Proceedings of the National Conference on Advances in Thermal Engineering September 23-
24, 2016, Jadavpur University, Kolkata, India
EFFICIENCY CALCULATION OF A BOILER OF A 500MW THERMAL
POWERPLANT BASED ON THE OPERATING DATA
Mr. Malay Kanti Naskar
Assistant Professor, Mechanical Department, Netaji Subhash Engineering College,
Souradeep Mitra
Student, Netaji Subhash Engineering College(B.Tech)
1E, Lake Temple Road
Kolkata – 700029 email: sourad20@gmail.com
Soudeep Saha
Student, Netaji Subhash Engineering College(BTech)
NIT Calicut (Mtech,pursuing)
18, Uttar Pally
P.O. Sodepur
Kolkata – 700110 email: soudeep.saha@gmail.com
Abstract
Energy and environment both are core for
human comfort and peripheral for global
survival now-a-days. Modern economic
pressure demands re-examination of the
existing power generating plants for various
options for their techno-economical and
efficient operations. This project presents a
detailed energy study based on the first law
analysis of a 500MW coal fired thermal power
station namely Durgapur Thermal Power
Station (DTPS). The boiler efficiency is
calculated using both direct, i.e., the usually
employed method and indirect method after
estimating the various heat losses in the
boilers. It highlights the positive features of
one of the boilers in this plant as well as, it
brings out areas where further detailing and
corrective measures are required for efficient
utilization of the sources available in the plant.
KEY WORDS: Thermal Power Station; boiler; first
law analysis; direct and indirect method.
I. INTRODUCTION
The principal functions of a power system are to
convert energy from various forms to electric
energy and to transmit this energy to consumers in
diversified areas. The smooth flow of energy to all
parts of a power system is a fundamental
requirement. To satisfy this requirement, it is
desirable that the power generation units be
properly controlled so that the production and
ATE 2016–PAPER NO
Shohom Singh
Student,Netaji Subhash Engineering College(B.Tech)
27/3, Khetra Mohan Naskar Road
Kolkata – 700040 email: shohom17@rediffmail.com
Prof. Sudip Simlandi
Assistant Professor of Jadavpur University in
Mechanical Engineering Department
consumption of energy can be maintained in
equilibrium at all times.
The role of efficiency monitoring lies in
maximizing generation from the thermal power
plants. In order to keep maximum output from a
given input, the units must run at the maximum
possible efficiency. Power plant performance
improvements at various stages help in improving
the power generation capacity. its efficiency (and
output) may be influenced by various factors such
as maladjustment of the controls, fouling, or a
change from specified operating conditions. Both
maximum output capability and efficiency should
therefore continue to be measured during its
working life, or at least those factors which affect
efficiency, mainly exit gas composition and
temperature. The purpose of this paper is finding
boiler efficiency and suggesting some
improvements that will enhance the boiler
performance.
(A) BOILER EFFICIENCY
The thermal efficiency of a boiler is the ratio of
usual energy output to the energy input. By far the
greatest component of the latter is the energy in the
fuel; that supplied as power to the auxiliaries being
negligible in comparison. Efficiency is 80-90%,
based on the gross calorific value (GCV), in typical
modern plants. Boiler efficiency depends solely on
the boilers ability to burn the fuel and transfer the
resulting heat to water and steam.
The difference between energy input and output is
the sum of the various energy losses from the
boiler. These are:
1) Dry flue gas loss. 𝑘𝑔
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑎𝑖𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑐𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛 ( )=
𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙
2) Evaporation of water formed due to 𝑂
[(11.6∗𝐶)+{34.8∗(𝐻2 − 2 )}+(4.35∗𝑆)]
hydrogen in fuel. 8
……(iii)
100
3) Moisture present in fuel.
4) Moisture present in air.
Where, C = percentage of carbon in fuel
5) Incomplete combustion.
H2= percentage of hydrogen in fuel
6) Radiation and Convection losses.
O2= percentage of oxygen in fuel
7) Loss due to unburnt fly ash.
S= percentage of sulphur in fuel
8) Loss due to unburnt bottom ash.
(B) THE MEASUREMENT OF BOILER 𝑂2 %
𝐸𝑥𝑐𝑒𝑠𝑠 𝑎𝑖𝑟 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 = ∗ 100 ……(iv)
EFFICIENCY STANDARDS 21−𝑂2 %

The two definitions of efficiency given above lead

(B) Loss due to Evaporation of Water
to two methods of measuring it:
formed due to Hydrogen in Fuel
1) By measuring input and output (this is called
the “Direct Method”) 9𝐻2 ∗{584+𝐶𝑝 (𝑇𝑓 −𝑇𝑎 )}
2) By measuring individual losses, totaling them 𝐿2 (%) = ∗ 100 ……..(v)
𝐺𝐶𝑉 𝑜𝑓 𝑓𝑢𝑒𝑙
and deducting the sum from 100%. (this is Where,
called the “Indirect Method”, but the terms Latent heat corresponding to partial pressure of water
‘losses method’ and ‘efficiency by difference’ vapour = 584 kcal/kg
are also used) H2 = kg of hydrogen present in fuel on 1 kg basis
It is now generally accepted that the indirect
method yields the more accurate results. It (C) Loss due to Moisture present in Fuel
identifies the loss areas which need attention
should a shortfall in efficiency below the expected 𝑀 ∗ {584 + 𝐶𝑝 (𝑇𝑓 − 𝑇𝑎 )}
𝐿3 (%) = ∗ 100 … … (𝐯𝐢)
value occur. Whereas the direct method needs to 𝐺𝐶𝑉 𝑜𝑓 𝑓𝑢𝑒𝑙
measure the output, which is around 80% of the (D) Loss due to Moisture present in Air
input, the indirect method only measures 20% of 𝐿4 (%) =
𝐴𝑐𝑡𝑢𝑎𝑙 𝑎𝑖𝑟 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑∗𝐻𝑢𝑚𝑖𝑑𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟∗𝐶𝑝 (𝑇𝑓 −𝑇𝑎 )
the input. A 1% error in the direct method therefore ∗ 100
𝐺𝐶𝑉 𝑜𝑓 𝑓𝑢𝑒𝑙
gives an error of 0.8 efficiency points, whereas a ………(vii)
similar error in the indirect method only gives an (E) Loss due to Incomplete Combustion
error of 0.2 efficiency points. The full analysis of 𝐿5 (%) = 𝑀𝐶𝑂 ∗ 5744 …….(viii)
the probability of errors occurring is much more Where, heat loss due to partial combustion of C = 5744
complex than this, but the basic principle is similar.
MCO = CO (in ppm) x 10-6 x Mf x 28 …….(ix)
MCO = CO formation Mf = fuel consumption in kg/hr
II. METHODOLOGY
(A) Dry Flue Gas Loss (%) (F) Radiation and Convection Loss
𝑇𝑓 −𝑇𝑎 (𝑇𝑠 −𝑇𝑎 )4
𝐿1 = 𝑚 ∗ 𝐶𝑝 ∗ (𝐺𝐶𝑉 ∗ 100 ……..(i) 𝐿𝑅&𝐶 = 0.548 ∗ [ ] + 1.957 ∗ (𝑇𝑠 − 𝑇𝑎 )1.25 ∗
𝑜𝑓 𝐹𝑢𝑒𝑙) 55.54 4
196.85∗𝑉𝑚 +68.9
√( ) ……(x)
68.9
Where, m= mass of dry flue gas formed due to
burning of 1 kg of fuel = Ts = boiler surface temperature; Vm = wind velocity
CO2 + SO2 + N2 + {O2 in flue gas} + {N2 in actual air 𝐿𝑅&𝐶 ∗𝐴𝑟𝑒𝑎 𝑜𝑓 𝑏𝑜𝑖𝑙𝑒𝑟
𝐿6 (%) = …..(xi)
supply} 𝐺𝐶𝑉 𝑜𝑓 𝑓𝑢𝑒𝑙∗𝐹𝑢𝑒𝑙 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒
Tf = temperature of flue gas at air pre-heater outlet
Ta = ambient temperature (G) Loss due to Unburnt Fly Ash
GCV = gross calorific value of fuel (coal) 𝐿7 (%) =
𝑇𝑜𝑡𝑎𝑙 𝑓𝑙𝑦𝑎𝑠ℎ 𝑐𝑜𝑙𝑙𝑒𝑐𝑡𝑒𝑑 𝑝𝑒𝑟 𝑘𝑔 𝑓𝑢𝑒𝑙 𝑏𝑢𝑟𝑛𝑡∗𝐺𝐶𝑉 𝑜𝑓 𝑓𝑙𝑦𝑎𝑠ℎ
CO2, SO2, N2 = mass of CO2, SO2, N2 formed due to ∗ 100
𝐺𝐶𝑉 𝑜𝑓 𝑓𝑢𝑒𝑙
burning of 1 kg of fuel ………(xii)
(H) Loss due to Unburnt Bottom Ash 𝐿8 (%) =
𝑇𝑜𝑡𝑎𝑙 𝑏𝑜𝑡𝑡𝑜𝑚 𝑎𝑠ℎ 𝑝𝑒𝑟 𝑘𝑔 𝑓𝑢𝑒𝑙 𝑏𝑢𝑟𝑛𝑡∗𝐺𝐶𝑉 𝑜𝑓 𝑏𝑜𝑡𝑡𝑜𝑚 𝑎𝑠ℎ
𝐴𝑐𝑡𝑢𝑎𝑙 𝑎𝑖𝑟 (
𝑘𝑔
) = (1 +
𝐸𝐴
) ∗ 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑎𝑖𝑟..(ii) ∗ 100
𝑘𝑔 𝑜𝑓 𝑓𝑢𝑒𝑙 100 𝐺𝐶𝑉 𝑜𝑓 𝑓𝑢𝑒𝑙
………(xiii)
Where, EA = excess air supplied
III. RESULTS AND DISCUSSIONS of boiler, and hence powerplant output. The majority of
the loss occurs due to dry flue gas (6.79%), hydrogen
(A) Input Sheet
in the fuel (4.50%), fly ash (8.33%). Thus as evident
Boiler efficiency calculation data Units
Ms = mass of steam/ day 3989.000 TPD the losses occur due to very inferior grade of fuel supply
as well as the non ability of the boiler to burn the fuel to
Hs = Enthalpy of steam in 833.000 Kcal/kg °C
kcal/ kg C the optimum required level. This is a matter of huge
concern as in total the plant thus incurs huge monetary
Hw =Enthalpy of feed 4040.000 Kcal/kg °C
losses due to this loss in efficiency.
water
Mf = Mass of fuel per day 1157.000 TPD
GCV = Gross Calorific 2440.000 Kcal/kg °C IV.CONCLUSION
value in Kcal/kg C The quantity of flue gases should be maintained at
Air supplied per hr 206.000 TPH minimum possible by good combustion control and
Mf = Mass of flue gas 6.550 T/T of fuel elimination of unwanted air infiltration through the boiler
Cp = Sp. Heat of flue gas 0.230 Kcal/kg °C enclosure by good maintenance.
Tf = Flue gas tem. 150.000 °C The heat loss to unburnt combustibles in the ash and grit
Ta = Amb. Tem. 40.000 °C may be high due to either high ash content or a very high
Cp = Sp heat of saturated 0.450 Kcal/kg °C carryover of particulates of high carbon content into the
steam boiler, as experienced with spreader stokers and fluidised
Humidity Factor 0.018 Kg/kg of beds. Some reduction of this loss can be obtained by
air
% C in ESP Ash 3.030 %
refiring of the grits from the boiler hoppers into the
furnace to burn off some of the remaining carbon. Coarse
% C in APH Ash 1.560 %
material from first stage is to be refired but complete
% C in BED Ash 0.500 %
refiring is to be prevented.
% Fixed C in Fuel 16.000 % As the output from a boiler reduces below the design of
% VM in Fuel 19.000 % 100% the values of the losses vary and will result in a
M = Moisture % 5.270 % change of boiler efficiency. The effects are:
% Ash in Fuel 58.000 % (a)The flue gas temperature will fall, giving a reduction
% Carbon 25.000 % of the dry flue gas and moisture losses.
(b)Excess air in the combustion chamber, and hence
% Hydrogen 1.930 %
oxygen content in the flue gases, will increase, thus
% Nitrogen 1.700 % increasing the dry gas and moisture in air losses.
% Sulphur in Fuel 1.000 % (c)The radiation loss will increase as a percentage of the
% Oxygen in Fuel 12.000 % heat input.
(d)The unburnt combustible loss may change depending
% O2 in flue gas 6.000 % upon the fuel and firing system.
Tf - Ta 110.000 °C Since size will be a factor,
ESP Flue Gas Inlet Temp. 160.000 °C for large boilers the efficiency may
Pressure Drop across ESP 15.000 mmWC peak at a load below 100%
From the provided data : maximum continuous rating
Efficiency (direct)=Ms.(Hs-Hw)/Mf.GCV = 85.20% (MCR).
Efficiency (indirect) = 80.05%
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(B) Boiler efficiencies of other Plants
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