Burner type: Todd Dynaswirl

JOHN ZINK INTERNATIONAL LUXEMBOURG SARL Boilers: 6162

KOCH CHEMICAL TECHNOLOGY GROUP
Customer: Descon Ltd.
Site: Bosicor - Karachi
Comments: Rev. # Drawn By: Checked By: Date: Reference drawing: MBBP00044.
Original design 1 KW 24/12/2009 Datasheet No: MBBP00044.
Client Comments 2 KW 11-Jan-10 JZ Reference Job No: 15090080
Revised Pilot Details 3 KW 19-Apr-10 PO No: 0026106 Rev.1

Boiler Data FUEL GAS

Boiler Steam Rate @ MCR 57 T/hr Burner Heat Input (LHV basis) @ DESIGN 25.25 MW
Operating Steam Pressure 43.1 Barg Burner Heat Input (LHV basis) @ PEAK 23.85 MW
Steam Temperature 380 Deg C Burner Heat Input (LHV basis) @ MCR 21.5 MW
Feedwater Temperature 150 Deg C Burner Heat Input (LHV basis) @ TURNDOWN 2.53 MW

Gas Data
Fuel Gas
No. of Burners 6 Compositon (mol%)
No. of Boilers 3 H2 20
No. of Burners per boiler 2 C1 38
C2 15
Site Elevation 50 m C3 19
Air relative humidity (design) 90% % C4 8
Air humidity 0.068 kg moisture / kg air C5+ -
Combustion air temperature (at MCR) 50 Deg C CO2 -
Flue Gas Temperature 400 Deg C N2 -
H2S - -
Furnace Dimensions Others 0.0
Depth 6,885 mm Actual LHV 11,603 kcal/kg
Width 2,550 mm Actual LHV 12,446 kcal/Nm3
Height (average) 4,009 mm Mol weight 23.98
Relative Density (SG) 0.83 Air = 1
Furnace pressure @ MCR 306 mm H2O(g) Ideal Gas Density 1.07 kg/Nm3
Operating Temperature 25 °C
Flame Data Stoic. Air required 13.59 Vol / Vol
Flame Length at 0 % FGR 4.5 m Gas pressure at design 1.02 bar(g)
Flame Diameter at 0 % FGR 1.3 m

Guaranteed Emissions
NOx (20% H2) (30%-100% MCR)- gas / oil (*) <100 / < 675 mg/Nm3 3% O2 dry basis FUEL OIL
CO (30%-100% MCR) - gas / oil <100 / < 170 mg/Nm3 3% O2 dry basis Burner Heat Input (LHV basis) @ DESIGN 25.25 MW
Particulate (30-100% MCR) - gas / oil(*) <10 / < 300 mg/Nm3 Burner Heat Input (LHV basis) @ PEAK 23.85 MW
SOx (Oil) 5950 mg/Nm3 Burner Heat Input (LHV basis) @ MCR 21.50 MW
Burner Heat Input (LHV basis) @ TURNDOWN 6.31 MW

Oil Data
Fuel Oil
Ignitor Detail (wt%)
Ignitor model Hegwein ZXA Continious operation
Fuel to Ignitor FLARE GAS ActualLHV 10,000 kcal/kg
Heat input 120 kW Specific gravity @ 15.6°C 0.96 Water=1
Fuel pressure 10 mbarg Operating Temperature - Deg C
Fuel flow 15 Nm3/hr Stoic. Air required 13.75 Vol/Vol
Air pressure 10 mbarg Oil Pressure at design 12.0 bar(g)
Air flow 20 Nm3/hr Steam atomizing pressure (constant) 6.0 bar(g)
Pilot Ignition system YES Steam consumption (at design / turndown) 98 / 115 kg/hr
Pilot Flame Detection YES

NOTE: (*) Emissions guarantee for oil with max. 0.4%N, max 0.1%ash and max 3.5%S.
Fuel Oil Viscosity must be between 15-20 Cst at burner inlet. Page 1
 JOHN ZINK INTERNATIONAL LUXEMBOURG SARL
KOCH CHEMICAL TECHNOLOGY GROUP

Fuel Gas operation ONLY

DESIGN PEAK MCR TURNDOWN
Fuel Flow Data - LHV BASIS 117.4% 111% 100% 80% 60% 40% 12%
Heat Release Per Boiler 50.5 47.7 43.0 34.4 25.8 17.2 5.9 MW
Heat Release per Boiler 43,417,077 41,050,217 36,982,178 29,585,742 22,189,307 14,792,871 5,097,165 Kcal/hr
Fuel Flow to Boiler 3,497 3,306 2,979 2,383 1,787 1,192 411 Nm3/hr
Fuel Flow to Boiler 3,742 3,538 3,187 2,550 1,912 1,275 439 kg/hr
Heat Release per Burner 25.24 23.87 21.50 17.20 12.90 8.60 2.96 MW
Fuel flow per Burner 1,871 1,769 1,594 1,275 956 637 220 kg/hr
Fuel flow per Burner 1,749 1,653 1,489 1,192 894 596 205 Nm3/hr
LHV 11,603 11,603 11,603 11,603 11,603 11,603 11,603 kcal/kg

Fuel pressure @ burner inlet 1.41 1.23 1.02 0.70 0.50 0.38 0.15 bar(g)

DESIGN PEAK MCR TURNDOWN

Combustion Air Data 117.4% 111% 100% 80% 60% 40% 12%
Boiler Exit Gas Oxygen Level (dry basis) 1.9 1.9 1.9 1.9 2.4 3.9 6.0 %
Boiler Excess Air level 10% 10% 10% 10% 13% 23% 40% %
Excess Air Level 1.10 1.10 1.10 1.10 1.13 1.23 1.40 XS Air
Stoic Air Requirement 13.59 13.59 13.59 13.59 13.59 13.59 13.59 Vol/Vol
Combustion air flow to Boiler (with excess air) 67,458 63,781 57,460 45,968 35,416 25,700 10,080 kg/hr
Combustion air flow per Burner (with excess air) 33,729 31,890 28,730 22,984 17,708 12,850 5,040 kg/hr
Combustion air flow per Burner (with excess air) 26,147 24,721 22,271 17,817 13,727 9,961 3,907 Nm3/hr
Combustion air flow per Boiler (with excess air) 52,293 49,443 44,543 35,634 27,455 19,923 7,814 Nm3/hr
Combustion air flow per Boiler (NFPA Minimum) 11,136 Nm3/hr

Burner RDL 201 179 146 94 53 24 12 mm H2O(g)

Combustion Air Temperature 50 Deg C

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 JOHN ZINK INTERNATIONAL LUXEMBOURG SARL
KOCH CHEMICAL TECHNOLOGY GROUP

Fuel Oil operation ONLY

DESIGN PEAK MCR TURNDOWN
Fuel Flow Data - LHV BASIS 117.4% 110% 100% 80% 60% 40% 25%
Heat Release to Boiler 50.5 47.3 43.0 34.4 25.8 17.2 10.8 MW
Heat Release per Boiler 43,417,077 40,680,396 36,982,178 29,585,742 22,189,307 14,792,871 9,245,544 Kcal/hr
Fuel Flow to Boiler 4,342 4,068 3,698 2,959 2,219 1,479 925 kg/hr
Fuel Flow to Burner 2,171 2,034 1,849 1,479 1,109 740 462 kg/hr
HHV 10,000 10,000 10,000 10,000 10,000 10,000 10,000 Kcal/kg
Heat Release per Burner 25.24 23.65 21.50 17.20 12.90 8.60 5.38 MW

Fuel pressure @ burner inlet 12 10.1 7.6 5.4 4.1 3.0 2.1 bar(g)

DESIGN PEAK MCR TURNDOWN

Combustion Air Data 117% 110% 100% 80% 60% 40% 25%
Boiler Exit Gas Oxygen Level (dry basis) 2.7 2.7 2.7 2.7 3.2 4.8 6.1 %
Boiler Excess Air level 15% 15% 15% 15% 18% 30% 41% %
Excess Air Level 1.15 1.15 1.15 1.15 1.18 1.30 1.41 XS Air
Stoic Air Requirement 13.75 13.75 13.75 13.75 13.75 13.75 13.75 kg/kg
Combustion air flow to Boiler (with excess air) 68,653 64,326 58,478 46,782 36,002 26,442 17,925 kg/hr
Combustion air flow per Burner (with excess air) 34,327 32,163 29,239 23,391 18,001 13,221 8,962 kg/hr
Combustion air flow per Boiler (NFPA Minimum) 14,620 kg/hr

Burner RDL 235 210 171 110 62 28 18 mm H2O(g)

Combustion Air Temperature 50 Deg C

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