BOILER EFFICIENCY

Steam Output

Radiation Loss

Second
Pass
Heat
ESP
Input
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

Second
Pass
Heat Furnace
Input 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
Heat Pass
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
Heat Pass
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    =  0.074%
9) Unaccounted Losses   = 1.327%
    Total Losses                     = 13.83%
 Data required for Boiler
Efficiency Calculations
Unit load MW
FW Flow at Econ inlet T/hr
Wet bulb Temp 0
C
Dry bulb Temp 0
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 Air Dry As fired
Moisture % %
Ash % %
Volatile Matter % %
Fixed Carbon % %
Gross Cal. Value Kcal/kg 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
 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
0
ANY INCREASE IN THE FGT MORE THAN 140 C 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 % Ash %
Volatile Matter % Volatile Matter %
Fixed Carbon % Fixed Carbon %
Gross Cal. Value % Gross Cal. Value %
 Data Required contd.
Unit load MW
FW Flow at Econ inlet T/hr
Wet bulb Temp 0
C
Dry BulbTemp 0
C
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
Coal sample is taken as received basis, heated for
calculation of
A) Total Moisture content = TM%

 Air Dry Basis

The sample is air dried for removal of surface
moisture and burned completely for
A) Inherent moisture content = M%
B) Ash percentage = 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) Kcal/kg

5) Net Calorific Value = [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)