Boiler Efficiency Indirect Method - Fuel Oil EXAMPLE

Fuel Oil Boiler Efficiency Calculation - Indirect Method

The American Society of Mechanical Engineers (ASME) PTC-4-1 Standard for Power Test Code Steam
Generating Units Indirect Method for calculating boiler efficiency consists of subtracting from 100
percent the total boiler losses. This method was used to determine the boilers instantaneous efficiency
and is described below, including formulas used, input data source and justification for assumptions
made.

The following parameters were used for this calculation;

Parameter Value Unit Source
Boiler Operating Pressure 13 barg Field observation
Boiler Capacity 12 t Field observation
Boiler Type Industrial watertube
Radiation & convection heat losses 3.0 % Assumption
Flue Gas Excess O2 5.0 % FG Analysis (14/11/2019)
Flue Gas CO 0 ppm FG Analysis (14/11/2019)
Flue Gas CO2% 14 % FG Analysis (14/11/2019)
Flue Gas Temperature (post-eco) (Tf) 413 C
o
FG Analysis (14/11/2019)
Ambient air temperature (Ta) 30.7 oC FG Analysis (14/11/2019)
Type of fuel used SFO100 Provided by customer
Fuel Calorific Value (GCVfuel) 41,036 kJ/kg Provided by customer
Fuel Hydrogen Content 12.8 % Assumption
Feedwater conductivity (FWcond.) 14 µS/cm Provided by customer
Feedwater temperature (FWT) 105 oC Field observation
Boiler water enthalpy (BWenthalpy) 830 kJ/kg Steam tables
Boiler water conductivity (BWcond.) 5,143 µS/cm Provided by customer
Fuel consumption (mf) 653 kg/hr. Estimation
Average Steaming Rate (Steamout) 9,000 kg/hr. Based on steam flowmeter data
Total Steaming Rate 216,000 kg/day Assumption (steaming rate x 24)
Specific heat capacity of air (Cpair) 1.088 kJ/kg C o
Assumption
Specific heat capacity of water (Cp water) 4.186 kJ/kg C o
Constant
Stoichiometric air to fuel ratio for fuel type 14.6 kgair/kgfuel Assumption

(Gross) Boiler Efficiency = 67.6 %

The Indirect Method for calculation boiler efficiency is described below;

The % excess air (EA) supplied;

EA = 31.3 %

Actual mass of air supplied/kg of fuel (Actual Air Supplied – AAS);

Where;
Theoretical air = 14.6 kgair/kgfuel stoichiometric air to fuel ratio for fuel type
ASS = 19.2 kg
Boiler Efficiency Indirect Method - Fuel Oil EXAMPLE

Boiler Losses;

(i) Dry Flue Gas Losses - the sensible heat energy carried away by the dry flue gases

Where;
mASS+fuel = 20.2 kg ASS + mass of fuel supplied {ASS + 1}
Cpair = 1.088 kJ/kg oC Specific heat capacity of air

(i) Dry Flue Gas Losses = 20.44 %

(ii) Wet Flue Gas Losses - the heat loss due to evaporation of water formed due to H 2 in fuel

Where;
2453 kJ/kg oC Latent heat corresponding to partial pressure of water vapor
1.885 kJ/kg C
o
specific heat capacity of superheated steam
H2 = 12.8 Wt% (typical hydrogen content of fuel)

(ii) Wet Flue Gas Losses = 7.96 %

(iii) Heat loss due to evaporation of moisture in fuel - heat loss due to moisture present in the fuel

Where;
mfuelH2O = Moisture content of fuel %
Note: Heat loss due to moisture in fuel is negligible as is assumed to be 0% in this calculation.

(iii) Heat Loss Due to Moisture in Fuel = 0.00 %

(iv) Heat Loss Due to Moisture in Air

Where;
Humidity factor = Ambient air humidity in terms of kg/kg of dry air
Note: Heat loss due to moisture in air is negligible as is assumed to be 0% in this calculation.

(iv) Heat Loss Due to Moisture in Air = 0.00 %

(v) Heat loss due to incomplete combustion of fuel
Boiler Efficiency Indirect Method - Fuel Oil EXAMPLE

Where;
C = Mass of carbon in fuel (%)
%CO = % carbon monoxide in flue gas
5744 = heat loss due to partial combustion of carbon constant
Note: Heat loss due to incomplete combustion is negligible as is assumed to be 0% in this calculation.

(v) Heat Loss Due to Incomplete Combustion = 0.00 %

(vii) Heat loss due to radiation and convection losses

Assuming Radiation & Convection losses are 3.0 % of boiler capacity

Radiation & Convection Losses = 360 kg/hr.

(vii) Heat Loss Due to Radiation & Convection Losses = 4.00 %

(viii) Heat loss due to blowdown losses

mBBD = approximate blowdown rate based on valve size & boiler operating pressure (kg/s)
Note: Heat loss due to bottom blowdown is negligible as is assumed to be 0% in this calculation.
Heat Loss Due to Bottom Blowdown = 0.00 %

Heat Loss Due to Surface Blowdown = 0.04 %

(viii) Heat Loss Due to Blowdown Losses = 0.04 %

Having calculated the magnitude of all the losses, the boiler efficiency is calculated by summing the
losses and subtracting them from 100.

(Gross) Boiler Efficiency = 67.6 %

pressure temperature Hwater (hf) Hevap (hfg) Hsteam (hg) specific volume pressure temperature
bar °C kJ/kg kJ/kg kJ/kg m3/kg bar °C
0 100.00 419.06 2,257.00 2,676.00 1.673 0 100.00
0.5 111.61 468.30 2,225.60 2,693.90 1.149 0.5 111.61
1 120.42 505.60 2,201.10 2,706.70 0.881 1 120.42
1.5 127.62 536.10 2,181.00 2,717.10 0.714 1.5 127.62
2 133.69 562.20 2,163.30 2,725.50 0.603 2 133.69
2.5 138.99 584.88 2,147.26 2,732.14 0.522 2.5 138.99
3 143.75 605.30 2,133.40 2,738.70 0.461 3 143.75
3.5 148.02 623.69 2,119.83 2,743.52 0.413 3.5 148.02
4 151.96 640.70 2,108.10 2,748.80 0.374 4 151.96
4.5 155.55 656.30 2,096.70 2,753.00 0.342 4.5 155.55
5 158.92 670.90 2,086.00 2,756.90 0.315 5 158.92
5.5 162.08 684.60 2,075.70 2,760.30 0.292 5.5 162.08
6 165.04 697.50 2,066.00 2,763.50 0.272 6 165.04
6.5 167.83 709.70 2,056.80 2,766.50 0.255 6.5 167.83
7 170.50 721.40 2,047.70 2,769.10 0.240 7 170.50
7.5 173.02 732.50 2,039.20 2,771.70 0.227 7.5 173.02
8 175.43 743.10 2,030.90 2,774.00 0.215 8 175.43
8.5 177.75 753.30 2,022.90 2,776.20 0.204 8.5 177.75
9 179.97 763.00 2,015.10 2,778.10 0.194 9 179.97
9.5 182.10 772.50 2,007.50 2,780.00 0.185 9.5 182.10
10 184.13 781.60 2,000.10 2,781.70 0.177 10 184.13
10.5 186.05 790.10 1,993.00 2,783.30 0.171 10.5 186.05
11 188.02 798.80 1,986.00 2,784.80 0.163 11 188.02
11.5 189.82 807.10 1,979.10 2,786.30 0.157 11.5 189.82
12 191.68 815.10 1,972.50 2,787.60 0.151 12 191.68
12.5 193.43 822.90 1,965.40 2,788.80 0.148 12.5 193.43
13 195.10 830.40 1,959.60 2,790.00 0.141 13 195.10
13.5 196.62 837.90 1,953.20 2,791.10 0.136 13.5 196.62
14 198.35 845.10 1,947.10 2,792.20 0.132 14 198.35
14.5 199.92 852.10 1,941.00 2,793.10 0.128 14.5 199.92
15 201.45 859.00 1,935.00 2,794.00 0.124 15 201.45
15.5 202.92 865.70 1,928.80 2,794.90 0.119 15.5 202.92
16 204.38 872.30 1,923.40 2,795.70 0.117 16 204.38
17 207.17 885.00 1,912.10 2,797.10 0.110 17 207.17
18 209.90 897.20 1,901.30 2,798.50 0.105 18 209.90
19 212.47 909.00 1,890.50 2,799.50 0.100 19 212.47
20 214.96 920.30 1,880.20 2,800.50 0.099 4 20 214.96
21 217.35 931.30 1,870.10 2,801.40 0.090 6 21 217.35
22 219.65 941.90 1,860.10 2,802.00 0.086 8 22 219.65
23 221.85 952.20 1,850.40 2,802.60 0.083 2 23 221.85
24 224.02 962.20 1,840.90 2,803.10 0.079 7 24 224.02
25 226.12 972.10 1,831.40 2,803.50 0.076 8 25 226.12
26 228.15 981.60 1,822.20 2,803.80 0.074 0 26 228.15
27 230.14 990.70 1,818.30 2,804.00 0.071 4 27 230.14
28 232.05 999.70 1,804.40 2,804.10 0.068 9 28 232.05
29 233.93 1,008.60 1,795.60 2,804.20 0.066 6 29 233.93
30 235.78 1,017.00 1,787.00 2,804.10 0.064 5 30 235.78
31 237.55 1,025.60 1,778.50 2,804.10 0.062 5 31 237.55
32 239.28 1,033.90 1,770.00 2,803.90 0.060 5 32 239.28
33 240.97 1,041.90 1,761.80 2,803.70 0.058 7 33 240.97
34 242.63 1,049.70 1,753.80 2,803.50 0.057 1 34 242.63
35 244.26 1,057.70 1,745.50 2,803.20 0.055 4 35 244.26
36 245.86 1,065.70 1,737.20 2,802.90 0.053 9 36 245.86
37 247.42 1,072.90 1,729.50 2,802.40 0.052 4 37 247.42
38 248.95 1,080.30 1,721.60 2,801.90 0.051 0 38 248.95
39 250.42 1,087.40 1,714.10 2,801.50 0.049 8 39 250.42
40 251.94 1,094.60 1,706.30 2,800.90 0.048 5 40 251.94
41 253.34 1,101.60 1,698.30 2,799.90 0.047 3 41 253.34
42 254.74 1,108.60 1,691.20 2,799.80 0.046 1 42 254.74
43 256.12 1,115.40 1,683.70 2,799.10 0.045 1 43 256.12
44 257.50 1,122.10 1,676.20 2,798.30 0.044 1 44 257.50
45 258.82 1,228.70 1,668.90 2,797.60 0.043 1 45 258.82
46 260.13 1,135.30 1,666.60 2,796.90 0.042 1 46 260.13
47 261.43 1,142.20 1,654.50 2,796.60 0.041 2 47 261.43
48 262.73 1,148.10 1,647.10 2,795.20 0.040 3 48 262.73
49 264.00 1,154.50 1,639.90 2,794.40 0.039 4 49 264.00
50 265.26 1,160.80 1,632.80 2,793.60 0.038 6 50 265.26
51 266.45 1,166.60 1,626.90 2,792.60 0.037 8 51 266.45
52 267.67 1,172.60 1,619.00 2,791.60 0.037 1 52 267.67
53 268.84 1,178.70 1,612.00 2,790.70 0.036 4 53 268.84
54 270.02 1,184.60 1,605.10 2,789.70 0.035 7 54 270.02
55 271.20 1,190.50 1,598.20 2,788.70 0.035 0 55 271.20
56 272.33 1,196.30 1,591.30 2,787.60 0.034 3 56 272.33
57 273.45 1,202.10 1,584.50 2,786.60 0.033 7 57 273.45
58 274.55 1,207.80 1,577.70 2,785.50 0.033 1 58 274.55
59 275.65 1,213.40 1,571.00 2,784.40 0.032 5 59 275.65
60 276.73 1,218.90 1,564.40 2,783.30 0.031 9 60 276.73
61 277.80 1,224.50 1,557.60 2,782.10 0.031 4 61 277.80
62 278.85 1,230.00 1,550.90 2,780.90 0.030 8 62 278.85
63 279.89 1,235.40 1,544.30 2,779.70 0.030 3 63 279.89
64 280.92 1,240.80 1,537.30 2,778.50 0.029 8 64 280.92
65 281.95 1,246.10 1,531.20 2,777.30 0.029 3 65 281.95
66 282.95 1,251.40 1,524.70 2,776.10 0.028 8 66 282.95
67 283.95 1,256.70 1,518.10 2,774.80 0.028 3 67 283.95
68 284.93 1,261.90 1,511.60 2,773.50 0.027 8 68 284.93
69 285.90 1,267.00 1,501.10 2,772.10 0.027 4 69 285.90
70 286.85 1,272.10 1,498.70 2,770.80 0.027 0 70 286.85
71 287.80 1,277.30 1,492.20 2,769.50 0.026 6 71 287.80
72 288.75 1,282.30 1,485.80 2,768.10 0.026 2 72 288.75
73 289.69 1,287.30 1,479.40 2,766.70 0.025 8 73 289.69
74 290.60 1,292.30 1,473.00 2,765.30 0.025 4 74 290.60
75 291.51 1,297.20 1,466.60 2,763.80 0.025 0 75 291.51
76 292.41 1,302.30 1,460.20 2,762.50 0.024 6 76 292.41
77 293.91 1,307.00 1,453.90 2,760.90 0.024 2 77 293.91
 78 294.20 1,311.90 1,447.60 2,759.90 0.023 9 78 294.20
79 295.10 1,316.70 1,441.30 2,758.00 0.023 6 79 295.10
80 295.96 1,312.50 1,435.00 2,756.50 0.023 3 80 295.96
81 296.81 1,326.20 1,428.70 2,754.90 0.022 9 81 296.81
82 297.66 1,330.90 1,422.50 2,753.40 0.022 6 82 297.66
83 298.50 1,335.70 1,416.20 2,751.90 0.022 3 83 298.50
84 299.35 1,340.30 1,410.00 2,750.30 0.022 0 84 299.35
85 300.20 1,345.00 1,403.80 2,748.80 0.021 7 85 300.20
86 301.00 1,349.60 1,397.60 2,747.20 0.021 4 86 301.00
87 301.81 1,354.20 1,391.30 2,745.50 0.021 1 87 301.81
88 302.61 1,358.80 1,385.20 2,744.00 0.020 8 88 302.61
89 303.41 1,363.30 1,379.00 2,742.30 0.020 5 89 303.41
90 304.20 1,367.80 1,372.70 2,740.50 0.020 2 90 304.20
92 305.77 1,376.80 1,360.30 2,737.10 0.019 7 92 305.77
94 307.24 1,385.70 1,348.00 2,733.70 0.019 2 94 307.24
96 308.83 1,394.50 1,335.70 2,730.20 0.018 7 96 308.83
98 310.32 1,403.20 1,323.30 2,726.50 0.018 3 98 310.32
100 311.79 1,411.90 1,310.90 2,722.80 0.017 8 100 311.79
102 313.24 1,420.50 1,298.70 2,719.20 0.017 4 102 313.24
104 314.67 1,429.00 1,286.30 2,715.30 0.017 0 104 314.67
106 316.08 1,437.50 1,274.00 2,711.50 0.016 6 106 316.08
108 317.46 1,445.90 1,261.70 2,707.60 0.016 2 108 317.46
110 318.83 1,454.30 1,249.30 2,703.60 0.015 8 110 318.83
112 320.17 1,462.60 1,237.00 2,699.60 0.015 4 112 320.17
114 321.50 1,470.80 1,224.60 2,695.40 0.015 0 114 321.50
116 322.81 1,479.00 1,212.20 2,691.20 0.014 7 116 322.81
118 324.10 1,487.20 1,199.80 2,687.00 0.014 4 118 324.10
120 325.38 1,495.40 1,187.30 2,682.70 0.014 1 120 325.38