BOILER EFFICIENCY

Steam Output

Radiation Loss

Heat
Input

Second
Pass
ESP
Furnace

Heat Input is Pulverised Coal

Heat Output is Superheated Steam

Efficiency Calculations
Standard Applied

:- ASME Standard PTC 4.1

Calculation Method :- Loss Method

Losses calculated as percentage of INPUT as 100%

Losses in Boilers

Heat
Input

Second
Pass
Furnace

ESP

1) Loss due to dry flue gas = 4.928%

Losses in Boilers Contd.

Second
Pass

Heat
Input

Furnace

ESP

2) Loss due to Unburnt Carbon

= 0.331%

Losses in Boilers Contd.

Second
Pass

Heat
Input

ESP
Furnace

3) Due to Sen. Heat of Bottom Ash

= 0.071%

4) Due to Sen. Heat of Fly Ash

= 0.102%

Losses in Boilers Contd.

Second
Pass

Heat
Input

ESP
Furnace

5) Radiation Losses

= 0.200%

Losses Related to Coal &

Ambient Air Quality
6) Loss due to moisture in Fuel = 1.263%
7) Loss due to Hydrogen in Fuel = 5.537%
8) Loss due to Moisture in Air
9) Unaccounted Losses

Total Losses

= 0.074%

= 1.327%

= 13.83%

Data required for Boiler

Efficiency Calculations
Unit load
MW
FW Flow at Econ
0
inlet
T/hr Wet bulb Temp
C
0
Dry bulb Temp
C Barometric
Pressure
mmHg Total Coal Flow
T/hr Unburnt C in BA
% Unburnt C in
FA
% Radiation & Unaccounted Losses
%
% Fly ash to Total Ash
%
% Bottom ash to Total ash
%

Data required.2
Proximate Analysis of Coal
Moisture
%
%
% Volatile Matter
Fixed Carbon
%
Kcal/kg

Air Dry

As fired

% Ash
%
%
% Gross Cal. Value
Kcal/kg

Ave FG O2 APH in
Ave FG O2 APH Out
Ave FG
CO2 APH in
Ave FG CO2 APH Out Ave FG CO APH in
Ave FG CO APH Out
Ave. FG Temp APH in
Ave. FG Temp APH Out Air to APH in
Air APH out
Total Primary Flow Total Air Flow L
Total Air Flow R
Design Ambient / Ref air Temp

Calculations
Ultimate Analysis

As fired Basis

1. Carbon = (Fixed Carbon AD+0.9(Vol Matter AD-14))

*GCV AF/GCV AD
2. Sulphur = 0.4 * GCV AF/GCV AD
3. Hydrogen = Vol.Matter AD*(7.35/(Vol Matter AD+10)0.013)* GCV AF/GCV AD
4. Moisture = Moisture AF
5. Nitrogen = (2.1-0.012 * Vol.Matter AD)* GCV AF/GCV AD
6. Oxygen = 100-(Carbon+Hydrogen+Nitrogen+Ash
AD+Moisture AD)* GCV AF/GCV AD
7. Ash = Ash AF

and 8. Gross Cal. Value=GCV AF

Calculations .. Losses
Dry Gas Loss = Sensible heat of dry gas*100/(GCV
AF*4.186) %
Carbon in fuel
%
Sulfur in fuel
%
Carbon in ash / kg of fuel
kg/kg coal
Specific Heat of Gas
kg/kg C
Avg. Flue gas temp - APH Out
0C

CONTROLLABLE LOSSES 1
FOLLOWING LOSSES CAN BE CONTROLLED
1. LOSS DUE TO DRY FLUE GAS
THE DESIGNER GIVES THIS LOSS AT THE FLUE GAS
0

APH OUTLET TEMP OF 140 C

ANY INCREASE IN THE FGT MORE THAN 1400C WILL
BE RESULTING IN MORE LOSSES. THIS TEMP HAS TO
BE CONTROLLED BY PROPER CLEANING OF THE
FURNACE

CONTROLLABLE LOSSES 2a
LOSSES DUE TO THE UNBURNT COAL IN BOTTOM
AND FLY ASH.
LOSS DUE TO UNBURNT IN BOTTOM ASH
THE DESIGNER GIVES THIS %AGE AS MAX 4.8 %
ANY INCREASE IN THIS PERCENTAGE BEYOND THIS
WILL RESULT IN MORE LOSSES
IF UNBURNT IN BOTTOM ASH IS MORE, THE
CULPRIT IS THE COAL MILL, CHECK THE
FINENESS OF PULVERISED COAL. CHECK THE
% RETENTION ON 50 MESH. IT SHALL NOT
EXCEED 1%.

CONTROLLABLE LOSSES 2b
CHECK THE UNBURNT IN FLY ASH SAMPLE TAKEN
FROM THE FIRST HOPPER OF ESP/BF
AS PER THE DESIGNER IT SHALL NOT EXCEED 0.8%.
IF UNBURNT IN FLY ASH EXCEEDS 0.8% IT
INDICATES INCOMPLETE COMBUSTION DUE TO
LESS AMOUNT OF AIR
CHECK FOR O2 % AT THE APH FG INLET FOR 2.8%,
INCREASE IF NECESSORY TO 3.2%. AGAIN CHECK
FOR UNBURNTS IN FLY ASH. SIMULTANIOUSLY
CHECK FOR AIR LEAKAGES/INGRESS IN THE
SECOND PASS

Losses Calculations
Assumptions:1. Fly Ash is 80% of Total Ash.
2. Bottom Ash is 20% of Total Ash
3. Sulphur is 0.4% in Coal

DATA REQUIRED
Fuel Properties
Proximate Analysis of Coal
Air Dry Basis

As Fired basis

Moisture %

Moisture %

Ash %
Volatile Matter %
Fixed Carbon %
Gross Cal. Value %

Ash %
Volatile Matter %
Fixed Carbon %
Gross Cal. Value %

Data Required contd.

Unit load

MW

FW Flow at Econ inlet

Wet bulb Temp
Dry BulbTemp

T/hr
0

Barometric Pressure
Total Coal Flow

T/hr

Unburnt Carbon in BA

Unburnt Carbon in FA

Data Required Contd.

Ave FG O2 APH in

Ave FG CO2 APH in

Ave FG CO APH in Ave FG O2 APH Out

Ave FG CO2 APH Out

Ave FG CO APH Out

Air to APH in Temp Air APH out Temp

Total Air Flow L

Total Air Flow R

Ave. FG Temp APH in

Ave. FG Temp APH Out
Total Primary Air Flow

GCV Calculations for Coal

Calculations of GCV
As fired Basis
Coalsampleistakenasreceivedbasis,heatedfor
calculationof
A)TotalMoisturecontent

=TM%

Air Dry Basis

Thesampleisairdriedforremovalofsurface
moistureandburnedcompletelyfor
A)Inherentmoisturecontent
B)Ashpercentage

=M%

=A%

GCV Calculations for Coal Contd.

1) Useful Heat Value

= 8900 138(A%+M%) kcal/kg

2) Gross Calorific Value = (UHV + 3645 75.4 M%)/1.466

(Air Dry Basis)

Kcal/kg

3) Ash % (As fired basis) = [A %] (100 - TM%)/(100 M%) %

4) Gross Calorific Value = [GCVAD] (100 - TM%)/(100 M%)
(As fired Basis)
5) Net Calorific Value

Kcal/kg
= [GCV] 10.02M% Kcal/kg

Calculations
Weight of Dry Gas = (Ca+S/2.67-100*U)/(12*CO2out)
Ca = % Carbon in fuel (Ultimate Analysis as Fired)
S = % Sulfur in fuel (Ultimate Analysis as Fired)
A = % of Ash in fuel (Ultimate Analysis as Fired)
Unburned C in Ash = Pfa/100*Cfa + Pba/100*Cba
U = Carbon in ash / kg of fuel=A/100*Cash/(100-Cash)
CO2 Out = Avg. CO2 Flue Gas -APH Out
Sensible Heat Dry Gas = Wd*30.6(Tgo-Trai)