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Final Term Exam (13/5/2013)

Benha University/Faculty of Engineering Conventional Power Stations
Mechanical Engineering Department Time Allowed: 4 hours
Fourth Year, Power Section Max. Marks=100
Please Answer All Questions
Steam Chart is allowed only
1. It is required to design the main parts of a vertical steam boiler of capacity 40 t/h with outlet state
at 50 bars and 550oC working with heavy fuel oil having the composition percentage:
C=80%, H2=11.8%, S=2.1% and O2 =6.1%.
Take =1.3, ambient air =25oC and inlet air to furnace is at 250oC. The heat loss from furnace due
to radiation and unburnt fuel is 13% and excess air coefficient is 21%. See Figure (1).
i. Calculate lower and higher calorific value for the fuel.
ii. Calculate theoretical air required for the combustion per kg fuel.
iii. Find fuel quantity required in kg/s for boiler efficiency 80%.
iv.Find a/f ratio, air quantity required in kg/s and gas specific heat, Cpg.
v. If furnace heating factor=1.2MW/m3, design furnace height for a square surface area of 5x5 m2.
vi. Calculate temperature distribution of flue gases through the furnace, evaporator, superheater,
economizer and air preheater parts.
vii. Find the stack height and nominal diameter if p=22mm of water at gas velocity=8m/s.
2
viii. If an evaporative heating factor = 100 kgs/m h, design the evaporative water tube-wall area.
ix. If a superheating overall heat transfer coefficient Ush=30W/m2oC, design superheater heating area
due convection and conduction heat transfer.
x.If an air preheater overall heat transfer coefficient Uah=12W/m2oC, design air preheater heating
area for gas and air velocities 8 and 9 m/s respectively.
xi. If water economizer overall heat transfer coefficient UEc=12W/m2oC, design water economizer
heating area using ribbed Cast Iron tubes type.
------------------------------
2. The daily load curve for a power station is given by the following correlation:
L= -0.4 t2 +10 t + 6, where t is the time in hours from 0 to 24 hours and L is in MW.
a) Draw the daily load curve and daily duration curve.
b) Calculate peak load and its time.
c) Calculate average load.
d) Calculate load factor.
e) If four equal units are used to supply this load curve; each equals 20 MW, calculate the
reserve factor of that station.
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3. Design condenser number of tubes that would handle 40t/h of 90% percent quality at 0.07 bars, as
well as 4t /h of 75oC drain water from the low pressure feed water heater, and 1.2t/h of 225 oC
drains saturated from the steam-jet air ejector. Fresh cooling water is available at 25oC. C1=2582
for one inch outer tube diameter, C2 =1.003 at Twi=25oC, C3=0.54 and C4=0.85 and a velocity of 1.8
m/s can be assumed. Assume tube-sheet pitching =7.5 tubes/m2/pass. See Figure (2).

Part I With Great Success, Dr Atef A Aly

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Flue gas
o
Super-heated Steam (output) of 550 C, 50 bars

Superheater

Water inlet
Boiler Part

o
Water Heater 230 C
(Economizer)
o
Air Preheater Air input 25 C
Evaporator

Exhaust of combustion Gases to smoke stack

F
Furnace part

Fuel o

Input
Secondary Air, 250 C

o
Primary Air, 250 C
5m

5m

Figure (1)

Dshell

10 m
Tube-sheet pitching/pass

Figure (2)

Part I With Great Success, Dr Atef A Aly

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1)
I) Calculate lower and higher calorific value for the fuel:
CVH = (4.18/100)[8080*(%C)+34500*((%H2)-(%O2)/8))+2220*(%S)]
= 4.18*(8080*0.8+34500*(0.11-0.061/8) + 2220*0.029) =43206 kJ/kg
CVL = 43206-588.76*4.18 *(9x0.118/100) = 40592kJ/kg.
ii) Find fuel quantity required in kg/s for boiler efficiency 80%:
B= [ms(hs-hfb)]/[mf*CVL] AND mf=(ms(hs-hfb))/(BCVL)
mf = 40(3550-4.18x230)/(0.8x40592) = 3.1947t/h = 1 kg/s
iii) Calculate theoretical air required for the combustion per kg fuel:
Substance Kgsub/kgf KgO2/kgf
C 0.8 2.133
H2 0.118 0.944
S 0.029 0.021
O2 0.061 -0.061
Sum 1 3.037
Theoretical air required for the combustion per kg fuel = 3.037x100/23 =13.206 kgair/kgf

iv) Find a/f ratio, air quantity required in kg/s and gas specific heat, Cpg:

(a/f)theoretical = 13.206

(a/f)actual = 13.206 x1.21 =15.979

mair = (a/f)actualx mf = 15.979 x 1 = 15.979

Excess air = 21 %
(A/F)= 1.20(A/F)th = 1.21x13.206= 15.684= kgair/kgf
mair = mf * (A/F)= 15.979x3.194= 51.243= t/h= 14 kg/s
mg= mair + mf = 51.243+ 3.194= 54.510= t/h= 15 kg/s
Flue gas (i) mi (kgi/kgf) Mi ni=(mi/Mi) xi=(ni/nt) xiMi
CO2 2.933 44 0.067 0.116 5.115
SO2 0.058 64 0.001 0.002 0.101
H2O 0.990 18 0.055 0.096 1.726
O2 0.626 32 0.020 0.034 1.092
N2 12.077 28 0.431 0.752 21.060
Sum 16.684 0.573 1 29.094
Mm=xiMi 29.094 kgg/kgf
Rg=(Ru/Mm) = 0.286 kJ/kgoC
Cp,g = 1.238 kJ/kgoC

Part I With Great Success, Dr Atef A Aly

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(v)
Furnace
Furnace loss 13 %
Hv= 1.20 MW/m3
A=5*5= 25 m2
H=(1-(%loss/100)) * (mf * CVL)/(Hv*A)
H= 1.0 M
(vi)
Furnace
(1-(%loss/100)) * mfCVL = mgCp,gTfg - maCp,aTa2
Tfg={(1-(%loss/100)) * mfCVL + maCp,aTa2} / mgCp,g
Tfg= 1859.0 o
C
Evaporator
mshfg=mgCp,g(Tfg-Tg1)
Tg1=Tfg- (mshfg)/(mgCp,g)
Tg1= 887.0 o
C
Superheater
ms(h1-hg)=mgCp,g(Tg1-Tg2)
Tg2=Tg1- (ms(h1-hg))/(mgCp,g)
Tg2= 439.2 o
C
Economizer
msCwater(Tsat-Tfb)=mgCp,g(Tg2-Tg3)
Tg3=Tg2- (msCwater(Tsat-Tfb))/(mgCp,g)
Tg3= 352.5 o
C
Air Preheater
maCp,a(Ta2-Ta1)=mgCp,g(Tg3-Tg4)
Tg4=Tg3- (maCp,a(Ta2-Ta1))/(mgCp,g)
Tg4= 180.9 o
C
(vii)
Stack
P = 22.0 mm H2O
Vg= 8.0 m/s
P = Hch(air-g) air =(Patm/RaTa1)= 1.18 kg/m3

Part I With Great Success, Dr Atef A Aly

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Hch= P/(air-g) g =(Patm/RgTg4)= 0.78 kg/m3

Hch= 54.5 m
mg=gVgAg
Ag=mg/gVg
Ag= 2.42 m2
D= (4Ag/) 1.76 M
(viii)
Design of Evaporator Water Tube-Wall Area
Evaporative heating factor = 100.0 kg/m2.h
A=ms/Evap.heating factor = 400.0 m2
(ix)
Design of Superheater Heating
Area
Ush= 108.0 kJ/h m2 oC
Qsh=ms(h1-hg)=AUshTlm,sh
A=ms(h1-hg)/UshTlm,sh
A= 1134.4 m2
Tgas,in=Tg1 Ts,out=T1 Tgas,out=Tg2 Ts,in=Tsat T1 T2 Tlm,sh
887.0 550 439.2 265 337.0 174.2 246.7

(x)
Design of Air Preheater Heating Area
Uah= 43.2 kJ/h m2 oC
Qpreheater=maCp,a(Ta2-Ta1)=AUahTlm,ah
A=maCp,a(Ta2-Ta1)/UahTlm,ah
A= 2106.5 m2

Tgas,in=Tg3 Tair,out=Ta,2 Tgas,out=Tg4 Tair,out=Ta,1 T1 T2 Tlm,ah

352.5 250 180.9 25 102.5 155.9 127.3
(xi)
Design of Water Economizer Heating Area
UEc= 43.2 kJ/h m2 oC

Part I With Great Success, Dr Atef A Aly

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QEconomizer=msCwTEco=AUEcTlm,Ec
A=msCwTEco/UEcTlm,Ec
A= 922.4 m2
Tgas,in=Tg2 Tw,out=Tsat Tgas,out=Tg3 Tw,in=Tfb T1 T2 Tlm,Ec
439.2 265 352.5 230 174.2 122.5 146.9

2) L= -0.4t2+10t+6

Daily load curve Daily Duration Curve

L,MW
L,MW

100 100

50 50

0 0
0 4 8 12 16 20 24 0 4 8 12 16 20 24

t,hr t,hr
dL/dt =-0.8t*+10 =0
t* = 12.5 hours
Lp= -0.4t2+10t+6 =-0.4x(12.5)2+10x12.5+6 = 68.5 MW
Lav =Eday/24

Eday = -0.4t2+10t+6)dt =(( ) ( ) ) = 1180.8MWh

Lav =1180.8/24 =49.2 MW

L.f = Lav/Lp = 49.2/68.5 = 0.718
R.f = LR/Lp = (20x4)/68.5 = 1.167

Part I With Great Success, Dr Atef A Aly

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3) Q = ms(hf+xhfg)+mwcwTw +mjhg - mthf

= (1000/3600)[40 (163+0.9x2409)+4x4.18x75 + 1.2x2803.3 45.2x163]=25137.3 kW
U= c1xc2xc3xc4 (v)0.5 = 2582x1.003x0.54x0.85(1.8)0.5/1000 =1.5947kW/m2oC
Tlm =[ (39-35)-(39-25)]/ln[(39-35)/ (39-25)] =7.98 oC
A = Q/UTlm =25137.3/(1.5947x7.98) = 1975.32 m2 = 2dNL=2x(22/7)x0.0254xNx10
N= 1237.23=1238 tubes
Area of tube plate section=2.5p x 3p sin 60 =7.5p2/2
Assume tube sheet pitching =7.5 tubes/m2/pass
Then area = 1238/7.5 = 165.067 m2 = DshellL=(22/7)x10Dshell
Dshell=5.25m
2.5p

1.25 p
p p
p p p
p p
p 2.5 p
3p sin60

p p p
p
p p
2.5 p
p p p
p p

1.25 p
o
60

Part I With Great Success, Dr Atef A Aly