BoilerCqlculotions

A. Whntis equivalentevaporation? Rateof heatsuppliedby fuel - Gf X (CV)lkcaVs

Ans It is thequantityof waterevaporated from and whereGr - rateof fuel buming,kgls
-
at 100'C to producedry saturatedsteamat 100"Cby G' (H H*t)
absorbingthe sameanount of heat as usedin the n. .. -
'rnoiler
Gf (Cv),
boilerunderactualoperatingconditions.
= Mnr(H-Hnr)/(U)1
M"q= Mn (H - Hwt)/539
whereG"/G1- actualevaporation- M*t
whereM"n - equivalentevaporation
Mact= actualmassof steamgeneratedper unit O. Whatis ecornmizereficiency?
massof fuel burnt Ans. It is dcfinedas the ratio of the heatabsorbed
I/ - total specifrcenthalpyof steamunderoperat- by theBFW in theeconomizer to theheatsuppliedby
ing conditions,kcaUkg the flue gasesin the economizcr,the temperatureof
H*, = specificenthalpyof feedwater,kcaVkg flue gasesbeingreckonedabovethe temperature of
Latentheatof dry, saturatedsteamat 100"c is 539 theair suppliedto the boiler
kcaVkg. MactA@
6rleon -=
A. What isfactor of evaporation? MrrCn(@1-@6)
Ans, It is the factorto be multipliedwith thequan- where AO - rise in BFW temperaturein the
tity of steamgeneratedunderworking conditionsto economizer
get the equivalentevaporation. M1,= r[&SSof flue gasesper unit massof fuel
Equivalentevaporation- Actual evaporation
Cp- sPecificheatof flue gases
x (f)
or M"n=M*.(f ) @f- flue gastemperature at inlet to economizer
O"ir - temperatureof air delivered to theboiler
or M$(H - Hwt)/539= M*rf
Ptoblem 6.1 A boiler generates4.5 t of super-
f=(H_H*t)/539
heatedsteam(500'C,9}kgflcmz abs.)pertonof coal
a. Wtut is boiler eftcienq? feed.
The BFW temperature- 45'C
Ans. It is lhe ratio of theheatload of he generated What is the equivalentevaporationfrom and at
steamto the heatsuppliedby the fuel overthe same 100'Cpcr tonofcoal?
period.
Heatload of generatedsteam Solution
= G"(H - H*,) kcaVs
Specific Enthalpy
whereG, = rateof steamgeneration,kg/s = 809 kcaVkg
82 Boller Operolion Englneedng

Sensibleheatof feedwaterat 45"C- 45 kcal/kg ^ Solution The equivalentevaporationfrom and at

Heat requiredto produce4.5 t steam(90 kgflcm' 100"Cis
abs.,500"C) M"q=Mn (H-Hwt)/Lrco
= 4.5 x f03 x (809 - 45) Now
= 3 438 x 103kcal Mrct- 8.5 kg steamPerkg of coal
Ijtent heatof dry, saturatedsteamat 100'C H*r'163'4kl&;g
- 539 kcaVkg- 539 x ld kcaUt H,r,- 830kJ/kg (at 14 bar)
Therefore, equivalent evaporation from and at -r - 0.96
100'c
L - 1957.7kJ&g (at 14 bar)
3 438x td tcat _ 6.379t per ton of coal
= __:_ H=Hw+xL
539x 105 kcat/t
Ans. = 830+ 0.96(1957.7)
Problem 5.2 A steamboilergenerates 7.5tonsof =27W.39kJ/kg
steamper ton of coal burned.Calculatethe equivalent Itoo - 2257klkg
evaporationftom and at 100'C per ton ofcoal from
the following data M"q = 8.5 Q7w.39-163'4)/2257
Steampdssure- 10kgflcm2.abs. = 9.588kg stearn/kgof coal
Drynessfraction- 0.95 = 9.59kg steam,zkgof coal
Feedwatertemperature- 50"C Ans.
fulution Working formula
Prcblem 6.4 A boiler produces 220 t o^fdry
Mg(H - H*,) saturatedsteampcr hourat apressure60kgflcm', abs.
M.s=-B- from feedwaterat a temperature of 120"c.
Coalconsumption- 1200VdaY
Mnr- 7'5Utof coal Calorific value of coal - 42O0kcaVkg
- 50x 103kcaVt 1% of coalescapes unbumt.
"*,'S kcaUkg
Determine
Hr"= 181.3x 103kcal/t (a) the equivalentevaporationper ton of coal
fred
.r - 0.95 (b) the eff,rciencY of the boiler
L-483x 103kcaVt (c) the overallefficiencyof the boiler
+ 0.95(483)l
H = H* + x L =t181.3 x 103 Solution
Step(I) Heat l-oad of Steam/Ton
= 640x lG kcal/t steamat 60kgflcm2abs.
inrhalpy of dry, saturated
M.n=1.5(6<O.tS - 50)x rc3/fi9 :665.4 kcaVkg
= 8.211t of steam/tof coal Enthalpyof waterat 120"C= 120kcaVkg
Ans. Therefore,heatrequiredto raiseI ton of steam
= td (66s.+- l2o) = 545.4x103kcal
Problem 6.3 A boileris workingat 14 bar and
EvaPoration
evaporates8.5kg of waterperkg of coalfired from Step(II) Equivalent -
the equivalent Coal consumption 1200VdaY= 59 Y6
BFW enteringat 39"C.Determine
Steam gencrated per ton ofcoal fred
evaporationfromandat 100"Cif thesteamis0.96dry
at thestopvalve. -22U50 - 4.4t
 Boller Colculoflont 83

Therefore,equivalentevaporation Equivalentevaporation,M"= M^(H - H)/L

(545.4x to3) = 8.321(2705- 425.036)x r03/Q257 x t}l)
= 4.4
539x 103 - 8.405ton stearn/ton
of coal
- 4.452ton of steam/tof coal Ans.
Ans, Step(III) Boiler Thermal Efficiency
Step(IID Boiler Efficiency WorkingFormula: Boiler ttrermalefficiency
Energyoutput=220 (545.4x 103)kcaVh - energyto stearn/energy
from fuel
Coal chargedto the boiler = 50 t/h Energyto steam
Actualcoalbumt - 50 (l - l/lm) - 49.5tJh
= 8.32r (2705- 425.03Ox t03 U
Therefore,energyinput- 49.5x I 03 (4200)kcaUh
(s4s.4xrd) Energyfrom fuel
- 220
_'rboiler
49.5x lo3 x42oo = 5400x t03 kcavt ofcoal

= 0.577 i.e. 57.7Vo = 5400x 4.1868x 103kJ/t of coal

Ans. Boiler thermalefficiency
Step(IV) Overall Efficiencyof the Boiler
_8.32r (2705- 425.036)xrO3
r- 1 r
220(545.4xt03)
- - 5400x4.1868x103
L'rboilerl- 5ox lo3 x42cn = 0.8391
= 0.5713 =83.91%
= 57.137o -84%
Ans. Ans.
Problem 6.5 A boilerconsurrc,s224tons of coal Problem 6.6 A boilersenerates 7.5tonsof steam
to produce1864tonsofsteamperday.The steamis per hour at 18 bar ( 1 b; - td ttlm2. The steam
dry, saturatedat 90 afrrr abs. Calculatethe boiler temperature is 598Kandthefeedwatertemperature is
thermalefficiency, and the equivalentevaporation 328K.
per ton of coal if the calorific value of coal is 5400 Whenfiredwith oil of calorificvalue47250kJkg,
kcal/kg of coal, the specihcenthalpyof feedwater theboilerplantachicvesanefficiencyof 85%.
beinga25.036U/kg of water. Thegenerated steamis fedto drivea turbinewhich
develops0.75 MW andexhaustsat 1.8bar,the dry-
Solution nessfractionof the steambeing0.97.
Step(I) Rateof Evaporation Determinethe rate of fuel consumptionand the
Massof steamproduced- 1864ton fractionof enthalpydrop,throughturbine,converted
Massof coal consumed-224ton to usefulwork.
Actualevaporationcapacity= 1864/224 If theturbineexhaustis directedfor processheat-
= 8.321t /t of coal ing, estimatethe heat transferavailableper ton of
Step(II) EquivalentEvaporation exhauststeamabove322.4K.
Evaporation capacity,M^= 8.321tltof coal
Solution
Sp.enthalpyof dry, satd.steam(90 atm.abs.), Step (I) Energy to RaiseSteam
H =2705kJ/kg Specificenthafy of generatedsteam
=2705 x t03kJtt = 3106- 0.84(3105- 3083)
Sp. enthalpyof BFW, Hw = 425.036W1k1 = 3 086.6 kJAg (by interpolation)
= 425.036x l0r U/t
Specificenthalpyof BFW at 328K
&1 Boller Operotlon Englneedng

-230.TlakJkE Step (V) Heat Transfer Available in Exhaust

Specific energyto nrise steam SteamAbove 322.4K
= 3086.68-230.274 Sp.enthalpyof exhauststeam- 2635.37kJftg
Sp.enthalpyof water at322.4K = 207 kJ/kB
=2 856.4kJ&g. Heat transfer availablein exhauststeamabove
Step (II) Rate of Fuel Oil Consumption 322.4K
Raleof steamgeneration-7.5 tlh - 7500kg/h -2635.37 -207
sp. energyto raisesteilrl - 2856.akJ&g -242E.37kl/Kg Ans.
Energy input to steanr/h- 7500 (2 856.4)kJ
Problem 6.7 The following observationswere
Boilerefficien"y=:ry4
Energyfrom fuel./h madein thecaseof a boiler fitted with aneconomizen
Rateof steamgeneration- 5 Vt of coal
=85*
Equivalentevaporationfrom andat 100'C
= 0.85 = 5.5 Vt of coal
Rateof firel consumption(Energyfrom oiVh) Boiler feedwatertemp.inlet to economizer
- 7500 Q856.4Y(0.85)(47250) = 100"C
- 533.408kg Temperature of BFW inlet to boiler - 180"C
Ans. Temlrrature of air suppliedto the boiler - 30'C
Step (III) Rate of Sp. Enthatpy Drop in Turbine Temperature of flue gasesenteringtheeconomizer
- 4O0"C
Sp.enthalPYof exhauststeam'
Weightof flue gasesproducedper ton of dry coal
H 2 =H n + x ' L =15t
"C
= 49O.7+ 0.97 Qzrl) Meanspecificheatof flue glses- 0.20kcaVkg
=2635.37kJ/kg Calorific valueof coal - 5400kcal/kg
Sp. enthalpyof inlet steam,Hr - 3086.68kJlkg Determine
(a) the boilerefficiencY
Sp.enthalPYdroPin turbine,.
(b) theeconomizerefficiencY
A,H=Ht-Hz (c) lhe combinedefficiencyof the wholeplant
= 3086.68-2635.37 Solution
= 451.31kJAg of steam Step(I) Heat OutPut
Steamgeneratedfromandat 100"C- 5.5Vtof coal
Steamfeed - 7.5 tlh - 7500/3600kds
burnt
Rateof sp.enthalpy drop in turbine
Therefore,heatoutput= 5.5 x 10' (539)kcaVtof
- 451.31(7 500/3600)kJ/s coal burnt
-940.229kJ|s Step(II) Heat InPut
Calorific valueof coal * 5400kcaVkg
Step (IV) Fraction of Enthalpy Convertedto Use' Therefore,heatinput - 5400 x l0r kcaVtof coal
fulWork
burnt
Energyoutput ftom turbine
Step(lII) Boiler EfficiencY
-0.75 MW
HeatOtttotrt- 5.5x l0' (539)
- 0.75x 103kw llboiler-
I . . . =
Heatllput 54O0x103
- 0.75x 103U.zs
= 0.5489i.e. 557o(approx)
Rateof enthalpydrop in turbine'94O'229 kJls Ans.
Fractionof enthalpydropconvertedto usefulwork Flue Gases
Step0V) Heat of
- 0.75xro3/90.229 Heatof theflue gasesenteringtheeconomizer
- 0.7976- 0.8
 Boller Cslculollonr 85

= 15x 103(0.20)(400- 30)kcayt Boiler HorsePower is a very commonlyusedunit

= 111x t04kcaVtofcoal for measuringthe capacity of a boiler. ASME
(American Society for Mechanical Engineers)
Step (V) Heat Absorbed by BFW in the definesaunitboilerhorsepowerastheboilercapacity
Economizer to evaporate15.653kg of BFW per hourfrom andat
Heat absorbedby BFW in the economizer 373 K into dry, satunted steam or equivalentin
= 5 x ld (180- 100)kcaVtof coal heatingeffect
Boiler h.p.- Equivalentevaporationfrom andat
=40x t04fcaUtofcoal
373"Kperhour/l5.653
Step(VI) EconomizerEfficiency
Problem 6.9 Aboilergenerates 6.5tof steamper
I"-o = (e0x t04 )/(ttl x 104)-0.3603 i.e.36%
ton of coal fired.
Ans' The steamis at l8 kgflcm2gauge
step (vII) combined Efficiency The boiler feedwatertemperature- 110"C
Heatabsorbed in theboiler- 5.5 x ld (539)kcaVt downstreamof deaerator
ofcoal Boilerefficiency-75%
Heatabsorbedin the@onomizer- 40 x 104kcaVt Factorof evaporation- l.l5
ofcoal Coof steam- 0.55kcaVkg"C
Total heatabsorbedin boilerandeconomizercom- Determine
bined (a) the tempcratxreof the steam
- 5.5x 103(539) + 40 x loa (b) thedegreeof superheat, if any
- 336.45x 104kcaVtof coal (c) the equivalentevaporationper ton of coal
burnt
Energy releasedby burning co3l - 5a00 x ld (d) thecalorific valueofcoal
kcaVtofcoal
Solution
'rcornD
n^^-. = 336'45x lOa -0.623i.e.62.30% StepP (I) SteamParameters
5aoox ld
Ans. Pressure- 19kgf/cm2.abs.
Sensibleheat,I/* - 213.1kcakg
Problem6.6 A boilerproduces
steamat 90
l,atentheat,L-455.1 kcaVkg
kgttcn? abs.at the rate 150t/h from the feedwaterat
temp.,@"- 20E.E'C
Satrrration
120"C.The steamis dry, saturated. Whatis theboiler
horsepower? Step(II) DegreeofSuperheat
Solution Total heatof the steam- Hw + L + CoAO
where,AO - degreeof superheat
Steanr,90kgflcm2
Totalheat- 655.7kcal/kg Sp.enthalpyof feedwater- Hrw
abs.Dry,sanrrated
Therefore,the factorof evaporation
Sensibleheatof BFlv at 120'C- 120kcaVkg
Equivalentevaporationfrom andat 100'C _H*+L+CoL/g.-Hr*
- 150x 103(655.7- t20)/539 539
- 149.08x td fgn 213.1+ 455.1+ 0.55(AO)- ll0
or 1.15=
539
Therefore,boilerhorsepower
AO= 112.09"C
= 149.08xrc3/$.653 Ans.
=9524.15 Step(III) Superheated SteamTemperature
Ans. AO- lrz.Ogrc
86 Boller Operollon Englneerlng

or, @-@"-112.09"C (c) thepercentage

of heatlossto the ash
-321"C (d) thepercentage
of heatlossunaccountedfor
or O=208.8+ 112.09=320.89'C
Ans. Solution
Step (IV) Heat Output Step(I) SteamParameters
Heat requiredto generatestearn SensibleHeat,If* - ?frO.1kcaVkg
= 6.5x ld (213.1+ 455.r+ 0.55AO - 110) l---Latent Heat, L - 466 kcakg
kcaVtof coal
Step(II) Heat Output Rate
= 6.5x 103(558.2+ 0.55x 112.09)kcaVtof coal Rateof stearngeneration- 16 t/h
= 4029.021x103kcavt of coal Heatoutputrate= 16x t03 (H, +xL-Hp)
Step(V) Heat Input = 16x 103(200.7+ 0.g x 466-30)
Calorific valueof coal - CV kcaVkg =9441.6x 103kcaUh
Energyreleasedper ton of coal burnt
Step(III) Heat Input Rate
- 103x CV kcal Coalconsumption- 2.5 Uh
Step(VI) Boiler Efficiency Calorific valueofcoal = 6540kcaVkg
Heatinput rate=2.5 x 103x 6540kcaVh
11.
''borrer=E;ffi -4029'o2lxlo'
.. HeatoutDut
ld x cv Step(IY) Boiler Efficiency
- Iboiler = Heatoutputrate,/Heatinput rate
or 0.75 4029.021ICY;
= 9441.6x103/Q.5x 103x 6540)
CY - 5372kcaVkgofcoal =0.5774 i.e. 57.74V0
Ans. Ans.
Step(VII) EquivalentEvaporation Step (V) Heat Load of Flue Gases
- 110)
6.5(2r3.r+ 455.1+ 0.55x 112.09 Fluegasesgenerated - 15Ut ofcoal
,r"q = Heatloadof flue gases
= 7.474t/t of coal bumt = 15x 103x 0.25(350- 25)
Ans. = 1218.75x ld kcaVtof coal
Prcblem 6.10 fbe following observationswere Step(VI) Heat GeneratedBy l Ton of Coal
madeduring the trial run of a boiler. Heatproduced by ltofcoal - 103x 65210 kcal
Steamgenerationrate= 16 Uh Step (VID Percentageof Heat llss to Flue Gases
Feedwatertemperature= 30"C
SteamqualitY= 0.9 dry = Ir2t8.75 x r03/ 651CIxl03l (100)
Steampressure- 15kgflcm' abs. = 18.63%
Coal consumption= 2.5 t/h Ans.
Calorific valueofcoal = 6540kcaVkg Step (VIID Percentage of Heat Loss to Ash
Ash + unburnt coal collectedfrom beneaththe Ash + unbunttcoalcollected- 0.2 Vh
grrtes= 0.2llh (Calorific value- 700 kcal/kg) Heatlossdueto ash+ unburntcoal
Weight of flue gts€s= 15Vt of coal fred =0.2x ld x 700kcaVh
Fluegastemperature- 350"C Heatgencratcdin the fumace
Average specific heat of flue gases= 0.25 =2.5x ld x 654OkcaVh
kcaVkg'C Therefore,percentage of heatlossto ash
Ambient air temperature- 25"C
Calculate 0.2x 103_x7ffi ,
__________. rl00)=0.85%
(a) the boilerefficiency 2.5x 10'x 6540
(b) the percentage of heatlossto the flue gases Ans.
 Boller Cdculctlonr 87

Step (IX) Percentageof Unrccounted Heat =7.5x rG x2879.55/tfr

x 45x ld
Usefulbeat- 57.74%
Heatlost to flue gases- 18.63% rt =firlkelh
Heatlost to ash- 0.85%
Total rccountedheat= 57.74+18.63+0.85 Step (V) Specific Enthalpy Drop in Turbine
--77.22%. Specificenthalpyofelhaust steam
.'. Unaccountedheat- 100- 77.22- 22.77% - H* + x L - 490.7+ 0.95(2210.8)
Ans.
- 2590.96U/kg
Ptoblem 6.ll A boiler genentes75 t of steam
per hour at pressure 1.8 MN/h' and temperature .'. Specificenthalpydrop in turbine
325'C ftom feedwaterat 49.4"C.Whenfircd with oil = 3086.45-2590.96
of caiorific value 45 MJftg, the boiler attains an = 495.45kl/lrg
efficiency of 78%. The steam (325'C, is fed to a
hubine that develops650 kW and exhaustsat 0.18 Step (VI) Rate of Enthalpy Drop in Turblne
I\,N/m2, the drynessfraction of steambeing0.95. Rateof steamfed to turbine
Determine -7.5llh
(a) the massof oil fired Perhour - 7.5x 1d/3600kgs
(b) the fraction of the enthalpydrop through the
turbine which is convertedto useful work Specificenthalpydrop in h[bine - 495.45kJlkg
Also determinethe heat transferavailableper kg .'. Rateof enthalpydropin turbine
of exhauststeamabove49.4"C,if theturbineexhaust = 495.45(7.5x 1dl3600) kJls
is usedfor processheating. = 1032.187 U/s
blution Step (YID Fraction of Enthalpy Drop Converted
Step (I) SpecificEnthalpy of GeneratedSteam to Usefull{ork
H =3rM - 0.84(3106- 3083) Energyoutprt from trbine
= 3086.45kJ/ke by interpolation) - 650kw
Step (II) SpecificEnthalpy of BFW (49A"C) - 650kJ/s
Hr*=2A6.9tJ/lrg Energyinputto turbine- 1032.187U/s
.'. Fraction of enthalpy drop convertedto useful
Step (IID Heat OutPut work
Energyrequiredto generatesteam - 65Cl/1032.187
= 3086.45-206.9
-0.629
=2879.55kJftg Ans.
The rate of steamgeneration- 7.5 Uh Step(VIID Heat Transfer from ExhaustSteam
The net heat available,for processheating,from
.'. Heatouput =7.5 x 103x2 879.55U/h
exhauststeamabove 49.4"C- ?59O.96-?n6.9 -
Step (IV) Rate of Oil Burning 2384.06kI/lr9
I.et the massof oil fired be fi vgn Ans.
Heatinput - Ifr x 45 x 103U/h Pr<iblem 6.12 A steamgenerationplant supplies
8500 kg of steamper hour at pressure0.75 MN/m".
Boilerefficierc! =78%
The steamis 0.95dry.
0.78= Heatouput/Heat input Feedwatertemlrnture = 41.5"C
Coal consumption- 900 kg/h
88 Bolbt Operollon Englneedng
Calorific value of coal -32450kJilrg
Determine
(a) theboilerefficiency
(b) theequivalentevaporationfrom andat 100"C Step (YI) Energy Required to Generate Sm
(c) thesavingin fuel consurnption,if by installing Under New Conditions
an economizerit is estimatedthat the feed-
water ternperatue could be raisedto 100"C,
assumingthat other coditions rcmainedun- econqnizer is incorporated
changedand the efficiercy of the boiler in-
creasesby 6%.
blwion
Step (I) SteamGeneration Fer Ton of Coal
Rateof steam generation- 8500 kgh
-
Coal consumption 900 kg/h
Therefore,steamgenerationper kg of coal
- 8500/900
- 9.44kg
.'. St€amgeneration/tonof coal
- 9440kg
-9.44t
Step (II) Specific Enthalpy of Steam Rais€d
H -- H* + x L -7@.3 + 0.95(2055.5)
=2662.025kl/kg
Step(III) Energr Required to GenerateSteam
Specificenthalpyof steamraised
-262.0?5kr/ltg
Specificenfhalpyof BFW - l139kJ/lKE
Hearouput = 26tr2025- 173.9
=2488.125kJAg of steam
Step (IV) Boiler Efficiency
HeatoutDut/ksof coal 2488.125,^
tl*r",=ffi#ff=ffi(g.u't
_ Steamquality: dry, saturated
=0.7238i.e. 72.38%
Ans.
Step(V) Equivalent Evaporatbn
Steamraisedper kg of coal - 9.4k9
Energyrequiredto gerrcmtethis steam
-9.44 (2488.125) U&g coal
Specificenthalpyof evaporationfrorn andat
100"C- 2?56.9kJft:g.
Equivalentevaporation= 9.44Q488.125>/2?56.9
= 10.40ke/ke of coal
Specificenthalpyof BFW at 100'C- 419.1U/kg
Energy required to generate steam when
-2662.U25- 419.1
-2242.9?5Wfrg
Energyto steury'h
=2242.925x 8 500kJ
Step (VII) Rate of Coal Consumption when
Economizer is Fitted
Erergy output -2242.98 x 8500kJ/h
Energyinput- Ifr x32a50Hth
Boilerefficiercy-72.38 + 6 -78.38%
2242.Y25x 8500
-
0.7838
Nl x32450
rt =749.57
kglh
Step(VIII) Savingin Fuel Consumption
Initial fuel consumptionrate - 900 kg/h
Modified fuel consumptionratewheneconomizer
is fiued -749.57 kglh
Savingin frcl consumption= 900- 749.57
= 150.43kg coal,zh
Ans.
PtoHem 6.13 The following obsenationswere
madeduring tbe trial run of a boilen
Rateof steamgeneration= 5 Uh
Steampressure= l0 kgf/cm2gauge
"C
Averagespecificbeatof steam- 0.55kcaUkg.
Redwater ternperature- 85'C
Roomternperature- 25"C
Atnospheric pressure- 1 kgflcm2
Fuel consumption- 650 kg coaVh
Calorificvalueofcoal - 7500kcaVkgofcoal
 Boiler Cqlculqlions 89

Moisturecontentof coal-2.5% Step(III) Coal Analysis

Fuelcontains: C - 86%:H - 5%: Ash - 9% Basis: lkg dry coal
Flue gastemperature- 300"C
Mean sp. heatof flue gines- 0.25kcaVkg"C Constitu{hemicalReaction Remorks
nt during combustion
Analysisof dry flue gases:
C+Or-+CO, Wt. of dry flue gas
C O z -l 0 % ; O 2 - 8 % ; N 2 - 8 2 %
(r2) (44) produced
Producea completeheatbalancesheettaking I kg - (2992n04)(86trm)
dry coal asthe basis. - 24.741kglkgof coal
Wt. of water vapour
Solution ur+)or-+ Hro
produced
Step (I) Energr to SteamPer kg of Dry Coal - (18/2)(5/loo)
(2) (18)
Steampressure = l0 kgf/cn? garye -0.a5kglkg of dry coal

= l1 kgflcm2 abs.
WL of moisturefired
Sensibleheatof steamat 1l kgflcm2abs. =0.025/0.975
- 185.7kcaUkg = 0.02564kg/kg of dry coal
Latentbeatofevaporationat 1I kgflcm2abs. Total wt. of watervapourin flue gases
- 478.4kcaVkg - 0.45+ 0.02564
Specificenthalpyof dry, saturatedsteamgeneraEd = 0.4756kg/kg of dry coal.
- 185.7+ 478.4 Step(IV) Heat L,oadof Water Vapour
- 664.1kcal/kg = 0.4756[638.8+ 0.55(300- 90) - 251
Specificenthalpyof feedwater= 85 kcal./kg =344.5kcaVkgof dry coal
Coalconsumption where638.8kcaVkg= totalheatof watervapour
- 650kdh at I kgflcm2abs.to which flue gasesarc discharged
Dry, coalconsumption = 650 (100-2.r/lm
Step(V) Heat Load of Dry Flue Gases
= 650x 0.975kg/h
Heatlossto flue gases
Energy to steam/kgcoal
- (664.r _ 85) (5000)/(650x 0.975) =24.741(0.25) (300- 25)
- 4568.836kcal = 17N.944 kcaVkgof dry coal
Step (II) Flue Gas Analysis Step(VI) HeatBalance
Basis: 100m3 of dry flue gas Basis: I kg of dry coal
Heat Input % Heat Expenditure 7o
Con- Volume Mol.v,t. Proportional Remarks
stituent -3 Mass Total hcat t00 Ijcat consumedin stearn @.92
supplied fonnation
- 7500kcal - 4568.836kcal
coz 10 44 44(lO)= 440 Carbon
content Ileat lost to flue gas 22.70
= 410(12/44) - 1700.944kcal
= l2O Heat lost to vapour 4.ffi
- 344kcal
o2 8 32 32(8\-2s6
Heat unaccounted for I1.80
82 28 28(82)-229< - 886.220kcal
100 t04 2992 7 500 kcal 100 7 500 kcal 100.00
90 Bolter OPerollon Englneedng
(ii) suPerbeater
Prcbtem 6.t4 During the tial run of aboilerthe
(iii) air heater
following datawere recorded (iv) economizer
CoalconsumPtion 8 3 . 1t (e) heatlost in the flue gas
Steamproduced 606 t Summarizethe overall result on the basisof I kg
Boiler: coal burnt.
SteamPressure 1.461MN/m2
-14.42^tn Sohttion
SteamtemPeraturc 470 K Step (I) Theoretical Air Requirements
Superheater: Basis: 100kgcoal
Superheated steamtempcrature 6 1 0K klmol kmol of Ot
Constituenl % W Molecular
Economizer: Element Weight Weight requircd for
Water inlet temPerature 353K complete
Watelroutlct tcmPerature 400 K combustion
Air heater: 5.208 5.208
320K c 62.5 t2
Air inlet temPerature 2.12512
380 K H 4.25 2 2.r25
Air outlet temPerature - 1.0625
FIuegasinlet temPerature 503 K
405 K o 5 . 1 I 32 0 . 1 5 9 (-) 0.lse
Flue gasoutlet temPerature o.o42
N t.2 28
S 0.85 32 o.o27 o.027
Fluc gasanalYsis(drYbasis) Ash 9.85
Coalanalysis(bYweight)
Moisture 16.24 IE
c 62.5% coz 13.2%(by volume) E - 6.1385
H 4.25% o2 4.85%( -do- )
o 5.tt% N2 81.95%( do- ) There,theoreticalair requirement
N t2%
= 6.1385(100/21)
s o.85%
Ash 9.85% 49.23 kmoV100kgcoal
Moisture 16.24% =29.23 (28.9)k9100 kg coal
Total rco% =844.744kglm kg coal
=8.447 kgftg of coal
Grosscalorific value- 30550kJftg (dry coal) AnS.
Boiler housetemPerature = 298 K
weight
(c/ The averagemolecular of air is 28'9)
Enthalpyof dry, saturatedsteamat 1.451MN/m2
=2791L<IkE. Step (II) Actual Air SirPPlied
100kg coal contains5.208kmol of C
Substances Sp ecif c H e ats(kJltg'K) 100kmol of dry flue gascontains13.2kmol of C
Dry flue gas 1.005 Therefore,the amountof flue gasproduced
Watervapor in flue gas 2.095 - 5.208(100/13.2)
Water 4.t81
=39.45kmoV100kg coal
Determine Let r mol of air be suppliedper 100 kg of coal
(a) theoreticalair requirementsper kg of coal burnL
(b) actualair suppliedperkg of coal fred thereforeby nitogen balancewe get'
(c) weightof flue gasperkg of coal bumed
(d) thermalefficienciesof 79x 4ffi+ 0.042-H (39.45)
(i) boiler
 Boller Colculollonc 9l

.'. .r - 4O.87kmoU100kg coal -2E9.25lU.kg

Therefure,the weightof air supplied Rateof steamgeneration/tof coal
- 40.87(28.9) =66/83.1r/t
- l l8l.l4kg/l00kgcoal -7 .292Vt of coal (or kJlkg coal)
- 11.81kgfu coal Therefore,the heattransferredto steany'kgof coal
burned
Nore % excessxi1= (ll.8l -8.47)(tU.,/8.# =7.2V) (2259.251)
=39.81% = 16474.458
kJ./kgcoal
Step(III) Weight of Flue Gas Grosscalorific valueof coal asfired
Basis: 100kmol
= 30550(100- 16.24)/100
Fluc Gas koiol Mohca- Wcight Wcightin39.45 = 25588.68kI/kg coal
Conslitaen ls kaolof Fluc Gas
t Weight Therefore,thermalefficiencyof the boiler
coz r3.2 4 13.2(44) 13.2(,14X39.45/100) = 16474.458/25588.68
-229.t25 = 0.6438 i.e. 64.38%
o2 4.85 32 4.85(32)4.8s(32)(3e.4sll
m) Ans,
- 61.226 2. Superheater
Net heattansferredto steamin the superheater
N2 81.95 28 8 1.95(2E)
8 l.9s(28x39.4sl
IOO)
= 905.219 =7.2T2(2.095)(610_ 470)
E= il95.57k9 =2138.74kJ/kgcoal
Therefore,thermalefficiencyof lhe superheater
Waterproduceddue to combustionof hydrogen
contentofcoal = 2138.7
4/25588.68
-2.18 kmol- 2.125(18)- 3E.25kg = 0.0835 i.e. 8.35%
Freemoisture- l6.24kg
Ans.
3. Air Heater
Therefore,the total weight of wet flue gas
Weightof air chargedto the boiler
- 1195.57+ 38.25+ 16.24
- 11.81kJ/kgcoal
- I 250.06kglm kg coal
Heatabsorbedby air in the air heater
- 12.50kgltg coal
= 11.81(1.005X380 - 320)
Ans'
Step(IV) Thermal Efliciencies =712.143kJ/kgcoal
l. Boiler Therefore,the efficiencyof the air heater
Total heatcontentof steamat 1.461MN/m2
=712.143/25588.68
-279lkItkg
= 0.0278 i.e. 2.78%
Total heatcontentof waterchargedto boiler
Ans.
=4.187(4N-273) 4. Economizer
= 531.749U/kg Heattransfcncd
to BFW
Therefore,the netheattansfened to steam =7.292(4.187X400
- 353)
=2791- 531.749 : 1434.985
kJ/kgcoal
92 Boller Operotlon Englneedng

Therefore,thermal efficiency of the economizpr - (2950.29

t?5588.68)(100)
- r434.985t25 588.68 = 1L.52%
:0.0560 i.e. 5.6Vo Tabulationof Result(Basis: I kg coalbumed)
Ans.
Heatrecovered %GCV % Elficiency
Step (V) Heat Lost to the Flue Gas (kJ) t^,ctcoal
Weight of the dry flue gas r5762 61.591
Boiler
= 11.95kJ/kgcoal Air Heater 712 2J8 78.34
|
Enthalpyof the dry flue gas Superheater 2t39 8.36
r
Economizer r435 s.6lJ
= 11.95(1.005)(405- 298) 29fl I l.53\
Heatto flue gas 21.66
= 1285U/kg coal Heat 259r 1o.t3i
unaccounted
Watercontentin flue gaseswhen100kg coalburnt
>- 100.00
-38.25 + 16.24
= 54.49k9 ProUem 5.15 A boiler generates6000kg steam
Therefore,the weight of watervapour/kgof coal per hourat 10kgf/cnt2from BFW at 4O"C.The steam
burnt is 0.97dry. The boiler is fired with coal at the rateof
- 0.5,149kg 700ke/husing16kg ofair (at 15'C) perkg ofcoal
fired.
Therefore,the enthalpyof waterin the flue gases Assumingtlre boiler efficiencyto be 70%, deter-
=0.5M9 t2.095(405- 311*)+24t1.2* mine
(a) excessair coefficient
+ 4.187(405- 298)
(b) flue gasternperaureleavingthe boiler
= 1665.29kJ/kgcoal Given
* fDewPoittt ofWet Flue Gasl The coal is composedof carbon and hydrogen
besidesits ashcontcnt12%.
Flue Gas kmol %
Conslituent Composition Combustion Heat Of Combustion
coz - s.2 12.24
(13.2/100x39.4s) C+Or-rCO, 8075kcaVkgofcarbon
o2 - l.e
(4.82/lm)(3e.4s) 4.47 Hr+ Or-+ H, O 34500kcaVkgof hydrogen
N2 (81.95/ .4s)- 32.33 7 6 . 1 3
100)(3e 'C
-3.02 Specificheatof flue gas- 0.25kcaVkg
Hzo 54.49t18 1.tl
18% of total heat generatedby coal is lost to
=242.46 > - 99.95 substancesotherthancoal.
thevapourpressure
Therefore, of watervapour Solution
- (7.ru99.9s)
(101.3) Step(I) Heat Contentof GeneratedSteam
=7.z}kN/m2 H=Hw+xL-Hrn
to thedewpoint311'Kand
whichcorresponds = 181+ 0.97(482)- { = 608.54kcal/kg
latentbeatof evaporation2411.2kJkg Step(II) Calorific Value of Coal
Therefore,the total heatlost to flue gas It can be determinedfrom the boiler efficiencv
- 1285+ 1665.29 relationship.
=2950.29kJ/kgcoa. Iboil", = HeatoutpuvHeatinput
Hence,the percentage
of heatlost to the flue gas Now HeatOutput= 6000(608.54)kcaVh
 Boller Colculqllonr 93

Heatinput- 700 x CV whereCV - calorif,rcvalue Heat Generated Heat Rcceivcd by

ofcoal (kcaVh) (kcaVh)
or 0.70- 6000 (608.54)/(700x CV) by coal: 70{l,Q452) Fluegas: 16.88(700X0.25XA@)
- 521640,0 - 29s4(A@)
CV - 7 4l?kcallkg
Step(IID Carbon and HydrogenContentsof'Coal Steam: 6000(608.54)- 3651240
Basis: I kg coal Sirbstances
otherthanflue gas:
Therefore,the coalcontains(l - 0.12),i.e. 4s2)(O.r8)- 9389s2
7 OO(7
0.88kg ofC + H per kg ofcoal fired.
By heatbalancing
If .r be thepart of CYkgof coal,then
2954(A@)+ 365Qa0 + 938952- 52164A0
.t (8075)+ (0.88- -rX3a500) =7452
.'. AO=211.98"C *212C
.r = 0.8669
Hencetheternperature
of the flue gasatthe biler
lc-"'b*l*lHyd'os;l outlet
I kg Coal 0.8669kg 0.0131kg -212 + L5-227'C
Step (IV) Theoretical Air Requirement for Com- Ans.
plete Combustion
PtoUem 6.16 A boiler is fired with coal having
Basis: I kg coal following percentage compositionby mass:
Elzme Combustion Weight OrRequirement C45Vo; H-54o; S-lVo; O-2.59o: Incom-
nt Reaction bustible-6.5%.
Determinethe boiler efficiency from the given
C + O, -+ CO, 0.8669kg o.E669QAn)
(r2) (32) -2.3rr7 kg data:
Excessair supplied= 407o
2H, + O, + 2HrO 0.0131kg o.or31(32t4) Fluegastemperatureat boiler exit = 170"C
(4) (32') - 0.1048kg Ambient air temperature- 25"C
Specificheatof flue gas- 0.25kcaVkg'C
E - 2.4165
kg Specificheatof steam= 0.48kcaVkg"C
Combustion Heat of Combustion
Since air contains 23% Oz by mass, the
stoichiometric(theoretical)air requirenrnt for com- C + Or--+ CO, 8075kcaVkg
pletecombustion S + Or---r SO, 222Okcdlkg
-2.4165 (100/23)
H, + Or----+ HrO 34500kcaVkg
= t0.506kg
heatloss- lSVo
Unaccounted
Step (V) ExcessAir Coefficient
Excessair coefficient= Actual air,/minimumair Solution
Step (I) Calorific Value of Coal
= 16/10.506
= I.523 Cv - 8075(c)+ 2220(5)+ 3a500(H- O/8)
AIlr. where, C, S, H & O standfor carbon,sulphur,
Step(VI) Enthalpyof Flue Gas hydrogenandoxygenpercentage.
Massof coal + massof air = Massof flue gas - 8075(0.85)+ 2220(0.0r)
(1 - 0.12)kg + 16kg = Massof flue gas + 3a500(0.05- 0.025/8)
or Massof flue gas- 16.88kg. - 8503 kcaUkg
94 Boiler Operolion Englneerlng

Step(II) StoichiometricOxygen = 2 (18\14

Basis: I kg fuel -9kg

Element Combustion Oxygen Rcquircd Per Mass of waterproduced/kgof coal (H-content:

Reoction Kg of Fuel 0.5%)burned
s) - 2.2666ks = 9 (0.05)kg
C + Or --r COt (32t12)(0.8
(r2) (32) = 0.45kg
- 0.01kg
S + O, ----+ SOt (3u32)(o.ot) Massofdry flue gasproduced/kgofcoal burnt
(32) (32) = 17.075- 0.45
ZHr+ Or-+ZHrO (324)(0.05)- 0.4kg = 16.625k9
2-2.6766k9 Step(VI) Heat Balance
Basis: I kg coal
Sincethefuelcontains0.025kg oxygen/kgof fuel'
theactualmassof 02 requirementperkgof coalburnt Heat Evolved Heal Lost To

-2.6766- 0.025 8 503kcal Fluegas(dry)

- r6.62s(0.25)(l7O-2s)
=2.6516k9 - 602.65 kcal
Step(III) Air Supplied Stcam (l atm pr€s$.)generatedfrom
Theoreticalmassof air requtement fuel burning
= 0.45 [/J + Cp (A@) -@.ir]
=2.5516(1m/23)
= 0.45 [639 + 0.48 (170 - 100) - 25]
- 11.5289
kg =297.42kcal
40%excessair suPPlied. Unaccountcd sourceg
Hencethe actualair suPPlied - (18/100)(E 503)
- I 530.54 kcal
= 1.4(11.5289)
= L6.l4kg/kg of coal Total - 2 424.61kca|

Step (IV) Massof Flue Gas Heatutilized= 8503 -2424.61

Massof combustiblesPerkg of coal = 6078.39kcalAg coal
- 1 - 0.065 Step(VID Boiler Efficiency
= 0.935kg Heatutilized
TlboiLr=
H*t ga"*aLd
Fuel + Air = FlueGas
0.935kg 16.14kg = FlueGas = 6078.39
8503
Hencethetotalmassof flue gas(inclusiveof waler = 0.7I 48 i.e. 7 1.487o
vapour)producedperkg of coalburnt Ans.
= 0.935+ 16.14
fuoblem 6.17 A water tube boiler operates
- t7.075kg 8400 h/year al 80o/oefficiency. The unit rated at
Step (V) Massof Dry Flue Gas 272L5kgh operates at7.82atm.
It burnsnaturalgasfor six monthsof the yearand
2H2 + O, ------+2HrO
No.2 fuel oil for the rest.
(4\ (2 x l8) Averageaurual boiler loadingis 6O%with an
Massof waterproduced/kgof H2 burned inputof 11347303 kcaVh.
 Boiler Colculotionr

lYlthout Economlzer
^ \
Naturalg:rsconsumption = 1274,25Nmr/h latwo
Fueloil (No.2)consumption= t.+S9m3n,J bd

Afier Addlng An Economl,zer

BFW flowate (includingblowdown)at60%lofi
- 17145kg/h
F l u og o ! o x h o u r t
Feedwatertenperatureat the economizerinlet
= 105"C
Feedwatertemperatureat the economizeroutlet
- 136'C
Fluegast€mperature ateconomizerinlet = 260'C
Fluegastemperatur€at economizeroutlet- 149"C
Determine
(a) the fuel savingusing the economizer
(b) totat annualfuel cost without insrallingthe
economizer
(c) total annualsavingof fuel alter installingthe
economizer
(d) thepaybackmonths,if theeconomizercostis
Rs. 500,000installed
Given: Nanral gascost = Rs. 1.06per Nm3 of
gas Flg. 6.1 Figureto the Problem6.17
Fueloil (No.2)cost- Rs I 255 perm3 of F.O.
x 100:5.85%
Solwion The additionof an economizqrto awater- s - 664368.78
rr347303
tubeboiler systemreducesfuel cosl
Ans'
The fuel savingusing the economizeris (b) Total operatingperid = 8400hlyear
Ilx 100 Naturalgasburnedfor 4200h andF.O.bumedfor
"- = _ _ _
rest4200h overtheyear.
whereS- fuel savingin perceht Annualcostof naturalgas
/^- r\
H= heatrecovere4
kcavh=ry =,zzo.zs[*l'
lx+200
rj-), r.06
r-R'-)
F - BFW flowrate, kg/h \n/ 1v.n/ 1N*,.,;
= Rs.5672961.
AO = 6z - 8l = temperaturcdifference of BFW
beforeand after the economizer Annualcostof fuel oil
Or - BFW temperatueat economizerinlet, 'C / r\
=r.45e r-!-)x tzss[4)
f+ l,<4200
Oz = BFW temperaturcat the economizeroutlet, \o/ \Year; l-'J
'c - Rs.7690389
B = boiler efTiciency Total annualcost of fuel prior to installation
(a) H= (17t45X136-105)/0.8 of economizer
= 664368.78kca1/h = Rs.5672961+ Rs.7690389
96 BollEr OPerollon Englneedng
year - 270
Number of operatingdays per
- Rs.13,363,350/-
Ans. Costof wasteheatboiler installed
a = Rs 3,000000/-
(c) After the installation of the economizer,
5.85%savingin fuel results' Maintenanceatrdoverheadexpenses
Annualsavingin naturalgas - 12%of the cAstof WHB
= Rs.5572961x 5'85/100 - the principal
Rate of interest payable 20% on
= Rs.331868/- arnount
Annualsavingin fuel oil cost StcanGenerationRate
DG SetLoad
= Rs.76903g9x 5.95.2100 4OVdaY
@%
- Rs. 449888/- too% 80 Uday
instalation
.'. Total annualsavingof fuel costafter steamat
of the economizer 1 ton ofcoal generates4'5 t of saturated
= Rs' 781756/- 10kg/cm2g
= Rs.331868+ Rs' ut49888
Ans. Costof coal - Rs 750 Perton
is
(d) The PaYback blution
y-HB,.
'-'rn"Bco"o*ics of lncorporating
ia)
ro -- E x 1 2 "ott of ebcricity puphased from the grid
A
whereP-paybackmonths -Rs l.l?KWH
E - installedeconomizercost' Rs the installa-
The cost of generatedelectricity after
Rs
A - annualfuel savingswith economizer' -- of WHB
tion '0.95/KWH
generated
frfonetarysavingsper unit electricity
. 'p-!''9SS
- ,.rz
Rs.781756 = Rs (1.12- 0.95)/KWH= Rs 0'17/KWH
= 9.21month, Averageelectricitygeneratior/day
on .
is hookedup =g#*MwH =67.5MwH
Problem 6-t8 A wasteheatboiler
set to produce steam from -270
with a diesel generator Numberof working daysper lear
with respecttopower
wasteheat. Therefore,monetarysavings
saturated steamof l0kg/c#
ATQVoDG'setload' purchasedfrorn the grid
rate of 40
g is producedin the wasteheatboiler at the
tor/daY.
--- - o/tl x'.*
67.5
nn.tug" ebcric energygenerated
per day varies [nffr)' [#, )
from65 to 70MWH. Rs3,098250/-peryear
Esttnate
, zzo(,days')=
thewasteheat [vear''1
tui-,n" oonomics of incorporating
boiler (b) PaybackPeriod Of WHB
(b) th; paybackperiodof the waste heat boiler Costof wasteheatboiler
Given = Rs 3,000'000/-
"o.t of purchasedelectrical energy from the
ih" Maintenarpeard overheads
- - Rs l.IZKWH
prid
'-
cor, of generatedelectricityafter the installation = l2Voof caPitalcostof WHB
'- WHB - Rs0.95/KWH
of = Rs 360'000/-
(t* includesoverheadsand depreciationchar- Interestol PrinciPalarnount
ges)
 Boller Colculollons

= 20%of Rs.3,000,000/- (a) Rateof Fuel Consumption

= Rs 600,000./- Averageelcclricenergygenerated
per day
Total steamgeneratedon 100%load- 80 Vday :67500 KWH
4.5tofcoal generat€I ton of steam Averagefuel consumptionper day
Amountof coal saved- 8C/4.5- 17.777tlday -6750014.025
Monetarysavings,on the basisof coal,per year
- 16770lL
- 750f-n,-)xn.t77(tro')"zzo[-@-) Massrateof fuel consumption
(ton/ (oayJ [vear.1
---^ / rt ) (. r<e) I I
- Rs359984?- =16770 o.e
WHB is an energy savingequipment.So it [dj,. [sf,j' ;i $6
qualifiesfor 100%depreciationin the lst year. - 628.875ke/h
Approximatesavingsin corporatetaxes(@ 55%) Ans.
perye:u (b) Flowrate of Flue Gas at 60% l-oad
- Rs 3000000x 0.55 -7.55 x 3600- 27180kgh
(c) UsefulHeatof Flue Gas
- Rs 16500004
Total heatrejectedby hot flue gasin the WHB
Net Savingsperyear
- Rs (3599842- 360000- 600000+ 1650000)
=27180
f+l'0.26f'9)x ezl -r70)
("c)
(n J [K8-u'
- Rs 4289842- = 1060020
kcaVh
Ps
Payback period= 3000000 x 12months Heatlostto radiation
ffiffi
- 106(n20x 5/100kcaVh
= 8.39months
Ans, = 53001kcaVlt
Ptoilem d.l9 lreterminethe Usefulheatavailablefor steamgeneration
(a) rateof fuel consumptionin kg/h = 1060020-53001
(b) efficiencyof WHB of problem6.18
= 1007019kcaVh
Given
I lt. of fuel generates4.025 KWH of electrical - Heatinput rate
energy (d) Heat Output
Specificgravityof liquid fuel - 0.90 Averagesteanr(10 kg/cm2g and saturated)
Exhaustgasflowrateandtemperature at 68%load generationrate
are7.55kg/sand325'C respectively.
- 40ttday
Fluegastemperature at WHB inlet - 320'C
Fluegastempentureat WHB outlet= 170'C = 40x l0ffil24kg/b
Averagefeedwatertemperatureto the boiler = 1666.66kg/h
- 75'C Averagefeedwatertemperature = 75'C
Specificheatof flue gas- 0.26kcaVkg'C Heatrequiredto generate1666.66kg steam
Assume59oradiationlosssufferedby theflue gas (10kg/cmzg andsaturated)
in theWHB. - 1666.66x (183- 75) + 1666.66x 478.4kcal
Solution The determinationof efficiency of the =977329kcal
wasteheatboileris to be madeon the basisof heat Heatoutputrate= 917329kcat/h
balance.
Heatinputrate= 1007019kcaVh
98 Boller OPerotlon Englneerlng

.'. Efficiency of waste heat boiler ni - numberof molesof i-th componentpresentin

theflue gasproduceddueto combustionof 1 kg fuel.
-mxLoo% En,- the meanspecificheatof i-th componentat
-97'05% ofc
Ans. "C
@1,= flue gastcmPerature'
BOILER HEAT BALANCE CALCULATIONS
(C) Heat lossdue to evaPoration
Basis: lkg fuel
HeatInput l. Moisture is formed due to combustionof
(A) Ilr - Grosscalorific valueof fuel' kcal hydrogenin the fuel. Loss of heatto evaporatethis
(B) Hz= Heatinput of fuel moisture
= c' (@r- @r)'kcal H8=M^L' kcal
"C Mm = tnilss of moisture formed by burning of
-
c specificheatof fuel, kcaVkg
'C
Ot - temperature
of fuel, hydrogenperkg of t'uel,kg H2Olkgfuel
"C of themoistureat the
@r- r€ferencetemperature, L = latcnthcatof evaporalion
(c) tt = Heatinput of air dew point of the flue gases,kcaVkg
= M"cr(@" - @r),kcal 2. Heat loss due to evaporationof moisture
presentin thc luel
M" massof input dry airlkg fuel, kg airlkg fuel
-
Hs= M*f L,kcal
ca- sP€ciltcheatof humid air
Mnrf= massof moisturepresentin the fuel' kg/kg
-0.24+ 0.46H,kcaVkgdry air "C
fuel
I/ - humidig of air, kg moisture&g dry air (D) Heat Lossdueto incompletecombustionof
'C
@a- air temperature, carbon as carbon monoxide.
Totalheatinput,I{ = Hr* Hr+ H3,kcal a,o=I c o l .x c x 5636.7
kcal
HeatOutput fEofrE.]
(A) Heat consumedin generatingsteam CO - Vo(by volume)of carbonmonoxidein the
l. EconomizerHo= Mw (he,,- h6r),kcal flue gas
Mw - fllass of feedwaterper unit massof fuel, COt- qo(by volume)of carbondioxidein theflue
gas
kg/kg tuel
C = c:ubonbumt per kg fuel burnt,kglkg fuel
iew - eothalpy of water at economizeroutlet'
(E) Heat lossdue to unburnt carbon
kcaVkg
Htr= M"(7 837'5)'kcal
ftfw= enthalpYof feedwater,kcaVkg
M" = 62ss of unconsunred carbonin refuse,kg/kg
2. Evaporator(Boiler) Hs= M"(/t, - i"*),kcal
fuel
M. - massof steamgenerationper unit massof (F) Heatlossdueto blowdorvn
fuel, kg steam/kgfuel
H tz= Mt t (hu* - /t1.."),
kcal
=
h, enthalpy of steamgenerated,
kcaVkg
Mbl = massof blowdownwater,kg/kg fuel
3. SuPerheaterHu= M"(Hu- hr)' kcal
ftuw= enthalpyof boilerwater,kcaVkg
/rr. = enthalpyof superheated
steam,kcal/kg (G) Unaccountedheatloss
(B) Heat lost in flue gases Hrt= Hi- (Hc+ H5+ Hu+ H, + Hg
Ht =2 n; ?0,(@s,- 25)' kcal + H n + H r c + H 1 . +H p )
 Boller Colculotlons 99

Prodem 6.fr A stoker-fired waterhrbeboiler Therefore,theoxygenutilizedfor hydrogenburn-

burnscoal-atthe rate of 4 Uh to generatesteamof 30 ing of fuel
kglcfl:Pabs and 430"C at the rate of 30 Vhour. =21.438-(12.85+6.5)
Evaluatethe boiler performancefrom the following
- 2.088kmol
data
(a) Component Proximateanalysisof coal 2Hz + 02 -----s 2H2O
Ash 12.7%(by weight) 2 kmols I kmol 2 kmols
Moisture 7.9%(by weight) Hydrogenbumt= 2 (2.088)= 4.176kmol
(b) Grosscalorific valueof coal - 6 250kcaUkg Waterproduced- 4.176kmol
(c) Component 3. Unburnt Carbon for 100kmol of
Flue Gas Arnlysis
Dry Flue Gas
coz t2.85% Carbonretainedin thecinder
02 6.580
)1\
N2 rest -ffix 4x 1000kg/h
(d) Carbonpresentin the cinder asunburntcom-
- ll0k9h
bustible-2.75%
(e) The feedwatertempenture - 90"C (FC+ VM) in coal
(f) Flue gastemperaturcat economizeroutlet = 100- (asb%+ moistureTo)
in coal
- 150\C
Fluegaspressureat economizeroutlet = 100- (12.7+7.9)=79.4Vo
- 755mmHg unbumtcarbon
".
(g) Air tempqratures
at burnerinlet 30"CDB and (FC + VM - unburntcarbon)
22"CWB. Ignorethepresence of sulphurand )7\
oxygenin coal. ===-?
't9.4-2.75 =0.0358
blwion The boiler performance,i.e. the overall Carbonin the flue gas
thermalefficiency of the boiler is to be evaluatedon - carbonin the CO2in the flue gas
thebasisof heatbalance.
Basis: 100kmol of dry flue gas. - 12.85kmol
1. OxygenSuppliedwith CombustionAir = 12.85x 12
N, in the flue gases = 154.2kg
- 100- (12.85+ 6.5)
Hydrogenin the flue gas
- 80.65kmol
- 4.176kmol
l0Okmol aircontains79kmol N2 and21 kmol 02
= 4.176x2
.'. 02 suppliedfor combustion
= 8.352kg
-(21179)x 80.65- 21.438kmol
2. Water Vapour ProducedDuring Total burntcombustible
Combustion - 154.2+ 8.352
C + 02 -----+ CO2 - r62.552kg
I kmol I kmol I kmol
Carbonunburntfor 100kmol ofdry flue gas
I kmol of CO2requiresI kmol of O, forcombus- = 0.0358x 162552
tion.
12.85kmol of CO2require12.85kmol of 02 = 5.8193
kg
for combustion. = 0.4849kmol
100 Boller Operotlon Englneedng

4. ExcessAir - (4.176+ 0.8985+ 2.203)kmol

C + O2+CO2 =7.277Sklrrol
l kmol l kmol l kmol
6. Compositionof Flue Gas
I kmol of C requiresI kmol . 3r for combustion
Component kmol mol%
.'. 0.4899kmol of C requires0.4899kmol of 02
for combustion coz 12.85 rr.97
.'. Oxygenrequiredto bum that unbumtcarbon- o2 6.5 6.05
0.4899kmol 10
N2 *x21.$8-80.&'7 75.179
.'. Excess02 supplied zl
Hzo 7.275 6.781
= 6.5- 0.4899= 6.0151kmol
lm.272 D.980
Total stoichiometric02 required
= 12.85+ 2.088+ 0.4899 7. Heat Input Rate
= 15.4229lnnol Rateof fuel buming- 4 ton coaVh
Grosscloritic valueof fuel - 6250kcaVkg
Therefore,excessair supplied Heatinput rate= 4 x 1000x 6250
_ 6.0151"Y rfl)'""
= 25000000kcaVh
15.4229 Ignoringtheheatinputof air (at 30'C), thenetheat
=39Vo. input rate - 25000000kcavh
5. Moisture Content of the Flue Gas 8. Heat Output Rate
100 kg coal contains7.9 kg free moisture and [A] Heat absorbedin generating superheat,ed
ll00 - (12.7 + 7.9)l i.e.T9.4kgcombustibles steam
Freemoistureappearingwith the combustionof Hn+ Hr+ Hu
162.552kg combustibles - 30,000x (787.8- 90.04)kcaUh
? o = 20932800kcaI/h
t9.4 where 787.8 kcal/kg - enthalpy of steam at
- 16.173kg= t6.tl3t18 kmol - 0.8985kmol 30 kgf/cm2absand at 4t0"C = h*
Frompsychrometricchart,humidityof air at 30'C 90.04kcaVkg= enthalPYof waterat 90'C
DB and22'C WB lBl Combustiblesleft in thecinder(asC)
- 13.4grr/kg dry air - I l0 kgih
1 ? 4 I Calorihcvalueof carbon(GCV - NCV)
= kmol HrO$ kmol dry air = 94.05kcaVmol
lg . 1000
q4 ()5
0.02158kmol water =# x 1000kcal/kg
= -- tz
ktnol dry uit
Heatlost in the combustibles
Therefore,thetotalmoistureenteringthecombus-
tion zone Hrr=Wx 1 0 0 0 xl l 0 k c a V h
= 0.02158x kmol of air containing21.438kmol
o2 =862125kcal,/h

= (0.02158)
r [+ x 2r.+38-] lCl Total freemoistureevaporatedfrom coal

- 2.203kmol
lLt I =l#x4ooo"%E
Therefore,total moisturein the flue gases = 305.055kg/h
 Boiler Colculoliom l0l

Now, partial pressureof water vapour in the flue innue

Heatrost ='lrt:lrT"i!;"'
83s€s
gas
= 755 x rnol frrction of water vap. in the flue gas
- 755 (7.I7 5l W7.2:12)mmltg Therefore,the rateof heatlossof flue gases
-51.20mmH9 - ee,ee 4,00cy
4.62( rd2.
s rr>(#EJ *"ro
Dew point of flue gases- 38"C
Latentheatof waterat 38"C- 575.83kcavkg = t,Ag6,06aY
Heat lost due to evaporationof free mois[re
9. Heat Balarrce
- 305.055x 575.83- 175660kcaYh
Hcd Input
[D] Heat loss due to evaporation of moisture Heat OutputRate
Rate
fonned due to cornbustion of hydrogen in the coal (kcaYh)
(kcd/h)
burnt
25,000,000 $1eamgeneration -2W3280083.73%
,, =l#r)G.*) (,sx57s.s3)rca,/h
[4#] Heatlossdueto -862125 3.4%
tmot urO unburntcombustibles
I ' ' -ks
lI 1g coarlf - - cornbustiblesl
-------------'
fkgcorrbustibleslf h lL kgcoal I Heatlossdueto - 175660 0.70%
evaporationoffree
I| _--tgHro lfll -:-r""rtl- 815408kcarl/h
moisture
I kmolH2oll tg J Heatlossdueto - El64$ 3.26%
evapcation of moishre
lEl Heat lost in flue gases(I/r) is evaluatedm the
formed due to
basis of rnean specific heat data of flue gas com- combustionof
ponents: hydrogenh thc fuel
Componcfi Mcan Sp.Hcat intlu Rangc25"-l50"C Heatlost to flue gases - 1886064 7.54%

coz 9.5 kcal/tmol'C Unaccountedheatloss-326943 Ln%

"C (by differerce)
Hzo 8.12kcalrtmol
"C Total - 25 000 000
o2 7.l2kcal/kmol
N2 7.00kcal,/kmol'C
(10) Overall ThermalEfficiency of the Boiler

Thercfore,for 1f/.272krnol of flue gas _ Heat oubut rate (steamgeneration)

Heat input rate (fuel combustion)
r\c^
' r t
(95)+7.275(8.12)+ 6.5(7.12\
= 12.E5
+8O.&7(7)kcaV'C =#ffffix roo=
83.73%
=79l.957kcal/"C
Steam tables
SpecificEnthalPY I Dpecrrrc
Pressure Temperature
(hfs) lSteam(hn)l Steam
Water(hf) | Evaporation
bar kPa kJ/kq I kJ/ks I kJ/kg lmJ/kg
absolute
0.30 30.0 69.10 289.23 2336.1 2625.3 5.229
0.50 50.0 81.33 340.49 2305.4 2645.9 3.24Q
o.7s 75.O 91.78 384.39 2278.6 2663.0 2.217
0.95 95.0 98.20 411.43 2261.8 2673.2 1.777
gauge
0 0 100.00 419.04 2257.0 2676.0 1.673
0.10 10.0 102.66 430.2 2250.2 2680.2 1.533
0.20 20.0 105.10 440.8 2243.4 2644.2 1.414
't.312
0.30 30.0 107.39 450.4 2237.2 2647.6
0.40 40.0 109.55 459.7 2231.3 2691.0 1.225
0.50 50.0 1 11 . 6 1 468.3 2225.6 2693.9 1.149
0.60 60.0 113.56 476.4 2220.4 2696.8 1.083
0.70 70.o 115.40 444.1 2215.4 2699.s 1.024
0.80 80.0 117.14 491.6 2210.5 2702.1 0.971
0.90 90.0 118.80 498.9 2205.6 2704.5 0.923
1.00 100.0 120.42 505.6 2201 .1 2706.7 0.881
1.10 110.0 1 2 1. 9 6 512.2 2197.0 2709.2 0.841
1.20 120.0 123.46 518.7 92.8 2711.5 0.806
1.30 130.0 124.90 524.6 88.7 2713.3 0.773
'1 126.28
.40 140.0 530.5 z 84.8 2715.3 0.743
1.50 150.0 127.62 536.1 z 8 1. 0 2717.1 0.714
1.60 160.0 128.89 5 4 1. 6 77.3 2718.9 0.689
1.70 170.0 130.13 547.1 73.7 2 7 2 0. 8 0.665
1.80 180.0 131 .37 552.3 z 70.1 2722.4 0.643
1.90 190.0 132.54 557.3 z 66.7 2724.0 0.622
'1
2.00 200.0 33.69 562.2 63.3 2725.5 0.603
2.20 220.0 135.88 5 7 1. 7 56.9 2724.6 0.568
2.40 240.O 138.01 580.7 2 50.7 2731.4 0.536
2.60 260.0 140.00 589.2 2 44.7 2733.9 0.509
2.80 280.0 1 4 1. 9 2 597.4 39.0 2736.4 0.483
3.00 300.0 143.75 605.3 33.4 2738.7 0.461
3.20 320.0 145.46 612.9 24.1 2741 .O 0.440
3.40 340.0 1 4 7. 2 0 620.0 22.9 2742.9 0.422
3.60 360.0 148.84 627.1 I 17.8 2744.9 0.405
3.80 380.0 150.44 634.0 z 12.9 27 46.9 0.389
4.00 400.0 1 5 1. 9 6 640.7 08.1 2748.4 0.374
4.50 450.0 155.55 656.3 2096.7 2753.0 0.342
5.00 500.0 158.92 670.9 2086.0 2756.9 0.315
5.50 550.0 162.08 684.6 2075.7 2760.3 0.292
6.00 600.0 |65.04 697.5 2066.0 2763.5 0.272
6.50 650.0 167.83 709.7 2056.8 2766.5 0.255
7.00 700.0 170.50 721.4 2047.7 2769.1 0.240
7.50 750.0 173.02 732.5 2039.2 2771.7 0.227
8.00 800.0 175.43 743.1 2030.9 2774.0 0.215
8.50 850.0 177.75 753.3 2022.9 2776.2 0.204
9.00 900.0 179.97 763.0 2015.1 2778.1 0.194
9.50 950.0 182.10 772.5 2 0 0 7. 5 2780.0 0.185
''| 2 7 8 1. 7 0.177
10.00 1000.0 84.13 7 8 1. 6 2000.1
10.50 1050.0 186.05 790.1 1993.0 2783.3 0.171
1. 0 0 1 10 0 . 0 18 8 . 0 2 798.8 1986.0 2744.4 0.163

splrax
' tsarco
EDB/1 1.01
 tables
S p e c i f i cE n t h a l p y Specific
Pressure Temperature Volume
Water(h1) Evaporation (h1n) S t e a m ( h n) Steam
bar gauge kPa kJ/kg kJ/kg kJ/kg ms/kg
I t.5U 1150.0 189.82 807.1 ffi
12 . o 0
1250
ft-oo -
IJ.3U

- 1t 4
4 5- o
0o

.-I C . U U
I3.JU
16-00
io_
17 . o 0
tsJo
19-OO
20^oo
E.oo
ias
22nO
23^00
24l 0
25-00
26-OO
2 7S O T
Z8-oo
29.o0
30.00
31.00
32'00
33.00 iei
34^OO
35-OO
#r
36-OO
37-OO
38-00
39-OO irffi
40-oo
?loo
43-OO
44nO
45-OO
ffi
46-OO
nno
ffi
Zs.oo
49nO
50s0
51i0
52-00
53.0O
54.oO
ffi
CC.UU
56-OO
ffi

1.02
splrax
' .lsarco
EDB/1
Steam tables
Specific Enthalpy lDpeolilc;
Pressure Temperature Volume

bar qauoe kPa "C @kJ/ks kJ/ks

S t e a m ( h-o ) | S t e a m
kJ/ko | m3/ko
I
57.00 s700.0 273.45 202.1 584.5 2786.6 0.0337
58.00 5800.0 274.55 207.8 577.7 2785.5 0.0331
59.00 5900.0 275.65 213.4 571.0 2784.4 0.0325
60.00 6000.0 276.73 218.9 564.4 2783.3 0.0319
61.00 6100.0 277.80 224.5 557.6 2782.1 0.0314
62.00 6200.0 278.85 230.0 550.9 2780.9 0.0308
63.00 6300.0 279.89 235.4 544.3 2779.7 0.0303
64.00 6400.0 280.92 240.8 537.3 2778.5 0.0298
65.00 6500.0 2 8 1. 9 5 246.1 5 3 1. 2 2777.3 0.0293
66.00 6600.0 282.95 251.4 524.7 2 7 76 . 1 0.0288
67.00 6700.0 283.95 256.7 518.1 2774.8 0.0283
68.00 6800.0 284.93 2 6 1. 9 511.6 2773.5 0.0278
69.00 6900.0 285.90 267.0 501.1 2772.1 0.0274
70.00 7000.0 28ti.85 272.'l 498.7 2770.4 O.A'274
7 1. 0 0 7100.u 247.4o 277 3 492.2 27b9.5 0.0266
72.OO 7200.0 244.7 5 282.3 485.8 2768.'t 0.0262
73.00 7300.0 289.ti9 247.3 479.4 276b.7 0.0258
74.OO 7400.0 290.tt0 292.3 473.0 2765.3 0.0254
75.00 7500.0 291.51 297.2 4tt6.6 2763.A 0.0250
76.00 7600.0 292.41 302.3 460.2 2762.5 0.0246
77.OO 7700.0 293.91 307.0 453.9 2760.9 Q.O242
78.00 7800.0 294.20 311.9 4 4 7. 6 2759.5 0.0239
29.00 7900.0 2 9 5 . 10 J t o 7 44't.3 2758.0 0.0236
80.00 8000.0 295.96 321 .5 435.0 2756.5 0.0233
8 1. 0 0 8100.0 296.81 326.2 424.7 2754.9 0"0229
82.00 8200.0 297.66 330.9 422.5 2753.4 0.0226
83.00 8300.0 298.50 335.7 416.2 2751.9 0.0223
84.00 8400.0 299.35 340.3 410.0 2750.3 0.0220
85.00 8500.0 300.20 345.0 403.8 2748.8 0.0217
86.00 8600.0 301.00 349.6 397.6 2 74 7 . 2 0.0214
87.00 8700.0 301.81 354.2 391.3 2745.5 0.0211
88.00 8800.0 302.61 358.8 385.2 2 74 4 . O 0.0208
89.00 8900.0 303.41 JOJ.J 379.0 2 74 2 . 3 0.0205
90.00 9000.0 304.20 367.8 372.7 2 74 0 . 5 0.0202
92.00 9200.0 305.77 376.8 360.3 2737.1 0.0 97
94.00 9400.0 307.24 385.7 348.0 2733.7 0.0 92
96.00 9600.0 308.83 394.5 335.7 2730.2 0.0 87
98.00 9800.0 310.32 403.2 323.3 2726.5 0.0 83
100.00 0000.0 311.79 411 I 310.9 2722.8 0.0 78
102.00 0200.0 313.24 420.5 2 9 8. 7 2 71 9. 2 0.0 74
104.00 0400.0 314.67 429.0 286.3 2715.3 0 . 0 70
06.00 10600.0 316.08 437.s 274.0 2711.5 0.0166
08.00 10800.0 317.46 445.9 2 6 1. 7 2707.6 0.0162
10.00 1000.0 318.83 454.3 249.3 2703.6 0 .0 5 8
12.00 12 0 0. 0 3 2 0. 1 7 462.6 237.0 2699.6 0.0 54
14.00 1400.0 3 2 1. 5 0 4 70 . 8 224.6 2655.4 0.0
16.00 1600.0 322.81 479.O 212.2 2 6 9 1. 2 0.0 47
18.00 ' 18 0 0 . 0 324.10 487.2 199.8 2687.0 0.0 44
20.00 2000.0 32s.38 495.4 187.3 2682.7 0.0 4 1

sprrax
' tsarco 1.03
EDB/1