 Heat rate (Η ) and thermal efficiency (ηth ):

KJ / KW . h Btu/ KW .h K cal/ KW .h
3600 3 412 860
ηth = ηth = ηth =
Η Η Η
 Fuel rate (ṁ fuel ) in kg/s
Pth
ṁfuel =
( HHV )fuel−as burned
- Pth :Thermal Power (Watt th)
Pe
Pth =
ηth
Pe : Electrical Power (Watt e)
- To determine the as-burned HHV: As burned HHV =( 1−M − A ) × Dry ash free HHV

 Theoretical (stoichiometric) gravimetric (m) dry (d) Air-Fuel ratio for COAL:

( AF ) theoretical m , d
=
1
0.232
( 2.66 × C+8 × H 2+ S−O2 )

- ( AF )
theoretical m ,d
: Kg air / Kg fuel (coal)
- To determine the as-burned mass fraction of each component of the coal:
As burned mass fraction=( 1−M −A ) × Dry ash free mass fraction
- Theoretical value – Using Dulong’s formula:
Dulong’s formula for HHV (O 2 <10 %) based on as-burned mass fraction of elements in the fuel:

HHV theoretical =33950 ×C+ 144200× H 2 – ( O2

8 )
+9400 × S

 Theoretical (stoichiometric) molar (mol) dry (d) Air-Fuel ratio for LIQUID & GASEOUS fuel:

( AF )
theoretical mol,d
=
1
0.21
( Z ( C )+ 0.25× Z ( H )+ Z ( S)−0.5 × Z (O) )

- ( )
A
F theoretical
: Kmol air / Kmol fuel
mol, d

- Z : nb of atoms of a given element in a mole of fuel.

 Relation between Theoretical gravimetric and molar Air-Fuel ratio:

( AF ) ( AF )
M air
= ×
theoretical m ,d theoreticalmol ,d M fuel
- M air =29 kg /kmol: Molar mass
- M fuel : Molar mass of Fuel

 Actual gravimetric (m) dry (d) Air-Fuel ratio for COAL:

( )
A
F actual m ,d
=
[
1 % N 2 ×28
0.768 12 ( % CO 2 +%CO )
×C b−N f
]
- ( AF )
actual m , d
: Kg air / Kg fuel (coal)

- C b=C −C r: Burned Carbon : Kg burned carbon / kg fuel (coal)

C : As burned mass fraction of Carbon
- N f : Nitrogen in fuel
- % N 2=100−( % CO 2+%CO+% O2) :ORSAT analysis
 From the refuse analysis:
Cr ( HHV )refuse
=
R ( HHV )carbon
- C r: mass of unburned Carbon per unit mass of fuel in the refuse (for Coals): Kg unburned carbon/ kg fuel
(refuse)
- (HHV )refuse: Given Kj/Kg
- R=A +Cr : Refuse (mass fraction): kg refuse in Kg coal
A : Ashmass fraction
- (HHV )carbon=32778 Kj / Kg

 Actual molar (mol) dry (d) Air-Fuel ratio for LIQUID & GASEOUS fuel:

( AF ) actual mol , d
=
1
0.79
¿

- ( AF )
actual mol,d
: Kmol air / Kmol fuel

- % N 2=100−( % CO 2+%CO+% O2) :ORSAT analysis

 Relation between Actual gravimetric and molar Air-Fuel ratio:

( ) ( )
A A M air
= ×
F actual m ,d F actualmol ,d M fuel

 Dilution Coefficient:

DC=
( F)
A
actual m ,d
>1
( AF ) theoreticalm ,d
 Percentage of excess air:
% Excess air=100 × ( DC−1 )

 Required Power for FANS (Horse Power)

∆P
HP=Q̇ ×
η
- HP : Power in Watts
- Q̇ : flow rate volumetric m3 /s
- η : efficiency of the fan
- ∆ P : Variation of pressure across the fan – fan static pressure (Pa)

(¿ . wg) Psf Psi 3 ¿ . wg× 249.9

HP=CFM × HP=CFM × HP=CFM × HP=m /s ×
6343 ×η 33000 ×η 229 ×η η
CFM= f t 3/min
 For FD fans:
- Mass flow rate of air:
ṁair =1.2 × ṁfuel × ( FA ) actualm ,d
× ( 1+w )
ṁ air : Kg/s
 ( electrical power /thermal efficiency )
ṁ fuel =
( HHV )fuel−asburned
Specific humidity w : (kg water/ kg air)
m water P water
w= =0.622
mair Pair
- P
Partial pressure of water: water =P v =φ × P g
Pg =Ps : Saturation pressure of water
φ : relative humidity in % Given
- Pair =P atm−P water=Patm −φ× Pg
φ × Ps
w=0.622
P atm−φ × Ps

- Volumetric flow rate of air:

ṁair
Q̇ air = 3
ρair =1 kg / m

Required mechanical power to drive FD-Fan:

∆P
HP=Q̇air ×
ηfan

 For ID fans:
- Mass flow rate of Flue gas:

ṁgas =1.2 × ṁfuel ×

[( A
F ) actualm ,w
+1−Rfuel gas
]
ṁgas : Kg/s
R fuel gas=R air : Refuse (mass fraction)
Actual gravimetric (m) wet air basis (w) Air-Fuel ratio: (Kg wet air/Kg fuel

( AF )
actual m ,w
= ( AF ) actualm ,d
× (1+ w )
- Volumetric flow rate of air:
ṁgas Rgas ×T gas
Q̇ gas= =ṁ gas
ρgas P gas

R gas=R air =287 J / Kg . K ; T gas (K ) ; Pgas (Pa) given

Required mechanical power to drive ID-Fan:

∆P
HP=Q̇ gas ×
ηfan

Indirect Method by ASME power test codes; to estimate Performance of a Boiler:

1. Heat lost with the dry flue gases (Dry gas loss) DGL: KJ/Kg fuel
q 1=DGL=wg C p ¿

- wg= ( AF )
actual m ,d
+1−R−M −9 H 2 , kg dry flue gas/ kg fuel

- C p=1005 J / Kg. K : Specific heat of flue gas=Specific heat of air

- T g , out : Outlet flue-gas temperature (℃ /K )
- T g ,∈¿ ¿: Inlet air temperature (℃ /K )
 - R=A +Cr : Refuse (mass fraction) A : Ash mass fraction
- M : Moisture mass fraction H 2: hydrogen mass fraction as-burned ultimate analyses

2. Heat lost with the water in flue gases (Moisture loss) ML: KJ/Kg fuel
q 2=ML= ( M + 9 H 2) ( hs−hw )
- h s: Specific enthalpy of superheated steam at T g , out and a pressure of 1 psia (7 KPa): KJ/Kg
- h w: Specific enthalpy of water at T g ,∈¿ ¿: KJ/Kg
- If T g , out > 300℃ : h s−h w =2442+2.1× T g ,out −4.2 ×T g ,∈¿ ¿
- If T g , out ≤ 300 ℃: h s−h w =2492.6+1.93 ×T g , out −4.2× T g ,∈¿¿
T g , out ; T g ,∈¿ ¿ in ℃

3. Moisture in combustion air loss MCAL: KJ/Kg fuel

q 3=MCAL= ( FA )
actualm ,d
× w ×C p ,w ׿
- w : humidity ratio of the entering air, Kg water/Kg dry air
φ × Ps
w=0.622
P atm−φ × Ps
Ps : saturation pressure of water vapor at T g ,∈¿ ¿
- C p ,w =1926 J / Kg . K : Specific heat of water vapor.

4. Losses in incombustible in Ash (Unburned-Carbon Loss) UCL: KJ/Kg fuel

q 4=UCL=( HHV )carbon ×C r =32778× Cr
- C r: mass of unburned Carbon per unit mass of fuel in the refuse (for Coals): Kg unburned carbon/ kg fuel (refuse)

5. Losses in incombustible in flue gases (Incomplete combustion) ICL: KJ/Kg fuel

q 5=
28
[ %CO
12 % CO2 +%CO
×C b × ( HHV )CO
]
- C b: mass of carbon burned per mass of fuel
- ( HHV )CO =10 127 KJ / Kg
- %CO and % CO 2: value directly from ORSAT analysis

6. Radiation and combustion losses RL: KJ/Kg fuel

q 6=RL=( HHV )fuel ×ζ
- ζ : radiation factor

 Energy balance:
- Total Losses: KJ/Kg fuel
Q L=q1 +q 2+ q3 +q 4 +q 5+ q6
- Useful heat transfer to the steam: KJ/Kg fuel
Quseful =( HHV )fuel −Q L
- Steam generator efficiency:
Quseful
η= ×100
QL

Feed water system FWP

  Total efficiency of FWP:
ηtotal− FWP=ηhydraulic × ηvolumetric × ηmechanical
 Hydraulic (Useful) Power of FWP: Watts
Phydraulic =Q̇ steam × ( P out , FWP−P¿, FWP )
- Q̇steam : m / s
3

- Pout , FWP ; P ¿, FWP: Pa

 Mechanical Power of FWP: Watts
Phydraulic
Pmechanical −FWP=
ηtotal− FWP
 Mechanical Power of BP: Watts
Q̇steam × ( Pout , BP−P¿ ,BP )
Pmechanical−BP=
ηtotal−BP
 System K coefficient of resistance:
H pump =H s + K Q̇steam 2 ⇛ ( ρw g ) H pump =( ρ w g ) H s+ ( ρw g ) K Q̇ steam2 ⇛ P out , FWP=Psteam(boiler ) + ( ρ w g ) K Q̇ steam2
4 3
- ρw g=10 N /m
L
- K=0.08 λ 5 : L: Length of pipe (m) / D: Diameter of pipe (m) / λ : friction coefficient
D
 Number of FWP stages (n )
Pout ,FWP −P ¿, FWP
n=
Pressure developped by each stage

 Specific speed ( N ¿¿ s)¿

nMP × √Q̇steam
Ns=
H each stage
- n MP : Main pump rotational speed (RPM)
3
- Q̇ steam : m / h
Pressure developped by each stage
- H each stage: Pump head for each stage ¿
ρw g=104 N /m 3

 Gear Box Design:

- BP: Boost pump
- EM: Electrical motor n EM : Speed of rotation (RPM)
- VSG: Variable speed turbo-gear
n MP
Gear ratio: r GB =¿
n EM
- MP: Main Pump
- Type: Simple cylindrical gear box with 2 gears (ratio of diameter = r GB )

- Torque on the pump shaft: (N.m)

Pmechanical −FWP ×60
T pump=
2 π × nMP

- Torque on the motor shaft: (N.m)

T pump ×r GB
T motor =
ηGB
- Calculation of shaft diameter:
When the shaft is subjected to twisting moment (or torque); the maximum stress is given by the torsion equation:
T τ 16 1 σ yield
= ⟹ τ d = 3 ×T = [ σ ] =
J ρ ρ=
2 πd 2 2 × FS
 where;
- T : Twisting moment acting on the shaft
π 4
- J= × d : Polar moment of inertia of the shaft about the axis of rotation
32
- τ : Torsional shear stress
d
- ρ= : Distance from neutral axis to the radius where d is the diameter of the shaft
2

Power plant condensers - Condenser Design

 From steam table – Saturated water pressure entry – at P:
T sat ; hfg : Latent enthalpy in KJ/Kg
 Heat load (Heat flow rate) : (watt)
Qsteam =ṁsteam × h fg ×quality steam
- ṁsteam: mass flow rate kg /s
 Log mean temperature difference in the condenser: ∆ T m in K
- LMTD Formula:
∆ T i−∆T 0
∆ T m=
ln
( )
∆ Ti
∆T 0
∆Ti

∆ T 0=TTD : Terminal Temperature difference in K

5 5
∆ T 0 in K = ∆ T 0 ( F)× ; ℃=( ℉−32 ) ×
9 9

∆ T i=T sat −T cooling water in K

 Overall heat transfer coefficient: U in W /m 2 . K

- Heat exchange institute method
U =C1 C2 C3 C 4 √ V
- Tube outer diameter: … C 1
- Fresh water temperature: … C 2
- Tube material: … C 3
- Clean tube C 4=0.85
- V : Velocity of water at inlet of tube in m/ s 1 ft / s=0.3048 m/s
 Heat exchange area A (m2 ¿
Q steam
Q Heat exhanger =U × A ×∆ T m ⇛ A=
U × ∆T m
- Q Heat exhanger =Q steam =Q water Heat balance
 Number of tubes for one pass n:
A
A=n × π × D outer × L⇛ n=
π × D outer × L
- A : Heat echange area (m 2 ¿
- Douter : Outer diameter of tube (m ) 1∈¿ 0.0254 m
- L: Length of tubes (m ) 1 ft =0.3048 m
Total number of tubes: n × nb of passes
 Required cooling water flow rate ṁwater in kg/s
 Qwater
ṁwater =
C p , water ×∆ T water
- C p ,w ater =4186 J / Kg . K : Specific heat of water.
- ∆ T water =T out ,water −T ¿, water in K
T out ,water =T sat −TTD ; T ¿, water=T cooling water
ṁ water
Volumetric flow rate of water: m 3 /s Q̇ water = 3
ρwater =1000 kg/ m
 Cooling Pump Mechanical Power
Q̇ water ×∆ Ptotal
Pmechanical , pump =
ηtotal− pump
- ∆ Ptotal =¿Pressure drop of condenser + Suction lines + discharge line =1.2 ×∆ Pcondenser : System Pressure drop
∆ Pcondenser =∆ Pwater box +∆ Ptubes
∆ P water box in ft
∆ Ptubes =¿ tube friction losses ×length of tubes in ft
⟹ ∆ Pcondenser =( ∆ Pwater box +∆ Ptubes ) × 0.3048 in m
⟹ ρwater × g × ∆ Pcondenser =10 4 × ∆ Pcondenser in Pa
⟹ ∆ Ptotal=1.2 × ∆ P condenser in Pa
 Maximum suction height of circulating Pumps

( H suction) max= (P −P v
atm
γ )−( NPSH )r−¿ suctionlosses
- Pv : Saturation Vapor pressure