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Calc 1 - Boiler Efficiency.

xls

1 of 3

http://www.exoeng.com/boilereffcalc.htm

Plant.

Performance at Tested Air Heater Leakage

Unit..
Locaon..

Furnace Data @ Tested AH Leakage:

Date..

Furnace Data @
3,476 MBtu/hr

Heat Input

Blend

Carbon

Coal A Coal B
Units
0%
Blend Fracon 100%
51.04
51.04
0.00
%
C

Total Air Flow

Hydrogen

H2

3.64

3.64

0.00

Furnace Excess Air

Sulfur

0.29

0.29

0.00

Wet Gas Flow Leaving Furnace

Oxygen

S
O2

12.74

12.74

0.00

Air Heater Exit Gas Data @ Tested AH Leakage:

Nitrogen

N2

0.66

0.66

0.00

Excess O2

Moisture

H2O

26.57

26.57

Ash

5.06

5.06

0.00

AH Gas Exit Temp Corrected (Measured)

Other

0.00

0.00

0.00

AH Gas Exit Temp Uncorrected (ie, No Leakage)

Total:

100.00

100.00

0.00

8,867

8,867

Fuel Data:

HHV
Moisture in Air
Addional Moisture

0.00

%
Btu/lb
0
m

0.0135 (lb/lb dry air)

Fuel Flow

pph

Fuel Flow

2,982,562

pph

Total Air Flow

Furnace Excess A

pph

Wet Gas Flow Le

Air Heater Exit


4.26

Excess O
Excess O

1
321

AH Gas Exit Temp

349

AH Gas Exit Temp

To correct the eciency for "Uncorrected AH Gas

To correct

Out Temp" enter "1" at right. If not, leave blank.

Out Temp"
361,584
9.97

Air Heater Leakage (%) (Mass Method)


Air Heater Leakage (%) O2 Method)

Air, Gas & Fuel Temperatures:

Steam Flow

392,027

3,625,951

Air Heater Leakage (pph)

0.0000 (lb/100lb fuel)

pph

15.56

(% by Vol)
Excess O2 Measurement Basis: 1 = Wet, 0 = Dry

Heat Input

Steam Flow

9.52

pph

Air Heater Leaka

Air Heater Leaka


Air Heater Leaka

Calculaon Reference Temp

80

We

3,987,536

pph

We

FD Fan Inlet Air Temp


Fuel Temperature (Default = Tref)

60

We

1,271,016

acfm

We

60

Flue Gas Constuents:


Oxygen (O2)

Boiler Eciency Losses, Manual Input:


Radiaon and convecon (Default = .17)

0.17

Carboc Dioxide (CO2)

Unaccounted for losses (Default = 0.50)

0.50

Sulfur Dioxide (SO2)

Ash Data:
Ash Locaon

(% by Volume)

Flue Gas Cons


Oxygen (O

4.26

12.93

Carboc Dioxi

0.02753

Sulfur Dioxid

Moisture (H2O)

11.93

Moisture (H

Nitrogen (N2)

70.85

Nitrogen (N

100.00

Total

Ash Split
(%)
20

LOI
(%)
0.26

Economizer Ash

0.26

Boiler Eciency Heat Losses @ Tested AH Leakage:

Air Heater Ash

0.00

Los

6.17

Los

75

0.26

Los

7.71

Los

Baghouse Ash

0.00

Los

0.14

Los

Dust Collector Ash

0.00

Los

0.02

Los

Boom Ash

Precipitator Ash

(Must
Total
100%)

Total Ash

100

Economizer Exit Gas Data:


2.50

Ex

Total

Boiler Ecienc

Los

0.17

Los

Ma

0.50

Ma

Tot

14.72

Tot

Boi

85.28

Boi

Fuel Flow Determinaon Data:


NOTES:

For total fuel ow determinaon enter at least one of the

yellow/red cells

following groups:
392,027

Gr

Design (or other) data set does not need to be completed. It is just available for

OR
Gr

are for input data, to be completed by user.

pph
MBtu/hr

OR
Group C: For non-reheat units, enter all of the following:
Steam Flow

pph

Steam Enthalpy
Feedwater Enthalpy

pph
pph

Fuel ow and heat input are not used to calculate boiler eciency, but are nece

Fuel Flow determinaon will aempt to access Group A data rst, Group B data s

Heat Input determinaon will aempt to access Group B data rst, Group A data

9/16/2014 4:19 PM

Calc 1 - Boiler Efficiency.xls

2 of 3

Steam Load:

http://www.exoeng.com/boilereffcalc.htm

Table 13A
Combustion Calculations - Btu Method

0 pph

Plant:

Client:

Date: 01/00/00

Location:

INPUT CONDITIONS - BY TEST OR SPECIFICATION


15.56
1 Excess air at economizer exit, % by weight

FUEL DATA - Coal


15 Ultimate An

16 Theo. Air, lb/100lb fuel

2 Entering air temperature, OF

Co

K1

60

3 Reference air temperature, F


4 Fuel temperature, OF
O

5 Flue gas temp leaving AH (including leakage), F


O

6 Flue gas temp leaving AH (excluding leakage), F


7 Moisture in air, lb/lb dry air
8 Additional moisture lb/100 lb fuel
9
10
11
12
13
14

% by wt.

80 A C

51.04

11.51

587.37

60 B S
321 C H2

0.29

4.31

1.25

3.64

34.28

124.79

349 D H2O
0.0135 E N2

26.57

0.0000

12.74
-4.32
F O2
5.06
G Ash
100.00
H Total
18 Higher heating value (HHV), Btu/lb fuel

Enthalpy of steam at 1 psi, T = [6]


Water from
fuel, as-fired Enthalpy of water at T = [3]
%
Moisture in air, %
Unburned carbon, %
Radiation and convection, %
Unaccounted for and manufacturers margin, %

40
41
42
43
44
45
46
47 Summation of losses, %
Credits
48 Heat in dry air, %
49 Heat in moisture in air, %
50 Sensible heat in fuel, %
51 Other, %
52 Summation of credits, %
53 Efficiency, %

0.0024 x [35D] x ([6] - [3])


H1 = (3.958E-5 x T + .4329) x T + 1062.2
H2 = [3] - 32
[29] x ([39] - [40]) / 100
0.0045 x [27D] x ([6] - [3])
[19] or [21] x 14,500 / [18]
ABMA curve

Summation [38] + [46]


.0024 x [26D] x ([2] - [3])
.0045 x [27D] x ([2] - [3])
(H at T[4] - H at T[3]) x 100 / [18]
Summation [48] through [51]
100 - [47] + [52]

[15] x K2

8.94

32.53

1.00

26.57

-55.04
658.37

59.10
8,867

0.02
7.42
0.01

[16H] x 100 / [18]


[19] x [18] / 14,500

COMBUSTION GAS CALCULATIONS, Quantity / 10,000 Btu Fuel Input


22 Theoretical air (corrected), lb/10,000 Btu
[20] - [21] x 1151 / [18]
23 Total Residue from fuel, lb/10,000 Btu
([15G] + [21]) x 100 / [18]
24
A At
B Leakage
C Leaving Furnace
15.559217103466114
13.826
25 Excess air, % by weight
26 Dry air, lb/10,000 Btu
(1 + [25] / 100) x [22]
0.12
27 H20 from air, lb/10,000 Btu
[26] x [7]
0.00
28 Additional Moisture, lb/10,000 Btu
[8] x 100 / [18]
0.67
29 H20 from fuel, lb/10,000 Btu
[17H] x 100 / [18]
30 Wet gas from fuel, lb/10,000 Btu
(100 - [15G] - [21]) x 100 / [18]
31
32
33 Total wet gas, lb/10,000 Btu
Summation [26] through [30]
0.78
34 Water in wet gas, lb/10,000 Btu
Summation [27] + [28] + [29]
35 Dry gas, lb/10,000 Btu
[33] - [34]
36 H20 in gas, % by weight
[100] x [34] / [33]
37 Residue, % by weight
100 x [24] / [33]

39

K2

0.66

19 Unburned carbon loss, % fuel input


20 Theoretical air, lb/10,000 Btu
21 Unburned carbon, % of fuel

EFFICIENCY CALCULATIONS, % Input from Fuel


Losses
38 Dry Gas, %

17 H20, lb/100 lb fuel

[15] x K1

7.42
0.06
D Leaving Air Heater
29.39
9.60
0.13
0.13
0.00
0.00
0.67
1.07
1.07

15.56
8.58
0.12
0.00

10.43
0.78
9.65
7.50
0.55

0.80

11.47
0.80
10.68
6.94
0.50

6.17
1,205.24
48.00
7.71
0.14
0.02
0.17
0.50
14.72
-0.461019
-0.011670
0.000000
0.000000
-0.47
84.81

9/16/2014 4:19 PM

Calc 1 - Boiler Efficiency.xls

3 of 3

Steam Load:

http://www.exoeng.com/boilereffcalc.htm

Table 13A
Combustion Calculations - Btu Method

0 pph

Plant:

Client:

Date: 01/00/00

Location:

INPUT CONDITIONS - BY TEST OR SPECIFICATION


15.56
1 Excess air at economizer exit, % by weight

FUEL DATA - Coal


15 Ultimate An

16 Theo. Air, lb/100lb fuel

2 Entering air temperature, OF

Co

K1

60

3 Reference air temperature, F


4 Fuel temperature, OF
O

5 Flue gas temp leaving AH (including leakage), F


O

6 Flue gas temp leaving AH (excluding leakage), F


7 Moisture in air, lb/lb dry air
8 Additional moisture lb/100 lb fuel
9
10
11
12
13
14

% by wt.

80 A C

51.04

11.51

587.37

60 B S
238 C H2

0.29

4.31

1.25

3.64

34.28

124.79

349 D H2O
0.0135 E N2

26.57

0.0000

12.74
-4.32
F O2
5.06
G Ash
100.00
H Total
18 Higher heating value (HHV), Btu/lb fuel

Enthalpy of steam at 1 psi, T = [6]


Water from
fuel, as-fired Enthalpy of water at T = [3]
%
Moisture in air, %
Unburned carbon, %
Radiation and convection, %
Unaccounted for and manufacturers margin, %

40
41
42
43
44
45
46
47 Summation of losses, %
Credits
48 Heat in dry air, %
49 Heat in moisture in air, %
50 Sensible heat in fuel, %
51 Other, %
52 Summation of credits, %
53 Efficiency, %

0.0024 x [35D] x ([6] - [3])


H1 = (3.958E-5 x T + .4329) x T + 1062.2
H2 = [3] - 32
[29] x ([39] - [40]) / 100
0.0045 x [27D] x ([6] - [3])
[19] or [21] x 14,500 / [18]
ABMA curve

[15] x K2

8.94

32.53

1.00

26.57

-55.04
658.37

59.10
8,867

0.02
7.42
0.01

[16H] x 100 / [18]


[19] x [18] / 14,500

COMBUSTION GAS CALCULATIONS, Quantity / 10,000 Btu Fuel Input


22 Theoretical air (corrected), lb/10,000 Btu
[20] - [21] x 1151 / [18]
23 Total Residue from fuel, lb/10,000 Btu
([15G] + [21]) x 100 / [18]
24
A At
B Leakage
C Leaving Furnace
15.559217103466114
81.174
25 Excess air, % by weight
26 Dry air, lb/10,000 Btu
(1 + [25] / 100) x [22]
0.12
27 H20 from air, lb/10,000 Btu
[26] x [7]
0.00
28 Additional Moisture, lb/10,000 Btu
[8] x 100 / [18]
0.67
29 H20 from fuel, lb/10,000 Btu
[17H] x 100 / [18]
30 Wet gas from fuel, lb/10,000 Btu
(100 - [15G] - [21]) x 100 / [18]
31
32
33 Total wet gas, lb/10,000 Btu
Summation [26] through [30]
0.78
34 Water in wet gas, lb/10,000 Btu
Summation [27] + [28] + [29]
35 Dry gas, lb/10,000 Btu
[33] - [34]
36 H20 in gas, % by weight
[100] x [34] / [33]
37 Residue, % by weight
100 x [24] / [33]

39

K2

0.66

19 Unburned carbon loss, % fuel input


20 Theoretical air, lb/10,000 Btu
21 Unburned carbon, % of fuel

EFFICIENCY CALCULATIONS, % Input from Fuel


Losses
38 Dry Gas, %

17 H20, lb/100 lb fuel

[15] x K1

7.42
0.06
D Leaving Air Heater
96.73
14.60
0.20
0.20
0.00
0.00
0.67
1.07
1.07

15.56
8.58
0.12
0.00

10.43
0.78
9.65
7.50
0.55

0.86

16.54
0.86
15.67
5.22
0.35

5.93
1,167.36
48.00
7.46
0.14
0.02
0.17
0.50

Summation [38] + [46]

14.23

.0024 x [26D] x ([2] - [3])


.0045 x [27D] x ([2] - [3])
(H at T[4] - H at T[3]) x 100 / [18]

-0.70
-0.02
0.00
0.00
-0.72
85.05

Summation [48] through [51]


100 - [47] + [52]

9/16/2014 4:19 PM