Stoichiometry of Combustion

and
Boiler Efficiency Calculations
By

Dr. S. A. Channiwala
Professor,
Mechanical Engineering Department
S.V. National Institute of Technology
Ichchhanath, Surat, Gujarat
CONTENTS

INTRODUCTION

STOICHIOMETRY OF COMBUSTION

ESTIMATION OF BOILER EFFICIENCY BY DIRECT METHOD

ESTIMATION OF BOILER EFFICIENCY BY INDIRECT METHOD OR LOSS

METHOD AS PER BS-2885

BASIS OF THE METHOD

ESTIMATION OF VARIOUS LOSSES

ESTIMATION OF BOILER EFFICIENCY

NUMERICAL EXAMPLES

PACKAGE BOILER

UKAI THERMAL POWER STATION PULVERISED FUEL FIRED BOILER

GIPCL THERMAL POWER STATION CIRCULATING FLUIDISED BED

BOILER WITH LIMESTONE ADDITION

CONCLUSIONS
 INTRODUCTION

FUEL - A substance basically comprising of C, H, O, N and S, which on

combustion liberates heat with minimum emissions.
CALORIFIC VALUE :

Energy content of fuel per unit mass or unit volume of fuel.

UNITS : kJ/kg or kcals/kg for Solid & Liquids

:kJ/nm3 or kcals/nm3 for Gaseous Fuels

Gross calorific value or Higher Heating Value :

Amount of heat energy liberated per unit mass or unit volume with H2O
in its liquid state under standard conditions [25C, 1atm. pressure]

Lower Calorific Value/Lower heating value :

Amount of heat energy liberated per unit mass or unit volume with H2O
in its vapour form under standard condition [25C, temp. 1 atm.
pressure]
FOR CONSTANT VOLUME COMBUSTION :
Qvh = GCVv=c = LCVv=c+ufg x mw
ufg = hfg –p.Vfg at 25C
= 2305 kJ/kg
mw = MC+9H, kg/kg of fuel
MC = Moisture, kg/kg of fuel
H = Hydrogen, kg/kg of fuel

FOR CONSTANT PRESSURE COMBUSTION :

Qph = Qpl + hfg . mw
GCVp=c = LCVp=c +hfg .mw
hfg = 2442.3 kJ/kg at 25C
mw = MC+9H
RELATION BETWEEN CONSTANT PRESSURE & CONSTANT VOLUME COMBUSTION
GCVp=c = GCVv=c +n.Ro.T
n = np - nr
= No. of Moles of Gaseous Product
- No. of moles of Gaseous Reactants
Ro = 8.314 kJ/kg mole- K
T = Temp. in K=298 K
 STOICHIOMETRY OF COMBUSTION
DATA :
Coal :
Ultimate analysis : Proximate : Analysis
C = 66.0 % FC = 50.19 %
H = 4.1 % VM=30.11 %
S = 1.7 % Ash = 7.7 %
O =7.2 % MC = 12.0 %
N= 1.3 %
MC = 12.0 % Excess Air= 40 %
Ash = 7.7 %
Gross CV=27 MJ/kg.

DETERMINE :-
(a) Theoretical Air Required
(b) Actual Air
(c) Composition of Flue Gas
(d) Density of Flue Gas at 0C & 25 C & at 160 C
(e) Adiabatic Flame Temperature

SOLUTION :-

1. Combustion of Carbon :
C  O2  CO2
12 kg 32 kg 44 kg
0.66 kg  1.76 kg 2.42 kg
2. Combustion Hydrogen :
1
H2  O2  H2O
2
2 kg 16 kg 18 kg
0.041 kg  0.328 kg  0.369 kg

3. Combustion of Sulphur :
S  O2  SO2
32 kg 32 kg 64 kg
0.017 kg  0.017 kg  0.034 kg

(a) Theoritical O2 Required :

O2 th  O2  c  O2  H  O2  s  O2 ] f
 1.76  0.328  0.017  0.072
 2.033 kg / kg of fuel
23 kg O2  77 kg N2  100 kg Air
2.033 kg O2  6.806 kg N2  8.839 kg of Air
 Theoretical air required for complete combustion is : 8.839 kg/kg of fuel

(b) Actual Air [40% excess] :-

O2  N2  Air
2.8462 kg  9.5284 kg  12.3746 kg
Air/Fuel = 12.3746 :1
 (c) Flue Gas Composition (With 40% Excess Air) :

Composition on Mol. Moles Composition on

Constituent Mass mass basis % Mass volume/mole
kg/kg of Basis %
fuel
Wet Dry Wet. Dry
Basis basis Basis basis
CO2 2.42 18.199 18.893 44
2.42/44=
12.253 13.042
0.055
{MC 0.12 - -
- - - -
{H2O 0.369 - -

H2O]fg 0.489** 3.677 0.00 18 0.02717 6.053 0.00

SO2 0.034 0.256 0.265 64 0.000531 0.118 0.126
O2]ex 0.8132* 6.115 6.349 32 0.02541 5.661 6.026
{N2}fuel 0.013
- - - - - -
{N2}air 9.5284

N2]fg 9.5414 71.753 74.492 28 0.34076 75.915 80.806

 mwet 13.2976
100.00 - 0.448871wet 100.00 -
kg/kg -

 mdry 12.8086
100.00 - 0.421701dry - 100.00
kg/kg
*2.8462-2.033 **0.12+0.369
 (d) Flue Gas Density :-

Meq  M x i i

(mol ) i (mol )
x i  Mole fraction   i

 (mol ) i y
Where ,
y   (mol ) i

mi
Now (Mol ) i 
M i
 mi 1   mi
 Meq   i M  y   Y
M
 i 


 mi  13.2976  29.6245 kg / kgmole
 moli 0.448871
Runiv 8314 [J / kgmole  K ]
 Req    280 .6456 J / kg  K
Meq 29.6245 (kg / kgmole )
P 1.0132  105
  2 5 C    1.2115 kg / m3
Req .T 280.6456  298
P 1.0132  105
&  0 C    1.3224 kg / m3
Req . T 280.6456  273
P 1.0132  105
&  1 6 0 C    0.8338 kg / m3
Req . T 280 .6456  433
Check : We know that
1 kg.-mole of any gas  22.4 m3 at 0 & 1 atm.
 0.448871  10.05471 m3
mass 13.2976
  C    1.3225 kg / m3
volume 10.05471

(e) Adiabatic Flame Temperature :-

GCV = LCV+mH2O. Levap

27000 = LCV+0.489 x 2305

LCV = 25872.86 kJ/kg

25872.86 = 13.2976 x 1.25 x (Tad-25)

Tad = 1581.54C
Home Work Example :
The following data refers to a heavy oil fired in a boiler
C=85.4 % N=0.10 %
H=11.4 % MC=0.10 %
S=2.8 % Ash=0.10 %
O=0.1 % GCV=42.900 kJ/kg
Cpfg = 1.36 kJ/kg-K
It is operated at 25% excess air levels.
Determine :-
(i) Amount of air required per kg of fuel
(ii) Flue gas analysis on dry basis
(iii) Density of wet flue gas
(iv) Adiabatic flame temperature
 ESTIMATION OF BOILER EFFICIENCY
DIRECT METHOD :
1.2 Efficiency of Boiler :-
Output Qu
1.2.1 Def . b  
Input Qin
. .
Output  ms hs  mfw hfw  Qu, kW
Input  Qin  Fuel Energy  Auxiliary Energy Consumption
.
 mf . GCVf  E aux , kW
.
Usually E aux  mf .GCVf
Qu
 th  .
 100
mf .  GCVf
1.2.2 Estimation By Direct Method :
. . .
Qu  ms hs  mfw .hfw  ms (hs  hfw )
.
Qin  mf .GCVf
Qu
 th  x100
Qin
Qu
& overall  .
 100
(m . GCVf  Paux )
NUMERICAL EXAMPLE :
A two hour boiler trial was conducted on a coal fired, smoke-tube boiler in a process
house & the following data was collected.
Rating : Equivalent Evaporation = 5 T/h
Max. Pressure = 10.5 kg/cm2
Av. Steam Pressure during trial = 7.5 kg/cm2 (g)
Barometric Pressure = 1.0132 bar
Av. Steam temperature = 179C
O2 in flue gas (dry basis) = 6.2 %
Ambient temperature = 35C
Unburnt in Ash = 7.2 %
Size of feed tank = 2.5m  x 3.0 m
Depression of water level during trial = 1.87m
Temperature of feed water = 70C
GCV of fuel = 27000 kJ/kg
Coal consumption during trial = 1025 kg
Determine :-
(i) Boiler output in kW
(ii) Equivalent evaporation in T/h
(iii) Boiler efficiency, in %
 We know that,
SOLUTION :-
Qu
  x100
Qin
.
Qu  ms (hs  hfw )
.
Qin  mf  GCVf
Now Steam Generation  A  H]feed tan k   fw / t

 xD 2  H   fw / t
4
.

ms   (2.5)2 x1.87 x1000 / 2  3600
4
 1.2749 kg / s
Psg = 7.5 kg/cm2 (g) = 7.3575 bar
Psabs = Psg + Pb = 7.3575 +1.0132 bar
= 8.3707 bar
Corresponding to Psabs = 8.3707 bar from steam tables :-
At P = 8.2 bar tsat = 171.5 C hg=2770.2 kJ/kg
At p = 8.4 bar tsat = 172.5 C hg=2771.2 kJ/kg
 At p = 8.3707 bar tsat = 172.35 C hg=2771.05 kJ/kg
Now as ts =179C > tsat = 172.35C steam is superheated. From steam tables.
At p = 8.0 bar t = 200C hg = 2839.3 kJ/kg
P = 9.0 bar t = 200C hg = 2833.6 kJ/kg
At p = 8.3707 bar t = 200C hg = 2837.19 kJ/kg
At p = 8.3707 bar t = 172.35C hg = 2771.05 kJ/kg
 At p = 8.3707bar t = 179C hg = 2786.96 kJ/kg
(iii) hffw = ?
From steam table at tfw=70C, hfw=293 kJ/kg

.
 Qu  ms (hs  hfw )  1.2749 x (2786 .96  293)
 3179 .55 kW
.
(iv) Qin  mf xGCV p  c
GCVp  c  GCVV  C  nRoT
n  np  nr
 0.421701  0.42924
 7.539 x 10 3
GCVp  c  27000  7.539 x103 x 8.314 x298
 26981 .32 kJ / kg
1025
Qin  x26981 .32  3841 .09 kW
2 x3600
Q
(v ) Boiler Efficiency  b  u x100
Qin
3179 .55
 b  x100  82.777 %
3841 .09
 (vi) Equivalent Evaporation :
.
Qu  meq xLevap at 1 atm and 100 C
.
3179 .55  meq x2256 .9
.
meq  1.4088 kg / s  5.0717 T / h

(vii) Steam to Fuel Ratio

(vii ) Steam to Fuel Ratio :
. .
1.2749
ms / mf   8.955 kg / kg of fuel
0.14236

(viii) Specific Equivalent Evaporation :

.
meq
SEE  .
mf
1.4088
  9.896 kg / kg of fuel
0.14236
 :II: INDIRECT OR LOSS METHOD :
Estimation of Boiler Efficiency By Indirect Method . [BS-2885]
Es

.
E dfg
.
E H 2O
BOILER
.
E fw
.
.
E loss
Ea
.
Ef

. .
E bd E ash
 BASIS OF THE METHOD :

Applying Energy Balance on Boiler :-

. . . . . . . . .
E fw  E f  Ea  E s  E d fg  E H2O  E bd  E los s  E as h
. . . . . . . . .
 Ef  (E s  E fw )  (E d fg  E a)  E H2O  E as h  (E bd  E les s )
. . . . . . .
 E f  E u  (E dfg  E a )  E H2O  E as h  E un
.
Divide by E f
. . . . . .
Eu (E d fg  E a) E H2O E as h E un
1 .
 .
 .
 .
 .
Ef Ef Ef Ef Ef
Muliply by 100
. . . . . .
Eu (E dfg  E a) E as h E H2O E un
100  .
x100  .
x100  .
x100  .
x100  .
x100
Ef Ef Ef Ef Ef
This is the Basis of Loss or Indirect Method
 DETERMINATION OF VARIOUS LOSSES
1. Dry Gas Loss : [Stack Loss]
.
mdfg.Cpfg.(Tfg  Tamb )
Qdrylos s   100 %
GCVf
Usually Cpfg  1.030 kJ / kg  K
2. Losses in Ash

(a) Loss due to combustibles in Ash

mub  GCVub
Qub   100
GCVf
GCVub  33820 kJ / kg

(b) Sensible heat loss in Ash :

mas h  Cpas h  (Tas h  Tamb )

Qas h   100
GCVf
mas h  mub  mas h,f
Cpas h  0.84 kJ / kg  K
Tas h  627 .68 C
(3) Loss due to hydrogen in fuel :

{mH2O  [h] / GCVf }  100

h  4.2(25  Tamb )  2442 .3  1.88 x(Tfg  25) kJ / kg

(4) Loss due to moisture in fuel :

mMC .h
QMC   100
GCVf
(5) Unaccounted Losses :-
(i) Radiation loss = 0.3 to 1.0 %
(ii) Blow down loss=0.1 to 0.5 %
(iii) Loss due to unburnt gas  0.1 to 1.0 %

Total unaccounted losses =1.5 %

THUS

BOILER EFFICIENCY =100-SUM OF VARIOUS LOSSES

NUMERICAL EXAMPLE :
The following data refers to a boiler trial conducted on a 5 T/h, 10kg/cm2, coal fired smoke
tube type boiler :-
Duration of trial : 1 hour
Coal consumption : 510 kg/h
Stack Temperature : 210C
O2 in flue gas : 6.2 %
[By orsat apparatus ]
Ambient Temperature : 35 C
Unburnt in Ash : 7.2 %
Steam pressure : 7.5kg/cm2 (g)
Steam temperature : 179 C
Feed water Temperature : 70 C
Fuel Analysis :
C=66.0 %, H=4.1 %, S=1.7 %, O=7.2 %, N=1.3%, MC=12.0%, Ash=7.7%
GCVf : 27000 kJ/kg
Determine :- (i) Various Losses,
(ii) Boiler Efficiency
(iii) Boiler Output
(iv) Steam generation in T/h
(v) Equivalent Evaporation in T/h
SOLUTION : Stoichiometry of Reactions :

Combustion of Carbon :
C  O2  CO2
12 kg 32 kg 44 kg
0.66 kg  1.76 kg 2.42 kg
Combustion of Hydrogen :
1
H2  O2  H2O
2
2 kg  16 kg 18 kg
0.041 kg  0.328 kg  0.369 kg
Combustion of Sulphur :
S  O2  SO2
32 kg  32 kg 64 kg
0.017 kg  0.017 kg  0.034 kg
O2  th  O2  c  O2  H  O2  s  O2 ] f
 1.76  0.328  0.017  0.072
 2.033 kg / kg of fuel
23 kg O2  77 kg N2  100 kg of Air
2.033 kg O2  6.806 kg N2  8.839 kg of Air
 FLUE GAS ANALYSIS

Constituent Mass Mol Mass Moles (wet) Moles % by Vol.

Kg/kg of fuel (dry) on Dry basis

CO2 2.42 44 0.055 0.055

(MC+ H2O) 0.489 18 0.02717 0.00 0.00

SO2 0.034 64 0.000531 0.000531

O2]ex 32 X 6.2

N2]f+N2]th [0.013+6.806]
28 0.243536 0.243536 -
= 6.819
N2]ex
28 3.762 X* -

N2]act 28

Air]th 8.839

Air]act
%Excess
Xwet 0.299067+4.
0.451525 100.00
Xdry 762X

* =79/21 by volume Xwet=Co2+MC+H2o+SO2+O2ex+N2act

Dry moles of flue gas  0.299067  4.762 X
% O2 6.2 X
   0.062
100 100 0.299067  4.762 X

X=0.02631 moles of excess O2

3.762 x =0.098978 moles of excess N2
Total moles of dry flue gas = 0.424355 moles
Total mass of dry flue gas = 12.8863 kg/ kg of fuel
 FLUE GAS ANALYSIS

Constituent Mass Mol Mass Moles (wet) Moles % by Vol.

Kg/kg of fuel (dry) on Dry basis

CO2 2.42 44 0.055 0.055 12.961

(MC+ H2O) 0.489 18 0.02717 0.00 0.00

SO2 0.034 64 0.000531 0.000531 0.1250

O2]ex 0.84192 32 0.02631 X=0.02631 6.2

N2]f+N2]th [0.013+6.806]
28 0.243536 0.243536 -
= 6.819
N2]ex 3.762
2.771384 28 -
X*=0.098978
N2]act 9.59038 28 0.342514 80.714

Air]th 8.839

Air]act 12.4653

%Excess 41.02%

Xwet 13.3753
0.451525 0.424355 100.00
Xdry 12.8863

* =79/21 by volume Xwet=Co2+MC+H2o+SO2+O2ex+N2act

 FLUE GAS ANALYSIS

Constituent Mass Mol Mass Moles (wet) Moles % by Vol.

Kg/kg of fuel (dry) on Dry basis

CO2 2.42 44 0.055 0.055 12.961

(MC+ H2O) 0.489 18 0.02717 0.00 0.00

SO2 0.034 64 0.000531 0.000531 0.1250

O2]ex 0.84192 32 0.02631 X=0.02631 6.2

N2]f+N2]th [0.013+6.806]
28 0.243536 0.243536 -
= 6.819
N2]ex 3.762 X=
2.77138 28 -
0.098978
N2]act 9.59038 28 0.342514 0.342514 80.714

Air]th 8.839

Air]act 12.4523

%Excess 40.88%

Xwet 13.3753
0.451525 0.424355 100.00
Xdry 12.8869

Xwet=Co2+MC+H2o+SO2+O2ex+N2act
 Dry moles of flue gas  0.299067  4.762 X
% O2 6.2 X
   0.062
100 100 0.299067  4.762 X
X=0.02631 moles of excess O2
3.762 x =0.098978 moles of excess N2
Total moles of dry flue gas = 0.424355 moles
Total mass of dry flue gas = 12.8863 kg/ kg of fuel
 mco2  ms o2  mo2 ]ex  mN 2
2. Calculation of Losses :
(i) Dry Gas Loss :[Stack Loss]
Qdfg  [mdfg.Cpdfg. (Tfg  Tamb ) / GCVf ]x100
 [12.8863 * 1.03 * (210  35) / 27000] x 100
 8.603 %
(ii) Losses in Ash
(a) Loss Due to Combustibles in Ash
mub mub
Now  0.072 
mas h mub  mas h, f
mub
  0.072
mub  0.077
 mub  0.005974 kg / kg of fuel
mas h  mub  mas h, f
 mas h  0.077  0.005974  0.082974 kg / kg of fuel
 mub xCVub
Qub   100
CVf
0.005974 x33820
  100
27000
 0.748 %

(b) Sensible heat loss in Ash :

mas h  Cpas h  (Tas h  Tamb )
Qs, as h   100
CVf
0.082974  0.84  (627 .68  35)
 Qs, as h   100
27000
 0.153 %

(iii) Loss due to H2 in Fuel :

mH2O.h
QH2   100
CVf
h  4.2(25  Tamb )  2442 .3  1.88(Tfg  25)
 4.2(25  35)  2442 .3  1.88(210  25)
 2748 .1 kJ / kg
mH2O  9  H  9  0.41  0.369 kg / kg of fuel
0.369  2748 .1
 QH2   100
27000
 3.756 %
(iv) Loss due to moisture in fuel :
mMC  h
QMc   100
CVf
0.12  2748 .1
  100
27000
 1.221 %
(v) Unaccounted losses :
(a) Radiation loss : 1.0%
(b)Blow down loss : 0.5
(c) Loss due to unburnt gas : 0.2%
-------------------
Qun = 1.5%
Total Losses : Qdfg  Qub  Qs, as h  QH2  QMC  Qun
 8.603  0.748  0.153  3.756  1.221  1.5
 15.981 %
 b  100  Losses  100  15.981  84.019 %
Qu Qu
  .
Qin m CVf
510
 Qu  0.84019   27000  3213 .73 kW
3600
. . .
 ms .hs  mfw .hfw  ms (hs  hfw )
From Steam table, at 70C Water Temperature
hfw=293 kJ/kg
For hs=?
Ps =7.5 kg/cm2 (g) +1.033 kg/cm2 (atm)
Pabs = 7.3575 x 105 N/m2 +1.0132 x 105
= 8.3707 x 105 N/m2 = 8.3707 bar
At this pressure
Tsat= ? hg= ?

At p=8.2 bar tsat= 171.5 C hg=2770.2 kJ/kg

At p=8.4 bar tsat= 172.5 C hg=2771.2 kJ/kg
At p=8.3707bar tsat=172.35 C hg=2771.05 kJ/kg

Now tsteam = 179 C > Tsat  steam is super heated

from superheated steam table :

At p=8.0 t=200 C hg=2839.3 kJ/kg

At p=9.0 t=200 C hg=2833.6 kJ/kg
At p=8.3707 t=200 C hg=2837.19 kJ/kg
At p=8.3707 & tsat=172.35, hg=2771.05 kJ/kg
At p=8.3707 & tsup = 179 C, hg=2786.96 kJ/kg
.
Now Qu  ms (hs  hfw )
.
3213 .73  ms (2786 .96  293 .0)
.
 ms  1.2866 kg / s  4.639 T / h
.
Qu  meq .Levap
.
3213 .73  meq  2256 .9
.
 EE  meq  1.42396 kg / s  5.126 T / h
 EFFICIENCY CALCULATION OF UKAI THERMAL POWER
STATION 210 MW UNIT.
INPUT DATA: Steam Generation = 625 T/h
Steam Pressure = 137 bar (abs.)
Steam Temperature = 520oC
Carbon % 39.93 Flue gas Temp. o C 152.00

Hydrogen % 4.55 Unburnt in Fly Ash % 0.75

Unburnt in Bottom
Nitrogen % 0.12 10.66
Ash %
O 2 (FUEL) % 7.24 % of Fly Ash 80.00

Sulphur % 0.44 % of Bottom Ash 20.00

Ash % 42.12 GCV kCal/kg 3812.71

Moisture % 5.60 GCV p=constt. kJ/kg 16075.25

O 2 (FLUE GAS) % 4.20 Ambient Temp. o C 35.00

 STOICHIOMETRY OF REACTION

(1) Combustion of Carbon :

C + O2 CO2
12 kg 32 kg 44 kg
0.3993 kg 1.0648 kg 1.4641kg
(2) Combustion of Hydrogen :
H + 1/2 O2 H 2O
2 kg 16 kg 18 kg
0.0455 kg 0.364 kg 0.4095 kg
(3) Combustion of Sulphur :
S + O2 SO2
32 kg 32 kg 64 kg
0.0044 kg 0.0044kg 0.0088 kg
 CALCULATION

(1) O2 Theoretical = 1.3607734 kg/kg of fuel.

= 2.666 x % C + 8.0 x % H + % S - % O2 Fuel

100 100 100 100

(2) Air Theoretical = 5.9164060 kg/kg of fuel

= O2 Theoretical + N2 Theoretical

= O2 Theoretical + 77 x O2 Theoretical
23
(3) X = 0.0116560

= %O2 in Flue Gas x No. of MolesWBof (CO2 + SO2 + H2O + N2fuel + N2Theoritical
)

100 – (%O2 in Flue Gas x 4.762)

 FLUE GAS ANALYSIS

MASS MASS COMPOSITION ON COMPOSITION ON

COMPO (WB) (DB) MASS BASIS VOL/MOLE BASIS
NO. OF NO. OF
NENT Mol. %WET %DRY MOLES MOLES %WET %DRY
Wt KG/KG KG/KG BASIS BASIS (WB) (DB) BASIS BASIS

CO2 44.0 1.46410 1.46410 18.084 19.187 0.0332750 0.033275 11.989979 13.222083

SO2 64.0 0.00880 0.00880 0.109 0.115 0.0001375 0.000137 0.049545 0.054637

H20+MC 18.0 0.46550 0.00000 5.750 0.000 0.0258611 0.000000 9.318533 0.000000

O2-Excess 32.0 0.37299 0.37299 4.607 4.888 0.0116560 0.011656 4.200000 4.631597

N2 fuel 28.0 0.0012 0.00120 0.0000429 0.000042

N2 Theoritical 28.0 4.55563 4.55563 0.1627012 0.162701

N2 Excess 28.0 1.22779 1.22779 0.0438498 0.043849

N2actual 28.0 5.78463 5.78463 71.45027 75.80910 0.2065938 0.206593 74.441943 82.091684

Airtheoritical 28.84 5.91641 5.91641 0.20515 0.20515

Airactual 28.84 7.51719 7.51719

% Excess
27.0567 27.0567
Air

TOTAL 8.0960 7.6305 100.00 100.00 0.27752 0.25166 100.00 100.00

 Calculated Results:

(1) Theoretical Nitrogen: (Kg/ Kg of fuel) = 4.5556326

= 77 x Theoretical Oxygen
23

(2) Theoretical Air: (Kg/ Kg of fuel) = 5.9164060

= Theoretical Oxygen + Theoretical Nitrogen

(3) Actual Air: (Kg/ Kg of fuel) = 7.5171922

(4) % Excess Air = 27.05673

 CALCULATION OF LOSSES

(5) % Dry Gas Losses = 5.7203

= [Total of Mass (DB) x 1.03x(Flue Gas Temp.–Ambient Temp.)] x 100

G.C.V. of fuel, kJ/Kg

(6) % Loss due to combustibles in fly ash = 0.536

= % Unburnt in fly ash x % Ash in fuel x % Fly ash x 33820

100 100 100

100 - % Unburnt in fly ash

GCV of fuel, kJ/Kg

(7) % Sensible Heat Loss in Fly Ash = 0.2076

= % Unburnt in fly ash x % Fly ash x % Ash in Fuel +

100 100
(100 - % Unburnt in fly ash)

% Fly ash x % Ash in fuel x 0.84x(Flue gas Temp. – Ambient Temp.) x100
100 100

( GCV of Fuel, kJ/Kg )

(8) % Loss due to combustibles in Bottom Ash = 2.1147

= % Unburnt in Bottom ash x % Bottom ash x % Ash in fuel x 33820

100 100 x 100

(100 - % Unburnt in Bottom Ash)

G.C.V. of fuel, kJ/Kg

(9) % Sensible Heat Loss in Bottom Ash = 0.29202

= % Unburnt in Bottom ash x % Bottom ash x % Ash in fuel +

100 100
100 - % Unburnt in Bottom ash

% Bottom ash x % Ash in fuel x [0.84 (627.68 – Ambient Temp.)] x 100

100 100

GCV of fuel, kJ/Kg

(10) % Loss due to Hydrogen in fuel = 6.72273

= 9 x % Hydrogen in fuel x 4.2 x (25 – Ambient Temp.) + 2442.3

100

+ 1.88 x (Flue gas Temp. – 25) x 100

G.C.V. of Fuel, kJ/Kg

(11) % Loss due to Moisture in fuel = 0.91970

= % Moisture in fuel x 4.2 x (25 – Ambient Temp.) + 2442.30 +

100

1.88 x (Flue gas Temp. - 25) x 100

G.C.V. of Fuel, kJ/Kg

(12) % Unaccounted loss = 1.5

(13)Total Losses = (5)+(6)+(7)+………..+(12)

= 18.0127 %

(14) Efficiency = 100 - Total Losses

= 100.00 – 18.0127

= 81.987 %
 EFFICIENCY CALCULATION OF GIPCL, SLPP, MANGROL
2*125 MW UNIT, CFBC BOILERS WITH LIMESTONE ADDITION]
INPUT DATA: Steam Generation = 390 T/h
Steam Pressure = 130 kg/cm2 (g)
Steam Temperature = 540 oC

Flue gas
Carbon % 33.50 140.00
Temp. o C
Unburnt in Fly
Hydrogen % 2.50 1.50
Ash %
Unburnt in
Nitrogen % 0.50 0.05
Bottom Ash %
O 2 (FUEL) % 9.00 % of Fly Ash 70.00
% of Bottom
Sulphur % 0.60 30.00
Ash
Ash % 12.50 GCV kCal/kg 3322.98
Moisture % 41.40 GCV p=c kJ/kg 13999.60
Ambient
O 2 (FLUE GAS) % 4.0 35.00
Temp. o C
INPUT DATA: MODIFIED CONSIDERING

LIME STONE ADDITTION = 8.00 % & FUEL = 92.00 %

Carbon % 30.82 Flue gas Temp. o C 140.00

Hydrogen % 2.30 Unburnt in Fly Ash % 1.50

Unburnt in Bottom
Nitrogen % 0.46 0.05
Ash %
O 2 (FUEL) % 8.28 % of Fly Ash 80.00

Sulphur % 0.552 % of Bottom Ash 20.00

Ash % +
=11.50+4.48
CaO (from GCV kCal/kg 3057.14
=15.98
limestone)
Moisture % 38.09 GCV p=constt. kJ/kg 12891.28
O 2 (FLUE GAS) % 4.0 Ambient Temp. o C 35.00
CO2 % (from
3.52
lime stone )
 STOICHIOMETRY OF REACTION

(1) Combustion of Carbon :

C + O2 CO2
12 kg 32 kg 44 kg
0.3082 kg 0.82187 kg 1.13007 kg
(2) Combustion of Hydrogen :
H + 1/2 O2 H 2O
2 kg 16 kg 18 kg
0.0230 kg 0.1840 kg 0.2070 kg
(3) Combustion of Sulphur :
S + O2 SO2
32 kg 32 kg 64 kg
0.00552 kg 0.00552 kg 0.01104 kg
 CALCULATION

(1) O2 Theoretical = 0.9285661kg/kg of fuel

= 2.666 x % C + 8.0 x % H + % S - % O2 Fuel

100 100 100 100

(2) Air Theoretical = 4.0372440 kg/kg of fuel

= O2 Theoretical + N2 Theoretical

= O2 Theoretical + 77 x O2 Theoretical
23
(3) X = 0.0084250

= %O2 in Flue Gas x No. of MolesWBof (CO2 + SO2 + H2O + N2fuel + N2Theoritical
)

100 – (%O x 4.762)

 FLUE GAS ANALYSIS
MASS MASS COMPOSITION ON COMPOSITION ON
(WB) (DB) MASS BASIS NO. OF VOL/MOLE BASIS
COMPO Mol. NO. OF
MOLES
NENT Wt MOLES(WB)
%WET %DRY (DB) %WET %DRY
KG/KG KG/KG
BASIS BASIS BASIS BASIS

CO2 44.0 1.16527 1.16527 19.310 21.394 0.0264833 0.0264833 12.573 14.881

SO2 64.0 0.01104 0.01104 0.183 0.203 0.0001725 0.0001725 0.0819 0.0969

H20 + MC 18.0 0.58788 0.00000 9.742 0.000 0.0326600 0.0000000 15.506 0.0000

O2-Excess 32.0 0.26960 0.26960 4.468 4.950 0.0084250 0.0084250 4.0000 4.7340

N2 fuel 28.0 0.0046 0.00460 0.0001643 0.0001643

N2 Theoritical 28.0 3.10868 3.10868 0.1110242 0.1110242

N2 Excess 28.0 0.88745 0.88745 0.0316947 0.0316947

N2actual 28.0 4.00073 4.00073 66.2974 73.45323 0.1428832 0.1428832 67.838 80.287

Airtheoritical 28.84 4.03724 4.03724 0.13999 0.13999

Airactual 28.84 5.19429 5.19429

% Excess
28.65941 28.6594
Air
TOTAL 6.03451 5.44663 100.00 100.00 0.21062 0.17796 100.00 100.00
 Calculated Results:

(1) Theoretical Nitrogen: (Kg/ Kg of fuel) = 3.1086779

= 77 x Theoretical Oxygen
23

(2) Theoretical Air: (Kg/ Kg of fuel) = 4.0372440

= Theoretical Oxygen + Theoretical Nitrogen

(3) Actual Air: (Kg/ Kg of fuel) = 5.1942942

(4) % Excess Air = 28.65941

 CALCULATION OF LOSSES

(5) % Dry Gas Losses = 4.56940

= [Total of Mass (DB) x 1.03x(Flue Gas Temp.–Ambient Temp.)] x 100

G.C.V. of fuel, kJ/Kg

(6) % Loss due to combustibles in fly ash = 0.511

= % Unburnt in fly ash x % Ash in fuel x % Fly ash x 33820

100 100 100

100 - % Unburnt in fly ash

GCV of fuel, kJ/Kg

(7) % Sensible Heat Loss in Fly Ash = 0.0888

= % Unburnt in fly ash x % Fly ash x % Ash in Fuel +

100 100
(100 - % Unburnt in fly ash)

% Fly ash x % Ash in fuel x 0.84x(Flue gas Temp. – Ambient Temp.) x 100
100 100

( GCV of Fuel, kJ/Kg )

(8) % Loss due to combustibles in Bottom Ash = 0.0042

= % Unburnt in Bottom ash x % Bottom ash x % Ash in fuel x33820 x 100

100 100
(100 - % Unburnt in Bottom Ash)

G.C.V. of fuel, kJ/Kg

(9) % Sensible Heat Loss in Bottom Ash = 0.12349

= % Unburnt in Bottom ash x % Bottom ash x % Ash in fuel +

100 100
100 - % Unburnt in Bottom ash

% Bottom ash x % Ash in fuel x [0.84 (627.68 – Ambient Temp.)] x 100

100 100

GCV of fuel, kJ/Kg

(10) % Loss due to Hydrogen in fuel = 4.20141

= 9 x % Hydrogen in fuel x 4.2 x (25 – Ambient Temp.) + 2442.3

100

+ 1.88 x (Flue gas Temp. – 25) x 100

G.C.V. of Fuel, kJ/Kg

(11) % Loss due to Moisture in fuel = 7.73355

= % Moisture in fuel x 4.2 x (25 – Ambient Temp.) + 2442.3 +

100

1.88 x (Flue gas Temp. - 25) x 100

G.C.V. of Fuel, kJ/Kg

(12)% Unaccounted loss = 1.5

(13) Total Losses = (5)+(6)+(7)+………..+(12)

= 18.7316 %

(14)Efficiency = 100 - Total Losses

= 100.00 – 18.7316

= 81.268 %
 Conclusion

• Maximize Useful Heat Energy

• Minimize Losses

-Improve combustion Efficiency

-Improve Heat Transfer Efficiency