Boiler-1 Aditya Cement Works Sept 21 09.09.

21
Date: Lab Report
A Boiler Parameters D Coal Analysis
Sl. No. Parameters Value UOM Sl. No. Particulars UOM Coal US IMP MOZAMBRB3 Total
1 Boiler O/L Steam generation 56583.3 kg/hr 1 Coal firing % 100 0 100
2 Boiler O/L Steam Pressure 65.00 kgf/cm2 2 Fixed Carbon % 51.48 55.57 51.48
3 Boiler O/L Steam Pressure 64.68 Bar(A) 3 Volatile Matter % 21.24 18.35 21.24
4 Boiler O/L Steam temp 495.00 Deg C 4 ASH % 25.88 24.30 25.88
5 Feed Water temp eco inlet 166 Deg C 5 Inherent Moisture % 1.40 1.78 1.40
6 Feed Water press eco inlet 84 kgf/cm2 6 Total moisture % 9.50 8.12 9.50
7 Feed Water press eco inlet 83 Bar(A) 7 Sulphur % 0.45 0.88 0.45
8 O2 in flue gas 6.5 % 8 GCV of Coal(ADB) K Cal/Kg 5665 5871 5665
9 Average flue gas temp APH outlet 125.00 Deg C
10 Ambient temp 25 Deg C
11 Humidity in air 0.0096 kg/kg of dry air

B Ash Details
Area % collection %LOI UOM Boiler Efficiency(Design) = 85.00 %
1 MDC %
2 APH % Boiler Efficiency by indirect method = #VALUE! % 82.7
3 ESP- I % 1) % Heat loss in dry flue gas ( L1) #VALUE!
4 ESP- II % 2) %Heat loss due to formation of water from H2 in fuel (L2) 3.16
5 ESP- 3 % 3) % Heat Loss due to moisture in fuel (L3) 1.14
6 ESP- 4 % 4) % Heat loss due to moisture in air ( L4) 0.08
7 Bottom ash % 10 % 5) % heat loss due to radiation 0.40
8 Fly Ash % 90 % 6) % heat loss due to unburnt in fly ash #VALUE!
9 Unburnt C in bottom Ash 3.50 % 7) % Heat loss due to unburnt in bottom ash #VALUE!
10 Unburnt C in fly Ash 25.00 % 8) Calcination Loss #VALUE!
9) Sensible Heat Loss- Fly ash #VALUE!
C Lime Details 10) Sensible Heat Loss- Bed ash #VALUE!
1 Lime stone cons. 0 MT 11) Sensible Heat Loss in Fly Ash due to lime stone #VALUE!
2 CaCO3 0 % 12) Sensible Heat Loss in Bed Ash due to lime stone #VALUE!
13) Sulphation Gain 0.30
14) Other losses ( CBD Loss Venting Loss etc.) 0.50

1751
Boiler-1 Aditya Cement Works Sept 21

ARB Method
Fixed Carbon % 47.25
Volatile Matter % 19.50
ASH % 23.76
Inherent Moisture % 1.29
Total moisture % 9.50
Sulphur % 0.45
GCV of Coal K Cal/Kg 5665.00

Steam Enthalpy = #VALUE! Kcal/kg

Feed Water Enthalpy = 166 Kcal/kg
Coal Consumption = #VALUE! kg/hr

Coal Qty Lime Qty Ash% Total Ash Lime/ Kg coal

#VALUE! 0.00 23.76 #VALUE! #VALUE!

Final Ash % #VALUE!

Boiler Efficiency By indierct method

Step-1 Find Theoretical Air Requirement

Theoretical air requirement for =[(11.61XC)+{34.78X(H2-O2/8)}+(4.35XS)]/100 kg/kg of fuel

complete combustion
=[(11.61X 53.02

= 6.458

Step 2 To find Excess air supplied

Actual O2 measured in flue gas = 6.5 %

% Excess air supplied (EA) = O2 X 100

21 - O2

= 6.5 X100/(21-

= 44.83 %

Step 3 To find actual mass of air supplied(AAS)

Actual mass of air supplied = {1+EA/100}Xtheorectical air

= {1+ 44.83

= 9.353 kg/kg of fuel

Step 4 To find actual mass of dry flue gas

Mass of dry flue gas consists of = Actual air supplied +1 kg fuel -(moisture +ash+hydrogen)/100

= 9.353 +1.00 -(

= #VALUE! kg/kg of fuel

Step 5 To find all loss

1) Heat loss in dry flue gas ( L1) = m X Cp X (Tf - Ta)

GCV of Fuel

= #VALUE! X

L1 = #VALUE! %

2) Heat loss due to formation of water from H2 in fuel (L2)

= 9 X H2 X {581+Cp(Tf - Ta)} X 100

GCV of fuel

= 9X 0.029

L2 = 3.16 %

3) Heat Loss due to moisture in fuel (L3)

= M X { 581 + Cp ( Tf - Ta ) } x 100
 GCV of fuel

= 0.0949506 X{ 581 + 0.45 (

L3 = 1.14 %

4) Heat loss due to moisture in air ( L4)

= AAS X humidity X Cp X ( Tf - Ta ) x 100

GCV of fuel

= 9.353 X

L4 = 0.08 %

5) Heat loss due to radiation (L5) = 0.40 %

L5 = 0.40 %

6) Heat loss due to unburnt in fly ash (L6)

% Ash in fuel = #VALUE!

Ratio of bottom ash to fly ash = 10 :
Unburnt carbon in fly ash = 25 %
Amount of fly ash in 1 kg of fuel = 0.9 X
= #VALUE! kg

Heat loss in fly ash = #VALUE! X

= #VALUE! Kacl/kg of fuel

% heat loss in fly ash = #VALUE! X100/

L6 = #VALUE! %

7) Heat loss due to unburnt in bottom ash (L7)

Unburnt carbon in bottom ash = 3.5 %

Amount of bottom ash in 1 kg of fuel = 0.1 X

= #VALUE! Kg

Heat loss in bottom ash = #VALUE! X

= #VALUE! Kcal/kg of fuel

% Heat loss in bottom ash = #VALUE! X

L7 = #VALUE!

8) Calcination Loss(L8) = lime stone rate X %CaCO3 X 426

GCV of Petcoke

= #VALUE! X 0
5200

L8 = #VALUE!

9) Sensible Heat Loss in Fly Ash

% Ash in fuel = #VALUE!
Ratio of bottom ash to fly ash = 10 :
Unburnt carbon in fly ash = 25.0 %
Amount of fly ash in 1 kg of fuel = 0.9 X
= #VALUE! kg/kg
Specific Heat of Ash = 0.22 Kcal/Kg Deg C
Fly ash Temp = 125.00
Ambient temp = 25
Loss L9 #VALUE!
10) Sensible Heat Loss in Bed Ash
% Ash in fuel = #VALUE!
Ratio of bottom ash to fly ash = 10 :
Unburnt carbon in fly ash = 4%
Amount of fly ash in 1 kg of fuel = 0.1 X
= #VALUE! kg/kg
Specific Heat of Ash = 0.22 Kcal/Kg Deg C
Fly ash Temp = 950.00
Ambient temp = 25
Loss L10 #VALUE!
11) Sensible Heat Loss in Fly Ash due to lime stone
Ratio of lime stone in Fly Ash 60
Fly ash due to lime = #VALUE! kg/kg
Specific Heat of Ash = 0.22 Kcal/Kg Deg C
Fly ash Temp = 125.00
Ambient temp = 25
 Loss L11 #VALUE!
12) Sensible Heat Loss in Bed Ash due to lime stone
Ratio of lime stone in Fly Ash 40
bed ash due to lime = #VALUE! kg/kg
Specific Heat of Ash = 0.22 Kcal/Kg Deg C
Fly ash Temp = 125.00
Ambient temp = 25
Loss 12 #VALUE!
13) Sulphation Gain (L13) = %Sulphur X 2X(56/64)X2146.8
GCV of Petcoke

= 0.0045 X 2 X (56/64) X 2146.8

5200

L13 = 0.33

14) Other losses (L14)

L14 = 0.50

Boiler Efficiency by indiect Method = 100-(L1+L2+L3+L4+L5+L6+L7-L8+L9+L10+L11+L12+L13+L14)

= 100-( #VALUE!
0.40
+
-
= #VALUE!

1) Calcination loss

Reaction Caco3 = cao + Co2

100 kg Heat used= 426 Kcal/kg caco3 56 kg 44 kg

2) sulphation gain cao + So2 + 1/2O2

56 kg 64 kg 16 kg

S + O2 = So2
32kg 32 kg 64 kg

1) Generation of So2/ kg of sulpher in fuel 2

2) CAO requirement/ kg of So2 0.8750
 Date: 0

Ultimate Analysis by Formula

Carbon % 53.02
Hydrogen % 2.92
Nitrogen % 1.71
Sulphur % 0.45
Ash % 23.76
IM % 1.29
Oxygen % 16.86
Total % 100.00
GCV of Coal 5200

61XC)+{34.78X(H2-O2/8)}+(4.35XS)]/100 kg/kg of fuel

+{34.78X( 2.92 - 16.86 /8)}+(4.35X 0.45 )]/100 kg /kg of fuel

6.5 )

A/100}Xtheorectical air

/100} X 6.458

kg/kg of fuel

l air supplied +1 kg fuel -(moisture +ash+hydrogen)/100

1.29 + #VALUE! + 2.92 )/100

kg/kg of fuel

x100

0.24 X ( 125 - 25 )X100

5200

2 X {581+Cp(Tf - Ta)} X 100

X{ 581 + 0.45X ( 125 - 25 )}X 100

5200

{ 581 + Cp ( Tf - Ta ) } x 100
 GCV of fuel

X{ 581 + 0.45 ( 125 - 25 )} X 100

5200

X humidity X Cp X ( Tf - Ta ) x 100
GCV of fuel

0.0096 X0.45( 125 - 25 ) X 100

5200

90

#VALUE! /100

25 X8084/( 100 -25 )

Kacl/kg of fuel

5200

#VALUE! /100

3.5 /100 X 8084/ ( 1 - 3.5 /100)

Kcal/kg of fuel

100/ 5200

1728

X 426

90

#VALUE! /100 Amb. Temp 37.32

Kcal/Kg Deg C

90

#VALUE! /100

Kcal/Kg Deg C

Kcal/Kg Deg C
 Kcal/Kg Deg C

L1+L2+L3+L4+L5+L6+L7-L8+L9+L10+L11+L12+L13+L14)

+ 3.16 + 1.14 + 0.08 +

+ #VALUE! + #VALUE! + ###
#VALUE! + ### + #VALUE! + ###
0.33 + 0.50 )

= Caso4
Heat gain= 2146.8 Kcal/ kg cao 136 kg