Analysis of Boiler:

The current boiler efficiency is calculated by direct method which is define as the energy gain of the
working fluid (water and steam) is compared with the energy content of the boiler fuel. In case of waste
heat boiler the later part is exhaust gases. The direct method can be written as:
Energy absorbed by the steam
=
Energy loss by the waste heat source

m evap
(h outlet hinlet )
=

Q C P (T outletT inltet )

Where
mevap
= mass flow rate of the steam evaporated

houtlet = enthalpy at the outlet of the superheater

hinlet = enthalpy at the inlet of the economizer
T inltet = density of the flue gas at nominal temperature

Q = Flow rate of flue gas at nominal temperature and pressure i.e. 20 oC and 1 atm.
C P = Specific heat of the flue gas at the average temperature

heco = enthalpy at outlet of economizer

m
total = total mass flow rate of feed water to AQC boiler

In case of AQC boiler a stream is of 6.2 t/hr is separated from economizer so the numerator part
of the efficiency is modified to:

m evap ( h outletheco )m h )
total (h eco inlet
=
Q C P (T outlet T inltet )

By using the above formula the efficiency of the boiler is found to be 85%. The calculation are
performed in the MS excel and shown in the appendix.
Properties of flue gas:
In case of the AQC boiler the inlet flue gases are just hot air with certain amount of dust
co5ntents (15 g/Nm3). Air contain 20.95% of oxygen gas, 78.09% of nitrogen, 0.933% of argon,
0.03% of carbon dioxide and 0.001% of other gases.
In order to calculate the specific heat of the hot air the following formula is utilized showing the
dependency of the specific heat on temperature:
 [ ]
2 3
28.11+0.001967 T +0.000004802 T 0.000000001966 T
Cp=
M

Where
T= average temperature of flue gas in the boiler
M= molecular mass of the flue gas
It is important to note that the constant and coefficient of the above formula are only for
air and changed with the composition of the flue gas so for the general case the Cp of each
content of flue gas is calculated separately and shown in appendix and which is then converted
into combine specific heat of the flue gas through following formula:
Xi
n

( C pi)
i=0
n

Xi
i =0
Cp=

Where
X i = percentage composition by volume of the particular gas present in flue gas

C pi = Specific heat of the particular gas present in flue gas at average temperature

The calculation for each gas is performed in MS excel through the given formula and tables are
available in the appendix.

Similarly density also vary with the temperature but as standard the flow rate of the gases are
always represent in term of nominal temperature thats why there is no need to find out its
dependency on temperature and pressure but as the composition of flue gas vary the density also
changes for which combined density is find out by the following formula
Xi
n

( i )
i=0
n

Xi
i=0
=

Where
X i = percentage composition by volume of the particular gas present in flue gas

i = density of the particular gas present in flue gas at nominal temperature

Similarly viscosity, thermal conductivity and Prandtl number also calculated through the similar
formulae:

Xi
Xi
Xi
n

( Pr i )
i=0
n

Xi
i=0
n

( k i)
i=0
n
, Pr=
Xi
i=0
n

( v i )
i=0
n
, k =
Xi
i=0
v=

Energy Balance for the AQC boiler:

Energy balance for Economizer:
Inlet temperature = 255oC
Outlet temperature = 165oC
Mass flow rate = density Flow rate = 49.86 kg/s
Specific heat = 1.01 KJ/kgoC

Energy loss by the flue gas = mC

P (T outlet T inltet )

= 4531.932338 W
Inlet temperature = 40oC
Outlet temperature = 196.284oC
Enthalpy at the inlet = 168.863 kJ/kg
Enthalpy at outlet = 835.687932 kJ/kg
Mass flow rate = 5.75 kg/s
Energy gain by the feed water = m evap (h outlet hinlet )

= 3834.240213 W

Energy balance for the evaporator:

Inlet temperature = 420oC
Outlet temperature = 255oC
Mass flow rate = density Flow rate = 49.86 kg/s
Specific heat = 1.01 KJ/kgoC

Energy loss by the flue gas = mC

P (T outlet T inltet )

= 8308.542621 W
Inlet temperature = 196.284oC (Saturated liquid)
Outlet temperature = 194.207166oC (Saturated vapour)
Enthalpy at the inlet = 835.687932 kJ/kg
Enthalpy at outlet = 2788.32105 kJ/kg
Mass flow rate = 5.75 kg/s

Energy gain by the feed water = m evap (h outlet hinlet )

= 7864.772298 W

Energy balance for the superheater:

Inlet temperature = 480oC
Outlet temperature = 420oC
Mass flow rate = density Flow rate = 49.86 kg/s
Specific heat = 1.01 KJ/kgoC

Energy loss by the flue gas = mC

P (T outlet T inltet )

= 3021.288226 W
Inlet temperature = 194.207166oC
Outlet temperature = 404oC
Enthalpy at the inlet = 2788.32105 kJ/kg
Enthalpy at outlet = 3268.97354 kJ/kg
Mass flow rate = 5.75 kg/s

Energy gain by the feed water = mevap (h outlet hinlet )

= 1935.961399W
Total energy loss by flue gas = 15861.76318 W
Total energy gain by steam = 13634.97391W
Efficiency = energy loss by flue gas / energy gain by steam
= 85.96%