BOILER EFFICIENCY SAMPLE CALCULATION

1 Theoritical air required 5.08

2 % of Excess air 41.41
3
4 Actual mass of air 7.18

5 Mass of Dry flue gas 7.44

6 Heat loss in Dry flue gas % 7.36
7 Heat loss due to formation of water % 3.56
8 Heat loss due to moisture in fuel % 1.48
9 Heat loss due to moisture in air % 0.27
10 Heat loss in Bottom Ash % 0.02
11 Heat loss in Fly Ash % 0.02
12 Loss due to partial combustion 0.01
13 Radiation losses % 2
14 Boiler Efficiency 85.28

Inputs to Boiler efficiency

Carbon 38.3
Hydrogen 1.95
Oxygen 1.36
Sulphur 0.5
Nitrogen 1.72
% of O2 actual as measured 6.15

Average flue gas temperature at APH outlet 162.5

Average atm temperature 32
GCV of fuel as fired 3167
Moisture 7.31

Humidity factor 0.0204

% of Unburnt in Bottom Ash 1.2
% of Unburnt in Fly Ash 2
CV of Bottom Ash 100
CV of Fly Ash 56
% of Ash in coal 52.49
Measured CO in ppm 22
% of CO 0.0022
Coal consumption 387200
Duration of test 2
Coal consumption in 1 Hr 193600
Generation 497000
Specific coal consumption 0.78
Mass of Flue Gas at APH Outlet 1440
SAMPLE CALCULATIONS
Remarks
kg/kg of fuel
kg/kg of fuel

kg/kg of fuel

kg/kg of fuel

Assumed

From Ultimate Analysis of Coal

From Ultimate Analysis of Coal
From Ultimate Analysis of Coal
From Ultimate Analysis of Coal
From Ultimate Analysis of Coal
Measured at APH Outlet

Measured at APH Outlet

Measured
Evaluated in the Lab
From Proximate Analysis of coal
From Standard Tables based on
relative humidity
Evaluated in the Lab
Evaluated in the Lab
Evaluated in the Lab
Evaluated in the Lab
From Proximate Analysis of coal
Measured at APH Outlet

Form Coal flow Integrators

kWh From Generator Meter 496666.666667
kg/kWh
TPH
Mass of flue gas at APH Outlet 1440.384 TPH

Feeder C Feeder d Feeder E Feeder F

233 232 254 249

Coal consumption in kgs 1161600

 1 Theoritical air required
2 % of Excess air
3
4 Actual mass of air
5 Mass of Dry flue gas
6 Heat loss in Dry flue gas %
7 Heat loss due to formation of water %
8 Heat loss due to moisture in fuel %
9 Heat loss due to moisture in air %
10 Heat loss in Bottom Ash %
11 Heat loss in Fly Ash %
12 Loss due to partial combustion
13 Radiation losses %
14 Boiler Efficiency

Inputs to Boiler efficiency

Carbon
Hydrogen
Oxygen
Sulphur
Nitrogen
% of O2 actual as measured
Average flue gas temperature at APH imlet
Average atm temperature
GCV of fuel as fired
Moisture
Humidity factor
% of Unburnt in Bottom Ash
% of Unburnt in Fly Ash
CV of Bottom Ash
CV of Fly Ash
% of Ash in coal
Measured CO in ppm
% of CO
Coal consumption
Duration of test
Coal consumption in 1 Hr
Generation
Specific coal consumption
Mass of Flue Gas at APH Inlet
Flue Gas Flow at APH Inlet
Remarks
5.08 kg/kg of fuel
24.26 kg/kg of fuel

6.31 kg/kg of fuel

6.57 kg/kg of fuel
14.59
3.97
1.65
0.54
0.02
0.02
0.89
2
76.32

38.3 From Ultimate Analysi of Coal

1.95 From Ultimate Analysi of Coal
1.36 From Ultimate Analysi of Coal
0.5 From Ultimate Analysi of Coal
1.72 From Ultimate Analysi of Coal
4.1 Measured at APH Outlet
325 Measured at APH Inlet
32 Measured
3167 Evaluated in the Lab
7.31 From Proximate Analysis of coal
0.0204 From Standard Tables
1.2 Evaluated in the Lab
2 Evaluated in the Lab
100 Evaluated in the Lab
56 Evaluated in the Lab
52.49 From Proximate Analysis of coal
22 Measured at APH Outlet
0.0022
387200 Form Coal flow Integrators
2
193600
497000 kWh From Generator Meter
0.78 kg/kWh
1272 TPH
 BOILER(9) EFFICIENCY
1 Theoritical air required 5.08
2 % of Excess air 68
3
4 Actual mass of air 8.53
5 Mass of Dry flue gas 8.79
6 Heat loss in Dry flue gas % 7.53
7 Heat loss due to formation of water % 3.52
8 Heat loss due to moisture in fuel % 1.47
9 Heat loss due to moisture in air % 0.28
10 Heat loss in Bottom Ash % 0.02
11 Heat loss in Fly Ash % 0.02
12 Loss due to partial combustion 1.2
13 Radiation losses % 2
14 Boiler Efficiency 83.96

Inputs to Boiler efficiency

Carbon 38.3
Hydrogen 1.95
Oxygen 1.36
Sulphur 0.5
Nitrogen 1.72
% of O2 actual as measured 8.5
Average flue gas temperature at APH imlet 145
Average atm temperature 32
GCV of fuel as fired 3167
Moisture 7.31
Humidity factor 0.0204
% of Unburnt in Bottom Ash 1.2
% of Unburnt in Fly Ash 2
CV of Bottom Ash 100
CV of Fly Ash 56
% of Ash in coal 52.49
Measured CO in ppm 22
% of CO 0.0022
Coal consumption 387200
Duration of test 2
Coal consumption in 1 Hr 193600
Generation 497000
Specific coal consumption 0.78
Mass of Flue Gas at ID Fan Outlet 1702
OILER(9) EFFICIENCY
Remarks
kg/kg of fuel
kg/kg of fuel Mass of flue gas at APH Outlet

kg/kg of fuel
kg/kg of fuel Feeder C Feeder d Feeder E
233 232 254

Coal consumption in kgs

From Ultimate Analysi of Coal

From Ultimate Analysi of Coal
From Ultimate Analysi of Coal
From Ultimate Analysi of Coal
From Ultimate Analysi of Coal
Measured at APH Outlet
Measured at APH Inlet
Measured
Evaluated in the Lab
From Proximate Analysis of coal
From Standard Tables
Evaluated in the Lab
Evaluated in the Lab
Evaluated in the Lab
Evaluated in the Lab
From Proximate Analysis of coal
Measured at APH Outlet

Form Coal flow Integrators

kWh From Generator Meter

kg/kWh
TPH
1701.744 TPH

Feeder F
249

1161600
 Mass Flow of Flue Gas in Various Zones

Sl No Particulars Qty Units

1 Mass of flue gas before APH 1272.0 TPH

2 Mass of flue gas after APH 1440.0 TPH

3 Mass of flue gas at ID Fan inlet 1702.0 TPH

4 Air ingress in the APH 13.2 %

5 Air ingress between APH and ID Fan 18.2 %

Practical
Allowable
Limit

10