Ammonia ppm Water pH /Cond @ 25 'c

0.01 7.7/1
0.05 8.3/2.5
0.1 8.6/3
0.5 8.8/4.0
1 9.3/7
5 9.8/14
10 9.9/NA

1 ppm equalent to conductivity

Nacl 1.89
NH3 6
Morpholine 0.5
Hcl 10.7
H2So4 7.3
Na2So4 1.57
Pure water 0.056 at 25 "c

Po4 pH
1 9.02
2 9.32
3 9.5
4 9.62
5 9.72
6 9.8
7 9.87
8 9.93
9 9.98
10 10.02
11 10.06
12 10.1
 SISCOL, 2 X 30 MW CPP
CHEMICAL DOSING AND BOILER BLOW DOWN CALCULATIONS
pH correction dosing
Advantages
1 Location DM - MB outlet Boiling Boint of Morp is 130 "c. Deaerator loss shall be very low
Morpholine -
2 Dosing chemical Tetrahydro - 1,4 - Distribution ratio water to vapour is 1 : 0.4
oxazine
Chemical formula C4H8ONH (87.12) At Boiling point 130 "c Morp liquid change to Vapour phase (600 "c)

4 Reaction at aqueous solution O -(C2H4)2 - NH + H2O ->/<- O - (C2H4)2-NH2OH

O - (C2H4)2-NH2OH ->/<- O-(C2H4)2-NH2 + OH-

3 Flow - m3/hr 4 pH shall be maintained on Feed water as well as Drum
4 Running Hrs 20 No formation of Insoluble salts with Co2 in Steam circuit
Residual Morpline to be checked in DM water and Deaerator outlet
5 Dosing ppm 4
water (Before Hydrazene dosing)
6 Purity of Chemical % 100 Deaerator Temp is to be noted
7 Expected Qty per day Kgs/20 hrs 0.32
8 Morp dosing Tank cap Ltrs 280 400 Ltrs capacity
9 Dosing Pump cap ltrs/hr 12 15 LPH for 80 % 12 LPH
10 Pump operating stroke % 80
11 Sampling points DM Storage tank After Deaerator (FWST)
12 Residual level 2.5 2.5 - 3.0 ppm
13 Residual level in Sat steam (Morp) 1.00 Morp in FW = Mor in CBD + Morp in Sat steam
14 Residual level in Drum (Morp) 1.50
 Ammonia Cyclo hexananine
40 "c 145 "c

Water to Vapour 1:0.8 1:04

Ammonia Cyclo hexananine

Ammonia carbonate
Ammonia ppm Water pH /Cond @ 25 'c
0.01 7.7/1
0.05 8.3/2.5
0.1 8.6/3
0.5 8.8/4.0
1 9.3/7
5 9.8/14
10 9.9/NA

Risk
Ammonia with DO and Copper will under go Galvanic
corrosion, it may lead for Economiser tube failure.
(Copper condenser tubes)
pH "-Log (H+)
H2O >< H+ OH- total
10 min -7 10 min -7 10 min -14
Pwater

0.1 N Hcl pH ????

"- log 10 -1

1 log 10
pH 1

0.1 NaOH pH ???

"- log 10 -1 NaoH cons

log 14 -log 1 log10(base) 13
13
 SISCOL, 2 X 30 MW CPP
CHEMICAL DOSING AND BOILER BLOW DOWN CALCULATIONS
pH correction dosing

DO (LP) removal dosing

1 Location BFW suction

Hydrazene
2 Dosing chemical
Hydrate

3 Chemical formula N2H4.H20

4 Reaction at 200 "c N2H4 -> N2 + H2O

5 Reaction at above 325 "c (Drum) N2H4 -> NH3 (Partly)

4 Boiling point 325 "c

5 Conversion at low temp (250 "c) N2 + H2O

6 Conversion at elevated temp (350 "c) Ammonia

7 Feed water Flow - TPH 90

8 Running Hrs 24

9 DO In BFW suction ppb 20

10 Dosing ppm 120

11 Purity of Chemical % 80

12 Aviable hydrazene in chemical % 51.2

13 Expected Qty per day as hydrazene Kgs 259.2

Expected Qty per day as N2H4.H2O Kgs 518.4

14 LP dosing Tank cap Ltrs 325

 15 Dosing Pump cap ltrs/hr 12

16 Pump operating stroke % 80

Eco Inlet
17 Sampling Points (preferbly at Eco
outlet)

18 Residual level 0.03 - 0.04 ppm

Analysis

Reaction
Fe (0) metal + o + Water --> Fe (OH)2
FE (OH)2 ---> Fe2+ + 2 (OH-)
Fe 2+ ----> Corrosion metal (Fe (o) ----> Fe 2+ (Increasing oxidation number)
Fe2+ ---> Fe3+ + OH- ----> Fe (OH)3 -----> Fe2O3
If DO and NH3 and Cu avail
Reaction
Cu + O + NH3 ---> (Cu(NH3)4) 2 +
Fe + Cu2+ ----> Fe2+ + Cu (Galvanic corr)
An Ca Corrosion prof Metal
CPP
DOWN CALCULATIONS
ng
Advantages
ing
Advantages
Reaction time for DO Vs
Chemicals to be 0.86 mts
Baffle plate in
Deaerator SS will
Co2 removed by Mec Deae, be recommended
DO in DM water
Wheras O2 removed chemcial (If MS plate will be
would be 8 ppm
reaction their due to DO -
corrosion will
happen)

N2H4 -> N2 + H2O

N2H4 -> NH3 (Partly) Chemical Hydrazene hydrate Hydrazene

Online analyser cross cheked

by Saturated sodiumsulphite Molecular formula N2 H4.H20 N2H4
which will absorn entire o2 80 %
purity

Molecular weight 50 32
Avail Hydazene from
51.200
Hydrazene hydrate %
Required dosing level in
ppb (100+O2 in BFP 120.000
suction)

Feed water flow TPD 90

Qty of Hydrazene
hydrate @ 80 % Pty
Assumption 518.4
chemical required
ml/day
30 times greater than DO Max allowable limit in
7 ppb
(1:30) thumb FW

Max allowable limit in

0.007 ppm
FW

450 Ltrs capacity

 15 LPH for 80 % 12 LPH

Indirectly means that DO will

be 7 ppb/0.007 ppm
Sample to be taken before
BFP, After cheical dosing and
DO has to be checked in
Condensate also

ncreasing oxidation number)

0.123711 0.282062

0.082474 0.352577

0.1824

1.25

0.228
 SISCOL, 2 X 30 MW CPP
CHEMICAL DOSING AND BOILER BLOW DOWN CALCULATIONS
pH correction dosing
HP (TSP) correction dosing

1 Location Steam Drum

Tri Sodium
2 Dosing chemical
Phosphate
3 Chemical formula (Unhydrated) Na3Po4
Chemical formula (hydrated) Na3Po4.12H2O
4 Reaction at 350 "c Na3Po4 + H2O ->/<- Na2HP
For 88 KSC Dis Silica ratio (steam/Drum) only vapour
5 0.0030
carry over ppm

7 Considering Mech and Vapour carry ppm 0.0050

Total Silica in Sat steam 0.0080

8 Feed water flow TPH 90
9 Silica in Feed water mg/ltr 0.0050
10 Total Silica gm/hr 0.45
12 Recommended for operation (mg/ltr) 1.5
13 Blow down qty (TPH) 0.3
Residual level of Phosphate ppm 3
14 TSP dosing for residual PO4 (Na3Po4) 5.178947368421
15 Expected Blowdown/Day TPH 7.2
16 Chemical Qty gms (Unhydrated) 37.28842105263
17 Dosing Tank capacity 250
15 Dosing Pump cap ltrs/hr 30
16 Pump operating stroke % 35 (10.5 LPH)
17 Sampling Points CBD drain
19 Expected sodium level in drum ppm 2.178947368421
20 Expected sodium level in steam ppm 0.007263157895

21 Dryness factor 99.66666666667

Unhydrated
Pressure Silica ratio between steam & Drum Na3 po4
0 0 164
35 0.001
70 0.01
105 0.1
140 1
175
210
Why boiler pH decreases when Fe present in Feed water Ratio of Na : PO4
Fe Fe 2+ ----> Fe3+ + OH- (OH from TSP & water) Normal TSP
Fe(OH)3 ----> Fe2O3 (Rust) Coordinated
OH Na3Po4 + H2O ---> Na2HPo4 + NaOH Conguruant
TSP : DSP

Reaction in drum
Na3Po4 + H2O ---> Na2H Po4 (Low insoluble) + NaOH (pH response)

HideOut 1
pH >> Correnponding phosphate - means - Film type scale formation in tubes

Hideout 2
When unit tripping reverse reaction will happened - conversion of Po4 to TSP
pH <<< (No free hydroxide for pH)
ALCULATIONS

Advantages
CBD and HP dosing line are to be
anti position and CBD at bottom
of the drum
Hydrated TSP contains 17.50 %
P2o5 and Unhydrated contains
26.06 % P2O5
164
380
a3Po4 + H2O ->/<- Na2HPO4 + NaOH
Ref Distribution ratio of Silica
graph
Work sheet for Dryness factor
and mech carry over
it may maximum of 0.012 ppm
90000 Ltrs
0.0050 mg/ltr
450 mg/hr

gm/hr x ltr/mgm

(Na3Po4 :1.73 &

Na3Po4.12H2O :3.90)

To ensure the Dryness factor

Phosphate has to be checked in
Steam once in a shift Po4 pH
1 9.02
2 9.32
Hydrated 3 9.5
Na3 Po4.12 H2O 4 9.62
380 5 9.72
6 9.8
7 9.87
8 9.93
9 9.98
10 10.02
11 10.06
 12 10.1

3.10
2.8:1
2.6:1
2.0:1.0 (70:30)

ation in tubes

Po4 to TSP
COP GAS COST BF GAS COST
Coal GCV Kcal/kg
Coal consumed in AFBC 11824 MT BF GAS GCV Kcal/Nm3
Steam Generated in AFBC 68400 Coal equ to 1 Nm3 BF Gas Kg of coal
Coal to steam ratio 5.7848444 Cost of coal Rs/Mt
BF Gas cost Rs/Nm3
COP Based steam 68400
Expected coal consumption 11824
Rate of coal 3999
Gas cost 47284176
 4100
700
0.1707317
4000
0.6829268
 Calcuation of Dryness (Purity) of steam (min 98.5%)
Silica in saturated steam
due to vapour carryover
A (pressure)
Silca in Saturated steam
Silica in saturated steam
due to Mech caryover
B (Dryness)

Silica in Sat steam/Silica

A) Vapour carryover in Drum Ratio (refer graph)
For 90 KSC 0.003 Data
Silica in drum water
(Analysis) ppm 1.5 Ref
Hence, Silica in Sat Steam
ppm 0.0045

B) Mechanical Carryover
(Dryness factor) Via Po4 in Sat Steam/Po4 in
(Na,Po4) Drum water Via Analysis
Po4 in sat steam ppm 0.01 data
Po4 in Drum 3.00 data
Wetness % 0.33 %
Purity of Sat steam 99.67 %
For Silica 0.0050 ppm
Total Silica in Satutated
steam 0.0095 ppm
Feed water Flow/hr TPH 90 Ref
Feed water silica 0.0050 ref
Atemperation % feed
water 2 Data

Atemperation feed water 1.8 TPH

Silica in Main Steam 0.0094 ppm
Recommended CBD qty 0.3 TPH
Actual qty 0.5 TPH
Excess qty 0.2 TPH
Enthaply CBD Press & Temp 90 KSC 350 "C 800 kcal
Heat loss per day at 85 % Boiler Eff 4517647 Kcal
Coal GCV 4200 Rs/mt
Equalat Coal 1076 Kgs/day
Cost saving 4660 Rs/day
Annum 1700765 Rs/Annum
Zone Description Value
1 pH 1 to 8.3 Total Acidity Mineral acidity + CO2 acidity
1 to 4 Mineral acidity
4 to 4.5 Methyl orange end point
4.5 to 8.0 Co2 acidity
> 8.3 Phenolphthalen alkilinity

3.10 Red
Acid zone of
pH values

Mineral acids 4.00 Pink Methyl orange indicator range

4.60 Orange
5.00 No carbonate alkalinity
Range of most netural
(Natural waters)

Carbondioxide
Neturality

7.00 Bicarbonate alkalinity

7.80

Colur less 8.30 No CO2 & OH alk HPH indicator range

Alkaline zone of pH values

Bicarbonate and carbonate alk

9.40
No CO2 & Bicarbonate alk

Pink 10.00 Carbonate alk

11.00 Hydroxide alk

Calculation of Three forms of Alkalinity (as CaCo3)

OH Co3 HCo3
HPh 0 0 0 Total Alk
Hph < 1/2 TA 0 2HPh TA - 2Hph
Hph Equal 1/2 TA 0 2Hph 0
HPh > 1/2 TA 2HPh-TA 2(TA-HPh) 0
Hph equal TA TA 0 0
OH Co3 HCo3
TA 500 -100 600 0
Hph 200 400 100
Order of Insoluablity of

Cation
Ca>Mg>Na>K

Anion
Co3>So4>Cl>No3
 Total hardness 350 ppm CaCo3
Alkalinity 250 ppm CaCo3

Temp or Carbonate

Permet or Non cabon

If TH > ALK
Carbonate Hardness =
250
Alaklinity
Non Carbonate
100
hardness = TH - Alk

If TH < Alk
Carbonate Hardness = 0
Total hardness
Non Carbonate 0
hardness = TH - Alk

Case I
Combination Study of constituents
Value to be entered
Total Alkalinity 250 ppm CaCo3
Calcium hardness 120 ppm CaCo3
Magnesium hardness 48 ppm CaCo3
Total hardness 168 ppm CaCo3
Total Iron 0.1 ppm as Fe
Sulphates 15 ppm as Sulphate
Chlories 40 ppm as Cl
Nitrate 3.9 ppm as No3
Silica 15 ppm as SiO2
TDS at (180"c) 210 ppm

CATIONS ANI

Since all Ca & Mg combined with Co3 the

very trace the ramaining anions are calcul

a If Ca < Alkalinity All Calcium would be present as CaCo3

Calcium Carbonate 120 ppm CaCo3 a Na2So4

If TH < Alkalinity All Magnesium would be present as MgCo3, in

analysis report Mg is reported as CaCo3. To
convert Mg from CaCo3 to MgCo3 multiple by As per analysis
0.84
b
 Magnesium Carbonate 40.32 ppm MgCo3

The Value excess over the hardness indicates

the presence of Bicarbonates of Sodium and
potassium. Usually Potasium occurs in trace
and hence all the bicarbonates are calculated as
Alkalinity > Total NaHCo3
c hardness b NaCl
Excess Alkalinity 82 ppm CaCo3
Convert in to NaHCo3 68.88 ppm NaHCo3 As per analysis

c NaNo3

As per analysis

Cations balanced A

Note: The water sample doesn't contain iron if it is present it is to be calculated as Fe2O3
Silica exist in free state and it will be probable combination

Probable combinations
1 CaCo3 120
2 MgCo3 40.32
3 NaHCo3 68.88
4 Na2So4 22.19
5 NaCl 65.95
6 NaNo3 5.35
7 Sio2 15
8 Iron 0
9 Total 337.69

Conclusion
TDS (Lab analysis) 210
TDS(Combination
study) 338

Case II
Combination Study of constituents
Value to be entered
Total Alkalinity 350 ppm CaCo3
Calcium hardness 416 ppm CaCo3
Magnesium hardness 276 ppm CaCo3
 Total hardness 692 ppm CaCo3
Total Iron 0.1 ppm as Fe
Sulphates 47.2 ppm as Sulphate
Chlories 304 ppm as Cl
Nitrate 77 ppm as No3
Silica 100 ppm as SiO2
TDS at (180"c) 1290 ppm

CATIONS

Ca hardness equal to the alaklinity is present as

CaCo3 and the excess over the alk. Would be
If Ca > Alkalinity CaSo4
a
CaCo3
Calcium Carbonate 350 ppm CaCo3

CaSo4
Excess Alkalinity 66 ppm CaCo3
26.4 ppm Ca
Ca So4 CaSo4
40 96 136
As Ca 47.2 66.87 CaSo4
CaSo4 66.87
So4 47.2
Ca used for CaSo4
formation 19.67 Ca

Calcium remain after

formation of CaCo3 26.40 Ca
Calcium remain after
formation of CaSo4 6.73 Ca
CaCl2
Ca Cl CaCl2
40 70.9 110.9
6.73 18.67 CaCl2
CaCl2 18.67
Ca 6.73
Chloride used for
CaCl2 formation 11.93

Total Chlorinde avail in

water 304 Cl
Balance Chloride
available 292.07 Cl

MgCl2
 Magnesium hardness 276 CaCo3
Convert to Mg for MgCl2 66.24 Mg
Mg Cl MgCl2
24 70.9 94.9
66.24 261.924 MgCl2
MgCl2 261.924
Mg 66.24
Chloride used for MgCl2 formation 195.684

Chloride remaining after formation of CaCl2 292.07 Cl

Chloride used for MgCl2 formation 195.684 Cl
Balance chloride avail 96.38 Cl
NaCl
The balance chloride may be used only for NaCl
Cl Na NaCl
35.45 23 58.45
96.38 158.91 NaCl
NaNo3

No3 Na NaNo3
62 23 85
77 105.565 NaNo3
Fe2O3
Fe O2 Fe2O3
55.9 48 103.9
0.1 0.19 Fe2O3

Note:
Silica exist in free state and it will be probable combination

Probable combinations
1 CaCo3 350
2 CaSo4 66.87
3 CaCl2 18.67
4 MgCl2 261.924
5 NaCl 158.91
6 NaNo3 105.56
7 Sio2 100
8 Fe2O3 0.19
9 Total 1061.94

Conslusion
TDS (Lab analysis) 1290
TDS(Combination
study) 1262 200 Hydration of Ca & Mg Cl2)
 ANIONS (So4,Cl and No3)

Mg combined with Co3 the Anions avail for combination of Na & K. As indicated K is
amaining anions are calculated in combination with Na only

So4 Na Na2So4
96 46 142

15 22.19 Parts of Na2So4

Cl Na NaCl
35.45 23 58.45
40 65.95 Parts of NaCl

No3 Na NaNo3
62 23 85
3.9 5.35 Parts of NaNo3
Anions balanced
Sl/No From Value To Value Multiple by Result 1 Result 2

1 CaCo3 50 Ca 25 0.5 25 50

2 Ca CaCo3 2.5 0 0

3 CaCo3 Mg 0.24 0 0

4 Mg CaCo3 0.84 0 0

5 CaCo3 NaHCo3 0.84 0 0

6 CaCo3 Co3 0.6 0 0

7 Co3 CaCo3 1.66 0 0

8 Co3 MgCo3 1.4 0 0

9 Co3 NaHCo3 1.4 0 0

10 Ca CaSo4 3.4 0 0

11 So4 CaSo4 1.42 0 0

12 Mg MgSo4 5 0 0

13 So4 MgSo4 1.25 0 0

14 K Na2So4 3.09 0 0

15 So4 Na2So4 1.48 0 0

16 Ca K2So4 2.23 0 0

17 Cl K2So4 1.81 0 0

18 Mg CaCl2 2.77 0 0

19 Cl CaCl2 1.56 0 0

20 Na MgCl2 3.95 0 0

21 Cl MgCl2 1.34 0 0

22 Na NaCl 2.54 0 0

23 Cl NaCl 88.62 1.65 0 53.709091

24 K KCl 1.91 0 0

25 Cl KCl 2.1 0 0

26 Ca Ca(No3)2 4.1 0 0

27 No3 Ca(No3)2 1.32 0 0

28 Mg Mg(No3)2 6.17 0 0

29 No3 Mg(No3)2 1.19 0 0

30 Na NaNo3 3.69 0 0

31 No3 NaNo3 1.37 0 0

 32 K NaNo3 2.59 0 0

33 No3 KNo3 1.63 0 0

34 N No3 4.43 0 0

35 No3 N 0.23 0 0

Sl/No Ion Mg/l to Meg/l Meg/l to Mg/l

1 Na 0.04349 22.9
2 K 0.02557 39.1
3 Ca 0.0499 20.04
4 Mg 0.08226 12.16
5 Ba 0.1456 68.67
6 Sr 0.02283 43.81
7 Zn 0.0306 32.68
8 Cu 0.03148 31.77
9 Pb 0.009653 103.6
10 Ni 0.03407 29.36
11 Fe 0.03581 27.92
12 Mn 0.0364 27.47
13 Al 0.1112 8.994
14 Fe 0.05372 18.62
15 Cr3+ 0.0577 17.33
16 Mn 0.07281 13.73
17 Cr6+ 0.1154 8.666
18 F 0.05264 19
19 Cl 0.02821 35.45
20 Br 0.01251 79.91
21 I 0.00788 126.9
22 No2 0.02174 46.01
23 No3 0.01613 62
24 HCo3 0.01639 61.01
25 OH 0.0586 17.01
26 Co3 0.03333 30
27 So3 0.02498 40.03
28 So4 0.02082 48.03
29 S 0.06238 16.03
30 Cro4 0.01724 58
31 Po4 0.03459 31.66
 PERIODIC CHART OF THE ELEMENTS

1 2 3 4 5 6 7 8 9 10

I-A II - A III - B IV - B V-B VI - B VII - B VIII

H1

Li 3 Be 4

Na 11 Mg 12

K 19 Ca 20 Sc 21 Ti 22 V 23 Cr 24 Mn 25 Fe 26 Co 27 Ni 28

Rb 37 Sr 38 Y 39 Zr 40 Nb 41 Mo 42 Tc 43 Ru 44 Rh 45 Pd 46

Cs 55 Ba 56 La 57 Hf 72 Ta 73 W 74 Re 75 Os 76 Ir 77 Pt 78

Fr 87 Ra 88 Ac 89 Rf 104 Db 105 Sg 106 Bh 107 Hs 108 Mt 109 Uun 110

Actinnide Lanthaanid
e series

Ce 58 Pr 59 Nd 60 Pm 61 Sm 62 Eu 63
series

Th 90 Pa 91 U 92 Np 93 Pu 94 Am 95
T OF THE ELEMENTS

11 12 13 14 15 16 17 18

I-B II - B III - A IV - A V-A VI - A VII - A In Gas

He 2

B5 C6 N7 O8 F9 Ne 10

Al 13 Si 14 P 15 S 16 Cl 17 Ar 18

Cu 29 Zn 30 Ga 31 Ge 32 As 33 Se 34 Br 35 Kr 36

Ag 47 Cd 48 In 49 Sn 50 Sb 51 Te 52 I 53 Xe 54

Au 79 Hg 80 Ti 81 Pb 82 Bi 83 Po 84 At 85 Rn 86

Uuu 111 Uub 112 Uut 113 Uuuq 114 Uup 115 Uuh 116 Uus 117 Uuo 118

Gd 64 Tb 65 Dy 66 Ho 67 Er 68 Tm 69 Yb 70 Lu 71

Cm 96 Bk 97 Cf 98 Es 99 Fm 100 Md 101 No 102 Lr 103

Sl/No Description

1 ACIDITY

2 ALKALINITY

Phenopthalien Alkalinity

Methyl orange Alkalinity

Key Points

3 Total hardness
 Meaning
Carbon dioxide and Mineral acids (Sulphuric and weakly disaccoaite acids). Iron
& Aluminium salts hydrolyse in water to release mineral acidity
Analysis against : 0.02 N Sodium hydroxide (1 ml of 0.02 N NaOH is equal to 1
ppm as CaCO3)
NaOH volume required for up to pH 4.5 is (Methyl orange) mineral acidity
Volume required for pH 8.3 (Phenopthalein) is called toal acidity (Co2)

Presence of Bicarbonate (HCo3),Carbonate(Co3) and Hydroxide(OH)

compounds of Ca,Mg,Na and K

Carbonate or Hydroxide or both alkalinity

One of the above Alk or Hydroxide & Carbonate together, or Carbonate &
Bicarbonate together

OH Alkalinity and HCo3 Alkalinity does not exist.

OH,Co3,HCo3 alkalinities can't exist together

Carbonate or Temporary Hardness -> HCo3 of Ca & Mg

Non carbonate or Permenant Hardness -> So4,Cl,No3 of Ca,Mg
Sl/No Reg Name Organisation
1 Water specialest Mr.Janakiraman Ganesh consultancy
Dr.Roy Thermax
Dr.Ram Sasai paper board

2 Coal Specilist Dr.Roy Inspectorate

Dr.Ram Sasai paper board
Ramakrishna CFRI

3 Cooling water Mr.C.S.Murthy Ion exchnage

Mr.Sanakaraman Thermax
Mr.Sundarajan Ion exchnage
Mr.Sunil Ion exchnage
Mr. Beds ltd
Mr.Siva Nalco (Chemline)
Mr.Puruthoman Sicagen
4 WHRB Mr.Ramakrishan CVL
Mr. Thermal system
5 Boilers Mr.Parhtiban
Mr.Janakiraman
6 Flue gas Mr.Sekar Nevco
Bala krishnan/Selva sri Nawal Ana Lab

7 Chemicals
8 DM Plant
9 Pretretment
10 RO Mr.Gurumurthy
11 UF Mr.Rajesh

12 Procedures
13 Refractories
14 Chlorine Mr.Jangannarayann 9840029244
Mr.Nazar 9840378508
Mr.Lathesh 9841327642

15 ISO Mr.Ramanathan

16 Analysis Mr.Anand ITTA Lab,Salem

17 Flow measuement Mr. Krishnan, Sr.manager Arudhara,chennai

18 Cladding for coolers Mr.M.suburamaniyan Arudhara,chennai
Contact number E Mail
9345499976

9840962032

9391674249
9325357466
9380354239

9443740080
9444427976

04344-329718 9894785841

9843260750 0427-2319264

445550110
9445003620
 TPH Press KSC Temp Enthp M.Kcal
Return condensate 98 90 90 8820
makeup water 2 45 45 90
Expected steam req 8 140 1120
Net Heat Avail 10030

Net Heat required at FW tank 108 0.3 145 145 15660

Source charactertics 3.12 181 673 673

Heat Enegry reqiuired 5630

Soruce enthp 673
Steam req TPH 8.3655275
 EFFICIENCY CALCULATION BY LOSS METHOD

27.09.07

PARAMETER UNIT VALUE

BOILER PARAMETERS
Day's av.power generation MWh 0.00
Day's av steam pressure kg/ cm2 0.0
Day's Av. Steam temperature deg C 0.0
Day's Av. FW temperature at eco inlet deg C 0.0
day's run hour hr 24.00
Day's av bed temp deg C 920
Day's av flue gas temp at APH o/l deg C 124
Amb. Temp deg C 31

FUEL ANALYSIS
Carbon % 78.99
Hydrogen % 6.05
Nitrogen % 1.41
Sulphur % 1.00
Oxygen % 12.56
Ash % 15.1
Moisture % 17.3
G.C.V (As fired) kcal/ kg 5200
FLUE GAS
O2 % 7.00
CO2 % 12.0
N2 % 81.0
LOI
Bed ash % 0.25
BB % 10.90
Eco % 10.62
APH % 8.80
ESP 1 % 20.77
ESP 2 % 19.07
ESP 3&4 % 16.52

CALCULATION
LOSS ON IGNITION % by weight
Bed ash % 0.03
BB % 2.73
Eco % 0.53
APH % 0.44
ESP 1 % 8.31
ESP 2 % 1.91
ESP 3&4 % 0.83
Total % 14.00
Carbon Loss % 3.81
Solid carbon loss % 2.46
Excess air % 48.67
Min. air reqd for combustion kg/kg 10.40
Total wet air reqd for combustion kg/kg 15.66
Total dry air reqd for combustion kg/kg 15.46
Total wet flue gas produced kg/kg 16.49
Total dry flue gas produced kg/kg 15.76
Sensible heat loss in flyash % 0.06
Sensible heat loss in bedash % 0.06
Loss due to moisture in air % 0.12
Loss due to moisture and Hydrogen in
% 8.59
fuel
Dry flue gas loss % 7.30
Radiation loss % 0.75

BOILER EFFICIENCY % 79.30

Direct Method
Steam (Compensated) T/day 2222.00

644
Enthapy diff kcal
Coal MT 366.00
GCV (ARB As fired) Kcal/Kg 5200.00
Eff % % 75.19

Steam fuel ratio Enthap 0.123846153846154

1 kg of steam required 0.123846153846154
1 MT 123.846153846154
2400 Mt required 297230.769230769
297.230769230769
Boiler Efficinety 75.19
Actual coal requirement 395.306249808178
Special calculations
Plant eff 860/SHR %
SHR THR/Boil Eff Kcal/Kwhr
SCC THR/Boil Eff * GCV
SCC SHR/GCV 0.65
SHR SCC* GCV 2762.5
 5720200
238341.66667
66.206018519
 350 Coal
Kju/kg 14.00 LOI
33822.88 8080 GCV of pure carbon
1131.2 GCV of Ash kcal/kg
52.92 MT of Ash
52920 kg of Ash
59863104 kcal/ total kg of Ash
5500 kcal/kg coal
10884.200727 Ewq coal kgs
10.884200727 Eq MT of coal

3.1097716364 % of coal

Excess air
50

mt coal/hr 14.166666667 49.00 kg/sec

mt/hr 215.9 2940 kg/mnt
kg/hr 215900 176400 kg/hr
39500

This at 520 "c and 76 kg/cm2 pressure (Lower

pressure maintained due to circulation rate)

Kg of coal
kgs
kgs/day
MT/day
%
MT/day
 POWER COST CALCULATIONS (WITH BLENDED COAL)
Sl/No Description Unit JSW Rengaraj
1 Blending ratio 75 25
2 Total Mositure % 25 5.46
3 Initial Moisture % 12 0.93
4 Ash % 16 15.85
5 VM % 36 26.54
6 GCV (ADB) Kcal/kg 6000 6250
7 AFT "c 1250 1000
8 Sulphur % 0.8 0.85
9 Lnaded cost Rs/MT 4230 0
10 FC % 36 56.68
11 GCV (ARB) Kcal/kg 5265 6188.4625
12 FC/VM ratio % 1 2.135644310475
Result
1 Total Mositure % 20.115 OK
2 Initial Moisture % 9.2325 OK
3 Ash % 15.9625 OK
4 VM % 33.635 Problem
5 GCV (ADB) Kcal/kg 4700 OK
6 AFT "C 1187.5 OK
7 Sulphur % 0.8125 OK
8 Landed cost Rs/Mt 3172.5 OK
9 FC % 41.17 OK
10 GCV (ARB) 5495.87 OK
11 FC/VM ratio Kcal/kg 1.28 OK
12 GCV/Cost ratio Kcal/Rs 1732.35 OK
Power Cost & Plant eff calculations
1 Expected steaming TPD 2149 Data
2 Enthalpy (Nett) (520 "c & 90 KSC) Kcal/Kg 680 Data
3 Boiler Eff % 0.78 Data
4 Specific steam consumption Mt/Kwhr 3.75 Data
5 Coal GCV (ARB) Kcal/Kg 5496
6 Expected coal consumption TPD 340.89
7 Cost of Coal Rs 1081474
8 Expected Power Generation Kwhr 573067
9 Expected Power cost (Direct) Rs/Kwhr 1.89
10 Specific coal consumption Kg/Kwhr 0.59
11 SHR kcal/kwhr 3269
12 Plant eff % 26.31
13 THR Kcal/Kwhr 2550
14 SCC Kg/Kwhr 0.59
15 Kcal equalent per Rs Kcal/Rs 1.7323454
16 Expected power cost (Indirect) Rs/kwhr 1.89
 Coal Analysis Report (Emprical Formula) Blenidng coal
SL.NO DESCRIPTION Unit RESULTS Remarks

1 Inherent Moisture % 7.98

2 Total Mositure % 16.44

3 Volatile Matter (proximate) % 37.12

4 Ash (proximate) % 13.72

5 Fixed Carbon (proximate) % 41.18

6 Sulphur (considering) % 0.8

7 GOD kcal/kg 6298.44

8 GCV (ADB) kcal/kg 5796

9 GCV (ARB) kcal/kg 5263

10 Carbon % 62.454

11 Hydrogen % 4.4964

12 Oxygen % -423.4951

13 Nitrogen % 2.6916
Ref ASME-PTC4.1,1964)
1 Total Moist % 20

2 IM % 10

3 Ash % 15

4 VM % 28.6

5 FC % 46.4

6 Sulphur % 0.6

1 Nitrogen % 1.757

2 Total Combustable (TC) % 75.000

3 VM as Combustable (V) % 38.133

4 Hydrogen as fired % 4.688

5 Total Carbon % 59.540

6 Carbon C % 58.940

7 Oxygen % 9.016
Common
Salt (Dry Matter soluble in Water
weight water other than Insoluble
basis) Cl- as Nacl NaCl matter Moisture %
 Coal Analysis reporting methods

Coal Analysis - Conversion from one to one

Sl/No Description uom DB ADB ARB
1 Total moisture % 8.5
2 Inherenet moisture % 0.95
3 Ash % 18.65 18.47 17.06
4 Volatile matter % 25.82 25.57 23.63
5 Fixed Carbon % 55.53 55.00 50.81
6 Sulphur % 0.50 0.50 0.46
7 GCV Kcal/kg 5850 5794 5353

DB ADB ARB
100-IM/100 100-TM/100

ADB ARB DB
100-TM/100-IM 100/100-IM

ARB ADB DB
100-IM/100-TM 100/100-TM
g methods

rom one to one