559.2
Rear 45.8 8.5 190.08 21.9 35559.2
Left 44.8 8.4 187.26 20.9 32963.2
Right 46.3 8.6 187.26 22.4 35834.8
Top 53.0 9.0 294.17 29.1 77458.7
1237577.1
O2 2.3700 6.0500 %
EA 0.1272 0.4047 % 0.28
inlet dry air quantity 5.6635 7.0545
Dry FG quantity 5.9078 7.2998 per kg of coal
Existing FGT 169.0000 oC
Moisture in flue gas 0.4169 0.4447 per kg of coal
heat to raise the ingress air temp.(amb. To FGT) 44.87 Kcal/kg of fuel
Heat required to raise the ingress moisture temp.(amb. To FGT) 1.68 Kcal/kg of fuel
Total 46.55 Kcal/kg of fuel
Raise in FGT in the absence of ingress air 32.7 oC
Actual FGT 201.73 oC

Gas temp 442 oK

Air 1.02 Kj/kg-oK
Gas temp 308.00 oK
Air 0.99 Kj/kg-oK
Mean sp. Heat 1.008 Kj/kg-oK
0.24