Note - All yellow cells are manditory to be filled

A B C D

CALCULATIONS FOR STEAM COST ESTIMATION

S.No Description units value

Boiler Details

1 Make Thermax

2 Model SM-40

3 Design Capacity, f & @1000C kg/hr 5000

4 Average steam generation kg/hr 2200

5 Design Pressure kg/cm2 10.5

6 Boiler operating Pressure kg/cm2 5

7 Fuel used Coal1 (Solid)

8 Boiler Efficiency (on GCV / Solid, NCV / Liquid) 70%

9 Average Feed Water Temperature oC 80

10 Fuel Cost ( specify per lit/ kg/ Nm3) Rs/unit 9

11 Calorific Value of Fuel (GCV / Solid, NCV / Liquid) kcal/kg 4500

12 Enthalpy of Steam at the operating Steam Pressure kcal/kg 657.8

13 Enthalpy of feed water kcal/kg 80

14 Fuel Density 1

15 Cost of Steam Rs/kg 1.65

 Bagasse (Solid) 3000-3500

Coal1 (Solid) 4500-5000

Coal2 (Solid) 4000

FO (Liquid) 9800

HSD (Liquid) 10500

Husk (Solid) 3000

LDO (Liquid) 10300

LPG (Gas) 10000

Ngas (Gas)

407.174603 Wood (Solid) 2800-3200

Technical Parameters Boiler Feed W

Steam Generation 2200 at 9bar

Make-up Water Addition 1935
Present Condition
ETP Steam Load 1375
% of Flash steam 0.1111111111 at 7bar

Flash steam qty 152.77777778 Not Recovered

Condensate qty 1222.2222222 Yes Recovered

Steam Load from API 2&3, S1&7, API 4 Main line 625
% of Flash steam 0.0648148148 at 3.5bar

Flash steam qty 40.509259259 Not Recovered

Condensate qty 584.49074074 Yes Recovered

Steam Load from API 4&5 Production 500

% of Flash steam 0.0648148148 at 3.5bar

Flash steam qty 32.407407407 Not Recovered

Condensate qty 467.59259259 Not Recovered

Boiler Blowdown HRS 50

% of Flash steam 0.1481481481 at 3.5bar
Flash steam qty 7.4074074074 Not Recovered
Condensate qty 42.592592593 Not Recovered
 Boiler Feed Water Heat & Mass Balance Estimation Sheet - Current System

Make up water *Edit Only Yellow cells

1935 Kg/h
30 Deg C

Condensate Flash Steam

1806.713 Kg/h 0 Kg/h
90 Deg C 640 K Cal/kg

Boiler Feed Water

2200 Kg/h
58.97143 Deg C
 Boiler Feed Water Heat & Mass Balance Estimation Sheet - Proposed System

Make up water *Edit Only Yellow cells

225.6944 Kg/h
34 Deg C

Condensate Flash Steam

2274.306 Kg/h 0 Kg/h
90 Deg C 640 K Cal/kg

Boiler Feed Water

2500 Kg/h
84.94444 Deg C
84.94444 Deg C

Client need to maintain Boiler Feed Tank @ approx equivalent to steam generation or to max of 1.5
times of steam generation
* Proposed System Calculations are done considering Condensate Recovery from API 2&3, S1&7, API 4
Main line + API 4&5 Production Unit + MEE & flash steam vented to atmoshpere i.e. no flash steam
recovdery in entire plant + Preheating Boiler Make-up Water through recommended Boiler Blowdown
Heat recovery system through only blowdown flash steam PHE