Foster Wheeler International Engineering & Consulting

(Shanghai) Co., Ltd.

Labuhan Angin CFB Operations & Maintenance Manual

SECTION 2
HEAT AND MATERIAL BALANCE

PROPRIETARY DATA
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Ltd. and will be returned upon request or when no longer needed by the recipient. Information contained
herein may not be communicated to others nor may this document be copied in whole or in part without
the express written consent of Foster Wheeler International Engineering & Consulting (Shanghai) Co.,
Ltd.

Company: FWIEC

PAGE i

Section: Two

Foster Wheeler Energy Corporation

Labuhan CFB Operations & Maintenance Manual

TABLE OF CONTENTS

HEAT AND MATERIAL BALANCE............................................................. i

BOILER LOAD ........................................................................................................................... 1
STEAM DATA ............................................................................................................................. 1
REHEAT DATA ........................................................................................................................... 1
MAKE UP SAND ......................................................................................................................... 2
LIMESTONE ANALYSIS ............................................................................................................. 2
FUEL MIXTURE .......................................................................................................................... 2
FUEL MIXTURE SUMMARY ...................................................................................................... 2
EFFICIENCY CALC ..................................................................................................................... 2
ENERGY BALANCE LOSSES ..................................................................................................... 3
HEAT INPUT ............................................................................................................................... 3
HEAT OUTPUT ........................................................................................................................... 3
MASS BALANCE ........................................................................................................................ 3
MASS BALANCE ........................................................................................................................ 4
GAS RECIRCULATION ............................................................................................................... 4
AIR PROPERTIES ........................................................................................................................ 4
AIR DISTRIBUTION .................................................................................................................... 4
BOTTOM ASH ANALYSIS .......................................................................................................... 4
FLY ASH ANALYSIS AT AIRHEATER OUTLET ........................................................................ 4
FLUE GAS ANALYSIS AT AIRHEATER OUTLET ..................................................................... 5
FLUE GAS PROPERTIES AT AIRHEATER OUTLET .................................................................. 5
FLUE GAS ANALYSIS AT AIRHEATER OUTLET ..................................................................... 5
RECIRCULATION FLY ASH ....................................................................................................... 5
EMISSION AT AIRHEATER OUTLET......................................................................................... 5
SO2 EMISSIONS .......................................................................................................................... 5
SO2 UNCONTROLLED ............................................................................................................... 6
SO2 UNCONTROLLED ............................................................................................................... 6
CO EMISSIONS ........................................................................................................................... 6
VOC EMISSIONS ........................................................................................................................ 6
HCl EMISSIONS .......................................................................................................................... 6
PARTICULATE EMISSIONS ....................................................................................................... 6

Company: FWEC

Section: Two

Foster Wheeler International Engineering & Consulting

(Shanghai) Co., Ltd.

Labuhan Angin CFB Operations & Maintenance Manual

HEAT AND MATERIAL BALANCE

Operating Mode
1 BOILER LOAD
Fuel
% Sulfur Capture
1.1 STEAM DATA
Main Steam Flow
Pressure
Temperature
Enthalpy
Ext. Steam Flow
Pressure
Temperature
Enthalpy
Sat Vapor Flow
Pressure
Temperature
Enthalpy
Sat Liquid Flow
Pressure
Temperature
Enthalpy
Blowdown Flow
% of Main Steam
Feedwater Flow
Pressure
Temperature
Enthalpy
Spray water Flow
Pressure
Temperature
Enthalpy
% of Main Steam
Spray Source
1.2 REHEAT DATA
RH Outlet Flow
Pressure
Temperature
RH Inlet Flow
Pressure
Temperature
Enthalpy

Company: FWIEC

I
% MCR BMCR
Perf. Coal
%
90

Kg/Hr
MPa
C
KJ/Kg
Kg/Hr
MPa
C
KJ/Kg
Kg/Hr
MPa
C
KJ/Kg
Kg/Hr
MPa
C
KJ/Kg
Kg/Hr
Kg/Hr
MPa
C
KJ/Kg
Kg/Hr
MPa
C
KJ/Kg

Kg/Hr
MPa
C
Kg/Hr
MPa
C
KJ/Kg

423000
10.500
542
3477.7
N/A

II
100
Perf. Coal
90

III
75
Perf. Coal
90

IV
50
Perf. Coal
90

409400
10.500
542
3477.7
N/A

305000
10.500
542
3477.7
N/A

206000
10.500
542
3477.7
N/A

406300
393400
294000
200900
11.29
11.27
11.1
10.98
319.3
319.1
318.0
317.2
2702.9
2703.4
2706.7
2709.0
410600
397500
297000
203000
11.29
11.27
11.1
10.98
319.3
319.1
318.0
317.2
1457.6
1456.6
1449.6
1444.7
4200
4100
3000
2100
1.00
1.00
1.00
1.00
410600
397500
297000
203000
11.47
11.44
11.25
11.11
222.1
220.5
203.0
185.0
955.9
948.6
869.8
790.2
16700
16000
11000
5100
12.29
12.29
12.29
12.29
211.12
211.118
186.118
150.074
956.1
948.8
870.2
790.8
3.94
3.92
3.62
2.46
Upstream of the feed stop & check valves

N/A

PAGE 1

N/A

N/A

Section: Two

N/A

Foster Wheeler Energy Corporation

2 MAKE UP SAND
Input Basis
Mass flow
Prc of fuel flow %

Labuhan CFB Operations & Maintenance Manual

0.14
0.20

Prc. of Fuel
0.13
0.10
0.20
0.20

0.07
0.20

Perf.

Perf.

Perf.

Perf.

m
Kg/Hr

98.3
0.88
0.00
0.00
0.2
0.35
0.62
2.0
187.5
0

98.3
0.88
0.00
0.00
0.2
0.35
0.62
2.0
187.5
0

98.3
0.88
0.00
0.00
0.2
0.35
0.62
2.0
187.5
0

98.3
0.88
0.00
0.00
0.2
0.35
0.62
2.0
187.5
0

wt-% af
wt-% af
wt-% af
wt-% af
wt-% af
wt-% af
wt-% af
wt-% af
%,daf

42.59
4.32
12.98
0.72
0.21
35.00
4.17
N/A
53.91

42.59
4.32
12.98
0.72
0.21
35.00
4.17
N/A
53.91

42.59
4.32
12.98
0.72
0.21
35.00
4.17
N/A
53.91

42.59
4.32
12.98
0.72
0.21
35.00
4.17
N/A
53.91

69648.8

67246.4

51946.3

36164.5

Kg/Hr

2.1 LIMESTONE MIXTURE

2.2 LIMESTONE ANALYSIS
CaCO3
MgCO3
CaO
MgO
H2O
CO2
Inerts
Reactivity Index
Particle Mean Size
Flow
2.3 FUEL ANALYSIS
input
Carbon
Hydrogen
Oxygen,
Nitrogen,
Sulfur,
Moisture,
Ash,
Chlorine
Volatile Matter
Total fuel flow

(%-wt)
(%-wt)
(%-wt)
(%-wt)
(%-wt)
(%-wt)
(%-wt)

% heat

Kg/Hr

2.5 FUEL MIXTURE SUMMARY (klb/hr)

Mixing basis:
Coal
kg/hr
Pet Coke
klb/hr

69650
N/A

Mass Ratio
67250
51950
N/A
N/A

3 EFFICIENCY CALC
INPUTS
Company: FWEC

PAGE 2

Section: Two

36160
N/A

Foster Wheeler International Engineering & Consulting

(Shanghai) Co., Ltd.

Efficiency Code
Rad. loss by
Fly Ash Split
Bottom Ash Temp.
3.1 ENERGY BALANCE
LOSSES
Dry Flue Gas
Moisture from Hydrogen
Moisture in Fuel
Unburned Carbon
Radiation
Moisture in Air
Unaccounted Losses
Manufacturers margin
SUM OF LOSSES
BOILER EFFICIENCY

%
C

% LHV
% LHV
% LHV
% LHV
% LHV
% LHV
% LHV
% LHV
% LHV
% LHV

Labuhan Angin CFB Operations & Maintenance Manual

ASME
ASME
90
150

ASME
ASME
90
150

ASME
ASME
90
150

ASME
ASME
90
150

4.80
0.51
0.47
0.69
0.23
0.19
0.00
1.44
8.5
91.5

4.74
0.51
0.46
0.68
0.24
0.19
0.00
1.01
8
92.00

4.14
0.44
0.40
0.69
0.31
0.16
0.00
2.18
8.5
91.5

4.43
0.39
0.36
0.59
0.45
0.17
0.00
1.95
8.5
91.5

3.2 HEAT INPUT

Combustion Air
Sensible Heat in Fuel
Fuel Inherent CaCO3
Fuel (LHV)
Fuel (HHV)
Net Heat In

MW
MW
MW
MW
MW
MW

0.000

0.000

0.000

0.000

0.490
323.992
358.918
324.482

0.473
312.817
346.538
313.289

0.365
241.643
267.692
242.009

0.254
168.230
186.365
168.484

3.3 HEAT OUTPUT

Steam
Flue Gas
Radiation
Bottom ash
Fly ash
Limestone Rxns
Unburned Carbon
Unacct & MFG
Net Heat Out

MW
MW
MW
MW
MW
MW
MW
MW
MW

296.909
19.367
0.749
0.009
0.068
0.473
2.234
4.673
324.482

288.226
18.488
0.750
0.009
0.457
0.457
2.132
3.431
313.289

221.444
12.458
0.750
0.007
0.353
0.353
1.673
5.281
242.009

154.161
9.017
0.750
0.005
0.246
0.246
0.992
3.422
168.484

Kg/Hr
Kg/Hr
Kg/Hr
Kg/Hr
Kg/Hr
Kg/Hr
Kg/Hr
Kg/Hr

493090
69650

301320
31248

512028
55296

510588
55152

0.14
562880
559990
2880
562880

0.13
543500
540720
2780
543500

0.10
419800
417650
2150
419800

0.07
347070
345590
1480
347070

3.4 MASS BALANCE

Combustion Air
Fuel flow
Limestone flow
Make up Sand flow
TOTAL INPUT
Gas flow from Combust.
Ash Flow
Total Output
Company: FWIEC

PAGE 3

Section: Two

Foster Wheeler Energy Corporation

Labuhan CFB Operations & Maintenance Manual

3.5 MASS BALANCE

Combustion Air
Gas Flow from Combust.
Total Gas Flow

m3n/s
m3n/s
m3n/s

3.6 GAS RECIRCULATION

Recirc. Gas

4 AIR PROPERTIES
Elevation
Atm pressure
Amb Air Temp.
Avg Air Temp. (Fan outlet)
Ref. Air Temp.
Mol. Weight
Kg H2O/kg dry air
4.1 AIR DISTRIBUTION
Excess Air
Primary Air Incl. Ash
cooler air
Secondary Air
Primary Air In Temp.
Secondary Air In Temp.
Other. Air In Temp.
4.2 BOTTOM ASH
ANALYSIS
CaCO3
CaO
MgO
CaSO4
Inert
Fuel Ash
Unburned Fuel
Na equivalent

107.80
122.81
122.81

104.09
118.58
118.58

80.40
180.40
91.59

67.95
67.95
75.75

N/A

N/A

N/A

N/A

30
103.0
30
44
44
28.48
0.022

30
103.0
30
44
44
28.48
0.022

30
103.0
30
44
44
28.48
0.022

30
103.0
30
44
44
28.48
0.022

%
%

20
By Fuel

25
By Fuel

20
By Fuel

20
By Fuel

%
C
C

0.00
44.00
44.00

0.00
44.00
44.00

0.00
44.00
44.00

0.00
44.00
44.00

44.00

44.00

44.00

44.00

wt-%
wt-%
wt-%
wt-%
wt-%
wt-%
wt-%
wt-%

0.00
19.00
0.00
0.56
4.83
66.45
9.15
0.00

0.00
19.03
0.00
0.56
4.84
66.52
9.05
0.00

0.00
19.00
0.00
0.56
4.83
66.43
9.18
0.00

0.00
19.27
0.00
0.54
4.90
67.35
7.94
0.00

8.72
2.53
67.88
16.05
0.00
4.82

8.72
2.53
67.88
16.05
0.00
4.82

8.72
2.53
67.88
16.05
0.00
4.82

meter
Kpa
C
C
C
Kg/mol

4.3 FLY ASH ANALYSIS AT AIRHEATER OUTLET

CaSO4
wt-%
8.72
Carbon
wt-%
2.53
Fuel Ash
wt-%
67.88
CaO
wt-%
16.05
MgO
wt-%
0.00
OTHERS
wt-%
4.82

Company: FWEC

PAGE 4

Section: Two

Foster Wheeler International Engineering & Consulting

(Shanghai) Co., Ltd.

Labuhan Angin CFB Operations & Maintenance Manual

FLUE GAS ANALYSIS AT AIRHEATER

OUTLET
4.4
CO2
SO2
O2
N2
H2O
Mol. Weight
Dust Content excluding
reinject
Density

vol-% wet
vol-% wet
vol-% wet
vol-% wet
vol-% wet
Kg/mol
Kg/Kg

12.49
0.02
2.96
67.04
17.49
28.39
0.005

12.49
0.02
2.96
67.04
17.49
28.39
0.005

12.49
0.02
2.96
67.04
17.49
28.39
0.005

12.49
0.02
2.96
67.04
17.49
28.39
0.005

Kg/m3n

1.267

1.267

1.267

1.267

4.5 FLUE GAS PROPERTIES AT AIRHEATER

OUTLET
Exit Gas Temp.
C 156.00
Pressure
KPa
100.3

154.73
100.5

140.64
101.6

129.64
102.1

4.6 FLUE GAS ANALYSIS AT AIRHEATER

OUTLET
CO2
Dry-%
SO2
Dry-%
O2
Dry-%
N2
Dry-%

15.14
0.03
3.59
81.25

15.14
0.03
3.59
81.25

15.14
0.03
3.59
81.25

15.14
0.03
3.59
81.25

4.7 RECIRCULATION FLY

ASH
Recirculation (Max.)

N/A

N/A

N/A

N/A

Fixed
3.000
3.59

Fixed
3.000
3.59

Fixed
3.000
3.59

Fixed
3.000
3.59

223.11
80.19
286.20
234.84
819.00
2.56
0.00

3% O2 Dry
223.13
223.10
77.43
59.80
286.20
286.20
234.84
234.84
819.00
819.00
2.55
2.56
0.00
0.00

223.36
41.68
286.20
234.00
819.00
2.45
0.00

5 EMISSION AT AIRHEATER
OUTLET
Guideline
O2 Basis:
Emission O2, dry %
Actual O2, dry %
5.1 SO2 EMISSIONS,
mg/MJ LHV
g/s
ppm dry vol @ 3% O2dry
ppm wet vol @ 3% O2dry
mg/m3n dry @3% O2dry
Percent Retention
Ca:S Molar Ratio
Ca:S Source
Company: FWIEC

Kg/Hr

PAGE 5

Section: Two

Foster Wheeler Energy Corporation

5.2 SO2 UNCONTROLLED

mg/m3n dry @3% O2dry
5.3 Nox UNCONTROLLED
mg/m3n dry @3% O2dry
5.4 CO EMISSIONS
mg/m3n dry @3% O2dry

Labuhan CFB Operations & Maintenance Manual

<750

<750

<750

<750

<450

<450

<450

<450

200.00

200.00

200.00

200.00

N/A

N/A

N/A

0.0

0.0

0.0

5.5 VOC EMISSIONS (C6H6 basis)

mg/m3n dry @6% O2dry

N/A

5.6 HCl EMISSIONS

mg/m3n dry @6% O2dry

0.0

5.7 PARTICULATE EMISSIONS

mg/MJ LHV
mg/m2n Dry

Company: FWEC

3.0 % O2 Dry
41.14
151.03

PAGE 6

41.15
151.03

41.14
151.03

41.19
151.03

Section: Two