BOILER NG CALCULATION

Component
Vol% Mol.Wt.
Methane
98.03
16
Ethane
0.69
30
Propane
0.03
44
Nitrogen
1.25
28
Total Mol. Wt.

XiMi
15.6848
0.207
0.0132
0.35
16.255 kg/kmol
345.4321747 kmol/hr

Total fuel flow rate to no of burners in service

where

PV = nRT
R
T1
P1

so

V1
V1

P2
T2

1 atm
0 C

5615 kg/hr

8314 Pa*M3/Kg.K
300.78 K
3500000 Pa
863817030.2
246.8048658 M3/hr

101325 Pa
273 K

P1*V1/T1 P2*V2/T2
V2
P1*V1*T2/P2*T1
V2
7737.823898 NM3/hr

REFORMER NG CALCULATION
Component
Vol%
Methane
98.03
Ethane
0.69
Propane
0.03072
Nitrogen
1.25

Mol.Wt.
16
30
44
28

XiMi
15.68469101
0.206724017
0.013518258
0.350245787

Total fuel flow rate to no of burners in service

where

so

V1
V1

P2
T2

PV = nRT
R
T1
P1

8314 Pa*M3/Kg.K
313 K
3000000 Pa

197.5925
197.5925 m3/hr

1 atm
0 C

101325 Pa
273 K

P1*V1/T1 P2*V2/T2
V2
P1*V1*T2/P2*T1
V2
5102.622 NM3/hr

kmol/h
223.35
1.57
0.07
2.85
227.84
16.3 kg/kmol
227.7914 kmol/hr
3713 kg/hr

EFFICIENCY & TOTAL AIR FLOW OF BOILER

Boiler Efficiency = (Heat Output/Heat Input)*100
Q * (Hg - Hf)
Boiler efficiency =

* 100
q * GCV

Where
Hg
Hf
NG flow
NG density

Enthalpy of saturated steam in kcal/kg of steam

Enthalpy of feed water in kcal/kg of water
7737.8239
0.727
5625.39798
12404.0025
5.62539798

NM3/hr
Kg/NM3
Kg/hr
lb/hr
T/hr

DATA :
Quantity of steam generated
Steam Pressure
Steam Temperature
Quantity of NG consumed
Feed water temperature
GCV of NG
Enthalpy of steam at 35 Bar
Enthalpy of feed water
Boiler Efficiency =

Hg
Hf

100
35
250
5.625397975
105
12966
670
105

TPH
Bar
C
TPH
C
Kcal/Kg
Kcal/Kg
Kcal/Kg

77.4620842 %

CH4
Mol%
C
H
S

Q
P
T
q

C2H6
98.03
73.5225
24.5075

C3H8
H2S (10ppm)
0.69
0.03
0.001
0.552 0.024545
0.138 0.005455
5.88235E-05
0.000941176

Total
74.09905
24.65101
0.000941
98.751

Theoritical air requirement

[11.6*C + (34.8*(H2- (O2/8))+ (4.35*S)]/100

1717.408
17.17408 kg/kg of fuel
96611.05 Kg/hr

Excess air supplied

[O2% / (21 - O2%)]*100

Assume 2% of oxygen in flue gas.

O2

2%

Excess air supplied (EA)

Actual mass of air supplied

Actual mass of air supplied

As per thermax total air consumption.

10.52632 %
[1 + (EA/100)] * Theoritical air
1.105263 * Theoritical air
18.98188 kg/kg of fuel
106781 kg/hr
103119 Kg/hr

kg/kg of fuel

Stack Losses for NG

Component

%
0.72
0.238
0.031
0.011

C
H
N2
O2
O2 dry
O2 dry
O2 dry

CO2 dry
CO2 dry

O2 wet* (1.222 - 0.012*O2wet)

1.196
2.392 %
11.368 - (0.556*O2 dry)
10.03005 %

Dry flue gas

N2

[((11*CO2 dry) + (8*O2dry) + (7*N2))*C]/(3*CO2 dry)

100 - O2 dry - CO2 dry
87.57795 %

Dry flue gas

Excess Air

Excess Air

534.608778
17.7669066 lb/lb of fuel
100 * O2 dry / [(0.2682*N2) - (O2 dry)]
239.2
21.09641
11.33842 %

Dry flue gas loss (LDG)

DG* Cp * (FGT - CAT)*100 * HHV

2.14133896 %

Loss due to moisture from combustion of hydrogen

LH

((9*H2*[(Enthalpy of vapor at 1 PSIa & FGT)- (Enthalpy of liquid at CAT)]*100 /

Hg

1055 + 0.467*FGT
1125.05 BTU/lb
CAT - 32
3 BTU/lb

Hf

LH

240343.11
10.4953323 %

Stack losses
Ls
LDG + Lh
12.6366713 %

(7*N2))*C]/(3*CO2 dry)

HHV

22900 BTU/lb
53261.68 kj/kg
12720.73 kcal/kg

t 1 PSIa & FGT)- (Enthalpy of liquid at CAT)]*100 / HHV

REQUIRED NG FLOW TO BOILER

WATER PREHEAT :
Economiser inlet
Economiser outlet
Flowrate
Heat capacity (Cp)
Q
Q

105
160
100000
1

M*Cp*(To - Ti)
5500000 Kcal/hr

FLUE GAS :
Flue gas outlet temp

150
302
35
95
17
210868
0.24

Flue gas inlet temp

Flue gas flow
Heat capacity (Cp)
Q
Q
Q

M*Cp*(To - Ti)
10475924.38 BTU/hr
2639622.695 Kcal/hr

C
C
kg/hr
Kcal/kgC

------------------------------- (1)

C
F
C
F
lb/lb of fuel
lb/hr
BTU/lbF

------------------------------- (2)

STEAM GENERATION :
M*Cp*(To - Ti) + m
Q
The latent heat of vaporization for water is

9000000 53960000
62960000 kcal/hr
------------------------------- (3)

BLOWDOWN LOSSES :
Blowdown (contineous)
(intermediate)
Blowdown inlet temp
Blowdown outlet temp
Q
Q
Total heat
GCV
NG Flow

539.6 kcal/kg

3000
1000
100
35

M*Cp*(To - Ti)
260000 Kcal/hr
71359622.69 Kcal/hr
12966 Kcal/kg
5504 Kg/hr

Kg/hr
Kg/hr
C
C

------------------------------- (4)