4th Year Mechanical Power

Conservation of Energy / MEP416 Assignment 2 (Energy Efficiency in Boilers)

Prof. Dr. Abdelhafez Hassanein Page 1 of 2

1) A steam boiler generates dry saturated steam at 10 barg. The fired fuel is coal of
gross heating value of 13400 kJ/kg. If the specific fuel consumption is 0.225 kg
fuel per kg steam and the feedwater temperature is 85 °C, find out the efficiency
of the boiler by direct method.

2) A steam boiler raises 5 ton/h of dry saturated steam at 9 barg. The boiler uses fuel
oil with a heating value of 41 MJ/kg. The fuel cost is EGP 4.25/kg. Feedwater
enters the boiler at 26 °C. The flue gas temperature is 315 °C. The exhaust gases
have an average specific heat of 1.15 kJ/kg.K. The amount of the exhaust gases
is 20.1 kg/kg of fuel. The boiler operates 8600 hours per year. Radiation and blow
down losses together are estimated as 3.5%. Calculate:
a) The fuel consumption in kg/h.
b) The combustion and the boiler efficiencies.
c) If an economizer is installed that would raise the temperature of the feedwater
entering the boiler to 100 °C, calculate the annual fuel savings in EGP.

3) A steam boiler raises 10 ton/hr using light fuel oil with a gravimetric analysis of
86% Carbon, 13% Hydrogen, and 1% Sulfur. The fuel costs EGP 3.65/lit, has a
specific gravity of 0.82, and a heating value of 42.5 MJ/kg. The boiler delivers
saturated steam at 800 kPa and operates 5820 hours per year. The feedwater
enters the boiler at 60 °C. An exhaust gas analysis showed that the oxygen
concentration was 7% while the exhaust gas and ambient temperatures were 220
and 27 °C, respectively. Radiation and blow down losses are 1.5 and 2%,
respectively. Determine:
a) The stoichiometric air-to-fuel ratio and actual air-to-fuel ratio.
b) The combustion and boiler efficiencies.
c) If a combustion control system was installed that reduced the exhaust gas
oxygen concentration in the exhaust from 7% to 4% at an investment of EGP
500000, find the percent fuel savings, the annual savings in EGP/year and the
simple payback period. You may use the Siegert formula:

 
qexh %  Texh  Ta  
A1
 B
 21  O 2 % 
Where A1 = 0.68 and B = 0.007
O2 %
Excessair factor 
21  O 2 %
4th Year Mechanical Power
Conservation of Energy / MEP416 Assignment 2 (Energy Efficiency in Boilers)
Prof. Dr. Abdelhafez Hassanein Page 2 of 2

4) Upon testing a fire tube boiler in a hospital, the following data were recorded:
Steam produced Saturated @ 9 barg
Fuel fired Light fuel oil
Fuel consumed 625 lit/h
Fuel specific gravity 0.85
Fuel heating value 37400 kJ/lit
Flue gas temperature 261 °C
Ambient temperature 29°C
Oxygen content 4% (vol.), dry basis
Radiation & blowdown losses 4%
Calculate the boiler efficiency and the rate of steam produced.
5) A steam boiler raises 12 tons/h of dry saturated steam at 1MPa. Feed water
enters the boiler at 1 MPa and 20 °C. The boiler utilizes heavy fuel oil with a
heating value of 40 MJ/kg as a fuel. The fuel cost is 3.6 EGP/kg. An exhaust gas
analysis was performed on the boiler at 101.3 kPa and 20 °C; during which the
exhaust gas temperature was found to be 167 °C and the oxygen concentration
was 15.61%. After the installation of a control system (Cost EGP 500,000), the
exhaust gas temperature was 182 °C and the O2 concentration was 6%. The
combined radiation and blow down losses can be assumed constant at 7% before
and after installation. The boiler operates 16 hours/day, 320 days/year. Find:
a) The combustion and boiler efficiencies before and after the installation of the
control system.
b) The percent change in fuel consumption as a result of the tune-up.
c) The annual money saving and the simple payback period.
Exhaust gas losses are given by the Siegert formula. For fuel oil, it reads as
above.
6) A department store has an average hot water requirement for all purposes of
11500 GJ/year; the load is constant allover the year with an average use of 3120
hours/year. A water heater using natural gas as a fuel and having an overall
efficiency of 80% is used to provide the required amount of hot water. The natural
gas has a heating value of 36.5 MJ/m3 and costs EGP 1.10/m3. The department
store produces solid waste at a rate of 676 tons/year. The cost of waste disposal
is EGP 150/ton and has a calorific value of 16 MJ/kg. It is suggested to install a
waste heat boiler having an efficiency of 70% to produce hot water for the store
using the waste as a fuel. The cost of the waste heat boiler is EGP 1,000,000.
Determine:
a) The percentage of hot water produced by the waste heat boiler.
b) The annual money saving and the simple payback period.