Draft of Boiler Efficiency Calculations

Boiler Efficiency
Indirect Method:
Boiler Heat Balance:
Input/Output Parameter
Heat Input in fuel
Various Heat losses in boiler
1. Dry flue gas loss
2. Loss due to hydrogen in fuel
3. Loss due to moisture in fuel
4. Loss due to moisture in air
5. Partial combustion of C to CO
6. Surface heat losses
7. Loss due to Unburnt in fly ash
8. Loss due to Unburnt in bottom ash
Total Losses
Boiler efficiency = 100 - (1+2+3+4+5+6+7+8)
Heat Loss due to dry Fuel Gas:
m
Cp
Tf
Ta
GCV
L1 #DIV/0!
Heat Loss due to evaporation of water formed due to H2 in fuel:
H2
Cp
Tf
Ta
GCV of Fuel
L2 #DIV/0!
Heat Loss due to moisture present in fuel
M
Cp
Tf
Ta
GCV of fuel
L3 #DIV/0!
Heat Loss due to moisture present in air:
AAS
Humidity Factor
Cp
Tf
Ta
GCV of fuel
L4 #DIV/0!
Heat Loss due to incomplete combustion:
% CO
C
%CO2
GCV of Fuel
L5 #DIV/0!
Heat Loss due to the radiation and convection
Vm 77
Ts 46
Ta 45
L6 29.11406
Boiler Efficiency
kCal/Kg of Fuel %
100
Where,
L1 = % Heat loss due to dry flue gas
m = Mass of dry flue gas in kg/kg of fuel
= Combustion products from fuel: CO2 + SO2 + Nitrogen in fuel + Nitrogen in the actual mass of air supplied + O2 in flue gas.
(H2O/Water vapour in the flue gas should not be considered)
Where
H2 = kg of hydrogen present in fuel on 1 kg basis
Cp = Specific heat of superheated steam in kCal/kgC
Tf = Flue gas temperature in C
Ta = Ambient temperature in C
584 = Latent heat corresponding to partial pressure of water vapour
where
M = kg moisture in fuel on 1 kg basis
Ta = Ambient temperature in C
584 = Latent heat corresponding to partial pressure of water vapour
where
AAS = Actual mass of air supplied per kg of fuel
Humidity factor = kg of water/kg of dry air
Ta = Ambient temperature in C (dry bulb)
where
% Heat loss due to partial conversion of C to CO When CO is obtained in ppm during the flue gas analysis
CO = Volume of CO in flue gas leaving economizer (%) CO formation (Mco) = CO (in ppm) x 106 x Mf x 28
CO2 = Actual Volume of CO2 in flue gas (%) or Mf = Fuel consumption in kg/hr
C = Carbon content kg / kg of fuel L5 = Mco x 5744*
* Heat loss due to partial combustion of carbon.
L6= Radiation loss in W/m2
Vm = Wind velocity in m/s
Ts = Surface temperature (K)
Ta = Ambient temperature (K)
Nitrogen in the actual mass of air supplied + O2 in flue gas.
When CO is obtained in ppm during the flue gas analysis
CO formation (Mco) = CO (in ppm) x 106 x Mf x 28
* Heat loss due to partial combustion of carbon.
Test Conditions and Precautions for Indirect Method Testing
A) The efficiency test does not account for:
Standby losses. Efficiency test is to be carried out, when the boiler is operating under a
steady load. Therefore, the combustion efficiency test does not reveal standby losses,
which occur between firing intervals
Blow down loss. The amount of energy wasted by blow down varies over a wide range.
Soot blower steam. The amount of steam used by soot blowers is variable that depends on
the type of fuel.
Auxiliary equipment energy consumption. The combustion efficiency test does not
account for the energy usage by auxiliary equipments, such as burners, fans, and pumps.
B) Preparations and pre conditions for testing
Burn the specified fuel(s) at the required rate.
Do the tests while the boiler is under steady load. Avoid testing during warming up of boilers
from a cold condition
Obtain the charts /tables for the additional data.
Determination of general method of operation
Sampling and analysis of fuel and ash.
Ensure the accuracy of fuel and ash analysis in the laboratory.
Check the type of blow down and method of measurement
Ensure proper operation of all instruments.
Check for any air infiltration in the combustion zone.
C) Flue gas sampling location
It is suggested that the exit duct of the boiler be probed and traversed to find the location of the
zone of maximum temperature. This is likely to coincide with the zone of maximum gas flow
and is therefore a good sampling point for both temperature and gas analysis.
D) Options of flue gas analysis
Check the Oxygen Test with the Carbon Dioxide Test
If continuous-reading oxygen test equipment is installed in boiler plant, use oxygen reading.
Occasionally use portable test equipment that checks for both oxygen and carbon dioxide. If the carbon
dioxide test does not give the same results as the oxygen test, something is wrong. One (or both)
of the tests could be erroneous, perhaps because of stale chemicals or drifting instrument calibration.
Another possibility is that outside air is being picked up along with the flue gas. This occurs if the
combustion gas area operates under negative pressure and there are leaks in the boiler casing.
Carbon Monoxide Test
The carbon monoxide content of flue gas is a good indicator of incomplete combustion with all
types of fuels, as long as they contain carbon. Carbon monoxide in the flue gas is minimal with
ordinary amounts of excess air, but it rises abruptly as soon as fuel combustion starts to be incomplete.
E) Planning for the testing
The testing is to be conducted for a duration of 4 to 8 hours in a normal production day.
Advanced planning is essential for the resource arrangement of manpower, fuel, water and
instrument check etc and the same to be communicated to the boiler Supervisor and
Production Department.
Sufficient quantity of fuel stock and water storage required for the test duration should be
arranged so that a test is not disrupted due to non-availability of fuel and water.
Necessary sampling point and instruments are to be made available with working condition.
Lab Analysis should be carried out for fuel, flue gas and water in coordination with lab personnel.
The steam table, psychometric chart, calculator are to be arranged for computation of boiler
Occasionally use portable test equipment that checks for both oxygen and carbon dioxide. If the carbon
ordinary amounts of excess air, but it rises abruptly as soon as fuel combustion starts to be incomplete.

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